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Dodge AD100 1990, Руководство по обслуживанию, Страница: 1 / 1134

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Содержание AD100 1990

Страница 1: ...1 9 9 0 SERVICE MANUAL REAR WHEEL DRIVE RAM TRUCK C H R Y S L E R W MOTORS ...

Страница 2: ... photocopying recording or otherwise with out the prior written permission of Chrysler Motors To order the special service tools used and illus trated please refer to the instructions on inside back cover Chrysler Motors reserves the right to change testing procedures specifications diagnosis or repair methods at any time without prior notice or incurring obligation Litho i n U S A Copyright 1989 ...

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Страница 4: ...RAMS 8W 1 Name Group page ELECTRICAL 8A 1 ALTERNATOR TEST PROCEDURES ON VEHICLE 8A 14 BATTERY TEST PROCEDURES ON VEHICLE 8A 2 BATTERY STARTING CHARGING SYSTEMS DIAGNOSTICS 8A 1 DIAGNOSTIC INFORMATION 8A 1 GROUP INDEX 8A 1 SPECIFICATIONS 8A 19 STARTER TEST PROCEDURES ON VEHICLE 8A 9 EMISSION CONTROL SYSTEMS 25 1 AIR INJECTION SYSTEM 25 17 EVAPORATIVE EMISSION CONTROLS 25 2 EXHAUST EMISSION CONTROLS...

Страница 5: ...EDURES 8N 1 SPEED CONTROL SYSTEM 8H 1 SERVICE PROCEDURES 8H 9 TEST PROCEDURES 8H 5 SPRINGS SHOCK ABSORBERS 17 1 GENERAL INFORMATION 17 1 SERVICE PROCEDURES 17 3 SPECIFICATIONS 17 12 STEERING 19 1 GENERAL INFORMATION 19 1 MANUAL STEERING GEAR SERVICE 19 6 POWER STEERING GEAR SERVICE 19 16 POWER STEERING PUMP SERVICE 19 39 SPECIFICATIONS 19 70 STEERING COLUMN SERVICE 19 54 STEERING LINKAGE SERVICE 1...

Страница 6: ...ystematic ap proach The tab locator at the right side of this page w i l l help you to quickly locate the first page of each group The first page of each group contains an al phabetical index to assist i n the location of the com ponent or system The information descriptions testing procedures and specifications were i n effect at the time this manual was released for printing Information describi...

Страница 7: ...nt identification plate contains infor mation regarding t h e vehicle model wheel base V I N Vehicle Identification Number T O N Or der Number and a l l production or special equip ment on the vehicle when i t was shipped from the factory Fig 3 Always refer to this plate when or dering parts The Equipment Identification Plate is located on the under hood panel i n the right front corner VEHICLE SA...

Страница 8: ...entification Label CHRYSLER U A i t ur MruK G V W R GAWR FRONT 1WITH TIRES i RIMS AT PSI COLD VEHICLE NUMBER IVEHICLE TYPE TRANSMISSION I VEHICLE IDENTIFICATION CODE I NUMBER MARKET U C B M CODE 90IN 3 Fig 5 Body Code Plate a line to punch the full 6 digits the balance of that line w i l l be left blank and the SEC code will be punched on the next line The last nine positions of line 7 will contai...

Страница 9: ...s located on the left front corner of the block be low the cylinder head Fig 7 TRANSMISSION IDENTIFICATION Specific light and medium duty vehicles referred to i n this manual can be identified by part number model and built date supplied on the Transmission Identification Tag Operation requirements are i n some instances dif ferent for each vehicle and engine combination and some internal parts w ...

Страница 10: ...s o s o D250 4 x 2 3327 mm 131 in 3 85 mm 149 in 3860 k g 8510 lbs s s o D250 4 x 2 3327 mm 131 in 3 85 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 k g 10 100 lbs S s o D350 4 x 2 3327 mm 131 in 4581 k g 10 100 lbs o s o W150 4 x 4 2921 mm 115 in 3327 mm 131 in 2858 k g 6300 lbs...

Страница 11: ... 3429 mm 135 in 4039 mm 159 in 4763 k g 10 500 lbs o s o W250 4 x 4 3327 mm 131 in 3860 k g 8510 lbs s s o W250 4 x 4 3327 mm 131 in 3860 k g 8510 lbs s s o W250 4 x 4 3327 mm 131 in 3860 k g 8510 lbs o s o W350 4 x 4 3327 mm 131 in 3946 k g 8700 lbs s s o W350 4 x 4 3327 mm 131 in 3946 k g 8700 lbs s s o W350 4 x 4 3327 mm 131 in 3946 k g 8700 lbs o s o W350 4 x 4 3429 mm 135 in 4581 k g 10 100 l...

Страница 12: ...945 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 ...

Страница 13: ...kg 10 100 lbs 11 000 lbs 1 2136 kg 2145 kg 4709 lbs 4729 lbs RAMCHARGER SPORT UTILITY MODEL FAMILY BODY 3 STYLE GVWR PAYLOAD ALLOWANCES 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 640...

Страница 14: ... 70 in 485 mm 19 1 in 2 15 m3 75 8 ft3 AD 2 AD 3 AD 7 3327 mm 131 in 1422 mm 56 in Chassis Cab 2438 mm 8 ft AD 3 AD 7 3249 mm 135 in 1524 mm 60 in Chassis Cab 2896 mm 9 5 ft AD 3 4039 mm 159 in 2134 mm 84 in Chassis Cab 3810 mm 12 5 ft AD 4 2692 mm 106 in Sport Utility 4 x 2 1778 mm 1588 mm 62 5 in 1062 mm 41 8 in 2 99 m3 105 8 ft3 AD 8 2692 mm 106 in Sport Utility 4 x 4 1778 mm 1588 mm 62 5 in 10...

Страница 15: ...n o f automotive fasteners Torx head fasteners m a y not b e identified as such t h r o u g h out this m a n u a l METRIC THREAD AND GRADE IDENTIFICATION Metric and SAE thread notations differ slightly The difference is illustrated i n Fig 2 Common metric fastener strength property classes are 9 8 and 12 9 w i t h the class identification em bossed on the head of each bolt Fig 3 Some metric nuts w...

Страница 16: ... REAR WINDOW WASHER PARKING BRAKE BRAKE FAILURE WINDSCREEN DEMISTING AND DEFROSTING Fig 5 International Symbols RK230 METRIC SYSTEM Artwork specifications and tightening references in this Service Manual are identified i n the metric system and i n the SAE system During any maintenance or repair procedures i t is important to salvage metric fasteners nuts bolts etc for reassembly I f the fastener ...

Страница 17: ... 6654 67 49 4167 87 64 1679 8 10 8465 28 37 9629 48 65 0793 68 92 1956 88 119 3120 8 5 9005 28 20 6517 48 35 4030 68 50 1542 88 64 9545 9 12 2024 29 39 3187 49 66 4351 69 93 5514 89 120 6678 9 6 6381 29 21 3893 49 36 1405 69 50 8918 89 65 6430 10 13 5582 3 40 6745 50 67 7909 70 94 9073 90 122 0236 10 7 3756 30 22 1269 90 36 8781 70 51 6293 90 66 306 1 1 14 9140 31 42 0304 51 69 1467 71 96 2631 91 ...

Страница 18: ...t x 0 3048 5 Metres M M x 3 281 Feet Yards x 0 9144 Metres M M x 1 0936 Yards Miles x 1 6093 Kilometres Km Km x 0 6214 Miles Miles Hr x 1 6093 Kilometres Hr Km h Km h x 0 6214 Miles Hr Feet Sec x 0 3048 Metres Sec M S M S x 3 281 Feet Sec Kilometres Hr x 0 27778 Metres Sec M S M S x 3 600 Kilometres Hr Miles Hr x 0 4470 Metres Sec M S M S x 2 237 Miles Hr COMMON METRIC EQUIVALENTS 1 Inch 25 Millim...

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Страница 20: ...Gross Vehicle Weight Rating of GVWR 3 856 k g 8 501 lbs or more must conform to the heavy duty emis sion standards see H E A V Y D U T Y CYCLE Mainte nance charts The GVWR for each vehicle appears on the Safety Certification label affixed to the lock pillar on the drivers door Fig 1 Additional information can be found i n the Owner s Manual provided w i t h the vehicle SEVERE SERVICE Vehicles oper...

Страница 21: ... PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance re pair or replacement of any device or element of de sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while i t is i n use 2 The use of the vehicle a...

Страница 22: ...tion and are further classified as grades 0 1 2 3 etc PARTS AND LUBRICATION RECOMMENDATIONS Your Chrysler Motors vehicle has been engineered to perform for you for years to come You will occa sionally require service and maintenance for your ve hicle and Chrysler M o t o r s recommends the use of M O P A R b r a n d parts a n d accessories Each MOPAR part has been specifically designed to maintain...

Страница 23: ...0 0 0 Drive Belt V Type Replace 0 Spark Plug Replace X 0 0 0 Air Filter Replace X 0 0 0 Fuel Filter Replace as necessary Coolant Flush Replace 36 months 24 months 48 000 km 30 000 miles thereafter 0 EGR Valve Tube Replace clean passengers at 60 months 02 02 PCV Breather Clean 0 0 PCV Valve Replace 60 months 02 Q2 Vacuum Emission Components Replace 60 months 0 0 Ignition Timing Adjust to Specs as n...

Страница 24: ... Air Filter Replace X X X X Crankcase Inlet Air Filter Clean X X X X Spark Plug Replace X X X Fuel Filter Replace as necessary Coolant Flush Replace 36 months 24 months 48 000 km 30 000 miles thereafter X EGR Valve Tube Replace X2 EGR Tube Clean Passengers X2 PCV Valve Replace X2 Vacuum Emission Components Replace X Ignition Timing Adjust to Specs as necessary X Ignition Cables Distributor Cap Rot...

Страница 25: ...Multi Purpose Lubricant Propeller Shaft Slip Spline ADl AD 2 2 piece P shaft 1 36 000 km 22 500 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 ADl AD2 4 36 000 km 22 500 miles or 2 years every engine oil change for off highway operation Multi purpose...

Страница 26: ...s 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 purpose grease ...

Страница 27: ...TE AND CAUSE THE CONVERTER TO OVERHEAT AND RUPTURE BOOSTER BATTERY WARNING TO PREVENT PERSONAL INJURY OR DAMAGE TO CLOTHING DO NOT ALLOW BAT TERY FLUID TO CONTACT EYES SKIN OR FAB RICS DO NOT LEAN OVER A BATTERY WHEN CONNECTING JUMPER CABLES OR ALLOW CA BLE CLAMPS TO TOUCH EACH OTHER KEEP OPEN FLAMES OR SPARKS AWAY FROM BAT TERY VENT HOLES ALWAYS WEAR EYE PROTEC TION WHEN WORKING WITH BATTERIES I ...

Страница 28: ...ls to start cables must be disconnected i n following order a Negative cable at engine ground b Negative cable at negative post on booster battery c Cable between positive post of both batter ies WARNING ANY PROCEDURE OTHER THAN ABOVE COULD RESULT IN 1 PERSONAL I N J U R Y CAUSED BY ELECTRO L Y T E SQUIRTING OUT BATTERY VENT 2 PERSONAL I N J U R Y OR PROPERTY D A M AGE D U E TO BATTERY EXPLOSION 3...

Страница 29: ...at will not unbalance the vehicle or dam age components such as hydraulic tines exhaust system or steering linkage ADJUSTMENT PAD Fig 7 Hoisting Single Post Hoist Typical TOWING RECOMMENDATIONS TOWING EQUIPMENT When towing a Chrysler Motors vehicle a SAE ap proved sling type towing device may be used Fig 8 A crossbeam and spacer blocks may be required for proper attachment Fig 9 I n most sling typ...

Страница 30: ...and 13 4WD vehicles may be towed transfer case i n neu tral on the front wheels for distances not to exceed 25 k m 15 miles For extended distances the front propeller shaft should be disconnected The steering wheel must be clamped i n the straight ahead position w i t h a steering wheel clamp ing device designed for towing service use CAUTION Do not use steering column lock to se cure front wheel ...

Страница 31: ...ar axle position hooks so as not to damage brake lines 3 Do not allow any of the towing equipment to bear on the fuel tank 4 Vehicle is not to be towed by hooking on the front or rear shock absorbers or coil springs 5 Do not lift or tow the vehicle by attaching to or wrapping around the bumper 6 A safety chain system completely independent of the primary lifting and towing attachment must be used ...

Страница 32: ... inoperative for one to three months re quire the following maintenance i n addition to those described above 1 Drain fuel tank and operate engine until carbu retor runs dry 2 Remove spark plugs and pour 2 ounces of spe cial rust preventive oil into each cylinder Crank the engine Replace plugs and tighten to 41 N m 30 ft lbs torque 3 Remove valve covers a n d coat rocker arms rocker arm shaft valv...

Страница 33: ...alve 17 Oxygen 02 Sensor 19 Rubber and Plastic Component Inspection 20 Spark Plugs 20 Throttle Control Linkage 16 Vacuum Operated Components 19 Vacuum Operated Emission Control Components 20 VISCOSITY Multi viscosity oils protect the engine over a wide range of operating temperatures and driving condi tions Therefore these oils can be used a l l year round Select o i l viscosity according to the l...

Страница 34: ...e Every 3 months or 4 800 k m 3 000 miles whichever occurs first i f the vehi cle is driven under any of the following conditions a Frequent driving i n dusty conditions b Frequent trailer pulling c Extensive idling d Frequent short trip driving less than 8 k m or 5 miles at temperatures below 10 F 12 C e More than 50 operation a t sustained high speeds over 112 km h 70 mph during hot weather abov...

Страница 35: ...the mileage or time intervals specified i n the Mainte nance Schedule i n this Group I f the solution is dirty or rusty or contains a considerable amount of sedi ment clean and flush w i t h a reliable cooling system cleaner Care should be taken i n disposing of the used engine coolant from your vehicle Used coolant indiscriminately discarded can present a problem to the environment Contact your d...

Страница 36: ...ing is weak or broken replace the spring FRONT RN965 Fig 5 Accelerator Linkage Pivot Areas Fig 6 Manifold Heat Control Valve AIR INJECTION SYSTEM A l l valves and switches i n the A i r Injection System and the air pump should be checked for proper oper ation and replaced i f necessary Inspect the check valve tubing for corrosion and replace i f excessive corrosion is evident CRANKCASE VENTILATION...

Страница 37: ...rce 2 W i t h engine stopped remove PCV valve and shake A clicking noise should be heard to indicate that the valve mechanism is free 3 I f the crankcase ventilation system meets the tests i n 1 and 2 above no further service is re quired I f not the PCV valve should be replaced and the system checked again Install a new Mopar PCV Valve or equivalent Do not attempt to clean t h e old P C V valve 4...

Страница 38: ...ugh they may not be so identified Use of fuels containing alcohol is not recommended unless the nature of the blend can be determined as being satisfactory G A S O H O L A mixture of 10 ethanol grain al cohol and 90 unleaded gasoline may be used i n your vehicle I f driveability problems are experienced as a result of using GASOHOL i t is recommended that the vehicle be operated on unleaded gasoli...

Страница 39: ...length of expo sure time to heat and contaminants are factors affecting the life of rubber and plastic components INCREASED SEALED TEST ELECTROLITE VENT CAPS INDICATOR ENVELOPE HOLD DOWN SEPARATORS RK92 Fig 11 Maintenance Free Battery To provide best vehicle performance and avoid ad verse effect on component life i t is recommended that the following components be inspected when performing other u...

Страница 40: ...ully seated and the nipple assemblies should not be removed from the distributor or coil towers EXHAUST SYSTEM The exhaust system must be properly aligned to prevent stress leakage and body contact I f the sys tem contacts any panel i t may amplify objectionable noises originating from the engine or the body Inspect the exhaust system at the mileage or time intervals specified i n the Maintenance ...

Страница 41: ...nd correct any possible leaks and fill the reservoir with clean moisture free brake fluid conforming to DOT 3 Page Manual Transmissions NP2500 Overdrive 5 Speed NP435 Overdrive 4 Speed 22 Propeller Shaft Universal Joints 26 Transfer Case 24 MUSS 116 standard only MOPAR Brake Fluid or equivalent w i l l provide the best clutch performance CAUTION Do not allow any petroleum base fluids to contaminat...

Страница 42: ...nce they may adversely affect the seals DRAIN AND FILL The NP2500 overdrive 5 speed and NP435 over drive 4 speed manual transmission should be drained and filled at the following intervals Fig 4 Light Duty Cycle Normal 60 000 km 37 500 miles Service Heavy Duty Cycle 58 000 km 36 000 miles Severe Service 29 000 km 18 000 miles 19000 43 Fig 4 Manual Transmission Drain and Fill Intervals GEARSHIFT LI...

Страница 43: ...smission MOPAR A T F PLUS Automatic Transmission Fluid Type 7176 should be used Dextron I I automatic transmission fluid should be used only i f the recommended fluid is not available 8 To prevent dirt and water from entering the transmission after checking or fluid replacement make certain that the dipstick cap is seated properly CAUTION Do not overfill the transmission SPECIAL ADDITIVES Chrysler...

Страница 44: ...ation NP241 Transfer Case RY682 Fig 10 Gearshift Mechanism Lubrication NP205 Transfer Case AXLES CONVENTIONAL DIFFERENTIAL FRONT AND REAR A l l truck rear axles contain SAE 80W 90 multipur pose type gear lubricant when delivered from the fac tory FREQUENCY OF OIL CHANGE Chrysler Motors does not recommend regularly scheduled oil changes for axles i n vehicles whose op eration is classified as norma...

Страница 45: ... seated i n cover Fig 12 Removing Filler Plug Front Driving Axle REAR AXLE LIMITED SLIP DIFFERENTIAL For rear axles equipped w i t h Auburn Gear A n t i Spin or Spicer Power Loc or Trac Loc Limited Slip Differentials follow the same inspection procedure and lubricant recommendations as outlined for axles with conventional differentials These limited slip differentials require the use of a friction...

Страница 46: ...AND 16 Under normal driving conditions highway type op eration lubricate every 12 000 k m 7 500 miles w i t h MOPAR Multipurpose Lubricant or equivalent I f vehicle is operated i n water the universal joints should be lubricated daily GREASE FITTINGS RK40 Fig 15 Universal Joint and Slip Spline with Grease Fittings Typical Fig 16 Constant Velocity Universal Joint Lubrication Points ...

Страница 47: ...When lubricating joints use only the special long life chassis grease such as MOPAR Multi mileage Lubricant or equivalent INSPECTION The front suspension ball joints should be inspected when ever a vehicle is serviced for other reasons Fig 1 Damaged seals should be replaced to prevent leakage or contamination of the grease LUBRICATION Ball joints are semi permanently lubricated at the factory w i ...

Страница 48: ...uld be maintained to the proper level indicated on cap dipstick Fig 2 Only fluids specially formulated for minimum ef fect on rubber hoses should be used MOPAR Power Steering Fluid or equivalent Fig 2 Power Steering Pump Typical WHEEL BEARINGS INSPECTION LUBRICATION INTERVALS FRONT WHEEL BEARINGS Inspect the lubricant whenever the rotors are re moved or service is performed on the brake system but...

Страница 49: ...ter nonconfined rubber does not constitute failure Lower control arm bushings may be visually i n spected by lifting the vehicle on a hoist and inspect ing from underneath Upper control arm bushing may be inspected by removing the front wheels I f failure exists replace bushing see Group 2 Front Suspension for the proper procedure BRAKES The vehicle is equipped w i t h disc brakes on the front and...

Страница 50: ...d by cracks or abrasions i n the rubber hose cover the hose should be replaced 2 Faulty installation can cause twisting wheel tire or chassis interference HEADLIGHTS To assure correct adjustment of headlight aiming it is recommended that the headlights be checked and i f necessary properly aimed every six months Changes i n front and rear suspension such as front suspension height and or deflectio...

Страница 51: ...r then proceed as described above i n or der to distribute the lubricant w i t h i n the lock cylin der The following mechanisms should be inspected cleaned and a l l pivot and sliding contact areas of these components lubricated as required w i t h the proper lubricant Fig 7 C O M P O N E N T S E R V I C E I N T E R V A L L U B R I C A N T Door Hinges As Required Engine Oil Door Latches As Requir...

Страница 52: ... ahead or angling i t to the right or left sector shear p i n this self locking pin locks the moldboard blade i n either a straight ahead or an angled plowing position i f the blade impacts ob structions w i t h strong force the p i n will shear to protect the snow plow and the vehicle from damage the is pin not used w i t h power angle plowing power angling cylinders these cylinders en able the o...

Страница 53: ... enables the plow blade to lower v i a gravity Solenoid valve A is designed to remain energized valve open during snow plow operation to provide a floating blade position which ensures that the plow blade is guided up down by the surface devia tions SOLENOID VALVE B The solenoid valve B cartridge contains a spool valve that is normally i n the de energized CLOSED position to allow the pressurized ...

Страница 54: ...nction of pro tecting against potential damage that can be caused by a n abnormally high opposite force from impact being applied against the end of the blade e g when the blade end contacts a curb or other immovable structure This type of action w i l l cause very high hydraulic pressure to accumulate i n one of the an gling cylinders When the hydraulic pressure increases sufficiently to open the...

Страница 55: ...1 4 ACCESSORIES TAN IGNITION SWITCH BLACK ANGLING CYLINDER B B OPERATING PRESSURE EXHAUST ESSS3 INTAKE OR DRAIN METERED FLOW RB525 Fig 2 Raise Blade Voltage Application Hydraulic Fluid Flow ...

Страница 56: ...IZED A COIL IV r B SOLENOID C SOLENOID PRESSURE RELIEF CHECK VALVE f CHECK VALVE c FILTER PUMP A SOLENOID LIFT CYLINDER A SOLENOID IN OPERATION U TANK PILOT CHECK POWER ANGLING CYLINDER LOWER AND FLOAT FORCE APPLIED AGAINST LIFT RAM OPERATING PRESSURE EXHAUST INTAKE OR DRAIN r g METERED FLOW RB526 Fig 3 Lower Float Blade Voltage Application Hydraulic Fluid Flow ...

Страница 57: ...1 6 ACCESSORIES IGNITION SWITCH L BLACK OHB OPERATING PRESSURE FZT I EXHAUST INTAKE OR DRAIN METERED FLOW RB527 Fig 4 Angle Blade Right Voltage Application Hydraulic Fluid Flow ...

Страница 58: ...H 0 ORANGE WITH WHITE TRACER TAN RED a i ANGLE FUSE i LIGHT GREEN D c IGNITION SWITCH BATTERY MOTOR SOLENOID SWITCH ENERGIZED MOTOR B SOLENOID C SOLENOID H OPERATING PRESSURE r I EXHAUST E S INTAKE OR DRAIN METERED FLOW J9001 1 Fig 5 Angle Blade Left Voltage Application Hydraulic Fluid Flow ...

Страница 59: ...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 leve...

Страница 60: ...ording to the following procedure 1 Hold a steel screwdriver blade approximately 1 8 inch above the retaining n u t on the coil to be tested 2 Have a helper position the control switch that energizes the applicable coil e g place the RAISE LOWER switch i n the LOWER and FLOAT positions to energize solenoid valve A coil CAUTION Do not connect an ohmmeter to a sole noid coil when voltage is applied ...

Страница 61: ...8WT BR Dl 18RD YL Dl 18RD YL PLOW CONTROL SWITCH UP DOWN 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 Dl 18RD YL SP3 18 WT RD SP3 18WT RD SP1 18WT BK SP418WT BR SP4 18WT BR SP4 18WT BR Dl 18RD YL SP5 18WT LG L I SP5 18WT LG T2 18LG RD 8901 3 Fig 6 Snow Plow Control Wiring Diagram ...

Страница 62: ... 1 Ml 6RD SNOW PLOW MOTOR FRONT SNOW PLOW FRAME G9 6BK h BLACK FRONT SNOW PLOW FRAME PLOW CONTROL SWITCH LEFT TO RIGHT SP4 18WT BR Dl 18RD YL SP5 18WT LG SP5 18WT LG SP3 18WT RD HOZ SNOW PLOW UP SOLENOID FRONT SNOW PLOW FRAME 16RD FW L SP1 18WT BK Ifl I BLACK FRONT SNOW PLOW FRAME i6bk pm l SNOW PLOW DOWN SOLENOID FRONT SNOW PLOW FRAME L SP5 18WT LG BLACK FRONT SNOW PLOW FRAME 16LG p5F SNOW PLOW R...

Страница 63: ...T END WIRING SEE SH 22 BLACK RIGHT SIDE RADIATOR YOKE PANEL BLACK 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 ...

Страница 64: ... ACCESSORIES 1 13 RB530 Fig 9 Power Unit Exploded View ...

Страница 65: ...not re move the bolts from the motor Retain or secure the motor end plate in place during removal then tem porarily install two 1 4 20 nuts on the motor attach ing bolts to retain the motor intact B o t h Prestolite a n d A m e r i c a n B o s c h motors are used i n snow p l o w p o w e r unit A Prestolite motor c a n be identified b y a domed top cover a n d the trade name stamped on the b o d y...

Страница 66: ...ct for external damage Discard the O ring seals 31 W i t h a l l the components removed from the block clean the block with compressed air to remove all foreign material POWER UNIT ASSEMBLY Before assembly ensure that a l l components are thoroughly clean and free of all foreign material Use replacement gaskets and seals during assembly Pe troleum jelly or a n equivalent lubricant may be used as a...

Страница 67: ...e pump housing Fig 9 Engage the gear shaft tang w i t h the notch i n the mo tor output shaft Tighten the motor to housing cap screws w i t h 5 N m 45 in lbs torque 13 Install the r a m and piston with replacement O ring seals Fig 9 14 Position the cover on the reservoir and secure it w i t h locknuts Fig 9 Tighten the locknuts w i t h 11 3 N m 100 in lbs torque POWER ANGLING CYLINDER SERVICE I f ...

Страница 68: ...urrent 0 83 Amperes Nominal resistance one ohmmeter probe to coil wire other to metal coil cover 9 0 10 ohms B and C Colls Applied Voltage 12 Volts DC Current 1 24 Amperes Nominal resistance one ohmmeter probe to coil wire other to metal coil cover 3 5 1 0 ohms SOLENOID SWITCH Applied Voltage 12 Volts DC Max Current 5 Amperes Nominal resistance one ohmmeter probe to coil wire other to metal foot 2...

Страница 69: ......

Страница 70: ...bracket A shock absorber is located inside each spring coil and i t is attached to the frame side rail bracket and to the lower suspension arm Both suspension arms have replaceable bushings at the inboard ends and replaceable ball studs at the outboard ends The lower suspension arms are equipped w i t h tension type ball studs The upper sus pension arms also control the caster and camber an gles v...

Страница 71: ... provides a means for inspec tion and for differential service without removing the complete front axle from the vehicle A small stamped metal axle gear ratio identifica tion tag is attached to the housing cover v i a one of the cover bolts This tag also identifies the number of ring gear and drive pinion gear teeth Refer to Group 17 Springs A n d Shock Absorbers for service information involving ...

Страница 72: ...ngle wheel toe position steering axis inclination and wheel toe out on turns turning radius A l l the angles and linear distances are mechani cally adjustable except the vehicle height the steer ing axis inclination and the wheel toe out position on turns turning radius Although not adjustable the measurements are valuable i n determining i f there are bent or damaged components involved par ticul...

Страница 73: ...ot adjustable and the damaged components must be replaced to correct mis alignment The wheel t o e o u t o n t u r n s turning radius is measured i n degrees and is the difference between the two front wheel turning angles This turning an gle difference is provided by the design of the steer ing linkage and is based on the wheelbase of the vehicle I t is not adjustable When the wheel toe out on tu...

Страница 74: ... WORN TIRE TREAD BROKEN OR WEAK REAR SPRING LOW 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 SU...

Страница 75: ... the caster angle appears to be correct and the axle is not bent or twisted a satisfactory test for as surance can be made by road testing the vehicle and observing the steering wheel return to center posi tion Before road testing check and correct the tire inflation pressures Be particularly careful to in flate both of the front tires with exactly the same pressure During the road test turn the s...

Страница 76: ...n the rear retainer and the rear bushing on the front end of the strut Fig 1 2 Carefully slide the strut into position for instal Page Steering Knuckle Removal Installation 13 Upper Ball Stud Replacement 12 Upper Suspension Arm Bushing Replacement 12 Upper Suspension Arm Removal Installation 11 lation Fig 1 Install the jounce bumper and the rear attaching bolts Tighten the bolts w i t h 129 N m 95...

Страница 77: ...er ball stud Fig 4 Turn the threaded por tion of the tool and lock the tool securely against the lower stud Fig 4 11 Expand the tool sufficiently enough to place force on the lower ball stud and then strike the steer ing knuckle sharply w i t h a hammer to loosen the stud D o n o t attempt t o force the stud o u t o f the steering k n u c k l e w i t h the loosening tool 12 Remove the loosening to...

Страница 78: ...he inside surface and install i t on the hub 11 Position the inboard brake pad on the brake caliper adapter w i t h the pad flanges engaged w i t h the adapter rails Slowly slide the caliper into posi tion i n the adapter and over the brake rotor A l i g n the caliper on the adapter rails Use care to avoid pulling the protective dust boot from the grooves as the caliper piston and boot slide over ...

Страница 79: ... Ball Stud Installation tool Fig 4 until the lower suspension arm ball stud can be properly positioned i n the steering knuckle bore 4 Install the retaining nuts on the ball studs and tighten the upper n u t w i t h 142 N m 105 ft lbs torque and the lower nut i f a 11 16 16 bolt w i t h 183 N m 135 ft lbs torque or i f a 3 4 16 bolt w i t h 237 N m 175 ft lbs torque Install replacement cotter pins...

Страница 80: ...the vehicle brakes and the front suspen sion for proper operation LOWER SUSPENSION ARM BUSHING REPLACEMENT REMOVAL 1 Remove the lower suspension arm according to instructions provided within the removal procedure 2 Use an arbor press and an appropriate size sleeve to force the original bushing from the lower suspension a r m bore INSTALLATION 1 Use a n arbor press a n d an appropriate size sleeve ...

Страница 81: ...der the outer end of the lower suspension arm and lower the vehicle so that the support compresses the coil spring 2 Remove the wheel tire 3 Remove the ball stud nuts Use Ball Stud Loos ening Tool C 3564 A to loosen the upper ball stud Fig 7 4 Use Tool C 3561 to un thread the upper ball stud from the upper suspension arm Fig 8 INSTALLATION 1 Thread the replacement ball stud into the upper suspensi...

Страница 82: ...k l e spindle threads otherwise t h e threads the bearing a n d t h e seal c o u l d be damaged 5 Remove the attaching screws and the brake splash shield Remove and discard the dust seal 6 Remove the cotter pin and the nut from the tie rod end ball stud 7 Install Puller Tool C 3894A Fig 11 and apply sufficient force with the tool to loosen the tie rod end ball stud from the steering knuckle arm bo...

Страница 83: ...Install the strut Fig 1 Tighten the strut to lower suspension arm bolts w i t h 136 N m 100 ft lbs torque Tighten the strut front nut w i t h 70 N m 50 ft lbs torque Install the spring pin 8 Connect the stabilizer bar i f equipped and tighten the link nut w i t h 11 N m 100 in lbs torque Fig 3 Remove the spring compressor tool Fig 4 9 Install the shock absorber bushing i n the frame rail bracket P...

Страница 84: ...e pinion gear shaft bearing preload torque is maintained by placing appropriate thick ness of shims between the differential housing shoul der and the outer bearing The differential case is supported by two tapered roller bearings that are press fitted on the differen tial case hubs The shims placed between the bearing and the differential case hub shoulder provide three functions Page Right Axle ...

Страница 85: ...N m 50 ft lbs torque The wheel bear ing end play after the final bearing adjustment should be w i t h i n 0 001 inch to 0 010 inch 0 03 to 0 25 mm 5 Install the retaining spring the driving hub and the retaining ring 6 Apply R T V sealant to the sealing edge of the dust cap and install i t on the hub 7 Position the inboard brake pad on the brake caliper adapter w i t h the pad flanges engaged w i ...

Страница 86: ...rfaces Remove the bearing seal 12 Use Tool D 131 the remove needle bearings from the spindle Fig 4 13 Carefully remove the axle shaft from the axle shaft tube Remove the seal from the axle shaft 14 Right side only disconnect the tie rod end ball stud from the steering knuckle arm bore Left side disconnect the drag link ball stud from the steering knuckle arm bore I f necessary refer to the removal...

Страница 87: ...ng assembly ASSEMBL Y INSTALLA TION 1 Clamp the steering knuckle right side up i n a vise Use Tool C 4212 L and Adaptor Tool Set C 4288 positioned as illustrated i n Figure 8 to carefully force the lower ball stud into the steering knuckle bore Install the snap retaining ring w i t h Snap Ring Pliers Tool C 4020 Fig 8 Lower Ball Stud Installation 2 Use Tool C 4212 L and Adaptor Tool Set C 4288 pos...

Страница 88: ...er axle shaft insert the intermediate outer axle shaft through axle shaft seal use care to avoid damaging the seal during this step RN328 Fig 11 Lubricating Seal install the shift motor housing gasket and cover ensure that the shift fork is correctly guided into the shift collar groove install the shift motor housing cover shield and bolts and tighten the bolts with 14 N T H 10 ft lbs torque and c...

Страница 89: ... remove the axle shaft from the axle shaft tube Remove the seal and the stone shield from the shaft INSTALLATION 1 Install the seal on the axle shaft stone shield w i t h the lip facing toward the axle shaft splines 2 Carefully insert the axle shaft into t h e axle shaft tube and avoid damaging the differential hous ing seal 3 Install the spindle and the splash shield Install the nuts and tighten ...

Страница 90: ...m the vise and insert one end of the spider into the bearing Insert opposite bearing and cap i n the yoke arm bore by hand and align i t with the spider 4 Place the yoke i n a vise and force the cap into the yoke arm bore and onto the spider Fig 14 5 Use a short plug or a socket wrench to force the bearing cap into the correct position and install the snap retaining ring 6 Repeat the instructions ...

Страница 91: ...the shift motor housing cover gasket and shield Fig 15 12 Carefully remove the intermediate axle shaft from the axle shaft tube Carefully slide the axle shaft through axle shaft seal to avoid damage to the seal 13 Remove the shift collar from the shift motor housing 14 Remove the inner axle shaft seal from the axle shaft tube and remove i t from the shift motor hous ing Certain vehicles could also...

Страница 92: ...9 Intermediate Shaft Bearing Installation 7 Lubricate the splined end of the intermediate axle shaft w i t h a liberal amount of multi purpose l u bricant and insert i t through inner axle shaft seal Use care t o a v o i d d a m a g i n g the seal 8 Install the shift motor housing gasket and cover Ensure t h a t t h e shift f o r k is correctly guided i n t o the shift collar groove 9 Install the ...

Страница 93: ...SEALANT TYPICAL J9003 85 A l l o w t h e sealant t o c u r e f o r f e w m i n u t e s I f f o r a n y reason t h e h o u s i n g cover is n o t i n stalled w i t h i n 20 m i n u t e s after a p p l y i n g the seal ant t h e sealant m u s t b e r e m o v e d a n d a n o t h e r b e a d o f sealant a p p l i e d 20 Install the housing cover on the differential housing w i t h the attaching bolts ...

Страница 94: ...t step 4 Disconnect the vacuum pump from the vacuum shift motor front port Fig 23 Connect the vacuum REAR PORT MOTOR J8902 57 Fig 23 Axle Vacuum Shift Motor pump to the vacuum shift motor rear port cap the port for the 4WD indicator lamp switch and apply 51 kPa 15 i n Hg of vacuum to the rear port 5 The shift motor should maintain the vacuum applied to the rear port for a minimum of 30 seconds I f...

Страница 95: ... N N E C T T H E S H I F T M O T O R V A C U U M H O S E S TEST FOR VACUUM IN VACUUM HOSE THAT CONNECTS TO INBOARD SHIFT MOTOR PORT VACUUM SHOULD BE BETWEEN 10 20 IN HG D I S C O N N E C T T H E S H I F T M O T O R V A C U U M H O S E S TEST FOR VACUUM IN VACUUM HOSE THAT CONNECTS TO INBOARD SHIFT MOTOR PORT VACUUM SHOULD BE BETWEEN 10 20 IN HG CHECK TRANSFER CASE REPAIR AS NECESSARY NO VACUUM OR ...

Страница 96: ...N HG NO VACUUM OR LOW VACUUM STOP ENGINE VACUUM OK INSPECT INTAKE MANIFOLD VACUUM SUPPLY HOSE CONNECTION TRANSFER CASE VACUUM SWITCH CONNECTION VACUUM RESERVOIR AND SHIFT SYSTEM VACUUM HOSES FOR PROPER CONNECTION RESTRICTION LEAKS AND DAMAGE REPAIR OR REPLACE AS NECESSARY CONNECT A VACUUM PUMP TO THE OUTBOARD SHIFT MOTOR PORT APPLY 15 INCHES HG VACUUM AND ROTATE LEFT WHEEL NO VACUUM FRONT AXLE CON...

Страница 97: ...E IN DOWNWARD POSITION TRANSFER CASE VENT TUBE NUT AND WASHER C VIEW IN DIRECTION OF ARROW W TORQUE LET POUNDS NEWTON METRES FULLY SEATED HAND TIGHTENED B 55 IN 6 15 FT 20 ALIGN WHITE TAPE TO END OF CLIP SHIFT MOTOR VIEW IN DIRECTION OF ARROW Z CLIP ROUTE HOSE TO REAR OF DISTRIBUTOR RESERVOIR ASSEMBLY FILTER MUST BE IN DOWNWARD POSITION TRANSFER v CASE VENT TUBE 8 CYLINDER RK722 Fig 24 Disconnect ...

Страница 98: ... bolts w i t h 14 N m 10 ft lbs torque STEERING KNUCKLE ARM REMOVAL INSTALLATION REMOVAL The drag link ball stud seals should be inspected for damage when the engine oil is changed 1 Raise and support the vehicle at a comfortable working height Remove the wheel cover and wheel tire 2 T u r n the front wheels to the left Remove the cotter pin and the retaining nut from the drag link ball stud R e m...

Страница 99: ...test distance to the steering knuckle arm and the distance B is the closest to the pitman steering gear arm Fig 28 Correct Drag Link Installation 2 Install and tighten the ball stud retaining nuts w i t h 81 N m 60 ft lbs torque Install replacement cotter pins 3 Install the wheel tire and the wheel cover Re move the supports and lower the vehicle TIE ROD END REPLACEMENT SERVICE INFORMATION The tie...

Страница 100: ... the retainer the bolts and the nuts at each side of the vehicle Fig 30 Tighten the nuts w i t h 102 N 75 ft lbs torque 2 Position the ends of the stabilizer bar over the links Install the outer insulator the outer retainer INSULATOR LINK ASSEMBLY SHAFT ASSEMBLY BUSHING NUT RETAINER BOLT ASSEMBLY VIEW D RN1034 Fig 30 Stabilizer Bar 4WD Vehicles and the nut on each link Fig 30 Tighten the nuts w i ...

Страница 101: ...s not necessary to remove the complete front axle from the vehicle for routine axle or differential service To replace the differential side gears i t is necessary to remove only the axle shafts the differ ential housing cover the lubricant and the differen t i a l case To replace the differential bearings i t is necessary to remove only the axle shafts the differ ential housing cover the lubrican...

Страница 102: ... e that t h e applicable bearing c u p rotated i n t h e differential h o u s i n g seat a n d caused excessive wear 11 Note the installation reference letters stamped into the differential bearing caps and into the differ ential housing machined sealing surface Fig 32 The letters are stamped horizontally on the left side and are stamped vertically on the right side of the differential housing Alw...

Страница 103: ...holddown clamps and the spreader tool from the differential housing Fig 33 24 Install the differential bearing caps and tighten the bolts finger tight until each bolt head is lightly seated on the bearing cap 25 Install a pilot stud at the right side of the dif ferential housing Attach Dial Indicator Tool C 3339 to the differential housing via the pilot stud w i t h the indicator plunger slightly ...

Страница 104: ...housing bore Fig 37 Record the thickness of the depth shims 34 Remove the inner bearing from the drive pin ion gear shaft w i t h Removal Tool C 293 PA and Plate Tools C 293 39 Fig 38 35 Clamp the differential case i n a vise equipped w i t h soft jaws Use a pin punch to force the pinion gear mate shaft lock pin from the differential case bore Fig 39 36 Remove the differential pinion gear mate sha...

Страница 105: ...ised metal on the shoulders of the bearing cup bores incurred during removal of the cups should be removed w i t h a hand stone 4 Examine the differential pinion gear mate shaft pinion gears side gears and thrust washers Fig 37 for wear and damage Replace all defective components I f either o f the differential p i n i o n gears is n o t reusable b o t h gears m u s t be replaced as a m a t c h e ...

Страница 106: ...paration distance when separating the differential housing If TOOL C 3339 RH411A Fig 42 Differential Housing Separation the housing is over separated it could be distorted or damaged which would necessitate replacement 10 Tighten the spreader tool turnbuckle Fig 42 and separate the differential housing only enough to install the differential case i n the housing Separate the differential housing a...

Страница 107: ...g separated 23 Remove the dial indicator tool and the pilot stud Fig 42 when the differential housing has been separated sufficiently to remove the differential case from the housing 24 Remove the differential case from the differen tial housing 25 Remove the holddown clamps and the spreader tool from the differential housing Fig 42 26 Install a replacement seal i n t h e right side axle shaft tub...

Страница 108: ...ed but the depth shims must be replaced measure the thickness of the original depth shims and build a replacement pack of depth shims with the same thickness I f equipped the o i l slinger located between the r e a r bearing a n d the t h r u s t face o f drive p i n i o n gear must be measured a n d t h e thickness i n c l u d e d w i t h the t o t a l s h i m p a c k thickness I f the original d...

Страница 109: ... following drive pinion gear depth i e t h e depth of the gear teeth mesh between the drive pin ion gear and the ring gear measurement and adjust ment procedure involves using Tool Set D 271 Fig 47 D 139 D 115 1 D 115 2 D 115 3 RK 784 Fig 47 Pinion Gear Depth Gauge Tool Set D 271 1 Insert Master Pinion Block Tool D 139 into the drive pinion gear shaft bore i n the differential hous ing Fig 48 Fig ...

Страница 110: ...icrometer and combine the shims necessary to obtain the total required depth shim pack thickness I f equipped t h e o i l slinger lo cated between t h e rear b e a r i n g a n d t h e t h r u s t face o f drive p i n i o n gear m u s t b e measured a n d the thickness i n c l u d e d w i t h t h e t o t a l s h i m p a c k thickness 7 Remove the measurement tools from the differ ential housing 8 P...

Страница 111: ...ard the arbor tool u n t i l the tip of the dial indicator plunger contacts the arbor tool Fig 51 Slide the gauge block tool with the dial indicator across and back and forth along the arbor tool while observing the dial indicator pointer Record the longest plunger travel distance whether inward or outward indicated by the pointer The d i a l indicator pointer s h o u l d i n d i c a t e a n i n w...

Страница 112: ... bearing preload torque The torque necessary to rotate the drive pinion gear shaft should be between 2 to 5 N m 20 to 40 in lbs PINION SEAL INSTALLER RY659A Fig 57 Drive Pinion Gear Shaft Seal Installation with replacement bearings The torque necessary to rotate the drive pinion gear shaft should be between 1 to 3 N m 10 to 20 in lbs w i t h original bearings If the drive pinion gear shaft bearing...

Страница 113: ...e g 0 1 2 1 2 etc I f the etched depth variance is a minus value add i t to the thickness measured and recorded in step 11 above I f the etched depth variance is a plus value subtract i t from the thickness mea sured and recorded i n step 11 above 13 Remove the arbor tool from the differential housing cavity and the other tools with the outer and inner bearings from the housing bore 14 Use Removal...

Страница 114: ...nd a replacement n u t on the shaft Tighten the n u t with 271 to 298 N n n 200 to 220 ft lbs torque RING GEAR BACKLASH ADJUSTMENT 1 Position Spreader Tool W 129 A on the differen tial housing w i t h the tool dowel pins seated i n the locating holes Fig 62 Install the holddown clamps and tighten the tool turnbuckle finger tight 2 Install a pilot stud at the left side of the differ ential housing ...

Страница 115: ... r i n g gear b a c k l a s h shims m u s t be placed on the h u b a t the r i n g gear side o f the differen t i a l case between t h e differential case a n d t h e differential bearing 9 Remove the dial indicator tool and the pilot stud Fig 63 from the differential housing Fig 63 Ring Gear Backlash Measurement 10 Remove the differential bearing caps 11 Position Spreader Tool W 129 A on the diff...

Страница 116: ...ent 24 Tighten the spreader tool turnbuckle Fig 62 and separate the differential housing only enough to install the differential case i n the housing Separate the differential housing a m a x i m u m distance o f 0 38 n u n 0 015 i n w i t h t h e spreader tool Mea sure the separation distance w i t h the dial indicator Fig 62 as the housing is being separated 25 Remove the dial indicator tool and...

Страница 117: ...of the teeth When the teeth contact patterns are obtained by the method described above they are likely to be rather small With a n actual operating load however the contact area increases 4 If after examining the ring gear contact pat terns i t is determined that the patterns resemble those illustrated i n Fig 68 the drive pinion gear is separated too much from the centerline of the ring PATTERNS...

Страница 118: ...AR RTV Sealant or an equivalent sealant around the bolt circle on the housing and on the cover Fig 72 A l l o w t h e seal ant t o c u r e f o r a f e w minutes I f f o r a n y reason the differential h o u s i n g cover is n o t installed w i t h i n 20 minutes after a p p l y i n g HEEl JNP PRIVE SIDE CONVEX HEEL END COAST SIDE CONCAVE J9003 78 Fig 71 Teeth Contact Patterns After Depth Shim Thic...

Страница 119: ...bility of premature axle failure re sulting from water contamination of the lubricant DRAIN AND REFILL 1 Drive the vehicle with the front axle shafts en gaged i e i n 4WD until the gear lubricant i n the axle attains the normal operating temperature 2 Raise and support the vehicle 3 Remove the lubricant fill holie plug from the dif ferential housing cover 4 Remove the differential housing cover an...

Страница 120: ...ng preload torque is provided via metal shims that are located between the drive pinion gear shaft outer bearing cup and the differential housing The differential case hubs rotate in the differential housing v i a two tapered roller bearings that are press fitted on the case hubs The shims that are installed between the bearings and the hub shoulder provide three functions to adjust and maintain t...

Страница 121: ...the wheel bearings Loosen the locknut and then re tighten with 41 54 N m 30 40 ft lbs torque while rotating rotor hub Loosen the locknut 135 to 150 6 Install the lock ring and the outer locknut Tighten the locknut with 88 N m 65 ft lbs torque minimum Bend one lock ring tang over the inner locknut and one tang over the outer locknut 7 The wheel bearing adjustment should produce an end play of 0 001...

Страница 122: ... u r n the wheel bearings slowly while applying pressure to inspect them for pitting and roughness Replace a l l excessively worn and defective wheel bearings I f a wheel bearing is pitted and or rough replace both the wheel bearing and the cup 5 I f the wheel bearings are acceptable for addi tional use remove the engine oil and pack them w i t h MOPAR Multi Mileage Lubricant or an equiv alent lub...

Страница 123: ...per to adaptor hex head screw Fig 3 5 Tap the adaptor lock and spring with a punch to remove them from between the brake caliper and the adaptor Fig 4 6 Carefully separate the brake caliper from the adaptor Support the caliper out of the way D o n o t a l l o w t h e caliper t o h a n g o r be supported b y t h e b r a k e f l u i d hose The inner brake pad will remain on the adaptor 7 Remove the ...

Страница 124: ...bearing and cap i n one yoke arm bore 2 Place the yoke i n a vise Fig 9 and force the needle bearing and cap into the correct position I n stall the snap retaining ring 3 Remove the yoke from the vise and insert one end of the spider into the bearing Insert opposite bearing and cap i n the yoke arm bore by hand and align i t with the spider 4 Place the yoke i n a vise and force the cap into the yo...

Страница 125: ...the lockwashers Remove the drive flange and discard the gasket or if equipped remove the locking hub I f necessary refer to the Dualmatic locking hub removal disassembly procedure 9 Straighten the lock ring tangs and use Tool DD 1241 JD Fig 2 to remove the outer locknut and the lock ring Remove the inner locknut and the outer wheel bearing Carefully slide the rotor hub from the steering knuckle sp...

Страница 126: ...994 to install the upper socket pin i n the axle shaft tube yoke upper arm bore Tighten the socket p i n w i t h 668 to 813 N m 500 to 600 ft lbs torque In stall the seal over the socket pin 5 Position the steering knuckle over the socket pin Fill the socket lower cavity with MOPAR Multi Mileage Lubricant or an equivalent lubricant Ma neuver the lower cap into place on the steering knuckle and the...

Страница 127: ...ring adjustment should produce an end play of 0 001 to 0 010 inch 0 025 to 0 254 mm 17 Install a replacement gasket on the hub I n stall the drive flange the lockwashers and the nuts Tighten the nuts w i t h 41 to 54 N m 30 to 40 ft lbs torque 18 Use Tool C 4020 to install the snap ring 19 Install the hub cap or if equipped install the Dualmatic locking hub I f necessary refer to the Dualmatic loc...

Страница 128: ...ent lubri cant REMOVAL Removal of a drag link ball stud from the steering knuckle a r m or the pitman steering gear arm b y methods other than using Tool C 4150 could damage the seal 1 Raise and support the vehicle at a comfortable working height Remove the applicable wheel cover and wheel tire 2 Turn the front wheels i n the direction that w i l l provide the best possible access to the drag link...

Страница 129: ...ckle a r m and install the retaining nut Tighten the n u t w i t h 61 N m 45 ft lbs torque 3 Remove the supports and lower vehicle to t h e surface 4 Adjust the toe position Refer to the procedure and the Specifications chart Position the adjustment sleeve clamp bolt at the bottom of the tie rod end Tighten the clamp bolt and nut with 34 41 N T H 25 30 ft lbs torque Test the vehicle steering COMPL...

Страница 130: ...w i t h compressed air 6 Loosen the differential housing cover bolts and drain the lubricant into a container Remove the bolts and the differential housing cover A close e x a m i n a t i o n o f the differential p r i o r t o disassembly c a n often reveal valuable i n f o r m a t i o n c o n c e r n i n g the extent a n d type o f repairs o r adjustments t h a t w i l l be necessary Because t h ...

Страница 131: ...ted or damaged which would necessitate replacement Fig 22 Differential Housing Separation 15 Tighten the spreader tool turnbuckle Fig 22 and separate the differential housing only enough to remove the differential case from the housing Sepa rate t h e differential h o u s i n g a m a x i m u m dis tance o f 0 38 m m 0 015 i n w i t h t h e spreader tool Measure the separation distance w i t h the ...

Страница 132: ...hould not exceed 0 003 inch 0 076 mm W h e n i n s t a l l i n g t h e r i n g gear o n t h e differen t i a l case i t is often possible t o reduce excessive r i n g gear r u n o u t b y positioning the r i n g gear w i t h its m a x i m u m r u n o u t m a r k located 180 de grees opposite t h e flange m a x i m u m r u n o u t m a r k 26 Remove the drive pinion gear shaft axle yoke nut and wash...

Страница 133: ...RH439 Fig 25 Model 60 Axle Differential Exploded View ...

Страница 134: ...ferential case 37 Remove the differential case from the vise 38 Remove the bearings from the differential case w i t h Removal Tool DD 914 P Adapter Ring Tools DD 914 8 Plate Tools DD 914 62 Screw Extension Tool DD 914 7 Button Tool DD 914 42 and a vise Fig 27 Use care a n d ensure that the adapter rings are situated so t h a t they d o not cause force t o be ex erted o n the b e a r i n g race Fi...

Страница 135: ...ck pin hole i n the pinion gear mate shaft w i t h the hole i n the differential case Fig 25 Insert and seat the lock pin i n the case and the shaft I f replacement gears a n d t h r u s t washers w e r e installed i t i s not necessary t o measure the gear b a c k l a s h The gear meshing w i l l be correct be cause c l o s e m a c h i n i n g tolerances a r e used d u r i n g m a n u f a c t u r...

Страница 136: ... i c k ness w i l l b e d e t e r m i n e d d u r i n g t h e r i n g gear b a c k l a s h adjustment after i n s t a l l a t i o n o f the d r i v e p i n i o n gear shaft 18 Remove the dial indicator tool and the pilot stud from the differential housing 19 Remove the differential bearing caps 20 Position Spreader Tool W 129 A on the differ ential housing w i t h the tool dowel pins seated i n th...

Страница 137: ... inches 79 45 m m t o the s t a n d a r d d e p t h o f 3 125 inches 79 37 mm o r i f the d e p t h variance is 3 m 8 t h e d r i v e p i n i o n gear w o u l d require 0 003 i n c h 0 08 m m m o r e i n s h i m thickness t h a n a d e p t h variance o f 0 i e o n e complete shim p a c k plus 0 003 i n c h o r 0 08 m m b y i n c r e a s i n g the thickness o f the shims 0 003 i n c h 0 08 m m t h ...

Страница 138: ...0 0 0 6 0 0 0 7 0 0 0 8 J8902 46 DRIVE PINION GEAR DEPTH MEASUREMENT AND ADJUSTMENT WITH TOOL SET D 271 The following drive pinion gear depth i e the depth of the gear teeth mesh between the drive pin ion gear and the ring gear measurement and adjust ment procedure involves using Tool Set D 271 Fig 34 1 Insert Master Pinion Block Tool D 120 into the drive pinion gear shaft bore i n the differentia...

Страница 139: ... k thickness 7 Remove the measurement tools from the differ ential housing 8 Place the depth shims into the drive pinion gear shaft rear bearing bore i n the differential housing and then force the rear bearing cup into the bore w i t h Bearing Cup Installation Tool D l l l and Driver Handle Tool C 4171 Ensure that the cup is correctly seated 9 Use Bearing Cup Installation Tool C 4203 and Driver H...

Страница 140: ...lock tool with the dial indicator across and back and forth along the arbor tool while observing the dial indicator pointer Fig 42 Rotating Drive Pinion Gear Shaft Record the longest plunger travel distance whether inward or outward indicated by the pointer The d i a l i n d i c a t o r pointer s h o u l d indicate a n i n w a r d o r o u t w a r d m a x i m u m t r a v e l distance t h a t closel...

Страница 141: ...l housing bore w i t h Seal Installation Tool C 3719 A and Driver Handle Tool C 4171 Fig 44 22 Install the drive pinion gear shaft axle yoke Fig 44 Drive Pinion Gear Shaft Seal Installation washer and a replacement nut on the shaft Tighten the n u t w i t h 325 to 406 N m 240 to 300 ft lbs torque 23 Use a Newton meter or an inch pound torque wrench Fig 42 to rotate the drive pinion gear shaft and ...

Страница 142: ...t not excessively tight R e c o r d t h e thickness o f t h e feeler gauge blade so t h a t i t c a n be used w h e n d e t e r m i n i n g the correct d r i v e p i n i o n gear d e p t h s h i m thickness 12 Observe the depth variance etched into the end of the drive pinion gear e g 0 1 2 1 2 etc I f the etched depth variance is a minus value add i t to the thickness measured and recorded i n st...

Страница 143: ...he left side of the differ ential housing Attach Dial Indicator Tool C 3339 to the differential housing via the pilot stud w i t h the indicator plunger slightly loaded against the oppo site side of the differential housing Fig 48 Zero the dial indicator pointer Fig 48 Differential Housing Separation CAUTION Do not exceed the specified separation distance when separating the differential housing I...

Страница 144: ...ator Tool C 3339 to the differential housing via the pilot stud w i t h the indicator plunger slightly loaded against the opposite side of the differential housing Fig 48 Zero the dial indicator pointer CAUTION Do not exceed the specified separation distance when separating the differential housing If the housing is over separated it could be distorted or damaged which would necessitate replacemen...

Страница 145: ...i n each cap corresponds to the letter stamped i n the differen tial housing Fig 51 Tighten the bearing cap bolts with 95 to 122 N m 70 to 90 ft lbs torque 29 Measure the ring gear backlash a t four equally spaced locations around the perimeter of the ring gear with a dial indicator Fig 52 The r i n g gear b a c k l a s h m u s t b e w i t h i n 0 004 0 009 i n c h 0 10 0 23 m m a n d i t c a n n ...

Страница 146: ...igh on the coast side and near the toe of the tooth To correct for this type teeth contact patterns increase the thickness of the depth shim located between the drive pinion gear and the drive pinion gear shaft inner rear bearing This will cause the high contact pattern on the drive side HEEL END DRIVE SIDE CONVEX HEEL END COAST SIDE CONCAVE J9003 74 Fig 54 Desired Teeth Contact Patterns With Ligh...

Страница 147: ...n 20 minutes after a p p l y i n g the sealant the sealant m u s t be r e m o v e d a n d another b e a d o f sealant applied 4 Install the housing cover on the differential housing w i t h the attaching bolts I n s t a l l t h e axle gear r a t i o identification t a g u n d e r one o f t h e cover bolts Tighten the cover bolts with 47 N m 35 ft lbs torque PATTERNS MOVE INWARD AND UP HJEj ENP PWY...

Страница 148: ...the vehicle w i t h the front axle shafts en gaged i e i n 4WD until the gear lubricant i n the axle attains the normal operating temperature 2 Raise and support the vehicle 3 Remove the lubricant fill hole plug from the dif ferential housing cover 4 Remove the differential housing cover and allow the original lubricant to completely drain from the housing and the axle shaft tubes 5 Flush the diff...

Страница 149: ...in lbs Shock Absorber Lower Nut AD150 D150 D250 D350 AWl50 W150 W250 with Model 44 Axle W250 W350 with Model 60 Axle 23 N m 200 in lbs 75N m 55 ft lbs 75 N m 55 ft lbs Shock Absorber Upper Nut AD 150 D150 D250 D350 AWl50 W150 W250 with Model 44 Axle W250 W350 with Model 60 Axle 34 N m 25 ft lbs 7 5 N m 55 ft lbs 75 N m 55 ft lbs Spring U Bolt Nut 149 N m 110 ft lbs Steering Linkage Ball Stud Nut A...

Страница 150: ...0 20 Caster 1 2 to 1 1 2 1 1 2 to 3 1 2 2 8 5 8 5 0 05 to 0 45 0 20 Toe In At Hub Height 1 2 to 1 1 2 1 1 2 to 3 1 2 2 8 5 8 5 0 05 to 0 45 0 20 Independent Front Suspension 2WD AD150 D150 D250 D350 Load Capacity lbs 3000 AD 3300 D150 D250 4000 D350 Ex Eqt D250 Alignment 2WD Acceptable Range Preferred Camber 0 t o l 1 2 1 to 2 1 2 0 0 to 0 50 0 25 33 33 Caster 0 t o l 1 2 1 to 2 1 2 0 0 to 0 50 0 ...

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Страница 152: ...completely interchangeable w i t h a standard differential case Page NOISE DIAGNOSIS 2 REAR AXLE ALIGNMENT 8 SPECIFICATIONS S6 TIRE WHEEL BALANCE 8 Page Model 60 60M and 70 Axies 1 MODEL 60 60M AND 70 AXLES The housing for Model 60 60M and 70 rear axles consists of an iron center casting differential hous ing w i t h axle shaft tubes extending from either side The axle shaft tubes are pressed into...

Страница 153: ... axles shafts that have tapered roller bearings Page Front Wheel Bearing Noise 3 Gear Noise Drive Pinion and Ring 3 General Information 2 Knock At Low Speeds 4 Pre Disassembly Inspection 4 Tire Noise 3 A l l rear axles produce noise to a certain extent Axles can be noisy i f they are not correctly adjusted or i f they lack sufficient lubrication Usually when incorrectly adjusted replacement gears ...

Страница 154: ... Abnormal gear noise is rare and i f i t exists i t is usually caused by scoring on the ring and drive pinion gears as a result of insufficient or incorrect l u bricant i n the differential housing The differential side gears and pinion gears very seldom are damaged because they are only loaded when the rear wheels rotate a t different speeds e g when the vehicle is turning Abnormal gear noise can...

Страница 155: ...ntial case and side gear as applicable BACKLASH CLUNK A loud clunk noise upon vehicle acceleration and deceleration can be caused by excessive clearance i n volving any of the following components or i n com bination differential pinion mate gear shaft to differential case bore axle shaft splines to differential side gear splines differential side gear hub to differential case coun terbore differe...

Страница 156: ...ncrease i n intensity as the vehicle speed is increased and it is not sensitive to engine torque A vibration that occurs within a specific speed range e g 55 to 65 mph or 88 to 105 km h and does not occur above that speed range is not caused by drive shaft unbalance Defective U joints or an incorrect drive shaft angle are usually the cause of vibration that occurs within a specific speed range ...

Страница 157: ...adjust 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 case exa...

Страница 158: ...e and 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 Replace gears ...

Страница 159: ...n t h e average F T R a n d R T R distance measurement the camber w i l l be negative I f the toe position and or the amount of camber is are not acceptable i n conjunction w i t h the abnor mal tire wear a bent or deformed rear axle shaft is most likely the cause TIRE WHEEL BALANCE INDEX Page General Information 8 GENERAL INFORMATION The off vehicle static rear tire wheel balancing method is pref...

Страница 160: ...the drive pinion gear shaft is located below the centerline of the ring gear The removable stamped steel cover located at the rear of the differ ential housing provides a means for inspection and for differential service without removing the com plete rear axle from the vehicle A small stamped metal axle gear ratio identifica tion tag is attached to the housing cover via one of the cover bolts The...

Страница 161: ...ING BEARING CUP SEAL AXLE SHAFT BEARING NUT WASHER DIFFERENTIAL HOUSING SEAL WASHER AXLE SHAFT BEARING SEAL AXLE SHAFT THREADED ADJUSTER LOCK BOLT FILL HOLE PLUG WASHER STUD BOLT J9003 52 Fig 1 Rear Axle With 8 3 8 Inch Ring Gear ...

Страница 162: ...AXLE SHAFT WASHER ADJUSTER LOCK CAP WASHER AXLE SHAFT STUD COLLAPSIBLE SPACER BOLT CUP THREADED ADJUSTER LOCK SCREW FILL HOLE PLUG BOLT Fig 2 Rear Axle With 9 1 4 Inch Ring Gear J9003 53 ...

Страница 163: ... fitting is located on the right axle shaft tube For a 9 1 4 inch diameter ring gear axle the fitting is lo cated on the left axle shaft tube I f the r e a r axle is submerged i n water the l u b r i c a n t m u s t be replaced immediately t o a v o i d the possibility o f p r e m a t u r e axle failure result i n g f r o m w a t e r c o n t a m i n a t i o n o f the l u b r i c a n t Sure Grip di...

Страница 164: ...e clean 2 Insert a replacement axle shaft bearing onto the pilot of the appropriate bearing installation Tool C 4198 for an 8 3 8 inch diameter ring gear axle tube or Tool C 4826 with Handle C 4171 for a 9 1 4 inch diameter ring gear axle tube CAUTION DO NOT use the replacement axle shaft seal to position or seat the bearing in the axle shaft bore because this will damage the seal and cause lubric...

Страница 165: ...g nuts i n the correct sequence Fig 9 w i t h the specified torque for the vehicle Re fer to Group 22 Tires And Wheels Fig 9 Wheel Lug Nut Tightening Sequence 8 Remove the supports and raise or lower the hoist until the vehicle is level 9 Remove the fill hole plug and fill the differen tial housing and the axle tubes w i t h lubricant refer to the Specifications chart for the type and the quan tit...

Страница 166: ...with the installation refer ence marks aligned 6 Seat the axle yoke on the drive pinion gear shaft with Tool C 3718 and Holding Tool C 3281 7 Remove the tools and install the Belleville washer the convex side of the washer must face out ward and the drive pinion gear shaft nut 8 Retain the drive pinion gear shaft axle yoke w i t h Holding Tool C 3281 and tighten the shaft n u t w i t h 285 N m 210...

Страница 167: ...g brake cables To ensure the correct driveline balance scribe alignment marks into the drive shaft U joint yoke and the drive pinion gear shaft axle yoke before removal of the drive shaft for installation reference 6 Disconnect the drive shaft yoke from the drive pinion gear shaft axle yoke and secure the drive shaft i n an upright position to prevent damage to the front U joint 7 Remove the shock...

Страница 168: ...r i n g assembly 9 Test for differential case side play w i t h a small pry bar or pinch bar Fig 15 placed between the left side of the differential housing and the dif ferential case flange Use a prying motion to deter mine i f any side play exists Ideally there should be no side play RING GEAR J9003 55 Fig 15 Differential Side Play Test Differential case side p l a y that is the result of the be...

Страница 169: ...r m u s t be retained w i t h their respective bearing as a m a t c h e d set Fig 18 Tool C 4164 In Axle Shaft Tube BEARING CUP BEARING DIFFERENTIAL CAP CASE J9003 86 Fig 19 Differential Bearing Cap Removed 16 Use a Newton meter or an inch pound torque wrench to measure the drive pinion gear shaft bear ing preload torque Rotate the drive pinion gear shaft axle yoke nut slowly with the torque wrenc...

Страница 170: ...3 mm i n item 10 above the differential case flange runout should be measured Install the dif ferential case w i t h the original bearing cups and threaded adjusters i n housing 24 Install the differential bearing caps and the bearing cap bolts Tighten the bearing cap bolts lightly and w i t h Tool C 4164 thread both of the threaded adjusters inward until all the bearing side play has been elimina...

Страница 171: ...e axle shaft splines should be smooth and without any excessive wear The seal contact sur faces on the axle shaft should be smooth and without any nicks scratches or blemishes Polish the axle shaft w i t h No 600 crocus c l o t h to remove slight surface damage w i t h o u t reduc i n g the diameter o f the axle shaft seal contact surface 6 The differential bearings and the drive pinion gear shaft...

Страница 172: ...the ring gear between the brass jaws of a vise and use pilot studs equally spaced at three locations to align the PILOT STUD FLANGE PILOT STUDS Fig 25 Differential Case To Heated Ring Gear Alignment heated ring gear w i t h the differential case Fig 25 9 Insert replacement ring gear bolts with left hand threads through the differential case flange and thread them into the r i n g gear Alternately ...

Страница 173: ... t the sleeve tool to rotate several revolutions dur ing the tightening operation to prevent brinelling the bearing cups or the bearings The position o f the d r i v e p i n i o n gear i n rela t i o n to the r i n g gear depth o f gear mesh is de t e r m i n e d b y t h e location o f t h e b e a r i n g c u p shoulders i n t h e differential h o u s i n g bores a n d b y the drive p i n i o n ge...

Страница 174: ...from the standard I f the number is negative add that value to the thickness of the depth shim se lected i n item 20 above I f the number is pos itive subtract that value from the thickness of the depth shim selected i n item 20 above I f the number is 0 no change is required Evaluate other drive pinion gear etched numbers i n a similar manner 20 Remove the tools from the differential housing 21 P...

Страница 175: ...e retaining n u t on the end of the drive pinion gear shaft 30 Retain drive pinion gear shaft axle yoke with Holding Tool C 3281 and initially tighten the drive pinion gear shaft nut enough to remove the bearing end play While initially tightening the nut rotate the drive pinion gear shaft to ensure that the bear ing rollers are correctly seated Fig 34 31 Tighten the drive pinion gear shaft n u t ...

Страница 176: ...mple i f the minimum backlash is 0 006 inch at one location the maximum can be no more than 0 009 inch at another location this variation represents the maximum permissi ble runout and i t is important to index the gears so that the same teeth are engaged during all back lash measurements i t is also important to maintain the specified threaded adjuster torque while adjusting the differ ential bea...

Страница 177: ...e that the lock teeth for 9 1 4 inch diameter ring gear axles are en gaged w i t h the adjuster threads and that the lock finger is engaged with adjuster hole for 8 3 8 inch diameter r i n g gear axles Tighten the lock screws w i t h 10 N m 90 in lbs torque DIFFERENTIAL SIDE GEAR CLEARANCE MEASUREMENT ADJUSTMENT The correct differential side gear clearance is ob tained by selection of a side gear ...

Страница 178: ...will determine the required thick ness of the replacement thrust washer F o r example i f t h e side gear clearance is 0 006 i n c h w i t h t h e axle shaft C clip l o c k installed a n d 0 015 i n c h w i t h the C clip l o c k removed the difference is 0 009 inch w h i c h is less t h a n 0 012 i n c h A d d 0 006 i n c h the clearance w i t h the C clip l o c k installed to the thrust washer t...

Страница 179: ... J9003 75 Fig 40 incorrect Teeth Contact Patterns Increase Depth Shim Thickness PATTERNS MOVE TOWARD CENTER AND DOWN HEEL END DRIVE HEEL END COAST SIDE CONVEX SIDE CONCAVE J9003 76 Fig 41 Teeth Contact Patterns After Depth Shim Thickness Is Increased 5 If after examining the contact patterns i t is de termined that the patterns resemble those illustrated in Fig 42 the drive pinion gear is too clos...

Страница 180: ...spir its or an equivalent product and dry the surfaces completely 11 Apply a 1 16 inch to 3 32 inch thick bead of MOPAR Silicone Rubber Sealant or an equivalent product along the bolt circle of the cover Fig 45 A l l o w t h e sealant t o c u r e f o r a f e w minutes I f f o r a n y reason t h e h o u s i n g cover is n o t i n stalled wdthin 20 minutes after a p p l y i n g t h e seal ant t h e ...

Страница 181: ...friction is easily over come during vehicle turns so that standard differential action allows the rear wheels to rotate at different speeds Also an extreme difference be tween t h e surface traction conditions at the rear wheels tires w i l l cause one wheel to spin similarly to the action of a standard differential Sure Grip differentials are similar to standard dif ferentials except for the incl...

Страница 182: ...cing the differential WARNING WHEN SERVICING VEHICLES WITH AN AXLE EQUIPPED WITH A SURE GRIP DIFFEREN TIAL DO NOT USE THE ENGINE TO ROTATE THE AXLE AND WHEELS UNLESS BOTH REAR WHEELS ARE RAISED FROM THE SURFACE AND THE VEHI CLE SUPPORTED A SURE GRIP DIFFERENTIAL EQUIPPED AXLE CAN EXERT ENOUGH DRIVING FORCE IF ONE WHEEL IS IN CONTACT WITH THE SURFACE TO CAUSE THE VEHICLE TO MOVE 1 W i t h the rear ...

Страница 183: ...defined by MIL L 2105 B and by A P I G L 5 quality specifica tions should be used for rear axles with a standard or a Sure Grip differential MOPAR Hypoid Gear Lubricant conforms to both of these specifications and is highly recommended for use w i t h Ram Truck and Ramcharger vehicles I n addition 4 ounces of MOPAR Hypoid Gear Lubricant Additive a friction modifier or an equivalent product must be...

Страница 184: ...s for inspection and for differential service without removing the complete rear axle from the vehicle A small stamped metal axle gear ratio identifica tion tag is attached to the housing cover via one of the cover bolts This tag also identifies the number of ring gear and drive pinion gear teeth The drive pinion gear shaft rotates within two ta pered roller bearings Figs 1 and 2 The drive pin ion...

Страница 185: ...ngs that are press fitted on the case hubs Figs 1 and 2 The shims that are installed between the bearings and the hub shoulder Figs 1 and 2 have three func tions to adjust and maintain the backlash between the ring gear and the drive pinion gear to establish a means for obtaining and then retain ing the differential bearing preload torque and to eliminate the differential side play AXLE SHAFT REMO...

Страница 186: ... surfaces are clean 2 I f the differential housing cover was removed apply a bead of MOPAR Silicone Rubber Sealant or an equivalent sealant around the cover bolt cir cle Install the differential housing cover Tighten the cover bolts with 47 N m 35 ft lbs torque I n s t a l l the axle gear r a t i o identification t a g u n d e r o n e o f the cover bolts 3 W i t h the vehicle body supported at the...

Страница 187: ...ssive by attempting to insert a 0 003 inch 0 076 mm thick feeler gauge blade between them Normally a 0 003 inch 0 076 mm thick feeler gauge blade should be too thick to be inserted between a bearing cap and cup I f the clearance i s more t h a n 0 003 i n c h 0 076 m m t h e cause c o u l d b e t h a t t h e applicable b e a r i n g c u p rotated i n t h e differential housing s e a t a n d caused...

Страница 188: ... h o u t r e m o v i n g the R W A L b r a k e exci t o r r i n g 15 The excitor ringer can be removed with a soft faced hammer Fig 6 Discard after removal 16 Install the differential case with the original bearing cups i n the differential housing 17 Remove the holddown clamps and the spreader tool from the differential housing Fig 4 Fig 6 Excitor Ring Removal 18 Install the differential bearing ...

Страница 189: ... Fig 8 For Model 70 axles mark the differential case halves Fig 9 for assembly reference remove the studs retaining the differential case halves together and separate the differential case 30 Remove the differential pinion gear mate shaft Fig 8 Pinion Gear Mate Shaft Lock Pin Removal Model 60 60M Axles from the differential case bores remove the differen tial pinion gears and remove the thrust was...

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Страница 191: ... the shoulders of the bearing cup bores incurred during removal of the cups should be removed with a hand stone 4 Examine the differential pinion gear mate shaft pinion gears side gears and thrust washers Figs 11 and 12 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 onl...

Страница 192: ...gear mate shaft w i t h the hole i n the differential case Fig 8 Insert and seat the lock pin i n the case and the shaft For Model 70 ax les align the reference marks Fig 9 install the studs and tighten them evenly w i t h 91 N m 67 ft lbs I f replacement gears a n d t h r u s t washers w e r e installed i t is not necessary t o measure the gear b a c k l a s h T h e gear meshing w i l l be correc...

Страница 193: ...ferential case i n the housing Separate the differential housing a m a x i m u m distance o f 0 38 m m 0 015 in with the spreader tool Mea sure the separation distance with the dial indicator Fig 17 as the housing is being separated 11 Remove the dial indicator tool and t h e pilot stud Fig 17 when the differential housing has been separated sufficiently to install the differential case in the hou...

Страница 194: ...ig 17 when the differential housing has been separated sufficiently to remove the differential case from the housing 24 Remove the differential case from the differen tial housing 25 Remove the holddown clamps and the spreader tool from the differential housing Fig 17 DRIVE PINION GEAR DEPTH INFORMATION Drive pinion gear shafts and ring gears are sup plied as matched sets only The identifying num ...

Страница 195: ... must be determined before install ing the differential case i n the housing I f a replacement gear set is being installed note the depth variance etched into both the original and the replacement drive pinion gear and alter the thickness of the original depth shims to compensate for the difference i n the depth variances Refer to the Drive Pinion Gear Depth Variance chart F o r example i f t h e ...

Страница 196: ...or Tool D 106 5 on the lowest step of the pinion height block tool Fig 25 Ensure that the gauge Fig 24 Pinion Height Block Tool Against Arbor Tool block tool is resting firmly on the lowest step of pin ion height block tool and zero the dial indicator pointer Fig 25 Drive Pinion Gear Depth Measurement 5 W i t h the dial indicator pointer zeroed move the gauge block tool toward the arbor tool until...

Страница 197: ...oke Fig 28 Do not install the bearing preload torque shims or the drive pinion gear shaft seal at this time 13 Seat the shaft bearings by tightening the axle yoke nut until i t requires 1 N m 10 in lbs torque to rotate the drive pinion gear shaft Fig 29 Use a Newton meter or an inch pound torque wrench to measure the torque 14 Measure the drive pinion gear depth of mesh with the ring gear Place th...

Страница 198: ...ve pinion gear face would be in creased i e it would increase the dial indicator plunger outward travel distance T h e shaft bearing preload torque shim thickness does not affect the depth of mesh adjustment The arrow on the ring gear indicates the method of increasing or decreasing shim thickness at the applicable side of the differential case to i n crease or decrease the ring gear b a c k l a s...

Страница 199: ...nion gear shaft front and rear bearings with MOPAR Hypoid Gear Lubricant or an equivalent product 6 Tighten the nut tool while retaining the com pression sleeve tool w i t h Tool C 3281 and force the drive pinion gear shaft bearing cups into the differ ential housing bearing cup bores A l l o w the com pression tool to rotate several revolutions d u r i n g the t i g h t e n i n g process to p e r...

Страница 200: ...tions to seat the bearing rollers 21 Use a Newton meter or an inch pound torque wrench to rotate the drive pinion gear shaft and measure the bearing preload torque Fig 34 Ro tate the shaft several complete revolutions before re cording the torque The Correct bearing preload torque is 1 to 3 N m 10 to 20 in lbs torque Fig 34 Rotating Drive Pinion Gear Shaft I f the drive p i n i o n gear shaft b e ...

Страница 201: ...nd the left side of the differential case Pry the dif ferential case ring gear as far as possible toward the right side of the differential housing and away from Fig 36 Ring Gear Backlash Measurement the drive pinion gear Fig 36 Observe the dial i n dicator plunger travel distance indicated by the pointer 8 Repeat the measurement several times until the indicated plunger travel distance is consist...

Страница 202: ...the cups on the bearings 22 Position Spreader Tool D 167 on the differen tial housing with the tool dowel pins seated i n the locating holes Fig 35 Install the holddown clamps and tighten the tool turnbuckle finger tight 23 Install a pilot stud at the left side of the dif ferential housing Attach Dial Indicator Tool C 3339 to the differential housing via the pilot stud w i t h the indicator plunge...

Страница 203: ...e tubes w i t h the specified quantity of MOPAR Hypoid Gear Lubricant or an equivalent product Refer to Rear Axle Specifica tions Install the fill hole plug and tighten w i t h 34 N m 25 ft lbs torque 7 Lower the vehicle and test the brakes and the axle for proper operation TRAC LOK DIFFERENTIAL SERVICE GENERAL INFORMATION Model 60 60M and 70 rear axles equipped w i t h a T r a c L o k differentia...

Страница 204: ...E 11 WASHER 12 PINION NUT 13 BEARING CUP 14 DIFFERENTIAL BEARING 15 BACKLASH PRELOAD SHIM 16 RING GEAR 17 DIFFERENTIAL CASE 18 RING GEAR BOLTS 19 CLUTCH PACKS 20 CLUTCH PACK RETAINERS 21 PINION THRUST WASHER 22 DIFFERENTIAL PINIONS 23 PINION SHAFT SNAP RINGS 24 DIFFERENTIAL SIDE GEARS 25 PINION SHAFT 26 PINION SHAFT LOCK PIN J8903 41 Fig 40 Trac Lok Differential Exploded View ...

Страница 205: ... lubricant at normal operat ing temperature raise and support the vehicle rear wheels free to rotate 2 Remove the fill hole plug from the differential housing cover and remove as much of the lubricant as possible w i t h a suction pump 3 F i l l the differential housing with MOPAR H y poid Gear Lubricant or an equivalent product I n stall the fill hole plug i n the cover and tighten i t w i t h 34...

Страница 206: ...nd 70 rear axles w i t h standard or Trac Lok differentials M O PAR Hypoid Gear Lubricant conforms to both of these specifications and is highly recommended for use with Ram Truck and Ramcharger vehicles I n ad dition 4 ounces of MOPAR Hypoid Gear Lubricant Additive or a n equivalent friction modifier product can be included with a re fill for T r a c L o k differen tials CAUTION If the rear axle ...

Страница 207: ...Plate Retainer Nut 8 3 8 Inch Axle 9 1 4 Inch Axle Model 60 60M 70 Axle 44 N m 33 ft lbs 47 N m 35 ft lbs 115 N m 85 ft lbs 41 47 N m 30 35 ft lbs 88 142 N m 65 105 ft lbs Drive Shaft U Joint Clamp Screw 21 N m 185 in lbs 19 23 N m 170 200 in lbs Spring U Bolt Nut 8 3 8 Inch Axle 9 1 4 Inch Axle Model 60 60M 70 Axle 61 N m 45 ft lbs 88 N m 65 ft lbs Min 244 N m 180 ft lbs 203 285 N m 150 210 ft lb...

Страница 208: ... 9 75 10 5 9 75 Number of Teeth Ring Gear 45 41 39 41 Drive Pinion Gear 14 10 8 10 Ratio to 1 3 21 4 1 4 88 4 10 Number of Teeth Ring Gear 39 45 39 41 Drive Pinion Gear 11 14 11 9 Ratio to 1 3 55 3 21 3 55 4 56 1 Number of Teeth Ring Gear 47 39 39 41 Drive Pinion Gear 16 11 10 10 Ratio to 1 2 94 3 55 3 90 4 10 1 Lubricant Capacity Pints 4 4 4 4 6 7 6 Liters 2 1 1 9 1 9 2 8 3 3 3 3 1 Not available ...

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Страница 210: ...amber and is located i n the same side of the instrument cluster as the red indi cator light The anti lock light alerts the driver i f an anti lock system fault occurs Page PARKING BRAKES 5 2 POWER BRAKE BOOSTER BRAKE PEDAL 20 REAR WHEEL ANTI LOCK BRAKES RWAL 53 RWAL SERVICE DIAGNOSIS 57 SERVICE ADJUSTMENTS 6 SERVICE DIAGNOSIS 2 Page Brake Fluid Lubricants Cleaning Solvents 1 Brake Safety Precauti...

Страница 211: ...king brake action wheel and tire condition checking for obvious leaks or component damage and testing brake pedal response A road test will confirm or deny the exist ence of a problem The final diagnosis procedure i n volves road test analysis and a visual inspection of brake components PRELIMINARY BRAKE CHECK 1 Check condition of tires and wheels Damaged wheels and worn damaged or underinflated t...

Страница 212: ... pedal effort may be due to lining that is water soaked contaminated glazed or badly worn The power booster or check valve could also be faulty Test the booster and valve as de scribed i n this section BRAKE DRAG Brake drag occurs when the lining is i n constant contact with the rotor or drum Drag can occur at one wheel all wheels fronts only or rears only I t is a product of incomplete brakeshoe ...

Страница 213: ...etal contact occurs I f the condition is allowed to continue rotors can become so scored that replacement is nec essary Thump Clunk Thumping or clunk noises during braking are fre quently n o t caused by brake components I n many cases such noises are caused by loose or damaged steering suspension or engine components How ever calipers that bind on the slide pins can gener ate a thump or clunk noi...

Страница 214: ...ly 15 20 inches 50 67 kPa vacuum at large end of check valve Fig 1 5 Vacuum should hold steady I f gauge on pump indicates any vacuum loss valve is faulty and must be replaced BOOSTER CHECK Fig 1 Vacuum Check Valve And Seal Typical Fig 2 Hand Operated Vacuum Pump Typical POWER BOOSTER VACUUM TEST 1 Connect a vacuum gauge to the booster check valve w i t h a short length of hose and a T fitting Fig...

Страница 215: ...eteriorate If fluid contamination is suspected drain off a sam ple from the master cylinder A suction gun can or similar device can be used for this purpose Empty the drained fluid into a glass container Contaminants in the fluid will cause the fluid to sep arate into distinct layers I f contamination has oc curred the system rubber seals hoses and cups must be replaced and the system thoroughly f...

Страница 216: ...forward stop followed by one reverse stop Repeat procedure 8 10 times to actuate adjuster mechanism and equalize adjustment Bring vehicle to complete standstill at each stop Incomplete rolling stops w i l l not activate the automatic adjusters Fig 3 Rear Brake Adjustment With Tool C 3784 TESTING DRUM BRAKE ADJUSTER OPERATION Place the vehicle on a hoist with a helper i n the driver seat to apply t...

Страница 217: ...n tainer partially filled w i t h brake fluid Be sure the end of the bleed hose is fully submerged i n fluid oth erwise air w i l l be drawn back into the system 7 Perform bleeding operations as follows a I f m a n u a l bleeding have the helper press the brake pedal to the floorpan Tighten the bleed screw at this point and and have the helper release the pedal Open the bleed screw and have the he...

Страница 218: ...toward pedal blade until switch plunger is fully depressed against spacer gauge without moving the pedal 5 Retighten the switch bracket screw to 9 N m 82 in lbs 6 Remove spacer Be sure that stop lamp switch does not prevent full pedal return Incomplete pedal return can cause brake drag and premature lining and rotor wear WITH SPEED CONTROL 1 Push switch through clip i n mounting bracket until swit...

Страница 219: ... a front rear brake malfunction The reservoir compartments are de signed to retain the necessary quantity of fluid needed to operate the functioning circuit Care must be excercised when removing installing the master cylinder connecting lines The threads i n the fluid ports can be damaged i f care is not prac ticed Start all brake line fittings by hand to avoid cross threading The a l u m i n u m ...

Страница 220: ...before removal 5 Remove the reservoir by firmly rocking i t from side to side Fig 4 Continue rocking until the res ervoir is free of the grommets Fig 4 Removing Installing Cylinder Reservoir 6 Remove and discard the grommets that secure the reservoir i n the cylinder body 7 Install new reservoir grommets i n the cylinder body 8 Lubricate the new reservoir grommets with clean brake fluid CAUTION Th...

Страница 221: ...etal tools of any kind to help ease t h e piston into place Sharp edge tools w i l l scratch the bore and cut the piston 3 I f the cylinder is equipped w i t h a stop screw for the secondary piston press the piston to the bottom of the bore and install the screw 4 Install the primary piston i n the bore 5 Press the pistons inward w i t h a wood dowel and install the piston snap ring Be sure the sn...

Страница 222: ...rakes are applied and retract when the brakes are released I f the valve is faulty replace the entire combination valve as an as sembly TESTING PRESSURE DIFFERENTIAL SWITCH 1 Have a helper sit i n the drivers seat to observe the brake warning light and apply the brake pedal 2 Raise the vehicle on a hoist 3 Connect a bleed hose to one of the rear wheel cylinders and immerse the hose end i n a conta...

Страница 223: ... i l l eventually P R E F E R R E D T O R Q U E 15 Nm 145 in lbs 11 Nm 100 ff lbs g 19 Nm 170 in lbs MASTER CYLINDER rust through causing leaks I n any case corroded or damaged brake lines should be replaced BRAKE LINE AND HOSE REPLACEMENT Factory replacement brake lines and hoses are rec ommended to ensure quality correct length and su perior fatigue life Care should be taken to make sure that br...

Страница 224: ......

Страница 225: ...en Fig 10 Rear Brake Lines And RWAL Components ...

Страница 226: ... SHIELD BRAKE HOSE AND RWAL SENSOR WIRING LET TORQUE LET POUNDS NEWTON METRES 145 IN 16 35 FT 47 X X 170 IN 19 X X 100 IN 11 X X 125 IN 14 BRAKE VALVE TUBE TO RIGHT FRONT BRAKE HOSE VIEW IN DIRECTION OF ARROW A GASKET 8905 54 CO CJ1 Fig 11 Brake Lines Two Wheel Drive Models ...

Страница 227: ...CLIP BRACKET AND SHIELD BRAKE VALVE TUBE v CUP TO FRONT BRAKE HOSE BRAKE HOSE AND RWAL SENSOR WIRING 60 FRONT AXLE LEFT FRONT BRAKE HOSE RIGHT BRAKE TUBE BRAKE HOSE BRACKET SCREW TUBE ASSEMBLY TO BRAKE VALVE 44 8FD FRONT AXLE SCREW VIEW IN DIRECTION OF ARROW A VIEW IN DIRECTION OF ARROW C BRAKE VALVE TUBE TO FRONT BRAKE HOSE V A L V E VIEW IN DIRECTION OF ARROW B ASSEMBLY Fig 12 Brake Lines Four W...

Страница 228: ...damaged tube w i t h tool C 3478 A or a n 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 i n flaring tool Center tube i n 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 i n gauge that ...

Страница 229: ...oster outlet connected to the engine intake manifold Power assist is gener ated utilizing a combination of vacuum and atmo spheric pressure to boost brake assist RESERVOIR The power brake booster is not a repairable component T h e booster must be replaced a s a n assembly i f diagnosis indicates a malfunction has occurred A suspended type brake pedal is used for all appli cations The pedal is att...

Страница 230: ... t h a n e w retaining clip 5 Tighten the booster locknuts to 25 N m 220 i n lbs torque 6 Install master cylinder on booster Then install and tighten cylinder mounting nuts to 19 23 N m 170 200 in lbs torque 7 Connect vacuum hose to booster check valve BRAKE PEDAL REMOVAL INSTALLATION 1 Disconnect booster push rod from pedal 2 Remove screw attaching pedal shaft to brake support 3 Slide shaft out o...

Страница 231: ...for a l l appli cations The pistons are made of a phenolic resin ma terial SPLASH SHIELD RK71 Fig 1 Chrysler Disc Brake Caliper Mounting Rear View Page Disc Brake Inspection 24 General Service Information 22 Rotor Inspection And Service 29 Rotor Installation 31 Rotor Removal 29 SHIELD RK72 Fig 2 Chrysler Disc Brake Caliper Mounting Front View Ventilated cast iron disc brake rotors are used for all...

Страница 232: ...Fig 3 Disc Brake Components ...

Страница 233: ...oper level However when the brakeshoes are replaced and the caliper pistons bottomed i n the bores the added fluid must be compensated for to avoid overfill and overflow Removing a small amount of fluid from the front brake reservoir before hand will prevent this condition DISC BRAKE INSPECTION Inspect the disc brake components whenever the caliper and brakeshoes are removed during service operati...

Страница 234: ...p frame on back of caliper 5 Remove bolts securing caliper retainer clips to caliper Then remove clips and anti rattle springs Fig 5 Fig 5 Removing Installing Retainer Clips and Anti Rattle Springs 6 Remove caliper by tilting i t rearward and lift ing up and off rotor Fig 6 BRAKES 5 25 Fig 6 Caliper Removal Installation 7 Remove outboard brakeshoe from caliper Fig 7 Use pry tool to remove shoe fro...

Страница 235: ... damaged i n any way i t w i l l be neces sary to overhaul the caliper Remove the O ring from the caliper adapter and clean the slide surfaces of the adapter and the ma chined ways on the caliper w i t h a wire brush and sandpaper BRAKESHOE INSTALLATION 1 Install inboard brakeshoe i n adapter Fig 8 2 I f new brakeshoes are being installed remove protective paper from noise suppresion gasket on out...

Страница 236: ...shoes and obtain firm pedal CALIPER REMOVAL 1 Raise vehicle and remove front wheels 2 Remove caliper retainer clips and anti rattle springs 3 Remove brakeshoes from caliper and adapter 4 Support caliper on box stool or similar device Place shop towels under caliper to absorb spilled brake fluid Then insert small wood block between caliper piston and caliper frame 5 Slowly press brake pedal to push...

Страница 237: ...n t from such materials can adhere to the cali per and piston Inspect the caliper piston The piston is made from a phenolic resin plastic material and should be smooth and clean Replace the piston i f cracked or scored Do not attempt to restore a scored piston by sanding or polishing The piston must be replaced i f damaged Inspect the caliper piston bore The bore can be lightly polished w i t h ho...

Страница 238: ...en fitting bolt to 47 N m 35 ft lbs torque B e sure hose is clear of chassis a n d suspension components a n d use n e w seal washers to secure hose fitting to caliper D o not reuse old washers 9 Fill master cylinder with Mopar brake fluid or equivalent meeting SAE and DOT standards J1703 and DOT 3 10 Bleed brakes Refer to procedure i n Service And Adjustments section 11 Install wheels and lower v...

Страница 239: ...Incorrect adjust ment c a n create a condition similar to excessive lateral runout M a x i m u m allowable rotor runout for a l l models is 102 m m 004 inch Fig 20 Checking Rotor Runout And Thickness Variation ROTOR THICKNESS VARIATION Variations i n rotor thickness w i l l cause pedal pul sation noise and shudder Measure rotor thickness at 6 to 12 points around the rotor face Fig 20 Position the ...

Страница 240: ... 240 300 in lbs while turning rotor 5 Recheck rotor runout as described previously 6 Loosen wheel bearing adjusting nut completely Then retighten nut finger tight Wheel bearing end play should be 0001 to 003 inch 7 Install nut lock on bearing adjusting nut Align lock slots with cotter pin hole and secure nut and lock w i t h new cotter pin 8 Clean grease cap Then coat interior of cap with wheel be...

Страница 241: ...aliper The linings are riveted to the shoes and the inner and outer shoes are not interchangeable Fig 1 Bendix Disc Brake Caliper Fig 2 Caliper Mounting Adapter Attachment DISC BRAKE OPERATION The significant feature of single piston caliper op eration is that the caliper is free to move laterally on the adapter slide surfaces Fig 3 A t brake application fluid pressure is exerted equally against t...

Страница 242: ...Fig 3 Bendix Disc Brake Caliper Operation ...

Страница 243: ...ses Front wheel bearing adjust ment and condition can also be checked at this time The bearings should be repacked and adjusted i f nec essary Brakeshoes With the caliper and brakeshoes on the vehicle check running clearance between the rotor and brakeshoes The shoe lining should either be i n very light contact w i t h the rotor or a maximum of 127 m m 005 inch running clearance I f clearance ex ...

Страница 244: ...unch or drift to tap the key out of the caliper Fig 7 Fig 6 Removing Installing Support Key Retaining Screw 7 Lift the caliper out of the adapter 8 Remove the outboard shoe from the caliper Fig 8 BRASS ROD Fig 7 Removing Caliper Support Key And Spring 9 Secure the caliper to a convenient chassis com ponent with wire Do not allow the brake hose to support caliper weight 10 Remove the inboard shoe a...

Страница 245: ...he anti rattle spring on the inboard brakeshoe and install the shoe i n the adapter Be sure the spring remains i n place and is positioned as shown Fig 9 The loop portion of the spring should face away from the rotor 2 Install the outboard shoe i n the caliper Free play should not exist between the shoe retaining flanges and machined surfaces on the caliper I f the shoe shoe cannot be pressed into...

Страница 246: ...ove dust boot from caliper 2 Remove caliper piston seal from caliper bore w i t h small wood or plastic tool D o n o t use m e t a l tools t o remove t h e seal M e t a l tools c a n scratch score t h e p i s t o n bore surface 3 Remove the bleeder screw from the caliper CLEANING AND INSPECTION Clean the slide surfaces of the caliper with a wire brush and emery cloth Then clean the caliper and pis...

Страница 247: ...han groove diameter at first b u t w i l l snap into place when properly positioned 5 Plug fluid inlet port and install bleeder screw 6 Coat caliper piston with brake fluid 7 Start piston into dust boot and bore Fig 15 Spread dust boot w i t h fingers Then work piston through boot and into bore A i r trapped below piston w i l l force boot around i t and into groove as piston is installed 8 Remove...

Страница 248: ... condi tion was experienced Measure runout w i t h a dial i n dicator Measure thickness w i t h a micrometer at a m i n i m u m of four points around the braking surfaces The rotor measurement points are shown i n Figure 16 CHECKING ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake shoe contact surface Replace the rotor i f i t is worn below m i n i m u m thickness or i f ...

Страница 249: ...owever when a rotor is scored or worn machining with cutting tools will be required CAUTION Do not refinish a rotor if machining would cause the rotor to fall below minimum allow able thickness ROTOR REMOVAL 1 Block brake pedal i n released up position 2 Raise vehicle to a comfortable working height and support w i t h jack stands 3 Remove wheel and tire assembly 4 Remove support key retaining scr...

Страница 250: ...heel bearings as follows a Back off adjusting nut b Retighten adjusting n u t to 54 N m 40 f t lbs while rotating hub and rotor c Back off adjusting nut approximately 135 to 150 degrees d Install lock ring and locknut 6 Tighten lock nut to a minimum of 88 N m 65 ft lbs Bearing end play should be 025 25 m m 001 010 inch 7 Bend one tang of lock ring over adjusting n u t and another tang over locknut...

Страница 251: ...F ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM EXTREME CARE SHOULD BE EXERCISED WHILE SERVICING BRAKE ASSEMBLIES OR COMPONENTS DO N O T CLEAN BRAKE ASSEMBLIES OR COMPONENTS WITH COMPRESSED AIR OR BY DRY BRUSHING USE A VACUUM CLEANER SPECIFICALLY RECOM MENDED FOR USE WITH ASBESTOS FIBERS IF A SUITABLE VACUUM CLEANER IS NOT AVAILABLE CLEANING SHOULD BE DONE WET USING A WA TER DAMPENED CLOTH DO NOT ...

Страница 252: ...12 Remove parking brake lever from secondary shoe 13 Remove primary shoe from support plate 14 Disengage parking brake lever from parking brake cable CLEANING AND INSPECTION Clean the brake components including the support plate and wheel cylinder exterior with a water dampened cloth or w i t h Mopar brake cleaner Do not use any other cleaning agents Replace the brakeshoes i f worn to within 76 m ...

Страница 253: ...nstalled on the correct brake unit The adjuster screws are marked L left and R right for identification Fig 8 10 Install adjuster lever and spring and connect adjuster cable to lever 11 Install secondary shoe retainers and spring 12 Install shoe spring Connect spring to second ary shoe first Then to primary shoe Fig 6 Brakeshoe Installation WASHER SOCKET STAMPED LETTER BUTTON NUT RH227A Fig 7 Adju...

Страница 254: ...ssary 4 Compress parking brake cable retainer tabs with a hose clamp Fig 9 Then push retainer and cable through and out of support plate Fig 9 Removing Parking Brake Cable From Support Plate 5 Disconnect brake line a t wheel cylinder 6 Remove wheel cylinder and brakeshoes from support plate 7 Remove bolts attaching support plate to axle and remove support plate BRAKE SUPPORT PLATE INSTALLATION 1 I...

Страница 255: ...LINDER 1 Lubricate wheel cylinder bore pistons piston cups and spring and expander w i t h clean brake fluid 2 Install first piston i n cylinder bore Then install cup i n bore and against piston B e sure l i p o f pis t o n c u p i s f a c i n g i n w a r d t o w a r d s p r i n g a n d ex pander a n d flat side i s against piston 3 Install spring and expanders followed by re maining piston cup an...

Страница 256: ...SHOE SPRING 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 ADJUSTER LEVER RETURN SPRING PARKING BRAKE LEVER AUTOMATIC ADJUSTER LEVER RN326A Fig 1 12 Inch Drum Brake Assembly ...

Страница 257: ... AND DISPOSITION OF DUST OR DIRT WHICH MAY CONTAIN ASBESTOS FIBERS BRAKE DRUM REMOVAL 1 Raise and support vehicle 2 Remove wheel and tire assembly 3 Remove axle shaft nuts washers and cones Strike axle shaft i n center with copper or dead blow hammer to loosen retaining cones 4 Remove axle shaft 5 Remove outer hub nut 6 Straighten and remove lock washer 7 Remove inner nut and bearing 8 Remove drum...

Страница 258: ... assembly Replace the assembly i f the star wheel threads on the n u t are damaged or the screw are severely rusted or corroded Discard the brake springs and retainer components i f worn distorted or collapsed Also replace the springs i f a brake drag condition had occurred Over heating w i l l distort and weaken the springs Inspect the brakeshoe contact pads on the support plate Fig 6 Remove ligh...

Страница 259: ...rfaced on a drum lathe when necessary Initial machining cuts should be limited to 12 20 m m 005 008 in at a time as heavier feed rates can produce taper and surface variation Final finish cuts of 025 to 38 m m 001 to 0015 in are recommended and w i l l generally pro vide the best surface finish Be sure the drum is securely mounted i n the lathe before machining operations A damper strap should alw...

Страница 260: ...reusable The original dust boots may be reused but only i f they are i n good condition ASSEMBLING WHEEL CYLINDER 1 Lubricate wheel cylinder bore pistons piston cups and spring and expander with clean brake fluid 2 Install first piston i n cylinder bore Then install cup i n bore and against piston B e sure l i p of p i s r ton cup is facing inward toward spring and ex pander and flat side is again...

Страница 261: ...nect the cable from the parking brake le ver on the secondary brakeshoe 8 Compress the cable retainer tabs and remove the cable from the support plate 9 Remove the cable from the guides and retaining clips Page Parking Brake Cable Adjustment 52 Rear Cable Replacement 52 10 Disconnect the cable from the equalizer and ratio lever 11 Remove the cable REAR CABLE INSTALLATION 1 Insert the cable through...

Страница 262: ...BS 15 8 N m 30 FT LBS 40 6 N m 17 IN LBS 1 9 N m 1 95 IN LBS 10 7 N mJ 35 FT LBS 47 4 N m NUT ASSEMBLY DASH PANEL SEAL ASSEMBLY FRONT CABLE ANCHOR BRACKET FRONT CABLE ri ASSEMBLY FRONT CABLE ASSEMBLY pm om wm W 3 5 0 LEFT REAR CABLE ASSEMBLY PAGE 1 OF 2 RR05E103 Fig 1 Parking Brake Cable Routing ...

Страница 263: ...5 54 BRAKES CABLE INTERMEDIATE BRACKET BOLT VIEW E Fig 2 Parking Brake Cable Attachment ...

Страница 264: ...lly operated system designed to retard rear wheel lockup during periods of high wheel slip and deceleration Retarding lockup is accomplished by modulating fluid pressure to the rear brsjke units Rear brake fluid apply pressure is modulated ac cording to wheel speed degree of wheel slip and rate of deceleration A sensor located in the rear axle housing converts differential case rotating speed into...

Страница 265: ...g 2 Anti Lock Electronic Control Module RWAL HYDRAULIC VALVE The hydraulic valve is a pressure controlling device and is operated by the electronic module The valve controls fluid apply pressure to the rear brake units during anti lock mode braking Fig 3 The valve is mounted on the driver side frame rail at the front of the vehicle The valve contains an accumulator an isolation valve and a dump va...

Страница 266: ...lve directly to the rear wheel cylinders Fig 5 Start Of Anti Lock Mode Braking When high pedal effort braking occurs the de crease i n exiter wheel rotating speed is noted and converted into a n electronic signal by the sensor This signal is transmitted to and processed by the control module The module determines that accept DUMP VALVE CLOSED SPRING ISOLATION VALVE OPEN FROM MASTER CYLINDER TO REA...

Страница 267: ...rced out and back into the hydraulic system ACCUMULATOR OPEN mini r v i i f f t i l DUMP VALVE ISOLATION VALVE CLOSED FROM MASTER CYLINDER Isolation Dump Valve Cycle Times Activation opening closing of the isolation and dump valves is continous during anti lock operation The valves cycle rapidly i n response to speed sensor inputs and control module signal commands Cycle times are measured in mill...

Страница 268: ... l be necessary Page System Fault Codes 59 SYSTEM FAULT CODES The microprocessor i n the electronic control module has a self test feature This feature is activated whenever the ignition switch is i n the On and Run positions I f a system fault is detected the control module w i l l illuminate the anti lock indicator lamp and store the fault code i n the microprocessor memory I f a fault code is g...

Страница 269: ...ing shorted to ground 9 Speed sensor wiring resistance usually high reading 10 Sensor wiring resistance usually low reading 11 Brake switch always on RWAL light comes on when 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 J90Q5 101 Fig 8 RWAL System Fault Codes Refer t...

Страница 270: ...ve from frame bracket VALVE INSTALLATION 1 Start brake lines i n hydraulic valve 2 Position valve on frame bracket 3 Install and tighten valve attaching nuts to 22 34 N m 16 25 ft lbs torque 4 Tighten valve brake lines 5 Bleed the hydraulic valve and brakes Refer to procedure i n Service Adjustments section 6 Lower vehicle CHECKING SPEED SENSOR AIR GAP 1 Remove sensor from differential 2 Measure a...

Страница 271: ...nsor wiring and remove sensor SENSOR INSTALLATION 1 Connect wires to sensor Be sure seal is se curely i n place between sensor a n d w i r i n g con nector 2 Install O ring on sensor if removed 3 Insert sensor i n differential housing 4 Install sensor shield 5 Install and tighten sensor attaching bolt to 19 29 N m 170 230 in lbs 6 Lower vehicle ELECTRONIC CONTROL MODULE REPLACEMENT The R W A L con...

Страница 272: ...00 1B or Model 60 Frt Axle Size inches Make Drum Type Wheel Cyl Bore 11 x 2 5 Chrysler Composite 938 23 8 m m 12 x 2 5 Bendix Cast Iron 1 00 25 4 m m 12x3 Bendix Cast Iron 1 125 28 57 mm MASTER CYLINDER Dand W 100 150 250 Chrysler Aluminum Two Section 1 125 bore D and W 250 350 Bendix Integral Cast One Piece 1 125 bore POWER BOOSTER D and W 100 150 250 mm 9 84 in Single Diaphragm Vacuum D and W 25...

Страница 273: ...il 115 175 13 20 POWER BRAKE Power Brake Booster Mounting Nuts 220 25 35 4 200 30 23 Brake Line Tube Nuts 3 8 or 7 16 115 175 13 20 1 2 or 9 16 140 200 15 23 120 162 DISC BRAKE CHRYSLER Adapter Mounting Bolts Dl 50 D250 AD150 no 149 W150 AWl 50 W250 150 203 D250 H D D350 160 216 Retainer and Anti Rattle Spring 200 25 DISC BRAKE BENDIX Adapter Mounting Bolts W350 and W250 Extra 160 216 15 20 RWAL H...

Страница 274: ... The master cylinder is connected to the clutch pedal and the slave cylinder is connected to the clutch release fork The clutch master cylinder is mounted on the drivers side of the dash panel adja Page Clutch Linkage Fluid 1 cent to the brake master cylinder The cylinder is op erated by a suspended type clutch pedal CLUTCH LINKAGE FLUID The clutch fluid reservoir master cylinder slave cylinder an...

Страница 275: ...maged slave cylinder line or connection However clutch fluid leaks w i l l usually be noted and corrected before severe contamination occurs Page Inspection And Diagnosis Charts 5 CLUTCH MISALIGNMENT Clutch components must be i n proper alignment w i t h the crankshaft and transmission input shaft Misalignment caused by excessive runout or warpage of any clutch component w i l l cause grab chatter...

Страница 276: ...3 Repeat the measurement at least twice for accuracy 9 Subtract each reading from the one 180 degrees opposite to determine magnitude and direction of runout Refer to Figure 3 and following example Bore runout example 000 007 007 inch 002 010 012 inch 004 005 009 inch 001 001 002 inch 002 inch I n the above example the largest difference is 012 inch and is called the total indicator reading TIR Th...

Страница 277: ... to the sample readings shown i n Figure 6 I f the low read ing was m i n u s 004 inch and the highest reading was plus 009 inch total runout is actually 013 inch 5 Total allowable face runout is 010 inch I f runout exceeds this figure runout w i l l have to be corrected Refer to Correcting Clutch Housing Face Runout INDICATOR PLUNGER DIAL INDICATOR CLUTCH HOUSING FACE INDICATOR MOUNTING STUD OR R...

Страница 278: ...duce misalignment and subsequent clutch problems Tighten a l l the clutch housing bolts to proper torque before installing any struts Also be sure the alignment dowels are i n place and seated i n 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 factory quality parts to avoid comebacks INSPECTION AND DIAGNOSIS CHA...

Страница 279: ... 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 ...

Страница 280: ...and 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 d...

Страница 281: ...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 180 grit 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 hew...

Страница 282: ...orroded a Replace both cylinders as assembly and reservoir 4 No 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 enga...

Страница 283: ...to specified 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 b...

Страница 284: ...ave the disc on the shaft and check runout w i t h a dial indicator Position the indicator plunger about 1 4 inch from the outer edge of the facing Runout should not exceed 5 m m 020 inch Obtain another clutch disc i f runout exceeds specified limit 2 Lubricate the crankshaft pilot bushing w i t h Mo par High Temperature grease The grease must be a high temperature type to be effective and remain ...

Страница 285: ...to the new housing 6 Lubricate the release fork and pivot contact sur faces w i t h Mopar H i g h Temperature wheel bearing grease before installation 7 A l i g n and install the clutch housing on the transmission Tighten the housing bolts closest to the alignment dowels first and to the torque values indi cated Fig 4 8 Install the transmission to engine strut after i n stalling the clutch housing...

Страница 286: ... Remove the screws attaching the clutch fluid reservoir to the dash panel 11 I f necessary remove the reservoir mounting bracket screws and remove the bracket from the dash panel 12 Pull the clutch master cylinder rubber seal from the dash panel Fig 6 13 Rotate the clutch master cylinder 45 degrees counterclockwise to unlock i t Then remove the cyl inder from the dash panel 14 Remove the clutch cy...

Страница 287: ...T FLUID LINES O i PREFERRED TIGHTENING TORQUE 4 1 1 Nm 100 In lbs y 23 Nm 200 in lbs 5 Nm 40 in lbs O 1 D 5 Nm 45 in lbs cz HI O PEDAL SHAFT CLUTCH SLAVE CYLINDER CLUTCH HOUSING BRACKET J900643 Fig 6 Clutch Linkage And Pedal Components ...

Страница 288: ...tch pedal 5 Remove and inspect the bushings i n the clutch pedal shaft bore and on the bushing on the pedal pin Replace any bushing that is worn or damaged 6 lubricate the pedal shaft pedal shaft bore and all the bushings with Mopar multi purpose grease or with a silicone grease 7 Insert the pedal pin into the cylinder push rod Then position the clutch pedal in the support 8 Slide the pedal shaft ...

Страница 289: ......

Страница 290: ...stem is pressurized and uses a centrifugal water pump to circulate coolant throughout the system Page ENGINE BLOCK HEATERS 24 SERVICE PROCEDURES 8 SPECIFICATIONS 25 A n optional factory installed maximum duty cool ing package is available on most models This pack age w i l l provide additional cooling capacity for vehicles used under extreme conditions such as trailer towing i n high ambient tempe...

Страница 291: ...IRCUIT IS ALWAYS OPEN EXCEPT WHEN IN AAAX A C OR OFF MODES HEATER INTAKE MANIFOLD COOLANT FLOW METERED FROM REAR TO FRONT AND BELOW EXHAUST HEAT CROSSOVER SHUT OFF VALVE A C ONLY COOLANT FLOW PUMP TO CYLINDER BLOCK UP THROUGH CYUNDER HEADS TO INTAKE MANIFOLD WATER BOX TO RADIATOR TO PUMP BYPASS THERMOSTAT CLOSED HIGH FLOW THERMOSTAT OPEN LOW FLOW RR07B52 Fig 1 Cooling System Routing ...

Страница 292: ... 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 Normal during temporary operation with heavy load towing a trailer high outdoor temperatures and or on a steep grade Improper refilling procedures can result in t...

Страница 293: ...MUM HOT WEATHER HEAVY LOAD 1 Verify gauge reading Is a high temperature reading indicated 2 Gauge reading at H without signs of boiling 3 Low coolant level in radiator and coolant reserve tank 4 Coolant level in radiator is low But not low in coolant reserve tank 5 Test coolant freeze point 6 Ensure proper coolant flow MAXIMUM UP TO TOP AMBIENT High Gauge Reading Hot Weather Heavy Load 1 Compare g...

Страница 294: ...t 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 of ...

Страница 295: ...ock 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 UGHT GLOWS ALL THE T...

Страница 296: ...d 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 COOUNG SYSTEM SU...

Страница 297: ...The water pump impeller is pressed onto the rear of a shaft that rotates i n a bearing pressed into the water pump body The body has a small hole to allow seepage to escape The water pump seals are lubri cated by the antifreeze i n the coolant mixture No additional lubrication is necessary A quick test to tell whether or not the pump is working is to check i f the heater warms properly A defective...

Страница 298: ...idler pulley will be supported by the rear mounting bracket 6 Loosen air pump pivot and adjusting bolt Re move drive belt 7 Remove air pump 8 Loosen power steering pump pivot and adjust ing bolt i f equipped Remove drive belt 9 Remove power steering pump front mounting bracket i f equipped Support power steering pump w i t h mechanics wire Do not let pump hang sup ported by hoses 10 Disconnect hea...

Страница 299: ...ne warm up and overall temperature control The ther mostat is designed to provide a m i n i m u m engine op erating temperature range of from 88 to 93 C 192 to 199 F and to be fully open for maximum coolant flow during operation i n hot ambient temperatures of approximately 104 C 220 F Above 104 C 220 F coolant temperature is controlled by the radiator fan and ambient temperature A n arrow plus th...

Страница 300: ...or the vehi cle model and engine type 1 Dip the replacement gasket i n water and install on intake manifold Fig 4 2 Insert thermostat spring side down through gasket into opening i n intake manifold Center ther mostat i n manifold CAUTION Tightening the housing unevenly or with out thermostat centered in recess in thermostat housing may result in a cracked housing 3 Install housing over thermostat...

Страница 301: ... t h a 50 50 mix ture of ethylene glycol antifreeze containing Alugard 340 2 and water Remove the radiator cap only for testing or when refilling the system after service Removing the cap unnecessarily can cause loss of coolant and allow a i r to enter the system which produces corrosion COOLANT LEVEL CHECK SERVICE The cooling system is closed and designed to main tain coolant level to the top of ...

Страница 302: ... h very dirty systems with evidence of partial plugging REVERSE FLUSHING RADIATOR Disconnect the radiator hoses from the radiator i n let and outlet Attach a section of radiator hose to the radiator bottom outlet fitting and insert the flushing gun Connect a water supply hose and a i r supply hose to the flushing gun CAUTION Internal radiator pressure must not ex ceed 138 kPa 20 psi as damage to r...

Страница 303: ...nt cams can be re formed i f done carefully Attach pressure tester 7700 A or an equivalent to the radiator filler neck Fig 7 Fig 7 Pressure Testing Cooling System Operate the tester pump to apply 103 4 kPa 15 psi pressure to the system I f the hoses enlarge ex cessively or bulge while testing replace as necessary Observe the gauge pointer and determine the condi tion of the cooling system accordin...

Страница 304: ...into a clean container for reuse WARNING DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR Drain sufficient coolant to allow thermostat re moval Refer to Thermostat Replacement Disconnect the water pump drive belt Add coolant to the radiator to bring the level to within 6 3 m m 1 4 in of...

Страница 305: ...sted by removing the overflow hose from the radiator filler neck nipple and attaching the hose of pressure tester tool 7700 A to the nipple I t will be necessary to disconnect the hose from it s adapter for the filler neck Pump air into the radiator The pres sure cap upper gasket should relieve at 69 124 kPa 10 18 psi and hold pressure at a minimum of 55 kPa 8 psi WARNING THE WARNING WORDS DO NOT ...

Страница 306: ...owing procedure to determine i f coolant is flowing through the cooling system 1 Idle engine u n t i l operating temperature is reached I f the upper radiator hose is w a r m to the touch the thermostat is opening and coolant is flow ing to the radiator WARNING HOT PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING USING A RAG TO COVER THE RADIATOR PRESSURE CAP OPEN RADIATOR CAP SLOWLY TO THE FIRST ...

Страница 307: ...ling system hoses The clamp size is identified by a letter stamped on the tongue Special pliers for re moving and installing the clamps are available from most automotive jobbers Ordinary worm gear type hose clamps can be re moved w i t h a straight screwdriver or a hex socket To p r e v e n t damage t o hoses o r clamps these hose clamps should be tightened to 4 1 N m 34 in lbs t o r q u e D o n ...

Страница 308: ...s t be replaced Inspect t h e f a n as follows 1 Remove fan and viscous drive assembly from engine Refer to Removal procedure 2 Disconnect fan from viscous drive unit 3 Lay fan on a flat surface with leading edge fac ing down W i t h tip of blade touching flat surface re place fan i f clearance between opposite blade and surface is greater than 2 0mm 090 inch Rocking motion of opposite blades shou...

Страница 309: ...ss of increased engine speed once the fan has reached its maximum operating speed i t w i l l not rotate any faster When the necessary engine cooling has been accomplished causing a reduction i n the temperature of the radiator discharge air the spring coil again reacts and the fan speed is reduced to the previous disengaged speed Fan Installation 1 Install fan to viscous drive unit Tighten mount ...

Страница 310: ... SQUEAK AT a Belt too loose Adjust belt tension IDLE b Dirt and or paint H Replace belt b imbedded in belt W Non uraform belt ft Replace belt d Misaligned pulleys d Align accessory drive d pulleys W Non uniform groove or H Replace pulley eccentric pulley BELT ROLLED a Broken cord in belt ft Replace beh OVER IN GROOVE b Belt too loose or too W Adjust bete tension OR BELT JUMPS b tight W Adjust bete...

Страница 311: ... TEST POINT J9007 41 Fig 2 Alternator Air Pump A C and Power Steering 3 9L 5 2L and 5 9L Engines J9007 72 Fig 4 Alternator Air Pumps A C and Power Steering Heavy Duty Cycle 5 9L Engine ALTERNATOR AND AIR CONDITIONING BELTS The alternator has a matched two belt system Both belts are tightened to the correct tension at the same time by the adjusting screw 1 Disconnect battery negative cable from bat...

Страница 312: ...00 in lbs torque T AIR PUMP BELT 1 Disconnect battery negative cable from battery 2 Loosen a i r pump lock screw Fig 5 or 6 3 Loosen air pump pivot screw and remove or re place belt 4 Insert a 1 2 inch breaker bar into the square hole i n the adjustment bracket at the rear of the pump and adjust belt tension Refer to the Belt Ten sion Chart i n the Specifications section for tension specifications...

Страница 313: ...e power cord to a grounded 110 120 volt A C electrical 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 BE SECURED IN ITS RE TAINING CLIPS AND ROUTED AWAY FROM EX HAUST MANIFOLDS AND MOVING PARTS REMOVAL 1 Disconnect battery negative cable from battery 2 Drain coo...

Страница 314: ...el 26 15 5 14 5 Cubic Inch Displacement J9007 74 Engine Models Thermostat Calibration Water Pump Impeller Remarks 3 9L 5 2L 5 9L All 195 F 91 C 3 85 Dia 6 Blades W O A C W A C W O A C Without Air C W A C With Air Condi Conditioning tioning J9007 66 CONVERSION CHART U S Quart 13 14 15 15 1 2 16 16 1 2 17 17 1 2 18 18 1 2 12L 13L 14L 14 6L 15L 15 6L 16L 16 5L 17L 17 5L J9007 67 TIGHTENING REFERENCE ...

Страница 315: ...ON Accessory Drive Bert Tension New Belt Used Belt Alternator dual belt drive 100 140 lbs 444 622 N 60 90 lbs 266 400 N Air Pump 100 140 lbs 60 90 lbs Air Pump 444 622 N 266 400 N Power Steering Pump 100 140 lbs 444 622 N 60 90 lb 266 40DN J9007 68 ...

Страница 316: ...CATIONS 19 STARTER TEST PROCEDURES ON VEHICLE 9 DIAGNOSTIC INFORMATION INTRODUCTION TO STARTING AND CHARGING SYSTEM DIAGNOSTICS The Battery Starting and Charging Systems oper ate i n conjunction w i t h one another and therefore must be thoroughly tested as a complete system I n order for the vehicle to start and charge properly i t must have a battery that w i l l perform to specifica tions The s...

Страница 317: ...period The capability of the battery to store electrical current comes from a chemical reaction between the sulfuric acid solution electrolyte and the lead plates i n each cell of the battery As the battery discharges the plates collect the acid from the electrolyte When the charging sys tem charges the battery the acid is forced out of the plates into the electrolyte The amount of acid spe cific ...

Страница 318: ...Battery Load Test for more information B L A C K O R D A R K 0 to 75 state of charge The battery is inadequately charged and must be charged until green dot is visible 12 4 volts or greater before the battery is tested or returned to use refer to Causes of Battery Discharging for more information Y E L L O W O R B R I G H T C O L O R WARNING DO NOT ATTEMPT TO CHARGE TEST OR ASSIST BOOST BATTERY WH...

Страница 319: ...est light does light proceed to step 4 The test light w i l l indicate IOD greater than 3 amps CAUTION IOD greater than 3 amps may damage milliampmeter 3 W i t h 12 volt test light still connected not l i t see step 2 connect an ammeter milliampere scale between the positive cable clamp and the battery positive post Fig 7 disconnect test light refer to instructions provided w i t h ammeter being u...

Страница 320: ...y load test w i l l verify the actual cranking performance based on the cold crank rating of the battery WARNING IF BATTERY SHOWS SIGNS OF FREEZ ING LEAKING LOOSE POSTS OR EXCESSIVELY LOW ELECTROLYTE LEVEL DO NOT TEST ACID BURNS OR EXPLOSIVE CONDITION MAY RESULT 1 Remove both battery cables negative first Bat tery top and posts should be clean I f green dot is not visible i n indicator charge the ...

Страница 321: ...level The battery cannot be refilled or charged i t must be replaced WARNING DO NOT CHARGE A BATTERY THAT HAS EXCESSIVELY LOW ELECTROLYTE LEVEL BATTERY MAY ARC INTERNALLY AND EXPLODE WARNING EXPLOSIVE GASES FORM OVER BAT TERY DO NOT SMOKE USE FLAME OR CREATE SPARKS NEAR BATTERY WARNING DO NOT ASSIST BOOST OR CHARGE A FROZEN BATTERY CASING MAY FRACTURE WARNING POISON CAUSES SEVERE BURNS BATTERY CON...

Страница 322: ...rage will be low As acid is forced from the plates inside the battery the current amperate w i l l rise Also the specific gravity of the electrolyte w i l l rise bringing the green dot into view CHARGING COMPLETELY DISCHARGED BATTERY The following procedure should be used to recharge a completely discharged battery Unless procedure is properly followed a good battery may be needlessly replaced 1 M...

Страница 323: ...ROCEED 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 AT OR ABOVE 9...

Страница 324: ...ate of charge 4 Battery w i l l endure load test 5 Battery cable connections at the starter motor and engine block and their condition 6 W i r i n g harness connector and terminal condi tion 7 Properly grounded STARTER FEED CIRCUIT TESTS The following procedure w i l l require a suitable volt ampere tester Fig 2 and a jumper wire 1 Connect a suitable volt ampere tester Fig 2 to the battery termina...

Страница 325: ...g operation will require a voltmeter ac curate to 1 10 of a volt 1 Disconnect the distributor cap and connector 2 W i t h all wiring harness and components con nected properly perform the following a Connect positive lead of the voltmeter to the battery negative post and negative lead to the bat tery negative cable clamp Fig 5 Rotate and hold the ignition switch key i n the START position Observe ...

Страница 326: ...AUSE POSSIBLE CAUSE 1 POSSIBLE CAUSE STARTER CONTROL CIRCUIT FAULTY SEE GROUP 8W WIRING DIAGRAMS i IGNITION SWITCH MISADJUSTEDOR FAULTY i RESISTANCE TO HIGH IN STARTER FEED CIRCUIT i STARTER CONTROL CIRCUIT FAULTY SEE GROUP 8W WIRING DIAGRAMS i RESISTANCE TO HIGH IN STARTER FEED CIRCUIT i STARTER RELAY FAULTY i STARTER ASSEMBLY FAULTY 1 DRIVE CLUTCH FAULTY BROKEN TEETH ON RING GEAR STARTER IsSEMBL...

Страница 327: ...t consists of a starter so lenoid starter relay ignition switch safety neutral switch automatic transmission and all their w i r i n g and connections Testing procedures for these components are as fol lows and should be followed i n order as described CAUTION Before performing any test disconnect distributor connector to prevent engine from start ing STARTER SOLENOID TEST Connect a heavy jumper w...

Страница 328: ...8B Battery Starter Service for starter removal procedures 1 Disconnect field coil wire from field coil termi nal Fig 12 FIELD COIL TERMINAL FIELD COIL CONNECTOR SOLENOID BATTERY TERMINAL SOLENOID TERMINAL STARTER MOTOR ASSEMBLY RR8BD31 Fig 12 Field Coil Wire Terminal 2 Check for continuity between solenoid terminal and field coil terminal w i t h a continuity tester There should be continuity Fig ...

Страница 329: ...ine Controller and air cleaner 8 Connect one end of a Jumper Wire to ground and with other end probe green R3 lead wire at back of alternator Fig 1 This w i l l generate a fault code CAUTION Do not connect blue J2 lead of wiring to ground Refer to Group 8W Wiring Diagrams for more information 9 Connect an engine tachometer and connect bat tery negative cable 10 Connect a variable carbon pile rheos...

Страница 330: ...connected alternator output wire 5 Connect positive lead of a test voltmeter range 0 18 volts minimum to alternator BAT terminal 6 Connect negative lead of test voltmeter to a good ground 7 Connect a n engine tachometer and reconnect battery negative cable 8 Connect a variable carbon pile rheostat C3950 between battery terminals Be sure carbon pile is i n Fig 1 Alternator Output Wire Resistance Te...

Страница 331: ...ypical USING ON BOARD DIAGNOSTIC SYSTEM OPERATION OF ON BOARD DIAGNOSTIC SYSTEM The Engine Controller monitors critical input and output circuits of the charging system making sure they are okay Some are checked continuously and some are only checked under certain conditions If the on board diagnostic system senses that one of the critical circuits is bad during a predetermined amount of time duri...

Страница 332: ...SIS TO BATTERY GROUND CABLE LOOSE ALTERNATOR GROUND WIRE LOOSE OR CORRODED WIRING CONNECTIONS AT BULKHEAD DISCONNECT CHECK FOR APPROXIMATELY 12 VOLTS AT FIELD INPUT BRUSH TERMINAL WITH IGNITION SWITCH ON CHARGING RESISTANCE TOO HIGH CORRODED OR SHORTED CABLES OR HIGH RESISTANCE ACROSS FUSIBLE LINK RESISTANCE O K TEST ALTERNATOR CURRENT OUTPUT CURRENT OUTPUT O K REFER TO USING ON BOARD DIAGNOSTIC S...

Страница 333: ...codes are 41 and 47 A n y number of codes can be displayed maximum of 8 faults can be stored as long as they are i n memory The lamp w i l l flash until a l l of them including 55 are displayed 55 End of test CHARGING SYSTEM FAULT CODES See Alternator Fault Code Chart for fault codes which apply to the charging system Refer to the Powertrain Diagnostic Procedures Manual to diag nose an On Board Di...

Страница 334: ...iver 25 amps and maintain a minimum terminal voltage of 10 5 volts at 27 C 80 F J908A 11 REDUCTION GEAR STARTER Manufacturer Nippondenso 5 91 5 2L 3 9L Part Number and 4379160 1 4 Kw 12 No of Fields 4 4 4 Conventional Gear Train Free Running Test Voltage 11 82 Amps 3625 rpm 7 5 Volts Cranking Amperage Draw Test 150 220 Amps Engine should be up to operating temperature Extremely heavy oil or tight ...

Страница 335: ......

Страница 336: ...liver necessary electricity will not accept electricity and w i l l not act as a capacitor Consequently the ve hicle s entire electrical system will be effected when this happens Standard equipment maintenance free batteries Fig 1 have no removable battery cell caps Water can not be added to the maintenance free battery The battery is completely sealed except for small vent holes i n the cover The...

Страница 337: ... Fig 3 Cleaning Battery CAUTION Care should be taken to ensure that so lution does not enter vent holes 5 Inspect battery case and cover for cracks or leakage I f cracks or leakage is present battery must be replaced 6 Inspect battery tray for damage caused by loss of acid from battery I f acid damage is present i t w i l l be necessary to clean area w i t h same solution de scribed i n Step 4 Fig...

Страница 338: ...ged hold down ledge 10 Install battery i n vehicle making sure that battery is properly positioned on battery tray Fig 2 11 Install battery hold down clamp making sure that i t is properly positioned on battery and tighten bolt to 12 N m 100 i n lbs 12 Place felt grease washer onto Positive bat tery post 13 Connect cable clamps to battery post making sure top of clamp is flush with top of post Fig...

Страница 339: ...cts causing starter motor to crank As soon as engine starts run ning clutch pinion gear overruns to protect starter armature from damage due to excessive speed Once the engine starts running the ignition key switch should be immediately returned to the r u n position to prevent excessive starter motor damage WARNING ALWAYS DISCONNECT THE BATTERY NEGATIVE CABLE BEFORE SERVICING THE STARTER STARTER ...

Страница 340: ......

Страница 341: ...up to operating temperature Extremely heavy oil or tight engine will increase starter amperage draw J908B 6 BATTERY SPECIFICATIONS Load lest Amps Cold CfonJang Rating 0 F Capacity 200 Amp 400 Amp 100 Minutes 250 Amp 500 Amp 110 Minutes 315 Amp 625 Amp 120 Minutes 350 Amp 700 Amp 120 Minutes CRANKING RATING is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7 2 v...

Страница 342: ...vehicle is equipped with a heavy duty package a 120 amp alternator is used ALTERNATOR REMOVAL AND INSTALLATION 1 Remove the battery negative cable 2 Remove alternator drive belt See Group 7 Cooling System for instructions 3 Remove the alternator mounting n u t top and bolt bottom and separate the alternator from the mounting plate Fig 1 4 Remove the B terminal nut 2 field terminal nuts ground and ...

Страница 343: ...ICATIONS ALTERNATOR SPECIFICATIONS TYPE PART NUMBER PULLEY GROOVES ENGINE RATING NIPPONDENSO 5234026 2 ALL 35 75 AMPS NIPPONDENSO 5234199 2 ALL 50 120 AMPS NIPPONDENSO 5234028 2 ALL 40 90 AMPS BOSCH 5235028 2 ALL 40 90 AMPS J908C 22 ...

Страница 344: ...e cap for cracks carbon paths broken towers white deposits on the inside caused by condensation entering the cap through cracks and damaged rotor button Fig 1 The machined surface of a terminal end faces to ward rotor w i l l indicate some evidence of erosion from normal operation The residue can be removed w i t h a sharp knife Examine the terminal ends for evidence of mechanical interference w i...

Страница 345: ...y seated The terminals and covers should be i n good condi tion Terminals should fit tightly to the ignition coil distributor cap and spark plugs The cover boot of the cable should fit tight around the coil tower dis tributor tower and spark plug insulator Loose cable connections can cause corrosion and increase resis tance resulting i n shorter cable service life To main tain proper sealing at th...

Страница 346: ...in spec ifications i n the resistance chart remove the cable from the distributor cap and connect the ohmmeter to the terminal ends of the cable I f resistance is still not within specifications replace the cable Inspect the coil tower for cracks corrosion or oil leaks Replace cables one at a time to ensure that the cor rect firing order is maintained Route the new cables i n the same manner as th...

Страница 347: ...gnosed as being caused by coolant i n the combustion chamber Spark plug performance is not affected by M M T deposits Cold Fouling Carbon Fouling Cold fouling is sometimes referred to as carbon fouling because the deposits that cause cold fouling are basically carbon Fig 8 A dry black deposit on one or two plugs i n a set may be caused by sticking J908D 15 Fig 8 Normal Operation and Cold Carbon Fo...

Страница 348: ...h e insulator from the center electrode Fig 11 Spark plugs with this condition must be replaced GROUND ELECTRODE CENTER ELECTRODE CHIPPED INSULATOR J908D 14 Fig 12 Preignition Damage Spark Plug Overheating Overheating is indicated by a white or gray center electrode insulator that also appears blistered Fig 13 The increase i n electrode gap will be consider ably i n excess of 0 001 inch per 1000 m...

Страница 349: ...ough the auto shutdown ASD relay Refer to Auto Shut down ASD Relay i n this section for relay opera tion By switching the ground path for the ignition coil on and off the SBEC adjusts ignition timing to meet changing engine conditions The amount of electronic spark advance provided by the SBEC is determined by four input factors coolant temperature engine rpm throttle position and available manifo...

Страница 350: ...le Board Engine Controller SBEC As engine load changes manifold pressure varies causing the M A P sensor output voltage to change resulting i n a different input voltage to the SBEC The input volt age level supplies the SBEC w i t h information relat ing to ambient barometric pressure during engine start up cranking and to engine load while the en IGNITION SYSTEMS 8D 7 gine is running The SBEC use...

Страница 351: ...sistor Inspect the coil for exter nal leaks and arcing Test coil according to coil tester manufacturer s i n structions Test coil primary resistance Test coil sec ondary resistance Replace any coil that does not meet specifications I f the ignition coil is replaced because of a burned tower carbon tracking or arcing at either the tower nipple or boot at the coil end of the secondary cable replace ...

Страница 352: ... pro ducing high secondary voltage Inspect the distribu tor rotor cap spark plug cables and spark plugs I f they are okay the ignition system is not the reason why the engine will not start I t w i l l be necessary to check the fuel system and engine mechanical items FAILURE TO START TEST To prevent unnecessary diagnostic time and wrong test results the Checking for Spark Test should be performed ...

Страница 353: ... Procedure sections Refer to On Board Diagnostics i n the Fuel Injection General D i agnosis sections of Group 14 COOLANT TEMPERATURE SENSOR TEST 1 Turn the ignition key to the off position Dis connect wire connector from coolant temperature sen sor 2 Connect one lead of ohmmeter to one terminal of coolant temperature sensor Fig 5 OHMMETER RR8DG20 Fig 5 Coolant Temperature Sensor Test 3 Connect th...

Страница 354: ... connecting it to the SBEC The Single Board Engine Controller SBEC is lo cated on the dash panel 1 Remove air cleaner duct from SBEC 2 Remove 3 module mounting screws Fig 1 3 Remove 60 way electrical connector from the SBEC Remove SBEC Fig 1 INSTALLATION 1 Connect 60 Way electrical connector to SBEC Fig 1 2 Mount SBEC to inside right front fender Fig 1 Install and tighten mounting screws 3 Install...

Страница 355: ...iagnosing com plaints of engine stalling creeping and hard shifting on vehicles equipped w i t h automatic transmissions Test procedures are as follows 1 Connect red lead of test tachometer unit to neg ative primary terminal of coil and black lead to a good ground 2 T u r n selector switch to the appropriate cylinder position of engine being tested 3 Turn tachometer r p m switch to 1 000 rpm posi ...

Страница 356: ...olant temperature sensor was disconnected connect the sensor and erase f a u l t codes using t h e Erase F a u l t Code M o d e o n the D R B I I Refer to Group 14 General Diagnosis On Board Diagnostics Fig 4 Distributor Hold Down DISTRIBUTOR REMOVAL 1 Disconnect distributor pickup lead wire at wir ing harness connectors 2 Unfasten distributor cap retaining clips and lift off distributor cap 3 Scr...

Страница 357: ...tion Rotor Removal and Installation 3 Remove hall effect pick up attaching screws on opposite sides of the distributor housing a n d care fully lift the hall effect pick up assembly from t h e distributor housing Fig 6 HALL EFFECT PICK UP ALIGNMENT GROVE DISTRIBUTOR HOUSING ATTACHING SCREW RR8DG33 Fig 6 Hall Effect Pick Up Removal and Installation Installation To reinstall hall effect pick up asse...

Страница 358: ...7 2 Basic Timing 2 10 BTDC 10 BTDC Shaft Side Play Not to Exceed 0 1mm 0 004 Not to Exceed 0 1mm 0 004 Shaft End Play 0 08 to 0 43mm 0 003 to 0 017 0 08 to 0 43mm 0 003 to 0 017 SBEC Single Board Engine Controller TBI Throttle Body Injection Fed Federal Cal California Can Canada J908D 52 IGNITION COIL Chrysler Chrysler Coil Prestolite UTC Diamond Primary Resistance at 7 0 8 0 F 1 34 1 55 1 34 1 55...

Страница 359: ...ft lbs Coolant Temperature Sensor 2 700 1 000 Ohms a t 9 3 C 200 F Preapplied 3 8 18 NPTF 27 Nm 20 ft lbs Throttle Body Temperature Sensor 2 5 600 14 600 Ohms at 12 C 70 F Mopar Silicone Heat Transfer Compound M12 x 1 5 11 Nm 100 in lbs Throttle Body Temperature Sensor 2 400 1 500 Ohms at 93 C 200 F Mopar Silicone Heat Transfer Compound M12 x 1 5 11 Nm 100 in lbs Temperature ratings are nominal va...

Страница 360: ...rking and service anti lock brakes the check engine system and maintenance re quired CHECK ENGINE I f the input from one of the following sensors fails an internal SBEC self check the controller turns on Page Message Center Diesel Engine 2 Message Center Gas Engine 1 Oil Pressure Warning Lamp 3 Speedometer Odometer System 4 Temperature and Oil Indicating System 3 Q D IS A v SI CD BRAKE CHECK ENGIN...

Страница 361: ...stem 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 w i l l remain on until the cause is corrected The light w i l l also come on when the parking brake is applied w i t h the ignition i n the O N position Refer to Group 5 Brakes for further information WATER IN FUEL The Water I n Fuel light is conne...

Страница 362: ... perature sending unit is low and a hot temperature w i l l be indicated on the gauge I n the oil pressure indicating system the sending unit resistance is actuated by a diaphragm as the oil pressure increases or decreases Low oil pressure causes high resistance H i g h pressure causes low re sistance OIL PRESSURE WARNING LAMP The oil pressure warning switch mounted on the engine is controlled by ...

Страница 363: ...ree Fig 7 3 To install the sensor reverse the removal pro cedures Tighten coupling nut to 17 N m 150 i n lbs RETAINER DISTANCE SENSOR J9021 99 Fig 7 Distance Sensor CLUSTER AND GAUGE SERVICE AND TESTING INDEX Page Cluster Bezel 8 Cluster Mask And Lens 9 Fuel Tank Sending Unit Test 5 Gauge And Gauge Circuit Testing 11 Gauge Replacement 11 Instrument Cluster Assembly 9 Lamp Bulb Replacement Message ...

Страница 364: ...lus one pointer width or minus two pointer widths 6 Move and clip sending unit float a r m to full stop The gauge should read Full or above RETURN TUBE FULL POSITION FUEL LEVEL SENDING UNIT PICKUP RESERVOIR EMPTY POSITION RR8EC69 Fig 2 Fuel Tank Sending Unit Test RESULTS 1 I f fuel gauge does not meet specifications check following items as possible causes a Wiring and connections between the gaug...

Страница 365: ...d causing i m proper positioning of sending unit pick up tube Re place or repair tank and recheck sending unit Refer to Fuel Tank Section of Group 14 Fuel Sys tem WARNING LAMP SYSTEM TESTS LOW OIL PRESSURE WARNING LAMP CIRCUIT TEST The low oil pressure warning lamp w i l l illuminate when the ignition key is turned to the O N position The lamp also illuminates i f the engine oil pressure drops bel...

Страница 366: ...etal housing The ohmmeter should read open Start the engine The ohmmeter should read between 30 to 55 ohms depending on engine speed oil temperature and oil viscosity I f the above results are not obtained replace the switch SENDING UNIT GAUGE SWITCH LIGHT 898E 2 Fig 4 Combination Oil Unit Terminals SEAT BELT WARNING SYSTEM For testing of this system refer to Section 8 M Seat Belt Warning Systems ...

Страница 367: ...mounted on the frame rail i n the engine compartment below the master cylinder CAUTION If wheel cylinder bleeder was opened check master cylinder fluid level Diesel The Brake light is also connected to a sensor that monitors vacuum in the brake booster system The Brake light when lit indicates LOW VACUUM Refer to the Diesel supplement for more information CLUSTER BEZEL REMOVAL 1 Disconnect battery...

Страница 368: ...ove 6 screws that retain cluster Pull clus ter rearward and disconnect 2 large connectors 9 Remove cluster INSTALLATION 1 Connect 2 large connectors to cluster 2 Position cluster to instrument panel and install 6 retaining screws 3 Install heater A C control 4 Connect PRND21 actuator to steering column i f equipped 5 Position upper steering column cover and slide upward until tangs snap into place...

Страница 369: ...emove printed circuit board mounting screws 5 Remove printed circuit board from cluster hous ing 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 hous ing install mounting screws and tighten 2 Install gauges 3 Install lamp socket assemblies Be sure illumi nation lamp diffusers are instal...

Страница 370: ...isconnect battery negative cable 2 Remove bezel Refer to Cluster Bezel Removal 3 Remove cluster mask and lens Refer to Cluster Mask and Lens Removal 4 Remove gauge mounting screws 5 Pull gauge rearward to remove For Installation reverse Removal procedures SPEEDOMETER ODOMETER 1 Disconnect battery negative cable 2 Remove bezel Refer to Cluster Bezel Removal 3 Remove cluster mask and lens Refer to C...

Страница 371: ...E GAUGE CIRCUIT TEST 1 Remove oil pressure gauge Refer to Gauge Re placement 2 Check for continuity i n the wire between the oil pressure sensor and the oil pressure gauge sensor input pin Figs 12 13 and 14 3 W i t h the ignition switch i n the O N position check for battery voltage across the B p i n and the Ground pin DISTRIBUTOR HOLDDOWN OIL PRESSURE SENDING UNIT ELECTRICAL CONNECTION RR14G147 ...

Страница 372: ...he Ground pin Fig 17 The instrument panel voltmeter indicates elec trical system battery voltage SPEEDOMETER 1 Remove speedometer assembly Refer to Gauge Replacement 2 Check for continuity i n the wire between the distance sensor connector and the speedometer dis tance sensor input pin Fig 18 3 With the ignition switch i n the O N position check for battery voltage across the B p i n and the Groun...

Страница 373: ...moval 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 assembly into printed cir cuit board 3 Install Instrument Cluster bezel assembly to i n strument panel Refer to Instrument Cluster installa tion 4 Connect battery negative cable FOUR WHEEL DRIVE INDICATOR LAMP 1 Pull bulb and sock...

Страница 374: ...RING AND RAISING When servicing the instrument panel and the Low ering and Raising of the steering column is required the following is the procedure for doing so Page Heater Control 16 Hood Release 19 Illumination Bulb Replacement 21 Message Center Module 19 Steering Column Lowering And Raising 15 Switches 16 This procedure is not for removing and replac ing the steering column Refer to Group 19 S...

Страница 375: ...wo control attaching screws 4 Pull control rearward 5 Disconnect illumination lamp and wire connec tions 6 Disconnect control cables 7 Remove control INSTALLATION 1 Position control near panel 2 Connect control cables to control see Heater A C Section 3 Connect illumination lamp and wire connec tors 4 Push control into panel 5 Install two control mounting screws 6 Install bezel 7 Install map lamp ...

Страница 376: ... stem assembly into switch 6 Install cluster bezel 7 Check operation of switch POWER MIRROR SWITCH Refer to Group 8T Power Mirrors AUXILIARY HEADLAMP SWITCH FIG 3 USED WITH SHOW PLOW OPTION Removal 1 Remove two screws on right side of snow plow control housing 2 Loosen two screws on left side of housing and slide housing to the right and pull away from instru ment panel 3 Remove four screws holdin...

Страница 377: ... Depress lock tabs on switch and push i t out of the instrument panel Installation 1 Hold wiring connector i n switch opening 2 Push switch on to wiring connector Control Assembly 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 connec tor then remove map lamp assembly In...

Страница 378: ...out switch and message center con nectors 4 Install instrument cluster bezel to panel 5 Install map lamp FUSEBLOCK AND FLASHERS FUSEBLOCK The fuseblock is located directly below the steering column on the lower steering column cover Removal 1 Push fuseblock locking tab on column cover downward and lower fuseblock The following compo nents plug into the fuseblock 1 Fuses 2 30 amp circuit breakers 3...

Страница 379: ...IRECTION OF ARROW A LIGHTER ELEMENT KNOB ASH TRAY ASSEMBLY RB491 Fig 5 Cigar Lighter and Ash Tray INSTALLATION 1 Insert shell through front of housing 2 Install clamp on shell turn clockwise tighten securely 3 Connect wiring to shell 4 Install lighter element 5 Install wires and close ash receiver ASH TRAY Fig 5 TRAY Removal 1 Open ash tray 2 Remove ash tray bin 4 Remove cigar lighter from housing...

Страница 380: ...h 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 i t will be in the closed position when installed CATCH Removal 1 Open glove box door 2 Remove catch mounting screws 3 Remove catch Installation 1 Position ca...

Страница 381: ...housing 2 Position housing and install six mounting screws 3 Connect wires to cigar lighter 4 Install b i n and close 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 i n bulb and socket 2 Replace cluster bezel 3 Install map l...

Страница 382: ...wl A l l ground straps should be securely mounted to a clean ground surface to work effec tively Radio resistance spark plug wires complete the i n terference suppression system Faulty or deteriorated spark plug wires should be replaced Fig 1 Page Radio Reception Mode 1 Radio Schematics 1 RADIO RECEPTION MODE I n some instances a radio may be changed from North American to European reception mode ...

Страница 383: ... BLACK XL GRAY X54 X54 BBIiailgmil 1 1 IBBBIlillalBil i i i i i iqM i i I I J T X56 X61 X56 E2 Ml X53 X53 X55 X55 L7 X12 LEGEND E2 ILLUMINATION 17 PARK LAMPS Ml BATTERY X12 ACC RUN X51 LEFT REAR X55 LEFT PNL DR X60 FEED RADIO SWITCHED X52 RIGHT REAR X56 RIGHT PNL DR X61 MUTE X53rLEFT PNL DR X57 LEFT REAR X54 RIGHT PNL DR X58 RIGHT REAR NOTE FOR WIRE COLORS REFER TO SECTION 8W WIRING DIAGRAMS J908F...

Страница 384: ...ARY WITH ENGINE SPEED CHECK ACCESSORY ELECTRICAL MOTORS SOLENOIDS AND SWITCHES AS RADIO FREQUENCY NOISE SOURCES FAULTY RADIO RADIO RECEPTION WEAK 11 SHORTED ANTENNA LEAD IN FAULTY RADIO NOISE VARIES WITH ENGINE SPEED RADIO RECEPTION DISTORTED i JL CHECK SECONDARY IGNITION FAULTY SPEAKER FAULTY RADIO REFER REPAIR OF RADIO TO AN AUTHORIZED SERVICE STATION LOOSE POWER OR ANTENNA CONNECTIONS LOOSE RAD...

Страница 385: ...nd battery i n circuit attach one test lead to concentric p i n on lead in connector and other test lead to t i p of mast The lamp should light indicating Continuity 2 Keeping one lead on connector pin clip other lead on antenna body assembly The lamp should NOT light I f i t does look for a short circuit i n the body or i n the cable probably at the connector 3 Remove clip lead from connector pin...

Страница 386: ...2 Pull antenna body and cable assembly from fender area and remove 13 Remove adapter on fender INSTALLATION 1 Route anteanna cable between fender and dash panel to A pillar area ADAPTER PR517 A Fig 7 Cap Nut and Adapter Fig 8 Removing or Installing Antenna Body 2 Insert antenna mast through hole i n fender and screw into antenna body 3 Pull assembly up and position into place and hold 4 Install ad...

Страница 387: ... g and antenna 6 Remove screw from ground strap INSTRUMENT PANEL 3 Insert radio into panel and install mounting screws 4 Install instrument cluster bezel 5 Install map lamp i f equipped 6 Connect fusible link DOOR MOUNTED SPEAKER REMOVAL 1 Remove remote control handle 2 Remove window regulator handle i f equipped 3 Remove pull strap i f equipped 4 Remove screw at top of armrest 5 Using a t r i m s...

Страница 388: ...om of speaker housing Fig 13 2 Lower speaker housing and pull bottom out al lowing retaining tab on top of housing to clear slot 3 Disconnect speaker connector and remove speaker Fig 13 Club Cap Speaker Installation INSTALLATION 1 Install wiring harness connector on speaker 2 Install retaining tab into clip 3 Install screws on the bottom of the speaker housing REAR SPEAKER RAMCHARGER 1 Remove scre...

Страница 389: ......

Страница 390: ...h Should test lamp illuminate the horn is ungrounded or faulty Ground ing can be verified by making a temporary jumper wire connection between horn bracket scratch through paint and the negative battery terminal W i t h the ground jumper wire still intact and the horn reconnected i f the horn still fails to sound when horn button or r i m is depressed replace the horn If the lamp fails to illumina...

Страница 391: ...Engine 4 Horn Replacement Gas Engine 2 HORN SWITCH HORN PAD ASSEMBLY REPLACEMENT REMOVAL 1 From underside of steering wheel remove horn pad mounting screws Figs 4 and 5 2 Pull pad up from wheel and disconnect electri cal leads 3 Remove pad INSTALLATION 1 Connect electrical leads to switch terminal on horn pad 2 Position pad into place on steering wheel i n stall mounting screws and tighten to 1 5 ...

Страница 392: ...RE T O H O R N BUTTON SWITCH G R O U N D E D O R HORN BUTTON SWITCH G R O U N D E D REFER T O TEST PROCEDURES REPLACE H O R N RELAY WITH A K N O W N G O O D O N E FIG 3 FAULTY HORN W R O N G FUSE SIZE TEST LIGHT ON FAULTY ORIGINAL RELAY TEST UGHT 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 FOR O P E N CIRCUIT I...

Страница 393: ...asher holding t h e horn bracket to the fender 3 Lower the horn and bracket toward the rear of the battery 4 Disconnect the horn electrical connector 5 Remove the horn and bracket assembly by working i t under the battery tray brace Fig 7 6 To install the horns reverse the removal proce dures HI NOTE LOW NOTE HORN BRACKET HORN BRACKET ASSEMBLY ASSEMBLY J908G 11 Fig 7 Horn Removal and Installation ...

Страница 394: ...EDURES 5 To disengage Normal brake application or a soft tap on the brake pedal w i l l disengage control unit without erasing speed memory Moving the slide switch to the OFF position or turning the ignition OFF also disengages the system and i n addition erases the speed memory T o resume after b r e a k i n g Momentarily move slide switch to RESUME Vehicle will resume to the previously memorized...

Страница 395: ...8H 2 SPEED CONTROL SYSTEM Fig 1 Speed Control System ...

Страница 396: ...HUNTING SURGE OR SPEED VARIATIONS AT LOW SPEEDS FUSE B L O W N L O C K U P T O R Q U E CONVERTER R O U G H N E S S V A C U U M LEAK A M P L I C A T I O N O F E N G I N E S U R G E SPEED C O N T R O L THROTTLE CABLE D I S C O N N E C T E D DEFECTIVE S E R V O IMPROPER STOP LAMP A N D SPEED C O N T R O L SWITCH ADJUSTMENT DEFECTIVE S B E C FAULTY ELECTRICAL CIRCUIT TESTS AND ADJUSTMENTS ARE DESCRIBE...

Страница 397: ...Y D O E S N O T RETURN T O N O R M A L IDLE SPEED CONTROL THROTTLE CABLE KINKED O R DAMAGED FAULTY ELECTRICAL CIRCUIT MOVE SUDE SWITCH TO THE THE RESUME POSITION VEHICLE SHOULD RESUME PRE VIOUSLY MEMORIZED SPEED STANDARD THROTTLE LINKAGE FAULTS DEFECTIVE S E R V O VEHICLE RESUMES S P E E D DEPRESS BRAKE PEDAL S P E E D C O N T R O L SHOULD D I S E N G A G E R E S U M E SPEED IS POSSIBLE B E L O W ...

Страница 398: ...d a W i t h key inserted i n ignition switch cycle switch to O N position three times On third cycle leave switch i n O N position b After switch has been cycled three times observe CHECK ENGINE indicator on instrument cluster I f a Fault Code is present indicator will flash blink i n a series which w i l l show which Fault Code is the problem i e three flashes i n rapid succession a slight pause ...

Страница 399: ...control switch test I f the switch is not at fault then check the main harness and repair as necessary 6 Touch the positive lead of the voltmeter to the terminal i n cavity number 50 The voltmeter should read 0 volts w i t h the speed control switch i n either the OFF or O N position W i t h switch i n either RE SUME or SET position the voltmeter should read battery voltage I f not perform the spe...

Страница 400: ...SUPPLY TEST 1 Disconnect vacuum hose at the servo and install a vacuum gauge i n the hose Fig 5 2 Start engine and observe gauge at idle Vacuum gauge should read at least ten inches of mercury 3 Connect vacuum supply hose SPEED CONTROL SWITCH CONTINUITY CHART SWITCH POSITION CONTINUITY BETWEEN OFF BR and YL BfeandYL ON BR and DB YLand DB YL and WT SET DB and WT YL and DB WT DB andWT DB and YL RESU...

Страница 401: ...mark on the core wire and the protective sleeve Fig 8 Fig 8 Pull Cable Out and Measure from Mark to Protective Sleeve 4 I f gap is not correct remove adjustment clip and push protective sleeve into housing to decrease gap or pull sleeve out of housing to increase gap Fig 9 Fig 9 Adjustment Clip Pulled Out of Slot to Move Sleeve 5 Install adjustment clip SPEED CONTROL CABLE ATTACHMENT SERVO 1 The s...

Страница 402: ...ottle body removing snap ring retain ing clip 3 Disconnect cable at servo and remove cable as sembly INSTALLATION 1 Locate cable through servo mounting bracket 2 Connect cable sleeve to servo stud align holes and install hairpin clip 3 Insert servo studs through holes i n cable and holes i n bracket install nut washers and tighten to 9 N i n 80 i n lbs Page Speed Control Switch 9 Speed Control Vac...

Страница 403: ...pward through upper housing Attach guide wire to switch w i r i n g harness and gently pull downward through column opening between lockplate and side of housing taking care to avoid damaging wires 3 Remove all slack from wires 4 On t i l t columns remove guide wire 5 Install wiring trough with plastic clips 6 Connect speed control switch electrical connec tor to instrument panel harness connector...

Страница 404: ...switch The cam push ing on the switch canceling finger returns the switch to the OFF position I f only momentary signaling such as indication of a lane change is desired the switch is actuated to a left or right intermediate detent position I n this po sition the signal lamps flash as described above but the switch returns to the OFF position as soon as the lever is released Fig 1 When the system ...

Страница 405: ...EDURES INDEX Turn Signal And Hazard Warning Switch Tests HAZARD WARNING SYSTEM DIAGNOSIS HAZARD WARNING SYSTEM DIAGNOSIS Page 2 SYSTEM DOES NOT FLASH FAULTY FUSE 1 OPEN CIRCUIT IN FEED WIRE TO SWITCH FAULTY CONTACT IN SWITCH OPEN OR GROUNDED CIRCUIT IN WIRING TO EXTERNAL LAMPS J908J 2 TURN SIGNAL AND HAZARD WARNING SWITCH TESTS The t u r n signal switch and hazard warning switch operate the same l...

Страница 406: ...EM DOB NOT CANCEL AFTER COMPLETION OF TURN BROKEN CANCELLING FINGER ON SWITCH DAMAGED OR MISSING CAM DRIVE PIN WHICH FITS INTO HOLE IN STEERING WHEEL HUB BROKEN OR LOOSE CANCELLING CAM FAULTY CONTACT IN SWITCH LOOSE OR FAULTY REAR WIRING HARNESS OR TERMINALS OPEN CIRCUIT TO FLASHER UNIT OPEN CIRCUIT IN FEED WIRE TO TURN SIGNAL SWITCH 1 INDICATC 1 ILLUMINATE 1 EXTERN 1 DOES N C R LAMP 1 S BRIGHTLY ...

Страница 407: ...10 and 9 10 and 8 On 6 and 4 6 and 5 6 and 8 6 and 9 J908J 5 SWITCH CONTINUITY CHART SERVICE PROCEDURES TURN SIGNAL HAZARD WARNING SWITCH REMOVAL 1 Disconnect battery negative cable 2 On the standard and optional steering wheels Figs 5 and 6 remove two horn pad mounting screws from underside of steering wheel ELECTRICAL LEADS HORN PAD MOUNTING SCREWS 2 J 908G 5 Fig 5 Standard Steering Wheel 3 Pull...

Страница 408: ...ssembly by gently pulling switch up from column while straightening and guiding wires up through column opening INSTALLATION 1 On standard columns lubricate turn signal switch pivot entire 360 around depth of column hole TO TURN SIGNAL WIRING WIRING TROUGH TO KEY IN LAMP WIRING TO KEY IN SWITCH WIRING TO SPEED CONTROL WIRING J O INTERMITTENT WIPE TO WINDSHIELD CONTROL UNIT WIPER WIRING RR8JC3 Fig ...

Страница 409: ... upper column housing Place switch i n right t u r n position Install three mounting screws and tighten Pull link i n position between t u r n signal switch and wiper washer switch pivot and secure w i t h screw Using Tool C 4156 install upper bear ing spring canceling cam and lock plate w i t h new retaining ring Install hazard warning knob w i t h screw 5 Connect w i r i n g harness connector In...

Страница 410: ...tests that are to be performed to locate the faulty part and the corrective action to be taken The same motor is used for standard and op tional systems I f the malfunction involves only the Delay mode switch or wiring refer to the Intermit tent Windshield Wiper Motor and Switch Service Procedures CONDITION Motor will not r u n i n any switch position PROCEDURE 1 Check for a blown fuse i n the fus...

Страница 411: ...TION DEFECTIVE MOTOR MOTOR WILL NOT RUN IAT ANY SPEED LOOSENESS OF THE MOTOR CRANK OR OTHER DRIVE PARTS MOTOR WILL NOT RUN CHECK VOLTAGE AT MOTOR VOLTAGE PRESENT DEFECTIVE MOTOR CHECK GROUND WIPER KNOCK WIPER KNOCKS AT EXTREME WIPE AXIAL OR WORN OUT FREEPLAY IN LINKAGE BLADES CHATTER FOREIGN SUBSTANCE SUCH AS BODY POLISH ON GLASS OR BLADES TWISTED ARM HOLDS BLADE AT WRONG ANGLE TO GLASS BENT OR DA...

Страница 412: ...ve voltmeter test lamp lead from termi nal H to terminal L of the w i r i n g harness g I f voltage is present there is a short i n the wiring or wiper switch CONDITION M o t o r w i l l r u n a t h i g h speed b u t n o t a t l o w speed M o t o r w i l l r u n a t l o w speed b u t n o t a t h i g h speed PROCEDURE 1 I f motor w i l l not r u n on high speed put switch in H I G H position and co...

Страница 413: ...ective motor b I f there is no continuity the problem is an open circuit i n the wiper control switch or wiring harness SWITCH TEST To test the switch first disconnect the switch wires from the body wiring at the connector Then using a continuity tester or an ohmmeter test for continuity no resistance between the terminals of the switch as shown i n the following continuity chart The iden tity of ...

Страница 414: ...ntinually w h e n w a s h i s operated but do not provide a n extra wipe when the wash control i s released PROCEDURE Replace the control unit Page Intermittent Wipe Switch Test 5 CONDITION Wipers start erratically during D E L A Y mode PROCEDURE 1 Verify that the ground connection at the instru ment panel is making good connection free from paint and is tight 2 Verify that the motor ground strap ...

Страница 415: ...TION CONTINUITY BETWEEN OFF PIN 1 13 PIN 3 10 PIN 4 11 PIN 5 12 DELAY PIN 1 13 PIN 3 10 PIN 4 16 PIN 4 11 PIN 4 PIN 5 12 PIN 8 15 PIN 9 16 PIN 11 16 PIN 9 11 LOW PIN 1 13 PIN 3 10 PIN 4 7 PIN 4 11 PIN 5 12 PIN 7 11 HIGH PIN 1 13 PIN 3 10 PIN 4 6 PIN 4 11 PIN 5 12 PIN 6 11 908K 6 Fig 11ntermittent Wipe Wiring Schematic ...

Страница 416: ...lass 3 Remove blade assembly from arm and wiping element from blade depending on type as follows Page Wiper Motor Replacement 8 Wiper Switch Replacement Standard Column 9 Wiper Switch Replacement Tilt Column 10 T Y P E 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 pinc...

Страница 417: ...K ARM 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 i n lbs torque 2 Install wiper motor DRIVE LINK ASSEMBLY LEFT PIVOT ASSEMBLY REMOVAL 1 Remove wiper arms 2 Remove screws attachin...

Страница 418: ...l mounting screws and tighten to 11 N m 95 in lbs torque 2 Install right pivot pin i n drive l i n k retainer bushing by snapping together w i t h channel lock pli ers 3 Position cowl cover into place install mounting screws and tighten securely 4 Install wiper arms WIPER SWITCH REPLACEMENT STANDARD COLUMN 1 Disconnect battery negative cable 2 Remove 4 screws attaching the lower steering column co...

Страница 419: ...1 8 Disconnect wash wipe switch connector and i f equipped intermittent wipe module connector and speed control connector Figs 12 and 13 9 Remove two screws that attach the lock housing to the lock housing and remove the lock housing cover 10 Remove the wipe wash switch assembly Fig 14 11 Pull the hider up the control stalk and remove the two screws that attach the control stalk sleeve to the wipe...

Страница 420: ...D CONTROL SWITCH AND LEVER C O V E R S X SILENCER RH1337 Fig 15 Multifunction Control Stalk a Remove one screw from left side of cover b Remove two screws one on each side of steering column c Remove one screw from brace on right side of cover and pull down to remove 3 On the standard and optional steering wheels MULTI FUNCTION CONTROL STALK WASH WIPE SWITCH RY347 Fig 16 Remove or install Control ...

Страница 421: ...oove w i t h screwdriver Fig 22 The full load of the upper bearing spring should not be relieved as the retaining ring will t u r n too easily making removal more difficult Remove lock plate canceling cam and upper bearing spring 9 Remove switch stalk actuator screw and arm 10 Push hazard warning knob i n and unscrew to remove TO TURN SIGNAL WIRING TO KEY IN LAMP WIRING KEY IN SWITCH WIRING TO SPE...

Страница 422: ...Insert a t h i n tool small screwdriver or shim stock into the slot next to the switch mounting screw boss right hand slot and depress spring latch at bottom of slot which releases lock Remove lock Fig 27 The buzzer switch can be pulled straight out of the housing Fig 28 A straightened paper clip or simi lar piece of stiff wire w i t h a hook bent on one end should be inserted i n the exposed loop...

Страница 423: ... to the wash wipe switch Figs 30 and 31 CAUTION Use tape to hold dimmer switch rod in place WINDSHIELD WIPER SWITCH HIDER WITHOUT SPEED CONTROL WITH HIDER SPEED CONTROL WIPER KNOB SWITCH AND LEVER COVER SILENCER RH1337 Fig 31 Multifunction Control Stalk 19 Remove wash wipe switch control knob from end of multifunction control stalk Fig 31 20 Rotate the control stalk shaft to the full clock wise po...

Страница 424: ...p Replacement 15 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 filler neck and remove pump mounting n u t and plastic washer 5 Remove pump from bottom reservoir ...

Страница 425: ...S FAULTY SWITCH FAULTY MOTOR WASHER DOES NOT OPERATE PROPERLY PUMP MOTOR RUNS MOTOR RUNS PUMP PUMPING FLUID SYSTEM OPERATES WITHOUT INTERRUPTION SYSTEM OUTPUT ADEQUATE WASHER SYSTEM OK SYSTEM OUTPUT LOW PINCHED OR LEAKY HOSES LEAKY OR RESTRICTED PLASTIC HOSE CONNECTOR POOR ELECTRICAL CONNECTIONS DEFECTIVE PUMP PUMP MOTOR I DOES NOT RUN LOOSE WIRING TERMINALS CORRODED TERMINALS BROKEN WIRES POOR GR...

Страница 426: ...i n Specifications DIAGNOSTIC PROCEDURES Always begin any electrical system failure diagno sis by testing a l l of the related fuses and circuit breakers i n the fuse block and engine compartment see Group 8 W Wiring Diagrams Conventional and halogen headlamp sealed beam units are physically and electrically interchangeable but i t is recommended that they not be intermixed on a given vehicle HEAD...

Страница 427: ... i n the OFF or Park po sition there should be 12 volts a t terminal B ONLY W i t h the headlamp switch O N and the dimmer switch i n H I G H B E A M position there should be 12 volts a t terminals A B and D With the headlamp switch i n the L O W BEiCM po sition there should be 12 volts at terminals A B and c W i t h the dimmer switch held i n the Flash to Pass position there should be 12 volts on...

Страница 428: ...Headlamp as described i n Headlamp Aim ing Procedures FRONT PARK AND TURN SIGNAL LAMP BULB 1 Remove screws from headlamp bezel Fig 1 2 Twist out park and turn signal lamp socket from back of lamp housing 3 Replace bulb To install reverse removal procedures Page License Lamp 6 Sealed Beam Replacememt 3 Side Marker Lamp And Bulb 3 Tail Stop Turn Signal Rear Side Marker And Back Up Lamps 3 Underhood ...

Страница 429: ...Twist i n socket 2 Position the lamp and install assembly mount ing screws I D AND CLEARANCE LAMPS FOR DUAL WHEEL MODEL To change bulb remove lamp WHEEL FLARE MOUNTED AND REAR CLEARANCE LAMPS 1 Pry out retaining clamps 2 Pull lens away from mounting plate 3 Disconnect electrical connector from bulb and lens assembly Figs 5 and 6 Fig 4 Tail Stop Turn Signal Rear Side Marker and Back Up Lamp CAB LAM...

Страница 430: ... LAMPS 8L S Fig 6 Rear Clearance Lamps Sweptline with Dual Wheels J908U59 Fig 8 Cargo Lamp Standard Cab 3 To install reverse the procedures ...

Страница 431: ...step bumper a n d separate lens from lamp twist out bulb 1 Remove 2 lamp assembly mounting screws 2 Remove lamp from bumper 3 Disconnect wire connector To install reverse the removal procedures CONNECTOR LAMP ASSEMBLY LICENSE PLATE SCREW SCREW LAMP ASSEMBLY LICENSE PLATE RR8LD24 Fig 11 License Plate Lamps Step Bumper WITHOUT REAR BUMPER 1 Remove screws holding lamp assembly to l i cense bracket Fi...

Страница 432: ...p as semblies These conditions must be corrected before a satisfactory adjustment can be made 4 Place vehicle on a level floor 5 Jounce front suspension through 3 oscillations by applying body weight to hood or bumper 6 Inspect tire inflation 7 Rock vehicle sideways to allow vehicle to as sume its normal position 8 I f gasoline tank is not full place a weight i n trunk of vehicle to simulate weigh...

Страница 433: ...ation fixtures to each unit with level vials on top Fig 4 3 Locate a true vertical plate glass window or smooth surface and secure aimers three to five feet apart so split image targets can be located i n viewing ports Fig 5 4 Set floor level dial at zero Fig 1 UNIT B OWNER CALIBRATION FIXTURE VIEWING PORT UNIT A VIEWING PORT RN984 Fig 5 Checking Aimer Calibration 5 Rotate thumb adjusting screws o...

Страница 434: ...ting consult local state laws 2 T u r n vertical adjusting screw Fig 6 u n t i l the level bubble is centered between the lines Fig 9 3 Repeat the last two steps on the opposite head lamp 4 Recheck target alignment on both aimers and readjust horizontal aim i f necessary 5 Repeat aiming process for a four headlamp sys tem on the second pair of lamps 6 Remove aimers by pressing vacuum release butto...

Страница 435: ...E LAMP REPLACEMENT 1 Remove the lamp assembly attaching screws and the ground wire connection Fig 12 2 Disconnect the lamp connector 3 To install the lamp assembly reverse the re moval procedures BULB REPLACEMENT 1 Remove the lens cover and remove the bulb 2 Install the replacement bulb and install the lens cover The replacement bulb is trade 105 Fig 12 Underhood Lamp Removal Installation INTERIOR...

Страница 436: ...nation 158 158 Note A 194 158 194 Note C 158 Non Dimming Anti Lock Brake Indicator Brake Indicator Lamp Check Engine Lamp Dome Lamp Fasten Seat Belt Indicator Lamp Four Wheel Drive Indicator Gate Ajar Indicator Lamp Glove Compartment Lamp High Beam Indicator Lamp Ignition Key Lamp Low Fuel Indicator Lamp Low Voltage Indicator Lamp Map Lamp Oil Pressure Indicator Lamp Rear Cargo Lamp Temperature In...

Страница 437: ...6054 1156 922 194 2057 168 6052 2057 Rear Bumper License Plate Lamp Standard Chrome Bumper Sill Mounted No Bumper Step Bumper Side Marker L a m p s Tail Stop and Turn Lamp Note A Tail Stop and Turn Lamp Note B 1155 168 168 168 2057 1157 NOTES A Tail Lamp Bulb Also Serves As Side Marker Lamp B Cab and Chassis J908L 69 CIRCUIT BREAKER Circuit Headlamps Amp 20 Location Integral with Switch J908L 57 ...

Страница 438: ...aped to the wiring harness Fig 1 SEAT BELT WARNING BUZZER INTERMITTENT WIPE MODULE RR8KC23 Fig 1 Seat Beit Warning Buzzer Location TEST PROCEDURES INDEX Page Seat Belt Buckle Switch Test 2 Timed Buzzer Relay Test TIMED BUZZER RELAY TEST Fig 2 PREPARATION 1 Remove timed buzzer relay 2 Connect one end of a jumper wire to a 12 volt supply 3 Connect a test lamp between terminal number 3 of buzzer and ...

Страница 439: ...A R N I N G LAMP O N ALL THE TIME S H O R T CIRCUIT B E T W E E N T E R M I N A L N U M B E R 5 O F BUZZER M O D U L E A N D G R O U N D O P E N CIRCUIT B E T W E E N TERMINAL 5 O F BUZZER M O D U L E A N D G R O U N D W I T H SEAT BELT U N B U C K L E D C H E C K R E S I S T A N C E B E T W E E N TERMINAL 3 O F BUZZER M O D U L E A N D G R O U N D S H O U L D BE A L M O S T Z E R O O H M S BULB F...

Страница 440: ...gs 4 5 3 Remove steering wheel w i t h puller C 3428B Fig 6 4 Remove 3 screws along bottom edge of steering column cover 5 Pull cover down to disengage slide tabs and re move cover 6 P r y out wiring trough retainers and lift off wir ing trough Fig 7 New retainers may be required for assembly TOOL Fig 5 Optional Steering Wheel Horn Pad Removal Fig 7 Wire Trough Cover ...

Страница 441: ... moval more difficult Remove lock plate cancelling cam and upper bearing spring STEERING SHAFT STEERING COLUMN Fig 10 Turn Signal Switch Fig 11 Remove Lock Plate Retaining Ring Using Tool C 4156 Place t u r n signal switch i n right turn position Re move screw which attaches link between turn signal switch and wiper washer switch pivot Remove screw which attaches hazard warning switch knob Fig 12 ...

Страница 442: ... t h screw Using Tool C 4156 install upper bear WARNING BUZZER CHIME MODULE 8M 5 Fig 13 Key In Switch ing spring cancelling cam and lock plate w i t h new retainer spring Install hazard warning knob with screw 4 Connect wiring harness connectors Figs 8 9 5 Install wiring trough to column w i t h four plas tic buttons 6 Position steering wheel master serration over missing tooth on steering shaft 7...

Страница 443: ......

Страница 444: ...NTROL SWITCH TIMER RELAY MODULE The control switch and timer relay are integrated into a single panel mounted assembly Actuating the switch energizes the electronic timing circuit which allows current to flow through the grid system for approximately 10 minutes or until either the control switch or ignition is turned off A n indicating lamp illuminates a lens inlaid i n the control switch TEST PRO...

Страница 445: ... DC voltmeter with 0 15 volt range con tact vertical bus bar connecting grid lines on passen ger side of vehicle point A of Fig 1 with negative lead of voltmeter W i t h positive lead of voltmeter contact vertical bus bar on driver side of vehicle point B of Fig 1 The voltmeter should read 10 14 volts 3 With negative lead of voltmeter contact a good body ground point The voltage reading should not...

Страница 446: ... FIRE OR FLAME CONTENTS CONTAIN 3 FLAMMABLE SOLVENTS KEEP OUT OF REACH OF CHILDREN 1 Mask repair area so conductive epoxy can be ex tended onto the line or the bus bar Fig 4 BREAK GRID LINE MASKING TAPE PR1509A 2 Follow instructions i n repair k i t for preparing damaged area 3 Remove package separator clamp and mix plas tic conductive epoxy thoroughly Fold i n half and cut center corner to dispen...

Страница 447: ...odule and twist i t to remove i t 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 ...

Страница 448: ...ing location Using an ohmmeter refer to Fig 1 to determine i f continuity is correct i n the Lock and Unlock switch positions I f these results are not obtained replace the switch SWITCH POSITION CONTINUITY BETWEB4 OFF PINS 1 4 PINS 2 5 LOCK PINS 2 3 PINS 1 4 UNLOCK PINS 3 4 PINS 2 5 The following wiring test sequence determines whether or not voltage is continuous through the body harness to swit...

Страница 449: ...im stick pry t r i m 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 Fig 3 Door Lock Motor Replacement INSTALLATION 1 Attach motor mounting bracket to door inside pa...

Страница 450: ...rom side to side front to rear and up and down then there is a good chance that the window is not bound tight i n the tracks TEST PROCEDURES INDEX Page Page Circuit Breaker Test 1 Switch Voltage Test 1 Switch Test 3 Window Motor Test 3 SWITCH VOLTAGE TEST The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch After removing left door s...

Страница 451: ...ALL 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 APPLY VOLTAGE TO MOTOR AND CHECK FOR PINION ROTATION PINION DOES NOT ROTATE REMOVE GEAR PINION AND EXAMINE FOR MISSING AND OR DAMAGED GEAR TEETH APPLY VOLTAGE TO MOTOR AND CHECK FOR PINION ROTATION PINI...

Страница 452: ...INS 2 3 DOWN PINS 1 4 898S 12 Fig 2 Passenger s Door Mounted Switch Continuity WINDOW MOTOR TEST 1 Connect positive lead from a test battery to ei ther of the two motor terminals 2 Connect negative lead from test battery to re maining motor terminal 3 The motor should now rotate i n one direction to either move window up or down a I f window happens to already be i n full U P position and motor is...

Страница 453: ...wdriver into notch on forward end of switch housing and push to depress locking tab Pull out and forward to remove switch bezel from door panel 3 Remove screws at bottom front and rear of t r i m panel 4 Remove screw behind remote handle 5 Using a device such as a t r i m stick pry t r i m panel away from door around perimeter and remove t r i m panel 6 Roll door watershield away from bottom of do...

Страница 454: ...ing screws 7 Install counter balance spring INSTALLATION 1 Insert upper regulator a r m into door mounted channel 2 Mount regulator to door panel w i t h 1 4 20 screws and nuts torqued to 10 N m 90 i n lbs 3 Slide glass onto regulator arms and into rear glass run 4 Connect motor electrical connector 5 Install plastic n u t and U n u t on vent wing as sembly 6 Install vent wing assembly into door 7...

Страница 455: ......

Страница 456: ...RROR SWITCH KNOB HEADLAMP SWITCH KNOB AND STEM RR8TC7 Fig 1 Power Mirror and Headlamp Switches Mirror Motor Test Procedure T E S T PROCEDURES INDEX Page 1 Mirror Switch Test Procedure Page 2 MIRROR MOTOR TEST PROCEDURE 1 Remove power mirror switch from mounting po sition refer to Service Procedures 2 Disconnect wiring harness at switch connector 3 Using 2 jumper wires one connected to a 12 volt so...

Страница 457: ... map lamp 2 Remove 6 screws which attach instrument clus ter bezel to instrument panel Fig 2 Make sure the screw below the Heater A C control is removed Fig 2 Instrument Cluster Bezel 3 Place column shift lever i n Position 1 4 Remove bezel by pulling top edge rearward to clear brow Disengage attaching clips around bottom of bezel and complete removal of bezel 5 I f the bezel has a four wheel driv...

Страница 458: ...shield away from lower rear cor ner of door to reveal inside panel access opening 7 Reach inside door and disconnect mirror w i r i n g at connector Spray grommet on mounting bracket cover with silicone to avoid grommet coming off when cover is moved u p on mirror stem 8 Remove mirror mounting bracket cover 1 screw and slide up on mirror stem Fig 4 9 Remove 3 mirror mounting bracket nuts 10 Pull m...

Страница 459: ......

Страница 460: ...tors 4 Wiring Diagrams 44 WIRING DIAGRAMS GENERAL INFORMATION Master wiring diagrams contain the latest informa tion available at time of publication These diagrams contain various wires wire routing wire color codes switches components fuses splices connectors con nector cavities and other information except distrib utor secondary wiring This is shown i n Figs 1 and 3 9L SIX CYLINDER ENGINE DISTR...

Страница 461: ...ers Cigar Lighter Lamps Clock Speed Control Power Antenna Power Amplifier Power Windows Power Mirrors Door Locks Y Injectors Z Fuel Injection System Grounds J908W 63 Each wire shown i n the diagrams contains a code Fig 3 which identifies the wires circuit gage and color The color is shown as a two letter code which can be identified by referring to the Wire Color Code Chart I f the wire has a trac...

Страница 462: ... figure to determine splice location within a wir ing harness Fig 6 All connectors a r e v i e w e d from t e r m i n a l e n d unless otherwise specified WIRING DIAGRAMS ELECTRICAL 8W 3 Fig 6 Locating a Wiring Harness Splice FUSIBLE LINKS Vehicle wiring harnesses are equipped with fusible links to protect against harness damage i n event of a short i n electrical system Fusible links are color co...

Страница 463: ... INCH OF INSOLATION EXISTING OF INSULATION FROM BOTH WIRES TIE WRAPS FROM BOTH WIRES 6 Allow to cool and wrap new splice w i t h a min i m u m of 3 layers of suitable electrical tape Single Fusible Link Replacement 1 Disconnect negative battery cable 2 Cut fusible link including connection insulator from main harness wire 3 Remove 1 inch of insulation from both new fus ible link and main harness w...

Страница 464: ...ADOUT OPEN CONTACT 0 SINGLE FILAMENT LAMP CLOSED CONTACT DUAL FILAMENT LAMP CLOSED SWITCH L E D LIGHT EMITTING DIODE OPEN SWITCH THERMISTOR c CLOSED GANGED SWITCH GAUGE OPEN GANGED SWITCH SENSOR TWO POLE SINGLE THROW SWITCH FUEL INJECTOR PRESSURE SWITCH E 36 DENOTES WIRE GOES THROUGH BULKHEAD DISCONNECT SOLENOID SWITCH S T C C O L U M N DENOTES WIRE GOES THROUGH STEERING COLUMN CONNECTOR Tffn MERC...

Страница 465: ...ER DOOR LOCKS RADIO AND CLOCK MEMORY POWER MIRRORS GLOVE BOX DOME READING MAP AND CARGO LAMPS UNDERHOOD LAMPS GAUGES BRAKE WARNING LAMP SEAT BELT WARNING LAMP AND BUZZER LOW OIL CHECK ENGINE EMR ANTI LOCK TAILGATE AND4WD LAMPS SPEED CONTROL LOW FUEL LAMP WAIT TO START LAMP WATER IN FUEL LAMP 13 20 AMP YL BACK UP LAMPS HEATED REAR WINDOW SWITCH AND TIMER 14 3 AMP VT INSTRUMENT PANEL LAMP A C HEATER...

Страница 466: ...ng Diesel Engine 17 Engine Compartment Wiring EFI Engine 16 Engine Wiring EFI Engine 22 Extended Cab Wiring 8 Four Wheel Drive Wiring 19 Frame Wiring 2 Instrument Panel Wiring 12 Interior Wiring 6 Roof Wiring 5 Snow Plow Control Wiring 15 Snow Plow Wiring 23 Starter Wiring 18 Steering Column Wiring 11 Stop Lamp and Parking Brake Switch Wiring 13 Tail Lamp Wiring 1 Tailgate Wiring 4 Transmission Wi...

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Страница 469: ...10 WIRING DIAGRAMS ELECTRICAL TO MAIN HARNESS TO SIDE MARKER LAMPS J908W 83 LENS Fig 3 Clearance Lamp Wiring with Dual Rear Wheels LIFTGATE AJAR SWITCH TO ROOF WIRING ...

Страница 470: ...8W 11 TO FRONT DOME LAMP TO VIEWX REAR DOME LAMP TO ROOF WIRING SPEAKER VIEWX J908W 85 TO TAILGATE GROUND Fig 5 Roof Wiring TO DOME LAMP TO REAR SPEAKER TO INSTRUMENT PANEL WIRING TO SEAT BELT WIRING Fig 6 Interior Wiring J908W 86 ...

Страница 471: ...Fig 7 Cab Wiring ...

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Страница 474: ... TO POWER MIRRORS TO REAR SPEAKERS TO DOOR WIRING J908W 89 Fig 10 Cowl Panel Wiring IGNITION SWITCH WINDSHIELD WIPER WIRING 8 WAY TURN SIGNAL WIRING 10WAY KEY IN LAMP WIRING 2 WAY INTERMITTENT WIPER WIRING 8 WAY KEY IN BUZZER WIRING 2 WAY J908W 90 Fig 11 Steering Column Wiring ...

Страница 475: ...EL ANTI LOCK CONTROL MODULE STEERING COLUMN VIEWP R W A L TEST CONNECTOR IGNITION SWITCH 50 WAY BULKHEAD DISCONNECT TO R WA L CONNECTOR VIEWP TO CLEARANCE AND IDENTIFICATION LEFT HEADLAMP i m p S POWER PRINTED SWITCH MIRROR CIRCUIT BOARD SWITCH CONNECTOR TO PARK BRAKE SWITCH WIRE RETAINER VIEWU VIEWZ IGNITION DIPPER SWITCH VIEWW CLUTCH INTERLOCK SWITCH DIESEL TO CLUTCH INTERLOCK SWITCH VIEWW KEY I...

Страница 476: ...RK BRAKE SWITCH PARK BRAKE LEVER STEERING COLUMN SUPPORT CONNECTOR STOP LAMP SWITCH Fig 13 Stop Lamp and Parking Brake Switch Wiring J908W 92 INSTRUMENT PANEL BLOWER SWITCH TO BLOWER MOTOR RESISTOR BLOCK Fig 14 A C Heater Wiring J908W 93 ...

Страница 477: ...SNOW PLOW CONTROL 00 2 CD o CD 30 S GO O HI 2 RAISE LOWER BLADE CONTROL SWITCH INSTRUMENT PANEL Fig 15 Snow Plow Control Wiring ...

Страница 478: ... RIGHT HEADLAMP G R O U N D STRAP WINDSHIELD WIPER MOTOR RIGHT PARKING AND TURN SIGNAL LAMP PART THROTTLE UNLOCK RELAY T O STARTER RELAY O BATTERY H VALVE T O CHASSIS WIRING SPEED C O N T R O L SERVO SINGLE BOARD ENGINE CONTROLLER VIEW IN DIRECTION OF ARROW Z VIEW IN DIRECTION O F ARROW W J908W 94 Fig 16 Engine Compartment Wiring EFI Engine ...

Страница 479: ... CANADA ONLY T O RIGHT HEADLAMP RIGHT PARK AND TURN SIGNAL LAMP HEATER C O N T R O L MODULE WINDSHIELD WIPER MOTOR TO CHASSIS WIRING T O AIR HEATER RELAY LEFT PARK AND TURN SIGNAL LAMP NGINE CONTROLLER VIEWZ STARTER RELAY J908W 95 CD O CD 30 s w m r m o o fig 17 Engine Compartment Wiring Diesel Engine ...

Страница 480: ... WIRING DIAGRAMS ELECTRICAL 8W 21 ...

Страница 481: ......

Страница 482: ...OVERDRIVE SOLENOID SAFETY NEUTRAL AND BACK UP LAMP SWITCH OXYGEN SENSOR AUTO TRANS W OVERDRIVE SPEEDOMETER SENSOR Fig 21 Transmission Wiring 4 X 4 TRANSFER CASE J908W 99 ...

Страница 483: ...D CONTROL ACTUATOR COMPRESSOR CAPACITOR IGNITION TO RIGHT SIDE SHIELD WIRING EGR SOLENOID EXHAUST MANIFOLD NUTS VIEW IN DIRECTION OF ARROW Y VIEW IN DIRECTION OF ARROW X VIEW IN DIRECTION OF ARROW W EHB ENGINE TO VIEW V VIEW IN DIRECTION I A T OF ARROW Z COOLANT TEMPERATURE SENSOR J908W 100 Fig 22 Engine Wiring EFI Engine ...

Страница 484: ... WIRING BATTERY GROUND SOLENOID HYDRAULIC CYLINDER COWL VIEW IN DIRECTION OF ARROW X YELLOW MOLD VIEW IN CIRCLE V TYPICAL LEFT RIGHT SIDES VIEW IN DIRECTION OF ARROW Z U W AUTO TRANSMISSION ONLY SEE VIEW Y FOR MANUAL TRANSMISSIONS RP988 Fig 23 Snow Plow Wiring ...

Страница 485: ...8W 26 WIRING DIAGRAMS ELECTRICAL ...

Страница 486: ... 5 6 C4 9 M1 4 C7 9 MM 1 C9 5 6 M2 4 C13 4 M2 1 1 D1 10 N5 6 E2 4 N51 5 11 G5 4 P51 6 G7 5 6 R9 11 H4 1 4 W1 7 H4 2 4 W8 1 7 H4 3 4 W8 2 7 J2 6 X2 3 J2 1 6 11 X2 1 3 J2 2 5 X2 2 3 J9 6 X2 3 4 J9 2 6 11 X2 4 3 K5 5 6 X2 5 3 K5 1 6 11 X2 6 3 K8 11 X2 7 2 3 K9 5 X2 8 3 L1 4 X33 1 1 L6 1 X34 1 1 L7 6 X53 7 L7 1 4 X54 7 L7 2 3 Z1 5 L7 3 3 Z1 1 11 ...

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Страница 489: ...8W 30 WIRING DIAGRAMS ELECTRICAL ...

Страница 490: ...WIRING DIAGRAMS ELECTRICAL 8W ...

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Страница 492: ... WIRING DIAGRAMS ELECTRICAL 8W 33 ...

Страница 493: ...Fig a Snow Plow Wiring Splices J908W 108 ...

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Страница 496: ...nector R W A L 25 Diagnostic Connector Service 27 Dual Solenoid Hydraulic Valve 26 Fuse 25 Ground 26 Module 25 Park Brake Switch 25 Wiring Diagram Sheet Number Resistor 26 Sensor 26 Stop Lamp Switch 26 Back Up Lamp Switch With Diesel Engine 7 Back Up Lamp Switch With EFI Engine 7 Battery 1 3 5 17 Brake Warning Indicator Lamp Diesel Engine 53 Brake Warning Indicator Lamp EFI Engine 54 Brake Warning...

Страница 497: ...uel Injection Ignition System 3 9 5 2 5 9L Engine 13 14 15 16 Air Switching Solenoid 14 Auto Shutdown Relay 14 Coolant Sensor With EFI Engine 16 Diagnostic Connector 13 Name Wiring Diagram Sheet Number Distance Sensor 16 Distributor 16 Exhaust Gas Recirculation Solenoid 14 Ground 15 Heated Oxygen Sensor 13 Ignition Coil 14 Injectors 13 Map Sensor 16 Oxygen Sensor 13 Purge Solenoid 14 Single Board ...

Страница 498: ... Headlamp Left Auxiliary Snow Plow 32 Headlamp Right 40 42 Headlamp Right Auxiliary Snow Plow 32 Headlamp Switch Controlled Interior Lamps 44 Headlamp Switch Title Lamp 44 Heater Switch Lamp 44 High Beam Indicator Lamp 55 Ignition Switch Lamp 45 Instrument Panel Illumination Lamps 53 54 55 Key In Lamp 45 License Lamp 76 Liftgate Ajar Lamp 47 Low Oil Pressure Lamp Diesel Engine 55 Low Oil Pressure ...

Страница 499: ...ontrol Module 11 Diode 11 Fuse 11 Ground 44 Indicator Lamp 11 L E D 11 Solenoid 11 Name Wiring Diagram Sheet Number Switch 11 Parking Brake Switch 25 27 Part Throttle Unlock Relay With EFI Engine 9 Park Throttle Unlock Solenoid With EFI Engine 11 Power Door Lock System 69 70 Circuit Breaker 69 Left Door Motor 69 Left Door Switch 69 Right Door Motor 70 Right Door Switch 70 Power Mirrors 71 72 Fuse ...

Страница 500: ...oller 60 Way Connector Diesel Cavity 3 23 Cavity 4 24 Cavity 5 24 Cavity 6 24 Cavity 9 23 Cavity 11 24 Cavity 12 24 Cavity 22 24 Cavity 25 T 24 Cavity 29 23 Cavity 30 23 Cavity 44 12 Cavity 45 24 Cavity 47 23 Cavity 55 12 Single Board Engine Controller 60 Way Connector EFI 77 Cavity 1 16 Cavity 2 16 Cavity 3 15 Cavity 4 16 Wiring Diagram Name Sheet Number Cavity 5 13 Cavity 6 13 Cavity 7 v 16 Cavi...

Страница 501: ...5 47 48 57 59 61 71 Splice M1 1 47 Splice M2 45 Splice M2 1 47 Splice N5 16 24 Splice P51 28 Splice R9 4 Splice W1 68 Splice W8 1 68 69 71 Splice W8 2 68 69 Splice X2 1 75 76 Splice X2 2 37 75 Splice X2 3 73 74 Splice X2 4 37 Splice X2 5 37 Splice X33 1 70 Splice X34 1 70 Splice X53 61 Splice X54 61 Splice Z1 14 Starter System 7 8 Automatic Transmission Jumper 8 Back Up Lamp Switch 7 Fuse 7 Manual...

Страница 502: ... 67 Transmission Oil Temperature 34 Turn Signal 52 Underhood Lamp 18 Windshield Washer Intermittent Wipe 49 Windshield Washer Standard 51 Wiring Diagram Name Sheet Number Windshield Wiper Intermittent 49 Temperature Gauge 55 Temperature Sending With Diesel Engine 21 Temperature Sending Unit With EFI Engine 22 Temperature Sensor Diesel Engine 21 Temperature Sensor EFI Engine 22 Transmission Oil Tem...

Страница 503: ... HEADLAMP V W f SWITCH EI 18TN SH 43 L2 14LG 1 HEADLAMPS DIMMER SWITCH SH 43 STOP LAMPS SH 7 5 7 6 KEY IN I HEADLAMP ON BUZZER SH 7 3 7 4 REAR WHEEL ANTI LOCK SH 2 5 2 6 2 7 2 8 X I 16RD HORNS SH 3 1 17 18BK7YL 1FUSE 1 4 3 AMP E2 200R X CLUSTER LAMPS SH 55 RADIO LAMPS SH 5 7 5 9 6 1 A C i HEATER CONTROL LAMP SH 44 ASH RECEIVER LAMP SH 44 SNOW PLOW CONTROL LAMP SH 44 OVERDRIVE LAMP SH 1 1 PARKING L...

Страница 504: ... 8 J2 14DB o FUSE 13 J J 20 AMP o FUSE 12 J ft 5 AMP J2 14DB Bl 18WT i BACK UP LAMPS SH 75 76 o FUSE 5 20 AMP 20RD RADIO I CLOCK SH 57 59 61 Dl 18RD YL i TURN SIGNAL FLASHER SH 52 SNOW PLOW LAMP I SOLENOIDS SH 33 34 REAR WHEEL ANTI LOCK MODULE SH 2 5 2 7 AUTO SHUTDOWN RELAY SH 14 OVERDRIVE SOLENOIDS SH 11 12 VOLTAGE REGULATOR SH 6 ALTERNATOR SH 4 6 VACUUM SENSOR SH 28 AIR SWITCHING SOLENOIDS SH 14...

Страница 505: ... ENGINE BLACK REAR OF BATTERY FUSIBLE LINK HYPALON WIRE 23 Al 6BK TO HAZARD FLASHER SEE SH 52 TO A C CLUTCH f SEE SH 64 r REAR OF BATTERY BLACK TO FUSE 11 SEE SH 45 AND T0 C13 SPLICE SPORT UTILITY ONLY SEE SH 35 48 C9 12BK Al 6BK Al 6BK Al 6BK TO STARTER RELAY t SEE SH 7 C13 18GY FUSIBLE LINK HYPALON WIRE Al 12RD AD 3 CHARGING SYSTEM WITH ELECTRONIC FUEL INJECTION IGNITION JMSU M ...

Страница 506: ...ERNATOR 50 120 ALTERNATOR SHOWN FUSIBLE LINK HYPALON WIRE J10 120R FUSIBLE LINK HYPALON WIRE C26 14BR 50 J10 12PKX J10 12PKX J l 120R FUSIBLE LINK HYPALON WIRE 49 Q Q Jl 1 2 R D Jl 12RD TO WIDE OPEN THROTTLE RELAY SEE SH 64 TO IGNITION SWITCH SEE SH 10 Al 12RD LI 18GY Jll 22WT L l 12RDX Jl1 14RD J l l 16RD Ll 12RDX 1 TO AUTO SHUTDOWN 1 RELAY SEE SH 14 TO SINGLE BOARD 4 ENGINE CONTROLLER CAVITY 3 S...

Страница 507: ...E WIRING5 SEE SH 19 TO AIR HEATERr CONTROLLER SEE SH 18 TO VACUUM f SENSOR SEE SH 28 TO A C CLUTCH CYCLING SWITCHV SEE SH 66 BODY GROUND LEFT YOKE FRONT OF BATTERY J2 14DB TO TRANSMISSION WIRING SEE SH 12 TO STARTER MOTOR SEE SH 7 BLACK REAR OF BATTERY TO STARTER RELAY SEE SH 7 FUSIBLE LINK HYPALON WIRE AD 5 CHARGING SYSTEM WITH DIESEL 5 9L ENGINE J908W 14 ...

Страница 508: ...BLE LINK HYPALON WIRE Al 12RD FUSIBLE LINK HYPALON WIRE JIO 20OR J l 200R 50 D Q JIO 12PK C13 20OR FUSIBLE LINK HYPALON WIRE J l 12RD 49 DO J l l 22WT 1 LI 18GY Ll 12RDX 50 120 ALTERNATOR RIGHT SIDE FORWARD OF ENGINE R6 6BK Al 12RD JIO 12PKX J l 12RD TO STARTER RELAY SEE SH 7 TO IGNITION SWITCH SEE SH 10 J l l 16RD L l 12RDX TO AUTO TRANS ENGINE CONTROLLER i CAVITY 3 SEE SH 23 T0 L1 SPLICE SEE SH ...

Страница 509: ...8W 50 WIRING DIAGRAMS ELECTRICAL TO CHARGING SYSTEM SEE SH 3 6 TO EBL SWITCH SEE SH 3 5 FUSE 1 3 20 AMP SEE SH 10 STARTER MOTOR LEFT LOWER REAR OF ENGINE AD 7 STARTER SYSTEM J908W 14 ...

Страница 510: ...CH SEE SH 10 S2 14YL S2 16YL XL S2 14YL 31 DIESEL ENGINE BLACK f t NEAR CLUTCH ROD MANUAL TRANSMISSION BLACK 7 18BK 18BK CLUTCH SWITCH ON CLUTCH ROD AUTOMATIC TRANSMISSION BLACK 7 S2 14YL BYPASS JUMPER TAPED TO WIRE HARNESS SWITCH CLOSES WHEN CLUTCH IS DEPRESSED J908W 14 STARTER SYSTEM AD 8 ...

Страница 511: ...4DB L X2 16GY J2 14DB U _ I U3 200R BK U3 200R BK J22 14DB TO 4 CHASSIS WIRING SEE SH 37 75 X2 16GY X9 14BK TO C9 GROUND CE PART THROTTLE UNLOCK RELAY LEFT SIDE DASH PANEL SEE SH 51 PART THROTTLE UNLOCK SOLENOID 3 SPEED AUTO TRANS J22 14DBX J22 14DB TO OVERDRIVE LOCK OUT U3 200R BK TRANSMISSION SEE SH 11 BLACK REAR OF ENGINE AD 9 PART THROTTLE UNLOCK 3 SPEED AUTOMATIC TRANSMISSION U908W 14 ...

Страница 512: ...CE SEE SH 5 DIESEL TO FUSE 1 30 AMP AIR CONDITIONING A N D HEATER FEED SEE SH 62 63 65 020 12BK RDX FUSE 2 Q2 30 A M P 14BKX CIRCUIT BREAKER CI 12BR TO P51 20BK GYX 0 Al Bl D J2 14DB 52 14YL 02 14BKX Wl 12TN BK H S s SEE SH 68 P51 20BK GYX FUSE 15 15 AMP Al FUSE 4 JO AMP FUSE 5 20 AMP FUSE 6 20 AMP B3 Jl 12RD JIO 12PKX Bl I 020 12BK RDX ODD X12 20RDX P51 20BK GY X P51 20BK GY X BASE OF STEERING CO...

Страница 513: ... WT OVERDRIVE MODULE LEFT CENTER OF INSTRUMENT PANEL SEE SH 4 4 U3 2 0 0 R B K GROUND SPLICE BLACK U3 200R BK 3 U40 2 0 0 R L G J 2 14DB 44 54 SINGLE BOARD ENGINE CONTROLLER SBEC 55 CONNECTOR SEE SH 7 7 RIGHT REAR OF ENGINE T 0 J 2 2 1 S P L I C E SEE SH 1 4 PART THROTTLE UNLOCK S O L E N O I D ON T R A N S M I S S I O N U3 200R BKX J2 14DB U40 200R LGX OVERDRIVE LOCKOUT SOLENOID AD 11 OVERDRIVE L...

Страница 514: ...L BK a a G5 20DB y NATURAL E10 20OR YL U4 200R WT 44 H4 20BK OVERDRIVE MODULE RIGHT SIDE ON BRAKE SUPPORT BRACKET U4 200R WT H4 20BK T0 H4 ll SPLICE SEE SH 44 SINGLE BOARD ENGINE CONTROLLER SBEC CONNECTOR SEE SH 78 55 44 U4 200R WT U4 200R WTX T0 J2 SPLICE SEE SH 5 U40 200R DB J2 14DB U40 200R LG o o o o o o O o O REAR OF ENGINE ON TRANSMISSION CF BLACK U40 200R DB J2 14DB OVERDRIVE LOCKOUT SOLENO...

Страница 515: ..._ BLACK ENGINE BLACK K8 20VT X nJ rTjn K7 180R DB 0 jh N5 18BK LB X jQ Zl 14DG BK C20 18BR N13 20DB OR 18WT DB 18TN Nil 18BK DG K5 16BKX K9 K9 V Q K7 18LB 18LB o L l 8 0 R RD RD i Q y i DB DK20 20LG DK21 20PK 27 34 16 15 41 5 11 12 6 22 45 25 SINGLE BOARD ENGINE CONTROLLER SBEC CENTER OF DASH PANEL 60 ENGINE WAY SINGLE BOARD CONTROLLER CONNECTORS SEE SH 77 AD 13 ELECTRONIC FUEL INJECTION IGNITION ...

Страница 516: ... YL Zl 16DG BK AUTO SHUTDOWN RELAY LEFT SIDE SHIELD TO CHARGING Jl 14RD i SYSTEM v SEE SH 4 J2 14DB I Kl 20PK I GREEN SEALJ N23 20BK 0R J2 14DB BLUE SEAL I AIR SWITCHING N23 20BK OR PURGE Kl 20PK 37 i ENG H ENG h TO A C WIDE OPEN THROTTLE RELAY SEE SH 64 Zl 16DG BK N23 20BK OR 36 EGR S6 20GY YL VACUUM SOLENOIDS 35 ENG IGNITION COIL RIGHT FENDER SIDE SHIELD J5 18BK YL Kl 20PK S6 20GY YL TO ALTERNAT...

Страница 517: ...MS ELECTRICAL N2 18BRX 30 28 40 60 29 3 20 32 56 SINGLE BOARD ENGINE CONTROLLER SBEC CENTER OF DASH PANEL 60 ENGINE WAY SINGLE BOARD CONTROLLER CONNECTOR SEE SH 77 AD 15 ELECTRONIC FUEL INJECTION IGNITION SYSTEM J908W 14 ...

Страница 518: ...BK L B N6 180R N7 18GY K13 18BK RD 23 ENG h 11 H ENG h N6 180R K10 20TN K13 18BK RD i 3 ENG N5 18BK LB 32 ENG N5 18BK LB N7 18GY BLACK TO LEFT PRINTED CIRCUIT BOARD CONNECTOR SEE SH 58 O O 5 4 O O J 3 2 67 N5 18BK LB 20WT 2 ls OR o m G7 20WT OR 43 DISTANCE SENSOR ON REAR OF TRANSMISSION G7 20WT 0R o a o GRAY K8 20VT WT K4 20DG RD N5 18BK LB MAP SENSOR THROTTLE BODY TO K4 20DG RD 1 K8 20VT WT K8 10...

Страница 519: ...L A4 6BK H Z S ZZ AH9 18BK LEFT FENDER SIDE SHIELD TO STARTER SYSTEM SEE SH 8 S21 18YL BK A7 6BK A7 6BK AX9 16BK c 9 9 TO COLD START r iftnp ADVANCE 1 l8 H SEE SH 19 S21 18YL BK S2 16YL TO MESSAGE S2 16YL J2 14DB 15 S2 16YL T DJ2 14DB J32 18DB WT J32 18DB WT S21 18YL BK 11 E5 20DG WT TO STARTER RELAY SEE SH 7 S2 18YL J2 14DB S22 180R BK S 2 18YL E5 20DG WT AD 17 DIESEL ENGINE WIRING J908W 14 ...

Страница 520: ...SOR SEE SH 28 SPLICE SEE SH 24 I I J9 16BK K32 20TN BK K5 K5 f g j 18BK 18BK BK WATER IN FUEL SENSOR IN FUEL FILTER TEMPERATURE SENSOR K5 14BK TO SPLICE SEE SH 5 T J2 14DB TO MESSAGE Q CENTER f T DIESEL SEE SH 53 K31 20BK PK f K31 20BK PK CO 38 K5 18BK N TO DIAGNOSTIC CONNECTOR DJ2 14DB 1 SEE SH 24 AUTO TRANSMISSION ONLY J32 18DB WT S21 18YL BK J2 14DB S22 180R BKX S 2 18YL E5 20DG WT AIR HEATER C...

Страница 521: ...AGRAMS ELECTRICAL TO AIR HEATER c CONTROLLER SEE SH 17 U32 18DB K5 16BKX REAR OF ENGINE 5TO K5 SPLICE SEE SH 18 FUEL HEATER REAR OF ENGINE SPLICE SEE SH 5 FUEL PUMP CENTER OF ENGINE AD 19 DIESEL ENGINE WIRING J908W 14 ...

Страница 522: ... 47 TO RIGHT SIDE COWL PANEL SPLICE SEE SH 40 42 L29 18BK Ml 18PK L28 18BK FUSE 11 10 AMP Ml 20PK C13 12BK RD L29 16BK 48 TO CHANGING SYSTEM y SEE SH 3 5 C13 12BK RDX L29 16BK L22 16BK RDX F MERCURY SWITCH BLACK REEL TYPE UNDERHOOD LIGHT CENTER OF HOOD INNER PANEL J908W 14 UNDERHOOD LAMP AD 20 ...

Страница 523: ...6 6 5 W 2 o o o o o GRAY BLACK 1 17 G20 20VT YL G 2 0 20VT YL G6 20GY f 66 20GY G60 20GY YL G60 20GY YLX TO RIGHT PRINTED CIRCUIT BOARD CONNECTOR SEE SH 56 BLACK REAR OF ENGINE OIL PRESSURE SENDING UNIT AND SWITCH AD 21 OIL PRESSURE SYSTEM FOR AND TEMPERATURE DIESEL ENGINE J908W 14 ...

Страница 524: ...O LEFT PRINTED CIRCUIT BOARD CONNECTOR SEE SH 56 1 7 66 20GY 1 5 ENG G60 20GY OR G20 20VT YL 16 H ENG h 26 H ENG h OIL PRESSURE SENDING UNIT AND SWITCH G60 20GY 0R G6 206Y TEMPERATURE SENDING UNIT RIGHT SIDE FRONT OF ENGINE i_ J908W 14 OIL PRESSURE AND TEMPERATURE SYSTEM FOR ELECTRONIC FUEL INUECTION IGNITION AD 22 ...

Страница 525: ... LAMP SW1 SEE SH 5 SEE SH 28 BLACK T S4 20BR YL TO STARTER RELAY SEE SH 7 G7 20WT OR 67 20WT 0R N5 20BK LB G7 20WT 0R TO DAYTIME RUNNING LAMP MODULE CANADA ONLY SEE SH 42 REAR OF ENGINE N5 20BK LB G7 20WT OR ON REAR OF TRANSMISSION 43 67 20WT OR TO LEFT PRINTED CIRCUIT BOARD CONNECTOR SEE SH 56 DISTANCE SENSOR ON REAR OF TRANSMISSION AD 23 AUTOMATIC TRANSMISSION WIRING DIESEL JSOBU M ...

Страница 526: ...CANADA ONLY SEE SH 42 TO ENGINE WIRING f SEE SH 18 19 r T0 Q 521 SPLICE SEE SH 18 TO VACUUM SENSOR SEE SH 2 8 DK5 16BK DIAGNOSTIC CONNECTOR K8 K7 20VT 180R WT DB J2 14DB N5 18BK L B DU2 14DB I H N 5 18BK LB l TO AIR HEATER CONTROLLER SEE SH 18 N5 20BK LB BLACK REAR OF ENGINE i I N5 18BK LB K7 180R DB K8 20VT WT THROTTLE POSITION TRANSDUCER J908W 14 AUTOMATIC TRANSMISSION WIRING DIESEL AD 24 ...

Страница 527: ...LS TEST CONNECTOR B01 18RD VTX B02 18RD VTX 7 f 7 t B01 18RD VTX B02 18WT VTX 25 D4 18WT TNX D3 20PK DBX P5 20GY BK X D4 18WT TNX D3 20PK DBX ATI 180R P51 20BK GYX DK 18BKX H40 20BK LGX TO INTERMITTENT WIPER MODULE SEE SH 49 GRAY D4 18WT TNX P51 20BK GYX P5 20GY BKX X4 20LG BRX Dl 14RD YLX AT1 180R IS1 16LGX ft 0 BOl 18RD VTX B02 18WT VTX DK 18BKX VS1 18LB H40 20BK LGX D3 20PK DBX DS1 14WT BRX BLA...

Страница 528: ...GY 1 0 TO HAZARD D4 1SWT FLASHER SWITCH SEE SH 52 R W A L SENSOR IN REAR DIFFERENTIAL O STOP LAMP AND SPEED CONTROL SWITCH WITH SPEED CONTROL STOP LAMP SWITCH WITHOUT SPEED CONTROL J908W 14 REAR WHEEL ANTI LOCK BRAKE GAS ENGINE SYSTEM AD 26 ...

Страница 529: ...C O N N E C T O R f B09 18RD VTX B02 18WT VT B01 18RD VT B02 18WT VT D4 18WT TN D 3 20PK DBX P2 20BK GYX D4 18WT TN D3 20PK DB ATI 180R P5 20GY BK X DK 18BK H40 20BK LGX TO INTERMITTENT WIPER MODULE SEE SH 49 GRAY D4 18WT TN P2 20BK GYX P5 20GY BKX X4 20LG BRX Dl 14RD YLX AT1 180R IS1 16LGX B01 18RD VTX B02 18WT VTX DK 18BKX VSi 18LB H40 20BK LGX D3 20PK DBX DS1 14WT BRX BLACK SERVICE DIAGNOSTIC C...

Страница 530: ... 52 D3 20PK DB D4 18WT TN B01 B02 18RD 18RD VT VT 1 D3 1 r TO 8PK DBX H4 18BK i r D4 20WT TN H4 20BK L D40 18WT PK i GROUND SPLICE SEE SH 44 RESISTOR 41 B01 20PK 18WT SPLICE SEE SH 5 O STOP LAMP SWITCH D40 18WT PK TO SINGLE BOARD ENGINE CONTROLLER CAVITY 29 SEE SH 23 TWISTED PAIR BLACK B02 20LG OR 1 1 C I 1 1 LEFT F E N D E R SIDE SHIELD R E A R L E E L ANT I L O C K B R A K E S Y S T E M J808U M ...

Страница 531: ... 77 TO TRANSFER CASE SWITCH SEE SH 67 X9 20BK T0 C9 SPLICE SEE SH 51 X32 20YL RD X31 20BR RD X33 20WT LG D40 18WT PK X36 20TN RD X35 20LG RD H BLACK SPEED CONTROL SERVO X30 20DB RD TO R W A L SEE SH 26 28 D40 18WT PK L D3 18PK DB D3 18PK DB TO SEAT BELT WARNING SYSTEM SEE SH 73 74 FUSED BATTERY FEED AD 29 ELECTRONIC SPEED CONTROL SYSTEM J908W 14 ...

Страница 532: ...2 20YL RD X31 20BR RD GROUND SPLICE SEE SH 44 20BK D3 18PK DB D3 18PK DB D40 18WT PKX D40 18WT PKX 41 SPEED CONTROL SWITCH ON STEERING COLLUMN STOP LAMP AND STOP LAMP SWITCH SPEED CONTROL SWITCH WITHOUT SPEED CONTROL WITH SPEED CONTROL J 9 0 8 W H ELECTRONIC SPEED CONTROL SYSTEM AD 30 ...

Страница 533: ...IATOR SUPPORT BLACK H2 18DG RD RIGHT SIDE OF RADIATOR SUPPORT BLACK TO A C CONNECTOR SEE SH 64 66 T H4 18BK 2 32 STRG COLUMN H4 18BK H4 20BK H2 18DG TO IGNITION KEY IN LAMP H4 18BK SEE SH 45 H4 18BK 25 ON FUSE BLOCK R SEE SH 83 STRG COLUMN STEERING COLUMN 3 STRG COLUMN H3 18BK RD H3 18BK RD HORN SWITCH RETAINER PLATE H4 18BK STEERING COLUMN GROUND AD 31 HORN SYSTEM J908W 14 ...

Страница 534: ...BLACK BLACK RIGHT SIDE RADIATOR YOKE PANEL BLACK BLACK RIGHT UPPER SNOW PLOW FRAME BLACK LEFT AUXILIARY PARK AND TURN SIGNAL LAMP J908W 14 TO FRONT END LIGHTING SEE SH 43 LEFT AUXILIARY HEADLAMP RIGHT AUXILIARY HEADLAMP RIGHT AUXILIARY PARK AND TURN SIGNAL LAMP SNOW PLOW EXTERIOR LIGHTING AD 32 ...

Страница 535: ...O W N SP4 18WT BRX i r SP4 18WT BRX 1 Dl 18RD YL tT L L SP4 18WT BRX 1 PLOW CONTROL SWITCH LEFT TO RIGHT Dl 18RD YLX TRANSMISSION OIL TEMPERATURE LAMP I4BKX TO IGNITION SWITCH SEE SH 10 i SP4 18WT BRX SP4 18WT BRXj SP4 18WT BR I SP1 18WT BKX l Dl 18RD YLX SP3 18WT RDX i i 1 SP3 18WT RDX SP1 18WT BKX SP4 18WT BR j SP4 18WT BRXI SP4 18WT BRXl Dl 18RD YL SP5 18WT LG i 1 SP5 18WT LG T2 18LG RDX AD 33 ...

Страница 536: ... i SNOW PLOW MOTOR FRONT SNOW PLOW FRAME G9 6BK E6 BLACK FRONT SNOW PLOW FRAME SP5 18WT LG 12 18LG RDX SP3 18WT RDX I 18WT BKX SNOW PLOW UP SOLENOID FRONT SNOW PLOW FRAME SP3 16RD SP1 16BK BLACK FRONT SNOW PLOW FRAME SNOW PLOW D O W N SOLENOID FRONT SNOW PLOW FRAME SP5 18WT LGX SP5 16LG nrn BLACK FRONT SNOW PLOW FRAME SNOW PLOW RIGHT SOLENOID FRONT SNOW PLOW FRAME TRANSMISSION OIL TEMPERATURE SWIT...

Страница 537: ...LICE f SEE SH 44 ILLUM LAMP FEED C13 12BK RD E2 220R H4 20BK Bl 18WT CIS 12BK 0RX Bl E2 18WT 220R ON 0 O F F MECHANICAL OFF ON SWITCH HEATED REAR WINDOW DEFOGGER SWITCH INSTRUMENT PANEL TIMER L E J O 48 C13 12BK RD CIS 12BK 0RX C13 12BK RD BLACK CIS 12BK 0R C15 12BK 0RX TO FUSE BLOCK CAVITY 11 SEE SH 45 BLACK LEFT C PILLAR BLACK IN TAIL GATE ELECTRICALLY HEATED REAR WINDOW AD 35 SPORT UTILITY JSOS...

Страница 538: ...SH 43 L7 18BK YL 17 18BK YL CLEARANCE LAMP L7 18BK YL L7 18BK YL L7 18BK YL L7 18BK YL BLACK L7 18BK IDENTIFICATION LAMP L7 18BK I DENT IFI CAT I ON LAMP L7 18BK AT LAMP BLACK IDENTIFICATION LAMP L7 18BK AT LAMP CLEARANCE LAMP J908W 14 FRONT CLEARANCE AND IDENTIFICATION LAMPS ROOF AD 36 ...

Страница 539: ...8W 80 WIRING DIAGRAMS ELECTRICAL SPLICE SEE SH 39 41 18GY L7 18BK YL L7 18BK YL L7 18BK YL AD 37 CLEARANCE AND IDENTIFICATION LAMPS DUAL REAR WHEELS J9G8W 14 ...

Страница 540: ...BODY LEFT SIDE L7 16BK X2 16GY BL X2 18GY L7 18BK YL L7 16BK X2 16GY L7 16BK X2 16GY L7 16BK X2 16GY L7 16BK X2 16GY BLACK REAR UNDERBODY RIGHT SIDE on an LEFT FENDER CLEARANCE LAMPS an on OLX an RIGHT FENDER CLEARANCE LAMPS an on FENDER CLEARANCE LAMPS DUAL REAR WHEELS AD 38 ...

Страница 541: ... HEADLAMP LEFT SIDE MARKER LAMP L7 18BK YL D6 18LG BLACK 18LG 18BK 18BK YLX L4 16VT L3 14RD OR D5 18TN 05 18TN D6 18LG D6 18LG T0 L7 T SPLICE 5 L7 18BK YL SEE SH 43 L3 14RD 0RX LEFT PARK AND TURN SIGNAL LAMP LEFT HEADLAMP GROUND L7 18BK YLX L7 18BK YL L7 18BK YL LEFT REAR RADIATOR YOKE PANEL GAS ENGINE ONLY TO REAR LIGHTING SEE SH 75 AD 39 FRONT END LIGHTING J908W 14 ...

Страница 542: ...9 18BK C9 14BK RIGHT HEADLAMP GROUND TO SPLICE SEE SH S i RIGHT HEADLAMP RIGHT SIDE MARKER LAMP RIGHT PARK AND TURN SIGNAL LAMP TO UNDERHOOD LAMP SEE SH 20 RIGHT REAR RADIATOR YOKE GAS ENGINE ONLY 18BK J908W 14 FRONT END LIGHTING AD 40 ...

Страница 543: ...8W 84 WIRING DIAGRAMS ELECTRICAL L33 16RD BK L33 16RD BKX LEFT REAR RADIATOR YOKE PANEL GAS ENGINE ONLY TO REAR LIGHTING SEE SH 75 AD 41 FRONT END LIGHTING CANADA J908W 14 ...

Страница 544: ...T HEADLAMP Q GROUND i G7 20WT OR J2 14DB L4 16VT L3 14RD OR L9 20BK L4 16VT DAYTIME RUNNING LIGHT MODULE ft o O o o o o o o O o y ENGINE COMPARTMENT LEFT SIDE TO G7 SPLICE SEE SH 23 TO J2 2 SPLICE SEE SH 14 GAS ENGINE _fT0 ENGINE WIRING SEE SH 6 DIESEL ENGINE L4 16VT L3 14RD 0R RIGHT HEADLAMP TO L29 18BK UNDERHOOD LAMP J SEE SH 20 RIGHT SIDE MARKER LAMP LEFT PARK AND TURN SIGNAL LAMP J908W 14 FRON...

Страница 545: ...ICAL i o R n 4 T 0 FUSIBLE LI 12RDX LINK FUSE 14 3 AMP TO LEFT DOOR SWITCH SEE SH 45 TO DAYTIME RUNNING LAMP MODULE SEE SH 42 CANADA ONLY L L4 16VT X f L3 14RD OR AD 43 HEADLAMP SWITCH 6 TO FRONT END LIGHTING SEE SH 39 41 J908W 14 ...

Страница 546: ... 87 TO EBL SWITCH SEE SH 35 SPORT UTILITY ONLY TO CIGAR LIGHTER SEE SH 48 r TO CARGO LAMP SWITCH SEE SH 45 f TO A C i HEATER WIRING SEE SH 63 65 TO GLOVE BOX LAMP SEE SH 48 J908W 14 HEADLAMP SWITCH CONTROLLED INTERIOR LIGHTING AD 44 ...

Страница 547: ...8W 88 WIRING DIAGRAMS ELECTRICAL T O COMBINED BUZZER SEE S H 73 74 K9KKKM K M K M K M K M TO BODY WIRING SPORT UTILITY ONLY SEE SH 47 AD 45 DOME LAMP MAP LAMPf AND CARGO LAMP JSOSW M ...

Страница 548: ...CK NEAR LAMP Y Y L6 L6 180R I80R VT VT M2 18BK YL Ml 18BK PK fcLJEL rum BLACK r n NEAR LAMP LEFT SIDE OF STEERING COLUMN BLACK M2 18BK YL Ml 18BK PK BLACK STANDARD CAB CLUB CAB M2 20YL Ml 18PK L6 180R VT L22 18BK RD TO UNDERHOOD 4 LAMP SEE SH 20 BLACK M 2 20YL 5 TO BODY WIRING SPORT UTILITY ONLY SEE SH 47 J908W 14 DOME LAMP AND CARGO LAMP AD 46 ...

Страница 549: ...2 2 0 1 FUSE 11 10 AMPS GRAY SEE SH 45 M4 20TN BK GREEN LEFT B PILLAR M2 18BK YL M2 18BK YLX Ml 18PK PK FRONT DOME READING LAMP BLACK H B Z LIFTGATE AJAR SWITCH LIFTGATE LATCH 18BK RD Ml 18PK TO UNDERHOOD LAMP SEE SH 20 M4 18TN BK BODY GROUND BLACK LEFT C PILLAR K2 12BK AD 47 LIFTGATE AJAR WARNING SYSTEM REAR DOME LAMPS SPORT UTILITY ONLY JSOSW M ...

Страница 550: ... n n t i t u U H4 20BK SEE SH 44 H4 20BK H4 18BK 1 CENTER OF INSTRUMENT PANEL BLACK X22 16RD TN FUSE 15 15 AMP TO HEADLAMP N SWITCH E l 18TN SEE SH 43 E2 200R FUSE 14 3 AMP ASH RECEIVER LAMP dx E2 200R H4 20BK Q2 14BKX TO IGNITION SWITCH SEE SH 10 SEE SH 44 H4 20BK J908W 14 C I G A R L I G H T E R A S H R E C E I V E R LAMP g G L O V E BOX LAMP AD 4 8 ...

Страница 551: ...IPER SWITCH ON STEERING COLUMN V9 18WT V3 18BR V4 18RD V7 18DGX V17 18DG YLX V3 18BRX STRG COLUMN ll V3A 18BR YLX STRG COLUMN V17 18DG YLX VIO 18BR V8 18VT V9 18WTX V7 18DG V6 18DB V5 1 8 D G H40 18BK LGX V6 18DB STRG COLUMN STRG COLUMN 12 STRG COLUMN V3 18BRX 14 V5 18DG STRG TCOLUMN V4 18RD YLX 13 18 TO REAR WHEEL H 4 Q H40 20 BK LG lc A N T I J QQ 18BK SEE SH 25 27 LG H4 16BK T0 H4 2 SPLICE SEE ...

Страница 552: ...7 18DG V6 18DB V5 18DG H40 18BK LGX TO IGNITION SWITCH SEE SH 10 MOUNTED O N BRACKET UNDER STEERING COLUMN 02 14BKX FUSE 6 20 AMP V6 18DB V6 18DB V6 18DB 36 fill 45 V3 18BRX f V3 18BR 35 V5 18DG V5 18DG V4 18RD YLX Y 46 nn V4 18RD YL INTERMITTENT WINDSHIELD WIPER MOTOR IN PLENUM LEFT SIDE V6 18DB DIESEL ONLY V3 18BRX V6 18DB V5 18DG V4 18RD YLX TO A C SYSTEM DIESEL ONLY SEE SH 66 PARK SWITCH J908W...

Страница 553: ...LY STRG COLUMN STRG COLUMN 46 STRG N COLUMN 16 V6 VIO 18DB 20BR V6 m V6 18DB f n l 29 FUSE 6 20 AMP 02 14BK SPLICE SEE SH 18 TO A C BLOWER MOTOR SEE SH 62 63 65 V6 VIO 18DB 20BR TO IGNITION SWITCH tr1 SEE SH 10 PARK SWITCH 2 SPEED WINDSHIELD WIPER MOTOR CENTER OF PLENUM TO A C SYSTEM DIESEL ONLY SEE SH 66 WINDSHIELD WASHER PUMP MOTOR UNDER WINDSHIELD WASHER RESERVOIR a V3 V6 V5 V4 18BR 18DB 18DG 1...

Страница 554: ...LECTRICAL 8W 95 TO IGNITION 4 SWITCH SEE SH 10 TO CHARGING 5 SYSTEM SEE SH 3 5 HAZARD WARNING FLASHER MOUNTED ON FUSE BLOCK SEE SH 83 TO REAR LIGHTING SEE SH 75 BLACK U908W 14 STOP TURN AND HAZARD FLASHER SYSTEMS AD 52 ...

Страница 555: ...IGNINTION SWITCH GROUND BULB TEST SEE SH 27 P2 20BK BRAKE WARNING SWITCH i VACUUM SWITCH SEE SH 27 E5 20DG WAIT TO START SWITCH SEE SH 17 ATI 180R ANTI LOCK MODULE SEE SH 27 G5 20DBX IGNITION 12V FEED SEE SH 54 H4 20BK GROUND H4 Y SPLICE SEE SH 44 G40 20DB RDX FUEL TANK LOW FUEL SWITCH SEE SH 73 AD 53 MESSAGE CENTER DIESEL JSOSU M ...

Страница 556: ...20BK GY SEE SH 25 P51 20BK GY SEE SH 10 ATI 180R BLACK TO R W A L MODULE IGNITION SWITCH GROUND TO R W A L 4 MODULE SEE SH 25 G29 22GY PKX EMISSION MAINTENANCE REMINDER SEE SH 15 K3 20BK PK X SEE SH 15 P5 20BK GY X SEE SH 25 P5 20GY BK X SEE SH 25 CHECK ENGINE LAMP TO R W A L MODULE BRAKE LAMP WARNING SWITCH TO COMBINED BUZZER SEE SH 73 74 TO SPEED CONTROL SEE SH 30 TO LEFT PRINTED CIRCUIT BOARD C...

Страница 557: ...8W 98 WIRING DIAGRAMS ELECTRICAL AD 5 5 C L U S T E R P R I N T E D C I R C U I T BOARD JSOSW M ...

Страница 558: ...SEE SH 47 G5 20DB IGNITION FEED 12 VOLTS SEE SH 54 LEFT CONNECTOR BLACK E2 200R ILLUMINATION LAMP FEED SEE SH 44 H4 20BK GROUND SEE SH 44 G4 20DB YLX FUEL GAUGE SENDING UNIT SEE SH 73 74 G6 20GY OIL PRESSURE LAMP SWITCH SEE SH 21 22 G5 20DB IGNITION FEED 12 VOLTS SEE SH 54 73 74 L33 16RD BKX HI BEAM INDICATOR LAMP SEE SH 39 41 05 18TN RI6HT TURN SIGNAL LAMP SEE SH 52 660 20GY YL OIL PRESSURE GAUGE...

Страница 559: ...E 4 10 AMP FUSE 14 3 AMP X12 20RD E2 200R SEE SH 44 E2 200R X12 20RD Ml 20PK 1 In 18BK YLX SEE SH 43 GRAY BEHIND RADIO L7 18BK YL X X55 20BR RDX X56 20DB RDX nl GRAY BLACK JL X56 18DG X55 18BR 0RX X58 18DB 0RX X57 18BR LBX X54 18VT X53 18DG X52 18DBX X51 18BR YLX FOR 2 SPEAKERS WIRING SEE SH 61 STEREO RADIO AD 57 STEREO RADIO 4 SPEAKERS J908W 14 ...

Страница 560: ... 1 8 D B W T X X58 18DB 0RX B E L O W B U L K H E A D Lb d X53 1 8 D G B L A C K X53 2 0 G N X55 1 8 B R O R X X55 2 0 B K LEFT F R O N T D O O R SPEAKER J908W 14 G R E E N X56 1 8 D G 9 RIGHT R E A R SPEAKER BLACK S C A T SPEAKER C O W L TOP RIGHT SIDE X56 1 8 D G X54 2 0 G N X56 2 0 B K RIGHT F R O N T UL l D O O R SPEAKER S T E R E O R A D I O 4 S P E A K E R S AD 5 8 ...

Страница 561: ...GNITION SWITCH SEE SH 10 TO BATTERY FEED SEE SH 3 5 GRAY BEHIND RADIO X56 18DB RD X55 18BR RDX X58 18DB 0R X57 18BR LB X54 18VT X 5 3 18DG X 5 2 18DB X51 18BR YL BLACK FOR 2 SPEAKERS WIRING SEE SH 61 K P QQQQQ STEREO RADIO AD 59 STEREO RADIO 4 SPEAKERS SPORT UTILITY J908W 14 ...

Страница 562: ... WIRING DIAGRAMS ELECTRICAL 8W 103 LEFT REAR SPEAKER B r 1 RIGHT REAR SPEAKER GREEN X56 20BK J908W 14 RIGHT FRONT WxjM DOOR SPEAKER S T E R E O R A D I O 4 S P E A K E R S S P O R T U T I L I T Y AD 6 0 ...

Страница 563: ...i H e BiQ TO BATTERY FEED SEE SH 3 5 L7 18BK YL FUSE 4 10 AMP FUSE 14 3 AMP X12 20RD SEE SH 43 L7 18BK YL X SEE SH 44 E2 200R X12 20RD Ml 20PK X58 20DB RD X X55 20BR RD X GRAY BEHIND RADIO X55 20BR RDX TO SPEAKER WIRING SEE SH 57 59 X56 20DB RDX BLACK GRAY BLACK SEE SH 45 STEREO RADIO AD 61 STEREO RADIO DUAL SPEAKERS JSOSW M ...

Страница 564: ... C7 16DG 4 2 C4 18TN HEATER BLOWER MOTOR RESISTOR RIGHT SIDE OF PLENUM C7 12DG 12BK HEATER BLOWER MOTOR RIGHT SIDE DASH PANEL TO WINDSHIELD WASHER V MOTOR SEE SH 49 51 C4 18TN C5 16LG C7 16DG BLACK C7 12DG HEATER BLOWER SWITCH Cl 12BR 2 NATURAL C7 12DG LEFT CENTER OF INSTRUMENT PANEL SPLICE SEE SH 51 J908W 14 HEATER AD 62 ...

Страница 565: ...0TN C4 10TN C7 12DG c7 1 C7 12DG BLACK 1 C 9 12BK 1 HEATER BLOWER MOTOR RIGHT SIDE DASH PANEL IN CENTER OF INSTRUMENT PANEL BLACK AIR CONDITIONER AND HEATER VACUUM SWITCH INSTRUMENT PANEL H4 18BK Cl 10BR C3 12WT DGX NATURAL C7 12DG Cl 10BR H4 18BK C2 18DB OR C2 18DB 0R Cl 12BR V9 20BK SPLICE SEE SH 51 TO WASHER MOTOR SEE SH 49 51 C7 12DG TO H4 21 SPLICE H 4 18BK 7 s r n y S E S H 4 H4 18BK Cl 12BR...

Страница 566: ...14 SEE SH 14 WIDE OPEN THROTTLE CUTOUT RELAY TO FUSIBLE LINK C SEE SH 4 C26 14BR T J2 14DB TO SINGLE BOARD ENGINE CONTROLLER CAVITY 27 34 SEE SH 13 T T N13 20DB OR C20 18BR LEFT FENDER SIDE SHIELD N13 20DB 0R C20 18DB OR f PROBE A C LOW PRESSURE SWITCH RIGHT FENDER SIDE SHIELD RIGHT SIDE SHIELD TO STEERING COLUMN SEE SH 31 T H4 18BK C20 18DB 0R C20 18DB WT ELECTRONIC CLUTCH CYCLING SWITCH J2 14DB ...

Страница 567: ... 16LG C7 12DG 5 C6 MLB 0 l3 C3 1 2 W T D G 2 C4 12TN FUSE 1 30 AMP TO IGNITIONv SWITCH SEE SH 10 HEATER BLOWER MOTOR RIGHT SIDE DASH PANEL TO WASHER MOTOR SEE SH 4 9 5 i NATURAL C20 18DB 0RX C20 18DB 0R 37 AD 65 A C HEATER DIESEL ENGINE J908W 14 ...

Страница 568: ...V6 18DB C20 I8BR RIGHT FENDER SIDE SHIELD TOP V6 18DB TO WIPER MOTOR SEE SH 50 51 TO STEERING COLUMN SEE SH 31 H4 18BK C20 18DB 0R BLACK C20 18DB OR C20 18DB OR A C L O W PRESSURE SWITCH RIGHT FENDER SIDE SHIELD J2 14DB C20 18DB 0R ELECTRONIC CLUTCH CYCLING SWITCH BLACK J2 14DB C20 18BR J908W 14 A C HEATER DIESEL ENGINE AD 66 ...

Страница 569: ...7 pu D I E S E L X4 2 0 L G O R BLACK REAR OF E N G I N E I X 4 2 0 L G B R X X 9 1 8 B K 2 0 5 TRANSFER CASE BLACK ON T R A N S F E R C A S E 4 0 GAS E N G I N E TRANSFER C A S E SWITCH 3 X4 2 0 L G B R X 9 18BK 205 TRANSFER CASE BLACK ON T R A N S F E R C A S E X9 2 0 B K BLACK X9 L E F T S I D E 18BK DASH P A N E L TRANSFER C A S E SWITCH X4 2 0 L G B R X 9 18BK TO S P E E D CONTROL SERVO S E E...

Страница 570: ...14BR W22 14VT FORWARD IN CAR Wl 12TN FRONT SIDE OF CONNECTOR SHOWN CONNECTOR GANG LEFT FRONT DOOR MASTER SWITCH UP RIGHT DOOR B POLARITY W T LB VT BR TN 8 POLARITY LB W T BR VT WINDOW MOVEMENT AND SWITCH DOWN FROM DOOR SWITCH UP FROM DOOR SWITCH W22 14WT Wl 12TN W22 14VT DOWN FROM MASTER SWITCH W22 14BR W12 14LB FORWARD IN CAR I UP UP FROM MASTER SWITCH FEED RIGHT FRONT WINDOW LIFT SWITCH CONNECTO...

Страница 571: ...PLICE SEE SH 44 TO POWER WINDOWS SEE SH 68 TO POWER _ X2 j i MIRROR 18BK SWITCH SEE SH 71 LEFT FRONT DOOR SWITCH VIEW FROM TERMINAL END W 5 14RD X36 18PK X34 14PK X33 140R X33 140R X34 14PKX RIGHT DOOR COWL TOP DISCONNECT OVER HEATER OR A C UNIT W5 14RD X36 14PK X35 140R X33 140RX X34 14PK NEAR MOTOR AD 69 ELECTRIC DOOR LOCKS J908W 14 ...

Страница 572: ... I TC _ NECTOR_ n n X36 14PK X33 140R LOCK X35 140R FORWARD TERMINAL END W5 14RD X34 14PK UNLOCK UP W5 14RD RIGHT FRONT DOOR SWITCH VIEW FROM TERMINAL END B L A C K TOPI i LK MI UNLK X36 X34 W5 X35 14PK 140RX 14RD 140R X36 14PK X35 140R X33 1 40R X X34 14PK X J908W 14 X34 I40RX X33 140R X34 14PKX ELECTRIC DOOR LOCKS RIGHT FRONT DOOR MOTOR X33 180R NEAR MOTOR X34 18PK AD 70 ...

Страница 573: ...8W 114 WIRING DIAGRAMS ELECTRICAL BLACK AT LEFT DOOR LEFT MIRROR BATTER FEED M 0 T 0 R S SEE SH 3 5 T I TO H4H SPLICE SEE SH 44 AD 71 POWER REMOTE M I R R O R S J908W 14 ...

Страница 574: ... K I D N S13 20YL OK EI Sll 2 0 W T S12 2 0 W T S14 20YL L H UP p LT LEFT M I R R O R G M RIGHT M I R R O R S23 2 0 D B S24 2 0 D B IF J O O R R T S12 1 8 W T S12 1 8 D G UP A LEFT M I R R O R LT D RIGHT M I R R O R RT B DN C V I E W O F S W I T C H INDEXING F R O M F R O N T O F S W I T C H P O W E R M I R R O R S W I T C H F U N C T I O N LEVER POSITION CIRCUIT M I R R O R DIRECTION A SK TL PB U...

Страница 575: ... 18PK DB M26 20LB Iffi E 5 D3 18PK DB i K H4 20BK E E Gil 20LG HT G5 20DB G10 20LG PRINTED CIRCUIT BOARD CONNECTOR SEE SH 56 BLACK GRAY LEFT WHEELHOUSE TO X2 2 GROUND SPLICE SEE SH 7 5 X2 16GY N0T USED G4 18DB YLX X2 16GY FUEL TANK SENDING UNIT WITH L O W FUEL LAMP SWITCH AD 73 DIESEL FUEL TANK GAUGE AND SEAT BELT WARNING SYSTEM J908W 14 ...

Страница 576: ... WIRING DIAGRAMS ELECTRICAL 8W 117 TO IGNITION SWITCH SEE SH 10 L FUEL TANK SENDING UNIT WITH LOW FUEL SWITCH AND PUMP J908W 14 ELECTRONIC FUEL INUECTION TANK GAUGE AND SEAT BELT WARNING SYSTEM AD 74 ...

Страница 577: ...2 SIGNAL 18GY LAMP CAB I CHASSIS SWEPT LINE BOX LEFT BACK UP LAMP LEFT TAIL STOP I TURN SIGNAL LAMP LEFT BACK UP LAMP LEFT TAIL STOP 1 TURN SIGNAL LAMP LEFT BACK UP LAMP 16 TO AH9 SPLICE J PART THROTTLE V x V 3 UNLOCK RELAY SEE SH 17 SEE SH 9 DIESEL BLACK GAS L7 18BK YLX ri JfEkiT 18GY E J j L B 2 18VT B O O _ L B 2 1 8 V T B K O Q j D8 18DG YL L7 18BKJ YL L7 18BK YLX 2 X2 BLACK X2 18GY RIGHT REAR...

Страница 578: ...CK B2 18VT BKX BLACK L7 18BK YLX D7 18BR YL X2 18GY RIGHT REAR FRAME RAIL BLACK L7 18BK YLX D7 18BR YLX I X 2 18GY B2 18VT BKX LICENSE LAMP WITHOUT BUMPER LICENSE LAMP LICENSE LAMP STEP BUMPER LICENSE LAMP STANDARD BUMPER RIGHT TAIL STOP i X2 TURN 18GY SIGNAL LAMP RIGHT BACK UP LAMP RIGHT TAIL STOP 8 TURN SIGNAL LAMP RIGHT BACK UP LAMP RIGHT TAIL STOP 8 TURN SIGNAL LAMP RIGHT BACK UP LAMP SPORT UT...

Страница 579: ...13 28 N31 18VT CLOSED THROTTLE SWITCH 15 29 040 18WT PKX BRAKE SENSE 15 29 30 S4 20BR YLX PARK NEUTRAL SWITCH 15 31 32 K3 20BK PKX CHECK ENGINE LAMP 15 33 K36 20TN RDX SPEED CONTROL VACUUM 29 34 N13 20DB 0RX A C W O T CUTOUT RELAY 13 35 S6 20GY YLX EGR SOLENOID 14 36 N23 20BK 0R AIR SWITCHING SOLENOID 14 37 38 39 40 N2 18BRX AUTOMATIC IDLE SPEED MOTOR 15 41 Nil 18BK DGX OXYGEN SENSOR 13 42 43 44 U...

Страница 580: ...LB K5 16BK K8 20VT WT J2 14DB J9 16BK J9 16BK K7 180R DBX DK21 20PK D40 18WT PK S4 20BR YLX U4200R WTX DK20 20LG G720WT 0RX U40 200R LGX DIRECT BATTERY FEED 23 SENSOR RETURN 24 SIGNAL GROUND 24 5 VOLT SUPPLY 24 IGNITION FEED 23 POWER GROUND 24 POWER GROUND 24 THROTTLE POSITION SENSOR 24 SCI TRANSMIT 24 BRAKE SENSE 23 PARK NEUTRAL SWITCH 23 OVERDRIVE LOCKOUT CONTROL 12 SCI RECEIVE 24 SPEED SENSOR P...

Страница 581: ...EEL ANTI LOCK REAR WHEEL ANTI LOCK HEADLAMP LOW BEAM 2 WIRES HEADLAMP HIGH BEAM 2 WIRES SPEED CONTROL GAS ENGINE ONLY SPEED CONTROL GAS ENGINE ONLY SPEED CONTROL GAS ENGINE ONLY SPEED CONTROL GAS ENGINE ONLY WAIT TO START LAMP DIESEL ONLY HIGH BEAM INDICATOR LAMP HIGH BEAM FEED D R L MODULE REAR WHEEL ANTI LOCK LEFT REAR TURN SIGNAL LAMP RIGHT REAR TURN SIGNAL LAMP WATER TEMPERATURE SENDING UNIT O...

Страница 582: ...EFT REAR SIGNAL LAMP RIGHT REAR SIGNAL LAMP TEMPERATURE SEND UNIT O R SWITCH OIL PRESSURE LAMP OIL PRESSURE GAUGE SEND UNIT LEFT FRONT TURN SIGNAL LAMP RIGHT FRONT TURN SIGNAL LAMP HAZARD FLASHER REAR WHEEL ANTI LOCK 2 WIRES REAR WHEEL ANTI LOCK 2 WIRES PARKING LAMPS BACK UP LAMP FEED LOW FUEL RELAY WINDSHIELD WASHER MOTOR IGNITION START HORNS UNDER HOOD LAMP BRAKE WARNING LAMP SWITCH WINDSHIELD W...

Страница 583: ...N X 2 FEED FROM BRAKE SWITCH 11 V3 18BRX WINDSHIELD WIPER 12 V3 18BRX 2 WINDSHIELD WIPER L O W SPEED 13 V4 18RD YLX WINDSHIELD WIPER HIGH SPEED 14 V5 18DG WINDSHIELD WIPER MOTOR 15 V6 18DB WINDSHIELD WIPER SWITCH FEED 16 VIO 20BR WINDSHIELD WASHER MOTOR 17 18 H40 18BK LGX 2 INTERMITTENT WIPER MODULE GROUND 19 M26 22LB KEY IN BUZZER 20 M16 20BK LBX LEFT FRONT DOOR JAMB SWITCH GROUND 21 22 23 24 J15...

Страница 584: ...INTERMITTENT WIPER MODULE WINDSHIELD WIPER LOW SPEED 49 51 J t_ 11 12 13 WINDSHIELD 14 WIPER SWITCH 15 CONNECTOR 16 17 18 13 V4 18RD WINDSHIELD WIPER HIGH SPEED 49 51 J t_ 11 12 13 WINDSHIELD 14 WIPER SWITCH 15 CONNECTOR 16 17 18 14 5 18DG 5 18DG INTERMITTENT WIPER MODULE WINDSHIELD WIPER MOTOR 49 51 J t_ 11 12 13 WINDSHIELD 14 WIPER SWITCH 15 CONNECTOR 16 17 18 15 6 18DB WINDSHIELD WIPER SWITCH F...

Страница 585: ... 18RDX H2 18DG RDX J2 14DB W5 14RD LI 12RDX HAZARD FLASHER SEE SH 52 HORN RELAY SEE SH 31 FUSE NUMBER AMPS COLOR STRIPE SHEET 1 30 GREEN 2 10 62 63 65 2 n CIRCUIT J U BREAKER SILVER CAN 2 10 68 3 20 YELLOW 1 52 4 10 RED 2 10 57 59 61 5 20 YELLOW 2 10 25 27 33 52 6 20 YELLOW 2 10 50 51 7 15 LT BLUE 1 31 8 20 YELLOW 1 43 9 20 YELLOW 1 73 74 10 n CIRCUIT J U BREAKER SILVER CAN 1 69 1 1 10 RED 2 20 45...

Страница 586: ...22 17 K10 20TN WTX COOLANT SENSOR 16 18 19 20 21 22 23 K13 18BK RD THROTTLE BODY TEMP SENSOR 16 24 25 26 G20 20VT YLX TEMPERATURE SENDING UNIT 22 27 Nl 18GY RDX AUTOMATIC IDLE SPEED MOTOR 15 28 N2 18BR WTX AUTOMATIC IDLE SPEED MOTOR 15 29 K8 20VT WTX 5 VOLT SUPPLY 13 30 31 N31 18VT THROTTLE KICKER MOTOR 15 32 N7 18GY BK DISTRIBUTOR REF PICKUP 16 33 K7 180R DBX THROTTLE POSITION SENSOR 13 34 C2 14D...

Страница 587: ......

Страница 588: ...nd a rear rope type seal The crankshaft rotation is clockwise when viewed from the front of the engine 5 2L 5 9L Engines Page 3 PISTONS The pistons are cast aluminum alloy t i n coated Three rings are used Piston pins press fitted into the rods join the pistons to forged steel connecting rods C A M S H A F T The cast iron camshaft is mounted i n four steel backed babbitt bearings A thrust plate lo...

Страница 589: ...ts with front and rear molded gaskets The intake manifold is also cored w i t h upper level EGR passages for balanced cylinder to cylinder EGR distribution V A L V E T R A I N Valve train has hydraulic roller lifters and exhaust valve rotators Rocker arms are either right or left and installed on a rocker a r m shaft attached to the cylinder head Viton valve stem seals provide positive intake valv...

Страница 590: ...d 5 9L engine description is listed be low Fig 5 90 V 8 99 3 x 84 0 mm 3 91 x 3 31 inch 5 9L 101 6 x 90 9 mm 4 0 x 3 58 inch 5 2 Liters 318 cubic inch 5 9 Liters 360 cubic inch 9 0 1 5 9L 8 1 1 191 N m 260 ft lbs 2 000 rpm 5 9L 208 Ntn 283 ft ibs 1 600 rpm 1 8 4 3 6 5 7 2 Pressure Feed Full Flow Filtration 3 8 Liters 4 Quarts Liquid Cooled Forced Circulation 15 6 Liters 16 5 Quarts 5 9L j 14 2 Lit...

Страница 591: ... n place while the RTV is still wet to the touch within 10 minutes The usage of a lo cating dowel is recommended during assembly to pre vent smearing of material off location Page Measuring With Plastigage 5 Repair Of Damaged Or Worn Threads 6 ENGINE PERFORMANCE To provide best vehicle performance and lowest ve hicle emissions i t is most important that the tune up be done accurately using the spe...

Страница 592: ...I n addition to deglazing i t w i l l reduce taper and out of round as well as removing light scuffing scoring or scratches Usually a few strokes will clean up a bore and maintain the required limits 2 Deglazing of the cylinder walls may be done us ing a cylinder surfacing hone Tool C 3501 equipped with 280 grit stones C 3501 3810 i f the cylinder bore is straight and round 20 60 strokes depending...

Страница 593: ...g of the crankshaft However before assembling the rod cap w i t h Plastigage i n place the J8909 60 Fig 3 Clearance Measurement crankshaft must be turned until the connecting rod to be checked starts moving toward the top of the en gine Only then should the cap be assembled and tightened to 61 N m 45 ft lbs torque Do not rotate the crankshaft while assembling the cap or the Plas tigage may be smea...

Страница 594: ...correct viscosity Measure bearings for correct clearance Replace crankshaft or grind journals Replace bent connecting rods MAIN BEARING NOISE Insufficient oil supply Low oil pressure Thin or diluted oil Excessive bearing clearance Excessive end play Crankshaft journal out of round worn Loose flywheel or torque converter Check engine oil level Refer to Group 0 Lubrication and Maintenance Check engi...

Страница 595: ... or incorrectly gapped spark plugs Dirt or water in fuel line or filter Faulty fuel pump Incorrect valve timing Blown cylinder head gasket Low compression Burned warped or pitted valves Plugged or restricted exhaust system Faulty ignition cables Faulty coil Refer to Group 8D Ignition System Install new rotor Remove and repair distributor Refer to Group 8D Ignition System Clean plugs and set gap Re...

Страница 596: ...ir hose and a l l plugs Install the PCV valve and breather cap hose See step 7 and check for higher pressure leaks occurring during nor mal engine operation 7 Clean the oil off the suspect oil leak area using a suitable solvent Drive the vehicle at various speeds approximately 24 k m 15 miles Check the engine for signs of an oil leak I f an oil leak is found repair per the service manual instructi...

Страница 597: ... A 3 Raise vehicle on hoist 4 Remove bolts and nuts from brackets and insu lators Fig 1 5 Raise engine w i t h lifting fixture only far enough to remove insulators INSTALLATION 1 W i t h engine raised SLIGHTLY install insula tors on frame crossmember Install bolt and washer assemblies Fig 1 2 Lower engine w i t h lifting fixture while guiding insulator studs into bracket 3 Install insulator to bra...

Страница 598: ...ter wires and oil pressure wire 13 Disconnect the power steering hoses i f equipped 14 Remove starter motor alternator charcoal canister and horns 15 Raise and support the vehicle on a hoist 16 Disconnect exhaust pipe at manifold 17 M a n u a l Transmission See Group 21 Transmissions for the Manual Transmission Removal procedure 18 A u t o m a t i c Transmission a Remove bell housing bolts and ins...

Страница 599: ...Disconnect closed ventilation system and evap oration control system from cylinder head cover 3 Remove cylinder head cover and gasket 4 Remove four rocker shaft bolts and retainers 5 Remove rocker arms and shaft assembly 6 I f rocker arm assemblies are disassembled for cleaning or replacement refer to Fig 1 for rocker arm identification and Fig 2 for positioning on the shaft 7 The exhaust rocker a...

Страница 600: ...es the span length i n inches i n any direction either replace head or lightly machine the head surface F O R E X A M P L E I f a 305 m m 12 inch span i s 0 102 mm 0 004 inch out of flat allowable is 305 X 0 00075 12 X 0 00075 equals 0 23 m m 0 009 inch This a m o u n t of o u t of flat is acceptable 3 The cylinder head surface finish should be 1 78 4 57 microns 70 180 microinches 4 Install new ga...

Страница 601: ...orque i n the tightening sequence shown i n Fig 8 Tighten the same bolts to 54 N m 40 ft lbs torque i n sequence shown Fig 8 RP126 Fig 8 Intake Manifold Bolt Tightening Sequence 17 Install exhaust manifolds and tighten bolts to 27 N m 20 ft lbs torque and tighten the nuts to 20 N m 15 ft lbs torque 18 Adjust spark plugs to specifications see Group 8D Ignition System Install the plugs and tighten t...

Страница 602: ...varnish deposits from inside of valve guides w i t h a reliable guide cleaner Measure valve stem guide clearance as follows a Install sleeve Tool C 3973 over valve stem and install valve Fig 11 The special sleeve places the valve at the correct height for checking w i t h a dial indicator Fig 11 Positioning Valve with Tool C 3973 b Attach dial indicator Tool C 3339 to cylin der head and set i t at...

Страница 603: ...should not ex ceed 0 051 m m 0 002 inch total indicator reading 3 Inspect the valve seat with Prussian blue to de termine where the valve contacts the seat To do this coat valve seat L I G H T L Y with Prussian blue then set valve i n place Rotate the valve w i t h light pressure I f the blue is transferred to the center of valve face contact is satisfactory I f the blue is trans ferred to the top...

Страница 604: ...re reground check valve stem height w i t h Tool C 3968 Fig 19 I f valve is too long grind off the t i p until length is within lim TOOL Fig 19 Measuring Valve Stem Length with Tool C 396B 3 Install new seals on a l l valve stems and over valve guides Fig 20 Install valve springs and valve retainers RETAINER SPRING INTAKE VALVE RH150A Fig 20 Installing Valve Cup Seal Spring and Retainer 4 Compress...

Страница 605: ...n align ment yoke retainer Fig 1 Before disassembling any part of the engine to cor rect tappet noise read the oil pressure at the gauge install a reliable gauge at pressure sending unit The pressure should be between 207 to 552 kPa 30 and 80 psi at 2000 R P M I f vehicle has no oil pres sure gauge check the oil level i n the oil pan The oil level i n the pan should never be above the F U L L mark...

Страница 606: ...ASSEMBLY 1 Pry out plunger retainer spring clip 2 Clean varnish deposits from inside of tappet body above plunger cap 3 Invert tappet body and remove plunger cap plunger check valve check valve spring check valve retainer and plunger spring Check valve could be flat or ball CLEANING AND ASSEMBLY 1 Clean all tappet parts i n a solvent that w i l l re move all varnish and carbon 2 Replace tappets th...

Страница 607: ...nkshaft should not be permitted to move I t may be necessary to block crankshaft to prevent rotation 3 Holding a scale with dimensional reading even with edge of a chain link apply torque i n the reverse direction 14 Nnn 30 ft lbs with cylinder heads in stalled or 20 Nnn 15 ft lbs cylinder heads re moved and note amount of chain movement Fig 4 Fig 4 Measuring Timing Chain Wear and Stretch 4 Instal...

Страница 608: ...adiator shroud back over engine and i n stall fan and belts 8 Install radiator shroud to radiator 9 Connect battery COVER INSTALLATION 1 Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs 2 Using a new cover gasket carefully install chain case cover to avoid damaging oil pan gasket A 3 175 m m 1 8 inch diameter bead of RTV sealer or equivalent is recommend...

Страница 609: ...i n higher o i l pressure a t idle c u p plugs have been pressed i n t o t h e o i l galleries b e h i n d t h e cam shaft t h r u s t plate Fig 11 Fig 11 Location of Cup Plugs in Oil Galleries INSTALLATION 1 Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to w i t h i n 51 m m 2 inches of its final position i n cylinder block Whenever a n engine h a s been r e b u i...

Страница 610: ...ition from which i t was removed Tappets must have a definite crown W h e n camshaft i s re placed a l l o f the tappets must be replaced CAMSHAFT BEARINGS ENGINE REMOVED FROM VEHICLE REMOVAL 1 W i t h engine completely disassembled drive out rear cam bearing core hole plug 2 Install proper size adapters and horse shoe washers part of Tool C 3132 A at back of each bear ing shell Drive out bearing ...

Страница 611: ...o slot i n top of drive gear w i l l be aligned i n a direction forward to wards left front intake manifold attaching bolt hole Fig 18 Fig 18 Position of Installed Distributor Drive Gear INSTALLATION DISTRIBUTOR 1 Hold the distributor over the mounting pad on cylinder block 2 T u r n rotor until i t points to approximate loca tion of No 1 tower terminal i n distributor cap Fig 19 3 Place distribut...

Страница 612: ...oroughly clean inside of cup plug hole i n cylin der block or head Be sure to remove old sealer Lightly coat inside of cup plug hole with Loctite Stud N Bearing Mount or equivalent Make certain the new plug is cleaned of all oil or grease Using proper drive plug drive plug into hole so that the sharp edge of the plug is at least 0 5 m m 0 02 inch inside the lead in chamfer I t is not necessary to ...

Страница 613: ... on the spacer ex pander must be inserted into the hole i n the oil ring groove over the piston pin front boss Fig 4 5 Arrange oil ring rail gaps on inboard side of piston Top of Fig 4 6 Install compression rings i n middle and top grooves using Ring Installer Tool C 4184 Be sure the compression ring identification mark a drill point a stamped letter O an oval depression or the word top is to the ...

Страница 614: ...main journals are 0 254 m m 0 010 inch undersize CRANKSHAFT MAIN JOURNALS The crankshaft journals should be checked for ex cessive wear taper and scoring Limits of taper or out of round on any crankshaft journals should be held to 0 025 m m 0 001 inch Journal grinding should not exceed 0 305 m m 0 012 inch under the standard journal diameter D O N O T grind thrust faces of No 3 main bearing DO NOT...

Страница 615: ...oth ends protrude 2 Using Tool C 3511 tap seal down into position until tool is seated i n bearing bore Fig 8 Fig 8 Installing Upper Lower Oil Seal with Tool C 3511 3 Hold tool i n this position and cut off the portion of seal that extends below the block or cap on both sides Fig 9 Fig 9 Trimming Upper Lower Oil Seal UPPER ROPE SEAL IN VEHICLE CRANKSHAFT INSTALLED 1 Remove defective upper seal and...

Страница 616: ...6 Position a transmission jack under the trans mission 17 Raise the transmission and engine jacks as re quired to allow for the oil pan removal 18 Remove the oil pan bolts and remove the oil pan CLEANING AND INSPECTION 1 Clean oil pan i n solvent and wipe dry w i t h a clean cloth Clean a l l gasket material from mounting surfaces of pan and block 2 Inspect oil drain plug and plug hole for strippe...

Страница 617: ...metal screw into cap b Clamp screw into a vise and while support ing oil pump remove cap by tapping pump body using a soft hammer Discard retainer cap and re move spring and relief valve Fig 13 Fig 13 Oil Pressure Relief Valve 2 Remove oil pump cover bolts and lock washers and lift off cover 3 Remove pump rotor and shaft and lift out outer rotor 4 Wash all parts i n a suitable solvent and inspect ...

Страница 618: ...ressure relief valve plunger for scoring and free operation i n its bore Small marks may be removed with 400 grit wet or dry sandpaper 9 The relief valve spring has a free length of ap proximately 49 5 m m 1 95 inches and should test between 19 5 and 20 5 pounds when compressed to 34 m m 1 11 32 inch Replace spring that fails to meet specifications Fig 21 10 I f oil pressure is low and pump is w i...

Страница 619: ...g is off position Remove oil pan and No 4 main bearing cap Use suitable flat dowel to remove plug Fig 23 Removing Oil Filter with Tool C 4065 6 Use Stud W Bearing mount adhesive on outside diameter of plug to ensure retention of position As semble engine and check o i l pressure OIL FILTER When servicing the oil filter avoid deforming the filter C A N b y installing the tool band strap ROCKER SHAF...

Страница 620: ...ard Cylinder Bore Out of Round Maximum allowable before reconditioning Cylinder Bore Taper Maximum allowable before reconditioning Reconditioning Working Limits for taper and out of round Maximum Allowable Oversize cylinder bore Tappet Bore Diameter Distributor Lower Drive Shaft Bushing press fit in block Shaft to Bushing Clearance PISTONS Type Material Land Clearance Diametrical Clearance at Top ...

Страница 621: ...lay Maximum Allowable Diametral Clearance Desired 1 Maximum Diametral Clearance Allowed 1 Diametral Clearance Desired 2 3 and 4 Diametral Clearance Allowed 2 3 and 4 Finish at Rear Oil Seal Surface MAIN BEARING JOURNALS Diameter Maximum Allowable Out of Round and or Taper Bearings for Service Available in Standard and the following undersizes CONNECTING ROD JOURNALS Diameter Maximum Allowable Out ...

Страница 622: ...ut Maximum Intake Valve Seat Angle Seat Width finish Exhaust Valve Seat Angle Seat Width finish Cylinder Head Gasket Thickness compressed VALVE GUIDES Type Guide Bore Diameter VALVES INTAKE Head Diameter Length overall Stem Diameter Standard Stem to Guide Clearance Maximum Allowable by rocking method Face Angle Valve for Service oversize stem diam Lift Zero lash Chain Steel Backed Babbitt 4 001 00...

Страница 623: ...en Maximum allowable out of plumb Valve spring installed height spring seat to retainer Use 1 16 spacer to reduce spacing height when over specifications Intake 6 Blue 2 00 192 6 4 78 88 lbs 1 11 16 170 184 lbs 1 5 16 1 16 1 5 8 1 11 16 Exhaust With Rotator 6 White 1 81 185 5 8 80 90 lbs 1 13 64 180 194 lbs 1 1 16 1 16 1 29 64 1 33 64 ENGINE LUBRICATION Pump Type Rotary Full Pressure Capacity qts ...

Страница 624: ...n of Identification 001 U S Crankshaft R or M M 2 3 etc Indicating No 2 3 main bearing journal and or R l 4 etc Indicating No 1 4 connecting rod journal Steel stamped near notch on number six crankshaft counterweight 010 U S Crankshaft RX or MX MX Indicates 010 U S all main journals and or RX Indicating 010 U S all rod journals Steel stamped near notch on number six crankshaft counterweight 020 O ...

Страница 625: ...ching Bolt Oil Filter Attaching Stud Oil Pressure Gauge Sending Unit Rocker Shaft Bracket Bolt Spark Plug Starter Mounting Bolt Temperature Gauge Sending Unit Vibration Damper Screw to Crankshaft Water Pump to Chain Case Cover Bolt A C Compressor Bracket to Water Pump Bolt A C Compressor to Bracket Nut A C Compressor Support Bolts AII Critical Fastners should be clean and lightly oiled Torque Newt...

Страница 626: ...ood and position fan to assure clearance for radiator top tank and hose 2 Install engine lifting fixture Tool C 3487 A w i t h adapter rods DD 2179 3 Raise vehicle on hoist 4 Remove nuts from brackets and insulators Fig 1 5 Raise engine w i t h lifting fixture only far enough to remove insulators INSTALLATION 1 With engine raised slightly install insulators and brackets 2 Lower engine w i t h lift...

Страница 627: ...se rear of transmission and engine SLIGHTLY 4 Remove mounting bolts and insulators Fig 4 INSTALLATION 1 Install insulators and mounting bolts Fig 4 2 Install the skid plate Fig 3 3 Lower the vehicle SKID PLATE ATTACHING BOLTS PU873 Fig 3 Skid Plate TRANSFER CASE ASSEMBLY BOLT WASHER SLEEVE INSULATOR 7 RAIL eg WASHER PLATE TAB TO RIGHT REAR RK 716 Fig 4 Engine Mounts Rear ENGINE ASSEMBLY CHECKING O...

Страница 628: ... a n s m i s s i o n a Raise and support the vehicle b Align the torque converter plate to the torque converter Install and tighten the bolts to 31 N m 270 i n lbs torque c Install bell housing bolts Tighten the bell housing bolts to 41 N m 30 ft lbs torque d Remove the C clamp e Install the inspection plate f Remove the transmission support 7 Position the exhaust pipe to the manifold Tighten the ...

Страница 629: ...asher Position the washer to eliminate the inter ference Install bolt and tighten as specified 7 Install closed crankcase ventilation system and evaporation control system CYLINDER HEADS The alloy cast iron cylinder heads shown i n Fig 3 are held i n place by 10 bolts The spark plugs are lo cated i n peak of the wedge between the valves REMOVAL 1 Drain cooling system and disconnect battery ground ...

Страница 630: ... and to the rear right bank The notch is al ways to left as facing cylinder head Make sure to i n stall the long stamped steel retainers i n the number two and four positions Tighten the bolts to 23 N m 200 i n lbs torque 9 Coat intake manifold side gaskets lightly w i t h sealer RIGHT and LEFT side gaskets are required Cutouts at top front of each gasket LT for left side and RT for right side ide...

Страница 631: ...d evaporation control system 26 F i l l cooling system 27 Install battery ground cable VALVES AND VALVE SPRINGS The valves are arranged i n line i n the cylinder heads and inclined 18 degrees The rocker shaft sup port and the valve guides are cast integral w i t h the heads REMOVAL 1 W i t h cylinder head removed compress valve springs using Tool C 3422 A Fig 8 2 Remove valve retaining locks valve...

Страница 632: ...amer by hand and clean guide thor oughly before installing new valve D O N O T a t t e m p t t o ream t h e valve guides f r o m s t a n d a r d d i r e c t l y t o 0 762 m m 0 030 inch Use step proce d u r e o f 0 127 m m f 0 381 m m a n d 0 762 m m 0 005 i n c h 0 015 i n c h a n d 0 030 i n c h so t h e valve guides m a y be reamed t r u e i n r e l a t i o n t o t h e valve seat REFACING VALVE...

Страница 633: ...Whenever valves have been removed for inspec tion reconditioning or replacement valve springs should be tested As an example the compression length of the spring to be tested is 1 5 16 inches Turn table of Tool C 647 Fig 16 until surface is i n line with the 1 5 16 inch mark on the threaded stud and the zero mark to the front Place spring over stud on the table and lift compressing lever to set to...

Страница 634: ...tall a dummy shaft The rocker arms should not be disturbed and left on shaft 6 W i t h air hose attached to adapter Tool C 3907 installed i n number 1 spark plug hole apply 620 to 689 kPa 90 to 100 psi air pressure Make sure pis ton i n cylinder is at TDC on the valve spring that is being removed 7 Using Tool C 3906 or C 4228 compress valve spring and remove retainer valve locks and valve spring 8...

Страница 635: ... rocker arm as valve closes In either case tappet assembly should be removed for inspection and cleaning REMOVAL 1 Remove the air cleaner 2 Remove valve cover and rocker assembly and push rods and identify push rods to insure installa tion i n original location 3 W i t h roller tappets remove intake manifold yoke retainer and aligning yoke 4 Slide Tool C 4129 through opening i n cylinder head and ...

Страница 636: ...ace 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 camshaft sprocket attaching bolt and apply torque i n direction of crankshaft rotation to take up slack 41 Nnn 30 ft lbs w i t h cylinder head installed or 20 N m 15 ft lbs cylinder heads removed W i t h a torque ap plied to the camshaft sprocket bolt crankshaft should not...

Страница 637: ...ne 3 Place the installing adapter C 4251 3 w i t h the thrust bearing and nut on the shaft Tighten nut un t i l tool is flush w i t h the t i m i n g chain cover Fig 6 Fig 6 Installing Oil Seal 4 Install vibration damper using Tool C 3688 Fig 7 5 Install retainer bolt and washer and torque to 183 N m 135 ft lbs torque 6 Install pulley on vibration damper and torque to 23 Nnn 200 in lbs torque 7 Se...

Страница 638: ...camshaft remove camshaft being careful not to damage cam bearings with the cam lobes 6 To reduce internal leakage and help maintain higher oil pressure at idle cup plugs have been pressed into oil galleries behind the camshaft thrust plate Fig 9 INSTALLATION 1 Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 2 inches of its final position i n cylinder block ...

Страница 639: ...nstallation of Camshaft Bearings with Tool C 3132A INSTALLATION 1 Install new camshaft bearings w i t h Tool C 3132 A by sliding the new camshaft bearing shell over proper adapter 2 Position rear bearing i n the tool Install horse shoe lock and by reversing removal procedure care fully drive bearing shell into place 3 Install remaining bearings i n the same manner Bearings must be carefully aligne...

Страница 640: ...3 Coat shaft and drive gear w i t h engine oil In stall the shaft so that after gear spirals into place i t w i l l index w i t h the oil pump shaft so slot i n top of drive gear w i l l point i n a direction parallel to the centerline of the crankshaft Fig 17 i I DISTRIBUTOR DRIVE PU192B Fig 17 Position or Installed Distributor Drive Gear INSTALLATION OF DISTRIBUTOR 1 Hold the distributor over th...

Страница 641: ...ed boring and honing operation should be closely coordinated w i t h the fitting of pis tons and rings i n order that specified clearances may be maintained ENGINE CORE OIL AND CAM PLUGS REMOVAL Using a blunt tool such as a drift or a screwdriver and a hammer strike the bottom edge of the cup plug Fig 1 With the cup plug rotated grasp firmly with pliers or other suitable tool and remove plug Fig 1...

Страница 642: ...o 0 062 inch for o i l ring steel rails i n standard size bores for new service rings M a x i m u m gap i n 0 127 m m 0 005 inch O S bores should be 0 907 m m 0 036 inch for compression rings and 1 778 m m 0 070 inch for oil ring steel rails 3 Measure side clearance between piston ring and ring land Fig 4 Clearance should be 0 038 to 0 076 m m 0 0015 to 0 003 inch for the top compression ring and ...

Страница 643: ...p 2 Before installing the ring compressor make sure the o i l ring expander ends are butted and the rail gaps located as shown i n Fig 5 3 Immerse the piston head and rings i n clean en gine oil slide the ring compressor Tool C 385 over the piston and tighten w i t h the special wrench part of Tool C 385 Be sure position of rings does not change during this operation 4 Install connecting rod bolt ...

Страница 644: ...e 5 9L engine 1 2 and 4 upper and lower bearings are grooved and are interchangeable on high perfor mance only Standard 5 9L engine uses plain lower main bearings except No 5 Upper and lower Number 3 bearing halves are have flanges to carry the crankshaft thrust loads and are N O T interchangeable with any other bearing halves i n the engine Fig 7 A l l bearing cap bolts removed during service pro...

Страница 645: ...l C 3511 tap seal down into position until tool is seated i n bearing bore Fig 9 Fig 9 Installing Upper Lower Oil Seal with Tool C 3511 3 Hold tool i n this position and cut off the portion of seal that extends below the block or cap on both sides Fig 10 LOWER ROPE SEAL CRANKSHAFT REMOVED 1 Install a new seal i n bearing cap so that both ends protrude 2 Using Tool C 3511 tap seal down into positio...

Страница 646: ...e remove engine oil dipstick 2 Raise vehicle Drain engine oil remove exhaust cross over pipe and remove left engine to transmis sion strut 3 Remove oil pan bolts and remove oil pan CLEANING AND INSPECTION 1 Clean oil pan i n solvent and wipe dry with a clean cloth Clean a l l gasket material from mounting surfaces of pan and block 2 Inspect oil drain plug and plug hole for stripped or damaged thre...

Страница 647: ...thoroughly Mating surface of the oil pump cover should be smooth Replace pump assembly i f cover is scratched or grooved 2 Lay a straightedge across the pump cover sur face Fig 18 I f a 0 038 m m 0 0015 inch feeler gauge can be inserted between cover and straight edge pump assembly should be replaced Fig 18 Checking Oil Pump Cover Flatness 3 Measure thickness and diameter of OUTER ro tor I f outer...

Страница 648: ...nches Replace spring that fails to meet specifications Fig 24 10 I f oil pressure is low and pump is within spec ifications inspect for worn engine bearings or other reasons for oil pressure loss RN98 Fig 24 Proper Installation of Retainer Cap OIL LINE PLUG The oil line plug is located i n the vertical passage i n the block between the Oil To Filter and Oil From Filter passages Fig 25 Improper ins...

Страница 649: ...ure retention of position 5 Assemble engine and check oil pressure OIL PUMP ASSEMBLY AND INSTALLATION 1 Assemble pump using new parts as required 2 Install new oil seal rings between cover and pump body Tighten cover bolts to 11 N m 95 i n lbs torque 3 Prime oil pump before installation by filling ro tor cavity w i t h engine oil 4 Install oil pump During installation slowly ro tate pump body to e...

Страница 650: ...face 3 Lubricate gasket of new filter w i t h clean engine oil 4 Install and tighten filter to 20 N m 15ft lbs torque or 3 4 to 1 turns after gasket contacts base Use filter wrench i f necessary 5 Start engine and check for leaks Fig 27 Removing Oil Filter with Tool C 4065 ...

Страница 651: ... 0 373 inch 0 0254 0 0762 mm 0 001 0 003 inch 0 4318 mm 0 017 inch 44Vfe 45 Lift Zero Lash 5 2L 9 474 mm 0 373 inch 5 9L 10 414 mm 0 410 inch Standard 0 127 mm 0 005 inch 0 381 mm 0 0015 inch 0 762 mm 0 030 inch VALVES EXHAUST 1 517 inch 5 9L 1 617 inch Length Overall 126 21 127 13 mm 4 969 5 005 inch 126 42 127 30 mm 4 977 5 012 inch 5 9L 126 44 127 30 mm 4 978 5 012 inch 9 423 9 449 mm 0 371 0 3...

Страница 652: ...bs Valve Open 33 34 mm 1 5 16 inch 5 2L Exhaust 801 863 N 180 194 lbs 27 38 mm 1 5 64 inch 5 9L Exhaust 805 876 N 181 197 lbs 26 99 mm 1 1 16 inch Max Allowable Out of Plumb 1 588 mm 1 16 inch Valve Spring Installed Intake 41 275 42 86 mm 1 5 8 1 11 16 inch 36 909 38 497 mm 1 29 64 1 33 64 inch Use a 1 16 inch spacer to reduce spacing height when over specifications TIMING CHAIN 68 links Pitch 9 5...

Страница 653: ...S 50 800 50 825 mm 2 000 2 001 inch 50 394 50 419 mm 1 984 1 985 inch 50 013 50 038 mm 1 969 1 970 inch 49 606 49 632 mm 1 953 1 954 inch 39 688 39 713 mm 1 5625 1 5635 inch CYLINDER BLOCK 99 31 99 36 mm 3 910 3 912 inch 5 9L 101 60 101 65 mm 4 000 4 002 inch Cylinder Bore Out of Round 0 005 inch Cylinder Bore Taper 0 010 inch 0 025 mm 0 001 inch 0 040 inch 22 99 23 01 mm 0 9051 0 9059 inch Distri...

Страница 654: ...ad Aluminum 5 9L 5 Babbitt 3 Main Bearing End Play 5 2L 0 051 0 178 mm 0 002 0 007 inch 5 9L 0 051 0 229 mm 0 002 0 009 inch 0 254 mm 0 010 inch 0 0127 0 0381 mm 0 0005 0 0015 inch 0 0381 mm 0 0015 inch 0 0127 0 0508 mm 0 0005 0 0020 inch 0 0635 mm 0 0025 inch Diagonal Knurling MAIN BEARING JOURNALS 63 487 63 513 mm 2 4995 2 5005 inch 5 9L 71 361 71 387 mm 2 8095 2 8105 inch 0 0254 mm 0 001 inch S...

Страница 655: ...s Fit in Rod 24 996 25 001 mm 0 9841 0 9843 inch 75 946 76 708 mm 2 990 3 020 inch 0 0000 0 0127 mm 0 0000 0 0005 inch Light Thumb Push 5 9L 0 0064 0 0191 mm 0 00025 0 00075 inch None 0 0178 0 0356 mm 0 0007 0 0014 inch Interference Standard 0 076 0 203 mm 0 003 0 008 inch PISTON RINGS 3 2 1 3 piece steel rail chrome face Ring Width 1 9558 1 9812 mm 0 077 0 078 inch 0 640 mm Max 0 0252 inch Max Ri...

Страница 656: ...4 mm 0 010 inch U S Crankshaft RXor MX MX Indicates 0 254 mm 0 010 inch U S all main journals and or RX Indicating 0 254 mm 0 010 inch U S all rod journals Milled flat on number eight crankshaft counterweight on 5 2L cranks On 5 9L cranks it is on the number three counterweight 0 508 mm 0 020 inch O S Cylinder Bores A Following engine serial number 0 203 mm 0 008 inch O S Tappets 3 8 diamond shape...

Страница 657: ...45 ft lbs 136 Nnn 100 ft lbs 143 Nnn 105 ft lbs 9 Nnn 80 in lbs 23 Nnn 200 in lbs 102 Nnn 75 ft lbs 88 Nnn 65 ft lbs 68 Nnn 50 ft lbs 68 N m 50 ft lbs 102 Nnn 75 ft lbs 27 Nnn 20 ft lbs 20 Nnn 15 ft lbs 33 Nnn 24 ft lbs 23 Nnn 200 in lbs 31 Nnn 270 in lbs 75 Nnn 55 ft lbs 75 Nnn 55 ft lbs 54 Nnn 40 ft lbs 115 Nnn 85 ft lbs 27 Nnn 20 ft lbs 23 Nnn 200 in lbs 11 Nnn 95 in lbs 41 Nnn 30 ft lbs 68 Nnn...

Страница 658: ...esult i n bulging or other distortion but exces sive heat w i l l not be the fault of the converter A fuel system air injection system or ignition system mal Heat Shields Manifold Heat Control Valve Page 1 2 function that permits unburned fuel to enter the con verter w i l l usually cause overheating I f a converter is heat damaged correct the cause of the damage at the same time the converter is ...

Страница 659: ...t manifold The thermostatic controlled valve directs heated exhaust gases to the heat cham ber in the intake manifold beneath the throttle body J9011 41 Systems Typical This helps vaporize the fuel mixture during the en gine warm up period When the valve is closed the exhaust gases are directed to the heat chamber through the right side of the exhaust crossover pas sage After circulating through t...

Страница 660: ...Y a Thermostat broken b Broken weak or missing anti rattle spring a Replace thermostat b Replace spring J9011 33 SERVICE PROCEDURES INDEX Page Page Exhaust Manifold 12 Manifold Heat Control Valve 13 Exhaust Pipe Mufflers Converters and Tailpipe 3 Torque Specifications 14 Intake Manifold 10 EXHAUST PIPE MUFFLERS CONVERTERS AND TAILPIPE REMOVAL GENERAL 1 Raise vehicle on hoist and apply penetrating ...

Страница 661: ...STEM AND INTAKE MANIFOLD STRUT TRANSMISSION CASE T O BLOCK TIGHTENING TORQUE 20 FT LBS 27 N m m 125 IN LBS 13 N m m 200 IN LBS 23 N m m 32 FT LBS 44 N m Fig 1 Single Exhaust System Light Duty Trucks Not Sport Utility ...

Страница 662: ...ING TORQUE S 20 FT LBS 27 N m m 125 IN LBS 13 N m m 200 IN LBS 23 N m m 32 FT LBS 44 N m MUFFLER TAIL PIPE TAIL PIPE FRONT CLAMP 135 159 WHEELBASE ARROW P FRAME CROSSMEMBER SUPPORT BRACE SUPPORT MUFFLER BOLT CLAMP TAPPING SCREW MUFFLER TAIL PIPE ARROW N K Ww 131 135 159 W H E E L B A S E V 4 UPPER FLOOR PAN HEAT SHIELD SHIELD ATTACHING BRACKET U NUT J9011 43 Fig 2 Single Exhaust System Light Duty ...

Страница 663: ...R BRAKE LINE FRONT SUSPENSION CROSSMEMBER BRAKE LINE SHIELD 2 WHEEL DRIVE 50 19 TYPICAL TYPICAL SLIP JOINT MUST BE FULLY ENGAGED TIGHTENING TORQUE 19 FT LBS 26 N m 200 FT LBS 23 N m 125 IN LBS 14 N m m 250 IN LBS 28 H m 32 FT LBS 42 N m 40 FT LBS 54 N m J9011 44 Fig 3 Dual Exhaust System Heavy Duty Trucks ...

Страница 664: ...159 WHEELBASE VIEW IN DIRECTION OF ARROW Y 3 FRAME 135 WHEELBASE 131 WHEELBASE INSULATORS MUFFLER PIPE 131 135 WHEELBASE VIEW IN DIRECTION OF ARROW X SHOULDER SCREW FRAME SCREWS WASHER CONVERTER PIPE S SHOULDER SCREW INSULATORS VIEW IN DIRECTION OF ARROW W FRAME VIEW IN DIRECTION OF ARROW Z TIGHTENING TORQUE 19 FT LBS 26 N m 200 IN LBS 23 N m 125 IN LBS 14 N m 250 IN LBS 28 N m 32 FT LBS 42 N m 40...

Страница 665: ...1 1 8 EXHAUST SYSTEM AND INTAKE MANIFOLD VIEW IN DIRECTION OF ARROW D J9011 46 Fig 5 Sport Utility Exhaust System ...

Страница 666: ...H CATALYTIC CONVERTER TO ENGINE TO MUFFLER VIEW B EXHAUST PIPE FRT EXHAUST PIPE REAR FRONT VIEWC EXHAUST PIPE MUFFLER CLAMP TYPICAL NUT SUPPORT SCREW FRAME REFERENCE VIEWC VIEW D FRONT HEAT SHIELD CATALYTIC CONVERTER LOWER HEAT SHIELD AD8 4 x 4 HEAT SHIELD UPPER HEAT SHIELD AD4 4 x 2 FRONT CROSSMEMEBER SKID PLATE UPPER HEAT SHIELD WITH 6 IN RAIL AD8 4 x 4 SCREW SPACER SCREW SCREW CONED WASHER USED...

Страница 667: ... dry w i t h com pressed air Inspect manifold for cracks Inspect mating surfaces of manifold for flatness with a straightedge Inspect exhaust crossover passages through mani fold I f passages are coated with hard black carbon they should be scraped clean and sandblasted to re move the carbon deposits INSTALLATION 1 Using a new gasket install the throttle body onto the intake manifold Tighten the b...

Страница 668: ... closed crankcase ventilation and evapo ration control systems 9 Install coil wires heat indicator sending unit wire heater hoses and bypass hose 10 Install distributor cap and wires Fig 12 Intake Manifold Bolt Tightening Sequence 3 9L Fig 13 Intake Manifold Bolt Tightening Sequence 5 2L 5 9L 11 Hook up the return spring 12 Connect the accelerator linkage and i f so equipped the speed control and ...

Страница 669: ...work valve back and forth u n t i l i t turns freely Be sure studs are fully seated INSTALLATION CAUTION If the studs came out with the nuts when removing the exhaust manifold install new studs Apply sealer on the coarse thread ends Wa ter leaks may develop at the studs if this precaution is not taken 1 Position the exhaust manifolds on the two studs located on the cylinder head Install conical wa...

Страница 670: ...enter end or tab is pointing to the left and the hook or outer end points down Install thermostat on the counterweight 6 A t 32 00 m m 1 24 inch mark one end of shaft w i t h a suitable dye Press counterweight on the marked end of the shaft until flush with shaft end 7 W i t h the counterweight end of the shaft facing you wrap the thermostatic spring 140 i n a counter clockwise direction Install t...

Страница 671: ...TORQUE 23 Nfn 200 in lbs 41 N m 30ft lbs 41 Nfn 30ft lbs 27 Nfn 20 ft lbs 20NTTI 15 ft lbs 41 Nfn 30 ft lbs 33 N m 24 ft lbs 15 N m 125 in lbs 34 N m 25 ft lbs 54 Nfn 40 ft lbs 41 N m 30 ft lbs 23 Nfn 200 in lbs 23 Nfn 200 in lbs 23 Nnn 200 in lbs 20 N m 175 in lbs J9011 34 ...

Страница 672: ...re the frames by their Resisting Bending Moment R R M term denoting the maximum bending the siderails can safely withstand Page SPECIFICATIONS 12 TIGHTENING REFERENCE 12 The resisting bending moment can be used for quick comparison of frames having different rail con figuration and materials The Resisting Bending Moment consists of two terms Section Modulus and Material Yield Strength Section Modu...

Страница 673: ...RIVETS 0 0 1 39 C HI ZD O H m oo CROSSMEMBER FUEL TANK SUPPORTS FRONT SPRING BRACKET Fig 1 AD8 Frame Structure with Body Mount and Spring Hanger Brackets ...

Страница 674: ...BRACKET ENGINE FRONT SUPPORT CROSSMEMBERS FUEL TANK SUPPORTS RN895 30 00 H 30 C o H C Z 30 m oo 0 0 1 0 0 Fig 2 AD4 Frame Structure with Body Mount and Suspension Brackets ...

Страница 675: ...MID FRAME CROSSMEMBER EXTRA 159 165 W B ENGINE SUSPENSION FRONT SUPPORT CROSSMEMBER ALL FASTENERS ARE RIVETS EXCEPT AS NOTED PU892C Fig 3 AD1 2 and 3 Frame Structure ...

Страница 676: ...Fig 4 ADS 6 and 7 Frame Structure ...

Страница 677: ...d measure between a l l points diagonally and parallel to siderails corre sponding measurements should not differ by more than 1 4 inch 5 Take measurement across at front and rear marks and by dividing distances i n half indicate the two points on floor 6 Stretch a chalk line between points 1 and 2 i n Fig 5 and snap string 7 Check to see how close centerline is to diagonal intersection points A B...

Страница 678: ...osen areas to deter mine frame alignment The procedures are recommended as follows 1 Place vehicle on level floor 2 I f vehicle is loaded make sure payload does not exceed specified limit and the load is distributed as evenly as possible For better accuracy of measure ments all payload should be removed 3 Check tires for recommended air pressure and adjust as necessary ...

Страница 679: ......

Страница 680: ... OF METAL INSIDE OF METAL l INSIDE OF METAL 37 68 CENTERLINE OF FRONT WHEELS 750 DIAMETER GAUGE HOLE 5 5 5 REAR OVERHANG SEE SPECIFICATIONS 30 CO I 30 CZ o H 30 m CO Fig 7 Frame Dimensions ADl 2 and 3 mm CO 1 CO ...

Страница 681: ...WHEELBASE CENTERLINE OF REAR WHEELS I SEE SPECIFICATIONS CENTERLINE OF FRONT WHEELS Fig 8 Frame Dimensions ADS 6 and 7 mm I ...

Страница 682: ...ric welding equipment as it retains heat i n a small area limiting the change of hardness of metal A damaged frame member is to be closely inspected for cracks I t is possible that cracks will appear as a result of straightening of a member I n either case crack or cracks are to be repaired as follows 1 Stop drill a t the end point of the crack with 1 8 inch drill 2 V groove crack to allow good we...

Страница 683: ... 6 188 477 3 43 8 71 109760 49787 38 25 97 15 AD5 6 131 332 6 17 18 2 32 6 210 533 3 88 9 86 124160 56319 42 25 107 31 AD7 135 318 7 20 18 2 73 7 194 493 5 02 12 75 160640 72866 48 25 122 55 CLUB CAB AD1 133 338 7 16 18 2 72 7 176 447 4 57 11 60 146240 66334 38 25 97 15 AD1 2 149 378 7 20 18 2 73 7 194 493 5 02 12 75 160640 72866 42 25 107 31 AD5 6 149 378 7 23 18 2 75 7 210 533 5 47 13 87 175040 ...

Страница 684: ...ng unleaded gasoline with the proper octane rating gasolines that contain deter gents and anti corrosion additives are recommended The use of gasoline containing these additives help improve fuel economy reduce emissions and main tain vehicle performance Low quality fuel can cause problems such as hard starting stalling and driveability deterioration I f problems of this type are experienced i t i...

Страница 685: ... of methanol gasoline blends may result in starting and driveability deterioration and damage to critical fuel system components Fuel system damage and vehicle performance prob lems resulting from the use of gasolines containing methanol are not the responsibility of Chrysler Mo tors and may not be covered by the new vehicle war ranty GASOLINES CONTAINING MTBE Fuels that are a mixture of unleaded ...

Страница 686: ...ESSURE RELEASE PROCEDURE 1 Loosen fuel filler cap to release fuel tank pres sure 2 Disconnect injector wiring harness from engine harness 3 Connect a jumper wire to ground terminal Number 1 of the injector harness Fig 2 to engine ground 4 Connect a jumper wire to the positive terminal Number 2 of the injector harness Fig 2 and touch the battery positive post for no longer than 5 sec onds This rele...

Страница 687: ...e fuel return hose from throttle body Connect a substi tute hose to the throttle body return nipple and place other end of hose i n clean container Repeat test I f pressure is now correct check for restricted fuel re t u r n line I f no change is observed replace fuel pres sure regulator MECHANICAL MALFUNCTIONS Mechanical malfunctions are more difficult to diag nose w i t h this system The Single ...

Страница 688: ...ervoir Fig 7 4 Remove the lower most coil of the drain tube out of the mounting lugs on top of the reservoir Fig 8 Care should be taken to avoid unsnapping the re t u r n line check valve cover from the bottom of the reservoir I f this cap comes free snap back into place Fig 8 RESERVOIR RR14G174 Fig 7 Removing Fuel Line Coil from Reservoir FUEL UNE COIL ASSEMBLY FUEL RETURN HOSE FUEL RETURN CHECK ...

Страница 689: ...ng Fuel Filter 5 Snap pump bracket collar into the reservoir Fig 9 6 Position coil tube onto reservoir so that the drain tube aligns w i t h mounting lugs on reservoir Fig 7 7 Snap lower most coil into mounting lugs on top of the reservoir 8 Snap the drain tube into the lugs on the bottom of the reservoir 9 Connect electrical wires to new sending unit Fig 6 10 Align index tab on new level unit w i...

Страница 690: ...l hose connections Ensure they are se cure and not leaking Hoses should be replaced i m mediately i f there is any evidence of degradation that could result i n failure Avoid contact w i t h clamps or other components that cause abrasions or scuffing Ensure that the rubber hoses are properly routed to prevent pinching and to avoid heat sources The hoses used on fuel injected vehicles are of spe ci...

Страница 691: ...ing back on fuel tube Fig 17 The tube should be locked i n place QUICK CONNECT FITTING SHOULDER RELEASE COLLAR NIPPLE J9014 188 Fig 16 Quick Connect Fitting Assembly To disconnect the fitting from the fuel tube pull the release collar back into the fitting and slide the fitting off of the fuel tube Fig 18 RELEASE COLLAR QUICK CONNECT FITTING J9014 189 Fig 17 Assembled Quick Connect Fitting PULL CO...

Страница 692: ... The hoses used on fuel injected vehicles are of a special construction due to the higher fuel pressures involved i n this system I f i t is necessary to replace these hoses only hoses marked EFM EFI may be used Page Fuel Tanks 10 Heat Shields 10 General Information 9 No Lead Fuel Tank Filler Tube 9 Pressure Vacuum Filler Cap 9 The hose clamps used on fuel injected vehicles are of a special rolled...

Страница 693: ...l Number 1 of the injector harness Fig 2 to engine ground 4 Connect a jumper wire to the positive terminal Number 2 of the injector harness Fig 2 and touch the battery positive post for no longer than 5 sec onds This releases system pressure 5 Remove jumper wires 6 Continue fuel system service FUEL TANKS DRAINING FUEL TANK 1 Remove fuel filler cap to release fuel tank pres sure 2 Perform Fuel Syst...

Страница 694: ...el tank enough to permit fuel gauge wire and fuel tubes to be discon nected from the fuel pump module at the top of the fuel tank To remove fuel tubes squeeze locking tabs on connector and pull tube back Fig 6 8 Lower fuel tank PRESSURE RELIEF ROLLOVER VALVE FUEL FILTER FUEL TUBES FUEL TANK ASSEMBLY J9014 191 Fig 3 Fuel Hose Connections to Fuel Tank Mid Frame Mounted Fuel Tanks INSTALLATION MID FR...

Страница 695: ...uipment is not avail able disconnect the fuel line and drain tank dry into a properly identified Gasoline safety container Re fer to Draining Fuel Tank 5 Raise vehicle on hoist 6 Place transmission jack under center of tank and apply slight pressure Disconnect the tank mounting straps J bolts and remove retaining straps Fig 7 7 Lower tank on transmission jack far enough to permit access to the fue...

Страница 696: ...connector to the fuel pump module at the top of the tank 3 Raise tank into position 4 Install tank mounting straps Connect J bolts and tighten the nuts as shown i n Fig 8 FUEL TANK FILLER TUBE HOSE CLAMP FUEL TANK FILLER CLAMP CLAMP J9014 186 Fig 9 Fuel Filler Tube and Vent Tube to Filler Neck Connections 5 Remove jack 6 Connect filler tube and a l l vent hoses Install new hose clamps and tighten ...

Страница 697: ...l vehicles pass a full 360 rollover without fuel leakage The pressure relief rollover valve Fig 13 is mounted at the top of the fuel pump module PRESSURE RELIEF ROLLOVER VALVE SCREWDRIVER Fig 13 Servicing Pressure Relief Rollover Valve REMOVAL 1 Remove fuel tank refer to Fuel Tanks section in this group 2 Wedge the blade of a straight screwdriver be tween the rubber grommet and the fuel tank where...

Страница 698: ... remove nuts from pedal shaft and bracket assembly studs Remove assembly from vehicle INSTALLATION Position assembly on dash panel and install retain ing nuts tighten to specifications From inside the vehicle hold up the pedal and install the throttle ca ble and cable retainer i n the upper end of the pedal shaft THROTTLE CABLE CAUTION Be careful not to damage or kink throttle or speed control cor...

Страница 699: ...hrottle body cam 2 Install the remaining cable housing end fitting into the dash panel grommet and attach the housing retainer clip from inside the vehicle 3 Install the ball end of the cable through the hole i n the pedal shaft and install the plastic cable retainer THROTTLE BODY THROTTLE CABLE BRACKET OF ARROW X RR14G164 Fig 3 Throttle Cable Attachment 5 2L and 5 9L Engine ...

Страница 700: ...sired air fuel 14 7 to 1 ratio by deter mining mass air flow and adjusts fuel injector pulse width to obtain the correct mass fuel flow Page Idle Contact Switch SBEC Input 20 Idle Speed Control ISC Actuator SBEC Output 24 Ignition C o i l S B E C Output 24 Lock Up Torque Convertor Solenoids SBEC Outputs 25 Manifold Absolute Pressure MAP Sensor SBEC Input 20 Modes of Operation 25 Overdrive Solenoid...

Страница 701: ... switches are considered SBEC Inputs The SBEC adjusts ignition timing based upon i n puts i t receives from sensors that react to engine Fig 1 Dual Point Injection Components RPM the distributor pick up manifold absolute pressure coolant temperature throttle position transmission gear selection automatic transmission vehicle speed and the idle contact switch These sen sors are considered SBEC Inpu...

Страница 702: ...or The SBEC w i l l de energize the A C clutch relay i f i t receives input from either the A C low pressure switch indicating a low refrigerant level or from the electric clutch cycling switching indicating evapora tor freezing BATTERY VOLTAGE SBEC INPUT The SBEC monitors the battery voltage input to determine fuel injector pulse width and alternator field control I f battery voltage is low the S...

Страница 703: ...e SBEC w i t h information relating to ambient baro metric pressure during engine start up cranking and to engine load while the engine is running The SBEC uses this input along w i t h inputs from other sensors to adjust air fuel mixture The M A P sensor is mounted on the throttle body Fig 6 and is connected to the throttle body w i t h a vacuum hose and to the SBEC electrically MAP SENSOR 3 WAY ...

Страница 704: ... on fuel temperature which allows the SBEC to enrichen the air fuel mixture for a hot restart condition J9014473 Fig 9 Throttle Body Temperature Sensor THROTTLE POSITION SENSOR TPS SBEC INPUT The Throttle Position Sensor TPS is mounted on the throttle body below the M A P sensor and con nected to the throttle blade shaft Fig 10 The TPS is a variable resistor that provides the Single Board Engine C...

Страница 705: ... OUTPUT The Single Board Engine Controller SBEC con trols the air conditioning compressor through the A C clutch relay Fig 13 By switching the ground path for relay on and off the SBEC is able to cycle the air conditioning compressor clutch based on changes i n engine operating conditions The relay is energized when the A C switch is closed A C has been selected and the blower motor switch is i n ...

Страница 706: ...to the solenoid de energizing i t which al lows vacuum to flow to the canister purge valve and purge fuel vapors through the throttle body The Purge Solenoid w i l l also be energized during certain idle conditions i n order to update the fuel delivery calibration CHECK ENGINE LAMP SBEC OUTPUT The Check Engine Lamp illuminates at the bottom of the instrument panel each time the ignition key is tur...

Страница 707: ...otor is mounted to the throttle body and controlled by the SBEC Fig 16 The throttle lever rests against an adjustment screw at the end of the actuator plung er The actuator extends or retracts to control en gine idle speed and to set throttle stop angle during deceleration Based on inputs from the various en gine control system sensors and switches the SBEC supplies current and a ground path to th...

Страница 708: ... or not the calculated in jector pulse width results i n the ideal air fuel ratio of 14 7 parts air to 1 part fuel B y monitoring the ex haust oxygen content through the 0 2 sensor the SBEC can fine tune the injector pulse width to achieve optimum fuel economy combined with low emission engine performance The dual point fuel injection system has the follow ing modes of operation Ignition switch O ...

Страница 709: ...se Mode When the engine is at operating temperature this is a CLOSED LOOP mode During cruising speed the following inputs are received by the SBEC coolant temperature manifold absolute pressure engine speed throttle position exhaust gas oxygen content gear position automatic transmission A C control positions The SBEC provides a ground path for the injector to precisely control injector pulse widt...

Страница 710: ... the next start up When the A S D relay is not energized battery voltage is shut off from the fuel pump fuel injector ignition coil and oxygen sensor heating element A l l fuel injection stops THROTTLE BODY The throttle body assembly Fig 2 0 or 2 1 is mounted on top of the intake manifold and contains the fuel injectors fuel pressure regulator idle speed control actuator throttle position sensor a...

Страница 711: ...RS CANISTER PURGE NIPPLE DIVERTER VALVE NIPPLE PCV NIPPLE THROTTLE LEVER FUEL PRESSURE REGULATOR IDLE SPEED CONTROL ISC ACTUATOR HEATED AIR INLET NIPPLE FUEL INJECTORS WIRING CONNECTOR FUEL RETURN NIPPLE MAP SENSOR FUEL INLET NIPPLE THROTTLE POSITION SENSOR TPS 8914 97 Fig 20 Throttle Body Assembly 3 9L Engine ...

Страница 712: ...DIVERTER VALVE NIPPLE CANISTER PURGE NIPPLE PCV NIPPLE FUEL PRESSURE REGULATOR IDLE SPEED CONTROL ISC ACTUATOR FUEL INJECTORS FUEL INJECTORS WIRING CONNECTOR MAP SENSOR FUEL RETURN NIPPLE FUEL INLET NIPPLE THROTTLE BODY TEMPERATURE SENSOR THROTTLE POSITION SENSOR TPS GO CO 8914 107 Fig 21 Throttle Body Assembly 5 2L and 5 9L Engines C O ...

Страница 713: ...lows past the injectors into the pressure regulator The fuel return port is blocked by the a spring loaded rubber diaphragm Fig 22 When fuel pressure reaches 100 kPa 14 5 psi i t pushes the diaphragm away from the fuel return port and fuel flows through the return line to the fuel tank The dia phragm is constantly moving from the open t o closed position to keep fuel pressure constant Fig 22 Fuel ...

Страница 714: ...Verify that the 60 way connector is fully i n serted into the socket on the Single Board Engine Controller SBEC Fig 2 2 Verify that hoses are securely attached to vapor canister Fig 3 3 Verify that alternator electrical wiring and the drive belt are correctly installed BOARD SINGLE ENGINE CONTROLLER SBEC DIAGNOSTIC TOOL THROTTLE POSITION SENSOR NEUTRAL SAFETY SWITCH DISTANCE SENSOR CHECK ENGINE LA...

Страница 715: ...connector is attached for Heated Oxygen Sensor 3 9L Engine Fig 7 9 Verify that 4 way connector is attached for Heated Oxygen Sensor 5 2L and 5 9L Engines Fig 8 10 Verify that the 2 way connector is attached to the A i r Switching Solenoid Fig 9 11 Verify that the 2 way connector is attached to the Canister Purge Solenoid Fig 9 12 Verify that the 2 way connector is attached to the EGR Solenoid Fig ...

Страница 716: ...RGE SOLENOID RR14G134 Fig 9 EGR Air Switching and Canister Purge Solenoids 16 Verify engine harness to main harness connec tions are fully inserted Fig 11 CANISTER PURGE SOLENOID RR14G163 Fig 10 EGR Air Switching and Canister Purge Solenoids Vacuum Connections 4 WAY ELECTRICAL CONNECTOR 8 WAY ELECTRICAL CONNECTOR RR14G149 Fig 11 Engine Harness to Main Harness Connection 17 On 5 2L or 5 9L engines ...

Страница 717: ...Electrical Connections 23 Verify that vacuum connections on the front and rear of Throttle Body are secure and not leaking Figs 15 and 16 24 Verify that heated air door and M A P sensor vacuum connections are connected and not leaking Fig 15 25 Verify that hose from PCV valve is securely attached to the manifold vacuum port Fig 16 26 Verify that the M A P sensor vacuum connector is attached to the...

Страница 718: ...ectrical Connector Fig 21 33 On automatic transmission equipped vehicles verify that the neutral safety switch electrical con nector is i n place Fig 22 34 I f vehicle is equipped w i t h a lock up torque convertor check Torque Converter Lockup Solenoid Electrical Connection Fig 22 35 I f vehicle has overdrive A 500 automatic transmission check Overdrive Solenoid Electrical Connection Fig 23 36 Ch...

Страница 719: ... SBEC can cels the Fault Code after 50 to 100 vehicle key on off cycles FAULT CODE DESCRIPTION When a fault code appears either by flashes of the check engine lamp or by watching the Diagnostic Tool i t indicates that the SBEC has recognized an abnormal signal i n the system Fault codes indicate the results of a failure but never identify the failed component directly To obtain fault codes from th...

Страница 720: ...15 Vehicle Speed Signal No distance sensor signal detected during road load conditions 17 Low Engine Temp Engine coolant temperature remains below normal operating temperatures during vehicle travel thermostat 21 Oxygen Sensor Signal or 0 2 Sensor Shorted High Neither rich or lean condition is detected from the oxygen sensor input Oxygen sensor input voltage maintained above normal operating range...

Страница 721: ...shorted condition detected in the EGR solenoid circuit Required change in air fuel ratio not detected during diagnostic test California emission packages only 33 A C Clutch Relay Oct An open or shorted condition detected in the A C clutch relay circuit 34 S C Servo Solenoids An open or shorted condition detected in the speed control vacuum or vent solenoid circuits 35 Idle Switch Shorted or Idle S...

Страница 722: ...arging Output Low Battery voltage sense input below target charging voltage during engine operation and no significant change in voltage detected during active test of alternator output 51 Lean F A Condition Oxygen sensor signal input indicates lean fuel air ratio condition during engine operation 52 Rich F A Condition or Excessive Leaning Oxygen sensor signal input indicates rich fuel air ratio c...

Страница 723: ...e entire switch circuit to the SBEC is functional OBTAINING SWITCH TEST MODE SWITCH TEST MODE Z l Voltage Sense Brake Switch Park Neutral Switch A C Switch Sense Speed Control On Off Speed Control Set Speed Control Resume Overdrive Override Close Throttle Switch CIRCUIT ACTUATION TEST MODE The purpose of the circuit actuation test mode is to check for the proper operation of output circuits of dev...

Страница 724: ...DE READ SENSOR VOLTAGE M A P Sensor Voltage Throttle Position M i n i m u m Throttle Oxygen Sensor Signal Coolant Temp Sensor T Body Temp Sensor 5 2L and 5 9L Engines Battery Temp Sensor READ SENSOR VALUES M A P Sensor Reading Throttle Opening Oxygen Sensor State Coolant Temperature T Body Temperature 5 2L and 5 9L Engines Battery Temperature Vehicle Speed ENGINE PARAMETERS MODE Engine Speed Total...

Страница 725: ... AND 5 9L 56 GY PK EMISSION MAINTENANCE REMINDER EMR LIGHT 22 OR LB THROTTLE POSITION SENSOR TPS 57 23 58 24 GY BK IGNITION DISTRIBUTOR REFERENCE PICK UP 59 25 PK SCI TRANSMIT 60 GY RD ISC MOTOR OPEN 26 WIRE COLOR CODES LB LIGHT BLUE VT VIOLET 27 BR A C SWITCH SENSE BK EJLACK LG LIGHT GREEN WT WHITE 27 BR A C SWITCH SENSE BR EJROWN OR ORANGE YL YELLOW 28 VT IDLE CONTACT SWITCH DB C ARK BLUE PK PIN...

Страница 726: ... 3 SPEED AUTO ONLYi m m SIX 1 2 FUEL INJECTORS Single Board Engine Controller System Schematic 3 9L Engine 4 CO ...

Страница 727: ... Z O u 3 SPEED AUTO ONLY A 999 86 a A I S M O T O R D 87A 87 vJUUUL 85 30 LOCK UN LOCK SOLENOID I P U R G E P U R G E S O L AIR S W I T C H E G R S O L C H K E N G LAMP O N O F F R E S U M E a o at Q O O Z U J 5 d 00 3 0 T 85 a r m 87 H J l CM E M R LAMP SHFT LP LOCK UP O D S O L A C RELAY S P E E D C O N T R O L V A C U U M 5 V E N T 85 i I I 52 AIR SWITCHING SOLENOID 36 TTTTIO f SOLENOID 35 EGR ...

Страница 728: ...S MOTOR m w STARTER j 1 2 FUEL INJEaORS IGNITION COIL J9014 178 Single Board Engine Controller System Schematic 5 9L Engine Normal Duty ...

Страница 729: ...4 0 0 0 CO FUEL INJECTORS J9014 179 Single Board Engine Controller System Schematic 5 9L Engine Heavy Duty ...

Страница 730: ...to ground terminal Number 1 of the injector harness Fig 1 to engine ground 4 Connect a jumper wire to the positive terminal Number 2 of the injector harness Fig 1 and touch the battery positive post for no longer than 5 sec onds This releases system pressure 5 Remove jumper wires 6 Continue fuel system service TERMINAL 1 TERMINAL 2 8914 123 Fig 11njector Harness Connectors THROTTLE BODY REMOVAL 1 ...

Страница 731: ...e body components w i t h new O rings and seals where applicable Never use silicone lubricants on O rings or seals damage may result Use care when removing fuel hoses to prevent damage to hose or hose nipple I f fuel system hoses are t o b e replaced o n l y hoses m a r k e d E F I E F M m a y b e used Always use new hose clamps of the correct type when reassembling and tighten hose clamps to 1 N ...

Страница 732: ...LE SPEED CONTROL ISC ACTUATOR HEATED AIR INLET NIPPLE CANISTER PURGE NIPPLE DIVERTER VALVE NIPPLE THROTTLE LEVER PCV NIPPLE FUEL PRESSURE REGULATOR FUEL RETURN NIPPLE FUEL INLET NIPPLE FUEL INJECTORS WIRING CONNECTOR MAP SENSOR C O CO THROTTLE POSITION SENSOR TPS 8914 97 Fig 3 Throttle Body Components 3 9L Engine CO ...

Страница 733: ...CTUATOR FUEL INJECTORS HEATED AIR INLET NIPPLE DIVERTER VALVE NIPPLE CANISTER PURGE NIPPLE FUEL INLET NIPPLE FUEL INJECTORS WIRING CONNECTOR MAP SENSOR FUEL RETURN NIPPLE PCV NIPPLE THROTTLE BODY TEMPERATURE SENSOR FUEL PRESSURE REGULATOR THROTTLE POSITION SENSOR TPS cn C D CO 8914 107 Fig 4 Throttle Body Components 5 2L and 5 9L Engines ...

Страница 734: ... SENSOR Removal 1 Remove air cleaner from engine 2 Disconnect throttle body temperature sensor electrical connector 3 Remove sensor Fig 6 Installation 1 Apply heat transfer compound provided w i t h new sensor to tip of new sensor 2 Install sensor and tighten to 12 Nnn 110 in lbs torque 3 Connect electrical connector to sensor 4 Install air cleaner THROTTLE BODY TEMPERATUR SENSOR RR14G154 Fig 6 Th...

Страница 735: ... the hole i n the front of the electrical connector gently pry the in jectors from the pod Fig 9 7 Make sure the injector lower O ring has been removed from the pod Fig 1 0 Installation 1 Install lower O ring on injector O ring should butt against plastic filter assembly Inspect both O rings for cuts or tears and replace i f necessary Fig 10 2 Align the injector terminal housing w i t h the lo cat...

Страница 736: ...VICE 1 Remove vacuum hose and electrical connector from sensor Fig 13 2 Remove sensor mounting screws and remove sensor Fig 13 3 Reverse the above procedure for installation Check the vacuum hose and electrical connections to the sensor THROTTLE POSITION SENSOR TPS Removal 1 Disconnect battery negative cable 2 Remove air cleaner 3 Disconnect 3 way connector at throttle position sensor 4 Remove thr...

Страница 737: ...I f vehicle mileage is greater than 1000 miles set to 2500 2600 r p m 5 2L a n d 5 9L Engine I f vehicle mileage is less than 1000 miles set to 2650 2750 r p m I f vehicle mileage is greater than 1000 miles set to 2750 2850 r p m 10 Shut off vehicle 11 Reconnect the ISC actuator motor electrical connector 12 Reconnect the Coolant Temperature Sensor Fig 16 Adjusting the Idle Speed Control ISC Actua...

Страница 738: ...ting screws Fig 19 3 Remove wiring connectors from SBEC Remove module 4 Reverse above procedure for installation Fig 19 Single Board Engine Controller SBEC HEATED OXYGEN SENSOR 02 SENSOR SERVICE On 3 9L engines the oxygen sensor is located i n the exhaust systems Y pipe Fig 20 O n 5 2L and 5 9L engines the oxygen sensor is located above the outlet of the left exhaust manifold Fig 21 Fig 20 Heated ...

Страница 739: ...and no additional compound is required 5 Tighten sensor to 27 N n n 20 ft lbs torque F o r m o r e i n f o r m a t i o n refer t o G r o u p 25 RR14G150 Fig 22 Heated Oxygen Sensor Electrical Connector 3 9L Engine SENSOR SPECIFICATIONS Component Number of Terminals Resistance a t F Thread Compound Thread Size Torque Coolant Temperature Sensor 2 7 000 to 13 000 Ohms About 21 C 70 F 700 to 1 000 Ohm...

Страница 740: ...distance between the transfer case and the front axle differential case caused by front suspension spring and axle move ment The internally splined slip yoke shaft slides fore and aft on the externally splined drive shaft to compensate for distance variation i e to shorten and lengthen the effective drive shaft length be Page Vibration 3 tween the front axle differential housing and transfer case ...

Страница 741: ...1 6 2 DRIVE SHAFTS AND UNIVERSAL JOINTS FRONT DRIVE SHAFT v S L EI2UI S C R E W S H A F T VIEW C J9016 18 Fig 1 Drive Shafts ...

Страница 742: ...rface can originate at the fol lowing locations wheels tires brake drums engine mounts engine accessories clutch torque converter transmission and drive shaft U joints axle yoke Tires that are out of round i e radial runout or wheels tires that are excessively unbalanced will cause a low frequency vibration that w i l l induce prominent mirror and door shake Tire and or wheel faults must be correc...

Страница 743: ... line angularity d Correct angularity e Rear spring center bolt not in seat e Loosen spring U bolts and seat center bolt f Worn U joint bearings f Replace U joint 9 Drive shaft damaged bent tube or out 9 Install replacement drive shaft of balance Install replacement drive shaft h Broken rear spring h Replace rear spring i Excessive runout or unbalanced condition i Reindex drive shaft 180 test and ...

Страница 744: ... 8 17 KM H ABOVE THE VIBRATION RANGE SHIFT TO NEUTRAL AND LET THE ENGINE IDLE AND COAST THROUGH THE VIBRATION RANGE ROAD TEST r VIBRATION GONE VIBRATES DURING COAST VIBRATION STOPS DURING COAST IN NEUTRAL OK o WHEEL TIRE BALANCE ADD BALANCE WEIGHTS HERE HEAVY SPOT SPINDLE TIRE OR WHEEL TRAMP OR WHEEL HOP CORRECTIVE WEIGHT LOCATION ADD BALANCE WEIGHTS HERE OF SPINDLE TO HEAVY SPOT WHEEL CORRECTIVE ...

Страница 745: ...DED 1 m CORRECTION NEEDED REPAIR OR REPLACE AS NECESSARY RADIALLY OBSERVE THE FRONT DRIVE SHAFT OPERATION 1 REMOVE THE REAR DRIVE SHAFT MARK THE SHAFT AND AXLE YOKE FOR ASSEMBLY REFERENCE 2 ROAD TEST WITH THE TRANSFER CASE IN4H ROAD TEST NO VIBRATION E OR NOTICEABLY REDUCED NO CHANGE IN VIBRATION LEVEL 0 INSPECT THE REAR DRIVE SHAFT CONDITION WORN BINDING WORN LOOSE BENT BRINELLED BINDING SLIP TUB...

Страница 746: ...WABLE RUNOUT AT EITHER YOKE IF THE RUNOUT IS EXCESSIVE REINDEX THE YOKE AND AAEASURE THE RUNOUT REPLACE THE YOKE IF REINDEXING DOES NOT CORRECT THE RUNOUT INSTALL THE DRIVE SHAFT ROAD TEST THE REPLACEMENT YOKE RUNOUT SHOULD BE MEASURED ALSO OK STOPJ O AAEASURE THE REAR DRIVE SHAFT RUNOUT WITH A DIAL INDICATOR C REINDEX THE SHAFT 180 AND AAEASURE THE RUNOUT REFER TO THE APPLICABLE SPECIFICATION CHA...

Страница 747: ... SHIMS TO CORREC T S ANGLE ROAD TEST OK OBSERVE THE REAR DRIVE SHAFT OPERATION 1 REMOVE THE FRONT DRIVE SHAFT AAARK THE SHAFT AND AXLE YOKES FOR ASSEMBLY REFERENCE 2 ROAD TEST WITH THE TRANSFER CASE IN 4H ROAD TEST NO VIBRATION OR NOTICEABLY REDUCED NO CHANGE IN THE VIBRATION LEVEL o o INSPECT THE FRONT DRIVE SHAFT CONDITION WORN BINDING WORN LOOSE BRINELLED BINDING U JOINT SLIP YOKE BENT EXCESSIV...

Страница 748: ... REINDEXING DOES NOT CORRECT THE RUNOUT INSTAl THE DRIVE SHAFT ROAD TEST AAEASURE THE FRONT DRIVE SHAFT RUNOUT WITH A DIAL INDICATOR O REINDEX SHAFT 180 REFER TO THE APPLICABLE SPECIFICATION CHART FOR THE AAAXIAAUAA ALLOWABLE RUNOUT OF THE SHAFT AAEASURE THE FRONT DRIVE PINION GEAR SHAFT AND FRONT DRIVE SHAFT ANGLES WITH AN INCLINOAAETER NOTE THE FRONT ANGLES ARE AAEASURED WITH THE SAME PROCEDURES...

Страница 749: ...nter support bearing is permanently lubri cated when assembled during manufacture and does not require additional lubrication during its service life A l l CV U joints s h o u l d be inspected f o r seal ex t e r n a l leakage a n d damage each time t h e vehicle is serviced I f seal e x t e r n a l leakage o r damage Page Service Information 10 Slip Yoke Service 20 U Joint Service 21 U Joint Yoke...

Страница 750: ...rew adjacent to the first clamp screw Fig 6 and repeat the vibration test 14 The combined weight of two clamp screws at the same position could cause an additional unbal anced condition I f so separate the clamp screws ap proximately 1 2 inch 1 4 inch above and 1 4 inch below the marked position and repeat the vibration test Fig 7 15 Continue to increase the separation distance between the clamp s...

Страница 751: ...when the yoke arms and bores at each end of the shaft are i n the same plane Fig 8 MEASUREMENT WITH A GAUGE BAR Use a straight piece of round stock metal w i t h the same outside diameter OD as the yoke bore diame ter for a slip f i t gauge bar 1 Remove the bearing caps and the spider from the yoke I f necessary refer to U J o i n t Service for the procedure 2 Insert the gauge bar into one yoke ar...

Страница 752: ...haft angle 5 Rotate the rear drive shaft until one of the shaft rear yoke bearing caps is facing downward 6 Attach the inclinometer magnet to the bearing cap and note the angle The inclinometer frame a n d degree scale m u s t face the same d i r e c t i o n i e either vehicle left o r vehicle right f o r b o t h measurements 7 The difference between the two angles is the drive shaft rear angle B ...

Страница 753: ... I f the drive shaft vertical angle is correct the axle drive pinion gear shaft angle should also be cor rect 16 A n incorrect drive shaft vertical angle is gen erally caused by rear axle drive pinion gear shaft yoke mis alignment I f the drive pinion gear shaft yoke is mis aligned inspect for loose spring to axle U bolts which would allow the axle tubes to rotate on the springs Also inspect for b...

Страница 754: ...ing as engine speed increases is highly responsive to rear axle drive pinion gear shaft yoke angle adjust ment This includes the center bearing support length adjustment for two piece drive shafts 8 Adjustment of the drive pinion gear shaft yoke vertical angle is accomplished by installing tapered shims between the rear springs and the rear axle spring pad and or correcting the center bearing sup ...

Страница 755: ...he vehi cle width short straightedge two large and two small C clamps rigid tape measure and large carpenter s square 1 Inspect the condition of the engine rear mounts Worn loose engine or transmission transfer case mounts could cause misalignment and cause an erro neous measurement 2 Position the vehicle on level surface or level the vehicle to eliminate the possibility of a n incorrect measureme...

Страница 756: ...D 350 vehicles equipped with a transmis sion extension housing and inboard slip yoke type used with Model W 150 W 250 and W 350 vehicles i e vehicles equipped w i t h a transfer case 1 Raise and support the vehicle 2 Mark the drive shaft and the rear axle drive pinion gear shaft yoke Fig 14 for installation align ment reference CAUTION Do not allow the drive shaft to drop or hang from either U joi...

Страница 757: ...AXLE DRIVE LUBRICANT FITTING SHAFT VIEW A FRONT AXLE SCREW CLAMP FRONT NUT VIEW E CREW CAB BOLT REAR AXLE TRANSMISSION TRANSFER CASE CLAMP BOOT LUBRICANT FITTING REAR DRIVE SHAFT VIEW D REAR AXLE SHAFT TWO PIECE FRAME LUBRICANT FITTING TRANSFER CASE FRONT FRAME LUBRICANT FITTING REAR DRIVE SHAFT VIEWC REAR OF TRANSFER CASE ONE PIECE REAR DRIVE SHAFT VIEW C REAR OF TRANSFER CASE INTERMEDIATE DRIVE ...

Страница 758: ...move the two center bearing support to bracket retaining nuts and bolts Fig 15 and re move the front half shaft with the center bearing from the vehicle TWO PIECE REAR DRIVE SHAFT INSTALLATION 1 Clean and lubricate the front half shaft and rear half shaft slip yoke splines 2 Position the front end of the front half shaft at the transmission transfer case Fig 14 and start the clamp screws a t the f...

Страница 759: ... nicks and burrs Do not damage the splines when engaging the yoke 2 Provide a support for the drive shaft during in stallation to prevent damage to the CV U joints 3 Visually align the drive shaft front U joint and drive the drive pinion gear shaft axle yoke installa tion reference marks and correctly mate the drive shaft CV joint yoke w i t h the transfer case output shaft yoke Fig 14 4 Install t...

Страница 760: ... ASSEMBL Y INSTALLA TION 1 Place the replacement slinger bearing and re tainer on the front half shaft splines Fig 15 Each component is press fitted on the splined half shaft 2 Use a rigid tube or pipe w i t h an I D larger than the OD of the splines to force the components for ward onto the shaft splines until they are seated at the shaft shoulder 3 Clean and lubricate the front half shaft and re...

Страница 761: ...will be the bearing cap receiver Place a socket wrench slightly smaller OD than the yoke bore against the opposite bearing cap This will be the bearing cap driver Position the yoke with the socket wrenches i n a vise Fig 19 5 Compress the vise jaws Fig 19 until the smaller socket wrench driver partially forces the opposite bearing cap out of the yoke bore and into the larger socket wrench receiver...

Страница 762: ...xtreme pressure EP lithium base type lubricant to the yoke bores the bearing caps the needle bearings the seals and the bearing contact surfaces on the spider cylinders 2 Position the spider cylinders i n the yoke bores insert the seals into the yoke bores and against the spider cylinders and tap the bearing caps with the needle bearings into the yoke bores far enough to re tain the spider in plac...

Страница 763: ... portion of a yoke in the vise Also to avoid distorting a yoke do not over tighten the vise jaws It can be helpful to saturate the bearing caps with penetrating oil prior to removal 3 Each bearing cap should be removed i n the se quence indicated i n Figure 23 This sequence re quires the least amount of disassembly time SECTION A A THRU LUBE FITTING J 9 0 1 6 2 2 A L I G N M E N T P U N C H A A A ...

Страница 764: ...e by forcing the spi der trunnion bushing from the link yoke Pull the flange yoke and the spider with the ball socket from the centering ball as a unit Fig 25 Bearing Cap Removal With Tool C 4365 4 WASHER LARGE OD 3 BALL SEATS Fig 26 CV Joint Components 2 Clean and inspect the ball socket bushing for wear I f the bushing is worn replace both the flange yoke and the spider 3 Pry the seal from ball ...

Страница 765: ...iculty is encountered i n s e a t i n g the r e t a i n e r s i n t h e grooves strike t h e yoke a r m s f i r m l y w i t h a h a m m e r t o seat the retainers 10 Lubricate the centering ball and socket and as semble the remaining half of the CV joint according to the same instructions above LUBRICATION 1 Use the lubricant provided with the ball seat service k i t to lubricate all the component...

Страница 766: ... ft lbs Yoke Axle 406 Nnn 300 ft lbs Yoke Transmission 237 Nnn 175 ft lbs Roller Bushing Clamp Bolt 1 4 28 19 Nnn 14 ft lbs Roller Bushing Clamp Bolt 5 16 24 34 Nnn 25 ft lbs Parking Brake to Flange Yoke Nut 47 Nnn 35 ft lbs Front Axle U Bolt Nut 17 Nnn 150 in lbs CV Joint Screw 88 Nnn 65 ft lbs Rear Axle Clamp Screw 19 Nnn 14 ft lbs Transfer Case Clamp Screw 19 Nnn 14 ft lbs Lubricant Fitting 3 N...

Страница 767: ......

Страница 768: ...k absorber is located inside each spring coil and i t is attached to the frame side rail bracket and to the lower suspen sion arm 4WD VEHICLES A l l four wheel drive 4WD Ram Truck and Ram charger vehicles are equipped w i t h a leaf spring op erated front suspension system Fig 2 The leaf springs are the fixed rate type and are attached to the frame side rail brackets and the front axle The front l...

Страница 769: ... manner u n t i l the vehicle weight dampens the oscillations move ments A shock absorber is designed to immediately dampen the spring movements by dissipating most of the spring energy which would otherwise continue to be alternately stored and then released A shock absorber converts mechanical spring en ergy into heat energy via the friction caused by the hydraulic fluid in the shock absorber wh...

Страница 770: ...ption that describes the condition requiring cor rection and follow the connecting arrows to the square s that describe s the possible cause s SPRING AND SHOCK ABSORBER DIAGNOSIS SPRING SAGS OR BOTTOMS SPRING NOISE SPRING BROKE SHOCK ABSORBERS NOISY SMOCK ABSORBER LEAKING FLUID FATIGUE FROM OPERATION ON SEVERE TERRAIN O R OVERLOADING LOOSE U BOLT NUTS SHOCK ABSORBERS NOT FUNCTIONING L O O S E EYE ...

Страница 771: ...5 Raise the vehicle remove the supports and lower the vehicle to the surface Tighten the retain ing bolts w i t h 23 N n n 17 ft lbs 200 in lbs torque FRONT 4WD VEHICLES REMOVAL 1 Raise the vehicle Position supports at the ex treme front ends of the frame rails and then lower the front of the vehicle onto the supports 2 T u r n the wheels i n the direction necessary to provide the best possible ac...

Страница 772: ...nd the inner retainer from the vehicle Fig 6 REAR INSTALLA TION 1 Before installing the shock absorber ensure that the bushings is inserted i n the shock absorber eyes Ensure t h a t t h e shock absorber is positioned o n t h e s p r i n g b r a c k e t s t u d w i t h retainers lo cated o n either side o f the b u s h i n g Fig 6 2 Position the inner retainer and shock absorber eye on the spring ...

Страница 773: ... shock absorber upper bushing from the bracket Fig 7 I f necessary refer to the removal procedure 7 Remove the strut bar Fig 7 I f necessary refer to the removal procedure 8 Install Spring Compressor Tool DD 1278 i n the spring Fig 8 and tighten the nut finger tight and then loosen the nut 1 2 of a turn 9 Remove the cotter pins and the lower and upper ball stud nuts at the steering knuckle 10 Inst...

Страница 774: ... brake caliper adapter with the pad flanges engaged w i t h the adapter rails Slowly slide the caliper into posi tion i n the adapter and over the brake rotor Align the caliper on the adapter rails Use care to avoid pulling the protective dust boot from the grooves as the caliper piston and boot slide over the inboard brake pad I f necessary refer t o G r o u p 5 Brakes f o r a d d i t i o n a l i...

Страница 775: ...le tube spring pad Figs 9 and 10 5 Install the U bolts replacement lockwashers and the retaining nuts Figs 9 and 10 6 Tighten the nuts until they force the lockwash ers flush against the spring bracket 7 Remove the supports and lower the vehicle so that the weight is being supported by the tires i e the springs 8 Tighten the spring retaining nuts according to the following specifications U bolt nu...

Страница 776: ...ese tips should not be lubricated but may be replaced i f excessively worn or missing Vehicles w i t h heavy duty suspensions do not have plastic tip liners INSTALLATION 1 Position the spring on the axle shaft tube so that the spring center bolt is inserted into the locat ing hole i n the axle tube spring pad Figs 11 12 and 13 2 Align the spring front eye w i t h the bolt hole i n the front bracke...

Страница 777: ...tallation procedure FRONT AND REAR SPRING EYE ROUND BUSHING The spring front rear eye round one piece bush ing can be replaced with the spring installed on the vehicle according to the following instructions 1 Raise and support the vehicle so that the spring is relaxed and the tires slightly contacting the sur face 2 As applicable remove the spring front or rear eye pivot bolt and remove the front...

Страница 778: ... support brackets and bolts nuts Figs 15 and 16 Tighten the bolts nuts w i t h 23 N n n 17 ft lbs 200 in lbs torque 2 Install the outer retainers and rubber bushings on the l i n k rods Figs 15 and 16 3 Install the link rod nuts Figs 15 and 16 Tighten the nuts w i t h 11 N n n 100 in lbs Fig 16 Stabilizer Bar 4WD Vehicles ...

Страница 779: ...Retaining Nut Front Jounce Bumper Bracket to Frame Nut 1 2 13 4WD 20 Nnn 180 in lbs 102 Nnn 75 ft lbs D 130 W 150 and Sport Utility Rear Jounce Bumper Retaining Nut Rear Jounce Bumper Mounting Bracket to Frame Nut 3 8 16 20 Nnn 180 in lbs 41 Nnn 30 ft lbs D and W230 and 350 Models Rear Jounce Bumper Retaining Nut 23 Nnn 200 in lbs STABILIZER BAR 2WD Vehicles Link Rod to Front Strut Rod Nuts 5 16 1...

Страница 780: ...ering gear and the steering linkage A power assisted steering system consists of a Page Steering System Description 1 steering gear the interconnecting hoses and fittings a belt driven power steering pump with an integral fluid reservoir Fig 2 and the steering linkage The power steering gear and pump can be adjusted and internally serviced Fig 2 Power Steering Pump Steering wheel movement is trans...

Страница 781: ...ear a power piston with gear teeth that are broached into the side of the piston which are i n WORMSHAFT ADJUSTER PLUG Fig 4 Manual Steering Gear constant mesh w i t h the pitman sector shaft gear teeth and a wormshaft that connects the steering column shaft to the power piston via a fabric and rubber coupler The steering valve located on top of the steering gear directs the flow of fluid i n the ...

Страница 782: ...column mounted gear shift selector mechanism The center slip type telescoping intermediate shaft is attached to the steering gear shaft w i t h a flexible coupler and to the steering column shaft w i t h a universal joint Both types of steering columns have anti theft pro visions plus they are energy absorbing i e collapse from impact i n the event of a front end collision SERVICE PRECAUTIONS Peri...

Страница 783: ...osen the applicable tie rod sleeve clamp nut and bolt and un thread the tie rod end from the sleeve INSTALLATION 1 Thread the replacement tie rod end into the tie rod sleeve 2 As applicable insert the tie rod end ball stud into the steering knuckle arm bore or the center link bore Fig 2 Install the stud retaining n u t and tighten i t w i t h 61 Nnn 45 ft lbs torque Install a re placement cotter p...

Страница 784: ... w i t h 54 N n n 40 ft lbs torque 3 Install the pitman steering a r m on the steer ing gear pitman sector shaft Tighten the retaining nut with 237 Nnn 175 ft lbs torque CAUTION Care must be exercised when installing a center link It is possible to install it back to front i e reversed position which will result in incor rect geometry and tie rod to center link and tie rod to strut interferences d...

Страница 785: ...lash adjustment is provided by the sector shaft gear ad justment screw which extends through the housing cover The sector shaft gear teeth and the ball nut rack teeth are designed so that a tighter meshing exists between the two when the front wheels are straight ahead Correct meshing between the sector shaft gear and ball nut rack teeth is obtained by adjusting an adjustment screw which moves the...

Страница 786: ... OPER TEND IMENT GEAR SHAFT ADJUSTED TOO TIGHT WORN OR INOPERATIVE SHOCK ABSORBERS TIRES OR WHEELS OUT OF BALANCE TESTS ADJUSTMENTS AND PROCEDURES ARE DESCRIBED IN THIS MANUAL ON VEHICLE ADJUSTMENTS Two adjustments are provided for m a n u a l steering gears Figs 2 and 3 The wormshaft bearing pre load torque adjustment and the ball n u t rack sector shaft gear teeth mesh lash adjustment WORMSHAFT ...

Страница 787: ...mber of rotations Turn the steering wheel back exactly half way to the center position 2 T u r n the sector shaft adjustment screw clock wise to remove a l l the lash that exists between the ball nut rack and sector shaft gear teeth and then tighten the adjustment screw locknut w i t h 47 N m 35 ft lbs torque 3 Rotate the steering wheel approximately 1 4 turn away from the overcenter position Then...

Страница 788: ... nut 4 Remove the pitman sector shaft adjustment screw locknut Remove the cover retaining bolts cover and gasket Fig 5 5 Slide the adjustment screw head Fig 6 out of the pitman sector shaft T slot and remove i t and the shim s 6 Retain the shim s for end play measurement during assembly 7 Remove the pitman sector shaft the worm shaft bearing preload torque adjustment plug lock nut and the adjustme...

Страница 789: ...19 10 STEERING COVER BEARING CAP Fig 6 Manual Steering Gear Exploded View J8919 12 ...

Страница 790: ...each ball nut cir cuit Insert the balls i n the ball nut circuits through the holes i n the ball guides Fig 10 EQUAL EQUAL THREADS THREADS TEETH DOWNWARD J8919 14 Fig 9 Wormshaft Ball Nut To a i d the r e c i r c u l a t i n g b a l l installation rotate w o r m s h a f t b a c k a n d f o r t h slightly w h i l e insert ing t h e balls WORMSHAFT RH43 Fig 10 Recirculating Ball Installation 5 Place...

Страница 791: ...t plug Fig 12 tighten the puller tool screw Fig 12 to expand and hold the legs i n position move the slide hammer weight outward to remove the bearing cup from the adjustment plug Fig 12 remove the adjustment plug from the vise and re move the spare locknut and install a replacement bearing cup i n the adjust ment plug with an appropriate installation tool Fig 13 2 Lubricate the wormshaft lower be...

Страница 792: ...hat reduces the end play t o b e l o w the specified l i m i t Fig 14 Adjustment Screw End Play Measurement 7 Inspect the wormshaft shaft upper bearing and bearing cup for wear looseness flat spots pitting cracks and other damage I f either the bearing or the bearing cup is damaged both components must be replaced 8 I f the cup fits loosely i n the housing trial fit a replacement cup I f the repla...

Страница 793: ...ver almost comes i n contact w i t h the gasket 14 Install the cover retaining bolts and finger tighten them only Continue tightening the adjust ment screw counterclockwise u n t i l the cover is tight against the gasket and then loosen the screw 1 2 ro tation 15 Tighten the cover bolts w i t h 61 N m 45 ft lbs torque CAUTION A protective wrap must be used to en close the shaft threads splines dur...

Страница 794: ...erse direction 1 2 of the total number of ro tations to center the ball nut pitman shaft place a low calibration e g inch pounds torque bar w i t h a socket wrench on the wormshaft splines Fig 19 and while rotating the wormshaft back and forth overcenter tighten the pitman shaft adjust ment screw until the torque required to rotate the shaft is 1 6 N m 14 in lbs TORQUE BAR AND SOCKET WRENCH J8919 ...

Страница 795: ...d loss Cap the ends of the hoses to prevent any entry of foreign ma terial 4 Disconnect the steering column shaft from the stub shaft 5 Raise and support the vehicle 6 Disconnect the center link from the pitman steering arm 7 Remove the pitman steering arm retaining nut and washer mark the pitman steering arm and the pitman shaft positions for installation reference and remove the pitman steering ...

Страница 796: ...steering ratio Safety goggles should be worn at a l l times when involved with power steering gear or pump service POWER STEERING SYSTEM SERVICE DIAGNOSIS To use the System Service Diagnosis charts look for the condition that describes the malfunction that requires correction then move to the right to the possible cause of the malfunction and then fur ther to the right for the correction I n most ...

Страница 797: ......

Страница 798: ...OISE IN STEERING GEAR 1 Gear loose on frame H Check gear to frame mounting screws Tighten screws to 88 N m 65 foot pounds torque 2 Steering linkage looseness 2 Check linkage pivot points for wear Replace if necessary 3 Pressure hose touching other parts of car 3 Adjust hose position Do not bend tubing by hand 4 Loose pitman shaft over center adjustment 4 Adjust to specifications NOTE A slight ratt...

Страница 799: ...and normal or heavier in opposite direction 1 Low oil level 2 Pump belt slipping 3 High internal leakage 1 Low oil level 2 Loose pump belt 3 Steering linkage hitting engine oil pan at full turn 4 Insufficient pump pressure 5 Check and adjust as necessary With front wheels still on alignment pads of front end machine disconnect pitman arm of linkage from pitman shaft of gear Turn front wheels by ha...

Страница 800: ... of car HARD STEERING OR LACK OF ASSIST 1 Loose pump belt 1 Adjust belt tension to specification 2 Low oil level NOTE Low oil level will also result in excessive pump noise 2 Fill to proper level If excessively low check all lines and joints for evidence of external leakage Tighten loose connectors 3 Steering gear to column misalignment 3 Align steering column NOTE IF CHECKS 1 THROUGH 5 DO NOT REV...

Страница 801: ...is securely tightened when installing it 1 Power steering fluid leakage is possible from the following steering gear areas hoses and fittings preload torque adjustment cap seal stub shaft seals housing ball plug pitman shaft cover gasket adjustment screw and locknut pitman shaft seals housing end plug seal and cracked or porous housing 2 Raise and support the front of the vehicle Clean the exterio...

Страница 802: ...sition the seal and the washer only far enough i n the shaft bore to provide sufficient clear ance for the second seal the outer backup washer and the retaining ring D o n o t force t h e seal against t h e i n n e r bore surface CAUTION For proper sealing ensure that the seals are spaced so that they are separately seated in the shaft bore 14 Install the double lip seal and the outer backup washe...

Страница 803: ...e steering wheel to the left and to the right and inspect for fluid leakage Add power steer ing fluid as required 12 Remove the drain pan POWER STEERING GEAR DISASSEMBLY CAUTION Cleanliness is extremely important when repairing a power steering gear Maintain the bench the tools and the components clean at all times Thoroughly clean the exterior of the gear with cleaning solvent before disassembly ...

Страница 804: ...TEFLON RING 26 O RING SEAL 27 TEFLON RING 28 SPOOL VALVE 29 O RING SEAL 30 O RING SEAL 31 WORMSHAFT 32 BEARING RACE 33 THRUST BEARING 34 BEARING RACE 35 NEEDLE BEARING 36 DUST SEAL 37 RETAINING SNAP RING 38 SEAL 39 ADJUSTMENT CAP 40 O RING SEAL 41 LARGE THRUST WASHER 42 THRUST BEARING 43 SMALL THRUST WASHER 44 SPACER 45 RETAINING RING 46 NEEDLE BEARING 47 SINGLE LIP SEAL 48 BACK UP WASHER 49 DOUBL...

Страница 805: ...om the housing and discard the gasket Fig 7 10 Rotate the stub shaft until the pitman shaft teeth are centered i n the housing Tap the end of the pitman shaft with a plastic tipped hammer and re move i t from the housing Fig 7 D o n o t disassem ble the p i t m a n shaft i t is serviced a n d replaced as a u n i t only 11 Insert an arbor tool i n the rack piston until i t stops at the end of the w...

Страница 806: ...h cleaning solvent Fig 12 Pitman Shaft Needle Bearing Removal 2 Inspect the pitman shaft bore I f i t is badly scored or worn replace the housing However slight scratches i n the bore are usually acceptable 3 Inspect the hose connector seats and the pop pet check valve I f they are deeply scored cracked or worn they must be replaced 4 Inspect the ball plug i n the housing Fig 13 I f fluid leakage ...

Страница 807: ...e the seal against the i n ner bore surface CAUTION For proper sealing ensure that the seals are spaced so that they are separately seated in the shaft bore 5 Install the double lip seal and the outer backup washer Fig 16 w i t h a seal installation tool Posi tion the seal and the backup washer only far enough in the shaft bore to provide sufficient clearance for the retaining ring 6 Install the r...

Страница 808: ...n stallation tool w i t h the bearing manufacturer s iden tification number facing toward the tool 3 Position the bearing and the tool over the inner bore and press the bearing into the bore until i t is flush w i t h the bottom surface of the outer bore 4 Insert the stub shaft oil seal far enough into the seal bore to provide sufficient clearance for the dust seal and the retaining ring Fig 18 5 ...

Страница 809: ...pecified distance because the spool valve could become cocked in the valve body 3 Pull outward on the cap end of the stub shaft until i t clears the valve body by approximately 6 35 mm 1 4 in 4 Carefully disengage the stub shaft locating p i n from the hole i n the spool valve and remove the stub shaft from the valve body Fig 2 1 5 Rotate the spool valve and remove i t from the valve body Fig 2 2 ...

Страница 810: ...without the spool valve dampener O ring seal installed I f the spool valve does not rotate easily within the valve body replace the complete valve body VALVE BODY AND STUB SHAFT ASSEMBLY 1 Lubricate the replacement inner O ring seals and the teflon rings Fig 24 with power steering fluid 2 Install the inner O ring seals i n the valve body ring grooves Fig 25 and install the teflon rings on top of t...

Страница 811: ...all return guides the wormshaft w i t h SECTOR TEETH BEARING SEAL CONTACT SURFACE J8919 50 Fig 27 Pitman Shaft Inspection an arbor tool and the recirculating balls E n s u r e t h a t all 24 balls a r e removed a n d retained 3 Remove the arbor tool from the wormshaft 4 Remove the teflon piston ring and the O ring seal from the rack piston Fig 28 RACK PISTON WORMSHAFT ASSEMBLY 1 Lubricate a l l of...

Страница 812: ...nd of the assembled rack pis ton with tool on wooden blocks Ensure that the rack piston is supported with wooden blocks after i t is inverted Fig 31 BALL RETURN GUIDE J8919 53 Fig 30 Ball Return Guide 11 Do not permit the tool to separate from the wormshaft until the rack piston is completely i n stalled on the wormshaft ARBOR 18919 54 POWER STEERING GEAR ASSEMBLY A l l components must be clean an...

Страница 813: ...sing The valve body is correctly seated when all or most of the fluid return hole in the steering gear housing is visible 4 Align the narrow slot i n the valve body w i t h the locating pin i n the wormshaft Fig 34 and insert the valve body into the steering gear housing seat the valve body i n the housing Fig 34 WORMSHAFT LOCATING PIN J8919 56 Fig 34 Valve Body Installation 5 Install a seal prote...

Страница 814: ...ng end gap n o t aligned with the hole inside the steering gear housing Tap lightly on the plug to en sure that the ring is seated properly 21 Adjust the wormshaft bearing preload torque J8919 58 Fig 36 Adjustment Cap Index Mark and the pitman shaft overcenter drag torque accord ing to the procedures listed within P o w e r Steering Gear Adjustments O n Bench POWER STEERING GEAR ADJUSTMENTS ON BEN...

Страница 815: ...as been adjusted Fig 38 Wormshaft Bearing Preload Torque Measurement 1 Rotate the pitman shaft adjustment screw coun terclockwise until i t is fully extended then rotate i t 180 degrees clockwise 2 Rotate the stub shaft from stop to stop count the total number of rotations and rotate the stub shaft i n the reverse direction 1 2 of the total number of rotations to center the steering gear W h e n t...

Страница 816: ...0 ft lbs torque af ter the adjustment is completed Fig 42 I f the ad j u s t m e n t screw is a l l o w e d to rotate w h i l e STEERING 19 37 Fig 41 Pitman Shaft Overcenter Drag Torque Measurement Fig 42 Tightening Adjustment Screw Locknut tightening the l o c k n u t the complete overcenter d r a g torque adjustment procedure m u s t be re peated 6 Install the steering gear according to the inst...

Страница 817: ... the following precautions be em ployed avoid sharp bends i n the hose a 5 inch approxi mate radius minimum is recommended hose must remain at least one inch away from a l l pulleys battery and brake tubing and two inches away from the exhaust manifold and protective plastic foam sleeves must be installed where the hose contacts other components or vehicle body metal 1 Wipe the hose open ends and ...

Страница 818: ... ball from its seat and al lows fluid to flow through a trigger orifice located i n the outlet fitting This reduces the pressure on the spring end of the flow control valve which then opens and allows the fluid to return to the intake side of the pump This action limits the maximum pressure output of the pump to a safe level W i t h normal operating conditions the pressure re quirements of the pum...

Страница 819: ...orque 2 Air in the oil Poor pressure hose connection Bleed system by operating steering from right to left full turn RATTLE NOISE IN 1 Vanes not installed properly 1 Install properly STEERING PUMP 1 Vanes not installed properly 2 Vanes sticking in rotor slots 2 Free up by removing burrs varnish 2 Vanes sticking in rotor slots or dirt SWISH NOISE IN 1 Defective flow control valve 1 Replace part STE...

Страница 820: ...urrs or dirt or replace Flush PRESSURE 1 Flow control valve stuck or inoperative 1 system 2 Pressure plate not flat against cam ring 2 Correct MOMENTARY 1 Low oil level in pump 1 Add power steering fluid as required INCREASE IN EFFORT Add power steering fluid as required WHEN TURNING WHEEL FAST TO 2 Pump belt slipping 2 Tighten or replace belt RIGHT OR LEFT 2 Pump belt slipping 2 Tighten or replac...

Страница 821: ...Extreme wear of cam ring 4 Scored pressure plate thrust plate or rotor 5 Vanes not installed properly 6 Vanes sticking in rotor slots 7 Cracked or broken thrust or pressure plate 1 Remove burrs or dirt Replace valve if damaged 2 Disassemble pump and correct 3 Replace parts Flush system 4 Replace parts Flush system 5 Install properly 6 Freeup by removing burrs varnish or dirt 7 Replace part J8919 7...

Страница 822: ... NUT TO 30 N m 22 FT LBS VIEW TIGHTEN FITTING TO 55 N m 40 FT LBS IF LEAKAGE PERSISTS REPLACE O RING SEAL VIEW B REPLACE RESERVOIR REPLACE DRIVESHAFT SEAL O RING ft VIEW REPLACE RESERVOIR 2 CHECK OIL LEVEL IF LEAKAGE PERSISTS WITH THE CORRECT LEVEL AND CAP TIGHT REPLACE THE CAP PR800C ...

Страница 823: ...mage i n t e r n a l components 7 W i t h the engine at a speed of approximately 600 to 800 rpm and the gauge valve open the initial pressure should be i n the range of 207 345 kPa 30 50 psi and should definitely be less than 690 kPa 100 psi I f the pressure is 690 kPa 100 psi or more inspect the hoses for restrictions and repair as necessary CAUTION The following test procedure involves testing t...

Страница 824: ... INSTALLATION Remove install power steering hoses with vehicle raised on a hoist Cap the hose open ends and the pump and steering gear ports to prevent entry of for eign material WARNING POWER STEERING FLUID AND PUMP COMPONENTS AND THE EXHAUST SYSTEM CAN BE EXTREMELY HOT IF THE ENGINE HAS BEEN RECENTLY OPERATING DO NOT START THE EN GINE WITH ANY LOOSE OR DISCONNECTED HOSES DO NOT ALLOW THE HOSES T...

Страница 825: ...just the tension ac cording to the adjustment procedure Refer to Cool i n g System Group 7 Tighten the adjustment bolts with 41 N m 30 ft lbs torque D o not p r y o n the p u m p reservoir use the square hole p r o v i d e d i n the bracket CAUTION Do not use automatic transmission fluid to fill the reservoir 6 Fill the reservoir with power steering fluid I f necessary refer to P u m p I n i t i a...

Страница 826: ...emove the end plate retaining ring Fig 10 insert a small punch i n the 3 1 mm 1 8 in diam eter hole i n the pump housing opposite the flow con trol valve orifice force the retaining ring upward w i t h a punch and remove the retaining ring from the pump housing by inserting a pry tool under the ring and turning i t 10 Remove the end plate and the spring from the pump housing Fig 9 I f the end plat...

Страница 827: ...STUD 31 FITTING PRESSURE HOSE J8919 1 Fig 9 Vane Submerged RETAINING RING J8919 84 Fig 10 End Plate Retaining Ring Removal 16 Remove the end plate O ring seal and the shaft seal Fig 14 Use care t o a v o i d damaging the p u m p housing bore Type Pump Exploded View Fig 11 Pump Shaft Removal PUMP CLEANING AND INSPECTION 1 Clean all the metal components with mineral spirits Fig 9 Either dry the comp...

Страница 828: ...ty and damage Fig 9 Replace the pump hous ing i f any of the conditions listed exist 7 Inspect the pressure hose flow control valve fit ting Fig 9 I f damaged replace i t 8 Inspect the end plate and retaining ring Fig 9 I f either one is damaged replace it Do not reuse the retaining ring i f i t is bent or distorted I f the con dition is uncertain replace the retaining ring 9 Inspect the bushing a...

Страница 829: ...tor Assembly Fig 18 Rotor Retaining Ring Installation 11 Place a large socket wrench on top of the pres sure plate and force the plate downward approxi mately 1 5 m m 1 16 in to seat i t Fig 22 12 Lubricate the end plate seal Fig 9 w i t h pe troleum jelly and install i t i n the second groove i n the pump housing bore 13 Install the spring i n the center groove i n the pressure plate Fig 9 14 Lub...

Страница 830: ...g seals Fig 25 after installing the fluid reser voir Re align the seals i f necessary 22 Install the mounting studs Fig 25 and tighten them with 48 N m 35 ft lbs torque 23 Install the O ring seal on the pressure hose flow control valve fitting Fig 25 and install the fit ROTOR VANE J8919 99 Fig 21 Rotor Vane Installation ting i n the flow control valve bore Tighten the fitting w i t h 55 N m 40 ft ...

Страница 831: ...ps Fluid with air i n i t will have a milky red color Maintain the reservoir full of fluid Because air is compressible it must be elimi nated from the fluid before normal steering a c tion can be obtained 5 Return the wheels to the straight ahead posi tion and operate the engine for an additional 2 to 3 minutes then stop the engine 6 Road test the vehicle to ensure that the steering system functio...

Страница 832: ...NOT REMOVE IF DEFORMED OR DISLODGED REPLACE HOUSING HOUSING CAP STUDS 48 NEWTON METRES 35 FOOT POUNDS SEAL FITTING 55 NEWTON METRES 40 FOOT POUNDS PR811A Fig 25 Pump Reservoir Seals PULLEY RH31 Fig 26 Pump Shaft Pulley Installation ...

Страница 833: ...umn jacket with a slotted mesh section de signed to shorten by rolling u p at its lower end SPRING a two piece slip type telescoping transmission gear shift tube interconnected by plastic inserts a two piece slip type telescoping steering shaft upper and lower shafts connected by plastic friction collars and shear pins and a support bracket that connects the steering col umn to the instrument pane...

Страница 834: ...act at the driver side When the column is installed i n the vehicle i t is normally not susceptible to damage However when it is removed special care must be taken during han dling When the column is removed from the vehicle actions such as a sharp blow on the end of the steer mn Column Shift ing shaft or the shift levers leaning on the column or dropping the column could shear or loosen the plast...

Страница 835: ... 8 11 Disconnect the automatic transmission shift indicator pointer cable from the shift housing if ap plicable TURN SIGNAL LEVER Fig 5 Turn Signal Lever 12 Remove the instrument panel steering column cover and the lower reinforcement 13 Remove the nuts that attach steering column support bracket to the instrument panel support 14 Carefully remove the lower section of the cou pler from the steerin...

Страница 836: ... applicable adjust the transmission shift linkage Whenever t h e steering c o l u m n is loos ened o r removed t h e shift linkage m u s t be ad j u s t e d a n d tested Refer to G r o u p 21 Transmission for the shift linkage adjustment STEERING 19 57 12 I f applicable connect the transmission shift se lector indicator pointer at its approximate original location 13 I f applicable slowly move the...

Страница 837: ...ach the bearing housing to the lock housing Fig 12 2 Remove the snap retaining ring from the up per end of the steering shaft Fig 12 CAUTION Do not allow steering shaft to slide out of the jacket 3 Remove the bearing housing from the shaft Fig 13 4 Remove the lock plate spring and the lock plate from the steering shaft Fig 13 5 Remove the steering column shaft from the lower end of the column Fig ...

Страница 838: ...e buzzer chime switch attaching screw hole A t the same time pull the key lock cyl inder out of the lock housing bore Fig 16 7 Grasp the lock lever and spring and pull them straight out of the lock housing Fig 16 STEERING 19 59 Fig 16 Key Lock Cylinder Lock Levers 8 Remove the four lock housing to column jacket hex head attaching screws and remove the lock hous ing plate and housing from jacket Fi...

Страница 839: ...eering shaft bearing Fig 20 for smooth operation and lubricate i t w i t h multi SHIFT HOUSING SHIFT TUBE KEY WAY JACKET PU938A Fig 19 Shift Tube Installation purpose N L G I grade 2 E P extreme pressure lubri cant e g MOPAR Multimileage Lubricant or an equivalent lubricant I f the bearing has any evi dence of roughness or wear i t should be replaced ...

Страница 840: ...RANK ASSEMBLY SPRING IN ASSEMBLED POSITION LET TORQUE N m TORQUE IN LBS 10 90 4 35 3 24 2 16 LOCK PLATE SPRING LOCK PLATE SCREW 4 JACKET ASSEMBLY IGNITION SWITCH ROD LOCK HOUSING COVER VIEW IN DIRECTION OF ARROW Y RN122 Fig 20 Upper Part Of Steering Column ...

Страница 841: ...der plunger spring and install i t on the lock housing 5 Install the shift lever gate on the lock housing Fig 23 6 Place the shift lever i n mid position if applica ble and seat the lock housing on top of the jacket Fig 23 Lock Housing Shift Gate while aligning the keyway i n the housing w i t h the slot i n the jacket Insert all four screws and slowly tighten each screw alternately and i n steps ...

Страница 842: ...snap retaining ring is in stalled i n the shaft groove 4 Lubricate the inside of the lock plate to pre vent rattle and install the lock plate on the steering column shaft Fig 13 5 Install the upper bearing snap retaining ring on the steering shaft Fig 12 6 Install the four screws that attach the bearing housing to the lock housing Fig 12 KEY LAMP AND TURN SIGNAL SWITCH INSTALLATION 1 Install the i...

Страница 843: ...switch Remove the sleeve Fig 26 8 Rotate the shaft i n the wash wipe multi func tion switch to the full clockwise position and remove the shaft by pulling i t straight out of the wash wipe switch Fig 26 9 Depress the lock plate with Depressing Tool C 4156 and pry the retaining ring out of the steering column shaft groove w i t h a small pry bar Fig 27 The f u l l tension of the u p p e r b e a r i...

Страница 844: ... end to hook the exposed wedge spring loop then pull straight out on the wire to remove both the spring and the switch 16 Remove the three housing cover screws and re move the housing cover Fig 25 With the cover re moved the wash wipe switch can be removed I f necessary t h e wash wipe switch pivot p i n can be forced out w i t h a punch Fig 31 Also i f necessary the tilt lever slot opening shield...

Страница 845: ...aft from the up per end of the steering column CAUTION Do not drop or contact the steering shaft with a heavy object because the plastic pins could shear 25 Separate the steering shaft by removing the center spheres and the anti lash spring Figs 35 and 36 Fig 35 Steering Column Shaft Separation Engagement Fig 36 Steering Column Shaft Centering Spheres 26 Remove the four bolts that attach the suppo...

Страница 846: ...ve the race out of the housing w i t h a hammer Repeat the process for the other race Do not re use the bearings INSPECTION 1 Inspect a l l the bearings and the bearing race seats for brinelling nicks scratches and exces sive wear 2 Inspect the steering column shaft centering spheres Fig 36 for nicks damage and excessive wear I f damage exists inspect the shaft couplers for nicks burrs and rough s...

Страница 847: ...tion a t the u p p e r shaft i s o n the same side as the master serration at the l o w e r shaft 15 Position the shift bowl i n the P A R K position turn counterclockwise to the stop Install the igni tion switch actuator rod from the bottom between the bowl and the steering column jacket Guide the back of the coupling into the support slot 16 Install the bearing housing over the steering column s...

Страница 848: ...ion switch actuator rod into the slider hole and attach i t loosely to the steering col umn jacket w i t h two screws Push the switch lightly up the column jacket toward the lock housing to re move the lash i n the actuator rod and tighten the attaching screws C a u t i o n should be exercised to prevent moving the switch out of the detent po sition Use o n l y the correct l e n g t h screws Tight...

Страница 849: ...New Gear Steering Fluid Dexron II less than 400 miles 640 k m 0 45 0 90 N m 4 to 8 in lbs or equivalent in addition to wormshaft bearing preload but not to exceed Steering Gear Lubricants Lubricate pitman shaft combined total of 2 N m 18 in lbs seals bearings races and rack piston recirculating balls with Used Gear petroleum jelly Lubricate all other over 400 miles 640 km 0 5 0 6 N m 4 to 5 in lbs...

Страница 850: ...w Locknut Power Steering Gear 38 N m 28 ft lbs Sector Shaft Cover Bolt Power Steering Gear 203 N m 150 ft lbs High Pressure Hose Fitting At Pump and Gear 30 N m 22 ft lbs Steering Wheel to Shaft Nut Non Tilt or Tilt Column 61 N m 45 ft lbs Steering Column Bracket to Support Stud Nut 2 N m 20 in lbs Steering Column Bracket to instrument Panel Support Nut 12 N m 110 in lbs Steering Column Shaft to S...

Страница 851: ......

Страница 852: ...rs The countershaft is not a press f i t i n the case bores The shaft has a 12 mm 005 inch diameter clearance A n expansion plug is pressed into a counter bore at the front of the case to prevent o i l Page NP435 MANUAL TRANSMISSION 36 NP205 TRANSFER CASE 130 NP241 TRANSFER CASE 138 Page Service Out Of Vehicle 5 Specifications 149 Tightening Reference 154 leakage around the countershaft The revers...

Страница 853: ...lt of insuf ficient lubricant non recommended lubricants or improper operation SLIPS OUT OF GEAR Transmission disengagement m a y be caused by misadjusted or damaged linkage or worn synchro nizer clutch teeth on the mainshaft gears Incorrect assembly w i l l also contribute to gear disengagement LOW LUBRICANT LEVEL Insufficient transmission lubricant is usually the result of leaks or inaccurate fl...

Страница 854: ...tion them on the floorpan Then install and tighten the cover and boot attaching screws 5 Reconnect the battery negative cable Page Shift Linkage Removal Installation 3 Speedometer Pinion And Adapter Service 3 GEARSHIFT LINKAGE ADJUSTMENT A n aligning tool is required to hold the levers i n the floor shift assembly i n the neutral crossover po sition for alignment The tool can be fabricated i n the...

Страница 855: ... are perfectly clean Dirt sand or foreign material will cause mis alignment resulting in speedometer pinion gear damage 1 Thoroughly clean the adapter flange and adapter mounting surface i n the extension housing These surfaces must be clean for proper adapter alignment and speedometer operation 2 Install a new O ring on the adapter 3 Lubricate the adapter oil seal and O ring w i t h transmission ...

Страница 856: ...ion 15 Transmission Assembly 11 Transmission Removal 5 TRANSMISSION REMOVAL 1 Shift the transmission into Neutral Then re move the shift lever linkage and control rods 2 Raise the vehicle and drain the transmission lu bricant 3 Mark the propeller shaft and rear axle yokes for assembly alignment 4 Disconnect and remove the propeller shaft 5 Disconnect the wires from the distance sensor Then loosen ...

Страница 857: ...re free of burrs be fore removal This is necessary to avoid damaging bores i n gearshift during removal which could result i n leakage after reassembly DRIVE PINION BEARING RETAINER GEARSHIFT HOUSING EXTENSION HOUSING SEAL BACKUP LAMP SWITCH 1 2 OPERATING LEVER Fig 2 Transmission Mounted In Repair Stand RH79 TRANSMISSION DISASSEMBLY GEARSHIFT HOUSING AND SHIFT MECHANISM REMOVAL 1 Remove reverse op...

Страница 858: ...EALS AND RETAINERS L E V E R SNAP SNAP PROMT RING RING BEARING J f FILL PLUG DRIVE PINION INPUT SHAFT MAINSHAFT ROLLER BEARINGS RETAINING RING NUTS SECOND GEAR STOP RING CLUTCH STOP 1 2 RING SLEEVE SNAP AND RING REVERSE GEAR SNAP RING BAFFLE GASKET J9021 101 Fig 3 Overdrive 4 Transmission Components ...

Страница 859: ...i f possi ble 8 Remove bolt holding extension housing and ro tate housing back to normal position 9 Remove drive pinion bearing retainer bolts and remove retainer and gasket Discard the gasket 10 Remove oil seal from retainer w i t h pry tool To avoid leakage around new seal do not nick or scratch seal bore i n retainer or surface on which seal bottoms 11 Tap drive pinion and bearing out front of ...

Страница 860: ...t h long nose pliers Fig 8 6 Hold rear bearing snap ring i n compressed po sition and pull mainshaft and bearing out of exten sion housing Fig 9 7 Remove mainshaft rear bearing snap ring Fig 10 8 Remove rear bearing from mainshaft with steel plates or bearing splitter and shop press Insert steel plates on front side of 1st speed gear and press mainshaft through and out of rear bearing Do not damag...

Страница 861: ...ase 5 Remove reverse idler gear from case and re move woodruff key from idler gear shaft 6 Following steps need only be performed i f oil leakage around reverse lever shaft was noted Fig 12 REMOVED LEVER RH93 Fig 12 Removing Reverse Idler Gear Shaft 7 Remove any burrs from reverse lever shaft to avoid damaging eases bore 8 Carefully push reverse lever shaft inward and remove i t from case 9 Remove...

Страница 862: ...zer clutch gears and sleeves I f there is evidence of chip ping or excessively worn teeth install new parts at reassembly Be sure each clutch sleeve slides easily on the clutch gear Synchronizer springs should be i n place with the tang inside the cavity of one strut and should not show signs of interference w i t h the polished gear cones or inside diameters of the clutch gears Inspect the stop r...

Страница 863: ...en press bearing onto drive pinion Be sure snap ring groove i n bearing is facing toward front Fig 17 Seat bearing fully against shoulder on pinion 9 Secure bearing on pinion shaft w i t h new inner snap ring Be sure snap ring is fully seated This snap ring is a select f i t for m i n i m u m end play 10 Lubricate mainshaft pilot roller bearings w i t h generous quantity of petroleum jelly and ins...

Страница 864: ... minimum end play 8 Install partially assembled mainshaft into ex tension housing far enough to engage bearing outer snap ring in slot in housing snap ring groove Fig 9 9 Compress outer snap ring with pliers Fig 8 Then push mainshaft into housing until rear bearing bottoms against thrust shoulder in housing 10 Release rear bearing outer snap ring and fully seat it in extension housing groove Fig 8...

Страница 865: ...countershaft bore at front of case GEARSHIFT HOUSING ASSEMBLY AND INSTALLATION FIGS 22 AND 23 1 Install interlock levers on pivot pin and secure with E clip Fig 22 2 Install interlock spring on levers w i t h pliers Fig 23 3 Lubricate shift lever shafts reverse lever and new shaft oil seals with petroleum jelly 4 Install shift lever shafts and reverse lever i n housing bores Fig 22 5 Install new o...

Страница 866: ...se which w i l l stay i n place dur ing high temperature operation Use recommended grease only 2 Apply t h i n coat of Mopar multipurpose high temperature grease on drive pinion splines and on release bearing slide surface of front bearing re tainer D o n o t lubricate e n d o f p i n i o n shaft c l u t c h disc splines o r clutch release levers 3 Mount transmission on jack and move i t under veh...

Страница 867: ...u bricant is used for improved durability and quiet op eration Lubricant drain and refill intervals are outlined i n Group O Lubrication and Maintenance SERVICE DIAGNOSIS The majority of transmission malfunctions are caused by insufficient lubricant incorrect lubricant misadjusted or damaged internal components loose attaching parts or improper operation HARD SHIFTING A low lubricant level damaged...

Страница 868: ...tio and tire size determines pin ion gear usage I f the gear must be replaced consult the parts catalogue for correct application ADAPTER AND PINION REMOVAL 1 Raise the vehicle and position a drain pan un der the speedometer adapter 2 Disconnect the wires from the distance sensor Fig 2 3 Loosen the distance sensor coupling and remove the sensor from the speedometer adapter Fig 2 4 Remove the bolt ...

Страница 869: ...apter EXTENSION HOUSING YOKE SEAL REPLACEMENT 1 Raise the vehicle and position a drain pan un der the extension housing 2 Mark position of the propeller shaft and rear axle yokes for alignment reference 3 Disconnect the propeller shaft at the axle yoke and remove the shaft 4 Remove the oil seal with tool C 3985 Fig 5 5 Install the new seal with tool C 3972 Fig 6 Start the seal i n the housing and ...

Страница 870: ...onents sure to route the harness as shown i n the illustra tion Do not allow the harness to contact hot or ro tating components Make sure the harness is clear of such components MANUAL TRANSMISSION 21 19 Fig 8 Transmission Harness Routing ...

Страница 871: ... 11 Support the transmission w i t h a suitable jack and remove the center crossmember 12 Remove the transmission to clutch housing bolts 13 Slide the transmission rearward until the i n put shaft clears the clutch disc 14 Pull the transmission completely away from the clutch housing and remove the transmission from under the vehicle 15 Thoroughly clean the transmission exterior preferably w i t h...

Страница 872: ... Fig 14 15 Note position of OD gear keyway Fig 15 16 Remove countershaft O D gear w i t h tool C 4982 Fig 16 MANUAL TRANSMISSION 21 21 Fig 7 Removing installing Detent Springs And Bullets Fig 8 Removing Installing Extension Housing Bolts 17 Note assembly sequence of tool C 4982 Fig 17 18 Remove mainshaft O D gear snap ring Fig 18 ...

Страница 873: ...er and anti spin pin Fig 19 20 Remove mainshaft OD gear Fig 20 21 Remove reverse OD hub snap ring Fig 21 Fig 12 Removing installing Shift Fork Pins Fig 13 Removing Installing 1 2 Shift Rail And Interlock Plates Fig 14 Removing Installing Countershaft OD Gear Snap Ring 22 Remove reverse OD Synchronizer fork and rail assembly Fig 22 23 Remove 3 4 shift rail and interlock plate Fig 23 ...

Страница 874: ...r assembly reference Fig 25 26 Remove reverse gear and caged needle bear ings Fig 26 MANUAL TRANSMISSION 21 23 Fig 18 Removing Installing Mainshaft OD Gear Snap Ring Fig 19 Removing installing Thrust Washer And Anti Spin Pin Fig 20 Removing Installing Mainshaft OD Gear 27 Remove reverse gear thrust washer and anti spin pin Fig 27 2 8 Remove center support bolts Fig 28 29 Note gear position prior t...

Страница 875: ...ling Reverse OD Synchronizer Fork And Rail Fig 23 Removing Installing 3 4 Shift Rail And Plate 30 Remove center support and gear set Fig 30 31 Fabricate alignment studs for reassembly Fig 31 Fig 26 Removing Installing Reverse Gear GEAR SET DISASSEMBLY 1 Note gear position for assembly reference Fig 32 ...

Страница 876: ...Installing Center Support Bolts 3 4 SYNCHRONIZER SLEEVE c Fig 31 Gear Case Alignment Studs TURN INPUT SHAFT SO THAT CUTAWAY FACES DOWN 3 4 SYNCHRONIZER 2ND GEAR ASSEMBLY 1ST GEAR CENTER SUPPORT PLATE 4TH SPEED SYNCHRONIZER STOP RING RN1187 COUNTERSHAFT GEAR RN1190 Fig 29 Gear Set Position 2 Remove center bearing snap ring and remove mainshaft and gear set from center support plate Fig 33 3 Remove ...

Страница 877: ...aining r i n g and two anti spin pins Fig 38 8 Note washer and retaining ring installation po sition for reference Fig 39 MAINSHAFT CENTER BEARING SNAP RING 3 4 SYNCHRONIZER ASSEMBLY 3RD SPEED GEAR RN1194 Fig 36 Removing Installing 3 4 Synchronizer Assembly 2ND SPEED GEAR RETAINING RING 3RD SPEED GEAR 2 3 SPLIT THRUST WASHER RN1T95 Fig 37 Removing Installing Third Gear 2ND SPEED GEAR RETAINING RIN...

Страница 878: ...1 Fig 43 Removing Installing First Gear And Needle Bearings 14 Note synchronizer component layout for as sembly identification Fig 44 INPUT SHAFT REMOVAL 1 Remove retainer bolts Fig 45 2 Remove retainer and gasket Fig 46 3 Remove front bearing locating snap ring This is largest snap ring Fig 47 4 Remove input shaft Fig 48 5 Remove mainshaft pilot bearing rollers from i n put shaft Fig 49 CENTER SU...

Страница 879: ...207 Fig 45 Removing Installing Front Bearing Retainer Bolts CLEANING AND INSPECTION Gear Case Clean transmission case thoroughly with a suitable Fig 46 Removing Installing Front Bearing Retainer solvent and dry w i t h compressed air The magnetic disc located on bottom of case can be removed for cleaning Wipe the disc clean with a cloth and rein stall the disc Inspect the case for cracks and strip...

Страница 880: ...ng by hand Inspect a l l bearing rollers for flat spots or brinnel ling Inspect a l l bearing roller spacers for signs of wear or galling Inspect roller contact surfaces of gear and shaft Install new parts as required Refer to the Bearing Bushing Seal Replacement procedure i n this section for bearing replacement procedures Lubricate the bearings with 10W 30 en gine oil A P I class SG CD after cle...

Страница 881: ...faces I f gear contact surfaces show signs of gall ing or excessive wear a new mainshaft should be i n stalled Inspect the snap ring grooves for burred edges I f rough or burred remove burrs with a fine file or cro cus cloth Inspect synchronizer hub splines on shaft for burrs also CENTER SUPPORT PLATE ARBOR PRESS RAM SUITABLE TOOL COUNTERSHAFT CENTER BEARING RN1217 Fig 53 Removing Countershaft Cen...

Страница 882: ...2 Install new seal w i t h tool C 3789 Fig 60 ARBOR PRESS MAINSHAFT AAAINSHAFT CENTER BEARING RN1204 Fig 58 Removing Center Bearing AAAINSHAFT AAAINSHAFT CENTER BEARING ARBOR PRESS RAM 1ST GEAR THRUST WASHER FLAT SIDE FACES GEAR PLATES 2 RN1205 Fig 59 Installing Center Bearing SEAL INSTALLING TOOL C 3789 Fig 60 Installing Bearing Retainer Seal COUNTERSHAFT GEAR BEARING REPLACEMENT 1 Remove bearing...

Страница 883: ...Cone 6 Remove front bearing cup w i t h shop press and suitable tool Fig 65 7 Install front bearing cup with tools C 4171 and C 4968 Fig 66 Fig 64 Installing Countershaft Gear Front Bearing Cone Fig 65 Removing Countershaft Gear Front Bearing Cup Fig 66 Installing Countershaft Gear Front Bearing Cup 8 Remove rear bearing cone w i t h tools C 4983 5 and C 4983 Fig 67 ...

Страница 884: ... snap ring Fig 71 2 Tap bearing out of extension housing Fig 71 3 Install new bearing and snap ring i n extension Fig 71 EXTENSION HOUSING BUSHING REPLACEMENT 1 Remove seal with tool C 3985 2 Remove bushing with tool C 3996 Fig 72 3 Install new bushing with tool C 3996 Fig 72 4 Install new housing seal w i t h tool C 3995 Fig 69 Removing Countershaft Gear Rear Bearing Cup Fig 70 Installing Counter...

Страница 885: ...tershaft gear i n support plate Fig 73 2 Install support plate and gear i n case 3 Install and tighten support to gear case bolts snug but not to final torque 4 Install original countershaft gear end play shim and attach extension to support and case 5 Attach dial indicator to front of case and posi tion indicator plunger against countershaft gear Fig 6 Move gear forward and zero indicator 7 Move ...

Страница 886: ... Figure 17 for installer tool components Fig 75 Installing Countershaft Overdrive Gear 5 Install countershaft overdrive gear snap ring Fig 14 FINAL ASSEMBLY 1 Install 1 2 shift rail and interlock plates Fig 13 2 Install shift fork pins Fig 12 3 Seat overdrive shift rail and blocker spring Fig 11 4 Apply bead of sealer to extension housing and install housing over gears and on center support plate ...

Страница 887: ...HARD SHIFTING A low lubricant level loose or worn shift lever or loose damaged shift housing components are com mon causes of hard shifting I f hard shifting is also accompanied by gear clash synchronizer stop rings or mainshaft clutch gear teeth may be worn or dam aged Hard shifting may also be caused by a loose or misaligned shift housing Either fault can result i n component bind and high shift...

Страница 888: ...1 Lower transfer case assembly and remove from under vehicle 12 Disconnect back up lamp switch lead 13 Install engine support fixture C 3487A with adapter tool DD 1279 firmly over frame rails Be sure support ends are up against underside of oil pan flange 14 Support transmission with a suitable jack 15 Remove transmission crossmember 16 Remove transmission to clutch housing bolts Slide transmissio...

Страница 889: ...SHAFT 1 Remove clutch gear snap ring 2 Remove clutch gear synchronizer outer stop ring to third speed gear shim s and third speed gear 3 Remove special split lock ring with two screw drivers Remove second speed gear and synchronizer 4 Remove first and reverse sliding gear REVERSE IDLER GEAR 1 Do not disassemble I f no longer serviceable re place as a n assembly complete w i t h integral bear ings ...

Страница 890: ...D G A S K E T S E C O N D S P E E D G E A R DRIVE P I N I O N B E A R I N G R E T A I N E R L O C K W A S H E R L O C K P L A T E T H R U S T W A S H E R C O U N T E R S H A F T G E A R B R O N Z E B U S H I N G U S E D I N P R O D U C T O N RN811 Fig 5 NP435 Transmission Components ...

Страница 891: ...21 40 MANUAL TRANSMISSION CAP RETAINER EXPANSION PLUGS THIRD AND FOURTH SPEED SHIFT FORK FORK SHOES DETENT BALL AND SPRING RETAINING CLIP RN807 Fig 6 Shift Cover Components ...

Страница 892: ... as reverse shift rail 7 Install first and second speed shift rail i n the same manner making sure the interlock plunger is in place 8 Check interlocks by shifting reverse shift rail into reverse position I t should not be possible to shift the other shift rails when this rail is shifted 9 I f shift lever is to be installed at this point l u bricate spherical ball seat and place cap i n place 10 I...

Страница 893: ... split washer i n each second from front hole on each side of cover and test gears for free rotation by shift ing gears through cover tower w i t h long screwdriver 16 Install remaining cover screws TRANSMISSION INSTALLATION 1 Lubricate the pilot bushing w i t h Mopar high temperature wheel bearing grease 2 Mount transmission on suitable jack and slide assembly under vehicle 3 Raise transmission u...

Страница 894: ...e converter is used w i t h A 998 999 transmis sions A 727 transmissions are equipped with a non lockup converter Page Transmission Controls And Components 47 Transmission Identification 47 Wide Ratio Planetary Gears 43 The converter impeller is connected to the engine crankshaft through the front cover which is welded to the impeller The turbine is splined to the trans mission input shaft and the...

Страница 895: ...I 45 FRONT PLANETARY GEAR SET FLEXIBLE DRIVE PLATE Fig 1 Automatic Transmission A 998 999 PR225 ...

Страница 896: ... IMPELLER Fig 2 Automatic Transmission A 727 P R 2 2 6 cn ...

Страница 897: ...DRIVING SHELL 4 6 THRUST WASHER BY150 Fig 3 Wide Ratio Gear Set A 998 999 ...

Страница 898: ...hicle speed The 1 2 shift control valve transmits 1 2 shift pressure to the accumulator pis ton to control kickdown band capacity on 1 2 upshifts and 3 2 downshifts The limit valve determines maximum speed a t which a 3 2 part throttle kickdown can be made Some transmissions do n o t have the limit valve and maximum speed for a 3 2 kickdown is at the detent position The shuttle valve has two funct...

Страница 899: ...o t start d o n o t a t t e m p t to s t a r t i t b y p u s h i n g o r t o w i n g the vehicle T h e transmission w i l l n o t p e r m i t engine s t a r t i n g i n this m a n n e r Mountain Driving Trailer towing or pulling heavy loads i n mountain ous terrain imposes severe loads on the transmission torque converter and fluid Shift the transmission into 2 or 1 range on steep upgrades which r...

Страница 900: ...air pressure test to check clutch band Operation Page General Information 49 Hydraulic Pressure Test 51 Lockup Torque Converter Diagnosis Chart 60 Preliminary Diagnosis 49 Road Test 50 Throttle Valve Linkage 50 Transmission Diagnosis Chart 59 Vehicle Is Disabled 1 Check fluid level and condition 2 Check for broken disconnected throttle linkage 3 Check for cracked leaking cooler lines or loose miss...

Страница 901: ...ehicle Service section for adjustment procedure GEARSHIFT LINKAGE Gearshift linkage adjustment is important because it positions the valve body manual valve Incorrect adjustment w i l l cause creeping i n Neutral prema ture clutch wear delayed engagement i n any gear or a no start i n Park or Neutral Proper operation of the neutral switch will provide a quick check of linkage adjustment Refer to t...

Страница 902: ...ght side of the case Fig 2 The front servo release pressure port is at the right side of the case just behind the filler tube opening Fig 2 The rear servo pressure port is at the right rear of the transmission case Fig 3 The governor pressure port is at the left side of case at the transmission rear Fig 3 PRESSURE TEST PROCEDURE Connect a tachometer to the engine Position the tachometer so i t can...

Страница 903: ...ot necessary to check governor operation unless shift speeds are incorrect or i f the transmission w i l l not downshift 2 Connect a test gauge to the governor pressure port Fig 3 3 Move the selector lever to D range 4 Apply brakes to stop wheels Start and r u n the engine a t curb idle speed and note pressure A t idle pressure should be zero to 1 1 2 psi maximum I f pressure exceeds this figure t...

Страница 904: ...ement The converter overrunning clutch is slipping when Stall speeds are 250 to 350 r p m below specified min i m u m and the vehicle operates properly at highway speeds but has poor low speed acceleration Stall Speed Normal I f stall speeds are normal b u t abnormal throttle opening is required to maintain highway speeds the converter overrunning clutch is seized and the torque converter must be ...

Страница 905: ...heck and adjust the transmission fluid level 3 Raise the vehicle Remove the converter hous ing dust cover and wipe as much fluid as possible from the converter housing 4 Fabricate a test probe Fig 7 Then attach the probe to the converter housing w i t h one of the dust shield bolts Fig 7 5 Have a helper r u n the engine at 2500 r p m with the transmission i n Neutral for two minutes then stop the ...

Страница 906: ...y Measure hole position on the con verter housing before drilling The pump vent tool is made from 1 4 inch rod and 3 16 plate Figs 13 14 The fabricated tools can a l l be made from m i l d steel or aluminum stock 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 WELD OR BRAZE Fig 10 Converter Hub Seal Cup A 727 BREAK EDGE 1...

Страница 907: ...RTER HUB SEAL CUP RH255 Fig 15 Vent Plug And Hub Seal Cup Installation FLARE CAP _ HOSE CLAMP AIR PUMP FLARED TUBE O N COOLER LINE FITTING RY254 Fig 16 Pressurizing Transmission CONVERTER HOUSING AREA LEAK CORRECTION 1 Remove the converter 2 Tighten the front band adjusting screw until the band is tight around the front clutch retainer This prevents the front clutch from coming out when the oil pu...

Страница 908: ...HE ENGINE WITH THE TRANSMISSION IN NO ABNORMAL NOISE MOVE THE SELECTOR TO A FORWARD DRIVE RANGE AND OBSERVE THE PROPELLER SHAFT FOR TURNING PROPELLER SHAFT TURNS BUT REAR WHEELS DO NOT TURN INSPECT FOR BROKEN REAR AXLE PARTS PROPELLER SHAFT DOES NOT TURN REMOVE THE TRANSMISSION OIL PAN INSPECT FOR DEBRIS ABNORMAL NOISE STOP ENGINE IMMEDIATELY REMOVE TRANSMISSION AND CONVERTER AS AN ASSEMBLY DISASS...

Страница 909: ...SION HOUSING TO CASE BOLTS EXTENSION HOUSING YOKE SEAL SPEEDOMETER ADAPTER O RING FRONT BAND ADJUSTING SCREW PU568 DIAGNOSIS GUIDE ABNORMAL NOISE1 INSPECT AND CORRECT THE TRANSMISSION FLUID LEVEL ROAD TEST TO VERIFY THAT AN ABNORMAL NOISE EXISTS IDENTIFY THE TYPE OF NOISE DRIVING RANGES AND CONDITIONS WHEN THE NOISE OCCURS GEAR NOISE OR GRINDING WHINE OR BUZZ NOISE KNOCK CLICK OR SCRAPE NOISE REMO...

Страница 910: ...t seal rings Governor support seal rings broken or worn Output shaft bearing and or bushing damaged Overrunning clutch not holding Kickdown band out of adjustment Incorrect throttle linkage adjustment Engine idle speed too low Aerated fluid Worn or broken input shaft seal rings Faulty oil pump Oil filter clogged Incorrect gearshift control linkage adjustment Low fluid level Low reverse servo band ...

Страница 911: ...LTY TORQUE CONVERTER X X X X X OUT OF BALANCE X FAILED LOCKING 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 LINKAGE MISADJUSTED X X CONDITION NO LOCKUP WILL NOT UNLOCK STAYS LOCKED UP TO TOO LOW A SPEED IN DIRECT LOCKS UP OR DRAGS IN LOW OR SECOND STALLS OR IS SLUGGISH IN REVERSE LOUD CHATTER DURING LOCKUP ENGAGEM...

Страница 912: ...NGINE RUNNING LINE 57 63 PSI PUMP SUCTION Fx r THROTTLE 0 10 PSI H H CONVERTER 57 63 PSI LUBRICATION 5 30 PSI TO LUBRICATION FRONT CLUTCH UBRICATION TORQUE CONVERTER OIL PRESSURES LINE 0 30 PSI H PUMP SUCTION y A SELECTOR LEVER IN PARK ENGINE RUNNING O 2 0 H CO 1 CO OIL FILTER J902M60 2 ...

Страница 913: ... 1 62 AUTOMATIC TRANSMISSION ...

Страница 914: ...AUTOMATIC TRANSMISSION 21 63 ...

Страница 915: ...G O V E R N O R V A L V E r REAR SERVO FRONT m SERVO ACCUMULATOR TO LUBRICATION FRONT CLUTCH 1UBRICATION IS CD CZ 30 Z co C O C O J902M63 ...

Страница 916: ......

Страница 917: ...21 66 AUTOMATIC TRANSMISSION O o ...

Страница 918: ... AUTOMATIC TRANSMISSION 21 ...

Страница 919: ...GOVERNOR VALVE r REAR CLUTCH REAR SERVO FRONT CLUTCH FRONT SERVO ACCUMULATOR SELECTOR LEVER IN TWO MANUAL SECOND CLOSED THROTTLE J902M67 ...

Страница 920: ...GOVERNOR VALVE r REAR CLUTCH REAR SERVO FRONT CLUTCH FRONT SERVO ACCUMULATOR TO 1LUBRICATION FRONT CLUTCH LUBRICATION SELECTOR LEVER IN ONE MANUAL LOW CLOSED THROTTLE M902M68 ...

Страница 921: ...21 70 AUTOMATIC TRANSMISSION ...

Страница 922: ...ge Adjustment 71 Rear Low Reverse Band Adjustment 72 Throttle Linkage Adjustment 72 Valve Body Control Pressure Adjustments 73 b Vehicle is used for Taxi Police Limousine or similiar commercial operations c Vehicle is used for trailer towing or heavy load hauling When the factory fluid is drained refill t h e transmission w i t h Mopar A T F Plus type 7176 or Dexron II automatic transmission fluid...

Страница 923: ...vel lock screw Fig 2 Be sure swivel slides freely on throttle rod so that re t u r n spring action is not restricted 4 Disassemble and clean linkage parts i f binding was encountered i n step 3 Clean linkage parts as necessary 5 Hold transmission throttle lever firmly forward against its internal stop and tighten swivel lock screw to 90 in lbs 10 Nnn torque 6 Lower vehicle 7 Check linkage freedom ...

Страница 924: ...e oil pan and install the pan on the transmission Tighten the pan bolts to 17 Nnn 150 in lbs torque 8 Lower the vehicle and refill the transmission w i t h Mopar A T F Plus type 7176 or Dexron II fluid Fig 4 Rear Band Adjustment Screw Location VALVE BODY CONTROL PRESSURE ADJUSTMENTS There are two control pressure adjustments on the valve body which are Line pressure and throttle pressure Because l...

Страница 925: ...e pressure approximately 9 k P a 1 2 3 psi T u r n i n g t h e adjusting screw counterclockwise i n creases pressure w h i l e t u r n i n g t h e screw clockwise decreases pressure THROTTLE PRESSURE ADJUSTMENT Insert gauge tool C 3763 between the throttle lever cam and kickdown valve Fig 6 Push the gauge tool inward to compress the kick down valve against the spring and bottom the throt tle valve...

Страница 926: ...hen press the seal into the adapter with tool C 4004 until the tool bottoms Fig 2 CAUTION Before installing the pinion and adapter assembly make sure adapter flange and mating area on the extension housing are clean Dirt or sand will cause misalignment resulting in speedom eter pinion gear damage 8 Thoroughly clean the adapter flange and adapter mounting surface i n the extension housing These sur...

Страница 927: ...m the case 4 Move the shift lever to Park and Neutral posi tions Verify that the switch operating lever fingers are centered i n the switch opening i n the case Fig 4 5 Install a new seal on the switch and install the switch in the case Tighten the switch to 34 N m 25 ft lbs torque 6 Test continuity of the new switch with the test lamp 7 Connect the switch wires and lower the vehicle 8 Top off the...

Страница 928: ...ap ring pliers remove the rear snap ring that retains the bearing on the shaft 2 Remove the bearing from the output shaft Note that A 727 transmissions have a second snap ring at the front of the shaft bearing A 998 999 transmis sions do not have this second snap ring 3 Install the new bearing on the shaft Be sure the large snap ring groove i n the outer circumference of the bearing is facing forw...

Страница 929: ...or and park gear assembly off the output shaft 8 Remove the bolts attaching the governor body to the gear and separate the two components 9 Remove the filter screen from the governor body CLEANING AND INSPECTION Thoroughly clean all the governor parts i n a suit able cleaning solution but do not use any type of caustic cleaning agents The weights and valves should slide freely i n the bores when c...

Страница 930: ...e gear 3 Replace the parking lock control rod i f neces sary 4 Install the extension housing as described i n this section VALVE BODY REMOVAL 1 Raise the vehicle 2 Remove the oil pan and drain the fluid 3 Loosen the clamp bolts and remove the throttle and manual valve levers from the manual valve shaft 4 Remove the neutral start and backup lamp switch Fig 4 5 Remove the filter from the valve body ...

Страница 931: ...PARATOR PLATE CHECK BALL REMOVAL 1 Remove transfer plate screws and remove trans fer plate and separator plate Fig 17 2 Remove lockup module solenoid retaining screw and pull solenoid out of transfer plate 3 Remove screws attaching transfer and separator plates and remove the separator plate from the transfer plate Fig 17 4 On 999 models remove and retain rear low re verse servo check ball Fig 17 ...

Страница 932: ...he valve body check balls Fig 18 Note check ball sizes and location for assembly refer ence SHUTTLE VALVE GOVERNOR PLUG REMOVAL FIG 19 1 Turn the valve body over 2 Remove the shuttle valve end plate Fig 19 3 Remove the governor plug end plate Fig 19 4 Remove the shuttle valve plug spring and gov ernor plugs Fig 19 Fig 18 Valve Body Check Balls 5 Remove the E clip and remove the shuttle valve secon...

Страница 933: ... Clean the valve body components i n clean solvent Dry the parts with compressed air Make sure a l l passages are clean and free from obstructions Inspect the throttle and manual valve levers and shafts D o not attempt t o straighten a bent shaft or correct a loose lever Replace these compo nents i f worn bent loose or damaged i n a n y way Inspect a l l of the valve body mating surfaces for scrat...

Страница 934: ...ugs into place during reassembly If the valves plugs and bores are free of distortion or burrs they should slide into place easily In addition do not over tighten the valve body screws during reassembly Overtightening will distort the valve body resulting in valve sticking cross leakage and unsatisfactory operation Tighten the screws alternately and evenly to 4 N m 35 in lbs torque SHIFT VALVE PRE...

Страница 935: ...le Fig 16 11 Install lockup module 9or stiffener plate on transfer and separator plates Be sure connecting tube is properly seated i n valve body and lockup module Then install and tighten module attaching screws to 4 N m 35 in lbs torque 12 Install new O ring on lockup solenoid nozzle Then install nozzle i n transfer plate bore and tighten retaining screw to 35 in lbs torque 13 Route lockup solen...

Страница 936: ...until the fluid exiting the cooler pressure line is clear and free from debris Replace t h e cooler i f f l u i d cannot b e p u m p e d t h r o u g h i t 5 Clear the flushing materials from the cooler and lines w i t h short pulses of compressed air Insert the a i r gun nozzle into the cooler return line and continue the short a i r pulses u n t i l all fluid is cleared from the cooler and lines ...

Страница 937: ... Coil or equivalent quality thread inserts Essentially repair consists of drilling out the worn ary Cooler or damaged threads tapping the hole w i t h a special tap and installing a thread insert into the tapped hole This procedure returns the hole threads to orig inal size Heli Coil or equivalent tools and inserts are readily available from most automotive parts suppliers ...

Страница 938: ...ires from neutral start switch and lockup solenoid i f so equipped 12 Disconnect gearshift rod and torque shaft as sembly from transmission When necessary to discon nect linkage rods from levers that use plastic grommets as retainers grommets should be replaced w i t h new ones Use pry tool to remove rod from grommet and cut away old grommet Use pliers to snap new grommet into lever and to snap ro...

Страница 939: ...uickly tap gear onto cover evenly with plastic or rawhide mallet Continue tapping gear until face of gear is even with scribe line made during re moval on the front cover 4 Before proceeding make sure gear is even with scribed line around full circumference of the front cover 5 The following suggestions are offered as an aid in welding the new ring gear to the converter D o not gas weld with oxy a...

Страница 940: ... l o c k a n d p r o t r u d e far enough t o h e l d transmission i n alignment 7 Coat pilot hub of torque converter w i t h Mopar high temperature grease 8 Raise transmission and align converter with drive plate 9 Move transmission forward Then raise lower or t i l t transmission to align converter housing with engine block dowels 10 Rotate converter so alignment marks scribed on converter are a...

Страница 941: ...ill tube Fig 9 Install new seal on tube before installation 23 Install engine to transmission struts i f equipped Fig 9 Tighten strut to transmission bolts first and to 17 N m 150 in lbs torque Tighten strut to engine bolts last and to 41 N m 30 ft lbs torque 24 Install exhaust components 4 ENGINE J9021 75 Fig 8 Transmission Wire Routing A 500 518 Fig 9 Strut And Fill Tube Mounting 25 Align and in...

Страница 942: ...s Oil Pan And Valve Body 1 Remove oil pan bolts and remove pan and gas ket Fig 2 Measuring Input Shaft End Play 2 Loosen clamp bolts and remove throttle and manual valve levers from manual shaft 3 Remove neutral switch 4 Remove valve body bolts and park lock rod E clip Lift valve up and off transmission and remove lock rod from valve body 5 Remove accumulator spring and piston Extension Housing 1 ...

Страница 943: ...nd retain thrust washer located between input and output shafts Planetary Gears Sun Gear Driving Shell 1 Lift and support output shaft and driving shell 2 Carefully slide assembly forward and out of case Be careful w i t h the finely machined surfaces of the output shaft Do not allow these surfaces to be come nicked or damaged during removal Rear Band Low Reverse Drum 1 Remove low reverse drum 2 L...

Страница 944: ...e should be 010 063 m m 0004 0025 in R E A C T I O N S H A F T S U P P O R T I N N E R G E A R O U T E R G E A R O R I N G P U M P H O U S I N G R N 3 1 S T R A I G H T E D G E Fig 6 Oil Pump And Reaction Shaft Support Components A 998 999 4 Mark the pump gears for assembly reference and remove the gears 5 Remove the seal rings from the reaction shaft support Fig 6 6 Clean the pump and support com...

Страница 945: ... pump body bore RN32 Fig 9 Replacing Oil Pump Bushing A 998 999 Fig 10 Staking Oil Pump Bushing A 998 999 3 Stake the new pump bushing i n two places w i t h a blunt punch Then remove burrs from the stake points w i t h a knife blade Fig 10 REPLACING REACTION SHAFT SUPPORT BUSHING A 998 999 1 Assemble the bushing remover tools SP 1191 3633 and 5324 Fig 11 Do not clamp any part of the reaction shaf...

Страница 946: ...upport to pump bolts to 20 N m 175 in lbs torque 10 Remove the assembly tool from the pump and support 11 Install a new pump seal w i t h tool C 4193 and handle C 4171 Be sure the seal lip faces inward 12 Install a new O ring on the pump body Fig 6 13 Lubricate the O ring and the lip of the pump seal w i t h transmission fluid or petroleum jelly 14 Set the assembled pump and support aside for asse...

Страница 947: ...hing into place until tool SP 5118 bottoms i n the pump cavity Fig 14 Keep the tool and bushing square w i t h the bore Do not allow the bushing to become cocked during installation 6 Stake the pump bushing i n two places with a blunt punch Then remove burrs from the stake points w i t h knife blade Fig 15 REPLACING REACTION SHAFT SUPPORT BUSHING A 727 1 Assemble cup tool SP 3633 nut SP 1191 and r...

Страница 948: ...ve the waved snap ring and remove the pressure plate clutch plates and driving discs Fig 17 2 Compress the return spring and spring retainer with compressor tool C 3575 A Fig 18 3 Remove the piston snap ring and spring re tainer Then remove the compressor tool 4 Remove the clutch piston and piston retainer Fig 17 5 Remove and discard the piston inner and outer seals Also discard the retainer snap ...

Страница 949: ...icate the new inner and outer piston seals with Door Ease or petroleum jelly 3 Install the new seals on the clutch piston Be sure the seal lips face the inside of the retainer 4 Install the clutch piston i n the retainer Use a twisting motion to seat the piston at the retainer bot Fig 19 Clutch Retainer Bushing Replacement A 998 999 torn D o n o t attempt t o force the piston straight i n This w i...

Страница 950: ...ed the lugs are damaged or i f the facing is flaking off Replace the steel plates i f heavily scored warped or broken Be sure the driving lugs on the discs and plates are also i n good condition The lugs must not be bent cracked or damaged i n any way Replace the piston springs and spring retainer i f ei ther are distorted warped or broken Check the lug grooves i n the clutch piston retainer The s...

Страница 951: ...or Ease or petroleum jelly 3 Install the new seals on the clutch piston Be sure the seal lips face the inside of the retainer 4 Install the clutch piston i n the retainer Use a twisting motion to seat the piston at the retainer bot tom D o not attempt t o force the piston straight in This w i l l fold the seals over causing leakage and c l u t c h slip 5 Install the clutch piston springs a On a 9 ...

Страница 952: ...scored warped or broken Be sure the driving lugs on the discs and plates are also i n good condition The lugs must not be bent cracked or damaged i n any way Replace the piston spring and wave spring i f part is distorted warped or broken Check the lug grooves i n the clutch piston retainer The steel plates should slide freely i n the slots Re place the piston retainer i f the grooves are worn or ...

Страница 953: ... proper clearance the steel plates discs and pressure plates may have to be changed 10 Coat the 2 thrust washer with petroleum jelly and install i t over the input shaft and into the piston retainer Use enough petroleum jelly to hold the washer i n place i n the retainer FEELER GAUGE RH295 Fig 28 Measuring Rear Clutch Pack Clearance All REAR CLUTCH A 727 CLUTCH DISASSEMBLY 1 Remove the selective s...

Страница 954: ...ol SP 3633 and hex n u t SP 1191 Fig 30 3 Hold the cup tool firmly against the clutch pis ton retainer Then thread the remover tool into the bushing as far as possible by hand 4 Thread the bushing remover an additional 3 4 turns using a wrench to firmly engage the tool i n the bushing 5 Tighten the hex nut with a wrench to pull the bushing out of the input shaft Fig 30 omponents A 727 6 Clean the ...

Страница 955: ...and the rear annulus gear support hub Fig 31 4 End play should be 12 1 21 m m 005 048 inch I f end play is incorrect the snap ring or thrust washer may have to be replaced PLANETERY GEARTRAIN DISASSEMBLY A 998 999 1 Remove selective snap ring and 3 thrust washer from front end of output shaft Fig 32 2 Remove planetary gear components from output shaft Fig 32 3 Remove snap ring and 4 thrust washer ...

Страница 956: ...gear driving shell and 6 thrust plate Fig 33 4 Remove snap ring and remove 7 thrust washer rear planetary gear 8 thrust plate rear r Train A 998 999 annulus and low reverse drum Fig 33 Geartrain Inspection Clean the geartrain components i n solvent and dry them with compressed air Check sun gear and driving shell condition Re place the sun gear as an assembly i f the gear or bushings are scored or...

Страница 957: ...led or damaged The clutch rollers springs and retainer are ser viced as an assembly Do not attempt to remove or disassemble the rollers and springs ear Train A 727 The clutch cam is attached to the case w i t h bolts The cam and shaft support must both be indexed to each other and to the case The support has an alignment arrow on i t indicat ing correct installation position The clutch cam has one...

Страница 958: ...RVO INSTALLATION 1 Lubricate the front servo bore i n the transmis sion case w i t h transmission fluid Then install the front servo assembly i n the bore w i t h a twisting mo tion Compress the servo w i t h tool C 3422 A Secure the servo w i t h a new snap ring and remove the com pressor tool 2 Lubricate the rear servo bore i n the transmis sion case w i t h transmission fluid Then install the r...

Страница 959: ...hes front band o i l pump reaction shaft support are much easier to install i f the transmission case is i n an upright position Two methods can be used to hold the transmission case upright The first method involves using a C clamp style transmission holding tool The second and simpler method only requires modifying a shop workbench Workbench modification involves drilling or cut ting a 8 89 cm 3...

Страница 960: ... provide correct end play Select fit washers are available for this purpose Refer to the specifications section for select fit washer thick nesses 4 Install two pilot stud tools C 3288 B i n the pump mounting holes Fig 41 5 Install a new pump gasket over the studs and Fig 40 Front Kickdown Band And Linkage seat the gasket i n the case 6 Coat the pump O ring w i t h Door Ease or petro leum jelly to...

Страница 961: ... plate i n the hous ing 6 Tighten the housing attaching bolts to 33 Nnn 24 ft lbs torque VALVE BODY ACCUMULATOR AND OIL PAN INSTALLATION 1 Make sure the neutral switch has n o t been in stalled i n the case it will interfere with valve body installation i f mounted in the case Fig 43 Accumulator Piston And Spring 2 Install new seal rings on the accumulator piston Fig 43 3 Lubricate the accumulator...

Страница 962: ...d for 3 9L and 5 2L applications The A 518 transmission is used for 5 2 and 5 9 L gas engine applications OVERDRIVE COMPONENTS The components i n the front section of the A 500 518 transmission are basically the same as those i n the applicable Chrysler transmission However dif ferent components are needed to attach the overdrive unit The three speed transmission has an intermediate shaft instead ...

Страница 963: ...IRE STEEL SEPARATOR PLATE J9021 143 Fig 2 A 500 Valve OVERDRIVE CONTROL AND OPERATION Fourth gear overdrive is electronically controlled and hydraulically activated A variety of sensor i n puts are supplied to the engine controller which op erates the valve body solenoids The solenoids energize and close a vent allowing a 3 4 upshift The engine electronic module also controls operation of the lock...

Страница 964: ...wire con dition A road test will determine i f further diagnosis dy Lower Housing is necessary The overdrive unit should not be re moved unless diagnosis reveals an actual overdrive fault ROAD TESTING Before road testing be sure fluid level and linkage adjustments are correct and that the overdrive cir cuit fuse and electrical connections are OK Observe engine performance during the road test A po...

Страница 965: ...LOCKUP FRONT REVERSE REAR O D O RUNNWG DRECT P Poric X X 2 21 X X X O 0rive Fht Second Third O D 274 1 54 1 00 69 X X X X X X X X X X X X X X X X X 2 Secood First Second 274 1 54 X X X X X X X X 1 Low 274 X X X X X J9021 80 Fig 1 Elements In Use In All Gear Ranges in 2 manual second gear position I f the transmis mission front section rear clutch may be slipping sion slips i n any other two forwar...

Страница 966: ...ction b Faulty wiring c Faulty engine controller 5 Excessively delayed overdrive shift 5 Incorrect overdrive piston bearing spacer a Faulty sensor 6 N o 4 3 downshift 6 Faulty lockup solenoid not venting a Lower valve body malfunction b Faulty wiring C Faulty engine controller 7 N o 4 3 downshift with overdrive off switch 7 Faulty overdrive off switch a Faulty engine controller b Faulty lockup sol...

Страница 967: ...rive unit off the inter mediate shaft Retain the bearing and select fit Fig 2 Removing Installing Overdrive Unit Attaching Bolts spacer that may remain on the overdrive piston rear of the transmission case sliding hub or intermediate shaft 13 Place several clean shop towels on the work bench 14 T i l t the overdrive unit to drain any fluid re maining i n the case Examine the fluid for clutch mater...

Страница 968: ...auto matic transmission valve bodies Refer to Maintenance and Adjustments i n the three speed transmission section for procedures OVERDRIVE UNIT DISASSEMBLY 1 Remove overdrive clutch wire retaining ring Fig 5 OVERDRIVE CLUTCH PACK WIRE RETAINING RING 8921 229 Fig 5 Remove Clutch Pack Retaining Ring 2 Remove overdrive clutch pack plates and discs Fig 6 Thickest plate is the clutch pressure plate Th...

Страница 969: ...lignment tool Fig 11 8 Expand the output shaft bearing snap ring w i t h expandable snap ring pliers Fig 11 Then lift the overdrive case off the geartrain Fig 10 Installing Alignment Tool C 6227 2 9 Remove the governor retaining snap ring and remove the governor and shaft key Fig 12 This prevents damaging the governor when the direct clutch spring is compressed i n an arbor press 10 Set gear train...

Страница 970: ...erdrive case downward on wood block to remove the rear bearing AUTOMATIC TRANSMISSION 21 119 Fig 14 Removing Governor Support And Pressure Tubes Fig 15 Removing Output Shaft Rear Bearing And Snap Ring Fig 16 Removing Reaction Plug And Snap Ring 15 Remove the reaction plug snap ring and the reaction plug Compress snap ring just enough to al low removal Fig 16 ...

Страница 971: ...o dis lodge the pawl shaft pawl and spring Fig 18 PARKING PAWL SPRING PAWL SHAFT REACTION PLUG J9021 93 Fig 18 Parking Pawl Components 18 Remove the seal and damper weight from the overdrive case Fig 19 19 Remove the park lock rod from the valve body if the rod or ball end are worn or damaged Fig 19 SEAL ACCESS PLATE CASE GASKET SPRING PLUG AND SNAP RING PARK LOCK ROD J9021 85 Fig 19 Overdrive Cas...

Страница 972: ...n assembly properly supported i n the press install spring compressor tool C 6227 1 i n the sliding hub Fig 20 Fig 20 Installing Clutch Spring Compressor Tool 3 Align the press r a m w i t h the compressor tool and have a helper operate the press to compress the direct clutch spring 4 When the spring and hub are compressed re move the large load retaining ring Fig 21 and the small load retaining s...

Страница 973: ...h drum off the annulus 14 M a r k annulus gear and output shaft for align ment at assembly Fig 29 15 Remove the annulus gear snap ring Then lightly tap the gear w i t h a plastic mallet to remove i f from the shaft Fig 30 16 Remove the output shaft front bearing CLEANING AND INSPECTION Clean the geartrain and case components w i t h sol vent Then dry a l l parts except the bearings w i t h compres...

Страница 974: ...lvage them Examine the overdrive and direct clutch discs and plates Fig 31 Replace the discs i f the facing is worn severely scored or burned and flaking off Re place the clutch plates i f worn heavily scored or cracked Check the lugs on the clutch plates for wear The plates should slide freely i n the drum Re place the plates or drum i f binding occurs SLIDING HUB DIRECT THRUST SUN PLANETARY GEAR...

Страница 975: ...ft bearing i f rough or noisy Replace the bearing snap rings i f dis torted or cracked Check the machined surfaces on the output shaft These surfaces should be clean and smooth Very m i nor nicks or scratches can be smoothed w i t h crocus cloth Replace the shaft i f worn scored or damaged i n any way Check condition of the governor components Re place the governor drive seal rings i f damaged Als...

Страница 976: ...race 8 Install the needle thrust bearing on the over running clutch race Fig 25 9 Install the overrunning clutch assembly Hold the assembly w i t h expanding type snap ring pliers Then install the assembly into the annulus gear and clutch drum w i t h a counterclockwise twisting motion Fig 25 10 Carefully install planetary gear assembly i n annulus gear Fig 35 11 Align planetary gear i n annulus w...

Страница 977: ... IN JURY DO NOT ATTEMPT TO COMPRESS THE SPRING WITH ANYTHING OTHER THAN THE COM PRESSOR TOOL AND SHOP PRESS 20 Mount the geartrain assembly i n a shop press Use a fixture that will support the assembly on the output shaft and annulus gear 21 Install compressor tool C 6227 1 and compress the clutch spring Fig 39 22 Install the load retaining snap ring Fig 39 23 Install the safety snap ring Fig 40 2...

Страница 978: ...ll it 4 Install the output shaft rear bearing i n the REACTION PLUG SNAP RING SNAP RING PLIERS 8921 240 Fig 42 Installing Reaction Plug And Snap Ring case Make sure the snap ring groove i n the bearing outer race is facing the front of the case Fig 43 5 Install the governor support and the governor pressure tubes i n the case Fig 44 The tubes are designed to be a slip fit 6 Install the governor su...

Страница 979: ...f tool C 6312 Fig 48 d Select the proper thickness end play spacer from the chart Fig 49 based on distance mea sured Fig 48 Intermediate Shaft Spacer Measurement 14 Determine the proper thickness thrust plate for the overdrive piston as follows Moasuramonfls Inches Spacer Part Number Spocw Tfucknoss Inches 7336 7505 7506 7675 7676 7855 7856 8011 4431916 4431917 4431918 4431919 159 158 176 175 194 ...

Страница 980: ...Intermediate Shaft Selective Spacer Location CAUTION Do not tilt the unit during installation Tilting the unit could cause the planetary gear and and overrunning clutch splines to rotate out of alignment If this happens it will be necessary to remove the overdrive unit and realign the compo nents with tool C 6227 2 7 Align the slip fit governor tubes and push the overdrive unit forward until i t t...

Страница 981: ... temperatures below 0 C 32 F and SAE 50 at temperatures above this point SAE multipurpose gear oils of API G L 5 quality can be used when heavy duty operation is antici pated SAE 80 90 and 140 are a l l acceptable Use SAE 80 when ambient temperatures are below 23 C 10 F or SAE 90 when temperature is above the stated range SAE 140 can be used when severe ser vice is anticipated or when ambient temp...

Страница 982: ...ry to locate the faulty bearing Gear noise is lower i n pitch and usually most no ticeable when engaged and under load Gear noise i n 4WD drive range only is an indicator that the front shaft gears are damaged Noise i n all ranges could be the idler or drive gears A n overhaul will be neces sary to determine which is at fault Frequently suspected transfer case noise may actu ally originate from an...

Страница 983: ...ires at the distance sensor 4 Loosen and disconnect the coupling nuts attach ing the sensor to the adapter and the adapter to the driven gear 5 Remove the sensor and adapter 6 Loosen and remove the driven gear 7 Lubricate the driven gear with engine or gear oil and install the gear i n the transfer case Tighten the gear to 11 N m 100 in lbs torque 8 Install the adapter and distance sensor Tighten ...

Страница 984: ... BEARING THRUST WASHER LOCK RING INPUT GEAR IDLER SHAFT COVER GASKET IDLER SHAFT IDLER GEAR BEARINGS BEARING RACES BEARING SPACER IDLER GEAR IDLER GEAR BEARING SHIMS WASHER IDLER SHAFT LOCK NUT THRUST WASHER PIN FRONT OUTPUT SHAFT SLIDING CLUTCH HIGH GEAR THRUST WASHER FRONT OUTPUT SHAFT FRONT BEARING BEARING SNAP RING FRONT OUTPUT SHAFT REAR BEARING BEARING RETAINER FRONT GASKET RETAINING RING TH...

Страница 985: ......

Страница 986: ... cover and gasket 4 Remove detent plug and 4WD indicator light switch from case Fig 4 5 Remove shift rail detent springs and balls Fig 4 Use pencil magnet to remove these components 6 Remove bolts attaching front bearing retainer to case 7 Tap front output shaft with plastic mallet to loosen it Then remove shaft retainer and gears Fig 5 8 Remove shaft snap ring Fig 6 9 Remove thrust washer gear be...

Страница 987: ...Fig 9 Then check end play Fig 9 End play should be 000 to 002 inch Add or remove shims as needed to adjust end play 3 Press shift rail seals into case Seals are wiper type and should be installed with seal lip outward 4 Install idler gear assembly and shaft tool i n case through front bore large end first T i l t case at 45 degree angle to ease bearing installation at boss Fig 10 5 Install idler s...

Страница 988: ...w snap ring Tap ring to seat i t and check end play End play should be 05 to 68 m m 002 to 027 in 21 Install pilot bearing rollers i n rear output shaft Use as much petroleum jelly as needed to hold bearing rollers i n place 22 Install pilot bearing thrust washer and new snap ring 23 Install retainer on rear output shaft install speedometer gear and spacer install bearing Fig 11 24 Install retaine...

Страница 989: ...ow range ratio The transfer case serial number also represents the date of build For example a serial number of 9 9 89 would represent September 9 1989 Transfer case operating ranges are selected w i t h a floor mounted shift lever The shift lever is connected to the transfer case range lever by an adjustable linkage rod Fig 2 A straight line shift pattern is used Range positions are marked on the...

Страница 990: ...ange Or reduce speed to 3 4 km h 2 3 mph before attempting to shift b Stop vehicle shift transmission to neutral shift transfer case to 2H mode and operate vehicle on 2H on dry paved surface c Lubricate repair or replace linkage or tighten loosen components as necessary d Drain and refill to edge of fill hole with MOPAR ATF PLUS Type 7176 or DEXRON II Automatic Transmission Fluid e Disassemble uni...

Страница 991: ...nents SPEEDOMETER GEAR SHAFT SEAL BEARING RETAINER SERVICE COMPONENT REMOVAL 1 Raise vehicle 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 u n derside of vehicle 5 Remove transfer case yoke retaining nut and seal washer Use tool C 3281 to hold yoke while re moving nut...

Страница 992: ...er into 4 H position Be sure lever is against 4 H gate Fig 4 3 Raise the vehicle 4 Loosen shift rod clamp screw until shift rod is free to slide i n swivel Fig 4 5 Verify that range lever is i n 4 H position verti cal Move lever i f necessary 6 Tighten shaft rod clamp screw to 90 in lbs torque 7 Lower vehicle 8 Check linkage operation SHIFT LINKAGE ADJUSTMENT PROCEDURE A _ o u n ARM2HT1 1 POSITION...

Страница 993: ...sion Be sure transfer case input gear splines are aligned with transmission output shaft Align splines by rotating transfer case rear output shaft yoke i f necessary D o n o t install a n y transfer case attaching nuts u n t i l t h e transfer case i s completely seated against t h e transmission 3 Align and install transfer case attaching nuts Tighten nuts to 47 Nnn 35 ft lbs 4 Install rear cross...

Страница 994: ...lling Rear Case 3 Remove sprocket and drive chain Fig 11 Tilt mainshaft for clearance i f necessary 4 Remove mainshaft mode fork and shift rail as assembly 5 Remove front output shaft Fig 11 DRIVE CHAIN RR21F39 Fig 9 Removing Installing Mode Spring DRIVEN SPROCKET RETAINING SNAP RING RY716 Fig 10 Removing Installing Sprocket Snap Ring MAINSHAFT FRONT OUTPUT SHAFT DRIVE CHAIN RR21F40 Fig 11 Removin...

Страница 995: ...ng and plunger Replace O ring on plug i f worn or cut 7 Remove shift sector and sector seals Fig 18 MAINSHAFT DISASSEMBLY 1 Remove Synchronizer snap ring Fig 19 2 Remove synchronizer sleeve and hub as assem bly Fig 20 I t is not necessary to disassemble the synchronizer components unless wear or damage is evident 3 Remove stop ring Fig 20 4 Remove drive sprocket from mainshaft Fig 21 Fig 14 Removi...

Страница 996: ...sembly Be sure the clutch sleeve slides easily on the clutch hub Synchronizer springs should be i n place w i t h the tang inside the cavity of one strut The rings should not exhibit any evidence of interference w i t h the pol ished gear cone or inside diameters of the clutch hub Inspect the stop ring for cracks and wear Replace the ring i f cracked or excessively worn on the threaded bore Check ...

Страница 997: ... 23 The front bearing is installed flush w i t h the end of the bore However the rear bearing is recessed slightly Be sure to install the bearings as shown i n Figure 23 4 Install the new sprocket bearings one at a time starting w i t h the front bearing Press the front bear ing flush w i t h the end of the bore as shown Fig 23 Then press the rear bearing into the sprocket until i t is 4 6 m m 11 ...

Страница 998: ...utput Bearing REPLACING FRONT OUTPUT SHAFT FRONT BEARING 1 Remove the bearing from the front case bore w i t h tool handle C 4171 remover tool C 4610 and a shop press Fig 29 2 Clean the bearing bore thoroughly 3 Install the new bearing with installer tool C 4210 tool handle C 4171 and a shop press Fig 30 REPLACING FRONT OUTPUT SHAFT REAR BEARING 1 Remove the bearing from the rear case bore w i t h...

Страница 999: ...ng Fig 15 5 Install shift sector and new sector shaft seals Install range lever on sector shaft and tighten at taching locknut to 10 Nnn 90 in lbs 6 Install range fork and hub Fig 13 7 Install front output shaft i n case Fig 12 8 Assemble mainshaft stop ring synchronizer and mainshaft drive sprocket Figs 18 19 20 9 Insert mode fork i n synchronizer sleeve Then install mainshaft and fork as assembl...

Страница 1000: ...id MANUAL OVERDRIVE 4 GENERAL SPECIFICATIONS Gsar Ratio First Second Third Overdrive Reverse Tolerances Clutch Housing Face Squareness Clutch Housing Bore Runout Countershaft Gear End Play Countershaft to Case Bore F i t Lubricant Capacity Type Downshift Speed Limits Overdrive to 3rd 3rd to 2nd 2nd to 1st 3 09 1 67 1 00 0 71 3 00 006 inch Max 008 inch Max 015 to 029 inch 005 to 0065 inch Loose 7 p...

Страница 1001: ...inch Lubricant Capacity 4 pints 1 9 liters Type SAE10W 30 Engine Oil API GRADE SG CD TIGHTENING REFERENCE Ft Lbs Nm Ft Lbs Nm Access Cover Bolts 21 28 Shift Assembly to Extension B o l t s 21 28 Back Up Lamp Switch 15 20 Speedometer Adapter Screw 8 11 Center Support to Case 4 0 54 Transmission to Clutch Housing Bolts 50 68 Extension Housing to Case Bolts 40 54 Transmission Drain Plug 30 41 Gearshi...

Страница 1002: ...Pump Screws 1 6 N m 14 in lbs 1 4 1 8 Nnn 12 15 in lbs Yoke Nut 149 NITI 110 ft lbs 122 176 N m 90 130 ft lbs Vacuum Switch 27 Nnn 20 ft lbs 20 34 Nnn 15 25 ft lbs Range Lever Nut 30 N m 22 ft lbs 27 34 Nnn 20 25 ft lbs Front Case to Rear Case Bolts 41 Nnn 30 ft lbs 35 46 Nnn 26 34 ft lbs Rear Retainer Bolts 24 N m 18 ft lbs 20 27 Nnn 15 20 ft lbs Extension Housing Bolts 41 N m 30 ft lbs 35 46 Nnn...

Страница 1003: ...ive A 998 A 999 A 500 2 74 1 54 1 to I 2 21 0 69 PUMP CLEARANCES 0035 to 0075 inch 0004 to 0025 inch 001 to 003 inch GEAR TRAIN END PLAY 005 to 048 inch 006 to 048 inch INPUT SHAFT END PLAY 022 to 091 inch 034 to 084 inch SNAP RINGS 060 to 062 inch 060 to 062 inch 068 to 070 inch 074 to 076 inch 076 to 078 inch 088 to 090 inch 098 to 100 inch 106 to 108 inch 040 to 044 inch 048 to 052 inch 062 to ...

Страница 1004: ...n 068 to 070 inch Red 083 to 085 inch Green 4 059 to 062 inch 5 059 to 062 inch 6 034 to 036 inch 7 059 to 062 inch 8 034 to 036 inch TIGHTENING REFERENCE Ft Lbs Nm ft Lbs Nm Cooler Line Fitting 155 Cooler Line Nut 85 Converter Drive Plate To Cranksaft Bolt 55 Converter Drive Plate to Torque Converter Bolt 270 Extension Housing to Transmission Case Bolt 18 10 75 31 Neutral Starter Switch Oil Pan B...

Страница 1005: ...er 30 41 Idler Shaft Cover 20 27 Idler Shaft Nut 138 187 NP241 Transfer Case Ft Lbs N m Detent Bolt 23 31 Drain and Fill Plugs 40 54 Front and Rear Yoke Nuts 120 163 Indicator Switch 18 24 Ft Lbs N m Shift Assembly to Extension B o l t s 21 28 Speedometer Drive Clamp Screw B 11 Transmission to Clutch Housing Bolts 50 68 Transmission Drain Plug 30 41 Transmission Fill Plug 30 41 Ft Lbs N m Shift Le...

Страница 1006: ...ave a n y lon belt overlay o n the c o r d plies t o p r o v i d e i n creased dimensional stability d u r i n g high speed operation IDENTIFICATION Bias ply tires are identified by the numerical des ignations of the tread width in inches and the bead r i m diameter i n inches and the code letter s designation for the tire type e g 7 50 16LT The example above identifies a l i g h t t r u c k LT ti...

Страница 1007: ...tested under controlled con ditions on a U S Government designated test course For example i n theory a tire with a tread wear rat ing of 300 would have a 50 percent better tread life than a tire w i t h a rating of 200 I n reality the rela tive tread wear performance of the various tires also greatly depends upon the driving habits of the owner and upon the actual driving conditions including tir...

Страница 1008: ... and tested for conformance w i t h the operating conditions normally encountered by these vehicles and for the tire load capacity The recommended c o l d inflation pressures for different load conditions i e light and full are listed on the Tire Inflation Pressures chart and on a decal affixed to the interior surface of the door pillar L o a d conditions light load maximum of two passengers plus ...

Страница 1009: ...PSI k P a 65 448 PSI k P a 70 433 PSI k P a 75 517 SO 551 2140 971 1430 649 1565 710 1690 767 1815 823 1930 875 2040 925 2140 971 2150 975 1365 619 1500 680 1630 739 1765 800 1875 850 1995 904 2150 975 1765 800 1360 617 1490 676 1625 737 1765 800 2150 975 1360 617 1490 676 1625 737 1765 800 1865 844 1985 900 2150 975 INFLATION PRESSURE ADJUSTMENT Correct tire inflation pressure is essential for sa...

Страница 1010: ...l ways be installed on the valve stem and tightened finger tight after air pressure measurement adjust ment The caps assist i n retaining air and also pre vent foreign material from entering the valve SPARE TIRE A conventional spare tire is standard equipment for a l l Ram Truck and Ramcharger vehicles ABNORMAL TIRE TREAD WEAR Abnormal tire tread wear can be caused by incor rect inflation pressure...

Страница 1011: ...R16 C 1 6 x 6 45 310 45 310 50 345 50 345 LT215 85R16 D 1 6 x 6 45 310 45 310 50 345 65 448 LT 215 85R16 D 1 6 x 6 50 350 50 345 65 448 65 448 LT 215 85R162 D 1 6 x 6 65 448 65 448 65 448 65 448 750 16 LT D 1 6 x 6 35 240 35 240 50 345 60 415 750 16 LT D 1 6 x 6 40 276 40 276 55 379 60 415 750 16 LT2 D 1 6 x 6 55 379 55 379 55 379 60 415 WITH DIESEL ENGINE LT 215 85R16 C 1 6 x 6 50 345 50 345 50 3...

Страница 1012: ...ELS STANDARD WHEELS The standard equipment wheels installed on Ram Truck and Ramcharger vehicles are drop center J type steel wheels with safety rims The steel wheels are the two piece type that consist of a r i m and center section spider The two sections are welded together to form a seamless air tight unit A wheel safety r i m has a ridge i e a raised edge located inboard of each r i m flange a...

Страница 1013: ...use caustic solutions or abrasive materials To clean white sidewalls and raised letters numbers use an approved whitewall cleaner only Do not use steel wool wire brushes or cleaning solutions that have a mineral o i l base e g gasoline paint thinner and turpentine These solutions are harmful to the tires and w i l l also discolor white sidewalls and raised let ters numbers Most white sidewall tire...

Страница 1014: ...to the interior surface of the driver side door pillar Because long wearing tires can be more suscepti ble to irregular tread wear i t is very important to rotate the tires at the specified interval to achieve the tread life potential of the tires Also correct wheel and tire balance and front end alignment must be maintained for extended tire tread life W i t h c o n t i n u e d severe operation e...

Страница 1015: ... the recommended air pressure only A t a speed of 15 mph 24 km h or less radial ply tires can cause a side to side or waddle motion Wheel balancing will not correct this condition Proper installation of radial ply tires is very impor tant Incomplete seating of the tire bead on the wheel r i m can produce a high frequency vibration at a speed above 45 mph 72 km h Incomplete bead seating can be dete...

Страница 1016: ...st effective method for balancing tires wheels is by the use of equipment that w i l l detect both static and dynamic unbalance Dynamic two plane balancing equipment is recommended CAUTION DO NOT balance a tire wheel that has been removed from a vehicle that has not been re cently driven at least 10 miles 16 km to eliminate any existing flat spot The flat spot results from the weight of the vehicl...

Страница 1017: ... lateral runout i e the tire horizontal deviation at the tire sidewall i m mediately above the buffing rib on the sidewall Fig 12 Identify and mark the tire radial and lateral major runouts for reference J9022 4 Fig 12 Tire Radial Lateral Runout Measurement The tire radial runout should not exceed 0 09 of an inch 2 29 mm and t h e tire lateral runout should not exceed 0 10 of an inch 2 54 mm I f t...

Страница 1018: ...sually occur within one or sometimes within two well de fined range of conditions i n terms of vehicle speed engine speed rpm and engine torque application ENGINE TORQUE SENSITIVE VIBRATION This vibration condition can be improved or caused to be more severe by either accelerating decelerat ing coasting or maintaining a constant vehicle speed and constant engine torque VEHICLE SPEED SENSITIVE VIBR...

Страница 1019: ... l H o p Vehicle speed sensitive mechanical vibration The wheel hop generates rapid up down movement i n the steering wheel and the instrument panel The v i bration is most noticeable i n the 20 40 mph 32 64 km h vehicle speed range The wheel hop will not cause vibration below 20 m p h 32 km h Wheel hop is caused by a tire wheel that has a radial runout of more than 0 045 of an inch 1 14 mm I f th...

Страница 1020: ...C Suspension a n d Steering Components Vehicle speed sensitive mechanical vibration Worn damaged or loose suspension steering compo nents i e steering dampener steering knuckles pit man a r m springs spring U bolts or center bolts shock absorbers tie rod ball stud ends etc can cause mechanical vibration at speeds above 20 mph 32 km h Identify and repair or replace the defec tive component s E A E ...

Страница 1021: ...ttern Fig 14 with the specified torque The lug nuts have right hand threads DUAL REAR WHEELS When Ram Truck Models D 350 and W 350 are equipped w i t h dual rear wheels a special heavy duty lug nut tightening wrench is required for cor rect lug nut tightening Fig 15 Therefore i t is rec ommended to remove and install dual rear wheels only when a proper facility and wrench are available The dual re...

Страница 1022: ...orce to a wheel cover at the immediate area of the tire valve stem hole A wheel cover is structurally stron ger and will withstand the force required for re moval and installation around the perimeter of the wheel cover away from the tire valve stem hole WARNING HANDLE WHEEL COVERS WITH EX TREME CARE DURING REMOVAL AND INSTALLA TION BECAUSE THE SHARP EDGES CAN CAUSE PERSONAL INJURY REMOVAL 1 To re...

Страница 1023: ...ng Repeat this procedure u n t i l each bearing is clean BRAKE INNER Fig 18 Front Hub Area Typical 9 D r y both bearings w i t h compressed air but do not spin the rollers After drying lubricate both bearings w i t h engine oil 10 T u r n the bearing rollers slowly while applying force and examine them for pitting and roughness I f the bearing rollers are pitted or rough replace the cup and the be...

Страница 1024: ...to 0 0030 inch wheel bearing end play 21 Clean the dust cap and apply a coat of lubri cant to the interior surface D o not fill the dust cap with lubricant Install the dust cap on the rotor hub 22 Install the inboard brake pad on the caliper adapter 23 Position the caliper over the rotor and install the retainer and the anti rattle spring Tighten the clips withl 2 inch bolt 20 N m 180 in lbs torqu...

Страница 1025: ......

Страница 1026: ... MIRROR BUTTON FIG 1 REPLACEMENT 1 Using a wax pencil locate and m a r k the mount ing position of the button on the outside of the wind shield 2 I f the vinyl pad had remained on the wind shield glass apply low heat to i t w i t h a n electric heat gun until the vinyl softens then peel the vinyl pad from the glass 3 Thoroughly clean the inner surface of the wind shield glass i n the mounting area...

Страница 1027: ...ply pressure for about one minute Proper location is essential as cement sets up very fast 10 Allow five minutes for the adhesive to set then remove any excess adhesive residue from the windshield i n the attachment area using an alcohol dampened cloth 11 Slide the mirror downward onto the button and tighten the screw COWL SIDE TRIM PANEL FIGS 2 AND 3 The t r i m panel is secured to the cowl side ...

Страница 1028: ...e the lock from the lock catch and remove the seat assembly from vehicle 4 The seat may be removed without the riser by removing bolts from seat to riser spacer INSTALLATION 1 To install seat assembly secure the hinge sec tion of the riser to the underbody w i t h nuts 2 The seat can be installed by mounting seat to riser spacers 3 Connect gas prop to seat 4 Lock should line up w i t h lock catch ...

Страница 1029: ...p half over top of seat and attach to buckle half as shown i n Fig 8 BELT TIP HALF BELT BUCKLE HALF RD156 Fig 8 Folding Rear Seat Retention CONSOLE FIG 11 1 Open console door 2 Located i n the bottom of the console are screws mounting console to underbody remove these screws 3 Remove console from vehicle HINGE HINGE PIN VIEW IN DIRECTION OF ARROW C PLATE VIEW IN DIRECTION OF ARROW D SEAT CUSHION R...

Страница 1030: ...rect alignment when installing the t r i m panels install the screws finger tight align the panels at each end and tighten the screws Use care not to overtighten the screws or the trim panels will be damaged INSIDE PANEL VIEW IN ROOF INNER BRACKET C I R C L E P A N E L SCREW SCREW iSS ga ASH PANEL H V RECEIVER BEZEL VIEW IN CIRCLE F UNTRIAAMED JOBS RIGHT SIDE ONLY ASH RECEIVER BEZEL I PANEL SCREW ...

Страница 1031: ...Seat Belt Mounting Folding Rear Seat and inboard retractors mounted on the seat frame rear cross member The center buckle t i p half is mounted to the latch mechanism Torque the belt bolts to 350 inch pounds 40 N m 17 N m SEAT BELTS AND RETRACTORS For assembly and views refer to Figs 1 5 The center belt mountings are typical Be sure when belts or retractors are replaced that the bolts are tightene...

Страница 1032: ...ND REAR ROOF INNER PANEL CENTERING HOLES HEADLINER FASTENER VIEW IN IRECTION ARROW C ROOF INNER PANEL REAR HEADLINER RETAINER OULDING SCREW TRIM PANEL SECTION A A 12 IN LBS TRIM 0 N m PANEL SECTION B B MOULDING CAP SECTION D D RB425 REMOVAL 1 Remove seats front and rear 2 Remove retainers and scuff plates JUMP SEAT Fig 6 Headliner AD4 and AD8 SEAT BELT RETRACTOR SEAT BELT BUCKLE VIEW IN CIRCLE Z J...

Страница 1033: ...ERBODY VIEW IN CIRCLE D CARPET OR MAT RN917 Fig 9 Carpet orMat Assembly Typical 4 Install storage tray 4 four screws 5 Install seat front and rear STORAGE TRAY FIG 10 The storage tray is located behind the front seat on all pickups The tray is secured to the floor pan by four 4 screws INSTALLATION AND REMOVAL 1 Position tray on floor pan 2 Insert four 4 screws 3 For removal reverse the above proce...

Страница 1034: ...ed to the panel assembly Refer to Fig 11 for assembly of back The folding jump seat is mounted to the trimmed underbody of the cab Place the seat assembly support studs through holes i n floor pan and secure w i t h nut and washers The floor covering is embossed on the backside for location of holes for jump seat installation VIEW IN DIRECTION OF BACK ARROW B ASSEMBLY J9023 55 Fig 11 Rear Jump Sea...

Страница 1035: ...r assemble with bolts plain washer lock washer and nuts Line up the bumper brackets w i t h the holes i n the frame and secure w i t h bolts nuts and washer When the as sembly is mounted to the vehicle check the align ment to body sheet metal For assembly procedures refer to Fig 1 REAR REMOVAL FIG 2 1 Remove bumper guards if so equipped 2 Remove bumper to bracket fasteners and lift bumper off of m...

Страница 1036: ...the latch assembly 6 Adjust the cable to shroud clip to insure slack between the clip and the latch 7 Test hood latch release for proper function HOOD ADJUSTMENTS FIGS 6 AND 7 THe hinge screw holes are oversized and elongated to permit up and down adjustment and fore and aft adjustment at the hood The hinge mounting at the fender panel provides up and down adjustment Fig 7 CABLE SHIELD BOLT RADIAT...

Страница 1037: ...ly but do not tighten 3 To align hood latch and striker see steps 1 thru 7 under Hood Alignment HINGE REPLACEMENT 1 Raise hood to full open position and loosen hood hinge bolts 2 Support the hood on the side the hinge is being removed Remove the hinge 3 Position new hinge against fender shield and install bolts and tighten snugly 4 A l i g n hood to hinge install bolts snugly do not tighten 5 To a...

Страница 1038: ... 8 Remove screws attaching splashshield to sup port 9 Remove front end sheet metal mount system including studs 10 Remove screws from right fender to right splashshield so that right fender panel can swing out pivoting at the cowl allowing disengagement from radiator core support panel CAUTION Care must be taken to avoid damage to fender or cowl panel 11 Remove radiator core support panel INSTALLA...

Страница 1039: ...4 Position brace to fender housing support and se cure w i t h C nut screw and washer 5 Position lower end of brace to battery tray 6 Secure with C nut screw and washer 7 Install battery and battery hold downs 8 Connect battery cables to battery posts FRONT END MOUNTING FIG 13 The front end sheet metal attaches to the body with spacers between the rear of fender and cowl to achieve sheet metal ali...

Страница 1040: ... 1 Install latch lock assembly 2 Engage right and left latch tubes to latch lock 3 Check ajar switch w i r i n g for installation 4 Install latch lock cover 5 Install liftgate t r i m panel 6 Check lock and latch for proper operation BODY 23 1i Fig 15 Liftgate Ajar Connection HINGE LIFTGATE Fig 17 REMOVAL 1 Support liftgate when removing a hinge 2 Remove hinge to liftgate bolts 3 Remove hinge to r...

Страница 1041: ...23 16 BODY Fig 16 Liftgate Latch and Striker Fig 17 Liftgate Installation ...

Страница 1042: ...Fig 18 Body Hold Down Mounting ...

Страница 1043: ... into left lower hinge 2 Place right side into slotted hinge RN921 Fig 19 Tailgate to Body 3 Install check arms to gate noting marking to correct position of arm and body 4 Bring gate up till top of check arm slotted sec tion slips onto hinge TAILGATE LOCK AND LINKAGE FIG 20 REMOVAL 1 Remove screws mounting lock to inner tailgate sheet metal 2 Lower handle and lock assembly out of opening i n fron...

Страница 1044: ...asher assemblies from struts to wheel housing 5 Remove units from vehicle INSTALLATION 1 Install bar assembly loosely tofloorpan 2 Install bar assembly loosely to side panels 3 Install struts to bar with bolts 4 Install struts to wheel housing 5 Secure all loose bolts and screws SAE CLASSIFICATION GRADE 5 GRADE 8 120 MARKINGS FOUND ON TOP OF BOLT HEAD INDICATE GRADE 60 RN885 Fig 22 Bolt Head Ident...

Страница 1045: ...quivalents torqued to 90 in lbs HINGE REPLACEMENT 1 Support door with a padded floor jack 2 Mark outline of hinge on door and body to aid in assembly 3 Remove hinge to body screws 4 Remove hinge to door screws and remove hinge Page General Information 20 Hinge Replacement 20 Latch Assembly 21 Linkage Adjustment 21 Lock Cylinder 22 5 Reverse above procedure for installation DOOR ADJUSTMENT Door adj...

Страница 1046: ...REMOVAL 1 Raise glass to full up position 2 Remove door t r i m panel or access panel 3 Disconnect all link attachments at latch 4 Remove latch attaching screws and lift latch out through access holes 5 Reverse above procedure for installation LINKAGE ADJUSTMENT 1 Locate the 312 8mm diameter access hole i n the door face at the latch area 2 Loosen door latch adjusting screw through the access hole...

Страница 1047: ... are available through MOPAR for repair of cylinders or an equivalent k i t may be used A l l nec essary components are supplied i n the k i t for repairs along w i t h a key code book and instructions Fig 5 Door Lock Cylinder Components When the key or code number is not available the following procedure should be used to establish the code number 1 Remove door lock cylinder from vehicle 2 Remove...

Страница 1048: ...e for installation 3 Remove t r i m panel and watershield 4 Working through access hole remove linkage and mounting plate to remote control 5 Remove remote control INSTALLATION 1 Slide remote control mounting plate through ac cess hole and into door 2 Connect linkage and install screws to remote control assembly 3 Install remote control handle and adjust for ward to eliminate excess handle travel ...

Страница 1049: ...t and its location on or i n the door assembly Care should b e exercised t o keep a l l under coating o r r u s t p r o o f i n g materials a w a y f r o m door components A significant cause o f door system malfunctions is c o n t a m i n a t i o n b y r u s t prevention materials BLIND RIVETS The 1 4 inch blind rivets used to secure various door components should be removed as follows drive out ...

Страница 1050: ...lower screws VENT WING GLASS REMOVAL 1 Remove t r i m panel 2 Remove screw from lower glass pivot 3 Remove upper glass pivot rivet and remove glass 4 Transfer latch handle to replacement glass INSTALLATION 1 Lubricate lower glass pivot w i t h Spray White Lube or equivalent 2 Install lower glass pivot into frame and install screw 3 Install upper glass pivot rivet 4 Install t r i m panel SIDE GLASS...

Страница 1051: ...Slide glass forward off of regulator arms and lower glass to door bottom INNER PANEL Fig 4 Window Regulator 6 D r i l l out regulator mounting rivets and remove regulator through access hole INSTALLATION 1 Insert upper regulator arm into door mounted channel 2 Mount regulator to door panel w i t h 1 4 20 screws and nuts torqued to 90 i n lbs 10 N m 3 Slide glass onto regulator arms and into rear g...

Страница 1052: ...n the outside from inside cab push one corner of glass out of weatherstrip Progressively force entire glass out of weatherstrip Page Roof Vent 31 Sliding Glass Section 28 Vented Side Window Club Cab 32 Windshield 27 5 Remove glass from opening 6 The weatherstrip will remain i n place on wind shield opening i f so desired INSTALLATION FIG 3 Mineral spirits only should be used as a lubricant to aid ...

Страница 1053: ...ush one corner of glass out of weatherstrip Progressively force entire glass from weatherstrip PU866 Fig 4 Rear Window Removal PU867 Fig 5 Rear Window Installation INSTALLATION 1 Assemble weatherstrip to glass 2 Insert mylar locking strip to weatherstrip i f ap plicable 3 Install cord i n weatherstrip retainer 4 Place the assembly to the glass opening 5 Install the assembly using the installation ...

Страница 1054: ...he sliding glass sections on the inside of cab with screws To service the latch or catch remove or replace screws LIFTGATE GLASS AND WEATHERSTRIP REMOVAL 1 Insert fiber stick between glass weatherstrip retainer and panel 2 With an assistant gently force glass and weath erstrip retainer away from frame 3 Remove glass and weatherstrip retainer assem bly from liftgate Sliding Glass Type INSTALLATION ...

Страница 1055: ...h an electric knife Miller tool 4386 or equivalent cut existing butyl tape as close as possi ble to fence flange 4 Remove the glass from opening by applying an even pressure to the glass INSTALLATION 1 Remove remaining butyl tape on body opening surface as close as possible to the metal surface I f original glass is to be installed remove all butyl tape from glass surface 2 Apply primer to glass a...

Страница 1056: ...arter Window 10 Install mouldings 11 Clean glass ROOF VENT Fig 14 VENT COVER REMOVAL 1 Open cover 2 D r i l l upper rivet head from cover handle 3 Remove vent cover hinge 4 Remove cover Fig 14 Roof Vent INSTALLATION 1 Install cover 2 Attach hinge 3 Install handle to cover using rivet i n Handle Package VENT COVER SEAL REMOVAL 1 Open cover 2 Remove cover hinge 3 Remove cover seal from frame INSTALL...

Страница 1057: ...ure 34 Color Sanding Buffing and Polishing 34 Corporate Identity Codes and Color Charts 38 Definitions Technical Terms 33 Fiberglass Finishes 37 BASE COAT CLEAR FINISH Vehicles today are sprayed i n a hospital clean en vironment to eliminate dirt and foreign substances The paint used is a two part application The base coat which is applied on top of a special eight stage primer gives the vehicle i...

Страница 1058: ...n of a primer is to act as a surfacer for the finished color coat I t also forms a bond between the metal surface and the color coat A glazing putty is used for filling i n small imper fections which are too deep to be taken care of by surfacer coats I t may be applied either before or af ter the last coat of primer surfacer REDUCERS Reducers are mixtures of volatile liquids used to reduce alkyd a...

Страница 1059: ...r 400 grit wet sanding paper can be used or 280 or 320 grit dry sanding paper can be used 3 Use blow gun w i t h approximately 30 pounds air pressure and a good tack rag to remove dust and dirt from complete work area and adjacent panels 4 Apply 3 4 inch masking tape to the breakline or breaklines and allow approximately 3 16 of an inch of the tape to overlap the breakline or breaklines then use t...

Страница 1060: ... a wax and grease re mover such as DX 330 ACRYLI CLEAN or equiva lent 2 Sand surface with 400 sandpaper and reclean surface as per step 1 3 Apply one full wet coat 4 Allow 10 to 15 minutes flash time 5 Apply a final full wet coat 6 Allow to dry 2 to 3 hours FLEXIBLE PANEL REPAIR It may not be necessary to replace a damaged flex ible panel Flexible panels are repairable using a product such as 3 M ...

Страница 1061: ...mes between double coats to avoid trapping thinner Trapped thinner can result i n pinholing or bubbling Most colors will have adequate hiding after a p p l y i n g t h e m i n i m u m n u m b e r o f double coats Some deep look colors m a y require additional double coats d A i r dry for approximately four hours at 70 85 F before installing or putting into service The n e w finish i s n a t u r a ...

Страница 1062: ... pockets or glass strands glaze a coat of body filler over the entire surface 5 Allow to cure sand and re clean 6 Apply primer or surfacer as directed 7 Allow to dry and sand smooth w i t h fine sand paper to minimize sand scratches 8 Blow surface off w i t h air and tack rag the sur face 9 I f enamel top coats are to be used a synthetic primer surfacer is also recommended 10 Apply color coats as ...

Страница 1063: ...N T Paint Code Color Name HE4 Colorado Red Clear Coat HY3 Sand Metallic Clear Coat JT8 Dark Tundra Metallic Clear Coat GG7 Dark Forest Green Metallic Clear Coat HQ7 Aquamarine Blue Metallic Clear Coat JB6 Dark Spectrum Blue Metallic Clear Coat JB2 Light Spectrum Blue Metallic Clear Coat GB4 Daytona Blue Metallic Clear Coat DX8 Black Clear Coat HS3 Dover Gray Metallic Clear Coat HA2 Sterling Silver...

Страница 1064: ... motor speed by selectively connecting i n series one two or none of the resistors to the blower motor A self adjusting clip on each of two control cables has been incorporated to simplify cable adjustment This clip snaps onto the control cable core wire and Page EVAPORATOR HEATER ASSEMBLY 36 HEATER 1 REFRIGERANT SYSTEM SERVICE PROCEDURES 2 2 Page Heater Diagnosis 2 Resistor Block 7 Service Proced...

Страница 1065: ...OUTING AIR IN HEATER CORE 1 too m i l ch hoot IMPROPERLY ADJUSTED TEMPERATURE CONTROL CABLE DISCONNECTED OR BROKEN KINKED TEMPERATURE CABLE BLEND AIR TEMP DOOR BINDING OR MISDIRECTED ENGINE THERMOSTAT DEFECTIVE LOW COOLANT FLOW INSUFFICIENT COOLANT IN SYSTEM DEFECTIVE THERMOSTAT WATER PUMP BELT LOOSE GREATER THAN 50 MIXTURE OF ANTIFREEZE ENGINE TEMPERATURE LOW SEE GROUP 7 ENGINE COOLING DIAGNOSIS ...

Страница 1066: ... COMPARTMENT ATTACH JUMPER WIRE FROM THE MOTOR FEEDWIRE TO THE POSITIVE POST OF THE BATTERY MAKE SURE THAT GROUND WIRE IS PROPERLY GROUNDED FOR THIS TEST NO VOLTAGE IN ANY SWITCH POSITION 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 MOTOR DOES NOT RUN REPLACE MOTOR MOTOR RUNS CHECK RE...

Страница 1067: ...STILL PRESENT NOISE GONE LO DSE TIGHTEN RE CHECK MOUNTING OK OK PROBLEM NOT IN BLOWER SYSTEM VIBRATION STILL PRESENT CHECK BLOWER SCROLL AREA FOREIGN AAATERIAL IN FAN OR SCROLL YES REMOVE FOREIGN AAATERIAL FAN RUBBING HOUSING NO REPLACE MOTOR RE CHECK VIBRATION GONE YES A TO DJUST ORRECT RE CHECK REMOVE BLOWER WHEEL AND OPERATE BLOWER MOTOR AT LOW SPEED REPLACE BLOWER WHEEL RE CHECK NOISE STILL PR...

Страница 1068: ...Fig 1 Heater Assembly RB457B ...

Страница 1069: ...nnect illumination light and switch wir ing 5 Remove cables 6 Remove control unit INSTALLATION 1 Install cables 2 Connect illumination light and switch wiring 3 Install unit i n instrument panel and secure with mounting screws TAB FLAG FLAG RETAINER MOUNTING SCREWQ HEATER CONTROL UNIT RB459 Fig 3 Heater Control 4 Move the leveis to the extreme right to adjust the clips 5 Install faceplate TEMPERAT...

Страница 1070: ... from plenum INSTALLATION 1 Install resistor block and secure with mounting screws 2 Install connector HEATER ASSEMBLY REMOVAL 1 Disconnect battery negative cable 2 Remove water hoses on engine side and plug hoses and inlets on package Fig 8 WATER HOSE CONNECTORS BLOWER MOTOR ASSEMBLY WATER HOSES BLOWER MOTOR WIRE RB464 Fig 8 Water Hose Connections 3 Remove right cowl side t r i m panel i f equipp...

Страница 1071: ...out through instrument cluster opening i f equipped 17 Remove screws attaching defroster duct to dash panel 18 Reach i n through instrument panel opening and disengage snaps to separate defroster duct into two pieces 19 Remove defroster duct halves through instru ment cluster opening INSTALLATION To install defroster duct reverse removal procedure AIR CONDITIONING INDEX Page Page A C System Compon...

Страница 1072: ... direct contact with open flame It is noncorrosive except when combined w i t h wa ter The following precautions must be observed when handling Refrigerant 12 Refrigerant 12 evaporates so rapidly at normal at mospheric pressures and temperatures that i t tends to freeze anything i t contacts For this reason ex treme care must be taken to prevent any liquid re frigerant from contacting the skin and...

Страница 1073: ...ary connection for a long service hose used when dis charging the system using a vacuum pump to pull a vacuum before charging the system and for con necting the supply of refrigerant when charging the system M a n i f o l d Gauge Valves should be closed when connecting the gauge set manifold to the service ports of the compressor The suction gauge valve at the left is opened to provide a passage b...

Страница 1074: ...ve 13 Overall Performance Test 16 Sight Glass Refrigerant Level Test 11 Testing System for Leaks 14 SIGHT GLASS REFRIGERANT LEVEL TEST The sight glass which is an integral part of the fil ter drier is a refrigerant level indicator Fig 1 To check the refrigerant level clean the sight glass and start the engine Place the air conditioning controls on A C the fan switch on high and the temperature lev...

Страница 1075: ...OFF NOISE STILL PRESENT NOISE GONE L C K D S E TIGHTEN RE CHECK MOUNTING OK OK 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 DJUST TORRECT RE CHECK REPLACE BLOWER WHEEL RE CHECK NOISE STILL PRESENT NOISE GONE REMOVE WHEE OPERATE MOT LOW...

Страница 1076: ...ture control lever to full cool po sition c Set A C blower motor on low speed and push A C button d Operate engine at 1300 r p m for approxi mately 5 minutes to stabilize the A C system and verify that refrigerant system is full e I f the compressor clutch cycles on and off 3 to 10 times per minute with temperature between 20 to 32 C 68 to 90 F the pressure cycling switch is normal I f the compres...

Страница 1077: ...t Level Leak Test LOW REFRIGERANT LEVEL LEAK TEST 1 Review the Safety Precautions section of this group to determine i f there is still R12 in the refrig J9024 32 Fig 4 Testing for Leaks erant system 2 Position the vehicle i n a breeze free work area to make i t less difficult to detect a small leak 3 W i t h the engine not running use an Electronic Leak Detector or equivalent and search for leaks...

Страница 1078: ... LEAK OIL ADDED IF REPLACING EVAPORATOR 60 ML 2 FL OZ CONDENSER 30 ML 1 FL OZ FILTER DRIER 30 ML 1 FL OZ REMOVE VISUALLY INSPECT FOR CONTAMINATION AND CLEAN H VALVE REPLACE COMPONENT C171 DRAIN OIL DISCHARG AND CORR E SYSTEM EOT LEAKS REPLACE FILTER DRIER CHECK FOR EVIDENCE OF OIL LEAKAGE i OIL LEAK NOTED NONE NOTED DISCHARGE SYSTEM ADD R 12 AS REQUIRED INSTALL NEW FILTER DRIER INSTALL REPLACEMENT...

Страница 1079: ...e temperature of the moisture carried i n the air Condensing the moisture i n the a i r transfers a great deal of heat energy into the evaporator fins and tubing This reduces the amount of heat the evaporator can absorb from the air Evaporator capacity used to reduce the amount of moisture i n the air is not wasted Wringing some of the moisture out of the air entering the vehicle adds to the comfo...

Страница 1080: ...SPEED EVAPORATOR SUCTION GAUGE PSIG kPag 1 COMPRESSOR DISCHARGE GAUGE PSIG kPag 2 POSSIBLE CAUSE 4 1000 J i HI 20 35 PSIG 140 TO 240 kPog 140 240 PSIG 966 TO 1656 kPag NORMAL 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 H VALVE STUCK OPEN IF CONDITIONS CANNOT BE MET H VALVE STUCK CLOSED IF CONDITIONS CANNOT BE MET RETURN RECIR...

Страница 1081: ...rt should reach 140 240 psig 966 to 1656 kPag Fig 6 I f head pressure of 140 240 psig 966 to 1656 kPag cannot be obtained check system charge level see system charging section 3 Put crushed dry ice on control head completely cover head for a m i n i m u m of 30 seconds WARNING EXTREME CARE MUST BE USED WHEN HANDLING DRY ICE AS SKIN INJURY CAN OCCUR IF PROTECTIVE GLOVES ARE NOT WORN PERFORMANCE TEM...

Страница 1082: ...Reconnect A C water valve vacuum hose gray and set temperature control i n cool position 5 Set engine speed at 1000 rpm and blower on H I The evaporator suction pressure should be i n the range of 20 30 psig 138 to 207 kPag I f compressor discharge is higher than 240 psig 1656 kPag check for restricted discharge line radiator overheating a i r i n system or faulty viscous fan drive I f discharge p...

Страница 1083: ... AT CLUTCH CHECK WIRING SWITCHES CLUTCH AMPERAGE AND GROUND AMPERAGE GREATER THAN 5 AMPS CLUTCH COIL PARTIALLY SHORTED BELTS SLIPPING ADJUST BELT TENSION REPLACE IF NECESSARY CLUTCH PULLEY RUBS ON COIL COIL MISMOUNTED SEIZED COMPRESSOR Y REPLACE COIL REPLACE COMPRESSOR AND CLUTCH ASSEMBLY OIL GREASE ON FRICTION SURFACES FRONT ALIGNMENT PIN LOOSE OR OUT OF SPECIFICATION REPLACE COMPRESSOR FRONT COV...

Страница 1084: ...TAGE AT CLUTCH LOW 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 CHECK WIRING AND SWITCHES DEFECTIVE COMPRESSOR BODY CHECK VOLTAGE DROPS FROM CLUTCH TOWARD BATTERY IF CONTACT OPEN CHECK REFRIGERANT CHARGE REPLACE COMPRESSOR IF CHARGE OK REPLACE SWITCH I DAMPE...

Страница 1085: ...ort of the compressor Connect the dis charge gauge test hose to the discharge service port Page Evacuating the System 23 Refrigerant Leak Repair Procedure 22 3 Connect one end of long test hose to the center manifold outlet and other end to refrigerant dispens ing manifold 4 Close two dispensing manifold valves and open remaining dispensing manifold valve Remove protec tive cap from opened valve W...

Страница 1086: ...HE SYSTEM Since the air conditioning refrigerant system is pressurized i t will be necessary to completely dis Partial Charge charge the system before replacing any refrigerant components The procedure is as follows 1 Install gauge set as described under manifold gauge set installation Make sure the gauge set valves are closed before attaching the hoses to the re frigerant system 2 Install a long ...

Страница 1087: ... the system 4 Continue to operate the pump for at least five minutes 5 Close manifold valves Turn off the vacuum pump and observe evaporator suction gauge for two minutes The vacuum level should remain constant ng the System I f the vacuum level falls off the system has a leak Charge the system with 1 pound 450 g of refriger ant Locate and repair a l l leaks Discharge the sys tem and repeat evacua...

Страница 1088: ...efrigerant gas starts escaping from the loose connection re tighten the hose CAUTION Do not heat refrigerant 12 above 125 F 52 C 5 Fully open all three refrigerant manifold valves and place the cans of refrigerant into a pan contain ig the System ing 125 F 52 C water The water will warm the charging can and aid i n the transfer of the charge into the system 6 Start the engine and move the controls...

Страница 1089: ... connection i n the refrigeration system Open fittings with caution even after the system has been discharged I f any pressure is no ticed as a fitting is loosened allow trapped pressure Page Handling Tubing and Fittings 26 Vacuum Control System Adjustments and Tests 27 to bleed off very slowly Never attempt to rebend formed lines to fit Use the correct line for the instal lation you are repairing...

Страница 1090: ... on the new belt See Chart Accessory Belt Drives Group 7 Cooling COMPRESSOR NOISE Noises that develop during air conditioning opera tion can often be misleading For example what sounds like a failed front bearing or connecting rod may be caused by loose bolts nuts mounting brack ets or a loose clutch assembly Improper belt tension is also often the source of an objectionable noise and can easily b...

Страница 1091: ...g on the push button switch This plug must be positioned all the way onto the 7 ports on the push button switch Fig 3 Vacuum Actuator Test CAUTION Do not use lubricant on the switch ports or in the holes in the plug as lubricant will damage the vacuum valve in the switch If it is difficult to properly position the connector plug all the way on the switch ports put a drop or two of clean water in t...

Страница 1092: ...SOR The following precautions should be observed when servicing the C 171 compressor 1 The A C refrigerant system must be completely discharged before performing any disassembly or re pair service to the compressor Fig 1 A C Clutch Assembly C 171 Compressor 2 Cleanliness is extremely important The work area must be clean and free of air borne dust and dirt 3 Use only wax free 500 SUS Saybolt Unifo...

Страница 1093: ...d then lock washer Fig 2 PU151A Fig 2 Removing Clutch Retaining Nut C 171 Compressor 5 Screw clutch front plate puller Tool C 4771 into hub Tighten enter screw and remove front plate and shims Fig 3 CAUTION Do not use screwdrivers between front plate assembly and pulley to pry off front plate be cause this may damage the front plate assembly 6 Remove pulley retaining snap ring w i t h Tool C 4574 ...

Страница 1094: ...ghten out the grease slinger if it has been distorted by tapping 4 Install pulley assembly retaining snap ring bevel side outward with snap ring pliers Tool C 4574 W i t h a screwdriver press a l l the way around the snap ring to make sure i t is properly seated i n the groove 5 I f the original front plate assembly and pulley assembly are to be reused the old shims can be used I f not place a tri...

Страница 1095: ...d discharge lines from the suction and discharge ports Cap the lines and the ports immediately to prevent moisture and dirt Fig 1 Crankshaft Key Removal Fig 2 Removing Compressor thru Bolts from entering the system 3 Disconnect clutch wire 4 Remove the compressor to bracket attaching bolts and remove compressor 5 Drain oil from the compressor suction and dis charge ports To service the compressor ...

Страница 1096: ...over facing up Using a brass drift or non metallic object press out gas seal plate Fig 6 Fig 6 Removing Gas Seal Plate 7 Remove shaft seal cartridge from crankshaft Fig 7 Fig 7 Removing Shaft Seal Cartridge 8 Carefully remove dowel pins valve plate suc tion reed valve and steel n gasket Discard steel n gasket See Figure 8 9 Remove rear cover by tapping the outside diam eter of the cover with plast...

Страница 1097: ...bling Compressor Rear End 13 Remove O ring and inspect for nicks cuts or burrs i f found Cut and discard 14 Inspect O ring sealing surface for scratches dirt or porosity I f a scratch or porosity is found compressor should be replaced ASSEMBLY 1 Install O ring by carefully stretching and pass ing a new dry O ring over the rear housing to center of compressor body 2 O i l new O ring with refrigeran...

Страница 1098: ...ion oil and install on crankshaft Car tridge must be properly positioned on slot of crank shaft 17 Lubricate crankshaft seal seat cavity of front housing with refrigeration oil 18 Lubricate crankshaft seal seat and seal seat O ring with refrigeration oil Install O ring on seal seat and install seal seat i n front cover using a socket that contacts the outer diameter of the seal seat plate Figs 14 ...

Страница 1099: ...he entire system and returns to the compressor by way of the suction port Some of this oil w i l l be trapped and retained i n various parts of the system Consequently once the system has been in operation the amount of oil left i n the compressor will always be less than the original amount Re placement compressors are also charged with 7 to 7 25 fl oz 207 214 ml When replacing a compres sor remo...

Страница 1100: ...ES HEAT DEFROST DOOR ACTUATOR DEFROSTER DUCT MOUNTING SCREW TEMPERATURE CONTROL CABLE RED FLAG MOUNTING HARNESS TAB VACUUM HARNESS MOUNTING NUT BLOWER MOTOR RECEIVER TEMPERATURE HEATER A C CONTROL LEVER CONTROL ASSEMBLY MOUNTING NUT BLOWER MOTOR FEED WIRES VACUUM LINES DRAIN TUBE R B 4 6 9 B Fig 1 Heater and Evaporator Assembly ...

Страница 1101: ...onsists of T e m p e r a t u r e Lever Controls the temperature of the discharge air i n a l l modes except Max A C and Off when the vacuum operated water valve is closed Moving the lever to the left provides cooler a i r and moving i t to the right provides warmer air B l o w e r Switch The system blower can be oper ated at four speeds from low at the bottom medium 1 at the lower center medium 2 ...

Страница 1102: ...OFF OFF MAX A C A C VENT SOLID UNE INDICATES ENGINE VACUUM VIOLET WATER VALVE ACTUATOR m ON OFF ACTUATOR RECIRCULATING GRAY OUTSIDE AIR SOLID UNE INDICATES ENGINE VACUUM VIOLET ACTUATOR VvVVA j HEAT PUSH BUTTON CONTROL VACUUM SWITCH RESTRICTOR IS PART OF VACUUM CONNECTOR AND NOT VISIBLE OUTSIDE AIR RN1001 Fig 2 Vacuum Circuits Air Conditioning and Heating ...

Страница 1103: ...NTROLS AND CIRCUITS The electrical feed for the air conditioning circuit is from two fuses i n the fuse block One 20 ampere fuse protects the compressor clutch circuit and one 30 ampere fuse protects the blower motor control circuit See Fig 3 for complete electrical control circuit CONTROL TEST Test operation of controls i n the following manner 1 Inspect compressor drive belt Adjust i f neces sar...

Страница 1104: ...r on control unit 5 Install control unit into instrument panel and secure with mounting screws 6 Install faceplate see Faceplate Installation EVAPORATOR CONTROL UNIT REMOVAL 1 Remove faceplate see Faceplate Removal 2 Remove attaching screws 3 Pull control unit out away from instrument panel 4 Disconnect blower control switch wiring connec tor 5 Disconnect three 3 wiring connectors to con trol 6 Di...

Страница 1105: ...wiring hang free 6 Remove mounting screw and slide left a i r duct out through instrument cluster opening Fig 1 INSTALLATION To install left bi level duct reverse removal proce dure AIR OUTLET ASSEMBLIES RIGHT SIDE REMOVAL Both right side outlets are held i n place with spring loaded retaining clips 1 With outlet facing out and louver vanes open grasp adjusting vane with fingers 2 Pull smoothly an...

Страница 1106: ...ving mounting screws at base and swinging out from the bottom to avoid catch and stops 6 Remove structural brace through glovebox opening Remove screws loosen nuts 7 Remove ash receiver 8 Remove right half of lower reinforcement by re moving screws attaching i t to the instrument panel and one to the cowl side t r i m panel 9 Detach radio ground strap 10 Remove center distribution duct see Air Con...

Страница 1107: ... new parts by reversing this disassembly proce dure INSTALLATION To install evaporator heater unit reverse removal procedure Be sure to refill the cooling system and evacuate and recharge the system Check operation of a l l controls and performance of the A C system Fig 7 Removing Blower Wheel ...

Страница 1108: ... the engine controller checks for the 60 000 82 500 and 120 000 mileage trip points When the current mileage matches one of the above mentioned trip points the EMR light is activated The following parts are to be replaced at the indi Page EXHAUST EMISSION CONTROLS 9 SERVICE PROCEDURES 22 cated mileage or when the emissions maintenance reminder light remains on continuously with the key i n the O N...

Страница 1109: ...French lan guages These labels are permanently attached and cannot be removed without defacing information and destroying i t I f any difference exists between the specifications or vacuum hose routing shown on the label and those shown i n the Service Manual those shown on the la bel should be used VECI LABEL CO m o IMPORTANT VEHICLE INFORMATION THIS VEHICLE CONFORMS TO U S EPA REGULATIONS APPLIC...

Страница 1110: ...LU6S 035 m GAP IDLE M A N A U T O T I M I N G 10BTC 108TC N O A D J U S T M E N T S N E E D E D F A M I L Y N0X E M I S S I O N LHUT2 3 r c v ntma JSSHL O P T I O N A L V A C U U M O P E R A T E D ACCESSORIES WHEN EQUIPPED I Fig 3 California VECI Label Typical Fig 5 Heavy Duty Cycle Label Typical mm mmm CONTROL IN AMATIQTT O O CO THIS VEHICLE WAS BUILT FOR SALE IN C A N A D A AND WAS DESIGNED TO M...

Страница 1111: ...dle is a tee i n the PCV system Refer to the ap propriate Engine Vacuum Schematic The evaporative canister is a feature on all models for the storage of fuel vapors from the fuel tank Only use fuel resistant hose when replacing evaporation control system hoses ROLLOVER AND PRESSURE RELIEF VALVE A l l vehicles are equipped w i t h a combination pres sure relief and rollover valve The dual function ...

Страница 1112: ... pressure vents into the canister Fuel va pors are temporarily held i n the canister until they can be drawn into the intake manifold The canister purge solenoid allows the canister to be purged at predetermined time and engine conditions CANISTER PURGE SOLENOID Vacuum for the evaporative canister is controlled by the Canister Purge Solenoid Fig 9 The solenoid is controlled by the Single Board Eng...

Страница 1113: ...ressure t h e fuel filler cap m u s t be r e m o v e d p r i o r t o discon necting any fuel system component POSITIVE CRANKCASE VENTILATION PCV SYSTEM A l l models are equipped w i t h a closed crankcase ventilation system Fig 11 This system consists of a crankcase P C V valve mounted on the cylinder head cover w i t h a hose extending from the valve to the base of the throttle body CRANKCASE VEN...

Страница 1114: ...s of moderate intake manifold vac u u m the plunger is only pulled part way back from the inlet resulting i n maximum vapor flow through the valve Fig 15 J8925 15 Fig 15 Moderate Intake Manifold Vacuum Maximum Vapor Flow INSPECTION AND SERVICE PROCEDURE 1 W i t h engine idling remove the PCV valve from cylinder head cover I f the valve is not plugged a hissing noise w i l l be heard as air passes ...

Страница 1115: ...les then blow out the passage w i t h shop air I f necessary use a smaller drill to avoid re moving any metal from the throttle body I t is n o t necessary t o disassemble t h e t h r o t t l e b o d y f o r this service CRANKCASE INLET AIR FILTER The crankcase inlet a i r cleaner Fig 19 must be kept clean and lubricated A t the recommended i n terval remove the crankcase inlet a i r cleaner and w...

Страница 1116: ...rature is performed by intake manifold vacuum The heated air temperature sensor i n the air cleaner senses inlet air temperature and controls the flow of vacuum to the air cleaner blend door diaphragm Fig 2 The amount of air allowed to enter from the VACUUM DIAPHRAGM AIR CONTROL VALVE SENSOR AIR HEATED fT BY MANIFOLD I mm l HEATED AIR ENTERS THROTTLE BODY RR25G55 Fig 2 Heated Air Inlet System Oper...

Страница 1117: ... i t h 20 inches of vacuum applied to the sensor the door should be i n the u p or heat on position I f the door does not rise to the heat on position check the vacuum dia phragm for proper operation 5 To test the diaphragm apply 25 inches of vac u u m w i t h vacuum pump Tool C 4207 or equivalent Fig 4 The diaphragm should not bleed down more than 10 inches i n 5 minutes The door should not lift ...

Страница 1118: ... supplied w i t h a new sensor 2 Remove and discard the sensor and gasket INSTALLATION 1 Position gasket onto sensor Install sensor into position i n a i r cleaner Fig 8 2 Support sensor outer edges and securely install retainer clip to ensure gasket forms a tight a i r seal D o n o t attempt t o adjust sensor 3 Connect vacuum hoses to sensor Fig 8 Air Temperature Sensor Installation OXYGEN SENSOR...

Страница 1119: ...m p o u n d T h e c o m p o u n d m u s t be removed f r o m t h e threads i n t h e ex haust m a n i f o l d p r i o r t o sensor installation 3 Clean the threads i n the exhaust manifold w i t h an 18 m m X 1 5 6E tap 4 I f the original sensor is to be reinstalled the sensor threads must be coated w i t h an anti seize compound Loctite 771 64 or equivalent New 0 2 sensors are packaged w i t h co...

Страница 1120: ...ult code i f the system has failed or is degraded and the dash mounted check engine light is turned on indicating immediate service is required The Diagnostic Sys tem Check is activated only during selected engine driving conditions to avoid incorrect diagnosis I f a malfunction is indicated by a check engine light and a fault code for EGR system proper opera VACUUM TRANSDUCER EXHAUST GAS BACK PRE...

Страница 1121: ... as vac u u m reaches 3 to 5 inches Hg and continue to drop as more vacuum is applied engine may even stall I f engine RPM momentarily drops the SBEC w i l l increase RPM through the AIS motor when i t senses a drop i n RPM exhaust gas is circulating through the system Successful completion of the EGR Gas Flow Test and the Control System Test indicates a fully functional EGR system I f engine spee...

Страница 1122: ... should remain open 30 seconds or longer If leakage occurs replace EGR valve transducer assembly If valve does not leak check control system EGR Valve Stem Does Not Move on System Test But Operates Normally on External Vacuum Source Defective control system or plugged passages Remove throttle body Inspect EGR vacuum source and associated passages in throttle body for obstructions Clean passages as...

Страница 1123: ...gasket on intake manifold 2 Install EGR valve Tighten mounting bolts to 23 N m 200 in lbs torque 3 Reconnect vacuum hose to valve transducer as sembly EGR DIAGNOSTIC SOLENOID REMOVAL 1 Remove vacuum hose and electrical connector from solenoids Fig 16 PRESS HERE Fig 16 Servicing the Solenoid Pack 2 Remove mounting fastener and remove solenoid pack 3 Depress tab on top of solenoid to be replaced and...

Страница 1124: ...re with the ability of the EGR system to control nitrous ox ide NOx emissions A i r is injected at either the ex haust manifold referred to as upstream or at a the catalytic convertor refereed to as downstream through the air switch relief valve The a i r switching valve is operated by manifold vacuum The vacuum supply for the air switch relief valve is controlled by the air switching solenoid The...

Страница 1125: ...25 18 EMISSION CONTROL SYSTEMS Fig 2 Air Injection System 5 2L Engine and Light Duty Cycle 5 9L Engines Fig 3 Air Injection System 5 9L Engine Heavy Duty Cycle ...

Страница 1126: ... steam or high pressure deter gent the centrifugal fan filter should be masked off to prevent liquids from entering the pump DIVERTER VALVE A diverter valve is used on some vehicles The pur pose of the diverter valve Fig 5 is to prevent back fire i n the exhaust system during sudden deceleration Fig 5 Diverter Valve Sudden throttle closure at the beginning of deceler ation temporarily creates an a...

Страница 1127: ...al to the switch relief valve A bleed orifice i n the vacuum line allows the vacuum signal to go to zero Without a vacuum signal the valve switches the air injection to the downstream location AIR SWITCHING SYSTEM A t start up the a i r switching solenoid is energized and air is injected upstream When the fuel injection system enters CLOSED LOOP operation air w i l l be injected downstream until a...

Страница 1128: ...n or replace clamps d Replace check valve a 1 With the engine running connect volt meter to the light blue with red tracer of the air switching solenoid connector and ground Voltmeter should pulse between 0 and 14 volts Solenoid is okay If the voltage pulses between 0 2 volts replace solenoid dual assembly Voltmeter not pulsating but reads within 1 volt of bat tery voltage perform next test a 2 Tu...

Страница 1129: ...lbow from a i r pump Fig 2 and 3 Installation 1 Install air pump pulley diverter valve switch relief valve and brackets on air pump Use new gas ket on pump flange Tighten t h e a i r pump pulley screws and outlet elbow mounting screws to 11 N m 95 in lbs torque Tighten bracket attachment bolts to 41 N m 30 ft lbs torque 2 Position pump assembly on engine and install the air hose to the diverter va...

Страница 1130: ... EMISSION CONTROL SYSTEMS 25 23 Fig 2 Air Injection System 3 9L Engine Fig 3 Air Injection System 5 2L Engine and Light Duty Cycle 5 9L Engines ...

Страница 1131: ...e air i n take hole Do not insert screwdriver blade between pump and filter I t is seldom possible to remove the fan without destroying it Do not attempt to remove the metal drive hub INSTALLATION Install the new filter fan by drawing i t into posi tion using the belt pulley and pulley mounting screws Draw the fan down evenly by alternately tightening the screws ensuring that the outer edge of the...

Страница 1132: ...ion valve on mounting flange and tighten mounting screws to 11 N m 95 i n lbs torque 3 Install air and vacuum hoses to valve CHECK VALVE Injection tube assemblies The check valve is not repairable and must be re placed w i t h a new check valve To determine i f the valve is not functioning normally remove the a i r hose from check valve inlet tube I f exhaust gas es capes from inlet tube the valve...

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