93 Dodge Truck Service Manual

1 9 9 3
SERVICE
MANUAL
D& W150-350
RAMCHARGER
REAR WHEEL DRIVE
TRUCK
CHRYSLER
CORPORATION
S E R V I C E MANUAL
1993 DODGE T R UC KS
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
CHRYSLER
W CORPORATION
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY ANY MEANS, ELECTRONIC, ME-
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER
CORPORATION.
Chrysler Corporation reserves the right to make changes in design or to make
additions to or improvements in its products without imposing any obliga-
tions upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright 1992 Chrysler Corporation 15 M 0 992
F O R E W O R D
The information contained in this service manual has been prepared for t he professional automotive tech-
nician involved in daily repai r operations. This manual does not cover theory of operation, which is addressed
in service t rai ni ng mat eri al . Information describing t he operation and use of st andard and optional equipment
is included in t he Owner' s Manual provided with t he vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for t he components.
The Component and System Index of t hi s manual identifies t he correct group for t he component or system
to be serviced. In addition, a Service Manual Comment form is included at t he rear of t hi s manual . Use t he
form to provide Chrysler Corporation wi t h your comments and suggestions.
To assist in locating a group title page, use t he Group Tab Locator on t he following page. The solid bar
after t he group title is aligned to a solid t ab on t he first page of each group. The first page of t he group has
a contents section t hat lists major topics wi t hi n t he group.
Tightening torques are provided as a specific value throughout this manual . This value represents t he
midpoint of t he acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using t he correct OEM fasteners. When re-
placing fasteners, always use t he same type (part number) fastener as removed.
Chrysler Corporation reserves t he ri ght to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any t i me without prior notice or incurring obligation.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in
t hi s manual may have changed from prior publications. These new t erms are in compliance with S.A.E.
recommended practice J1930. This terminology st andard (J1930) is required to comply with t he 1993
California Air Research Board (CARB) requi rement s.
GROUP TAB LOCATOR
I ntroduction
0 Lubrication and Mai ntenance
2 Front S uspensi on and Axl e
3 Rear S uspensi on and A xl es
5 Brakes
6 Cl utch
7 C ool i ng S yst em
8 Electrical
9 E ngi nes
11 E xhaust S yst em and I ntake Mani fol d
1 3
F r a m e
and Bumper s
14
F u e l
S yst em
1 6 Propeller S haf t s
19 Steering
2 1 T r ansmi ssi on and Transfer C a s e
2 2 Wheel s and Tires
2 3
B o d
y C omponent s
24 Heating and Air Condi ti oni ng
2 5 E mi ssi on Control S yst ems
C omponent and S yst em I ndex
Servi ce Manual C omment For ms (Rear of Manual )
Navigation Tools: Click on the "Group" below, or use
the Bookmarks to the left.
INTRODUCTION
I N T R O D U C T I O N
DESIGNATIONS, LABELS/PLATES/DECALS,
CODES AND DIMENSIONS/WEIGHTS .
C O N T E N T S
page
MEASUREMENT AND TORQUE
. . . 1 SPECIFICATIONS
page
. 11
D E S I G N A T I O N S , L A B E L S / P L A T E S / D E C A L S , C O D E S A N D D I M E N S I O N S / WE I G H T S
INDEX
page
Engine and Transmission/ Transfer Case
Identification 2
E ngi ne/ Transmi ssi on/ GV WR 4
Equipment Identification Plate 3
International Vehicle Control and Display
Symbol s 10
Major Component Identification 3
VEHICLE DESIGNATIONS
The Vehicle Code chart lists description and code
for Ram Truck and Sport Utility vehicles. The codes
are used to identify vehicle types in charts, captions
and in service procedures. The vehicle codes are dif-
ferent t han t he Vehicle Identification Number (VIN)
or t he wheelbase/model code.
VEHICLE SAFETY CERTIFICATION LABEL
A certification label is attached to t he left side
B-pillar. The label certifies t hat t he vehicle conforms
to Federal Motor Vehicle Safety St andards (FMVSS).
The label also lists the:
Month and year of vehicle manufacture
Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight rat i ngs (GAWR's) are
based on a mi ni mum rim size and maxi mum cold tire
inflation pressure
Vehicle Identification Number (VIN)
Type of vehicle
Type of rear wheels (single or dual)
Bar code
Month, Day and Hour (MDH) of final assembly
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE
The Vehicle Identification Number (VIN) plate is
attached to t he top left side of t he i nst rument panel.
The VIN contains 17 characters t hat provide data
concerning t he vehicle. Refer to t he decoding chart to
determine t he identification of a vehicle.
page
Trailer Towing Specifications 4
Vehicle Code Plate 2
Vehicle Designations 1
Vehicle Dimension 4
Vehicle Identification Number ( VIN) Plate 1
Vehicle Safety Certification Label . . . . . . . . . . . . . 1
Vehicle Weights 4
VEHICLE CODE DESIGNATIONS
V E HI C L E C O D E = A D ( D O D G E R A M
PI C K U P & C H A S S I S C A B)
V E HI C L E
F A M I L Y L I N E
D E S C R I PT I O N
AD1 D150
AD2 D250
AD3 D350
PI CKUP
4x 2
AD5 W15 0
AD6 W25 0
AD7 W35 0
PI CKUP
4x 4
AD2 D250
AD3 D350
C HA S S I S CAB
4x 2
A D 6 W25 0
AD7 W35 0
C HA S S I S CAB
4x 4
AD4 AD10 0
AD4 AD15 0
SPORT UTILITY
4x 2
AD8 AD10 0
AD8 A D 150
SPORT UTILITY
4x 4
J90 I N-32
2 INTRODUCTION

MF D BY
GAWR FRONT
GAWR REAR
CH RY SLE R
CORPORATI ON
DATE OF MFR GVWR
WITH TI RES
WITH TI RES
R I MS AT
R I MS AT
PS I COLD
PSI COLD
THI S VEHI CLE C ONFOR MS TO ALL APPLI CABLE FEDERAL MOTOR VEHI CLE SAFETY
STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.
SI NGLE DUAL
MDH:
BAR C OD E
VEHI CLE MADE IN
4648503 J 9 H N - 2 5
Fig. 1 Vehicle Safety Certification Label
The Vehicle Identification Number is also im-
printed on t he:
Body Code Pl at e
Equi pment Identification Pl at e
Vehicle Safety Certification Label
And on a frame rail.
VEHICLE CODE PLATE
A met al vehicle code plate (Fig. 2) is attached to
top, ri ght side of cowl below cowl grille. There can be
a maxi mum of seven rows of vehicle information im-
printed on t he plate. The information should be read
from left to right, st art i ng wi t h line 1 at t he bottom
of t he plate up to line 7 (as applicable) at t he top of
t he code plate.
Refer to t he decoding chart to decode lines 1
t hrough 3.
Lines 4 t hrough 7 on t he plate are imprinted in se-
quence according to t he following descriptions:
3-character sales code
3-digit numerical code
6-digit SEC code
If t here is not enough space left in t he row for all
of t he 6-digit SEC code:
The unused space will remai n bl ank
The code will be listed in t he next row.
The last nine positions of row 7 will contain a
2-digit code and a 6-digit serial number.
The last code on a vehicle code plate will be fol-
lowed by t he imprinted word END. When two plates
are required, t he last available spaces on t he first
plate will be imprinted with t he letters CTD (for con-
tinued).
When a second vehicle code plate is necessary, t he
first four spaces on each row will not be used because
of t he plate overlap.
To retrieve information from a vehicle code plate:
Illuminate t he plate with a shop light
View t he plate via t he cowl grille slots
Record t he needed coded information.
ENGINE AND TRANSMISSION/TRANSFER CASE
IDENTIFICATION
Refer to Group 9Engines for all engine identifi-
cation data.
Refer to Group 21Transmissions for all t ransmi s-
sion/transfer case identification data.
VEHICLE IDENTIFICATION NUMBER (VIN) DECODING
C ount r y
1 = United States
2 = Canada
3 = Mexico
V ehi cl e T ype
4 = Multipurpose
Passenger
5 = Bus
6 = Incomplete
7 = Truck
G V WR a n d
Hydr aul i c Br a k e s
0001
3001
4001
5001
6001
7001
8001
9001
10,001
Bus or I
3000
4000
5000
6000
7000
8000
9000
10,000
14,000
nc.
Truck Line
E = Ramcharger 4x2
Chassis Cab 4x2
Pickup 4x2
M = Ramcharger 4x4
Chassis Cab 4x2
Pickup 4x4
E ngi nes
X = 3.9L (MPI)
Y = 5.2L (MPI)
Z = 5.9L (EFI)
5 = 5.9L HDC
8 = 5.9L Turbo Diesel
Sequential
Serial Number
Six Digit Numbers
S er i es
0 = 150S Job Rated
1 = 150 Job Rated
2 = 250 Job Rated
3 = 350 Job Rated
Bo d y
3 = Club Cab
6 = Conventional Cab
9 = Sport Utility 2 DR
Pl ant L ocat i on
S = Dodge City
M = Lago Alberto
J931N-18
INTRODUCTION
PRI MARY S E C ON D A R Y
PAINT PAINT
VINYL ROOF
C ODE
VEHI CLE
O R D E R -
NUMBE R
PA I N T -
PI
PROCEDURE (2)
(1)
XXX ) XXXXX) X XXX xxxxxx
X)0C xxxx xxxx xxxx xxx
XXX x xxxxxxxxxxxxxxxxx
T R A N S M I S S I O N I VEHI CLE I DE NT I FI C AT I ON
C O D E J N U MBE R
MARKE T U-C-B-M
C O D E 90 I N - 3
Fig. 2 Vehicle Code Plate
VEHICLE CODE DECODING
VEHI CLE
MOD E L
N U MBE R
E N G I N E
- C O D E
- I N T E R I O R
TRI M C O D E
Line #1 Digit 1-3 Transmission Sales Code
Digit 4
Open Space
Digit 5
Market Code - U-C-B-M
Digit 6
Open Space
Digit 7-23
Vehicle Identification No.
Line #2 Digit 1-3 Paint Procedure
Digit 4
Open Space
Digit 5 -8
Primary Paint
Digit 9
Open Space
Digit 10 - 13
Secondary Paint
Digit 14
Open Space
Digit 15 -18
Trim Code
Digit 19
Open Space
Digit 20 -22
Engine Sales Code
Digit 23
Open Space
Line #3 Digit 1-12 Vehicle Order Number
Digit 13
Open Space
Digit 14-16
Vinyl Roof Code (Door Combo Digit
Code - Pillette)
Digit 17 Open Space
Digit 18- 23
Model
J901N-20
MAJOR COMPONENT IDENTIFICATION
Refer to t he applicable group for identification
data.
EQUIPMENT IDENTIFICATION PLATE
The Equi pment Identification Pl at e is located at
t he right, front corner of t he inner hood panel. The
plate lists information concerning t he vehicle as fol-
lows:
The model
The wheelbase
The VIN (Vehicle Identification Number)
The T.O.N, (order number)
The optional and special equipment installed on
t he vehicle
Refer to t he information listed on t he plate when
ordering replacement part s.
r
W l l EQUI PMENT I DENTI FI CATI ON mmm
MODE L S V . I . N . T . O. N .
C ODE N O . DESCRI PTI ON C ODE N O . DESCRI PTI ON
. ^
Fig. 3 Equipment Identification Plate
4 INTRODUCTION

VEHICLE DIMENSIONS
V E HI C L E
F A M I L Y
WH E E L BA S E
A V A I L A BL E
C A B T O
A XL E
B O D Y
TY PE
Sf AN D AI D SOD I E S AVAI LABLE
V E HI C L E
F A M I L Y
WH E E L BA S E
A V A I L A BL E
C A B T O
A XL E
B O D Y
TY PE
N O M I N A L
LE N GTH
(LOAD SPACE D M E N S I O N S (2)
V E HI C L E
F A M I L Y
WH E E L BA S E
A V A I L A BL E
C A B T O
A XL E
B O D Y
TY PE
N O M I N A L
LE N GTH
LE N GTH
M A X .
WI D T H HE I G HT V O L U M E
AD- 1 AD- 5 2921 mm
(115 in)
Sweptline 1981 mm
(6 .5 ft)
1981 mm
(78 in)
1778 mm
(70 in)
485 mm
19.1 in)
1.71 m
3
(60.35 ft
3
)
AD- 1 AD- 2
AD- 3 AD- 5
AD- 6 AD- 7
3327 mm
(131 in)

Sweptline 2438 mm
(8 ft)
2489 mm
(98 in)
1778 mm
(70 in)
485 mm
(19.1 in)
2.15 m
3
(75.8 ft
3
)
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 m
3
(105.8 ft
3
)
AD- 8 2692 mm
(106 in)
Sport
Utility
4 x 4
1778 mm 1588 mm
(62.5 in)
1062 mm
(41.8 in)
2.99 m
3
(105.8 ft
3
)
AD- 1 3378 mm
(133 in)
Sweptline 1981 mm
(6.5 ft)
1984 mm
(78.1 in)
1778 mm
(70 in)
485 mm
(19.1 in)
1.71 m
3
(60.4 ft
3
)
AD- 1 AD- 2
AD- 5 AD- 6
3785 mm
(149 in)
Sweptline
Club Cab
2438 mm
(8 ft)
2489 mm
(98 in)
1778 mm
(70 in)
485 mm
(19.1 in)
2.15 M
3
(75.8 ft
3
)
Driver seat to tailgate.
(2) Based on S . A . E . procedure Jl 100. J901N-34
VEHICLE WEIGHTS
The Vehicle Weights chart provides:
The Gross Vehicle Weight Rat i ng (GVWR),
The payload
The curb weight for each vehicle type/wheelbase
TRAILER TOWING SPECIFICATIONS
The Trailer Towing Specifications chart provides:
The maxi mum t rai l er tongue weight
The maxi mum t rai l er weight
The maxi mum combined weight of t he trailer/load/
towing vehicle with a specific engine/transmission/
axle combination.
VEHICLE DIMENSION
The Vehicle Dimension chart provides t he dimen-
sions for each type of Ram Truck, Ram Chassis Cab
and Ramcharger vehicle.
ENGINE/TRANSMISSION/GVWR
The Engine/Transmission/GVWR chart provides
t he maxi mum load dat a for each vehicle combina-
tion.

INTRODUCTION 5
ENGINE/TRANSMISSION/QVWR
R A M P I C K U P
V E HI C L E
L I N E
WH E E L BA S E G V WR
E N G I N E & S A L E S C O D E T R A N S M I S S I O N
V E HI C L E
L I N E
3. 9L
EFI
E HB
5 .2L
EFI
ELG
5 .9L
EFI
E M G
5 . 9L
EFI
E M J
5 .9L
D I E S E L
ETA
5 - S P
M A N .
O . D .
4- S P
M A N .
O . D .
4- S P
M A N .
3- S P
A U T O
4- S P
A U T O
O . D .
D150
4x 2
2921 mm
(115 in)
3327 mm
(131 in)
2495 kg
(5500 lbs)
S S O
o
D150
4x 2
2921 mm
(115 in)
3327 mm
(131 in)
2495 kg
(5500 lbs)
O S
o o o
D150
4x 2
2921 mm
(115 in)
3327 mm
(131 in)
2495 kg
(5500 lbs)
O s o
D150
4x 2
3327 mm
(131 in)
2722 kg
(6000 lbs)
S
s o o
D150
4x 2
3327 mm
(131 in)
2722 kg
(6000 lbs)
o s o o o
D150
4x 2
3327 mm
(131 in)
2722 kg
(6000 lbs)
o s o
D150
4x 2
3378 mm
(33 in)
3785 mm
(149 in)
2722 kg
(6000 lbs)
s s o
D150
4x 2
3378 mm
(33 in)
3785 mm
(149 in)
2722 kg
(6000 lbs)
o s o
D250
4x 2
3327 mm
(131 in)
3357 kg
(7400 lbs)
s
s o
D250
4x 2
3327 mm
(131 in)
3357 kg
(7400 lbs)
o s o o
D250
4x 2
3327 mm
(131 in)
3357 kg
(7400 lbs)
o s o
D250
4x 2
3785 mm
(149 in)
3357 kg
(7400 lbs)
s s o
D250
4x 2
3785 mm
(149 in)
3357 kg
(7400 lbs)
o s o
D250
4x 2
3327 mm
(131 in)
3785 mm
(149 in)
3860 kg
(8510 lbs)
s s o
D250
4x 2
3327 mm
(131 in)
3785 mm
(149 in)
3860 kg
(8510 lbs)
O s o
D350
4x 2
3327 mm
(131 in)
3946 kg
(8700 lbs)
s s o
D350
4x 2
3327 mm
(131 in)
3946 kg
(8700 lbs)
O
s o
D350
4x 2
3327 mm
(131 in)
4581 kg
(10,100 lbs)
S
s o
D350
4x 2
3327 mm
(131 in)
4581 kg
(10,100 lbs)
o s o
W15 0
4 x 4
2921 mm
(115 in)
3327 mm
(131 in)
2858 kg
(6300 lbs)
2903 kg
(6400 lbs)
s s o
W15 0
4 x 4
2921 mm
(115 in)
3327 mm
(131 in)
2858 kg
(6300 lbs)
2903 kg
(6400 lbs)
o s o
W15 0
4 x 4
2921 mm
(115 in)
3327 mm
(131 in)
2858 kg
(6300 lbs)
2903 kg
(6400 lbs)
o s o
W15 0
4 x 4
3785 mm
(149 in)
2903 kg
(6400 lbs)
s s o
W15 0
4 x 4
3785 mm
(149 in)
2903 kg
(6400 lbs)
o s o
W25 0
4 x 4
3327 mm
Q31 in)
3/85 mm
(149 in)
3402 kg
(7500 lbs)
s s o
W25 0
4 x 4
3327 mm
Q31 in)
3/85 mm
(149 in)
3402 kg
(7500 lbs)
o s o
W25 0
4 x 4
3327 mm
(131 in)
3785 mm
(149 in)
3860 kg
(8510 lbs)
s s o
W25 0
4 x 4
3327 mm
(131 in)
3785 mm
(149 in)
3860 kg
(8510 lbs)
o s o
W35 0
4x 4
3327 mm
(131 in)
3946 kg
(8700 lbs)
s s o
W35 0
4x 4
3327 mm
(131 in)
3946 kg
(8700 lbs)
o s o
W35 0
4x 4
3327 mm
(131 in)
4581 kg
(10,100 lbs)
s s o
W35 0
4x 4
3327 mm
(131 in)
4581 kg
(10,100 lbs)
o s o
S = S T ANDAR D O = OPTI ONAL = Not available in California J90 I N- 39
6 INTRODUCTION

ENGINE/TRANSMISSION/GVWR (CONT'D)
R A M C H A S S I S C A B
E N G I N E & S A L E S C O D E T R A N S M I S S I O N
V E HI C L E
L I N E
3. 9L
EFI
E HB
5 . 2 L
EFI
E L G
5 .9L
EFI
E M G
5 .9L
EFI
E M J
5 .9L
D I E S E L
ETA
5 - S P
M A N .
O . D .
4- S P
M A N .
O . D .
4- S P
M A N .
3- S P
A U T O
4- S P
A U T O
O . D .
D250
4 x 2
3327 mm
(131 in)
3357 kg
(7400 lbs)
S s
3860 kg
(8510 lbs)
s S o 3860 kg
(8510 lbs)
s s o
O S o
D350
4 x 2
3327 mm
(131 in)
3946 kg
(8700 lbs)
s s o D350
4 x 2
3327 mm
(131 in)
3946 kg
(8700 lbs)
s s o
3429 mm
(135 in)
4039 mm
(159 in)
4581 kg
(10,100 lbs)
s s o
3429 mm
(135 in)
4039 mm
(159 in) 4763 kg
(10,500 lbs)
o s o
W25 0
4 x 4
3327 mm
(131 in)
3860 kg
(8510 lbs)
s s o W25 0
4 x 4
3327 mm
(131 in)
3860 kg
(8510 lbs)
s s o
o s o
W35 0
4 x 4
3327 mm
(131 in)
3946 kg
(8700 lbs)
s s o W35 0
4 x 4
3327 mm
(131 in)
3946 kg
(8700 lbs)
s s o
o s o
3429 mm
(135 in)
4581 kg
(10,100 lbs)
s s o
4989 kg
(11,000 lbs)
o s o
R A M C H A R G E R S P O R T U T I L I T Y
D100
4x 2
2692 mm
(106 in)
2540 kg
(5600 lbs)
S S
D150
4x 2
2692 mm
(106 in)
2540 kg
(5600 lbs)
S S
W10 0
4 x 4
2692 mm
(106 in)
2722 kg
(6000 lbs)
S S O
W15 0
4 x 4
2692 mm
(106 in)
2722 kg
(6000 lbs)
S S o
W15 0
4 x 4
2692 mm
(106 in)
2903 kg
(6400 lbs)
S S o
W15 0
4 x 4
2692 mm
(106 in)
2903 kg
(6400 lbs)
S S o
S = S T A N D A R D
O = OPT I ONAL
= Not available in California.
= California Only. J901N-35

INTRODUCTION 7
VEHICLE WEIGHTS
R A M P I C K U P
M O D E L /
F A M I L Y
BODY (3)
STYLE
G V WR
PA Y L O A D
A L L O WA N C E (1)
C U R B
WE I G H T (2)
D150 AD1
4x 2
61 2495 kg 5500 lbs 853 kg 1880 lb 1642 kg 3620 lbs D150 AD1
4x 2
62 2495 kg
2722 kg
5500 lbs
6000 lbs
804 kg
1021 kg
1772 lbs
2252 lbs
1691 kg
1700 kg
3728 lbs
3748 lbs
D150 AD1
4x 2
31 2722 kg 6000 lbs 852 kg 1878 lbs 1870 kg 4122 lbs
D150 AD1
4x 2
D250 AD2
4x 2
62 3357 kg
3860 kg
7400 lbs
8510 lbs
1527 kg
1952 kg
3366 lbs
4304 lbs
1830 kg
1908 kg
4034 lbs
4206 lbs
D250 AD2
4x 2
32 3357 kg
3860 kg
7400 lbs
8510 lbs
1369 kg
1846 kg
3019 lbs
4070 lbs
1987 kg
2014 kg
4381 lbs
4440 lbs
D350 AD3
4x 2
62(4) 3946 kg
4581 kg
8700 lbs
10,100 lbs
2001 kg
2485 kg
4411 lbs
5478 lbs
1945 kg
2097 kg
4289 lbs
4622 lbs
W15 0 AD5
4x 4
61 2858 kg 6300 lbs 978 kg 2156 lbs 1880 kg 4144 lbs W15 0 AD5
4x 4
W15 0 AD5
4x 4
W25 0 A D 6
4x 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
W25 0 A D 6
4x 4
32 3402 kg
3860 kg
7500 lbs
8510 lbs
1259 kg
1664 kg
2775 lbs
3668 lbs
2143 kg
2196 kg
4725 lbs
4842 lbs
W35 0 AD7
4x 4
(1) Payload includes maximum weight of driver, passengers, cargo and optional equipment not included in pavload or GV W package
- rayload allowance for Chassis Cabs is not supplied due to large variations or body equipment installed.
(2) Includes base engine
(3) Body Style Cab Bed Length
61 Std. 1981 mm (6.5 ft
62 Std. 2438 mm 8.0 ft
31 Club 1981 mm 6.5 ft
32 Club 2438 mm 8.0 ft
63 Std. N.A
64 Std. N.A.
71 Sport Utility N.A.
(4) Dual Rear Wheels
J90 I N-36
8 INTRODUCTION

VEHICLE WEIGHTS (CONT'D)
R A M C HA S S I S CAB
M O D E L /
F A M I L Y
BO D Y ( 3)
S TYLE
G V WR
PA Y L O A D
A L L O WA N C E (1)
C U R B
WE I G H T (2)
D250 AD2
4 x 2
62 3357 kg
3860 kg
7400 lbs
8510 lbs
1721 kg
1740 kg
3794 lbs
3835 lbs
D350 A D 3
4 x 2
62 3946 kg 8700 lbs
ID
1794 kg 3954 lbs D350 A D 3
4 x 2
4581 kg
4763 kg
10,100 lbs
10,500 lbs
..,
1963 kg
1972 kg
4327 lbs
4347 lbs
D350 A D 3
4 x 2
"111
4581 kg
4763 kg
10,100 lbs
10,500 lbs
1.1
2032 kg
2043 kg
4479 lbs
4505 lbs
W25 0 A D 6
4 x 4
62 3860 kg 8510 lbs
1.)
1886 kg 4158 lbs
W35 0 AD7
4 x 4
62 3946 kg 8700 lbs
ID
2038 kg 4494 lbs W35 0 AD7
4 x 4
4581 kg
4990 kg
10,100 lbs
11,000 lbs
ID
2136 kg
2145 kg
4709 lbs
4729 lbs
R AMC HAR GE R - SPORT UTILITY
M O D E L /
F A M I L Y
BO D Y ( 3)
S TYLE
G V WR
PA Y L O A D
A L L O WA N C E S )
C U R B
WE I G HT ( 2 )
D100 AD4
4x 2
71 2540 kg 5600 lbs 603 kg 1330 lbs 1937 kg 4 270 lbs
D150 AD4
4 x 2
71 2540 kg 5600 lbs 606 kg 1336 lbs 1934 kg 4 26 4 lbs
W10 0 AD8
4 x 4
71 2722 kg 6000 lbs 618 kg 136 3 lbs 21 03 kg 4 6 37 lbs
W15 0 AD8
4 x 4
71 2722 kg
2903 kg
6000 lbs
6400 lbs
621 kg
796 kg
136 9 lbs
1755 lbs
21 02 kg
21 07 kg
4 6 31 lbs
4 6 4 5 lbs
(1) Payload includes maximum weight of driver, passengers, cargo and optional equipment not included in payload or GV W package
- Payload allowance for Chassis Cabs is not supplied due to large variations of body equipment installed.
!
2) Includes base engine
3) Body Style Cab Bed Length
6V Std. 1981 mm [6.5 ft)
62 Std. 2438 mm 8.0 ft
31 Club 1981 mm 6.5 ft
32 Club 2438 mm 8.0 ft
63 Std. N.A
64 Std. N.A.
71 Sport Utility N. A.
(4) Dual Rear Wheels
J90I N- 38
TRAILER TOWING SPECIFICATIONS
A L L O WA BL E T O N G U E WE I G H T S
M a x . T ongue
M o d e l G V WR We i g h t
D/ W15 0 / 15 0 S Ramcharger All 800
D/ W2 5 0 All 900
D/ W35 0
Single Rear Wheels All 1000
Dual Rear Wheels All 1200
G C WR - G R O S S C O M B I N E D WE I G H T R A T I N G
(Total t r uck, t r ai l er , c a r g o , peopl e & f l ui ds)
A XL E R A T I O S
E N G I N E T R A N S M I S S I O N 3. 5 4 3. 90 4. 10 4. 5 6
D - 15 0
3.9L Man. 5-spd. 8,000 8,000
Auto. 3-spd. 8,800 9,200
Auto. 4-spd. O / D 8,800 9,200
5.2L Auto. 3-spd. 11,500 12,500
Auto. 4-spd. O / D 10,500 10,500
Auto. 4-spd. H.D. 11,500 12,500
5.9L Auto. 4-spd H.D. 12,000 13,000 13,500 14,000
D - 2 5 0
3.9L Auto. 3-spd. 8,800 9,200
5.2L Auto. 4-spd. O / D 10,500 10,500
Auto. 4-spd. H.D. 11,500 12,500
5.9L Auto. 4-spd. H.D. 12,000 13,000 13,500 14,000
D - 35 0
5.9L Auto. 4-spd. H.D. 12,000 13,000 13,500 14,000
W- 15 0
3.9L Auto. 4-spd. H.D. 8,800 9,200
5.2L Auto. 4-spd. H.D. 11,500 12,500
5.9L Auto. 4-spd. H.D. 12,000 13,000 13,500 14,000
W- 2 5 0
5.9L Auto. 3-spd. 12,000 13,000 13,500 14,000
W- 35 0
5.9L Auto. 3-spd. 12,000 13,000 13,500 14,000
Auto. 4-spd. H.D. 12,000 13,000 13,500 14,000
R a mc h a r g e r 4 x 2
5.2L Auto. 4-spd. H.D. 11,500 12,500
5.9L Auto. 4-spd. H.D. 12,000 13,000 13,500 14,000
R a mc h a r g e r 4 x 4
5.2L Auto. 4-spd. H.D. 11,500 12,500
5.9L Auto. 4-spd. H.D. 12,000 13,000 13,500 14,000
10 INTRODUCTION

INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
ID
HIGH BEAM
P
F O G UGHTS
-&
HEADLIGHTS,
PARKING UGHTS,
PANEL UGHTS TURN SIGNAL
A
HAZARD WARNING
WINDSHIELD
WASHER
WINDSHIELD
WIPER
WINDSHIELD WIPER
AND WASHER
<W
WINDSCREEN
DEMISTING
AND DEFROSTING
*
VENTILATING FAN
8 M f
REAR WINDOW
DEFOGGER
sp
REARWINLX)W
WIPER
CD
l
m
REAR WINDOW
WASHER FUEL
ENGINE COOLANT
TEMPERATURE
BATTERY CHARGING
CONDITION ENGINE OIL SEAT BELT
()
()
k y
11 J
LIGHTER BRAKE FAILURE PARKING BRAKE FRONT HOOD
REAR HOOD
(TRUNK) HORN
11 J
LIGHTER
93IN-9
INTERNATIONAL VEHICLE CONTROL AND DISPLAY
SYMBOLS
The graphic symbols illustrated in t he chart below
are used to identify various i nst rument controls. The
symbols correspond to t he controls and displays t hat
are located on t he i nst rument panel.

INTRODUCTION 11
M E A S U R E M E N T A N D T O R Q U E S P E C I F I C A T I O N S
INDEX
page
Metric and E ngl i sh/ SAE Conversi on 11
Specification Notations 11
SPECIFICATION NOTATIONS
WA R N I N G : T HE U S E O F I N C O R R E C T A T T A C HI N G
H A R D WA R E C A N R E S U L T I N C O M PO N E N T D A M -
A G E A N D / O R PE R S O N A L I N J U R Y.
It is important to ret ai n t he original at t achi ng
hardware for assembly of the components. If t he at-
taching hardware is not reusable, hardware with
equivalent specifications must be used.
METRIC AND ENGLISH/SAE CONVERSION
The following chart will assist in converting metric
uni t s to equivalent English and SAE units, or vise
versa.
TORQUE SPECIFICATIONS
TORQUE CHARTS
A torque chart for fasteners is provided at t he end
of each group (of service information). Refer to t he
St andard Torque Specifications chart to determine
torque values not listed in t he group (Figs. 1 and 2).
It is important to be aware t hat t he torque values
listed in t he chart are based on clean and dry bolt
page
Torque Specifications 11
t hreads. Reduce t he torque value by 10 percent when
the bolt t hreads are lubricated and by 20 percent if
new.
BOLT THREAD AND GRADE/CLASS
IDENTIFICATION
THREAD IDENTIFICATION
SAE and metric bolt/nut t hreads are not t he same.
The difference is described in t he Thread Notation
chart.
GRADE/CLASS IDENTIFICATION
The SAE bolt st rengt h grades range from grade 2
to grade 8. The higher t he grade number, t he great er
t he bolt st rengt h. Identification is determined by t he
line mar ks on t he top of each bolt head (Fig. 1). The
actual bolt st rengt h grade corresponds to t he number
of line mar ks plus 2.
A grade 2 bolt has no line marks on top of t he bolt
head
A grade 5 bolt has 3 line marks on top of t he bolt
head
A grade 7 bolt has 5 line marks on top of t he bolt
head
CONVERSION FORMULAS AND EQUIVALENT VALUES
Multiply
in-lbs
ft-lbs
By
x 0.11298
x 1.3558
To Get
= Newton-Meters (N*m)
= Newton-Meters (N*m)
Multiply
N*m
iy
x 8.851
x 0.7376
B G e f
- in-fbs
- ft-lbs
Inches Hg (60F)
psi
x 3.377
x 6.895
= Kilopascals (kPa)
= Kilopascals (kPa)
kPa
kPa
x 0.2961
x 0.145
Inches Hg
- psi
Inches
Feet
Yards
Miles
x 25.4
x 0.3048
x 0.9144
x 1.6093
Millimeters (mm)
= Meters (M)
- Meters (M)
= Kilometers (Km)
mm
M
M
Km
x 0.03937
x 3.281
x 1.0936
x 0.6214
Inches
- Feet
= Yards
Miles
mp h
Feet/Sec.
Kilometers/Hr.
mp h
x 1.6093
x 0.3048
x 0.27778
x 0.4470
= Kilometers/Hr. (Km/h)
Meters/Sec. (M/S)
Meters/Sec. (M/S)
= Meters/Sec. (M/S)
Km/h
M/ S
M/ S
M/S
x 0.6214
x 3.281
x 3.600
x 2.237
- mph
= Feet/Sec.
= Kilometers/Hr.
mph
C O M M O N MI TRI C EQUI VALENTS
1 Inch = 25 Millimeters 1 Cubic Inch 16 Cubic Centimeters
1 Foot - 0.3 Meter 1 Cubic Foot 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile =1.6 Kilometers
J91IN-1
12 INTRODUCTION
STANDARD TORQUE SPECIFICATIONS
BOLT TORQUE
BOLT
O R A M 5 G R A D E S
SI Z E M*fn ft-lbs Nfft
ft-abs
(in-lbs) (In-lbs)
1/4-20 11 (95) 14 (125)
1/4-28 11 (95) 17 (150)
5/16-18 23 (200) 31 (270)
5/16-24 27 20 34 25
3/8-16 41 30 54 40
3/8-24 48 35 61 45
7/16-14 68 50 88 65
7/16-20 75 55 95 70
1/2-13 102 75 136 100
1/2-20 115 85 149 110
9/16-12 142 105 183 135
9/16-18 156 115 203 150
5/8-11 203 150 264 195
5/8-18 217 160 285 210
3/4-16 237 175 305 225
J89IN-9
THREAD NOT A TIONSAE AND METRIC
INCH
5/16-18
METRIC
M8 X 1.25
THREAD
MAJOR
DIAMETER
IN INCHES
NUMBER
OF
THREADS
PER INCH
THREAD DISTANCE
MAJOR BETWEEN
DIAMETER IN THREADS IN
MILLIMETERS MILLIMETERS
PR606B
A grade 8 bolt has 6 line marks on top of the bolt
head
The most commonly used metric bolt strength
classes are 9.8 and 12.9. The metric strength class
identification number is imprinted on the head of the
bolt (Fig. 2). The higher the class number, the
SAE CLASSIFICATION
GRADE 5 GRADE 8
MARKINGS FOUND
ON TOP OF BOLT
HEAD INDICATE
GRADE
120 60
GRADE 2 GRADE 5 GRADE 8
(SAE) BOLTSIDENTIFICATION MARKS CORRESPOND
TO BOLT STRENGTHINCREASING NUMBERS
REPRESENT INCREASING STRENGTH.
J89IN-11
Fig. 1 SAE Bolt Grade Identification
great er t he bolt strength. Some metric nut s are im-
printed with a single-digit st rengt h class on t he nut
face.
METRIC BOLTSIDENTIFICATION CLASS NUMBERS
CORRESPOND TO BOLT STRENGTH INCREASING NUMBERS
REPRESENT INCREASING STRENGTH. J89IN-10
Fig. 2 Metric Bolt Class Identification
METRIC CONVERSION
Refer to t he Metric Conversion chart to convert
torque values listed in metric Newton-meters (Nm).
Also, use t he chart to convert between millimeters
(mm) and inches (in.)

INTRODUCTION 13
METRIC CONVERSION
i n- l bs to N m N * m to in- lbs
i n- l b N m i n- l b N m i n- l b N m i n- l b N @m i n- l b N m
2 .2260 42 4.745 3 82 9.2646 122 13.7839 162 18.30 32
4 .45 19 44 4.9713 8 4 9.490 6 124 14.0099 1 6 4 18.5292
6 .6779 46 5 .1972 8 6 9.7165 126 14.2359 166 18.75 5 2
8 .90 39 48 5 .4232 88 9.9425 128 14.4618 168 18.9811
10 1.1298 5 0 5 .6492 90 10.1685 130 14.6878 170 19.2071
12 1.3558 5 2 5 .875 1 92 10.3944 132 14.9138 172 19.4331
14 1.5818 5 4 6.10 11 94 10.6204 134 15.1397 174 19.65 90
16 1.8077 5 6 6.3270 96 10.8464 136 15 .36 57 176 19.885 0
18 2.0 337 5 8 6.5 5 30 98 11.0723 138 15.5917 178 20 .1110
20 2.25 97 60 6.7790 100 11.2983 1 4 0 15.8176 1 8 0 20 .3369
22 2.485 6 62 7.0 0 49 102 11.5243 142 16.0436 182 2 0 . 5 6 2 9
24 2.7116 64 7.230 9 104 11.7502 14 4 16.2696 184 2 0 . 7 8 8 9
26 2.9376 6 6 7.45 69 106 11.9762 1 4 6 16.4955 1 8 6 21.0 148
28 3.1635 68 7.6828 108 12.2022 148 16.7215 1 88 21.240 8
30 3.3895 70 7.90 88 110 12.4281 150 16.9475 1 90 21.4668
32 3.615 5 72 8.1348 112 12.6541 152 17.1734 192 21.6927
34 3.8414 74 8.360 7 114 12.8801 154 17.3994 194 21.9187
36 4.0 674 76 8.5 867 116 13.1060 156 17.625 3 196 22.1447
38 4.2934 78 8.8127 118 13.3320 158 17.8513 198 22.370 6
40 4.5 193 80 9.0 386 120 13.5580 160 18.0773 20 0 22.5 966
in- lb N m in-lb N m in- lb N m in- lb
.2
.4
.6
.8
1
1.2
1.4
1.6
1.8
2
2.2
2.4
2.6
2.8
3
3.2
3.4
3.6
3.8
4
1.7702
3. 54 04
5.3107
7. 08 09
8.8511
10.6213
12.3916
14.1618
15.9320
17.7022
19.4725
21.2427
23.0 129
24.7831
26.5 5 34
28.3236
30 .0 938
31.8640
33.6342
35 .40 45
4.2
4.4
4.6
4.8
5
5.2
5.4
5 .6
5 .8
6
6.2
6.4
6.6
6.8
7
7.2
7.4
7.6
7.8
8
37.1747
38 . 94 4 9
40.7152
42.4854
4 4 . 2 5 %
46.0 25 8
47.7961
49.5 663
5 1.3365
53.1067
54 . 8 7 7 0
56 . 6 4 7 2
58.4174
60 .1876
61.95 79
63.7281
65 .4983
67.2685
69.0 388
70.8090
8.2
8.4
8.6
8.8
9
9.2
9.4
9.6
9.8
10
10.2
10.4
10.6
10.8
11
11.2
11.4
11.6
11.8
12
72.5 792
74.3494
76.1197
77.8m
79.6601
81.430 3
83.20 0 6
84.970 8
86.7410
88.5112
90 .2815
92.0517
93.8219
95.5921
97.3624
99.1326
100.9028
102.6730
104.4433
106.2135
12.2
12.4
12.6
12.8
13
13.2
13.4
13.6
13.8
14
14.2
14.4
14.6
14.8
15
15.2
15.4
15.6
15.8
16
107.9837
109.7539
111.5242
113.2944
115.0646
116.8348
118.6051
120.3753
122.1455
123.9157
125.6860
127.4562
129.2264
130.9966
132.7669
134.5371
136.3073
138.0775
139.8478
141.6180
16.2
16.4
16.6
16.8
17
17.2
17.4
17.6
17.8
18
18.5
19
19.5
20
20 .5
21
22
23
24
25
ft-lbs to N * m N m to ft-lbs
ft-lb N m ft-lb N m ft-lb Nm ft-lb N m ft-lb N m N m ft-lb N m ft-ib N m ft-lb Nm ft-lb N m ft-lb
1 1.3558 21 28.4722 41 55. 58 8 5 61 82.7049 81 109.8212 1 .7376 21 15.9888 41 30 .240 ) 61 44.9913 81 5 9.7425
2 2.7116 22 29.8280 42 56 . 94 4 4 62 84 .0 60 7 82 111.1770 2 1.4751 22 16.2264 42 30 .9776 62 45 .7289 82 60.4801
3 4.0 675 23 31.1838 43 58.3002 63 85.4165 83 112.5328 3 2.2127 23 16.9639 43 31.7152 63 46.4664 83 61.2177
4 5.4233 24 32.5 396 4 4 59.6560 64 86.7723 84 113.8888 4 2.9502 24 17.7015 4 4 32.4527 64 47.20 40 84 61.95 5 2
5 6.7791 25 33,895 4 45 61.0118 65 88.1281 85 115.2446 5 3.6878 25 18.4391 45 33.1903 65 47.9415 85 62.6928
6 8.1349 26 35 .25 13 46 62.3676 66 89.4840 86 116.6004 6 4.4254 26 19.1766 46 33.9279 66 48.6791 86 63.430 3
7 9.4907 27 36.6071 47 63.7234 67 90 .8398 87 117.9562 7 5.1629 27 19.9142 47 34.6654 67 49.4167 87 64.1679
8 10.8465 28 37.9629 48 65 .0 793 68 92.195 6 88 119.3120 8 5 .90 0 5 28 20.6517 48 35.4030 68 50.1542 88 64.95 45
9 12.2024 29 39.3187 49 66.4351 69 93.5514 89 120.6678 9 6.6381 29 21.3893 49 36.140 5 69 5 0 .8918 89 65 .6430
10 13.5582 30 40 .6745 5 0 67.7909 70 94.90 73 90 122.0236 10 7.375 6 30 22.1269 5 0 36.8781 70 5 1.6293 90 66.380 6
11 14.9140 31 42.0 30 4 51 69.1467 71 96.2631 91 123.3794 11 8.1132 31 22.8644 51 37.6157 71 5 2.3669 91 67.1181
12 16.2698 32 43.3862 52 70 .5 0 25 72 97.6189 92 124.7352 12 8.8507 32 23.6020 52 38.3532 72 5 3.10 45 92 67.85 5 7
13 17.6256 33 44.7420 5 3 71.85 83 73 98.9747 93 126.0910 13 9.5 883 33 24.3395 5 3 39.0 90 8 73 53.8420 93 68.5 933
14 18.9815 34 4 6 .0 978 54 73.2142 74 100.3316 94 127.4468 14 10.3259 34 25.0771 5 4 39.8284 74 5 4.5 720 94 69.330 8
15 20 .3373 35 47.45 36 5 5 74.5700 75 101.6862 95 128.8026 15 11.0634 35 25.8147 5 5 40.5659 75 5 5 .3172 95 70 .0 684
16 21.6931 36 4 8.80 94 5 6 75 .925 8 76 103.0422 9 6 130.1586 16 11.8010 36 26.5522 5 6 41.3035 76 56.0547 96 70 .80 60
17 23.0 489 37 5 0 .165 3 57 77.2816 77 104.3980 97
13].5144 17
12.5386 37 27.2898 57 42.0 410 77 5 6.7923 97
71.5435
18 24.4047 38 51.5211 58 78.6374 78 105.7538 98 132.8702 18 13.2761 38 28.0274 5 8
42.77m
78 5 7.5 298 98 72.2811
19 25 .760 5 39 5 2.8769 5 9 79.9933 79 107.1196 99 134.2260 19 14.0137 39 28.7649 5 9 43.5162 79 58.2674 9 9 73.0187
20 27.1164 40 54.2327 60 81.3491 80 108.4654 100 135.5820 20 14.7512 40 29.5025 60 44.2537 80 5 9.0 0 5 0 100 73.7562
i n. to mm mm to in.
in. mm in. mm in. mm in. mm in. mm mm in. mm in.
mm in. mm in. mm in.
.01 .254 .21 5.334 .41 10.414 .61 15.494 .81 20.574 .01 .00039 .21 .00827 .41 .01614 .61 .02402 .81 .03189
.02 .508 .22 5 .5 88 .42 10.668 .62 15.748 .82 20.828 .02 .0 0 0 79 .22 .00866 .42 .01654 .62 .02441 .82 .03228
.03 .762 .23 5.842 .43 10.922 .63 16.002 .83 21.082 .0 3 .00118
.23 . 00906 .43 .01693 .63 .02480 .83 .03268
.04 1.016 .24 6.0 96 .4 4 11.176 .6 4 16.256 .84 21.336 .04 .00157
.24 . 0094 5 . 4 4 .01732 .64 .02520 .84 .03307
.0 5 1.270 .25 6.35 0 .45 11.430 . 6 5 16.510 .85 21.590 .0 5 .00197 .25 .00984 .45 .01772 .65 .02559 .85 .0 3346
.06 1.524 .26 6.60 4 .46 11.684 .66 16.764 .86 21.844 .06 .00236 .26 .01024 . 4 6 .01811 66 .02598 .86
.03m
.07 1.778 .27 6.85 8 .47 11.938 .67 17.018 .87 22.098 .07 .00276
.27 .01063 .47 .01850
.67
.02638 .87 .03425
.0 8 2.032 .28 7.112 .48 12.192 .68 17.272 .88 22.352 .08 .00315
.28 .01102 .48 .01890 .68 .02677 .88 .03465
.0 9 2.286 .29 7.366 .49 12.446 .69 17.526 .89 22.606 .0 9 .00354 .29 .01142 .49 .01929 .69 .02717 .89 .03504
.10 2.540 .30 7.620 .50 12.700 .70 17.780 .90 22.860 .10 .00394 .30 .01181 .50 .01969 .70 .02756 .90 .03543
.11 2.794 .31 7.874 .51 12.954 .71 18.034 .91 23.114 .11 .00433
.31 .01220 .51 .02008 .71 .02795 .91 .03583
.12 3.048 .32 8.128 .52 13.208 .72 18.288 .92 23.368 .12 .00472
.32 .01260 .52 .02047 .72 .02835 .92 .03622
.13 3.302 .33 8.382 .5 3 13.462 .73 18.542 .93 23.622 .13 .00512 .33 .01299 .5 3 .02087 .73 .02874 .93 .03661
.14 3. 5 % .34 8.6 36 .54 13.716 .74 18.796 .94 23.876 .14 .00551
.34 .01339 .54 .02126 .74 .02913 .94 .03701
.15 3.810 .35 8.890 .55 13.970 .75 19.050 .95 24.130 .15 .00591
.35 .01378 .5 5 .02165 .75 .02953 .95 .03740
.16 4.064 .36 9.144 .56 14.224 .76 19.304 .96 24.384 .16 .00630 .36 .01417 .5 6 .02205 .76 .02992 .96 .03780
.17 3.318 .37 9.398 .57 14.478 .77 19.558 .97 24.638 .17 .00669 .37 .01457 .57 .02244 .77 .03032 .97 .03819
.18 4.572 .38 9.652 .58 14.732 .78 19.812 .98 24.892 .18 .00709 .38 .01496 .5 8 .02283 .78 .03071 .98 .0 385 8
.19 4.826 .39 9.90 6 .5 9 14.986 .79 2 0 . 0 % .99 25.146 .19 .00748
.39 .01535 .5 9 .02323 .79 .03110 .99 .03898
.20 5.080 .40 10.160 .60 15.240 .80 20.320 1.00 25.400 .20 .00787 .40 .01575 .60 .02362 .80 .03150 1.00 .03937
J901 N- 1 0

LUiRICATlON AND MAINTENANCE 0 - 1
C ON T E N T S
page page
CH ASSIS AND BODY 28 ENGINE MAINTENANCE 14
DRIVETRAIN . , , , 22 GENERAL INFORMATION 1
GE N E RA L I N F ORM A TI ON
I NDE l
page
Classification of Lubricants . 3
Components Requiring No Lubrication 4
Fuel Requirements . 2
Introduction 1
Lubrication and Replacement Parts
Recommendation 3
page
Routine Maintenance 2
Starting Assi stance (Jump Starting) 9
Vehicle Lifting Recommendations . . . . . . . . . . . . 10
Vehicle Noise Control 2
Vehicle Towing Recommendations 11
INTRODUCTION
Lubrication and mai nt enance is divided into re-
quired and recommended service tasks. The required
service t asks must be completed to verify the emis-
sion controls function correctly. The recommended
service t asks should be completed to mai nt ai n safety
and durability.
This information will assist t he service personnel
in providing maxi mum protection for each owner' s
vehicle.
Conditions can vary with individual driving habits.
It is necessary to schedule mai nt enance as a time in-
terval as well as a distance interval.
It is t he owner' s responsibility to determine t he ap-
plicable driving condition. Also to have t he vehicle
serviced according to t he mai nt enance schedule, and
to pay for t he necessary part s and labor.
Vehicles with a Gross Vehicle Weight Rating
(GVWR) of 3 855 kg (8,500 lbs.) or less must conform
to light duty emission standards. Vehicles with a
Gross Vehicle Weight Rating (GVWR) of 3 856 kg
(8,501 lbs.) or more must conform to heavy duty
emission st andards.
The GVWR for each vehicle is listed on t he Safety
Certification Label. This label is affixed to t he driver
side door pillar (Fig. 1).
Additional maintenance and lubrication informa-
tion is listed in t he Owner' s Manual.
M m r v CHRYSLER DATE OF MFR
M F D B Y
CORPORATION
GVWR
GAWR FRONT
GAWR REAR
WITH TI RES
WITH TI RES
RI MS AT
R I MS AT
PSI COLD
PSI COLD
THI S VEHI CLE C ONF OR MS TO ALL APPLI CABLE FEDERAL MOTOR VEHI CLE SAFETY
STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.
SI NGLE DUAL
BAR CODE
VEHI CLE MADE IN
4648503 J9UN-25
Fig. 1 Vehicle Safety Certification Label
SEVERE DRIVING CONDITIONS
Vehicles subjected to severe driving conditions
should decrease t he interval between component
maintenance. Severe driving conditions are defined
as:
Frequent short t ri p driving less t han 24 km (15
miles)
Frequent driving in dusty conditions
Trailer towing
Extensive engine idling
Sustained high speed operation
Desert operation
Frequent st art i ng and stopping
Cold climate operation
L U B R I C A T I O N A N D M A I N T E N A N C E
0 - 2 LUBRICATION AND MAINTENANCE
Commercial service
When a vehicle is continuously subjected to severe
driving conditions, lubricate:
Body components
All t he driveline coupling joints
Steering linkage
More often t han normal driving conditions
DUSTY AREAS
With t hi s type of severe driving condition, special
care should be given to t he:
Engi ne air cleaner filter
PCV filter
Crankcase ventilation system
Brake booster control valve air filter.
Verify t hat t he filters and t he associated compo-
nent s are clean. Also verify t hat they are functioning
effectively. This will minimize t he amount of abra-
sive particles t hat ent er t he engine.
OFF-ROAD (4WD) OPERATION
After off-road (4WD) operation, inspect t he under-
side of t he vehicle. Inspect the:
Tires
Body st ruct ure
Steering components
Suspension components
Exhaust system
Threaded fasteners
HARSH SURFACE ENVIRONMENTS
After extended operation in harsh environments,
t he brake drums, brake linings, and rear wheel bear-
ings should be inspected and cleaned. This will pre-
vent wear and errat i c brake action.
ROUTINE MAINTENANCE
The following rout i ne mai nt enance is recommended
on a monthly basis:
TIRESInspect t he t i res for unusual wear/damage.
Determine if t he inflation pressure is adequate for
t he vehicle load.
BATTERYInspect and clean t he t ermi nal s.
Tighten t he t ermi nal s if necessary.
FLUIDSDetermine if t he component fluid levels
are acceptable. Add fluid, if necessary.
LIGHTS/ELECTRICALTest all t he electrical sys-
t ems in t he vehicle for proper operation.
It is also recommended t hat t he engine oil and t he
washer fluid level be determined at each fuel fill-up.
VEHICLE NOISE CONTROL
Vehicles wi t h a GVWR of 4 535 kg (10,000 lbs), or
more, are required to comply wi t h Federal Exterior
Noise Regulations (Fig. 2).
VEHICLE NOISE EMISSION CONTROL INFORMATION
DATE OF VEHICLE MANUFACTURE
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE EMI SSI ON
APPLICABLE TO MEDIUM AND HEAVY DUTY TRUCKS.
THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE
PROHIBITED BY THE NOISE CONTROL ACT OF 1972. (A) THE REMOVAL OR
RENDERING INOPERATIVE, OTHER THAN FOR PURPOSES OF MAINTENANCE,
REPAIR. OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR ELEMENT OF
DESIGN (LISTED IN THE OWNERS MANUAL) INCORPORATED INTO THIS VEHICLE
IN COMPLIANCE WITH THE NOISE CONTROL ACT: (B) THE USE OF THIS VEHICLE
AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS BEEN REMOVED OR
RENDERED INOPERATIVE.
PU626D
Fig. 2 Vehicle Noise Emission Control Information
Label
UNAUTHORIZED DEFEAT OF NOISE
CONTROL COMPONENTS
Federal law prohibits removal, altering or other-
wise defeating any noise control component. This in-
cludes before or after t he vehicle is in use. Federal
law also prohibits t he use of a vehicle after a noise
control component is defeated.
REQUIRED MAINTENANCE/SERVICE FOR
NOISE CONTROL
The following mai nt enance is required after each
6-month or 9 600 km (6,000 miles) interval. This will
ensure t hat t he vehicle noise control components are
operating properly.
EXHAUST SYSTEM
Inspect exhaust system for exhaust leaks and dam-
aged components. The exhaust hangers, clamps and
U-bolts should be attached and in good condition.
Burned or rupt ured mufflers, damaged exhaust pipes
should be replaced. Refer to Group 11Exhaust Sys-
t em/ Int ake Manifold for service information.
AIR FILTER HOUSING/CANISTER
Inspect t he air filter assembly for proper fit. Verify
t he cover is securely attached to t he housing/canis-
ter. Inspect all t he air filter housing hoses for con-
nections. The gasket between t he air filter housing
and t hrot t l e body must be in good condition. The air
filter element should be clean and serviced according
to t he mai nt enance schedule.
FUEL REQUIREMENTS
GASOLINE ENGINES
All engines require t he use of unleaded gasoline to
reduce the effects of lead to t he environment. Also
unleaded fuel is necessary to prevent damage to t he
catalytic convert er/ 0
2
sensor. The fuel must have a
mi ni mum octane rat i ng of 87 based on t he (R + M)/2
calculation method.

LUBRICATION AND MAINTENANCE 0 - 3
CAUTION: UNLEADED FUEL ONLY must be used in
vehi cl es equi pped with a catal yst emi ssi on control
syst em. All vehi cl es have r emi nder s printed on the
i nstrument panel bel ow the fuel gauge and on the
fuel filler door. The vehi cl es al so have fuel filler
t ubes that are speci al l y desi gned to accept onl y the
smal l - diameter noz z l es. It i s illegal to by pas s the
desi gn of an unl eaded fuel filler tube.
DIESEL ENGINES
All Ram Truck and Ram Cab/Chassis Diesel en-
gines normally can use number 2D Diesel fuel for
most year-round operations. A fuel conforming to
ASTM Specification D-975 is recommended. For ex-
t reme cold-weather, number I D Diesel fuel is recom-
mended.
CLASSIFICATION OF LUBRICANTS
Lubricating fluids and chassis lubricants are clas-
sified according to st andards recommended by the:
Society of Automotive Engi neers (SAE)
American Petroleum Inst i t ut e (API)
National Lubricating Grease Inst i t ut e (NLGI)
ENGINE OIL
SAE VISCOSITY GRADE
An SAE viscosity grade is used to specify t he vis-
cosity of engine oil. SAE 30 specifies a single viscos-
ity engine oil.
Engine oils also have multiple viscosities. These
are specified with a dual SAE viscosity grade which
indicates t he cold-to-hot t emperat ure viscosity range
(Fig. 3).
API SERVICE GRADE
The API Service Grade specifies t he type of perfor-
mance t he engine oil is intended to provide. The API
Service Grade specifications also apply to energy con-
serving engine oils (Fig. 3).
For maxi mum gasoline engine protection, use API
Service Grade SG, SG/CD or SG/CE engine oil.
For maxi mum Diesel engi ne protection, use
API Service CE or SG/CE engi ne oil.
GEAR LUBRICANTS
A dual grade is also used to specify t he viscosity of
multi-purpose gear lubricants.
The API grade designation identifies gear lubri-
cants in t erms of recommended usage.
OIL
QUALITY
SAE
VISCOSITY
GRADE
FUEL
ECONOMY
NOTATION
J 91 004
Fig. 3 SAE Oil Viscosity Grade & API Service Grade
CHASSIS COMPONENT AND WHEEL BEARING
LUBRICANTS
The chassis and wheel bearing lubricants are iden-
tified by t he NLGI Certification Symbol. The symbol
contains a coded designation. This identifies t he us-
age and quality of t he lubricant.
The letter G wi t hi n t he symbol designates wheel
beari ng lubricant. The letter L designates chassis lu-
bricant. When t he l et t ers are combined, t he lubricant
can be used for dual applications. Use only lubricants
t hat display t he NLGI Certification Symbol.
N A T I O N A L L U BR I C A T I N G
G R E A S E I NS T I T UT E
NLGI
AUTOMOTIVE
WH E E L B E A R I N G & C H A S S I S
L U B R I C A N T
G C - L B
-CERTIFICATION
SYMBOL
USAGE AND
QUALITY DESIGNATION
J 9 2 0 W 7
Fig. 4 NLGI Lubricant Container Certification/
Identification Symbol
LUBRICATION AND REPLACEMENT PARTS
RECOMMENDATION
Ram Trucks are engineered to provide many years
of dependable operation. However, lubrication service
and mai nt enance are required for each vehicle. When
necessary, MOPARbrand lubricants and genuine re-
placement part s are recommended.
COMPONENTS REQUIRING NO LUBRICATION
There are many components t hat should not be lu-
bricated. The components t hat should not be lubri-
cated are:
Air pumps
Generator bearings
Brake booster cylinder
Clutch release bearings
Distributors
Drive belts
Drive belt idler pulleys
Drive shaft center bearings
Idler arms
Rubber bushings
St art er motor bearings
Suspension st rut bearings
Rear spring shackle bolts
Rear wheel bearings (not equipped with a Dana
or 70 axle)
Throttle control cables
Throttle linkage ball joints
Wat er pump bearings
GASOLINE ENGINE MAINTENANCE SCHEDULE
LIGHT DUTY CYCLE
SCHEDULED MAINTENANCE FOR EMISSIONS CONTROL - PROPER VEHICLE PERFORMANCE
Inspection and service is also necessary any rime a malfunction is observed or suspected.
X = Scheduled maintenance for all vehicles.
O = Scheduled maintenance for all vehicles, Recommended for proper vehicle performance.
Where both time and mileage Miles (Thousand)
are shown, follow the interval
which occurs first. Kilometers (Thousand)
7'A 15 22'A 30 37'A 45 52'A 60 67'A 75 82'A 90 97'/2 105 112'A 120 Where both time and mileage Miles (Thousand)
are shown, follow the interval
which occurs first. Kilometers (Thousand) 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192
Coolant Condition, Coolant Hoses/Clomps X X X X X X O O O O O O O O o O
Exhaust SystemCheck X X X X X X O O O o O O O o o o
OilChange (6 months) X X X X X X O O O o o O O o o o
Oil FilterChange (2nd Oil Change) X X X o o O o o
Spark PlugReplace X 0 o o
Air FilterReplace X o O o
CoolantFlush/Replace (36 months) &
2 4 months/48 000 km (30,000 miles) thereafter
O X X
PCV ValveReplace if Necessary O' O' O'
BatteryReplace O
This maintenance is recommended by Chrysler Corporation to the owner, but is not required to maintain the warranty.
GASOLINE ENGINE MAINTENANCE SCHEDULE
HEAVY DUTY CYCLE
Inspection and service is also necessary anytime a malfunction is observed or suspected.
Wh e n both time and mi l eage are Mi l es (Thousand)
shewn, follow the interval
which occurs first. Kilometers (Thousand)
6 12 18 24 30 36 42 48 5 4 60 66 72 7 8 82V2 84 90 96 102 108 Wh e n both time and mi l eage are Mi l es (Thousand)
shewn, follow the interval
which occurs first. Kilometers (Thousand) 9.6 19 2 9 38 48 5 8 67 77 85 96 106 116 125 132 135 1 4 5 154 164 174
Coolant Condition, Coolant Hoses/Clamps X X X X X X X X X X X X X X X X X X
Exhaust System Check X X X X X X X X X X X X X X X X X X
Oil Change (6 Months)
X X X X X X X X X X X X X X X X X X
Oil Filter Change (2nd Oil Change) X X X X X X X X X
Drive Belt Tension Inspect & Adjust X' X X
1
X X ' X
Drive Belts (V-Type) Replace X
Air Filter/Air Pump Air Filter Replace X X X X
Crankcase Inlet Air Filter (6 & 8 Cyl. Eng. Only) 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 X
2
EGR Tube Clean Passengers X
2
PCV Valve Replace X
2
Vacuum Emission Components Replace X
Ignition Timing Adjust to Specs, as necessary X
Ignition Cables, Distributor C ap & Rotor Replace X
Manifold Heat Control Valve Lubricate X
Battery Replace X
Oxygen Sensor Replace X
2
1
For California vehicles, this maintenance is recommended by Chrysler Motors to the owner but, is not required to maintain the warranty on the air pump drive belt.
2
Requires Emission Maintenance Reminder Light. If so equipped, these parts are to be replaced at the indicated mileage, or when the emissions maintenance
reminded light remains on continuously with the key in the "on" position, whichever occurs first.
J9100-20
DIESEL ENGINE MAINTENANCE SCHEDULE
HE AV Y DUTY CYCLE Inspection and service is also necessary any time a malfunction is observed or suspected.
Iff both time and distance Miles (Thousand)
are listed, use the interval
that ends first. Kilometers (Thousand)
6 12 18 24 30 36 42 4S 54 60 66 72 78 84 90 96 102 108 Iff both time and distance Miles (Thousand)
are listed, use the interval
that ends first. Kilometers (Thousand) 9,6 19 29 38 48 58 67 77 85 96 106 116 125 135 145 154 164 174
Coolant Condition, Coolant Hoses/Clamps (12 months)
Coolant Flush/Replace (36 months) & 24 months/
48 000 km (30,000 miles) thereafter
O
OilChange (6 months) X X X X X X X X X X X X X X X X X X
Oil FilterReplace (Every Oil Change) X X X X X X X X X X X X X X X X X X
Drive BeltsReplace As Necessary X X X X X X
Air FilterReplace X X X X
Air FilterClean (California Only) e

Air Filter CanisterClean o o o o
Fuel FilterService When Necessary
Injection Pump Timing & Engine Idle Speed
Check & Adjust
9
Underhood Rubber/Plastic ComponentsInspect/Replace
X All vehicles O All vehicles except California. Recommended for California. California only. Recommended for all vehicles.
CHASSIS LUBRICATION
For l i g h t duty cycle v e h i c l e s G V W resting of 3 855 K g (8,500 lbs ) and b e l o w .
Component T r u c k M o d e l s Fittings S e r v i c e I n t e r v a l L u b r i c a n t
Center Link AD1 A D 2
A D 4
2 36 0 0 0 km ( 2 2 , 5 0 0 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
(Multi-Mileage Lubricant)
Drag Link Bali joints AW1 AW 2
A W 8
2 12 0 0 0 km ( 7, 5 0 0 miles) or 6 months Multi-purpose grease - NGLI grade 2 EP
Gearshift Mechanism
Overdrive 4
AD1 1 3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
(Multi-Purpose Lubricant)
Parking Brake Ratio
Lever Pivot
A D 1 A D 2 A D 4
AW1 A W 8
3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
Propeller Shaft U-joint AW1 AW2
A W 8
3 (1 Piece
rear
P/shaft)
12 0 0 0 km ( 7, 5 0 0 miles) or 6 months Multi-purpose grease - NGLI grade 2 EP
Propeller Shaft Slip Spline A D 1 A D 2
( 2 piece P/shaft)
1 3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or 2 years. For severe
service, every 480 0 km ( 3, 0 0 0 miles) or 3 months.
Daily, if vehicle is operated in water
Multi-purpose grease - NGLI grade 2 EP
Suspension Ball Joints A D 1 A D 2 4 3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or 2 years every engine
oil change for off-highway operation
Tie Rod Ball Joints AD1 AD2
A D 4
AW1 AW 2
A W 8
4
2
3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or 2 years
12 0 0 0 km ( 7, 5 0 0 miles) or 6 months. Daily, if
vehicle is operated in water
NP-241 Transfer Case Shift
Lever Pivot
A W1 AW2
A W8
As Required Multi-purpose grease - NGLI grade 2 EP
Wheel Stop A D 1 A D 2 A D 4 3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or as required Wax Type Lubricant
Constant Velocity Joint
(Front P/shaft)
A W1 AW2
A W8
1 12 0 0 0 km ( 7, 5 0 0 miles) Multi-purpose grease - NGLI grade 2 EP
>
J9000-59
>
CHASSIS LUBRICATION (CONT'D)
For heavy duty cycle vehicles GV W rating of 3 856 K g (8,501 Sbs.) and above.
Component Truck Models Fittings Service Interval Lubricant
Center Link AD2- 3 2 39 000 km (24,000 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
Drag Link Ball Joints AW3 2 9 6 00 km (6,000 miles) or 6 months Multi-purpose grease - NGLI grade 2 EP
Constant Velocity Joint
(Front P/shaft)
AW 3 1 9 6 00 km (6,000 miles) Multi-purpose grease - NGLI grade 2 EP
P/shaft U-Joints AW3 3 9 6 00 km (6,000 miles) or 6 months. For severe
service, every 1 6 00 km (1,000 miles). Daily, if
vehicle is operated in water.
P/shaft Slip Spline AW 3 (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.
Suspension Ball Joints AD2-3 4 39 000 km (24,000 miles) Multi-purpose grease - NGLI grade 2 EP
Tie Rod Ball Joints AD2-3
AW2-3
4
2
39 000 km (24,000 miles) or 2 years
9 6 00 km (6,000 miles) or 6 months
NP-205 Transfer Case
Shift Linkage
AW2- 3 As required Light Engine Oil
NP-24 1 Transfer Case Shift
Lever Pivot
AW2 As required Multi-purpose grease - NGLI grade 2 EP
J9000-60

FLUID CAPACITIES
C O O L I N G S YS T E M QU A R T S LI TERS PO WE R S T E E R I N G PI N T S LI TERS
3.9L E N GI N E 15.1 14.3 ALL 2.7 1.28
5.2L E N G I N E (
2
W D ) 17.0 16.1 R E A R A XL E PI N TS LI TE RS
5.2L E N G I N E (
4
W D ) 16.5 15.6 CHRYSLER BVa Inch (210 mm) 4.4 2.08
5.9L E N GI N E
( 2
W D ) 15.5 14 .7 CHRYSLER 9Va Inch (235 mm) 4.5 2.13
5.9L E N GI N E (
4
W D ) 15.0 14.2 D A N A 60 6.0 2.84
5.9L DIESEL E N GI N E ( M AN . TRAN S. ) 15.5 14.7 D A N A 70 7.0 3.31
5.9L DIESEL E N G I N E ( AUTO, TRAN S) 16.5 15.6 F R O N T A XL E PI N TS LI TERS
E N GI N E C RAN K C ASE Q UARTS LI TE RS D A N A 44 FBJ 5.6 2.65
3.9L, 5.2L & 5.9 E N G I N E S 4.0* 3.8* D A N A 60 F 6.5 3.07
5.9L DIESEL E N G I N E S 12.0* 11.4** TRAN SM I SSI ON - AUTOM ATI C Q UARTS LI TERS
FUEL TAN K G A L L O N LI TERS A 727 (5.9L E NGI NE ) 8.4 7.9
STANDARD 3.9L & 5.2L E NGI NE S 22.0 83.0 A 998 (3.9L E NGI NE ) 8.6 8.1
OPTI ONAL 3.9L & 5.2L E N GI N E S 30.0 113.0 A 999 (5.2L E NGI NE ) 8.6 8.1
5.9L E N G I N E {G OR D) 30.0 113.0 A 518 (5.2L & 5.9L E NGI NE S ) 10.2 9.6
A D 100 & A W 100 34.0 128.0 TRAN SM I SSI ON - M AN UAL Q UARTS LI TERS
T R A N S F E R C A S E PI N T S LI TERS NV 4500 4.0 3.8
NP-205 4.5 2.13 GETRAG 360 (5 Speed) 3.5 3.3
NP-241 6.0 2.84
* Add 0.5 qt. or 0.45 liter when the oil filter is changed
* * Add 1 qt. or 0.9 liter with oil filter change
STARTING ASSISTANCE (JUMP STARTING)
WA R N I N G : D O N O T A T T E M PT T O PU S H O R T O W A
V E H I C L E T O S T A R T T HE E N G I N E . U N B U R N E D
F U E L C O U L D E N T E R C A T A L Y T I C C O N V E R T E R
A N D I G N I T E A F T E R T HE E N G I N E I S S T A R T E D .
T HI S C O U L D C A U S E T HE C O N V E R T E R T O O V E R -
HE A T A N D R U PT U R E .
BOOSTER BATTERY
WA R N I N G : T O PR E V E N T PE R S O N A L I N J U R Y O R ,
D O N O T A L L O W BA T T E R Y A C I D T O C O N T A C T
E Y E S , S K I N O R C L O T HI N G . D O N O T L E A N O V E R A
BA T T E R Y WH E N C O N N E C T I N G J U M PE R C A B L E S .
D O N O T A L L O W T HE PO S I T I V E A N D N E G A T I V E
C A B L E C L A M P S T O C O N T A C T E A C H O T HE R .
K E E P O PE N F L A M E S A N D S P A R K S A WA Y F R O M
T HE BA T T E R Y E L E C T R O L Y T E V E N T H O L E S . A L -
WA Y S WE A R E Y E PR O T E C T I O N WH E N I N V O L V E D
WI T H V E H I C L E BA T T E R I E S .
If it becomes necessary to use a booster bat t ery and
j umper cables to st art an engine, use the following
procedure.
J9200-86
(1) Engage t he parki ng brake. Shift t he automatic
transmission to PARK (if a manual transmission,
shift to NEUTRAL).
(2) Turn off all lights, and all other electrical
loads.
(3) Observe t he bat t ery condition indicator (Fig. 5).
If t he bat t ery condition indicator is light/bright col-
ored (or yellow), replace t he bat t ery. Do not attempt
to jump start an engi ne when the condition indi-
cator is light/bright col ored (or yellow). If t he
condition indicator is dark in t he center (but without
a green dot), proceed with connecting t he j umper ca-
bles.
WA R N I N G : T HE E L E C T R O L Y T E ( AC I D) I N A D I S -
C H A R G E D BA T T E R Y C A N F R E E Z E . D O N O T AT -
T E M PT T O J U M P S T A R T A N E N G I N E B E F O R E
D E T E R M I N I N G T HE C O N D I T I O N O F T HE BA T T E R Y
E L E C T R O L Y T E . T HE BA T T E R Y C O U L D E XPL O D E
A N D C A U S E S E V E R E PE R S O N A L I N J U R Y.
C A U T I O N : D o not permit the metal surf aces on the
vehi cl es to contact. T hi s coul d establ i sh gr ound
(negative) continuity between the vehicle bodi es.
T hi s coul d cause the on- board comput ers to be
damaged. In addition it coul d reduce the amount of
current flow t hrough the starter motor.
0 - 1 0 LUBRICATION AND MAINTENANCE

O.K.TO
JUMP
START
BATTERY
CONDITION
INDICATOR
DO NOT
JUMP
START
J9100-26
D A R K E N E D I N D I C A T O R WI T H G R E E N DOT
L E T T E R S U k -
F L U I D Lt- E:L .
D A R K E N E D I N D I C A T OR NO G R E E N DOT
BA T T E R Y C H A R G E 10'//
Ft UI D L E V E l OK
L I G HT O R BR I G H T I N D I C A T O R
R A T - c c i , C H A P C; F R ^ ' ^ O w h
AM. w - GE FlAf S
t
I l l BE
r- ! F- r tjr
r
? STA F r O U n C A I
:
Fi g. 5 Battery Condition indicator
(4) At t ach a red j umper cable connector clamp to
t he positive (4-) t ermi nal on t he booster bat t ery. At-
tach t he other red cable connector clamp to t he pos-
itive ( +) t ermi nal on t he discharged bat t ery (Fig. 6).
C A U T I O N : D o not allow the positive ( + ) and nega-
tive (-) cabl e cl amps to contact each other. D o not
lean over the battery when connecti ng the cabl e
cl amps.
WARNING: D O NOT CONNECT A JUMPER CABLE
CONNECTOR CLAMP TO THE NEGATIVE POST OF
THE DISCHARGED BATTERY.
(5) Connect a black j umper cable connector clamp
to t he negative (-) t ermi nal on t he booster bat t ery.
Connect t he other black j umper cable connector
clamp to a good ground source on t he engine t hat is
to be st art ed (Fig. 7).
Verify the engi ne ground (negative) contact
surface area is free of grease. Make sure there is
a good connecti on to bare metal. The engi ne
ground (negative) connecti on must provi de good
electrical continuity.
(6) St art t he engine.
WARNING: THE USE OF ANY JUMPER CABLE DIS-
CONNECTION PROCEDURE OTHER THAN THAT
DESCRI BED BELOW COULD RESULT IN:
PERSONAL INJURY CAUSED BY BATTERY
ACID SQUIRTING FROM THE BATTERY VENTS
PERSONAL INJURY AND/OR PROPERTY DAM-
AGE CAUSED BY BATTERY EXPLOSION
DAMAGE TO THE BOOSTER VEHICLE OR THE
DISABLED VEHICLE CHARGING SYSTEM.
(7) After t he engine is started, t he j umper cables
must be disconnected in t he following order:
Black (negative) cable connector clamp from t he
engine ground contact
Black (negative) cable connector clamp from t he
negative t ermi nal (-) on t he booster bat t ery
Red (positive) cable connector clamps from t he pos-
itive ( + ) t ermi nal s on both batteries
BATTERY NEGATIVE
CABLE TERMINAL
POSITIVE
JUMPER
CABLE
BATTERY
J9000-37
Fig. 6 Positive Jumper Cable Connection
ENGINE BATTERY
GROUND NEGATIVE
NEGATIVE CABLE
-JUMPER
CABLE
BATTERY
J9000-38
Fig. 7 Both Jumper Cables Connected On Disabled
Vehicle
PORTABLE STARTING UNIT
There are many types of portable st art i ng uni t s
available for st art i ng engines. Follow t he manufac-
t urer' s instructions.
VEHICLE LIFTING RECOMMENDATIONS
Refer to t he Owner' s Manual for emergency vehicle
lifting procedures.
FLOOR JACK
When properly positioned, a floor jack can be used
to lift a vehicle (Fig. 8). Support t he vehicle in t he
raised position with jack stands at t he front and rear
ends of the frame rails.
CAUTION: D o not attempt to lift a vehicle with a
floor jack posi ti oned under:
LUBRICATION AND MAINTENANCE 0 - 1 1
J DRIVE-ON HOIST
I FRAME CONTACT HOIST
TWIN POST CHASSIS HOIST
FLOOR JACK RROOD30
Fig. 8 Correct Vehicle Lifting Locations
An axle tube
A body side sill
A steering linkage component
A drive shaft
The engine or transmission oil pan
The fuel t ank
A front suspension arm
Use the correct frame rail lifting l ocat i ons only
(Fig. 8).
HOIST
A vehicle can be lifted with:
A single-post, frame-contact hoist
A twin-post, chassis hoist
A ramp-type, drive-on hoist
When a frame-contact type hoi st is used, verify
that the lifting pads are posi ti oned properly
(Fig. 8).
WA R N I N G : WH E N A S E R V I C E PR O C E D U R E RE -
QU I R E S TH E RE M OV AL OF TH E RE AR AXLE, F UE L
TANK, O R S PA RE TI RE , E I TH E R:
PLACE ADDITIONAL WEIGHT ON THE REAR
END OF THE VEHICLE
ATTACH THE VEHICLE TO THE HOIST
PLACE JACK STANDS UNDER THE VEHICLE
FOR SUPPORT TO PREVENT TIPPING WHEN
THE CENTER OF BALANCE CHANGES
4WD VEHICLES
A st andard hoist can be used to lift a 4WD vehicle.
The hoist should be inspected for adequate clearance.
The lift arms, pads or ramps should be adjusted to
ensure t hat t here is adequate clearance (Fig. 9).
ADJUSTMENT PAD
i i 7
M A I N T A I N CLEARANCE
HOIST ARM
RK44
Fig. 9 Lifting 4WD Vehicle With Single-Post
Hoist Typical
When a twin-post hoist is used, a 4 x 4 x 12-inch
wood spacer also could be required. Place t he wood
spacer under t he front axle (opposite t he differential
housing). This will mai nt ai n balance and level lift-
ing.
C A U T I O N : The bl ock that i s used must be secured
in a saf e manner. T hi s will ensure that it will not un-
bal ance the vehicle.
VEHICLE TOWING RECOMMENDATIONS
When it is necessary to tow a Ram Truck, t he rec-
ommended method is either:
t he sling-type, rear-end raised towing method; or
t he wheel-lift towing method with a tow dolly lo-
cated under t he front wheels.
A vehicle with flat-bed haul i ng equipment can also
be used to t ransport a disabled vehicle.
SLI NG-TYPE
FLAT BED RR0OD29
Fig. 10 Tow Vehicles With Approved Equipment

A vehicle equipped with SAE approved sling-type
towing equipment can be used (Fig. 10). However,
many vehicles are equipped with air dams, spoilers,
and/or ground effect panels. In this case a wheel-lift
towing vehicle or a flat-bed haul i ng vehicle is recom-
mended (Fig. 10). If a flat bed device is used, t he ap-
proach angle should not exceed 15 degrees.
GROUND CLEARANCE
The lifted wheels of t he disabled vehicle should be
a mi ni mum of 10 cm (4 in.) off t he ground. Make
sure t here is enough clearance at t he opposite end.
This is critical when towing over rough t errai n. If
necessary, the rear ground clearance can be in-
creased by removing t he wheels from t he lifted end
and t hen towing with t he lifted end closer to t he
ground. If t he rear wheels are removed, secure t he
brake drums. A 20 cm (8 in.) ground clearance must
be mai nt ai ned between brake drums or rotors and
t he ground.
SAFETY PRECAUTIONS
The following safety precautions must be consid-
ered when preparing for and during a vehicle towing
operation:
Remove exhaust pipe tips t hat interfere with t he
tow sling and crossbar
Padding should be placed between t he tow sling/
crossbar and any painted surfaces
If t he vehicle is damaged, secure t he loose and pro-
t rudi ng part s
Always use a safety chain system t hat is indepen-
dent of t he lifting and towing equipment
When placing tow hooks on t he rear axle, position
t hem so they do not damage t he brake t ubi ng or
hoses
Do not allow any of t he towing equipment to con-
tact t he fuel t ank
Do not tow t he vehicle by connecting to t he front
or rear shock absorbers
The operator should not go under a vehicle while
it is lifted by t he towing equipment. The vehicle
should first be supported by safety st ands
Do not allow passengers in a vehicle being towed
Observe all state and local laws involving warni ng
signals, night illumination, speed, etc.
Do not exceed a towing speed of 48 km/h (30 mph)
Avoid towing distances of more t han 24 km (15
miles) whenever possible
Do not attach tow chains or a tow sling to a
bumper, t he steering linkage, t he universal joints, or
a drive shaft
REAR-END RAISED TOWING
It is recommended t hat t he rear-end raised towing
method be used. Vehicles can be towed with t he front
wheels on t he ground for extended distances at
speeds not exceeding 48 km/h (30 mph) (Fig. 11).
(1) Attach the J-hooks around t he axle shaft tubes
outboard of t he rear springs.
(2) Position and center t he sling under and for-
ward of t he rear bumper.
(3) Attach safety chains (with pads) at each end of
t he rear bumper.
(4) Turn t he ignition switch to t he OFF position to
unlock t he steering wheel.
(5) Clamp t he steering wheel with t he front wheels
in t he st rai ght ahead position.
C A U T I O N : D o not use the steering col umn lock to
secure front wheel in the strai ght- ahead posi ti on.
(6) Shift t he transmission to NEUTRAL.
POSI TI ON CENTER BAR FORWARD OF BUMPER -
/ J - H O O K S OUTBOARD OF SPRI NGS RN967A
Fig. 11 Rear-End Raised Towing
FRONT'END RAISED TOWING
If a vehicle cannot be towed from t he rear, t he
front-end raised towing method normally can be
used (Fig. 12).
(1) Center t he sling with t he bumper and position
it at t he frame front crossmember.
C A U T I O N : U se tow chai ns with J - hooks for con-
necting to the di sabl ed vehi cl e' s lower suspensi on
ar ms. Never use T - hooks.
(2) Route the J-hooks and tow chains over t he
steering linkage outboard of t he coil spring.
(3) Attach t he J-hooks to t he outer end of t he
lower suspension arms.
(4) Raise t he vehicle.
(5.) Attach t he safety chains to t he disabled vehicle
at t he frame rails.
Vehicles equipped with a MANUAL TRANSMIS-
SION can be towed with t he rear wheels on t he

ground. Do not exceed speeds of 48 km/h (30 mph) or
a distance of 24 km (15 miles). The transmi ssi on
must be i n neutral.
Front-end raised towing for a vehicle equipped
with an AUTOMATIC TRANSMISSION is not rec-
ommended.
C AUT I ON: l t i s not recommended to flat tow a vehi -
cle.
LOCKED VEHICLE TOWING
When a locked vehicle must be towed, use a tow
dolly or flat bed haul er.
POSITION CENTER BAR A N D WOOD BEAM BEHIND
BUMPER AND AHEAD OF STRUTS TO SUPPORT
CHAINS CLEAR OF SWAY BAR RN966
Fig. 12 Front-End Raised TowingTypical

E N G I N E M A I N T E N A N C E
INDEX
page
Air Injection Systems/ Ai r Pump . 17
Air-Conditioner Compressor 21
Battery 19
Cooling Syst em 15
Crankcase Ventilation Syst em 17
Diesel Engi ne Air Filter Canister 17
Drive Belts 20
Engine Air Cleaner Filter Element 16
Engine Break-In 14
Engine Oil 14
Engine Oil Change and Filter Replacement 15
Ex haust Gas Recirculation ( E GR) Syst em . . . . . . 19
page
Ex haust Manifold Heat Control Val ve . 17
Ex haust System , 21
Fuel System 18
H oses and Fittings 16
Ignition Cabl es, Distributor Cap and Rotor . . . . . . 19
Ignition Timing . 19
Ox ygen ( 0
2
) Sensor 19
Rubber/ Plastic Components 20
Spark Pl ugs . 19
Throttle Control Linkage 18
V acuum Operated, Emi ssi on Control
Components 19
ENGINE BREAK-IN
After first st art i ng a new engine, allow it to idle
for 15 seconds before shifting into a drive gear. Also:
Drive t he vehicle at varying speeds less t han 88
km/h (55 mph) for t he first 480 km (300 miles).
Avoid fast acceleration and sudden stops.
Do not drive at full-throttle for extended periods of
time
Do not drive at constant speeds
Do not idle t he engine excessively
A special break-in engine oil is not required. The
original engine oil installed is a high quality lubri-
cant.
New engines tend to consume more fuel and oil un-
til after t he break-in period has ended.
ENGINE OIL
SPECIFICATIONS
API SERWICE GRADE
Use an engine oil t hat conforms to API Service
Grade S
5
SG/CD or SG/CE. MOPARprovides engine
oils t hat conform to all of these service grades.
SULFATED ASHDI ESEL ENGINES
Oils t hat contain an excessive amount of sulfated
ash can cause deposits to develop on Diesel engine
valves. These deposits can result in valve wear.
SAE WISC0SITY
An SAE viscosity grade is used to specify t he vis-
cosity of engine oil. SAE 30 specifies a single viscos-
ity engine oil.
Engi ne oils also have multiple viscosities.
10W-30
<
5W-30
1 1 1
F - 2 0 0 10 20 32 60 80 100
C - 2 9 - 18 - 12 - 7 0 16 27 38
ANTICIPATED TEMPERATURE RANGE
BEFORE NEXT OIL CHANGE J9000-39
Fig. 1 Temperature/Engine Oil ViscosityGasoline
Engines
-12C
-18C
10F
0 F -
15W-40
- 2 3 c ( ^ - 1 0
e
F
I
10W-30
WITH WITHOUT BLOCK HEATER
BLOCK SYNTHETIC OIL
HEATER 10W-30 5W-30
J9100-29
Fig. 2 Temperature/Engine Oil ViscosityDiesel
Engines
ENERGY G0NSERWING OIL
An Energy Conserving type oil is recommended for
gasoline engines. They are designated as either EN-
ERGY CONSERVING or ENERGY CONSERVING
II.
OIL LEVEL INDICATOR (DIPSTICK)
GASOLINE ENGINES
The engine oil indicator is located at t he ri ght
front of the engine.

DIESEL ENGINES
The Diesel engine oil level indicator is located at
t he left center of t he engine, above t he fuel injection
pump (Fig. 3).
Fig. 3 Diesel Engine Oil Dipstick
ACCEPTABLE OIL LEVEL
To mai nt ai n proper lubrication of an engine, the
engine oil must be mai nt ai ned at an acceptable level.
For gasoline engines, t he acceptable levels are indi-
cated between t he ADD and F U L L marks on oil dip-
stick. For Diesel engines, t he acceptable levels are
indicated between t he L (low) and H (high) mar ks on
oil dipstick.
The oil level should be checked periodically. The
vehicle should be on a level surface. Wait for five
mi nut es after stopping t he engine. For gasoline en-
gines, add oil only when t he level indicated on the
dipstick is at or below t he ADD mark. For Diesel en-
gines, add oil only when the level indicated on the
dipstick is between t he L and H marks. N ever oper-
at e a Di esel engi ne w he n the oi l l evel i s bel ow
t he L ma r k. The distance between the L and H
mar ks represents 1.9L (2 Qts) engine oil.
CAUTI ON : Do not overfill an engi ne crankcase with
oil. Thi s will cause oil aeration and result in a de-
crease in the engi ne oil pressure.
ENGINE OIL CHANGE AND FILTER REPLACEMENT
WA R N I N G : PR O T E C T I V E C L O T HI N G A N D G L O V E S
S H O U L D B E WO R N . E XPO S E D S K I N S H O U L D B E
WA S H E D WI T H S O A P A N D WA T E R T O R E M O V E
U S E D E N G I N E OI L . D O N OT U S E G A S O L I N E , T HI N-
N E R , O R S O L V E N T S T O R E M O V E E N G I N E OI L
F R O M S K I N . D O N OT PO L L U T E . D I S PO S E O F U S E D
E N G I N E OI L PR O PE R L Y .
ENGINE OIL FILTER
All engines are equipped wi t h a throw-away type
oil filter. The same type of filter is recommended
when t he filter is changed.
OIL CHANGE AND FILTER REPLACEMENT
Bring engine up to normal operating t emperat ure.
A more complete drai nage of oil will result.
(1) Remove t he drain hole plug and drain t he en-
gine oil from t he crankcase.
(2) Install t he drain hole plug with a replacement
gasket.
For gasol i ne engi nes, the oil filter shoul d be
repl aced duri ng every second engi ne oil change.
For Diesel engi nes, the oil filter shoul d be re-
pl aced during every engi ne oil change.
(3) Rotate t he oil filter counterclockwise to remove
it.
(4) Clean t he engine cylinder block oil filter boss.
(5) Apply a light coat of new engine oil to t he rub-
ber seal on t he oil filter.
(6) Install and hand t i ght en t he oil filter 1/2 to 3/4
of a t ur n clockwise.
(7) Add new engine oil at t he fill hole location on
top of t he engine cylinder head cover. Wipe off any
spilled oil.
(8) Observe t he oil level on t he dipstick.
CAUTI ON : D o not overfill the engi ne cr ankcase with
oil.
(9) St art t he engine. Observe the oil pressure
gauge or warni ng lamp (as applicable). If t he oil
pressure does not increase, stop t he engine immedi-
ately. Check oil level.
COOLING SYSTEM
WA R N I N G : U S E E XT R E M E C A U T I O N WH E N T HE
E N G I N E I S O PE R A T I N G . D O N OT PU T Y O U R
H A N D S N E A R T HE D R I V E BE L T ( S ) , PU L L E Y S O R
F AN BL AD E . D O N OT S T A N D I N A D I R E C T L I N E
W I TH TH E F AN BL A D E .
INSPECTION SCHEDULE
Determine t he coolant level. Inspect t he cooling
system hoses/clamps after each service interval has
elapsed.
COOLANT LEVEL
It is recommended t hat t he engine coolant level be
inspected at least once a month during periods of hot
weather.
With t he engine at normal operating t emperat ure,
check the coolant level in t he coolant reserve t ank.
The coolant level must be at least above t he ADD
mark. Add coolant to t he coolant reserve t ank only.

COOLANT FREEZ E PROTECTION
Cooling systems contain a 50/50 mi xt ure of anti-
freeze (ethylene glycol) and distilled water. This is
t he recommended coolant mixture.
It is recommended t hat t he degree of coolant pro-
tection be tested every 12 months. If t he coolant is
contaminated or rusty, t he cooling system should be
drained, flushed. Refill with a 50/50 mi xt ure of fresh
coolant. Refer to Group 7Cooling Systems for addi-
tional information.
SYSTEM INSPECTION
WA R N I N G : I F T HE E N G I N E H A S B E E N R E C E N T L Y
O PE R A T E D , D O N O T R E M O V E T HE R A D I A T O R
C A P. T HI S WI L L A V O I D Y O U BE I N G S C A L D E D
WI T H HOT , PR E S S U R I Z E D C O O L A N T .
(1) Test t he radiator cap for proper sealing and op-
eration. Use caution when removing t he radi at or cap
to avoid contact with hot coolant. Place a heavy rag
or towel over t he cap and t ur n to t he first stop. Do
not press down. Pause to allow t he pressure to re-
lease t hrough t he overflow tube. Then press down
and t ur n counterclockwise to remove t he cap.
(2) Inspect t he coolant overflow t ubi ng and t he
connections at t he coolant reserve t ank and at t he
radiator.
(3) Inspect t he entire cooling system for leaks. A
black-light detector can be used as an aid in detect-
ing t he source of coolant leaks.
(4) Inspect t he radiator and air conditioner con-
denser fins for debris, etc.
(5) If necessary, refer to Group 7Cooling Systems
for additional information and service procedures.
RADIATOR CAP
The radi at or cap must be completely tightened to
provide proper pressure. Inspect and test radi at or cap
when cooling system service is performed.
MAIN, FLUSH AND FILL
WA R N I N G : A N T I - F R E E Z E ( E T HY L E N E G L Y C O L ) I S
PO I S O N O U S . K E E P O U T O F T HE R E A C H O F C HI L -
D R E N .
Drain, flush, and fill t he cooling system at t he in-
terval specified in mai nt enance schedule. For proper
service instructions see Group 7, Cooling System.
HOSES AND FITTINGS
It is recommended t hat rubber hoses be periodi-
cally inspected. Inspect all hose fittings for looseness
and corrosion.
ENGINE AIR CLEANER FILTER ELEMENT
MAINTENANCE SCHEDULE
With normal driving conditions, t he engine air
cleaner filter element should be replaced:
Light-Duty Cycl e- af t er each 48 000 km (30,000
miles) interval has elapsed
Heavy-Duty Cycl e- af t er each 38 000 km (24,000
miles) interval has elapsed
When t he vehicle is operated in dusty areas, t he
filter element should be replaced more often.
For Diesel engines, t he air filter canister should be
cleaned at t he same time t he filter is replaced.
SERVICE/REPLACEMENT
(1) Remove t he air cleaner cover.
(2) Remove t he air cleaner filter (Fig. 4).
C A U T I O N : Do not t ap t he filter or i mmerse t he filter
medium in liquid t o remove t rapped debri s.
(3) Clean filter by blowing t he trapped debris from
t he filter with compressed air (Fig. 5). Direct t he air
in t he opposite direction of normal i nt ake air flow.
Keep t he air nozzle at least two inches away from
t he filter.
(4) If t he filter has become partially sat urat ed with
oil, replace t he filter. Inspect t he crankcase ventilat-
ing system for proper operation.
(5) Wash t he air cleaner cover and body with
cleaning solvent. Wipe it dry.
(6) Install t he air cleaner filter element. Attach
t he cover to t he body (Fig. 4).
Fig, 4 Engine Air Oeaner Typical

Fig. 5 Cleaning Filter ElementTypical
DIESEL ENGINE AIR FILTER CANISTER
The Diesel engine air filter should be cleaned after
each interval specified in t he Diesel engine mai nt e-
nance schedule.
When t he vehicle is operated in dusty areas, t he
canister should be cleaned more frequently.
EXHAUST MANIFOLD HEAT CONTROL VALVE
The exhaust manifold heat valve should be ser-
viced after t he interval specified in t he mai nt enance
schedule has elapsed.
SERVICE
The exhaust manifold heat valve is located at t he
left manifold (Fig. 6). Test t he valve for non-re-
stricted movement.
Fig. 6 Manifold Heat Control Valve
Fig. 7 Positive Crankcase Ventilation
SystemTypical
SYSTEM OPERATION
Each PCV system is comprised of an air inlet filter,
a flow-control (PCV) valve, and t he associated hoses.
The air inlet filter is located at t he cylinder head
cover (Fig. 7).
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE DRIVE BELT(S), PULLEYS OR
FAN BLADE. DO NOT STAND IN A DIRECT LINE
WITH THE FAN BLADE.
(1) With t he engine idling, accelerate momen-
tarily. The valve shaft counterweight should move
CLOCKWISE.
(2) If no movement is observed, either t he shaft is
binding or t he t hermost at spring is weak or broken.
(3) If t he t hermost at spring is weak or broken, re-
place t he spring.
(4) Verify t he manifold is COOL. Apply
MOPARRust Penet r ant (or an equivalent product)
to each end of t he valve shaft at t he bearings (Fig.
6).
(5) Allow t he solvent to penet rat e for a few min-
utes. Then, rotate t he valve shaft back and forth un-
til it t ur ns without restriction.
AIR INJECTION SYSTEMS/AI R PUMP
Air injection system/air pump valves and switches
should be periodically tested for proper operation. In-
spect t he check valve t ubi ng for corrosion. Replace it
if excessive corrosion exists.
CRANKCASE VENTILATION SYSTEM
All gasoline engines are equipped with a positive
crankcase ventilation (PCV) system. The PCV sys-
tem prevents emission of residual engine oil vapor
from t he crankcase (Fig. 7).

A crankcase ventilation system must be clean to
provide good operation and durability. Periodic main-
tenance is necessary. Replace t he PCV valve. Re-
move residual combustion deposits from t he hoses
and t hrot t l e body/intake manifold passages.
The PCV valve should be replaced and t he system
should be serviced at t he interval specified in main-
tenance schedule. If a vehicle is routinely used for
short trips, t he crankcase ventilation system could
possibly require more mai nt enance.
CRANKCASE AIR INLET FILTER
Replace or clean, t he air inlet filter at t he i nt erval
specified in mai nt enance schedule.
More frequent PCV system mai nt enance could be
required for:
Vehicles routinely used for short t ri ps
Vehicles routinely involved in stop and go traffic
operation
Vehicles routinely involved in extended periods of
engine idle
MAINTENANCE
Clean and lubricate t he crankcase air inlet filter
according to t he following procedure.
(1) Disconnect t he fresh air hose from t he port on
t he crankcase air inlet filter housing (Fig. 8).
(2) Remove t he air filter housing from t he cylinder
head cover (Fig. 8). Clean t he filter in kerosene or a
similar solvent.
(3) Lubricate t he filter by i nvert i ng t he housing
and filling it with SAE 30 viscosity engine oil.
(4) Insert t he air filter housing nipple in t he cylin-
der head cover grommet. Connect t he fresh air hose
to t he upper port (Fig. 8).
J9000-52
Fig. 8 Crankcase Air Inlet Filter
THROTTLE CONTROL LINKAGE
Transmission linkage pivot pin areas (Fig. 9),
should be serviced. The areas lubricated every second
oil change with a multi-purpose lubricant (NLGI GC-
LB).
PIVOT AREAS
Fig. 9 Transmission Linkage Pivot Areas
FUEL SYSTEM
INSPECTION
The fuel system filler cap, nozzle, tubes, hoses, and
connections should be inspected periodically.
FUEL FILTER
The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diag-
nosis and service procedures refer to Group 14, Fuel
System.
GASOLINE ENGINE FUEL REQUIREMENTS
All gasoline engines require fuel t hat has a mini-
mum octane rat i ng of 87 determined by t he (R +
M)/2 calculation method.
The use of a brand of unleaded gasoline t hat con-
t ai ns additives is recommended. Gasoline with addi-
tives will improve fuel economy and reduce
emissions.
ALCOHOL/GASOLINE BLENDS
Many brands of blended unleaded gasoline a m now
available.
Unleaded gasoline is blended with oxygenated-type
fuels to produce a clean air gasoline in many areas.
The use of t hi s type of blended fuel is recommended.
ETH ANOLUnleaded gasoline and ethanol
blended fuels are a mi xt ure of 10 percent ethanol
and 90 percent unleaded gasoline. This is an accept-
able blend of fuel.
MTBE MTBE blended fuels are a mi xt ure of un-
leaded gasoline and up to 15 percent MTBE (Methyl
Tertiary Butyl Ether). Unleaded gasoline blended
with MTBE is acceptable.

ETBE This fuel is a mi xt ure of unleaded gasoline
and up to 17 percent ETBE (Ethyl Tertiary Butyl
Ether). Unleaded gasoline blended wi t h ETBE is ac-
ceptable.
METHANOLDo not use unleaded gasoline
blended with methanol. The use of t hi s type of alco-
hol can result in engine performance and damage to
critical components. Engi ne probl ems that result
from the use of methanol possi bl y will not be
covered by the new vehi cl e warranty.
Certain brands of unleaded gasoline contain a per-
centage of unidentified alcohol. These types of un-
leaded gasoline are not recommended.
ADDITIVES MIXED WITH GASOLINE
Use of fuel system cleaning additives should be
avoided. Many of these solutions could contain highly
active solvents. This type of solvent can be harmful
to t he gasket and di aphragm mat eri al within t he
fuel system.
DIESEL ENGINE FUEL REQUIREMENTS
All Diesel engines normally can use number 2D
Diesel fuel for most year-round operations. A fuel
conforming to ASTM Specification D-975 is recom-
mended. For extreme cold-weather operation (below
-18C/0F), or for prolonged cold-climate operation ei-
ther:
Use No. ID fuel, or
Add an equal quant i t y of kerosene to No. 2D fuel
(a 50/50 mixture).
Both methods provide protection against fuel gel-
ling and waxing.
Diesel fuel seldom is without water contamination.
To help prevent fuel system malfunctions, drain all
accumulated water from t he separators periodically.
VACUUM OPERATED, EMISSION CONTROL
COMPONENTS
The following emission controls should be replaced
at t he interval specified in the maintenance sched-
ule:
Bi-level purge check valves
Delay valves
Heated air t emperat ure sensor (HATS)
Air cleaner vacuum motors
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Replace t he EGR valve and tube, and clean the
passages at t he interval specified in maintenance
schedule. If necessary, refer to Group 25Emission
Control Systems for additional information.
OXYGEN (0
2
) SENSOR
Replace t he 0
2
sensor at t he interval specified in
mai nt enance schedule.
IGNITION CABLES, DISTRIBUTOR CAP AND
ROTOR
Replace t he ignition cables, distributor cap, and ro-
tor at t he i nt erval specified in mai nt enance schedule.
Inspect t he distributor for excessive wear and re-
place, as necessary. Refer to Group 8DIgnition Sys-
t ems for additional information.
IGNITION TIMING
Test and adjust, if necessary, t he ignition t i mi ng at
the interval specified in mai nt enance schedule. Refer
to t he specifications listed on t he engine Emission
Control Information label. Refer to Group 8DIgni-
tion Systems and to Group 25Emission Control
Systems for additional service information.
SPARK PLUGS
Replace t he spark plugs at t he interval specified in
mai nt enance schedule. Refer to t he Spark Plugs
chart below and to Group 8DIgnition Systems for
additional service information.
SPARK PLUGS
E N GI N E S PA R K
PL U G
S PA R K
PL UG G A P
T OR QUE
3.9L
5.2L
5.9L
RN12YC
R N 12 YC
RN12YC
0.9 mm (0.035 in.)
0.9 mm (0.035 in.)
0.9 mm (0.035 in.)
41 N*m (30 ft. lb.)
41 NVn (30 ft. lb.)
41 N*m (30 ft. lb.)
J9100-17
BATTERY
Replace bat t ery at interval specified in mai nt e-
nance schedule.

SERVICE INFORMATION
All vehicles are equipped with a maintenance-free
(MF) bat t ery when shipped from t he factory (Fig. 10).
A maintenance-free bat t ery does not have removable
cell caps and does not require additional water.
Each MF bat t ery has a visual bat t ery condition in-
dicator (Fig. 11). When an adequate bat t ery charge
exists, t he indicator will have a GREEN dot. When
bat t ery charging is necessary, t he indicator will be
dark. When t he indicator is light brown colored or
yellow, t he bat t ery should be replaced.
INSPECTION
WA R N I N G ; WE A R S A F E T Y G L A S S E S , R U B B E R
G L O V E S A N D PR O T E C T I V E C L O T HI N G WH E N S E R -
V I C I N G A BA T T E R Y . T HE BA T T E R Y E L E C T R O L Y T E
C O N T A I N S S U L F U R I C A C I D A N D WI L L C A U S E
H A R M I F I T C O N T A C T S S K I N , E Y E S O R C L O T HI N G .
I F S U L F U R I C A C I D C O N T A C T S S K I N O R E Y E S , G E T
I M M E D I A T E M E D I C A L A T T E N T I O N . D O N O T S M O K E
I N T HE V I C I NI T Y O F A BA T T E R Y . K E E P O PE N
F L A M E S A N D S P A R K S A WA Y F R O M BA T T E R Y
F I L L E R C A P S B E C A U S E E XPL O S I V E G A S I S A L -
WA Y S PR E S E N T .
Bat t ery mai nt enance should be completed before
t he beginning of every winter season.
Use t he following bat t ery mai nt enance and inspec-
tion procedure.
(1) Disconnect t he bat t ery negative cable and t hen
t he positive cable.
(2) Clean t he bat t ery cables and t ermi nal posts
wi t h a wire brush and a bat t ery t ermi nal cleaner.
(3) Remove t he bat t ery holddown strap. Clean t he
bat t ery t r ay wi t h a solution of baki ng soda and wa-
ter. Rinse and dry t he bat t ery t ray.
(4) Position t he bat t ery in t he t ray and install t he
holddown st rap. Do not over-tighten t he nut s.
(5) Connect t he bat t ery positive cable and t hen t he
negative cable to t he bat t ery.
(6) Apply a small amount of chassis lubricant (or
an equivalent protective coating) to t he cable t ermi -
nals.
RUBBER/PLASTIC COMPONENTS
INSPECTION
Components should be inspected at t he same t i me
as scheduled underhood mai nt enance is conducted.
Rubber/plastic components should be replaced imme-
diately if t here is any evidence of wear.
Inspect t he exterior surface of rubber hoses and ny-
lon t ubi ng for evidence of heat damage. The rubber
hose and nylon t ubi ng located close to an exhaust
manifold should be given special attention. Verify
t he nylon t ubi ng located at these areas has not col-
lapsed.
INCREASED
ELECTROUTE
CAPACITY
SEALED
VENT CAPS
TEST
INDICATOR
ENVELOPE
SEPARATORS
BATTERY
HOLD DOWN
RK92
Fig. 10 Maintenance-Free (MF) Battery
O.K. TO
JUMP
START
BATTERY
C O N D I T I O N
I N D I C A T O R
J9100-26
D A R K E N E D I N D I C A T OR WI T H G R E E N DOT
BA T T E R Y C H A R G E OK '
F L U I D L E V E L OK
D A R K E N E D I N D I C A T OR N O G R E E N DOT
BAT T E R Y C H A R G E L OW
F L U I D L E V E L O K
L I G HT O R BR I G H T I N D I C A T O R
BAT T E R Y C H A R G E U N K N O WN
F L U I D uEv' EL L OW
( C H A R G E MAY S T I L L BE
S U F F I C I E N T TO START YO U R C A R )
Fig. 11 Battery Condition Indicator
Inspect all t he hose connections. Verify t hey are se-
cure and t here is no fluid leakage.
ENGINE MOUNTS
Inspect t he rubber in t he engine mount s for exces-
sive wear. Slight wear at t he ends will not affect t he
functioning of an engine mount. If excessive engine
movement is detected, t he engine mount(s) should be
replaced.
DRIVE BELTS
Replace t he drive belt(s) and adjust t he drive ten-
sion at t he interval specified in mai nt enance sched-
ule. If necessary, refer to Group 7Cooling Systems.

ROUTINE INSPECTION
It is recommended t hat t he drive belt(s) be rou-
tinely inspected for cracks, fraying and excessive
wear. Replace as necessary.
EXHAUST SYSTEM
An exhaust system must be properly aligned to
prevent stress, leakage, and vehicle body contact.
Inspect the exhaust system at t he interval specified
in maintenance schedule.
INSPECTION
Inspect for cracked or loose joints, corrosion dam-
age, and worn or broken hangers. Replace all compo-
nent s t hat are damaged. Do not at t empt repair. Also,
inspect for t he following conditions and correct as
necessary:
Exhaust system leaks, misalignment
Contact with body panels or the frame
Catalytic converter bulging or excessive heat dam-
age
C A U T I O N : A catalytic converter will become con-
taminated if leaded gasol i ne i s burned in the en-
gi ne. If thi s occur s, the complete converter must be
replaced.
AIR-CONDITIONER COMPRESSOR
LUBRICANT AND REFRIGERANT
The lubricant level in t he compressor should be
checked if t here are indications t hat oil was lost.
Loss of lubricating oil usually accompanies a loss of
refrigerant. The presence of bubbles in sight glass in-
dicates t hat loss of refrigerant has occurred.
For additional information involving t he A/C sys-
tem, refer to Group 24Heater And Air Condition-
ing.
D R I V E T R A I N
INDEX
page
Ax l es 25
Clutch and Brake Pedal Bushi ngs . . . . . . . . . . . . 22
Clutch Master Cylinder 22
Drive Shafts 26
page
Front Ax le U-Joint and Pivot Beari ngs . . . . . . . . . 26
Transfer Case (4WD Vehicles) . . . . . . . . . . 24
Transmi ssi ons . 22
CLUTCH AND BRAKE PEDAL
If t he clutch and brake pedal mechanism squeaks,
t he pivot bushings should be lubricated (Fig. 1). Use
MOPARMulti-Purpose Lubricant, or an equivalent.
CLUTCH MASTER CYLINDER
HYDRAULIC FLUID LEVEL
The clutch mast er cylinder fluid level should be in-
spected at t he same t i me as underhood mai nt enance
is conducted. The fluid level should be at indicating
line (Fig. 1). If t he fluid level is low, locate and cor-
rect any possible leaks. Fill t he reservoir with clean,
moisture-free brake fluid.
FLUID SPECIFICATION
The only fluid recommended for use is
MOPARBrake Fluid, or an equivalent product. The
SLAVE
CYLINDER
CLUTCH
HOUSI NG
23 Nm (200 I N. LBS.)
product is identified as SAE J-1703 or DOT 3 flu-
id.Do not use any other type of fluid.
C A U T I O N : Never use reclaimed brake fluid or fluid
from an unseal ed container. D o not use fluid that
has been opened and allowed to st and for an ex-
tended length of time.
TRANSMISSIONS
SPECIAL ADDITIVES
Chrysler Motors does not recommend t he addition
of any special additives to a transmission. Black
light detection dye can be used as an aid in detecting
fluid leaks.
RESERVOIR
STUD
VIEW I N DIRECTION
GtAKBQWZ
LUBRICATE
CLUTCH
PEDAL
23 N
#
m
(200 I N. LBS.)
5 Nm
(40 I N. LBS
MASTER
CYLINDER
COTTER PIN
NUT 23 N*m (200 I N. LBS.)
WAVE WASHER
RETAINING RI NG
BRAKE PEDAL
VIEW I N DIRECTION FLAT WASHER
OF ARROW Y RR06F1
Fig. 1 Clutch & Brake Pedal Mechanism

GEAR SHIFTER BOOTS
Inspect t he shifter boots periodically for stone and
heat damage. Replace, if necessary.
SEVERE DRIVING CONDITIONS
The interval between t he transmission drai n and
refill mai nt enance should be decreased to:
NV4500 manual transmissionevery 29 000 km
(18,000 miles)
Automatic transmissionevery 19 000 km (12,000
miles)
A severe driving condition includes:
Extended operation with heavy cargo loads
Driving in deep mud or snow
Off-road operation (4WD)
Trailer towing
Operation as a commercial vehicle
Snow plowing
MANUAL TRANSMISSIONS
INSPECTION/LUBE OIL LEVEL
The transmission should be checked for l eaks when
other service is necessary under t he vehicle. To check
the lube oil level, remove the fill hole plug (Fig. 2 ).
If t he level is below t he bottom of t he fill hole, raise
the level to the bottom of the fill hole with:
Castrol Syntorq for NV4500 transmissions
SAE 5W-30 engine oil (API Service SG, SG/CD or
SG/CE) for Getrag 360 transmissions.
Fig. 2 NV4500 Manual Transmission
DRAIN AND FILL
The NV4500 transmission fluid should be changed
according to t he intervals listed in t he Manual
TransmissionDrain & Refill Intervals chart below.
Also, refer to t he Fluid Capacities chart.
AUTOMATIC TRANSMISSIONS
FLUID LEWEL
It is recommended t hat t he fluid (ATF) level in au-
tomatic transmissions be checked while involved
with other underhood maintenance.
Vehi cl e operati on wi th an incorrect ATF level
will greatl y reduce the life of the transmission.
Fig. 3 Getrag 360 Manual Transmission
MANUAL TRANSMISSION-DRAIN & REFILL
INTERVALS
Normal
Service
Light Duty Cycle
60 000 km 37,500 miles
Heavy Duty Cycle
58 000 km 36,000 miles
Severe
Service
29 000 km 18,000 miles
J9000-43
The condition of t he ATF also should be deter-
mined. If t he ATF is dark in color and has a strong
odor, t he fluid should be changed. Also t he filter
should be replaced and the bands adjusted.
The following procedure must be used to check the
automatic transmission fluid (ATF) level.
(1) Position t he vehicle on level ground.
(2) Operate t he engine at idle speed.
(3) Apply t he parki ng brake.
(4) Place t he gear selector in N (neutral).
(5) Remove t he dipstick from t he tube. Wipe it
clean and determine if the ATF is hot or warm.
Hot ATF has a temperature of approxi matel y
82C (180F). Warm ATF i s when its temperature
is be t we e n 29-52C (85-125F).
(6) Wipe t he dipstick clean and completely insert it
into t he tube. Remove the dipstick from t he t ube and
observe the ATF level.
(7) If the ATF is hot, t he level should be in t he
crosshatched area t hat is marked OK.
(8) If the ATF is warm, t he level should be be-
tween t he two dimples.

C A U T I O N : D o not overfill the t r ansmi ssi on.
(9) Adjust t he level of t he ATF accordingly.
It is i mpor t a nt to us e t he cor r ect fluid in a n
automatic t r ans mi s s i on. MOPARATF PLUS
(ATF Type 7176) shoul d be us ed. Dexron II
ATF can be used if the recommended fluid is not
available,
(10) Insert t he dipstick into t he tube.
DRAI N, FILTER CHANGE, BAND ADJUSTMENT AND REFILL
The chart below lists t he intervals at which t he
transmission should be serviced. Also, refer to t he
Fluid Capacities chart for fill capacity.
AUTOMATIC TRANSMISSION SERVICE IN-
TERVALS
N or mal
Usage
Light Duty Cycle
60 000 km 37,500 miles
Heavy Duty Cycle
38 000 km 24,000 miles
S evere
U sage
19 000 km 12,000 miles
J9100-19
It is very i mportant to use the correct fluid in
an automatic transmi ssi on. MOPARATF PLUS
(ATF Type 7176) shoul d be used. An equi val ent
Dexron II ATF coul d be used onl y if the recom-
mended fluid is not available.
The torque converter does not have a drai n plug.
No at t empt should be made to drai n t he converter.
Refer to Group 21 Transmissions for transmission
drai n and refill procedures.
TRANSFER CASE (4WD VEHICLES)
INSPECTION
The NP205 and NP241 transfer cases fluid level
should be checked whenever mai nt enance is neces-
sary under t he vehicle.
FLUID LEVEL
The vehi cl e must be level when the fluid level
is checked.
The transfer case drai n fill hole plugs are located
at t he rear of t he housing (Figs. 4 and 5).
Determine t he transfer case fluid level according to
t he following procedure.
(1) Raise and support t he vehicle.
(2) Remove t he fill hole plug (Figs. 4 and 5) from
t he transfer case. The fluid level should be at t he
bottom edge of t he fill hole. The level can be slightly
below t he bottom edge of t he fill hole if t he fluid is
cold.
(3) If t he level is not acceptable, raise t he fluid
level to t he bottom edge of t he fill hole with:
MOPARATF PLUS or an equivalent Dexron II
ATF for NP241 transfer case
Multi-purpose gear oil (API GL-5) or engine oil
(API SG, SG/CD O R SG/CE) for NP205 transfer
cases.
Add fluid in small amounts to raise the level.
(4) Install t he fill hole plug (Figs. 4 and 5).
Tighten t he fill hole plug to 27 N-m (20 ft-lbs)
torque.
(5) Remove t he support and lower t he vehicle.
Fig. 4 HP241 Transfer Case
Fig. 5 NP205 Transfer Case
FLUID DRAIN AND REFILL
The transfer case fluid should be changed every 60
000 km (37,500 miles). For vehicles subject to t he
HEAVY DUTY CYCLE Maintenance Schedule, a 58
000 km (36,000 miles) interval is recommended.
(2) Remove t he fill hole plug (Figs. 4 and 5) from
t he transfer case.
(3) Place an appropriate container under t he t rans-
fer case drain hole plug (Figs. 4 and 5).
(4) Remove t he drai n hole plug. Drain t he fluid
from t he transfer case into t he container.

CAUTI ON : D o not overtighten the drain and fill hole
plugs. Over- ti ghteni ng can stri p the hol e t hr eads
and/ or crack the al umi num housi ng.
(5) Install t he drain hole plug (Figs. 4 and 5) in
t he transfer case. Tighten t he drai n hole plug to 27
N*m (20 ft-lbs) torque.
(6) Fill t he transfer case to t he bottom edge of t he
fill hole (Figs. 4 and 5) with:
ATF for NP241 transfer cases
(API SG, SG/CD or SG/CE) for NP205 transfer cases.
(7) Install the fill hole plug (Figs. 4 and 5) in t he
transfer case. Tighten t he plug to 27 Nm (20 ft-lbs)
torque.
(8) Remove t he support and lower t he vehicle.
FLUID SPECIFICATION
ATF for NP241 transfer cases
(API SG, SG/CD or SG/CE) for NP205 transfer cases
NP20I MULTI-PURPOSE GEAR OIL/ENGINE OIL SELECTION
MULTI-PURPOSE GEAR OI L- i f t he anticipated
mi ni mum t emperat ure will:
Be above 32C ( 90F) - use SAE 140, API GL-5;
Decrease to as low as -23C (-10F)-use SAE 90,
API GL-5; and
Be below -23C (-10F)-use SAE 80, API GL-5.
ENGINE OILif t he anticipated mi ni mum tem-
perat ure will be:
Above 0C (32F)-use SAE 50, API SG, SG/CD or
SG/CE;
Below 0C ( 32F) - use SAE 30, API SG, SG/CD or
SG/CE.
SHIFT MECHANISM-NP241 AND NP205
The transfer case shift mechanism should be
cleaned and lubricated as necessary.
Lubricate t he pivot, t he sliding contact areas and
t he shift linkage pivot ends wi t h light-weight engine
oil (Figs. 6 and 7).
AX LES
INSPECTION/LUBRICANT LEVEL
For normal vehicle operation, periodic axle lubri-
cant level checks are not necessary. The exterior of
t he axle housing should be inspected for leakage.
Check the lubricant level to confirm t he leakage.
LUBRICANT LEVEL
(1) Raise t he vehicle wi t h an axle or wheel type
hoist. Support t he vehicle.
(2) The rear axle differential housings have a rub-
ber, PRESS-IN type fill plug (Fig. 8). Pry t he fill
TRANSMISSION
ASSEMBLY
GEARSHIFT
MECHANISM
TRANSFER CASE
SCREWS (2)
50 FT. LBS.
(68 N*m)
CLAMP
SHIFT ROD
SCREW
80 I N. LBS.
(9 N*m)
RP1091
Fig. 6 Shift Mechanism LubricationNP241 Transfer
Case
Fig.
RY682
7 Shift Mechanism LubricationNP205 Transfer
Case
plug from t he differential housing. The front axle
(4WD vehicles)*differential housings have a thread-
ed-type fill plug (Fig. 9). Un-t hread the fill plug from
t he differential housing.
(3) The lubricant level should be within 12 mm
(1/2 in) of t he fill hole for t he 8.25 and 9.25 rear ax-
les. The lubricant level should be between 12mm (1/2
in) and 24mm (1 in.) of t he fill hole for t he Dana ax-
les.
(4) If necessary, add lubricant to raise t he level to
t he acceptable position.
(5) Install t he fill hole plug in the differential
housing (Figs. 8 and 9).
DRAIN AND REFILL
Periodic axle lubricant change for normal vehicle
operation is not necessary. Refer to the chart below-

"PRESS-IN" TYPE
FILLER PLUG
RK43
t
Fig. 8 Rear Axle Fill Plug LocationTypical
Fig. 9 Front Axle (4 WD) Fill Plug Location
.All axl es contai n SAE 80W-90 multi-purpose
type hypoi d gear lubricant when del i vered from
the factory.
Use the same mai ntenance procedures for rear
axl es equi pped wi th a limited-slip differential.
C A U T I O N : Water contami nated gear lubricant will
result in possi bl e failure of the axle differential
component s. Operation of the vehicle in water, will
require that:
The l ubri cant be drained
The differential housing flushed (except limited-
slip differentials)
The differential refilled wi t h fresh lubricant
LUBRICANT VISCOSITIES FOR ANTICIPATED
TEMPERATURE RANGES
Anticipated Temp. Range Recommended SAE Grade
Above 32C SAi 140
(90F) SAE SOW-140 (90F)
S \ E 85W-140
- 23C to 32C SAE 90
(-10F to 90F) SAE 80W-90 (-10F to 90F)
SAE 80W-140
oAE 85W-140
(ielow -23C SAE 75W
(-10F) SAE 75W-90 (-10F)
SAE 80W
SAE 80W-I40
J9000-56
LUBRICANT SPECIFICA TION
A multi-purpose lubricant should be used in all ax-
les with either a st andard or a limited-slip differen-
tial. A friction additive must also be used in 8.25 and
9.25 limited-slip differentials. The use of a friction
modifier is helpful in preventing axle chatter. Dana
axles do not require any friction additive.
FRONT AXLE U-JOINT AND PIVOT BEARINGS
MODEL W350 (WITH DANA 60 AXLE)
For vehicles subject to the LIGHT DUTY CYCLE
Maintenance Schedule, lubricate t he pivot bearings
at each 12 000 km (7,500 miles) interval. For vehi-
cles subject to t he HEAVY DUTY CYCLE Mainte-
nance Schedule, lubricate t he pivot bearings at each
9 600 km (6,000 miles) interval.
LUBRICATION SPECIFICATION
Lubricate t he pivot bearings with a multi-purpose
lubricant, grade 2 EP.
Do not use hi gh pressure to lubricate the front
axl e uni versal drive joints.
MODELS WiOO, W150, W250 (WITH DANA 44
AXLE)
The front axle universal joint and pivot bearings
are permanent l y lubricated and normally do not re-
quire service.
DRIVE SHAFTS
SLIP-YOKE LUBRICATION
When equipped with lube fittings, it is recom-
mended t hat t he slip-yoke splines be lubricated every
9 600 km (6,000 miles). For severe usage, lubricate
t he splines every 1 600 km (1,000 miles).
The method described below will ensure complete
lubrication of t he slip-yoke splines.
(1) Clean t he Zerk type lubrication fittings.
(2) Use a lubricant dispenser to force lubricant
into t he slip yoke fittings.

(3) Continue lubricating unt i l it appears at t he
pressure relief hole in t he expansion plug located at
t he slip-yoke end.
(4) Cover t he pressure relief hole with a finger.
Continue to force lubricant into t he fitting unt i l it
appears at t he slip-yoke seal.
U-JOINT INSPECTION
U-joint seals should be inspected for damage when-
ever t he vehicle is serviced for other reasons (Fig.
10). If ext ernal leaks or damage exists, t he U-joint
coupler should be replaced.
Fig. 10 U-Joint Seal Inspection
U-JOINT/CV-JOINT LUBRICATION
Lubrication of u-joint couplers t hat are not
equipped with lube (Zerk) fittings is not necessary.
Replacement U-joints are equipped with lube fittings.
If installed, lubricate t hem according to t he informa-
tion provided below.
Lubricate t he U-joint and CV-joints every 12 000
km (7,500 miles) for LIGHT DUTY CYCLE vehicles.
For HEAVY DUTY CYCLE vehicles, t he couplers
should be lubricated every 9 600 km (6,000 miles).
Refer to Figures 11 and 12. If t he vehicle is operated
in water, t he U-joint/CV-joint couplers should be lu-
bricated daily.
If a vehi cl e, is used i n a severe driving condi-
tion, lubricate t he U-joint/CV-joints every 4 800
km (3,000 miles). Lubricate Ram Truck Model
W350 U-joint/CV-joint coupl ers every 1 600 k m
(1,000 miles).
A severe driving condition includes:
GREASE FITTINGS RK40
Fig. 11 Rear Drive Shaft U-Joint
Fig. 12 Front Drive Shaft CV-Joint (4WD)
Off-road driving
Driving in deep mud or snow
When 1/3 or more of t he vehicle operation involves
driving with a full-load.
LUBRICANT SPECIFICATION
Drive shaft slip yokes and U-joint/CV-joint couplers
should be lubricated with a NLGI GC-LB lubricant.
The U-joints/CV-joint couplers should be lubricated
with MOPARMultipurpose Lubricant, NLGI GC-
LB).

CHASSIS AND BODY
page
Body Component Mechani sms 32
Front Suspensi on Ball Joints 28
Front Wheel Beari ngs 29
H eadl amps 32
Lower and Upper Suspensi on Arm Bushi ngs . . . . 30
Manual Steering Gear 28
STEERING LINKAGE
INSPECTION
When a vehicle is raised for mai nt enance under
t he vehicle, all steering components should be
checked.
LUBRICATION SCHEDULE
The steering linkage is lubricated with a chassis
lubricant. However, it is recommended t hat t he link-
age be inspected and lubricated after each:
24 000 km (15,000 miles) interval or every 6
months, for 2WD vehicles subject to t he LIGHT
DUTY CYCLE Mai nt enance Schedule
9 600 km (6,000 miles) interval or every 6 months,
for 2WD vehicles subject to t he HEAVY DUTY CY-
CLE Mai nt enance Schedule
12 000 km (7,500 miles) interval or every 6
months, for 4WD vehicles subject to t he LIGHT
DUTY CYCLE Mai nt enance Schedule
9 600 km (6,000 miles) interval or every 6 months,
for 4WD vehicles subject to t he HEAVY DUTY CY-
CLE Mai nt enance Schedule.
LUBRICATION
(1) Inspect t he steering linkage for looseness and
excessive wear.
(2) Replace, all rupt ured seals and damaged steer-
ing linkage components. Damaged seals should be re-
placed to prevent leakage and contamination of t he
lubricant.
C A U T I O N : U se care to prevent lubricant from con-
tacting the brake rotors.
(3) Lubricate t he steering linkage:
Clean t he Zerk type lubrication fittings on t he tie-
rod and center link ball-stud ends
Lubricate t he ball studs wi t h MOPARMulti-Mile-
age Lubricant
Wipe t he excess lubricant from t he exterior sur-
faces of t he ball joints
page
Power Brake System 30
Power Steering System . . 29
Rear Wheel Bearings 30
Speedometer Cabl e 33
Steering Linkage 28
Tires 32
FRONT SUSPENSION BALL JOINTS
INSPECTION
When a vehicle is raised for lubrication/general
mai nt enance, t he ball joints should be inspected.
LUBRICATION SCHEDULE
The front suspension ball joints are lubricated dur-
ing manufacture with a long-life chassis lubricant.
However, it is recommended t hat t he ball joints be
inspected and t he studs lubricated:
At each 36 000 km (22,500 miles) interval or every
2 years, for vehicles subject to t he LIGHT DUTY CY-
CLE Maintenance Schedule
At each 9 600 km (6,000 miles) interval or every 2
years, for vehicles subject to t he HEAVY DUTY CY-
CLE Maintenance Schedule.
4WD vehi cl es that are frequently dri ven off-
road shoul d be lubricated at every engi ne oil
change.
LUBRICATION
(1) Inspect t he front suspension. Exami ne t he ball
studs for looseness and excessive wear.
(2) Replace all torn ball-stud seals and damaged
ball joints. Damaged seals should be replaced to pre-
vent leakage and contamination.
C A U T I O N : U se care to prevent lubricant from con-
tacting the brake rotors.
(3) Lubricate t he ball studs:
Clean t he Zerk type lubrication fittings on t he
ball-stud ends
Lubricate t he ball studs with MOPARMulti-Mile-
age Lubricant
Wipe t he excess lubricant from t he exterior sur-
faces of t he ball joints
MANUAL STEERING GEAR
LUBRICATION
Manual steering gears are permanent l y lubricated
duri ng manufacture. Periodic lubrication is not nec-
essary.

POWER STEERING SYSTEM
SERVICE SCHEDULE
FLUID LEWEL
WA R N I N G . T HE PO WE R S T E E R I N G F L UI D L E V E L
S H O U L D A L WA Y S B E C H E C K E D WITH T HE E N -
G I N E O F F TO PR E V E N T PE R S O N A L I N J U R Y.
The power steering fluid should be checked when-
ever t he engine is being serviced for other reasons.
Clean t he outside of t he cap before removing. The
fluid should be at t he proper level indicated on cap
dipstick (Fig. 1).
Fig. 1 Power Steering Reservoir & CapTypical
The reservoir fluid level can be determined wi t h
the fluid either hot or cold. If t he fluid level is below
the FULL HOT or FULL COLD marks on the dip-
stick, add power steering fluid. The dipstick is at-
tached to t he reservoir cap (Fig. 1).
FLUID SPECIFICATION
MOPAR
0 3 )
Power Steering Fluid is highly recom-
mended.
FRONT WHEEL BEARINGS
INSPECTION/LUBRICATION SCHEDULE
2WD VEHICLES
It is recommended t hat 2WD front wheel bearings
be inspected for proper lubrication whenever t he
brake rotors are removed or at least:
At each 39 000 km (24,000 miles) interval for ve-
hicles subject to t he LIGHT DUTY CYCLE Mainte-
nance Schedule
hicles subject to t he HEAVY DUTY CYCLE Mainte-
nance Schedule
The beari ngs shoul d be cl eaned and re-packed
with a hi gh temperature, multi-purpose EP lu-
bricant.
4WD VEHICLES
It is recommended t hat 4WD front wheel bearings
be inspected for proper lubrication whenever t he
brake rotors are removed or at least:
hicles subject to the LIGHT DUTY CYCLE Mainte-
nance Schedule
hicles subject to the HEAVY DUTY CYCLE Mainte-
nance Schedule
For vehi cl es used for extensi ve off-road, 4WD
operation, the front wheel beari ngs shoul d be in-
spected every 1 600 km (1,000 miles).
The beari ngs shoul d be cl eaned and re-packed
wi th a hi gh temperature, multi-purpose EP lu-
bricant whenever the disc brake rotors are re-
surfaced.
INSPECTION
If t he lubricant:
Is not sufficient
Contaminated with foreign particles
Appears dry or has been contaminated with wat er
to produce a milky appearance, t he bearings should
be cleaned and re-packed with lubricant.
C A U T I O N : D o not add lubricant to the wheel bear-
i ngs. R e- pack completely. Mi xi ng of different t ypes
of lubricants in wheel beari ngs shoul d be avoi ded.
T hi s coul d possi bl y result in excessi ve thinning and
l eakage of the lubricant.
LUBRICATION
(1) Discard t he original seal.
(2) Clean t he original lubricant from t he bearings
and from t he hub cavity (Figs. 2 and 3).
(3) Inspect t he beari ng rollers for indications of
pitting. Light bearing roller discoloration is consid-
ered normal. A wheel bearing must be replaced if
any serious damage exists.
(4) Re-pack t he bearings with a high t emperat ure,
multi-purpose NLGI GC-LB lubricant. The use of a
bearing packer is recommended. A small amount of
fresh lubricant also should be added to t he hub cav-
ity.
BEARING INSTALLA TION/ADJUSTMENT
(1) Install t he hub/rotor (with i nner beari ng and
seal) on steering knuckle spindle.
(2) Install t he outer bearing, t he t hrust washer
and t he nut.
(3) Tighten wheel bearing nut to 27-34 N^m (240-
300 in. lbs.) torque while rot at i ng hub/rotor. This
will seat t he bearings.
(4) Loosen t he nut 1/4 of-a-turn (90), t hen t i ght en
it finger-tight.
0 - 30 LUBRICATION AND MAINTENANCE -
Fig. 2 Front Wheel Bearing2WD Vehicles
Fig. 3 Front Wheel & Spindle Bearings4WD
Vehicles
(5) Position nut lock on t he nut wi t h one pair of
slots aligned with t he cotter pin hole. Install t he cot-
t er pin.
(6) Install t he dust cap and wheel/tire. Tighten t he
wheel lug nut s to 115 N*m (85 ft. lbs.) torque. Install
t he wheel cover.
LUBRICANT SPECIFICATION
Use a high t emperat ure, multi-purpose NLGI
GC-LB lubricant (MOPARWheel Beari ng Lubricant,
or an equivalent lubricant).
REAR WHEEL BEARINGS
LUBRICATION
DANA 60 AND 70 AXLES
The rear wheel bearings for vehicles equipped with
a Dana 60 or 70 axle should be cleaned and re-
packed whenever t he rear brakes are serviced. Refer
to Group 3Rear Axles for t he service procedure.
CHRYSLER AXLES ,
Vehicles equipped with 8 3/8-inch and 9 1/4-inch
axles have axle shaft bearings instead of wheel bear-
ings. These bearings are lubricated by t he axle hous-
ing sump.
LOWER AND UPPER SUSPENSION ARM
BUSHINGS
INSPECTION SCHEDULE
The lower and upper suspension arm bushings
should be inspected each time t he underside of t he
vehicle is serviced.
INSPECTION
The lower suspension ar m bushings can be visually
inspected by rai si ng t he vehicle on a hoist and in-
specting from underneat h. The upper suspension ar m
bushings can be inspected after removing t he front
wheels. If failure exists, replace t he bushing (refer to
Group 2Front Suspension for t he proper proce-
dures).
The suspensi on arm bushi ngs never shoul d be
lubricated.
GUIDELINES
(1) Faul t y bushings are detected by t he bushi ng
being off-center in relation to t he outer sleeve.
(2) Total failure is evident by excessive movement
within t he bushing.
(3) Small cracks in t he outer, non-confined rubber
does not indicate failure of t he rubber. '
POWER BRAKE SYSTEM
Vehicles are equipped with power disc brakes at
t he front wheels and drum brakes at t he rear wheels.
MASTER CYLINDER
FLUID LEVEL INSPECTION
The brake fluid level should be inspected at t he
same t i me as other underhood service is done (Fig.
4). If necessary, add fluid to raise t he level to t he
bottom of t he split rings. With disc-brakes, t he fluid
level can be expected to lower as t he brake pads
wear. However, a low fluid level can also be caused
by a leak, and repai r will t hen be necessary.

Fig. 4 Master Cylinder Fluid Level
FLUID SPECIFICATION
Power brake systems require MOP ARHeavy-D uty
Brake Fluid, or an equivalent product identified with
FMVSS No. 116, DOT-3 and SAE J-1703 St andard
designations.
Use fresh brake fluid only when adding fluid to t he
reservoir. Never use reclaimed fluid, fluid t hat does
not conform to t he DOT/SAE Standards, or fluid from
a container t hat has been left open.
C A U T I O N : U se of a brake fluid that has a lower ini-
tial boiling point then specified by F M V S S N o. 116
or D O T 3 coul d result in sudden brake failure dur-
ing hard, prol onged braking.
C A U T I O N : D o not allow petroleum base fl ui ds to
contaminate the brake fluid. S eal damage will re-
sult.
BRAKE SYSTEM INSPECTION
(1) Inspect t he brake pads and linings for excessive
wear, cracks and broken rivets.
(2) Inspect brake pads and linings for contamina-
tion with brake fluid, axle lubricant and/or other flu-
ids.
(3) Replace the front brake pads and t he rear
brake linings if they are worn to within 0.78 mm
(1/32 in) of a rivet head.
(4) Operate t he rear brake self-adjuster lever and
pivot. Test t he operation of t he self-adjuster screw for
ease of movement.
(5) Inspect t he self-adjuster components for frayed
cables, loose or overheated springs, and a binding
condition.
(6) Inspect t he caliper dust boots for damage/tears
and indications of brake fluid leakage. Inspect t he
bushings and pins for corrosion, t ears and a binding
condition.
(7) Inspect t he rear wheel cylinder dust boots for
fluid leaks. Inspect t he pistons and cylinder bores for
proper appearance.
(8) Inspect t he brake differential warni ng valve
and housing for indications of leakage, kinked hoses
and loose fittings.
BRAKE FLUID HOSES/TUBING
The rubber brake fluid hoses should be inspected
for:
Correct length
Severe surface cracking
Swelling
Pulling
Scuffing
Excessively worn areas
If the hose fabric casi ng is exposed either by
cracks or abrasi ons in the rubber cover, the
hose shoul d be replaced.
Faul t y brake fluid hose installation can cause
twisting, and wheel/tire or chassis interference.
(1) Inspect all t he hoses for ki nks, a distorted con-
dition and fluid leakage.
(2) Inspect t he hose and t ubi ng routing under t he
vehicle. Verify t hat no hose/tubing is rubbing against
any exhaust system or other underbody components.
PARKING BRAKE LUBRICATION
The pivot and sliding contact areas of t he parki ng
brake ratio lever should be lubricated to mai nt ai n
ease of operation (Fig. 5).
(1) Apply MOPARSpray White Lube or equiva-
lent to t he sliding contact areas.
(2) Lubricate the control lever pivot areas with en-
gine oil.
PARKING BRAKE FUNCTIONAL TEST AND INSPECTION
(1) Engage t he parki ng brake pedal and t hen re-
lease it.
(2) Test it for smooth operation and vehicle-hold-
ing capability.
(3) Inspect t he parki ng brake cables for kinks,
fraying and a binding condition.
(4) With t he parki ng brake released, t he rear
wheels should rotate without restriction. Adjust t he
parki ng brake cable tension, if necessary.
(5) Repair any parki ng brake malfunctions.
BRAKE OPERATIONAL TEST
(1) Drive t he vehicle and test for proper brake ac-
tion.

Fig. 5 Parking Brake Ratio Lever Lubrication
(2) Note any indication of brake overheating,
wheel dragging or t he vehicle pulling to one side.
(3) Eval uat e any performance complaints received
from t he owner/operator.
(4) Repair t he brake system as necessary (refer to
Group 5Brakes for additional information and ser-
vice procedures).
BODY COMPONENT MECH ANISMS
LUBRICATION REQUIREMENTS
All operating mechanisms and linkages should be
lubricated when necessary. This will mai nt ai n ease
of operation and provide protection agai nst rust and
excessive wear. The door weat herst ri p seals should
be lubricated to prolong t hei r life as well as to im-
prove door sealing.
LUBRICANT SPECIFICATIONS
All applicable exterior and interior vehicle operat-
ing mechanisms should be:
Inspected
Cleaned
All t he pivoting/sliding contact areas on t he mech-
anisms should t hen be lubricated.
MOPARMulti-Mileage Lubricant or an equiva-
lent, should be used to lubricate t he mechanisms.
The door weat herst ri p seals should be lubricated
with silicone lubricant spray. Refer to t he Body Lu-
bricant Specifications chart below for additional lu-
bricant applications.
LUBRICATION
(1) When necessary, lubricate t he cab and cargo
box operating mechanisms with t he specified lubri-
cants.
(2) Apply silicone lubricant to a cloth and wipe it
on door seals to avoid over-spray t hat can soil pas-
senger clothing.
(3) Before applying lubricant, t he component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The hood latch, latch release mechanism, latch
st ri ker and safety latch should be lubricated periodi-
cally.
(5) The door lock cylinders should be lubricated 2
times each year (preferably aut umn and spring):
Spray a small amount of lock cylinder lubricant di-
rectly into t he lock cylinder
Apply a small amount to the key and insert it into
t he lock cylinder
Rotate it to t he locked position and t hen back to
t he unlocked position several times
Remove t he key. Wipe t he lubricant from it with a
clean cloth to avoid soiling of clothing.
TIRES
RECOMMENDED MAINTENANCE
The condition of the tires should be inspected. The
inflation pressures tested/corrected at t he same time
as t he engine oil is changed and the oil filter is re-
placed.
The tires/wheels should be rotated periodically to
ensure even t read wear. The tires/wheels should be
rotated at the first 12 000 km (7,500-miles) interval.
Thereafter, at each 24 000 km (15,000-miles) inter-
val.
INSPECTION
Inspect t he tires for excessive wear, damage. Test
t he tires for t he recommended inflation pressure and
adjust t he pressure accordingly. Refer to t he tire in-
flation pressure decal located on the left door face.
Also to Group 22Tires And Wheels for tire pres-
sure charts, tire replacement, and treadwear indica-
tors.
ROTATION
Tires/wheels should be rotated according to t he rec-
ommended interval. The first tire/wheel rotation is
t he most important for establishing t he prevention of
uneven t read wear. After rotation, adjust t he tire in-
flation pressure to t he air pressure recommended on
t he decal located on t he left door face.
Refer to Group 22Tires And Wheels for t he rec-
ommended method of tire/wheel rotation.
HEADLAMPS
Every six months check t he headlamp beams to en-
sure t hat t he headlamp beams are correctly posi-
tioned.
AIM ADJUSTMENT
Refer to Group 8LLamps for headlamp aim ad-
j ust ment procedures.

BODY LUBRICANT SPECIFICATIONS
C O M PO N E N T SERVI CE I NTERVAL LUBRI CANT
Door Hinges As Required Engine Oil
Door Latches As Required Multi-Purpose Grease NLGI GC-LB
(Water Resistant) (1)
Hood Latch Release Mechanism & Safety Latch As Required
(When Performing
Other Underhood
Services)
Multi-Purpose Grease NLGI GC-LB 2 EP (2)
Hood Hinges As Required Engine Oil
Seat Regulator & Track Release Mechanism As Required Multi-Purpose Grease NLGI GC-LB 2 EP (2)
Tailgate Hinge As Required Multi-Purpose Grease NLGI GC-LB 2 EP (2)
Tailgate Support Arms As Required Engine Oil
Tailgate Latches As Required White Spray Lubricant (3)
Tailgate Release Handle (Pivot & Slide Contact Surfaces) As Required Multi-Purpose Grease NLGI GC-LB 2 EP (2)
Window System Components (Regulators, Tracks, Rods
& Channel Areas Except Glass Run Weatherstrips
and Felt Lubricator, if Equipped)
As Required White Spray Lubricant (3)
Lock Cylinders Twice/Year Lock Cylinder Lubricant (4)
Parking Brake Mechanism As Required Multi-Purpose Grease NLGI GC-LB (1)
1. Mopar Wheel Bearing Grease (High Temperature)
2. Mopar Multi-Mileage Lubricant
3. Mopar Spray White Lube
4. Mopar Lock Cylinder Lubricant
J9200-58
SPEEDOMETER CABLE
SERVICE INFORMATION
Speedometer cable lubrication is not necessary. For
service information involving noisy or erratic cables,
refer to Group 8EInst rument Panel and Gauges.
/

FRONT SUSPENSION AND AXLE 2 - 1
CONTENTS
page
FRONT SUSPENSION2WD VEHICLES . . . . . . 7
FRONT SUSPENSION4 WD VEHICLES 14
FRONT WHEEL ALIGNMENT . . . . . . . . . . . . . . . 3
GENERAL INFORMATION 1
page
MODEL 44 FRONT AXLE 17
MODEL 80 FRONT AXLE 4 9
TORQUE SPECIFICATIONS 75
GENERAL INFORMATION
FRONT SUSPENSION2WD VEHICLES
All two-wheel drive (2WD) Ram Truck and Ram-
charger vehicles ar e equipped wi t h (Fig 1);
Steering knuckles
Stabilizer bar (optional)
Suspension arms
St rut rod
Coil springs
Dual-action shock absorbers
Jounce bumpers (used to limit t he travel of t he
suspension)
The upper and lower suspension arms (Fig. 1) have
replaceable bushi ngs located at t he inboard end. Re-
placeable ball studs are located at t he outboard end.
The lower suspension arms are equipped with ten-
sion-type ball studs. The upper suspension arms also
provide for caster and camber adjustments.
STABI LI Z ER BAR J9102-67
Fig. 1 Front Suspension2WD Vehicles
FRONT SUSPENSION4 WD VEHICLES
All four-wheel drive (4WD) Ram Truck and Ram-
charger vehicles are equipped with (Fig 2);
Leaf-springs (fixed-rate type)
Stabilizer bar (optional)
Jounce bumpers (used to limit t he t ravel of t he
suspension)
Air-adjustable shock absorbers are installed on ve-
hicles equipped with t he Heavy Dut y Snow Pl ow
Pa c k a g e wi t h t he Di esel engi ne. Refer to t he Own-
ers Manual for additional information.
FRONT DRIVE AXLE
The front axle on 4WD Ram Truck and Ram-
charger vehicles has a hypoid gear differential.
Model 44 and 60 axles consists of an iron center cast-
ing wi t h axle shaft t ubes extending from either side.
Ram Truck and Ramcharger vehicles equipped for
st andard duty 4WD operation use t he Model 44 front
axle.
Vehicles equipped for heavy duty 4WD operation use
a Model 60 front axle. The Model 60 front axle has lock-
ing hubs t hat must be engaged for 4WD operation.
The steel cover provides a means for service with-
out removing t he complete axle.
A met al axle gear ratio identification t ag is at-
tached to t he housing cover via one of t he cover
bolts. Thi s t ag also identifies t he number of ri ng and
pinion gear teeth.
IDENTIFICATION
Model 44 and 60 axles have t he assembly part
number and gear ratio listed on a t ag. The t ag is at-
tached to t he left side of t he housing cover (Fig. 3, 4).
Build dat e identification codes on axles are stamped
on t he axle shaft tube cover side.
LUBRICANTS
Multi-purpose API GL 5 quality hypoid gear lubri-
cant should be used for front axles. MOPAR Hypoid
Gear Lubri cant conforms to these specifications.
The axle has a fitting for a vent hose used to re-
lieve i nt ernal pressure.
If t he f r ont axl e i s s ubme r ge d i n wat er , t he lu-
br i c a nt mus t be r epl aced i mmedi at el y.
F R O N T S U S P E N S I O N A N D A X L E
2 - 2 FRONT SUSPENSION AND AXLE
FRONT WH EEL ALIGNMENT
GENERAL INFORMATION
Front wheel alignment involves the correct posi-
tioning of t he tire contact patch in relation to t he
pavement. The positioning is accomplished t hrough
t he suspension and steering linkage adjustments. An
alignment is essential for efficient steering and direc-
tional stability. The most important factors of front
end al i gnment are camber, caster and toe position.
Rout i ne i ns pect i on of t he fr ont s us pe ns i on a n d
s t eer i ng c ompone nt s i s a good pr event at i ve
ma i nt e na nc e pr act i ce. I ns pec t i on al so hel ps t o
e ns ur e safe oper at i on of the vehi cl e.
CAMBER is the number of degrees the top of the
wheel is tilted either inward or outward. An excessive
negative camber angle will cause tread wear at the in-
side of the tire. An excessive positive camber angle will
cause tread wear at the outside of the tire (Fig. 1),
CASTER is t he number of degrees of forward or
rearward tilt of t he steering knuckles. Forward tilt
provides a negative caster angle. Rearward tilt pro-
vides a positive caster angle (Fig. 1).
WHEEL TOE POSITION is t he difference between
t he leading and t rai l i ng inside edges of t he front
tires (Fig. 1). Incorrect wheel toe position is t he most
common cause of unstable steering and steering
wheel off-center. The wheel toe position is t he final
front wheel alignment adjustment.
STEERING AXIS INCLINATION ANGLE is mea-
sured in degrees and is t he angl e t hat the steering
knuckles are tilted (Fig. 1). The inclination angle has
a fixed relationship wi t h t he camber angle. Thi s will
not change except when a spindle or ball stud is
damaged or bent. The angle is not adjustable and t he
damaged component(s) must be replaced to correct
mis-alignment.
CAUTI ON : Do not attempt to modify any suspensi on
or steering component by heating and bendi ng.
PRE-ALIGNMENT INSPECTION
Before st art i ng a front wheel alignment, t he follow-
ing inspection and necessary corrections must be
completed.
(1) Tires with t he same recommended air pressure,
size, and tread wear. Refer to Group 22, Wheels and
Tires for diagnosis information.
(2) Front wheel bearings for wear or adjustment.
(3) Ball studs and linkage pivot points, steering
gear for looseness, roughness, binding or a sticking
condition. Refer to Group 19, Steering for additional
information.
CASTER
POSITIVE CASTER
STEERING WH EEL CENTER
i 0.5 C C W
0 5 C W
C C W = COUNTER CLOCKWISE
C W - CLOCKWISE
CAMBE R
NEGATIVE CAMBER (SHOWN)
TOP OF WHEEL INBOARD
POSITIVE CAMBER (NOT SHOWN)
TOP OF WHEEL OUTBOARD
N OMI N AL- PRE F E RRE D
THE NOMI NAL VALUE IS
THE PREFERRED VALUE
LEFT/RIGHT DIFFERENCE
THE VALUE Of THE LEFT SIDE
MI NUS THE VALUE OF THE
RIGHT SIDE
EX.
I f FT CASTER - +6 5
RIGHT CASTER +8.0
LEFT/RIGHT DIFFERENCE
65 8.0 = 1 5
TOE
NEGATIVE TOE (TOE OUT) B>A
POSITIVE TOE (TOE IN) 6<A
FRONT Of VEHICLE
ft
THRUST ANGLE
ANGLE OF REAR AXLE RELATIVE TO VEHICLE CENTERUNE
(+) AXLE POINTS LEFT (-) AXLE POINTS RIGHT
PRODUCTI ON TOLERANCE
THE RANGE Of ACCEPTABLE
VALUES AROUND THE NOMI NAL
- PREFERRED
PRODUCTION +6.5 A7.5
PREFERRED: +7.0
TOLERANCE: 0.5
J9302-61
Fig. 1 Wheel Alignment Measurements

I
FRONT E N D | | * ?
E
;
LOOSE OR WOR N
FRONT WHEEL
BEARI NGS
LOOSE C
S HO C K S
MOUNTir
WAR
SHOCK A
) R WOR N
JSORBER
nIG HARD-
E OR
BSORBER
E XC i S S I V E PLAY
S T E E R I NG
L I N K A GE
LOOSE OR WOR N
FRONT WHEEL
BEARI NGS
LOOSE C
STEERINC
SHAFT C
) R WOR N
7 COLUMN
OUPLI NG
DIFFICULT
S T E E R I NG
LOOSE OR WOR N
WHEEL BEARI NGS
TIRE/V
OUT OF f
VHEEL
JA LANCE
LOW OR UNEVEN
TIRE AIR PRESSURE
LO(
WHEEL B
DSE
EARI NGS
LOW OR UNEVEN
TIRE AIR PRESSURE
1 v s n c i E i
I 1 PULLS TO I
I | O N E S I DE j
LOOSE, WOR N OR
GLAZ ED P/S
PUMP BELT
LOW OR UNEVEN
TIRE PRESSURE
WHILE BR
REFE
BRAKES
AKI NG
R TO
SERVICE
LOOSE STEERING
GEAR-TO-FRAME
RAIL BOLTS
LOOSE STEERING
GEAR-TO-FRAME
RAIL BOLTS
UNEVEN TIRE TREAD
WEAR, OR EX-
CESSIVELY WOR N
TIRE TREAD
BROKEN OR WEAK
REAR SPRI NG
LOW
POWER STEERING
FLUID LEVEL
BROKEN OR WEAK
REAR SPRI NG
WOR N
UPPER SUSPENSI ON
ARM BUSHI NGS
WOR N TIE-
ROD END
BALL STUDS
WOR N TIE-
ROD END
BALL STUDS
SHOCK ABSORBER
NOT FUNCTI ONI NG
CORRECTLY
LACK OF ASSI ST
FROM POWER
STEERING PUMP
LOOSE OR WOR N
SUSPENSI ON
BUSHI NGS
WO R N LOWER
S US PE NS I ON ARM
PIVOT BUSHI NGS
INCORRECT
STEERING GEAR
ADJUSTMENT
LOOSE OR WOR N
SUSPENSI ON ARM
BUSHI NGS
INCORRECT
STEERING GEAR
ADJUSTMENT
BALL STUDS
REQUIRE
LUBRICATION
INCORRECT FRONT
WHEEL ALI GNMENT
(EITHER CASTER
OR CAMBER)
LOOSE LOWER
S US PE NS I ON ARM
LOOSE OR WOR N
UPPER S US PE NS I ON
ARM BALL STUDS
LOOSE OR WOR N
SUSPENSI ON ARM
BUSHI NGS
STEERING GEAR
LUBRICANT LEVEL
LOW
WO R N ISOLATOR
PAD BETWEEN COIL
SPRI NG A N D
FRAME BRACKET
INCORRECT FRONT-
WHEEL ALI GNMENT
(PARTICULARLY
CASTER)
INCORRECT FRONT
WHEEL ALI GNMENT
INCORRECT
STEERI NG GEAR
ADJUSTMENT
STEERING
GEAR
MALFUNCTI ON
INCORRECT FRONT
WHEEL ALI GNMENT
(PARTICULARLY
CASTER)
J9002-97
SUSPENSION AND STEERING SYSTEM DIAGNOSIS

(4) Front wheels for excessive radial, l at eral
runout and unbalance. Refer to Group 22, Wheels
and Tires for diagnosis information.
(5) Suspension components for wear and noise. Check
components for correct torque. Refer to Groups 2 and 3,
Suspension and Axle for additional information.
WHEEL ALIGNMENT MEASUREMENTS/ADJUSTMENTS
The front wheel alignment positions must be set to
t he specified limits. This will prevent abnormal tire
tread wear.
The e qui pme nt manuf act ur er ' s r e c omme nda -
t i ons for us e of t hei r eq ui pment s houl d al ways
be fol l owed. Al l d amage d fr ont s us pe ns i on sys-
t em c ompone nt s s h oul d be r epl aced. D o not at -
t empt to s t r ai ght en a ny bent c omponent .
CAMBER AND CASTER-2WD VEHICLES
Camber and caster angle adjustments involve repo-
sitioning t he upper suspension ar m cam adjustment
bolts (Fig. 2). Alignment adjustments are accom-
plished by loosening t he nut s and changing t he posi-
tion of t he cam bolt.
(1) Remove all foreign mat eri al from t he adjust-
ment bolt t hreads.
(2) Record t he camber and caster measurement s
before loosening t he adjustment bolt nut s.
(3) The camber angle should be adjusted as near as
possible to t he preferred angle. The caster should be
t he same at both sides of t he vehicle. Refer to t he
Specifications chart.
CAMBER AND CASTER4WD VEHICLES
For 4WD vehicles, t he correct wheel camber (verti-
cal tilt) angle is factory preset at zero degree (0).
Camber cannot be altered by adjustment.
CAUTION: D o not attempt to adj ust the camber an-
gl e by heating or bendi ng the ax l e or any s us pe n-
si on component . If camber angl e i s incorrect, the
component ( s) c ausi ng an incorrect angl e must be
repl aced.
(1) It is i mport ant t hat t he camber (vertical tilt)
angle be t he same for both front wheels.
(2) The camber angle should be measured with ac-
curate wheel al i gnment equipment. The acceptable
range is -1 to +1. Refer to t he Specifications chart.
Road test t he vehicle and observe t he steering
wheel return-to-center position.
Bef or e r o a d t est i ng, c hec k a nd cor r ect t he t i r e
i nfl at i on pr e s s ur e s . Infl at e bot h of t he f r ont t i r es
wi t h exact l y t he s ame pr es s ur e.
Duri ng t he road test, make vehicle t ur ns to both
t he left and right. If t he steering wheel ret urns to-
ward t he center position unassisted, t he caster angle
is correct. However, if t he steering wheel does not re-
t ur n toward t he center position unassisted, an incor-
rect caster angle is probable.
(1) The caster angle is factory preset at positive
two degrees ( + 2). The acceptable range is +1/2 to
+ 3 1/2.
(2) The caster angle should be measured with ac-
curat e wheel al i gnment equipment.
(3) Caster angle can be adjusted by installing ta-
pered shims between t he front axle pads and the
spring brackets. The caster angle should be adjusted
as near as possible to t he preferred angle.
(4) Record t he caster measurement before remov-
ing t he original shims from t he spring pads.
(5) The caster should be t he same at both sides of
t he vehicle. Refer to t he Specifications chart.
RN1030
Fig. 2 Caster & Camber Adjustment Location2WD
Vehicles
WHEEL TOE POSITION
The wheel toe position adjustment should be t he fi-
nal front wheel alignment adjustment. In all in-
stances, follow t he equipment manufacturer' s
recommended procedure.
(1) Secure t he steering wheel with the front wheels
in t he straight-ahead position. For vehicles equipped
with power steering, st art t he engine before straight-
ening t he wheels.
With power steering, the engi ne shoul d be op-
erating duri ng the wheel toe position adjust-
ment.
(2) Loosen t he tie rod adjustment sleeve clamp
bolts (Fig. 3).
(3) Adjust t he wheel toe position by rot at i ng t he
tie rod adjustment sleeve (Fig. 3).
Rotate each tie-rod end in the direction of
sl eeve rotation duri ng the adjustment (Fig. 3).
This will ensure that both tie-rod ends are at the
center of their travel.
(4) If applicable, t ur n t he ignition switch off.

(5) Position the adjustment sleeve clamps so t he
ends ar e not l ocat ed at t he sleeve slot. Tighten t he
clamp bolt nut s to 26 N*m (225 in. lbs.) torque.
Tighten Model D350 and all 4WD vehicle (heavy
duty tie rods) nut s to 34 N*m (25 ft. lbs.) torque. En-
sure clamp bolts are located at t he underside of t he
sleeve.
CLAMP RN1036
Fig. 3 Toe Position Adjustment (Typical)
ALIGNMENT SPECIFICATIONS
A L I G N M E N T ( 4WD ) A S G S PT A BL E R A N G E PR E F E R R E D
Camber - r t o + r 0
"Caster + 1/2to 37* +2
King Pin Inclination 8.5 8.5
Toe-In (at Hub Height) -0.05to +0.45 0.20
A L I G N M E N T ( 2 WD ) AC C E PT ABL E R A N G E PR E F E R R E D
Camber 0to 1 +1/2
'Caster -1to +2 +1/2
Toe-in (at Hub Height) 0to 0.50 0.25
Turning Angle (Base Tire) Left and Right 33
3 3
J9102-64
*lf vehicle wander s, caster shoul d be i ncreased. If steering effort is very hi gh (especially when corneri ng) , caster shoul d be decr eased.
TIE RODS

FRONT SUSPENSION AND AXLE 2 7
F R O N T S U S P E N S I O N 2WD VEHICLES
INDEX
page
Coil Spri ngs 9
Lower Ball Stud . 10
Lower Suspensi on Arm 10
Lower Suspensi on Arm Bushi ng 11
Lower Suspensi on Arm Strut 8
Service Information 7
Shock Absorber 9
page
Stabilizer Bar 8
Steering Knuckle 13
Upper Ball Stud 11
Upper Suspensi on Arm 11
Upper Suspensi on Arm Bushi ng Replacement . . . 12
Wheel H ub and Beari ngs 7
SERVICE INFORMATION
Periodic lubrication of t he front suspension (steer-
ing) system components is required. Refer to Group
0, Lubrication And Maintenance for t he service in-
terval.
Rubber bushi ngs must never be lubricated.
All front suspensi on component s that are
cushi oned by rubber shoul d be ti ghtened wi th
the suspensi on system at the normal height.
WHEEL HUB AND BEARINGS
REMOVAL
(1) Block t he brake pedal in t he up (non-depressed)
position.
(3) Remove the wheel.
(4) Remove bolts from t he disc brake caliper.
(5) Separat e t he disc brake caliper from t he rotor.
Position and support t he caliper away from t he im-
mediate work area. Do not al l ow the caliper to
hang from the brake fluid hose.
(6) Remove the dust cap, cotter pin, and remai ni ng
hub components from t he spindle (Fig. 1).
C A U T I O N : U se care to prevent the inner wheel bear-
i ng and bearing seal from contacti ng the steering
knuckle spi ndl e threads duri ng removal (Fi g. 1).
Otherwise, the threads, beari ng, and seal coul d all
be damaged.
(7) Carefully slide the wheel hub/rotor from steer-
ing knuckle spindle (Fig. 1).
(8) For beari ng cleaning or replacement, remove
t he seal and inner wheel beari ng from t he wheel
hub/rotor bore (Fig. 1).
CLEANING AND INSPECTION
(1) Thoroughly clean both wheel bearings and in-
terior of t he hub/rotor (Fig. 1). Remove all of the
residual lubricant.
(2) To clean t he bearings:
Soak t hem in an appropriate cleaning solvent
BRAKE I NNER
Fig. 1 Front Wheel Bearings & Hub/Rotor
Strike t he flat of each beari ng against a hardwood
block several t i mes
Fl ush beari ng between strikes
Repeat t he procedure above until each bearing is
clean
Dry t he bearings with compressed air but do not
spin t hem
(3) After cleaning, apply engine oil to each bear-
ing.
(4) Rotate each bearing slowly while applying
downward force. Exami ne t he rollers for pitting and
roughness. Replace worn or otherwise defective bear-
ings. If a beari ng has pitted and/or rough surfaced
rollers, replace both t he bearing and bearing cup
(Fig. 1).
(5) If reusable, remove t he engine oil from each
bearing. Pack each bearing with multi-purpose
NLGI, grade 2, EP-type lubricant. Place t he bearings
in a clean, safe place.
Ensure that lubricant is forced into all the cav-
ities bet ween the beari ng cage and rollers.

INSTALLATION
(1) If a beari ng and cup must be replaced, remove
t he cup from t he wheel hub/rotor bore (Fig. 1). Use a
brass drift or an appropriate removal tool to t ap out
t he cup.
(2) Install t he replacement beari ng cup(s) with an
appropriate installation tool.
(3) Apply lubricant to surface area of t he wheel
hub/rotor bore. Install t he i nner wheel beari ng in t he
hub/rotor. Install a replacement beari ng seal with an
appropriate seal installation tool.
(4) Inspect t he beari ng and seal contact surfaces on
t he steering knuckle spindle for burrs and/or rough-
ness (Fig. 1).
(5) Remove all t he rough contact surfaces from t he
spindle. Apply a coating of multi-purpose NLGI,
grade 2, EP-type lubricant to t he spindle surface.
CAUTION: Us care to prevent the inner wheel bear-
ing and bearing seal from contacting the steering
knuckle spindle threads during removal (Fig. 1).
Otherwise, the threads, bearing, and seal could be
damaged.
(6) Carefully slide t he wheel hub/rotor onto t he
spindle.
Install t he outer wheel bearing, t he washer and
nut.
(7) Tighten t he nut to 41 to 54 Nnn (30 to 40 ft.
lbs.) torque while rot at i ng t he wheel hub/rotor. Stop
t he hub/rotor and loosen t he nut to completely re-
lease t he beari ng preload torque. Next, t i ght en t he
nut finger-tight, install t he nut lock. Install a re-
placement cotter pin.
(8) The wheel beari ng adjustment (above) should
have 0.001 to 0.003 inch (0.254 to 0.0762 mm) end
play.
(9) Clean t he dust cap. Apply a coating of multi-
purpose NLGI, grade 2, EP-type lubricant to i nt ernal
surface. Install t he cap.
Do not fill the dust cap wi th lubricant.
(10) Install t he brake caliper, refer to Group 5,
Brakes.
(11) Install t he wheel and tire, refer to Wheel and
Tire Installation in t hi s section. Lower t he vehicle.
LOWER SUSPENSION ARM STRUT
REMOVAL
(2) Use a small drift and a hammer to drive t he
spring pin from t he front of t he st rut . Remove t he
spring pin, nut , ret ai ner and bushi ng from t he end of
t he st rut (Fig. 2).
(3) Remove t he st rut rear bolts and jounce bumper
from t he bracket. Remove t he st rut from t he vehicle
(Fig. 2).
NUT
FRONT RETAINER STRUT J9002-120
Fig. 2 Lower Suspension Arm Strut Removal/
Installation
INSTALLATION
(1) Position t he rear ret ai ner and rear bushi ng on
t he front end of t he st rut (Fig. 2).
(2) Carefully slide t he st rut into position. Install
t he rear bolts. Tighten t he bolts to 182 Nnn (135 ft.
lbs.) torque.
(3) Install t he front bushing, front ret ai ner and
nut at t he front end of t he strut. Tighten t he nut
with 70 Nnn (52 ft. lbs.) torque.
(4) Install t he spring pin.
STABILIZER BAR
REMOVAL
(1) Remove t he link rod nut at each end of t he sta-
bilizer bar (Fig. 3).
Fig. 3 Stabilizer Bar
4
FRONT SHOCK ABSORBER J9017-29
Fig. 4 Coil Spring Suspension
INSTALLATION
(1) Extend shock fully, install retainer on shock
absorber. Install bushing and sleeve, make sure they
are not worn or broken.
(2) Guide shock up through coil spring. Install top
retainer and nut. Tighten nut to 34 Nnn (25 ft. lbs.)
torque.
(3) Align lower end of shock and install mounting
bolts. Tighten bolts to 23 Nnn (200 in. lbs.) torque.
FRONT SUSPENSION AND AXLE 2 - i
Fig. 5 Spring Compressor & Ball Stud Loosening
Tools Installed
(8) Remove the loosening tool. Slowly loosen the
coil spring compressor tool until all tension is re-
lieved from the spring. Remove the spring compres-
sor and spring with the rubber isolation pad.
(2) Remove the outer retainers and rubber bush-
ings from the link rods (Fig. 3).
(3) Remove the bolts or nuts from the U-shaped
stabilizer bar support brackets. Remove the stabilizer
bar from the vehicle (Fig. 3).
INSTALLATION
(1) Position the stabilizer bar ends over the link
rods. Install the U-shaped support brackets and bolts/
nuts (Fig. 3). Tighten the bolts/nuts to 23 Nnn (200
in. lbs.) torque.
(2) Install the outer retainers and rubber bushings
on the link rods (Fig. 3).
(3) Install the link rod nuts (Fig. 3). Tighten the
nuts to 11 Nnn (100 in. lbs.).
SHOCK ABSORBER
REMOVAL
(1) Raise vehicle on hoist. Position support stands
on frame and lower front hoist.
(2) Remove upper nut and retainer.
(3) Remove two lower mounting bolts, lower shock
from suspension arm (Fig. 4).
(4) Remove support stands and lower vehicle to
ground.
COIL SPRINGS
REMOVAL
(1) Raise vehicle on hoist. Position support stands
on frame and lower front hoist. Remove front tire.
(2) Remove brake caliper assembly, refer to Group
5, Brakes.
(3) Remove shock absorber.
(4) Remove lower control arm strut.
(5) Install Spring Compressor DD-1278 in the
spring (Fig. 5). Tighten the nut finger-tight, and
then loosen the nut 1/2 of-a-turn.
(6) Remove cotter pins and ball joint nuts.
(7) Install Ball Stud Remover C-3564-A on the
lower ball stud (Fig. 4). Turn the threaded portion of
the tool and lock the tool securely against the lower
stud (Fig. 5). Expand the tool enough to place force
on the lower ball stud. Strike the steering knuckle
sharply with a hammer to loosen the stud. Do not
attempt to force the stud out of the steeri ng
knuckl e wi th the l ooseni ng tool.

INSTALLATION
(1) Position t he spring and isolation pad on t he
suspension arm. Install t he spring compressor tool.
Compress t he spring unt i l t he lower suspension ar m
can be properly positioned in t he steering knuckle.
(2) Install t he nut s on t he ball studs. Tighten t he
upper nut to 142 Nnn (105 ft. lbs.) torque. Tighten
t he lower nut .
* 11/16-16 bolt, to 183 Nnn (135 ft. lbs.) torque
3/4-16 bolt, to 237 Nnn (175 ft. lbs.) torque
Install replacement cotter pins.
(3) Install t he strut.
(4) Connect t he stabilizer bar.
(5) Install t he shock absorber.
(6) Install t he brake splash shield on t he steering
knuckle. Tighten t he screws to 23 Nnn (200 in. lbs.)
torque.
(7) Carefully install t he hub/rotor and bearings.
(8) Install the brake caliper, refer to Group 5, Brakes.
(9) Install the wheel and tire, refer to Wheel and Tire
Installation within this section. Lower the vehicle.
(10) Test t he vehicle brakes and t he suspension for
proper operation.
LOWER SUSPENSION ARM
REMOVAL
(1) Follow procedure under Coil Spring Removal.
(2) Remove hex-head mount i ng bolt from t he cross-
member.
(3) Remove t he lower suspension arm from vehicle.
INSTALLATION
(1) Position lower suspension arm on vehicle.
(2) Install mount i ng bolt, t i ght en finger-tight.
(3) Follow procedure under Coil Spring Installa-
tion.
(4) Lower t he vehicle to t he surface with t he
wheels/tires supporting t he vehicle weight. Tighten
t he lower suspension arm mount i ng bolt to 305 Nnn
(225 ft. lbs.) torque.
LOWER BALL STUD
INSPECTION
(1) Raise t he front of t he vehicle. Install safety
floor stands under both lower suspension arms as far
outboard as possible. The upper suspension arms
must not contact t he rebound bumpers.
(2) Install a dial indicator and clamp assembly to
t he lower suspension arm.
(3) Position indicator plunger agai nst knuckle ar m
and zero indicator.
(4) Raise and lower the wheel with a pry bar under
the center of the tire. Measure the axial movement of
the knuckle with respect to the suspension arm.
(5) If t he t ravel of t he suspension ar m is 0.020
inch (0.51 mm) or more, replace t he ball joint.
REMOVAL
(1) Follow procedure under Coil Spring Removal.
(2) Remove ball joint seal. Use assembled Remov-
er/Installer C-4212 to force t he ball stud out of t he
lower suspension ar m bore (Fig. 6).
Fig. 6 Lower Bail Stud Removal
INSTALLATION
(1) Force t he replacement ball stud into t he lower
suspension arm bore with assembled Remover/In-
staller C-4212 (Fig. 7).
Fig. 7 Lower Ball Stud Installation

(2) Position t he seal over the ball stud (if neces-
sary, use a replacement seal). Force portion of t he
seal downward on t he ball stud housing with an ap-
propriate size socket wrench unt i l i t is securely
locked in place.
(3) Install lower suspension ar m using procedure
under Lower Suspension Arm Installation.
LOWER SUSPENSION ARM BUSHING
REMOVAL
(1) Follow procedure under Coil Spring and Lower
Suspension Arm Removal.
(2) Use an arbor press and an appropriate size
sleeve to force t he original bushing from t he lower
suspension ar m bore.
INSTALLATION
(1) Use an arbor press and an appropriate size
sleeve to force t he replacement bushi ng into t he
lower suspension ar m bore. Ensure t hat it is com-
pletely seated in t he bore.
(2) Install the lower suspension arm according to in-
structions provided within the installation procedure.
UPPER SUSPENSION ARM
REMOVAL
(1) Raise t he vehicle. Position support stands un-
der t he frame rai l and lower t he front of t he hoist.
Remove t he wheel/tire.
(2) Remove shock absorber, refer to above proce-
dures.
(3) Install Spring Compressor DD-1278 (Fig. 5) .
Tighten t he nut finger-tight and t hen loosen it 1/2 of-
a-turn.
(4) Remove t he cotter pins and t he ball stud nut s.
(5) Install Ball Stud Remover C^3564-A (Fig. 8).
Turn t he threaded portion of t he tool to lock it se-
curely agai nst t he upper ball stud (Fig. 8). Spread
t he tool enough to apply force agai nst t he upper ball
stud. Strike t he steering knuckle sharply wi t h a
hammer to loosen t he upper ball stud. Do not at-
t empt to force t he ball stud out of t he steering
knuckle bore with t he loosening tool.
(6) Remove t he loosening tool. Remove the nut s,
eccentric (cam) bolts and suspension arm from t he
vehicle (Fig. 9).
INSTALLATION
(1) Position t he suspension arm and install t he ec-
centric (cam) bolts (Fig. 9). and nut s finger-tight.
(2) Install upper ball stud into steering knuckle.
Install nut s on t he ball studs. Tighten to 142 N (105
ft. lbs.) torque. Install replacement cotter pins.
(3) Remove t he spring compressor tool (Fig. 5).
Fig. 8 Ball Stud Loosening Tool Installed
(4) Install t he shock absorber. Ti ght en nut to 34
N*m (25 ft. lbs.) torque and lower bolts to 23 N*m
(200 in. lbs.) torque.
(5) Install the wheel/tire. Raise the vehicle, remove
the support stands and lower the vehicle to the surface.
(6) Adjust t he caster and camber angles. Tighten
t he eccentric (cam) nut s to 95 N*m (70 ft. lbs.)
torque.
UPPER BALL STUD
INSPECTION
(1) Position a floor jack under t he lower suspension
arm. Raise t he wheel and allow t he tire to lightly
contact t he floor (vehicle weight relieved from t he
tire).
(2) Grasp t he top of t he tire and apply force in and
out. Look for any movement at t he bal l j oi nt s be-
tween t he upper suspension ar m and steering
knuckle.
(3) If any lateral movement is evident, replace t he
ball joint.
REMOVAL
(1) Position a support under the outer end of t he
lower suspension arm. Lower the vehicle so t hat t he
support compresses t he coil spring.
(2) Remove t he wheel/tire.
(3) Remove t he ball stud nut s. Use Ball Stud Re-
mover C-3564-A to loosen t he upper ball stud (Fig.
8).
(4) Use Wrench C-3561 to un-t hread t he upper ball
stud from t he upper suspension arm.

1Nut
2Lockwasher
3Cam
4Bushing
5Ball Joint
6Locknut
7Upper Suspension Arm
8Upper Ball Joint Seal
9Bumper
10Sleeve
11Cam and Bolt
J9202-98
SP-3952A
Fig. 9 Upper Suspension Arm Removal/Installation
INSTALLATION
(1) Thread t he replacement ball stud into t he up-
per suspension arm bore as far as possible by hand.
Use Wrench C-3561 to t i ght en t he ball stud to 169
Nm (125 ft. lbs.) torque. Ensure that the ball stud
is compl etel y s eat ed agai ns t the arm.
(2) Install and seat t he replacement ball stud seal.
(3) Insert t he upper ball stud into steering
knuckle. Install ball stud nut s. Tighten t he nut s to
142 N
#
m (105 ft. lbs.) torque. Install replacement cot-
t er pins.
(4) Install t he wheel/tire. Remove t he support and
lower t he vehicle to t he surface.
BUSHI NG
SP-3953
RH393
UPPER SUSPENSION ARM BUSHING
REPLACEMENT
REMOVAL
(1) Follow procedure under Upper Suspension Arm
Removal.
(2) Place t he upper suspension ar m in a vise. As-
semble Remover/Installer C-3962 and Adaptor
SP-3953 (Fig. 10) over t he bushing. Tighten t he nut s
and force t he bushing out of t he ar m bore.
INSTALLATION
Be sure the suspensi on arm is supported
firmly at the area where the bushi ng is bei ng
Fig. 10 Upper Suspension Arm Bushing Removal
forced in the bore. Do not use oil or any other
lubricant to aid the installation.
(1) Position flange end of t he replacement bushing
in Remover/Installer C-3962. Support suspension arm
firmly and force t he bushi ng in t he suspension arm
bore (from outside). Tighten until t he flanged end is
seated on t he arm (Fig. 11).
(2) Follow procedure under Upper Suspension Arm
Installation.

Fig. 11 Upper Suspension Arm Bushing installation
STEERING KNUCKLE
REMOVAL
(1) Block t he brake pedal in t he up position. Raise
t he vehicle and remove t he wheel cover and wheel/
tire. Remove t he brake caliper, refer to Group 5,
Brakes.
(2) Remove t he brake rotor from t he spindle. Refer
to Wheel Hub and Bearings service procedures
within t hi s Group.
(3) Remove t he brake splash shield. Remove and
discard t he dust seal.
(4) Remove t he cotter pin and t he nut from t he tie-
rod end ball stud.
(5) Install Puller Tool C-3894A (Fig. 12) and apply
sufficient force with the tool to loosen t he tie-rod end
ball stud from the steering knuckle arm bore.
Fig. 12 Tie-Rod End Ball Stud Removal
Fig. 13 Steering Knuckle
(16) Remove t he brake adapt er and steering
knuckle bolts from t he steering knuckle. Separate
t he components.
INSTALLATION
(1) Install t he brake adaptor on t he steering
knuckle. Tighten t he bolts to 136 Nnn (100 ft-lbs)
torque.
(2) Align t he steering knuckle ar m bolt holes with
t he steering knuckle bolt holes. Install t he bolts and
t i ght en to 291 Nnn (215 ft-lbs) torque.
(6) Remove t he shock absorber from t he vehicle,
refer to t he removal procedures.
(7) Install Spring Compressor Tool DD-1278 in t he
spring (Fig. 5). Tighten t he nut finger-tight, and
t hen loosen t he nut 1/2 of-a-turn.
(8) Remove t he cotter pins and t he lower and up-
per ball stud nut s at t he steering knuckle.
(9) Install Ball Stud Loosening Tool C-3564-A on
t he lower ball stud (Fig. 4). Tur n t he threaded por-
tion of t he tool and lock the tool securely against t he
lower stud (Fig. 5). Expand t he tool enough to place
force on t he lower ball stud. St ri ke t he steering
knuckle sharply with a hammer to loosen t he stud.
Do not attempt to force the stud out of the steer-
i ng knuckl e wi th the l ooseni ng tool.
(10) Remove t he loosening tool and remove t he
lower ball stud from t he steering knuckle bore wi t h
an appropriate tool.
(11) Reverse t he position of Ball Stud Loosening
Tool C-3564-A, and remove t he upper ball stud.
(12) Remove t he loosening tool.
(13) Remove t he upper ball stud from t he steering
knuckl e bore with an appropriate tool.
(14) Slowly loosen t he coil spring compressor tool
(Fig. 5) until all tension is relieved from t he spring.
(15) Separate t he steering knuckl e and t he steer-
ing knuckle arm from t he ball studs (Fig. 13).

(3) Mount t he knuckle to t he suspension arms and
install t he nut s. Tighten t he upper nut to 142 Nnn
(105 ft-lbs) torque and t he lower nut .
11/16-16 bolt, to 183 Nnn (135 ft-lbs) torque
3/4-16 bolt, to 237 Nnn (175 ft-lbs) torque
Install replacement cotter pins.
(4) Connect t he tie-rod end. Install and t i ght en t he
nut to 61 Nnn (45 ft-lbs) torque. Install a replace-
ment cotter pin.
(5) Position a replacement dust seal on t he steer-
ing knuckle. Install t he splash shield and t i ght en t he
bolts to 24 Nnn (18 ft. lbs.) torque.
(6) Install t he shock absorber, refer to t he installa-
tion procedures.
(7) Install t he hub/rotor, refer to t he procedures
above.
Brakes for additional installation information.
Tire Installation in t hi s section. Lower t he vehicle.
(10) Test t he vehicle brakes and t he front suspen-
sion for proper operation.
F R O N T S U S P E N S I O N 4WD V E H I C L E S
STABI LI Z ER BAR
REMOVAL
(1) Remove t he link rod nut at each end of t he sta-
bilizer bar (Fig. 1).
STABILIZER BAR
FRONT
STABILIZER BAR
BUSHING
RETAINER
LINK ROD
J9017-37
Fig. 1 Stabilizer Bar
(2) Remove t he outer ret ai ners and rubber bush-
ings from t he link rods (Fig. 1).
(3) Remove t he bolts or nut s from t he U-shaped
stabilizer bar support brackets. Remove t he stabilizer
bar from t he vehicle (Fig. 1).
INSTALLATION
(1) Position t he stabilizer bar ends over t he link
rods. Install t he U-shaped support brackets and bolts/
nut s (Fig. 1). Tighten t he bolts/nuts to 23 Nnn (200
in. lbs.) torque.
(2) Install t he outer ret ai ners and rubber bushings
on t he link rods (Fig. 1).
(3) Install t he link rod nut s (Fig. 1). Tighten t he
nut s to 11 Nnn (100 in. lbs.).
SHOCK ABSORBER
SERVICE INFORM A TION
Air-adjustable shock absorbers are installed on ve-
hicles equipped with t he Heavy Dut y Snow Pl ow
Pa c k a g e a nd Di esel engi ne.
REMOVAL
(1) Remove t he shock absorber upper nut and re-
t ai ner from t he frame bracket (Fig. 2).
PLATE
BRACKET
NUT
AXLE
NUT
AXLE
J9202-99
Fig. 2 Shock Absorber (4 WD)
(2) Remove t he shock absorber lower nut and re-
t ai ner from t he axle. Pull t he shock outward at top
and swing down to remove.
(3) Remove t he inner ret ai ners from t he mount i ng
studs.
INSTALLATION
(1) Before installing t he shock absorber, ensure
t hat t he bushing is inserted in t he shock absorber
eye.

Ensure the shock absorber is posi ti oned on the
stud wi th retainers correctl y l ocated (Fig. 2) .
(2) Position t he i nner ret ai ners on t he mount i ng
studs.
(3) Install t he shock on t he upper and lower stud
and install t he outer ret ai ners.
(4) Install t he nut s on t he frame bracket and axle
(Fig. 2) .
(5) Tighten t he shock absorber upper and lower
nut s;
Standard shock upper and lower nut to 75 Nnn (55
ft. lbs.) torque
Air-adjustable shock upper nut to 75 Nm (55 ft.
lbs.) torque, lower nut to 271 Nnn (200 ft. lbs.)
torque
C A U T I O N : Vehi cl es with air s h o c k s M U S T maintain
a minimum pressure of 10 to 15 psi (70 to 105 kPa).
Operation below the specified minimum pressures
may cause damage.
(6) Remove t he supports and lower t he vehicle.
LEAF SPRINGS
REMOVAL
(1) Raise and support t he frame unt i l all weight is
removed from t he front springs.
(2) With the front tires in contact with t he surface,
position support st ands under t he frame side rails.
(3) Remove t he nut s, lockwashers, U-bolts t hat at-
tach t he spring to t he axle shaft tubes (Fig. 3).
SPRING
BRACKET
SPRING
BRACKET
SPRING
SHACKLE
PLATE
FRONT
SPRING
AXLE TUBE U-BOLT
LEFT SIDE
J9017-33
Fig. 3 Front Suspension
(4) Remove the spring front eye pivot nut and bolt,
rear spring shackle nut s, shackle plates. Remove t he
spring from t he vehicle (Fig. 3).
INSTALLATION
(1) Align t he spring front eye with t he bolt hole i n
t he frame bracket and install t he pivot bolt and nut
(Fig. 3).
(2) Position t he shackle plates at t he spring rear
eye and frame rai l bracket. Install t he nut s (Fig. 3).
(3) Tighten t he shackle pl at e nut s and front pivot
bolt nut unt i l all slack is t aken up.
(4) Position t he spring on t he axle tube wi t h t he
spring center bolt seated in locating hole in axle t ube
pad (Fig. 3).
(5) Install t he U-bolts, new lockwashers and nut s.
(6) Tighten t he nut s snug against t he spring
bracket.
(7) Remove t he supports and lower t he vehicle
with t he weight being supported by t he tires.
(8) Tighten t he spring nut s according to t he follow-
ing specifications:
Model 44 Axle:
U-bolt/Stud nut s - 115 Nnn (85 ft. lbs.) torque
Front pivot bolt/nut 135 Nnn (100 ft. lbs.) torque
Rear shackle bolt/nut 81 Nnn (60 ft. lbs.) torque
Model 60 Axle:
U-bolt nut s - 129 Nnn (95 ft. lbs.) torque
Front pivot bolt/nut - 135 Nnn (100 ft. lbs.) torque
Rear shackle bolt/nut - 108 Nnn (80 ft. lbs.)
torque
SPRING LE AF - RE PLACE ME NT
If a spring has acquired a set (lost significant
height), it should be replaced.
(1) Remove t he spring from t he vehicle. If neces-
sary, refer to t he removal procedure.
(2) Remove t he spring leaf alignment clips.
(3) Clamp t he spring in a vise. Remove t he nut
and center bolt (Fig. 4).
SPRING CENTER RATCHET
AND
SOCKET
WRENCH
Fig. 4 Leaf Spring Disassembly
(4) Insert a long drift or punch into t he center bolt
hole and slowly release t he vise jaws.
2 - 1 6 FRONT SUSPENSION AND AXLE

(5) Remove t he spring from t he vise. Replace t he
broken/defective leaf. Insert a long drift or punch
into t he spring center bolt hole.
(6) Position t he spring between vise j aws and
slowly t i ght en t he vise jaws. Keep t he spring leaves
aligned with t he long drift or punch.
(7) Remove t he drift/punch from t he spring center
bolt hole. Install a replacement center bolt and nut
(Fig. 4).
(8) Tighten t he nut to 27 N*m (20 ft. lbs.) torque.
An al t ernat e is to t i ght en unt i l t he center of t he
spring has no gaps. Use a maxi mum of 54 N*m (40 ft.
lbs.) torque for t hi s method.
(9) Install t he al i gnment clips.
(10) Install t he spring in t he vehicle. If necessary
refer to t he installation procedure.
LEAF SPRING EYE BUSHING REPLACEMENT
(1) Assemble tools shown (Fig. 5). Tighten t he nut
located at t he socket wrench end of t he t hreaded rod
unt i l t he bushing is forced out.
(2) Assemble and align t he bushi ng installation
tools.
(3) Align t he bushi ng with t he spring eye and
t i ght en t he nut located at t he socket wrench end of
t he threaded rod. Tighten unt i l t he bushi ng is forced
into t he spring eye.
The bushi ng must be centered in the spri ng
NUT
PIPE
(RECEIVER)
SPRING
EYE
SOCKET
WRENCH
(DRIVER)
NUT
FLAT
WASHER
THREADED
ROD
J8917-20
Fig. 5 Spring Eye Bushing Removal
eye. The ends of the bushi ng must be flush or
slightly recessed wi thi n the end surfaces of the
spring eye.

M OD E L 4 4 F RON T AXLE
INDEX
page
Ax le Shaft and U-Joint Service 2 3
Complete Ax le Removal/Installation 31
Differential Assembl y 35
Differential Di sassembl y . 32
Drain and Refill 19
General Information 17
H ub, Spindle and Ax le Shaft 20
Intermediate Ax le Shaft 30
Lubricant 17
GENERAL INFORMATION
Model 44 front axles (Fig. 1) consists of an iron
center casting with axle shaft tubes extending from
either side.
The integral type housing, hypoid gear design has
t he centerline of the pinion set below t he centerline
of the ri ng gear.
The axle shaft disconnect housing is welded to t he
left axle shaft tube. A splined, two-piece axle shaft is
located on t he left side and it is engaged or disen-
gaged by a shift collar. The collar is moved by a shift
fork controlled by a vacuum shift motor. The shift
motor is operated by engine vacuum controlled by a
switch located at t he transfer case.
The axles are equipped with full-floating axle
shafts, meani ng t hat loads are supported by t he spin-
dles attached to t he steering knuckles.
The removable, stamped steel cover provides a
means for inspection and service without removing
t he complete axle from t he vehicle.
page
Pinion Gear Depth Measurement and Adj ustment
with Tool Set C- 37 1 5- B 4 0
with Tool Set D- 1 1 5- 4 4 . . . 38
Pinion Shaft Seal 19
Specifications 4 8
Steering Knuckle Arm 31
Steering Knuckle, Upper and Lower Ball St uds . . 24
V acuum Shift Motor 26
A small, stamped met al axle gear ratio identifica-
tion t ag is attached to t he housing cover via one of
t he cover bolts. This t ag also identifies t he number of
ring gear and pinion gear teeth.
The differential case is a one-piece design. The dif-
ferential pinion mat e shaft is ret ai ned wi t h a roll
pin. Differential bearing preload and ri ng gear back-
lash are adjusted by t he use of shims located between
t he differential beari ng cones and case.
LUBRICANT
cant should be used for Model 44 axles. MOPAR Hy-
poid Gear Lubricant conforms wi t h these
specifications and is recommended.
C A U T I O N : If a front axle i s submer ged in water, the
axle lubricant must be replaced immediately.
J9202-105
Fig. 1 Model 44 Front Axle
DRAIN AND REFILL
(1) Drive t he vehicle until t he gear l ubri cant
reaches normal operating t emperat ure.
(2) Raise and support the vehicle.
(3) Remove t he lubricant fill hole plug from t he
differential housing cover.
(4) Remove t he differential housing cover. Allow
t he original lubricant to completely drain from t he
housing and axle shaft tubes.
(5) Wi t h st andard differential, clean t he differen-
tial and t he housing cavity with a flushing oil (or
light engine oil). This will remove t he residual lubri-
cant and foreign mat t er. Do not use water, steam,
kerosene or gasol i ne for flushing.
(6) Scrape t he residual gasket from the housi ng
and cover mat i ng surfaces. Clean t he mat i ng sur-
faces wi t h mi neral spirits. Install a new cover gas-
ket. Apply a bead of MOPAR Silicone Rubber
Sealant on t he housing cover (Fig. 2). Al l ow the
seal ant to cure for a few mi nutes.
SEALING
SURFACE
CONTOUR OF BEAD
BEAD
THICKNESS
6.35mm (1/ 4 ") J9302-30
Fig. 2 Sealant On Housing Cover
Install the housi ng cover within 5 mi nutes af-
ter appl yi ng the sealant. If not installed the seal-
ant must be removed and another bead appl i ed.
(7) Install t he cover on t he differential wi t h t he
bolts. Install t he identification tag. Tighten t he cover
C A U T I O N : Overfilling the differential can result in
the lubricant f oami ng and overheating.
(8) Refill t he differential housing with t he speci-
fied quant i t y of MOPAR Hypoid Gear Lubricant.
(9) Install t he fill hole plug and tighten to 34 N
#
m
(10) Road test t he vehicle.
PINION SHAFT SEAL
REMOVAL
(2) Mark the U-joint, pinion yoke, and pinion shaft
for reference.
(3) Disconnect t he drive shaft from t he pinion
yoke. Secure the drive shaft in an upri ght position to
prevent damage to t he rear U-joint.
(4) Remove t he pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove t he
pinion yoke (Fig. 3).
(5) Mark the positions of the yoke and pinion gear
for installation al i gnment reference.
SPECIAL TOOL
C-3281
SPECIAL TOOL
C-452 J9102-31
Fig. 3 Pinion Yoke Removal
(6) Use Remover C-748 to remove t he pinion gear
seal (Fig. 4).
PI NI ON SEAL
SPECIAL TOOL
C-748
Fig. 4 Pinion Seal Removal
J9203-55

INSTALLATION
(1) Apply a light coating of gear lubricant on t he
lip of pinion seal. Install t he new seal (Fig. 5) use In-
staller W-147-E and Handle C-4171.
Fig. 5 Pinion Seal Installation
(2) Align t he installation reference marks and po-
sition t he yoke on t he pinion gear.
(3) Install t he pinion yoke, washer, and nut on
shaft. Tighten t he nut to 271-298 Nm (200-220 ft.
lbs.) torque (Fig. 6).
DIFFERENTIAL
Fig. 6 Tightening Pinion Shaft Nut
(4) Align t he installation reference mar ks and at-
tach the drive shaft to t he yoke.
(5) Add API grade GL 5 hypoid gear lubricant to
t he differential housing, if necessary.
(6) Lower t he vehicle.
HUB, SPINDLE AND AXLE SHAFT
REMOVAL/DISASSEMBLY
(1) Raise and support t he front of vehicle.
(3) Remove t he brake caliper and adapter, refer to
Group 5, Brakes. Support t he caliper to t he frame
st ruct ure with wire.
(4) Remove t he dust cap and drive hub snap ri ng
(Fig. 7).
Fig. 7 Drive Hub Snap Ring
(5) Remove the drive hub and spacer (Fig. 8).
(6) Remove t he wheel beari ng outer lock nut with
Wrench C-4170-A (Fig. 9).
(7) Remove t he lock washer and i nner lock nut
(Fig. 10).
(8) Remove t he hub and rotor assembly from t he
spindle.
(9) Remove t he nut s t hat at t ach t he spindle to t he
steering knuckle. Remove t he spindle from t he
knuckle, use a soft faced mallet if necessary to t ap
loose (Fig. 11).
(10) Pull t he axle shaft (with spacer, seal and
slinger) from t he steering knuckle (Fig. 12).
(11) Clamp t he spindle in a soft-jawed vise. Do not
clamp at t he bearing contact surfaces. Remove t he
beari ng seal.
(12) Use Puller D-131 to remove needle bearings
from t he spindle (Fig. 13).

Fig. 8 Spacer Removal/Installation
Fig. 9 Wheel Bearing Lock Nut Removal
ASSEMBL Y/INSTALLA TION
(1) Add Wheel Bearing Grease lubricant (NLGI
Grade 2, EP or an equivalent lubricant) to t he bear-
ings. Install a new needle beari ng in t he spindle with
Installer D-122 and Handle C-4171 (Fig. 14).
(2) Lubricate and install a new spindle seal with
Installer D-155 and Handle C-4171 (Fig. 15).
(3) Install t he seal with lip facing t he axle shaft
splines (Fig. 16). Lubricate t he seal (Fig. 17) with
Wheel Beari ng Grease lubricant (NLGI Grade 2, EP
LOCK WASHER I NNER LOCK NUT
Fig. 10 Lock Washer Removal/Installation
Fig. 11 Spindle Removal
(4) Right side only: carefully install t he axle shaft
t hrough t he knuckle into t he axle housing. Ensure
t he axle shaft splines are engaged with t he differen-
tial side gears. Avoi d damagi ng the differential
seals.
(5) Left side only: remove t he shift motor housing
from axle. Position t he shift collar on the intermedi-
ate axle shaft. Install t he axle shaft, ensure t he axle
shaft splines are engaged wi t h t he shift collar. In-
stall t he shift motor (ensure t he fork is engaged with
t he shift collar) and t i ght en t he bolts to 14 Nnn (10
ft. lbs.) torque.
(6) Install t he spacer on t he axle shaft end.
(7) Install t he brake splash shield and spindle on
t he steering knuckle. Install new nut s and t i ght en to
34-41 Nnn (25-35 ft. lbs.) torque (Fig. 18).
J9202-79
Fig. 12 Axle Shaft Removal
Fig. 13 Spindle Needle Bearing Removal
(8) Install t he hub and rotor assembly onto t he
spindle. Add Wheel Beari ng Grease lubricant (NLGI
ings.
(9) Install t he wheel beari ng i nner lock nut on t he
spindle with Wrench C-4170 (Fig. 19). Tighten t he
lock nut to 68 N*m (50 ft. lbs.) torque to seat t he
bearings.
(10) Loosen t he i nner lock nut . Tighten to 41-54
N*m (31-39 ft. lbs.) torque while rot at i ng t he hub and
rotor assembly.
(11) Back off t he i nner lock nut 135-150 degrees to
set t he free play.
(12) Install t he tabbed lock washer in t he nearest
hole in t he washer (Fig. 8). Install and t i ght en t he
outer nut lock with Wrench C-4170 (Fig. 19 ) to 68
Nm (50 ft. lbs.) torque. The end play after t he final

Fig. 14 Spindle Needle Bearing Installation
Fig. 15 Seal Installation
beari ng adjustment should be wi t hi n 0.001 inch to
0.010 inch (0.03 to 0.25 mm).
(13) Install t he spacer, driving hub and ring (Fig.
7, 8). Ensure t he ri ng is seated.
(14) Apply MOPAR Silicone Rubber Sealant to
t he edge of t he dust cap and install cap onto hub.
(15) Install t he brake caliper and adapter, refer to
Group 5, Brakes.
TireInstallation within t hi s section. Lower t he ve-
hicle.
STEERING AXLE SHAFT

RN328
Fig. 17 Lubricating Axle Shaft Seal
Fig. 18 Spindle Installation
AXLE SHAFT AND U-JOINT SERVICE
DISASSEMBLY
(1) Remove t he snap ri ngs from t he yokes.
Fig. 19 Wheel Bearing Lock Nut Installation
(2) Position t he U-joint on t he top of t he vise j aws
(Fig. 20) . Do not t i ght en t he vise.
Fig. 20 Bearing Cap Removal
(3) Use a mal l et to drive t he vertical yoke down-
ward to remove t he upper needle bearing and cap out
(Fig. 20) .
(4 ) Reverse t he position of t he yoke and remove op-
posite needle beari ng and cap (Fig. 20) .
(5) Remove t he yoke from t he spider.
(6 ) Position t he open ends of t he spider in a soft-
jawed vise. Repeat steps 3 and 4 (above) to remove
remai ni ng beari ngs and caps.
(7) Remove t he spider from t he yoke.
(8) Clean and inspect all t he components. Clean
any rust from t he axle shaft splines. Retain each
bearing and cap separate. If any component is exces-
sively worn or damaged, replace t he U-joint.
ASSEMBLY
(1) Insert t he needle beari ng and cap in one yoke
ar m bore.
(2) Place t he yoke in a vise (Fig. 21) and press t he
needle beari ng and cap into position. Install t he snap
ring.
Fig. 21 Bearing Cap installation
(3) Remove t he yoke from t he vise and insert one
end of t he spider into t he bearing. Insert opposite
beari ng and cap in t he yoke ar m bore by hand and
align it with t he spider.
(4) Place t he yoke in a vise and press t he cap into
t he yoke ar m bore and onto t he spider (Fig. 22).
YOKE
RH403
Fig. 22 Bearing Cap & Spider Installation
(5) Use a short plug or a socket wrench to force t he
beari ng cap into t he correct position and install t he
snap ring.
(6) Repeat t he instructions in steps 1 t hrough 5 for
installing remai ni ng bearings, caps and yoke.
STEERING KNUCKLE, UPPER AI D LOWER BALL STUDS
REMOVAL/DISASSEMBLY
(1) Remove axle shaft, refer to Hub, Spindle and
Axle Shaft Removal.
(2) Disconnect t he tie-rod end from t he steering
knuckle arm.
(3) Remove t he cotter pin from t he upper ball stud
nut . Remove t he upper and lower ball stud nut s (Fig.
23). Discard t he lower nut.
WR E N C H
STEERI NG
KNUCKLE
J9202-83
Fig. 23 Upper Ball Stud Nut Removal
(4) Separate t he steering knuckle from t he t ube
wi t h a soft hammer (Fig. 24).
RAWHI DE
HA M M E R
UPPER
BALL STUD
STEERI NG
KNUCKLE
J9202-84
Fig. 24 Steering Knuckle Removal

FRONT SUSPENSION AND AX LE 2 - 25
(5) Remove t he sleeve from t he upper yoke wi t h
Wrench C-4169 (Fig. 25). Discard t he sleeve.
Fig. 25 Sleeve Removal/Installation
(6) Remove t he snap ri ng ret ai ni ng t he lower ball
stud wi t h Snap Ring Pliers (Fig. 26).
Fig. 26 Snap Ring Removal/Installation
(7) Remove t he lower ball stud from steering
knuckle with Remover/Installer C-4212-L and Adap-
tor Set C-4288 (Fig. 27).
(8) Re-position t he tools and remove t he upper ball
stud (Fig. 28).
(9) Clean all components with solvent and dry
with compressed air. Inspect all t he components for
Fig. 28 Upper Ball Stud Removal
burrs, chips, excessive wear and cracks. Replace com-
ponents as necessary.
(1) Install lower ball stud with Remover/Installer
C-4212-L and Adaptor Set C-4288 (Fig. 29). Install
t he snap ring ret ai ni ng t he lower ball stud. Ensure
t he ri ng is seated.
(2) Inst al l t he upper ball stud wi t h Remover/In-
staller C-4212-L and Adaptor Set C-4288 (Fig. 30).
Install new rubber boots over both ball studs. Re-
move t he steering knuckle from t he vise.

Fig. 29 Lower Ball Stud Installation
(3) Thread new sleeve into t he upper yoke wi t h
Wrench C-4169 (Fig. 25). Allow two t hreads to re-
mai n exposed at t he top.
(4) Position steering knuckle on t he yoke arms. In-
stall a new lower ball stud nut and t i ght en to 108
Nnn (80 ft. lbs.) torque.
(5) Tighten t he sleeve in upper yoke ar m to 54 N*
(40 ft. lbs.) torque wi t h Wrench C-4169.
(6) Install t he upper ball stud nut and t i ght en to
136 Nnn (100 ft. lbs.) torque. Tighten t he nut unt i l
C-4212-L
C- 4288- 1
J9202-90
Fig. 30 Upper Ball Stud Installation
t he cotter pin can be installed. Do not loosen t he nut
to align t he hole and t he slot. Install a new cotter
pin.
VACUUM SHIFT MOTOR
VACUUM CONTROL SYSTEM (FIG. 31)
The disconnect axle control system consists of;
Vacuum control switch on t he transfer case
Air vent filter
Shift motor
Indicator switch
Vacuum switch
Two check valves
And a harness
Refer to Group 21, Transmi ssi ons for addi-
tional information.
NUT
LEFT ENGINE
MOUNT
LEFT ENGINE MOUNT
NUT ANDyv
WASHER <C>
VIEW IN DIRECTION
OF ARROW W
T O R QU E
LET.
P O U N D S
NEWTON
METRES
FULLY SEATED
HAND TIGHTENED
55 IN. 6
15 FT. 20
CLI P
ALIGN WHITE TAPE
TO END OF CLIP
VIEW IN DIRECTION
OF ARROW Z
WITH V-6
CLIP.
SHIFT MOTOR
ROUTE HOSE TO
REAR OF DISTRIBUTOR
VI EW IN DIRECTION
OF ARROW Z
VIEW I N DIRECTION
OF ARROW X
J9102-61
Fig. 31 Disconnect Axle Vacuum Hose Routing
DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS
TWO-WHEEL DRI VE OPERATI ON DIAGNOSIS
F O U R - WHE E L D R I V E
I N D I C A T O R LI GHT WI L L
N O T G O O U T WH E N
T R A N S F E R C A S E S E L E C T OR
I S M O V E D F R O M 4H TO
2H PO S I T I O N .
R A I S E V E HI C L E S O ALL
F O U R WH E E L S A R E
FREE T O ROTATE.
I N S PE C T I N D I C A T O R
S WI T C H A N D WI R I N G O N
SHI FT M O T O R H O U S I N G
FOR D A M A G E A N D
S HOR T - C I R C UI T .
REPAI R A S N E C E S S A R Y .
Y E S i
START E N G I N E D E PR E S S BR A K E
PE DAL . PLACE T R A N S F E R
C A S E S E L E C T OR I N 2 H PO S I T I O N
A N D T R A N S M I S S I O N I N
D R I V E ( AUT OMAT I C ) O R FI RST
G E A R ( M A N U A L ) . E A S E OFF F R O M
BR A K E A N D LET WH E E L S ROTATE
SLOWLY.
TEST C O M PL E T E
F R O N T D R I V E
S HA F T D O E S
N O T ROTATE.
F R O N T D R I V E
S HAF T ROTATES.
F O U R - WHE E L D R I V E
I N D I C A T O R LI GHT
R E M A I N S O N .
I N S PE C T T R A N S F E R
C A S E L I N K A G E .
PLACE T R A N S M I S S I O N
I N N E U T R A L . TEST FOR V A C U U M
I N V A C U U M H O S E
THAT C O N N E C T S TO
I N B O A R D SHI FT
M O T O R PORT.
( V A C U U M S H O U L D BE
BE T WE E N 10-20 I N . HG. )
C HE C K T R A N S F E R
C A S E . REPAI R
A S N E C E S S A R Y .
N O V A C U U M
O R L O W V A C U U M .
V A C U U M O K
I N S PE C T I N T A K E M A N I F O L D
V A C U U M SUPPLY H O S E C O N N E C T I O N ,
T R A N S F E R C A S E V A C U U M S WI T C H
C O N N E C T I O N , V A C U U M R E S E R V O I R ,
A N D S HI FT S YS T E M V A C U U M H O S E S
F OR PR O PE R C O N N E C T I O N , R E S T R I C T I O N ,
A I R L E A K S , A N D D A M A G E . REPAI R O R R E PL AC E
A S N E C E S S A R Y .
S T OP E N G I N E
r ~
F R O N T AXL E
D I S C O N N E C T S .
I N S PE C T V A C U U M
H O S E S FOR A I R L E A K S , K I N K S , ETC.
RE PAI R A S N E C E S S A R Y .
F R O N T AXL E
D O E S N O T
D I S C O N N E C T .
R E M O V E SHI FT M O T O R
H O U S I N G C O V E R . C O N N E C T
V A C U U M PU M P T O
SHI FT M O T O R PORT.
R E PL AC E SHI FT M O T O R
IF A R M A T U R E D O E S
N O T M O V E I N A N D O U T
FREELY.
F R O N T AXL E
WI L L N O T D I S C O N N E C T .
J9002-95
R E M O V E SHI FT M O T O R H O U S I N G
C O V E R . I N S PE C T SHI FT F O R K ,
C O L L A R , A N D AXL E S HA F T S .
REPAI R O R RE PLACE A S
N E C E S S A R Y
DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS (CONT'D)
FOUR-WHEEL DRI VE OPERATI ON D I A G N O S I S
FOUR - WHE E L DR I V E I NDI C AT OR
LI GHT D O E S N O T LI GHT WH E N
T R A N S F E R C A S E SELECTOR I N
4H O R 4L PO S I T I O N .
R A I S E V E HI CLE S O ALL FOUR
WHE E L S A R E FREE TO ROTATE.
START E N G I N E , D E PR E S S BR AKE PEDAL.
PLACE T R A N S F E R C A S E SELECTOR I N 4H
PO S I T I O N A N D T R A N S M I S S I O N LEVER I N
DRI V E (AUTOMATI C) O R I N FIRST G E A R
( MA N U A L ) TO C O N F I R M T R ANS FE R C A S E
E N G A G E M E N T I N 4H. LET WHE E L S
ROTATE SLOWLY.
FRONT DR I V E
SHAFT D O E S
N OT ROTATE.
F R ONT DR I V E
S HAFT T U R N S .
I NS PE C T T R ANS FE R
C A S E L I N K A G E .
C HE C K T R ANS FE R
C A S E . REPAI R A S
N E C E S S A R Y.
F R O N T AXLE
C O N N E C T S .
F OU R - WHE E L DR I V E
I N D I C A T OR LI GHT
D O E S N O T LIGHT.
I NS PE C T F WD I NDI C AT OR
S WI T C H, WI R I N G , A N D
L AMP FOR D A M A G E .
REPAI R A S N E C E S S A R Y.
R E C O M M E N D A T I O N :
C HE C K V A C U U M
SHI FT S YS T E M
FOR PROPER
O PE R A T I O N .
PLACE T R A N S M I S S I O N
LEVER I N N E U T R A L
PO S I T I O N .
FR ONT AXLE
D O E S N O T
C O N N E C T .
R E M O V E V A C U U M H O S E S
FR OM AXLE SHI FT
MOT OR PORTS.
START E N G I N E . TEST FOR V A C U U M
AT H O S E R E M O V E D F R OM OUT-
BO A R D PORT O N SHI FT M O T O R ,
S HO U L D BE BE T WE E N 10-20 I N HG .
N O V A C U U M
O R L OW V A C U U M.
S TOP E N G I N E
H
V AC UUM O K
I N S PE C T I NTAKE M A N I F O L D
V A C U U M SUPPLY H O S E C O N N E C T I O N ,
T R A N S F E R C A S E V AC UUM S WI T C H
C O N N E C T I O N , V A C U U M R E S E R V OI R , A N D SHI FT
S YS T E M V A C U U M H O S E S FOR PROPER C O N N E C T I O N ,
R E S T R I C T I O N , L E AKS , A N D D A M A G E .
REPAI R O R REPLACE A S N E C E S S A R Y.
C O N N E C T A V A C U U M PU MP
TO THE O U T BO A R D
SHI FT MO T O R PORT.
APPLY 15 I N C H E S HG . V A C U U M
A N D ROTATE LEFT WHE E L .
N O V A C U U M
FR ONT AXLE
C O N N E C T E D .
C HE C K T R ANS FE R C A S E
V A C U U M S WI T C H. REPLACE
O R REPAI R IF S WI T C H
PL U N G E R I S DIFFICULT TO
M O V E O R BI N D S .
FRONT AXLE
D O E S N O T
C O N N E C T .
I NS PE C T V A C U U M H O S E S
FOR L E AKS , K I N K S , ETC.
REPAI R A S N E C E S S A R Y.
R E MO V E SHI FT MO T O R
H O U S I N G C O V E R . C O N N E C T
V A C U U M PU MP TO
SHI FT MO T O R PORT.
REPLACE SHI FT M O T O R
IF AR MAT UR E D O E S
N OT M O V E I N A N D O U T
FREELY.
C OV E R . I NS PE C T SHI FT FOR K,
C OL L AR , A N D AXLE S HAFT S .
REPAI R O R REPLACE A S
N E C E S S A R Y.
* R E M O V E SHI FT M O T O R H O U S I N G
N E C E S S A R Y.
FRONT AXLE
WI LL N O T C O N N E C T .
N E C E S S A R Y.
FRONT AXLE
WI LL N O T C O N N E C T .
N E C E S S A R Y.
J9002-96

REMOVAUDISASSEMBL Y
(2) Disconnect t he vacuum and wiring connector
from t he shift housing.
(3) Remove t he shift motor housing cover, gasket
and shield from t he housing.
(4) Remove t he E-clips from t he shift motor hous-
ing and shaft. Remove shift motor and shift fork
from t he housing (Fig. 32).
Fig. 32 Vacuum Shift Motor Components
(5) Remove t he O-ring seal from t he shift motor
shaft.
(6) Clean and inspect all t he components. If any
component is excessively worn or damaged, it should
be replaced.
ASSEMBL Y/IHSTALLA TION
(1) Install a replacement O-ring seal on t he shift
motor shaft (Fig. 32).
(2) Insert t he shift motor shaft t hrough t he hole in
t he housing and shift fork. The shift fork offset
should be toward t he differential.
(3) Install t he E-clips on t he shift motor shaft and
housing.
(4) Install t he shift motor housing gasket and
cover. Ensure the shift fork is correctly gui ded
into the shift collar groove.
(5) Install t he shift motor housing shield and bolts.
Tighten t he bolts to 14 N*m (10 ft. lbs.) torque.
INTERMEDIATE AXLE SHAFT
REMOVAL/DISASSEMBLY
(1) Remove t he vacuum motor housing from t he
axle, refer to Vacuum Shift Motor Removal.
(2) Remove t he hub, spindle and axle shaft, refer
to t he removal procedures above.
(3) Remove t he shift collar from t he shift motor
housing.
(4) Remove t he differential housing cover and
drain t he lubricant.
(5) Push the i nt ermedi at e axle shaft toward t he
center of t he vehicle. Remove t he C-lock from t he
shaft and side gear in t he differential.
(6) Remove t he intermediate axle shaft with Re-
mover/Installer D-354-4 and Adaptor D-354-3 (Fig.
33).
J9202-104
Fig. 33 intermediate Axle Shaft Removal/Installation
(7) Remove t he i nt ermedi at e axle shaft beari ng
with Tool D-354-4, Tool D-354-1, and Slide Hammer
C-637 (Fig. 34, 35).
(8) Remove t he needle bearing from intermediate
axle shaft with Remover/Installer D-330 (Fig. 34, 35).
RK724
Fig. 34 Intermediate Shaft Bearing Removal
(9) Remove t he i nner axle shaft seal from t he shift
motor housing. Certain vehicles could also have a
seal guard; discard both components. The guard is
not used wi t h a replacement seal.

Fig. 35 Disconnect Axle Service Tools
ASSEMBLY/INSTALLATION
(1) Install t he needle beari ng in the end of t he in-
termediate shaft with Inst al l er D-328 and Driver
Handle C-4171 (Fig. 36).
RK 727
Fig. 36 Intermediate Shaft Bearing installation
(2) Install t he i nt ermedi at e axle shaft beari ng with
Tool D-354-4, Tool 354-2 and Slide Hammer C-637
(Fig. 34, 35).
(3) Install t he i nt ermedi at e axle shaft with Tool
D-354-4 and Adaptor Tool D-354-3.
(4) Install t he C-lock in t he axle shaft and side
gear.
(5) Clean t he t ube bore and remove any rust from
t he seal area.
(6) Place t he axle shaft seal on Tool 5041-1 and po-
sition in housing. Thread Tool 5041-2 t hrough t he
seal into Tool 5041-1. Install Tool 5041-3 and nut on
the end of t he threaded bar tool. Tighten the nut un-
til t he tool contacts t he t hreaded bar shoulder.
(7) Install t he shift collar on t he splined end of t he
intermediate axle shaft.
(8) Lubricate t he splined end of the intermediate
axle shaft with multi-purpose lubricant.
(9) Install t he axle shaft, spindle and hub, refer to
the installation procedures above.
(10) Install t he shift motor housing, refer to Vac-
uum Shift Motor Installation.
STEERING KNUCKLE ARM
REMOVAL
(1) Inst al l Puller C-4150 on each drag-link ball
stud. Apply sufficient force with t he tool to loosen
the drag-link ball stud from the steering arm.
(2) Remove t he lock nut s t hat at t ach t he steering
arm to t he knuckle (Fig. 37). Tap t he steering ar m to
loosen it from the knuckle. Pry upward to remove.
Fig. 37 Steering Knuckle Arm Removal
INSTALLATION
(1) Position t he steering arm on t he knuckle. In-
stall t he nut s. Tighten t he nut s to 122 Nm (90 ft.
lbs.).
(2) Position the drag link at steering knuckle arm.
(3) Install and t i ght en t he ball stud nut to 81 N*m
(60 ft. lbs.) torque. Install new cotter pins.
COMPLETE AXLE REMOVAL/INSTALLATION
SERVICE INFORMATION
It is not necessary to remove t he complete front
axle from t he vehicle for routine service. If the hous-
ing or axle shaft tubes are damaged, t he complete
axle can be removed and installed via t he following
procedures.
REMOVAL
(1) Remove t he front wheels/tires.
(2) Mark the front drive shaft and t he pinion yoke
for installation alignment reference.
(3) Disconnect t he front drive shaft from t he axle
yoke. At t ach t he drive shaft to t he frame rail wi t h
wire.
(4) Remove t he cotter pin, nut, and disconnect t he
drag link from t he steering knuckle arm (left side
only). Discard the cotter pin.

(5) Disconnect flexible brake fluid hose fittings at
t he frame crossmember. Pl ug t he hoses at t he fit-
tings.
(6) Remove t he shock absorber lower nut and stud
from t he axle shaft tube bracket. Remove t he nut s
and disconnect t he stabilizer bar links from t he
spring brackets.
(7) Disconnect t he vacuum hoses and wi ri ng con-
nections from t he shift motor housing.
(8) Remove nut s and t he washers from t he spring
U-bolts. Remove t he complete front axle from t he ve-
hicle.
INSTALLATION
(1) Position t he front axle under t he front of t he
vehicle with t he axle spring pads under t he springs.
Place t he spring brackets over t he springs. Make
sure t he stabilizer bar link bolt holes face toward t he
rear of t he vehicle.
(2) Install t he spring U-bolts, washers and nut s.
Refer to Front Suspension 4WD Vehicles within
t hi s group.
(3) Install t he shock absorber. Refer to Front Sus-
pension 4WD Vehicles within t hi s group.
(4) Connect t he stabilizer bar links to t he spring
brackets. Refer to Front Suspension-4WD Vehicles
wi t hi n this group.
(5) Remove plugs and connect t he brake hose fit-
t i ngs. Refer to Group 5, Brakes.
(6) Connect t he drag-link ball stud to t he steering
knuckle arm. Refer to Group 19, Steering.
(7) Connect t he drive shaft to t he pinion yoke wi t h
t he installation reference mar ks aligned. Install t he
washers and t he nut s and t i ght en to 19 N*m (14 ft.
lbs.) torque.
(8) Connect t he vacuum hoses and wi ri ng connec-
tions to t he shift motor housing.
(9) Remove t he supports, lower t he vehicle and re-
move t he block from t he brake pedal.
Bleed and adjust t he brakes
Lubricate all t he ball stud fittings
Inspect t he differential housing lubricant level. Re-
fer to Group 0, Lubrication and Mai nt enance.
(11) Lower t he vehicle and test t he axle and sus-
pension operation.
DIFFERENTIAL DI SASSEMBLY
REMOVAL/DISASSEMBLY
(1) Note the installation reference letters
stamped on the beari ng caps and housi ng ma-
chi ned seal i ng surface (Fig. 38).
(2) Remove t he differential beari ng caps.
(3) Position Spreader W-129-A with t he tool dowel
pins seated in t he locating holes (Fig. 39). Install t he
holddown clamps and t i ght en t he tool t urnbuckl e fin-
ger-tight.
INSTALLATION
EFERENCE LETTERS
J9003-92
Fig. 38 Bearing Cap Identification
SPECIAL TOOL
MODEL 44- W- 12 9- A
MODEL 60 - D- 167
DIAL
INDICATOR
ar"P
J9202-113
Fig. 39 Differential Housing Separation
(4) Install a pilot stud at t he left side of t he differ-
ential housing. Attach Dial Indicator to housing pilot
stud. Load t he indicator plunger agai nst t he opposite
side of t he housing (Fig. 39) and zero t he indicator.
C A U T I O N : D o not spread over the specified di s-
tance. If the housi ng i s over- separated, it coul d be
distorted or damaged.
(5) Separate t he housing enough to remove t he
case from t he housing. Separate housi ng a maxi-
mum di stance of 0.38 mm (0.015 in) wi th the
spreader tool. Measure t he distance with t he dial
indicator (Fig. 39).
(6) Remove t he dial indicator.
(7) Pry t he differential case loose from t he hous-
ing. To prevent damage, pivot on housing with t he
end of t he pry bar agai nst case.
(8) Remove t he case from housing. If they are re-
usable, ret ai n t he differential bearing cups and bear-
ings together as matched sets.

(9) Clamp the differential case in a vise equipped
with soft jaws. Remove and discard the ring gear
bolts. Tap the ring gear with a rawhide mallet and
remove (Fig. 40).
RING GEAR
SPECIAL TOOL
C-3281
SPECIAL TOOL
C-452 J9102-31
RAWHIDE
HAMMER
J9202-76
Fig. 40 Ring Gear Removal
(10) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
(11) Use Remover C-748 to remove the pinion gear
seal.
(12) Remove oil slinger, front bearing and shims
(Fig. 42). Record the thickness of the shims. This will
save time if they should become misplaced.
(13) Remove the front pinion bearing cup with Re-
mover D-158 and Handle C-4171 (Fig. 43).
(14) Remove the rear bearing cup from housing
(Fig. 44). Use Remover D-162 and Handle C-4171.
(15) Remove the depth shims from the housing
bore. Record the thickness of the depth shims.
(16) Remove the inner bearing from the pinion
with Puller C-293-PA and Plate C-293-39 (Fig. 45).
PINION
YOKE
WASHER
SLINGER
PINION
PRELOAD
SHIMS
FRONT
BEARING
CUP
PINION PRELOAD
SPACER
PINION
NUT
PINION
OIL SEAL
FRONT
BEARING
CONE
SHOULDER FOR
PINION PRELOAD SPACER
J9203-63
Fig. 42 Pinion Front Bearing and Preload Shims

SPECIAL TOOL SPECIAL TOOL
D-158 C- 4171
Fig. 44 Rear Bearing Cup Removal
(17) Clamp t he differential case in a vise equipped
wi t h soft jaws. Use a pin punch to remove t he pinion
gear mat e shaft lock pin (Fig, 46).
(18) Remove t he mat e shaft with a drift and ham-
mer (Fig. 47).
(19) Rotate t he differential side gears and remove
t he pinion mat e gears and t hr ust washers (Fig. 48).
(20) Remove t he differential side gears and t hr ust
washers.
(21) Remove t he case from t he vise.
SPECIAL
TOOL
C-293-PA
Fig. 46 Mate Shaft Lock Pin Removal
(22) Remove t he bearings from t he differential
case with Press C-293-PA, Pl ug C-293-3, Pl at e
C-293-18 and a vise (Fig. 49).
Use care that adapter rings are pl aced so they
do not damage the beari ng cage.
(23) Remove beari ng shims from case hubs and
mar k t hem (with hub identity) for assembly refer-
ence. Record t he thickness of t he shims.
CLEANING/INSPECTION
(1) Wash and clean all t he differential components
with cleaning solvent. Dry with compressed air.
Do not steam cl ean the differential compo-
nents.
(2) Clean t he axle shaft tubes. Insert a stiff wire
into each tube, at t ach a clean cloth to t he wire at t he

PINION MATE SHAFT
ADAPTERS
DRIFT
J9203-60
Fig. 47 Mate Shaft Removal
THRUST
WASHER
PINION
MATE GEAR SIDE GEAR J9203-61
Fig. 48 Pinion Mate Gear Removal
housing opening. Draw the wire (and cloth) from the
housing outward t hrough t he t ube.
(3) Inspect the differential and pinion gear bearings.
Inspect the differential case and housing.
Bearings and cups should have a smooth appear-
ance.
Bearing races must not be distorted or cracked
Cup and beari ng must be repl aced as a
matched set only.
All machined surfaces in the housing and on bearing
caps should be smooth and without any raised edges.
Pinion gear front and rear bearing cup bores
should be smooth
Raised met al on shoulders of cup bores should be
removed with a hand stone
PLUG
SPECIAL
TOOL
C-293-PA
J9202-42
Fig. 49 Differential Bearing Removal
(4) Exami ne t he differential pinion mat e shaft,
pinion gears, side gears and t hr ust washers for wear
and damage. Replace all defective components.
If either of the differential pi ni on gears is not
reusabl e, both gears must be repl aced as a
matched set only. Do not repl ace only one gear.
(5) Exami ne t he ri ng gear and t he pinion gear for
worn and chipped teeth. Exami ne t he ri ng gear for
damaged bolt t hreads.
If repl acement of either gear is necessary, both
must be repl aced as a matched set only.
(6) Inspect t he pinion yoke for cracks, worn
splines, pitted areas, and a rough/corroded seal con-
tact surface. Repair or replace t he yoke as necessary.
(7) Inspect t he pinion beari ng preload shims for
cracks, damage and distortion. Install replacement
shims (if necessary) for the preload torque adjust-
ment.
DIFFERENTIAL ASSEMBLY
ASSEMBLY
(1) Install t he following components in t he differ-
ential case.
Differential side gears and t hr ust washers
Pinion gears and t hrust washers

Pinion gear mat e shaft (align holes in shaft and
case)
(2) Install and seat t he lock pin in t he differential
case and mat e shaft with a punch and hammer (Fig.
50). Peen met al par t of case over pin in two places.
If repl acement gears and thrust washers were
installed, it is not necessary to measure the gear
backl ash. Correct fit is due to cl ose machi ni ng
tol erances during manufacture.
Fig. 50 Mate Shaft Pin installation
(3) Invert t he differential case and st art two ri ng
gear bolts. This will provide case-to-ring gear bolt
hole al i gnment (Fig. 51).
(4) Install new ri ng gear bolts and al t ernat el y
t i ght en to 61-81 N*m (45-60 ft. lbs.) torque.
(5) Lubricate all differential components with hy-
poid gear lubricant.
(6) Place Mast er Differential Bearing D-345
(D-135) on t he case hubs (Fig. 52).
(7) Install a pilot st ud at t he ri ght side of housing.
Attach Dial Indicator C-3339 to t he pilot stud. Load
indicator plunger agai nst t he back of t he ri ng gear
(Fig. 53).
(8) Insert a small pry bar between t he beari ng cap
and left side of differential case. Pry t he case as far
as possible to ri ght side (Fig. 53). Zero t he dial indi-
cator pointer.
(9) Pry t he case to left side and record t he t ravel
distance.
The measurement above is the shi m thi ckness
necessary for case zero end-play. The total
thi ckness will be determi ned duri ng the ri ng
gear backl ash adjustment.
(10) Remove indicator and pilot stud.
TORQUE
Fig. 51 Ring Gear Bolt Hole Installation
SPECIAL TOOL
D-345
J9203-20
Fig. 52 Master Bearing Tools On Hubs
PINION GEAR DEPTH INFORMATION
Gears are supplied as matched sets only. The iden-
tifying numbers for t he ring and pinion gear are
etched into t he face of each gear (Fig. 54). A plus ( + )
number, mi nus (-) number or zero (0) is etched into
t he face of t he pinion gear. This number is t he
amount (in t housandt hs of an inch) t he depth varies
from t he st andard depth setting. The st andard depth
provides t he best tooth contact pat t ern.

Fig, 53 Differential Case End Play Measurement
DRIVE PINION
Fig. 54 Pinion Gear ID Numbers
The st andard depth is t he distance (Fig. 55) from
the centerline of t he axle shaft/ring gear to the
shoulder of t he rear pinion bearing.
Compensation for depth variance is achieved by
shims placed adjacent to t he pinion gear r ear bearing
cup (Fig. 56).
If a new gear set is being installed, note t he depth
variance etched into t he original and new pinion
gear. Add or subtract t he thickness of t he original
depth shims to compensate for t he difference in t he
depth variances. Refer to t he Depth Variance charts.
For Example:
If a positive marki ng, t hi s means t he shim pack
must decrease by the same number of t housandt hs.
If a negative marki ng, t hi s means t he shim pack
must increase by t he same number of t housandt hs.
Fig. 55 Pinion Gear Standard Depth/Distance
DRIVE
Fig. 56 Shim Locations
If marked zero will use t he nominal setting as de-
t ermi ned in t hi s procedure.
Shims are available in 0.003-inch, 0.005-inch,
0.010-inch, and 0.030-inch thicknesses.
If original gear set is installed but t he depth shims
replaced, measure t he thickness of t he original depth
shims. Build a replacement pack of depth shims wi t h
t he same thickness.
If equi pped, the oil slinger must be measured
and the thi ckness i ncl uded wi th the total shi m
pack thi ckness.
The shim thickness for t he new pinion gear must
be determined before installing t he differential case.
AXLE DEPTH
MODEL SETTING

PINION GEAR DEPTH VARIANCE
Or@iftî Linton IsptocMnwtt HnSn Oi or Itoplli fflttanct Or@iftî Linton
- 4 - 2 - 1 0 + 1 -ft + 3 +4
+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+ 3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001
+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002
+ 1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003
0 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 - 0.003 -0.004
- 1 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
- 2 + 0.002 + 0.001 . 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
- 3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
- . 4
0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
PINION GEAR DEPTH MEASUREMENT AND
ADJUSTMENT WITH TOOL SET D-1114 4
The following gear depth measurement and adjust-
ment procedure involves using Tool Set D-115-44.
(1) Insert Master Pinion Block D-139 into t he dif-
ferential housing (Fig. 57).
PI NI ON BLOCK TOOL
PI NI ON BLOCK TOOL
J8902-46
DIFFERENTIAL
HOUS I NG
ARBOR DI SC TOOL
ARBOR
TOOL
J9003-103
DIFFERENTIAL
HOUS I NG J9003-101
Fig. 57 Pinion Block In Shaft Bore
(2) Place Disc D-115-4 on Arbor D-115-3 and posi-
tion in t he bearing cradles (Fig. 58). This is t he cen-
terline of t he ri ng gear/axle shaft.
(3) Place Pinion Height Block D-115-1 on top of
mast er pinion block tool and agai nst arbor tool (Fig.
59).
(4) Place Gauge Block D-115-2 and Dial Indicator
D-106-5 on lowest step of block tool (Fig. 60). Zero
t he dial indicator pointer.
Fig. 58 Disc & Arbor In Housing
(5) Move t he gauge block toward t he arbor unt i l
t he indicator plunger contacts t he arbor tool (Fig.
60). Slide t he gauge block across t he arbor while ob-
serving indicator. Record t he longest travel distance,
whet her inward (-) or outward (+), indicated by t he
pointer.
The di stance indicated, plus or mi nus the
amount etched in the gear is the requi red thick-
ness.
(6) Measure t he thickness of each depth shim with
a micrometer and combine t he shims necessary for
total required pack thickness. Include oil sl i nger
thi ckness wi th the total shim pack thi ckness if
required.
(7) Remove t he measurement tools from t he differ-
ential housing.

Fig. 59 Pinion Height Block Against Arbor
Fig. 60 Pinion Gear Depth Measurement
(8) Place t he depth shims in t he pinion gear rear
bearing bore. Install t he bearing cup (Fig. 61) with
Installer D-145 and Handl e C-4171.
Ensure t he cup is correctly seated.
(9) Install t he pinion front bearing cup with In-
staller D-144 and Handl e C-4171 (Fig. 62).
(10) Install the r ear beari ng (and slinger if used)
on t he pinion gear with Installer W-262 until com-
pletely seated (Fig. 63).
(11) Assemble preload shims onto pinion and in-
stall t he pinion gear in housing.
(12) Install pinion front bearing, oil slinger, yoke,
washer and nut. Install t he yoke with Installer
C-3718 and Wrench C-3281 (Fig. 64).
(13) Tighten t he yoke nut to 271-298 N-m (200-220
ft. lbs.) torque.
(14) Check beari ng preload torque with an inch
pound torque wrench (Fig. 65). The torque necessary
to rotate t he pinion gear should be;
Original Bearings 1 to 3 N*m (10 to 20 in. lbs.)
New Bearings 2 to 5 N*m (20 to 40 in. lbs.)
SPECIAL TOOL
C-4171 J9202-95
Fig. 61 Pinion Rear Bearing Cup Installation
SPECIAL TOOL
D-144 SPECIAL
Fig. 62 Pinion Front Bearing Cup Installation
If t he preload torque is not within t he specified tol-
erance, correct t he shim thickness accordingly (Fig.
66);
Increase t he preload torque, decrease t he shim
thickness
Decrease t he preload torque, increase t he shim
thickness
lip of pinion seal. Install t he new seal (Fig. 68) with
Installer W-147-E and Handle C-4171
(17) Install t he yoke wi t h Installer C-3718 and
Wrench C-3281 (Fig. 64).
(18) Install a new yoke nut and t i ght en to 271 to
298 N-m (200 to 220 ft. lbs.) torque.

S H I M PA C K S RY660
J9103-21
Fig. 64 Pinion Yoke Installation
ADJUSTMENT WITH TOOL SET C-3715-B
The al t ernat e measurement and adjustment proce-
dure involves usi ng Axle Measurement Gauge Set
C-3715-B.
(1) Install t he pinion rear beari ng cup (Fig. 69)
with Installer D-145 and Handl e C-4171
(2) Install t he pinion front beari ng cup wi t h In-
staller D-144 and Handle C-4171 (Fig. 70).
As s embl e C- 3 7 1 5 - B Tool Set a s des cr i bed;
Position Spacer (SP-5586) over Shaft (SP-5385)
Position pinion rear beari ng on shaft
Position tools (with bearing) in t he housing
Install Sleeve (SP-5585)
Install pinion front bearing
m Install Sleeve (SP-3194-B), Washer (SP-534) and
Nut (SP-3193)
(3) Prevent compression sleeve tool from t ur ni ng
with Wrench C-3281. Tighten t he nut to seat t he pin-
ion bearings in t he housing (Fig. 71). Allow t he
sleeve to t ur n several times duri ng t he t i ght eni ng to
prevent brinelling t he beari ng cups or t he bearings.
De pt h shim(s) a r e pos i t i oned be t we e n t he pi n-
i on ge a r r e a r be a r i ng a n d pi ni on ge a r t o pr ovi de

FRONT SUSPENSION AND AXLE 2 - 4 1
SPECIAL TOOL
D-145
HANDLE
C-4171
SPECIAL
TOOL
C-4171 J9202-95
SPECIAL TOOL
D-144
SPECIAL
TOOL
C-4171
SPECIAL
TOOL
W-147-E
(J25104)
J9202-19
the separati on di stance. The required thi ckness
of the depth shim(s) is determi ned accordi ng to
the fol l owi ng information.
(4) Loosen t he compression nut tool. Lubricate t he
pinion gear front and rear bearings with gear lubri-
cant. Re-tighten t he compression nut tool to 1 to 3
Nm (15 to 25 in. lbs.) torque. Rotate t he pinion gear
several complete revolutions to align the beari ng
rollers.
(5) Install Gauge Block SP-5260 at t he end of SP-
526. Install Cap Screw (SP-536) and t i ght en with
Wrench SP-531.
(6) Position Crossbore Arbor (SP-5183) in t he dif-
ferential housing.
J9202-35
Center t he arbor in cradles so equal space exists at
both ends. Position t he bearing caps on t he arbor
tool. Install the bolts. Tighten t he cap bolts to 14
N*m (10 ft. lbs.) torque.
(7) Trial fit depth shim(s) or feeler gauge between
t he crossbore arbor and gauge block (Fig. 72). The fit
must be snug but not tight (drag friction of a
feeler gauge blade).
Depth shi ms are available in 0.001-inch incre-
ments from 0.020 i nch to 0.038 i nch.
(8) Note t he etched number on t he face of t he drive
pinion gear (e.g., -0, - 1, -2, + 1 , +2, etc.). The num-
bers represent thousands-of-an-inch deviation from
t he st andard. If t he number is - (negative), add t hat
value to t he required thickness of t he depth shim(s).
If t he number is + (positive), subtract t hat value
DIFFERENTIAL
HOUSING
HAMMER
DRIVER
HANDLE
YOKE
HOLDING
TOOL
C-3281
Fig. 71 Seating Pinion Bearings
SPACER
J9002-91
DEPTH SHI MS
HERE
REAR PI NI ON
BEARI NG
SHAFT
BEARI NG CAP ARBOR J9203-53
Fig. 72 Depth Shim(s) Selection
from t he thickness of t he depth shim(s). If t he num-
ber is 0, no change is necessary.
(9) Remove t he tools from t he differential housing.
(10) Remove t he rear beari ng cup from housing
(11) Position depth shims in housing rear beari ng
cup bore.
with Installer D-145 and Handle C-4171.
(13) If t he depth of mesh has been followed accord-
ing to t he instructions above, good gear t eet h contact
should exist.
(14) Install t he rear beari ng (and slinger if used)
on t he pinion gear with Installer W-262 unt i l com-
pletely seated (Fig. 74).
(15) Install pinion in housing bore.
washer and nut . Install t he yoke with Installer
J9203-58
PRESS
DRIVE
PI NI ON GEAR
SHAFT
REAR BEARING ^
INSTALLATION
TOOL
DRIVE
PI NI ON GEAR
OIL
SUNGER
J9302-68
Fig. 74 Pinion Rear Bearing Installation
ft. lbs.) torque.
(19) Check bearing preload torque with an inch
Original Bearings 1 to 3 N-m (10 to 20 in. lbs.)
New Bearings 2 to 5 N-m (20 to 40 in. lbs.)
77);
FRONT SUSPENSION AND AXLE 2 43
SPECIAL DIFFERENTIAL
TOOL HO U S I N G
J9103-21
Fig. 76 Rotating Pinion Gear
thickness
thickness
Inst al l er W-147-E and Handle C-4171.
(22) Install t he yoke with Installer C-3718 and
(23) Install a new yoke nut and tighten to 271-298
N*m (200-220 ft. lbs.) torque.
REMOVE SHIMS
SHIM PACKS RY660
C-452 J9102-31
RING GEAR BACKLASH ADJUSTMENT
(1) Place Master Differential Bearing D-135
(D-345) on t he case hubs.
(2) Install a pilot stud at t he ri ght side of housing.
indicator plunger against t he back of t he ri ng gear
(Fig. 81). Ensure ri ng and pinion gear t eet h are
tightly meshed. Zero t he indicator.
and left side of differential case. Pry t he case as far
as possible to ri ght side (Fig. 81). Zero t he dial indi-
cator pointer.
(4) Repeat the measurement several times to check
consistency. Record t he t ravel distance.
TOOL HOUSING
J9103-21
The measurement shows shi m thi ckness neces-
sary to eliminate ring gear backl ash. Subtract
this thi ckness from case zero end-play shi m
thi ckness. The shi ms must be pl aced at the ri ng
gear side bet ween the case and bearing.
(6) Remove t he differential case from housing.
(7) Remove t he mast er beari ng tools from t he dif-
ferential case hubs.

Fig. 81 Ring Gear Backlash Measurement
(8) Position t he backlash shims (with determined
thickness) on case hub (ring gear side). Install bear-
ing on t he hub with Installer D-156 and Handle
C-4171 (Fig. 82) .
Fig. 82 Differential Bearing Installation
(9) Position t he remai ni ng zero end-play shims on
hub at opposite side of case. Include an additional
0.015-in (0.38-mm) thick shim on this hub. This will
provide t he required differential bearing preload
torque.
4 _ _ _ _ _ _ _ _ _ _ _ _
(10) Install beari ng on hub wi t h Installer D-156
and Handle C-4171 (Fig. 82).
(11) Install new axle shaft oil seal in differential
housing with Installer D-112-44. Apply lubricant to
lip of seal.
(12) Match each bearing cup wi t h beari ng (origi-
nal). Install t he cups on t he beari ngs.
(13) Position Spreader W-129-A with t he tool
dowel pins seated in t he locating holes (Fig. 83). In-
stall t he holddown clamps and t i ght en t he tool t urn-
buckle finger-tight.
(14) Install a pilot stud at t he left side of t he dif-
ferential housing. Attach Dial Indicator to housing
pilot stud. Load t he indicator pl unger agai nst t he op-
posite side of t he housing (Fig. 83) and zero t he indi-
cator.
C A U T I O N : Do not spread over the specified di s-
(15) Separate t he housing enough to install t he
case in t he housing. Separate housi ng a maxi mum
di stance of 0.38 mm (0.015 in) wi th the spreader
tool. Measure t he distance with t he dial indicator
(Fig. 83).
(17) Install case in t he housing. Ensure t he differ-
ential bearings are fully seated. Remove t he
spreader.
(18) Observe t he assembly reference marks and po-
sition t he bearing caps at t hei r original locations
(Fig. 84). Tighten t he bearing cap bolts to 95-122
N-m (70-90 ft. lbs.) torque.
(19) Rotate assembly several revolutions to seat
bearings. Measure backlash at t hree equally spaced
locations with a dial indicator (Fig. 85).
Fig. 84 Differential Bearing Cap Reference Letters
The ring gear backl ash must be wi thi n 0.004 -
0.009 i nch (0.10 - 0.23 mm). It cannot vary more
than 0.002 i nch (0.05 mm) bet ween the points
checked.
(20) Excessive backlash is corrected by moving t he
ring gear t eet h closer to t he pinion gear teeth. Insuf-
ficient backlash is corrected by moving t he ri ng gear
away from t he pinion gear. Backlash correction is ac-
complished by t ransferri ng shims from one side to
the other.
If t he mesh and backlash steps have been followed
in t he procedures above, good gear t eet h contact pat-
t erns should exist.
RING mMR TEETH CONTACT PATTERN
ANALYSIS
The ring gear t eet h contact pat t erns will show if
t he pinion gear depth shim(s) have t he correct thick-
ness. It will also show if t he ri ng gear backlash has
been adjusted correctly. The backlash must be main-
tained within t he specified limits until t he correct
t eet h contact pat t erns are obtained.

(1) Apply a t hi n coat of hydrated ferric oxide, to
t he ri ng gear teeth.
(2) Rotate t he ring gear one complete revolution in
both directions while a load is being applied. Insert a
pry bar between t he differential housing and t he case
flange. This action will produce distinct contact pat-
t erns on both t he drive side and coast side of t he ri ng
gear teeth.
(3) Note pat t erns in compound. Refer to (Fig. 86 )
for interpretation of contact pat t erns and adjust ac-
cordingly.
(4) Install t he axle shafts. Refer to Axle Shaft In-
stallation wi t hi n this group.
(5) Install t he housing cover. Refill t he differential
with lubricant. Refer to Axle Shaft Installation.
DRIVE SI DE
OF RI NG
GEAR TEETH
HEEL TOE
COAST SI DE
OF RI NG
GEAR TEETH
TOE HEEL
DESIRABLE CONTACT PATTERN.
PATTERN S HOULD BE CENTERED
O N THE DRIVE SIDE OF T OOT H.
PATTERN S HOUL D BE CENTERED O N
THE COAS T SIDE OF T OOT H,
BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE S HOULD ALWAYS
BE S O M E CLEARANCE BETWEEN
CONTACT PATTERN A N D TOP OF
THE T OOT H.
R I NG GEAR BACKLASH CORRECT
THI NNER PI NI ON GEAR DEPTH
SHI M REQUI RED.
RI NG GEAR BACKLASH CORRECT.
THICKER PI NI ON GEAR DEPTH
SHI M REQUI RED.
PI NI ON GEAR DEPTH SHI M
CORRECT DECREASE RI NG
GEAR BACKLASH.
CORRECT I NCREASE RI NG
GEAR BACKLASH.
Fig. 86 Gear Teeth Contact Patterns
J9003-24
2 - 4 8 FRONT SUSPENSION AND AXLE

SPECIFICATIONS
MODEL 44 FRONT AXLE
Axle Type Semi-floating, hypoid
Application D-TRK
Ring Gear Diameter 8.50 in. (21.59 cm)
Lubricants MOPAR Gear Lubricant or
equivalent SAE 75W-90,
API Grade GL-5, MIL-L-2105C
Disconnect Type Vacuum operated
Lubricant Capacity 5.6 pts. (2.65L)
Axle Model Dana M44F
Axle Ratio.. 3.54
To 1 3.92
4.09
Track 66.9 in.
GAWR 3500 lbs.
Differential Bearing
Preload Shim
0.015 in. 0.38 mm
Differential Side
Gear-to-Case Clearance.. 0.000-0.007 in. 0.00-0.18 mm
Ring Gear Backlash 0.005-0.008 in. 0.12-0.20 mm
Drive Pinion Gearshaft Bearing
Break-Away Preload Torque
Original Bearings 10-20 in. lbs. 1 -2 Nm
Replacement Bearings 20-40 in. lbs. 2-5 Nm
Drive Pinion Gear Depth Select shims
Standard Setting 2.625 in. 66.6 mm
Side Gear Clearance (max.)... 0.006 in. 0.15 mm
Case Runout (max.) 0.006 in. 0.15 mm
J9202-106

M O D E L 6 0 FRONT A X L E
INDEX
page
Ax le Shaft and U-Joint Service 5 5
Differential Assembl y 6 3
Differential Di sassembl y 59
Drain and Refill 51
General Information 4 9
Locking H ubs, Spindle and Ax le Shaft 52
Lubricant 51
page
with Tool Set C- 7 5 8 - D6 6 8
with Tool Set D- 1 1 6 6 6
Specifications 7 5
Steering Knuckle, Upper and Lower K ingpins . . . 56
GENERAL INFORMATION
Model 60 front axles (Fig. 1) consist of an iron cen-
t er casting with axle shaft tubes extending from ei-
t her side. The tubes are pressed into and welded to
t he centerline of t he pinion set below t he centerline
of t he ri ng gear.
shafts, meani ng t hat loads are supported by t he spin-
dles attached to t he steering knuckles. Two t apered
opposed roller bearings allow t he hub and rotor as-
sembly to rotate on t he spindle.
tion t ag is attached to t he housing cover via one of
ri ng gear and pinion gear t eet h.
ferential pinion mat e shaft is ret ai ned wi t h a roll
pin. Differential bearing preload and ri ng gear back-
lash are adjusted by t he use of shims located between
t he differential beari ng cones and case.
BEARING SEAL BUSHING SLINGER U-JOINT AXLE SHAFT NUT WASHER
SPINDLE
STEERING
ARM AND CAP
STUDS
LEFT
STEERING
KNUCKLE
BEARING CAP
f
BOLT
Fig. 1 Model 60 Front Axle
MATE
SHAFT SCREW
GASKET
OR
SEALER
COVER
PLUG
J9202-67
oi
3 0
O
e
m
22
o
>
x
w
LUBRICANT
cant should be used for Model 60 axles. MOPAR Hy-
poid Gear Lubricant conforms to these specifications
and is recommended.
C A U T I O N : If a front axle i s submer ged in water, the
DRAIN AND REFILL
(1) Drive t he vehicle unt i l the gear lubricant
(3) Remove t he lubricant fill hole plug from the
t he original lubricant to completely drai n from the
(5) With st andard differential, clean t he differen-
t i al and t he housing cavity wi t h a flushing oil (or
light engine oil). This will remove the resi dual lubri-
(6) Scrape t he residual gasket from t he housing
faces with mi neral spirits. Install a new cover gas-
Sealant on t he housing cover (Fig. 2). Al l ow the
seal ant to cure for a few mi nutes.
SEALING
SURFACE
CONTOUR OF BEAD
BEAD
THICKNESS
6.35mm (1/4
J9302-30
Fig. 2 Sealant On Housing Cover
Install the housi ng cover wi thi n 5 mi nutes af-
ter appl yi ng the sealant. If not installed the seal-
ant must be removed and another bead applied.
(7) Install the cover on t he differential with t he
bolts. Install the identification tag. Tighten t he cover
the lubricant f oami ng and overheati ng.
(8) Refill t he differential housing with t he speci-
(9) Install the fill hole plug and t i ght en to 34 Nm
PINION SHAFT SEAL
REMOVAL
(2) Mark t he drive shaft yoke and pinion yoke for
installation al i gnment reference.
(3) Remove t he drive shaft from t he yoke.
(4) Rotate t he pinion gear t hree or four times.
(5) Remove the pinion yoke nut and washer. Use
(6) Mark t he positions of t he yoke and pinion gear
SPECIAL TOOL
C-3281
SPECIAL TOOL
C-452 J9102-31
seal (Fig. 4).
INSTALLATION
lip of pinion seal. Install t he new seal (Fig. 5) use In-
staller C-3719-A and Handle C-4735
shaft. Tighten t he nut to 339-366 N-m (250-270 ft.
(4) Align t he installation reference marks and at-
t ach the drive shaft to t he yoke.

PI N I O N SEAL
J9203-55
Fig. 4 Seal Removal
SPECI AL T O O L
G4735
J9203-56
(6 ) Lower t he vehicle.
LOCKING H UBS, SPINDLE AND AXLE SHAFT
REM0VAL/D1SASSEMBL Y
(1) Raise and support t he front of vehicle.
(3) Remove t he brake caliper, refer to Group 5,
Brakes. Support t he caliper to t he frame st ruct ure
with wire.
DIFFERENTIAL
(4) Remove t he allen-head screws t hat ret ai n t he
cap to the hub (Fig. 7).
Fig. 7 Allen-Head Screw Removal
(5) Remove t he snap ri ng ret ai ni ng t he axle shaft
in t he hub (Fig. 8).
(6 ) Remove t he lock ri ng from t he groove in t he
hub (Fig. 9) .
(7) Install two allen-head screws in hub locking
body (to assist in removal). Remove t he hub locking
body assembly from t he hub (Fig. 10).
_ _ _ . ^ FRONT SUSPENSION AND AXLE 2 - 53
SCREWDRIVER J9202-70
Fig. 9 Lock Ring Removal
(8) Remove t he wheel beari ng outer lock nut from
t he spindle with Wrench 7158 (Fig. 11). Remove t he
tabbed lock washer from t he spindle.
(9) Remove t he wheel beari ng i nner lock nut ri ng
from t he spindle with Wrench 7158 (Fig. 11).
(10) Remove t he hub and rotor assembly from t he
spindle.
(11) Remove t he nut s t hat at t ach t he spindle to
t he steering knuckle. Remove t he spindle from t he
knuckle, use a soft faced mallet if necessary to t ap
loose (Fig. 12).
SNAP HUB LOCKING PRESSURE CLUTCH SNAP
RING SEAL CAP J9202-71
Fig. 10 Locking Hub Components
Fig. 11 Lock Nut Ring Removal
(12) Pull t he axle shaft (with spacer, seal and
slinger) from t he steering knuckle (Fig. 13).
(13) Clamp t he spindle in a soft-jawed vise. Do not
clamp at t he beari ng contact surfaces. Remove t he
beari ng seal.
(14) Use Puller D-131 to remove needle bearings
from the spindle (Fig. 14).
(1) Install needle bearing in t he spindle with In-
staller C-4370 and Handle C-4171 (Fig. 15).
Fig. 12 Spindle Removal
SEAL J9202-73
Fig. 13 Axle Shaft Removal
Fig. 14 Spindle Needle Bearing Removal
(2) Install a new spindle seal with Installer C-4373
and Handl e C-4171 (Fig. 16).
(3) Install t he seal with lip facing t he axle shaft
splines (Fig. 17). Lubricate t he seal (Fig. 18) wi t h
Wheel Beari ng Grease lubricant (NLGI Grade 2, EP

Fig. 15 Spindle Needle Bearing Installation
Fig. 16 Spindle Seal Installation
(4) Carefully install t he axle shaft t hrough t he
knuckle into t he axle housing. Ensure t he axle shaft
splines are engaged with t he differential side gears.
(5) Install t he spacer on t he axle shaft end.
(6) Install t he brake splash shield and brake cali-
per support bracket.
(7) Install t he splash shield and spindle on t he
steering knuckle. Install t he nut s and t i ght en to 81-
108 N-m (60-80 ft. lbs.) torque (Fig. 19).

Fig. 17 Axle Shaft Seal Installation
Fig. 19 Spindle Installation
(8) Install t he hub and rotor assembly on t he spin-
dle. Add Wheel Beari ng Grease lubricant (NLGI
ings.
Fig. 20 Bearing Cap Removal
(3) Use a mallet to drive t he vertical yoke down-
ward to remove t he upper needle beari ng and cap
(Fig. 20).
(4) Reverse t he position of the yoke and remove op-
posite needle bearing and cap (Fig. 20).
(9) Install t he wheel beari ng i nner lock nut on t he
spindle wi t h Wrench 7158 (Fig. 11). Ti ght en t he lock
nut to 68 N*m (50 ft. lbs.) to seat t he bearings.
(10) Loosen t he i nner lock nut . Ti ght en to 41-54
N*m (31-39 ft. lbs.) torque while rot at i ng t he hub and
rotor assembly.
(11) Back off t he i nner lock nut 135-150 degrees to
set t he free play.
(12) Install t he tabbed lock washer in t he nearest
hole in t he washer. Install and t i ght en t he outer lock
nut wi t h Wrench 7158 (Fig. 11) to 217-278 N-m (160-
205 ft. lbs.) torque. The end play after t he final bear-
ing adjustment should be within 0.001 inch to 0.010
inch (0.03 to 0.25 mm).
(13) Inst al l t he locking body assembly in t he hub.
(14) Install the lock ri ng in t he groove in t he hub.
Ensure t he ri ng is seated.
(15) Install t he snap ri ng on t he end of t he axle
shaft. Ensur e t he snap ri ng is seated.
(16) Inst al l t he cap onto t he hub. Ensure t he seal
is in place and not distorted.
(17) Install and t i ght en t he allen-head screws to
4-5 N-m (35-45 in. lbs.) torque.
Brakes.
(19) Install the wheel and tire, refer to Wheel and
Tire Installation within this section. Lower the vehicle.
AXLE SHAFT AND U-JOINT SERVICE
DISASSEMBLY
(1) Remove t he snap rings from t he yokes.
(2) Position t he U-joint on the top of t he vise jaws
(Fig. 20). Do not t i ght en t he vise.
Fig. 21 Bearing Cap installation
(3) Remove t he yoke from t he vise and insert one
end of t he spider into t he bearing. Insert opposite
beari ng and cap in t he yoke ar m bore by hand and
align it wi t h t he spider.
(4) Place t he yoke in a vise and press t he cap into
t he yoke ar m bore and onto t he spider (Fig. 22).
(5) Use a short plug or a socket wrench to force t he
beari ng cap into t he correct position and install t he
snap ring.
(6) Repeat t he instructions in steps 1 t hrough 5 for
installing remai ni ng bearings, caps and yoke.
STEERING KNUCKLE, UPPER AND LOWER
KINGPINS
REMOVAL
(1) Remove axle shaft, refer to Axle Shaft And
U-Joint Service.
(2) Remove t he steering knuckl e upper cap (Fig.
23).
(3) Remove t he spring and ret ai ner (Fig. 24). Dis-
card t he gasket.

Fig. 22 Bearing Cap & Spider Installation
Fig. 23 Upper Cap Removal
(4) Remove t he steering knuckle lower cap (Fig.
25).
(5) Dislodge t he cap from t he steering knuckle and
yoke.
(6) Remove t he tapered bushi ng from t he top of t he
ki ngpi n in t he knuckle (Fig. 26). Remove t he
knuckl e.
(7) Use Remover/Installer D-192 to remove t he up-
per kingpin (Fig, 27). Discard t he seal.
(8) Use Tool C-4212-1, C-4366-1 and C-4366-2 to
remove lower ball socket from lower ar m bore (Fig.
28). Discard t he grease seal, ret ai ner and lower bear-
i ng cup.
(5) Remove t he yoke from t he spider.
(6) Position t he open ends of t he spider in a soft-
jawed vise. Repeat steps 3 and 4 (above) to remove
remai ni ng bearings and caps.
(7) Remove t he spider from t he yoke.
(8) Clean and inspect all t he components. Clean
any rust from t he axle shaft splines. Retain each
beari ng and cap separate. If any component is exces-
sively worn or damaged, replace t he U-joint.
ASSEMBLY
(1) Insert t he needle beari ng and cap in one yoke
ar m bore.
(2) Place t he yoke in a vise (Fig. 21) and press t he
needle beari ng and cap into position. Install t he snap
ring.

Fig. 24 Spring and Retainer Removal
LOWER KINGPIN
A N D RETAINER
C AP
^ J9202-51
Fig. 25 Lower Cap Removal
INSTALLATION
(1) Apply sealant to the mating surface of the
grease retainer. Lubricate the lower ball socket with
MOPAR Multi-Mileage Lubricant (or equivalent).
(2) Install the grease retainer in the yoke bore
with the concave side facing the upper kingpin.
(3) Use Remover/Installer C-4212-L, C-4366-3, and
C-4366-4 (Fig. 29) to install a new grease seal and
lower bearing cup.
(4) Fill the area in grease retainer with specified
grease, grease bearing cone and install. Install new
king pin bearing oil seal. Reposition Tools C-4212-L,
TAPERED
BUSHING
J9202-53
Fig. 26 Tapered Bushing Removal
J9202-66
Fig. 27 Upper Kingpin Removal
C-4366-3 and C-4366-5 (Fig. 30) and press the lower
bearing cup and seal into yoke lower arm bore.
(5) Use Remover/Installer D-192 to install the up-
per kingpin (Fig. 31). Tighten the kingpin to 668-813
N-m (500-600 ft. lbs.) torque. Install the seal over the
kingpin.
(6) Install the knuckle on the axle yoke.
(7) Insert the tapered bushing over the upper king
pin (Fig. 32).
(8) Fill the socket lower cavity with MOPAR
Multi-Mileage Lubricant (or equivalent). Install the
lower king pin and retainer cap on the steering
knuckle (Fig. 33). Install the capscrews and tighten
to 95-122 N-m (70-90 ft. lbs.) torque.
(9) Install the retainer and compression spring on
the tapered bushing.

C-4366-2
C-4366-1
RH432A
C-4212-L
Fig. 28 Lower Ball Socket Removal
C-4212-L
C-4366-3
C-4366-4
RH433A
Fig. 29 Lower Bearing Cup Installation
(10) Install a new gasket over t he steering knuckle
upper studs. Install t he upper cap (and steering ar m
C-4212-L
C-4366-3
RH434A
Fig. 30 Lower Bearing & Seal Installation
TORQUE
WRENCH
SEAL
J9202-66
Fig. 31 Upper Kingpin Installation
on t he left side). Install t he bolts/nuts and t i ght en to
96-122 N*m (70-90 ft. lbs.) torque.
(11) Lubricate t he upper and lower ki ng pin
t hrough t he fittings wi t h MOPAR Multi-Mileage Lu-
bricant (or equivalent).

TAPERED
BUSHI NG
J9202-53
Fig. 32 Tapered Bushing Installation
J9202-52
Fig. 33 Lower King Pin and Retainer Installation
(12) Install t he axle shaft, refer to Axle Shaft and
U-Joint Installation.
SERVICE INFORMATION
It is not necessary to remove t he complete front
axle from t he vehicle for rout i ne service. If t he hous-
ing or axle shaft tubes are damaged, t he complete
axle can be removed and installed via t he following
procedures.
REMOVAL
(1) Block t he brake pedal in t he up position. Raise
and support t he vehicle at a comfortable working
height.
(2) Remove t he front wheels/tires.
(3) Mark t he front drive shaft and the pinion yoke
for installation alignment reference.
(4) Disconnect t he front drive shaft from t he axle
yoke. At t ach t he drive shaft to t he frame rail with
wire.
(5) Remove t he cotter pin, t he nut , and disconnect
t he drag l i nk from t he steering knuckle arm (left
side only). Discard t he cotter pin.
(6) Disconnect flexible br ake fluid hose fittings at
t he frame crossmember. Pl ug t he hoses at t he fit-
tings.
(7) Remove t he shock absorber lower nut and stud
from t he axle shaft t ube bracket. Remove t he nut s
and disconnect t he stabilizer bar links from t he
spring brackets.
(8) Remove nut s and t he washers from t he spring
U-bolts. Remove t he complete front axle from t he ve-
hicle.
INSTALLATION
(1) Position t he front axle under t he front of t he
vehicle with t he axle spring pads under t he springs.
Place t he spring brackets over t he springs. Make
sure t he stabilizer bar link bolt holes face toward t he
rear of t he vehicle.
(2) Install t he spring U-bolts, washers and nut s.
Refer to Front Suspension 4WD Vehicles within
t hi s group.
(3) Install t he shock absorber. Refer to Front Sus-
pension4 WD Vehicles wi t hi n this group.
(4) Connect t he stabilizer bar links to t he spring
brackets. Refer to Front Suspension4WD Vehicles
within t hi s group.
(5) Remove plugs and connect t he brake hose fit-
tings. Refer to Group 5, Brakes.
(6) Connect t he drag-link ball stud to t he steering
knuckle arm. Refer to Group 19, Steering.
(7) Connect t he drive shaft to t he pinion yoke with
t he installation reference mar ks aligned. Install t he
washers and t he nut s and t i ght en to 19 N-m (14 ft.
lbs.) torque.
(8) Remove t he supports, lower t he vehicle and re-
move t he block from t he brake pedal.
Bleed and adjust t he brakes
Lubricate all t he ball stud fittings
Inspect t he differential housing lubricant level. Re-
fer to Group 0, Lubrication and Maintenance.
(10) Lower t he vehicle and test t he axle and sus-
pension operation.
REMOVAL/DISASSEMBLY
(1) Note the installation reference letters
stamped on the beari ng caps and housi ng ma-
chi ned seal i ng surface (Fi g. 34).

Fig. 34 Bearing Cap identification
(3) Position Spreader D-167 with t he tool dowel
pins seated in t he locating holes (Fig. 35) . Install t he
ger-tight.
SPECIAL TOOL DIAL
MODEL 4 4 - W- 1 29- A INDICATOR
C A U T I O N : D o not spread over the speci fi ed di s-
(5) Separat e t he housing enough to remove t he
case from t he housing. Se pa r a t e hous i ng a maxi-
mum di stance of 0.38 mm (0.015 in) wi t h t he
spreader tool. Measure t he distance with t he dial
indicator (Fig. 35).
end of t he pry bar agai nst case.
usable, ret ai n t he differential beari ng cups and bear-
with soft jaws. Remove and di scard t he ri ng gear
bolts. Tap t he ring gear with a rawhide mallet and
remove (Fig. 36).
C-452 J9102-31
seal (Fig. 4).
(12) Remove oil slinger, front bearing and shims
(Fig. 38). Record t he thickness of t he shims. This will
save time if they should become misplaced.
(13) Remove t he front pinion beari ng cup with Re-
mover D-158 and Handle C-4171 (Fig. 39).
(15) Remove t he depth shims from t he housing
bore. Record t he thickness of t he depth shims.
PINION
YOKE
WASHER
SLINGER
PINION
PRELOAD,
SHIMS
FRONT
BEARING
CUP
PINION
N U T
PINION
OIL SEAL
PINION PRELOAD
SPACER
FRONT
BEARING
CONE
SHOULDER FOR
PINION PRELOAD SPACER
J9203-63
D-158 C-4171
HA MME R DRIVER
HANDLE
FRONT
BEARING CUP
J9203-57
J9203-58
Fig. 39 Front Bearing Cup Removal
(16) Remove t he pinion r ear bearing (Fig. 41). Use
Puller DD-914-P, Adapter Ring DD-914-9 and Pl at e
C-293-37.
(17) Remove the differential side gears and t hrust
washers.
(19) Remove t he bearings (Fig. 42) with:
Remover DD-914-P
Adapter Ring DD-914-8
Pl at e DD-914-62

SPECIAL TOOL
DD-914-P
J9203-59
Fig. 41 Pinion Rear Bearing Removal
Screw Extension DD-914-7
Button DD-914-42
Use e a r e t ha t a d a p t e r r i ngs a r e pl aced so t hey
do not damage t he be a r i ng cage.
gear mat e shaft lock pin (Fig. 43).
mer (Fig. 44).
(24) Remove axle shaft oil seals from differential
housing with a pry bar.
CLEANING/INSPECTION
(1) Wash and clean all t he differential components
wi t h cleaning solvent. Dry with compressed air.
Do not steam cl ean the differential compo-
nents.
into each tube, at t ach a clean cloth to t he wire at t he
housing opening. Draw t he wire (and cloth) from t he
housing outward t hrough t he tube.
(3) Inspect t he differential and pinion gear bear-
ings. Inspect t he differential case and housing.
ance.

THRUST
WASHER
Cup and be a r i ng must be r epl aced as a
ma t c he d set onl y.
All machined surfaces in t he housing and on bear-
i ng caps should be smooth and without any raised
edges.
Pinion gear front and rear bearing cup bores
should be smooth
removed with a hand stone.
(4) Exami ne t he differential pinion gear mat e
shaft, pinion gears, side gears and t hrust washers for
wear and damage. Replace all defective components.
If either of the differential pinion gears is not
ma t c he d set onl y. Do not r epl ace onl y one gear .
(5) Exami ne t he ring gear and t he pinion gear for
worn and chipped teeth. Examine t he ri ng gear for
damaged bolt t hreads.
t act surface. Repair or replace t he yoke as necessary.
(7) Inspect t he pinion beari ng preload shims for
cracks, damage and distortion. Install replacement
shims (if necessary) for t he preload torque adjust-
ment.
ASSEMBLY
ential case (Fig. 47).
case)
case and mat e shaft with a punch and hammer (Fig.
46). Peen metal par t of case over pin in two places.
If repl acement gears and thrust washers were
installed, it is not necessary to measure the gear
backl ash. Correct fit i s due to cl ose machi ni ng
tol erances duri ng manufacture.
Fig. 46 Mate Shaft Pin Installation
(3) Invert t he differential case and st art two ring
hole alignment (Fig. 47).
(4) Install new ring gear bolts and alternately
t i ght en to;
Grade 8 bolts to 136-163 N*m (100-120 ft. lbs.)
torque
Grade 9 bolts (7 radial lines) to 169-183 N*m (125-
135 ft. lbs.) torque.
(Fig. 49).
and ri ght side of differential case. Pry t he case as far
as possible to left side (Fig. 49). Zero t he dial indica-
tor pointer.
(9) Pry t he case to ri ght side and record t he
t ravel distance.
Fig. 47 Ring Gear Bolt Hole installation
MASTER BEARING
RY6 52
The measurement above is the shim thi ckness
necessary for case zero end-play. The total
thi ckness will be determi ned duri ng the ring
gear backl ash adjustment.
tifying numbers for t he ri ng and pinion gear are

Fig. 49 Differential Case End Play Measurement
t he face of t he pinion gear. This number is t he
provides t he best t eet h contact pat t ern.
DRIVE PINION
t he centerline of t he axle shaft/ring gear to t he
Model 60 axle, t he st andard depth/distance is
5.000 inches (127.0 mm).
shims placed adjacent to t he pinion gear rear bearing
cup (Fig. 52).
depth shims to compensate for t he difference in t he
TORQUE

AXLE DEPTH
MODE L SETTING
For Example:
If a positive marki ng, this means t he shim pack
must decrease by t he same number of t housandt hs.
If a negative marki ng, this means t he shim pack
must increase by t he same number of t housandt hs.
If marked zero will use t he nominal set t i ng as de-
termined in this procedure.
Shims are available in 0.003-inch, 0.005-inch,
0.010-inch, and 0.030-inch thicknesses.
If original gear set is installed but t he depth shims
shims. Build a replacement pack of depth shims with
DRI VE
If equi pped, t he oil sl i nger mus t be me a s ur e d
a n d t he t hi cknes s i ncl uded wi t h t he t ot al s hi m
pa c k t hi cknes s .
The shim thickness for t he new pinion gear must
be determined before installing t he differential case.
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
Original Pinion
Gear Depth
Variance
- 4 - 3 - 2 - 1 0 + 1 -ft + 3
+ 4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+S +0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001
4- 1 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002
4- 1 + 0.005 + 0.004 + 0.003 +0.002 + 0.001 0 -0.001 -0.002 -0.003
0 + 0.004 +0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
- I + 0.003 + 0.002 + 0.001 0 -0 .001 -0.002 -0.003 -0.004 -0.005
- 2 + 0.002 + 0.001 0 -0.001 -0.002 -0 .003 -0.004 -0.005 -0.006
- 3 + 0.001 0 -0 .001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
- 4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
J8902-46

ADJUSTMENT WITH TOOL SET D-116
ment procedure involves using Tool Set D-116.
(1) Insert Master Pinion Block D-120 into t he dif-
ferential housing (Fig. 53).
tion in t he beari ng cradles (Fig. 54). This is t he cen-
terline of t he ri ng gear/axle shaft.
(3) Place Pinion Height Block D-116-1 on top of
master pinion block tool and against arbor tool (Fig.
55).
(4) Place Gauge Block D-115-2 and Dial Indicator
D-106-5 on lowest step (Fig. 56). Zero t he dial indi-
cator pointer.
the indicator plunger contacts the arbor tool (Fig.
56). Slide t he gauge block across t he arbor while ob-
serving indicator. Record t he longest t ravel distance,
whether inward (-) or outward ( + ), indicated by t he
pointer.
Pl unger travel di stance i ndi cated, pl us or mi-
nus the amount etched i n gear is requi red thick-
ness.
(6) Measure t he thickness of each depth shim with
total required pack thickness. Incl ude oil slinger
thi ckness wi th the total shim p a c k thi ckness.
ential housing.
(8) Place t he depth shims in t he pinion gear rear
beari ng bore. Install t he beari ng cup (Fig. 57) with
Installer D- l l l and Handle C-4171.
staller C-4203 and Handle C-4171 (Fig. 58) .
on t he pinion gear with Installer C-3095-A unt i l
completely seated (Fig. 59).

SPECIAL TOOL
D-111
PRESS
DRIVE
PI NI ON GEAR
SHAFT
REAR BEARI NG'
INSTALLATION
TOOL
SPECIAL
TOOL
C-4171 J9203-65
DRIVE
PINION GEAR
OIL
SUNGER
J9302-68
Fig. 57 Pinion Rear Bearing Cup Installation Fig. 59 Pinion Rear Bearing Installation
BEARI NG CUP
INSTALLATION TOOL C-4203
DRIVER
HANDLE
TOOL
C-4171
SPECIAL
TOOL
C-3718
DIFFERENTIAL
HO U S I N G
SPECIAL
TOOL
C-3281
washer and nut. Install the yoke with Installer
C-3718 and Wrench C-3281 (Fig. 6 0) .
ft. lbs.) torque.
New Bearings 2 to 5 N-m (20 to 40 in. lbs.)
62);
Increase t he preload torque, decrease the shim
thickness
J9103-21
thickness
lip of pinion seal. Install t he new seal (Fig. 64) wi t h
Installer C-3719-A and Handle C-4735
(17) Install the yoke with Installer C-3718 and

T O R QU E WR E N C H
SPECIAL T O O L
C- 32 81
RH418A
Ml
R E MOV E S HI MS
BE A R I N G
PRELOAD
SHIM PACK
PINION
L O C A T I N G
SHIM PACK
DIFFERENTIAL BEARING
S H I M PACKS RY660
(18) Install a new yoke nut and t i ght en to 339-366
ADJUSTMENT WITH TOOL SET C-758-D6
dure involves usi ng Pinion Depth Measurement
Gauge Set C-758-D6 (Fig. 65).
with Installer D- l l l and Handl e C-4171.
staller C-4203 and Handl e C-4171 (Fig. 67).
Assembl e C-758-D6 Tool Set as descri bed (Fig.
68);
SPECIAL TOOL
C-452 J9102-31
SPECIAL TOOL
C 473 5
S P- 5 184
C - 3719- A
DIFFERENTIAL
HOUSING
J9203-56
SPECIAL TOOL SET
C - 75 8- D 6
J9203-67
Fig. 65 Pinion Adjustment Tools
.
C-4171 J9203-65
BE A R I N G C U P DRI VER
INSTALLATION TOOL C-4203 HANDLE
Position Spacer (SP-5814 for Model 60) over Shaft
(SP-526)
Position pinion r ear beari ng on shaft
Install pinion front bearing
Install Sleeve (SP-535-A), Washer (SP-534) and
Nut (SP-533) .
(3) Prevent compression sleeve tool from t urni ng
with Wrench C-3281. Tighten t he nut to seat t he pin-
ion bearings in t he housing (Fig. 68). Allow t he
sleeve to t ur n several times duri ng the t i ght eni ng to
prevent brinelling t he beari ng cups or t he bearings.
Depth shim(s) are posi ti oned between the pin-
ion gear rear beari ng and pi ni on gear to provi de
the separati on di stance. The required thi ckness
of t he depth shim(s) is determi ned accordi ng t o
the following information.
pinion gear front and rear bearings wi t h gear lubri-
cant. Re-tighten t he compression nut tool to 1 to 3
Nnn (15 to 25 in. lbs.) torque. Rotate t he pinion gear
several complete revolutions to align t he beari ng
rollers.
526. Install Cap Screw (SP-536) and tighten wi t h
Wrench SP-531.
ferential housing.
Center the arbor in cradles so equal space exists at
both ends. Position t he bearing caps on t he arbor
tool. Install t he bolts. Tighten t he cap bolts to 14
(7) Trial fit depth shim(s) between t he crossbore
arbor and gauge block (Fig. 69). The depth shi m(s)
fit must be snug but not tight (drag friction of a
SPACER
BEARING CAP ARBOR J9203-53
SPECIAL TOOL

Depth shims are avai l abl e i n O.OOl-ineh incre-
ments from 0.020 i nch to 0.038 inch.
t he standard. If t he number is - (negative), add t hat
(10) Remove t he rear bearing cup from housing
(Fig. 70) with Remover D-162 and Handle C-4171.
HAMMER DRIVER
HANDLE
PRESS
DRIVE
PI NI ON GEAR
SHAFT
REAR BEARI NG'
INSTALLATION
TOOL
DRIVE
PI NI ON GEAR
OIL
SUNGER
J9302-68
SPECIAL
TOOL
C-3718
DIFFERENTIAL
HO U S I N G
J9203-58
cup bore.
with Installer D- l l l and Handle C-4171.
should exist.
ft. lbs.) torque.
SPECIAL
TOOL
C-3281
J9103-21
(19) Check bearing preload torque with an inch
to rot at e the pinion gear should be;
New Bearings 2 to 5 Nm (20 to 40 in. lbs.)
74);
thickness

TORQUE WR E N C H
SPECI AL T O O L
G 32 81
RH418A
thickness
BEARI NG
PRELOAD
SHIM PACK
PINION
LOCATING
SHIM PACK
DIFFERENTIAL BEARING
SHIM PACKS RY660
Installer C-3719-A and Handle C-4735
(23) Install a new yoke nut and tighten to 339-366
SPECIAL TOOL
C-452 J9102-31
SPECIAL TOOL
C-4735
SPECIAL TOOL
C-3719-A
DIFFERENTIAL
HOUSING
J9203-56
(1) Place Mast er Differential Bearing D-343
At t ach Dial Indicator C-3339 to t he pilot stud. Load
indicator plunger against t he back of the ring gear
(Fig. 78). Ensure ring and pinion gear teeth are
(3) Insert a small pry bar between t he bearing cap
and right side of differential case. Pry t he case as far
as possible to left side (Fig. 78). Zero the dial indica-
tor pointer.
(4) Repeat t he measurement several times to check
consistency. Record the t ravel distance.
The measurement above shows shim thickness
necessary to eliminate ring gear backl ash. Sub-

SPECIAL DI FFE R E NT I AL
TOOL HOUSING
J9103-21
tract this thi ckness from case zero end-pl ay
shim thi ckness. The shi ms must be pl aced at the
ring gear side bet ween the case and beari ng.
(6 ) Remove t he differential case from housing.
ing on t he hub with Installer C-4025-A and Handle
C-4171 (Fig. 79).
0.015-in (0.38-mm) thick shim on t hi s hub. This will
provide t he required differential beari ng preload
torque.
(10) Install beari ng on hub with Installer
C-4025-A and Handle C-4171 (Fig. 79).
(11) Install new axle shaft oil seals in differential
housing with Installer D-195. Apply lubricant to lip
of seals.
(12) Match each bearing cup with beari ng (origi-
nal). Install t he cups on t he bearings.
ger-tight.
(14) Install a pilot stud at t he left side of t he dif-
pilot stud. Load t he indicator plunger agai nst t he op-
cator.
tance. If the housing i s over- separated, it coul d he
case in the housing. Se pa r a t e hous i ng a ma xi mum

SPECIAL TOOL
.MODEL 4 4 - W - 1 2 9 - A
MODEL 6 0 - D-16 7 DIAL
INDICATOR
J9202-114
TOOL
C-3339
tool. Measure t he distance with t he dial indicator
(Fig. 80).
spreader.
(18) Observe t he assembly reference mar ks and po-
sition t he bearing caps at t hei r original locations
(Fig. 81). Tighten t he beari ng cap bolts to 95-122
Nnn (70-90 ft. lbs.) torque.
(19) Rotate t he assembly several revolutions to
seat t he bearings. Measure backlash at t hree equally
spaced locations with a dial indicator (Fig. 82).
checked.
(20) Excessive backlash is corrected by moving the
ri ng gear t eet h closer to t he pinion gear teeth. Insuf-
complished by transferring shims from one side to
t he other.
If the mesh and backlash steps have been followed
RING GEAR TEETH CONTACT PATTERN
ANALYSIS
The ri ng gear teeth contact pat t erns will show if
tained within t he specified limits until t he correct
t he ring gear teeth.
t erns on both t he drive side and coast side of t he ri ng
gear teeth.
(3) Note pat t erns in compound. Refer to (Fig. 83)
cordingly.
stallation within t hi s group.
DRIVE SIDE
OF RI NG
GEAR TEETH
HEEL TOE
COAST SIDE
OF RI NG
GEAR TEETH
TOE HEEL
DESIRABLE CONTACT PATTERN.
PATTERN S HOULD BE CENTERED
O N THE DRIVE SIDE OF T OOT H.
PATTERN S HOULD BE CENTERED O N
THE COAST SIDE OF T OOT H,
BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE S HOULD ALWAYS
BE S O ME CLEARANCE BETWEEN
CONTACT PATTERN A N D TOP OF
THE TOOTH.
THI NNER PI NI ON GEAR DEPTH
SHI M REQUI RED.
THICKER PI NI ON GEAR DEPTH
SHI M REQUI RED.
CORRECT DECREASE RI NG
GEAR BACKLASH.
CORRECT I NCREASE RI NG
GEAR BACKLASH.
J9003-24
SPECIFICATIONS
MODEL 60 FRONT AXLE
Axle Type........ Semi-floating, hypoid
Application D-TRK
Ring Gear Diameter 9.75 in. (24 .76 cm)
Locking Hubs Manual type
Lubricant Capacity 6 .5 pts. (3.1L)
Axle Model Dana M6 0F
Axle Ratio......... 3.54
Tol 4 .10
4 .56
Track... 6 5.7 in.
GAWR.................... 4 500 lbs.
T ORQ U E S PE C I F I C A T I ON S
Preload Shim 0.015 in. 0.38 mm
Differential Side
Gear-to-Case Clearance.. 0.000-0.007 in. 0.00-0.18 mm
Ring Gear Backlash 0.005-0,008 in. 0.12-0.20 mm
Drive Pinion Gearshaft Bearing
Break-Away Preload Torque
Original Bearings.... 10-20 in. lbs. l - 2N m
Replacement Bearings. 20-4 0 in. lbs. 2-5 Nm
Drive Pinion Gear Depth Select shims
Standard Setting.... 3.125 in. 79.37 mm
Side Gear Clearance (max.) 0.006 in. 0.15 mm
Case Runout (max.) 0.006 in. 0.15 mm
J9202-107
FRONT SUSPENSION COMPONENTS- 2WD FRONT SUSPENSION COMPONENTS- 4WD
F R O N T S U S PE N S I O N C O M PO N E N T S
% W H E E L D R I V E
F R O N T S U S PE N S I O N C OM PON E N TS
4 W H E E L D R I V E
D E S C R I PT I O N T O R O U E
Brake Rotor Dust Shield
Jounce Bumper to Bracket....
Lower Suspension Arm Pivot.
Lower Ball Stud Nut
(11/ 16 -18 Bolt)...............
Lower Ball Stud Nut
(3/4 -16 Bolt).....
Shock Absorber Upper Nut..
Shock Absorber Lower Bolt ..
Stabilizer Bar Retainer Bolts .
Stabilizer Bar Link Nut
Steering Arm to Knuckle
5/ 8- 1 8 Bolt/Nut .............
3/ 4 -16 Bolt/Nut
. 20 N-m (180 in. lbs.
.... 41 N-m (30 ft. lbs.
305 N-m (225 ft. lbs.
183 N-m (135 ft. lbs.
237 N-m (175 ft. lbs.
.... 34 N-m (25 ft. lbs.
. 23 N-m (200 in. lbs.
. 23 N-m (200 in. lbs.
. 11 N-m (100 in. lbs.
Strut/Jounce Bumper to
Suspension Arm Bolt/Nut.
Strut Front Nut
Upper Ball Stud Nut
290 N-m (215 ft. lbs.
330 N-m (225 ft. lbs.
.. 129 N-m (95 ft. lbs.
.... 68 N-m (50 ft. lbs.
14 2 N-m (105 ft. lbs.
J9202-108
D E S C R I PT I O N T O R QU E
Jounce Bumper to Bracket ....
Stabilizer Bar Retainer Bolts..
Stabilizer Bar Link Nut
Shock Absorber/Jounce
Bracket to Frame
Shock Absorber (Standard)
Upper and Lower Nut
Shock Absorber (Air Adjust)
Upper Nut
Shock Absorber (Air Adjust)
Lower Nut
Spring U-bolt/Stud Nuts
(Model 44) ...
Spring Front Pivot Nut
(Model 44)
Spring Rear Shackle Nut
(Model 44)
Spring U-bolt/Stud Nuts
(Model 60)
Spring Front Pivot Nut
(Model 60)
Spring Rear Shackle Nut
(Model 60)
... 41 N-m (30 ft. lbs.)
23 N-m (200 in. lbs.)
11 N-m (100 in. lbs.)
.. 101 N-m (75 ft. lbs.)
.... 75 N-m (55 ft. lbs.)
.... 75 N-m (55 ft. lbs.)
271 N-m (200 ft. lbs.)
.. 115 N-m (85 ft. lbs.)
135 N-m (100 ft. lbs.)
.... 81 N-m (60 ft. lbs.)
.. 129 N-m (95 ft. lbs.)
135 N-m (100 ft. lbs.)
,. 108 N-m (80 ft. lbs.)
J9202-109
MODEL 44 AXLE MODEL 60 AXLE
F R O N T A XL E M O D E L 4 4 F R O N T A XL E M O D E L # 0
Bearing Cap Bolts 95 to 122 N-m
(70 to 90 ft. lbs.)
Brake/Spindle Splash Shield 34 to 41 N-m
(25 to 35 ft. lbs.)
Differential Cover Bolts 47 N-m (35 ft. lbs.)
Fill Hole Plug 34 N-m (25 ft. lbs.)
Lower Ball Stud Nut 108 N-m (80 ft. lbs.)
Pinion Yoke Nut 271 to 298 N-m
(200 to 220 ft. lbs.)
Shift Motor Housing Bolts 14 N-m (10 ft. lbs.)
Spindle Wheel Bearing
Outer Lock Nut...... 68 N-m (50 ft. lbs.)
Steering Knuckle Arm Nuts 122 N-m (90 ft. lbs.)
Ring Gear Bolts 61 to 81 N-m
(45 to 60 ft. lbs.)
Upper Ball Stud Nut 136 N-m (100 ft. lbs.)
Upper Yoke Sleeve 54 N-m (40 ft. lbs.)
J9202-110
Bearing Cap Bolts
Brake Splash Shield/Spindle.
Differential Cover Bolts
Fill Hole Plug
Lower King Pin Cap Screws...
Pinion Yoke Nut.
Spindle Wheel Bearing
Outer Lock Nut
Ring Gear Bolts (Grade 8)
Upper King Pin Cap
Upper King Pin
95 to 122 N-m
(70 to 90 ft. lbs.)
68 to 81 N-m
(50 to 60 ft. lbs.)
47 N-m (35 ft. lbs.)
34 N-m (25 ft. lbs.)
95 to 122 N-m
(70 to 90 ft. lbs.)
339 to 366 N-m
(250 to 270 ft. lbs.)
.... 217 to 278 N-m
(160 to 205 ft. lbs.)
136tol63N- m
(100 to 120 ft. lbs.)
..... 169 to 183 N-m
(125 to 135 ft. lbs.)
96 to 122 N-m
(70 to 90 ft. lbs.)
668 to 813 N-m
(500 to 600 ft. lbs.)
J9202-111

REAR SUSPENSION AND AXLE 3 - 1
C O N T E N T S
page
8 3/8 and 9 1/4 AXLE 11
MODEL 60 and 70 AXLES 29
POWER-LOK DIFFERENTIAL 55
REAR SUSPENSI ON2WD and
4WD VEHICLES 3
page
SERVICE DIAGNOSIS 6
SPECIFICATIONS 27
SURE-GRI P DIFFERENTIAL SERVICE 28
TRAC-LOK DIFFERENTIAL 51
G E N E R A L I N F O R M A T I O N
SUSPENSION
Ram Truck rear suspensions are comprised of;
Drive axle
Leaf springs
Jounce bumpers (used to limit t he travel of t he
suspension)
All Ram Truck and Ramcharger vehicles are
equipped with leaf-type rear springs. The springs
have a one-piece, rubber bushing pressed into t hei r
mai n leaf front eye. Model 150 and Ramcharger ve-
hicles are equipped wi t h a fixed-rate type leaf spring.
Progressive-rate type rear leaf springs are st andard
equipment for all Model 250 and 350 vehicles.
AX LES
The 8 3/8, 9 1/4-Inch , Model 60 and 70 axle hous-
ings consist of a cast iron center section. They also
have two steel axle shaft tubes t hat are pressed into
and welded to t he differential housing.
t he complete axle from the vehicle.
Both axle types are equipped with a remote vent
fitting.
tion t ag is attached to the housing cover.
The rear wheel anti-lock (RWAL) brake speed sen-
sor is attached to t he top, forward exterior of t he dif-
ferential housing. A seal is located between t he
sensor and the wire harness connector. The seal
must be in-plaee when the wi re connector is
connected to the sensor. The RWAL brake exciter
ri ng is press-fitted onto the differential case agai nst
t he flange.
A rear axle equipped with a Sure-Grip differential
is optionally available for both Ram Truck and Ram-
charger vehicles. The Sure-Grip has a two-piece case
t hat is interchangeable wi t h a st andard differential.
A limited-slip differential is optional on Model 60,
and 70 r ear axles. The Model 60 uses t he Trac-Lok
differential and t he Model 70 uses t he Power-Lok dif-
ferential. The Trac-Lok differential uses a one-piece
case while t he Power-Lok differential uses a two-
piece case. Both use t he same i nt ernal components as
a st andard differential, plus two clutch disc packs.
IDENTIFICATION
The axle differential covers can be used for identi-
fication (Fig. 1, 2, 3).
Model 60 axle has t he assembly part number and
gear ratio listed on a tag. The t ag is attached to t he
left side of t he housing cover (Fig. 3). Build date
identification codes on axles are stamped on t he axle
shaft t ube cover side.
LUBRICANTS
Multi-purpose, hypoid gear lubricant should be
used for rear axles with either a st andard or a Sure-
Grip differential. The lubricant should have MIL-L-
2105-B and by API GL 5 quality specifications.
MOPAR Hypoid Gear Lubricant conforms to both of
t hese specifications. In addition, 4 ounces of Hypoid
Additive must be included with a re-fill for Sure-Grip
differentials.
If the rear axle is submerged in water, the lu-
bri cant must be repl aced immediately. Avoi d
axl e failure resulting from water contami nati on
of the lubricant.
R E A R S U S P E N S I O N A N D A X L E
3 - 2 REAR SUSPENSION AND AXLE

DI FFERENTI AL IDENTIFICATION D I F F E R E N T I A L
FILL PLUG J 9202- 4 0
Fig. 3 Model 60 and 70 Differential Cover
Fig. 1 Differential Cover 8 3/8 Inch Axle
IDENTIFICATION
TAG
J9203-32
Fig. 2 Differential Cover 9 1/4 Inch Axle

R E A R S U S P E N S I O N 2 WD a n d 4 WD V E H I C L E S
SPRING AND SHOCK DIAGNOSIS
A squeak noise from t he shock absorber or spring
bushings can be produced if movement bet ween t he
rubber bushi ngs and t he metal occurs. This noise can
usually be stopped by tightening t he at t achi ng nut s.
If the squeak noise persists, inspect for damaged and
worn bushings, and attaching components. Repair as
necessary if any of these conditions exist.
The shock absorber bushings do not requi re any
type of lubrication. Do not lubricate t he bushi ngs to
reduce bushi ng noise. Grease or mi neral oil-base lu-
bricants will deteriorate t he bushi ng rubber.
The shock absorbers are not reflllable or adjust-
able. If a malfunction occurs, t he shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force t he piston into and out
of t he cylinder four or five times. The action through-
out each stroke should be smooth and even.
The spring eye and shock absorber bushi ngs do not
require any type of lubrication. Do not at t empt to
stop spring bushing noise by lubricating t hem.
Grease and mi neral oil-base lubricants will deterio-
rat e t he bushi ng rubber.
If t he vehicle is used for severe, off-road operation,
t he springs should be examined periodically. Check
for broken and shifted leafs, loose and missing clips,
and broken center bolts.
VEHICLE LOADING AND WEIGHT DISTRIBUTION
A vehicle should always be loaded so the vehicle
weight center-line is located immediately forward of
t he rear axle. Correct vehicle loading provides proper
front tire-to-road contact. This resul t s in maxi mum
vehicle handl i ng stability and safety. Refer to Spring
and Shock Absorber Diagnosis chart for further in-
formation.
Incorrect wei ght distribution shoul d be consid-
ered as a possi bl e cause for erratic steering,
spri ng failure or tire wear.
SPRING AND SHOCK ABSORBER DIAGNOSIS
FATI GUE F R OM
O PE R A T I O N
O N S E V E RE
T E R R AI N O R
O V E R L O A D I N G
L O O S E
U-BOLT
N U T S
S HO C K
A BS O R BE R S
N O T
F U N C T I O N I N G
L O O S E EYE BOLT
O R NUT
O R
WO R N BU S H I N G S
WO R N
SEAL
BROKE N
LEAVES
WO R N
BUSHI NGS
U N D E R C O A T I N G
O N S HO C K
A BS OR BE R
CYLI NDER
D A M A G E D
FLUID
R E S E R V OI R
VEHICLE
OV E R L OADE D
LEAF-TIP
LI NE RS WO R N
O R M I S S I N G
VEHI CLE
O V E R L O A D I N G
O R S E V E RE
C O R R O S I O N
AI R TRAPPED
I NTERNALLY
I NT E R NAL
S HO C K
A BS OR BE R
DEFECT
J9017-17

SHOCK ABSORBER
REMOVAL
(2) Remove t he ret ai ni ng locknut and bolt from t he
frame crossmember at t he upper end of t he shock ab-
sorber (Fig. 1).
BOLT
S PR I N G
BR A C K E T
A N D S T U D
L O C K N U T
BU M PE R
L O C K N U T
O U T E R
I N N E R R E T A I N E R
R E T A I N E R J90 T7-31
Fig. 1 Rear Shock Absorber
(3) Remove t he locknut and t he outer ret ai ner
from t he spring bracket stud (Fig. 1).
(4) Remove t he rear shock absorber and t he i nner
ret ai ner from t he vehicle (Fig. 1).
INSTALLATION
(1) Before installing t he shock absorber, ensure
t hat t he bushi ng is inserted in t he shock absorber
eye.
Ensure the shock absorber is posi ti oned on the
stud wi th the retai ners correctly l ocated on ei-
ther side of the bushi ng (Fig. 1).
(2) Position t he i nner ret ai ner and shock absorber
eye on t he spring bracket stud. Install t he outer re-
t ai ner and t he locknut (Fig. 1). Tighten t he locknut
finger-tight.
(3) Rotate t he shock absorber upward and position
t he upper end at t he frame crossmember.
(4) Align and insert t he bolt t hrough t he upper
shock absorber eye and t he crossmember (Fig. 1).
(5) Install t he locknut on t he upper bolt and
t i ght en it finger-tight.
(6) Remove t he supports and lower t he vehicle to
t he surface.
(7) Tighten t he shock absorber nut s to 82 N*m (60
ft. lbs.) torque.
SPRINGS
REMOVAL
(1) Raise and support t he frame until all weight is
removed from t he rear springs.
The vehi cl e must be rai sed under the frame
si de rail at the crossmember behi nd the axle.
Use care to avoi d bendi ng the side rail flange.
(2) Position support st ands under t he frame side
rails.
(3) Remove t he nut s, lockwashers, and U-bolts t hat
at t ach t he spring to t he axle (Fig. 2, 3 and 4).
U- BOLT
S PR I N G
S PR I N G
S HA C K L E
F R A M E
RAI L
L O C K N U T
L O C K N U T
L O C K N U T
A XL E T UBE
BR A C K E T A N D S T U D
N U T J9017-3Q
Fig. 2 Spring W-150 Vehicles
U - B O L T ^ U-BOLT
~ ' PLATE
IB*
AUXILIARY SPRI NG
SPRI NG
F R A M E
R AI L
PI V O T
BR A C K E T
^ . , _ BOLT
' P I V O T ' W A ^ H F P ^ i n^gJ \ BRACKE T
BR A C K E T WASHER ^
FR ONT C3> >>JL ^ T ^
1
A XL E T U BE
L O C K N U T H r S PR I N G BR A C K E T J9017-34
Fig. 3 Spring & Auxiliary SpringD-250, 350
Vehicles

Fig. 4 Spring & Auxiliary SpringW-250, 350
Vehicles
(4) Remove the nut s and bolts from t he spring
front and rear eyes. Remove t he spri ng from t he ve-
hicle (Figs. 2, 3 and 4).
INSTALLATION
(1) Position the spring on t he axle shaft tube so
t hat t he spring center bolt is inserted into t he locat-
ing hole in t he axle t ube spring pad (Figs. 2, 3 and
4).
(2) Align t he spring front eye with t he bolt hole in
t he front bracket and install t he eye pivot bolt and
nut (Figs. 2, 3 and 4).
(3) Align t he spring rear eye with t he bolt hole in
t he spring shackle or t he rear bracket (as applicable)
and install t he spring eye pivot bolt and nut (Figs. 2,
3 and 4).
(4) Tighten the spring front and r ear eye pivot bolt
nut s unt i l all separation between t he metal is re-
moved.
(5) Install the U-bolts, replacement lockwashers
and the ret ai ni ng nut s (Figs. 2, 3 and 4).
(6) Tighten the nut s unt i l they force t he lockwash-
ers flush against t he spring bracket.
(7) Align t he auxiliary spring wi t h the pri mary
spring (Figs. 2, 3 and 4).
(8) Remove the supports and lower t he vehicle so
t hat t he weight is being supported by t he tires.
(9) Tighten the spring ret ai ni ng nut s according to
the following specifications:
U-bolt nut s (1/2-20) - 88 N*m (65 ft. lbs.) torque
# U-bolt nut s (9/16-18) - 149 N-m (110 ft. lbs.)
torque
REAR SUSPENSION AND AXLE 3 5
Fig. 5 Leaf Spring Disassembly
(4) Insert a long drift or punch into t he center bolt
hole and slowly release t he vise jaws.
(5) Remove t he spring from t he vise. Replace t he
broken/defective leaf. Insert a long drift or punch
into the spring center bolt hole.
(6) Position t he spring between vise jaws and
slowly t i ght en t he vise j aws. Keep the spring leaves
aligned with t he long drift or punch.
(7) Remove t he drift/punch from the spring center
bolt hole. Install a replacement center bolt and nut
(Fig. 5).
(8) Tighten t he nut to 20 N-m (15 ft. lbs.) torque.
An al t ernat e is to t i ght en unt i l t he center of t he
spring has no gaps. Use a maxi mum of 54 N*m (40 ft.
lbs.) torque for t hi s method.
(9) Install t he al i gnment clips.
(10) Install t he spring in t he vehicle. If necessary
refer to t he installation procedure.
LEAF SPRING EYE BUSHING REPLACEMENT
(1) Assemble tools shown (Fig. 6). Tighten t he nut
located at t he socket wrench end of t he t hreaded rod
until the bushi ng is forced out.
(2) Assemble and align t he bushing installation
tools.
Spring front and rear eye pivot bolt nut (1/2-20)
88 Nm (65 ft. lbs.) torque
135 Nm (100 ft. lbs.) torque
183 N-m (135 ft. lbs.) torque
SPRING LEAFREPLACEMENT
If a spring has acquired a set (lost significant
height), it should be replaced.
(1) Remove t he spring from t he vehicle. If neces-
sary, refer to t he removal procedure.
(2) Remove t he spring leaf alignment clips.
(3) Clamp t he spring in a vise. Remove t he nut
and center bolt (Fig. 5).

NUT PIPE
SOCKET
WRENCH
(DRIVER)
FLAT THREADED
WASHER ROD J8917-20
Fig. 6 Spring Eye Bushing Removal
(3) Align t he bushi ng with t he spring eye and
t i ght en t he nut located at t he socket wrench end of
t he t hreaded rod. Tighten unt i l t he bushing is forced
into t he spring eye.
The bushi ng must be centered in the spri ng
eye. The ends of the bushi ng must be flush or
slightly recessed wi thi n the end surfaces of the
spri ng eye.
8ERW1GE DIAGNOSIS
INDEX
page
Driveline Snap 8
Gear and Bearing Noi se 7
Limited Slip Differential 8
page
Low Speed K nock . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear Ax le Alignment . . . . . . . . . . . . . . . . . . . . . . . 7
Tire Noi se 7
Vibration 8
GENERAL INFORMATION
Axle beari ng problem conditions are usually caused
by:
Insufficient or incorrect l ubri cant
Foreign mat t er/ wat er contamination
Incorrect beari ng preload torque adjustment
When serviced, t he beari ngs must be cleaned thor-
oughly. They should be dried wi t h lint-free shop tow-
els. Never dry beari ngs wi th compressed air.
This will overheat them and brinell the beari ng
surfaces. This will result i n noi sy operati on after
r epai r .
Axle gear problem conditions are usually t he resul t
of:
Insufficient lubrication
Incorrect or contaminated lubricant
Overloading (excessive engine torque)
Incorrect clearance or backlash adjustment
Insufficient lubrication is usually t he result of a
housing cover leak. It can also be from worn axle
shaft or pinion gear seals. Check for cracks or porous
areas in t he housing or tubes.
Usi ng t he wrong lubricant will cause overheating
and gear failure. Gear tooth cracking and beari ng
spalling are indicators of this.
Axle component breakage is most often t he result
of:
Severe overloading
Insufficient lubricant
Incorrect lubricant
Improperly tightened components
Common causes of overloading is from full-throttle
acceleration. Overloading occurs when towing
heavier t han normal loads. Component breakage can
occur when t he wheels are spun excessively. Insuffi-
cient or incorrect lubricants contribute to breakage
t hrough overheating. Loose differential components
can also cause breakage.
Incorrect beari ng preload or gear backlash will not
result in component breakage. Mis-adjustment will
produce enough noise to cause service repair before a

RfAR SUSPENSION AND AXLE 3 - 7
failure occurs. If a mis-adjustment condition is not
corrected, component failure can result.
REAR AXLE ALIGNMENT
MEASUREMENT
The following procedure can be used to determine
if abnormal rear t i re t read wear is t he result of a
bent or deformed rear axle shaft.
(1) Raise both rear wheels off t he surface with a
frame contact hoist.
(2) Attach a one-inch long piece of maski ng tape at
the center of each tire t read for use as reference
marks.
(3) Rotate t he rear wheels unt i l both reference
marks face t he front of t he vehicle. Measure t he dis-
tance between t he outside edges of t he two pieces of
tape. Record this measurement as t he front of t i re
(FTR) measurement .
(4) Rotate the rear wheels until both reference
marks face t he rear of t he vehicle. Measure t he dis-
tance between t he outside edges of t he two pieces of
tape. Record this measurement as t he rear of tire
(RTR) measurement.
(5) Subtract t he (RTR) measurement from t he
(FTR) measurement to obtain t he amount of wheel
toe. The acceptable rear wheel toe-in position is 1/16
inch (1.6 mm) to 3/16 inch (4.8 mm) toe-out.
(6) Rotate the rear wheels until t he reference
marks are facing downward. Measure the distance
between t he outside edges of t he two pieces of tape.
Record this measurement as t he bottom of tire (BTR)
measurement.
(7) Average t he (FTR) and t he (RTR) distance
measurements. Subtract t he (BTR) measurement
from this average distance to obtain t he camber. The
acceptable amount of camber is 1/16 inch to 3/32 inch
(1.6 to 2.4 mm).
(FTR + RTR) DI VI DED BY 2 (TWO) MI NUS
BTR EQUALS CAMBER
If the (BTR) di stance measurement is l ess than
the average FTR and RTR di stance measure-
ment, the camber will be posi ti ve ( + ). If the
(BTR) distance measurement is greater than the
average FTR and RTR di stance, the camber will
be negati ve ( - ).
If t he toe position or camber is not acceptable, a
bent or deformed rear axle shaft is most likely t he
cause.
TIRE NOISE
Check tires t hat are damaged, unbalanced, incor-
rectly inflated. Tires t hat have deep t reads can emit
sounds like axle noise. Differentiate between t i re and
axle noise during a road test.
Tire noise will usually vary with different road
conditions. Tire noise is sensitive to inflation pres-
sure. The pitch of t i re noise changes when t he vehi-
cle speed is varied.
Drive t he vehicle over different road surfaces. Note
t he changes in t he noise. If the noise changes, t he
tires are t he source of t he noise.
Refer to Group 22, Wheels and Tires for additional
information.
GEAR AND BEARING NOISE
GEAR NOISE
Axle gear noise can be caused by insufficient lubri-
cant. Incorrect backlash, tooth contact, or worn/dam-
aged gears can cause noise.
Gear noise usually happens at a specific speed
range. The range is 30 to 40 mph, or above 50 mph.
The noise can also occur during a specific type of
driving condition. These conditions are, acceleration,
deceleration, coast, or constant load.
When road testing, accelerate t he vehicle to t he
speed range where t he noise is t he greatest. Shift
out-of-gear and coast through t he peak-noise range.
If t he noise stops or changes greatly, check for insuf-
ficient lubricant. Incorrect ring gear backlash, or
gear damage can cause noise changes.
Differential side and pinion gears can be checked
by t ur ni ng the vehicle. They usually do not cause
noise in straight-ahead driving. These gears are
loaded duri ng vehicle t urns. If noise does occur dur-
ing vehicle t urns, t he side or pinion gears could be
worn or damaged. A worn pinion gear mat e shaft can
also cause a snapping or a knocking noise.
BEARING NOISE
The axle shaft, differential and pinion gear bear-
ings can all produce noise when worn or damaged.
Bearing noise can be either a whining, or a growling
sound.
Pinion gear bearings have a constant-pitch noise.
This noise changes only with vehicle speed. Pinion
beari ng noise will be higher because it rotates at a
faster rat e. Drive t he vehicle and load t he differen-
tial. If beari ng noise occurs t he pinion rear beari ng is
t he source of t he noise. If t he bearing noise is heard
during a coast, front beari ng is t he source.
Worn, damaged differential bearings usually pro-
duce a low pitch noise. Differential beari ng noise is
similar to pinion bearing. The pitch of differential
beari ng noise is also constant and varies only with
vehicle speed.
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes
when t he bearings are loaded. Road test t he vehicle.
Turn t he vehicle sharply to t he left and to t he right.
This will load t he bearings and change t he noise

level. Where axle bearing damage is slight, t he noise
is usually not noticeable at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock is generally caused by a worn
U-joint or by worn side-gear t hr ust washers. A worn
pinion gear shaft bore will also cause low speed
knock.
VIBRATION
Vibration at t he rear of t he vehicle is usually
caused by a:
Damaged drive shaft
Missing drive shaft balance weight
Worn, out-of-balance wheel and t i res
Loose wheel lug nut s
Worn U-joint
Loose spring U-bolts
Loose/broken rear springs or shackles
Damaged axle shaft bearings
Loose pinion gear nut
Excessive pinion yoke r un out
Bent axle shaft
Check for loose or damaged front-end components
or engine/transmission mounts. These components
can contribute to what appears to be a rear-end vi-
bration. Do not overlook engine accessories, brackets
and drive belts.
All driveline components should be examined be-
fore st art i ng any repair.
Refer to Group 22, Wheels and Tires for additional
information.
DRIVELINE SNAP
A snap or clunk noise when t he vehicle is shifted
into gear (or t he clutch engaged), can be caused by:
High engine idle speed
Loose engine/transmission/transfer case mount s
9 Worn U-joints
Loose spring shackles or U-bolts
Loose pinion gear nut and yoke
Excessive ri ng gear backlash
Excessive differential side gear-to-case clearance
A wo r n bus hi ng i n t he t r ans mi s s i on ext ens i on
hous i ng c a n al so c a us e noi se.
The source of a snap or a clunk noise can be deter-
mined with t he assistance of a helper. Raise t he ve-
hicle on a hoist wi t h t he wheels free to rot at e.
Instruct t he helper to shift t he transmission into
gear. Listen for t he noise, a mechanics stethoscope is
helpful in isolating t he source of a noise.
LIMITED SLIP DIFFERENTIAL
Under normal traction conditions, engine torque is
divided evenly. With low-traction surfaces, engine
torque is transferred to t he wheel with t he most t i re
traction. When diagnosing a limited-slip differential
problem condition, t he wheel with t he least traction
can continue spinning.
The most common problem is a chat t er noise when
t ur ni ng corners. Check for incorrect or contaminated
lubricant. Replace t he gear lubricant if necessary.
With Sure-Grip differentials add a container of
MOPAR Hypoid Gear Additive
This will correct t he condition in most instances. If
t he chat t er persists, clutch damage could have oc-
curred.
After changing t he lubricant, drive t he vehicle and
make 10 to 12 slow, figure-eight t urns. This maneu-
ver will pump lubricant through t he clutches.
SERVICE DIAGNOSIS
Condition Possi bl e Cause Correction
WHE E L N O I S E
A XL E S HA F T N O I S E
A XL E S HA F T BR O K E
D I F F E R E N T I A L C A S E
C R A C K E D
D I F F E R E N T I A L G E A R S
S C O R E D
L O S S O F L UBR I C ANT
(a) Wheel loose.
(b) Faulty, brinelled wheel bearing.
(a) Misaligned axle shaft tube.
(b) Bent or sprung axle shaft.
(c) End play in drive pinion bearings.
(d) Excessive gear backlash between ring
gear and pinion gear.
(e) Improper adjustment of drive pinion
gear shaft bearings.
(f) Loose drive pinion gearshaft yoke nut.
(g) Improper wheel bearing adjustment.
(h) Scuffed gear tooth contact surfaces.
(a) Misaligned axle shaft tube.
(b) Vehicle overloaded.
(c) Erratic clutch operation
(d) Grabbing clutch.
(a) Improper adjustment of differential
bearings.
(b) Excessive ring gear backlash.
(c) Vehicle overloaded.
(d) Erratic clutch operation.
(a) Insufficient lubrication.
(b) Improper grade of lubricant.
(c) Excessive spinning of one wheel/tire.
(a) Lubricant level too high.
(a) Tighten loose nuts.
(b) Faulty or brinelled bearings must be
replaced.
(a) Inspect axle shaft tube alignment.
Correct as necessary.
(b) Replace bent or sprung axle shaft.
(c) Refer to Drive Pinion Bearing Pre-Load
Adjustment.
(d) Check adjustment of ring gear
backlash and pinion gear. Correct as
necessary.
(e) Adjust drive pinion shaft bearings.
(f) Tighten drive pinion gearshaft yoke nut
with specified torque.
(g) Readjust as necessary.
(h) If necessary, replace scuffed gears.
(a) Replace broken axle shaft after
correcting axle shaft tube alignment.
(b) Replace broken axle shaft. Avoid
excessive weight on vehicle.
(c) Replace broken axle shaft after
inspecting for other possible causes.
Avoid erratic use of clutch.
(d) Replace broken axle shaft. Inspect
clutch and make necessary repairs or
adjustments.
(a) Replace cracked case; examine gears
and bearings for possible damage. At
reassembly, adjust
differential bearings properly.
(b) Replace cracked case; examine gears
and bearings for possible damage. At
reassembly, adjust ring gear backlash
properly.
(c) Replace cracked case; examine gears
and bearings for possible damage.
Avoid excessive weight on vehicle.
(d) Replace cracked case. After inspecting
for other possible causes, examine
gears and bearings for possible
damage. Avoid erratic use of clutch.
(a) Replace scored gears. Scoring marks
on the drive face of gear teeth or in
the bore are caused by instantaneous
fusing of the mating surfaces. Scored
gears should be replaced. Fill rear
differential housing to required capacity
with proper lubricant. Refer to
Specifications.
(b) Replace scored gears. Inspect all
gears and bearings for possible
damage. Clean and refill differential
housing to required capacity with
proper lubricant.
(c) Replace scored gears. Inspect all
gears, pinion bores and shaft for
damage. Service as necessary.
(a) Drain excess lubricant by removing fill
plug and allow lubricant to level at
lower edge of fill plug hole.
J9003-49
3 - 1 0 REAR SUSPENSION AND AXLE
SERVICE DIAGNOSIS (CONT'D)
Condition Possi bl e Cause Correction
AX L E OV E RH E ATI N G
GE AR TE E TH BROK E
( RI NG GE AR AN D
PI NI ON)
AX L E N OI SE
(b) Worn ax le shaft seals.
(c) Cracked differential housing.
(d) Worn drive pinion gear shaft seal.
(e) Scored and worn yoke.
(f) Ax le cover not properly sealed.
(a) Lubricant level too low.
(b) Incorrect grade of lubricant.
(c) Bearings adjusted too tight.
(d) Ex cessive gear wear.
(e) Insufficient ring gear backlash,
(a) Overloading.
(b) Erratic clutch operation.
(c) Ice-spotted pavements.
(d) Improper adjustments.
(a) Insufficient lubricant.
(b) Improper ring gear and drive pinion
gear adjustment.
(c) Unmatched ring gear and drive
pinion gear.
(d) Worn teeth on ring gear or drive
pinion gear.
(e) Loose drive pinion gear shaft bearings.
(f) Loose differential bearings.
(g) Misaligned or sprung ring gear.
(h) Loose differential bearing cap bolts.
(b) Replace worn seals.
(c) Repair or replace housing as
necessary.
(d) Replace worn drive pinion gear shaft
seal.
(e) Replace worn or scored yoke and seal.
(f) Remove cover and clean flange and
reseal.
(a) Refill differential housing.
(b) Drain, flush and refill with correct
amount of the correct lubricant.
(c) Readjust bearings.
(d) Inspect gears for ex cessive wear or
scoring. Replace as necessary.
(e) Readjust ring gear backlash and
inspect gears for possible scoring.
(a) Replace gears. Ex amine other gears
and bearings for possible damage.
Replace parts as needed. Avoid
overloading of vehicle.
(b) Replace gears and ex amine the
remaining parts for possible damage.
Avoid erratic clutch operation.
(c) Replace gears. Ex amine the remaining
parts for possible damage. Replace
parts as required.
(d) Replace gears. Ex amine other parts for
possible damage. Ensure ring gear
backlash is correct.
(a) Refill ax le with correct amount of the
proper lubricant. Al so inspect for leaks
and correct as necessary.
(b) Check ring gear and pinion gear teeth
contact pattern.
(c) Remove unmatched ring gear and
drive pinion gear. Replace with
matched gear and drive pinion gear
set.
(d) Check teeth on ring gear and drive pi-
nion gear for correct contact.
If necessary, replace with new
matched set.
(e) Adjust drive pinion gearshaft bearing
preload torque.
(f) Adjust differential bearing preload
torque.
(g) Measure ring gear runout.
(h) Tighten with specified torque.
J9003-50

8 3/8 and 9 1/4 AXLE
INDEX
page
Ax le Shaft, Seal and Bearing Service . . . . . . . . . 11
Differential Service 16
Information 11
INFORMATION
The 8 3/8 and 9 1/4 axle (Fig. 1) housi ng consist of
a cast iron center section. They also have two steel
axle shaft tubes t hat are pressed into and welded to
means for inspection and service wi t hout removing
LUBRICANT
Multi-purpose, hypoid gear lubricant should be
used for 8 3/8 and 9 1/4 axles. The l ubri cant should
have MIL-L-2105C and API GL 5 qual i t y specifica-
tions. MOPAR Hypoid Gear Lubricant conforms to
both of t hese specifications.
Refer to Group 0, Lubrication and Mai nt enance for
additional information.
C A U T I O N : If a rear axle i s submer ged in water, the
DRAIN AND REFILL
(1) Drive t he vehicle unt i l t he gear lubricant
(3) Remove t he lubricant fill hole pl ug from t he
t he original lubricant to completely drai n from t he
(5) Wi t h st andard differential, clean t he differen-
tial and t he housing cavity with a flushing oil (or
light engine oil). This will remove t he residual lubri-
C A U T I O N : D O N O T F L U S H S ure- Gri p differentials.
S ure- Gri p differentials may be cleaned onl y by wi p-
ing with cl ean, lint-free cl ot hs.
(6 ) Scrape t he residual seal ant from t he housing
faces with mi neral spirits. Apply a bead of MOPAR
Silicone Rubber Sealant on t he housing cover (Fig.
2). Al l ow the seal ant to c ur e for a few mi nut es .
page
Lubricant 11
Pinion Depth Measurement and Adjustment with
Gauge Set 20
Pinion Seal Replacement 14
Install the housi ng cover wi thi n 5 mi nutes af-
t er appl yi ng the sealant. If not installed, the
sealant must be removed and another bead ap-
plied.
(7) Install t he cover on t he differential. Install t he
identification tag. Tighten t he cover bolts to 47 N
#
m
the lubricant f oami ng and overheati ng.
(8) Refill t he differential wi t h t he specified quan-
tity of MOPAR Hypoid Gear Lubricant. With Sure-
Grip differentials, add a container of MOPAR
Hypoid Gear Lubricant Additive.
(9) Install t he fill hole plug.
AXLE SHAFT, SEAL AND BEARING SERVICE
C A U T I O N : When rear axle servi ce i s necessary,
both rear wheel s must be rai sed off the surface s o
that they are free to rotate. Be caut i ous when the
tires are bei ng rotated by the engi ne or by other
means.
C A U T I O N : If equi pped with a S ure- Gri p differential,
do not rotate either axle shaft unl ess both are prop-
erly in-place. Rotation of one axle shaft without the
other bei ng installed can result in mi sal i gnment of
the si de gear s/ spl i nes. T hi s will necessitate si de
gear re-alignment before the axle shaft can be in-
stalled.
AXLE SHAFT REMOVAL
(2) Remove t he wheel.
(3) Remove t he brake drum.
(4) Clean all t he foreign mat eri al from housing
cover area.
(5) Loosen t he housing cover bolts. Drai n t he lubri-
cant from t he housing. Remove t he housing cover.
(6 ) Rotate t he differential case so t he pinion mat e
gear shaft lock screw is accessible. Remove t he lock
screw and t he pinion mat e gear shaft from t he case
(Fig. 3).

HUB AXLE
SHAFT
DIFFERENTIAL
HOUSING
FRONT
BEARING
VENT
FITTING
SEAL
AXLE AXLE
SHAFT SHAFT
BE A R I N G TUBE
BE A R I N G
C A P
WASHER
L O C K
STUD
SI DE
GE AR
CLIP
NUT
BOLT
DIFFERENTIAL
BE A R I N G
BE A R I N G
C UP
ADJUS T E R
L O C K
C OV E R
BOLT
PLUG
H O U S I N G
COVER
BOLT
J9003-109
Fig. 1 8 3/8-Inch Or 9 1/4-Inch Axle

SEALANT
1/16-TO
3/32-I NCH
(1.59-TO
38-AAM)
THICK BEAD
DIFFERENTIAL
HOUSI NG
COVER
(TYPICAL) J9003-85
Fig, 2 Sealant On Homing Cower
PI NI ON
GEAR
MATE
SHAFT
O
DI FFERENTI AL
CAS E
LOCK
SCREW
J9003-110
Fig. 3 Pinion Mate Shaft Lock Screw
(7) Push t he axle shaft in toward t he center of t he
vehicle. Remove t he axle shaft C-clip lock from t he
axle shaft (Fig. 4).
(8) Remove t he axle shaft. Use care to prevent
damage to t he axle shaft beari ng.
(9) Inspect the axle shaft beari ng contact surface
area for indications of wear.
i f wear ex i st s, t he ax l e shaft a n d bear i ng
should be r epl ac ed. N o r ma l bear i ng cont act on
t he shaft wi l l be a dul l gr a y a n d it c oul d appear
to be l i ght l y dent ed.
ADJUSTER , SIDE
LOCK ^ GEAR
AXLE
SHAFT !
C-CLIP
LOCK
J9003-111
Fig. 4 Axle Shaft C-Clip Lock
(10) If any of t hese conditions exist, t he axle shaft
and beari ng must be replaced.
The normal appearance will be a dull gray
surface that coul d appear slightly dented.
AXLE SHAFT SEAL AND BEARING REMOVAL
(1) Remove the axle shaft seal with a small pry
bar.
(2) Remove t he beari ng if it appears damaged or
t he axle shaft shows any of the conditions described
above.
(3) Remove t he axle shaft bearing.
8 3/8-inch di amet er (Fig. 5), use Remover C-4167
and Slide Hammer C-637
9 1/4-inch di amet er (Fig. 6), use Remover C-4828
SPECIAL TOOL
C - 637
SPECIAL TOOL
C-4167
AX LE
SH AF T
TU1E
J9103-11
Fig. 5 Bearing Removal (8 3/8-Axle)
3 - 18 REAR SUSPENSION
Fig. 6 Bearing Removal (9 1/4-Axle)
(4) Inspect t he axle shaft t ube bore for roughness
and burrs. Remove as necessary.
C A U T I O N : I nspect the housi ng bore for burrs. R e-
move a s necessary.
BEARING AND SEAL INSTALLATION
Al ways install a new seal.
(1) Wipe t he bore in t he axle shaft t ube clean.
(2) If t he original beari ng is not reusable, install a
new bearing.
8 3/8-Axle use Installer C-4198 wi t h Handle
C-4171
9 1/4-Axle use Installer C-4826 wi t h Handle
C-4171
C A U T I O N : D O N O T use the new axle shaft seal to
posi ti on or seat the bearing in the axle shaft bore.
(3) Insert t he beari ng into t he t ube. Ensure t hat
t he beari ng is not cocked and is seated firmly agai nst
t he t ube shoulder.
(4) Install t he new axle shaft seal (Fig. 7).
8 3/8-Axle use Installer C-4203 and Handl e C-4171
9 1/4-Axle use Installer C-4826 and Handl e C-4171
Fig. 7 Axle Shaft Seal Installation
(5) When t he tool cont
(face), t he seal will be a
depth.
AXLE SHAFT INSTALL*
(1) Lubricate t he bearin
t he axle shaft and engage
gear. Use care to prevei
damagi ng the axle shaft
(2) Insert t he C-clip loi
(Fig. 4). Push t he axle s
C-clip lock.
(3) Insert t he pinion ge
Install t hrough t he t hrust
Align t he hole in t he shaf
Install t he lock screw wit
Tighten t he screw to 11 I
s
3).
(4) Clean t he cover anc
Refer to t he Drai n and Re
(5) Install t he brake drv
(6) Install t he wheel an
Tire Installation within th
cle.
(7) Raise or lower t he
level.
(8) Remove t he fill hole
housing with lubricant. I
chart for t he type and t h
hole plug.
(9) Lower t he vehicle. T
correct operation.
PINION SEAL RE PLACE ! !
C A U T I O N : The fol l owi ng
s o the correct pinion bea
tained. If not completely f
failure of the rear axle.
REMOVAL
(1) Raise and support tr
(2) Mark t he U-joint, pi]
for reference.
(3) Disconnect t he drh
yoke. Secure t he drive sha
prevent damage to t he re*
(4) Remove t he rear w
drums to prevent any dr
false beari ng preload torq
(5) Use a Newton-mete
wrench to measure t he p
t at e t he pinion shaft sev(
wrench. Note t he indicate
moved t hrough several re'
(13) Install t he brake drums.
(14) Install t he wheels. Lower
(15) Adjust hoist so vehicle k
Check t he differential housing h
essary, add sufficient amount .
COMPLETE AXLE REMOVAL/ IN!
It is not necessary to remov
from t he vehicle for routine or d
t he differential housing or axle
aged, t he complete axle can 1
stalled.
REMOVAL
(1) Raise t he vehicle to a <
height t hat will permi t support t
at t he front of t he rear springs.
(2) Block t he brake pedal in t l
position with a wooden block.
(3) Remove t he rear wheels. '.
brake drum retaining cl i ps oi
(4) Disconnect t he brake flui
t he wheel cylinders. Cap t he fit
of brake fluid.
(5) Remove t he vent hose froi
pie.
(6) Remove t he brake tee be
t he brake fluid tubes from t he c
(7) Disconnect t he parki ng bn
U-joint, pinion yoke, and pinion
Mark the U-joint, pi ni on y o l
for reference.
(8) Disconnect t he drive she
yoke. Secure t he drive shaft in a
prevent damage to t he rear U-jc
(9) Remove t he shock absorl
nut s and bolts. Remove t he reai
t he U-bolts and t he spring br ad
(10) Remove t he complete axL
(11) Wash and clean t he outei
ing and tubes. Use an appropri;
and dry t he surface with comprc
INSTALLATION
(1) Position t he rear axle sj
spring center bolts.
(2) Install t he spring U-bolts
absorber lower bolts. Tighten tl
fled torque.
(3) Connect t he parki ng brake
(4) Connect t he brake fluid
wheel cylinders. Bleed and adjui
(5) Align t he installation refer
t he drive shaft yoke to t he pinii
U-joint clamp bolts to 19-23 N
torque.
(6) Install t he rear wheels. Ti|
correct t i ght eni ng sequence.
REAR SUSPENSION AN i AXLE 3 - 17
(3) El i mi nat e any side play in t he differential case.
Attach Dial Indicator to Pilot stud C-3288-B. Place
t he indicator plunger at a ri ght angle (90) to t he
ri ng gear (Fig. 11). The plunger should exert a slight
force against t he gear face.
DIAL
INDICATOR
Fig. 11 Ring Gear Runout Measurement
(4) Measure t he runout by t ur ni ng t he ri ng gear
several complete revolutions. Observe t he dial indica-
tor pointer. Mark the ri ng gear and t he differential
case at t he areas of maxi mum runout. The ri ng gear
runout should not exceed 0.005 inch (0.13 mm). If t he
runout exceeds 0.005 inch (0.13 mm), a damaged dif-
ferential case could be t he cause.
The marki ng on the differential case will be
very useful later duri ng the differential case
runout. Remove the rear wheel anti-lock
(RWAL) sensor.
(5) Mark the differential housing and t he differen-
tial bearing caps for installation reference (Fig. 12).
(6) Remove t he beari ng t hreaded adjuster lock
from each bearing cap. Loosen t he bolts, but do not
remove t he bearing caps.
(7) Loosen t he t hreaded adjusters wi t h Wrench
C-4164 (Fig. 13).
(8) Hold t he differential case in place. Remove t he
bearing caps (Fig. 14), adjusters and t he differential
case.
Each differential beari ng cup and threaded
adjuster must be kept wi t h their respecti ve bear-
ing.
PINION GEAR SHAFT REMOVAL
(1) Remove t he pinion gear nut and washer. Use
Puller C-452 and Wrench C-3281 to remove t he pin-
ion gear yoke.
Fig. 12 Housing & Caps Marked For Installation
Reference
Fig. 13 Threaded Adjuster Tool
Fig. 14 Differential Bearing Cap Removed
(2) Use Pul l er C-748 to remove t he pinion seal.
Discard t he seal.
(3) Force t he pinion gear out t he front beari ng to

remove t he shaft and front bearing. Thi s wi l l dam-
age t he f r ont be a r i ng r ol l er s a n d be a r i ng c up.
The f r ont be a r i ng a n d c up mus t be r epl aced.
Discard t he beari ng collapsible spacer.
(4) Remove t he front and rear beari ng cups with
Remover C-4306 and Handle C-4171.
(5) Remove t he rear beari ng from t he pinion shaft
with Puller C-293-PA and Adapter (Fig. 15). Remove
and record t he pinion gear depth shims.
8 3/8 use Adapter C-293-42
9 1/4 use Adapter C-293-37
SPECIAL
TOOL
C-293-PA
Fig. 15 Inner Bearing Removal
RING GEAR
Do not r emove t he r i ng ge a r f r om cas e unl es s
t he r u n o u t mus t be me a s ur e d.
(1) Clamp t he case (with t he ri ng gear bolts facing
upward). Use a vise equipped with soft j aws (brass).
(2) Remove and discard t he ri ng gear bolts. The
bol t s ha ve l ef t - hand t hr e a ds . Use a hammer and a
brass drift to force t he ri ng gear loose from t he case
pilots. Remove t he ri ng gear.
CASE FLANGE RUNOUT MEASUREMENT
(1) If t he ri ng gear runout exceeded 0.005 inch
(0.13 mm), case flange runout should also be mea-
sured. Install t he case wi t h t he beari ng cups and t he
t hreaded adjusters close to t hei r original position.
(2) Install t he beari ng caps and bolts. Tighten t he
bolts lightly. Use Wrench C-4164 (Fig. 12) to t hread
both adjusters inward. Remove all side play.
(3) At t ach Dial Indicator to measure t he flange
runout . The plunger should contact t he ri ng squarely
between t he outer edge and t he gear at t achi ng bolt
holes (Fig. 16).
Fig. 16 Case Flange Runout Measurement
(4) Rotate t he differential case several times. Ob-
serve t he dial indicator pointer. Mark t he area of
maxi mum flange runout. The differential case flange
runout must not exceed 0.003 inch (0.08 mm). If t he
runout exceeds t he amount replace t he differential
case.
You can r e duc e excessi ve r i ng ge a r r unout by
posi t i oni ng t he r i ng gear r u n o u t ma r k 180 de-
gr ees oppos i t e t he fl ange r unout ma r k.
(5) Remove t he differential beari ng cap bolts. Re-
move t he differential case from t he differential hous-
ing.
DIFFERENTIAL CASE DISASSEMBLY
(1) Rotate t he side gears unt i l t he pinion gears are
located at t he differential case opening and remove
t hem.
(2) Remove t he side gears and t he t hrust washers.
(3) Remove t he differential bearings from t he case
hubs with Puller C-293-PA, Adapter (Fig. 17).
8 3/8 use Adapter C-293-48 and Pl ug SP-3289
8 1/4 use Adapter C-293-48 and Pl ug C-293-3
(1) Clean all of t he differential components in
cleaning solvent. Allow t he bearings to either air dry
or dry t hem with a lint-free cloth. Dry t he other com-
ponents with compressed air.
(2) Exami ne each component for wear or damage.
(3) Replace shims, bearings and cups as a set only.
Replace bearings and cups if either is galled, worn,
cracked, or damaged.
(4) Inspect t he differential side and pinion gears.
Replace any gear t hat is worn, cracked or chipped.
(5) Inspect t he differential case. Replace t he case if
cracked or damaged.
Pol i s h e a c h axl e shaf t wi t h No. 600 cr ocus
cl ot h. Thi s c a n r emove sl i ght sur f ace da ma ge .
Do not r e duc e t he di amet er of t he axl e shaft seal
cont act sur f ace. When pol i shi ng, t he cr ocus

REAR SUSPENSION AND AXLE 3 - 1 1
A D A PT E R S
cl ot h s houl d be moved a r o u n d t he ci r cumf er -
ence of t he shaf t (not i n-l i ne wi t h t he shaft ).
When r epl aci ng a dr i ve pi ni on gear bear i ng,
al ways r epl ace t he be a r i ng a n d c up as a
ma t c he d set onl y.
(6) Inspect t he axle shaft C-clip locks for cracks
and excessive wear. Replace t hem if necessary.
(7) Test each t hreaded adjuster to determine if it
rotates freely.
(8) If an adjuster binds, repai r t he damaged
t hreads or replace t he adjuster.
EXCITER RING REPLACEMENT
The ring gear must be removed before t he RWAL
brake exciter ri ng can be replaced.
(1) Remove exciter ring with a hammer and drift.
(2) Heat t he replacement exciter ri ng with a heat
l amp or by i mmersi ng in a hot fluid. The tempera-
t ure should not exceed 149C (300F). Do not us e a
t or c h t o h e a t t he r i ng.
(3) After heat i ng, quickly position t he exciter ri ng
on t he differential case adjacent to t he flange.
DIFFERENTIAL CASE ASSEMBLY
(1) Lubricate all t he differential case components
with gear lubricant.
(2) Place t he t hrust washers on t he differential
side gears. Position t he gears i n t he differential case
counterbores.
If r e pl a c e me nt si de ge a r s or t hr us t wa s h e r s
a r e us ed, r ef er t o Di fferent i al Si de Ge a r Cl ear-
a nc e Me a s ur e me nt And Adj us t ment .
(3) Position t he t hrust washers on t he differential
pinion gears. Mesh t he pinion gears with t he side
gears. En s u r e t hat t he pi ni on ge a r s a r e exact l y
180 degr ees oppos i t e each ot her .
(4) Rotate t he side gears to align t he pinion gears
and t hr ust washers. Align t hese components with t he
mat e shaft bores in t he case.
(5) If t he r i ng gear was removed, clean all contact
surfaces. Use an Arkansas stone or fine file to re-
move any sharp areas from t he chamfered inside di-
amet er.
(6) If removed, heat ring gear with a heat lamp or
by immersing in a hot fluid. The t emperat ure should
not exceed 149C (300F). Do not us e a t or c h t o
h e a t t he r i ng.
(7) Position heated gear on case. Use two equally
spaced Pilot Studs C-3288-B to align t he gear with
t he flange holes (Fig. 18).
J9203-24
Fig. 18 Case-To-Ring Gear Alignment
(8) Install replacement ri ng gear bolts (with left
hand threads). Alternately and evenly t i ght en each
bolt to 95 N-m (70 ft. lbs.) torque.
C A U T I O N : When installing a differential beari ng,
never appl y force to the bearing cage because bear-
i ng damage will result.
(9) Place a differential beari ng on each hub (Fig.
19).
8 3/8, use Installer C-4340 and Handle C-4171
9 1/4, use Installer C-4213 and Handle C-4171

SPECIAL TOOL
C-4171
SPECIAL TOOL
8- 3/ 8- C- 4340
9.1/ 4- C- 42 13
J9203-33
PINION DEPTH MEASUREMENT AND ADJUSTMENT
WITH GAUGE SET
(1) Use pinion gear adjustment gauge set and con-
t i nue t he assembly:
8 3/8, use C-3715-B (Fig. 20)
9 1/4, use C-758-D6 (Fig. 21)
(2) Install front (outer) beari ng cup use Installer
D-130 and Handl e C-4171.
(3) Install r ear (inner) beari ng cup.
8 3/8 axles, use Installer C-4308 and Handl e
C-4171
9 1/4 axles, use Installer C-4310 and Handl e
C-4171
8 3/8 axl es assembl e C-3715-B Tool Set as de-
scri bed (Fig. 20);
SPECIAL TOOL SET
G3715-B
SP-6030
SP-5 36
SP-531 J9203-51
Fig. 20 8 3/8 Axle Pinion Adjustment Tools
Install pinion front beari ng
Install Spacer (SP-6022)
Install Sleeve (SP-3194-B), Washer (SP-534) and
Nut (SP-3193)
9 1/4 axl es as s embl e C-758-D6 Tool Set a s de-
s cr i bed (Fig. 21);
SPECIAL TOOL
C-758-D6 SP-6018
SP-5 36-* -<S^
Fig. 21 9 1/4 Axle Pinion Adjustment Tools
and
Install Spacer (SP-6022)
Install Sleeve (SP-535-A), Washer (SP-534)
Nut (SP-533)
(4) Prevent compression sleeve tool from t ur ni ng
wi t h Wrench C-3281.
Tighten t he nut to seat t he pinion bearings in t he
housing (Fig. 22). Allow t he sleeve to t ur n several
t i mes duri ng t he t i ght eni ng to prevent brinelling t he
beari ng cups or t he bearings.
Depth shim(s) are posi ti oned bet ween the pin-
i on gear rear beari ng and pi ni on gear to provi de
the separati on di stance. The requi red thi ckness
pinion gear front and rear bearings with gear lubri-
cant. Re-tighten t he compression nut tool to 1-3 N*m
(15-25 in. lbs.) torque. Rotate t he pinion gear several
complete revolutions to align t he beari ng rollers.
(6) Install Gauge Block.
8 3/8 axles (Fig. 20)
Install Gauge Block SP-5383 at t he end of SP-5385
Install Cap Screw (SP-536) and t i ght en with
Wrench SP-531
9 1/4 axles (Fig. 21)

Install Gauge Block SP-6020 at t he end of SP-526
Install Cap Screw (SP-536) and t i ght en with
Wrench SP-531
(7) Position Crossbore Arbor in t he differential
housing.
8 3/8 (Fig. 20); (SP-6029)
9 1/4 (Fig. 21); (SP-6018)
(8) Center t he tool. Place a piece of 0.002 inch
shim stock at each end of t he arbor. Position t he
beari ng caps on t he arbor tool. Install the at t achi ng
bolts. Tighten t he cap bolts to 14 N*m (10 ft. lbs.)
torque.
arbor and gauge block (Fig. 23). The depth shim(s)
SPACER
BEARING CAP ARBOR J9203-53
Depth shi ms are avai l abl e in 0.001-inch incre-
ments from 0.020 i nch to 0.038 i nch.
(10) Note t he etched number on t he face of t he
drive pinion gear (e.g., -0, - 1 , -2, + 1 , +2, etc.). The
numbers represent thousands-of-an-inch deviation
from t he standard. If t he number is - (negative), add
t hat value to t he required thickness of t he depth
shim(s). If t he number is + (positive), subtract t hat
value from t he thickness of t he depth shim(s). If t he
number is 0, no change is necessary.
(11) Remove t he tools from t he differential hous-
ing.
(12) Position t he depth shim(s) on t he pinion gear.
Install t he rear beari ng (Fig. 24). Be sure t he contact
surfaces are clean and without foreign particles.
8 3/8 axles use Installer C-4040
Original Pinion
Gear Depth
Variance
R e p l a c e m e n t Pinion Gear Depth Variance
Original Pinion
Gear Depth
Variance
- 4 - 3 - 2 - 1 0 + 1 +2 +3 +4
+4 +0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+ 3 + 0.007 + 0.006 + 0.005 +0.004 +0.003 + 0.002 + 0.001 0 -0.001
+2 + 0.006 + 0.005 + 0.004 + 0.003 +0.002 + 0.001 0 -0.001 -0.002
+ 1 + 0.005 + 0.004 + 0.003 +0.002 + 0.001 0 -0.001 -0.002 -0.003
0 +0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
- 1 + 0.003 + 0.002 + 0.001 0 - 0 0 0 1 -0.002 -0.003 -0.004 -0.005
- 2 + 0.002 + 0,001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
- 3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
- 4 0 - 0.001 -0.002 -0.003 -0.004 -0.005 -0,006 -0.007 -0.008
J8902-46
9 1/4 axles use Installer C-3095
Fig. 24 Shaft Rear Bearing Installation
(13) Lubricate t he pinion gear front and rear bear-
ings with gear lubricant.
(14) Install t he pinion gear in t he housing. Install
t he new collapsible spacer at t he end of t he pinion
gear. Install t he pinion gear front bearing.
(15) Install t he pinion yoke with Remover/Installer
It is necessary to use the tool s (above) to cor-
rectly seat the front beari ng on the drive pi ni on
gear shaft (Fig. 25).
C A U T I O N : U se care to prevent col l apsi ng preload
col l apsi bl e spacer duri ng installation of the yoke
and seati ng the front beari ng.
(16) Remove yoke and tools from t he pinion gear.
(17) Install t he new pinion gear shaft seal (Fig.
26).
8 3/8-inch diameter use Seal Installer C-4076-A
and Handl e C-4735-1
9 1/4-inch di amet er use Seal Installer C-3980-A or
C-4109-A and Handl e C-4735
The seal is correctly installed when the seal
flange contacts the face of the differential hous-
i ng flange.
The outer perimeter of the seal is pre-coated
wi th a speci al sealant. An additional appl i cati on
of seal ant is not required.
(18) Install t he pinion yoke with Remover/Installer
C-3718 and Wrench C-3281.
(19) Remove t he tools. Install t he Belleville
washer. The convex side of t he washer must face out-
ward. Install t he pinion nut .
4
J9103-21
Fig. 26 Pinion Gear Seal Installation
(20) Retain pinion yoke with Wrench C-3281. Ini-
tially t i ght en t he drive pinion gear shaft nut enough
to remove t he beari ng end play. While tightening, ro-
t at e t he pinion shaft to ensure t he beari ng rollers are
correctly seated.
(21) Tighten t he pinion nut to (Fig. 27) 285 N*m
(210 ft. lbs.) torque (minimum).
(22) Remove t he tools from t he shaft. Rotate t he
pinion several complete revolutions (both directions)
to additionally seat t he beari ng rollers.
C A U T I O N : Never l oosen the pinion gear nut to de-
crease the pi ni on gear bearing preload torque. If the
speci fi ed preload torque i s exceeded, a replacement
col l apsi bl e spacer must be installed. The torque se-
quence will have to be repeated.
TOOL HOUSING

Fig. 27 Tightening Pinion Gear Nut
(23) Measure t he pinion beari ng preload torque by
rot at i ng pinion shaft with a Newton-meter or an
inch-pound torque wrench. The correct beari ng pre-
load torque is 2-4 N-m (20-30 in. lbs.). This torque
value is with replacement bearings and pinion nut
tightened to a mi ni mum of 285 N-m (210 ft. lbs.)
torque (Fig. 28).
When usi ng original pi ni on rear beari ng and a
repl acement front bearing. The correct prel oad
torque is 1 N-m (10 in. lbs.) torque i n addition to
the torque measured and recorded duri ng disas-
sembly.
Fig. 28 Bearing Preload Torque Measurement
The beari ng prel oad torque shoul d be constant
during a compl ete revol uti on of the drive pinion
gear shaft. If the prel oad torque vari es during
rotation of the shaft, there is an internal bi ndi ng
that must be corrected before final assembl y.
(24) If t he specified torque is not obtained, t i ght en
t he nut in small increments unt i l t he preload torque
is obtained.
The differential will be unacceptabl e for use if
the final nut torque i s l ess than 285 N-m (210 ft.
lbs.) torque. If the prel oad torque is not wi thi n
the specified range thi s is al so unacceptabl e.
DIFFERENTIAL CASE INSTALLATION
(1) Apply a coating of hypoid gear lubricant to t he
differential bearings, beari ng cups and threaded ad-
j ust ers. A dab of grease can be used to keep t he ad-
j ust ers in position. Carefully position t he assembled
differential case in t he housing.
(2) Observe t he reference marks and install t he
differential bearing caps at t hei r original locations
(Fig. 29) .
Fig. 29 Bearing Caps & Bolts
(3) Install t he beari ng cap bolts (Fig. 29). Tighten
t he upper bolts to 14 N-m (10 ft. lbs.) torque. Tighten
t he lower bolts finger-tight until t he bolt head is
lightly seated.
DIFFERENTIAL BEARING PRELOAD AND RING
GEAR BACKLASH ADJUSTMENT
The following must be considered when adjusting
bearing preload and gear backlash:
The maxi mum ri ng gear backlash variation is
0.003 inch (0.076 mm)
Mark t he gears so t he same t eet h are meshed dur-
ing all backlash measurement s
Mai nt ai n t he torque while adjusting t he bearing
preload and ri ng gear backlash
Excessive adjuster torque will introduce a high
bearing load and cause premat ure beari ng failure.
Insufficient adjuster torque can result in excessive
differential case free-play and ri ng gear noise
Fig. 30 Threaded Adjuster Tool
(2) Install Dial Indicator (Fig. 31). Position t he
plunger against t he drive side of a ri ng gear tooth.
Measure t he backlash at 4 positions (90 degrees
apart) around t he ri ng gear. Locate and mar k t he
area of mi ni mum backlash.
(3) Rotate t he ri ng gear to t he position of t he least
backlash. Mark t he gear so t hat all future backlash
measurement s will be t aken wi t h t he same gear
t eet h meshed.
(4) Loosen t he right-side, t i ght en t he left-side
threaded adjuster. Obtain backlash of 0.003 to 0.004
inch (0.076 to 0.102 mm) with each adjuster tight-
ened to 14 N-m (10 ft. lbs.) torque. Seat t he beari ng
cups with t he procedure described above.
(5) Tighten t he differential beari ng cap bolts;
8 3/8 axles to 95 N-m (70 ft. lbs.) torque
9 1/4 axles to 136 N-m (100 ft. lbs.) torque
(6) Use Wrench C-4164 to t i ght en t he right-side
t hreaded adjuster to 102 N-m (75 ft. lbs.) torque. Seat
t he beari ng cups with t he procedure described above.

Continue to t i ght en t he right-side adjuster and seat
bearing cups unt i l t he torque remai ns constant at
102 N-m (75 ft. lbs.)
(7) Measure t he ri ng gear backlash. The range of
backlash is 0.006 to 0.008 inch (0.15 to 0.203 mm).
Continue increasing t he torque at t he right-side
threaded adjuster unt i l t he specified backlash is ob-
tained.
The left-side t hr e a de d adj ust er t or que s houl d
ha ve appr oxi mat el y 102 N-m (75 ft. lbs.) t or que .
If t he t or que i s cons i der abl y l ess, t he compl et e
adj us t ment pr oc e dur e mus t be r epeat ed.
(8) Tighten t he left-side threaded adjuster unt i l
102 N-m (75 ft. lbs.) torque is indicated. Seat t he
beari ng rollers with t he procedure described above.
Do this until t he torque remai ns constant.
(9) Install t he threaded adjuster locks . Ensure t he
lock finger is engaged with t he adjuster hole.
Tighten t he lock screws to 10 N-m (90 in. lbs.)
torque.
SIDE GEAR CLEARANCE MEASUREMENT AND
ADJUSTMENT
When measuri ng side gear clearance, check each
gear independently. If it necessary to replace a side
gear, replace both gears as a matched set.
(1) Install t he axle shafts and C-clip locks and pin-
ion mat e shaft. If necessary, refer to t he installation
located within this group.
(2) Measure each side gear clearance. Insert a
matched pair of feeler gauge blades between t he gear
and differential housing on opposite sides of t he hub
(Fig. 32).
(3) If side gear clearances is no more t han 0,005
inch. Determine if t he shaft is contacting t he pinion
gear mat e shaft. Do not r emove t he feel er gauges ,
i ns pect t he axl e shaf t wi t h t he feel er gauge in-
s er t ed be hi nd t he si de gear . If t he end of t he axle
shaft is not contacting t he pinion gear mat e shaft,
t he side gear clearance is acceptable.
Insufficient adjuster torque will not support t he
ri ng gear correctly and can cause excessive differen-
tial case free-play and ri ng gear noise
The di fferent i al be a r i ng c ups wi l l not al ways
i mmedi at el y follow t he t hr e a de d adj us t er s as
t hey a r e moved dur i ng adj us t ment . En s u r e accu-
r a t e be a r i ng c up r e s pons e s t o t he adj us t ment s .
Mai nt ai n t he gear t eet h e nga ge d ( meshed) as
ma r ke d. The be a r i ngs mus t be s eat ed by r api dl y
r ot at i ng t he pi ni on ge a r a hal f t u r n b a c k a n d
fort h. Do t hi s five t o t en t i mes e a c h t i me t he
t hr e a de d adj us t er s a r e adj ust ed.
(1) Use Wrench C-4164 to adjust each t hreaded ad-
j ust er inward (Fig. 30). Adjust unt i l t he differential
bearing free-play is eliminated. Allow some ri ng gear
backlash (approximately 0.01 inch/0.25 mm) between
t he ring and pinion gear. Seat t he beari ng cups with
t he procedure described above.
Fig. 32 Side Gear Clearance Measurement
(4) If clearance is more t han 0.005 inch (axle shaft
not contacting mat e shaft), record t he side gear clear-
ance. Remove t he t hr ust washer and measure its
thickness with a micrometer. Add t he washer thick-
ness to t he recorded side gear clearance. The sum of
gear clearance and washer thickness will determine
required thickness of replacement t hrust washer
(Fig. 33).
SIDE GEAR CLEARANCE 0.007
THRUST WASHER THI CKNESS + 0.033
TOTAL 0.040
I ^ ^ 0.040
REPLACEMENT WASHER THI CKNESS - 0.037
NEW SIDE GE AR CLEARANCE 0.003
J9203-31
Fig. 33 Side Gear Calculations
In some cases, t he end of t he axle shaft will move
and contact t he mat e shaft when t he feeler gauge is
inserted. The C-clip lock is prevent i ng t he side gear
from sliding on t he axle shaft.
(5) If t here is no side gear clearance, remove t he
C-clip lock from t he axle shaft. Use a micrometer to
measure t he t hr ust washer thickness. Record t he
thickness and re-install t he t hrust washer. Assemble
t he differential case without t he C-clip lock installed
and re-measure t he side gear clearance.
(6) Compare both clearance measurement s. If t he
difference is less t han 0,012 inch (0.305 mm), add
clearance recorded when t he C-clip lock was installed
to t hrust washer thickness measured. The sum will
determine t he required thickness of t he replacement
t hr ust washer.
(7) If clearance is 0.012 inch (0.305 mm) or
greater, both side gears must be replaced (matched
set) and t he clearance measurement s repeated.
(8) If clearance (above) continues to be 0.012 inch
(0.305 mm) or greater, t he case must be replaced.
ANALYSIS
The ri ng gear t eet h contact pat t erns will show if
ness. It will also show if the ri ng gear backlash has
tained wi t hi n t he specified limits unt i l t he correct
Excessive backlash is corrected by moving t he ring
gear t eet h closer to t he pinion gear t eet h
Insufficient backlash is corrected by moving t he
ring gear away from t he pinion gear
(1) Apply yellow ferrous (iron) oxide compound to
both drive and coast sides of ri ng gear teeth.
both directions.
for i nt erpret at i on of contact pat t erns and adjust ac-
cordingly.
stallation wi t hi n this group.
(5) Inst al l t he housing cover. Refill t he differential
(6) Inst al l t he RWAL brake speed sensor and cover
onto t he axle housing. Tighten t he sensor to 24 N*m
DRI VE SI DE
O F R I N G
GE AR TEETH
HEEL T O E
C O A S T SI DE
O F R I N G
GE AR TEETH
T O E HEEL
DESIRABLE C O N T A C T PATTERN.
PATTERN S H O U L D BE CENTERED
O N THE DRI VE SI DE O F T O O T H .
PATTERN S H O U L D BE CE NTE RE D O N
THE C O A S T SI DE O F T O O T H ,
BUT M A Y BE SLI GHTLY T O WA R D
THE T O E . THERE S H O U L D ALWAYS
BE S O M E C L E AR ANC E BETWEEN
C O N T A C T PATTERN A N D T O P O F
THE T O O T H .
R I N G GE AR BACKLAS H CORRECT.
T HI N N E R PI N I O N GE AR DEPTH
S HI M R E QUI R E D.
R I N G GE AR BAC KL AS H CORRECT.
T HI C K E R PI N I O N GE AR DEPTH
PI N I O N GE AR DEPTH S HI M
CORRECT. DE C R E AS E R I N G
GE AR BAC KL AS H.
PI N I O N GEAR DEPTH S HI M
CORRECT. I N C R E A S E R I N G
GE AR BAC KL AS H.
J9003-24

SPECIFICATIONS
8 1/4 INCH AXLE
Axle Type .Semi-floating, hypoid
Ring Gear Diam.. ....8.25 in. (20.95 cm)
Lubricant............................. .........SAE 80W-90
Lube Capacity..... 70 oz. (2.08 L)
Sure-Grip Additive ....4 oz. (118 ml)
Diff. Case Cl earance. . 0.005 in. (0.12 mm)
Ring Gear Backlash.0.005-0.008 in. (0.12-0.20 mm)
Pinion Beari ng Preload........ 10-20 in.lbs. (1-2 N*m)
Case Flange Runout ................0.003 in. (0.076 mm)
Ring Gear Runout ....0.005 in. (0.127 mm)
AXLE RATIO
m
...,GEAR/TEETH COMBINATION
3.55:1..... 39/11
3.90:1............ ...............39/10
9 1/4 INCH AXLE
Axle Type .............Semi-floating, hypoid
Ring Gear Di am 9.25 in. (23.50 cm)
Lubricant ....................SAE 80W-90
Lube Capacity ........76 oz. (2.26 L)
Diff. Case Clearance 0.005 in. (0.12 mm)
Ring Gear Backlash.0.005-0.008 in, (0.12-0.20 mm)
Pinion Bearing Prel oad. 10-20 in.lbs. (1-2 Nnn)
Case Fl ange Runout ................0.003 in. (0.076 mm)
Ring Gear Runout..... .......0.005 in. (0.127 mm)
AXLE RATIO ........GEAR/TEETH COMBINATION
3.55:1. .......39/11
3.90:1.............. 39/10
8 1/4 AND 9 1/4 INCH REAR AXLE
DESCRIPTION TORQUE
8-3/8 Axle Differential
Bearing Cap Bolt
Bearing Cap Bolt
Brake Backing Plate
Differential Housing Cover
Bolt....
Pinion Yoke Nut (Minimum
Torque)
Ring Gear Bolt
RWAL Brake Sensor...........
95 N*m (70 ft. lbs.)
136 Nm(100ft. lbs.!
... 64 N*m (48 ft. lbs.]
47 Nm (35 ft. lbs.)
285 N*m (21 Oft. lbs.)
... 95 N*m (70 ft. lbs.)
... 24 N*m (18 ft. lbs.)
J9203-69

S U R E - G R I P DIFFERENTIAL SERVICE
GENERAL INFORMATION
The Sure-Grip differential is an option available in
t he 8 1/4 and 9 1/4 inch rear axles (Fig. 1).
EXCITER
RI NG
RI NG
GEAR
DIFFERENTIAL
CASE
BEARI NG
BEARI NG
J9003-119
Fig. 1 Sure-Grip Differential
With t he exception of t he Sure-Grip differential
case, all t he axle components are identical to t he
st andard axle. The Sure-Grip has a two-piece differ-
ential case. The case is completely interchangeable
with a st andard differential case (Fig. 2). Sure-Grip
differential removal and installation is same as stan-
dard differential.
DIFFERENTIAL
CASE
PI NI ON
GEAR
COI L SPRI NG
LUBRICATION
WELL
SI DE GEAR
CLUTCH
LUBRI CATI ON
G R O O V E S
J9003-120
Fig. 2 Sure-Grip Differential Components
The action of a st andard differential will allow t he
rear wheels to rot at e at different speeds when t he ve-
hicle is t urni ng. This differential will divide t he en-
gine torque equally between t hem. This is a
desirable and normal function of a differential. A
Sure-Grip differential transfers additional engine
torque to t he rear wheel t hat has t he better traction
surface. The Sure-Grip differential allows t he driving
wheel with better traction to develop more driving
torque t han t he other wheel. The Sure-Grip is not a
locking type differential.
IDENTIFICATION
Raise both rear wheels off t he surface and rot at e
t hem. If both rear wheels rot at e in t he same direc-
tion, t he vehicle is equipped with a Sure-Grip differ-
ential. Another method of identification is by
removing t he housing cover fill hole plug. Exami ne
(with a flashlight) t he differential case components
t hrough t he lubricant fill hole.
SERVICE INFORMATION
When Sure-Grip differential service is necessary,
both r ear wheels must be raised off t he surface so
they are free to rotate.
A Sure-Grip differential case is not repairable.
If defective, it must be repl aced as a compl ete
unit only. Do not attempt to di sassembl e and re-
pair the case components.
Follow t he same procedure outlined under Stan-
dard Differential for Removal and Installation.
DIFFERENTIAL TEST
C A U T I O N : Whenever a rear axle i s bei ng servi ced,
RAI SE BOTH RE AR W H E E L S off the sur face.
A Sure-Grip differential can be tested without re-
moving t he differential case from t he housing.
(1) Position t he vehicle on a hoist with t he ignition
OFF. Put t he transmission selector lever in PARK
(automatic transmission) or in first gear (manual
transmission).
(2) At t empt to manual l y rotate each rear wheel.
(3) If difficult to manual l y rotate either wheel, t he
Sure-Grip differential is functioning normally. If
easy, t he differential is not functioning normally and
should be replaced.
A Sure-Grip differential case i s not repairable.
If defective, it must be repl aced as a compl ete
unit only. Do not attempt to di sassembl e and re-
pair the case components.
DIFFERENTIAL NOISE
Noise complaints involving a Sure-Grip should be
eval uat ed to determine t he source of t he noise. If a
noise occurs while t he vehicle is t urni ng, t he proba-
ble cause is incorrect or insufficient gear lubricant.
The drai n and clean procedure should be used for
possible elimination of t he noise before replacing t he
differential.

WARNING: WHEN SERVICING VEHICLES WITH
SURE-GRI P, DO NOT USE THE ENGINE TO ROTATE
THE AXLE AND WHEELS. BOTH REAR WHEELS
MUST BE RAISED AND THE VEHICLE SUPPORTED.
A SURE-GRI P AXLE CAN EXERT ENOUGH FORCE
(IF ONE WHEEL I S IN CONTACT WITH THE SUR-
FACE) TO CAUSE THE VEHICLE TO MOVE.
LUBRICATION
Multi-Purpose Gear Lubricant, as defined by MIL-
L-2105-B (API GL-5) should be used in all axles.
MOPAR Hypoid Lubricant is recommended or equiv-
alent.
In Sure-Grip differentials 4 ounces of MOPAR Hy-
poid Gear Lubri cant Additive must be added wi t h
each re-fill.
It is recommended the vehicle be driven t hrough 10
to 12 slow, figure-eight t urns. This ensures t he lubri-
cant is thoroughly pumped t hrough t he Sure-Grip
differential clutches.
MODEL 6 0 a n d 7 0 AXLES
INDEX
page
Ax le Shaft Removal/Installation 32
Complete Ax le Removal/Installation . . . . . . . . . . . 3 3
Differential Assembl y 38
Differential Di sassembl y 34
Drain and Refill 31
Lubricant 31
GENERAL INFORMATION
The housing (Fig. 1) consists of an iron center cast-
ing wi t h axle shaft tubes extending from ei t her side.
The tubes are pressed in to form a one-piece axle
housing.
t he centerline of t he pinion set below t he centerline
of t he ri ng gear.
shafts, meani ng t hat loads are supported by t he axle
housing tubes. The full-float axle shafts are ret ai ned
by bolts attached to t he hub. The hub rides on two
bearings at t he outboard end of t he axle t ube. The
axle shafts can be removed without disturbing or re-
moving t he wheel bearings. The wheel beari ngs are
opposed tapered roller bearings t hat are par t of t he
hub/drum assembly.
page
Pinion Gear Depth Measurement and Adjustment with
Tool Set C-758-D6 43
Pinion Gear Depth Measurement and Adj ustment with
Tool Set D- 1 1 6 . 40
Specifications 50
Wheel Bearing Service 33
A small, stamped metal axle gear ratio identifica-
tion t ag is attached to t he housi ng cover via one of
ri ng and pinion teeth.
ferential pinion mat e shaft is retained wi t h a roll
pin. Model 70 axles with t he optional Powr-Lok use a
two piece differential case. Differential beari ng pre-
load and ri ng gear backlash are adjusted by t he use
of shims located between t he differential bearing
cones and case.
CO
Fig. 1 Model 60 and 70 Rear Axle

REAR SUSPENSI ON AND AXLE 3 - 31
LUBRICANT
Hypoid gear lubricant, as defined by MIL-L-2105-B
and API GL 5 is t he specified lube. MOPAR Hypoid
Gear Lubricant conforms wi t h both of these specifica-
tions and is highly recommended.
CAUTI ON : If a rear ax le i s submer ged in water, the
ax le lubricant must be repl aced immediatel y,
DRAIN AND REFILL
(1) Drive t he vehicle unt i l t he gear lubricant
(3) Remove t he lubricant fill hole plug from t he
(4) Remove the differential housing cover. Allow
the lubricant to completely drai n from t he housing
and axle shaft tubes.
(5) Fl ush the differential and t he housing cavity
with a flushing oil to remove residual lubricant and
foreign mat t er. D o not us e wat er , st eam, ker os ene
or gasol i ne for flushing,
(6) Scrape t he residual gasket from t he housing
faces with mi neral spirits. Install a new cover gas-
Sealant on t he housing cover (Fig. 2). Allow t he seal-
ant to cure for a few minutes.
SEALING
SURFACE
CONTOUR OF BEAD
BEAD
THICKNESS
6.35mm (1/4")
J9302-30
Fig. 2 Sealant On Housing Cower
I nst al l t he h ous i ng c over wi t hi n 5 mi nut es af-
ter appl y i ng the seal ant . I f not i nst al l ed, t he
seal ant mus t be r emov ed a n d a not he r be ad ap-
pl i ed.
(7) Install t he cover on t he differential. Install the
identification tag. Ti ght en t he cover bolts to 47 N
e
m
CAUTI ON : Overfil l ing the differential" can resul t in
the lubricant foami ng and overheati ng.
(8) Refill t he differential housing with the speci-
With Trac-Lok differentials, add a container of Trac-
Lok Lubricant additive.
(9) Install t he fill hole plug. Tighten to 34 N-m (25
ft. lbs.) torque.
(10) Road test t he vehicle. Drive the vehicle and
make 10 to 12 slow, figure-eight t urns. This maneu-
ver will pump lubricant t hrough clutch discs.
PINION SHAFT SEAL
REMOVAL
(2) Mark t he U-joint, pinion yoke, and pinion shaft
for reference.
(3) Disconnect t he drive shaft from the pinion
yoke. Secure t he drive shaft in an upri ght position to
prevent damage to t he rear U-joint.
(5) Mark t he positions of t he yoke and pinion gear
SPECIAL TOOL
C-3281
SPECIAL TOOL
C-452
J9102-31
seal (Fig. 4).
INSTALLATION
lip of pinion seal. Install t he new seal (Fig. 5);
Model 60 use Inst al l er C-3719-A and Handle
C-4735
Model 70 use Inst al l er C-359 and Handle C-4735

PINION SEAL
J9203-55
Fig. 4 Pinion Seal Removal
SPECIAL TOOL
C-4735
J9203-56
shaft. Tighten t he nut to 339-366 N-m (250-270 ft.
(4) Align t he installation reference mar ks and at-
t ach t he drive shaft to t he yoke.
DIFFERENTIAL
AXLE SHAFT REiOWAL/INSTALLATlON
C A U T I O N : R A I S E BO T H R E A R WH E E L S off the sur-
face whenever a rear axle i s being servi ced.
REMOVAL-MODEL 60
(1) Remove t he axle shaft flange bolts.
(2) Slide t he axle shaft out from t he axle t ube (Fig.
1).
INSTALLATION-MODEL 60
(1) Clean t he gasket contact surface area on t he
flange with an appropriate solvent. Install a new
flange gasket and slide t he axle shaft into t he tube
(Fig. 1).
(2) Install t he bolts and t i ght en to 95 Nm (70 ft.
lbs.) torque.
REMOVAL-MODEL 70
(1) Remove t he axle shaft flange lock nut s.
(2) Strike t he axle shaft sharply in t he center of
t he flange with a hammer to t he loosen t he tapered
dowels. Slide t he axle shaft out from t he axle tube
(Fig. 1).
INSTALLATION-MODEL 70
(1) Clean the gasket contact surface area on t he
flange with an appropriate solvent. Install a new
flange gasket and slide t he axle shaft into t he tube
(Fig. 1).
(2) Install t he tapered dowels and t he lock nut s.
Tighten t he lock nut s to 95 N*m (70 ft. lbs.) torque.

WHEEL BEARING SERVICE
REMOVAL
(1) Remove t he axle shaft, refer to t he removal
procedure.
(2) Remove t he nut lock and adjustment nut .
(3) Remove t he hub and dr um assembly. The outer
wheel bearing will slide out as t he hub is being re-
moved.
(4) Place hub on bench and remove inner grease
seal. Discard seal.
(5) Remove inner wheel bearing. Inspect wheel
bearings for wear. Replace as necessary.
(1) Thoroughly clean both wheel bearings and in-
terior of t he hub. Remove all of t he residual lubri-
cant.
(2) To clean t he bearings:
Soak t hem in an appropriate cleaning solvent
Strike t he flat of each beari ng against a hardwood
block several times
Flush beari ng between strikes
Repeat t he procedure above until each bearing is
clean
Dry t he bearings with compressed ai r but do not
spin t hem
(3) After cleaning, apply engine oil to each bear-
ing.
(4) Rotate each beari ng slowly while applying
downward force. Exami ne t he rollers for pitting and
roughness. Replace worn or otherwise defective bear-
ings. If a bearing has pitted and/or rough surfaced
rollers, replace both the beari ng and beari ng cup.
(5) If reusable, remove t he engine oil from each
bearing. Pack each beari ng with multi-purpose
NLGI, grade 2, EP-type lubricant.
Ensure that lubricant is forced into all the cav-
ities bet ween the beari ng cage and rollers.
INSTALLATION
(1) If a bearing and cup must be replaced, remove
the cup from the hub bore. Use a brass drift or an
appropriate removal tool to t ap out t he cup.
(2) Install t he replacement beari ng cup(s) with an
appropriate installation tool.
(3) Apply lubricant to surface area of t he hub bore.
Install the inner wheel bearing in t he hub. Install a
replacement bearing seal with an appropriate seal
installation tool.
(4) Inspect the beari ng and seal contact surfaces on
t he axle for burrs and/or roughness.
(5) Remove all t he rough contact surfaces from t he
axle. Apply a coating of multi-purpose NLGI, grade
2, EP-type lubricant to t he axle.
C A U T I O N : U se care to prevent the inner wheel bear-
ing and bearing seal from contacti ng the axle
threads duri ng installation. Otherwise, the t hreads,
beari ng, and seal coul d be damaged.
(6) Carefully slide t he hub onto t he axle. Install
t he outer wheel bearing, t he locktab and outer wheel
beari ng locknut.
(7) Tighten t he adjustment nut to 163-190 Nnn
(120-140 ft. lbs.) torque while rot at i ng t he wheel.
(8) Loosen t he adjustment nut 1/3 of-a-turn (120
degrees) to provide 0.001-inch to 0.008-inch wheel
bearing end play.
(9) Tap t he nut lock into t he spindle keyway and
adjustment nut .
(10) Install t he axle shaft, refer to t he installation
procedure.
REMOVAL
It is not necessary to remove t he complete axle
from t he vehicle for routine or differential service. If
t he differential housing or axle shaft tubes are dam-
aged, t he complete axle can be removed and in-
stalled.
(1) Raise t he rear of the vehicle unt i l t he r ear
wheels are not contacting t he surface. Support t he
vehicle body at t he front of t he rear springs.
(2) Use a wooden block to ret ai n t he brake pedal
in t he up position.
(3) Remove t he axle shafts, wheels, hubs and
brake drums. If necessary, refer to t he applicable re-
moval procedures.
(4) Disconnect t he brake line and cap t he fittings
to prevent loss of brake fluid.
(5) Disconnect t he parki ng brake cables.
Scribe installation alignment reference marks
on drive shaft U-joint and on pi ni on yoke.
(6) Disconnect t he drive shaft U-joint from t he pin-
ion yoke. Secure it in an upright position to prevent
damage to t he U-joint.
(7) Remove t he rear shock absorbers and t he r ear
spring U-bolts from t he axle.
(8) Remove t he rear axle from t he vehicle.
INSTALLATION
(1) If t he differential housing cover was removed,
ensure differential housing and cover mat i ng sur-
faces are clean.
(2) If cover was removed, apply a bead of MOPAR
Silicone Rubber Sealant around t he cover bolt circle.
Install t he differential housing cover. Tighten t he
cover bolts to 47 Nm (35 ft. lbs.) torque. Install the
axle gear ratio identification tag under one of
the cover bolts.
(3) With t he vehicle body supported at t he front of
t he rear springs, position t he axle under t he r ear
springs.

(4) Install t he spring U-bolts and t i ght en t he nut s
with t he specified torque.
(5) Install t he shock absorbers.
(6) Connect t he parki ng brake cables.
(7) Connect t he brake lines. Install t he hubs and
brake drums. Adjust t he wheel bearings (refer to
Wheel Beari ng Adjustment).
(8) Remove t he block from t he brake pedal. Bleed
and adjust t he brakes.
(9) Connect t he drive shaft to t he pinion yoke wi t h
t he reference mar ks aligned. Tighten t he U-joint
clamp bolts to 21 N-m (16 ft. lbs./186 in. lbs.) torque.
(10) Install t he r ear wheels and t i ght en t he lug
nut s with t he specified torque (refer to Group 22,
Wheels And Tires).
(11) Raise t he rear of t he vehicle, remove t he sup-
ports, level t he vehicle and position t he supports.
(12) Remove t he fill hole plug from t he differential
housing cover. Fill t he differential housing to t he
correct level wi t h MOPAR Hypoid Gear Lubricant, or
an equivalent product.
Add 4 ounc e s of MOPAR Hypoi d Ge a r Lubr i -
c a nt Addi t i ve for Tr ac- Lok e qui ppe d axl es.
(13) Install t he fill hole plug. Remove t he supports
and lower t he vehicle.
(14) Road test t he vehicle to evaluate t he resul t s of
t he repair.
RE MO VA L/DISA SSEMBL Y
Remove t he RWAL b r a k e s ens or holddown
bol t a n d pul l t he s ens or f r om t he di f f er ent i al
hous i ng. The s ens or mus t be r e move d t o pr e ve nt
d a ma g e wh e n di s as s embl i ng or as s embl i ng t he
di fferent i al c ompone nt s .
(1) Not e t he i nst al l at i on r ef er ence l et t er s
s t a mpe d on t he be a r i ng c a ps a n d hous i ng ma-
chi ned seal i ng s ur f ace (Fig. 7) .
Fig. 7 Bearing Cap identification
ger-tight.
SPECIAL TOOL DIAL
MODEL 44- W- 12 9- A INDICATOR
C A U T I O N : Do not spread over the specified di s-
(5) Separate t he housing enough to remove t he
case from t he housing. Se pa r a t e hous i ng a maxi -
mu m di s t ance of 0.38 mm (0.015 in) wi t h t he
s pr e a de r t ool . Measure t he distance with t he dial
indicator (Fig. 8).
end of t he pry bar against case.
usable, ret ai n t he differential beari ng cups and bear-
wi t h soft jaws. Remove and discard t he ri ng gear
bolts. Tap t he ring gear with a rawhide mallet and
remove (Fig. 9).
seal (Fig. 4).
(12) Remove oil slinger, front beari ng and shims
(Fig. 11). Record t he thickness of t he shims. This will
save t i me if they should become misplaced.
(13) The excitor ri ng can be removed with a soft-
faced hammer (Fig. 12). Discard after removal.
SPECIAL TOOL
C-3281
EXCITOR
RING
RING
GEAR
8903-32
(14) Remove the front pinion beari ng cup with Re-
mover D-158 and Handl e C-4171 (Fig. 13).
(Fig. 14).
Model 60 use Remover D-162 and Handle C-4171
SPECIAL TOOL
C-452 J9102-31
Model 70 use Remover D-159 and Handl e C-4171
(16) Remove t he depth shi ms from t he housing
bore. Record t he thickness of t he depth shims.
(17) Remove t he pinion r ear beari ng (Fig. 15);
Model 60 use Puller DD-914-P, Adapter Ring DD-
914-9 and Pl at e C-293-37
Model 70 use Puller DD-914-P, Adapter Ring DD-
914-9 and Pl at e DD-914-95
(18) Remove t he differential side gears and t hr ust
washers.
PINION
YOKE
WASHER
SLINGER
PINION
PRELOAD
SHIMS
FRONT
BEARING
CUP
PINION
NUT
PINION
OIL SEAL
PINION PRELOAD
SPACER
FRONT
BEARING
CONE
SHOULDER FOR
' PINION PRELOAD SPACER
J9203-63

FRONT
BEARI NG CUP
J9203-57
Fig. 13 Front Bearing Cup Removal
(20) Remove t he beari ngs (Fig. 16) with:
Remover DD-914-P
Adapter Ring DD-914-8
Pl at e DD-914-62
Screw Extension DD-914-7
Button DD-914-42
Use care that adapter ri ngs are pl aced so they
do not damage the beari ng cage.
PI NI ON
SPECIAL TOOL
DD-914-9
SPECIAL TOOL
G293-37
J9203-59
Fig. 15 Pinion Rear Bearing Removal
gear mat e shaft lock pin (Fig. 17).
mer (Fig. 18).
GLEANING/INSPECTION
(1) Wash and clean all components with cleaning
solvent and dry with compressed air.
Do not s t eam cl ean t he di fferent i al compo-
nents.
into each tube, at t ach a clean cloth to the wire at t he
THRUS T
WASHER
MATE GEAR SIDE GEAR J9203-61
housing opening. Draw t he wire (and cloth) from t he
housing outward t hrough t he tube.
(3) Inspect t he differential and pinion gear bear-
ings. Inspect t he differential case and housing.
ance with no broken/dented surfaces on t he bearing
rollers or t he roller contact surfaces
Cup and beari ng must be repl aced as a
matched sets only.
All machined surfaces in t he housing and on bear-
ing caps should be smooth and without any raised
edges
Pinion gear front and rear beari ng cup bores
should be smooth
removed with a hand stone
(4) Examine t he differential pinion gear mat e
shaft, pinion gears, side gears and t hr ust washers for
wear and damage. Replace all defective components.
If either of the differential pi ni on gears is not
matched set only. Do not repl ace onl y one gear.
(5) Examine t he ri ng gear and t he pinion gear for
worn and chipped teeth. Exami ne t he ri ng gear for
damaged at t achi ng bolt t hreads.
tact surface. Repair or replace t he yoke as necessary.
ASSEMBLY
(1) Align t he exciter ri ng t ab wi t h t he slot in dif-
ferential case (Fig. 20).
Fig. 20 Exciter Ring Alignment
(2) Invert t he differential case and st art two ri ng
hole al i gnment (Fig. 21).
Fig. 21 Ring Gear Bolt Hole Alignment
(3) Press t he exciter ri ng onto t he differential case
using t he ri ng gear as a pilot (Fig. 22).

SLOT 8903-36
Fig. 22 Ring Gear Bolt Hole Alignment
(4) Install new ri ng gear bolts and al t ernat el y
t i ght en to;
Grade 8 bolts to 136-163-N-m (100-120 ft. lbs.)
torque
Grade 9 bolts (7 radi al lines) to 169-183 Nm (125-
135 ft. lbs.) torque
case)
case and mat e shaft wi t h a punch and hammer (Fig.
23). Peen met al part of case over pin in two places.
If r e pl a c e me nt gear s a n d t hr us t wa s he r s we r e
i nst al l ed, It i s not neces s ar y t o me a s ur e t he ge a r
ba c kl a s h. Cor r ect fit i s due t o cl ose ma c hi ni ng
t ol er ances dur i ng ma nuf a c t ur e .
(8) Place Master Differential Rearing D-343
indicator plunger agai nst t he back of t he ri ng gear
(Fig. 25).
(10) Insert a small pry bar between t he beari ng
cap and left side of differential case. Pry t he case as
far as possible to ri ght side (Fig. 25). Zero t he dial
indicator pointer.
(11) Pry t he case to left side and record t he t ravel
distance.
The me a s ur e me nt above i s t he shi m t hi cknes s
ne c e s s a r y for cas e zer o end- pl ay. The t ot al
t hi cknes s will be det er mi ned dur i ng t he r i ng
ge a r ba c kl a s h adj us t ment .
(7) Inspect t he pinion beari ng preload shims (Fig.
1) for cracks, damage and distortion. Install replace-
ment shims (if necessary) for t he preload torque ad-
j ust ment .
(8) Inspect t he RWAL brake exciter ri ng for dam-
age and missing teeth. If not removed, ensure t he
ri ng is firmly pressed onto t he differential case. Re-
place t he ri ng if loose or damaged.
PUNCH
TOOL C-3339
MATE
SHAFT
LOCKPIN
J9203-64
Fig. 23 Mate Shaft Pin installation
SPECIAL TOOL
D-343
(D-117)
DIFFERENTIAL
CASE
SPECIAL TOOL
D-343
(D-117)
J9103-20
tifying numbers for t he ri ng and pinion gear are
t he face of t he pinion gear. Thi s number is t he
provides t he best t eet h contact pat t ern.
8903-29
Fig. 25 Differential Case End Play Measurement
PRODUCTION
NUMBERS
DRIVE PINION
GEAR DEPTH
VARIANCE
GEAR MATCHING NUMBER
(SAME AS RING GEAR NUMBER) J9003-100
t he centerline of t he axle shaft/ring gear to t he
5.000 inches (127.00 mm)
5.375 inches (136.525 mm)
shims placed adjacent to t he pinion gear rear bearing
cup (Fig. 28).
depth shims to compensate for the difference in t he
For Example:

DEPTH
SETTING
5.000-
BEARI NG
SHOULDER
CENTER LINE
OF AXLESHAFT'
RI NG GEAR
J9302-75
If a positive marki ng, t hi s means t he shim pack
must decrease by t he same number of t housandt hs
If a negative marki ng, t hi s means t he shim pack
must increase by t he same number of t housandt hs
If marked zero will use t he nominal setting as de-
t ermi ned in t hi s procedure
Individual depth shims are available in
0.003-inch
0.005-inch
0.010-inch
0.030-inch
If original gear set is installed but the depth shims
shims. Build a replacement pack of depth shims wi t h
DRIVE
PI NI ON
BEARI NG
PRELOAD
SPACER/SHI M
\ DRIVE
\ ^ PI NI ON GEAR
DEPTH
DIFFERENTIAL
BEARING
SHI M
J9002-32
If equi pped, the oil slinger must be measured
and the thi ckness i ncl uded wi th the total shi m
pack thi ckness.
Depth shim thickness for t he new pinion gear must
be determined before installing differential case in
housing.
ADJUSTMENT WITH TOOL SET D-116
ment procedure involves using Tool Set D-271.
Or l f l f Mi l Mi i t on Or l f l f Mi l Mi i t on
- 3 - 2 - 1 0 + 1 + 2 + 3 +4
+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+ 3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0 .0 0 1
+2 + 0 0 0 6 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0 .0 0 1 - 0 .0 0 2
+ 1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0 .0 0 1 - 0 .0 0 2 - 0 . 0 0 3
0 + 0.004 + 0.003 + 0.002 + 0.001 0 - 0 0 0 1 - 0 .0 0 2 - 0 .0 0 3 - 0 .0 0 4
- 1 + 0.003 + 0.002 + 0.001 0 -0 .0 0 1 -0 .0 0 2 - 0 .0 0 3 - 0 .0 0 4 - 0 .0 0 5
- 2 + 0.002 + 0.001 0 -0 .0 0 1 -0 .0 0 2 - 0 .0 0 3 - 0 .0 0 4 - 0 .0 0 5 - 0 .0 0 6
- 3 + 0.001 0 - 0 .0 0 1 - 0 .0 0 2 - 0 .0 0 3 - 0 .0 0 4 - 0 .0 0 5 - 0 .0 0 6 - 0 .0 0 7
- 4 0 -0 .0 0 1 - 0 .0 0 2 - 0 .0 0 3 - 0 .0 0 4 - 0 .0 0 5 - 0 .0 0 6 - 0 .0 0 7 - 0 .0 0 8
J8902-46

(1) Insert Master Pinion Block into the differential
housing (Fig. 29);
Model 60 use Tool D-120
Model 70 use Tool D-137
tion in t he beari ng cradles (Fig. 30). This is t he cen-
terline of t he ring gear/axle shaft.
(3) Place Pinion Hei ght Block D-116-1 on top of
master pinion block tool and agai nst arbor tool (Fig.
31).
(4) Firmly place Gauge Block D-115-2 and Dial In-
dicator D-106-5 on t he lowest step of pinion height
block tool (Fig. 32). Zero t he dial indicator pointer.
the indicator plunger contacts t he arbor tool (Fig.
32). Slide t he gauge block across along the arbor
while observing indicator. Record t he longest travel
distance, whet her inward (-) or outward ( + ), indi-
cated by t he pointer.
The pl unger travel di stance i ndi cated, pl us or
minus the vari ance etched in the gear is the re-
quired thi ckness for the depth shims.
(6) Measure t he thickness of each depth shim wi t h
total required pack thickness. Incl ude oil slinger
thi ckness wi th the total shim pack thi ckness.
ential housing.
(8) Place t he depth shims in t he pinion gear r ear
beari ng bore. Install t he bearing cup (Fig. 33);
Model 60 use Installer D - l l l and Handle C-4171
Model 70 use Installer C-4204 and Handle C-4171
Ensure the cup is correctly seated.
(9) Install t he pinion front beari ng cup with In-
staller C-4203 and Handle C-4171 (Fig. 34).
(10) Install t he rear bearing (and slinger if used)
SPECIAL TOOL
D-111
PRESS
DRIVE
PINION GEAR
SHAFT
REAR BEARING"
INSTALLATION
TOOL
SPECIAL
TOOL
C-4171 J9203-65
DRIVE
PINION GEAR
OIL
SLINGER
J9302-68
Fig. 33 Pinion Rear Bearing Cup installation Fig. 35 Pinion Rear Bearing Installation
BEARI NG CUP
INSTALLATION TOOL C-4203
DRIVER
HANDLE
TOOL
C-4171
SPECIAL
TOOL
C-3718
DIFFERENTIAL
HO U S I N G
SPECIAL
TOOL
C-3281
ft. lbs.) torque.
to rot at e t he pinion gear should be;
Original Bearings 1-3 Nnn (10-20 in. lbs.)
New Bearings 2-5 Nnn (20-40 in. lbs.)
38);
Increase the preload torque, decrease t he shim
thickness
thickness
J9103-21
Model 60 use Installer C-3719-A and Handle
C-4735

Nnn (250-270 ft. lbs.) torque.
ADJUSTMENT WITH TOOL SET C-758-D6
dure involves usi ng Pinion Depth Measurement
Gauge Set C-758-D6 (Fig. 41).
(1) Install t he pinion rear beari ng cup (Fig. 42);
Model 60 use Installer D- l l l and Handle C-4171
(2) Install t he pinion front beari ng cup with In-
staller C-4203 and Handl e C-4171 (Fig. 43).
C-452 J9102-31
SPECIAL TOOL
C-4735
J9203-56
As s embl e C-758-D6 Tool Set a s des cr i bed (Fig.
41);
Position Spacer (SP-5814 for Model 60) or (SP-5587
for Model 70) over Shaft (SP-526)
Install Sleeve (SP-535-A), Washer (SP-534) and
Nut (SP-533)
(3) Prevent compression sleeve tool from t urni ng
with Wrench C-3281.
Tighten t he nut to seat t he pinion bearings in t he
housing (Fig. 44). Allow t he sleeve to t ur n several
times duri ng t he t i ght eni ng to prevent brinelling t he
bearing cups or t he bearings.
3 - 44 REAR SUSPENSION AND AXLE _ _ _ . _
SPECIAL TOOL SET
Fig. 41 Pinion Adjustment Tools
SPECIAL TOOL
C-4171 J9203-65
Depth shim(s) are posi ti oned bet ween the pin-
i on gear rear beari ng and pi ni on gear to provi de
the separati on di stance. The requi red thi ckness
pinion gear front and rear beari ngs wi t h gear lubri-
cant. Re-tighten t he compression nut tool to 1-3 N-m
(15-25 in. lbs.) torque. Rotate t he pinion gear several
complete revolutions to align t he beari ng rollers.
526. Install Cap Screw (SP-536) and t i ght en with
Wrench SP-531.
ferential housing.
Center t he arbor in cradles so equal space exists at
both ends. Position t he beari ng caps on t he arbor
BEARI NG CUP DRIVER
INSTALLATION TOOL C-4203 HANDLE
tool. Install t he at t achi ng bolts. Tighten t he cap bolts
to 14 N-m (10 ft. lbs.) torque.
arbor and gauge block (Fig. 45). The depth shim(s)
Depth shi ms are available i n 0.001-inch incre-
ments from 0.020 i nch to 0.038 inch.
t he standard. If t he number is - (negative), add t hat
(Fig. 46),
* Model 60 use Remover D-162 and Handle C-4171
*> Model 70 use Remover D-159 and Handle C-4171

REAR SUSPENSION AND AXLE 3 - 4 S
SPACER
DEPTH SHI MS
HERE
REAR PI NI ON
BEARI NG
SHAFT
BEARI NG CAP ARBOR J9203-53
HAMMER DRIVER
HANDLE
J9203-58
cup bore.
(12) Install t he pinion rear beari ng cup (Fig. 42);
Model 60 use Installer D- l l l and Handl e C-4171
Model 70 use Installer C-4204 and Handl e C-4171
should exist.
PRESS
DRIVE
PINION GEAR
SHAFT
REAR BEARING ^
INSTALLATION
TOOL
DRIVE
PI NI ON GEAR
OIL
SUNGER
J9302-68
washer and nut . Install t he yoke wi t h Installer
SPECIAL
TOOL
C-3718
DIFFERENTIAL
HO U S I N G
SPECIAL
TOOL
C-3281
J9103-21
(18) Ti ght en t he yoke nut to 339-366 Nnn (250-270
ft. lbs.) torque.
to rot at e t he pinion gear should be;
Original Bearings 1-3 Nnn (10-20 in. lbs.)
New Beari ngs 2-5 Nnn (20-40 in. lbs.)
If t he preload torque is not wi t hi n t he specified tol-
50);
thickness
thickness

C-452 J9102-31
C-4735
SPECIAL TOOL
C-4735
J9203-56
(22) Install t he yoke wi t h Installer C-3718 and
(Fig. 54). Ensure ri ng and pinion gear t eet h are

TOOL HOUSING
J9103-21
Fig. 53 Pinion Yoke installation
and ri ght side of differential case. Pry t he case as far
as possible to left side (Fig. 19). Zero t he dial indica-
tor pointer.
(4) Repeat t he measurement several times to check
consistency. Record t he t ravel distance.
The measurement above shows shi m thi ckness
necessary to eliminate ring gear backl ash. Sub-
tract thi s thi ckness from case zero end-play
shi m thi ckness. The shims must be pl aced at the
ri ng gear si de bet ween the case and beari ng.
(6) Remove t he differential case from housing.
i ng on t he hub;
C-4171 (Fig. 55)
Model 70 HD use Installer C-4190 and Handle
C-4171
0.015-in (0.38-mm) thick shim on t hi s hub. This will
provide t he required differential beari ng preload
torque.
(10) Install beari ng on hub;
C-4171 (Fig. 55)
Model 70 HD use Installer C-4190 and Handle
C-4171
(11) Match each beari ng cup with beari ng (origi-
nal). Install t he cups on t he bearings.
ger-tight.
(13) Install a pilot st ud at t he left side of t he dif-

SPECIAL TOOL
.MODEL 44- W- 12 9- A
MODEL 60 - D- 167
(18) Rotate t he assembly several revolutions to
seat bearings. Measure backlash at t hree equally
spaced locations with a dial indicator (Fig. 58).
pilot stud. Load t he indicator plunger agai nst t he op-
cator.
case in t he housing. Separate hous i ng a maxi mum
tool. Measure t he distance with t he dial indicator.
spreader.
(17) Observe t he assembly reference mar ks and po-
sition t he beari ng caps at t hei r original locations
(Fig. 57). Ti ght en t he beari ng cap bolts to 95-122
INSTALLATION
EFERENCE LETTERS
TOOL
C-3339
8903-31
^ J9003-92
checked.
(19) Excessive backlash is corrected by moving t he
ri ng gear t eet h closer to t he pinion gear teeth. Insuf-
complished by transferring shims from one side to
t he other.
If t he mesh and backlash steps have been followed
ANALYSIS
The ring gear t eet h contact pat t erns will show if
t ai ned within t he specified limits unt i l t he correct
t he drive and coast side of ri ng gear teeth.
t erns on both t he drive side and coast side of t he ring
gear teeth.
cordingly.
stallation within this group.

DRI VE SI DE
O F R I N G
GE AR TEETH
H E E ^ ^ ^ ^ ^ ^ ^ T O E
C O A S T SI DE
O F R I N G
GE AR TEETH
T O E ^ ^ ^ ^ ^ ^ ^ ^ ^ E L
DESI RABLE C O N T A C T PATTERN.
PATTERN S H O U L D BE CE NTE RE D
O N THE DRI VE SI DE O F T O O T H .
PATTERN S H O U L D BE CE NTE RE D O N
THE C O A S T SI DE O F T O O T H ,
BUT M A Y BE SLI GHTLY T O WA R D
THE T O E . THERE S H O U L D ALWAYS
BE S O M E C L E AR ANC E BETWEEN
C O N T A C T PATTERN A N D T O P O F
THE T O O T H .
R I N G GE AR BACKLAS H C O R R E C T
T HI N N E R PI N I O N GE AR DEPTH
R I N G GE AR BACKLASH C OR R E C T
T HI C K E R PI N I O N GE AR DE PTH
C OR R E C T DE C R E AS E R I N G
GE AR BAC KL AS H.
CORRECT. I N C R E A S E R I N G
GE AR BAC KL AS H.
J9003-24

(6) Install t he RWAL brake speed sensor and cover
onto t he axle housing. Tighten t he sensor to 24 N
s
m
SPECIFICATIONS
REAR AXLE MODEL 60 AND 70
Ax le Type . . . . . . . . . . . . . . . . . . . . . . Full-Floating Hypoid
Application D-TRK
Ring Gear Diameter
Model 60. . . . . . . . . . . . . . .24.76 cm (9.75 in.)
Model 70 . . . . . . . . . . . . . . . . . . . . . .26.67 cm (10.5 in.)
Differential
Model 60 . . . . . Standard/Track-Lok
Model 70 Standard/Powr-Lok
Lubricant Capacity
Model 60 . . . . . 2.84L (6.0 pts)
Model 70 .3.31L (7.0 pts)
Ax le Model M 60, M 70
Ax le Ratio to 1
Model 60 .4.10, 4.56
Model 7 0 . . . . . . 3.07, 3.54, 4.10,4.56
Track
Model 60 . 64.0 in.
Model 70 w/dual rear wheels. . . . . . . . .73.0 in., 68.0 in.
w/single rear wheels . . . . . . . . . . . . . .64.0 in.
GAW R (lbs.)
Mode 60 5800, 6200
Mode 70 . 6900*, 7500*, 6200
*denotes dual rear wheels
Preload Shi m. 0.38 mm (0.015 in.)
Differential Side
Gear to Case Clearance .0.00-0.18 mm (0.000-0.007 in.)
Ring Gear Backlash . . . . . .0.12-0.20 mm (0.005-0.008 in.)
Drive Pinion Gear Bearing
Breakaway Preload Torque
Original Bearings 1.2 N-m (10-20 in. lbs.)
Replacement Bearings 2-5 N-m (20-40 in. lbs.)
Drive Pinion Gear Depth . . . . . . . . . . . . . . . . . Select Shims
Standard Setting
Model 60 . . . .79.37 mm (3.125 in.)
Model 70 . 88.90 mm (3.50 in.)
Side Gear Clearance (max.) 0.015 mm (0.006 in.)
Case Runout (max.) .0.015 mm (0.006 in.)
J9302-77
T R A C - L O K D I F F E R E N T I A L
SERVICE INFORMATION
Model 6 0 rear ax l es equipped wi t h Tr ac- Lok differ-
ential ar e optionally available for Ram Truck vehi-
cles.
DIFFERENTIAL NOISE
Noise complaints involving Trac-Lok should be
evaluated to determine t he source of t he noise. If a
ble cause is incorrect or insufficient gear lubricant.
Replace t he axle gear lubricant and add MOPAR Hy-
poid Gear Lubricant Additive. If t he chat t er persists,
clutch disc damage could have occurred.
W ARN I N G: W H E N SE RV I CI N G V E H I C L E S W I TH A
TRAC- L OK D I F F E RE N TI AL, D O N OT US E TH E E N -
GI N E TO ROTATE TH E AX L E AN D W H E E L S. BOTH
RE AR W H E E L S M UST BE RAI SE D , F ROM TH E SUR-
F AC E AN D TH E V E H I CL E SUPPORTE D . TRAC - L OK
C AN E X E RT E N OUGH D RI V I N G F ORC E TO C A US E
TH E V E H I CL E TO M OV E .
(4) Place a block of wood t hat is 2 inches high and
a mi ni mum of 3 inches wide in front of one of t he
front tires.
(5) With a gradual throttle opening, at t empt to
slowly drive the vehicle over t he block of wood.
(6) If t he Kraft paper slips out before t he front
wheel moves over t he block of wood; reposition t he
vehicle so paper and board are under t he opposite
rear wheel. At t empt to drive over t he block of wood
t he second time.
(7) If the front wheel moves over t he block of wood,
t he axle can be considered to be functioning nor-
mally.
LUBRICANTS
The lubricant recommended for Trac-Lok differen-
tial is API grade GL 5. A container of Trac-Lok Lu-
bricant (friction modifier) should be added after
service.
Refer to Group 0, Lubrication and Maintenance for
DIFFERENTIAL TEST
(1) Drive t he vehicle to thoroughly war m up t he
lubricant in t he rear axle.
(2) Place a large piece of Kraft paper over a
smooth Formica board.
(3) Drive t he vehicle over t he Formica board unt i l
one r ear wheel/tire is in t he center of t he board and
paper.
COMPONENTS
The Trac-Lok (limited-slip) differential components
are illustrated in (Fig. 1). Refer to t hi s illustration
duri ng repair service for component detail and t hei r
location.
DIFFERNTIAL
CASE
THRUST WASHER
PI NI ON
S NAP RI NG
SHAFT
LOCK
PIN
CLUTCH PACK
PI NI ON
MATE
SHAFT J9203-13
Fig. 1 Trac-Lok Differential
DI SASSEMBLY
Service to t he Trac-Lok differential requi res t he
use of Tool Set C-4487 (J-23781). Refer to differential
overhaul in t he Model 6 0 section for differential case
removal and installation.
(1) Clamp one axle shaft in a vise (with protective
jaws) wi t h t he splined end upward (Fig. 2).
US E
AXLE
SHAFT
A S HO L D I N G
FIXTURE
(EXTEND N O
M O R E T HA N
2 3/4 I N.)
J8903-42
~ Fig. 2 Axle Shaft As Holding Fixture
(2) Place shop towels under t he differential gear to
avoid gear damage during removal of t he ri ng gear
(Fig. 3) .
RING GEAR
BOLTS UPWARD
DI FFERENTI AL
O N AXLE
SHAFT
(3) Position t he differential case on t he axle shaft
(Fig. 3).
(4) Remove and discard t he ri ng gear bolts. They
are not reusable.
(5) Remove t he case from t he fixture. Remove t he
ri ng gear from t he case by t appi ng it with brass drift
and a hammer.
(6 ) Position t he case on t he fixture.
(7) Remove t he pinion gear mat e shaft ret ai ni ng
roll pin (Fig. 4).
DIFFERENTIAL
CASE
PI NI ON
GEAR MATE
SHAFT
PUNCH
LOCKPI N
J9003-95
Fig. 4 Pinion Gear Mate Shaft Lock Pin Removal
(8) Remove t he pinion gear mat e shaft. Use a ham-
mer and a brass drift and t ap t he shaft out.
(9) Install and lubricate Step Pl at e C-4487-1 (Fig.
5).
SPECIAL
TOOL
C-4487-1
DIFFERENTIAL
CASE
LOWER
SIDE
GEAR J9203-4
J8903-43
Fig. 5 Step Plate Tool Installation
Fig. 3 Differential Case On Shaft

REAR SUSPENSION AND AX LE 3 - 3
(10) Assemble Threaded Adapter C-4487-3 into top
side gear. Thread forcing Screw C-4487-2 into
adapter until it becomes centered in adapter plate.
(11) Use a small screw driver, position it in slot of
Threaded Adapter C-4487-3 (Fig. 6). This will pre-
vent adapter from turning.
SOCKET
THREADED
ADAPTER
DISC
C-4487-3
THREADED
ROD
C-4487-2
DISC
C-4487-1
J9203-1
Fig. 6 Threaded Adapter Installation
(12) Tighten forcing screw tool enough to relieve
clutch pack tension. Remove both pinion thrust
washers (Fig. 7).
SPECIAL
TOOL
C-4487-2
(13) Loosen the forcing screw tool until the clutch
pack tension is relieved.
(14) Insert Turning Bar C-4487-4 in case. Rotate
case with tool until pinion gears can be removed
(Fig. 8). Remove tools from the case.
THREADED
ROD
C-4487-2
SPlCIAL
tOOL
C-4487-4
J9203-2
Fig. 8 Pinion Gear Removal
(15) Remove top side gear and clutch pack. Keep
plates in correct order during removal (Fig. 9).
(16) Remove case from fixture. Remove remaining
clutch pack.
SIDE GEAR
AND CLUTCH DISC
PACK
DIFFERENTIAL
CASE
PINION GEAR
THRUST
WASHER
FEELER
"GAUGE
33
X
/
J9203-3
Fig. 7 Remove Pinion Thrust Washer
RETAINER
SPECIAL TOOL
C-4487-1
J9203-5
Fig. 9 Side Gear & Clutch Disc Removal
(17) Remove clutch pack retaining clips. Mark
each clutch pack for installation reference.
3 - 54 REAR SUSPENSION AI D AXLE

(1) Clean all components in cleaning solvent. Dry
components with compressed air.
(2) Inspect clutch pack plates for wear, scoring or
damage. Replace both clutch packs if any one compo-
nent in either pack is damaged.
(3) Inspect side and pinion gears. Replace any gear
t hat is worn, cracked, chipped or damaged.
(4) Inspect differential case and pinion shaft. Re-
place if worn or damaged.
ASSE MBLY
(1) The clutch discs are replaceable as complete
sets only. If one cl utch disc pack is damaged,
both packs must be repl aced. Lubricate each com-
ponent wi t h gear lube before assembly and installa-
tion.
(2) Assemble t he clutch discs into packs (Fig. 10).
(3) Secure disc packs with ret ai ni ng clips (Fig. 10).
(4) Position assembled clutch disc packs on t he
side gear hubs.
CLUTCH PACK
RETAINER
J8903-50
Fig. 10 Clutch Disc Pack
(5) Position case on fixture (Fig. 3).
(6) Inst al l clutch pack and side gear in lower bore
(Fig. 11). Be sure cl utch pack retaining clips re-
mai n i n posi ti on and are seated i n the case
pockets.
(7) Install lubricated Step Pl at e C-4487-1 on first
clutch pack (Fig. 12).
(8) Install t he upper side gear and clutch disc pack
(Fig. 12).
(9) Hold assembly in position. Insert Threaded
Adapter C-4487-3 into top side gear, insert forcing
Screw C-4487-4 (Fig. 6).
Fig. 11 Clutch Discs & Lower Side Gear Installation
UPPER SIDE
GEAR AND CLUTCH
DISC PACK
Installation
(10) Tighten forcing screw tool to compress clutch
discs.
(11) Install pinion gears. Rotate case with Turni ng
Bar C-4487-4. Make sure holes of pinion mat e gears
are aligned wi t h case.

(12) Tighten forcing screw to compress t he conned
plates. Lubricate and install pinion gear t hrust
washers with a small screw driver.
(13) Insert and t ap t he pinion shaft into the differ-
(14) Secure pinion shaft with new roll pin. St ake
roll pin to differential case.
Fig. 13 Pinion Gear Mate Shaft installation
POWER-LOK DIFFERENTIAL
SERVICE INFORMATION
Model 70 rear axles equipped with a Power-Lok
differential are optionally available for Ram Truck
vehicles (Fig. 1).
F LANGE BUTTON BOLTS
PI NI ON
AAATE SHAFT J9203-71
Fig. 1 Power-Lok Differential
DIFFERENTIAL NOISE
Noise complaints involving a Power-Lok should be
evaluated to determine t he source of the noise. If a
ble cause is incorrect gear lubricant. Replace axle
gear lubricant and add MOPAR Hypoid Gear Lubri-
cant Additive. This will correct t he condition in most
instances. However, if t he chatter persists, clutch
disc damage could have occurred.
WARNING: WHEN SERVICING VEHICLES WITH A
POWER-LOK DIFFERENTIAL, DO NOT USE THE EN-
GINE TO ROTATE THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED FROM THE SUR-
FACE AND THE VEHICLE SUPPORTED. POWER-
LOK CAN EXERT ENOUGH DRIVING FORCE (IF
ONE WHEEL IS IN CONTACT WITH THE SURFACE)
TO CAUSE THE VEHICLE TO MOVE.
DIFFERENTIAL TEST
(1) Drive t he vehicle to thoroughly warm up t he
lubricant in t he rear axle.
(2) Place a large piece of Kraft paper over a
smooth Formica board. Ensure Formica board is on a
flat and level surface.
(3) Drive t he vehicle over the Formica board unt i l
one r ear wheel is in t he center of t he board and pa-
per.
(4) Place a block of wood t hat is 2 inches high and
a mi ni mum of 3 inches wide in front of one of t he
front tires.
(5) With a gradual throttle opening, at t empt to
slowly drive t he vehicle over t he block of wood.
(6) If the Kraft paper slips out from under the rear
wheel before t he front tire moves over t he block of
wood; reposition t he vehicle so paper and board are
under t he opposite rear wheel. At t empt to drive over
t he block of wood t he second time.
CLUTCH
PLATES
J9203-72
BUTTON
HALF
FLANGE
HALF
Fig. 2 Case Marked
(7) If the front wheel moves over the block of wood,
the axle can be considered to be functioning normally.
LUBRICANTS
The lubricant recommended for Power-Lok differ-
ential is API grade GL 5. A container of Trac-Lok
Lubricant (friction modifier) should be added after
service.
Refer to Group 0, Lubrication and Mai nt enance for
FLANGE HALF CLUTCH
RI NG
J9203-73
Fig. 3 Cover Half Removal
DISASSEMBLY
(1) Mark t he ri ng gear half and cover half for in-
stallation reference (Fig. 2).
(2) Remove t he case at t achi ng bolts and remove
t he button cover half (Fig. 3).
(3) Remove t he pinion mat e gear, side gear (clutch)
ri ng and clutch pack shaft (Fig. 4). Keep these part s
with t he button cover half for correct installation in
t hei r original positions.
PI NI ON MATE
GEAR
SCREW
PLATE DISHED
DI S C
PLATE DISHED
DI S C
PI NI ON AAATE
C R O S S SHAFT
BUTTON HALF
J9203-74
Fig. 4 Power-Lok Components

(4) Remove t he same part s listed above from t he
ri ng gear flange half of t he case. (Fig. 4). Keep t hese
part s with t he flange cover half for correct installa-
tion in t hei r original positions.
(1) Clean all components (Fig. 4) in cleaning sol-
vent. Dry components with compressed air.
(2) Inspect clutch pack plates for wear, scoring or
damage. Replace both clutch packs if any one compo-
nent in either pack is damaged.
(3) Inspect side and pinion gears. Replace any gear
t hat is worn, cracked, chipped or damaged.
(4) Inspect differential case and pinion shaft. Re-
place if worn or damaged.
ASSEMBLY
(1) The clutch discs are replaceable as complete
sets only. If one cl utch disc pack is damaged,
both packs must be replaced. Lubricate each com-
ponent with gear lube before assembly and installa-
tion.
(2) Clamp one axle shaft in a vise (with protective
jaws). Tighten shaft in vise with t he splined end ex-
tending approximately 76.2 mm (3.0 inches) upward
(Fig. 5).
Fig. 5 Axle Shaft As Holding Fixture
(3) Sat urat e t he clutch plates with Hypoid Gear
Lubricant or Additive. Assemble clutch packs into
t he side gear plate in exactly the same position as re-
moved (Fig. 6).
(4) Line up t he plate ears and install t he assem-
bled pack into t he flange half (Fig. 7). Make sure
Fig. 6 Clutch Pack Assembly
the cl utch plate l ugs enter the sl ots in the case.
Al so make sure the clutch pack bottoms out on
the case.
Fig. 7 Clutch Pack Installation
(5) Install pinion mat e shafts and pinion mat e
gears (Fig. 8). Make sure shafts are correctly in-
stalled accordi ng to the al i gnment marks.
(6) Lubricate and install t he other side gear and
clutch pack as done above in Step 3 (Fig. 8).

SIDE GEAR
AL I GNME NT PI NI ON GEARS
MA R K S A N D MATE SHAFT J9203-78
Fig. 8 Clutch Pack Installation
(7) Correctly align and assemble but t on half to
flange half. Install case body screws finger tight.
(8) Place case assembly onto axle shaft fixture
(Fig. 9). Install another axle shaft into opposite side
gear. Tighten body screws al t ernat el y and evenly.
Tighten screws to 89-94 Nm (65 to 70 ft. lbs.) torque.
Both axl e shafts must be inserted ALL the way
on each side to align BOTH splines.
If bolt heads have 7 radial lines stamped on t he
head, t i ght en these to 122-136 N-m (90 to 100 ft. lbs.)
torque.
(9) Remove differential assembly from axle shaft.
I ns pect t ha t e a c h pi ni on mate cross shaft is tight
on its ramp. Or cl earance shoul d not be more
than 0.254 mm (0.010 in.) and equal at all four
shaft ends.
Fig. 9 Case Half Installation
T O R Q U E S P E C I F I C A T I O N S
REAR SUSPENSION COMPONENTS
8 3/8 AND 9 1/4 INCH AXLE
REAR S US PE NS I ON C OMPONE NT S
D E S C R I PT I O N TORQUE
Jounce Bumper to Bracket 20 N-m (180 in. lbs.)
Jounce Bumper/Bracket to
Frame (Round) 41 N-m (30 ft. lbs.)
Jounce Bumper/Bracket to
Frame (Block)......... 23 N-m (200 ft. lbs.)
Shock Lower Nut 82 N-m (60 ft. lbs.)
Shock Upper Nut 82 N-m (60 ft. lbs.)
Spring Center Bolt 20 N-m (15 ft. lbs.)
Spring U-Bolt Nut (1/2-20) 88 N-m (65 ft. lbs.)
Spring U-Bolt Nut (9/16-18) 149 N-m (110 ft. lbs.)
Spring Front and Rear Pivot
Bolt/Nut (1/2-20) 88 N-m (65 ft. lbs.)
Bolt/Nut(5/8-18).... 135 N-m (100ft. lbs.)
Bolt/Nut (3/4-16) 183 N-m (135 ft. lbs.)
Spring Pad to Frame (Aux) 41 N-m (30 ft. lbs.)
J9203-82
DESCRIPTION TORQUE
Bearing Cap Bolt
Bearing Cap Bolt
Brake Backing Plate ,
Differential Housing Cover
Bolt
Pinion Yoke Nut (Minimum
Torque)
Ring Gear Bolt...
RWAL Brake Sensor
95 N*m (70 ft. lbs.)
136 N*m(10 0 ft. lbs.)
... 64 N*m (48 ft. lbs.)
4 7 N*m (35 ft. lbs.;
2 85 N t t i (210 ft. lbs.)
... 95 N* m (70 ft. lbs.)
... 24 N*m (18 ft. lbs.)
J9203-69
MODEL 60 AND 70 AXLE
REAR AXLE MO D E L 60 a n d 70
DESCRI PTI ON TORQUE
Axle Flange to Hub Bolts.
Bearing Cap Bolts
95 N-m (70 ft. lbs.)
... 95 to 122 N-m
(70 to 90 ft. lbs.)
Case Half Bolts (Powr-Lok) ..
Case Half Bolts Heavy Duty
(Powr-Lok)
Differential Cover Bolts
Fill Hole Plug
RWAL Brake Sensor
89 to 94 N-m
(65 to 70 ft. lbs.)
122 to 136 N-m
(90 to 100 ft. lbs.)
47 N-m (35 ft. lbs.)
34 N-m (25 ft. lbs.)
136 to 163 N-m
(100 to 120 ft. lbs.)
169 to 183 N-m
(125 to 135 ft. lbs.)
24 N-m (18 ft. lbs.)
J9203-83

B R A K E S
BRAKES 5 - 1
C O N T E N T S
page
BENDIX DISC BRAKE 37
BRAKE ADJUSTMENTS- BRAKE BLEEDING . . 7
BRAKE DIAGNOSIS 3
CHRYSLER DISC BRAKE 27
DRUM BRAKES- ELEVEN INCH 46
DRUM BRAKES- TWELVE INCH 50
MASTER CYLI NDER-COMBI NATI ON
page
V ALV E - BRAKE LINES 10
PARKING BRAKES 56
POWER BRAKE BOOSTER- BRAKE PEDAL . . 20
POWER BRAKE VACUUM PUMP- DI E S E L
ENGINE . . . 2 2
REAR WHEEL ANTILOCK (RWAL) BRAKES . . 59
SPECIFICATIONS 65
INDEX
page
Antilock Rear Wheel Brakes 1
Brake Components 1
BRAKE COMPONENTS
AD models are equipped with front disc and rear
drum brakes. Power assist brakes and rear wheel an-
tilock brakes are st andard equipment on all models.
A dual reservoir mast er cylinder and single or dual
diaphragm, vacuum operated power brake booster is
used for all applications. Models wi t h t he Cummi ns
diesel engine option are also equipped wi t h a vacuum
pump assembly to operate t he power brake booster.
Front disc brake uni t s consist of single piston, slid-
ing-type calipers with semi metallic brakeshoe lin-
ing. Vented disc brake rotors are used on all models.
Bendix calipers are used on 4-wheel drive models
and on diesel engine models. Chrysler disc brake cal-
ipers are used for all other applications.
Rear drum brakes are dual shoe uni t s wi t h an au-
tomatic adjustment mechanism. Bendix and Chrysler
drum brake assemblies are used.
A combination valve is used on all models. The
valve consists of a front brake met eri ng (hold-off)
valve and a front/rear pressure differential switch.
A red, brake indicator and warni ng light is used to
alert t he driver if a pressure differential exists be-
tween t he front and rear hydraulic systems. The
light also al ert s t he driver when t he parki ng brakes
are applied. The light is located at t he left side of t he
i nst rument cluster.
An additional indicator light is used for t he ant i -
lock system. This light is amber and is located in t he
page
Brake Fluid/Lubricants/Cleaning Sol vents 1
Brake Safety Precautions 2
same side of t he i nst rument cluster as t he red indi-
cator light. The antilock light alerts t he driver if a
system fault occurs.
ANTILOCK REAR WHEEL BRAKES
All AD models are equipped with antilock r ear
brakes. The system is designed to ret ard wheel
lockup duri ng periods of high wheel slip when brak-
ing.
Retarding wheel lockup is accomplished by modu-
lating fluid pressure to t he wheel brake uni t s. Refer
to t he Rear Wheel Anti-Lock Brake section for oper-
ation and service information.
BRAKE FLUID/LUBRICANTS/CLEANING SOLVENTS
Recommended fluid for all AD models is Mopar
brake fluid or equivalent meeting SAE J1703 and
DOT 3 st andards.
Use Mopar mul t i mileage grease to lubricate cali-
per slide surfaces, drum brake pivot pins and shoe
contact points on t he backing plates. Use GE 661 or
Dow 111 silicone grease (or equivalent) on caliper
bushings and slide pins.
Use fresh br ake fluid or Mopar brake cleaner to
clean or flush brake system components. These are
t he only cleaning mat eri al s recommended.
5 - 2 BRAKES

C A U T I O N : Never use gasol i ne, kerosene, al cohol ,
motor oil, t r ansmi ssi on fluid, or any fluid contai ni ng
mineral oil to cl ean the syst em component s. T hese
fluids damage rubber cups and seal s. If syst em
contami nati on i s suspect ed, check the fluid for dirt,
di scol orati on, or separati on into distinct l ayers.
Drain and f l ush the syst em with new brake fluid if
contami nati on i s suspect ed.
BRAKE SAFETY PRECAUTIONS
WA R N I N G : D U S T A N D D I R T O N B R A K E PA R T S
T HA T A C C U M U L A T E S D U R I N G N O R M A L U S E M A Y
C O N T A I N A S B E S T O S F I B E R S . BR E A T H I N G E XC E S -
S I V E C O N C E N T R A T I O N S O F A S B E S T O S F I B E R S
C A N C A U S E S E R I O U S BO D I L Y H A R M . E XE R C I S E
C A R E WH E N S E R V I C I N G B R A K E C O M PO N E N T S .
D O N O T C L E A N B R A K E C O M PO N E N T S WI T H C O M -
P R E S S E D A I R O R BY D R Y BR U S H I N G . U S E A V A C -
U U M C L E A N E R S PE C I F I C A L L Y D E S I G N E D F O R
R E M O V I N G B R A K E D U S T T HA T M A Y A S B E S T O S
F I B E R S . I F A S U I T A BL E V A C U U M C L E A N E R I S N O T
A V A I L A BL E , C L E A N I N G S H O U L D B E D O N E U S I N G
A WA T E R D A M PE N E D C L O T H . D O N O T C R E A T E
D U S T BY S A N D I N G , G R I N D I N G , O R S H A V I N G
B R A K E L I N I N G S U N L E S S PR O PE R L Y V E N T E D
E QU I PM E N T I S U S E D . D I S PO S E O F A L L D U S T A N D
D I R T T HA T M A Y C O N T A I N A S B E S T O S F I B E R S I N
S E A L E D B A G S O R C O N T A I N E R S . T HI S WI L L MI N I -
M I Z E E XPO S U R E T O Y O U R S E L F A N D O T H E R S .
F O L L O W A L L R E C O M M E N D E D PR A C T I C E S PR E -
S C R I B E D BY T HE O C C U PA T I O N A L S A F E T Y A N D
HE A L T H A D M I N I S T R A T I O N A N D T HE E N V I R O N -
M E N T A L PR O T E C T I O N A G E N C Y F O R T HE H A N -
D L I N G , PR O C E S S I N G , A N D D I S PO S I T I O N O F D U S T
O R D I R T WHI C H M A Y C O N T A I N A S B E S T O S FI -
B E R S .

BRAKES i - 3
BRAKE DIAGNOSIS
INDEX
page
Brake Warning Lights 3
Diagnosing Brake Probl ems . . . . . . . . . . . . . . . . . 4
Di agnosi s Procedures 3
Low V acuum SwitchDiesel Model s 3
page
Master Cylinder/ Power Booster Test 5
Power Booster Check Valve Test . . . . . . . . . . . . . 6
Power Booster V acuum Test . . . . . . . . . . . . . . . . . 6
Testing Diesel Engi ne V acuum Pump Output . . . . 6
DIAGNOSIS PROCEDURES
Brake diagnosis involves det ermi ni ng if t he prob-
lem is related to a mechanical, hydraulic or vacuum
operated component. A preliminary check, road test-
ing and component inspection can all be used to de-
termine a problem cause.
Road t est i ng will ei t her verify proper brake opera-
tion or confirm t he existence of a problem. Compo-
nent inspection will, in most cases, identify t he
actual par t causing a problem.
The first diagnosis step is the preliminary check. This
involves inspecting fluid level, parking brake action,
wheel and tire condition, checking for obvious leaks or
component damage and testing brake pedal response.
A road test will confirm t he existence of a problem.
Final diagnosis procedure involves road test analysis
and a visual inspection of brake components.
BRAKE WARNING LIGHTS
The red brake warni ng light is connected to t he
parki ng brake switch and to t he pressure differential
switch in t he combination valve.
The red light will i l l umi nat e when t he parki ng
brakes are applied or when a fluid pressure drop oc-
curs in t he front or r ear brake circuit. The light will
also illuminate for approximately 2-4 seconds at en-
gine st art up. This is a self t est feature designed to
check bulb and circuit operation each time the en-
gine is started.
The amber antilock light is connected to t he anti-
lock rear brake hydraul i c valve. The light will illu-
mi nat e if a fault occurs within t he antilock system.
LOW VACUUM SW I TCH - DI E SE L MODELS
On diesel models, the red brake warning light is also
used to alert the driver of a low brake booster vacuum
condition. The warning light is in circuit with a vacuum
warning switch mounted on the driver side fender
panel. The vacuum side of the switch is connected to the
power brake booster. The electrical side of the switch is
connected to the brake warning light.
The low vacuum switch monitors booster vacuum
level whenever t he engine is runni ng. If booster vac-
uum falls below 8.5 inches vacuum for a mi ni mum of
10 seconds, t he switch completes t he circuit to t he
warni ng light causing it to i l l umi nat e. The warni ng
light is designed to differentiate between a low vac-
uum condition and a hydraulic circuit fault.
PRELIMINARY BRAKE CHECK
(1) Check condition of tires and wheels. Damaged
wheels and worn, damaged, or underinflated tires can
cause pull, shudder, tramp, and a condition similar to
grab.
(2) If complaint was based on noise when braking,
check suspension components. Jounce front and rear of
vehicle and listen for noise t hat might be caused by
loose, worn or damaged suspension or steering compo-
nents.
(3) Inspect brake fluid level and condition. Note
t hat t he front disc brake reservoir fluid level will
drop in proportion to normal lining wear. Al so note
that brake fluid tends to darken over time. This
is normal and shoul d not be mi staken for con-
tami nati on. If the fluid is still clear and free of
foreign material, it is OK.
(a) If fluid level is abnormally low, look for evi-
dence of leaks at calipers, wheel cylinders, brake-
lines and mast er cylinder.
(b) If fluid appears contaminated, drai n out a
sample. If fluid is separated into layers, or obvi-
ously contains oil or a substance other t han brake
fluid, t he system seals and cups will have to be re-
placed and t he hydraulic system flushed.
(4) Check parki ng brake operation. Verify free
movement and full release of cables and pedal. Also
note if vehicle was being operated with parki ng
brake partially applied.
(5) Check brake pedal operation. Verify t hat pedal
does not bind and has adequate free play. If pedal
lacks free play, check pedal and power booster for be-
ing loose or for bind condition. Do not road t est unt i l
condition is corrected.
(6) If components checked appear OK, road t est t he
vehicle.
ROAD TESTING
(1) If complaint involved low brake pedal, pump
t he pedal and note if t he pedal comes back up to nor-
mal height.
(2) Check brake pedal response with transmission
in Neut ral and engine runni ng. Pedal should remai n
firm under steady foot pressure.
5 - 4 BRAKES

(3) During road test, make normal and firm brake
stops in 25-40 mph (40-64 Km/h) range. Note faulty
brake operation such as pull, grab, drag, noise, low
pedal, etc.
(4) Inspect suspect brake components and refer to
problem diagnosis information for causes of various
brake conditions.
COMPONENT INSPECTION
Fluid leak points and dragging brake units can usu-
ally be located without removing any components. The
area around a leak point will be wet with fluid. The
components at a dragging brake unit (wheel, tire, rotor)
will be quite warm or hot to the touch.
Other brake problem conditions will require compo-
nent removal for proper inspection. Raise the vehicle
and remove the necessary wheels for better visual ac-
cess.
DIAGNOSING BRAKE PROBLEMS
PEDAL FALLS AWAY
A brake pedal t hat falls away under steady foot
pressure is t he result of a system leak. The leak
point could be at a brakeline, fitting, hose, or caliper.
Int ernal leakage in t he mast er cylinder caused by
worn or damaged piston cups, may also be t he prob-
lem cause.
If leakage is severe, fluid will be evident at or around
the leaking component. However, internal leakage in
the master cylinder may not be physically evident. Re-
fer to the cylinder test procedure in this section.
LOW PEDAL
If a low pedal is experienced, pump t he pedal sev-
eral times. If t he pedal comes back up, worn lining
and worn rotors or drums are t he likely causes.
A decrease in fluid level in t he mast er cylinder res-
ervoirs may only be t he result of normal lining wear.
Fluid level can be expected to decrease in proportion
to wear. It is a result of t he outward movement of
caliper and wheel cylinder pistons to compensate for
normal wear. Top off t he reservoir fluid level and
check brake operation to verify proper brake action.
SPONGY PEDAL.
A spongy pedal is most often caused by air in the sys-
tem. Thin brake drums or substandard brake lines and
hoses can also cause a spongy pedal. The proper course
of action is to bleed the system and replace thin drums
and suspect quality brake lines and hoses.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or high pedal effort may be due to
lining t hat is wat er soaked, contaminated, glazed, or
badly worn. The power booster or check valve could
also be faulty.
On diesel engine models, high pedal effort may be
t he result of a low vacuum condition. If t he booster
and check valve are OK, t he problem may be related
to a vacuum pump hose, hose connection, hose fit-
ting, pump diaphragm, or drive gear. Vacuum pump
output can be checked with a st andard vacuum
gauge. Vacuum output should range from 8.5 to 25
inches vacuum. If vacuum pump output is within
limits, check t he power booster and check valve as
described in this section.
BRAKE DRAG
Brake drag occurs when t he lining is in constant
contact with t he rotor or drum. Drag can occur at
one wheel, all wheels, fronts only, or rears only. It is
a product of incomplete brakeshoe release. Drag can
be minor or severe enough to overheat t he linings,
rotors and drums.
Brake drag can also effect fuel economy. If undetec-
ted, minor brake drag can be misdiagnosed as an en-
gine or transmission/torque converter problem.
Minor drag will usually cause slight surface charring
of the lining. It can also generate hard spots in rotors
and drums from the overheat-cool down process. In most
cases, the rotors, drums, wheels and tires are quite
warm to the touch after the vehicle is stopped.
Severe drag can char t he brake lining all t he way
through. It can also distort and score rotors and
drums to t he point of replacement. The wheels, tires
and brake components will be extremely hot. In se-
vere cases, t he lining may generat e smoke as it chars
from overheating.
Some common causes of brake drag are:
seized or improperly adjusted parki ng brake cables
loose/worn wheel bearing
seized caliper or wheel cylinder piston
caliper binding on corroded bushings or rusted
slide surfaces
loose caliper mount i ng bracket
drum brakeshoes binding on worn or damaged sup-
port plates
misassembled components.
If brake drag occurs at all wheels, the problem may
be related to a blocked master cylinder return port, or
faulty power booster t hat binds and does not release.
BRAKE FADE
Brake fade is a product of overheating caused by
brake drag. However, brake overheating and subse-
quent fade can also be caused by riding t he brake
pedal, maki ng repeated high deceleration stops in a
short t i me span, or constant braki ng on steep moun-
t ai n roads. Refer to t he Brake Drag information in
t hi s section for additional causes.
PEDAL PULSA TION
Pedal pulsation is caused by components t hat are
loose, out of round, or worn beyond tolerance limits.

BRAKES 5 - 5
Disc brake rotors with excessive lateral runout or
thickness variation, or out of round brake drums are
the primary causes of pulsation. Other causes are loose
wheel bearings or calipers and worn, damaged tires.
PULL
A front pull condition could be t he result of con-
t ami nat ed lining in one caliper, seized caliper piston,
binding caliper, loose caliper, loose or corroded slide
pins, improper brakeshoes, or a damaged rotor.
A worn, damaged wheel bearing or suspension compo-
nent are further causes of pull. A damaged front tire
(bruised, ply separation) can also cause pull.
A common and frequently misdiagnosed pull condi-
tion is where direction of pull changes after a few
stops. The cause is a combination of brake drag fol-
lowed by fade at one of t he brake uni t s.
As t he draggi ng brake overheats, efficiency is so
reduced t hat fade occurs. Since t he opposite brake
uni t is still functioning normally, its braki ng effect is
magnified. This causes pull to switch direction in fa-
vor of t he normally functioning brake unit.
When diagnosing a change in pull condition, re-
member t hat pull will ret urn to t he original direction
if t he dragging brake uni t is allowed to cool down
(and is not seriously damaged).
REAR BRAKE GRAB OR PULL
Rear grab or pull is usually caused by an improperly
adjusted or seized parking brake cable, contaminated
lining, bent or binding shoes and support plates, or im-
properly assembled components. This is particularly
true when only one rear wheel is involved. However,
when both rear wheels are affected, the master cylinder
or proportioning valve could be at fault.
BRAKES DO NOT HOLD AFTER DRIVING
THROUGH DEEP WATER PUDDLES
This condition is generally caused by water soaked
lining. If the lining is only wet, it can be dried by driv-
ing with the brakes very lightly applied for a few min-
utes. However, if the lining is thoroughly wet and dirty,
disassembly and cleaning will be necessary.
BRAKE NOISE
Squeak/Squeal
Brake squeak or squeal may be due to linings t hat
are wet or contaminated with brake fluid, grease, or oil.
Glazed linings and rotors with hard spots can also con-
tribute to squeak. Dirt and foreign material embedded
in the brake lining can also cause squeak/squeal.
A very loud squeak or squeal is frequently a sign of
severely worn brake lining. If the lining has worn
through to the brakeshoes in spots, metal-to-metal con-
tact occurs. If the condition is allowed to continue, ro-
tors can become so scored that replacement is necessary.
Thump/Clunk
Thumpi ng or clunk noises duri ng br aki ng are fre-
quently not caused by brake components. In many
cases, such noises are caused by loose or damaged
steering, suspension, or engine components. How-
ever, calipers t hat bind on t he slide pins, or slide sur-
faces, can generat e a t hump or clunk noise. Worn
out, improperly adjusted, or improperly assembled
rear brakeshoes can also produce a t hump noise.
Chatter
Brake chat t er is usually caused by loose or worn
components, or glazed/burnt lining. Rotors with hard
spots can also contribute to chat t er. Additional
causes of chat t er are out of tolerance rotors, brake
lining not securely attached to t he shoes, loose wheel
bearings and contaminated brake lining.
Brakelining Contamination
Brakel i ni ng contamination is usually a product of
leaking calipers or wheel cylinders, driving t hrough
deep wat er puddles, or lining t hat has become cov-
ered wi t h grease and grit during repair.
Wheel and Tire Problems
Some conditions at t ri but ed to brake components
may actually be caused by a wheel or t i re problem.
A damaged wheel can cause shudder, vibration and
pull. A worn or damaged t i re can also cause pull.
Severely worn tires with very little t read left can
produce a grab-like condition as t he t i re loses and re-
covers traction.
Flat-spotted tires can cause vibration and wheel
t r amp and generate shudder duri ng brake operation.
A t i re with i nt ernal damage such as a severe
bruise or ply separation can cause pull and vibration.
MASTER CYLINDER/POWER BOOSTER TEST
(1) St art engine and check booster vacuum hose
connections. Hissing noise indicates a vacuum leak.
Correct any leaks before proceeding.
(2) Stop engine and shift transmission into Neu-
t r a l
(3) Pump brake pedal unt i l all vacuum reserve in
booster is depleted.
(4) Press and hold brake pedal under light foot
pressure.
(a) If pedal holds firm, proceed to step (5).
(b) If pedal does not hold firm and falls away,
mast er cylinder is faulty (internal leakage).
(5) St art engine and note pedal action.
(a) If pedal falls away slightly under light foot
pressure t hen holds firm, proceed to step (6 ).
(b) If pedal is effort is high, or no pedal action is
discernible, power booster or vacuum check valve is
faulty. Install known good check valve and repeat
steps (2) t hrough (5).
5 - 6 BRAKES

(c) On diesel models, vacuum pump hose or
pump component may have malfunctioned. Check
pump out put with vacuum gauge and repair as
necessary. Refer to service procedures in Power
Booster/Vacuum Pump section.
(6) Rebuild booster vacuum reserve as follows: Re-
lease brake pedal. Increase engine speed to 1500
rpm, close t hrot t l e and immediately t ur n off ignition.
(7) Wait a minimum of 90 seconds and try brake ac-
tion again. Booster should provide two or more vacuum
assisted pedal applications. If vacuum assist is not pro-
vided, perform booster and check valve vacuum tests.
Also check vacuum output on diesel models.
POWER BOOSTER CHECK VALVE TEST
(1) Disconnect vacuum hose from check valve.
(2) Remove check valve and valve seal from
booster (Fig. 1).
(3) Hand operated vacuum pump can be used for
t est (Fig. 2).
(4) Apply 15-20 inches (50-67 kPa) vacuum at
large end of check valve (Fig. 1).
(5) Vacuum should hold steady. If gauge on pump
indicates any vacuum loss, valve is faulty and must
be replaced.
BOOSTER
CHECK
VALVE APPLY TEST
\ VACUUM HERE
Fig. 1 Vacuum Check Vaive And Seal
J9005-80
Fig. 2 Typical Hand Operated Vacuum Pump
POWER BOOSTER VACUUM TEST
(1) Connect a vacuum gauge to the booster check
valve with a short length of hose and a T-fitting (Fig.
3).
(2) St art and r un engine at idle speed for one
mi nut e.
(3) Clamp hose shut between vacuum source and
check valve (Fig. 3).
(4) Stop engine and observe vacuum gauge.
(5) If vacuum drops more t han one inch vacuum
(33 millibars) within 15 seconds, either booster dia-
phragm or check valve are faulty.
SHORT
CONNECTING CHECK
VACUUM
GAUGE
J9005-81
Fig. 3 Booster Vacuum Test Connections
TESTING DIESEL ENGINE VACUUM PUMP OUTPUT
On models with a Cummi ns turbo diesel engine, a
low vacuum condition in t he brake booster will cause
t he brake warni ng light to illuminate.
The following test checks output and condition of the
vacuum pump and interconnecting hoses. However, a
more comprehensive testing procedure is provided in
the Power Brake Booster-Brake Pedal-Vacuum Pump
section. Refer to the procedure for "Diagnosing A Low
Vacuum Condition" in that section.
(1) Check pump vacuum and booster hoses and
connections. Make sure hoses are in good condition
and securely attached. Run engine and check for vac-
uum leaks. Replace leaking hoses before proceeding.
(2) Disconnect vacuum hose at booster and connect
vacuum gauge to hose end.
(3) Run engine at curb idle speed and note vacuum
reading. Then r un engine at 1/2 to 3/4 t hrot t l e and
note vacuum reading again.
(4) Vacuum should range from 8.5 to 25 inches
vacuum at various t hrot t l e openings. Vacuum should
hold steady and not drop below 8.5 inches.
(5) If vacuum output is OK, check booster and
check valve as described in this section. However, if
vacuum is low, or does not hold steady, vacuum
hoses or pump components are faulty.

BRAKES i - 7
BRAK E AD J USTM E N TS- BRAKE BLEEDING
INDEX
page
Brake Fluid and Level 7
Brake Syst em Bleeding 8
Rear Brake Adjustment 7
BRAKE FLUID AND LEWEL
RECOMMENDED FLUID
The only brake fluid recommended for AD models
is Mopar brake fluid, or an equivalent fluid meeting
SAE J 1 7 03 and DOT 3 st andards.
Use new brake fluid only, to top off the master
cylinder or refill the system* Never use re-
cl ai med fluid, fluid not meeti ng the SAE / DOT
standards, fluid marked 70R1, or fluid from a
contai ner that has been left open for any l ength
of time. Usi ng non recommended or unspeci fi ed
fluid can result in brake failure after hard pro-
l onged braking.
BRAKE FLUID LEWEL
Always clean the mast er cylinder cover before
checking fluid level. If not cleaned, dirt from t he
cover could enter t he fluid. Also check t he cover seal
and replace it if torn or distorted.
Correct fluid level is to t he bottom of t he ri ng in-
dicators on models wi t h a plastic reservoir and to
within 1/4 inch of t he reservoir rim on all others.
If necessary, add fluid to bring up to the proper level.
Note t hat on disc brake equipped vehicles, fluid level
can be expected to fall as the brake pads wear.
BRAKE FLUID CONTAMINATION
Oil in t he fluid will cause brake system rubber
seals to soften and swell. The seals may also become
porous and begin to deteriorate.
If fluid contamination is suspected, drai n off a sam-
ple from t he mast er cylinder. A suction gun or simi-
lar device can be used for t hi s purpose.
Empty t he drained fluid into a glass container.
Cont ami nant s in t he fluid will cause t he fluid to sep-
arat e into distinct layers. If contamination has oc-
curred, t he system rubber seals, hoses and cups must
be replaced and t he system thoroughly flushed with
clean brake fluid.
Remember that brake fluid tends to darken
over time. Do not confuse this normal condi ti on
wi th contami nati on.
REAR BRAKE ADJUSTMENT
The rear drum brakes are equipped with a self ad-
j ust i ng mechanism. Under normal circumstances, t he
only time adjustment is required is when t he brake-
page
Stop Light Switch Adj ustment 9
Wheel Nut Tightening 9
shoes are replaced; removed for access to other part s;
or when one or both drums are replaced.
Adjustment can be performed with a st andard
brake gauge or with adjusting tool C-3784.
ADJUSTMENT WITH STANDARD BRAKE GAUGE
(1) Verify t hat left/right automatic adjuster lever
and cable ar e properly connected and t hat parki ng
brakes are fully released. Be sure t here is slack in
cables.
(2) Insert brake gauge i n drum. Expand gauge un-
til gauge i nner legs contact dr um braki ng surface.
Then lock gauge in position (Fig. 1).
Fig. 1 Adjusting Gauge To Brake Drum
(3) Reverse gauge and install it on brakeshoes
(Fig. 2). Position gauge legs at shoe centers as
shown. If gauge does not fit (too loose/too tight), ad-
j ust shoes.
(4) Pull t he shoe adjuster st ar wheel away from
t he automatic adjuster lever.
(5) Turn t he adjuster st ar wheel (by hand) to ex-
pand or ret ract t he brakeshoes. Continue adjustment
unt i l t he gauge outside legs are a light drag-fit on
t he shoes (Fig. 2).
(6) Repeat adjustment at t he opposite brakeshoe
assembly.
(7) Install t he brake drums and wheels and lower
t he vehicle.
(8) Make final adjustment. Drive vehicle and make
one forward stop followed by one reverse stop. Repeat
procedure 8-10 times to act uat e adjuster mechanism
and equalize adjustment. Bring vehicle to complete
i - 8 BRAKES

BRAKE SHOE'S
Fig. 2 Adjusting Brakeshoes To Gauge
standstill at each stop. Incomplete, rolling stops will
not activate t he automatic adjusters.
ADJUSTMENT WITH TOOL C-3784
(1) Release parki ng brakes fully. Be sure t here is
slack in cables.
(2) Raise vehicle so all wheels are free to t urn.
(3) Remove rubber plugs from access holes in sup-
port plates.
(4) Insert adjusting Tool 0-3784 into st ar wheel of
adjuster screw. Turn st ar wheel counterclockwise
(move tool upward) unt i l slight drag is felt when
road wheel is rotated.
(5) Insert t hi n screwdriver or length of welding rod
into support plate access hole and push adjuster lever
out of engagement wi t h st ar wheel (Fig. 3). Do not
bend lever or distort lever spring.
(6) Hold adjuster lever away from st ar wheel. Then
back off st ar wheel unt i l shoe drag on drum is elim-
inated.
(7) Repeat above adjustment at opposite wheel. Be
sure adjustment is equal.
(8) Install access hole plugs in support plate.
(9) Adjust t he parki ng brake after wheel brake ad-
j ust ment .
(10) Make final adjustment. Drive vehicle and
make one forward stop followed by one reverse stop.
Repeat procedure 8-10 t i mes to act uat e adjuster
mechanism and equalize adjustment. Bring vehicle to
complete standstill at each stop. Incomplete, rolling
stops will not activate adjuster mechanism.
CHECKING DRUM BRAKE ADJUSTER
OPERATION
(1) Place vehicle on hoist, with helper in driver
seat to apply brakes.
(2) Remove access plugs from support plates.
(3) Back off adjuster screw st ar wheel approxi-
mately 20-30 notches.
(4) Observe adjuster screw st ar wheel and spin
drum and road wheel rapidly in a reverse direction.
Fig. 3 Rear Brake Adjustment With Tool C-3784
(5) Have helper apply brakes firmly. Fi rm applica-
tion will cause secondary shoe to move and engage
rot at i ng drum.
(6) Normal shoe "wrap-up" effect should move sec-
ondary shoe enough to cause adjuster cable to pull
adjuster lever up and t ur n st ar wheel.
BRAKE SYSTEM BLEEDING
The brake system can be bled manual l y or with
pressure equipment. Manual bleeding requires t he
aid of a helper. Pressure equipment allows t he sys-
t em to be bled by one person.
All models are equipped with a front brake meter-
ing (hold off) valve. The met eri ng valve is located
wi t hi n t he combination valve. The met eri ng valve
balances brake action between t he front disc and
rear drum brakes during initial brake application.
The met eri ng valve is designed to hold off fluid
flow to t he front disc brakes at pressures between 3
and 135 psi (20.68 and 930.8 kPa).
Pressures generated by gravity or manual type
bleeding techniques will not affect the valve. How-
ever, pressure bleeding equipment will generate
enough fluid pressure (20 to 30 psi) to close t he valve
and prevent fluid flow to t he front brakes. As a re-
sult, t he valve must be held open with special tool
C-4121 when using pressure bleeding equipment.
BLEEDING PROCEDURE
(1) If new or overhauled master cylinder will be used,
be sure to bleed cylinder before installation. Refer to
bleeding procedure in Master Cylinder section.
(2) If mast er cylinder has not been serviced, clean
mast er cylinder and cover to prevent dirt ent eri ng
reservoirs. Then remove cover.
(3) If pressure bleeding t ank C-3496-B will be
used, install adapter C-4578 on mast er cylinder.
Then prepare t ank for bleeding according to instruc-
tions provided by supplier. Be sure to purge air from
t ank lines before use.
BRAKES i - 9
Fig. 4 Metering Valve Hold Off Tool
(4) If pressure bleeding equipment will be used, hold
metering valve open with tool C-4121. Tool is installed
on valve stem to hold it (and valve) open (Fig. 4).
CAUTI ON : Under no condition shoul d a rigid cl amp,
wedge or block be used to press the valve stem in-
ward to hol d the valve open. Thi s practice could dam-
age the valve resulting in val ve failure and l oss of
front brake action. Note that the val ve stem is in its in-
nermost position when there is no pressure present.
No attempt shoul d be made to further depress the
valve stem.
(5) Bleed system in following sequence and bleed
only one wheel or valve at a t i me:
mast er cylinder
RWAL hydraulic valve
right rear wheel
left rear wheel
right front wheel
left front wheel
(6) Bleed master cylinder first. If replacement cylin-
der will be installed, bleed cylinder on bench before in-
stalling it.
(7) If ma nua l bl eedi ng:
(a) Fill mast er cylinder wi t h fresh fluid and open
all bleed screws. Close bleed screws when fluid be-
gins to trickle from each bleed screw opening.
(b) Top off mast er cylinder with fresh fluid.
(c) Clean bleed screw on RWAL valve. Then in-
stall bleed hose on bleed screw. Insert end of hose
in clear container partially filled wi t h brake fluid.
Be sure hose end is immersed in brake fluid or air
will be drawn back into valve.
(d) Have helper press and hold brake pedal to
floorpan. Then tighten bleed screw at t hi s point
and have helper release pedal.
(e) Open bleed screw and have helper press pedal
down again. Continue bleeding unt i l only clear,
bubble free fluid flows into glass container.
(f) Continue bleeding operations at remai ni ng
wheel brake uni t s.
(8) If pr e s s ur e bl eedi ng:
(a) Clean bleed screw on RWAL valve. Then in-
stall bleed hose on bleed screw. Insert end of hose
in clear container part i al l y filled with brake fluid.
Be sure hose end is immersed in brake fluid or air
will be drawn back into valve.
(b) Open bleed screw at RWAL valve and allow
fluid to flow t hrough valve.
(c) Stop bleeding when only clear, bubble free
fluid flows into fluid container.
(d) Continue bleeding operations in recom-
mended sequence at wheel brake uni t s. St art with
left rear wheel.
(9) Repeat bleeding procedure if system indicator
lights r emai n on or if pedal still feels spongy.
WHEEL NUT TIGHTENING
The wheel attaching nuts must be tightened properly
to ensure efficient brake operation. Overtightening the
nuts or tightening them in the wrong sequence could
cause distortion of the brake rotors and drums.
Impact wrenches are not t he best tools for tighten-
ing wheel nut s. A torque wrench should be used for
t hi s purpose at all times.
The correct t i ght eni ng sequence is i mport ant in
avoiding rotor and drum distortion. The correct se-
quence is in a diagonal crossing pat t ern (Fig. 5).
Seat t he wheel and install t he wheel nut s finger
tight. Tighten the nut s in t he sequence to 1/2 re-
quired torque. Then repeat the t i ght eni ng sequence
to final specified torque.
STOP LIGHT SWITCH ADJUSTMENT
The plunger-type stop light switch is attached to
t he brake pedal bracket. The switch is directly actu-
ated by a t ang on t he brake pedal. Switch adjust-
ment is as follows:
(1) Push switch t hrough clip in mounting bracket
until switch is sealed agai nst bracket. Brake pedal
will move forward slightly.
(2) Gently pull back on brake pedal as far as it will
go.
(3) Switch will rat chet rearward to correct posi-
tion. Fur t her adjustment is not required.
S - 10 BRAKES

MASTER CYLINDERCOMBINATION VALVEBRAKE LINES
INDEX
page
Bleeding New or Overhauled Master Cylinder . . . 12
Brake Lines and H oses 13
Combination V al ve Operation 1 3
Combination V al ve Removal/Installation . . . . . . . . 13
Combination V al ve Testing . . . . . . . . . . . . . . . . . 1 3
page
General Information . 10
Master Cylinder Installation 12
Master Cylinder Removal 10
Master Cylinder ServiceIntegral Cylinder 11
Master Cylinder ServiceTwo- Section Cylinder . . 11
GENERAL INFORMATION
Two types of mast er cylinder are used on AD mod-
els. A two-section mast er cylinder with a removable
reservoir is used on D and W150/250 models (Fig. 1).
An integral (one-piece) mast er cylinder with built-in
fluid reservoirs is used on D and W 250/350 heavy
duty models (Fig. 2).
Two-Section Master Cylinder
The two-section mast er cylinder consists of t he cyl-
inder body and a removable fluid reservoir. The pri-
mary and secondary pistons are located in t he
al umi num body section. The removable reservoir is
made of nylon reinforced wi t h glass fiber and is t he
only serviceable component.
The fluid compartments of t he nylon reservoir are
interconnected to permit fluid level equalization.
However, t he equalization feature does not affect cir-
cuit separation in t he event of a front/rear hydraulic
system malfunction. The reservoir compartments are
designed to ret ai n t he necessary quant i t y of fluid
needed to operate t he functioning circuit.
Care must be exercised when removing/installing
t he mast er cylinder connecting lines. The t hreads in
t he fluid ports can be damaged if care is not prac-
ticed. St art all brake line fittings by hand to avoid
cross t hreadi ng.
The al umi num body secti on of the master cyl-
i nder is not a repai rabl e component. If di agnosi s
i ndi cates that an internal mal functi on has oc-
curred, the al umi num body secti on must be re-
pl aced as an assembl y.
Integral Master Cylinder
The one-piece mast er cylinder is a vent i ng type
with integral fluid reservoirs. The pri mary and sec-
ondary piston assemblies are located in t he cylinder
bore. The cylinder is a fully serviceable component
and can be overhauled when necessary.
Combination Valve
A two-way combination valve is used on all AD
models (Fig. 3). The two-way valve contains a front
brake met eri ng valve and a pressure differential
valve and switch.
OUTLETS MASTER CYLINDER BODY RF494
Fig. 2 Integral Master Cylinder
MASTER CYLINDER REMOVAL
(1) Disconnect pri mary and secondary brake tubes
at mast er cylinder.
(2) Install plugs in cylinder outlet ports and brake
t ubes to prevent dirt entry.
(3) Remove nut s at t achi ng mast er cylinder to
power brake booster.
(4) Remove mast er cylinder from power brake
booster mounting studs.

BRAKES 5 - 11
F R O M M A S T E R C YL I N D E R ^ S WI T C H A S S E M BL Y
Fig. 3 Two-Way Combination Valve
MASTER CYLINDER SE RV I CE - TWO- SE CTI ON
CYLINDER
The onl y servi ceabl e component on the two-
section cylinder i s the nyl on reservoir. If the cyl-
inder body or internal components are worn or
damaged, the cyl i nder body must be repl aced as
an assembl y.
RESERVOIR REPLACEMENT- TWO-SECTION
CYLINDER
(1) Clean reservoir exterior and mast er cylinder
body.
(2) Remove reservoir caps and drain fluid from cyl-
inder.
(3) Mount mast er cylinder in vise. Clamp vise jaws
on al umi num body.
(4) Note position of reservoir before removal. This
is important as reservoir can be installed backwards
if care is not exercised.
(5) Remove reservoir by firmly rocking it from side
to side (Fig. 4). Continue rocking until reservoir is
free of grommets.
Fig. 4 Removing/Installing Cylinder Reservoir
(6) Remove and discard grommets securing reser-
voir in cylinder body.
(7) Install new reservoir grommets i n cylinder
body.
(8) Lubricate new reservoir grommets with clean
brake fluid.
C A U T I O N : The reservoir can be installed back-
war ds if care i s not exerci sed. I nstall the reservoir
s o the fluid fill information ( on the reservoir si de) i s
on the same si de a s the fluid outlet ports in the cyl-
inder body (Fig. 4).
(9) St art reservoir into grommets. Then rock reser-
voir side to side unt i l fully seated. Reservoir bottom
surface should touch grommets after installation.
(10) Bleed mast er cylinder before installing i t in
vehicle. Refer to procedure in t hi s section.
MASTER CYLINDER SERVI CE-I NTEGRAL
CYLINDER
The integral (one-piece) cylinder is a fully service-
able component. It can be overhauled to restore per-
formance when necessary. Overhaul procedure is as
follows.
INTEGRAL CYLINDER DISASSEMBLY AND
INSPECTION
(1) Remove cylinder cover (Fig. 5).
(2) Drain fluid from cylinder reservoirs.
(3) Mount cylinder in vise.
(4) Press cylinder pistons inward with wood dowel
and remove piston snap ring (Fig. 6).
(5) Remove pri mary piston assembly from cylinder
bore. Discard piston assembly.
(6) If cylinder is equipped wi t h piston stop screw
for secondary piston, remove stop screw before pro-
ceeding.
(7) Remove secondary piston with compressed air
applied through brakeline port or compensator port
at bottom of reservoir. Discard piston assembly after
removal.
C O V E R C O V E R
C L A M P RF4 95
Fig. 5 Removing/Installing Cylinder Cover
i - 12 BRAKES

Fig. 6 integral Cylinder Components
Cylinder Cleaning And Inspection
Clean t he cylinder body and cover with brake fluid
or brake cleaner only. Do not use any other type of
solvents, or cleaning agent.
Inspect t he cylinder body and bore. Light discolor-
ation of t he cylinder bore is normal and is an accept-
able condition. The bore should be smooth and free of
scores, scratches, corrosion and rust. Replace t he cyl-
inder if t he bore is worn, scored, or corroded.
Do not hone t he bor e in an at t empt to restore t he
surface finish. Replace t he cylinder if t he bore is
damaged in any way. Also replace t he cylinder if t he
body is cracked, porous, or t he compensator port at
t he bottom of each reservoir is blocked or damaged.
Inspect t he cover and gasket. Replace t he gasket if
distorted, cut, or torn. Replace t he cover and retain-
ing wire if either component is distorted or damaged
in any way.
Do not reuse t he old piston assemblies. Discard
these part s as soon as they are removed. Install re-
placement pri mary and secondary piston assemblies
only.
INTEGRAL CYLINDER ASSEMBLY
(1) Coat cylinder bore and replacement piston as-
semblies with liberal quant i t y of clean brake fluid.
(2) Install secondary piston assembly in bore wi t h
a t ur ni ng motion. Do not use met al tools of any ki nd
to help ease piston into bore. Sharp edge tools will
scratch bore and cut piston seals.
(3) If cylinder is equipped with stop screw for sec-
ondary piston, press piston to bottom of bore and in-
stall screw.
(4) Install pri mary piston in bore.
(5) Press pistons inward with wood dowel and in-
stall piston snap ring. Be sure snap ri ng is fully
seated.
(6) Install new gasket on cover if necessary.
(7) Install cover ret ai ni ng wire on cylinder if re-
moved.
(8) Fill and bleed mast er cylinder on bench before
installing it in vehicle. Refer to following procedure.
BLEEDING NEW OR OVERHAULED MASTER
CYLINDER
A new or overhauled mast er cylinder should be
purged of all air before installation on t he vehicle.
Cylinder bleeding is performed on t he bench.
Bleeding tools for t he integral mast er cylinder in-
clude fabricated bleed tubes and a wood dowel.
Bleeding tools for t he two-section mast er cylinder in-
clude bleed tubes C-4029 and a wood dowel (Fig. 7).
CYLINDER BLEEDING PROCEDURE
(1) Mount mast er cylinder assembly in vise.
(2) Attach bleed tubes to cylinder outlet ports and
insert tubes in reservoir fluid compartments (Fig. 7).
Bleed tubes can be fabricated from steel or copper
t ubi ng and appropriate size fittings.
(3) Fill reservoir with fresh brake fluid.
(4) Press cylinder pistons inward with wood dowel.
Then release pistons and allow t hem to r et ur n under
spring pressure.
(5) Continue bleeding operations unt i l air bubbles
are no longer visible in fluid.
Fig. 7 Master Cylinder Bleeding Two-Section
Cylinder Shown
MASTER CYLINDER INSTALLATION
(1) Bleed mast er cylinder on bench before installa-
tion.
(2) Position mast er cylinder on studs of power
brake unit.
(3) Align power brake push rod with mast er cylin-
der piston.
(4) Install and t i ght en cylinder at t achi ng nut s to
23 N-m (200 in. lbs.).
(5) Connect front and rear brakelines to cylinder.
St art brakeline fittings by hand.
(6) Tighten brakeline fittings to 19 Nm (170 in.
lbs.).
(7) Bleed brakes.

BRAKES 5 - 13
COMBINATION VALVE OPERATION
METERING (HOLD-OFF) VALVE
The met eri ng valve is used to balance brake action
between t he front disc and rear drum brakes. The
valve met ers (holds-off) full apply pressure to t he
front disc brakes unt i l the rear brakeshoes are in full
contact with t he drums.
The valve is designed to mai nt ai n front brake fluid
pressure at 3-30 psi until t he hold-off limit of 117 psi
is reached. At this point, t he met eri ng valve opens
completely permi t t i ng full fluid apply pressure to t he
front disc brakes.
PRESSURE DIFFERENTIAL SWITCH AND
VALVE
The pressure differential switch is connected to t he
brake warni ng light. The switch is triggered by
movement of t he switch valve. The purpose of t he
switch is to monitor fluid pressure in t he separat e
front/rear brake hydraulic circuits.
A decrease or loss of fluid pressure in either hy-
draulic circuit will cause t he switch valve to shut t l e
forward or rearward in response to a pressure differ-
ential.
Movement of t he switch valve will push t he switch
plunger upward. This closes t he switch i nt ernal con-
tacts completing t he electrical circuit to t he warni ng
light. The switch valve will remai n in an act uat ed
position unt i l repair restores system pressures to nor-
mal levels.
COMBINATION VALVE TESTING
TESTING METERING VALVE
Metering valve operation can be checked visually
and with t he aid of a helper.
Observe t he met eri ng valve stem while a helper
applies and releases t he brakes. If t he valve is oper-
at i ng correctly, t he stem will extend slightly when
t he brakes are applied and ret ract when t he brakes
are released.
If t he valve is faulty, replace t he entire combina-
tion valve as an assembly.
TESTING PRESSURE DIFFERENTIAL SWITCH
(1) Have helper sit in drivers seat to observe brake
warni ng light and to operate brake pedal.
(2) Raise vehicle on hoist.
(3) Connect bleed hose to left or right rear wheel
cylinder. Then immerse hose end in glass j ar par-
tially filled wi t h brake fluid.
(4) Have helper press and hold brake pedal all t he
way down and observe warni ng light.
(a) If warni ng light illuminates, switch is operat-
ing correctly.
(b) If light fails to illuminate, check circuit fuse,
bulb and wiring. Repair as necessary and repeat
test steps (3) and (4).
(5) If warni ng light still fails to i l l umi nat e, check
brakel i ght and park brake switches (and wiring)
with test l amp. Repair or replace par t s as necessary
and test differential pressure switch operation again.
(6) If warni ng light still does not i l l umi nat e,
switch is faulty. Replace combination valve, bleed
brakes and verify proper switch and valve operation.
COMBINATION VALVE REMOVAL/INSTALLATION
VALVE REMOVAL
(2) Mark or t ag brake lines connected to valve for
assembly reference.
(3) Disconnect lines at valve (Fig. 8).
(4) Disconnect wires from differential pressure
switch.
(5) Remove bolts at t achi ng valve to frame bracket
and remove valve.
VALVE INSTALLATION
(1) Mount new valve on bracket and t i ght en valve
and bracket screws/nuts securely.
(2) Connect brakelines to valve. Tighten fittings to
16 N*m (145 in. lbs.)
(3) Connect wires to pressure differential switch
t ermi nal .
(4) Bleed brakes.
(5) Lower vehicle and verify proper brake opera-
tion.
BRAKE LINES AND HOSES
BRAKE LINE AND HOSE INSPECTION
Flexible rubber hose is used at both front brakes
and at t he rear axle junction block. Inspect t he hoses
whenever t he brake system is serviced, at every en-
gine oil change, or whenever t he vehicle is in for ser-
vice.
Inspect t he hoses for surface cracking, scuffing, or
worn spots. Replace any brake hose immediately if
t he fabric casing of the hose is exposed by cracks or
abrasion.
Also check brake hose installation. Faul t y installa-
tion can result in kinked, twisted hoses, or contact
with t he wheels and tires or other chassis compo-
nents. All of these conditions can lead to scuffing,
cracking and eventual failure.
The steel brake lines should be inspected periodi-
cally for evidence of corrosion, twists, ki nks, leaks, or
other damage. Heavily corroded lines will eventually
rust t hrough causing leaks. In any case, corroded or
damaged brake lines should be replaced.
5 - 14 BRAKES

Fig. 8 Combinat
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 t aken to make
sure t hat brake line and hose mat i ng surfaces are
Valve Mounting
clean and free from nicks and burrs. Also remember
t hat ri ght and left brake hoses are not interchange-
able.
Use new copper seal washers at all caliper connec-
tions (Fig. 9). Be sure brake line connections are
properly made (not cross threaded) and tightened to
recommended torque.
Brake line routing, connections and t i ght eni ng ref-
erence information is outlined in Figures 9 t hrough
12.
Fig. 9 Front Brake Lines
Fig. 10 Rear Brake Lines And RWAL Components
TUBE ASSEMBLY MASTER
CYLINDER TO BRAKE
VALVE REAR (SECONDARY)
BRACKET A N D SHIELD
BRAKE HOSE A N D RWAL
SENSOR WI RI NG
LET.
TORQUE
LET.
POUNDS
NEWTON
METRES
x ! ^
145 I N. 16
X X
35 FT. 47
170 I N. 19
100 I N. 11
12 5 I N. 14
BRAKE VALVE TUBE
TO RIGHT FRONT
BRAKE HOSE
VIEW I N DIRECTION
OF ARROW A
SCREW < >
GASKET
8905-54
Fig. 11 Brake LinesTwo-Wheel Drive Models
LET.
TORQUE
LET.
POUNDS
NEWTON
METRES
145 I N. 16
125 I N. 14
100 I N . 11
170 I N . 19
<C> SCREW
RIGHT BRAKE
< A> TUBE
<A> RIGHT
BRAKE TUBE <C>
BRAKE HOSE
BRAKE VALVE TUBE
TO FRONT BRAKE HOSE VALVE
VIEW I N DIRECTION OF ARROW B ASSEMBLY
8905-55
Fig. 12 Brake LinesFour-Wheel Drive Models

BRAKES 5 - 1 9
BRAKE LINE EMERGENCY REPAIR
Mopar preformed met al brake line is recommended
and preferred for all repairs. However, double-wall
steel line can be used for emergency repair when fac-
tory replacement part s are not readily available.
Special, heavy duty tube bending and flaring
equipment is required to prepare double wall br ake
line. Special bending tools are needed to avoid ki nk-
ing or twisting met al brake line. In addition, special
flaring tools are needed to provide t he inverted-type,
double flare required on met al br ake lines.
Use tool C-4047 to provide t he inverted, double
flare (Fig. 8). Heavy duty t ube bending tools are
available t hrough t he dealer tool program.
Flaring Procedure
(1) Cut off damaged tube with tool C-3478-A or an
equivalent t ubi ng cutter.
(2) Ream cut edges of t ubi ng to ensure proper
flare.
(3) Install replacement t ube nut on section of t ube
to be repaired.
(4) Insert tube in flaring tool. Center tube in area
between vertical posts.
(5) Place gauge form A over t he end of t he t ube
(Fig. 13).
(6) Push t ubi ng t hrough flaring tool jaws unt i l
tube contacts recessed notch in gauge t hat mat ches
tube diameter.
(7) Squeeze flaring tool j aws to lock t ubi ng in
place.
(8) Insert plug on gauge A in t he tube. Then swing
compression disc over gauge and center t apered flar-
i ng screw in recess of compression di sc
(9) Tighten tool handle unt i l plug gauge is seated
on jaws of flaring tool. This st art s inverted flare (Fig.
13).
(10) Remove plug gauge and complete inverted
flare (Fig. 8).
(11) Remove flaring tools and verify t hat inverted
flare is correct. Flared end must be even, not dis-
torted, too t hi n, or cracked.
RH222
Fig. 13 Brakeline Flaring Tools
5 - 20 BRAKES

POWER BRAKE BOOSTERBRAKE PEDAL
INDEX
page
Brake Pedal Installation 21
Brake Pedal Removal 21
General Information . . . . . . . . . . . . . . . . . . . . . . . 20
page
Power Brake Booster Installation . . . . . . . . . . . . . 21
Power Brake Booster Removal 21
GENERAL INFORMATION
Power brakes are st andard on all AD models. A
single or dual diaphragm, vacuum power brake
booster is used.
AD and W150 models are equipped with a single
di aphragm booster uni t (Fig. 1). D and W250/350
models are equipped wi t h a dual di aphragm booster.
The booster uni t consists of a single housing di-
vided into separat e chambers by one or two i nt ernal
di aphragms. The outer edge of t he di aphragm is se-
cured to t he housing.
The booster push rod, which connects t he booster to
t he brake pedal and mast er cylinder, is attached to
t he center of t he diaphragm. A check valve is used in
t he booster outlet connected to t he engine i nt ake
manifold.
Power assist is produced by a combination of vac-
uum and atmospheric pressure to boost brake assist.
The power brake booster is not a repairable
component. The booster must be repl aced as an
assembl y if di agnosi s i ndi cates a malfunction
has occurred.
AD models with t he Cummi ns diesel engine are
equipped with a dual di aphragm power brake
booster. A separate vacuum pump assembly supplies
t he vacuum needed for booster operation (Fig. 2) .
The diesel vacuum pump and t he power steering
pump are combined into a single assembly. Both
pumps are operated by a drive gear pressed onto t he
vacuum pump shaft. The drive gear is operated by
t he camshaft gear.
A suspended-type brake pedal is used for all appli-
cations. The pedal is attached to t he pedal support
bracket with a pivot shaft. The pedal, bolt and bush-
ings are all serviceable components.
RESERVOI R PEDAL SHAFT
RETAINER
SCREW
MASTER CYLI NDER
AND BOOSTER ASSEMBLY
<5 >
I RETAINER
CLIP
TIGHTENING TORQUE
' A> 200 I N.- LBS . (23 N-m)
> 35 I N.- LBS . (4 N.m)
LOCKNUT
RK721
Fig. 1 Power Brake Booster And Pedal Mounting

BRAKES 5 - 21
VACUUM
GEAR ADAPTER
J9105-94
Fig. 2 Diesel Vacuum And Power Steering Pump
Assembly
POWER BRAKE BOOSTER REMOVAL
(1) Disconnect vacuum hoses from booster check
valve.
(2) Remove nut s at t achi ng mast er cylinder to
booster and move cylinder away from booster.
(3) Inside vehicle, remove clip t hat secures booster
push rod to brake pedal (Fig. 1). Use screwdriver to
ease clip off pedal pivot pin.
(4) Remove locknuts from booster mount i ng studs.
(5) Slide booster away from dash and out of engine
compartment.
POWER BRAKE BOOSTER INSTALLATION
(1) If new booster is not equipped with check valve
and seal, transfer these part s to new booster.
(2) Align and position booster on dash panel.
(3) Install locknuts on booster mount i ng studs fin-
ger tight.
(4) Install booster push rod on brake pedal pin and
secure the rod wi t h a ne w ret ai ni ng clip.
(5) Tighten booster locknuts to 25 N t h (220 in.
lbs.) torque.
(6) Install mast er cylinder on booster. Then install
and tighten cylinder mount i ng nut s to 19-23 Nnn
(170-200 in. lbs.) torque.
(7) Connect vacuum hose to booster check valve.
BRAKE PEDAL REMOVAL
(1) Disconnect booster push rod from pedal.
(2) Remove screw at t achi ng pedal shaft to brake
support.
(3) Pull pedal shaft out of support j ust enough to
remove brake pedal.
(4) Slide pedal off shaft and remove it from vehi-
cle.
BRAKE PEDAL INSTALLATION
(1) Lubricate pedal shaft and bore in brake pedal
with Mopar multi-mileage grease.
(2) Position pedal on shaft. Then slide shaft
t hrough pedal and into support.
(3) Secure pedal shaft to support with ret ai ni ng
screw.
(4) Attach push rod to pedal.
(5) Verify correct pedal and brake operation before
moving vehicle.
5 - 22 BRAKES
POW E R BRAK E VACUUM PUMPD I E SE L E N GI N E
INDEX
page
Low V acuum Warning Switch 22
Pump Adapter Replacement . 25
V acuum Pump Di agnosi s . . . . . . . . . . . . . . . . . . 23
V acuum Pump Operation . . . . . . . . . . . . . . . . . . 23
page
V acuum Pump Replacement 24
V acuum Pump Serviceability 22
V acuumSteeri ng Pump Assembl y Installation . . 26
V acuumSteeri ng Pump Assembl y Removal . . . 23
GENERAL INFORMATION
The power brake booster vacuum pump and t he
power steering pump are combined into a single as-
sembly on diesel models (Fig. 1). Both pumps are op-
erated by a drive gear attached to t he vacuum pump
shaft.
The vacuum pump is a constant displacement,
vane-type pump. Vacuum is generated by four vanes
mounted in t he pump rotor. The rotor is located in
t he pump housing and is pressed onto t he pump
shaft.
The vacuum and steering pumps are operated by a
single drive gear pressed onto t he vacuum pump
shaft. The drive gear is operated by t he camshaft
gear.
The vacuum and power steering pump shafts are
connected by a coupling. Each pump shaft has an
adapter wi t h drive lugs t hat engage in t he coupling.
The vacuum pump rot at i ng components are lubri-
cated by engine oil. Lubricating oil is supplied to t he
pump t hrough an oil line at t he underside of t he
pump housing.
The complete assembly must be removed in order
to service either pump. However, t he power steering
pump can removed and serviced separately when
necessary.
VACUUM PUMP SERVICEABILITY
The vacuum pump is not a serviceable component.
If diagnosis indicates a pump malfunction, t he pump
must be replaced as an assembly. Do not disassemble
or at t empt to repai r t he pump.
The combined vacuum and steering pump assembly
must be removed for access to either pump. However,
t he vacuum pump can be removed without havi ng to
disassemble t he power steering pump.
If t he power steering pump requires service, simply
remove t he assembly and separate t he two pumps.
Refer to t he pump removal and installation proce-
dures in t hi s section.
LOW VACUUM WARNING SWITCH
A vacuum switch is used to monitor output of t he
vacuum pump. The switch is in circuit with t he
brake warni ng light.
VACUUM
PUMP
DRIVE
GEAR
PUMP
ADAPTER
POWER
STEERING
PUMP
J9105-94
Fig. 1 Diesel Vacuum And Power Steering Pump
Assembly
A vacuum hose connects t he switch to t he power
brake booster. A wire harness connects t he switch to
t he brake warni ng light.
The switch is mounted on t he driver side i nner
fender panel j ust below t he hood hinge (Fig. 2) ,
b
L O W
V A C U U M
WARNI NG
S WI TCH
SWI TCH
HA R N E S S
J9105-95
Fig. 2 Diesel Vacuum Switch Location

BRAKES 5 - 23
VACUUM PUMP OPERATION
Vacuum pump output is t r ansmi t t ed to t he power
brake booster t hrough a supply hose. The hose is con-
nected to an outlet port on t he pump housing and to
t he check valve in t he power br ake booster.
Pump output ranges from a mi ni mum of 8.5 to 25
inches vacuum.
The pump rotor and vanes are rot at ed by t he pump
drive gear. The drive gear is operated by t he cam-
shaft gear.
Booster vacuum level is monitored by a warni ng
switch (Fig. 2). The switch consists of a vacuum
chamber t hat measures vacuum level and a sensor in
circuit with t he brake warni ng light.
The vacuum chamber is connected to t he booster
check valve by a vacuum supply hose. A wire har-
ness connects t he switch sensor to t he brake warni ng
light. If booster vacuum falls below 8.5 inches for
8-10 seconds or more, the switch sensor completes
t he circuit to t he warni ng light causing it to illumi-
nat e.
VACUUM PUMP DIAGNOSIS
Vacuum pump diagnosis involves checking pump
output with a vacuum gauge. The low vacuum warn-
ing switch can also be checked wi t h a vacuum gauge.
Refer to t he diagnosis procedure in t hi s section.
A standard vacuum gauge can be used to check
pump output when necessary. Simply disconnect t he
pump supply hose and connect a vacuum gauge to
t he outlet port for testing purposes. Vacuum should
hold steady in a range of approximately 8.5 to 25
inches at various engine speeds.
DIAGNOSING LOW VACUUM OUTPUT
CONDITION
A low booster vacuum condition or a faulty low
vacuum warni ng switch will cause t he brake warn-
ing light to illuminate. If t he light does go on and in-
dicates t he existence of a low vacuum condition,
check t he vacuum pump, booster and warni ng switch
as follows:
(1) Check vacuum pump oil feed line. Verify t hat
line connections are secure and not leaking. If leak-
age is noted and pump is noisy, replace pump.
(2) Disconnect supply hose to booster. Connect vac-
uum gauge to t hi s hose and r un engine at various
throttle openings. Output should range from 8.5 to
25 inches vacuum. If vacuum is consistently below
8.5 inches, problem is with vacuum hoses or pump
component. If output is wi t hi n specified limits, con-
tinue testing.
(3) Check booster operation as described in diagno-
sis section. Replace check valve, vacuum hoses, or
booster if necessary. However, if booster operation is
correct but warni ng light is still on, continue testing.
(4) Disconnect vacuum hose at warni ng switch.
Plug hose and connect hand vacuum pump to switch.
(5) St art and run engine.
(6) Apply 8.5 to 9 inches of vacuum to warni ng
switch and observe war ni ng light. If l i ght goes out,
switch vacuum hose is ei t her loose or leaking. If
light remai ns on, leave engine runni ng and continue
testing.
(7) Apply 20-25 inches vacuum to switch and ob-
serve warni ng light operation. If light now goes out,
switch is at fault and should be replaced. If light re-
mains on, continue testing.
(8) Reconnect vacuum hoses and replace original
warni ng switch with known good switch. Run engine
and observe warni ng light operation. If light is now
off, old switch is faulty. If light remai ns on, problem
is in wi ri ng between switch and warni ng light.
VACUUM- STEERI NG PUMP ASSEMBLY REMOVAL
(1) Disconnect bat t ery negative cable.
(2) Position drain pan under power steering pump.
(3) Disconnect vacuum and steering pump hoses
from respective pumps (Fig. 3).
Fig. 3 Vacuum And Steering Pump Hose
Connections
(4) Disconnect oil pressure sender wires at sender
(Fig. 4).
(5) Remove oil pressure sender (Fig. 4).
(6) Disconnect lubricating oil feed line from fitting
at underside of vacuum pump (Fig. 5).
(7) Remove lower bolt t hat attaches pump assem-
bly to engine block (Fig. 6).
(8) Remove bottom, inboard nut t hat attaches
adapter to steering pump (Fig. 6). This nut secures a
small bracket to engine block. Nut and bracket must
be removed before pump assembly can be removed
from block.
S - 24 BRAKES

LINE J9105-96
Fig. 5 Oil Feed Line Connection At Pump
(9) Remove upper bolt t hat at t aches pump assem-
bly to engine block (Fig. 7).
(10) Remove pump assembly from vehicle (Fig. 8).
VACUUM PUMP REPLACEMENT
(1) Remove nut s at t achi ng vacuum pump to
adapter (Fig. 8).
(2) Remove vacuum pump from adapt er (Fig. 9).
Turn pump gear back and forth to disengage pump
shaft from coupling if necessary.
(3) Inspect adapter O-ring (Fig. 9). Replace O-ring
if cut or torn.
PUMP ASSEMBLY
SOTTOM-INIOAiD
ADAPTER BRACKET NUT J9105-97
Fig. 6 Adapter And Pump Mounting Fastener
Location
Fig. 7 Removing Pump Assembly Upper Mounting
Bolt
(4) Lubricate adapt er O-ring with engine oil.
(5) Note position of drive slots i n coupling. Then
rot at e drive gear to align t angs on vacuum pump
shaft wi t h coupling (Fig. 10).
(6) Verify t hat pump is seated in adapter and cou-
pling.
(7) Install and t i ght en pump at t achi ng nut s and
washers.

BRAKES 5 - 25
ADAPTER
J9105-98
Fig. 8 Pump Assembly Removal
COUPLING
O-RI NG PUMP
ADAPTER
J9105-99
Fig. 9 Vacuum Pump Removed From Adapter
ROTATE DRIVE
GEAR TO ALIGN
TANGS J9105-102
Fig. 10 Aligning Pump Shaft Drive Tangs
PUMP ADAPTER REPLACEMENT
(1) Remove coupling from adapt er (Fig. 11).
(2) Remove remai ni ng adapt er at t achi ng nut s and
remove adapt er from steering pump (Fig. 12).
(3) If steering pump will be serviced, remove
spacer from each inboard mount i ng stud on pump
(Fig, 12).
Fig. 11 Removing/Installing Pump Drive Coupling
Fig. 12 Steering Pump Mounting Stud Spacer
Locations
5 - 26 BRAKES
Fig. 13 Positioning Gasket On Pump Mounting
Flange
(2) Insert pump assembly upper at t achi ng bolt in
mount i ng flange and gasket. Use sealer or grease to
hold bolt in place if necessary.
(3) Position pump assembly on engine and install
upper bolt (Fig. 14). Tighten upper bolt only enough
to hold assembly in place at t hi s time.

Fig. 14 Installing Pump Assembly On Engine
(4) Working from under vehicle, install pump as-
sembly lower at t achi ng bolt. Then t i ght en upper and
lower bolt to 77 Nm (57 ft. lbs.) torque.
(5) Position bracket on steering pump inboard
stud. Then install remai ni ng adapter at t achi ng nut
on stud. Tighten nut to 24 Nm (18 ft. lbs.) torque.
(6) Connect oil feed line to vacuum pump connec-
tor. Tighten line fitting securely.
(7) Install oil pressure sender and connect sender
wires.
(8) Connect steering pump pressure and r et ur n
lines to pump. Tighten pressure line fitting to 30
N-m (22 ft. lbs.) torque.
(9) Connect vacuum hose to vacuum pump.
(10) Connect bat t ery cables, if removed.
(11) Fill power steering pump reservoir.
(12) Purge air from steering pump lines. St art en-
gine and slowly t ur n steering wheel left and ri ght to
circulate fluid and purge air from system.
(13) Stop engine and top off power steering reser-
voir fluid level.
(14) St art engine and check brake and steering op-
eration. Verify t hat power brake booster is providing
vacuum assist and firm brake pedal is obtained.
Then verify t hat steering action is correct. Do t hi s
before moving vehicle.
(4) Clean and lubricate pump shaft with engine
oil.
(5) Install spacers on steering pump studs (Fig.
12).
(6) Install O-ring on adapter (Fig. 11).
(7) Position adapter on pump studs.
(8) Install at t achi ng nut s on outboard stud and on
t he two upper pump studs. Do not install nut on
lower, inboard stud at t hi s time. Tighten nut s to 24
(9) Install coupling on pump shaft. Be sure cou-
pling is securely engaged in shaft drive t angs.
(10) Install vacuum pump on adapter. Rotate drive
gear unt i l t angs on pump shaft engage in coupling.
Verify t hat pump is seated before installing attach-
ing nut s.
(11) Install and t i ght en vacuum pump at t achi ng
nut s.
V ACUUM- STE E RI NG PUMP ASSEMBLY
INSTALLATION
(1) Position new gasket on vacuum pump mount-
ing flange (Fig. 13). Use Mopar perfect seal, or sili-
cone adhesive/sealer to hold gasket in place.

BRAKES 5 - 27
CH RY SLE R D I S C BRAK E
INDEX
page
Caliper Installation . 33
Caliper Overhaul 32
Caliper Removal 31
Disc Brake Inspection 29
Disc Brakeshoe Installation , 31
GENERAL INFORMATION
DISC BRAKE COMPONENTS
The Chrysler disc brake consists of a sliding type,
single piston caliper and a ventilated disc brake rotor
(Figs. 1 and 2).
Each caliper is mounted on an adapter attached to
the steering knuckle (Fig. 2). Each- caliper slide lat-
erally on surfaces machined on t he caliper and
mounting adapter. The adapters support t he caliper
and mai nt ai n fore and aft alignment of t he caliper
and brakeshoes. Two ret ai ner clips are used to main-
t ai n caliper al i gnment but permit lateral movement
needed for caliper operation.
Non-metallic caliper pistons are used for all applica-
tions. The pistons are made of a phenolic resin material.
Ventilated, cast iron disc brake rotors are used for all
applications. The rotors are serviceable and can be ma-
chined to restore surface finish when necessary.
RETAINER CLIP \
SPLASH
SHIELD RK71
Fig. 1 Chrysler Disc Brake Caliper MountingRear
View
page
Di sc Brakeshoe Removal 29
Rotor Inspection and Service . . . . . . . . . . . . . . . . 34
Rotor Installation . 35
Rotor Removal 34
SHIELD RK72
Fig. 2 Chrysler Disc Brake Caliper MountingFront
View
The outboard brake shoe has flanges t hat locate
and position t he shoe on t he caliper fingers (Fig. 3) .
Braki ng force on this shoe is t aken by t he caliper.
The inboard shoe is held in position by t he adapt er
and reacts directly on t he adapter.
The caliper is a one-piece casting with t he inboard
side containing t he single piston cylinder bore (Fig.
3). A square cut piston seal is located in a machined
groove in t he cylinder bore. A rubber dust boot is
used to prevent dirt, water, road splash from enter-
i ng t he caliper piston bore. The boot is located in a
counterbore machined into t he outboard end of t he
caliper piston bore.
DISC BRAKE OPERATION
The significant feature of caliper operation is t hat the
caliper is free to move laterally on the slide surfaces.
At brake application, fluid pressure is exerted
equally against t he caliper piston and all surfaces of
t he caliper piston bore.
Pressure applied to t he piston is t ransmi t t ed di-
rectly to t he inboard brakeshoe to press t he shoe lin-
i ng against t he rotor. At t he same t i me, pressure
applied to t he caliper bore surfaces, causes t he cali-
per to slide inward laterally. The inward movement
RK48

BRAKES 5 - 29
presses t he outboard shoe lining agai nst t he opposite
side of t he rotor to complete braki ng action.
The application or release of fluid pressure causes
only a very slight movement of t he caliper and pis-
ton. At brake release, t he piston and caliper r et ur n
to t he non-applied position.
The brakeshoes do not ret ract an appreciable dis-
tance from t he rotor. The mi ni mal runni ng clearance
between t he lining and rotor provides improved re-
sponse and reduced pedal travel. It also helps in pre-
venting dirt and foreign mat eri al from lodging
between t he shoe and rotor surfaces.
DISC BRAKE LINING WEAR COMPENSATION
Normal lining wear is compensated for by extension
of the caliper piston and by lateral movement of the cal-
iper in the adapter. Piston position is also determined
in part by the square cut piston seal (Fig. 4).
Normal disc brake lining wear will cause t he cali-
per piston to extend enough to mai nt ai n proper pedal
height and brake response. The caliper bore will re-
ceive t he ext ra fluid needed to compensate for t he ad-
ditional piston extension.
As the piston extends during brake application, t he
square-cut seal is deflected outward (Fig. 4). When
brake pressure is released, t he seal st rai ght ens and
ret urns to a normal relaxed position. Although t he
amount of seal movement is quite small, it is enough
to ret ract t he piston to t he necessary mi ni mum run-
ning clearance.
As lining wear occurs, t he fluid level in t he front
brake reservoir will decrease. This is a normal con-
dition and only requires adding enough fluid to re-
store proper level. However, when t he brakeshoes are
replaced and t he caliper pistons bottomed in t he
bores, t he added fluid must be compensated for to
avoid overfill and overflow. Removing a small
amount of fluid from t he front brake reservoir before-
hand will prevent this condition.
PISTON CALIPER
DUST BOOT RN102
Fig. 4 Caliper Piston Seal Operation
DISC BRAKE INSPECTION
Inspect t he disc brake components whenever t he
caliper and brakeshoes are removed during service
operations or routine mai nt enance.
Check condition of the rotor, brakeshoe lining, caliper
and brake hoses. Front wheel bearing adjustment and
condition can also be checked at this time. The bearings
should be repacked and adjusted if necessary.
Brakeshoes
With t he caliper and brakeshoes on t he vehicle,
check runni ng clearance between t he rotor and
brakeshoes. The shoe lining should ei t her be in very
light contact with t he rotor or have a maxi mum of
0.127 mm (0.005 in.) r unni ng clearance. If clearance
exceeds t he stated amount, apply t he brakes several
t i mes and recheck clearance. If clearance is still ex-
cessive, either t he shoes are severely worn or t he cal-
iper piston could be binding in t he bore.
Hoses And Adapter
Inspect condition of t he brake lines and hoses. Re-
place either front hose if cut, torn, or t he reinforcing
fabric is visible. Check condition of t he met al brake-
lines. Replace any line t hat is badly rusted, leaking
or damaged in any way.
Clean and lubricate t he slide surfaces of t he caliper
and adapter. Use Mopar high t emperat ure grease for
t hi s purpose. Also verify t hat t he caliper adapter
bolts are secure and tightened to proper torque.
Fluid Level
Check t he mast er cylinder fluid level. Mai nt ai n
fluid level to t he bottom of t he indicator rings on the
reservoir. Note t hat front disc brake fluid level can
be expected to drop slightly as normal lining wear
occurs. Use Mopar brake fluid or equivalent meeting
SAE and DOT st andards J1703 and DOT 3. Use
clean brake fluid from a sealed container only.
Rotors
Check t he rotor surfaces for excessive wear, discol-
oration, scoring, rust, scale, or cracks. Also look for
damaged or severely rusted vent i l at i ng segments. If
pedal pulsation was experienced, check wheel bear-
ing adjustment and condition. If t he bearings are
OK, also check rotor runout and thickness variation.
DISC BRAKESHOE REMOVAL
(1) If front brakeshoes are to be replaced, remove
approximately 1/3 of fluid from mast er cylinder front
brake reservoir with suction gun.
(2) Raise and support vehicle.
(3) Remove front wheels.
(4) Press caliper pistons to bottom of bore with
large C-clamp. Position clamp screw on outboard
brakeshoe and position clamp frame on rear of cali-
per.
(5) Remove bolts securing caliper ret ai ner clips to
caliper. Then remove clips and ant i -rat t l e springs
(Fig. 5).
5 - 31 BRAKES
Fig. 5 Removing/installing Retainer Clips and
Anti-Rattle Springs
(6) Remove caliper by t i l t i ng it rearward and lift-
ing up and off rotor (Fig. 6).
Fig. 6 Caliper Removal/Installation
(7) Remove outboard brakeshoe from caliper (Fig.
7). Use pry tool to remove shoe from caliper if
flanges are tight,
(8) Remove inboard brakeshoe from caliper mount-
ing adapter (Fig. 8).
(9) Support caliper on box, stool, or front control
arm. Do not al l ow brake hose to support wei ght
of caliper. This practice coul d damage hose.
(10) Remove O-ring from caliper adapter.

Fig. 7 Removing Outboard Brakeshoe
Fig. 8 Removing/Installing Inboard Brakeshoe
Replace bonded disc brakeshoes if t he lining is
worn to a thickness of 4 mm (3/16 in.) or less. Re-
place riveted shoes if the lining is worn to within 1.5
mm (1/16 in.) of t he rivet heads.
If shoe replacement is necessary, replace t he shoes
on both sides at t he same time. Do not replace t he
shoes on one side only. This practice could result in
unequal braki ng effort and brake pull. Note t hat it is
normal for the inboard shoe lining to exhibit slightly
more wear t han t he outboard shoe lining.
Check for piston seal leaks which will be evident
by brake fluid in and around t he boot area and in-

BRAKES 5 - 31
board lining. Also check condition of t he caliper pis-
ton dust boot. If leakage is evident or if t he boot is
cut, torn, or damaged in any way, it will be neces-
sary to overhaul t he caliper.
Remove the O-ring from the caliper adapter and clean
the slide surfaces of the adapter and the machined ways
on the caliper with a wire brush and sandpaper.
DISC BRAKESHOE INSTALLATION
(1) Install inboard brakeshoe in adapt er (Fig. 8).
(2) If new brakeshoes are being installed, remove
protective paper from noise suppression gasket on
outboard shoe.
(3) Install and adjust outboard brakeshoe in cali-
per as follows:
(a) Check vertical movement of outboard shoe in
caliper. Shoe should fit tightly and not exhibit ver-
tical movement (free play). Fl ange must also fit
tightly on caliper finger to el i mi nat e free play and
prevent shoe rat t l e (Fig. 9).
(b) If free play is evident, remove shoe from cal-
iper.
(c) Bend shoe ret ai ni ng flange and t ri al fit shoe
in caliper. Continue bending flange unt i l shoe is
light interference fit in caliper (Fig. 10).
(d) Reinstall outboard brakeshoe in caliper. If
shoe is difficult to install, use C-clamp to seat shoe
(Fig. 11).
OUTBOARD SHOE MACHINED
Fig. 9 Outboard Brakeshoe Positioned On Caliper
Finger
(4) Lubricate slide surfaces of caliper mount i ng
adapter and machined ways on caliper with Mopar
high t emperat ure, or multi-mileage grease.
(5) Install O-ring in adapter, if removed.
(6) Carefully install caliper over rotor and into
adapter. Do not di spl ace or damage the pi ston
dust boot when i nst al l i ng the caliper.
Fig. 10 Adjusting Outboard Brakeshoe Retaining
Flange
Fig. 11 Seating Outboard Brakeshoe
(7) Align caliper in adapter and install caliper re-
t ai ner clips and ant i -rat t l e springs (Fig. 5). Tighten
ret ai ner screws to 20 Nm (180 in. lbs.) torque.
(8) Install wheels and lower vehicle.
(9) Top off mast er cylinder fluid level.
(10) Apply brakes several times to seat caliper pis-
tons and brakeshoes and obtain firm pedal. Do this
CALIPER REMOVAL
(1) Raise vehicle and remove front wheels.
(2) If caliper will only be removed for shoe replace-
ment or access to other component, press caliper pis-
ton to bottom of bore with large C-clamp.
(3) Remove caliper ret ai ner clips and ant i -rat t l e
springs.
(4) Disconnect brake hose fitting at caliper.
(5) Remove caliper from rotor.
(6) Remove brakeshoes from caliper and adapter.
5 - 32 BRAKES

CALIPER OVERHAUL
CALIPER DISASSEMBLY
(1) Drain old fluid out of caliper.
(2) Pad outboard shoe side of caliper interior with
a mi ni mum 2.54 cm (1 in.) thickness of shop towels
(Fig. 12). Towels will prevent piston damage when
piston comes out of bore.
(3) Remove caliper piston with short burst s of com-
pressed air. Apply air pressure t hrough fluid inlet
port of caliper (Fig. 12).
CAUTI ON : D o not bl ow the pi st on out of the cal iper.
This practice will usual l y resul t in sever e pi st on
damage. Us e onl y enough air pr essur e to ease the
piston out of the bore. In addi ti on, do not attempt to
catch the piston as it l eaves the cal iper bore. Thi s
practice will result in per sonal inj ury.
Fig. 12 Caliper Piston Removal
(4) Remove piston dust boot. Collapse boot with
screwdriver or punch and remove boot (Fig. 13).
(5) Remove caliper piston seal with wood pencil or
plastic tool (Fig. 14). Do not use met al tools as t hey
could scratch piston bore.
Clean t he caliper components (Fig. 15) wi t h Mopar
brake cleaner, fresh brake fluid, or denat ured alcohol
only. Do not use gasoline, kerosene, t hi nner, or any
similar type of solvent. These products can leave a
residue t hat is damaging to pistons and seals.
Dry t he caliper and piston with compressed air or
allow t hem to air dry. Do not use rags or shop tow-
els. Li nt from such mat eri al s can adhere to t he cali-
per and piston.
Fig. 14 Removing Caliper Piston Seal
Inspect t he caliper piston. The piston is made from
a phenolic resin (plastic material) and should be
smooth and clean. Replace t he piston if cracked or
scored. Do not at t empt to restore a scored piston by
sanding or polishing. The piston must be replaced if
damaged.
If t he cal i per pi st on mus t be r epl aced, i nst al l
t he s a me t ype of pi st on i n the cal i per . Never in-
t er change phenol i c r esi n a n d steel pi st ons. The
pi s t on seal s, seal gr ooves, cal i per bor e a n d pi s-

BRAKES 5 - 33
BLEEDER CALIPER I N BO A R D ANTI-RATTLE
PISTON SPRING RH242A
Fig. 15 Caliper Components
t on t ol er ances a r e di fferent for r es i n a nd st eel
pi st ons a n d cal i per s. Do not i nt er mi x t hes e com-
ponent s at any t i me.
Inspect t he caliper piston bore. The bore can be
lightly polished wi t h Honing Tool C-4095 to remove
very minor surface imperfections (Fig. 16). How-
ever , t he cal i per mus t be r e pl a c e d if t he bor e i s
sever el y cor r oded, r us t ed, s cor ed, or if pol i shi ng
woul d i ncr eas e bor e di amet er mor e t ha n 0.025
mm (0.001 in.).
Fig. 16 Lightly Polishing Piston Bore With Tool
C-4095
CALIPER ASSEMBLY
(1) Coat caliper piston bore, new piston seal and
piston with brake fluid.
(2) Install new piston seal in caliper bore. Be sure
seal is fully seated in groove (Fig. 17).
(3) Install new dust boot on caliper piston. Seat
boot in piston groove.
(4) St art caliper piston in bore with a rotating mo-
tion. When piston is st art ed in seal, push piston only
part way into bore (Fig. 18). Mai nt ai n uniform pres-
sure on piston to avoid cocking it in bore.
Fig. 17 Installing Caliper Piston Seal
Fig. 18 Installing Caliper Piston
(5) Press caliper piston to bottom of bore and seat
piston dust boot with Installer C-4690 and Tool Han-
dle C-4171 (Fig. 19).
(6) Install caliper bleed screw if removed.
CALIPER INSTALLATION
(1) Clean slide surfaces of caliper mount i ng
adapt er wi t h wire brush. Then lubricate adapt er
slide surfaces with Mopar multi-mileage, or high
t emperat ure grease.
(2) Install inboard brakeshoe in adapter.
(3) Install outboard brakeshoe in caliper. Be sure
shoe is light press fit in caliper. Refer to installation
procedure in Brakeshoe Replacement section.
(4) Lubricate caliper slide surfaces Mopar multi-
mileage, or high t emperat ure grease.
(5) Install O-ring in adapter, if removed.
5 - 34 BRAKES

b o o t
>TALLir
TOOL
Fig. 19 Seating Piston Dust Boot
(6) Install caliper over rotor and into adapter.
(7) Align caliper in adapter and install caliper re-
t ai ner clips and ant i -rat t l e springs. Tighten ret ai ner
clip screws to 20 N*m (180 in. lbs.) torque.
(8) Connect brake hose to caliper. Tighten fitting
bolt to 47 Nm (35 ft. lbs.) torque. Be s ur e hos e i s
clear of chassi s and s us pens i on c ompone nt s a n d
use new seal wa s h e r s t o s ecur e hos e fi t t i ng t o
caliper. Do not reuse ol d wa s he r s .
(9) Fill mast er cylinder with Mopar brake fluid or
equivalent meet i ng SAE and DOT st andards J1703
and DOT 3.
(10) Bleed brakes. Refer to procedure in Service
And Adjustments section.
(11) Install wheels and lower vehicle.
(12) Apply brakes several times to seat caliper pis-
tons and brakeshoes. Be sure firm pedal is obtained
ROTOR REMOVAL
(2) Remove wheel and tire assembly.
(3) Remove caliper assembly. Do not allow brake
hose to support caliper. Support caliper on stool, or
suspend caliper wi t h wire attached to nearby body or
suspension component.
(4) Remove grease cap, cotter pin, nut lock, adjust-
ing nut , t hr ust washer and outer wheel bearing.
(5) Remove rotor from spindle.
(6) Remove rotor shield and seal if either is to be
serviced.
ROTOR INSPECTION AND SERVICE
rotor condition
The rotor braki ng surfaces should not be refinished
unless actually necessary. Light surface rust and
scale can be removed in a l at he equipped wi t h dual
sanding discs.
Rotor surfaces can be restored by machining in a
disc brake l at he if surface scoring and wear are light.
The rotor should be replaced if:
severely scored
tapered
has hard spots
is cracked
too t hi n
machining would cause rotor thickness to fall be-
low mi ni mum thickness requi rement s
Check rotor lateral runout and thickness variation
if pedal pulsation or an occasional low pedal condi-
tion was experienced. Measure runout with a dial in-
dicator. Measure thickness with a micrometer at a
mi ni mum of four points around t he braki ng surfaces.
CHECKING ROTOR MINIMUM THICKNESS
Measure rotor thickness at t he center of t he brake-
shoe contact surface. Replace t he rotor if it is worn
below mi ni mum thickness, or if refinishing would re-
duce thickness below t he allowable mi ni mum. Rotor
mi ni mum thickness is usually specified on t he rotor
hub (Fig. 20).
Fig. 20 Typical Location Of Rotor Minimum
Thickness Limit
ROTOR RUNOUT
Check rotor lateral runout with Dial Indicator
C-3339 as shown in the top view (Fig. 21). Excessive

BRAKES 5 - 35
lateral r unout will cause brake pedal pul sat i on and
rapid, uneven wear of t he brakeshoes. Position t he
dial indicator plunger approximately 2 5 . 4 mm ( 1 in.)
from t he rotor outer edge.
Be s ur e wheel be a r i ng adj us t ment i s c or r e c t
bef or e checki ng r ot or r unout . I ncor r ect adj ust -
me nt c a n cr eat e a condi t i on si mi l ar t o excessi ve
l at er al r unout -
Maximum allowable rotor runout for all models is
0 . 10 2 mm ( 0 . 0 0 4 in.).
Fig. 21 Checking Rotor Runout And Thickness
Variation
ROTOR THICKNESS VARIATION
Variations in rotor thickness will cause pedal pul-
sation, noise and shudder.
Measure rotor thickness at 6 to 12 points around
the rotor face (Fig. 2 1) . Position t he micrometer ap-
proximately 19,05 to 2 5 . 4 mm ( 3/ 4 to 1 in.) from t he
rotor outer circumference for each measurement as
shown in t he bottom view (Fig. 2 1) .
Thickness should not vary by more t han 0 . 0 13 mm
( 0 . 0 0 0 5 in.) from point-to-point on t he rotor. Refinish
or replace t he rotor if necessary.
ROTOR REFINISHING
Rotor braki ng surfaces can be refinished by sand-
ing and/or machi ni ng in a disc brake lathe. The lathe
must be capable of machining both rotor surfaces si-
multaneously wi t h dual cutter heads (Fig. 2 2 ) . A
brake l at he capable of machi ni ng only one side at a
time will produce a tapered rotor.
The disc brake l at he should also be equipped with
a grinder at t achment , or dual sanding discs for final
cleanup or light refinishing (Fig. 2 2 ) .
If t he rotor surfaces only need minor cleanup of
rust, scale, or scoring, use abrasive discs to clean up
t he rotor surfaces. However, when a rotor is scored or
worn, machi ni ng wi t h cutting tools will be required.
CAUTION: D o not refinish a rotor if machi ni ng
woul d cause rotor t hi ckness to fall below mi ni mum
al l owabl e.
Fig. 22 Rotor Refinishing Equipment
ROTOR INSTALLATION
(1) Inspect and repack wheel beari ngs if necessary.
Install new grease seal if i nner beari ng is removed
for repacking.
(2 ) Install rotor on spindle.
(3) Install outer bearing, t hrust washer and nut .
(4) Tighten wheel bearing adjusting nut to 2 7- 34
N t h ( 2 40 - 30 0 in. lbs.) while t ur ni ng rotor.
(5) Recheck rotor runout as described previously.
5 - 36 BRAKES

(6) Loosen wheel beari ng adjusting nut completely.
Then ret i ght en nut finger tight. Wheel beari ng end
play should be maxi mum of 0.002 to 0.076 mm
(0.0001 to 0.003 in.).
(7) Install nut lock on beari ng adjusting nut . Align
lock slots with cotter pin hole and secure nut and
lock with new cotter pin.
(8) Clean grease cap. Then coat interior of cap
with wheel beari ng grease.
(9) Install caliper, wheel and tire assembly and
lower vehicle.
(10) Check and adjust mast er cylinder fluid level.
(11) Apply brakes several t i mes to seat brake-
shoes. Be sure to obtain firm pedal before moving ve-
hicle.

BRAKES 5 - 37
BE N D I X D I S C B R A K E
INDEX
page
Caliper Overhaul 4 1
Di sc Brake Inspection 39
Di sc Brakeshoe Installation 4 0
Di sc Brakeshoe Removal . 39
GENERAL SERVICE INFORMATION
The Bendix disc brake assembly consists of a single
piston, sliding type caliper and ventilated rotor (Fig. 1).
A splash shield is used to protect t he rotor. The
shield is bolted to t he adapter and protects t he bear-
ings and inboard surface of t he rotor from road
splash. The wheel protects t he outboard surface of
t he rotor and brake assembly.
The caliper slides laterally on surfaces machined
into t he caliper and mounting adapter. The adapt er
is bolted to t he steering knuckle (Fig. 2). The caliper
is positioned in t he adapter with a support key and
spring (Fig. 1). A ret ai ni ng screw is used to secure
t he support key.
The inboard brakeshoe is mounted in t he caliper
adapter. The outboard brakeshoe is mounted in t he
caliper. The linings are riveted to t he shoes, and t he
inner and outer shoes are not interchangeable.
DISC BRAKE OPERATION
The significant feature of caliper operation is t hat
t he caliper is free to move laterally on t he adapt er
slide surfaces (Fig. 3).
Fig. 1 Bendix Disc Brake Caliper
page
General Service Information 37
Rotor Inspection and Service . . . . . . . . . . . . . . . . 4 3
Rotor Installation 4 5
Rotor Removal 4 5
Fig. 2 Caliper Mounting Adapter Attachment
At brake application, fluid pressure is exerted
equally agai nst the caliper piston and all surfaces of
t he caliper piston bore.
Pressure applied to t he piston is t ransmi t t ed di-
rectly to t he inboard brakeshoe pressing t he shoe lin-
ing against t he rotor. At t he same time, pressure
applied to t he caliper bore surfaces, causes t he cali-
per to slide inward laterally. The inward movement
presses t he lining of t he outboard shoe agai nst t he
opposite side of the rotor to complete braki ng action
(Fig. 3).
Any application or release of brake fluid pressure
causes only a very modest movement of t he caliper
and piston. At brake release, t he piston and caliper
ret urn to t he non-applied position.
The brakeshoes do not ret ract an appreciable dis-
tance from t he rotor. The mi ni mal runni ng clearance
provides the improved response and reduced pedal
travel; It also helps in prevent i ng dirt and foreign
mat eri al from lodging between t he shoe and rotor
surfaces.
BRAKES 5 - 39
DISC BRAKE LINING WEAR COMPENSATION
Normal lining wear is compensated for by exten-
sion of t he caliper piston and by l at eral movement of
t he caliper in t he adapter. Piston position is also de-
termined in par t by t he square cut piston seal (Fig.
4).
Normal disc brake lining wear will cause t he cali-
per piston to extend enough to mai nt ai n proper pedal
height and brake response. The caliper bore will re-
ceive t he extra fluid needed to compensate for t he ad-
ditional piston extension.
As t he piston extends during brake application, t he
square-cut seal is deflected outward (Fig. 4). When
brake pressure is released, t he seal st rai ght ens and
ret urns to a normal relaxed position. Although t he
amount of seal movement is quite small, it is enough
to ret ract t he piston to t he necessary mi ni mum run-
ning clearance.
Fluid level in t he front brake reservoir will de-
crease as lining wear occurs, t he. This is a normal
condition and only requires adding enough fluid to
restore proper level. However, when t he brakeshoes
are replaced and t he caliper pistons bottomed in t he
bores, t he added fluid must be compensated for. This
is necessary to avoid overfill and overflow. Removing
a small amount of fluid from t he front brake reser-
voir beforehand will prevent t hi s condition.
Fig. 4 Caliper Piston Seal Operation
DISC BRAKE INSPECTION
Inspect t he disc brake components whenever t he
caliper and brakeshoes are removed duri ng service
operations or routine mai nt enance.
Check condition of t he rotor, brakeshoe lining, cal-
iper and brake hoses. Front wheel beari ng adjust-
ment and condition can also be checked at t hi s time.
The bearings should be repacked and adjusted if nec-
essary.
Brakeshoes
With t he caliper and brakeshoes on t he vehicle,
check runni ng clearance between t he rotor and
brakeshoes. The shoe lining should either be in very
light contact with t he rotor or a maxi mum of 0.127
mm (0.005 in.) r unni ng clearance. If clearance ex-
ceeds t he stated amount , apply t he brakes several
times and recheck clearance. If clearance is still ex-
cessive, either t he shoes are severely worn or t he cal-
iper piston could be bi ndi ng i n the bore.
Hoses And Adapter
Inspect condition of t he br ake lines and hoses. Re-
place ei t her front hose if cut, torn, or the reinforcing
fabric is visible. Check condition of t he met al brake-
lines. Replace any line t hat is badly rusted, leaking
or damaged in any way.
Clean and lubricate t he adapt er slide surfaces. Use
Mopar multi-mileage or hi gh t emperat ure grease for
t hi s purpose. Also verify t hat t he caliper adapt er
bolts are secure and t i ght ened to proper torque.
Fluid Level
Check t he mast er cylinder fluid level. Mai nt ai n
fluid level to t he bottom of t he indicator ri ngs on t he
reservoir. Note t hat front brake fluid level can be ex-
pected to drop slightly as normal lining wear occurs.
Use Mopar brake fluid or equivalent meeting SAE
and DOT st andards J1703 and DOT 3. Use clean
brake fluid from a sealed container only.
Rotors
Check rotor surfaces for excessive wear, discolora-
tion, scoring, rust , scale, or cracks. Also look for
damaged or severely rust ed ventilating segments. If
pedal pulsation was experienced, check wheel bear-
ing adjustment and condition. If t he bearings are
OK, also check rotor r unout and thickness variation.
DISC BRAKESHOE REMOVAL
(1) Remove approximately 1/3 of fluid from mast er
cylinder front brake reservoir with a suction gun.
(3) Remove wheel and t i re assemblies.
(4) Press caliper pistons to bottom of bore wi t h
large C-clamp (Fig. 5). Position clamp screw on out-
board shoe and clamp frame or rear of caliper hous-
ing.
(5) Remove support key ret ai ni ng screw (Fig. 6).
(6) Remove caliper support key and spring. Use
pin punch or drift to t ap key out of caliper (Fig. 7).
(7) Lift caliper out of adapter.
(8) Remove outboard shoe from caliper (Fig. 8).
(9) Secure caliper to convenient chassis component
with wire. Do not allow brake hose to support caliper
weight.
(10) Remove inboard shoe and ant i -rat t l e spring
from caliper adapt er (Fig. 9). Note position of spring
for installation reference.
Inspect t he shoe lining for wear. Replace riveted
shoes if t he lining is worn to within 1.5 mm (1/16 in.)
of t he rivet heads. Replace bonded lining if thickness
is 3 mm (3/16 in.) or less.
5 - 40 BRAKES

Fig. 6 Removing/Installing Support Key Retaining
Screw
If t he shoe lining will be reused, do not i nt ermi x
t he shoes. Keep t hem with t he caliper t hey were re-
moved from.
Exami ne t he caliper piston area for evidence of
leaks. Also check condition of t he piston boot. Over-
haul t he caliper if leakage is evident or t he boot is
cut or torn.
Clean r ust and corrosion from t he support key and
t he caliper and adapter slide surfaces (machined
ways) wi t h a wire brush. Then lubricate t he slide
surfaces wi t h Mopar multi-mileage grease, or equiv-
alent.
DISC BRAKESHOE INSTALLATION
(1) Install ant i -rat t l e spring on inboard brakeshoe
and install shoe in adapter. Be sure spring remai ns
in place and is positioned as shown (Fig. 9). Loop
portion of spring should face away from t he rotor.
BRASS ROD
\
Fig. 7 Removing Caliper Support Key And Spring
Fig. 8 Removing/Installing Outboard Brakeshoe
(2) Install outboard shoe in caliper. Free play
should not exist between shoe ret ai ni ng flanges and
machined surfaces on caliper. If shoe cannot be
pressed into place by hand, use a C-Clamp. If a
C-Clamp is used, protect shoe with wood block (Fig.
10).
(3) Position caliper over rotor and in adapt er (Fig.
11). Be careful to avoid damagi ng piston dust boot
duri ng installation.
C A U T I O N : Verify that the brake hose i s straight
and not twisted, kinked, or t ouchi ng any c ha s s i s
component s.

BRAKES 5 - 4 1
Fig. 9 Removing/Installing Inboard Brakeshoe
Fig. 10 Seating Outboard Brakeshoe In Caliper
(4) Seat caliper in adapter.
(5) Place support spring on support key. Then in-
sert spring and key between caliper and adapter.
(6) Tap support key and spring into place with pin
punch or drift (Fig. 12).
(7) Align notch in support key wi t h screw hole in
caliper.
(8) Install support key ret ai ni ng screw. Tighten
screw to 20 Nm (15 ft. lbs.) torque. Be sure shoul-
der on screw is fully s eat ed i n s uppor t key
notch.
(9) Install wheel and t i re assembly and lower vehi-
cle.
(10) Top off mast er cylinder fluid level.
(11) Pump brake pedal to seat shoes and restore
normal pedal height. Do not move vehicle until firm
pedal is obtained.
CALIPER
Fig. 11 Caliper Installation
CALIPER
Fig. 12 Installing Support Key And Spring
CALIPER OVERHAUL
CALIPER REMOVAL
(1) Raise vehicle and support on hoist or jack-
stands.
(2) Remove wheel and tire assemblies.
(3) Clean brake hose and t ubi ng connections at
calipers and brake hoses.
(4) Remove screw ret ai ni ng caliper support key
and spring and t ap support key and spring out wi t h
a drift or pin punch.
(5) Remove calipers and brakeshoes from adapters
(6) Disconnect caliper brake hoses at frame brack-
ets and remove calipers.
(7) Cover brake lines to prevent dirt entry.
5 - 4 2 BRAKES

CALIPER DISASSEMBLY.
(1) Drai n old fluid out of caliper.
(2) Pad outboard shoe side of caliper interior with
a mi ni mum 2.54 cm (1 in.) thickness of shop towels
(Fig. 13). Towels will prevent piston damage when it
comes out of bore.
(3) Remove caliper piston with short burst s of com-
pressed air. Apply air pressure t hrough fluid inlet
port of caliper (Fig. 13).
CAUTI ON: Do not bl ow the pi st on out of the cal i-
per. This practice will usual l y resul t in sever e pi s-
ton damage. Use only enough air pr essur e to ease
the piston out of the bore. In addi ti on, do not at-
tempt to catch the piston as it l eaves the caliper
bore. This practice will resul t in per sonal inj ury.
PISTON J9105-66
Fig. 13 Caliper Piston Removal
(4) Remove dust boot from caliper.
(5) Remove caliper piston seal from caliper bore
wi t h small wood or plastic tool. Do not us e met al
t ool s t o r e move seal . Met al t ool s c a n s c r a t c h or
s cor e bor e sur f ace.
(6) Remove bleed screw from caliper.
Clean t he slide surfaces of t he caliper wi t h a wire
brush and emery cloth. Then clean t he caliper and
piston wi t h Mopar brake cleaner, fresh brake fluid,
or denat ured alcohol only. Do not use any other type
of solvent or cleaning agent.
Dry t he caliper and piston wi t h compressed air or
allow t hem to air dry. Do not use rags or towels to
dry t he caliper and piston. Lint from such mat eri al s
can adhere to t he piston and caliper.
Inspect t he caliper piston, piston bore and t he seal
and boot grooves. Replace t he piston if corroded, pit-
ted, scored, or worn. Do not at t empt to restore t he
piston surface by sanding. Replace t he piston if nec-
essary.
Very light scratches or corrosion in t he piston bore
can usually be cleaned up with a fiber brush, or by
polishing wi t h a honing tool or crocus cloth. How-
ever, t he caliper should be replaced if t he bore is se-
verely corroded, scored, or if honing and polishing
would increase bore diameter by more t han 0.050
mm (0.002 in.).
Dark brown or black st ai ns on t he piston are
caused by t he piston seal and are a normal condition.
In addition, light discoloration of t he piston bore is
also normal. This discoloration is acceptable as long
as t he bore and piston surfaces are in good condition.
If t he cal i per pi s t on mus t be r epl aced, i nst al l
t he s a me t ype of pi st on i n t he cal i per . Never in-
t e r c ha nge phenol i c r es i n a n d st eel pi s t ons . The
pi s t on seal s, seal gr ooves, cal i per bor e a n d pi s-
t on t ol er ances a r e di fferent for r es i n a n d st eel
pi s t ons a nd cal i per s . Do not i nt er mi x t hes e com-
pone nt s at a ny t i me.
The caliper bore can be lightly polished to remove
minor scratches or corrosion. However, polishing op-
erations should not remove any more t han 0.012 mm
(0.0005 in.) from t he bore surface. Replace t he caliper
if t he bore is severely scored or corroded. Use crocus
cloth or 400 grit honing stones soaked in fresh brake
fluid to polish t he bore surface. Be sure to flush and
clean t he caliper thoroughly afterward. All residue
generated by polishing must be removed to avoid po-
t ent i al damage to t he piston, seal and bore after as-
sembly.
Inspect and clean t he inboard shoe ant i -rat t l e
spring, support key spring, ret ai ni ng screw and cali-
per support key (Fig. 14). Replace these components
if worn or damaged.
SHOE AND SHOE AND CALIPER BLEEDER SCREW
SEAL BOOT ANTI-RATTLE SPRING RN1059
Fig. 14 Caliper Components

BRAKES 5 - 4 3
CAMPER ASSEMBLY
(1) Mount caliper in vise equipped with protective
jaws. Do not overtighten vise. Excessive pressure
could cause bore distortion and piston binding.
(2) Lubricate new piston seal and piston bore wi t h
fresh brake fluid.
(3) Install new piston seal in bore groove (Fig. 15).
Position seal in one area of groove and gently work i t
around and into remai nder of groove until seated. Be
sure seal is not twisted or rolled over.
Fig. 15 Installing Caliper Piston Seal
(4) Lubricate new dust boot with fresh brake fluid
and install it in caliper (Fig. 16). Work boot into
groove with fingers. Boot will seem larger t han
groove diameter at first but will snap into place
when properly positioned.
(5) Pl ug fluid inlet port and install bleeder screw.
(6) Coat caliper piston with brake fluid.
(7) St art piston into dust boot and bore (Fig. 16).
Spread dust boot wi t h fingers. Then work piston
t hrough boot and into bore. Air trapped below piston
will force boot around i t and into groove as piston is
installed.
(8) Remove plug from inlet port and loosen bleeder
screw.
(9) Carefully press piston into bore with t ur ni ng
motion until fully bottomed. Apply force uniformly to
avoid cocking piston (Fig. 16).
(10) Seat dust boot with suitable size installer tool
if necessary.
CALIPER INSTALLATION
(1) Install brakeshoes in caliper and adapter.
Fig. 16 Installing Caliper Piston
(2) Connect brake hose to brake line on frame
bracket. Tighten hose fitting to 13-20 Nm (115-175
in. lbs.) torque.
(3) Connect brake hose to caliper. Use new seal
washers when connecting fitting to caliper. Do not
t i ght en hose fitting at this time.
(4) Lubricate caliper and adapter slide surfaces
wi t h Mopar hi gh t emperat ure grease, or an equiva-
lent grease.
(5) Install and secure caliper in adapter.
(6) Fill mast er cylinder and bleed brakes.
(7) Install wheel and t i re assemblies and lower ve-
hicle.
ROTOR INSPECTION AND SERVICE
ROTOR CONDITION
Rotor condition and tolerances can be checked with
t he rotor mounted on t he axle. However, wheel bear-
ing end play should be reduced to zero before check-
ing l at eral runout .
The rotor braki ng surfaces should not be machined
unless actually necessary. Light surface rust and
scale can be removed in a l at he equipped wi t h dual
sanding discs.
Worn, or scored rotor surfaces can be restored by
machi ni ng in a disc brake l at he but only if surface
scoring and wear are light.
The rotor should be replaced if:
severely scored
tapered
has hard spots
cracked
warped
too t hi n
machining would cause rotor thickness to fall be-
low mi ni mum thickness requi rement s
5 - 44 BRAKES

Check rotor l at eral runout and thickness variation
if pedal pulsation or an occasional low pedal condi-
tion was experienced. Measure runout with a dial in-
dicator. Measure thickness with a micrometer at a
mi ni mum of four points around t he braki ng surfaces.
The rotor measurement points are shown in Figure
17.
Fig. 17 Rotor Measurement Points
CHECKING ROTOR MINIMUM THICKNESS
Measure rotor thickness at t he center of t he brake-
shoe contact surface. Replace t he rotor if it is worn
below mi ni mum thickness, or if refinishing would re-
duce thickness below t he allowable mi ni mum. Rotor
mi ni mum thickness is usually specified on t he rotor
hub.
ROTOR THICKNESS VARIATION
Variations in rotor thickness will cause pedal pul-
sation, noise and shudder.
Measure rotor thickness at 6 to 12 points around
t he rotor face (Fig. 18). Position t he micrometer ap-
proximately 25.4 mm (1 in.) from t he rotor outer cir-
cumference for each measurement (Figs. 17 and 19).
Thickness should not vary by more t han 0.025 mm
(0.001 in.) from point-to-point on t he rotor. Refinish
or replace t he rotor if necessary.
ROTOR RUNOUT
Check rotor l at eral runout with Dial Indicator
C-3339 (Fig. 18). Excessive lateral runout will cause
brake pedal pulsation and rapid, uneven wear of t he
brakeshoes.
Position t he dial indicator plunger approximately
25.4 mm (1 in.) in from t he rotor edge. Be s ur e
wheel be a r i ng e nd pl ay is r e duc e d t o zer o bef or e
checki ng r unout . Maximum allowable runout is
0.127 mm (0.005 in.).
Fig. 18 Checking Rotor Runout And Thickness
Variation
ROTOR REFINISHING
Rotor braki ng surfaces can be refinished by sand-
ing and/or machining in a disc brake lathe. The l at he
must be capable of machining both rotor surfaces si-

BRAKES 5 - 4 5
multaneously with dual cutter heads. Equi pment ca-
pable of machining only one side at a t i me will
produce a tapered rotor.
The l at he should also be equipped wi t h a grinder
at t achment or dual sanding discs for final cleanup or
light refinishing.
If t he rotor surfaces only need minor cleanup of
rust, scale, or scoring, use abrasive discs to clean up
t he rotor surfaces. However, when a rotor is scored or
worn, machining with cutting tools will be required.
C A U T I O N : D o not refinish a rotor if machi ni ng
woul d cause the rotor to fall below mi ni mum allow-
able t hi ckness.
ROTOR REMOVAL
(1) Raise and support front of vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove support key ret ai ni ng screw (Fig. 6).
(4) Remove caliper support key and spring with
pin punch or drift (Fig. 19).
Fig. 19 Removing Caliper Support Key And Spring
(5) Remove caliper and brakeshoes from adapter.
Do not al l ow brake hose to support caliper
weight. Support caliper on stool, or secure cali-
per to nearby frame or chassi s component wi th
wire.
(6) Remove hub cap.
(7) Remove drive flange snap ri ng with Tool
C-4020 (Fig. 20).
(8) Remove flange nut s and lock washers and re-
move drive flange. Discard t he flange gasket.
(9) St rai ght en t ang on lock ring.
(10) Loosen outer locknut and adjusting nut with
Tool DD-1241-JD (Fig. 19). Then remove outer lock-
nut, lock ring, inner adjusting nut and outer bearing.
(11) Remove hub and rotor from spindle.
Fig. 20 Removing Drive Flange Snap Ring
(12) Remove seal and i nner beari ng from hub if
beari ng or seal requires service.
(13) If wheel beari ng races require service, remove
t hem with suitable remover tools or wi t h brass drift.
(14) Clean rotor and hub and wheel bearings in
solvent.
ROTOR INSTALLATION
(1) Repack wheel bearings and coat spindle with
Mopar high t emperat ure beari ng grease.
(2) Install new bearing races, bearings and seals in
hubs if necessary.
(3) Install hub on spindle and install outer beari ng
and inner adjusting nut .
(4) Tighten adjusting nut to 68 Nrni (50 ft. lbs.)
with Special Tools DD-1241-JD and C-3952 to seat
bearings.
(5) Adjust wheel bearings as follows:
(a) Back off adjusting nut .
(b) Retighten adjusting nut to 54 N*m (40 ft. lbs.)
while rot at i ng 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 mi ni mum of 88 Nm (65
ft. lbs.). Beari ng end play should be 0.025 - 0.25 mm
(0.001 - 0.010 in.).
(7) Bend one t ang of lock ri ng over adjusting nut
and another t ang over locknut to secure t hem.
(8) Install new gasket on hub and install drive
flange, lock washers and nut s. Tighten nut s to 41 -
54 Nm (30 - 40 ft. lbs.).
(9) Install flange snap ri ng with Tool C-4020.
(10) Install hub cap.
(11) Install caliper and brakeshoes. Tighten sup-
port ret ai ni ng screw to 20 Nnn (15 ft. lbs.) torque.
(12) Install wheel and t i re assembly and lower ve-
hicle.
i - 46 BRAKES

D RUM B R A K E S E L E V E N I N CH
INDEX
page
Brake Drum Inspection and Refinishing . . . . . . . . 48
Brake Drum Installation . . . . . . . . . . . . . . . . . . . . 4 8
Brake Drum Removal 4 6
Brake Shoe Installation . 4 7
Brake Support Plate Installation 4 9
Brake Support Plate Removal . . . . . . . . . . . . . . . 4 9
page
Brakeshoe Removal . . . . . . . . . . . . . . . . . . . . . . 4 6
Cleaning and Inspection 4 7
Wheel Cylinder Installation 50
Wheel Cylinder Overhaul 4 9
Wheel Cylinder Removal 4 9
GENERAL INFORMATION
Chrysler eleven inch rear drum brakes are used on
D and W150 models (Fig. 1). All applications are two
shoe, i nt ernal expanding uni t s with a self adjuster
mechanism. A single wheel cylinder is used to ex-
pand the dual brakeshoes. The lower ends of t he
brake shoes are connected by a st ar wheel adjusting
screw which is part of t he self adjusting mechanism.
SUPPORT
PLATE
PARKING
BRAKE
STRUT AND
SPRI NG
RETURN
SPRI NG
ANCHOR
PLATE
RETURN CABLE
SPRI NG
G U
J
D E
PRIMARY
SHOE AND
LI NI NG
SHOE SPRI NG
ADJUSTER SCREW
ASSEMBLY
ADJUSTER
LEVER
LEVER
SPRI NG
PARKI NG
BRAKE
LEVER
ADJUSTER
CABLE
A N D
SPRI NG
SHOE
RETAINER,
SPRI NG
A N D PIN
SECONDARY
SHOE A N D
LI NI NG
J9005-62
Fig. 1 Eleven Inch Drum Brake Assembly
BRAKE DRUM REMOVAL
(2) Remove wheel and tire.
(3) Remove clip nut s securing brake drum to wheel
studs.
(4) If drum is difficult to remove, ret ract brake-
shoes as follows:
(a) Remove rear plug from access hole in support
plate.
(b) Insert a t hi n screwdriver into access hole and
push self adjusting lever away from adjuster screw
star wheel.
(c) Insert Tool C-3784 into brake adjusting hole
and rotate adjuster screw st ar wheel to ret ract
brakeshoes.
(5) Remove brake drum.
(6) Inspect brakelining for wear, alignment, or ev-
idence of leakage from axle or wheel cylinder.
BRAKESHOE REMOVAL
(1) Remove rear wheel and drum.
(2) Remove shoe r et ur n springs with Tool C-3785
(Fig. 2).
SHOE
RETURN
SPRI NG
SPECIAL TOOL
(REMOVI NG A N D
INSTALLING)
SHOE TO SHOE
SPRI NG
LEVER
SPRI NG
ADJUSTI NG
LEVER R H2 2 5 A
Fig. 2 Removing/Installing Shoe Return Springs
(3) Remove adjuster cable. Slide cable eye off an-
chor pin and remove cable from adjuster lever.
(4) Remove cable guide from secondary shoe and
remove anchor plate from anchor pin.
(5) Remove adjuster lever. Disengage lever from
spring by sliding lever forward to clear pivot and
work lever out from under spring.
(6) Remove adjuster lever spring from pivot.
(7) Disengage and remove shoe spring from brake-
shoes.
BRAKES 5 - 47
(8) Disengage and remove adjuster screw assembly
from brakeshoes.
(9) Remove brake shoe ret ai ners, springs and pins
with Tool C-4070, (Fig. 3).
Fig. 3 Removing/Installing Shoe Retainers, Springs
and Pins
(10) Remove secondary brakeshoe from support
plate.
(11) Remove st rut and ant i r at t l e spring (Fig. 4).
Fig. 4 Removing/Installing Strut And Spring
(12) Remove parki ng brake lever from secondary
shoe.
(13) Remove pri mary shoe from support plate.
(14) Disengage parki ng brake lever from parki ng
brake cable.
Clean t he brake components, including t he support
plate and wheel cylinder exterior, with a wat er
dampened cloth or wi t h Mopar brake cleaner. Do not
use any other cleaning agents and do not use com-
pressed air to remove dirt and dust.
Replace t he brakeshoes if worn to within 1.5 mm
(1/16 in.) of t he rivet heads or if bonded lining is less
t han 4 mm (3/16 in.) thick. Exami ne t he lining con-
t act pat t ern to det ermi ne if t he shoes are bent or t he
drum is tapered. The lining should exhibit contact
across t he ent i re width. Shoes exhibiting contact only
on one side should be replaced and t he drum checked
for runout or taper.
Clean and inspect t he adjuster screw assembly. Re-
place t he assembly if t he star wheel t hreads are
damaged, or t he components are severely rusted or
corroded.
Discard t he brake springs and ret ai ner components
if worn distorted, or collapsed. Also replace t he
springs if a brake drag condition had occurred. Over-
heat i ng will distort and weaken t he springs.
Inspect t he brakeshoe contact surfaces on t he sup-
port pl at e (Fig. 5). Remove light rust and scale from
these surfaces with 180 grit emery cloth or sandpa-
per. However, replace t he support plate if any of t he
contact surfaces are worn or rusted through. Also re-
place t he plate if it is bent or distorted.
Fig. 5 Shoe Contact Surfaces
BRAKE SHOE INSTALLATION
(1) Lubricate anchor pin and brakeshoe contact
pads on support plate (Fig. 5) with Mopar multi-pur-
pose, or high t emperat ure grease.
(2) Lubricate adjuster screw socket, nut , button
and screw t hread surfaces with Mopar multi purpose,
or high t emperat ure grease.
(3) At t ach parki ng brake cable to lever. Then con-
nect lever to secondary shoe.
(4) Install pri mary shoe on support plate. Secure
shoe wi t h new spring ret ai ners and pin (Fig. 6).
(5) Install spring on parki ng brake st rut and en-
gage st rut in pri mary shoe (Fig. 6).
(6) Install secondary shoe on support plate (Fig. 6).
Insert st rut in shoe and guide shoe onto anchor pin.
Temporarily secure shoe with ret ai ni ng pin.
(7) Install anchor plate and adjuster cable eyelet
on support plate anchor pin.
5 - 48 BRAKES

Fig. 6 Brakeshoe Installation
(8) Install cable guide in secondary shoe and posi-
tion cable in guide.
(9) Assemble adjuster screw (Fig. 7). Then install
and engage adjuster screw in brakeshoes.
CAUTI ON : Be sur e the adj uster sc r ews are in-
stal l ed on the correct brake unit. The adj uster
sc r ews are mar ked L (left) and R (right) for identifi-
cati on ( F i g. 8).
' WASHER SOCKET STAMPED LETTER
BUTTON NUT RH227A
Fig. 7 Adjuster Screw Components
(10) Install adjuster lever and spring and connect
adjuster cable to lever.
(11) Install secondary shoe ret ai ners and spring.
(12) Install shoe spring. Connect spring to second-
ary shoe first. Then to pri mary shoe.
(13) Verify adjuster operation. Pull adjuster cable
upward. Cable should lift lever and rot at e st art
wheel. Be sure adjuster lever properly engages st ar t
wheel teeth.
(14) Adjust brakeshoes to drum with brake gauge.
Refer to Service Adjustments section for procedure.
BRAKE DRUM INSPECTION AND REFINISHING
BRAKE DRUM REFINISHING
The brake drums can be resurfaced on a drum
l at he when necessary. Initial machi ni ng cuts should
be limited to 0.12 - 0.20 mm (0.005 - 0.008 in) at a
time as heavier feed rat es can produce t aper and sur-
face variation. Fi nal finish cuts of 0.025 to 0.038 mm
(0.001 to 0.0015 in.) are recommended and will gen-
erally provide the best surface finish.
Be sure t he drum is securely mounted in t he l at he
before machining operations. A damper st rap should
always be used around t he drum to reduce vibration
and avoid chatter marks.
BRAKE DRUM REFINISH LIMITS
The maxi mum allowable diameter of t he drum
braki ng surface is stamped or cast into t he drum
outer edge (Fig. 8). Generally, a drum can be ma-
chined to a maxi mum of 1.52 mm (0.060 in.) oversize.
Always replace t he drum if machining would cause
drum diameter to exceed indicated size limit.
Fig. 8 Location Of Brake Drum Maximum Allowable
Diameter
BRAKE DRUM RUNOUT
Measure drum diameter and runout with an accu-
rat e gauge. The most accurate method of measure-
ment involves mount i ng t he driim in a brake l at he
and checking variation and runout with a dial indi-
cator. Variations in drum diameter should not exceed
0.076 mm (0.003 in.). Drum runout should not exceed
0.20 mm (0.008 in.) out of round. Refinish t he drum
if runout or variation exceed these values.
BRAKE DRUM INSTALLATION
(1) Clean drum with Mopar brake cleaning solvent
or with a soap and wat er solution only. Do not use
any other cleaning agents and do not use compressed
air to remove dirt and dust.

BRAKES 5 - 49
(2) Adjust brake shoes to drum wi t h a brake
gauge.
(3) Install and secure drum to wheel studs with
new ret ai ni ng nuts/clips.
(4) Install rubber access plugs in support plate if
removed.
(5) Install wheel and t i re.
BRAKE SUPPORT PLATE REMOVAL
(1) Remove wheel and t i re and brake drum.
(2) Remove axle shaft and retainer. Refer to Group
3 for procedures.
(3) Remove pri mary brakeshoe for access to park-
ing brake cable if necessary.
(4) Compress parki ng brake cable ret ai ner tabs
with a hose clamp (Fig. 9). Then push ret ai ner and
cable t hrough and out of support plate.
AIRCRAFT TYPE
HOSE CLAMP
RB763
Fig. 9 Removing Parking Brake Cable From Support
Plate
(5) Disconnect brake line at wheel cylinder.
(6) Remove wheel cylinder and brakeshoes from
support plate.
(7) Remove bolts at t achi ng support plate to axle
and remove support plate.
BRAKE SUPPORT PLATE INSTALLATION
(1) If new support plate is being installed, apply
bead of Mopar silicone sealer around wheel cylinder
mount i ng surface. Then transfer wheel cylinder to
new support plate.
(2) Apply bead of Mopar silicone sealer around
axle mount i ng surface of support plate.
(3) Install support pl at e on axle flange. Ti ght en at-
taching bolts to 47-68 N-m (35-50 ft. lbs.).
(4) Install parki ng brake cable in support plate.
(5) Install axle shaft and ret ai ner.
(6) St art brakeline in wheel cylinder and install
cylinder on support pl at e. Tighten brakel i ne fitting
after cylinder installation.
(7) Connect parki ng brake cable to lever on sec-
ondary shoe and install brakeshoes on support plate.
(8) Adjust brakeshoes to drum with br ake gauge.
(9) Install brake drum and wheel and t i re.
(10) Bleed br ake system.
WHEEL CYLINDER REMOVAL
(1) Raise vehicle and remove wheel and brake
drum.
(2) Disconnect wheel cylinder brakeline.
(3) Remove brakeshoe r et ur n springs and move
shoes out of engagement with cylinder push rods.
(4) Remove cylinder at t achi ng bolts and remove
cylinder from support plate.
WHEEL CYLINDER OVERHAUL
WHEEL CYLINDER DISASSEMBLY
(1) Remove push rods and boots (Fig. 10).
(2) Press pistons, cups and spring and expander
out of cylinder bore.
(3) Remove bleed screw.
SPRI NG
CYLINDER
PISTON
CUP
CUP
EXPANDERS
BOOT
PISTON '
BLEED SCREW PUSH ROD ' J9005-66
Fig. 10 Wheel Cylinder Components
Clean t he cylinder and pistons with fresh br ake
fluid or brake cleaner only. Do not use any other
cleaning agents. Dry t he cylinder and pistons with
compressed air. Do not use rags or shop towels to dry
t he cylinder components. Lint from such mat eri al s
can adhere to t he cylinder bores and pistons.
Inspect t he cylinder bore. Light discoloration and
dark st ai ns in t he bore are normal and will not im-
pair cylinder operation. If desired, t he bore can be
lightly polished but only with crocus cloth. Replace
t he cylinder if t he bore is scored, pitted or heavily
corroded. Honing t he bore to restore the surface is
not recommended.
Inspect t he cylinder pistons. The piston surfaces
should be smooth and free of scratches, scoring and
corrosion. Replace the pistons if worn, scored, or cor-
roded. Do at t empt to restore t he surface by sandi ng
or polishing.
5 - 50 BRAKES

Discard t he old piston cups and t he spring and ex-
pander. These part s are not reusable. The original
dust boots may be reused but only if t hey are in good
condition.
ASSEMBLING WHEEL CYLINDER
(1) Lubricate wheel cylinder bore, pistons, piston
cups and spring and expander wi t h clean brake fluid.
(2) Install first piston in cylinder bore. Then in-
stall cup in bore and agai nst piston. Be s ur e l i p of
pi ston cup is faci ng i nward (toward spri ng and
expander) and flat si de i s agai nst piston.
(3) Install spring and expanders followed by re-
mai ni ng piston cup and piston.
(4) Install boots on each end of cylinder and insert
push rods in boots.
(5) Install cylinder bleed screw.
WHEEL CYLINDER INSTALLATION
(1) Apply bead of Mopar silicone sealer around cyl-
inder mount i ng surface of support plate.
(2) Connect brake line to cylinder. Mount cylinder
on support plate and install cylinder at t achi ng bolts.
(3) Install wheel brake components.
(4) Install brake drum and wheel and bleed
brakes.
DRUM BRAKESTWELVE INCH
INDEX
page
Brake Drum Installation 54
Brake Drum Removal 52
Brake Drum Service 54
Brake Shoe Installation 53
Brakeshoe Removal 52
Cleaning and Inspection 52
GENERAL INFORMATION
Twelve inch rear drum brakes are used on D and
W 250/350 models (Fig. 1). All applications are dual
shoe, i nt ernal expanding uni t s with a self adjusting
mechanism. A single wheel cylinder is used to ex-
page
Support Plate Installation 55
Support Plate Removal 55
Wheel Cylinder Installation 55
Wheel Cylinder Overhaul . . . . . . . . . . . . . . . . . . . 54
Wheel Cylinder Removal . 54
pand t he dual brakeshoes. The lower ends of t he
brake shoes are connected by a st ar wheel adjuster
screw which is part of t he self adjusting mechanism
(Fig. 1).
SHOE HOLD-
DOWN PIN
WH EEL CYLI NDER
PRI MARY S HOE
UPPER
S HOE - TO- S HOE S PR I NG
SHOE
HO L D - D O WN S PR I NG
LOWER- SHOE- TO- SHOE
S PR I NG
ANTI -RATTLE S PR I NG
FLAT WASHER
A N C HO R BOLT
WHEEL CYLI NDER BOLTS
ADJUS TI NG
HOLE COVER
A N C HO R
BOLT
NUT
S HOE HOLD-
D O WN PIN
BA C K I N G PLATE
AUT OMAT I C ADJUSTER
CABLE
ADJUSTER LEVER
PI VOT PI N
S E C ONDAR Y SHOE
PA R K I N G
BRAKE LEVER
ADJUSTER LEVER
RETURN S PR I NG
AUT OMAT I C
ADJUSTER LEVER RN326A
Fig. 1 Twelve Inch Drum Brake Assembly
5 - 52 BRAKES

BRAKE DRUM REMOVAL
(2) Remove wheel and tire assembly.
(3) Remove axle shaft nut s, washers and cones.
Strike axle shaft in center with copper or dead blow
hammer to loosen ret ai ni ng cones.
(4) Remove axle shaft.
(5) Remove outer hub nut .
(6 ) St rai ght en and remove lock washer.
(7) Remove inner nut and bearing.
(8) Remove drum. If drum is difficult to remove,
ret ract brakeshoes as follows:
(a) Remove rear plug from access hole in support
plate.
(b) Insert a t hi n releasing tool (or screwdriver)
into access hole and push self adjusting lever away
from adjuster screw st ar wheel (Fig. 2).
(c) Insert t hi n screwdriver, or Tool C-3784 into
access hole and rot at e adjuster st ar wheel to re-
t ract brakeshoes (Fig. 2).
Fig. 2 Retracting Brakeshoes
(9) Remove brake drum.
(10) Inspect brakel i ni ng for wear, al i gnment , or
evidence of leakage from axle or wheel cylinder.
BRAKESHOE REMOVAL
(1) Unhook adjuster lever r et ur n spring from lever
(Fig. 1).
(2) Remove lever and r et ur n spring from lever
pivot pin (Fig. 1).
(3) Unhook adjuster lever from adjuster cable as-
sembly (Fig. 1).
(4) Remove shoe-to-shoe upper spring (Fig. 3).
(5) Remove shoe holddown springs (Fig. 4).
(6 ) Disconnect parki ng brake cable from parki ng
brake lever.
(7) Remove both brakeshoes, shoe-to-shoe lower
spring and adjuster nut as assembly (Fig. 5).
(8) If support plate or wheel cylinder are to be ser-
viced, remove anchor bolt and nut t hat at t aches
parki ng brake lever to support plate. Then remove
RK60A
Fig. 3 Removing/Installing Shoe-To-Shoe Upper
Spring
Fig. 4 Removing/Installing Shoe Holddown Springs
lever, washer, spring, cam plate, anchor bolt bushing
and adjuster cable (Fig. 1).
Clean t he brake components, including t he support
plate and wheel cylinder exterior, with a wat er
dampened cloth or with Mopar brake cleaner. Do not
use compressed air.
Replace t he brakeshoes if t he lining is worn to
within 1.5 mm (1/16 in.) of t he rivet heads or if
bonded lining is less t han 4 mm (3/16 in.) thick. Ex-
ami ne t he lining contact pat t ern to determine if t he
shoes are bent or t he drum is tapered. The lining
should exhibit contact across t he entire width. Shoes
exhibiting contact only on one side should be re-
placed and t he drum checked for runout or taper.

BRAKES 5 - 53
Fig. 5 Removing/installing Brakeshoes
Clean and inspect t he adjusting nut and pivot
screw assembly. Replace t he assembly if t he st ar
wheel t hreads on t he nut are damaged, or t he screw
are severely rusted or corroded.
Discard t he brake springs and ret ai ner components
if worn distorted, or collapsed. Also replace t he
springs if a brake drag condition had occurred. Over-
heat i ng will distort and weaken t he springs.
Inspect t he brakeshoe contact pads on t he support
plate (Fig. 6). Remove light rust and scale from t he
pads with fine sandpaper. However, replace t he sup-
port plate if any of t he pads are worn or rusted
through. Also replace t he plate if it is bent or dis-
torted.
Fig. 6 Support Plate Brakeshoe Contact Pads
BRAKE SHOE INSTALLATION
(1) If parki ng brake lever was removed, install an-
chor bolt bushing, cam plate, lever, spring, washer
and anchor bolt and nut (Fig. 1).
(2) Coat contact pads on support plate (Fig. 6) with
Mopar high t emperat ure grease, or equivalent,
(3) If both sets of brakeshoes were removed, verify
t hat adjusting nut s are installed on correct side of
vehicle. Pivot screw and adjusting nut have left hand
t hreads on left side brake assembly and ri ght hand
t hreads on ri ght side assembly.
(4) Lubricate and assemble adjusting nut and pivot
screw.
(5) Assemble adjusting nut , shoe-to-shoe lower
spring and both brakeshoes. Then position t he as-
sembled components on t he support plate.
(6) Install brakeshoe holddown springs and pins
(Fig. 4). Be sure holddown pins are seated in support
plate and springs are connected as shown (Fig. 7).
SH OE HOLD DOWN PIN
HOLD D OW N
SPRI NG
BACK I NG PLATE RN1064
Fig. 7 Holddown Spring And Pin Attachment
(7) Connect parki ng brake cable to parki ng brake
lever. Be sure cable end is properly secured in lever
(Fig. 8).
Fig. 8 Connecting Parking Brake Cable
(8) Install shoe-to-shoe upper spring (Fig. 3).
(9) Position adjuster lever ret urn spring on pivot.
(10) Install adjuster lever.
5 - 54 BRAKES

(11) Attach adjuster cable to adjuster lever. Be
sure cable is properly routed.
(12) Adjust brakeshoes to drum with brake gauge.
BRAKE DRUM INSTALLATION
(1) Position drum on axle housing.
(2) Install beari ng and i nner nut . Adjust beari ng
as described in Group 3.
(3) Install locking washer and outer nut . Bend
locking washer to secure it.
(4) Place new gasket on hub and install axle shaft,
cones, lock washers and nut s.
(5) Install wheel and t i re assembly.
(6) Remove support stands and lower vehicle.
BRAKE DRUM SERVICE
BRAKE DRUM REFINISHING
The brake drums can be resurfaced on a drum
lathe when necessary. Initial machining cuts should
be limited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a
time as heavier feed rat es can produce t aper and sur-
face variation. Fi nal finish cuts of 0.025 to 0.38 mm
(0.001 to 0.0015 in) are recommended and will gen-
erally provide t he best surface finish.
Be sure t he drum is securely mounted in t he l at he
before machi ni ng operations. A damper st rap should
always be used around t he drum to reduce vibration
and avoid chat t er marks.
BRAKE DRUM REFINISH LIMITS
The maxi mum allowable diameter of t he drum
braki ng surface is stamped or cast into t he drum
outer edge (Fig. 9). Generally, a drum can be ma-
chined to a maxi mum of 1.5 mm (0.060 in.) oversize.
Always replace t he drum if machining would cause
drum diameter to exceed indicated size limit.
BRAKE DRUM RUNOUT
Measure drum diameter and runout with an accu-
rat e gauge. The most accurate method of measure-
ment involves mount i ng t he drum in a brake l at he
and checking variation and runout with a dial indi-
cator.
Variations in drum diameter should not exceed
0.076 mm (0.003 in). Drum runout should not exceed
0.20 mm (0.008 in.) out of round. Refinish t he drum
if runout or variation exceed these values.
WHEEL CYLINDER REMOVAL
(2) Remove brake drum and brakeshoes as de-
scribed in t hi s section.
(3) Remove anchor bolt and nut and remove
washer, spring, parki ng brake lever, adjuster cable,
cam plate and anchor pin bushing.
(4) Loosen brakel i ne at wheel cylinder.
(5) Remove wheel cylinder bolts.
Fig. 9 Location Of Brake Drum Maximum Allowable
Diameter
(6) Disconnect brakeline and remove wheel cylin-
der.
WHEEL CYLINDER OVERHAUL
WHEEL CYLINDER DISASSEMBLY
(1) Remove push rods and boots (Fig. 10).
(2) Press pistons, cups and spring and expander
from cylinder bore.
(3) Remove bleed screw.
Fig. 10 Wheel Cylinder Components
Clean t he cylinder and pistons with clean brake
fluid or brake cleaner only. Do not use any other
cleaning agents. Dry t he cylinder and pistons with
compressed air. Do not use rags or shop towels to dry
t he cylinder components. Lint from such mat eri al s
can adhere to t he cylinder bores and pistons.

BRAKES 5 - 55
Inspect t he cylinder bore. Light discoloration and
dark st ai ns in t he bore are normal and will not im-
pair cylinder operation. If desired, t he bore can be
lightly polished but only wi t h crocus cloth. Replace
t he cylinder if t he bore is scored, pitted or heavily
corroded. Honing t he bore to restore t he surface is
not recommended.
Inspect t he cylinder pistons. The piston surfaces
should be smooth and free of scratches, scoring and
corrosion. Replace t he pistons if worn, scored, or cor-
roded. Do at t empt to restore t he surface by sanding
or polishing.
Discard t he old piston cups and t he spring and ex-
pander. These part s are not reusable. The original
dust boots may be reused but only if they are in good
condition.
ASSEMBLING WHEEL CYLINDER
(1) Lubricate wheel cylinder bore, pistons, piston
cups and spring and expander wi t h ^clean brake fluid.
(2) Inst al l first piston in cylinder bore. Then in-
stall cup in bore and agai nst piston. Be s ur e l i p of
pi st on c u p is f aci ng i n wa r d ( t owar d s pr i ng a n d
expander ) a nd flat si de is agai ns t pi st on.
(3) Install spring and expanders followed by re-
mai ni ng piston cup and piston.
(4) Install boots on each end of cylinder and insert
push rods in boots.
(5) Install cylinder bleed screw.
WHEEL CYLINDER INSTALLATION
(1) St art brakeline into cylinder.
(2) Position cylinder on support plate and install
cylinder at t achi ng bolts.
(3) Tighten brakel i ne fitting and cylinder attach-
ing bolts.
(4) Install anchor pin bushing, cam plate, adjuster
cable, parki ng br ake lever, spring washer and anchor
bolt and nut .
(5) Install brakeshoes and brake drum as described
in t hi s section.
(6) Install axle shaft.
(7) Install wheel and t i re.
(8) Remove supports and lower vehicle.
SUPPORT PLATE REMOVAL
(2) Remove wheel and tire.
(3) Remove axle shaft.
(4) Remove brake drum, brake shoes and wheel
cylinder as described in t hi s section.
(5) Remove bolts/nuts at t achi ng support pl at e to
axle and remove support plate.
SUPPORT PLATE INSTALLATION
(1) Transfer wheel cylinder and parki ng brake le-
ver components to replacement support plate.
(2) Position support plate on axle and install at-
taching bolts/nuts.
(3) Lubricate shoe contact surfaces of support plate
with Mopar multi-purpose, or high t emperat ure bear-
ing grease.
(4) Install brakeshoes. Adjust shoes to drum with
brake gauge.
(5) Install brake drum.
(6) Install axle shaft.
(7) Install wheel and tire.
(8) Remove supports and lower vehicle.
5 - 56 BRAKES

PARKING BRAKES
GENERAL INFORMATION
The parki ng brake mechani sm on AD models is a
t hree cable system operated by a foot pedal assembly
(Figs. 1 and 2).
The foot pedal is mounted on t he driver side cowl
panel. The front cable is at t ached to t he pedal assem-
bly. An i nt ermedi at e cable connects t he front cable to
t he rear cables. An equalizer and ratio lever connect
t he r ear cables to t he i nt ermedi at e cable. The rear
cables are connected to t he secondary brakeshoes by
a lever attached to each shoe.
PARKING BRAKE CABLE ADJUSTMENT
(1) Adjust r ear drum brakes before adjusting park-
ing brake cables.
(2) Release parki ng brakes fully.
(3) Raise vehicle.
(4) Loosen adjusting nut on front cable unt i l t here
is slack in all cables.
(5) Rotate r ear wheels and t i ght en cable adjusting
nut unt i l slight drag is created at wheels.
(6 ) Continue rot at i ng rear wheels and loosen cable
adjusting nut unt i l all drag is eliminated.
(7) Back off cable adjusting nut an additional two
full t ur ns.
(8) Apply parki ng brake several times.
(9) Release parki ng brakes. Then verify t hat rear
wheels rot at e freely wi t h no evidence of drag.
(10) Lower vehicle.
REAR CABLE REPLACEMENT
REAR CABLE REMOVAL
(1) Release parki ng brakes fully.
(2) Raise vehicle.
(3) Remove adjusting nut from front cable.
(4) Remove r ear wheels.
(5) Remove brake drums.
(6 ) Remove brakeshoes and parki ng brake st rut
and spring.
(7) Disconnect cable from parki ng brake lever on
secondary brakeshoe.
(8) Compress cable ret ai ner t abs and remove cable
from support plate.
(9) Remove cable from guides and ret ai ni ng clips.
(10) Disconnect cable from equalizer and rat i o le-
ver.
(11) Remove cable.
REAR CABLE INSTALLATION
(1) Insert cable t hrough support plate hole and
seat cable.
(2) Connect cable to lever on secondary brakeshoe.
(3) Install brakeshoes, parki ng brake st rut and
spring, shoe r et ur n and holddown springs and self
adjuster components.
(4 ) Install cable in cable guide and install cable re-
t ai ni ng clips, if equipped.
(5) Connect cable to ratio lever and equalizer.
(6 ) Adjust rear brakes and install brake drum and
wheel.
(7) Adjust parki ng brake cable.
FRONT CABLE REPLACEMENT
FRONT CABLE REMOVAL
(1) Remove front cable adjusting nut .
(2) Remove clip securing cable to anchor bracket
and slide cable out of bracket.
(3) Remove ret ai ner at t achi ng cable to pedal as-
sembly frame.
(4 ) Disengage cable from pedal clevis.
(5) Remove cable grommet (or seal) from floor pan.
(6 ) Remove front cable.
FRONT CABLE INSTALLATION
(1) Insert cable t hrough floor pan.
(2) Connect cable to pedal clevis and install cable
ret ai ner.
(3) Seat cable grommet (or seal) in floorpan.
(4 ) Route cable to anchor bracket and i nt ermedi at e
cable.
(5) Secure cable in anchor bracket with U-clip.
(6 ) Connect cable to adjusting link and install ca-
ble adjusting nut .
(7) Adjust r ear brakeshoes, if necessary.
(8) Adjust parki ng brake cable as described in t hi s
section.
INTERMEDIATE CABLE REPLACEMENT
(1) Remove adjusting nut from front cable.
(2) Disengage i nt ermedi at e cable from ratio lever
or cable equalizer.
(3) Remove cable.
(4 ) Connect new cable to ratio lever or cable equal-
izer.
(5) Connect cable to adjusting link.
(6 ) Insert front cable in adjusting link and install
cable adjusting nut .
(7) Adjust brakeshoes if necessary.
(8) Adjust parki ng brake cable as described in t hi s
section.

BRAKES 5 - 57
PAGE 1 OF 2 RR05E103
i - i 8 BRAKES
CABLE INTERMEDIATE BRACKET BOLT
VIEW E
Fig. 2 Parking Brake Cable Attachment

BRAKES 5 - 59
REAR WH EEL ANTILOCK (RWAL) BRAKES
page
Antilock Component Service 6 3
Antilock Service Di agnosi s 6 2
Checki ng Speed Sensor Air Gap . . . . . . . . . . . . . 6 4
Clearing A Fault Code . . . . . . . . . . . . . . . . . . . . . 6 3
Electronic Control Module Replacement . . . . . . . . 6 4
Fault Code Capacity 6 2
Fault Code Identification 6 2
page
Hydraulic V al ve Replacement 6 3
Speed Sensor Replacement . . . . . . . . . . . . . . . . 6 4
System Components . . . . . . . . . . . . . . . . . . . . . . 59
System Fault Codes . . . . . . . . . . . . . . . . . . . . . . 6 2
System Operation 6 1
GENERAL INFORMATION
A rear wheel antilock brake system is st andard
equipment on all AD models. It is an electronically
operated system designed to ret ard rear wheel lockup
duri ng periods of high wheel slip and deceleration.
Retarding lockup is accomplished by modulating
fluid pressure to t he rear brake uni t s.
Rear brake fluid apply pressure is modulated ac-
cording to wheel speed, degree of wheel slip and rat e
of deceleration. A sensor located in t he rear axle
housing converts differential rot at i ng speed into elec-
tronic signals. The signals are t ransmi t t ed to t he
electronic brake control module for processing. The
control uni t determines rat e of deceleration and
wheel slip from these signals.
SYSTEM COMPONENTS
Basic system components include an electronic
brake control module, a hydraulic pressure control
valve, a speed sensor and exciter ri ng and an anti-
lock warni ng lamp (Fig. 1).
A standard master cylinder and vacuum power
brake booster are used for all applications.
ANTILOCK ELECTRONIC CONTROL MODULE
The electronic module controls all phases of anti-
lock mode brake operation. The module is separate
from other electrical circuits in t he vehicle and oper-
ates independently.
The module is located on t he passenger side cowl
panel under t he dash (Fig. 2) . The system hydraulic
valve, speed sensor and indicator lamps are all in cir-
SPEED
S E NS OR
EXCITER
R I NG
j 3l a
RWAL
ELECTRONIC
CONTROL
MODULE
AXLE
HOU S I N G
HYDRAULIC
VALVE
J9005-96
Fig. 1 Rear Wheel Antilock Brake System (RWAL)
5 - 60 BRAKES
Fig. 2 Antilock Electronic Control Module
RWAL HYDRAULIC VALVE
The hydraulic valve is a pressure controlling device
and is operated by t he electronic module. The valve
controls fluid apply pressure to t he r ear brake uni t s
duri ng antilock mode braki ng (Fig. 3). The valve is
mounted on t he driver side frame rail at t he front of
t he vehicle.
The valve contains an accumulator, an isolation
valve and a dump valve. The accumulator is operated
by fluid and spring pressure. The two valves are op-
erated by electrical solenoids. The solenoids are oper-
ated by t he antilock control module.
The hydraulic valve components are inactive dur-
ing periods of normal braki ng effort. The valve com-
ponents are activated only when braki ng effort and
rat e of wheel slip and deceleration are hi gh (antilock
mode).
Duri ng normal braki ng t he valve allows free flow
of brake fluid to t he rear brake uni t s. In antilock
mode, t he valve will decrease, hold or increase fluid
apply pressure as needed.

CONNECTOR J9005-99
Fig. 3 RWAL Hydraulic Valve
SPEED SENSOR AND EXCITER RING
A single pole, variable reluctance speed sensor is
used to t ransmi t speed and rat e of deceleration in-
put s to t he control module (Fig. 4). The sensor is ac-
t uat ed by an exiter ring on t he differential case.
The sensor is mounted at t he top of t he rear axle
housing directly over t he gear-type exiter ri ng (Fig.
1). The exciter ring is pressed onto t he differential
case next to t he ring gear.
The exciter ri ng is t he sensor trigger mechanism.
As t he ring rotates, t he t eet h on the ri ng will inter-
rupt t he magnetic field around the sensor pole. The
rat e of interruption is converted into speed signals
which are t ransmi t t ed to t he control module.
Fig. 4 RWAL Speed Sensor
ANTILOCK INDICATOR LAMP
The amber colored indicator lamp is located in t he
i nst rument panel. The lamp alerts t he driver if a sys-
t em fault occurs.
The antilock and brake warni ng lamps are both in
circuit with t he electronic module. The module will
cuit with t he module. The module contains a micro-
processor t hat operates t he system and performs
system diagnostic checks.
Speed sensor i nput s are continuously monitored
and interpreted by t he module. The module deter-
mines wheel speed and rat e of deceleration from
these i nput s and activates t he appropriate solenoid
in t he hydraulic valve when necessary.
The module microprocessor also contains a self test
program. The program is activated when t he ignition
switch is t urned to t he On position. In t hi s mode, t he
module checks indicator light operation, t he system
electrical circuits and t he pressure limiting valve so-
lenoids.
The brake warni ng and antilock indicator lamps
are illuminated for approximately two seconds dur-
ing t he system self test cycle.

BRAKES 5 - 61
cause t he two lamps to i l l umi nat e or flash to al ert
t he driver t hat system operation is either normal or
t hat a fault has occurred.
SYSTEM OPERATION
During light brake applications, rear wheel decel-
eration and/or slip is not sufficient to activate t he an-
tilock system. Brake fluid apply pressure at t he rear
wheels is normal. However, when braki ng effort, de-
gree of wheel slip and rat e of deceleration approach
programmed limits, sensor i nput s will cause t he
module to activate t he system.
Normal Braking Mode
In normal braki ng mode, t he hydraulic valve com-
ponents are inactive. The isolation valve is open and
t he dump valve and accumulator are closed. Fluid
flows unimpeded t hrough t he isolation valve directly
to t he rear wheel cylinders (Fig. 5).
ACCUMULATOR CLOSED
ACCUMULATOR CLOSED
0\ m
m
0 UUb F t
L
DUMP
VALVE
CLOSED
SPRING
ISOLATION
VALVE
OPEN
FROM
MASTER
CYLINDER
TO REAR BRAKES
J9005-93
Fig. 5 Valve Position And Fluid Flow-Normal
Braking
Start Of Antilock Mode Braking
When high pedal effort braki ng occurs, t he de-
crease in exiter wheel rot at i ng speed is converted
into an electronic signal by t he sensor. This signal is
t ransmi t t ed to and processed by, t he control module.
The module determines t hat acceptable limits of
wheel slip/deceleration are about to be exceeded. The
module activates t he hydraulic valve at this point.
The control module t ransmi t s a signal to the isola-
tor valve solenoid which closes t he valve (Fig. 6 ).
Closing t he valve prevents further fluid flow to t he
rear wheel cylinders. This action isolates t he rear
brakes from the mast er cylinder. The net effect is to
decrease rear brake apply pressure to t he point
where t he wheels will continue to rotate and not
lock.
Additional Pressure Relief During Antilock Mode Braking
The dump valve and accumulator are hydraulically
connected and serve as additional pressure limiting
ISOLATION
VALVE
CLOSED
FROM
MASTER
CYLINDER
DUMP
VALVE
CLOSED
TO REAR BRAKES
J9005-94
Fig. 6 Valve Position And Fluid Flow At Start Of
Anti-Lock Mode Braking
devices. The accumulator and dump valve remai n
closed duri ng initial closing of the isolation valve.
However, if pressure exerted by fluid captured in t he
wheel cylinders and lines is high enough to lock t he
wheels, t he dump valve and accumulator are acti-
vated (Fig. 7).
When captured fluid pressure is high, t he control
module opens t he dump valve (Fig. 7). Since t he
dump valve is connected to t he accumulator, a por-
tion of t he captured fluid is diverted t hrough t he
valve and into t he accumulator. The amount of fluid
diverted is sufficient to reduce apply pressure to an-
tilock levels.
When rear brake pressure requi rement s ret urn to
normal levels, t he accumulator spring closes t he ac-
cumulator. Fluid in t he accumulator is forced out
and back into t he hydraulic system.
ACCUMULATOR
OPEN
DUMP
VALVE
OPEN
ISOLATION
VALVE
CLOSED
FROM
MASTER
CYLINDER
FROM REAR BRAKES TO ACCUMULATOR
J9005-95
Fig. 7 Dump Valve And Accumulator Position In
Pressure Relief Mode
i - 62 BRAKES

Isolation/Dump Valve Cycle Times
Activation (opening/closing) of t he isolation and
dump valves is continuous duri ng antilock operation.
The valves cycle rapidly in response to speed sensor
inputs and control module signal commands. Cycle
times are measured in milliseconds.
As t he demand for antilock mode brake operation
is decreased, t he module deactivates t he hydraulic
valve components to restore normal brake operation.
ANTILOCK SERVICE DIAGNOSIS
GENERAL INFORMATION
An antilock system malfunction will be indicated
by illumination of t he amber antilock warni ng lamp.
The red brake warni ng lamp may also illuminate.
If a problem occurs, system diagnosis should begin
with a fluid level check followed by a visual exami-
nation of t he system electrical and hydraulic connec-
tions. If obvious defects (low fluid, leaks, loose
connections, etc.) are not evident, road test t he vehi-
cle. A road test should help determine if a malfunc-
tion is actually related to an antilock component.
Duri ng t he road test, note if other conditions are
evident such as a low pedal, pull, grab, or similar
condition. Remember t hat brake malfunctions such
as low fluid, system leaks, parki ng brakes partially
applied, will also affect t he antilock system. The idea
is to determine if a malfunction is actually related to
an anti-lock component.
If a road test does reveal a problem, repeat t he
road test with t he owner driving. Make sure t he
owner is not riding t he brake pedal, or has forgotten
to release t he parki ng brakes. Ei t her situation will
generate a fault and cause t he antilock light to illu-
mi nat e.
SYSTEM FAULT CODES
The antilock control module generat es flash codes
to help identify t he cause of an antilock system fault.
Two different control modules are used with t he
1992/1993 RWAL system. A type I module is used in
some early production models. All remai ni ng produc-
tion models are equipped wi t h a type II module.
The type I and II modules are identified by t he way
fault codes 9 and 11 are processed. If t he vehicle has
a type I module, codes 9 and 11 are not erased when
t he ignition switch is t urned to Off position. If t he
vehicle has a type II module, codes 9 and 11 are
erased when t he switch is t urned to Off.
FAULT CODES WITH TYPE I CONTROL
MODULE
The microprocessor in t he electronic control module
has a memory and a self t est feature. The self test
feature is activated whenever t he ignition switch is
t urned to Accessory or Run position.
If a system fault is detected, t he control module il-
l umi nat es t he antilock light and stores t he fault code
in memory. Faul t codes are retained in memory even
after t urni ng t he ignition switch to Off position.
FAULT CODES WITH TYPE II CONTROL
MODULE
The microprocessor in t he electronic control module
has a memory and a self test feature. The self test
feature is activated whenever t he ignition switch is
t urned to Accessory or Run position.
If a system fault is detected, t he control module
will illuminate t he antilock indicator lamp and store
fault codes 1 t hrough 8, 10 and 12 through 15 in t he
microprocessor memory. When one of these fault
codes is generated, t he control module will ret ai n t he
code after t he ignition switch is t urned to t he Off po-
sition.
When fault code 9 is generated, t he code only re-
mai ns in microprocessor memory while t he ignition
switch is in Run position. Turni ng t he ignition
switch to Off position erases fault code 9. However, if
t he problem still exists when t he switch is t urned
back to Run position, code 9 will reappear in memory
after 20 seconds and t he antilock light will illumi-
nat e once again.
When fault code 11 is generated, t he antilock light
will illuminate when vehicle speed exceeds approxi-
mately 60.35 km/h (37.5 mph). Code 11 only remai ns
in memory while t he ignition switch is in t he Run
position and t he fault is present.
When t he cause of a fault code 11 is corrected, t he
antilock light goes off. Code 11 is erased when t he ig-
nition switch is t urned to Off position. However, if
t he problem cause still exists when t he ignition
switch is t urned to Run position, code 11 will reap-
pear when vehicle speed exceeds approximately 60.35
km/h (37.5 mph).
FAULT CODE CAPACITY
The microprocessor memory will store and display
only one fault code at a time. The stored code can be
displayed by grounding t he RWAL diagnostic connec-
tor.
FAULT CODE IDENTIFICATION
To determine what t he fault code is, momentarily
ground t he RWAL diagnostic connector and count
t he number of times t he amber antilock lamp
flashes. Faul t codes and typical malfunctions are out-
lined in Figure 8. Note t hat when a fault code is gen-
erated, t he red brake warni ng lamp will also
i l l umi nat e.
The initial flash will be a long flash followed by a
number of short flashes. The long flash indicates t he
beginning of t he fault number sequence and t he
short flashes are a continuation of t hat sequence.

BRAKES 5 - 63
You must count the l ong flash al ong wi th the
short fl ashes for an accurate fault code count.
CLEARING A FAULT CODE
To clear a fault code, disconnect t he control module
connector or disconnect t he bat t ery for a mi ni mum of
five seconds. Duri ng system retest, wai t 30 seconds
to be sure t he fault code does not reappear.
FAULT
C O D E
N U M BE R T YPI C A L FAI L UR E DETECTED
1 Not used.
2 Open isolation valve wiring or bad control
module.
3 Open dump valve wiring or bad control
module.
4 Closed RWAL valve switch.
5 Over 16 dump pulses generated in 2WD
vehicles (disabled for 4WD).
6 Erratic speed sensor reading while rolling.
7 Electronic control module fuse pellet open,
isolation output missing, or valve wiring
shorted to ground.
8 Dump output missing or valve wiring 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.
J9005-101
Fig. 8 RWAL System Fault Codes
ANTILOCK COMPONENT SERVICE
The rear wheel antilock (RWAL) components are
serviced as assemblies only. The module, hydraul i c
control valve, speed sensor and exciter ri ng are not
repairable. These components must be replaced if di-
agnosis indicates a fault.
HYDRAULIC VALVE REPLACEMENT
VALVE REMOVAL
(1) Raise vehicle.
(2) Disconnect valve-to-sensor harness connector
(Fig. 9).
(3) Disconnect brake lines connecting hydraul i c
valve to rear brakes and to combination valve.
(4) Remove hydraulic valve at t achi ng screws and
remove valve from frame bracket (Fig. 9).
VALVE INSTALLATION
(1) St art brake lines in hydraulic valve.
(2) Position valve on frame bracket.
(3) Install and t i ght en valve at t achi ng nut s to
22-34 N-m (16-25 ft. lbs.) torque.
(4) Tighten valve brake lines.
(5) Bleed hydraulic valve and brakes. Refer to pro-
cedure in Service Adjustments section.
(6) Lower vehicle.
J 9005- 1 1 2
Fig. 9 RWAL Hydraulic Valve Attachment
5 - 64 BRAKES

Fig. 10 Checking
CHECKING SPEED SENSOR AIR GAP
(1) Remove sensor from differential.
(2) Measure and record distance from underside of
sensor flange to end of sensor pole piece (Fig. 10).
Distance should be 27.17 to 27.43 mm (1.07 to 1.08
in.). This measurement represents dimension B.
(3) Measure distance between sensor mount i ng
surface of differential case and t eet h at top of exciter
ri ng (Fig. 10). Distance should be 27.56 to 28.45 mm
(1.085 to 1.12 in,). This distance represents dimen-
sion A.
(4) Subtract dimension B from dimension A to de-
t ermi ne sensor air gap which is dimension C (Fig.
10).
(5) Air gap should be mi ni mum of 0.12 mm (0.005
in.) and a maxi mum of 1.27 mm (0.050 in.).
(6) If air gap is not wi t hi n stated limits, proceed
as follows:
(a) Replace sensor if dimension B is not wi t hi n
limits specified in step (2).
(b) Replace exciter wheel or repair differential if
dimension A is not within limits specified in step
(3).
(c) Replace sensor and exciter wheel if both com-
ponents are out of tolerance.
SPEED SENSOR REPLACEMENT
SENSOR REMOVAL
(2) Remove bolt securing sensor to differential
housing.
(3) Remove sensor shield and sensor from differen-
tial housing.
(4) Disconnect sensor wiring and remove sensor.
SENSOR INSTALLATION
(1) Connect wires to sensor. Be sure seal i s se-
curel y i n pl ace bet ween sensor and wi ri ng con-
nector.
(2) Install O-ring on sensor (if removed).
(3) Insert sensor in differential housing.
SENSOR FLANGE
DIMENSION A
- DIMENSION B
DIMENSION C
SENSOR POLE
PIECE 8905-34
Sensor Air Gap
(4) Install sensor shield.
(5) Install and t i ght en sensor at t achi ng bolt to
19-29 Nnn (170-230 in. lbs.).
(6) Lower vehicle.
ELECTRONIC CONTROL MODULE REPLACEMENT
The RWAL control module is at t he passenger side
of t he vehicle. On models wi t h A/C, t he module is at-
tached to t he dash panel near t he defroster duct and
resistor board (Fig. 11).
To remove t he module, remove t he at t achi ng
screws, disconnect t he module harness connector and
remove t he module. After installing t he new module,
t i ght en t he module at t achi ng screws to 2.3 Nm (21
in. lbs.) torque.
Fig. 11 Anti-Lock Control Module Mounting

S P E C I F I C A T I O N S
BRAKES 5 - 65
Description Torque Description Torque
Brake Booster Mounting Nuts 25 Nm (220 in. lbs.)
Brakeline/Brake Hose Fittings:
3/8 or 7/16 13-20 Nrn (115-175 in. lbs.)
1/2 or 9/16 15-23 Nm (140-200 in. lbs.)
Brake Pedal Shaft Retainer
Screw 4 Ntn (35 in. lbs.)
Caliper Adapter Mounting Bolts:
D150/250 149 Nm (110 ft. lbs.)
W150/250 203 Nm (150 ft. lbs.)
D250/350 (heavy duty) 216 Nrn (160 ft. lbs.)
W250/350 216 Nm (160 ft. lbs.)
Caliper-To-Brake Hose
Fitting Bolt 48 Nm (35 ft. lbs.)
Caliper Retainer and
Anti-Rattle Spring Screw 25 Nm (200 in. lbs.)
Caliper Retainer Screw
(keylock type) 20 Nm (15 ft. lbs.)
Master Cylinder
Mounting Nuts 19-26 Nm (170-230 in. lbs.)
RWAL Valve Bolts/Nuts 22-34 Nrn (16-25 ft. lbs.)
Rear Brake Support Plate
Bolts/Nuts:
7/16 101 Nm (75 ft. lbs.)
1/2 115 Nm (85 ft. lbs.)
Rear Brake Support Plate
Retainer Nut:
8-3/8 axle 44 Nm (33 ft. lbs.)
9-1/4 axle 47 N-m (35 ft. lbs.)
model 60/70 axle 115 N-m (85 ft. lbs.)
Wheel Cylinder
Mounting Bolts 15-25 Nm (130-230 in. lbs.)
Wheel Lug Nuts:
8-3/8 axle 142 Nm (105 ft. lbs.)
9-1/4 axle 142 Nrn (105 ft. lbs.)
model 60/70 axle coned nut 281 Nm (200 ft. lbs.)
model 60/70 flanged 5/8-18 nut. . 441 Nrn (325 ft. lbs.)
model 60/70 flanged 1-1/8 nut . . 644 Nrn (475 ft. lbs.)
J9205-44
CLUTCH 6 - 1
CLUTCH
CONTENTS
page
CLUTCH DIAGNOSIS 2
CLUTCH COMPONENTS
MECHANICAL COMPONENTS
The clutch mechanism in A D models with a gas or
diesel engine consists of a single, dry-type clutch disc
and a di aphragm style clutch cover. A hydraulic
linkage is used to engage/disengage t he clutch disc
and cover.
The transmission input shaft is supported in t he
crankshaft by a bearing. A sleeve type release bear-
ing is used to operate t he clutch cover pressure plate.
The release bearing is operated by a release fork in
the clutch housing. The fork pivots on a ball stud
mounted inside t he housing. The release fork is actu-
ated by a hydraulic slave cylinder mount ed in t he
housing. The slave cylinder is operated by a clutch
master cylinder mounted on t he dash panel. The cyl-
inder push rod is connected to the clutch pedal.
The clutch disc has cushion springs i n t he disc hub.
The clutch disc facing is riveted to t he hub. The fac-
ing is made from a non-asbestos mat eri al . The clutch
cover pressure plate is a di aphragm type wi t h a one-
piece spring and multiple release fingers. The pres-
sure plate release fingers are preset during
manufacture and are not adjustable.
A 265 mm clutch disc and cover are used in models
with a 3.9L engine. A 280 mm clutch disc and cover
are used in models with a 5.2L, or 5.9L engine.
A 330 mm clutch disc and cover are used in models
equipped with t he optional 5.9L Cummi ns diesel en-
gine. Some diesel models are also equipped with a
clutch pedal interlock switch. The switch is in circuit
with t he st art er relay and is actuated by t he clutch
pedal and push rod. The clutch pedal must be fully
depressed in order to st art t he engine.
HYDRAULIC LINKAGE COMPONENTS
The hydraulic linkage consists of a remote reser-
voir, clutch mast er cylinder, clutch slave cylinder
and interconnecting fluid lines.
The clutch mast er cylinder is connected to t he
clutch pedal and t he slave cylinder is connected to
t he clutch release fork. The mast er cylinder is
mounted on t he drivers' side of the dash panel adja-
cent to t he brake mast er cylinder.
page
CLUTCH SERVICE 11
CLUTCH LINKAGE FLUID
The clutch fluid reservoir, mast er cylinder, slave
cylinder and fluid lines are prefilled with fluid at t he
factory duri ng assembly operations.
The hydraulic system should not require additional
fluid under normal circumstances. In fact, the reser-
voir fluid level will actual l y i ncrease as normal
cl utch wear occurs. For this reason, it is impor-
tant to avoi d overfilling, or removi ng fluid from
the reservoir.
If inspection or diagnosis indicates additional fluid
may be needed, use Mopar brake fluid, or an equiv-
al ent meeting SAE and DOT st andards J1703 and
DOT 3. Do not use any other type of fluid.
CLUTCH COMPONENT LUBRICATION
Proper clutch component lubrication is important
to satisfactory operation. The correct lubricant and
not overlubricating are equally important. Apply rec-
ommended lubricant sparingly to avoid disc and pres-
sure plate contamination.
Clutch and transmission components requiring lu-
brication are:
pilot beari ng
release lever pivot ball stud
release lever contact surfaces
clutch disc hub splines
clutch pedal pivot shaft bore
clutch pedal bushings
input shaft splines
input shaft pilot hub
transmission front beari ng ret ai ner slide surface
Do not appl y grease to any part of the clutch
cover, or disc.
RECOMMENDED LUBRICANTS
Use Mopar multi-purpose grease for t he clutch
pedal bushings and pivot shaft. Use Mopar high tem-
perat ure grease (or equivalent) for all other lubrica-
tion requirements. Apply recommended amounts and
do not over lubricate.
6 - 2 CLUTCH

C L U T C H D I A G N O S I S
INDEX
page
Clutch Problem Causes , 2
General Di agnosi s Information 2
GENERAL DIAGNOSIS INFORMATION
Unless t he cause of a clutch problem is obvious, a
road test and component inspection will be required
for accurate diagnosis.
A road test will help determine the type of fault
while component inspection will identify t he problem
component.
Duri ng a road test, drive t he vehicle at normal
speeds. Shift t he transmission t hrough all gear
ranges and observe clutch action.
If chatter, grab, slip, or improper release is experi-
enced, remove and inspect t he clutch components.
However, if t he problem is noise or hard shifting,
further diagnosis is needed. The transmission or an-
other driveline component may actually be at fault.
Careful observation duri ng a road test will help
narrow t he problem area.
CLUTCH PROBLEM CAUSES
CONTAMINATION
Fluid contamination is one of t he more common
causes of clutch malfunctions. Oil, water, or clutch
fluid on t he clutch contact surfaces will result in
faulty operation. The usual result is chatter, slip, or
grab.
Duri ng inspection, note if any components are con-
t ami nat ed with oil, hydraulic fluid, or water/road
splash.
Oil contamination indicates a leak at either t he
rear mai n seal or transmission input shaft.
Oil leakage produces a residue of oil on t he hous-
ing interior and on t he clutch cover and flywheel.
Heat buildup caused by slippage between the cover,
disc and flywheel, can sometimes bake t he oil residue
onto t he components. The glaze-like residue ranges
in color from amber to black.
Road splash contamination means dirt and wat er
are ent eri ng t he clutch housing due to loose bolts,
housing cracks, vent openings, or t hrough t he slave
cylinder opening. Driving t hrough deep wat er pud-
dles can force water/road splash into t he housing
t hrough such openings.
An additional problem caused by wat er contamina-
tion and especially by st eam cleaning, involves
clutch disc sticking and poor release.
Wat er and st eam vapors can be absorbed by t he
clutch facing mat eri al . If t he vehicle sits idle for long
page
Inspection and Di agnosi s Charts 5
periods after wat er contamination, t he force exerted
by t he pressure plate may cause t he disc to bond it-
self to t he flywheel or pressure plate.
Frequently, t he only remedy for t he above condi-
tion is component replacement. To avoid t hi s prob-
lem, a vehicle should be driven as soon as possible to
heat and dry t he clutch components.
Clutch fluid leaks are from a loose or damaged
slave cylinder line or connection. However, clutch
fluid leaks will usually be noted and corrected before
severe contamination occurs.
CLUTCH MISALIGNMENT
Clutch components must be in proper alignment
with t he crankshaft and transmission i nput shaft.
Misalignment caused by excessive runout or warpage
of any clutch component will cause grab, chatter and
improper clutch release.
Flywheel Runout
Common causes of runout are heat warping, im-
proper machining, mounting t he flywheel on a dirty
crankshaft flange, incorrect bolt tightening, or im-
proper seating on t he crankshaft flange shoulder.
Very light scratches or surface roughness on t he
flywheel face can be cleaned up by scuff sanding with
180 grit emery cloth. However, if t he surface is
warped or severely scored, replace t he flywheel.
Do not machi ne the flywheel. The flywheel
face is manufactured wi th a uni que surface con-
tour. Machi ni ng woul d negate this feature and
coul d result in unsatisfactory operation.
Clean t he crankshaft flange before mounting t he
flywheel. Dirt and grease on the flange surface may
cock t he flywheel causing runout.
Use new bolts when remounting a flywheel and se-
cure t he bolts with Mopar Lock And Seal, or Loctite
242. Tighten flywheel bolts to specified torque only.
Overtightening could distort the flywheel hub caus-
ing runout.
Clutch Cover And Disc Runout
Check t he clutch disc before installation. Axial
(face) runout of a new disc should not exceed 0.5 mm
(0.020 in.). Measure runout about 6 mm (1/4 in.)
from t he outer edge of t he disc facing. Obtain an-
other disc if runout is excessive.

CLUTCH 6 - 3
Check condition of t he clutch before installation. A
warped cover or di aphragm spring will cause grab
and incomplete release or engagement .
Be careful when handl i ng t he cover and disc. Im-
pact can distort t he cover, di aphragm spring, release
fingers and t he hub of t he clutch disc.
Use an al i gnment tool when positioning t he disc on
the flywheel. The tool prevent s accidental misalign-
ment which could resul t i n cover distortion and disc
damage.
A frequent cause of clutch cover distortion (and
consequent misalignment) is improper bolt tighten-
ing. To avoid warping t he cover, t i ght en t he bolts al-
ternately (in a diagonal pat t ern) and evenly (2-3
t hreads at a time) to specified torque.
Clutch Housing Misalignment And Runout
Clutch housing al i gnment is i mport ant to proper
operation. The housing bore mai nt ai ns al i gnment be-
tween t he crankshaft and t ransmi ssi on input shaft.
Misalignment can cause noise, incomplete clutch
release and chatter. It can also resul t in premat ure
wear of t he pilot beari ng, cover release fingers and
clutch disc. In severe cases, mi sal i gnment can also
cause premat ure wear of t he t ransmi ssi on i nput
shaft and bearing.
Housing face mi sal i gnment is generally caused by
incorrect seating on t he engine or transmission, loose
housing bolts, missing al i gnment dowels or housing
damage. Infrequently, mi sal i gnment may also be
caused by housing mount i ng surfaces t hat are not
parallel.
If housing mi sal i gnment is suspected, housing bore
and face runout can be checked wi t h a dial indicator
as described in t he following two procedures:
MEASURING CLUTCH HOUSING BORE
RUNOUT
(1) Remove t he clutch housing and st rut .
(2) Remove t he clutch cover and disc.
(3) Replace one of t he flywheel bolts wi t h a 7/16-20
threaded rod t hat is 10 in. (25.4 cm) long (Fig. 1).
The rod will be used to mount t he dial indicator.
(4) Remove t he release fork from t he clutch hous-
ing.
(5) Reinstall t he clutch housing. Ti ght en t he hous-
ing bolts nearest t he al i gnment dowels first.
(6) Mount t he dial indicator on t he threaded rod
and position t he indicator plunger on t he surface of
the clutch housing bore (Fig. 2).
(7) Rotate t he crankshaft unt i l t he indicator
plunger is at t he top center of t he housing bore. Zero
the indicator at t hi s point.
(8) Rotate the crankshaft and record t he indicator
readings at eight points (45 apart ) around t he bore
(Fig. 3). Repeat t he measurement at least twice for
accuracy.
(9) Subtract each readi ng from t he one 180 oppo-
site to determine magni t ude and direction of runout.
Refer to Fi gure 3 and following example.
Bore runout example:
0.000 - (-0.007) = 0.007 in.
+ 0.002 - (-0.010) = 0.012 in.
+ 0.004 - (-0.005) = 0.009 in.
-0.001 - ( + 0.001) = -0.002 in. ( = 0.002 inch)
In t he above example, t he largest difference is
0.012 in. and is called t he total indicator reading
(TIR). This means t hat t he housing bore is offset
from t he crankshaft centerline by 0.006 in. (which is
1/2 of 0.012 in.).
On gas engines, t he acceptable maxi mum TIR for
housing bore runout is 0.010 inch. If measured TIR is
more t han 0.010 in. (as in t he example), bore runout
will have to be corrected with offset dowels. Offset
dowels are available in 0.007, 0.014 and 0.021 in.
sizes for t hi s purpose (Fig. 4). Refer to Correcting
Housing Bore Runout for dowel installation.
On diesel engi nes, the acceptabl e maxi mum
TIR for housi ng bore runout is 0.015 i nch. How-
ever, unl i ke gas engi nes, offset dowel s are not
available to correct runout on diesel engi nes. If
bore runout exceeds the stated maxi mum on a
diesel engi ne, it may be necessary to repl ace ei-
ther the cl utch housi ng, or transmi ssi on adapter
plate.
CORRECTING CLUTCH HOUSING BORE
RUNOUT (GAS ENGINE ONLY)
On gas engine vehicles, clutch housing bore runout
is corrected wi t h offset dowels. However, if bore
runout exceeds 0.015 in. TIR on a diesel equipped
model, t he clutch housing, or transmission adapter
plate may have to be replaced. Offset dowels are not
available for diesel models.
The dial indicator reads positive when t he plunger
moves inward (toward indicator) and negative when
it moves out ward (away from indicator). As a result,
t he lowest or most negative readi ng determines t he
direction of housing bore offset (runout).
In t he sample readings shown in Fi gure 3 and in
step (7) above, t he bore is offset toward t he 0.010
inch reading. To correct this, remove t he housing and
original dowels. Then install t he new offset dowels in
t he direction needed to center t he bore with t he
crankshaft centerline.
In t he example, TIR was 0.012 inch. The dowels
needed for correction would have an offset of 0.007
in. (Fig. 4).
Install t he dowels with t he slotted side facing out
so they can be t urned with a screwdriver. Then in-
stall t he housing, remount t he dial indicator and
check bore runout again. Rotate t he dowels unt i l t he
TIR is less t han 0.010 in. if necessary.
If a TIR of 0.053 in. or great er is encountered, it
may be necessary to replace t he clutch housing.
e - 4 CLUTCH

7/16 - 20 THREAD NUT
10 INCHES LONG
J9006-25
CLUTCH
HOU S I N G
BORE J9006-26
Fig. 2 Checking Clutch Housing Bore Runout
.000
CLUTCH
HOU S I N G
q r o e {Smm READINGS)
J 9
006- 27
Fig. 3 Housing Bore Measurement Points And
Sample Readings
MEASURING CLUTCH HOUSING FACE
RUNOUT (GAS AND DIESEL ENGINES)
(1) Reposition t he dial indicator plunger on t he
housing face (Fig. 5). Place t he indicator plunger at
t he ri m of t he housing bore as shown.
(2) Rotate t he crankshaft unt i l t he indicator
plunger is at t he 10 O'clock position on t he bore.
Then zero t he dial indicator.
SLOT SHOWS DIRECTION OFFSET
DOWEL
D O WE L S E L E C T I ON
TI R
V A L U E
OFFSET D O WE L
REQUIRED
0.011 -0 .0 21 inch 0.007 inch
0.022 - 0.035 inch 0.014 inch
0.036 - 0.052 inch 0.021 inch
J9206-7
Fig. 4 Housing Bore Alignment Dowel Selection
(3) Measure and record face runout at four points
90 apart around t he housing face (Fig. 6). Perform
t he measurement at least twice for accuracy.
(4) Subtract t he lowest reading from t he highest to
determine total runout. As an example, refer to t he
sample readings shown in Figure 6. If t he low read-
ing was mi nus 0 . 0 0 4 in. and t he highest readi ng was
pl us 0 . 0 0 9 in., total runout is actually 0 . 0 13 inch.
(5 ) Total allowable face runout is 0 . 0 10 inch. If
runout exceeds t hi s figure, runout will have to be
corrected. Refer to Correcting Clutch Housing Face
Runout.
CORRECTING CLUTCH HOUSING FACE
RUNOUT
Housing face runout , on gas or diesel engines, can
be corrected by installing shims between t he clutch
housing and transmission (Fig. 7) . The shims can be
made from shim stock or similar mat eri al s of t he re-
quired thickness.
As an example, assume t hat face runout is t he
same as shown in Figure 6 and in step (4) above. In
t hi s case, t hree shims will be needed. Shim thick-
nesses should be 0 . 0 0 9 in. (at t he 0 . 0 0 0 corner), 0 . 0 12
in. (at t he - 0 . 0 0 3 corner) and 0 . 0 13 in. (at t he - 0 . 0 0 4
corner).
After installing t he clutch assembly and housing,
t i ght en t he housing bolts nearest t he alignment dow-
els first.
Clutch housing preferred bolt torques are:
41 N-m ( 30 ft. lbs.) for 3/ 8 in. diameter bolts
68 Nnn ( 5 0 ft. lbs.) for 7/ 16 in. diameter bolts
47 N t h ( 35 ft. lbs.) for diesel clutch housing bolts
Duri ng final transmission installation, install t he
shims between t he clutch housing and transmission
at t he appropriate bolt locations.

CLUTCH 6 - 5
INDICATOR
PLUNGER
DIAL INDICATOR
CLUTCH
HOUSING
FACE
INDICATOR MOUNTING
STUD OR ROD J9006-29
Fig. 5 Measuring Clutch Housing Face Runout
+ .009
CLUTCH
HOUSING
FACE
CIRCLE
(AT RIM
OF BORE)
,004
(SAMPLE READINGS)
J9006-30
Fig. 6 Housing Face Measurement Points And
Sample Readings
INSTALLATION METHODS AND PARTS
USAGE
Distortion of clutch components duri ng installation
and the use of non-standard components are addi-
tional causes of clutch malfunction.
Improper clutch cover bolt t i ght eni ng can distort
the cover. The usual resul t is clutch grab, chat t er
CUT/DRILL
BOLT
HOLE
TO SIZE
SHIM
STOCK
MAKE SHIM
1-INCH
DIAMETER
J9006-31
Fig. 7 Housing Face Alignment Shims
and rapid wear. Tighten t he cover bolts as described
in t he Clutch Service section.
Improperly seated flywheels and clutch housings
are other causes of clutch failure. Improper seat i ng
will produce mi sal i gnment and subsequent clutch
problems.
Tighten t he clutch housing bolts to proper torque
before installing any st rut s. Also be sure t he align-
ment dowels are in place and seated in t he block and
housing beforehand.
The use of non-standard or low quality part s can
also lead to problems and wear. Use t he recom-
mended factory quality part s to avoid comebacks.
INSPECTION AND DIAGNOSIS CHARTS
The clutch inspection chart (Fig. 8) outlines items
to be checked before and during clutch installation.
Use t he chart as a check list to help avoid overlook-
ing potential problem sources duri ng service opera-
tions.
The diagnosis chart s describe common clutch prob-
lems, causes and correction. Faul t conditions are
listed at t he top of each chart. Conditions, causes and
corrective action are outlined in t he indicated col-
umns.
The chart s are provided as a convenient reference
when diagnosing faulty clutch operation.
6 - 6 CLUTCH
1 Check clutch housing bolts. Tighten if loose. Be sure
housing is fully seated on engine block.
2 Check flywheel condition. Scuff sand flywheel face
to remove glaze. Clean surface with a wax and
grease remover afterward. Replace flywheel if
severely scored, worn or cracked. Secure flywheel
with new bolts (if removed). Do not reuse old bolts.
Use Lock and Seal on bolts.
3 Tighten clutch cover bolts 2-3 threads at a time, alter-
nately and evenly (in a diagonal pattern) to specified
torque. Failure to do so could warp the cover.
4 Check release fork. Replace fork if distorted or worn.
Make sure ball stud and release bearing contact sur-
faces are lubricated.
5 Check release fork pivot. Be sure pivot is tight and
ball end is lubricated.
6 Transmission input shaft bearing will cause noise,
chatter, or improper release if damaged. Check con-
dition before installing transmission.
7 Inspect release bearing slide surface of trans, front
bearing retainer. Surface should be smooth, free of
nicks, scores. Replace retainer if necessary. Lubricate
slide surface before installing release bearing.
8 Check input shaft seal if clutch cover and disc were
oil covered. Replace seal if worn, or cut.
9 Do not replace release bearing unless actually faulty.
Replace bearing only if seized, noisy, or damaged.
10 Check clutch cover diaphragm spring and release
fingers. Replace cover if spring or fingers are bent,
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, or damaged. If clutch problems ocurred,
check runout, to be sure housing is square with
flywheel and transmission input shaft.
13 Verify that housing alignment dowels are in position
before installing housing.
14 Clean engine block surface before installing clutch
housing. Dirt, grime can produce misalignment.
15 Make sure side of clutch disc marked "flywheel side"
is toward flywheel.
16 Check rear main seal if clutch disc and cover were
oil covered. Replace seal if necessary.
17 Check crankshaft flange (if flywheel is removed). Be
sure flange is clean and flywheel bolt threads are
in good condition.
18 Check pilot bearing. Replace bearing if dam-
aged. Lube with high temp. Grease before in-
stallation.
19 Check transmission input shaft. Clutch disc must
slide freely on shaft splines. Lightly grease
splines before installation. Replace shaft if
splines or pilot bearing hub are damaged.
20 Check flywheel bolt torque. If bolts are loose,
replace them. Use Mopar Lock and Seal to secure
new bolts.
21 Check clutch disc facing. Replace disc if facing is
charred, scored, flaking off, or worn. Al so
check runout of new disc. Runout should not ex-
ceed 0.5 mm (0.02 in.).
J9206-9
Fig. 8 Clutch Inspection Points
CLUTCH 6 - 7
CLUTCH SLIPS
C ondi t i on F ound C a us e C or r ect i on
1. Disc facing worn out. a) Normal wear.
b) Driver frequently "r i des"
(slips) clutch. Results in rapid
wear overheating.
c) Insufficient clutch cover
di aphragm spring tension.
Replace clutch disc. Al so replace
cover if spring is weak or pressure
plate surface is damaged.
2. Clutch disc facing
contaminated with oil, grease,
or clutch fluid.
a) Leak at rear main seal or at
transmission input shaft seal.
b) Excessive amount of grease
applied to input shaft splines.
c) R oad spl ash, water entering
housing.
d) Sl ave cylinder leaking.
a) , b), c), d) Replace leaking
seals. A ppl y less grease to
input shaft splines. Replace
clutch disc (do not clean and
reuse). Cl ean clutch cover and
reuse only if cover is in good
condition. Replace slave
cylinder if leaking.
3. Clutch is running partially
di sengaged.
Release bearing sticking-binding.
Does not return to normal running
position.
Verify that bearing is actually
binding, then replace bearing 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 . Wr ong 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
di aphragm spring, warped,
distorted.
a) Rough handling (impact) bent
cover, spring, or disc.
b) Incorrect bolt tightening
sequence and method caused
warped cover.
Install new disc or cover as needed.
Follow installation/tightening
instructions.
7. Facing on flywheel side of disc
torn, gouged, worn.
Flywheel surface scored and nicked. Reduce scores and nicks by sanding
or surface grinding. Replace
flywheel if scores-nicks are deeper
than .0 0 2-.0 0 4 inch.
8. Clutch disc facing burnt
(charred). Flywheel and cover
pressure plate surfaces heavily
gl azed.
a) Frequent operation under high
l oads or hard acceleration
conditions.
b) Driver frequently "r i des"
(slips) clutch. Results in rapid
wear and overheating of disc
and cover.
Scuff sand flywheel. Replace clutch
cover and disc. Alert driver to
problem cause.
J90 0 6-21
6 - 8 CLUTCH
IMPROPER CLUTCH RELEASE
C ondi t i on Found C ause C or r ect i on
1. Clutch disc warped. New disc not checked for axial
runout before installation.
Replace disc. Be sure runout of new
disc is less than .5 mm (.020 in.).
2. Clutch disc binds on input
shaft splines.
a) Clutch disc hub splines
damaged during installation.
b) Input shaft splines rough,
damaged.
c) Corrosion, rust formations on
splines of disc and input shaft.
Cl ean, smooth and lubricate disc
and shaft spines. Replace disc
and/or input shaft if splines are
severely damaged.
3. Clutch disc rusted to flywheel
and/or pressure plate.
Occurs in vehicles stored, or not
driven for extended periods
of time. Al so occurs after steam
cleaning if vehicle is not used for
extended period.
Remove clutch cover and disc. S and
rusted surfaces clean with 180 grit
paper. Replace disc cover, and
flywheel if corrosion is severe.
4. Clutch disc facing sticks to
flywheel.
Vacuum may form 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
J
9
r
>t paper.
5 . Clutch disc too thick. Wrong disc installed. Replace disc.
6. Pilot bushing seized or loose. a) Bushing cocked during
installation.
b) Bushing defective.
c) Bushing not lubricated.
d) Clutch misalignment.
a) , b), c), d) Lubricate and install
new bushing. Check and
correct any misalignment.
7. Clutch will not di sengage
properly.
a) Low clutch fluid level.
b) Clutch cover loose.
c) Wrong clutch disc.
d) Disc bent, distorted during
installation.
e) Clutch cover di aphragm spring
bent or wraped during
transmission instalation.
f) Clutch disc installed
backwards.
g) Release fork bent or fork pivot
is loose or damaged.
h) Clutch master or slave cylinder
fault.
a) Top off reservoir and check for
leaks.
b) Tighten bolts.
| c) Install correct disc.
d) Repalce disc.
e) Replace cover.
f) Remove and reinstall disc
correctly. Be sure disc side
marked "to flywheel" is
actually toward flywheel.
g) Replace fork and pivot if worn
or damaged.
h) Replace master and slave
cylinder as assembly.
J90 0 6-22

CLUTCH 6 - 9
CLUTCH GRAB/CHATTER
Condition Found C ause
T
C or r ect i on
1. Clutch disc facing covered with
oil, grease, or clutch fluid.
a) Oil leak at rear main or input
shaft seal.
b) Too much grease applied to
splines or disc and input shaft.
a) Correct leak and replace disc
(do not clean and reuse the
disc).
b) A ppl y lighter grease coating
to splines and replace disc (do
not clean and reuse the disc).
2. Clutch disc and/or cover
warped, or disc facings exhibit
unusual wear or appear to be
wrong type.
Incorrect or substandard parts. Replace disc and/or cover with
correct parts.
3. Clutch master or slave cylinder
plunger draggi ng- bi ndi ng.
a) Master or slave cylinder
components worn or corroded.
a) Replace both cylinders as
assembly (and reservoir).
4. N o fault found with clutch
components.
a) Problem actually related to
suspension or driveline
component.
b) Engine related problem.
a) Further diagnosis required.
Check engine/transmission
mounts, propeller shafts and
U-joints, tires, suspension
attaching parts and other
driveline components as
needed.
b) Check EFI and igniton systems.
5 . Partial engagement of clutch
disc (one side worn-opposite
side gl azed and lightly worn).
a) Clutch pressure plate position
setting incorrect or modified.
b) Clutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly).
c) Clutch disc damaged or
distorted.
a) Replace clutch cover and disc.
b) Replace clutch cover and disc.
c) Replace disc.
d) Check alignment and runout of
flywheel, disc, or cover and/or
clutch housing. Correct as
necessary.
J90 0 6- 23
6- 1 0 CLUTCH

CLUTCH NOISE
Condition F ound Cause Correction
1. Clutch components damaged
or worn out prematurely.
Incorrect or sub-standard clutch
parts.
Replace with parts of correct type
and quality.
2. Pilot beari ng damaged. a) Bearing cocked during
installation.
b) Bearing not lubricated prior
to installation.
c) Bearing defect.
a), b), c) Replace beari ng.
Be sure it is properly
seated and lubricated
before installing clutch.
d) Check and correct
misalignment caused by
excessive runout of flywheel,
disc, cover or clutch housing.
Replace input shaft if bearing
hub is damaged.
3. Loose components. Attaching bolts loose at flywheel,
cover, or clutch housing.
Tighten bolts 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 l oad, 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 bearing defect.
c) Release bearing misaligned.
a) Replace clutch cover and
bearing.
b) Replace bearing.
c) Check and correct runout of
clutch components. Check front
bearing retainer sleeve surface.
Replace if damaged.
6. Release bearing is noisy. Release bearing defect. Replace bearing.
7. Clutch pedal squeak. a) Pivot pin loose.
b) Pedal bushings worn out or
cracked.
Tighten pivot pin. Replace bushings
if worn or damaged. Lubricate pin
and bushings with silicone base
lubricator chassis grease.
J9206-10

CLUTCH S - 11
CLUTCH SERVICE
INDEX
page
Clutch Cover and Di sc InstallationAll 11
Clutch Cover and Di sc Removal Al l . 11
Clutch H ousing Installation 13
Clutch H ousing Removal 12
Clutch Linkage Service 14
CLUTCH COVER AND DISC REMOVALALL
(1) Raise vehicle.
(2) Remove transmission and remove transfer case
if equipped. Refer to Group 21 for procedures.
(3) Remove clutch housing from engine.
(4) Support engine with wood block and adjustable
jack stand (Fig. 1). Supporting engine is necessary to
avoid undue strain on engine mount s.
Fig. 1 Supporting Engine With Jack Stand And
Wood Block (Diesel Model Shown)
(5) If clutch cover will be reused, mar k position of
cover on flywheel wi t h pai nt or scriber (Fig. 2).
(6 ) Insert clutch al i gnment tool in clutch disc and
into pilot bushing. Tool will hold disc in place when
cover bolts are removed.
(7) If clutch cover will be reused, loosen cover bolts
evenly, only few t hreads at a t i me, and in a diagonal
pat t ern (Fig. 3). This relieves cover spring tension
evenly to avoid warping.
(8) Remove cover bolts completely and remove
cover, disc and al i gnment tool.
CLUTCH COVER AND DISC INSTALLATION - ALL
(1) Check runout and free operation of new clutch
disc:
(a) Install disc on transmission i nput shaft
splines and check fit. Disc should slide freely on
splines.
page
Clutch Pedal Installation 17
Clutch Pedal Removal . 15
Flywheel Service . 17
Pilot Bearing Replacement 14
Rel ease Bearing Replacement 13
Fig. 2 Marking Clutch Cover Position
J9106-17
Fig. 3 Clutch Cover Bolt Loosening/Tightening
Pattern
(b) Leave disc on shaft and check disc runout
wi t h dial indicator.
6- 1 2 CLUTCH
(c) Position indicator plunger about 1/4 inch from
outer edge of disc facing.
(d) Runout should not exceed 0.5 mm (0.020 in.).
Obtain another clutch disc if runout exceeds t hi s
limit.
(2) Lubricate crankshaft pilot beari ng with Mopar
hi gh t emperat ure beari ng grease.
(3) Insert clutch alignment tool in clutch disc hub,
(4) Verify t hat clutch disc is positioned correctly.
Side of hub marked "Flywheel Side" should face fly-
wheel (Fig. 4). If disc is not marked, position raised
side of disc hub toward clutch cover and t ransmi s-
sion.
CLUTCH
DISC
"FLYWHEEL SIDE"
STAMPED ON
THIS SURFACE
J9006-33
Fig. 4 Clutch Disc Position (Typical)
(5) Insert alignment tool in pilot beari ng and posi-
tion disc on flywheel surface (Fig. 5).
(6) Position clutch cover over disc and onto fly-
wheel (Fig. 5).
CLUTCH COVER
AND DISC
CLUTCH DISC
ALIGNMENT TOOL
FLYWHEEL.
J9106-18
Fig. 5 Clutch Disc And Cower Alignment/installation
(7) Align and hold clutch cover in position and in-
stall cover bolts finger tight.
(8) Ti ght en cover bolts evenly and a few t hreads at
a t i me. Cover bol t s mus t be t i ght ened evenl y a n d
t o speci fi ed t or que to avoi d di s t or t i ng cover .
Ti ght en 5/16 in. diameter bolts to 23 N-m (17 ft.
lbs.)
Tighten 3/8 in. diameter bolts to 41 N-m (30 ft.
lbs.).
(9) Remove release lever and release bearing from
clutch housing. Apply Mopar high t emperat ure bear-
ing grease to bore of release bearing, release lever
contact surfaces and release lever pivot stud (Fig. 6).
CLUTCH
HOUSING
COAT
RELEASE
FORK PI VOT
BALL STUD
WITH
HI GH TEMP.
GREASE
RELEASE
FORK
(HI GH TEMP.
GREASE)
LUBE
POI NTS
(HI GH TEMP.
GREASE)
APPLY LIGHT COAT
HI GH TEMP. GREASE
TO RELEASE BEARI NG
BORE
LUBE
POI NTS
J9106-19
Fig. 6 Clutch Release Component Lubrication
Points
(10) Apply light coat of Mopar high t emperat ure
beari ng grease to splines of transmission i nput shaft
and to release beari ng slide surface of transmission
front beari ng ret ai ner (Fig. 7). Do not overlubri-
cate shaft splines. Grease contami nati on of disc
will result.
(11) Install release lever and beari ng in clutch
housing.
(12) Install clutch housing (Figs. 8 and 9). Be sure
housing is properly seated on al i gnment dowels be-
fore t i ght eni ng housing bolts.
(13) Install transmission/transfer case.
(14) Check fluid level in clutch mast er cylinder.
transmission and
CLUTCH HOUSING REMOVAL
(1) Raise vehicle and remove
transfer case if equipped.
(2) Remove clutch housing bolts and remove hous-
ing from engine (Figs. 8 and 9).
(3) Clean housing mount i ng surface of engine
block wi t h wax and grease remover.

CLUTCH 6 - 13
APPLY LIGHT COAT OF
HI-TEMP GREASE TO THESE
SURFACES BEFORE INSTALLATION J9106-15
Fig. 7 Input Shaft Lubrication Points (Typical)
ENGINE BLOCK CLUTCH DISC AND COVER
J9006-32
Fig. 8 Clutch Housing InstallationGas Engine
(4) Verify t hat clutch housing alignment dowels
are in good condition and properly seated.
(5) Transfer slave cylinder, release fork and boot,
fork pivot stud and wire/hose brackets to new hous-
ing.
CLUTCH HOUSING INSTALLATION
(1) Lubricate release fork and pivot contact sur-
faces with Mopar Hi gh Temperat ure wheel bearing
grease before installation.
Fig. 9 Clutch Housing/Transmission
InstallationDiesel Engine
(2) Align and install clutch housing on t ransmi s-
sion. Tighten housing bolts closest to al i gnment dow-
els first and to torque values indicated (Figs. 8 and
9).
(3) Install transmission-to-engine st rut after in-
stalling clutch housing. Tighten bolt at t achi ng st rut
to clutch housing first and engine bolt last.
(4) Install transmission and transfer case if
equipped. Refer to procedure in Group 21.
RELEASE BEARING REPLACEMENT
(1) Remove transmission.
(2) On models wi t h gas engine and new style re-
lease fork, remove clutch housing for access to re-
lease fork, pivot stud and release beari ng ret ai ner
springs.
(3) Disconnect release bearing from release fork
and remove beari ng (Fig. 10).
(4) Inspect beari ng slide surface on transmission
front beari ng ret ai ner. Replace ret ai ner if slide sur-
face is scored, worn or cracked.
(5) Inspect release lever and pivot stud. Be sure
stud is secure and in good condition. Be sure lever is
not distorted or worn. Replace release lever ret ai ner
spring if bent or damaged.
(6) Lubricate crankshaft pilot bearing, i nput shaft
splines, beari ng ret ai ner slide surface, lever pivot
ball stud and release lever pivot surface wi t h Mopar
hi gh t emperat ure bearing grease.
(7) Install release lever and release bearing. Be
sure lever and beari ng are properly secured.
(8) Install clutch housing, if removed.
6 - 14 CLUTCH
(9) Install transmission. Also install transfer case
on 4-wheel drive models.
Fig. 10 Clutch Release Fork And Bearing
PILOT BEARING REPLACEMENT
(1) Remove transmission and clutch housing.
(2) Remove clutch cover and disc.
(3) Remove pilot bearing. Use blind hole puller
tools such as those included in Snap-On set CG40CB
to remove bearing.
(4) Clean beari ng bore wi t h solvent and wipe dry
with shop towel.
(5) Install new beari ng with clutch al i gnment tool
(Fig. 11). Keep beari ng st rai ght duri ng installation.
Do not allow beari ng to become cocked. Tap beari ng
into place unt i l flush with edge of beari ng bore. Do
not recess bearing.
BEARING SEAL
MUST FACE
J9206-8
Fig. 11 Typical Method Of Installing Pilot Bearing
(6) Lubricate beari ng with Mopar high tempera-
t ure grease, or an equivalent quality grease.
(7) Install clutch cover and disc.
(8) Install clutch housing, transmission and t rans-
fer case on 4-wheel drive models.
CLUTCH LINKAGE SERVICE
The cl utch master cylinder, remote reservoir,
sl ave cylinder and connecti ng l i nes are all ser-
vi ced as an assembl y. These components cannot
be servi ced separately. The l i nkage cyl i nders
and connecti ng lines are seal ed units. They are
prefilled wi th fluid duri ng manufacture and
must not be di sassembl ed nor di sconnected.
LINKAGE REMOVAL
(1) Raise vehicle.
(2) On diesel models, remove slave cylinder shield
from clutch housing (Fig. 12).
Fig. 12 Slave Cylinder ShieldDiesel Models
(3) Remove nut s at t achi ng slave cylinder to studs
on clutch housing flange.
(4) Remove slave cylinder from clutch housing
(Fig. 13).
(5) Disengage slave cylinder fluid line from under-
vehicle ret ai ner clips.
(6) Lower vehicle.
(7) On diesel models, disconnect clutch pedal inter-
lock switch wires.
(8) Carefully remove locating clip from clutch mas-
t er cylinder mounting bracket (Fig. 14).
(9) Remove ret ai ni ng ring, flat washer and wave
washer t hat at t ach clutch mast er cylinder push rod
to clutch pedal (Fig. 14).

CLUTCH 6 - 15
Fig. 13 Slave Cylinder Removal/Installation
(10) Slide clutch mast er cylinder push rod off pedal
pin.
(11) Inspect condition of bushi ng on clutch pedal
pin. Remove and replace bushi ng if worn or dam-
aged.
(12) Verify t hat cap on clutch mast er cylinder res-
ervoir is tight. This will avoid spillage duri ng re-
moval.
(13) Remove screws t hat at t ach clutch fluid reser-
voir to dash panel.
(14) If necessary, remove reservoir mount i ng
bracket screws and remove bracket from dash panel.
(15) remove clutch mast er cylinder rubber seal
from dash panel (Fig. 14).
(16) Rotate clutch mast er cylinder 45 counter-
clockwise to unlock it. Then remove cylinder from
dash panel.
(17) Remove clutch cylinders, reservoir and con-
necting lines from vehicle.
LINKAGE INSTALLATION
(1) Tighten cap on clutch fluid reservoir to avoid
spillage duri ng installation.
(2) Position cylinders, connecting lines and reser-
voir in vehicle.
(3) Insert clutch master cylinder in dash panel. Ro-
t at e cylinder 45 clockwise to lock it in place.
(4) Lubricate mast er cylinder rubber seal with liq-
uid dish soap to ease installation. Then seat seal in
dash and around cylinder. Unlock cylinder to install
seal if necessary. Then relock cylinder after seal in-
stallation.
(5) Position clutch fluid reservoir on dash panel
and install reservoir screws. Ti ght en screws to 5 Nm
(6) Install reservoir mount i ng bracket on dash
panel, if removed.
(7) Install replacement bushi ng on clutch pedal pin
if necessary.
(8) Install clutch mast er cylinder push rod on
clutch pedal pin. Secure rod with wave washer, flat
washer and ret ai ner ring.
(9) On diesel models, disconnect clutch interlock
st ar t switch wires.
(10) Install locating clip in clutch mast er cylinder
mount i ng bracket.
(11) Raise vehicle.
(12) Install slave cylinder. Be sure cap at end of
cylinder rod is seated in release lever. Check this be-
fore installing cylinder at t achi ng nut s.
(13) Install and t i ght en cylinder at t achi ng nut s to
23 N*m (200 in. lbs.) torque.
(14) Lower vehicle.
(15) If new linkage has been installed, remove
plastic shipping stop from mast er cylinder push rod.
Do t hi s after installing slave cylinder and before op-
erat i ng linkage.
(16) Operate linkage several t i mes to verify proper
operation.
CLUTCH PEDAL REMOVAL
(1) Remove ret ai ni ng ring, flat washer and wave
washer t hat secure clutch mast er cylinder push rod
to clutch pedal pin (Fig. 14).
(2) Remove fastener t hat secure pedal shaft to
pedal support.
(3) Slide pedal shaft out left side of pedal support
and out of clutch pedal.
(4) Slide push rod off clutch pedal pin and remove
clutch pedal.
(5) Remove and inspect bushi ngs in clutch pedal
shaft bore and on bushi ng on pedal pin. Replace any
bushi ng t hat is worn or damaged.
en
PEDAL
SUPPORT
CYLINDER
FLUID
RESERVOIR
PEDAL
SHIFT
CLUTCH FLUID LINE
(DIESEL ENGI NE)
CLUTCH FLUID LINE
(GAS ENGI NE)
SLAVE
CYLINDER
O
I
e
HI
O
x
CLUTCH
HOUS I NG
WITH
G A S
ENGI NE
CLUTCH
HOUS I NG SLAVE
CYLINDER
WITH
DIESEL
ENGI NE
SHIELD
J9206-1
Fig. 14 Clutch Linkage And Pedal Components

CLUTCH 6- 17
CLUTCH PEDAL INSTALLATION
(1) Lubricate pedal shaft, pedal shaft bore and all
bushings with Mopar Multi Mileage grease.
(2) Insert pedal pin into cylinder push rod. Then
position clutch pedal in support.
(3) Slide pedal shaft t hrough clutch pedal bore and
bushings.
(4) Install bolt t hat ret ai ns pedal shaft in support.
(5) Secure push rod to pedal pin wi t h wave washer,
flat washer and ret ai ni ng ring.
FLYWHEEL SERVICE
Inspect t he flywheel whenever t he clutch disc,
cover and housing are removed for service. Check
condition of t he flywheel face, hub, r i ng gear teeth,
and flywheel bolts.
Minor scratches, burrs, or glazing on t he flywheel
face can be scuff sanded with 180 grit emery cloth.
However, t he flywheel should be replaced if t he disc
contact surface is severely scored, heat checked,
cracked, or obviously worn.
Cleanup of minor flywheel scoring should be per-
formed with surface grinding equipment. Remove
only enough mat eri al to reduce scoring (approximate-
ly 0.001 - 0.003 in.). Heavy stock removal is not rec-
ommended. Replace t he flywheel if scoring is severe
and deeper t han 0.076 mm (0.003 in.). Excessive
stock removal can result in flywheel cracking or
warpage after installation; it can also weaken t he
flywheel and interfere with proper clutch release.
Check flywheel runout if mi sal i gnment is sus-
pected. Runout should not exceed 0.08 mm (0.003
in.). Measure runout at t he outer edge of t he fly-
wheel face with a dial indicator. Mount t he dial in-
dicator on a stud installed in place of one of t he
flywheel at t achi ng bolts.
Clean t he crankshaft flange before mount i ng t he
flywheel. Dirt and grease on t he flange surface may
cock t he flywheel causing excessive runout .
Check condition of t he flywheel hub and at t achi ng
bolts. Replace the flywheel if t he hub exhibits cracks
in t he area of t he at t achi ng bolt holes.
Install new at t achi ng bolts whenever t he flywheel
is replaced and use Mopar Lock N' Seal, or Loctite
242 on replacement bolt t hreads.
Recommended flywheel bolt torques are:
75 Nm (55 ft. lbs.) for gas engine flywheels
137 N*m (101 ft. lbs.) for diesel flywheels
Inspect t he t eet h on t he st art er ri ng gear. If the
teeth are worn or damaged, the fl ywheel shoul d
be repl aced as an assembl y. This is the recom-
mended and preferred method of repair.
In cases where a new flywheel is not readily avail-
able, a replacement r i ng gear can be installed. How-
ever, t he following precautions must be observed to
avoid damagi ng t he flywheel and replacement gear.
(a) Mark position of t he old gear for al i gnment
reference on t he flywheel. Use a scriber for t hi s
purpose.
(b) Wear protective goggles or approved safety
glasses. Also wear heat resistent gloves when han-
dling a heat ed ri ng gear.
(c) Remove t he old gear by cutting most of t he
way t hrough i t (at one point) with an abrasive cut-
off wheel. Then complete removal with a cold chisel
or punch.
(d) The ri ng gear is a shri nk fit on t he flywheel.
This means t he gear must be expanded by heat i ng
in order to install it. The method of heati ng and
expandi ng the gear is extremel y important. Ev-
ery surface of t he gear must be heated at t he same
time to produce uniform expansion. An oven or
similar enclosed heat i ng device must be used. Tem-
perat ure required for uniform expansion is
325-350 F.
C A U T I O N : Never use an oxy/acetylene torch to re-
move the ol d gear, or to heat and expand a new
gear. The hi gh temperature of the torch flame will
cause localized heating and damage the flywheel. I n
addition, usi ng the torch to heat a replacement gear
will cause uneven heating and expansi on. The torch
flame will al so anneal the gear teeth resulting in
rapid wear and damage after installation.
(e) The heat ed gear must be installed evenly to
avoid mi sal i gnment or distortion. A shop press and
suitable press plates should be used to install t he
gear if at all possible.
(f) Be sure to wear eye and hand protection.
Heat resistent gloves and safety goggles are needed
for personal safety. Also use met al tongs, vise
grips, or similar tools to position t he gear as neces-
sary for installation.
(g) Allow t he flywheel and ri ng gear to cool
down before installation. Set t he assembly on a
workbench and let it cool in normal shop air.
C A U T I O N : D o not use water, or compr essed air to
cool the flywheel. The rapid cool i ng produced by
water or compr essed air can distort, or crack the
gear and flywheel.
C O O L I N G S Y S T E M
CONTENTS
page
DIAGNOSIS . . . 4
ENGINE ACCESSORY DRIVE BELTS 40
ENGINE BLOCK HEATERS 48
GENERAL INFORMATION
Throughout this group, references are made to partic-
ular vehicle models by alphabetical designation or by
the particular vehicle nameplate. A chart showing a
breakdown of alphabetical designations is included in
the Introduction section at the beginning of this man-
ual.
5.9L gas powered engines will be' referred to as ei-
ther: LDC (Light Duty Cycle) or HDC (Heavy Duty
Cycle).
COOLING SYSTEM
The cooling system regulates engine operating tem-
perat ure. It allows t he engine to reach normal oper-
page
SERVICE PROCEDURES 15
SPECIFICATIONS ; 49
at i ng t emperat ure as quickly as possible. It also
mai nt ai ns normal operating t emperat ure and pre-
vents overheating.
The cooling system also provides a means of heat-
ing t he passenger compartment and cooling t he auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal wat er
pump to circulate coolant throughout t he system.
An optional factory installed maxi mum duty cool-
ing package is available on most models. This pack-
age will provide additional cooling capacity for
vehicles used under extreme conditions such as
t rai l er towing in high ambient t emperat ures.
N O T E : HE AT E R
C O O L A N T F L O W
C I R C U I T I S A L WA Y S
O PE N E XC E PT
WH E N I N M A X . A / C
O R O F F M O D E S
HE AT E R
I NTAKE MA N I F O L D
C O O L A N T FL OW "METERED"
FR OM REAR T O
FR ONT A N D BE L OW
EXHAUST HEAT
C R O S S O V E R
S HU T O F F V A L V E
A / C O N L Y
C O O L A N T FL OW - PUMP T O
CYLI NDER BLOCK, UP T HR OU GH
CYLI NDER HE A D S T O I NTAKE
MA N I F O L D WAT E R BOX T O
R A D I A T O R - T O PUMP
B Y P A S S
THERMOSTAT C L O S E D - H I G H FL OW
THERMOSTAT O PE N - L O W FL OW
J9207-18
Fig. 1 Cooling System Routing3.9U5.2L EngineTypical
7 - 2 COOLING SYSTEM

NOTE: HEATER
C OOL ANT FLOW
CIRCUIT IS AL WAYS
OPE N EXCEPT
WHE N I N M A X. A / C
OR OFF MO D E S
HEATER
INTAKE MANIFOLD
COOLANT FLOW "METERED"
FROM REAR TO
FRONT A N D BELOW
EXHAUST HEAT
CROSSOVER
SHUT OFF VALVE
A / C ONLY
COOLANT FLOW - PUMP TO
CYLINDER BLOCK, UP THROUGH
CYLINDER HEADS TO INTAKE
MANIFOLD WATER BOX TO
RADIATOR TO PUMP
BYPA S S
THERMOSTAT C L O S E D - HI G H FLOW
THERMOSTAT OPEN - LOW FLOW
CYLINDER HEAD
RR07B52
Fig. 2 Cooling System Routing5.9L (V-8 Gas)Typical
All vehicles are equipped wi t h either a 3.9L (V-6),
a 5.2L (V-8), a 5.9L (LDC-gas V-8), a 5.9L (HDC-gas
V-8) or a 5.9L (in-line 6 cylinder diesel) engine.
As coolant t emperat ure reaches approximately
220F, t he engine idle speed is increased by t he pow-
ert rai n control module (PCM) to provide increased
cooling system performance. The PCM was formerly
referred to as t he engine controller or SBEC.
COOLING SYSTEM COMPONENTSEXCEPT
DIESEL ENGINE
The cooling system consists of:
A down-flow radi at or
Thermal viscous fan drive
Fan shroud
Radiator pressure cap
Thermost at
Coolant reserve/overflow system
Transmission oil cooler (automatic transmission)
Coolant
Wat er pump (to circulate coolant)
Hoses and hose clamps
Coolant flow circuits for 3.9L (V-6) and 5.2L (V-8)
engines wi t h wat er cooled i nt ake manifolds are
shown in figure 1.
Coolant flow circuits for 5.9L (V-8 Gas) engines
with wat er cooled i nt ake manifolds are shown in fig-
ure 2.
COOLING SYSTEM COMPONE NTS- DI E SE L
ENGINE
Coolant flow circuits for 5.9L (diesel) engines with
wat er cooled i nt ake manifolds are shown in figure 3.
The cooling system (Fig. 3) consists of: a cross-flow
radiator, engine driven cooling fan, t hermal viscous
fan drive, fan shroud, radiator pressure cap, thermo-
stat, coolant reserve/overflow system, transmission
oil cooler (if equipped with an automatic t ransmi s-
sion), coolant, wat er pump, hoses and hose clamps.
SYSTEM COOLANT ROUTI NG- DI ESEL ENGINE
Coolant is drawn from radi at or into t he wat er
pump. Wat er pump output is directed to t he engine
oil cooler cavity of t he cylinder block (Fig. 4).
From t he oil cooler cavity, t he coolant circulates
around each cylinder. It t hen crosses to t he lift pump
side of engine where it flows up into cylinder head
t hrough openings in top of cylinder block (Fig. 4).
Coolant flows past t he valve bridges (Fig. 5), to ex-
haust manifold side of engine, to t hermost at . As cool-
ant flows toward t he t hermost at , it provides cooling
for t he injector nozzle.
When thermostat is closed (engine is below operating
temperature), coolant flows through bypass passage to
water pump inlet (Fig. 6). Once operating temperature
is reached, the thermostat opens and blocks the bypass
passage. Coolant then flows to the radiator inlet.

COOLING SYSTEM 7 - 3
Fig. 3 Diesel Engine Cooling System-Typical
1. Coolant Flow from Cylinder Block
2. C ool ant to Thermostat Housi ng
Fig. 4 Cylinder Block Coolant Routing-Diesel Engine
F i g 6
coolant Flow at Thermostat-Diesel Engine
DIAGNOSIS
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused t he com-
plaint. Abnormal loads on t he cooling system such as
t he following may be t he cause:
1. PROLONGED I DLE, VERY HI GH AMBI-
ENT TEMPERATURE, SLI GHT TAI L WI ND AT
I DLE, SLOW TRAFFI C, TRAFFI C J AMS, HI GH
SPEED OR STEEP GRADES.
Driving techniques t hat avoid overheating are:
Idle with A/C off when t emperat ure gauge is at
end of normal range.
* Increasing engine speed for more ai r flow is recom-
mended.
2. TRAI LER TOWI NG:
Consult Trai l er Towing section of owners manual .
Do not exceed limits.
3. AI R CONDI TI ONI NG; ADD-ON OR AFTER
MARKET:
A maxi mum cooling package should have been or-
dered wi t h vehicle if add-on or after mar ket A/C is
SYMPTOM AND ACTION
S Y M PT O M
installed. If not, maxi mum cooling system compo-
nent s should be installed for model involved per
manufacturer' s specifications.
4 . RECENT SERVI CE OR ACCI DENT RE-
PAI R:
Determine if any recent service has been performed
on vehicle t hat may effect cooling system. This may
be:
Engi ne adjustments (incorrect timing)
Slipping engine accessory drive belt(s)
Brakes (possibly dragging)
Changed part s. Incorrect wat er pump or pump ro-
t at i ng in wrong direction due to belt not correctly
routed
Reconditioned radiator or cooling system refilling
(possibly under filled or air trapped in system).
If investigation reveals none of t he above as a
cause for an engine overheating complaint, refer to
t he following Symptom and Action chart:
PRELIMINARY FIRST)
ACTION
Blinking Engine Temperature
Warning Light or High Gauge
indication - Without Coolant Loss
Normal during temporary operation with heavy load, towing a trailer, high
outdoor temperatures, and/or on a steep Loss grade.
Coolant Loss
Hot Vehicle (Not Engine)
Heat Damage,
Hot Carpet, Seat,
Hot Catalytic Converter,
Smoke, Burnt Odor
Hot Engine
Crackling Noise
Hot Smell
Severe Local Hot Spots
Coolant Color
Coolant Reserve Bottle
Level Changes
Coolant Not Returning
To Radiator
Improper refilling procedures can result in trapped air in the system. Subsequent
operation of the pressure cap and coolant reserve system will deaereate the
cooling system. A low coolant level will then result in the Coolant Reserve
Tank. Add coolant. If condition persists, refer to System Diagnosis.
Check heat shielding, exhaust system, engine emission controls, ignition
timing, engine misfiring.
A moderate amount of sound from heating metal can be expected with any
vehicle. However, a crackling sound from trie thermostat housing, a hot smell
and/or severe local hot spots on an engine can indicate blocked coolant
passages, bad castina, core sand deposits and subsequent blockage,
cracked cylinder block or head, or blown cylinder head gasket. Usually
accompanied with coolant loss.
Coolant color is not necessarily an indication of adequate temperature or
corrosion protection.
Level changes are to be expected as coolant volume fluctuates with engine
temperature. If the level in the bottle is between the Maximum and Minimum
marks at normal engine operating temperature, the level should return to
within that range after operation at elevated temperatures.
Coolant will not return to the radiator if the radiator cap vent valve does not
function, if an air leak destroys vacuum, or if the overflow passage is
blocked or restricted. Inspect all portions of the overflow passage, pressure
cap, filler neck nipple, hose, and passages within the bottle for vacuum leak
only. Coolant return failure will be evident by a low level in the radiator.
Reserve bottle level should increase during heat-up.
J9207-31

COOLING SYSTEM DIAGNOSIS (EXCEPT DIESEL)
CONDI TI ON A N D C HI C K
OPTI ONAL M G A U G E READS LOW
(!) Verify gauge reading. Is a low temperature indicated?
(2) Is code 17 recorded in On Board Diagnostics memory?
(3) Is the gauge reading in the cold range?
(4) Low coolant level during cold ambient temperatures
(accompanied with poor heater performance).
(5) Coolant level is correct.
GAUGE HEADI NG HI GH. N O PRESSURE BLOW OFF FROM
RADIATOR PRESSURE C AP OR STEAM FROM COOLANT
RESERVE TANK.
(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.
DI AGNOS I S
30 TO 40
GAUGE TRAVEL
IS NORMAL
Normal Gauge Travel
(1) Inspect temperature gauge sending unit. Refer to Group 8,
Electrical. Repair or replace sending unit as necessary.
(2) If code 17 is recorded, replace the thermostat. If not, the
thermostat is not the cause of the low gauge reading.
(3) Inspect for disconnected sending unit electrical connector or
incorrect sending unit. Ensure that gauge sending unit is installed
and not an indicator light switch.
(4) WA R N I N G : DO NOT REMOVE THE RADIATOR CAP OF A
HOT, PRESSURIZ ED E NGI NE . SERI OUS I NJURY C A N
RESULT FROM SCALDI NG COOLANT.
Inspect coolant level in the coolant reserve tank and radiator.
Inspect system for leaks.
(5) Inspect heater door controls. Refer to Group 24, Heating and
Air Conditioning.
TO TOP AMBIENT
High Gauge Reading Hot Weather Heavy Load
(1) Compare gauge reading to High Gauge Reading Illustration
above.
(2) Inspect for grounded gauge, sending unit or circuit. Refer to
Group 8, Electrical.
(3) a Pill to full.
b Inspect for leaks in system and repair as necessary,
c Ensure radiator pressure cap was shut tight. Verify proper
operation of the radiator cap upper and lower seals.
(4) a Fill to full,
b Inspect for leaks in the system and repair as necessary,
c Inspect for leaks in the coolant reserve tank to radiator
hose.
d Verify proper operation of the radiator cap upper and
lower seals.
(5) a Adjust coolant solution to 50/50 mixture of anti-freeze and
water. Refer to Coolant in this group,
b If a reading is not recorded or below 50, the mixture is
too rich. Clean system and fill with a 50/50 mixture of
anti-freeze and water. Refer to Coolant in this group.
(6) a With the thermostat open and a slight amount of coolant
removed, inspect for coolant flow through the radiator at
the filler neck opening,
b Determine reason for lack of coolant flow and repair as
necessary.
J9007-69

COOLING SYSTEM DIAGNOSIS (EXCEPT DIESEL)CONTINUED
Condition and Checks Diagnosis
(7) Other possible causes. (7) a If symptom occurs during high speed operation inspect for
plugged air inlet side of the radiator or condenser,
plugged radiator core tubes, add on A/C package without
proper radiator, engine not operating within specifications,
dragging brakes, trailer towing or hill climbing, or an
insect screen.
b If symptom occurs during high or low speed operation
inspect for: thermostat being stuck partially open if ambient
temperature is below 70F and the vehicle has high
mileage, plugged air inlet side of the radiator or
condenser, add on A/C with incorrect radiator.
c If symptom occurs during low speed operation only, inspect
the radiator fan drive. Repair as necessary.
TEMPERATURE GAUGE READS HOT. PRESSURE CAP VENTS
RESULTING I N STEAM AND COOLANT TRANSFER TO
COOLANT RESERVE TANK.
(1) Coolant level low in radiator and coolant reserve tank. (1) a Fill cooling system and vent trapped air.
b Inspect for leaks. Repair as necessary.
c Ensure that pressure cap is completely shut and seals.
d If level is low in radiator but normal in the coolant reserve
tank, check the filler cap to coolant reserve bottle
connection and pressure cap seal.
(2) Test coolant freeze point. (2) Adjust coolant to 50/50 mix of anti-freeze and water. Refer to
Coolant section in this group.
(3) Ensure coolant is flowing through system. (3) a With the coolant level low and the thermostat open, check
for coolant flow through the radiator at the filler neck.
b If a metal cracking sound is heard, inspect for core sand
restricting coolant flow through the water jacket and/or a
faulty cylinder head casting.
(4) Thermostat stuck in the closed position (prevalent in cold ambient
temperatures).
(4) Replace thermostat if found to be stuck in closed position. Refer
to the Thermostat Testing section in this group.
(5) Cylinder head gasket leak. (5) Inspect for leaking cylinder head gasket with a commercially
available Block Leak Tester.
J9007-57

COOLING SYSTEM DIAGNOSIS (EXCEPT DIESELJ-GONTINUED
CONDITION AND CHECKS DIAGNOSIS
TEMPERATURE GA U GE IS I NCONSI STENT, CYCLES AND/OR IS
ERRATIC.
(1) Is cycle normal.
MID
(a) Normal Gauge Reaction to Thermostat Cycle.
MID
(b) Normal Gauge Reaction at Stop After Heavy Use.
(c) Hot Water Build-Up is Normal at Stop after Heavy Use.
(2) Is coolant in radiator low (air will build up in the cooling system (2) Fill system, vent trapped air and check for leaks,
and cause the thermostat to open late).
(3) Is a cylinder head gasket leak allowing exhaust gas to enter (3) a Test for leaking cylinder head gasket leak with a
cooling system (exhaust gas building up in the cooling system will commercially available Block Leak Tester,
cause the thermostat to open late).
b Check for coolant in engine oil.
c Inspect for white steam from exhaust system.
(4) Water pump impeller loose on shaft. Loose accessory drive belt. (4) Repair or replace as necessary.
(5) Air leak on the suction side of the water pump (allows air to build (5) Find leak and repair,
up in cooling system causing thermostat to open late).
WARNING LIGHT GLOWS ALL THE TIME (VEHICLE NOT
EQUIPPED WITH GAUGE).
(1) Inspect temperature gauge sending unit. The warning light sending (1) Ensure that a warning light sending unit is installed,
unit has a screwdriver slot in the electrode (used for calibration).
Gauge sending units do not have a slot in the electrode.
NO GAUGE READING INITIALLY THEN HOT INDICATION
(VEHICLE EQUIPPED WITH GAUGE).
(1) Gauge stationary until very hot, then moves immediately to "H" (1) Vehicle is equipped with sending unit for light not gauge.
J9007-70
Condition and Check Diagnosis
PRESSURE CAP VENTS TO ATMOSPHERE AND COOLANT
RESERVE TANK. TEMPERATURE GAUGE READING ABOVE
NORMAL BUT NOT HIGH.
(1) Test radiator pressure cap relief pressure. Refer to Radiator
Pressure cap section in this group.
(1) Replace cap if relief pressure is lower than 14 psi.
COOLANT LOSS VISIBLE ON GROUND BELOW VEHICLE, BUT
NO PRESSURE CAP BLOW OFF.
(1) Inspect system for leaks. (1) Repair as necessary.
COOLANT LOSS PAST PRESSURE CAP TOP SEAL, VISIBLE ON
RADIATOR FILLER NECK.
(1) With normal gauge reading. (1) a Pressure cap not installed tightly.
b Pressure cap top seal leaks.
c Pressure cap diaphragm bowed.
d Damaged radiator filler neck.
e Pressure cap top seal out of position.
(2) With high or low gauge reading on new vehicle. (2) a Kinked coolant reserve system hose.
b Coolant reserve system tank plastic tube plugged,
c Pressure cap seal out of position.
DETONATION OR PREIGNITION. NOT CAUSED BY IGNITION
OR ENGINE CONDITIONS.
(1) Check engine coolant freeze point. If the tester does not register
a reading or if the reading is below 50F, inspect ethylene-
glycol/water ratio. A 100 percent solution of ethylene-glycol in
the system causes the engine to run hotter and possibly overheat.
(1) a Adjust coolant solution to 50/50 water ethylene-glycol
mixture.
b If 100 percent ethylene-glycol solution is found in system,
clean and flush system before replacing with 50/50 mixture
of ethylene-glycol and water.
COOLING SYSTEM HOSES COLLAPSE ON COOLDOWN.
(1) Inspect pressure cap vent valve. (1) a Gasket swell can prevent valve from opening,
b Replace pressure cap.
(2) Coolant reserve tank hose plugged or kinked. (2) Repair as necessary.
(3) Inside of pressure cap plugged. (3) Clean cap or replace if necessary.
COOLING SYSTEM SUSPECTED AS CAUSE OF INADEQUATE
AIR CONDITIONING SYSTEM PERFORMANCE.
(1) Inspect for plugged radiator and/or condenser. (1) Clean with low pressure water from fan side.
(2) Inspect for missing air seals in the recirculating air path. (2) Repair as necessary.
EXCESSIVE FAN NOISE
(1) Inspect for loose or bent fan blades. (1) Replace fan.
(2) Inspect clearance between fan and adjacent part. (2) Repair or replace as necessary.
(3) Inspect radiator and condenser for incoming air obstructions. (3) Clean air path with low pressure water from fan side.
(4) Inspect viscous fan drive. (4) Replace if viscous drive does not operate properly.
HEAT ODOR
(1) Was temperature gauge reading high? (1) If YES, refer to GAUGE READING HIGH. If NO, refer to steps
2, 3, and 4.
(2) Are all heat shields in place? (2) If YES, refer to steps 3 and 4. If NO, repair as required.
(3) If the air side of the heat exchanger plugged? (3) Clean as necessary.
(4) Engine running rich causing catalytic converter to overheat. (4) Repair as necessary.
POOR DRIVEABIUTY. SUSPECT THERMOSTAT FAILED I N OPEN
POSITION.
(1) Check On-Board Diagnostics. Is code 17 set in memory? (1) If YES, replace thermostat. If NO, refer to the appropriate
Driveability Manual.
J9007-59

Condition and Chock D i agnosi s
POOR HEATER PERFORMANCE. SUSPECT
THERMOSTAT FAILED I N OPEN POSI TI ON.
(1) Does gauge read low? (1) If YES, replace thermostat. If N O , inspect the auxiliary heater
vacuum water valve. The valve should be open except when the
climate controls are OFF or in the M A X A/ C mode.
(2) Is coolant level low? (2) Fill cooling system and inspect for leaks. Repair as necessary.
(3) Check On-Board Diagnostics. Is code 17 set in memory? (3) If YES, replace thermostat. If N O , inspect the auxiliary heater
vacuum water valve. The valve should be open except when the
climate controls are OFF or in the MAX A / C mode.
J9007-61
7 - 1 0 COOLING SYSTEM

DIESEL COOLING SYSTEM DIAGNOSIS
CONDI TI ON A N D C HE C K S DI AGNOS I S
OPTI ONAL 60F GAUGE RE AD S LOW
30 T O 40
GAUGE TRAVEL
IS N O R M A L
(1) Verify gauge reading. Is a low temperature indicated?
(2) Thermostat stuck in open position?
(3) Is the gauge reading in the cold range?
(4) Low coolant level during cold ambient temperatures (accom-
panied with poor heater performance).
(5) Coolant level is correct.
M I D
Normal Gauge Travel
(1) Inspect temperature gauge sending unit. Refer to Group 8,
Electrical. Repair or replace sending unit as necessary.
(2) If Yes, replace the thermostat. If not, the thermostat is not the
cause of the low gauge reading.
(3) Inspect for disconnected sending unit electrical connector or
incorrect sending unit. Ensure that gauge sending unit is in-
stalled and not an indicator light switch.
(4) WARNI NG: DO NOT R E MOV E THE RADI ATOR C A P
OF A HOT, PR E S S U R I Z E D ENGI NE. S E R I O U S I N-
JURY C A N RESULT FROM S C AL DI NG COOLANT.
Inspect coolant level in the coolant reserve tank and radiator.
Inspect system for leaks.
(5) Inspect heater door controls. Refer to Group 24, Heating and
Air Conditioning.
G A U G E R E ADI NG HI GH. NO PR E S S U R E BLOW OFF
FROM RADI ATOR PR E S S U R E C A P OR S T E AM FROM
COOLANT R E S E R V E TANK.
X
(1) Verify gauge reading. Is a high temperature reading indi-
cated?
(2) Gauge reading at "H" without signs of boiling.
(3) Low coolant level in radiator and coolant reserve tank.
M A XI M U M HOT
WE ATHE R
HE AV Y L O A D
M A XI M U M UP
T O TOP AMBI E NT
High Gauge Reading Hot Weather Heavy Load
(1) Compare gauge reading to High Gauge Reading Illustration
above.
(2) Inspect for grounded gauge, sending unit or circuit. Refer to
Group 8, Electrical.
(4) Coolant level in radiator is low. But not low in coolant reserve
tank.
(5) Test coolant freeze point.
(3) a -
b
(4) a -
b
d
(5) a -
(6) Ensure proper coolant flow.
(6) a-
b
Fill to full.
I nspect for leaks in system and repair
a s necessary.
Ensure radiator pressure cap was shut
tight. Verify proper operation of the radiator
cap upper and lower seal s.
Fill to full.
I nspect for leaks in the system and repair
a s necessary.
I nspect for leaks in the coolant reserve
tank to radiator hose.
Verify proper operation of the radiator cap
upper and lower seal s.
Adjust coolant solution to 5 0 /5 0 mixture of
anti-freeze and water. Refer to Coolant
in this group.
If a reading is not recorded or below - 5 0 .
the mixture is too rich. Cl ean system and fill
with a 50/50 mixture of anti-freeze and water.
Refer to Coolant in this group.
With the thermostat open and a slight amount
of coolant removed, inspect for coolant flow
through the radiator at the filler neck opening.
Determine reason for lack of coolant flow
and repair as necessary. J9107-22

COOLING SYSTEM 7- 11
DIESEL COOLING SYSTEM DIAGNOSIS-CONTINUED
Condition and Chocks Diagnosis
(7) Other possible causes. (7) a If symptom occurs during high speed operation inspect for
plugged air inlet side of the radiator or condenser,
plugged radiator core tubes, add on A/ C package without
proper radiator, engine not operating within specifications,
dragging brakes, trailer towing or hill climbing, or an
insect screen.
b If symptom occurs during high or low speed operation
inspect for: thermostat being stuck partially open if ambient
temperature is below 70F and the vehicle has high
mileage, plugged air inlet side of the radiator or
condenser, add on A/C with incorrect radiator.
c If symptom occurs during low speed operation only, inspect
the radiator fan drive. Repair as necessary.
TEMPERATURE G A U G E READS HOT. PRESSURE CAP VENTS
RESULTING I N STEAM A N D COOLANT TRANSFER TO
COOLANT RESERVE TANK.
(1) Coolant level low in radiator and coolant reserve tank. (1) a Fill cooling system and vent trapped air.
b Inspect for leaks. Repair as necessary.
c Ensure that pressure cap is completely shut and seals.
d If level is low in radiator but normal in the coolant reserve
tank, check the filler cap to coolant reserve bottle
connection and pressure cap seal.
(2) Test coolant freeze point. (2) Adjust coolant to 50/50 mix of anti-freeze and water. Refer to
Coolant section in this group.
(3) Ensure coolant is flowing through system. (3) a With the coolant level low and the thermostat open, check
for coolant flow through the radiator at the filler neck.
b If a metal cracking sound is heard, inspect for core sand
restricting coolant flow through the water jacket and/or a
faulty cylinder head casting.
(4) Thermostat stuck in the closed position (prevalent in cold ambient
temperatures).
(4) Replace thermostat if found to be stuck in closed position. Refer
to the Thermostat Testing section in this group.
(5) Cylinder head gasket leak. (5) Inspect for leaking cylinder head gasket with a commercially
available Block Leak Tester.
J9007-57

CONDITION AND CHECKS DIAGNOSIS
T E MPE R AT UR E GA U GE I S I NCONSI STENT, C YC L E S
AND/OR I S ERRATIC. J
(1) Is cycle normal.
(a)
Normal Gauge Reaction to Thermostat Cycle. Normal Gauge Reaction to Thermostat Cycle.
MID
(b)
Normal Gauge Reaction at Stop After Heavy Use.
(c)
Hot Water Build- Up I s Normal at Stop after Heavy
Use.
(2) Is coolant in radiator low (air will build up in the cooling
system and cause the thermostat to open late).
(2)
Fill system, vent trapped air and check for leaks.
(3) Is a cylinder head gasket leak allowing exhaust gas to
enter cooling system (exhaust gas building up in the
cooling system will cause the thermostat to open late).
(3)
a Test for leaking cylinder gasket leak with a
commercially available Block Leak Tester,
b Check for coolant in enaine oil.
c Inspect for white 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 up in cooling system causing thermostat to open late).
(5)
Find leak and repair.
PR E S S U R E C A P V E NT S T O A T MOS PHE R E AND C OOL -
ANT R E S E R V E TANK. T E MPE R AT UR E GA U GE R E AD-
I NG A BO V E NOR MAL BUT NOT HI GH.
(1) Test radiator pressure cap relief pressure. Refer to Radiator
Pressure cap section in this group.
ID
Replace cap if relief pressure is lower than 14 psi.
COOLANT L O S S V I S I BL E ON GR OUND BE LOW VEHI -
C L E , BUT NO PR E S S U R E C A P BL OW OFF.
(1) Inspect system for leaks.
(1)
Repair as necessary. J9107-23

COOLING SYSTEM 7 - 1 3
CONDI TI ON AND C HE C K S DI AGNOS I S
COOLANT L O S S PAST PR E S S U R E C AP TOP S E A L ,
V I S I BL E ON RADI ATOR FI LLER NECK.
(1) With normal gauge reading.
(1)
a Pressure cap not installed tightly.
b Pressure cap top seal leaks.
c Pressure cap diaphragm bowed.
d Damaged radiator filler neck.
e Pressure cap top seal out of position.
(2) With high or low gauge reading on new vehicle. (2) a Kinked coolant reserve system hose. (2) With high or low gauge reading on new vehicle.
b Coolant reserve system tank plastic tube plugged.
c Pressure cap seal out of position.
DETONATI ON OR PREI GNI TI ON. NOT C A U S E D BY I GNI -
TI ON OR ENGI NE CONDI TI ONS.
(1) Check engine coolant freeze point. If the tester does not regis-
(1)
a Adjust coolant solution to 5 0 /5 0 water
ter a reading or if the reading is below 50F, inspect ethyl- ethylene-glycol mixture.
ene-glycol/ water ratio. A 100 percent solution of ethylene- b If 100 percent ethylene-glycol solution is found
glycol in the system causes the engine to run hotter and possi- in syst em, clean and flush syst em before
bly overheat. replacing with 50/50 mixture of
ethylene-glycol and water.
COOLI NG S YS T E M HO S E S C OL L A PS E ON C OOL DOWN.
(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.
COOLI NG S YS T E M S U S PE C T E D A S C A U S E OF I NADE-
QUATE AI R CONDI TI ONI NG S YS T E M PE R F OR MA N C E .
(1) Inspect for plugged radiator and/or condenser.
( D
Clean with low pressure water from fan side.
(2) Inspect for missing air seals in the recirculating air path. (2) Repair as necessary.
E XC E S S I V E FAN NOI S E
(1) Inspect for loose or bent fan blades.
(1)
Replace fan.
(2) Inspect clearance between fan and adjacent part.
(2) Repair or replace as necessary.
(3) Inspect radiator and condenser for incoming air obstructions.
(3)
Clean air path with low pressure water from fan side.
(4) Inspect viscous fan drive.
(4) Replace if viscous drive does not operate properly.
HEAT ODOR
(1) Was temperature gauge reading high?
(1)
If YES, refer to GAUGE READING HIGH. If N O , refer to steps
2, 3, and 4.
(2) Are all heat shields in place?
(2) If YES, refer to steps 3 and 4. If N O , repair as required.
(3) Is the air side of the heat exchanger plugged? (3) Clean as necessary.
(4) Engine running rich causing catalytic converter to overheat. (4) Repair as necessary.
POOR DRI VEABI LI TY. S U S PE C T THERMOSTAT FAI LED
IN OPE N POSI TI ON.
(1) Thermostat stuck in open position?
0 1
Replace thermostat. ._ _
0
.
Jy 10 7- 2 4

CONDI TI ON AND C HE C K S DI AGNOS I S
POOR HEATER PE R F OR MA N C E . S U S PE C T
THE RMOS TAT FAI LED IN OPE N POSI TI ON.
(1) Does gauge read low?
(1)
If YES, replace thermostat. If N O , inspect the auxiliary
heater vacuum water valve. The valve should be open
except when the climate controls are OFF or in the MAX
A / C mode.
(2) Is coolant level low?
(2) Fill cooling system and inspect for leaks. Repair as neces-
sary.
(3) Thermostat failed in open position?
(3) If YES, replace thermostat. If N O , inspect the auxiliary
heater vacuum water valve. The valve should be open
except when the climate controls are OFF or in the MAX
A / C mode. J9107-25

SERVICE PROCEDURES
INDEX
page
Coolant 26
Coolant Reserve/ Overflow Syst em 30
Cooling Syst em Cl eani ng/ Reverse Flushing 28
Cooling System F anDi esel E ngi ne . 37
Cooling Syst em F anGas E ngi nes 36
Cooling System H oses 34
Draining Cooling System 27
Pressure Testing Radiator Caps . . . . . . . . . . . . . 32
Radiator Pressure Cap 31
Radiators 32
Refilling the Cooling System 28
WATER PUMPSEX CEPT DIESEL
A centrifugal water pump circulates coolant
through t he water jackets, passages, i nt ake manifold,
radiator core, cooling system hoses and heat er core.
The pump is driven from the engi ne crankshaft by a
drive belt.
The wat er pump impeller is pressed onto t he rear
of a shaft t hat rotates in a beari ng pressed into t he
water pump body. The body has a small hole for ven-
tilation. The water pump seals are lubricated by an-
tifreeze in t he coolant mi xt ure. Additional
lubrication is not necessary.
A quick t est to determine if pump is working is to
check if heat er warms properly. A defective wat er
pump will not be able to circulate heated coolant
through t he long heat er hose to t he heat er core.
The wat er pump on all models can be removed
without discharging t he air conditioning system (if
equipped).
REMOVAL
The wat er pump on all gas powered engines is
bolted directly to t he engine t i mi ng chain case/cover.
A gasket is used as a seal between t he water pump
and t i mi ng chain case/cover.
If water pump is replaced because of bearing/shaft
damage or leaking shaft seal, t he mechanical cooling
fan assembly should also be inspected. Inspect for fa-
tigue cracks, loose blades or loose rivets t hat could
have resulted from excessive vibration. Replace fan if
any of these conditions are found. Also check condi-
tion of t he t hermal viscous fan drive. Refer to Vis-
cous Fan Drive in t hi s group.
(1) Disconnect negative bat t ery cable from bat t ery.
(2) Drain cooling system. Refer to Drai ni ng Cool-
ing System in t hi s group.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
(3) Disconnect t hrot t l e cable from clip at top of fan
shroud.
page
Testing Cool ing Syst em for Leaks . 29
Thermostat 22
Transmi ssi on Oil Cool erDiesel 35
Transmi ssi on Oil Cool erEx cept Diesel 35
Transmi ssi on Oil-To-Air Cooler 36
V i scous F an Drive 38
Water Pump Bypass H oseAl l Gas Powered
E ngi nes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Water Pumps5 . 9 L Diesel 18
Water PumpsE x cept Diesel 15
(4) Unsnap coolant reserve/overflow t ank (up and
out) from t he T-slots on side of fan shroud (Fig. 1)
and lay aside. Do not disconnect hose or drain cool-
ant from t ank.
(5) Remove the fan shroud from t he radiator. Do
not remove shroud from vehicle at this time.
FAN
SHROUD
J9107-67
Fig. 1 Fan ShroudExcept Diesel
(6) Remove upper radi at or hose at radiator. Special
Clamp Tool number 6094 (Fig. 2) may be used to re-
move t he constant tension clamps.
(7) The t hermal viscous fan drive is attached
(threaded) to t he wat er pump hub shaft (Fig. 3). Re-
move t he fan/fan drive assembly from wat er pump by
t urni ng t he mount i ng nut counterclockwise (as
viewed from front). Threads on t he fan drive are
RI GHT HAND. A Snap-On 36 MM Fan Wrench
(number SP346 from Snap-On Cummi ns Diesel Tool
Set number 2017DSP) can be used. Place a bar or
screwdriver between t he wat er pump pulley bolts
(Fig. 3) to prevent t he pulley from rot at i ng.
If wat er pump is being replaced, do not unbolt fan
blade assembly (Fig. 3) from the t hermal control fan
drive.

HOS E CLAMP HOS E
J9207-36
Fig. 2 Hose Clamp Tool
(8) Remove fan blade/fan drive and fan shroud as
an assembly from vehicle.
After removing fan blade/fan drive assembly, do
not place t he t hermal viscous fan drive in t he hori-
zontal position. If stored horizontally, t he silicone
fluid in t he viscous drive could drain into its beari ng
assembly and contaminate t he bearing lubricant.
Do not remove t he wat er pump pulley bolts at t hi s
time.
FAN BLADE WATER WATER PUMP
VI SCOUS FAN DRIVE
J9307-32
Fig. 3 Fan Blade and Viscous Fan DriveTypical
(9) Remove accessory drive belt as follows: The
drive belt is equipped with a spring loaded automatic
tensioner (Figs. 4 or 5).
3.9L/5.2L/5.9L LDC-Gas Engines: Relax t he tension
from t he belt by rot at i ng t he tensioner clockwise (as
viewed from front) (Fig. 4). When all belt tension has
been relaxed, remove accessory drive belt.
5.9L HDC-Gas Engines: Relax t he tension from t he
belt by rot at i ng t he tensioner counterclockwise (as
viewed from front) (Fig. 5). When all belt tension has
been relaxed, remove accessory drive belt.
Fig. 4 Belt Tensioner3.9L/5.2L/5.9L LDC-Gas
Engine
Fig. 5 Belt Tensioner5.9L HDC-Gas Engine
(10) Remove t he four wat er pump pulley-to-water
pump hub bolts (Fig. 3) and remove pulley from ve-
hicle.
(11) Remove t he lower radiator hose and heat er
hose from wat er pump.

COOLING SYSTEM 7- 17
(12) Loosen heat er hose coolant ret urn t ube
mounting bolt (Figs. 6 or 7) and remove tube from
water pump. Discard the old t ube O-ring.
Fig. 6 Coolant Return Tube3.9L/5.2L/5.9L LDC-Gas
Engine
Fig. 7 Coolant Return Tube5.9L HDC-Gas Engine
(13) Remove t he seven wat er pump mounting bolts
(Fig. 8).
(14) Loosen t he clamp at t he wat er pump end of
bypass hose (Fig. 3). Slip t he bypass hose from t he
water pump while removing pump from vehicle. Do
not remove t he clamp from t he bypass hose.
Fig. 8 Water Pump BoltsTypical
(15) Discard old gasket.
C A U T I O N : D o not pry the water pump at timing
chai n case/ cover. The machi ned surf aces may be
damaged resulting in l eaks.
INSPECTION
Replace wat er pump assembly if it has any of t he
following conditions:
The body is cracked or damaged
Wat er leaks from t he shaft seal. This is evident by
traces of coolant below t he vent hole
Loose or rough t ur ni ng bearing. Also inspect t her-
mal fan drive
Impeller rubs either t he pump body or t i mi ng
chain case/cover
INSTALLATION
(1) Clean gasket mat i ng surfaces.
(2) Usi ng a new gasket, install wat er pump to en-
gine as follows: Guide wat er pump nipple into bypass
hose as pump is being installed. Install wat er pump
bolts (Fig. 8). Tighten wat er pump mounting bolts to
40 N-m (30 ft. lbs.) torque.
(3) Spin wat er pump to be sure t hat pump impeller
does not rub against t i mi ng chain case/cover.
(4) Install a new O-ring to t he heat er hose coolant
ret urn t ube (Figs. 6 or 7). Coat t he new O-ring wi t h
antifreeze before installation.
(5) Install coolant r et ur n tube and its mount i ng
bolt to engine (Figs. 6 or 7). Be sure the slot in t ube
bracket is bottomed to mount i ng bolt. This will prop-
erly position ret urn tube.
(6) Connect radi at or lower hose to water pump.
(7) Connect heat er hose and hose clamp to coolant
ret urn tube.
(8) Install wat er pump pulley. Tighten bolts to 27
N*m (20 ft. lbs.) torque. Place a bar or screwdriver
between wat er pump pulley bolts (Fig. 3) to prevent
pulley from rotating.

(9) Relax tension from aut omat i c belt tensioner
(Figs. 4 or 5). Install drive belt.
C A U T I O N : W hen instal l ing the serpenti ne ac c essor y
drive belt, belt must be routed correctl y. If not, en-
gi ne may overheat due to water pump rotating in
wrong direction. Refer to ( F i gs, i , 10 or 11) for cor-
rect belt routi ng. The correct belt with correct
l ength must be used.
*I F VEHICLE IS NOT EQUI PPED WITH POWER
STEERING, THIS WILL BE AN IDLER PULLEY. J9307-26
Fig. 9 Belt Routing3.9U5.2L/5.9L LDC-Gas Engine
AUTOMATIC
TENSIONER
AUTOMATIC
TENSIONER
J9307-56
Fig. 11 Belt Routing5.9L HDC-Gas
EngineWithout A/C
(10) Position fan shroud and fan blade/viscous fan
drive assembly to vehicle as a complete unit.
(11) Install fan shroud.
(12) Install fan blade/viscous fan drive assembly to
wat er pump shaft.
(13) Fill cooling system. Refer to Refilling Cooling
System in t hi s group.
(14) Connect negative bat t ery cable.
(15) St art and warm t he engine. Check for leaks.
WATER PUMPS5.9L DIESEL
The diesel engine wat er pump draws coolant from
radi at or outlet and circulates it through engine,
heat er core and back to radiator inlet. The crank-
shaft pulley drives t he water pump via a serpentine
drive belt (Fig. 12). An automatic belt tensioner (Fig.
12) is used to prevent t he belt from slipping.
REMOVAL
(1) Disconnect t he negative bat t ery cable at bat-
tery.
(2) Drai n cooling system. Refer to Drai ni ng Cool-
ing System in t hi s section.
(3) Remove t he accessory drive belt. Refer to t he
Engi ne Accessory Drive Belt section of this group.
(4) Remove wat er pump mount i ng bolts (Fig. 13).
(5) Clean wat er pump sealing surface on cylinder
block.
J9307-55
Fig. 10 Belt Routing5.9L HDC-Gas Engine-With
A/C
INSTALLATION
(1) Install new O-ring seal in groove on wat er
pump (Fig. 14).
(2) Install wat er pump. Tighten mounting bolts to

MOUNT.
BOLT
3/8
SQUARE
HOLE
ACCE SSORY
DRIVE BELT
AUTOMATIC
BELT
T E NS I ONE R J9307-59
Fig. 12 Water Pump5.91 Diesel
o ~ "
o
rSCREW (2)
v
' ^
o v X N n
J 9 1 0 7 - 5
N
Fig. 13 Pump Removal/Installation5.9L Diesel
O- RI N G
SEAL
WATER
PUMP
GROOV E
J910 7-6
Fig. 14 Pump O-ring Seal5.9L Diesel
(3) Install accessory drive belt. Refer to t he Engi ne
Accessory Drive Belt section of this group.
System in t hi s section.
(5) Connect bat t ery cable.
WATER PUMP BYPASS HOS E - A L L GAS
POWERED ENGINES
A wat er pump bypass hose (Fig. 15) is used be-
tween t he i nt ake manifold and wat er pump on all
gas engines. To test for leaks, refer to Testing Cool-
ing System for Leaks in t hi s group.
FAN BLADE
ASSEMBLY
THREADED
NUT
WATER
PUMP
PULLEY PULLEY
BOLTS
WATER PUMP
THREADED SHAFT
(WATER PUMP HUB)
VI SCOUS FAN DRIVE
CRANKSHAFT
PULLEY
J9307-32
Fig. 15 Water Pump Bypass HoseTypical
WITHOUT AIR CONDITIONING (A/C)
RE10WAL
(1) Part i al l y drain cooling system. Refer to Drain-
ing Cooling System in t hi s group.
Do not waste reusable coolant. If t he solution is
clean, drain t he coolant into a clean container for re-
use.
(2) Loosen both bypass hose clamps and position to
t he center of hose. Special Clamp Tool number 6094
(Fig. 16) may be used to remove t he constant tension
clamps.
(3) Remove hose from vehicle.
INSTALLATION
(1) Position bypass hose clamps to t he center of
hose.
(2) Install bypass hose to engine.
(3) Secure both hose clamps.
System in this group.

HOSE CLAMP HOSE
J9207-36
WITH AIR CONDITIONING (A/C)
REMOVAL
If equipped with A/C, t he generator and A/C com-
pressor along with t hei r common mount i ng bracket
(Fig. 17) must be partially removed. Removing t he
generator or A/C compressor from t hei r mount i ng
bracket is not necessary. Also, discharging t he A/C
system is not necessary. Do not remove any refrig-
erant lines from A/C compressor.
SUPPORT BRACKET (ROD)
GENERATOR/COMPRESSOR
MOUNTING BRACKET
J9307-66
Fig. 17 GeneratorA/C Compressor Mounting
Bracket Typical
WARNI NG; T HE A/ C S YS T E M I S UNDER PR E S S U R E
E V E N WI T H T HE E N G I N E O F F . R E F E R T O R E F R I G -
E R A N T WAR NI NGS IN GROUP 24 , HEATI NG A N D
AI R CONDI TI ONI NG.
(2) Part i al l y drai n cooling system. Refer to Drain-
ing Cooling System in t hi s group.
clean, drai n t he coolant into a clean container for re-
use.
(3) Remove upper radi at or hose clamp at radiator.
Special Clamp Tool number 6094 (Fig. 16) may be
used to remove t he constant tension clamps. Remove
hose at radiator.
(4) Disconnect t hrot t l e cable from clip at radiator
fan shroud.
(5) Unpl ug wiring harness from A/C compressor.
(6) Remove t he ai r cleaner assembly.
(7) Remove accessory drive belt. Refer to Belt Re-
moval/Installation in t he Engi ne Accessory Drive
Belt section of this group.
(8) 3.9L/5.2L/5.9L LDC-Gas: The drive belt idler
pulley must be removed to gain access to one of t he
A/C compressor/generator bracket mounting bolts.
Remove t he idler pulley bolt and remove idler pulley
(Fig. 18).
GENERATOR/COMPRESSOR
AND BRACKET
SUPPORT BRACKET
IGNITION
COIL BRACKET
Fig. 18 Idler Pulley-3.9U5.2U5.9L LDC-Gas Engine
5.9L HDC-Gas: The automatic belt tensioner/pul-
ley assembly must be removed to gain access to one
of t he A/C compressor/generator bracket mount i ng
bolts. Remove t he tensioner mount i ng bolt (Fig. 19)
and remove tensioner.
(9) Remove t he engine oil dipstick tube mounting
bolt at t he side of t he A/C-generator mounting
bracket.
(10) Disconnect t hrot t l e body control cables. Refer
to Accelerator Pedal and Throttle Cable in Group 14,
Fuel System.

(11) Remove heat er hose coolant r et ur n t ube
mount i ng bolt (Figs. 20 or 21) and remove t ube from
engine. Discard t he old t ube O-ring,
Fig. 20 Coolant Return Tube-3.9U5.2U5.9L LDC-
Gas Engine
(12) Remove bracket-to-intake manifold bolts
(number 1 and 2 Fig. 17).
(13) Remove remai ni ng bracket-to-engine bolts
(Figs. 22 or 23).
(14) Lift and position generator and A/C compres-
sor (along wi t h t hei r common mount i ng bracket) to
gain access to bypass hose. A block of wood may be
Fig. 21 Coolant Return Tube5.9L HDC-Gas Engine
Fig. 22 Bracket Bolts-3.9U5.2U5.9L LDC-Gas
Engine
used to hold assembly in position.
(15) Loosen and position both hose clamps to t he
center of bypass hose. Special Clamp Tool number
6094 (Fig. 16) may be used to remove t he constant
tension clamps. Remove hose from vehicle.
INSTALLATION
(1) Position bypass hose clamps to t he center of
hose.

Fig. 23 Bracket Bolts5.9L HDC-Gas Engine
(2) Install bypass hose to engine.
(3) Secure both hose clamps.
(4) Install generator-A/C mount i ng bracket assem-
bly to engine. Tighten bolts (number 1 and 2 Fig. 17)
to 54 Nnn (40 ft. lbs.) torque. Tighten bracket mount-
ing bolts (Figs. 22 or 23) to 40 N-m (30 ft. lbs.)
torque.
(5) Install a new O-ring to t he heat er hose coolant
ret urn tube (Figs. 20 or 21). Coat t he new O-ring
with antifreeze before installation.
(6) Install coolant ret urn tube and its mounting
bolt to engine (Figs. 20 or 21).
(7) Connect t hrot t l e body control cables.
(8) Install oil dipstick mounting bolt.
(9) 3.9L/5.2L/5.9L LDC-Gas: Install idler pulley.
Tighten bolt to 54 Nnn (40 ft. lbs.) torque.
5.9L HDC- Gas: Install automatic belt tensioner
assembly to mount i ng bracket. A dowel pin is located
on back of tensioner (Fig. 24). Align t hi s to dowel
hole (Fig. 25) in tensioner mounting bracket. Tighten
bolt to 41 N-m (30 ft. lbs.).
(10) Install drive belt. Refer to Belt Removal/In-
stallation in t he Engine Accessory Drive Belt section
of t hi s group.
C A U T I O N : When installing the serpentine accessor y
drive belt, the belt must be routed correctly. If not,
the engi ne may overheat due to the water pump ro-
tating in the wr ong direction. Refer to Belt S chemat -
i cs in the E ngi ne A ccessor y Drive Belt secti on of
thi s gr oup for correct belt routing. The correct belt
with the correct length must be used.
(11) Install ai r cleaner assembly.
BELT TENSIONER
DOWEL PIN J9307-63
Fig. 24 Tensioner Dowel Pin5.9L HDC-Gas Engine
Fig. 25 Tensioner Mounting Bracket Dowel
Hote5.9L HDC-Gas Engine
(12) Install upper radiator hose to radiator.
(13) Connect t hrot t l e cable to clip at radiator fan
shroud.
(14) Connect wiring harness to A/C compressor.
(16) St art and war m t he engine. Check for leaks.
THERMOSTAT
GENERAL INFORMATION
The thermostat on all gas powered engines is lo-
cated beneath t he t hermost at housing at t he front of
t he i nt ake manifold (Fig. 26). The t hermost at has an
air bleed notch.
The t hermost at of t he 5.9L diesel engine is located
in t he t hermost at housing at front of cylinder head.
This is on exhaust manifold side of engine (Fig. 27).
The t hermost at is a wax pellet driven, reverse pop-
pet choke type. The wax pellet is located in a sealed
container at t he spring end of t he t hermost at . When
heated, the pellet expands, overcoming closing spring

THERMOSTAT
MACHINED GROOVE
J9207-14
Fig. 26 Thermostat Gas Engines
Fig. 27 Thermostat5.9L DieselTypical
tension and wat er pump pressure to force t he valve
to open. Coolant leakage into t he pellet container
will cause t he t hermost at to fail in t he open position.
Thermostats very rarel y stick. Do not at t empt to free
a t hermost at with a prying device.
The same t hermost at is used for winter and sum-
mer seasons. An engine should not be operated with-
out a t hermost at , except for servicing or testing.
Operating without a t hermost at causes longer engine
warmup time, unreliable warmup performance, in-
creased exhaust emissions and crankcase condensa-
tion t hat can resul t in sludge formation.
C A U T I O N : D o not operate an engi ne without a ther-
mostat, except for servi ci ng or testi ng.
THERMOSTAT OPERATION-EXCEPT DIESEL
The t hermost at controls t he operating t emperat ure
of t he engine by controlling t he amount of coolant
flow to t he radiator. The t hermost at is closed below
88C (192F). When t he coolant reaches t hi s temper-
at ure, t he t hermost at begins to open, allowing cool-
ant flow to t he radiator. This provides quick engine
warm-up and overall t emperat ure control. The ther-
mostat is designed to provide a mi ni mum engine op-
erat i ng t emperat ure of 88 to 93C (192 to 199F). It
should be fully open for maxi mum coolant flow dur-
ing operation in hot ambient t emperat ures of approx-
imately 104C (220F). Above 104C (220F), coolant
t emperat ure is controlled by the radiator, fan and
ambient t emperat ure.
An arrow plus t he word UP is stamped on t he
front flange next to t he air bleed. The words TO
RAD are stamped on one ar m of t he t hermost at .
They indicate t he proper installed position.
TESTING-ALL ENGINES
The computer On-Board Diagnostics include a
mode for a t hermost at open-too-soon failure condi-
tion. The Malfunction Indicator Light (formerly
called t he Check Engine Light) will not be lit by an
open-too-soon condition. But, if it has failed open, a
Diagnostic Trouble Code (DTC) number 17 will be
set. Do not change a t hermost at for lack of heat as
indicated by t he i nst rument panel gauge or heat er
performance unless a DTC number 17 is present. Re-
fer to t he Diagnosis section of this group for other
probable causes.
The more common type of t hermost at failure, usu-
ally found on high milage vehicles, is a t hermost at
failed in t he shut position. The t emperat ure gauge (if
equipped) will give an indication of t hi s condition.
Depending upon length of time t hat vehicle is oper-
ated, pressure cap may vent. This will expel st eam
and coolant to coolant reserve/overflow t ank and to
surface below vehicle. Refer to t he Diagnosis section
of t hi s group. Also refer to t he DRB II diagnostic
scan tool.
On-Board Diagnostics for t he 5.9L diesel engine
can be obtained t hrough t he DRB II scan tool.
Vehicles equipped with a 5.9L diesel engine do not
have t he DTC number 17 malfunction indicator lamp
(check engine lamp) feature.
REMOVAL-ALL GAS POWERED ENGINES
WA R N I N G : D O N OT L O O S E N T HE R A D I A T O R
D R A I N C O C K WI T H T HE S Y S T E M HOT A N D P R E S -
S U R I Z E D . S E R I O U S B U R N S F R O M T HE C O O L A N T
C AN OCCUR.
use.

If t he t hermost at is being replaced, be sure t hat
t he replacement is t he specified t hermost at for t he
vehicle model and engine type.
Factory installed t hermost at housings on 3.9L/5.2L/
5.9L engines are installed on a gasket with an ant i -
stick coating. This will aid in gasket removal and
clean-up.
(1) Disconnect negative battery cable at battery.
(2) Drain cooling system until coolant level is be-
low thermostat. Refer to Draining Cooling System in
this group. If not equipped with ai r conditioning, pro-
ceed to step number 4.
(3) If equipped with air conditioning:
(a) Remove t he support bracket (rod) located
near t he rear of generator (Fig. 28).
Fig. 28 Support BracketGenerator Mounting
Bracket-to-intake Manifold Typical
(b) The drive belt must be removed. Refer to Belt
Removal/Installation in the Engine Accessory
Drive Belt section of t hi s group.
(c) The generator must be partially removed. Re-
move t he two generat or mounting bolts. Do not re-
move any wiring at generator. If equipped with
4WD, unplug t he 4WD indicator lamp wiring har-
ness (located near rear of generator).
(d) Remove generator. Position generator to gain
access for t hermost at gasket removal.
(4) Remove upper radiator hose clamp. Special
Clamp Tool number 6094 (Fig. 29) may be used to re-
move t he constant tension clamps. Remove upper ra-
diator hose at t hermost at housing.
(5) Position t he wiring harness (behind t he ther-
most at housing) to gai n access to t hermost at hous-
ing.
(6) Remove t hermost at housing mounting bolts,
t hermost at housing, gasket and t hermost at (Fig. 30).
Discard old gasket.
HOS E CLAMP HOS E
J9207-36
THERMOSTAT
MACHI NED GROOVE
J9207-14
Fig. 30 ThermostatGas Engines
INSTALLATION-ALL GAS POWERED
ENGINES
(1) Clean mat i ng areas of i nt ake manifold and
t hermost at housing.
(2) Install t hermost at (spring side down) into re-
cessed machined groove on intake manifold (Fig. 30).
(3) Install gasket on i nt ake manifold and over
t hermost at (Fig. 30).
(4) Position t he t hermost at housing to t he i nt ake
manifold. Note t he word FRONT stamped on t he
housing (Fig. 31). For adequate clearance, t hi s mus t
be placed towards t he front of vehicle. The housing
should be slightly angled forward after installation
to i nt ake manifold.
(5) Install two housing-to-intake manifold bolts.
Tighten bolts to 23 N-m (200 in. lbs.) torque.

Fig. 31 Thermostat Position
CAUTI ON; Housi ng must be tightened evenly and
thermostat must be centered into r ecessed gr oove
in intake manifold. If not, it may result in a cracked
housi ng, damaged intake manifold threads or cool -
ant leak.
(6) Install upper radiator hose to t hermost at hous-
ing.
(7) Air conditioned vehicles:
(a) Install generator. Tighten bolts to 41 N-m (30
ft. lbs.).
(b) Install support bracket (generator mount i ng
bracket-to-intake manifold) (Fig. 28). Tighten bolts
C A U T I O N : When installing the serpentine accessor y
drive belt, the belt must be routed correctly. If not,
tating in the wr ong direction. Refer to Belt S chemat -
i cs in the E ngi ne A ccessor y Drive Belt sect i on of
thi s gr oup for correct engi ne belt routing. The cor-
rect belt with the correct length must be used.
System i n t hi s Group.
(9) Connect negative bat t ery cable to bat t ery.
(10) St ar t and warm engine. Check for leaks.
THERMOSTAT OPERATION
r
-5.9L DIESEL
ENGINE
The t hermost at controls t he operating t emperat ure
of t he engine by controlling t he amount of coolant
flow to t he radiator. When coolant t emperat ure is be-
low 83C (181F), t he t hermost at is closed. Coolant is
routed back to t he wat er pump inlet t hrough t he by-
pass (Fig. 32).
Fig. 32 Thermostat Operation5.9L Diesel
When coolant t emperat ure reaches 83C (181F),
t he t hermost at begins to open allowing coolant flow
to t he radiator. This provides quick engine warm-up
and overall t emperat ure control. The t hermost at is
designed to provide a mi ni mum engine operating
t emperat ure of 83C (181F) and to be fully open for
maxi mum coolant flow at approximately 95C
(203F). Above 95C (203F), coolant t emperat ure is
controlled by t he radiator, fan and ambient tempera-
t ure.
The t hermost at is equipped with t hree air bleeds
on t he flange. The air bleeds will vent air when t he
system is filled. It also acts as a check valve to block
t he flow of coolant duri ng engine operation.
REMOVAL-DIESEL
W ARN I N G: D O N OT L OOSE N TH E RAD I ATOR
D RAI N C OC K W I TH TH E SY STE M H OT AN D PRE S -
SURI Z E D . SE RI OUS BURN S F ROM TH E COOL AN T
C AN OCCUR.
use.
moval/Installation in t he Engine Accessory Drive
Belt section in t hi s group.
(3) Drai n cooling system unt i l coolant level is be-
low thermostat. Refer to Drai ni ng Cooling System in
t hi s section.
(4) Remove radiator hose clamp and hose from
t hermost at housing. Special Clamp Tool number
6094 (Fig. 29) may be used to remove t he constant
tension clamps.
(5) Loosen generator pivot bolt.
Fig. 33 Generator Mounting Bolts5.9L Diesel
(7) Remove t hermost at housing mounting bolts.
(8) Remove t hermost at housing, lifting bracket and
t hermost at (Fig. 34).
Fig. 34 Thermostat Removal5.9L Diesel
(9) Clean t he mat i ng surfaces of t he t hermost at
housing and t he cylinder head.
INSTALLA TIONDIESEL
(1) Install t he t hermost at in t he housing.
(2) Position t he t hermost at seal with t he shoulder
towards t he housing (Fig. 35).
(3) Install thermostat, lifting bracket, seal and
housing. Tighten t he mounting bolts to 24 Nm (18
ft. lbs.) torque.
(4) Position generator in place. Tighten mounting
bolt to 24 N*m torque. Tighten pivot bolt to 43 N*m
(5) Install accessory drive belt. Refer to Belt Re-
moval/Installation in t he Engi ne Accessory Drive
Belt section of t hi s group.
(6) Connect bat t ery cable to bat t ery.

Fig. 35 Thermostat Seai5.9L DieselTypical
COOLANT
The cooling system is designed around t he coolant.
Coolant flows t hrough t he engine wat er jacket ab-
sorbing heat produced duri ng engine operation. The
coolant carries t he heat to radi at or and heat er core.
Here it is transferred to t he ambi ent air passing
t hrough t he radiator and heat er core fins. The cool-
ant also removes heat from t he automatic t ransmi s-
sion fluid in vehicles equipped with an automatic
transmission.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
mi xt ure depends upon climate and vehicle operating
conditions. The coolant performance of various mix-
t ures follows:
Pure Water-Water can absorb more heat t han a
mi xt ure of water and ethylene-glycol. This is for pur-
pose of heat transfer only. Wat er also freezes at a
higher t emperat ure and allows corrosion.
100% Ethylene-Glycol-The corrosion inhibiting
additives in ethylene-glycol need t he presence of wa-
t er to dissolve. Without water, additives form depos-
its in system. These act as insulation causing
t emperat ure to rise to as high as 149C (300F). This
t emperat ure is hot enough to melt plastic and soften
solder. The increased t emperat ure can result in en-
gine detonation. In addition, 100 percent ethylene-
glycol freezes at -22C (-8F).
50/50 Ethylene-Glycol and Water-Is t he recom-
mended mixture, it provides protection agai nst freez-
ing to -37C (-35F). The antifreeze concentration
must al ways be a mi ni mum of 44 percent, year-
round in all climates. If percentage is lower, engine
part s may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
(6) Remove generator mounting bolt (Fig. 33).

down to -67.7C (-90F). A hi gher percentage will
freeze at a warmer t emperat ure. Also, a higher per-
centage of antifreeze can cause t he engine to over-
heat because specific heat of antifreeze is lower t han
t hat of water.
CAUTI ON : Ri cher antifreeze mi x tures cannot be
measur ed with normal field equi pment and can
c ause pr obl ems associ at ed with 1 00 percent ethyl-
ene- gl ycol .
COOLANT SELECTION-ADDITIVES
The presence of al umi num components in t he cool-
ing system requires strict corrosion protection. Main-
t ai n coolant at specified level wi t h a mi xt ure of
ethylene-glycol based antifreeze and water. Only use
an antifreeze containing ALUGARD 340-2 such as
Mopar Antifreeze. If coolant becomes contaminated
or looses color, drai n and flush cooling system and
fill with correctly mixed solution.
A 0.25 percent emulsifiable oil is added to t he ra-
diator at t he factory to prevent solder corrosion.
CAUTI ON : D o not use cool ant addi ti ves that are
cl ai med to i mprove engi ne cool i ng.
COOLANT SERVICE-EXCEPT DIESEL
It is recommended t hat t he cooling system be
drained and flushed at 84,000 kilometers (52,500
miles) or 3 years, whichever occurs first. Then every
two years or 48,000 kilometers (30,000 miles), which-
ever occurs first.
COOLANT SERVICE-DIESEL ENGINE
It is recommended t hat t he cooling system be
drained and flushed every 24 mont hs or 38,600 kilo-
meters (24,000 miles), whichever occurs first.
COOLANT LEVEL CHECK-ROUTINE
Do not remove radiator cap for routine cool ant
level i nspecti ons. The cool ant level can be
checked at the cool ant reserve/ overfl ow tank.
The coolant reserve/overflow system provides a
quick visual method for det ermi ni ng t he coolant
level without removing t he radi at or pressure cap.
With engine idling and at normal operating temper-
at ure, observe coolant level in coolant reserve/over-
flow t ank. The coolant level should be between t he
MIN and MAX (diesel engine) or ADD and FULL
(gas engines) marks.
ADDING ADDITIONAL COOLANT-ROUTINE
Do not remove the radiator cap to add cool ant
to the system. When adding coolant to mai nt ai n t he
correct level, do so at t he coolant reserve/overflow
t ank with a 50/50 mi xt ure of ethylene-glycol ant i -
freeze (containing Alugard 340-2 ) and water. Re-
move t he radiator cap only for testing or when
refilling t he system after service. Removing cap un-
necessarily can cause loss of coolant and allow ai r to
enter system. This produces corrosion.
COOLANT LEVEL CHECK-SERVICE
The cooling system is closed and designed to main-
t ai n coolant level to t he top of t he radiator.
W ARN I N G: D O N OT OPE N RAD I ATOR D RAI N C OC K
W I TH E N GI N E RUN N I N G OR W H I LE E N GI N E I S H OT
AN D COOL I N G SY STE M I S UN D E R PRE S S URE .
When vehicle servicing requires a coolant level
check in t he radiator, drain several ounces of coolant
from t he radiator drain cock. Do this while observing
t he coolant reserve/overflow system t ank. The cool-
ant level in t he reserve/overflow t ank should drop
slightly. If not, inspect for a leak between radi at or
and coolant reserve/overflow system connection. Re-
move radiator cap. The coolant level should be to t he
top of t he radiator. If not and if coolant level in re-
serve/overflow t ank is at t he ADD (gas engines) or
MIN (5.9L diesel engine) mark, check for:
An air leak in t he coolant reserve/overflow t ank
An air leak in t he radiator filler neck
Leak in t he pressure cap seal to t he radiator filler
neck
LOW COOLANT LEVEL-AERATION
If t he coolant level in t he radiator drops below t he
top of t he radiator core tubes, air will enter t he sys-
tem.
Low coolant level can cause t he t hermost at pellet
to be suspended in air instead of coolant. This will
cause t he t hermost at to open later, which in t ur n
causes higher coolant t emperat ure. Air trapped in
cooling system also reduces t he amount of coolant
circulating in t he heat er core. This may result in low
heat output.
DEAERATION
As t he engine operates, air trapped in t he cooling
system gat hers under t he radiator cap. The next t i me
engine is operated, t hermal expansion of coolant will
push trapped air past radi at or cap into coolant re-
serve/overflow t ank. Here it escapes to atmosphere in
t he t ank. When engine cools down t he coolant, it will
be drawn from reserve/overflow t ank into radiator to
replace removed air.
DRAINING COOLING SYSTEM
WA R N I N G : D O N O T R E M O V E T HE C Y L I N D E R
B L O C K D R A I N PL U G S O R L O O S E N T HE R A D I A T O R
D R A I N PL U G WI T H S Y S T E M HOT A N D U N D E R
P R E S S U R E . S E R I O U S B U R N S F R O M C O O L A N T
C A N O C C U R .
DO NOT WASTE reusable coolant. If t he solution
is clean, drain t he coolant into a clean container for
reuse.
(1) St art t he engine and place t he heat er control
t emperat ure selector in t he Full On position. Engi ne
vacuum is needed to act uat e t he heat er controls.
(2) Turn t he ignition off.
(3) Do not remove radi at or cap when drai ni ng cool-
ant from reserve/overflow t ank. Open radi at or drai n
plug and when t ank is empty, remove radi at or cap. If
t he coolant reserve/overflow t ank does not drain, re-
fer to t he Testing Cooling System for Leaks section
in this group. The coolant need not be removed from
t ank unless t he system is being refilled wi t h fresh
mixture.
(4) On vehicles equipped with gas powered en-
gines, remove t he cylinder block drain plugs. These
are located on t he sides of t he block towards t he
front of engine, j ust above t he oil pan (Fig. 36).
Fig. 36 Drain PlugsGas Powered
EnginesTypical
(5) Remove radi at or pressure cap.
REFILLING THE COOLING SYSTEM
Clean cooling system prior to refilling. Refer to
Cooling System Cleaning section of this group.
(1) Install t he cylinder block drain plugs (Fig. 36).
(2) Close radi at or drai n plug.
(3) Fill t he cooling system wi t h a 50/50 mi xt ure of
water and antifreeze.
(4) Fill coolant reserve/overflow t ank to t he MAX
(5.9L diesel engine) or FULL (gas engines) mark.
(5) St art and operate engine unt i l t hermost at
opens. Upper radi at or hose should be warm to touch.
(6) If necessary, add 50/50 wat er and antifreeze
mi xt ure to t he coolant reserve/overflow t ank to main-
t ai n coolant level. This level should be between t he
MAX and MIN (5.9L diesel engine) or ADD and
FULL (gas engines) marks. The level in t he reserve/
overflow t ank may drop below the MIN (or ADD)
mar k after t hree or four warm-up and cool-down cy-
cles.
COOLING SYSTEM CLEANING/REVERSE FLUSHING
CLEMMING
Drai n cooling system and refill wi t h water. Run
engine with radi at or cap installed unt i l upper radi a-
tor hose is hot. Stop engine and drai n wat er from
system. If wat er is dirty, fill system wi t h wat er, r un
engine and drai n system. Repeat unt i l wat er drai ns
clean.
REVERSE FLUSHING
Reverse flushing of cooling system is t he forcing of
wat er through t he cooling system. This is done usi ng
ai r pressure in t he opposite direction of normal cool-
ant flow. It is usual l y only necessary with very dirty
systems with evidence of partial plugging.
REVERSE FLUSHING RADIATOR
Disconnect radi at or hoses from radi at or inlet and
outlet. Attach a section of radiator hose to radi at or
bottom outlet fitting and insert flushing gun. Con-
nect a wat er supply hose and air supply hose to
flushing gun.
CAUTI ON : Internal radiator pr essur e must not ' ex -
ceed 138 kPa (20 psi ) as damage to radiator may re-
s ul t
Allow radi at or to fill with water. When radi at or is
filled, apply air in short blasts. Allow radi at or to re-
fill between blasts. Continue t hi s reverse flushing
unt i l clean wat er flows out t hrough rear of radi at or
cooling t ube passages. Have radi at or cleaned more
extensively by a radi at or repair shop.
REVERSE FLUSHING ENGINE-EXCEPT
DIESEL
Drai n cooling system. Remove t hermost at housing
and thermostat. Install t hermost at housing. Discon-
nect radiator upper hose from radiator and at t ach
flushing gun to hose. Disconnect radi at or lower hose
from wat er pump and at t ach a lead-away hose to wa-
t er pump inlet fitting.
CAUTI ON ; On vehi cl es equi pped with a heater water
control val ve, be sur e heater control val ve i s c l osed
(heat off). Thi s will prevent cool ant flow with scal e
and other deposi t s from entering heater cor e.
Connect wat er supply hose and air supply hose to
flushing gun. Allow engine to fill with wat er. When
engine is filled, apply air in short blasts, allowing
system to fill between air blasts. Continue unt i l
clean wat er flows t hrough the lead away hose.
+
Fig. 37 Reverse-flushing5.9L Diesel
(5) Attach wat er supply hose to heat er tube.
(6) Back-flush t he engine unt i l clean water exits
t he wat er pump inlet.
CHEMICAL CLEANING
In some instances, use a radi at or cleaner (Mopar
Radiator Kleen or equivalent) before flushing. This
will soften scale and other deposits and aid flushing
operation.
CAUTI ON; Follow manufacturers instructions when
using these products.
TESTING COOLING SYSTEM FOR LEAKS
ULTRAVIOLET LIGHT METHOD
A leak detection additive i s available t hrough t he
part s depart ment t hat can be Sidfled to cooling sys-
tem. The additive is highly visible under ultraviolet
Fig. 38 Leak Detection Using Black LightTypical
PRESSURE TESTER METHOD
The engine should be at normal operating temper-
at ure. Recheck t he system cold if cause of coolant
loss is not located duri ng t he warm engine examina-
tion.
WARNI NG: H OT, PRE SSURI Z E D COOL AN T C AN
C A US E I NJURY BY SC AL D I N G.
Carefully remove radiator pressure cap from filler
neck and check coolant level. Push down on cap to
disengage it from stop tabs. Wipe inside of filler neck
and examine lower inside sealing seat for nicks,
cracks, paint, dirt and solder residue. Inspect radia-
tor-to-reserve/overflow t ank hose for i nt ernal obstruc-
tions. Insert a wire t hrough t he hose to be sure it is
not obstructed.
Inspect cams on outside of filler neck. If cams are
bent, seating of pressure cap valve and tester seal
will be affected. Bent cams can be reformed if done
carefully. Attach pressure tester (7700 or an equiva-
lent) to radiator filler neck (Fig. 39).
Operate tester pump to apply 103.4 kPa (15 psi)
pressure to system. If hoses enlarge excessively or
Remove lead away hose, flushing gun, water sup-
ply hose and air supply hose. Remove t hermost at
housing and install t hermost at . Install t hermost at
housing with a replacement gasket. Refer to Thermo-
st at Replacement. Connect radi at or hoses. Refill cool-
ing system with correct antifreeze/water mi xt ure.
Refer to Refilling t he Cooling System.
REVERSE FLUSHING ENGINE-DIESEL
(1) Drain t he cooling system.
(2) Disconnect t he upper hose from t he radiator.
(3) Disconnect t he radi at or lower hose from t he
wat er pump.
CAUTI ON; Be sure the heater control valve is
closed (heat off). This will prevent coolant flow with
scale and other deposits from entering the heater
core.
(4) Remove t he heat er core i nl et hose from tube
(Fig. 37).
light (black light). Pour one ounce of additive into
cooling system. Place heat er control uni t in HEAT
position. St ar t and operate engine until radi at or up-
per hose is warm to touch. Aim black light (tool
C-4555 or an equivalent) at components to be
checked. If leaks are present, black light will cause
additive to glow a bri ght green color.
The black light can be used in conjunction with a
pressure t est er to determine if any external leaks ex-
ist (Fig. 38).

C OOL I NG SYSTEM
Fig. 39 Pressure Testing Cooling SystemTypical
bulges while testing, replace as necessary. Observe
gauge pointer and determine condition of cooling sys-
tem according to following criteria:
Hol ds Steady: If pointer remai ns steady for two
mi nut es, serious coolant leaks are not present in sys-
tem. However, t here could be an i nt ernal leak t hat
does not appear with normal system test pressure. If
it is certain t hat coolant is being lost and leaks can-
not be detected, inspect for interior leakage or per-
form Int ernal Leakage Test.
Drops Slowly: Indicates a small leak or seepage is
occurring. Exami ne all connections for seepage or
slight leakage with a flashlight. Inspect radiator,
hoses, gasket edges and heat er. Seal small leak holes
with a Sealer Lubricant (or equivalent). Repair leak
holes and inspect system agai n with pressure ap-
plied.
Drops Quickly: Indicates t hat serious leakage is
occurring. Exami ne system for external leakage. If
leaks are not visible, inspect for i nt ernal leakage.
Large radi at or leak holes should be repaired by a
reputable radiator repai r shop.
INTERNAL LEAKAGE INSPECTION
Remove engine oil pan drai n plug and drain a
small amount of engine oil. If coolant is present in
t he pan, it will drai n first because it is heavier t han
oil. An al t ernat i ve method is to operate engine for a
short period to churn t he oil. After t hi s is done, re-
move engine dipstick and inspect for wat er globules.
Also inspect transmission dipstick for wat er globules
and transmission fluid cooler for leakage.
W ARN I N G: W I TH PRE S S U RE TE STE R TOOL 7700
I N STAL L E D ON RAD I ATOR, D O N OT AL L OW PRE S -
S URE TO E X C E E D 110 K PA (20 PSI ) . PRE S S URE
W I LL BUI LD UP Q UI CK L Y I F A C OM BUSTI ON L E AK
I S PRE SE N T. TO RE L E A S E PRE S S URE , ROC K
TE STE R F ROM SI D E TO SI D E . W H E N RE M OV I N G
TE STE R, D O N OT TURN TE STE R M ORE TH AN 1/2
TURN IF SY STE M I S UN D E R PRE S S URE .
Operate engine without pressure cap on radiator
unt i l t hermost at opens. Attach a Pressure Tester to
filler neck. If pressure builds up quickly it indicates
a combustion leak exists. This is usually t he result of
a cylinder head gasket leak or crack in engine. Re-
pair as necessary.
If t here is not an immediate pressure increase,
pump t he Pressure Tester. Do t hi s unt i l indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.
Because t he vehicle is equipped with a catalytic
converter, do not remove spark plug cables or short
out cylinders (non-diesel engines) to isolate compres-
sion leak.
If t he needle on dial of pressure tester does not
fluctuate, race engine a few times to check for an ab-
normal amount of coolant or steam. This would be
emi t t i ng from exhaust pipe. Coolant or steam from
exhaust pipe may indicate a faulty cylinder head
gasket, cracked engine cylinder block or cylinder
head.
A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-
able Block Leak Check tool. Follow manufacturers
instructions when using this product.
COMBUSTION LEAKAGE TEST-WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
W ARN I N G: D O N OT RE M OV E CY L I N D E R BL OC K
D RAI N PL UGS OR L OOSE N RAD I ATOR D RAI N -
C OC K WI T H S Y S T E M HOT A N D U N D E R P R E S -
S U R E . SE RI OUS BURN S F ROM COOL AN T C A N
OC C UR.
Drai n sufficient coolant to allow t hermost at re-
moval. Refer to Thermost at Replacement. Disconnect
wat er pump drive belt.
Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of top of t hermost at housing.
C A U T I O N : Avoi d overheating. D o not operate en-
gi ne for an excessi ve period of time. Open drain-
cock immediately after test to eliminate boil over.
St art engine and accelerate rapidly t hree times, to
approximately 3000 rpm while observing coolant. If
i nt ernal engine combustion gases
%
are leaking into
cooling system, bubbles will appear in coolant. If
bubbles do not appear, i nt ernal combustion gas leak-
age is not present.
COOLANT RESERVE/0WERFL0W SYSTEM
The coolant reserve/overflow system (Fig. 40 or 41)
works in conjunction with t he radiator pressure cap.

It utilizes t hermal expansion and contraction of cool-
ant to keep coolant free of trapped air. It provides a
volume for expansion and contraction of coolant. It
also provides a convenient and safe method for
checking coolant level and adjusting level at atmo-
spheric pressure. Thi s is done without removing ra-
diator pressure cap. It also provides some reserve
coolant to cover minor leaks and evaporation or boil-
ing losses.
FAN
SHROUD
J9107-67
Fig. 40 Coolant Reserve/Overflow TankGas
Engines
Fig. 41 Coolant Reserve/Overflow TankDiesel
Engines
Refer to Coolant Level CheckService, Deaeration
and Radiator Pressure Cap sections in t hi s group for
coolant reserve/overflow system operation and ser-
vice.
Should t he reserve/overflow t ank become coated
with corrosion or emulsifiable oil, it can be cleaned
with detergent and water. Rinse t ank thoroughly be-
fore refilling cooling system as described in t he Cool-
ant section of this group.
TANK REMOVAL
(1) Remove overflow hose at reserve/overflow t ank.
(2) Unsnap t he coolant reserve/overflow t ank from
fan shroud. Lift st rai ght up. The fan shroud is
equipped with T-shaped slots to at t ach t he t ank.
TANK INSTALLATION
(1) Snap t ank into fan shroud.
(2) Install overflow hose to t ank.
RADIATOR PRESSURE CAP
Radiators are equipped with a pressure cap, which
releases pressure at some point within a range of 97-
124 kPa (14-18 psi). The pressure relief point (in
pounds) is engraved on top of cap.
The cooling system will operate at pressures
slightly above atmospheric pressure. This resul t s i n a
hi gher coolant boiling point allowing increased radi-
ator cooling capacity. The cap (Fig. 42) contains a
spring-loaded pressure relief valve t hat opens when
system pressure reaches release range of 97-124 kPa
(14-18 psi).
Fig. 42 Radiator Pressure Cap and Filler
NeckTypical
A vent valve in t he center of cap allows a small
coolant flow t hrough cap when coolant is below boil-
ing t emperat ure. The valve is completely closed
when boiling point is reached. As t he coolant cools, it
contracts and creates a vacuum in t he cooling sys-
t em. This causes t he vacuum valve to open and cool-
ant in t he reserve/overflow t ank to be drawn t hrough
its connecting hose into radiator. If t he vacuum valve
is stuck shut, t he radiator hoses will collapse on cool-
down. Clean t he vent valve (Fig. 42).
A rubber gasket seals radiator filler neck to pre-
vent leakage. This is done to keep system under

pressure. It also mai nt ai ns vacuum duri ng coolant
cool-down allowing coolant to r et ur n from reserve/
overflow t ank.
RADIATOR CAP-TO-FILLER NECK
SEAL-PRESSURE RELIEF CHECK
The pressure cap upper gasket (seal) pressure relief
can be tested by removing overflow hose from radia-
tor filler neck nipple. Attach hose of pressure tester
tool 7700 or equivalent to nipple. It will be necessary
to disconnect hose from its adapt er for filler neck.
Pump air into radiator. The pressure cap upper gas-
ket should relieve at 69-124 kPa (10-18 psi) and hold
pressure at a mi ni mum of 55 kPa (8 psi).
W ARN I N G; TH E W ARN I N G W ORD S - D O N OT
OPE N H OT ON RAD I ATOR PRE S S U RE C AP, A RE
A SAF E TY PRE CAUTI ON . W H E N H OT, PRE S S URE
BUI L D S UP I N COOL I N G SY STE M . TO PRE V E N T
SC AL D I N G OR I N J URY , RAD I ATOR C AP SH OUL D
N OT BE RE M OV E D W H I LE SY STE M I S H OT
AN D / OR UN D E R PRE S S URE .
Do not remove radi at or cap at any t i me except for
t he following purposes:
Check and adjust antifreeze freeze point
Refill system with new antifreeze
Conducting service procedures
Checking for vacuum leaks
W ARN I N G; I F V E H I CL E H AS BE E N RUN RE CE N TL Y ,
W AI T AT L E AST 15 M I N UTE S BE F ORE RE M OV I N G
RAD I ATOR C AP. W I TH A RAG, SQ UE E Z E RAD I A-
TOR UPPE R H OSE TO C H E C K IF SY STE M I S UN -
D E R PRE S S URE . PL AC E A RAG OV E R C AP AN D
W I TH OUT PUSH I N G C AP D OW N , ROTATE IT
C OUN TE R- C L OC K W I SE TO F I RST STOP. AL L OW
F LUI D TO E S C A PE TH ROUGH TH E COOL AN T RE -
SE RV E / OV E RF L OW H OSE I NTO RE SE RV E / OV E R-
F L OW TAN K . SQ UE E Z E RAD I ATOR UPPE R H OSE
TO D E TE RM I N E W H E N PRE S S U RE H AS BE E N RE -
L E ASE D . W H E N COOL AN T AN D STE AM STOP BE -
I N G PUSH E D I NTO TAN K AN D SY STE M PRE S S U RE
D ROPS, RE M OV E RAD I ATOR C AP C OM PL E TE L Y .
PRESSURE TESTING RADIATOR CAPS
Remove cap from radiator. Be sure t hat sealing
surfaces are clean. Moisten rubber gasket with wat er
and install cap on pressure t est er 7700 or an equiv-
al ent (Fig. 43).
Operate tester pump to bri ng pressure to 104 kPa
(15 psi) on gauge. If pressure cap fails to hold pres-
sure of at least 97 kPa (14 psi) replace cap. Refer to
CAUTI ON below.
The pressure cap may t est properly while posi-
tioned on tool 7700 (or equivalent). It may not hold
pressure or vacuum when installed on radiator. If so,
Fig. 43 Pressure Testing Radiator Cap
inspect radiator filler neck and cap's top gasket for
damage. Also inspect for dirt or distortion t hat may
prevent cap from sealing properly.
C A U T I O N : Tool 7700 i s very sensi ti ve to smal l air
l eaks, whi ch will not cause cool i ng syst em prob-
l ems. A pressure cap that does not have a history
of cool ant l os s shoul d not be replaced just because
it l eaks sl owl y when tested with thi s tool. A dd water
to tool. Turn tool upsi de down and recheck pres-
sure cap to confirm that cap needs replacement.
INSPECTION
Hold cap at eye level, ri ght side up. The vent valve
(Fig. 42) at bottom of cap should open. If rubber gas-
ket has swollen and prevents vent valve from open-
ing, replace cap.
Hold cap at eye level, upside down. If any light can
be seen between vent valve and rubber gasket, re-
place cap. Do not use a repl acement cap that has
a spri ng to hol d vent shut. A replacement cap
must be t he type designed for a coolant reserve/over-
flow system with a completely sealed diaphragm
spring and a rubber gasket. This gasket is used to
seal to radiator filler neck top surface. Use of proper
cap will allow coolant r et ur n to radiator.
RADIATORS
3.9L, 5.2L and 5.9L Gas Engines: The radiator is a
down-flow type (vertical tubes).
5.9L Diesel Engines: The radi at or is a cross-flow
type (horizontal tubes).

The radiator supplies sufficient heat transfer to
cool t he engine and automatic transmission (if
equipped).
RADIATOR COOLANT FLOW CHECK
Use t he following procedure to determine if coolant
is flowing t hrough t he cooling system.
(1) Idle engine until operating t emperat ure is
reached. If t he upper radiator hose is warm to t he
touch, t he t hermost at is opening and coolant is flow-
ing to t he radiator.
W ARN I N G: H OT, PRE SSURI Z E D COOL AN T C AN
C A US E I N J URY BY SCAL D I N G. USI N G A RA G TO
C OV E R TH E RAD I ATOR PRE S S URE C AP, OPE N
RAD I ATOR C AP SL OW L Y TO TH E F I RST STOP.
TH I S W I LL AL L OW AN Y BUI LT- UP PRE S S U RE TO
V E N T TO TH E RE SE RV E / OV E RF L OW TAN K . AF TE R
PRE S S URE BUI LD - UP H AS BE E N RE L E A S E D , RE -
M OV E C AP F ROM F I LLE R N E CK .
(2) Drain a small amount of coolant from t he radi-
ator until t he ends of the radiator tubes are visible
t hrough t he filler neck. Idle t he engine at normal op-
erat i ng t emperat ure. If coolant is flowing past t he
exposed tubes, t he coolant is circulating.
RADIATOR REMOVAL-EXCEPT DIESEL
W ARN I N G; D O NOT RE M OV E THE CY L I N D E R
BL OC K D RAI N PL UGS OR L OOSE N THE RAD I ATOR
D RAI N C OC K W I TH TH E SY STE M H OT AN D UN D E R
PRE S S URE . SE RI OUS BURN S F ROM COOL AN T
C AN OC C UR.
(2) Drai n t he cooling system. Refer to Drai ni ng
Cooling System.
(3) Disconnect throttle cable from clip at radi at or
fan shroud.
(4) Remove hose clamps and hoses from radiator.
Special Clamp Tool number 6094 (Fig. 44) may be
used to remove t he constant tension clamps.
(5) Remove coolant reserve/overflow t ank hose
from radiator filler neck nipple.
(6) If equipped with an automatic transmission
(except diesel), disconnect oil cooler hoses at radi at or
lower t ank.
(7) Remove fan shroud mounting bolts/clips and
position shroud rearward on engine (Fig. 45).
(8) Loosen radiator lower mounting bolts. Remove
t he upper mount i ng bolts. Lift radiator st rai ght up
and out of engine compartment. Take care not to
damage radi at or cooling fins or tubes.
INSTALLATION
(1) Position shroud rearward on engine.
(2) Slide radi at or into position. Place behind radi-
ator support with lower mount i ng holes (slots) rest-
HOSE CLAMP
TOOL 6094
HOS E
CLAMP
J9207-36
RADIATOR SHROUD
MOUNTI NG MOUNTI NG
BOLTS CUPS
RADIATOR
V
1
FAN S H R O U D ^
J9207-44
Fig. 45 Radiator and Fan ShroudGas Engines
ing on loosened bottom mount i ng bolts. Install upper
mount i ng bolts. Tighten all mount i ng bolts to 11
N*m (95 in. lbs.) torque.
(3) Connect radiator hoses.
(4) Connect transmission oil cooler lines to bottom
t ank. Tighten hose clamps to 4 N
#
m (35 in. lbs.)
torque.
(5) Position fan shroud on radi at or flange. Install
mount i ng clips (Fig. 45).
(6) Connect throttle cable to fan shroud.
(7) Position heat er controls to full he a t position.
(8) Fill cooling system with coolant. Refer to Refill-
ing Cooling System in this group.
(9) Operate engine unt i l it reaches normal temper-
at ure. Check cooling system and aut omat i c t ransmi s-
sion (if equipped) fluid levels.
RADIATOR REMOVAL-DIESEL
(1) Disconnect negative bat t ery cable from battery.

W ARN I N G; D O N OT RE M OV E TH E CY L I N D E R
BL OC K D RAI N PL UGS OR L OOSE N TH E RAD I ATOR
D RAI N C OC K W I TH TH E SY STE M H OT AN D UN D E R
PRE S S URE . SE RI OUS BURN S F ROM COOL AN T
C AN OC C UR.
(2) Drai n t he cooling system. Refer to Drai ni ng
Cooling System in t hi s group.
(3) Remove hose clamps and hoses from radiator.
Remove coolant reserve/overflow t ank hose from ra-
diator filler neck nipple.
(4) Remove fan shroud ret ai ni ng clips. The shroud
has two t abs t hat fit into clips in t he bottom of t he
radiator. Lift t he shroud up and position it back onto
t he engine (Fig. 46).
Fig. 46 Radiator and Fan Shroud5.9L Diesel
Engine
(5) Remove radi at or top mount i ng brackets. The
brackets fit over support dowels on t he radi at or inlet
t ank (Fig. 46).
(6) The bottom of t he radiator has two dowels t hat
fit into holes in t he lower support panel. Taki ng care
not to damage radi at or cooling fins or tubes, lift ra-
diator st rai ght up out of engine compartment
INSTALLATION
(1) Position shroud rearward on engine.
(2) Lower radi at or into position. The dowels on t he
bottom of t he radi at or fit into al i gnment holes in t he
lower support panel.
(3) Install top mount i ng brackets. Tighten mount-
ing bolts to 23 N*m (17 in. lbs.) torque.
(4) Connect radi at or hoses. Install hose clamps.
(5) Position fan shroud on radiator flange. Install
ret ai ni ng clips.
(6) Place heat er controls in full he a t position.
(7) Fill cooling system with coolant. Refer to Refill-
ing Cooling System in this group.
(8) Operat e engine until it reaches normal temper-
at ure. Check cooling system.
RADIATOR DRAINCOCK SERVICE
The radiator draincock is replaceable. Unscrew t he
draincock in a clockwise direction and remove from
radiator. Install replacement draincock.
COOLING SYSTEM HOSES
Rubber hoses route coolant to and from t he radia-
tor, i nt ake manifold and heat er core. Radiator lower
hoses are spring-reinforced to prevent collapse from
wat er pump suction at moderate and high engine
speeds.
Inspect t he hoses at regul ar intervals. Replace
hoses t hat are cracked, feel brittle when squeezed or
swell excessively when system is pressurized. The
use of molded replacement hoses is recommended.
When performing a hose inspection, inspect radiator
lower hose for proper position and condition of
spring.
RADIATOR
J9207-35
Fig. 47 Radiator HosesTypical
HOSE CLAMPS
Constant tension hose clamps are used on some
cooling system hoses. The clamp size is identified by
a l et t er stamped on t he tongue. Special Clamp Tool
number 6094 (Fig. 48) may be used to remove t he
constant tension clamps.
Ordinary worm gear type hose clamps (when
equipped) can be removed with a st rai ght screw-
driver or a hex socket. To pr e ve nt da ma ge t o
hos es or cl amps , t he hos e c l a mps s houl d be
t i ght ened to 4 Nm (34 in. lbs.) torque. Do not
over t i ght en hos e cl amps .

HOSE CLAMP
TOOL 6094
HOSE
CLAMP
J9207-36
Fig. 48 Hose damp Tool
TRANSMISSION OIL COOLEREXCEPT DIESEL
The automatic transmission oil is cooled when it
passes t hrough a cooler in t he radi at or lower t ank
(Fig. 49 and 50).
h*-TRANSMISSION
- OIL COOLER
FRONT OF VEHICLE
AUTOMATI C
TRANSMISSION
PRESSURE LINE
6 AND 8 CYLINDER ENGINE RETURN LINE
RY402
Fig. 49 Top View of Transmission Oil Cooling
CircuitExcept DieselTypical
COOLING TUBE
(CUT-A-WAY)
DRAIN COCK
HOSE
CLAMP
HOSE TO
COOLER LINE
HOSE TO
COOLER LINE
RY401
Fig. 50 Automatic Transmission Oil CoolerExcept
Diesel Typical
In case of a leak in t he transmission oil cooler, en-
gine coolant may become mixed with transmission
fluid or transmission fluid may ent er engine cooling
system. Both cooling system and transmission should
be drained and inspected in t he event cooler is leak-
ing.
REPLACING OIL COOLER IN BOTTOM TANK
Remove radiator. Refer to Radiator removal in t hi s
group. The servicing should be performed by a qual-
ified repair facility.
Once t he repaired or replacement radi at or has been
installed, fill t he cooling system and inspect for
leaks. Refer to Refilling Cooling System and Testing
Cooling System For Leaks sections in this group. If
t he transmission operates properly after repai ri ng
t he leak, drai n t he transmission and remove t he
transmission oil pan. Inspect for sludge and/or rust .
Inspect for a dirty or plugged inlet filter. If none of
these conditions are found, t he transmission and
torque convertor may not require reconditioning. Re-
fer to Group 21 for automatic transmission servicing.
1 RANSMI SSI 0N OIL COOLER- DI ESEL
The transmission oil cooler is mounted to a bracket
on t he turbocharger side of the engine (Fig. 51).
TRAN SM I SSI ON
OI L
COOLE R
Fig. 51 Automatic Transmission Oil Cooler5.9L
Diesel
REMOVAL
In case of a leak in t he transmission oil cooler, en-
gine coolant may become mixed with transmission
fluid or transmission fluid may ent er engine cooling
system. Both cooling system and transmission should
be drained and inspected in t he event cooler is leak-
ing.
(1) Disconnect negative bat t ery cable at bat t ery.
(2) Drai n cooling system. Refer to Draining Cool-
ing System.
(3) Disconnect coolant lines from cooler.
(4) Disconnect transmission oil lines from cooler.
Pl ug cooler lines to prevent oil leakage.
(5) Remove oil cooler mounting straps.
(6) Lift oil cooler off of mounting bracket.
INSTALLATION
(1) Position oil cooler on bracket.
(2) Install mount i ng straps.
(3) Connect transmission oil lines to cooler.

(4) Connect coolant hoses to cooler.
(5) Connect bat t ery cable to battery.
(6 ) Fill cooling system. Refer to Refilling Cooling
System in t hi s section.
(7) Check transmission oil level and fill as neces-
sary.
TRANSMISSION OIL/TO-AIR COOLER
Oil to ai r transmission coolers are mounted ahead
of t he radi at or and operate in conjunction with t he
mai n cooler (Figs, 52 or 53). The transmission oil is
routed t hrough t he mai n cooler first, t hen t he auxil-
iary cooler, before ret urni ng to t he transmission.
FRONT
OIL-TO-AIR
COOLER
RADIATOR
RADIATOR GRILL
SUPPORT
RETURN
J O
_ TRANSMISSION
* PRESSURE
(FROM BOTTOM COOLER)
VIEW IN CIRCLE J9007-75
Fig. 52 Transmission Oil-to-Air CoolerExcept
Diesel Typical
AUXILIARY
OIL TO AIR
COOLER
J9107-73
Fig. 53 Transmission Oil-to-Air CoolerDiesel
EngineTypical
COOLING SYSTEM FANGAS ENGINES
Also refer to Viscous Fan Drive in t hi s group for
REMOVAL
(2) Remove t hrot t l e cable at top of fan shroud.
(3) Unsnap coolant reserve/overflow t ank from fan
shroud and lay aside. The t ank is held to shroud
with T-shaped slots. Do not disconnect hose or drain
coolant from t ank.
(4) The t hermal Viscous Fan Drive/Fan Blade As-
sembly is attached (threaded) to water pump hub
shaft (Fig. 54). Remove fan blade/viscous fan drive
assembly from wat er pump by t urni ng mounting nut
counterclockwise as viewed from front. Threads on
viscous fan drive are RI GHT HAND. A Snap-On 36
MM Fan Wrench (number SP346 from Snap-On
Cummi ns Diesel Tool Set number 2017DSP) can be
used. Place a bar or screwdriver between wat er pump
pulley bolts (Fig. 54) to prevent pulley from rotating.
Do not at t empt to remove fan/viscous fan drive as-
sembly from vehicle at this time.
FAN BLADE
ASSEMBLY
THREADED
NUT
WATER
PUMP
PULLEY PULLEY
BOLTS
WATER PUMP
THREADED SHAFT
(WATER PUMP HUB)
VISCOUS FAN DRIVE
CRANKSHAFT
PULLEY
J9307-32
Fig. 54 Fan Blade/Viscous Fan DriveGas Engines
Do not unbolt fan blade assembly (Fig. 54) from
viscous fan drive at t hi s time.
(5) Remove fan shroud at t achi ng hardware (two
bolts at bottom-two clips at top).
(6) Remove fan shroud and fan blade/viscous fan
drive assembly as a complete uni t from vehicle.
After removing fan blade/viscous fan drive assem-
bly, do not place viscous fan drive in horizontal po-
sition. If stored horizontally, silicone fluid i n t he
viscous fan drive could drain into its bearing assem-
bly and cont ami nat e lubricant.

CAUTI ON : D o not remove water pump pulley-to-wa-
ter pump bol ts ( F i g. 54 ) , Thi s pul l ey i s under spr i ng
t ensi on.
(7) Remove four bolts securing fan blade assembly
to viscous fan drive (Fig. 54).
INSPECTION
The fan cannot be repaired. If fan is damaged, it
must be replaced. Inspect fan as follows:
(1) Remove fan blade and viscous fan drive as an
assembly from t he engine. Refer to preceding Re-
moval procedure.
(2) Remove fan blade assembly from viscous fan
drive uni t (four bolts).
(3) Lay fan on a flat surface wi t h leading edge fac-
ing down. With tip of blade touching flat surface, re-
place fan if clearance between opposite blade and
surface is greater t han 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in t hi s manner.
WA R N I N G : D O N O T A T T E M PT T O BE N D O R
S T R A I G H T E N F A N B L A D E S I F N O T WI T HI N S PE C I -
F I C A T I O N S .
(4) Inspect fan assembly for cracks, bends, loose
rivets or broken welds. Replace fan if any damage is
found,
C A U T I O N : If fan blade assembl y i s replaced be-
cause of mechani cal damage, water pump and vi s-
cous fan drive shoul d al so be i nspected. T hese
component s coul d have been damaged due to ex-
cessi ve vibration.
INSTALLATION
(1) Install fan blade assembly to viscous fan drive.
Tighten bolts (Fig. 48) to 23 N*m (17 ft. lbs.) torque.
(2) Position fan shroud and fan blade/viscous fan
drive assembly to vehicle as a complete unit.
(3) Install fan shroud.
(4) Install fan blade/viscous fan drive assembly to
water pump shaft (Fig. 54).
(5) Install coolant reserve/overflow t ank to fan
shroud. Snaps into position.
(6) Install throttle cable to fan shroud.
(7) Connect negative bat t ery cable.
COOLING SYSTEM F AN- DI E SE L ENGINE
REMOVAL
(2) Remove the fan shroud mount i ng bolts. Posi-
tion fan shroud towards engine.
C A U T I O N : Do not remove the fan puHey bol ts. T hi s
pulley i s under spr i ng t ensi on.
(3) The t her mal viscous fan drive/fan blade assem-
bly is attached (threaded) to t he fan hub shaft (Fig.
55). Remove t he fan blade/fan drive assembly from
fan pulley by t urni ng t he mount i ng nut clockwise (as
viewed from front). Threads on t he viscous fan drive
are LEFT HAND. A Snap-On 36 MM Fan Wrench
(number SP346 from Snap-On Cummins Diesel Tool
Set number 2017DSP) can be used. Place a bar or
screwdriver between t he fan pulley bolts to prevent
pulley from rotating.
THREADED
Fig. 55 Fan Blades/Viscous Fan Drive-5.9L Diesel
(4) Remove t he fan shroud and t he fan blade/vis-
cous drive as an assembly from vehicle.
(5) Remove fan blade-to-viscous fan drive mount-
ing bolts.
Inspect t he fan for cracks, loose rivets, loose or
bent fan blades.
INSPECTION
The fan cannot be repaired. If t he fan is damaged,
it must be replaced. Inspect t he fan as follows:
(1) Remove fan blade and t hermal viscous fan
drive assembly from engine. Refer to t he preceding
Removal procedure.
(2) Remove fan blade assembly from t hermal vis-
cous fan drive uni t (four bolts).
(3) Lay fan on a flat surface with leading edge fac-
ing down. With tip of blade touching flat surface, re-
place fan if clearance between opposite blade and
surface is great er t han 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.

W ARN I N G: DO N OT ATTE M PT TO BE N D OR
STRAI GH TE N F AN BL A D E S IF N OT WITHIN SPE C I -
F I CATI ON S.
(4) Inspect fan assembly for cracks, bends, loose
rivets or broken welds. Replace fan if any damage is
found.
CAUTION; If the fan bl ade assembl y is repl aced be-
c ause of mechani cal damage, the fan pul l ey and
v i s c ous fan drive shoul d al so be i nspect ed. These
c omponent s coul d have been damaged due to ex -
c essi ve vi brati on.
INSTALLATION
(1) Install fan blade assembly to viscous fan drive.
Tighten mount i ng bolts.
(2) Position t he fan shroud and fan blade/viscous
fan drive to t he vehicle as an assembly.
(3) Install viscous fan drive assembly on fan hub
shaft. Tighten mount i ng nut to 57 N*m (42 ft. lbs.)
torque.
(4) Install fan shroud bolts.
(5) Install bat t ery cable to bat t ery.
VISCOUS FAN DRIVE
The t hermal viscous fan drive (Figs. 54 or 55) con-
sists of t he viscous fan drive clutch and a thermo-
static spring coil mounted on its front face (Fig. 56).
The viscous fan drive clutch is a silicone-fluid-filled
coupling connecting fan blade assembly to wat er
pump shaft. The coupling allows fan to be driven in a
normal manner at low engine speeds. It will limit top
speed of fan to a predetermined maxi mum level at
higher engine speeds.
The thermostatic spring coil (Fig. 56) reacts to t he
t emperat ure of radi at or discharge air. It engages
drive clutch for hi gher fan speed if air t emperat ure
from radiator rises above a certain point. Unt i l addi-
tional engine cooling is necessary, fan will remai n at
a reduced rpm regardless of engine speed. Only when
sufficient heat is present in t he air, will t he viscous
fan drive clutch engage. This air flowing t hrough ra-
diator core will cause a reaction to thermostatic
spring coil. Fan speed will t hen increase to provide
necessary additional engine cooling.
MO U N T I N G NUT
TO WATER PUMP
Fig. 56 Viscous Fan Drive
CAUTION; If v i s c ous fan drive i s repl aced because
of mechani cal damage, cool i ng fan bl ades shoul d
al so be i nspect ed. I nspect for fatigue c r ac ks, l oose
bl ades or l oose rivets that coul d have resul ted from
ex c essi ve vi brati on. Repl ace fan bl ade assembl y if
any of t hese condi t i ons are found. Al s o i nspect wa-
ter pump beari ng and shaft assembl y for any re-
lated damage due to a v i s c ous drive mal functi on.
Regardless of increased engine speed, once t he fan
has reached its maxi mum operating speed, it will not
rot at e any faster. When t he necessary engine cooling
has been accomplished causing a reduction in tem-
perat ure of radi at or discharge air, t he spring coil
again reacts. This will cause fan speed to be reduced
to its previous disengaged speed.
TESTING VISCOUS FAN DRIVE
In case of engine overheating, inspect t hermal vis-
cous fan drive for proper operation. Observe move-
ment of thermostatic spring coil and shaft. Lift end
of thermostatic spring up and out of ret ai ni ng slot in
fan drive (Fig. 57). Rotate spring counterclockwise
unt i l a stop is felt. The gap between end of coil and
ret ai ni ng clip should be approximately 12 mm (0.5
inch) (Fig. 58). Replace uni t if shaft does not rotate
with coil. After testing, install end of coil in slot of
ret ai ni ng clip.
REMOVAUINSTALLA TION
For removal and installation procedures, refer to
Cooling System Fans in t hi s group.
Fig. 57 Disconnecting End of Thermostatic
Fig.
58 Testing Spring and Shaft Rotation-Typical
SpringTypical
ENGINE ACCESSORY DRIVE BELTS
INDEX
page
Automatic Belt Tensioner 4 5
Belt Di agnosi s 4 0
Belt Removal/Installation . 4 0
page
Belt Schemati cs 4 0
Belt Tensi on 4 0
GENERAL INFORMATION
All vehicles are available with either a 3.9L (V-6),
a 5.2L (V-8), a 5.9L (gas V-8) or a 5.9L (in-line 6 cyl-
inder diesel) engine.
The accessory drive components are operated by a
single, crankshaft driven, serpentine drive belt on all
engines. An automatic belt tensioner is used to main-
tain correct belt tension at all times. Refer to Auto-
matic Belt Tensioner proceeding in this group.
BELT DIAGNOSIS
SERPENTINE DRIVE BELT DIAGNOSIS-ALL
ENGINES
When diagnosing serpentine drive belts, small
cracks that run across ribbed surface of belt from rib
to rib (Fig. 1), are considered normal. These are not a
reason to replace belt. However, cracks running
along a rib (not across) are not normal. Any belt
with cracks running along a rib must be replaced
(Fig. 1). Also replace belt if it has excessive wear,
frayed cords or severe glazing.
Refer to the Serpentine Drive Belt Diagnosis charts
for further belt diagnosis. Also refer to Automatic
Belt Tensioner proceeding in this group.
BELT SCHEMATICS
The following belt routing schematics are pub-
lished from the latest information available at the
time of publication. If anythi ng differs bet ween
these schemati cs and the Belt Routi ng Label,
use the schemati cs on Belt Routi ng Label. This
label is located in the engine compartment.
BELT TENSION
ALL ENGINES
Correct accessory drive belt tension is required to
be sure of optimum performance of belt driven en-
gine accessories. If specified tension is not main-
tained, belt slippage may cause; engine overheating,
lack of power steering assist, loss of air conditioning
capacity, reduced generator output rate and greatly
reduced belt life.
It is not necessary to adjust belt tension on any en-
gine. All engines are equipped with an automatic
belt tensioner. The tensioner maintains correct belt
tension at all times. For other tensioner information
NORMAL CRACKS
BELT OK
NOT NORMAL CRACKS
REPLACE BELT
J9007-44
Fig. 1 Serpentine Accessory Drive Belt Wear
Patterns
and removal/installation procedures, refer to Auto-
matic Belt Tensioner proceeding in this group. Due
to use of this belt tensioner, do not attempt to use a
belt tension gauge on any engine.
BELT REMOVAL/INSTALLATION
C aut i on: D o not attempt to check belt t ensi on with
a belt t ensi on gauge on vehi cl es eq ui pped with an
automatic belt tensioner. Refer to Automati c Belt
Tensi oner in thi s gr oup.
3.9L/5,2U5*9L LDC-GAS ENGINES
REMOVAL
Drive belts on these engines are equipped with a
spring loaded automatic belt tensioner (Fig. 7). This
belt tensioner will be used on all belt configurations,
such as with or without power steering or air condi-
tioning. For more information, refer to Automatic
Belt Tensioner, proceeding in this group.
(1) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 7).

SERPENTINE DRIVE BELT DIAGNOSIS-EXCEPT DIESEL ENGINE
Condition Possible Cause Correction
RIB CHUNKING
(ONE OR MORE RIBS
HAS SEPARATED
FROM BELT BODY)
( 1) Foreign objects imbedded in
pulley grooves.
(2) Installation damage.
(1) Remove foreign objects from
pulley grooves. Replace belt.
(2) Replace belt.
RIB OR BELT WEAR
(1) Put ley (s) misaligned.
(1) Align pulley(s).
(2) Abrasive environment. (2) Clean pulley(s). Replace
belt if necessary.
(3) Rusted pulley(s).
(3) Clean rust from pulley(s).
(4) Sharp or jagged pulley groove tips. (4) Replace pulley.
(5) Rubber deteriorated.
(5) Replace belt.
LONGITUDINAL
BELT CRACKING
(CRACKS BETWEEN
TWO RIBS)
(1) Belt has mistracked from pulley
groove.
(2) Pulley groove tip has worn away
rubber to tensile member.
(1) Replace belt.
(2) Replace belt.
BELT SLIPS
(1) Belt slipping because of
insufficient tension.
(1) Adjust tension.
(2) Belt or pulley subjected to
substance (belt dressing, oil,
ethylene glycol) that has reduced
friction.
(2) Replace belt and clean pulleys.
(3) Driven component bearing failure. (3) Replace faulty component bearing.
(4) Belt glazed and hardened from
heat and excessive slippage.
(4) Replace belt.
"GROOVE JUMPING"
(BELT DOES NOT
MAINTAIN CORRECT
POSITION ON
PULLEY)
(1) Belt tension either too
high or too low.
(2) Pulley(s) not within design
tolerance.
(1) Adjust belt tension.
(2) Replace pulley(s).
(3) Foreign object(s) in grooves.
(3) Remove foreign objects from
grooves.
(4) Pulley misalignment.
(5) Belt cordline is broken. (5) Replace belt.
BELT BROKEN
(NOTE: IDENTIFY
AND CORRECT
PROBLEM BEFORE
NEW BELT IS
INSTALLED)
(1) Excessive tension.
(2) Tensile members damaged during
belt installation.
(3) Severe misalignment.
(1) Replace belt and adjust tension
to specification.
(2) Replace belt.
(4) Bracket, pulley, or bearing
failure.
(4) Replace defective component and
belt.
NOISE
(OBJECTIONAL
SQUEAL, SQUEAK,
bR RUMBLE IS
HEARD OR FELT
WHILE DRIVE BELT
IS IN OPERATION)
(1) Belt slippage.
(2) Bearing noise.
(3) Belt misalignment.
(4) Beit-to-pulley mismatch.
(1) Adjust belt.
(2) Locate and repair.
(3) Align belt/pulley(s).
(4) Install correct belt.
E8907-143

SERPENTINE DRIVE BELT DIAGNOSIS-DIESEL ENGINE
RIB C HU N K I N G
(1)
Foreign objects imbedded in
(1)
Remove foreign objects from
(ONE O R M O R E RIBS
(1)
pulley grooves.
pulley grooves. Replace belt.
HAS SEPARATED
pulley grooves.
Replace belt.
FROM BELT BODY) (2) Installation damage. (2)
Replace belt.
RIB OR BELT WEAR
(1)
Pulley(s) misaligned. (1) Align pulley(s).
(2)
Abrasive environment. (2) Clean pulley(s). Replace
(2)
belt if necessary.
(3) Rusted pulley(s). (3)
Clean rust from pulley(s).
(4)
Sharp or jagged pulley groove tips. (4) Replace pulley.
(5)
Rubber deteriorated. (5) Replace belt.
L ONGI T UDI NAL
(1)
Belt has mistracked from (1) Replace belt.
BELT C R A C K I N G
(1)
pulley groove.
Replace belt.
(CRACKS BETWEEN
T WO RIBS)
pulley groove.
Replace belt.
(CRACKS BETWEEN
T WO RIBS) (2) Pulley groove tip has worn away (2)
Replace belt.
(2)
rubber to tensile member.
BELT SLIPS
(1)
Belt slipping because of
0)
Replace tensioner.
(1)
insufficient tension.
(2)
Incorrect belt. (2) Replace belt.
(3) Belt or pulley subjected to (3) Replace belt and clean pulleys.
substance (belt dressing, oil,
ethylene glycol) that has
reciuced friction.
(4) Driven component bearing failure. (4) Replace faulty component bearing.
(5) Belt glazed and hardened from (5) Replace belt.
(5)
heat and excessive slippage.
"G R O O V E J U MPI N G "
(1)
Belt tension either too (1) Replace tensioner.
(BELT D O E S N OT
5
(1)
high or too low.
Replace tensioner.
MAI NTAI N CORRECT
high or too low.
POSI TI ON O N PULLEY) (2) Incorrect belt. (2) Replace belt.
(3)
Pulley(s) not within design (3) Replace pulley(s).
tolerance.
(4)
Foreign object(s) in grooves. (4) Remove foreign objects
from grooves.
(5)
Pulley misalignment. (5) Check and Replace.
(6)
Belt cordline is broken. (6) Replace belt.
BELT BROKE N
0)
Excessive tension.
0)
Replace belt and
(NOTE: IDENTIFY
0)
tensioner.
A N D CORRECT
PROBLEM BEFORE (2) Incorrect belt. (2) Replace belt.
NEW BELT IS
(2) Replace belt.
INSTALLED) (3) Tensile members damaged during (3) Replace belt. (3)
belt installation.
(4)
Severe misalignment. (4) Check and replace.
(5) Bracket, pulley, or bearing (5) Replace defective component
(5)
failure. ana belt.
NOI S E
0)
Belt slippage.
(1)
Replace belt or belt tensioner.
(OBJECTI ONAL
0)
Belt slippage. Replace belt or belt tensioner.
S QUE AL, S QUE AK, (2) Bearing noise. (2) Locate and repair.
OR RUMBLE IS
(2) Bearing noise.
HEARD OR FELT
(3)
Belt misalignment. (3) Replace belt.
WHILE DRIVE BELT
(3)
Belt misalignment. Replace belt.
IS I N OPERATI ON) (4) Belt-to-pulley mismatch. (4) Install correct belt.
J9107-74

*IF VEHICLE IS NOT EQUIPPED WITH POWER
STEERING, THIS WILL BE AN IDLER PULLEY. J9307-26
Fig. 2 Beit Routing - 3.9U5.2L/5.9L LDC-Gas Engine
AUTOMATIC
TENSIONER
J9307-55
Fig. 3 Beit Routing5.9L HDC-Gas EngineWith
A/C
(2) Rotate tensioner assembly clockwise (as viewed
from front) until tension has been relieved from belt.
(3) Remove belt from idler pulley first.
(4 ) Remove belt from vehicle.
INSTALLATION
CAUTI ON : W hen instal l ing serpenti ne ac c essor y
drive belt, belt must be routed correctl y. If not, en-
AUTOMATIC
TENSIONER
J9307-56
Fig. 4 Belt Routing5.9L HDC-Gas EngineWithout
A/C
'POWER STEERING PUMP IS NOT BELT DRIVEN
Fig. 5 Belt Routing-5.9L Diesel-With A/C
wrong direction. Refer to (Fi g. 2) for correct engi ne
belt routing. The correct belt with correct length
must be used.
(1) Position drive belt over all pulleys except idler
pulley. This pulley is located between generator and
A/C compressor.

Fig. 6 Belt Routing-5.9L Diesel-Without A/C
Fig. 7 Belt Tensioner-3.9L/5.2U5.9L LDC-Gas
Engine
(3) Rotate socket/wrench clockwise. Place belt over
idler pulley. Let tensioner rot at e back into place. Re-
move wrench. Be sure belt is properly seated on all
pulleys.
(4 ) Check belt indexing mar ks. Refer to t he pro-
ceeding Automatic Belt Tensioner for more belt in-
formation.
5.9L HDC-GAS ENGINE
REMOVAL
Drive belts are equipped with a spring loaded au-
tomatic belt tensioner (Fig. 8). This belt tensioner
will be used on all belt configurations, such as with
or without power steering or air conditioning. For
more information, refer to Automatic Belt Tensioner,
proceeding in t hi s group.
of automatic tensioner (Fig. 8). (The t hreads on t hi s
bolt are left hand).
(2) Relax t he tension from the belt by rot at i ng t he
tensioner counterclockwise (as viewed from front)
(Fig. 8). When all belt tension has been relaxed, re-
move belt from tensioner pulley first and other pul-
leys last.
INSTALLATION
C A U T I O N : When installing serpentine accessor y
drive belt, belt must be routed correctly. If not, en-
wr ong direction. Refer to ( Fi gs. 3 or 4) for correct
engi ne belt routing. The correct belt with correct
length must tê used.
C A U T I O N : if the pulley i s to be removed from the
tensi oner, its mounti ng bolt has left hand threads.
(1) Position drive belt over all pulleys except ten-
sioner pulley.

(3) Rotate socket/wrench counterclockwise. Install
belt over tensioner pulley. Let tensioner rot at e back
into place. Remove wrench. Be sure belt is properly
seated on all pulleys.
59L DIESEL ENGINE
REMOVAL
Drive belts on diesel engines are equipped with a
spring loaded automatic belt tensioner (Fig. 9). Fig-
ure 9 di spl ays the tensi oner for vehi cl es wi thout
ai r condi t i oni ng.
This belt tensioner will be used on all belt config-
urations, such as with or without air conditioning.
For more information, refer to Automatic Belt Ten-
sioner, proceeding in this group.
Fig. 9 Belt Tensioner5.9L Diesel EngineTypical
(1) A 3/8 inch square hole is provided in t he auto-
matic belt tensioner (Fig. 9). At t ach a 3/8 inch drive-
long handle rat chet to t hi s hole.
(2) Rotate rat chet and tensioner assembly counter-
clockwise (as viewed from front) unt i l tension has
been relieved from belt.
(3) Remove belt from wat er pump pulley first.
(4) Remove belt from vehicle.
INSTALLATION
C A U T I O N : When installing serpentine accessor y
drive belt, belt must be routed correctly. If not, en-
wrong direction. Refer to ( F i gs. 5 or 6) for correct
engi ne belt routing. The correct belt with correct
length must be used.
(1) Position drive belt over all pulleys except wa-
t er pump pulley.
(2) Attach a 3/8 inch rat chet to tensioner.
(3) Rotate rat chet and belt tensioner counterclock-
wise. Place belt over wat er pump pulley. Let ten-
sioner rot at e back into place. Remove ratchet. Be
sure belt is properly seated on all pulleys.
AUTOMATIC BELT TENSIONER
Drive belts on all engines are equipped wi t h a
spring loaded aut omat i c belt tensioner (Figs. 10, 11
or 12). Thi s belt tensioner will be used with all belt
configurations, such as with or without power steer-
ing or air conditioning.
C aut i on: D o not attempt to check belt t ensi on with
a belt t ensi on gauge on vehi cl es equi pped with an
automati c belt tensi oner.
Fig. 10 Belt Tensioner3.9U5.2U5.9L LDC-Gas
Engine
On 3.9L/5.2L and 5.9L LDC-gas engines, t he ten-
sioner is equipped with an indexing arrow (Fig. 13)
on back of tensioner and an indexing mark on ten-
sioner housing. If a new belt is being installed, arrow
must be within approximately 3 mm (1/8 in.) of in-
dexing mar k (Point BFig. 13). Belt is considered
new if it has been used 15 mi nut es or less. If t hi s
specification cannot be met, check for:
The wrong belt being installed (incorrect length/
width)
Worn bearings on an engine accessory (A/C com-
pressor, power steering pump, wat er pump, idler pul-
ley or generator)
A pulley on an engine accessory being loose
Misalignment of an engine accessory
Belt incorrectly routed. Refer to (Figs. 2, 3 or 4)
On 3.9L/5.2L and 5.9L LDC-gas engines, a used
belt should be replaced if tensioner indexing arrow
has moved beyond point A (Fig. 13).
7 - 4S COOLING SYSTEM

PULLEY
BOLT
IDLER
i Ul LTPULLEY-
TENSIONER
MOUNTI NG
BOLT
TENSIONER
ASSEMBLY
TENSIONER \ r
U L L C
, \ , / ^ J9307- 64 ,
Fig. 11 Beit Tensioner5.9L HDC-Gas Engine
MOUNT.
BOLT
3 / 8
SQUARE
HOLE
ACCESSORY
DRIVE BELT
AUTOMATIC
BELT
TENSIONER
J 9307- 59
Fig. 12 Belt Tensioner5.9L Diesel EngineTypical
3MLm.2Lm.9L LDGGA8 ENGINES
REMOVAL
moval/Installation in this group.
(2) Disconnect wiring and secondary cable from ig-
nition coil.
(3) Remove ignition coil from coil mount i ng
bracket (two bolts). Do not remove coil mount i ng
bracket from cylinder head.
(4) Remove tensioner assembly from mount i ng
bracket (one nut) (Fig. 13).
W ARN I N G: BE C A US E OF H I GH SPRI N G PRE S -
SURE , D O NOT A T T E M PT T O D I S A S S E M B L E A U T O -
M A T I C TE N SI ON E R. UNI T I S SE RV I C E D A S AN
A S S E M BL Y ( E X CE PT F OR PULLE Y ) .
TENSIONER
MOUNTING NUT
INDEXING
ARROW
INDEXING
MARK
J9207-17
Fig. 13 indexing Marks-3.9L/5.2L/5.9L LDC-Gas
Engine
(5) Remove pulley bolt. Remove pulley from ten-
sioner.
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 Nnn (45 ft. lbs.).
(2) Install tensioner assembly to mount i ng bracket.
An indexing t ab is located on back of tensioner.
Align t hi s t ab to slot in mount i ng bracket. Tighten
nut to 67 Nnn (50 ft. lbs.) torque.
(3) Connect all wiring to ignition coil.
(4) Install coil to coil bracket. If nut s and bolts are
used to secure coil to coil bracket, t i ght en to 11 Nnn
(100 in. lbs.) torque. If coil mounting bracket has
been tapped for coil mounting bolts, t i ght en bolts to
5 Nnn (50 in. lbs.) torque.
C A U T I O N : T o prevent damage to coil case, coil
mounti ng bol ts must be torqued.
(5) Install drive belt. Refer to Belt Removal/Instal-
lation in this group.
(6) Check belt indexing marks (Fig. 13).

5.9L HDC'GAS ENGINE
REMOVAL
moval/Installation in this group.
(2) Remove tensioner mounting bolt (Fig. 11) and
remove tensioner.
CAUTI ON : If the pul l ey i s to be r emoved from the
tensi oner, its mount i ng bolt has left hand t hr eads.
SURE , D O N OT ATTE M PT TO D I S A S S E M BL E AUTO-
M ATI C TE N SI ON E R. UNI T I S SE RV I C E D A S AN
INSTALLATION
(1) Install pulley and pulley bolt to tensioner (ob-
serve the previous CAUTION). Tighten bolt to 88
(2) Install tensioner assembly to mounting bracket.
A dowel pin is located on back of tensioner (Fig. 14).
Align this to dowel hole (Fig. 15) in tensioner mount-
ing bracket. Tighten bolt to 41 N-m (30 ft. lbs.)
torque.
lation in this group.
5.9L DIESEL ENGINE
REMOVAL
moval/Installation i n t hi s group.
(2) Remove tensioner mounting bolt (Fig. 12) and
remove tensioner.
SURE , D O N OT ATTE M PT TO D I S A S S E M BL E AUTO-
M ATI C TE N SI ON E R. UNI T I S SE RV I C E D A S AN
BELT TENSIONER
DOWEL PIN J9307-63
Fig. 14 Tensioner Dowel Pin5.9L HDC-Gas Engine
Fig. 15 Tensioner Mounting Bracket Dowel
Hole5.9L HDC-Gas Engine
INSTALLATION
(1) Install pulley to tensioner.
(2) Install tensioner assembly to mount i ng bracket.
A dowel is located on back of tensioner. Align this
dowel to hole in tensioner mount i ng bracket. Tighten
bolt to 41 N*m (30 ft. lbs.) torque.
lation in t hi s group.
7 - 4 8 COOLING SYSTEM

ENGINE BLOCK HEATERS
GENERAL INFORMATION
DESCRIPTION AND OPERATION
An optional engine block heat er is available with
for all models. The heat er is equipped with a power
cord t hat is located behind t he grille. The cord is at-
tached to an engine compartment component with
tie-straps. The heat er warms t he engine providing
easier engine st art i ng and faster warm-up in low
t emperat ures. The heat er is mounted in a core hole
of t he engine cylinder block (in place of a freeze plug)
with t he heat i ng element immersed in engine cool-
ant . The power cord is located behind t he radi at or
grille. Connect t he power cord to a grounded 110-120
volt AC electrical outlet with a grounded, t hree 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
(2) Drai n coolant from radiator and cylinder block.
(3) Remove pow^r cord from heat er (Fig. 1 or 2).
(4 ) Loosen bolt at center of block heater. Remove
block heat er.
INSTALLATION
(1) Thoroughly clean cylinder block core hole and
block heat er seat.
(2) Insert block heat er (with element loop pointing
down).
(3) Wi t h heat er fully seated, t i ght en center bolt se-
curely.
(4 ) Fill cooling system with recommended coolant.
Refer to Refilling Cooling System section in t hi s
group.
Fig. 1 Engine Block HeaterExcept Diesel
Fig. 2 Engine Block HeaterDiesel Engine
SPECIFICATIONS
GENERAL INFORMATION
The following specifications are published from t he
latest information available at t he time of publica-
tion. If a nyt hi ng differs bet ween the specifica-
t i ons f ound on t he Vehi cl e Emi s s i on Cont r ol
I nf or mat i on (VECI) label and the fol l owi ng spec-
i fi cat i ons, use speci f i cat i ons on VECI l abel . The
VECI label is located in t he engine compartment.
DRIVE BELT TENSION
All engines are equipped with a spring loaded au-
tomatic belt tensioner. Do not at t empt to check belt
tension with a belt tension gauge on vehicles
equipped wi t h an aut omat i c belt tensioner. Refer to
Automatic Belt Tensioner in this group.
CAPACITIES
E N G I N E M O D E L D R I V E
C APAC I T Y
E N G I N E M O D E L D R I V E QU A R T S LI TERS
3.9L D150, D250 2 WD 15.1 14.0
5.2L D150, D250, D350 2 WD 17.0 16.0
5.2L RAMCHARGER 4WD 16.5 15.7
5.2L W15 0 , W25 0 , W35 0 4WD 17.0 16.0
5.9L D150, D250, D350 A N D R AMC HAR GE R 2 WD 15.5 14.7
5.9L RAMCHARGER 4WD 15.0 14.0
5.9L W15 0 , W25 0 , W35 0 4WD 15.5 14.7
DIESEL ALL M A N U A L 16.0 15.1
DIESEL ALL AUTOMATI C 17.0 16.1
J9207-41
TORQUE
D I SCM Pf l ON T O R QU E TORQUi
Automatic Belt Tensioner Pulley
Bol t- 3.9l / 2.5L/ 5.9LLDC
Gas Engine 61 N-m (4 5 ft. lbs.)
Automatic Belt Tensioner Pulley
Bolt - 5.9L HDC Gas Engine 88 N-m (65 ft. lbs.)
Automatic Belt Tensioner-to-
Mounting Bracket - 3.9L/5.2L/
5.9L I DC Gas Engine 67 N-m (50 ft. lbs.)
Automatic Belt Tensioner-to-
Mounting Bracket - 5.9L
HDC Gas Engine 41 N-m (30 ft. lbs.)
Fan Shroud Mounting Nuts 11 N-m (95 in. lbs.)
Hose Clamps 4 N-m (34 in. lbs.)
Idler Pulley Mounting Bolt -
All Gas Engines 61 N-m (45 ft. lbs.)
Radiator Mounting Bobs 11 N-m (95 in. lbs.)
Radiator Top Mounting Brackets-
Diesel Engine...... 23 N-m (17 in. lbs.)
Thermal Viscous Fan-to-Hub-
Diesel Engine 57 N-m (42 ft. lbs.)
Thermostat Housing Bolts -
All Except Diesel 23 N-m (200 in. lbs.)
Thermostat Housing Bolts -
Diesel Engine 24 N-m (18 ft. lbs.)
Water Pump Mounting Bolts -
Water Pump Pulley Bolts -
Water Pump Mounting Bolts -
Diesel Engine 24 N-m(18ft. lbs.)
J9307-6 0

E L E C T R I C A L
ELECTRICAL 8A - 1
Group
AUDIO SYSTEMS 8F
BATTERY/STARTER/GENERATOR SERVICE . . 8B
BATTERY/STARTING/CHARGING SYSTEMS
DIAGNOSTICS 8A
HORNS 8G
IGNITION SYSTEMS 8D
INSTRUMENT PANEL AND GAUGES 8E
LAMPS 8L
POWER LOCKS 8P
I N D E X
Group
POWER MI RRORS 8T
POWER WINDOWS 8S
REAR WINDOW DEFOGGER 8N
TURN SIGNALS AND HAZARD WARNING
FLASHERS 8J
VEHICLE SPEED CONTROL SYSTEM 8H
WARNING BUZ Z ER SYSTEM 8U
WINDSHIELD WIPERS AND WASHERS 8K
WIRING DIAGRAMS 8W
B A T T E R Y / S T A R T I N G / C H A R G I N G S Y S T E M S D I A G N O S T I C S
C O N T E N T S
page page
BATTERY TEST PROCEDURES 2 GENERATOR TEST PROCEDURES ON VEHICLE . 13
ENGINE STARTER MOTOR TEST PROCEDURES . . 9 SPECIFICATIONS 18
The Battery, Starting, and Charging Systems oper-
ate with one another, and therefore, must be thor-
oughly tested as a complete system. In order for the
vehicle to start and charge properly, it must have a
battery t hat will perform to specifications. The starter
motor, generator, wiring, and electronics also must
perform within specifications. Group 8A covers Start-
ing (Fig. 1) and Charging (Fig. 2) System diagnostic
procedures. These procedures include t he most basic
conventional methods to On-Board Diagnostics (OBD)
built into the Powertrain Control Module (PCM).
Use of an ammeter, volt/ohmmeter, bat t ery
charger, carbon pile rheostat (load tester), and 12
volt test light will be required.
All OBD sensing systems are monitored by t he
PCM. The PCM will store in memory any detectable
failure in t he monitored circuits. Refer to Usi ng On-
Board Diagnostic System in this group for more in-
formation.
NEGATIVE
BATTERY
CABLE
A
7
POSITIVE
BATTERY
CABLE
BATTERY
J918A-11
Fig. 1 Starting System ComponentsTypical
8A - 2 ELECTRICAL

MALFUNCTION
I N D I C A T O R
LAMP
D I A G N O S T I C S C A N
TOOL
PO WE R T R A I N C O N T R O L
MODULE
GENERATOR
BATTERY
J938A-23
Fig. 2 Charging System ComponentsTypical
BATTERY TEST PROCEDURES
INDEX
page
Battery Chargi ng 6
Battery Load Test 5
Battery Open Circuit Voltage Test . . . . . . . . . . . . . 4
Causes of Battery Discharging 3
GENERAL INFORMATION
The bat t ery stores, stabilizes, and produces electri-
cal current. A bat t ery must be able to accept a
charge and produce high-amperage current over an
extended period. A chemical reaction t akes place be-
tween sulfuric acid solution (electrolyte) and lead + /-
plates in each cell of t he bat t ery. As t he bat t ery
discharges, t he plates collect acid from t he electro-
lyte. When t he charging system charges t he bat t ery,
wat er is converted to sulfuric acid in t he bat t ery. The
amount of acid (specific gravity) in t he electrolyte
can be measured with a hydrometer. A factory in-
stalled bat t ery has a built-in t est indicator to help
determine state-of-charge. The factory installed bat-
t ery is also nonrefillable, wat er can not be added.
The bat t ery is vented to release gases t hat are cre-
page
Ignition Off Draw ( I OD) 4
State of Charge Test Usi ng Test Indicator . . . . . . . 3
Test Indicator 3
ated when t he bat t ery is being charged. The bat t ery
top, posts, and t ermi nal s should be cleaned when
other underhood mai nt enance is performed (Fig. 3) .
W ARN I N G: DO NOT ATTE M PT TO ASSIST BOOST,
CHARGE, OR TEST BATTERY WHEN ELECTRO-
LYTE LEVEL I S BELOW THE TOP OF THE PLATES
(YELLOW OR BRIGHT COLOR IS VISIBLE). PER-
SON AL I N J URY M AY OC C UR.
When t he electrolyte level is below t he top of t he
plates (yellow or bri ght indicator), t he bat t ery must
be replaced. The bat t ery must be completely charged
(green indicator) and t he top, posts, and t ermi nal s
should be properly cleaned before diagnostic proce-
dures are performed. Refer to Group 8B - Battery/
St art er Service, for additional information.

ELECTRICAL 8A - 3
Fig. 3 Battery Construction and Test Indicator
TEST INDICATOR
A test indicator (hydrometer) built into t he top of
t he battery case, provides visual information for bat-
tery testing (Fig. 4). The t est indicator is to be used
with diagnostic procedures described in t hi s group. It
is important when usi ng t he test indicator t hat t he
battery is relatively level and has a clean top to see
correct indications. A light may be required to view
indicator.
W ARN I N G: D O N OT US E OPE N F L AM E . E X PL OSI V E
GA S E S F ORM ABOV E BATTE RY .
Fig. 4 Built in Test Indicator
STATE OF CHARGE TEST USING TEST INDICATOR
The built-in test indicator (hydrometer) measures
t he specific gravity of t he electrolyte. Specific gravity
(SG) of the electrolyte will indicate state-of-charge
(voltage); although, t he test indicator will not indi-
cate cranking capacity of t he bat t ery. Refer to Bat-
tery Load Test for more information. Look into t he
sight glass and note t he color of t he indicator (Fig.
5), refer to t he following description as color indi-
cates:
GREEN- 7 5 to 100% state-of-charge
The battery is adequately charged for more t est i ng
or ret urn to use. If t he vehicle will not crank for a
maxi mum 15 seconds, refer to Bat t ery Load Test for
more information.
BLACK OR DARK0 to 75% state-of-charge
The bat t ery is inadequately charged and must be
charged unt i l green dot is visible (12.4 volts or
greater) before t he bat t ery is tested or ret urned to
use. Refer to Causes of Bat t ery Discharging for more
information.
YELLOW OR BRIGHT COLOR
W ARN I N G: D O N OT ATTE M PT TO C H ARGE , TE ST,
OR A S S I S T BOOST BATTE RY W H E N Y E L L OW OR
BRI GH T C OL OR I S V I SI BL E . PE RSON AL I N J URY
M AY OC C UR.
A yellow or bright color indicates wat er (electro-
lyte) level in bat t ery is below t he test indicator (Fig.
5). Wat er can not be added to a mai nt enance free
bat t ery. The bat t ery must be replaced. A low electro-
lyte level may be caused by an over charging condi-
tion. Refer to Generator Test Procedures On Vehicle
in t hi s group.
TEST INDICATOR/STATE OF CHARGE
I f V W , "TCfV
REPLACE BATTERY
l UUTu / O t u L
f
REPLACE BATTERY
SBl
ill, iMMiMMMMSMM^MM
GREEN BLACK YELLOW 898A-3
Fig. 5 Test Indicator Sight Glass
CAUSES OF BATTERY DISCHARGING
It is normal to have a small (5 to 20 milliamperes)
draw from t he bat t ery with t he ignition in t he OFF
position, and ALL lamps OFF. The constant draw is
due to various electronic features or accessories t hat
require electrical current with t he ignition OFF to
function properly. If a vehicle is not used for a period
of 20 days or more, t he black bat t ery disconnect
should be disconnected. The disconnect is located be-
hind t he bat t ery on t he engine wiring harness. This
will prevent bat t ery discharging.
ABNORMAL BATTERY DISCHARGING
(1) Corroded bat t ery posts and t ermi nal s.
(2) Loose or worn generator drive belt.
(3) Electrical loads t hat exceed t he output of t he
charging system due to equipment or accessories in-
stalled after delivery.
(4) Slow driving speeds (heavy traffic conditions)
or prolonged idling with high-amperage electrical
systems in use.
(5) Defective electrical circuit or component caus-
ing excess Ignition Off Draw (IOD).
(6) Defective charging system.
(7) Defective battery.
8A - 4 ELECTRICAL

IGNITION OFF DRAW (IOD)
Ignition off draw refers to power being drained
from t he bat t ery with the ignition t urned off. A nor-
mal vehicle electrical system will draw from 5 to 20
milliamps. A vehicle t hat has not been operated for
an extended period of time (approximately 20 days)
may discharge t he bat t ery to an i nadequat e level.
Bat t ery drai n should not exceed approximately 20
MA (20 milliamps = 0.020 amps).
The 20 MA are needed to supply PCM memory,
digital clock memory, and ETR (electronically t uned
radio) memory.
Excessive bat t ery drain is caused by i t ems left
t urned on, internally shorted generator, or intermit-
t ent short in wiring.
If t he IOD is excessive (over 20 milliamperes), t he
defect must be found and corrected before replacing a
bat t ery. In most cases t he bat t ery can be charged
and ret urned to service.
TEST PROCEDURE
Tes t i ng for hi gher a mpe r a ge I OD mus t be per -
f or med first t o pr e ve nt da ma ge t o mos t milliamp
met er s .
Verify t hat all electrical accessories are OFF. Tur n
off all lights, remove ignition key, and close all
doors. If t he vehicle is equipped with electronic acces-
sories (illuminated entry, high line radio), allow t he
systems to automatically shut off (time out), up to 3
mi nut es.
(1) After det ermi ni ng t hat t he underhood l amp is
operating properly t hen disconnect bulb.
(2) Disconnect negative cable from bat t ery.
(3) Connect a typical 12 volt t est light (low watt-
age bulb) between t he negative cable clamp and t he
bat t ery negative t ermi nal .
The t est light may light brightly for up to 3 min-
ut es or may not light at all (depending on t he elec-
trical equipment). The t erm brightly being used
t hroughout t he following tests, implies t he bright-
ness of t he t est light will be t he same as if it were
connected across t he battery.
The t est light must be securely clamped to t he neg-
ative cable and bat t ery t ermi nal . If t he t est light be-
comes disconnected during any of t he IOD test, t he
electronic t i mer function will be activated and all
t est s must be repeated.
(4) After 3 mi nut es, t he test light should t ur n OFF
or be DIMLY lit (depending on t he electrical equip-
ment). If t he t est light remai ns brightly lit do not
disconnect it. Remove each fuse or circuit breaker
(refer to Group 8 - Wiring Diagrams) unt i l test light
is ei t her OFF or DIMLY lit. This will el i mi nat e t he
hi gher amperage draw.
If test light is still bright after disconnecting each
fuse and circuit breaker, disconnect t he wi ri ng har-
ness from t he generator. Refer to Generator Testing
in t hi s group. Do not disconnect t he test light.
After higher amperage IOD has been corrected, low
amperage IOD may be checked.
It is now safe to install milliamp met er to check for
low amperage IOD.
(5) With test light still connected, securely clamp
an ammet er between bat t ery negative t ermi nal and
negative bat t ery cable.
If the test light or the milliamp meter circuit i s
broken the vari ous timer circuits will start. Do
not open any doors or turn on any electrical ac-
cessori es wi th the test light di sconnected or the
meter may be damaged.
(6) Disconnect t est light. The current draw should
not exceed 0.020 amp. If it exceeds 20 milliamps iso-
late each circuit by removing circuit breakers and
fuses. The meter readi ng drops once t he high current
problem is found. Repair t hi s section of t he circuit,
whether it is a wiring short or component failure.
BATTERY OPEN CIRCUIT VOLTAGE TEST
A bat t ery voltage (no load) t est will indicate t he
state of charge of a bat t ery t hat will pass t he Bat t ery
Load Test described in t hi s section. Before proceed-
i ng wi th this test or the Battery Load Test the
battery must be compl etel y charged as de-
scri bed in Battery Charging i n this section.
If a bat t ery has a no load voltage readi ng of 12.4
volts or great er but will not endure a load test, it is
defective and should be replaced. Refer to Group 8B,
Bat t ery/ St art er Service for instructions. To test bat-
tery no load voltage, perform t he following operation:
(1) Before measuri ng open circuit voltage, t he sur-
face charge must be removed from plates. Turn head
lights on for 15 seconds t hen allow up to 5 mi nut es
for voltage to stabilize.
(2) Remove both bat t ery cables, negative first.
(3) Using a voltmeter connected to t he bat t ery
posts, see instructions provided wi t h voltmeter, mea-
sure open circuit voltage (Fig. 6).
This voltage readi ng will indicate st at e of charge,
but will not reveal cranki ng capacity. Refer to Bat-
tery Open Circuit Voltage chart.
BATTERY OPEN CIRCUIT VOLTAGE
Open Circuit Volts
Percent Chang
11.7 volts or less
0%
12.0
25%
12.2
50%
12.4
75%
12.6 or more
100%
918A-3

ELECTRICAL 8A - i
898A-7
Fig. 6 Testing Open Circuit Voltage
BATTERY LOAD TEST
W ARN I N G: IF BATTE RY S H OW S SI GN S OF F RE E Z -
I NG, L E AK I N G, L OOSE POSTS, OR E X C E SSI V E L Y
LOW E L E C TROL Y TE L E V E L , D O N OT TE ST. ACI D
BURN S OR E X PL OSI V E CON D I TI ON M AY RE SUL T.
A bat t ery load test will verify t he actual cranki ng
performance based on t he cold crank rat i ng of t he
battery.
Before performi ng the battery l oad test, the
battery must be FULLY CHARGED.
(1) Remove both bat t ery cables, negative first. Bat-
tery top and posts should be clean. If green color is
not visible in indicator, charge t he battery, see Bat-
tery Chargi ng Procedures in t hi s section.
(2) Connect a suitable Volt-Ammeter-Load tester
(Fig. 7) to t he bat t ery posts (Fig. 8). Refer to operat-
ing instructions provided with t he. t est er being used.
Check t he open circuit voltage (no load) of t he bat-
tery. Voltage should be equal to or greater t han 12.4
volts (Fig. 7) with green color visible in t est indica-
tor.
898A-8
I NDUCTI ON
AMPME TE R
CLAMP
POSITIVE
CLAMP
NEGATIVE
CLAMP
J908A- 1 2
Fig. 8 Volt-Ammeter-Load Tester Connections
(3) Rotate t he load control knob (Carbon pile rheo-
stat) to apply a 300 amp load for 15 seconds t hen
control knob to off (Fig. 9). This will remove t he sur-
face charge from the battery.
Fig. 7 Volt-Amps-Load Tester Typical
898A-10
Fig. 9 Remove Surface Charge from Battery
(4) Allow t he bat t ery to stabilize to open circuit
voltage (may t ake up to 5 minutes).
(5) Rotate t he load control knob to mai nt ai n a load
(50% of cold crank ratingsee specifications) for a
mi ni mum 15 seconds (Fig. 10). After 15 seconds,
record t he (loaded) voltage reading and r et ur n t he
load control to off.
(6) Voltage drop will vary according to bat t ery
t emperat ure at t he time of t he load test. Bat t ery
t emperat ure can be estimated by t he t emperat ure of
exposure over t he preceding several hours. If t he bat-
t ery has been charged, boosted, or loaded a few min-
ut es prior to test, t he bat t ery would be somewhat
warmer. Refer to Load Test Temperat ure chart for
proper loaded voltage reading.
(7) If bat t ery passes load test, it is in good condi-
tion. No further tests are necessary. If it fails load
test, it should be replaced.
8A - 6 ELECTRICAL

Fig. 10 Load 50% Cold Crank Rating Note Voltage
LOAD TEST TEMPERATURE
Minimum Voltage Temperature Minimum Voltage
P c
9.6 70 and above 21 and above
9.5 6 0 16
9.4 50 10
9.3 4 0 4
9.1 30 -1
8.9 20 -7
8.7 10 -12
8.5 0 18
J908A-4
BATTERY CHARGING
A bat t ery is completely charged when it has:
an open circuit voltage of 12.4 volts or more.
has enough cranki ng capacity (minimum 9.6 volts
when loaded for 15 seconds to 50% of cold cranki ng
amperage r at i ng at 21C/70F).
A green color, in t he t est indicator on t he top of t he
battery, indicates t he bat t ery is charged enough for
further testing. A black color indicates t he bat t ery
voltage st at e of charge is below 75%. A yellow or
bright color indicates t he bat t ery has excessively low
electrolyte level. The bat t ery cannot be refilled or
charged, it must be replaced.
W ARN I N G: D O N OT C H ARGE A BATTE RY TH AT
H AS E X C E SSI V E L Y L OW E L E CTROL Y TE L E V E L .
BATTE RY M AY A RC I N TE RN AL L Y AN D E X PL OD E .
W ARN I N G: E X PL OSI V E GA S E S F ORM OV E R BAT-
TE RY , D O N OT S M OK E , USE F L AM E , OR C RE ATE
S PA RK S N E AR BATTE RY .
W ARN I N G: D O N OT ASSI ST BOOST OR C H ARGE A
F ROZ E N BATTE RY , C ASI N G M AY F RAC TURE .
W ARN I N G: POI SON , C A US E S S E V E RE BURN S.
BATTE RY CON TAI N S SUL F URI C ACI D , AV OI D C ON -
TACT WITH SK I N , E Y E S, OR CLOTH I N G. I N E V E N T
OF CON TACT, F L USH W I TH W ATE R AN D C AL L
PH Y SI CI AN I M M E D I ATE LY . K E E P OUT OF RE AC H
OF CH I L D RE N .
CAUTI ON : Di sconnect the vehi cl e' s battery negati ve
cabl e before char gi ng battery to avoi d damage to
electrical syst ems. D o not ex ceed 16 .0 vol ts whil e
char gi ng battery.
Bat t ery electrolyte will bubble inside of case while
being charged properly. If t he electrolyte boils vio-
lently or is discharged from t he vent holes while
charging, immediately reduce charging rat e or t ur n
off charger and evaluate bat t ery condition.
Some bat t ery chargers are equipped with polarity
( + to +/ - to -) sensing devices to protect t he charger
or bat t ery from being damaged if improperly con-
nected. If t he bat t ery st at e of charge is too low for
t he polarity sensor to detect, t he sensor must be by-
passed for charger to operate. Refer to operating in-
structions provided with bat t ery charger being used.
CAUTI ON : Char ge battery until test indicator ap-
pear s gr een. D o not over char ge.
It may be necessary to jostle t he bat t ery or vehicle
to bri ng t he green ball into view in t he test indicator
when t he state-of-charge has reached 75%.
BATTERY CHARGING TIME TABLE
Charging Amperage 5 Amps 10 Amps 20 Amps
Open Circuit Voltage Hours Charging at21C (70F)
12.25 to 12.39 6 H rs. 3H rs. 1.5 Hr.
12.00 to 12.24 8H rs. 4 H rs. 2H rs
11.95 to 12.09 12Hrs. 6 H rs. 3H rs.
10.00 to 11.95 14 Hrs. 7H rs. 3.5 Hrs.
10.00 to 0
See Charging Completely
Discharged Battery
928A-19
After t he bat t ery has been charged, green indica-
tor, perform a load test to determine cranki ng capac-
ity. If t he bat t ery will endure a load test, r et ur n t he
bat t ery to use. If battery will not endure a load test,
it must be replaced. Clean and inspect bat t ery hold
downs, t ray, t ermi nal s, posts, and top before complet-
ing service, see Group 8B - Battery/Starter/Generator
Service.
CHARGING TIME REQUIRED
The time required to charge a bat t ery will vary de-
pending upon t he following factors:

ELECTRICAL 8A - 7
(1) Size of Bat t ery A completely discharged
large heavy-duty bat t ery requires more t han twice
t he recharging t i me as a completely discharged small
capacity battery.
WA R N I N G : N E V E R E XC E E D 20 A M PS WH E N
CH ARGI N G A COLD (-1C/30F) BATTERY, PE R-
SON AL I N J URY M AY RESULT.
(2) Temper at ur e A longer time will be needed
to charge a bat t ery at -18C (0F) t han at 27C
(80F). When a fast charger is connected to a cold
battery, current accepted by bat t ery will be very low
at first. Then, in time, t he bat t ery will accept a
higher rat e as bat t ery warms.
(3) Charger Capacity A charger t hat supplies
only 5 amperes requires a much longer charging
time t han a charger t hat supplies 20 amperes.
(4) State Of Charge A completely discharged
bat t ery requires more charging time t han a part i al l y
charged battery. Electrolyte is nearly pure wat er in a
completely discharged battery. At first t he charging
current amperage will be low. As acid is forced from
t he plates, inside t he battery, t he current amperat e
will rise. Also, t he specific gravity of t he electrolyte
will rise, bringing t he green dot into view.
CHARGING COMPLETELY DISCHARGED
BATTERY
The following procedure should be used to recharge
a completely discharged bat t ery. Unless procedure is
properly followed, a good bat t ery may be needlessly
replaced.
(1) Measure voltage at bat t ery posts with a volt-
meter, accurate to 1/10 volt (Fig, 11). If below 10
volts, t hen charge current will be low and it could
t ake some t i me before it accepts a current in excess
of a few milliamperes. Such low current may not be
detectable on ammet ers built into many chargers.
(2) Connect charger leads. Some chargers feature
polarity protection circuitry which prevents operation
unless charger is connected to bat t ery posts correctly.
A completely discharged bat t ery may not have
enough voltage to activate t he protection circuitry,
even t hough leads are connected properly. This
makes it appear t hat bat t ery will not accept charging
current. Refer to instructions provided wi t h bat t ery
charger being used.
VOLT SELECTOR FIELD SELECTOR TEST SELECTOR
898A-12
Fig. 11 Voltmeter Accurate to 1/10 Volt Connected
(3) Bat t ery chargers vary in t he amount of voltage
and current they provide. For time required for bat-
t ery to accept measurabl e charger current at various
voltages, refer to Charge Rat e chart. If charge, cur-
rent is still not measurabl e at end of charging times,
t he bat t ery should be replaced. If charge current is
measurabl e during chargi ng time, t he bat t ery may
be good and charging should be completed in t he nor-
mal manner.
V ol t age Hours
16.0 volts maximum up to 4 hrs.
14.0 to 15.9 volts up to 8 hrs
13.9 volts or less up to 16 hrs.
J928A-6
8A - 8 ELECTRICAL
B A T T E R Y D I AGN OSTI C S CH ART
STARTER WO N T C R A N K
BROKEN/CRACKED
F. C. = 1
REPLACE BATTERY*
V I S U A L INSPECTION
CHECK FOR OBVI OUS DAMAGE SUCH AS CRACKED OR
BROKEN CASE THAT S HOWS LOSS OF ELECTROLYTE,
TERMINAL DAMAGE, LOOSE OR CORRODED
CONNE CT I ONS , CLEAN A N D TIGHTEN CONNECTORS
STARTER STILL WO N T C R A N K
PROCEED TO STARTER TEST
PROCEDURES O N VEHICLE I N THIS GROUP
N O O BV I O U S D A M A G E
CHECK TEST I NDI CATOR/OPEN CIRCUIT VOLTAGE
POSSIBLE CAUSEI0D-REFER
TO I GNI TI ON OFF DRAW SECTI ON
TEST I N D I C A T O R / O PE N CI RCUI T VOLTAGE TEST
1. TURN HEADLAMPS O N FOR 15 S E C ONDS
2. TURN HEADLAMPS OFF FOR 5 MI NUTES TO ALLOW
BATTERY VOLTAGE TO STABILIZE
3. REMOVE NEGATIVE, THEN POSITIVE CABLE.
ELIMINATE EXCESS
F. C. = 3
IOD
N O EXCESS IOD FOUND
CHARGE BATTERY-REFER
TO C HAR GI NG BATTERY
CHARGE
ACCEPTED
GREEN BALL S HO WI N G A N D
OPEN CIRCUIT VOLTAGE
ABOVE 12.40 VOLTS**
WO N T ACCEPT C HA R G E
F. C = 4
1. N O GREEN BALL S HO WI N G
2. OPE N CIRCUIT VOLTAGE BELOW 12.40
VOLTS. SEE C HAR GI NG COMPLETELY
DI SCHARGED BATTERY
YELLOW OR BRIGHT INDICATOR
F. C. = 2
DO NOT CHARGE, BOOST, OR
TEST, ELECTROLYTE BELOW
INDICATOR. REPLACE BATTERY,
CHECK C HAR GI NG SYSTEM
T
STARTER STILL WO N T C R A N K
PROCEDURES O N VEHICLE I N
THIS GROUP
L OA D TEST
DI SCHARGE BATTERY AT 300 AMPERES FOR 15 S E C ONDS . ALLOW BATTERY
TO RECOVER FOR 15 S E C ONDS . CONNECT VOLTMETER A N D AMPERE LOAD
EQUAL TO 1/2 THE COLD C R A N K I N G AMPERE RATING OF THE BATTERY FOR
15 S E C ONDS . OBSERVE VOLTAGE AT 15 S E C ONDS WITH LOAD O N .
NOT E : ESTI MATE TEMPERATURE OF BATTERY.
REFER TO L OA D TEST VOLTAGE CHART.
VOLTAGE AT OR ABOVE
9.6 VOLTS AT ROOM
(70 DEG. F) TEMP.
VOLTAGE BELOW
9.6 VOLTS AT ROOM
(70 DEG. F) TEMP.
PASSED LOAD TEST
RETURN BATTERY TO USE
FAILED LOAD TEST
F. C. = 5
* REPLACE BATTERY
L OA D TEST VOLTAGE C HA R G E
ESTIMATED
ELECTROLYTE
TEMPERATURE
70
60
50
40
30
20
10
0
(21C ) & ABOVE
(16 C
(16C
(4 C
H C
1-7C
(- 12C
(- 18C
MI NI MUM
REQUI RED
VOLTAGE
UNDER
15 SEC. LOAD
9.6
9.5
9.4
9.3
9.1
8.9
8.7
8.5
VOLTMETER MU S T BE ACCURATE
TO 1/10 VOLT
STARTER ST8LL WO N T C R A N K
PROCEDURES O N VEHICLE I N
THIS GROUP
N OT E S : * AFTER C H A R G I N G O R R E PL A C I N G A BATTERY,
C HE C K THE V E HI C L E ' S C H A R G I N G S YS T E M, A N D
C L E A N A N D TI GHTE N BATTERY C O N N E C T O R S
(REFER TO APPLI CABLE S E C T I O N S OF T HI S
S E R V I C E M A N U A L ) .
FAI LURE C O D E (F.C) CHART
FAILURE CODE (R C )
NUMBER
CONDI TI ON
1
2
3
4
5
BROKEN/CRACKED
YELLOW/BRIGHT INDICATOR
I GNI TI ON OFF DRAW
BATTERY WON' T ACCEPT CHARGE
BATTERY FAILED LOAD TEST
** CHECKING O PE N CI RCUI T VOLTAGE WI L L
M O N I T O R ' ' G R E E N BALL" I N D I C A T I O N
FOR ALL 6 CELLS.
J938A-22

ELECTRICAL 8A - 9
E N G I N E S T A R T E R M O T O R T E S T P R O C E D U R E S
GENERAL INFORMATION
The st art i ng system consists of an:
ignition switch
st art er rel ay
park/ neut ral position switch (automatic t ransmi s-
sion)
clutch switch (diesel engi ne-manual transmission)
wiring harness
battery
st art er motor with an i nt egral solenoid.
These components form 2 separat e circuits. A high
amperage circuit t hat feeds t he st art er motor up to
300+ amps-gas engine; 500+ amps-diesel engine,
and a control circuit t hat operates on less t han 20
amps (Fig. 1).
a.
BATTERY
+ 1
I GNI T I ON SWI TCH
1 AUTOMATIC TRANSMI SSI ON
J NEUTRAL SAFETY SWITCH I
4-
"JL"
MOTOR m, ...
S T A
3 -
T E R
S O L E N O , D n
l h
STARTER RELAY
1 "
898A-14
Fig. 1 Starting System Components
STARTER SYSTEM DIAGNOSTIC INSPECTIONS
Before removing any uni t from t he st art er motor
system for repair, perform t he following inspections:
BATTERY INSPECTION
To determine condition of t he bat t ery, perform the
testing procedure outlined i n t he Bat t ery Section.
WIRING INSPECTION
Inspect wiring for damage. Inspect all connections
at t he st art er motor solenoid, park/ neut ral position
switch (if equipped), back-up lamp switch connector,
ignition/start switch, and bat t ery (including all
ground connections). Clean and t i ght en all connec-
tions as required.
SOLENOID, RELAY AND IGNITION/START
SWITCH INSPECTION
Inspect t he solenoid, relay and switch to determine
their condition. Also, if equipped with automatic
transmission, inspect condition of t he park/ neut ral
position switch. Testing information can be found in
the following pages.
If t he following components are working properly
remove t he st art er motor and follow procedures in
t he Testing Section.
bat t ery
wiring
switch
solenoid
relay
park/ neut ral position switch
COLD CRANKING TEST
(1) Bat t ery must first pass load and voltage drop
t est s and be fully charged before proceeding. Refer to
Bat t ery Test Procedures.
(2) Connect a suitable volt-ampere tester to t he
bat t ery t ermi nal s (Fig. 2). Refer to t he operating in-
structions provided wi t h the tester being used.
POSITIVE
CLAMP
898A-15
NEGATIVE
CLAMP
I NDUCTI ON
AMPME TE R
CLAMP
Fig. 2 Volt-Amps Tester Connections (Typical)
(3) Fully engage parki ng brake, place manual
transmission in NEUTRAL, automatic transmission
in PARK.
(4) Verify t hat all lights and accessories are OFF.
(5) Remove coil secondary cable from distributor
and connect to ground.
(6) Rotate and hold t he ignition switch (key) in t he
START position. Note cranking voltage and amper-
age.
(a) If voltage reads above 9.6 volts and amperage
draw reads above (220 amps gas engine) (550 amps
diesel) go to St art er Feed Circuit Tests.
(b) If voltage reads 12.5 volts or great er and am-
perat e reads 0 to 10 amps, go to St art er Control
Circuit Tests.
A col d engi ne will i ncrease starter motor cur-
rent.
STARTER FEED CIRCUIT TESTS - (W0LTAGE DROP
METHOD)
The voltage drop tests will determine if t here is ex-
cessive resistance in t he high current circuit. When
performing these t est s, it is i mport ant t hat t he volt-
met er be connected to t he t ermi nal s t hat t he cables
are connected to instead of to t he cables themselves.
For example, when t est i ng between t he bat t ery and
solenoid, touch t he voltmeter t est probes to t he bat-
8A - 10 ELECTRICAL

STARTING SYSTEM DIAGNOSIS
TEST C O N D I T I O N S
PLACE GE A R SELECTOR I N PARK OR NEUTRAL A N D SET PARK BRAKE OR EQUI VALENT.
VERIFY BATTERY STATE-OF-CHARGE A N D C R A N K I N G CAPACITY, SEE BATTERY S E C T I ON.
C L E AN BATTERY TOP, POSTS, A N D TE RMI NALS .
VERIFY ALTERNATOR DRI VE BELT T E N S I O N .
D I S C O N N E C T A N D G R O U N D COI L CABLE.
S YMPTOM SYMPTOM SYMPTOM SYMPTOM SYMPTOM
STARTER FAILS TO STARTER FAILS TO STARTER ENGAGES, STARTER ENGAGES STARTER DOES NOT
ENGAGE. NO SOUNDS ENGAGE SOLENOID FAILS TO TURN DRIVE CLUTCH DISENGAGE AFTER
OR RELAY CLICKS ENGI NE. DOME LIGHT SPINS OUT ENGI NE STARTS
DIMS
POSSI BLE CAUSE POSSI BLE CAUSE POSSI BLE CAUSE POSSI BLE CAUSE POSSI BLE CAUSE
STARTER CONTROL RESISTANCE TOO RESISTANCE TOO DRIVE CLUTCH FAULTY I GNI TI ON SWITCH
CIRCUIT FAULTY HIGH I N STARTER HIGH I N STARTER FAULTY
FEED CIRCUIT FEED CIRCUIT
BROKEN TEETH
I GNI TI ON SWITCH O N RI NG GEAR STARTER RELAY
FAULTY STARTER CONTROL STARTER ASSEMBLY FAULTY
CIRCUIT FAULTY FAULTY
STARTER ASSEMBLY
PARK/NEUTRAL FAULTY STARTER ASSEMBLY
POSITION STARTER SOLENOI D ENGI NE FAULTY
SWITCH FAULTY SEIZ ED
(AUTO TRANS.)
STARTER
FAULTY OR
STARTER
MISADJUSTED STARTER ASSEMBLY IMPROPERLY
FAULTY MOUNTED
STARTER RELAY REFER TO
FAULTY APPROPRIATE GROUP
AND SECTION OF THIS
MANUAL FOR PROPER
STARTER ASSEMBLY SERVICE AND TEST
FAULTY PROCEDURES FOR THE
COMPONENTS
INVOLVED
J938A-9
t ery post and t he solenoid t hreaded stud. The follow-
ing operation will require a voltmeter, accurate to
1/10 of a volt.
Before performing t he tests, assure t he following
procedures are accomplished:
Disconnect t he distributor connector (gas engine).
Disconnect both wires on t he fuel solenoid (diesel
engine) (Fig. 3) .
Verify t hat :
all lights and accessories are OFF
transmission shift selector is in PARK (automatic)
or NEUTRAL (manual)
parki ng brake is applied
bat t ery is fully charged (refer to Bat t ery Test Pro-
cedures).
(1) Connect positive lead of voltmeter to bat t ery
negative post. Connect negative lead of voltmeter to
bat t ery negative cable clamp (Fig. 4). Rotate and
Fig. 3 Diesel Engine Fuel Solenoid

ELECTRICAL 8A - 11
hold the ignition switch (key) in the START position.
Observe the voltmeter. If voltage is detected, correct
poor contact between the cable clamp and post.
VOLTMETER
VOLTMETER
BATTERY
898A-17
Fig. 4 Test Battery Connection Resistance
(2) Connect positive lead of voltmeter to battery
positive post. Connect negative lead of voltmeter to
battery cable positive clamp (Fig. 4 ). Rotate and hold
the ignition switch (key) in the START position. Ob-
serve the voltmeter. If voltage is detected, correct
poor contact between the cable clamp and post.
(3) Connect a voltmeter to measure between the
battery positive post and the center of the B +
starter solenoid stud (Fig. 5).
BATTERY
STARTER
MOTOR VOLTMETER 898A-20
Fig. 5 Test Positive Battery Cable Resistance
(Typical)
(4) Rotate and hold the ighition with (key) in the
START position. If voltage reads above 0.2 volt, cor-
rect poor contact at battery cable to solenoid connec-
tion. If reading is still above 0.2 volt, replace positive
battery cable.
(5) Connect the voltmeter to measure between the
battery negative post and the engine block (Fig. 6 ).
(6) Rotate and hold the ignition with (key) in the
rect poor contact at ground cable attaching point.
Voltage reading still above 0.2 volt, replace ground
cable.
ENGINE , ^ J ^ P
GROUND \ BATTERY
898A-18
Fig. 6 Test Ground Circuit Resistance
(7) Connect positive voltmeter lead to starter mo-
tor housing. Connect negative lead of voltmeter to
battery negative terminal (Fig. 7).
STARTER
MOTOR
BATTERY
VOLTMETER
898A-26
Fig. 7 Test Starter Motor Ground (Typical)
(8) Rotate and hold the ignition switch (key) in the
rect poor starter to engine ground.
If resistance tests detect no feed circuit failures, re-
move the starter motor and go to Bench Testing
Starter Solenoid.
STARTER CONTROL CIRCUIT TESTS
The starter control circuit consists of a:
starter solenoid
starter relay
ignition switch
park/neutral position switch (automatic transmis-
sion)
clutch switch (diesel engine-manual transmission)
all their wiring and connections.
Testing procedures for these components are as fol-
lows and should be followed in order as described.
C A U T I O N : Before performing any test, di sconnect
distributor connector to prevent engi ne from start-
i ng.
Di sconnect both wi res on fuel sol enoi d (diesel en-
gi ne).
8A - 12 ELECTRICAL

ENGINE STARTER RELAY
STARTER RELAY CONNECTIONS
GROUND SOLENOID
(85) TERMINAL
(87)
J928B-1
RELAY OPERATION/TESTING
OPERATION
The Bat t ery t ermi nal is connected to bat t ery volt-
age (B + ) at all t i mes.
The Solenoid t ermi nal is connected to t he bat t ery
t ermi nal in t he energized position which supplies
bat t ery voltage to t he operated device.
The Ignition terminal is connected to the electromag-
net and usually connected to a switched power source.
The Ground t ermi nal is connected to t he electro-
magnet and is usually grounded by a switch or PCM.
TESTING
Resistance value between t he ground and ignition
t ermi nal s (electromagnet) is 75 5 ohms for resistor
relays and 865 ohms for diode relays.
Connect a bat t ery to t he ignition t ermi nal and
connect ground to t he ground t ermi nal . There should
be continuity between t he bat t ery and solenoid ter-
minals (contact closed).
ENGINE STARTER RELAY REPLACEMENT
The st art er relay is located on t he driver' s side in-
ner fender (Fig. 8).
PART THROTTLE A / C C L UT C H STARTER A U T O S HU T
U N L O C K RELAY RELAY RELAY D O WN RELAY
Fig. 8 Starter Relay
(1) Replace t he relay as required.
(2) Test relay operation.
IGNITION SWITCH TEST
After testing st art er solenoid and relay and t hey
check out okay, trouble is probably with ignition
switch or its wiring.
Check all wiring for opens and shorts and connec-
tions for being loose or corroded.
BENCH TESTING STARTER SOLENOID
Refer to Group 8B - Bat t ery St art er Service for
st art er removal procedures.
(1) Disconnect field coil wire from field coil t ermi -
nal (Fig. 9) .
Fig. 9 Field Coil Wire Terminal
(2) Check for continuity between solenoid t ermi nal
and field coil t ermi nal with a continuity tester.
There should be continuity (Fig. 10).
Fig. 10 Continuity Test Between Solenoid Terminal
and Field Coil Terminal
(3) Check for continuity between solenoid t ermi nal
and solenoid housing. There should be continuity
(Fig. 11).
S O L E N O I D
RR8BD33
Fig. 11 Continuity Test Between Solenoid Terminal
and Solenoid Case
(4) If t here is continuity solenoid is good. If t here
is no continuity in either test solenoid has an open
circuit and is defective. Replace t he st art er motor.
(5) Install st art er as described in Group 8B - Bat-
t ery St art er Service.
(6) Connect field coil wire to field coil t ermi nal
(Fig. 9) .

ELECTRICAL 8A - 13
GENERATOR TEST PROCEDURES ON V E H I C L E
INDEX
page
Current Output Test . . . . . . . . . . . . . . . . . . . . . . 14
Diagnostic Procedures 13
Generator Output Wire Resistance Test . . . . . . . 13
page
H ow to Use Malfunction Indicator ( Check Engine)
Lamp for Fault Codes 17
Operational Check with Voltmeter . . . . . . . . . . . . 1 3
Usi ng On- Board Diagnostic Syst em 15
GENERAL INFORMATION
The generat or is belt-driven by t he engine. All en-
gines use serpentine drive.
The amount of DC current produced by t he gener-
ator is controlled by the Powertrain Control Module
(PCM).
All vehicles are equipped with On Board Diagnos-
tics (OBD). All OBD sensing systems are monitored
by the PCM. The PCM will store in electronic mem-
ory any detectable failure within the monitored cir-
cuits. Refer to USING ON-BOARD DIAGNOSTIC
SYSTEM in t hi s group for more information.
OPERATIONAL CHECK WITH VOLTMETER
When t he ignition switch is t urned to t he RUN po-
sition, bat t ery potential will register on t he voltme-
ter. Duri ng engine cranking a lower voltage will
appear on t he meter. With t he engine runni ng, a
voltage readi ng higher t han t he first readi ng (igni-
tion in RUN) should register.
DIAGNOSTIC PROCEDURES
If t he indicator does not operate properly, or if an
undercharged or overcharged battery condition oc-
curs, t he following procedures may be used to diag-
nose t he charging system.
Remember t hat an undercharged bat t ery is often
caused by:
accessories being left on overnight
or by a defective switch
which allows a bulb, such as a t r unk or glove box
light, to stay on (refer to Ignition Off Draw).
WISUAL INSPECTION
Inspect condition of bat t ery cable t ermi nal s, bat-
tery posts, connections at engine block, st art er motor
solenoid and relay. They should be clean and tight.
Repair as required.
Inspect all fuses in t he fuse block for tightness in
receptacles. They should be properly installed and
tight. Repair or replace as required.
Inspect generator mounting bolts for tightness. Re-
place or torque bolt as required (refer to Torque
Specifications).
Inspect generator drive belt condition and tension.
Tension or replace belt as required. Refer to Belt
Tension Specifications.
Inspect connection at generator B+ output. It
should be clean and tight. Repair as required.
GENERATOR OUTPUT WIRE RESISTANCE TEST
(FIG. 1)
Generator output wire resistance t est will show
amount of voltage drop across generator output wire
between generator BAT t ermi nal and bat t ery posi-
tive post.
PREPARATION
(1) Before st art i ng test make sure vehicle has a
fully charged battery. Test and procedures on how to
check for a fully charged bat t ery are shown in Bat-
t ery section of t hi s Group.
(2) Turn OFF ignition switch.
(4 ) Disconnect generator output wire from genera-
tor output Bat t ery terminal.
(5) Connect a 0-150 ampere scale D.C. ammet er in
series between generator BAT t ermi nal and discon-
nected generator output wire. Connect Positive lead
to generator BAT t ermi nal and Negative lead to dis-
connected generator output wire.
(6) Connect Positive lead of a t est voltmeter
(Range 0-18 volts minimum) to disconnected genera-
tor output wire. Connect negative lead of t est voltme-
t er to bat t ery positive cable at positive post.
(7) Connect one end of a Jumper Wire to ground
and with other end probe green K20 lead wire at
back of generator (Fig. 1). (This will generat e a fault
code).
C A U T I O N : D o not connect blue A142 lead of wiring
to gr ound. Refer to Gr oup 8W - Wi ri ng D i agr ams for
more information.
(8) Connect an engine tachometer and connect neg-
ative cable to battery.
(9) Connect a variable carbon pile rheost at be-
tween bat t ery t ermi nal s. Be sure carbon pile is in
"Open" or "Off position before connecting leads. See
Bat t ery Section, Load Testing for instructions.
TEST
(1) St art engine. Immediately after st art i ng, re-
duce engine speed to idle.
8A - 14 ELECTRICAL
CASE GROUND FIELD
TERMINALS
142-DG/OR
BATTERY
VOLTAGE
\
ALTERNATOR
CASE
GROUND
GROUND
ALTERNATOR
BATTERY
TERMINAL
ENGINE
CONTROLLER
TO ENGINE
CONTROLLER
TERMINAL
51
LESS THAN
"BATTERY VOLTAGE
m^mm i A21 DB-
20 AMP FUSE
A14 RD \
AUTO
SHUTDOWN
RELAY
IGNITION SWITCH
POWER
DISTRIBUTION
CENTER
JUMPER WIRE
TO GROUND
TEST
AMMETER
TEST
VOLTMETER
2
i
D I S C O N N E aE D
ALTERNATOR
OUTPUT
WIRE
ACC
OFF
J938A-17
CARBON PILE
RHEOSTAT
Fig. 1 Generator Output Wire Resistance Test (Typical)
(2) Adjust engine speed and carbon pile to main-
tain 20 amperes flowing in circuit. Observe voltmeter
reading. Voltmeter reading should not exceed 0.5
volts.
RESULTS
If a higher voltage drop is indicated, inspect, clean
and tighten all connections between generator BAT
terminal and battery Positive post. A voltage drop
test may be performed at each connection to locate
connection with excessive resistance. If resistance
tested satisfactorily, reduce engine speed, turn off
carbon pile and turn off ignition switch.
(1) Disconnect negative cable from battery.
(2) Remove test ammeter, voltmeter, carbon pile,
and tachometer.
(3) Remove "Jumper Wire".
(4) Connect generator output wire to generator
BAT terminal post. Tighten to 5 to 6 Nnn (45 to 75
in. lbs.).
(5) Connect negative cable to battery.
(6) Use DRB II Scan Tool to erase diagnostic trou-
ble code.
CURRENT OUTPUT TEST
Current output test determines whether or not gen-
erator is capable of delivering its rated current out-
put.
PREPARATION
(1) Before starting any tests make sure vehicle has
a fully charged battery. Test and procedures on how
to check for a fully charged battery are shown in
Battery section of this Group,
(3) Disconnect generator output wire at the gener-
ator battery terminal.
(4) Connect a 0-150 ampere scale D.C. ammeter in
series between generator BAT terminal and discon-
nected generator output wire (Fig. 2). Connect posi-
tive lead to generator BAT terminal and negative
lead to disconnected generator output wire.
(5) Connect positive lead of a test voltmeter (range
0-18 volts minimum) to generator BAT terminal.
(6) Connect negative lead of test voltmeter to a
good ground.
(7) Connect an engine tachometer and connect neg-
ative cable to battery.
(8) Connect a variable carbon pile rheostat be-
tween battery terminals. Be sure carbon pile is in
Open or Off position before connecting leads. See
Battery section, Load Testing for instructions.
(9) Connect one end of a Jumper Wire to ground
and with other and probe green K20 lead wire at
back of generator (Fig. 2). (This will generate a fault
code).

ELECTRICAL 8A - 15
a
C A S E G R O U N D
CAPACITOR
ALTERNATOR
~L
FIELD
TERMINALS
A 142-DG/OR
BATTERY
VOLTAGE
K20-DG !
GROUND
CASE
GROUND
til
ALTERNATOR
BATTERY
TERMINAL
ENGINE
CONTROLLER
TO ENGINE
CONTROLLER
TERMINAL
51
LESS THAN
BATTERY VOLTAGE
A21 DB-
. . . . . IGNITION SWITCH
20 AMP FUSE
AUTO A H ^
SHUTDOWN POWER
RELAY DISTRIBUTION
\ CENTER
TEST
AMMETER
JUMPER WIRE
TO GROUND
TEST
VOLTMETER
GO
5 n
DISCONNECTED
ALTERNATOR
OUTPUT
WIRE
GROUND
ACC
Bl
OFF
RUN
OFF
START*T
|ACC
CARBON PILE
RHEOSTAT
J938A-18
Fig. 2 Generator Current Output TestTypical
C A U T I O N : D o not connect blue A142 lead of wiring
to gr ound. Refer to G r oup 8W - Wi ri ng D i agr ams for
more information.
TEST
(1) Start engine. Immediately after starting reduce
engine speed to idle.
(2) Adjust carbon pile and engine speed in incre-
ments until a speed of 1250 rpm and voltmeter read-
ing of 15 volts is obtained.
C A U T I O N : D o not allow vol t age meter to read above
16 vol t s.
(3) The ammeter reading must be within limits
shown in generator specifications in back of this
group for that size of generator being tested.
RESULTS
(1) If reading is less than specified and generator
output wire resistance is not excessive, the generator
should be replaced. Refer to Group 8B - Generator
Service for information.
(2) After current output test is completed reduce
engine speed, turn off carbon pile and turn off igni-
tion switch.
(4) Remove test ammeter, voltmeter, tachometer
and carbon pile.
(5) Remove Jumper Wire (Fig. 2).
(6) Connect generator output wire to generator
BAT terminal post. Tighten nut to 5-6 Nnn (45-75 in.
lbs.).
(8) Use DRB II Scan Tool to erase diagnostic trou-
ble code.
USING ON-BOARD DIAGNOSTIC SYSTEM
OPERATION OF ON-BOARD DIAGNOSTIC
SYSTEM
The Powertrain Control Module monitors critical
input and output circuits of the charging system
making sure they are okay. Some are checked contin-
uously and some are only checked under certain con-
ditions.
If the OBD system senses that one of the critical
circuits is bad, it will consider this a real problem
and put a DTC into memory. Each input and output
circuit monitored by the OBD system has its own
DTC. The DTC will stay in memory as long as the
circuit continues to be bad. If the problem does not
occur again after the code is put into memory, the
Powertrain Control Module will clear the memory af-
ter 50 to 100 engine starts.
8A - 16 ELECTRICAL
CHARGING SYSTEM DIAGNOSTICS
I MPROPER
C HA R G I N G
CHECK BATTERY
C O N D I T I O N
SEE BATTERY
S E CTI ON FOR
DETAILS
C OR R ODE D
BATTERY CABLES
OR TERMI NALS
DRI VE BELTS
LOOS E
LOOS E OR
C OR R OD E D
WI R I N G
C O N N E C T I O N S AT
GE NE R AT OR
LOOSE OR
C OR R OD E D
WI R I N G
TERMI NAL BLOCK
LOOS E
C HA S S I S TO
BATTERY G R O U N D
CABLE
LOOS E
GE NE R AT OR
G R O U N D WI R E
LOOSE OR
C OR R OD E D
WI R I N G
BULKHEAD
D I S C ON N E C T
CHECK FOR
APPROXI MATELY
12 VOLTS AT FIELD
I NPUT BRUSH
TERMI NAL WI HT
I G N I T I O N S WI T CH
" O N "
U N S '
OR
CHAF
rEADY
L OW
K3ING
TEST
GE NE R AT OR
OUTPUT WI RE
RESI STANCE
C HA R G I N G
RESI STANCE
T OO HI GH
C OR R OD E D OR
SHORTED CABLES
OR HI GH
RESI STANCE
A C R O S S FUSIBLE
LI NK
RESI STANCE
O.K.
TEST
GE NE R AT OR
CURRENT
OUTPUT
CURRENT
OUTPUT
O. K.
REFER TO
U S I N G O N - BO A R D
D I A G N O S T I C
SYSTEM
o\
CHAR
/ER
. G I N G
G R O U N D E D
GE NE RATOR FIELD
WI R E , FIELD
TERMI NAL, OR
C O N N E C T I O N S
1 N O
1 ALTERf
ISY
MATOR
WO R N OR
FRAYED
DRI VE BELT
REFER TO
U S I N G O N - BO A R D
D I A GN OS T I C
SYSTEM
GE NE RATOR
M O U N T I N G
LOOSE
FAULTY
GE NE R AT OR
FAULTY
GE NE RATOR
FOR MOR E I N F OR MA T I ON REFER TO
THE POWE R T R AI N D I A G N O S T I C PROCEDURES
M A N U A L C O V E R I N G THE VEHI CLE I NV OLV E D
* S E E GR OUP 8W, WI R I N G D I A G R A M S FOR
CI RCUI T A N D C O M PO N E N T I N F OR MA T I ON
FAULTY
GE NE R AT OR
J938A-V0

ELECTRICAL 8A - 17
DIAGNOSTIC TROUBLE CODES
Diagnostic trouble codes are 2 digit numbers
flashed on Malfunction Indicator lamp (Check En-
gine) t hat identify which circuit is bad. In most cases
they do not identify which component in a circuit is
bad. A DTC description can be read using t he DRB II
scan tool. Refer to Group 14 - Fuel Systems for more
information. Therefore, a DTC is only a result, not
necessarily t he reason for t he problem. However, in
some cases, as a resul t of t he design of the driveabil-
ity test procedure, a DTC can be the reason for the
problem. It is i mport ant t hat t he test procedure be
followed in order to underst and what t he DTC of the
on-board diagnostic system are trying to tell.
HOW TO USE MALFUNCTION INDICATOR (CHECK
ENGINE) LAMP FOR FAULT CODES
To activate this function cycle the ignition switch
on-off-on-off-on within 5 seconds and any DTC stored
in the Powertrain Control Module will be displayed.
The Check Engine l amp will display a DTC by flash-
i ng on and off. There is a short pause between
flashes and a longer pause between digits. All codes
displayed are two digit numbers with a four second
pause between codes.
An example of a code is as follows:
(1) Lamp on for 2 seconds, t hen t ur ns off.
(2) Lamp flashes 4 times pauses and t hen flashes
1.
(3) Lamp pauses for 4 seconds, flashes 4 times,
pauses and t hen flashes 7 times.
The two codes are 41 and 47. Any number of codes
can be displayed (maximum of 8 faults can be stored)
as long as they are in memory. The lamp will flash
unt i l all of t hem (including 55) are displayed (55 =
End of test).
CHARGING SYSTEM FAULT CODES
See Generator Faul t Code Chart for fault codes
which apply to t he charging system. Refer to t he
Powert rai n Diagnostic Procedures Manual to diag-
nose an On-Board Diagnostic System, Faul t Code.
GENERATOR DIAGNOSTIC TROUBLE CODE (DTC)
DTC Type
Mal function
Indicator
Lamp Circuit
When Monitored
By the Logic
Modul e When Put Into Memory
Actuator
Test
Sensor
Read
Test
41 Fault Yes
Generator Field
Control
(Charging System)
All the time when
the ignition switch
is on.
An open or shorted condition in
the generator field
control circuit.
Yes None
46 Fault Yes
Charging System
Voltage
All the time when the
engine is running.
If the battery sense voltage is
more than 1 volt above the
desired control voltage for
more than 20 seconds.
None Yes
47 Fault Yes
Charging System
Voltage
Engine rpm above
1,500 rpm
Battery voltage 1 volt less
than set point during engine
operation and no change in
voltage during internal PCM
test performed on generator
field.
None Yes
J938A-20
8A - 18 ELECTRICAL

BATTERY SPECIFICATIONS
Load
Test
(Amps)
Col d
Cranki ng
Rating @ 0F
Reserve
Capacity
300 Amp 600 Amp 120 Minutes
C R A N K I N G R A T I N G is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 volts or greater at
specified temperature.
RESERVE C APAC I T Y R A T I N G is the length of time a battery can deliver 25 amps and maintain a minimum terminal voltage of
10.5 volts at27C (80 F).
J938A-25
GAS ENGINE STARTER DIESEL ENGINE STARTER
Manuf act ur er N i ppondenso
Engine Application 5.9L, 5.21 e\ 3.9L
Part Number and 53005984
Power Rating 1.4 Kw
Voltage 12
No. of Fields 4
No. of Poles. 4
Brushes 4
Drive Reduction
Gear Train
Free Running Test
Voltage 11
Amperage Draw . . . . . . . . . . . . 73 Amps
Minimum Speed rpm 3601 rpm
Solenoid Closing Voltage 7.5 Volts
Cranking Amperage Draw Test . . . 125-200 Amps*
* Engine should be up to operating temperature. Extremely heavy
oil or tight engine will increase starter amperage draw.
J938B-14
R E D U C T I O N G E A R S T ART E R
M a nuf a c t ur e r N i p p o n d e n s o
Engine Application 5.9L
Part Number and
Power Rating . . . . . . . . . . . . . .
4428221
3 kw
Voltage 12
No. of Fields 4
No. of Poles 4
Brushes . . . . . . . . . . . . . . . . . . . . 4
Drive Conventional
Gear Train
Free Running Test
Voltage .
Amperage Draw
Minimum Speed rpm
11
220 Amps Max.
4200 rpm Min.
Solenoid Closing Voltage. 8 Volts
Cranking Amperage Draw Test . . 450-550 Amps*
* Engine should be up to operating
heavy oil or tight engine will increase
temperature. Extremely
starter amperage draw.
J918B-21

ELECTRICAL 8A - 19
GENERATOR SPECIFICATIONS
T YPE PA R T N U M B E R PUL L E Y G R O O V E S E N G I N E R A T I N G
NI PPONDENSO 53008646 7 ALL GASOLINE 75 AMPS
NI PPONDENSO 5234374 8 DIESEL 120 AMPS
J938B-28
BATTERY/STARTER/GENERATOR SERVICE 8B - 1
C O N T E N T S
page page
BATTERY SERVICE PROCEDURES 1 SPECIFICATIONS 9
GENERATOR SERVICE 6 STARTER SERVICE PROCEDURES 4
B A T T E R Y S E R V I C E P R O C E D U R E S
GENERAL INFORMATION
This section will cover t he Bat t ery service, re-
moval, and installation procedures only. For diagnos-
tic procedures, see Group 8 A - Bat t ery/ St art i ng/
Chargi ng Systems Diagnostics.
The Maintenance Free Bat t ery (Fig. 1) does not
have removable battery cell caps. Wat er can not be
added to this battery. The bat t ery is sealed, except
for small vent holes in t he top. The chemical compo-
sition inside of t he battery produces an extremely
small amount of gases at normal charging voltages.
The bat t ery is equipped with a test indicator (Fig. 1)
t hat display colored balls to indicate bat t ery state-of-
charge.
Green Indicator = Full charge
Black Indicator = Discharged
Yellow Indicator = Battery replacement required
Fig. 1 Maintenance Free Battery
BATTERY VISUAL INSPECTION AND SERVICE
(1) Make sure ignition switch is on OFF position
and all bat t ery feed accessories are OFF.
(2) Disconnect and remove bat t ery cables at bat-
tery. Remove NEGATIVE cable first.
W ARN I N G: W E AR A SUI TABL E PAI R OF RUBBE R
GL OV E S ( NOT TH E H OUSE H OL D TY PE ) W H E N RE -
M OV I N G A BATTE RY BY H AN D . SAF E TY GL A S S E S
SH OUL D AL SO BE W ORN . IF TH E BATTE RY I S
C RA C K E D OR L E AK I N G TH E E L E CTROL Y TE C AN
BURN TH E SK I N AN D E Y E S.
(3) Remove bat t ery hold down (Fig. 2) and remove
bat t ery from vehicle.
Fig. 2 Battery Holddown
B A T T E R Y / S T A R T E R / G E N E R A T O R S E R V I C E
8B - 2 BATTERY/STARTER/GENERATOR SERVICE

(4) Clean top of bat t ery wi t h a solution of clean
warm wat er and baki ng soda. Scrub area wi t h a stiff
bristle brush and wipe off wi t h a cloth moistened
with ammoni a or baki ng soda in wat er (Fig. 3).
be necessary to clean area with same solution de-
scribed in Step (4 ) (Fig. 4 ) .
(7) Clean bat t ery post with a suitable bat t ery post
cleaning tool (Fig. 5).
TERMINAL
BRUSH
TEST
INDICATOR
BATTERY
Fig. 3 Cleaning Battery
C A U T I O N : Care shoul d be taken to ensure that
sol ut i on does not enter vent hol es.
(5) Inspect bat t ery case and cover for cracks or
leakage. If cracks or leakage is present, bat t ery must
be replaced.
(6) Inspect bat t ery t ray for damage caused by loss
of acid from battery. If acid damage is present it will
J928B-30
Fig. 5 Cleaning Battery Post
(8) Clean inside surfaces of t ermi nal clamps with a
suitable bat t ery t ermi nal cleaning tool (Fig. 6 ) . Re-
place damaged or frayed cables and broken t ermi nal
clamps.
BATTERY
CABLE
WASHER
NUT
BATTERY HOLD
D OWN
HOLD DOWN
STUD
HOLD
DOWN
STUD
BATTERY
TRAY
J928B-3f
A
Fig. 4 Battery Tray
J908B-13
Fig. 6 Cleaning Battery Cable Terminal
Fig. 7 Battery Cables Disconnected
(9) Inspect bat t ery for proper or damaged hold
down ledge.
(10) Install bat t ery in vehicle maki ng sure t hat
bat t ery is properly positioned on bat t ery t ray (Fig.
2).
(11) Install bat t ery hold down clamp, maki ng sure
t hat it is properly positioned on bat t ery. Tighten bolt
to 12 N-m (100 in. lbs.).
(12) Place felt oil washer onto Positive ( + ) bat t ery
post.
(13) Connect cable clamps to bat t ery post maki ng
sure top of clamp is flush wi t h top of post (Fig. 7).
(14) Tighten clamp nut securely.

S T A R T E R S E R V I C E P R O C E D U R E S
GENERAL INFORMATION
This section will cover the St art er removal and in-
stallation. For diagnostic procedures, see Group 8A -
Battery/Starting/Charging Systems Diagnostics.
STARTING SYSTEM DESCRIPTION
The st art er system circuits consist of:
a bat t ery
engine st art er motor and solenoid
st art er relay
ignition switch
park/ neut ral position switch (automatic t ransmi s-
sion)
clutch interlock switch (manual transmission-die-
sel)
connecting wires and bat t ery cables.
Turni ng t he ignition switch to the st art position,
causes t he st art er relay points to close allowing cur-
rent to energize solenoid windings. This causes sole-
noid plunger and clutch shift lever to move engaging
clutch pinion gear into ri ng gear. At t he same time
t he solenoid contacts close causing st art er motor to
crank. As soon as engine st art s runni ng clutch pin-
ion gear overruns to protect st art er ar mat ur e from
damage due to excessive speed. Once t he engine
st art s runni ng, t he ignition key switch should be im-
mediately ret urned to t he r un position to prevent ex-
cessive st art er motor damage.
W ARN I N G: A L W A Y S D I SCON N E CT N E GATI V E CA-
BL E F ROM BATTERY BE F ORE SE RV I CI N G TH E
STARTE R.
STARTER MOTOR REMOVAL AND INSTALLATION
EXCEPT DIESEL
(2) Remove wire t ermi nal connector from st art er
motor (Fig. 1).
(3) Remove mount i ng bolt and nut securing st art er
to bellhousing (Fig. 2).
(.4) Move st art er forward to clear lower mount i ng
stud and st art er gear housing nose. This allows
st art er to come down past t he exhaust pipe (Fig. 3).
To install, reverse removal procedures.
Fig. 2 Remove or Install Starter Mounting Bolt and
Nut

Fig. 3 Remove or Install Starter Motor
STARTER MOTOR REMOVAL AND INSTALLATION
DIESEL
(2) Remove bat t ery cable by pulling rubber boot up
and removing nut (Fig. 1).
(3) Remove solenoid wire from solenoid.
(4) Remove st art er motor mount i ng bolts (Figs. 1
and 2).
INSTALLATION
(1) Install st art er motor. Tighten bolts to 68 Nm
(50 ft. lbs.).
(2) Attach solenoid wire. Tighten solenoid nut to 6
Nm (55 in. lbs.).
(3) Attach bat t ery cable to st art er motor. Tighten
cable nut to 10 N*m (90 in. lbs.).
(4) Connect negative cable to bat t ery.
Fig. 2 Remove Or Install Starter Motor Mounting
Bolt

G E N E R A T O R S E R V I C E
C O N T E N T S
page
GENERATOR REPLACEMENT-
DIESEL ENGINE 8
GENERAL INFORMATION
This section will cover generator removal and in-
stallation. The generator is not serviceable. Informa-
tion covering on-vehicle t est i ng can be found in
Group 8A - Battery/Starting/Charging/System Diag-
nostics.
The st andard equipment generator on t he D and W
bodies is t he 75 amp generator. The Ramcharger is
equipped with t he 90 amp generator. When a vehicle
is equipped with a heavy duty package or diesel en-
gine, a 120 amp generator is used.
GENERATOR REPLACEMENT -3.9L/5 .2L/5 .9L-LDC
GAS ENGINE
Drive belts on these engines are equipped wi t h a
belt tensioner is used on all belt configurations. For
more information, refer to Group 7 - Cooling, Belt
Removal/Installation.
REMOVAL
(3) Rotate tensioner assembly clockwise (as viewed
from front) unt i l tension has been relieved from belt.
(6 ) Remove lower generator mount i ng bolt and nut
(Fig. 2).
(7) Remove upper generat or mount i ng bolt and re-
move generator.
(8) Remove B+ t ermi nal nut , 2 field t ermi nal
nut s, ground, and harness hold down nut s (Fig. 3).
Remove wire connectors.
INSTALLATION
(1) Install harness to generator. Tighten nut s as
follows:
Ground t ermi nal , B+ t ermi nal and Wire Harness
Hold Down 7-10 N*m (60-90 in. lbs.).
Field t ermi nal s 2.5-3 N-m (20-30 in. lbs.).
(2) Install generator. Ti ght en both bolts to 41 Nm
(30 ft. lbs.).
page
GENERATOR REPLACEMENT3.9L/ 5.2L/
5.9L-LDC GAS ENGINE 6
GENERATOR REPLACEMENT5.9L HDC-GAS
ENGINE 7
Fig. 1 Automatic Belt TensionerBelt Removal/
Installation
Fig. 2 Generator Mounting Bolts

Fig. 3 Remove or install Wire Connector Assembly
CAUTI ON: When installing serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump ro-
tating in the wrong direction. Refer to Group 7 -
Cooling System for correct engine belt routing. The
correct belt with the correct length must be used
(3) Position drive belt over all pulleys except t he
idler pulley. This pulley is located between t he gen-
erator and A/C compressor.
(4) Attach a socket/wrench to pulley mount i ng bolt
of t he aut omat i c tensioner (Fig. 1).
(5) Rotate socket/wrench clockwise. Place belt over
idler pulley. Let tensioner rot at e back into place. Re-
move wrench. Be sure belt is properly seated on all
pulleys.
(6) Check belt indexing mar ks. Refer to Group 7 -
Cooling, Automatic Belt Tensioner.
GENERATOR REPLACEMENT5.9L HDC-GAS
ENGINE
Drive belts on these engines are equipped with a
belt tensioner is used on all belt configurations. For
more information, refer to Group 7 - Cooling, Belt
Removal/Installation.
REMOVAL
(2) Attach a socket/wrench to pulley mount i ng bolt
of automatic tensioner (Fig. 4). The t h r e a d s on t hi s
bol t a r e left ha nd.
Fig. 4 Automatic Belt Tensioner5.9L HDC-Gas
Engine
(3) Rotate tensioner assembly counterclockwise (as
viewed from front) unt i l tension has been relieved
from belt.
(6) Remove lower generator mount i ng bolt and nut
(Fig. 5).
Fig. 5 Generator Mounting Bolts
(7) Remove upper generator mount i ng bolt and re-
move generator.

Fig. 6 Remove or Install Wire Connector Assembly
INSTALLATION
(1) Install harness to generator. Tighten nut s as
follows:
Ground t ermi nal , B+ t ermi nal and Wire Harness
Hold Down 7-10 Nun (60-90 in. lbs.).
Field t ermi nal s 2.5-3 Nun (20-30 in. lbs.).
(2) Install generator. Tighten both bolts to 41 Nun
(30 ft. lbs.).
CAUTI ON : When instal l ing the serpentine accessor y
drive belt, the belt M UST be routed correctly. If not,
tating in the wrong direction. Refer to G r oup 7 -
C ool i ng S yst em for correct engi ne belt routing. The
correct belt with the correct length must be used
(3) Position drive belt over all pulleys except wa-
ter pump pulley.
(4) Attach a 3/8 inch rachet to tensioner.
(5) Rotate rat chet and belt tensioner counterclock-
wise. Place belt over wat er pump pulley. Let ten-
sioner rotate back into place. Remove ratchet. Be
sure belt is properly seated on all pulleys.
GENERATOR REPLACEMENTDIESEL ENGINE
(1) Remove negative cable from bat t ery.
(2) Remove generator drive belt. See Group 7 -
Cooling System, for instructions.
(4) Remove upper mount i ng bolt and nut (Fig. 7).
(5) Remove lower mounting bolt.
(6) Remove generator from t he vehicle.
(7) To install generator, first t i ght en lower mount-
ing bolt to 43 Nun (32 ft. lbs.). Tighten upper bolt to
24 Nun (18 ft. lbs.).
Fig. 7 Remove or Install Generator Mounting Bolts
Load
Test
(Amps)
cold
Cranki ng
Rat i ng @ 0F
Reserve
Capaci ty
300 A mp 600 Amp 120 Minutes
C R A N K I N G R A T I N G is the current a battery can deliver for 30 seconds anej maintain a terminal voltage of 7.2 volts or greater at
specified temperature.
RESERVE CAPACI TY R A T I N G is the length of time a battery can deliver 25 amps and maintain a minimum terminal voltage of
10.5 volts at 27 C (80 F).
J938A-25
GAS ENGINE DIESEL ENGINE
Manuf act urer N i ppondenso
Engine Application 5.9L, 5.2L & 3.9L
Part Number and 53005984
Power Rating 1.4 Kw
Voltage 12
No. of Fields 4
No. of Poles. 4
Brushes 4
Drive Reduction
Gear Train
Free Running Test
Voltage 11
Amperage Draw 73 Amps
Minimum Speed rpm 3601 rpm
Solenoid Closing Voltage 7.5 Volts
Cranking Amperage Draw Test . . . 125-200 Amps*
* Engine should be up to operating temperature. Extremely heavy
oil or tight engine will increase starter amperage draw.
J938B-14
RE D UCTI ON GE AR STARTE R
M a nuf a c t ur e r N i p p o n d e n s o
Engine Application 5.9L
Part Number and
Power Rating
4428221
3 kw
Voltage 12
No. of Fields 4
No. of Poles 4
Brushes 4
Drive Conventional
Gear Train
Free Running Test
Voltage
Amperage Draw
Minimum Speed rpm
11
220 Amps Max.
4200 rpm Min.
Solenoid Closing Voltage 8 Volts
Cranking Amperage Draw Test . . 450-550 Amps*
* Engine should be up to operating temperature. Extremely
heavy oil or tight engine will increase starter amperage draw.
J918B-21
GENERATOR SPECIFICATIONS
TY PE PH UT H U M S I R PULLE Y GROOV E S E N GI N E R A T I N G
NIPPONDENSO 53008646 7 ALL GASOLINE 75 AMPS
NIPPONDENSO 5234374 8 DIESEL 120 AMPS
J938B-28
BATTERY SPECIFICATIONS

IGNITION SYSTE MS 8D - 1
C O N T E N T S
page page
COMPONENT IDENTIFICATION/SYSTEM DIAGNOSTICS/SERVICE PROCEDURES 7
OPERATION 1 IGNITION SWITCH 25
COMPONENT REMOVAL/INSTALLATION . . . . . 18 SPECIFICATIONS 28
COMPONENT IDENTIFICATION/SYSTEM OPERATION
INDEX
page
Automatic Shut Down ( ASD) Rel ay 1
Camshaft Position Sensor 2
Crankshaft Position Sensor 2
Distributors 3
Engine Coolant Temperature Sensor . . . . . . . . . . . 4
page
Ignition Coil 3
Intake Manifold Charge Air Temperature Sensor . . 4
Manifold Absolute Pressure ( MAP) Sensor 4
Powertrain Control Modul e ( PCM) . 5
Throttle Position Sensor 5
GENERAL INFORMATION
Throughout this group, references are made to par-
ticular vehicle models by alphabetical designation or
by the particular vehicle nameplate. A chart showing
a breakdown of alphabetical designations is included
in the Introduction group at the beginning of this
manual.
5.9L gas powered engines will be referred to as ei-
ther: LDC (Light Duty Cycle), or HDC (Heavy Duty
Cycle).
This section of the group, Component Identifica-
tion/System Operation, will discuss ignition system
operation and will identify ignition system compo-
nents.
For diagnostic procedures and adjustments, refer to
the Diagnostics/Service Procedures section of this
group.
For removal and installation of ignition system
components, refer to the Component Removal/Instal-
lation section of this group.
For other useful information, refer to On-Board Di-
agnostics in the General Diagnosis sections of Group
14, Fuel System in this manual.
For operation of the DRB II Diagnostic Scan Tool,
refer to the appropriate Powertrain Diagnostic Proce-
dures service manual.
An Ignition specifications section is included at the
end of this group. A general Maintenance Schedule
(mileage intervals) for ignition related items can be
found in Group 0, Lubrication and Maintenance. This
schedule can also be found in the Owners Manual.
IGNITION SYSTEMS
The ignition systems used on all engines are basi-
cally identical. Similarities and differences between
the systems will be discussed.
A sequential multi-port fuel injection system is
used on all gas powered engines.
The ignition system is controlled by the powertrain
control module (PCM) on all engines. The PCM was
formerly referred to as the SBEC or engine control-
ler.
The ignition system consists of:
Spark Plugs
Ignition Coil
Secondary Ignition Cables
Ignition distributor. Contains rotor and camshaft
position sensor
Powertrain Control Module (PCM)
Crankshaft Position Sensor
AUTOMATIC SHUT DOWN (ASD) RELAY
The automatic shut down (ASD) relay is located in
the engine compartment (Fig. 1). As one of its func-
tions, the ASD relay will supply battery voltage to
the ignition coil. The ground circuit for the ASD re-
lay is controlled by the powertrain control module
(PCM). The PCM regulates ASD relay operation by
switching the ground circuit on-and-off.
IGNITION SYSTEMS
8D - 2 IGNITION SYSTEMS

A/ C CLUTCH RELAY STARTER RELAY
DATA LINK CONTROL
C ON N E C T OR MODULE J 9314- 164
Fig. 1 Auto Shut Down Relay
CAMSHAFT POSITION SENSOR
The camshaft position sensor is located in t he igni-
tion distributor (Fig. 2) on all engines.
Fig. 2 Camshaft Position Sensor Typical
The camshaft position sensor contains a hall effect
device called a sync signal generator to generat e a
fuel sync signal. This sync signal generator detects a
rot at i ng pulse ri ng (shutter) on t he distributor shaft.
The pulse ri ng rot at es 180 degrees t hrough t he sync
signal generator. Its signal is used in conjunction
with t he crankshaft position sensor to differentiate
between fuel injection and spark events. It is also
used to synchronize t he fuel injectors with t hei r re-
spective cylinders.
When t he leading edge of t he pulse ri ng (shutter)
ent ers t he sync signal generator, t he following oc-
curs: The i nt errupt i on of magnetic field causes t he
voltage to switch hi gh resul t i ng in a sync signal of
approximately 5 volts.
When t he t rai l i ng edge of t he pulse ri ng (shutter)
leaves t he sync signal generator, t he following oc-
curs: The change of t he magnetic field causes t he
sync signal voltage to switch low to 0 volts.
For component testing, refer to the Diagnostics/Ser-
vice Procedures section of this group.
For removal and installation of this component, re-
fer to t he Component Removal/Installation section of
this group.
CRANKSHAFT POSITION SENSOR
The sensor is bolted to t he top of cylinder block
near t he rear of t he right cylinder head (Fig. 3).
Fig. 3 Crankshaft Position SensorTypical
* Engine speed and crankshaft position are provided
t hrough t he crankshaft position sensor. The sensor
generates pulses t hat are t he input sent to t he pow-
ert rai n control module (PCM). The PCM interprets
t he sensor i nput to determine t he crankshaft posi-
tion. The PCM t hen uses this position, along with
other inputs, to determine injector sequence and ig-
nition timing.
The sensor is a hall effect device combined with an
i nt ernal magnet. It is also sensitive to steel within a
certain distance from it.
SENSOR OPERATION-3.9L ENGINE
The flywheel/drive plate has groups of notches at
its outer edge. On 3.9L V-6 engines, t here are t hree
sets of double notches and t hree sets of single
notches (Fig. 4) .
The notches cause a pulse to be generated when
t hey pass under the sensor. The pulses are t he i nput
to t he PCM.
The engine will not operate if the PCM does not re-
ceive a crankshaft position sensor input.
For component testing, refer to t he Diagnostics/Ser-
vice Procedures section of this group.

IGNITION SYSTEMS 8D - 3
For removal and installation of this sensor, refer to
the Component Removal/Installation section of t hi s
group.
CRANKSHAFT
POSITION
SENSOR
NOTCHES-
FLYWHEEL
CRANKSHAFT
POSI TI ON-
SENSOR
NOTCHES*
.FLYWHEEL
J9314-88
^^j^jV^ J9314-89
Fig. 4 Sensor Operation3.9L Engine
SENSOR OPERATION'-5.2U5.9L ENGINES
On 5.2L and 5.9L engines, t he flywheel/drive plate
has 8 single notches, spaced every 45 degrees, at its
outer edge (Fig. 5).
The notches cause a pulse to be generated when
they pass under t he sensor. The pulses are t he i nput
to t he PCM. For each engine revolution, t here are 8
pulses generated on V-8 engines.
The engine will not operate if t he PCM does not re-
vice Procedures section of t hi s group.
For removal and installation of t hi s component, re-
this group.
DISTRIBUTORS
ALL ENGINES
All engines are equipped with a camshaft driven
mechanical distributor, containing a shaft driven dis-
tributor rotor. They are equipped with an i nt ernal
camshaft position (fuel sync) sensor. This sensor pro-
vides fuel injection synchronization and cylinder
identification.
Distributors do not have built in centrifugal or vac-
uum assisted advance. Base ignition t i mi ng and all
timing advance is controlled by t he powertrain con-
trol module (PCM). Because ignition t i mi ng is con-
Fig. 5 Sensor Opera tion5.2L/5.9L Engine
trolled by t he PCM, base ignition timing i s not
adjustable on any of these engi nes.
The distributor is held to t he engine in t he conven-
tional method usi ng a holddown clamp and bolt. Al-
t hough the distributor can be rotated, i t will
have no effect on ignition timing.
All distributors contain an i nt ernal oil seal t hat
prevents oil from entering t he distributor housing.
The seal is not serviceable.
t hi s group.
IGNITION COIL
Bat t ery voltage is supplied to t he ignition coil pos-
itive t ermi nal from t he ASD relay.
The powertrain control module (PCM) opens and
closes t he ignition coil ground circuit for ignition coil
operation.
Base ignition timing is not adjustable on any
engi ne. By controlling t he coil ground circuit, t he
PCM is able to set t he base t i mi ng and adjust t he ig-
nition t i mi ng advance. This is done to meet changing
engine operating conditions.
The ignition coil is not oil filled. The windings are
embedded in an epoxy compound. This provides heat
and vibration resistance t hat allows t he ignition coil
to be mounted on t he engine.
3.9L/5.2L/5.9L LDC-Gas Engines: The coil is
mounted to a bracket t hat is bolted to t he front of
the ri ght engine cylinder head (Fig. 6). This bracket
is also used to mount t he automatic belt tensioner.
8D - 4 IGNITION SYSTE MS

Fig. 6 ignition Coil3.9L/5.2L/5.9L LDC-Gas
Engines
Fig. 7 Ignition Coil5.9L HDC-Gas Engine
5.9L HDC-Gas Engines: The coil is mounted to a
bracket t hat is bolted to t he automatic belt tensioner
mount i ng bracket (Fig. 7).
t hi s group.
ENGINE COOLANT TEMPERATURE SENSOR
The sensor provides an i nput voltage to t he power-
t rai n control module (PCM) rel at i ng coolant temper-
at ure. The PCM uses t hi s input, along wi t h i nput s
from other sensors, to det ermi ne injector pulse width
and ignition timing. As coolant t emperat ure varies,
t he coolant t emperat ure sensor resistance will
change, resul t i ng in a different i nput voltage to t he
PCM.
When t he engine is cold, t he PCM will operate in
t he Open Loop Cycle. It will demand slightly richer
air-fuel mi xt ures and hi gher idle speeds, unt i l nor-
mal operating t emperat ures are reached. Refer to
Modes Of Operation in Group 14, Fuel System for a
description of Open and Closed Loop operation.
The sensor is installed in t he i nt ake manifold near
t he t hermost at housing (Fig. 8).
Fig. 8 Coolant Temperature SensorTypical
t hi s group.
INTAKE MANIFOLD CHARGE AIR TEMPERATURE
SENSOR
The sensor element extends into t he i nt ake mani -
fold air st ream. It provides an i nput voltage to t he
powertrain control module (PCM) indicating i nt ake
manifold ai r t emperat ure. The i nput from t hi s sensor
is used along with i nput s from other sensors to de-
t ermi ne injector pulse width. As t he t emperat ure of
t he air-fuel st ream in t he manifold varies, t he sensor
resistance will change. This will result in a different
i nput voltage to t he PCM. For more information, re-
fer to Group 14, Fuel System.
This sensor is installed i n t he i nt ake manifold
(Figs. 9 or 10).
t hi s group.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
The MAP sensor reacts to absolute pressure in t he
i nt ake manifold and provides an i nput voltage to t he
powertrain control module (PCM). As engine load
changes, manifold pressure varies, causing t he MAP
sensor voltage to change. This change results in a
different i nput voltage to t he PCM. The i nput volt-
age level supplies t he PCM wi t h information. This
rel at es to ambi ent barometric pressure during engine

THROTTLE ^
BODY
u
BRACKET
y ^S UPPORT BRACK E T / |
C H A RGE A I R
ijmmmmk TE M PE RATURE S E N S O R
THROTTLE
BODY
Fig. 9 Sensor Location3.9L EngineTypical
INTAKE MANIFOLD
' b AIR TEMPERATURE
S E N S OR
J9314-162
Fig. 10 Sensor Location5.2L/5.9L
EnginesTypical
start-up (cranking) and to engine load while t he en-
gine is runni ng. The PCM uses this input, along wi t h
inputs from other sensors, to adjust air-fuel mi xt ure.
For more information, refer to Group 14, Fuel Sys-
tem.
The MAP sensor is mounted to t he t hrot t l e body
(Fig. 11). It is connected to t he t hrot t l e body with an
L-shaped rubber fitting and to t he PCM electrically.
this group.
POWERTRAIN CONTROL MODULE (PCM)
The powertrain control module (PCM) is located in
t he engine compartment behind t he bat t ery (Fig. 12).
The PCM was formerly referred to as t he SBEC or
engine controller.
The ignition system is controlled by t he PCM.
Base ignition timing by rotation of distributor
is not adjustable.
MANI FOLD
ABSOLUTE
PRESSURE
SENSOR
TORQUE CONVERTER
CLUTCH RELAY
ELECTRICAL J l p ^
CONNECTOR ^ g i s !
Fig. 11 MAP SensorTypical
A / C CLUTCH RELAY STARTER RELAY
AUTO SHUTDOWN RELAY
FUEL PUMP RELAY
DATA LINK
CONNECTOR
POWERTRAIN
CONTROL
MODULE J9314-164
Fig. 12 PCM LocationTypical
The PCM opens and closes t he ignition coil ground
circuit to operate t he ignition coil. This is done to ad-
j ust ignition timing, both initial (base) and advance,
for changing engine operating conditions.
The amount of electronic spark advance provided
by t he PCM is determined by five input factors: Cool-
ant t emperat ure, engine rpm, i nt ake manifold tem-
perat ure, manifold absolute pressure and t hrot t l e
position.
this group.
For diagnostics, refer to t he appropriate Powertrain
Diagnostic Procedures service manual for operation
of t he DRB II scan tool.
THROTTLE POSITION SENSOR
The sensor is mounted on t he throttle body (Fig.
13). It is connected to t he t hrot t l e blade shaft. The
sensor is a variable resistor. It provides t he power-
t rai n control module (PCM) with an i nput signal
(voltage) t hat represents t hrot t l e blade position. As

t he position of t he t hrot t l e blade changes, t he resis-
tance of t he sensor changes.
The PCM supplies approximately 5 volts to t he
sensor. The sensor output voltage (input signal to t he
PCM) represents t he t hrot t l e blade position. The
PCM receives an input signal voltage from t he sen-
sor. This will vary in an approximate range of from 1
volt at mi ni mum throttle opening (idle), to 4 volts at
wide open t hrot t l e. Along wi t h inputs from other sen-
sors, t he PCM uses t he sensor input to determine
current engine operating conditions. It also will ad-
j ust fuel injector pulse width and ignition timing.
this group.
MANI FOLD ABSOLUTE
Fig. 13 Throttle Position Sensor Typical

IGNITION SYSTE MS 80 - 7
DIAGNOSTICS/SERW1CE PROCE D URE S
INDEX
page
Camshaft Position Sensor Test . . . . . . . . . . . . . . . 7
Crankshaft Position Sensor Test 8
Distributor Cap 8
Distributor Rotor 8
Engine Coolant Temperature Sensor Test 10
Ignition Coil 8
Ignition Secondary Circuit Di agnosi s 10
GENERAL INFORMATION
This section of t he group, Diagnostics/Service Pro-
cedures, will discuss basic ignition system diagnos-
tics and service adjustments.
For system operation and component identification,
refer to t he Component Identification/System Opera-
tion section of t hi s group.
For removal or installation of ignition system com-
ponents, refer to t he Component Removal/Installa-
For other useful information, refer to On-Board Di-
agnostics in t he General Diagnosis sections of Group
14, Fuel System in this manual .
For operation of t he DRB II Diagnostic Scan Tool,
refer to t he appropriate Powert rai n Diagnostic Proce-
dures service manual .
Refer to RelaysOperation/Testing in t he Group
14, Fuel System section of t hi s service manual .
CAMSHAFT POSITION SENSOR TEST
The camshaft position sensor is located in t he dis-
tributor on all engines.
To perform a complete t est of t hi s sensor and its
circuitry, refer to t he DRB II diagnostic scan tool.
Also refer to t he appropriate Powert rai n Diagnostics
Procedures manual . To t est t he sensor only, refer to
t he following:
For this test, an anal og (non-digital) voltmeter
is needed. Do not remove t he distributor connector
from t he distributor. Using small paper clips, insert
t hem into t he backside of t he distributor wire har-
ness connector to make contact with t he t ermi nal s.
Be sure t hat t he connector is not damaged when in-
serting t he paper clips. At t ach voltmeter leads to
these paper clips.
(1) Connect t he positive ( + ) voltmeter lead into
t he sensor output wire. This is at done t he distribu-
tor wire harness connector. For wire identification,
refer to Group 8W, Wi ri ng Di agrams.
page
Ignition Timing 12
Intake Manifold Char ge Air Temperature Sensor
Test 12
Manifold Absolute Pressure ( MAP) Sensor Test . 12
Ox ygen Sensor Tests 17
Powertrain Control Modul e ( PCM) . . . . . . . . . . . . 14
Spark Plug Secondary Cabl es 16
Spark Pl ugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Throttle Position Sensor Test 17
(2) Connect the negat i ve (-) voltmeter lead into t he
ground wire. For wire identification, refer to Group
8W, Wiring Diagrams.
(3) Set t he voltmeter to t he 15 Volt DC scale.
(4) Remove distributor cap from distributor (two
screws). Rotate (crank) t he engine unt i l t he distribu-
tor rotor is pointed towards t he rear of vehicle. The
movable pulse ri ng should now be wi t hi n t he sensor
pickup.
(5) Turn ignition key to ON position. Voltmeter
should read approximately 5.0 volts.
(6) If voltage is not present, check t he voltmeter
leads for a good connection.
(7) If voltage is still not present, check for voltage
at t he supply wire. For wire identification, refer to
Group 8W, Wiring Di agrams.
(8) If voltage is not present at supply wire, check
for voltage at pin-7 of powertrain control module
(PCM) 60-way connector. Leave t he PCM connector
connected for this test.
(9) If voltage is still not present, perform vehicle
test using t he DRB II diagnostic scan tool.
(10) If voltage is present at pin-7, but not at t he
supply wire:
(a) Check continuity between t he supply wire.
This is checked between t he distributor connector
and pin-7 at the PCM. If continuity is not present,
repair t he harness as necessary.
(b) Check for continuity between t he camshaft
position sensor out put wire and pin-44 at t he PCM.
If continuity is not present, repair t he harness as
necessary.
(c) Check for continuity between t he ground cir-
cuit wire at the distributor connector and ground.
If continuity is not present, repair t he harness as
necessary.
(11) While observing t he voltmeter, crank t he en-
gine with ignition switch. The voltmeter needle
should fluctuate between 0 and 5 volts while t he en-
gine is cranking. This verifies t hat t he camshaft po-
sition sensor in t he distributor is operating properly
and a sync pulse signal is being generated.

If sync pulse signal is not present, replacement of
t he camshaft position sensor is necessary.
For removal or installation of ignition system com-
ponents, refer to t he Component Removal/Installa-
CRANKSHAFT POSITION SENSOR TEST
To perform a complete test of t hi s sensor and its
Procedures manual . To test t he sensor only, refer to
t he following:
The sensor is located on t he top of cylinder block
near t he rear of ri ght cylinder head (Fig. 1).
(1) Near t he r ear of i nt ake manifold, disconnect
sensor pigtail harness connector from mai n wiring
harness.
(2) Place an ohmmet er across t ermi nal s B and C
(Fig. 2). Ohmmet er should be set to lK-to-lOK scale
for t hi s test. The met er readi ng should be open (no
resistance). Replace sensor if a low resistance is indi-
cated.
DISTRIBUTOR CAP
INSPECTION
Remove t he distributor cap and wipe it clean wi t h
a dry lint free cloth. Visually inspect t he cap for
cracks, carbon pat hs, broken towers, or damaged ro-
tor button (Figs. 3 and 4 ) . Also check for white de-
posits on t he inside (caused by condensation ent eri ng
VIEW LOOKING INTO
CPS CONNECTOR J938D-7
Fig. 2 Sensor Connector
t he cap t hrough cracks). Replace any cap t hat dis-
plays charred or eroded t ermi nal s. The machined
surface of a t ermi nal end (faces toward rotor) will in-
dicate some evidence of erosion from normal opera-
tion. Exami ne t he t ermi nal ends for evidence of
mechanical interference with t he rotor tip.
Fig. 3 Cap InspectionExternalTypical
DISTRIBUTOR ROTOR
Visually inspect t he rotor (Fig. 5) for cracks, evi-
dence of corrosion, or t he effects of arcing on t he
met al tip. Also check for evidence of mechanical in-
terference with t he cap. Some charring is normal on
t he end of t he met al tip. The silicone-dielectric-var-
nish-compound applied to t he rotor tip for radio in-
terference noise suppression, will appear charred.
This is normal. Do not remove the charred com-
pound. Test t he spring for insufficient tension. Re-
place a rotor t hat displays any of these adverse
conditions.
IGNITION COIL
To perform a complete test of t he ignition coil and
its circuitry, refer to t he DRB II diagnostic scan tool.

Fig. 4 Cap InspectioninternalTypical
INSUFFICIENT
SPRING
TENSI ON
CORRODED EVIDENCE OF
PHYSICAL
CONTACT
WITH CAP J908D-48
Fig. 5 Rotor InspectionTypical
Procedures manual . To test t he coil only, refer to t he
following:
The ignition coil (Figs. 6 or 7) is designed to oper-
ate wi t hout an ext ernal ballast resistor.
Fig. 6 Ignition Coil-3.9U5.2U5.9L LDC-Gas Engine
Inspect t he ignition coil for arcing. Test t he coil ac-
cording to coil t est er manufacturer' s instructions.
Test t he coil pri mary and secondary resistance. Re-
place any coil t hat does not meet specifications. Refer
to t he Ignition Coil Resistance chart.
If t he ignition coil is being replaced, t he secondary
spark plug cable must also be checked. Replace cable
if it has been burned or damaged.
IGNITION COIL RESISTANCE
PRIMARY RESISTANCE SECONDARY RESISTANCE
COIL (MANUFACTURER) 2!-27C (70-80F) 21-27C (70-80F)
Diamond 0.97 - 1.18 Ohms 11,300- 15,300 Ohms
Toyodenso 0 .95 - 1.20 Ohms 11,300- 13,300 Ohms
J918D-2

Arcing at t he tower will carbonize t he cable boot,
which if it is connected to a new ignition coil, will
cause t he coil to fail.
If t he secondary coil cable shows any signs of dam-
age, it should be replaced with a new cable and new
t ermi nal . Carbon t racki ng on t he old cable can cause
arcing and t he failure of a new ignition coil.
ENGINE COOLANT TEMPERATURE SENSOR TEST
To perform a complete test of t hi s sensor and its
t he following:
The sensor is located in a wat er passage of t he in-
t ake manifold next to t he t hermost at housing (Fig.
8).
(1) Disconnect wire harness connector from sensor
(Fig. 8). On engines wi t h air conditioning, do not pull
directly on wiring harness. Fabricate an L-shaped
hook tool from a coat hanger (approximately eight
inches long). Place t he hook part of tool under t he
connector for removal. The connector is snapped onto
t he sensor. It is not equipped wi t h a lock type t ab.
COOLANT
TEMPERATURE
SENSOR
SENSOR RESISTANCE (OHMSJ
V
J9314-78
(2) Test t he resistance of t he sensor with a high in-
put impedance (digital) volt-ohmmeter. The resis-
tance should be less t han 1340 ohms at normal
engine operating idle t emperat ure. For resistance
values, refer to t he Sensor Resistance chart. Replace
t he sensor if it is not wi t hi n t he range of resistance
specified in t he chart.
(3) Test continuity of t he wire harness. This is
done between powertrain control module (PCM) wire
harness connector terminal-2 and t he sensor connec-
tor t ermi nal . Also check continuity between wire
harness terminal-4 to t he sensor connector t ermi nal .
Repair t he wire harness if an open circuit is indi-
cated.
T E MPE R AT UR E R E S I S T A N C E ( O HM S )
C F M I N M A X
- 40 - 40 291,490 381,710
- 2 0 - 4 85,850 108,390
- 10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
25 77 9,120 10,880
30 86 7,370 8,750
40 104 4,900 5,750
50 122 3,330 3,880
60 140 2,310 2,670
70 158 1,630 1,870
80 176 1,170 1,340
90 194 860 970
100 212 640 720
110 230 480 540
120 248 370 410
J928D-4
IGNITION SECONDARY CIRCUIT DIAGNOSIS
CHECKING FOR SPARK
C A U T I O N : When disconnecting a hi gh voltage cabl e
from a spark plug or from the distributor cap, twist
the rubber boot sl i ghtl y (1/2 turn) to break it l oose.
G r asp the boot (not the cable) and pull it off with a
st eady, even force.
(1) Disconnect t he ignition coil secondary cable
from center tower of t he distributor cap. Hold t he ca-
ble t ermi nal approximately 12 mm (1/2 in.) from a
good engine ground (Fig. 9).
CHECK HERE
FOR SPARK
IGNITION
COIL 9 1 8 D- 1 8
Fig. 9 Checking for SparkTypical
*
(1) Unplug t he ignition coil harness connector at
t he coil (Figs. 10 or 11).
Fig. 10 Coil Harness Connector3.9/5.2L/5.9L
LDC-Gas Engine
(2) Connect a set of small j umper wires (18 gauge
or smaller) between t he ignition coil and coil electri-
cal connector (Fig. 12).
Fig. 11 Coil Harness Connector5.9L HDC-Gas
Engine
IGNITION COIL COIL CONNECTOR
J928D-13
Fig. 12 Coil TerminalsTypical
(3) Determine t hat sufficient bat t ery voltage (12.4
volts) is present for t he st art i ng and ignition sys-
t ems.
(4) Crank t he engine for 5 seconds while monitor-
ing t he voltage at t he coil positive t ermi nal (Fig. 12):
If t he voltage remai ns near zero duri ng t he entire
period of cranking, refer to On-Board Diagnostics in
Group 14, Fuel Systems. Check t he powertrain con-
trol module and auto shut down relay.
If voltage is at near bat t ery voltage and drops to
zero after 1-2 seconds of cranking, check t he power-
t r ai n control module circuit. Refer to On-Board Diag-
nostics in Group 14, Fuel Systems.
If voltage remai ns at near bat t ery voltage duri ng
t he entire 5 seconds, t urn t he key off. Remove t he
60-way connector (Fig. 13) from t he powertrain con-
trol module (PCM). Check 60-way connector for any
spread t ermi nal s.
(5) Remove test lead from t he coil positive termi-
nal . Connect an 18 gauge j umper wire between t he
bat t ery positive t ermi nal and t he coil positive termi-
nal .
W ARN I N G: B E V E RY C ARE F UL W H E N TH E E N GI N E
I S CRAN K I N G. D O N OT PUT Y OUR H AN D S N E AR
TH E PUL L E Y S, BE L TS OR TH E F AN . D O N OT
W E AR L OOSE F I TTI NG CL OTH I N G.
(2) Rotate (crank) t he engine with t he st ar t er mo-
tor and observe t he cable t ermi nal for a steady arc. If
steady arcing does not occur, inspect t he secondary
coil cable. Refer to Spark Pl ug Cables in t hi s group.
Also inspect t he distributor cap and rotor for cracks
or burn mar ks. Repair as necessary. If steady arcing
occurs, connect ignition coil cable to t he distributor
cap.
(3) Remove a cable from one spark plug.
(4) Using insulated pliers, hold the cable t ermi nal
approximately 12 mm (1/2 in.) from the engine cylin-
der head or block while rot at i ng the engine wi t h t he
st art er motor. Observe t he spark plug cable t ermi nal
for an arc. If steady arcing occurs, it can be expected
t hat the ignition secondary system is" operat i ng cor-
rectly. If steady arcing occurs at the spark pl ug ca-
bles, but t he engine will not st art , connect t he DRB
II diagnostic scan tool. Refer to t he Powert rai n Diag-
nostic Procedures service manual .
FAILURE TO START TEST
To prevent unnecessary diagnostic time and wrong
test results, t he previous Checking For Spark test
should be performed prior to t hi s test.
W ARN I N G: SE T PARK I N G BRA K E OR BL OC K TH E
D RI V E W H E E L S BE F ORE PROC E E D I N G W I TH TH I S
TE ST.

X X
o o o o o o o o o o
, 0 0 0 0 0 0 0 0 0 0
\ 2 1 4 1 3 %
l OOOOOOOOOO
OOOOOOOOOO
si 20
fcji ÔQOOOOOOJ
r ~ - - -
#
o o o o o o o o o o .
CONNECTOR
T E RM I N A L S I D E
S H O W N
J908D-42
Fig. 13 PCM 60-Way Connector
(6) Make t he special j umper shown in Fi gure 14.
Using t he jumper, moment ar i l y ground terminal-19
of t he 60-way connector. A spark should be generated
at t he coil cable when t he ground is removed.
C A PA C I T OR
G R O U N D
THIS
CLIP
C ON N E C T TH I S-
AL L I GATOR
CLIP
M OM E N T A RI L Y
G R O U N D TH I S
C L I P TO C OI L ^
N E GA TI V E
AL L I GATOR CL I P
PR1003
Fig. 14 Special Jumper Ground-to-Coil Negative
Terminal
(7) If spark is generated, replace t he powertrain
control module (PCM).
(8) If spark is not seen, use t he special j umper to
ground t he coil negative t ermi nal directly.
(9) If spark is produced, repai r wiring harness for
an open condition.
(10) If spark is not produced, replace t he ignition
coil.
IGNITION TIMING
Ba s e (Initial) i gni t i on t i mi ng Is NOT adj us t abl e
on a ny engi ne. Do not a t t e mpt to adj us t I gni t i on
t i mi ng by r ot at i ng t he di s t r i but or .
All ignition t i mi ng functions are controlled by t he
powertrain control module (PCM). Refer to On-Board
Diagnostics in t he Multi-Port Fuel InjectionGen-
eral Diagnosis section of Group 14, Fuel Systems for
more information. Also refer to t he appropriate Pow-
ert rai n Diagnostics Procedures service manual for
operation of t he DRB II Scan Tool.
SENSOR TEST
To perform a complete test of t hi s sensor and i t s
Procedures manual . To t est t he sensor only, refer to
t he following:
(1) Disconnect t he wire harness connector from t he
sensor (Figs. 15 or 16).
THROTTLE ^
BOD Y ^
BRACK E T
S U PPO R T BRACK E T /
CHARGE AIR
TE M PE RATURE S E N S OR
Fig. 15 Sensor Location--3.9L EngineTypical
I N TAK E M A N I F OL D
AI R TE M PE RATURE
W
S E N S OR
J9314-162
Fig. 16 Sensor Location5.2U5.9L
EnginesTypical
(2) Test t he resistance of t he sensor with a i nput
impedance (digital) volt-ohmmeter. Do not remove
t he sensor from t he engine for testing. For resistance
values, refer to t he Sensor Resistance chart. Replace
t he sensor if it is not within t he range of resistance
specified in t he chart.
(3) Test t he resistance of t he wire harness. This is
done between t he powertrain control module (PCM)
wire harness connector terminal-2 and t he sensor
connector t ermi nal . Also check continuity between
terminal-4 to t he sensor connector t ermi nal . Repair
t he wire harness as necessary if t he resistance is
great er t han 1 ohm.
t hi s group.
TEST
To perform a complete test of MAP sensor (Fig. 17)
and its circuitry, refer to DRB II tester and appropri-
SENSOR RESISTANCE (OHMS)
T E MPE R AT UR E R E S I S T ANC E ( O H M S )
C F M I N M A X
- 40 - 40 291,490 381,710
- 2 0 - 4 85,850 108,390
- 10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
25 77 9,120 10,880
30 86 7,370 8,750
40 104 4,900 5,750
50 122 3,330 3,880
60 140 2,310 2,670
70 158 1,630 1,870
80 176 1,170 1,340
90 194 860 970
100 212 640 720
110 230 480 540
120 248 370 410
J928D-4
ate Powert rai n Diagnostics Procedures manual . To
test t he MAP sensor only, refer to t he following:
(1) Inspect t he rubber fitting from t he MAP sensor
to t he t hrot t l e body (Fig. 18). Repair as necessary.
MANIFOLD ABSOLUTE
PRESSURE SENSOR
J9314-86
Fig. 17 Manifold Absolute Pressure (MAP)
Sensor Typical
C A U T I O N : When testing the M A P sensor , be sure
that the harness wi res are not damaged by the test
meter probes.
AAAP SENSOR
MOU N T I N G SCREWS
RUBBER FITTING
J9314-87
Fig. 18 Rubber FittingMAP Sensor-to-Throttle
Body
(2) Test t he MAP sensor output voltage at t he
MAP sensor connector between t ermi nal s A and B
(Fig. 19). Wi t h t he ignition switch ON and t he en-
gine OFF, out put voltage should be 4-to-5 volts. The
voltage should drop to 1.5-to-2.1 volts with a hot,
neut ral idle speed condition.
A. Ground
B. Output Voltage
C. 5 Volts
J8914-91
Fig. 19 MAP Sensor Connector Terminals
(3) Test powertrain control module (PCM) termi-
nal-1 for t he same voltage described above to verify
t he wire harness condition. Repair as necessary.
(4) Test MAP sensor supply voltage at sensor con-
nector between t ermi nal s A and C (Fig. 19) with t he
ignition ON. The voltage should be approximately 5
volts (0.5V). Five volts (0.5V) should also be at
terminal-6 of the PCM wire harness connector. Re-
pair or replace t he wire harness as necessary.

(5) Test t he MAP sensor ground circuit at sensor
connector terminal-A (Fig. 19) and PCM connector
terminal-4. Repair t he wire harness if necessary.
(6) Test t he MAP sensor ground circuit at t he
PCM connector between terminal-4 and t ermi nal -11
with an ohmmeter. If t he ohmmeter indicates an
open circuit, inspect for a defective sensor ground
connection. Refer to Group 8W, Wiring for location of
t hi s connection. If t he ground connection is good, re-
place t he PCM. If terminal-4 has a short circuit to 12
volts +, correct t hi s condition before replacing t he
PCM.
POWERTRAIN CONTROL MODULE {PCM)
The PCM (formerly called t he SBEC or engine -con-
troller) is located in t he engine compartment (Fig.
20).
DATA UNK CONTROL
CONNECTOR MODULE J9314-164
Fig. 20 PCM Location
The ignition system is controlled by t he PCM.
t hi s group.
For diagnostics, refer to t he appropriate Powert rai n
Diagnostic Procedures service manual for operation
of t he DRB II scan tool.
SPARK PLUGS
For spark plug removal, cleaning, gap adjustment
and installation, refer to t he Component Removal/In-
stallation section of t hi s group.
Spark plug cable boot heat shields are pressed into
t he cylinder head to surround each cable boot and
spark plug (Fig. 21). These shields protect t he spark
plug boots from damage (due to intense engine heat
generated by t he exhaust manifolds) and should not
be removed. After t he spark plug cable has been in-
stalled, t he lip of t he cable boot should have a small
air gap to t he top of t he heat shield (Fig. 21).
Faul t y carbon and/or gas fouled plugs generally
cause hard st art i ng, but t hey will clean up at hi gher
engine speeds. Faul t y plugs can be identified in a
Fig. 21 Heat Shields
number of ways: poor fuel economy, power loss, de-
crease in engine speed, hard st art i ng and, in general,
poor engine performance.
Remove t he spark plugs and examine t hem for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in t he order
in which they were removed from t he engine. An iso-
lated plug displaying an abnormal condition indi-
cates t hat a problem exists in t he corresponding
cylinder. Replace spark plugs at t he i nt erval s recom-
mended in t he mai nt enance chart in Group 0, Lubri-
cation and Maintenance.
Spark plugs t hat have low mileage may be cleaned
and reused if not otherwise defective. Refer to t he
following Spark Pl ug Condition section of t hi s group.
CONDITION
NORMAL OPERATING
The few deposits present on t he spark plug will
probably be light t an or slightly gray in color. This is
evident with most grades of commercial gasoline
(Fig. 22). There will not be evidence of electrode
burni ng. Gap growth will not average more t han ap-
proximately 0.025 mm (.001 in) per 1600 km (1000
miles) of operation. Spark plugs t hat have normal
wear can usually be cleaned, have t he electrodes
filed, have t he gap set and t hen be installed.
Some fuel refiners in several areas of t he United
St at es have introduced a manganese additive (MMT)
for unleaded fuel. During combustion, fuel with
MMT causes t he entire tip of t he spark plug to be
coated with a rust colored deposit. This rust color can
be misdiagnosed as being caused by coolant in t he
combustion chamber. Spark plug performance is not
affected by MMT deposits.
COLD FOULING/CARBON FOULING
Cold fouling is sometimes referred to as carbon
fouling. The deposits t hat cause cold fouling are ba-

J908D-15
Fig. 22 Normal Operation and Cold (Carbon) Fouling
sically carbon (Fig. 22). A dry, black deposit on one
or two plugs in a set may be caused by sticking
valves or defective spark plug cables. Cold (carbon)
fouling of t he entire set of spark plugs may be caused
by a clogged air filter or .repeated short operating
times (short trips).
ELECTRODE GAP BRIDGIMG
Electrode gap bridging may be traced to loose de-
posits in t he combustion chamber. These deposits ac-
cumulate on t he spark plugs duri ng continuous stop-
and-go driving. When t he engine is suddenly
subjected to a high torque load, deposits part i al l y liq-
uefy and bridge t he gap between electrodes (Fig. 28).
This short circuits the electrodes. Spark pl ugs with
electrode gap bridging can be cleaned using st andard
procedures.
GROUND
ELECTRODE
J908D-11
Fig. 23 Electrode Gap Bridging
SCAVENGER DEPOSITS
Fuel scavenger deposits may be either white or yel-
low (Fig. 24). They may appear to be harmful, but
this is a normal condition caused by chemical addi-
tives in certain fuels. These additives are designed to
change t he chemical nat ur e of deposits and decrease
spark plug misfire tendencies. Notice t hat accumula-
tion on t he ground electrode and shell area may be
heavy, but the deposits are easily removed. Spark
plugs with scavenger deposits can be considered nor-
mal in condition and can be cleaned using st andard
procedures.
GROUND
ELECTRODE
COVERED
J908D-12
Fig. 24 Scavenger Deposits
CHIPPED ELECTRODE INSULATOR
A chipped electrode insulator usually results from
bending t he center electrode while adjusting t he
spark plug electrode gap. Under certain conditions,
severe detonation can also separate t he insulator
from t he center electrode (Fig. 25). Spark plugs wi t h
this condition must be replaced.
GROUND
J908D-13
Fig. 25 Chipped Electrode Insulator
PREIGNITION DAMAGE
Preignition damage is usually caused by excessive
combustion chamber t emperat ure. The center elec-
trode dissolves first and t he ground electrode dis-
solves somewhat l at t er (Fig. 26). Insulators appear
relatively deposit free. Determine if t he spark plug
has t he correct heat range rat i ng for t he engine. De-
t ermi ne if ignition t i mi ng is over advanced, or if

other operating conditions are causing engine over-
heat i ng. (The heat range rat i ng refers to t he operat-
ing t emperat ure of a part i cul ar type spark plug.
Spark plugs are designed to operate within specific
t emperat ure ranges. This depends upon t he thickness
and length of t he center electrodes porcelain insula-
tor.)
GROUND
ELECTRODE
CENTER
ELECTRODE
DISSOLVED
J908D-14
Fig. 26 Preignition Damage
SPARK PLUG OVERHEATING
Overheating is indicated by a white or gray center
electrode insulator t hat also appears blistered (Fig.
27). The increase in electrode gap will be consider-
ably in excess of 0.001 inch per 1000 miles of opera-
tion. This suggests t hat a plug wi t h a cooler heat
range rat i ng should be used. Over advanced ignition
timing, detonation and cooling system malfunctions
can also cause spark plug overheating.
BLISTERED
WHITE OR
J908D-16
Fig. 27 Spark Plug Overheating
SPARK PLUG SECONDARY CABLES
Spark plug heat shields are pressed into t he cylin-
der head to surround each spark plug cable boot and
ai r gap to t he top of t he heat shield (Fig. 28).
TESTING
Spark plug cables are sometimes referred to as sec-
ondary ignition cables or secondary wires. The cables
transfer electrical current from t he distributor to in-
dividual spark plugs at each cylinder. The spark plug
cables are of nonmetallic construction and have a
built in resistance. The cables provide suppression of
radio frequency emissions from t he ignition system.
Check t he high-tension cable connections for good
contact at t he ignition coil, distributor cap towers
and spark plugs. Termi nal s should be fully seated.
The t ermi nal s and spark plug covers should be in
good condition. Termi nal s should fit tightly to t he ig-
nition coil, distributor cap and spark plugs. The
spark plug cover (boot) of t he cable should fit t i ght
around t he spark plug insulator. Loose cable connec-
tions can cause corrosion and increase resistance, re-
sul t i ng in shorter cable service life.
Clean t he high tension cables with a cloth moist-
ened with a nonflammable solvent and wipe dry.
Check for bri t t l e or cracked insulation.
When t est i ng secondary cables for damage with an
oscilloscope, follow t he instructions of t he equipment
manufacturer.
If an oscilloscope is not available, spark plug cables
may be tested as follows:
C A U T I O N : D o not leave any one spark pl ug cabl e
di sconnect ed for l onger than necessar y duri ng test-
i ng. T hi s may cause possi bl e heat damage to the
catalytic converter. Total test time must not exceed
ten mi nutes.
Wi t h t he engine not runni ng, connect one end of a
t est probe to a good ground. St art t he engine and r un
t he other end of t he test probe along t he ent i re
l engt h of all spark plug cables. If cables are cracked

IGNITION SYSTEMS 80 - 17
or punctured, t here will be a noticeable spark j ump
from t he damaged area to t he t est probe. The cable
runni ng from t he ignition coil to t he distributor cap
can be checked in t he same manner. Cracked, dam-
aged or faulty cables should be replaced with resis-
tance type cable. This can be identified by t he words
ELECTRONIC SUPPRESSION printed on t he cable
jacket.
Use an ohmmeter to test for open circuits, exces-
sive resistance or loose t ermi nal s. Remove t he dis-
tributor cap from t he distributor. Do not r emove
cabl es from cap. Remove cable from spark plug.
Connect ohmmeter to spark plug t ermi nal end of ca-
ble and to corresponding electrode in distributor cap.
Resistance should be 250 to 1000 Ohms per inch of
cable. If not, remove cable from distributor cap tower
and connect ohmmeter to t he t ermi nal ends of cable.
If resistance is not within specifications as found in
t he Spark Pl ug Cable Resistance chart, replace the
cable. Test all spark plug cables in this manner.
SPARK PLUG CABLE RESISTANCE
M I N I M UM M AX I M UM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
J908D-43
To test ignition coil-to-distributor cap cable, do not
remove t he cable from t he cap. Connect ohmmet er to
rotor button (center contact) of distributor cap and
t ermi nal at ignition coil end of cable. If resistance is
not within specifications as found in t he Spark Plug
Cable Resistance chart, remove t he cable from t he
distributor cap. Connect t he ohmmeter to t he termi-
nal ends of t he cable. If resistance is not within spec-
ifications as found in t he Spark Pl ug Cable
Resistance chart, replace t he cable. Inspect t he igni-
tion coil tower for cracks, burns or corrosion.
For removal and installation of spark plug cables,
refer to Spark Plug Secondary Cables in t he Compo-
nent Removal/Installation section.
THROTTLE POSITION SENSOR TEST
To perform a complete test of this sensor and its
Also refer to t he appropriate Powertrain Diagnostics
t he following:
The t hrot t l e position sensor can be tested wi t h a
digital voltmeter. The center t ermi nal of t he sensor
connector is t he output t ermi nal (Fig. 29).
MANI FOLD ABSOLUTE
Fig. 29 Sensor TestingTypical
Wi t h t he ignition key in t he ON position and en-
gine not runni ng, check the sensor output voltage at
t he center t ermi nal wire of t he connector. Check t hi s
at idle (throttle plate closed) and at wide open throt-
tle (WOT). At idle, sensor output voltage should be
great er t han 200 millivolts. At wide open t hrot t l e,
sensor output voltage must be less t han 4,8 volts.
The output voltage should increase gradually as t he
t hrot t l e plate is slowly opened from idle to WOT.
OXYGEN SENSOR TESTS
For diagnosis, removal or installation, refer to
Group 14, Fuel Systems in t hi s manual .

COMPONENT REMGWAL/INSTALLATION
INDEX
page
Camshaft Position Sensor , 18
Distributor Service 20
Engine Coolant Temperature Sensor 20
Ignition Coil 21
page
Intake Manifold Charge Air Temperature Sensor . 22
Manifold Absolute Pressure ( MAP) Sensor . . . . . 22
Ox ygen ( 0
2
) Sensor 22
Powertrain Control Modul e ( PCM) 22
Spark Plug Secondary Cabl es 24
Spark Pl ugs 23
Throttle Position Sensor ( TPS) 24
GENERAL INFORMATION
This section of t he group, Component Removal/In-
stallation, will discuss t he removal and installation
of ignition system components.
For basic ignition system diagnostics and service
adjustments, refer to t he Diagnostics/Service Proce-
dures section of t hi s group.
AUTOMATIC SHUT DOWN (ASb) RELAY
The automatic shut down (ASD) relay is located in
t he engine compartment (Fig. 1).
TORQUE CONVERTER
CLUTCH RELAY
AUTO SHUTDOWN RELAY
FUEL PUMP RELAY
DATA UNK
CONNECTOR
POWERTRAIN
CONTROL
MODULE J9314-164
Fig. 1 Auto Shut Down Relay
REMOVAL
(2) Remove t he relay by pulling from connector.
INSTALLATION
(1) Check t he t ermi nal s in t he relay connector for
corrosion or damage before installation.
(2) Push t he relay into t he connector.
The camshaft position sensor is located in t he dis-
t ri but or (Fig. 2) .
REMOVAL
Distributor removal is not necessary to remove
camshaft position sensor.
CAMSHAFT
POSITION
SENSOR
SYNC
SI GNAL
GENERATOR
DISTRIBUTOR
ASSEMBLY
J9314-82
Fig. 2 Camshaft Position SensorTypical
screws).
(3) Disconnect camshaft position sensor wiring
harness from mai n engine wiring harness.
(4) Remove distributor rotor from distributor shaft.
(5) Lift t he camshaft position sensor assembly from
t he distributor housing (Fig. 2) .
INSTALLATION
(1) Install camshaft position sensor to distributor.
Align sensor into notch on distributor housing.
(2) Connect wiring harness.
(3) Install rotor.
(4) Install distributor cap. Tighten mount i ng
screws.
REMOVAL
The sensor is bolted to t he top of t he cylinder block
near t he rear of ri ght cylinder head (Fig. 3) .

(1) Remove t he spark plug cable loom and spark
plug cables from valve cover mount i ng stud at rear
of ri ght valve cover (Fig. 3). Position spark plug ca-
bles to top of valve cover.
(2) Disconnect 2 hoses at Exhaust Gas Recircula-
tion (EGR) valve. Note position of hoses at EGR
valve before removal.
(3) Disconnect electrical connector and hoses at
electric EGR transducer (EET). Note position of
hoses at EET before removal.
(4) Remove 2 EGR valve mount i ng bolts and re-
move EGR valve. Discard old EGR gasket.
(5) Disconnect electrical connector at engine oil
pressure sending unit.
(6) To prevent damage to oil pressure sending unit,
a special tool, such as number C-4597 must be used
(Fig. 4). Remove sending uni t from engine.
(7) Loosen EGR t ube mounting nut at i nt ake man-
ifold.
(8) Remove 2 EGR tube mount i ng bolts at exhaust
manifold (Fig. 3) and remove EGR t ube. Discard old
gasket at exhaust manifold.
(9) Disconnect crankshaft position sensor pigtail
harness from mai n wiring harness.
(10) Remove 2 sensor (recessed hex head) mount-
ing bolts (Fig. 3) and remove sensor.
INSTALLATION
(1) Position crankshaft position sensor to engine
and install mount i ng bolts. Tighten bolts to 8 N
#
m
(2) Connect mai n harness electrical connector to
sensor.
IGNITION SYSTE MS 8 0 - 1 9
Fig. 4 Oil Pressure Sending
UnitRemoval/Installation
(3) Clean t he EGR tube and exhaust manifold (at
EGR tube mount i ng point) of any old gasket mate-
rial.
(4) Install a new gasket to exhaust manifold end of
EGR tube and install EGR tube to both manifolds.
Tighten mount i ng nut at i nt ake manifold. Tighten 2
mount i ng bolts at exhaust manifold to 23 N
#
m (204
in. lbs.) torque.
(5) Coat t he t hreads of t he oil pressure sending
uni t with t hread sealant. Do not allow any of t he
t hread sealant to get into t he sending uni t opening,
or t he opening at t he engine. Install sending uni t to
engine and t i ght en to 14 Nm (130 in. lbs.) torque.
Install electrical connector to sending unit.
(6) Clean t he i nt ake manifold and EGR valve of
any old gasket mat eri al .
(7) Install a new EGR valve gasket at i nt ake man-
ifold.
(8) Install EGR valve to i nt ake manifold. Tighten
2 bolts to 23 Nm (200 in. lbs.) torque.
(9) Position EET and install its electrical connec-
tor. Connect hoses between EGR valve and EET.
Connect hose between mai n vacuum harness and
EET.
(10) Install spark plug cable loom and spark plug
cables to valve cover mount i ng stud.

WARNING: HOT, PRESSURIZED COOLANT C AN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR. RE-
FER TO GROUP 7, COOLING.
REMOVAL
(1) Partially drain cooling system. Refer to Group
7, Cooling.
(2) Disconnect electrical connector from sensor
(Fig. 5).
Engi nes wi th air conditioning: When removing
the connector from sensor, do not pull directly on
wiring harness. Fabricate an L-shaped hook tool
from a coat hanger (approximately eight inches
long). Place the hook part of tool under the connector
for removal. The connector is snapped onto the sen-
sor. It is not equipped with a lock type tab.
(3) Remove sensor from intake manifold.
Fig. 5 Coolant Temperature Sensor Typical
INSTALLATION
(1) Install sensor.
(2) Tighten to 7 Nnn (5.5 ft. lbs.) torque.
(3) Connect electrical connector to sensor.
The sensor connector is symmetrical (not indexed).
It can be installed to the sensor in either direction.
(4) Replace any lost engine coolant. Refer to Group
7, Cooling System.
DISTRIBUTOR SERVICE
REMOVAL
C A U T I O N : Ba s e ignition timing i s not adjustabl e on
any engi ne. Di stri butors do not have built in centrif-
ugal or vacuum assi st ed advance. Ba s e i gni ti on
timing and ti mi ng advance are controlled by the
powertrain control modul e ( PC M ) . Because a con-
ventional timing light can not be used to adjust di s-
tributor posi ti on after installation, note posi ti on of
distributor before removal .
(1) Disconnect negative battery cable at battery.
screws).
(3) Mark the position of distributor housing in
relationship to engine or dash panel. This is done
to aid in installation.
Before distributor is removed, the number one cyl-
inder must be brought to the top dead center (TDC)
firing position.
(4) Attach a socket to the Crankshaft Vibration
Damper mounting bolt.
(5) Slowly rotate engine clockwise, as viewed from
front, until indicating mark on crankshaft vibration
damper is aligned to 0 degree (TDC) mark on timing
chain cover (Fig. 6).
Fig. 6 Damper-To-Cover Alignment MarksTypical
(6) The distributor rotor should now be aligned to
the CYL. NO. 1 alignment mark (stamped) into the
camshaft position sensor (Fig. 7). If not, rotate the
crankshaft through another complete 360 degree
turn. Note the position of the number one cylinder
spark plug cable (on the cap) in relation to rotor. Ro-
tor should now be aligned to this position.
(7) Disconnect camshaft position sensor wiring
harness from main engine wiring harness.
(8) Remove distributor rotor from distributor shaft.
(9) Remove distributor holddown clamp bolt and
clamp (Fig. 8). Remove distributor from vehicle.
CAUTION: D o not crank engi ne with distributor re-
moved. Distributor/crankshaft relationship will be
l ost.
DISTRIBUTOR J9314-81
Fig. 7 Rotor Alignment Mark
Fig. 8 Distributor Holddown Clamp
INSTALLATION
If engine has been cranked while distributor is re-
moved, establish t he relationship between distributor
shaft and number one piston position as follows:
Rotate crankshaft in a clockwise direction, as
viewed from front, unt i l number one cylinder piston
is at top of compression stroke (compression should
be felt on finger with number one spark plug re-
moved). Then continue to slowly rot at e engine clock-
wise unt i l indicating mark (Fig. 6) is aligned to 0
degree (TDC) mark on t i mi ng chain cover.
(1) Clean top of cylinder block for a good seal be-
tween distributor base and block.
(2) Lightly oil t he rubber O-ring seal on t he dis-
tributor housing.
(3) Install rotor to distributor shaft.
(4) Position distributor into engine to its original
position. Engage tongue of distributor shaft with slot
in distributor oil pump drive gear. Position rotor to
t he number one spark plug cable position.
(5) Install distributor holddown clamp and clamp
bolt. Do not t i ght en bolt at this time.
(6) Rotate t he distributor housing unt i l rotor is
aligned to CYL. NO. 1 alignment mark on the cam-
shaft position sensor (Fig. 7).
(7) Tighten clamp holddown bolt (Fig. 8) to 22.5
(8) Connect camshaft position sensor wiring har-
ness to mai n engine harness.
(9) Install distributor cap. Ti ght en mount i ng
screws.
IGNITION COIL
The ignition coil is an epoxy filled type. If the coil
is replaced, it must be replaced wi t h t he same type.
REMOVAL
3.9L/5.2L/5.9L LDC-Gas Engines: The coil is
mounted to a bracket t hat is bolted to t he front of
t he ri ght engine cylinder head (Fig. 9). This bracket
is also used to mount t he aut omat i c belt tensioner.
5.9L HDC-Gas Engines: The coil is mounted to a
bracket t hat is bolted to the aut omat i c belt tensioner
mounting bracket (Fig. 10).
Fig. 9 Ignition Coil-3.9U5.2U5.9L LDC-Gas
Engines

(1) Disconnect t he wiring and secondary cable from
t he ignition coil (Figs. 9 or 10).
W ARN I N G: ( 3. 9L/ 5. 2L/ 5. 9L L D C - GAS E N GI N E S) D O
N OT RE M OV E TH E COI L M OUN TI N G BRACK E T- TO-
CY L I N D E R H E AD M OUN TI N G BOL TS. TH E COI L
M OUN TI N G BRAC K E T I S UN D E R A C C E S S ORY
D RI V E BE L T TE N SI ON . IF TH I S BRAC K E T I S TO BE
RE M OV E D F OR AN Y RE A S ON , AL L BE L T TE N SI ON
M UST F I RST BE RE L I E V E D . RE F E R TO TH E BE L T
SE CTI ON OF GROUP 7, COOL I N G SY STE M .
(2) Remove ignition coil from coil mounting
bracket (two bolts).
INSTALLATION
(1) Install t he ignition coil to coil bracket. If nut s
and bolts are used to secure coil to coil bracket,
tighten to 11 Nm (100 in. lbs.) torque. If t he coil
mounting bracket has been tapped for coil mounting
bolts, t i ght en bolts to 5 Nm (50 in. lbs.) torque.
(2) Connect all wiring to ignition coil.
SENSOR
REMOVAL
The charge air t emperat ure sensor is located in
right-front side of i nt ake manifold (Figs. 11 or 12).
Fig. 11 Sensor Location3.9L EngineTypical
(1) Disconnect electrical connector at sensor (Figs.
11 or 12).
(2) Remove sensor from i nt ake manifold.
INSTALLATION
(1) Install sensor to i nt ake manifold.
(2) Tighten t he sensor to 13 N-m (10 ft. lbs.)
torque.
(3) Install electrical connector.
Fig. 12 Sensor Location5.2L/5.9L
EnginesTypical
For removal and installation, refer to Manifold Ab-
solute Pressure Sensor in group 14, Fuel Systems.
OXYGEN (0
2
) SENSOR
For diagnostics and removal/installation proce-
dures, refer to Group 14, Fuel Systems, in t hi s man-
ual.
REMOVAL
The PCM is located in t he engine compartment be-
hi nd t he bat t ery and under t he left front fender (Fig.
13).
DATA UNK CONTROL
(2) Disconnect positive bat t ery cable at bat t ery.
(3) Remove bat t ery holddown clamps and remove
bat t ery.
(4) Remove 60-way electrical connector from PCM.
(5) Remove t he t hree PCM mount i ng bolts (Fig.
14).

PCM
M O U N T I N G
PCM CONNECTOR
CONNECTOR M O U N T I N G
BOLT J9314-165
Fig. 14 PCM Removal/Installation
(6) Remove PCM from vehicle.
INSTALLATION
(1) Check pins in PCM 60-way connector for dam-
age. Repair as necessary.
(2) Position PCM and install mount i ng bolts.
Tighten bolts to 4 Nm (35 in. lbs.) torque.
(3) Connect 60-way electrical connector to t he
PCM.
(4) Install battery.
(5) Connect bat t ery cables to bat t ery (positive ca-
ble first).
SPARK PLUGS
Spark plug cable heat shields are pressed into t he
cylinder head to surround each cable boot and spark
plug (Fig. 15). These shields protect t he spark plug
boots from damage (due to intense engine heat gen-
erated by t he exhaust manifolds) and should not be
removed. After t he spark plug cable has been in-
air gap to t he top of t he heat shield (Fig. 15).
If removal of t he heat shield(s) is necessary, re-
move t he spark plug cable and compress t he sides of
shield for removal. Each shield is slotted to allow for
compression and removal. To install t he shields,
align shield to machined opening in cylinder head
and t ap into place wi t h a block of wood.
PLUG REMOVAL
(1) Always remove spark plug or ignition coil ca-
bles by grasping at t he cable boot. Turn t he cable
boot 1/2 t ur n and pull st rai ght back in a steady mo-
tion. Never pull directly on t he cable. Int ernal dam-
age to cable will result.
(2) Prior to removing the spark plug, spray com-
pressed ai r around t he spark plug hole and t he area
around t he spark plug. This will help prevent foreign
material from ent eri ng t he combustion chamber.
(3) Remove t he spark plug using a quality socket
with a rubber or foam insert.
(4) Inspect t he spark plug condition. Refer to
Spark Pl ugs in t he Diagnostics/Service Procedures
section of t hi s group.
PLUG CLEANING
The plugs may be cleaned using commercially
available spark plug cleaning equipment. After
cleaning, file t he center electrode flat with a small
point file or jewelers file before adjusting gap.
PLUG GAP ADJUSTMENT
Check t he spark plug gap with a gap gauge tool. If
t he gap is not correct, adjust it by bending t he
ground electrode (Fig. 16). Never attempt to adjust
the gap by bendi ng the center electrode.
SPARK PLUG GAP
All Engi nes: .89 mm (.035 in).
PLUG INSTALLATION
Always t i ght en spark plugs to t he specified torque.
Over t i ght eni ng can cause distortion resulting in a
change in t he spark plug gap.
When replacing t he spark plug and ignition coil ca-
bles, route t he cables correctly and secure t hem in
the appropriate ret ai ners. Fai l ure to route the cables
properly can cause t he radio to reproduce ignition
noise. It could cause cross ignition of t he spark plugs,
or short circuit t he cables to ground.
(1) St art t he spark plug into t he cylinder head by
hand to avoid cross t hreadi ng.
(2) Tighten spark plugs to 35-41 N-m (26-30 ft.
lbs.) torque.
(3) Install spark plug cables over spark plugs.

.040
GAUGE
S PA R K
"PL U G
J908D-10
Fig. 16 Setting Spark Plug GapTypical
SPARK PLUG SECONDARY CABLES
C A U T I O N : When di sconnect i ng a hi gh vol tage cabl e
from a spark pl ug or from the distributor cap, twist
the rubber boot sl i ghtl y (1/2 turn) to break it l oose.
G r asp the boot (not the cable) and pull it off with a
steady, even force.
Install cables into t he proper engine cylinder firing
order (Figs. 17 or 18).
FRONT
O F
E N G I N E
C L O C K WI S E ROTATI ON
1-6-5-4-3-2
J9314-80
Fig. 17 Engine Firing Order3.9L V-6 Engine
When replacing t he spark plug and coil cables,
route t he cables correctly and secure in t he proper
a
F R O N T
O F
E N G I N E
C L O C K WI S E R O T A T I O N
1-8-4-3-6-5-7-2
J9314-79
Fig. 18 Engine Firing Order5.2U5.9L V-8 Engines
ret ai ners. Fai l ure to route t he cables properly can
cause t he radio to reproduce ignition noise. It could
also cause cross ignition of t he plugs, or short circuit
t he cables to ground.
When installing new cables, make sure a positive
connection is made. A snap should be felt when a
good connection is made between t he plug cable and
t he distributor cap tower.
Spark plug cable boot heat shields are pressed into
t he cylinder head to surround each cable boot and
ai r gap to t he top of t he heat shield (Fig. 19).
SPARK PLUG BO O T
- HEAT SHI ELD J9314-94
THROTTLE POSITION SENSOR (TPS)
For removal and installation, refer to Throttle Po-
sition Sensor in Group 14, Fuel Systems.
IGNITION SWITCH
INDEX
General Information
page
. . 25
GENERAL INFORMATION
The ignition switch is located in t he steering col-
umn. The Key-In-Switch and Halo Light are i nt egral
wi t h the ignition switch. Refer to Group 8M for Key-
In-Switch and Halo Light diagnosis.
IGNITION SWITCH AND KEY CYLINDER SERVICE
REMOVAL
(1) Disconnect negative bat t ery cable.
(2) Tilt column: Remove t i l t lever (counterclock-
wise).
(3) Remove upper and lower shrouds (Fig. 1).
STEERING
WHEEL
NUT
TILT UPPER
LEVER SHROUD
PANEL
BRACKET
SPACER
CLOCK SPRING
LOWER
SHROUD
NUT J928J-2
Fig. 1 Shroud Removal/InstallationTypical
(4) Remove ignition switch mount i ng screws
(Snap-on torx bit tool TTXR20B0 or equivalent re-
quiredFig. 2).
(5) Gently pull switch away from t he column. Re-
lease two connector locks on t he 7-terminal wiring
connector. Remove t he connector from t he ignition
switch (Fig. 3).
(6) Release connector lock on t he Key-In-Switch
and Halo Light 4-terminal connector (Fig. 3).
(7) Remove t he key cylinder from t he ignition
switch as follows:
Ignition Switch and K ey Cylinder Service
page
. . 25
STEERING
COLUMN
IGNITION
SWITCH
908D-14
Fig. 2 Ignition Switch Screw Removal
KEY-IN SWITCH &
HALO LIGHT
MULTIFUNCTION
SWITCH
IGNITION
SWITCH
TURN SIGNAL
SWITCH & LEVER
SPEED
CONTROL J918J- 2
Fig. 3 Key in Switch and Halo Lamp Connector
(a) With t he key inserted and t he ignition switch
in t he lock position, proceed as follows: Use a small
screwdriver to depress t he key cylinder ret ai ni ng
pin flush with t he key cylinder surface (Fig. 4).
(b) Rotate t he key clockwise to t he OFF position.
The key cylinder should now be unseated from t he
ignition switch assembly (Fig. 5).
C A U T I O N : Do not remove key cylinder at thi s time.
(c) With key cylinder in unseated position (key
cylinder bezel about 1/8 inch above ignition switch
SMALL
SCREWDRIVER
KEY CYLINDER
RETAI NI NG PI N
KEY CYLINDER
RETAI NI NG PI N
I GNI TI ON
SWI TCH 908D-15
Fig. 4 Key Cylinder Retaining Pin
KEY CYLINDER
BEZEL
j HALO LIGHT
^ R I NG 908D-16
Fig. 5 Unseated Key Cylinder
halo light ring), proceed as follows: Rotate t he key
counterclockwise to t he Lock position and remove
t he key.
(d) Remove key cylinder (Fig. 6).
INSTALLATION
(1) Install electrical connectors to switch. Make
sure t hat t he switch locking t abs are fully seated in
t he wiring connectors.
(2) Mount ignition switch to t he column (Fig. 7).
i - i - i i \ I G N I T I O N
SWITCH
HALO LIGHT
R I NG
908D-17
Fig. 6 Key Cylinder Removal
Park-lock dowel pin on ignition switch assembly
must engage with column park-lock slider linkage
(Fig. 8). Verify ignition switch is in lock position
(flag is parallel with t he ignition switch terminals)
(Fig. 6). Apply a dab of grease to flag and pin. Posi-
tion park-lock link and slider to mid-travel. Position
ignition switch against lock housing face. Be sure pin
is inserted into park-lock link contour slot. Tighten
ret ai ni ng screws to 2 N
#
m (17 in. lbs.) torque.
FASTENER
LOCATIONS
LOCATING
PIN
PARK LOCK
'DOWEL PIN
IGNITION
SWITCH
ELECTRICAL
CONNECTI ON
COLUMN
LOCK
FLAG
908D-18
Fig. 7 Ignition Switch View From Column
(3) Assemble cover to t he column (3 screws).
Tighten ret ai ni ng screws to 2 Nm (17 in. lbs.)
torque.
(4) Tilt column: Install tilt lever (clockwise).
(5) Install negative bat t ery cable.
(6) Install key cylinder.
(a) Wi t h key cylinder and ignition in lock posi-
tion, gently insert key cylinder into ignition switch
assembly until it bottoms.
(b) Insert key. While gently pushing on t he key
cylinder (inward) toward t he ignition switch, rotate
key clockwise to end of travel.

Fig. 8 Ignition Switch Mounting Pad
(7) Check for proper operation of push-to-lock, halo
lighting, Accessory, Lock, Off, Run, St art , column
lock and shift lock (if applicable).
IGNITION SWITCH CIRCUITS
. _ _ | .
1 2 3 4 5 6 7
I G N I T I O N S WI T C H C O N N E C T O R
L O O K I N G I N T O S WI T C H
WI RE
CAVI TY
WI RE
C OL OR
APPL I C AT I ON
1 YELLOW STARTER RELAY
2 DARK BLUE I G N I T I O N RUN/START
3 WHITE / BLACK
BRAKE WA R N I N G
LAMP
4 PI NK/ BLACK
I GN I T I ON SWI TCH
BATTERY FEED
5
BL A C K / O R A N G E
OR BLACK/TAN
RUN AC C E S S OR Y
6 BLACK / WHITE AC C E S S OR Y
7 RED
I GN I T I ON SWI TCH
BATTERY FEED
J938D-18

GENERAL INFORMATION
latest information available at the time of publica-
tion. If anythi ng differs bet ween the specifica-
tions found on the Vehi cl e Emi ssi on Control
Information (VECI) label and the fol l owi ng spec-
ifications, use specifications on VECI label. The
SPECIFICATIONS
VECI label is located in t he engine compartment.
IGNITION TIMING
Ignition timing is not adjustable on any engine.
Refer to Ignition Timing in t he Diagnostics/Service
Procedures section of this group for more informa-
tion.
IGNITION COIL
C O i i TOYODSNSO
Primary Resistance .95- 1.20 Ohms .96- 1.18 Ohms
Secondary Resistance at 70 - 80 F 11,300- 13,300 Ohms 11,300 - 15,300 Ohms
SPARK PLUGS
J918D-25
E ngi ne
S p a r k Pl ug
A ppl i cat i on G a p
T i ght eni ng
Torque
S i ze E ngi ne O r i gi na l
E q ui pment
R epl acement
A ppl i cat i on G a p
T i ght eni ng
Torque
S i ze
3.9L/5.2L/5.9L RC12YC RC12YC All
.035
(0.9mm)
41 N m
(30 ft. lbs.)
14mm
%" Reach
J928D-23
SPARK PLUG CABLE RESISTANCE ENGINE FIRING ORDER-3.9L V-6 ENGINE
M I N I M UM M AX I M UM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
J908D-43
a
FRONT
OF
ENGINE
CLOCKWISE ROTATION
1 -6-5-4-3-2
,
V ^ y

J9314-80
ENGINE FIRING ORDER5.2L/5.9L V-8 EN-
GINES
TORQUE
FRONT
OF
E N G I N E
CLOCKWI SE ROTATION
1-8-4-3-6-5-7-2
Description Torque
Crankshaft Position Sensor..
Distributor Hold Down Bolt..
Powertrain Control Module
Mounting Screws............
Powertrain Control Module
(PCM) Elect. Connector...
Spark Plugs
All Engines
8 N* m (70 in. lbs.)
23 Nm(17ft.ibs.)
1 Nm (9 in. lbs.)
4 N* m (35 in. lbs.)
4 1 N<>m (30 ft. lbs.)
J9314 -16 6
J9314-79
1
^ ^ ^ INSTRUMENT PANEL AND GAUGES 8E - 1
CONTENTS
page
CLUSTER AND GAUGE SERVICE PROCEDURES . 12
CLUSTER AND GAUGE TEST PROCEDURES . . i
GENERAL INFORMATION . 1
page
MESSAGE CENTER-DIESEL ENGINE . . . . . . . . 4
MESSAGE CENTER-GAS ENGINE . . . . . . . . . . 3
SWITCH AND PANEL COMPONENT SERVICE . 16
GENERAL I N F O R M A T I O N
INDEX
page
Generator Indicating System 2
Distance Sensor 2
Electronic Digital Clock 3
Fuel Level Indicating Syst em 1
page
Malfunction Indicator ( Check Engine) 3
Oil Pressure Warni ng Lamp . . . . . . . . . . . . . . . . . 2
Speedometer/ Odometer Syst em 2
Temperature and Oil Indicating System . . . . . . . . . 2
D-body trucks have an i nst rument cluster which
includes gauges for fuel level, coolant t emperat ure,
oil pressure, and charging system voltage (Fig. 1).
When t he ignition switch is in t he OFF position all
t he gauges will show a reading except t he voltage
gauge. However, t he readings are only accurate
when t he ignition switch is in t he ON position.
The cluster also includes warni ng lamps for:
seat belt warni ng
low oil pressure
high beam
left and ri ght t ur n signals
check engine.
J908E-66
Fig. 11nstrument Cluster
FUEL LEVEL INDICATING SYSTEM (FIG. 2)
A hinged float arm in the fuel tank raises or lowers
depending on the fuel level. The float arm contacts a
variable resistor in the gauge sending unit. This pro-
vides a change of resistance in the fuel gauge circuit
with any up or down movement of the float. This sender
resistance is shown as fuel level on the gauge.
Resistance is great est when t he fuel level in t he
t ank is low and t he float ar m drops. With high resis-
tance current flow is low and consequently positions
t he i nst rument panel gauge pointer to low.
Resistance in t he circuit is at a mi ni mum when t he
t ank is full and t he float arm is raised. With resis-
tance at a mi ni mum, current flow is high registering
full on t he i nst rument panel gauge.
12 VOLTS
TO
GAUGE
I P
FUEL TANK
S E NDI NG UNIT
FLOAT
SENDI NG
UNIT
1 :
1
j ^ f C O N N E C T O R
!g| yj-
FUEL
GAUGE
FUEL
TANK
J098E-47
Fig. 2 Fuel Level Indicating System
INSTRUMENT PANEL AND GAUGES
8E - 2 INSTRUMENT PANEL AND GAUGES

TEMPERATURE AND OIL INDICATING SYSTEM
(FIG. 3)
The operation of t he t emperat ure and oil pressure
indicating systems are identical. In t he t emperat ure
system t he sending uni t resistance varies in direct
relationship to t he t emperat ure of t he coolant.
When t he engine is cold, t he resistance of t he tem-
perat ure sending uni t is high and a cold t emperat ure
will be indicated on t he gauge.
When t he engine is hot, t he resistance of t he tem-
perat ure sending uni t is low and a hot t emperat ure
will be indicated on t he gauge.
In t he oil pressure indicating system t he sending
uni t resistance is actuated by a di aphragm as t he oil
pressure increases or decreases. Low oil pressure
causes high resistance. High pressure causes low re-
sistance.
12 VOLTS
T O
G A U G E
T E MPE R AT UR E /
OIL GAUGE
TEMPERATURE/OIL
SENDI NG UNIT
J908E-48
Fig. 3 Temperature/Oil indicating System
OIL PRESSURE WARNING LAMP
The oil pressure warni ng switch, mounted on t he
engine, is controlled by engine oil pressure.
When engine oil pressure is normal, t he switch is
held in t he OFF or OPEN position. This stops cur-
rent from flowing to t he oil pressure warni ng lamp
on i nst rument panel.
When t he engine oil pressure is low, t he switch is
in t he ON or CLOSED position. This allows current
to flow to t he oil pressure warni ng l amp in t he in-
st rument cluster causing t he warni ng l amp to illumi-
nat e.
GENERATOR INDICATING SYSTEM (FIG. 4)
The voltmeter gauge senses t he voltage of t he elec-
trical system.
VOLTAGE / * \
G A U G E P/
J908E-49
Fig. 4 Generator Indicating System
SPEEDOMETER/ODOMETER SYSTEM
The speedometer/odometer system consists of an
electric speedometer and pushbut t on reset odometer
mounted in t he cluster. The system also includes t he
wire harness from t he cluster to t he distance sensor
at t he transmission, and t he adapter and pinion in
t he transmission. The speedometer/odometer has t he
same appearance as a conventional version but it
eliminates t he cable-driven mechanical system. A
signal is sent from a transmission mounted distance
sensor to t he speedometer/odometer circuitry t hrough
t he wiring harness. By eliminating t he speedometer
cable, i nst rument cluster service and removal is im-
proved. Refer to Group 21 - Transmission for select-
ing t he proper pinion, and selecting and indexing t he
proper adapter.
DISTANCE SENSOR
DISTANCE SENSOR TEST
For testing of t he distance sensor and related com-
ponents refer to t he Vehicle Diagnostics Test Proce-
dure Manual .
DISTANCE SENSOR REMOVAL AND
INSTALLATION
(1) Remove harness connector from sensor. Be sure
weat her seal stays on harness connector.
(2) Remove sensor by loosening sensor coupling
nut from t he pinion gear adapter unt i l sensor is free
(Fig. 5).
(3) To install t he sensor, reverse t he removal pro-
cedures. Tighten coupling nut to 17 Nm (150 in. lbs.)

INSTRUMENT PANEL AND GAUGES 8E - 3
MALFUNCTION INDICATOR (CHECK ENGINE)
Fig. 5 Distance Sensor
If t he input from one of t he following sensors fails
an i nt ernal Powertrain Control Module (PCM) self
check, t he PCM t ur ns on t he Check Engi ne Lamp.
The PCM t hen substitutes a modified signal in place
of t he one t hat failed unt i l a repai r is made:
Manifold Absolute Pressure (MAP) Sensor
Throttle Position Sensor
Coolant Temperat ure Sensor
Bat t ery Voltage Sense
Bat t ery Voltage Too High
Refer to t he appropriate Powert rai n Diagnostic
Test Procedures manual for further information.
ELECTRONIC DIGITAL CLOCK
The electronic digital clock is i n t he radio. The
clock and radio each use t he display panel built into
t he radio. A digital readout indicates t he t i me in
hours and mi nut es whenever t he ignition switch is in
t he ON or ACC position.
When t he ignition switch is in t he OFF position or
when t he radio frequency is being displayed, t i me
keeping is accurately maintained.
The procedure for setting t he clock varies slightly
with each radio. The correct procedure is described
under t he individual radio operating instructions re-
ferred to in t he Owner Manual supplied with t he ve-
hicle.
MESSAGE CENTERGAS ENGINE
The message center (Fig. 6), located above t he
Heater-A/C controls, includes warni ng lamps for t he:
brake systems (parking and service)
ABS brakes
liftgate open (Ramcharger only)
maintenance required.
O/ D
BR A K E (P)(7
GA T E O PE N
MAI NT R E QD .
J938E-54
Fig. 6 Message CenterGas Engine
EMISSIONS MAINTENANCE REMINDER
This system is designed to act as a reminder t hat
scheduled vehicle emissions mai nt enance should be
performed. It is not i ntended to indicate a warn-
ing or that a state of emergency exi sts whi ch
mus t b e cor r ect ed t o i ns ur e safe vehi cl e oper a-
t i on. The components covered by t he system include
t he EGR system, PCV valve, and oxygen sensor.
Refer to Group 25 - Emissions, for further informa-
tion.
ABS WARNING LIGHT
This light monitors t he ABS Brake System. This
light will come on when t he ignition key is t urned to
t he ON position and may stay on for as long as
t hi rt y seconds. If t he ABS light remai ns on or comes
on duri ng driving, it indicates t hat t he ABS portion
of t he brake system is not functioning. Refer to
Group 5 - Brakes for further information.
BRAKE SYSTEM WARNING LIGHT
The dual brake system provides a reserve braki ng
capability in t he event of a failure to a portion of t he
hydraulic system. Fai l ure of either of t he dual sys-
t em is indicated by t he brake warni ng light which
will glow when t he service brake pedal is depressed.
The light will remai n on unt i l t he cause is corrected.
The light will also come on when t he parki ng
brake is applied wi t h t he ignition in t he ON position.
Refer to Group 5 - Brakes for further information.

MESSAGE CENTERDIESEL ENGINE
The message center (Fig. 7), which is located above
t he Heater-A/C controls, includes warni ng lamps for
t he:
brake systems (parking and service brakes)
ABS brakes
wat er in fuel
wai t to st art (controlled by Air Heat er Control
Module)
Low Fuel.
B R A K E
C U M M I N S
T U R B O DI ES EL,
LOW
FUEL
D I E SE L F UE L ON L Y
WA T E R I N F U E L
WA I T T O S T A R T
J938E-55
Fig. 7 Message CenterDiesel Engine
ABS WARNING LIGHT
This light monitors t he ABS Brake System. This
light will come on when t he ignition key is t urned to
t he ON position and may stay on for as long as
t hi rt y seconds. If t he ABS light remai ns on or comes
on duri ng driving, it indicates t hat t he ABS portion
of t he brake system is not functioning. Refer to
Group 5 - Brakes for further information.
BRAKE SYSTEM WARNING LIGHT
The Brake light is connected to a sensor t hat mon-
itors vacuum in t he brake booster system. The Brake
light when lit indicates LOW VACUUM.
The dual brake system provides a reserve braki ng
capability in t he event of a failure to a portion of t he
hydraulic system. Fai l ure of either of t he dual sys-
t em is indicated by t he brake warni ng light which
will glow when t he service brake pedal is depressed.
The light will remai n on unt i l t he cause is corrected.
The light will also come on when t he parki ng
brake is applied with t he ignition in t he ON position.
Refer to Group 5 - Brakes for further information.
WATER IN FUEL
The Wat er In Fuel light is connected to a sensor lo-
cated in t he fuel filter. If wat er collects in t he fuel/
wat er separator filter, t he Wat er In Fuel indicator
will light.
WAIT TO START
The Wait To St art light is connected to a sensor
t hat monitors i nt ake air t emperat ure in t he i nt ake
manifold. If i nt ake air t emperat ure is low and igni-
tion switch is in ON position, t he PCM sends current
to t he i nt ake manifold ai r heat ers and t he Wait To
St art light. This i nt ake manifold preheat cycle is
controlled by an electronic Air Heat er Control Mod-
ule.
LOW FUEL
The Low Fuel light is connected to a sensor in t he
fuel t ank. When t he fuel level reaches approximately
1/6 of a t ank, t he words LOW FUEL will illuminate
and remai n on unt i l fuel is added.

C L U S T E R A N D GAUGE TEST PR O C E D U R E S
INDEX
page
Fuel Gauge Circuit Test 9
Fuel Tank Sendi ng Unit Test 5
Oil Pressure Gauge Circuit Test . . . . . . . . . . . . . . 9
Sendi ng Unit ( Sensor) Test 5
page
Speedometer 10
Temperature Gauge Circuit Test 8
Voltage Gauge Circuit Test 10
Warni ng Lamp System Tests 6
C A U T I O N : Di sconnect battery negative cabl e, in en-
gi ne compartment, before servi ci ng instrument
panel. When power i s required for test pur poses,
connect battery cabl e (for test only).
Di sconnect battery negati ve cable after test
and before conti nui ng servi ce procedures.
SENDING UNIT (SENSOR) TEST
When a problem occurs with a cluster gauge, be-
fore disassembling t he cluster to check t he gauge,
check for a defective sending uni t (sensor) or wiring.
(1) Sending uni t s and wiring can be checked by
grounding t he connector leads, at the sending unit,
in t he vehicle.
C A U T I O N : When connecti ng an input terminal to
gr ound, D o Not leave the connecti on grounded for
more than a few seconds.
(2) With t he ignition in t he ON position; a
grounded i nput will cause t he oil, fuel or tempera-
t ure gauge to read at or above maxi mum.
FUEL TANK SENDING UNIT TEST
(1) Disconnect wire from t ermi nal on fuel t ank
sending uni t (Fig. 1).
FUEL PUMP SUPPLY
INPUT TO G A U G E
S E NDI NG UNIT G R O U N D
FUEL PUMP G R O U N D
J928E-49
Fig. 1 Fuel Tank Sending Connector Terminals
(2) Connect wire to a known good sending unit.
(3) Connect a j umper wire between sending uni t
fuel pick up t ube and a good ground.
(4) Check fuel gauge as described in following
steps. Allow at least t hree mi nut es at each t est point
for gauge to settle. Lightly tapping i nst rument clus-
t er may help position pointer.
FUEL GAUGE SYSTEM DIAGNOSIS
FUE L G A U G E S Y S T E M D I A G N O S I S
FUEL G A U G E
DOE S NOT
R E A D FULL
FAULTY PRINTED
CI RCUI T BOAR D
FUEL G A U G E
I N O PE R A T I V E
OR E RRATI C
FUEL G A U G E
I N A C C U R A T E
E
1
I
CHECK FAULTY WI RI NG OR TANK DEFORMED
TANK NOT FULL C OMPON E N T S CHECK
CHECK ALL WI RI NG
I NC L UDI NG
G R O U N D
i
FAULTY FUEL G A U G E
S E N D I N G UNIT
i
1 FUEL C
1 DOES
1 R E A D 1
pAUGE I
> N 0 ? 1
E MPTY 1
r
TANK N O T EMPTY
CHECK
PROPER ALI GNME NT
OF PICKUP A N D
SENDER ASSEMBLY.
REFER T O GR OU P 14
FAULTY FUEL
G A U G E
J908E-74

(5) Clip float ar m of sending uni t to its empty stop
(Fig. 2) and t ur n ignition key to ON position. The
gauge should read Empty, plus one pointer width, or
mi nus two pointer widths.
(6) Move and clip sending uni t float ar m to full
stop. The gauge should read Full, or above.
Fig. 2 Fuel Tank Sending Unit Test
RESULTS
(1) If fuel gauge does not meet specifications, check
following items as possible causes;
(a) Wiring and connections between t he gauge
sending uni t and multiple connector.
(b) Wiring and connections between multiple
connector and printed circuit board t ermi nal s.
(c) Circuit continuity between printed circuit
board t ermi nal s and gauge t ermi nal s.
If these items check okay, fuel gauge is defective
and must be replaced.
(2) If t he fuel gauge meets specifications check fuel
t ank and original installed fuel t ank sending uni t as
follows:
(a) Carefully remove fuel t ank sending uni t from
t ank.
(b) Connect sending uni t wire and j umper wire
as described in t he procedure.
(3) If fuel gauge now checks wi t hi n specifications,
originally installed sending uni t is electrically okay,
check following as possible cause:
(a) Ground st rap from sending uni t to fuel line
for continuity.
(b) Sending uni t deformed. Make sure sending
uni t float ar m moves freely and pick up t ube is not
bent so t hat it contacts bottom of t ank. Inspect
float for any signs of damage or leaks.
(c) Sending uni t improperly installed. Install
properly.
(d) Mounting flange on fuel t ank for sending
uni t deformed. Feel for interference fit of sending
uni t to bottom of t ank. It is permissible to bend
pick up t ube down a little near mount i ng flange to
gain interference fit.
(e) Fuel t ank bottom deformed causing improper
positioning of sending uni t pick up tube. Replace or
repai r t ank and recheck sending unit. Refer to Fuel
Tank Section of Group 14 - Fuel System.
WARNING LAMP SYSTEM TESTS
LOW OH. PRESSURE WARNING LAMP
CIRCUIT TEST
The low oil pressure warni ng lamp will i l l umi nat e
when t he ignition key is t urned to t he ON position.
The l amp also illuminates if t he engine oil pressure
drops below a safe oil pressure level.
To t est t he system t ur n ignition key to t he ON po-
sition.
If the l amp fails to light, inspect for a broken or
disconnected wire at t he oil pressure combination
uni t . The combination uni t is located at t he r ear of
t he engine (Fig. 3). If t he wire at t he connector
checks good, pull connector loose from t he switch and
wi t h a j umper wire ground connector to t he engine
(Fig. 4). Wi t h t he ignition key t urned to t he ON po-
sition check t he warni ng lamp. If l amp still fails to
light, inspect for a burned out bulb or disconnected
socket in t he cluster.
If light comes on, proceed and st art engine. If t he
l amp remai ns on, immediately t ur n engine off and
check engine oil pressure according to procedures as
outlined in Group 9 - Engine of t hi s manual . If t he
oil pressure meets specifications, check for a
grounded wire and/or replace t he oil pressure send-
ing uni t (refer to combination oil uni t test).
Fig. 3 Oil Pressure Sending UnitGas Engine

STEERING
PUMP
ENGI NE BLOCK
J 9 U9 - 7 4
Fig. 4 Oil Pressure Sending UnitDiesel Engine
COMBINATION OIL UNIT TEST (FIG. 5)
The combination oil uni t has 2 functions:
(1) The normal closed circuit keeps t he oil pressure
warni ng l amp on unt i l t here is oil pressure.
(2) The sending provides a resistance t hat varies
with oil pressure.
To t est t he normally closed oil lamp switch, discon-
nect t he locking connector and measure t he resis-
tance between t he switch t ermi nal and t he met al
housing. The ohmmeter should read 0 ohms. St art
t he engine.
If t here is oil pressure, t he ohmmeter should read
an open circuit.
To t est t he sending uni t , measure t he resistance
between t he sending uni t t ermi nal and t he met al
housing. The ohmmeter should read open, St art t he
engine.
The ohmmet er should read between 30 to 55 ohms,
depending on engine speed, oil t emperat ure, and oil
viscosity.
If t he previous results are not obtained, replace t he
switch.
SEAT BELT WARNING SYSTEM
For t est i ng of this system refer to Section 8M -
Seat Belt Warni ng Systems.
BRAKE SYSTEM WARNING LAMP (FIG. 6)
The brake warni ng lamp illuminates when t he
parki ng brake is applied with t he ignition key
turned ON. The same lamp will also i l l umi nat e
should one of t he two service brake systems fail
when t he brake pedal is applied. To test t he system
t ur n t he ignition key ON, and apply t he parki ng
brake. If t he lamp fails to light, inspect for a burned
out bulb, disconnected socket, a broken or discon-
ENGINE WARNI NG LAMP DI AGNOSI S
OIL PRESSURE FUNCTION
TURN
IGNITION
SWITCH "OH"
(DO NOT
ISTART ENGINE)!
LAMP "OFF' LAMP "O N "
DEFECTIVE
BULB
START AND IDLE
ENGINE
BULB SOCKET
OR WIRING
OPEN
LAMP STAYS
" O N "
TURN OFF
ENGINE
LAMP GOES
"OFF"
DEFECTIVE
SWITCH
CHECK FOR
GROUNDED
WIRING
WARNING
LIGHT OK
CHECK FOR
LOW OIL
LEVEL
ENGINE OIL
PRI SSURi
LOW
REFER TO
ENGINE SERVICE
DIAGNOSIS
ENGIM
PRES
0
IE OIL 1
SURE 1
, K
I
DEFECTIVE
SWITCH
TEST ENGINE
OIL PRESSURE
PR1448C
S WI TCH
(LIGHT)
SENDING UNIT
(GAUGE)
898E-2
Fig. 5 Combination Oil Unit Terminals
nected wire at t he switch. The lamp also lights when
t he ignition switch is t urned to t he START position.
To test t he service brake warni ng system,
(1) Raise t he vehicle on a hoist.
(2) Open a wheel cylinder bleeder while a helper

BRAKE
WA R N I N G
LAMP
SWITCH
TO BRAKE
WA R N I N G
LAMP
PR! 451
Fig. 6 Brake Warning Lamp Switch
depresses t he brake pedal and observes t he warni ng
lamp.
If t he lamp fails to light, inspect for:
a burned out bulb
disconnected socket
a broken or disconnected wire at t he switch.
If t he bulb is not burned out and t he wire continu-
ity is proven, replace t he brake warni ng switch. The
switch is in t he brake line Tee fitting mounted on
t he frame rail in t he engine compartment below t he
mast er cylinder.
C A U T I O N : If wheel cylinder bleeder w as opened
check master cylinder fluid level.
On Diesel Model s The Brake light is also con-
nected to a sensor t hat monitors vacuum in t he
brake booster system. The Brake light when lit indi-
cates LOW VACUUM. Refer to Group 5 - Brakes for
more information.
TEMPERATURE GAUGE CIRCUIT TEST
(1) Remove t emperat ure gauge. Refer to Gauge Re-
placement.
(2) Check continuity in t he wire between t he tem-
perat ure sensor and t he t emperat ure gauge (sensor
i nput pin) (Figs. 7, 8 and 9).
(3) With t he ignition switch in t he ON position,
check for bat t ery voltage across t he B + pin and t he
Ground pin.
(TURN IGNITION KEY "ON"
(DO NOT START ENGINE
I RELEASE PARKING BRAKE) I
I
[ WARNING LIGHT GOES I
"ON" I
1 (LIGHT SHOULD BE "OFF")!
X
APPLY PARKI NG BRAKE
(WARNI NG LIGHT
SHOULD G O "ON")
BRAKE SYSTEM
LEAKING FLUID
X
WARNING LIGHT
FAILS TO GO "ON"
GROUNDED WI RI NG BULB BURNED OUT
SHORTED PARKI NG BRAKE
OR BRAKE WARNI NG SWITCH
X
DISCONNECTED OR FAULTY
BULB SOCKET
FAULTY BRAKE SYSTEM
PROPORTIONING
VALVE UNIT*
BROKEN WIRE OR WIRE
DISCONNECTED AT PARKI NG
BRAKE SWITCH
X
FAULTY PARKI NG
BRAKE SWITCH
X
APPLY SERVICE BRAKES
(WARNI NG LIGHT
SHOULD NOT G O "ON")
JZ
X
TEST SERVICE BRAKE
WARNI NG
SYSTEM FUNCTI ON*
X
WARNING LIGHT GOES
" O N "
WARNING LIGHT
DOES NOT GO "ON"
BRAKE SYSTEM
LEAKING FLUID
OPEN CIRCUIT IN WI RI NG
TO SERVICE BRAKE SWITCH
X
GROUNDED WI RI NG OR
SHORTED BRAKE WARNI NG
SWITCH
LOOSE BULKHEAD
CONNECTOR
X
FAULTY BRAKE SYSTEM
PROPORTIONING
VALVE UNIT*
FAULTY SERVICE BRAKE
SWITCH
X
TESTS ARE DESCRIBED
I N APPROPRIATE
SECTION OF SERVICE
MANUAL
FAULTY SERVICE BRAKE
SYSTEM PROPORTIONING
VALVE UNIT*
PR1449A
INSTRUMENT PANEL AND GAUGES 8E - S
J938E-34
Fig. 7 Coolant Temperature SensorGas Engine
A I R
TEMPERATURE
SWITCH
- COOLANT
TEMPERATURE
SWITCH
Fig. 8 Coolant Temperature SensorDiesel Engine
OIL PRESSURE GAUGE CIRCUIT TEST
(1) Remove oil pressure gauge. Refer to Gauge Re-
placement.
(2) Check for continuity in t he wire between t he
oil pressure sensor and the oil pressure gauge (sensor
input pin) (Figs. 10, 11, 12 and 13).
check for bat t ery voltage across t he B+ pin and t he
Ground pin.
J90 8E- 6i _
Fig. 9 Temperature Gauge Pins
TEMPERATURE/OIL/FUEL GAUGE DIAGNOSIS
GAUGE INDICATES HIGHER
OR LOWER T H A N ACTUAL
I
FAULTY WIRING
FAULTY SENDING UNIT*
FAULTY INSTRUMENT PANEL
GAUGE*
ERRATIC GAUGE OPERATION
'TEST
PROCEDURES
DESCRIBED
ARE
IN
APPROPRIATE
SECTION
OF
SERVICE
MANUAL
LOOSE OR DIRTY ELECTRICAL CONNECTIONS
FAULTY INSTRUMENT PANEL
GAUGE*
J908E-52
FUEL GAUGE CIRCUIT TEST
(1) Remove fuel gauge assembly. Refer to Gauge
Replacement.
fuel t ank sending uni t and t he gauge (fuel level in-
put pin) (Figs. 14 and 15).
(3) Wi t h t he ignition switch in t he ON position,
Ground pin.
G R O U N D OI L PRESSURE
S E N S OR INPUT
J908E-70
Fig. 10 Oil Pressure Sending UnitGas Engine
STEERING
PUMP
ENGI NE BLOCK
J9119-74
Fig. 11 Oil Pressure Sending UnitDiesel Engine
S E N D I N G U N I T
( G A U G E )
S WI T C H
(LIGHT)
898E-2
Fig. 12 Combination Oil Unit Terminals
VOLTAGE GAUGE CIRCUIT TEST
(1) Remove voltage gauge. Refer to Gauge Replace-
ment.
Fig. 13 Oil Pressure Gauge Pins
r FUEL PUMP SUPPLY
0 INPUT TO G A U G E
- S E N D I N G UNIT G R O U N D
-FUEL PUMP G R O U N D
J928E-49
Fig. 14 Fuel Tank Sending Connector Terminals
FUEL GAUGE
INPUT
^ G R O U N D y J908E-71
Fig. 15 Fuel Gauge Pins
check for bat t ery voltage across t he B+ pin and t he
Ground pin (Fig. 16).
The instrument pa ne l vol t met er i ndi cat es elec-
t r i cal system battery vol tage.
SPEEDOMETER
(1) Remove speedometer assembly. Refer to Gauge
Replacement.

Fig. 16 Voltmeter Pins
distance sensor connector and t he speedometer (dis-
tance sensor i nput pin) (Fig. 17).
Ground pin.
Fig. 17 Speedometer Pins
(4) Perform distance sensor test. Refer t o General
Information - Distance Sensor in t hi s section.
(5) If all previous tests prove good, replace speed-
ometer.

CLUSTER AND GAUGE SERVICE PROCEDURES
INDEX
page
Cluster Bezel 12
Cluster Mask and Lens 12
Fuel Gauge 1 3
Instrument Cluster Assembl y 12
Lamp Bulb Repl acement Message Center . . . . . 15
CLUSTER BEZEL
REMOVAL
(2) Tape or cover steering column to prevent dam-
age to pai nt .
(3) Remove 2 screws and remove map lamp.
C A U T I O N : Map l amp must be removed to prevent
damage to instrument panel.
(4) Remove 6 screws which at t ach cluster bezel to
base panel (Fig. 1). Make sure t he screw below t he
Heater-A/C control is removed.
(5) Place column shift lever in Position " 1 " .
(6) Remove bezel by pulling top edge rearward to
clear brow. Disengage at t achi ng clips around bottom
of bezel and complete removal of bezel.
(7) If bezel is equipped with a four wheel drive in-
dicator, remove bulb socket as bezel is removed.
(8) Disconnect message center wires.
INSTRUMENT
CLUSTER BEZEL J938E-51
Fig. 1 instrument Cluster Bezel
INSTALLATION
(1) Connect bulb socket for four wheel drive indi-
cator if equipped.
(2) Connect message center wires.
(3) Engage at t achi ng clips around bottom of bezel,
roll bezel into position.
(4) Install 6 mount i ng screws.
page
Lamp Bul bs . . 1 5
Printed Circuit Board 1 3
PRN D 2 1 Indicator . 15
Specifications 1 5
Speedometer/ Odometer 14
(5) Install map lamp.
(6) Remove tape from steering column.
CLUSTER MASK AND LENS
REMOVAL
(2) Remove cluster bezel.
(3) Remove 8 screws holding mask and lens.
(4) Remove mask and lens.
INSTALLATION
(1) Position mask and lens.
(2) Install 8 screws.
(3) Install cluster bezel.
INSTRUMENT CLUSTER ASSEMBLY (Fig. 2)
REMOVAL
(2) Tape or cover steering column to prevent dam-
age to paint.
(3) Remove bezel.
(4) Remove lower steering column cover 4 screws.
(5) Spread upper steering column cover out of t he
locking t angs and slide downward.
(6) Disconnect PRND21 actuator cable from steer-
ing column if equipped.
(7) Loosen heat er and A/C control. Pull rearward
to clear forward mount on cluster housing.
(8) Remove 6 screws t hat ret ai n cluster. Pull clus-
t er rearward and disconnect 2 large connectors.
(9) Remove cluster.
INSTALLATION
(1) Connect 2 large connectors to cluster.
(2) Position cluster to i nst rument panel and install
6 ret ai ni ng screws.
(3) Install heat er A/C control.
(4) Connect PRND21 actuator to steering column if
equipped.
(5) Position upper steering column cover and slide
upward unt i l t angs snap into place.
I NSTRUMENT
PANEL
M A P LAMP
BRACKET
HEADLAMP
SWITCH
CLUSTER
ASSEMBLY
HEADLAMP
SWITCH MO U N T I N G
NUT
C A R G O LAMP SW I TC H
BEZEL A N D APPLI QUE
HEADLAMP
KNOB A N D STEM
BRACKET-AAAP LAMP M O U N T I N G
Fig. 2 Instrument Panel
(6) Position lower steering cover and install 4
screws.
(7) Install bezel.
(8) Remove protective cover from steering column.
(10) Check to see t hat all i nst rument s are func-
tioning properly.
PRINTED CIRCUIT BOARD
A visual inspection of t he conductors should be
made for cracks or damaged circuits. If no visual
damage is evident, each circuit should be tested for
continuity with an ohmmet er or a test light. Should
an open circuit be detected, t he printed circuit board
should be replaced.
REMOVAL (FIG. 3J
(1) Remove i nst rument cluster. See cluster re-
moval.
(2) Remove l amp socket assemblies.
(3) Remove gauge mount i ng screws and remove
gauges.
(4) Remove printed circuit board mount i ng screws.
(5) Remove printed circuit board from cluster hous-
ing.
HEADLAMP
SWITCH BEZEL
CLUSTER MA S K
A N D LENS J928E-46
Cluster and Switches
INSTALLATION
C A U T I O N : D o not overtighten mount i ng scr ews or
damage to circuit board and/ or cluster housi ng will
occur.
(1) Position printed circuit board on cluster hous-
ing, install mounting screws and t i ght en.
(2) Install gauges.
(3) Install lamp socket assemblies. Be sure illumi-
nation lamp diffusers are installed.
(4) Install i nst rument cluster.
FUEL GAUGE
TEMPERATURE GAUGE
VOLTAGE GAUGE
OIL PRESSURE GAUGE
It is not necessary to remove i nstrument clus-
ter from vehi cl e for gauge repl acement.
When removing gauge assemblies (Fig. 4) from
cluster, gauge must be pulled st rai ght out, not
twisted, or damage to gauge pin and/or printed cir-
cuit board may result.
(2) Remove bezel. Refer to Cluster Bezel Removal.
(3) Remove cluster mask and lens. Refer to Cluster
Mask and Lens Removal.

VOLTAGE
GAUGE
Fig. 3 instrument Cluster Printed Circuit Board
SPEEDOMETER
OIL PRESSURE
GAUGE
TEMPERATURE
GAUGE FUEL GAUGE
Fig. 4 Cluster With Mask Removed
J908E-69
(4 ) Remove gauge mount i ng screws.
(5) Pull gauge rearward to remove.
For Installation, reverse Removal procedures.
SPEEDOMETER/ODOMETER
It is not ne c e s s a r y to remove i nstrument cl us-
t er from vehi cl e for speedometer repl acement.
When removing speedometer (Fig. 4) from cluster,
gauge must be pulled st rai ght out, not twisted, or
damage to gauge pin and/or printed circuit board
may result.
(4) Remove mount i ng screws ret ai ni ng speedome-
ter/odometer to housing.
(5) Pul l speedometer/odometer rearward to remove.
For Installation, reverse Removal procedures.

PRND21 INDICATOR
REMOVAL
(3) Remove cluster assembly. Refer to Instrument
Cluster Removal.
(4) Remove screws attaching PRND21 mechanism
to cluster housing.
(5) Remove PRND21 mechanism.
INSTALLATION
(1) Position PRND21 mechanism to cluster hous-
ing.
(2) Install mounting screws.
(3) Install cluster assembly.
(4) Install mask-lens.
(5) Install bezel.
LAMP BULBS
CLUSTER ILLUMINATION LAMPS
TURN SIGNAL INDICATOR LAMPS
LOW OIL PRESSURE INDICATOR LAMP
HIGH BEAM INDICATOR LAMP
CHECK ENGINE LAMP
SEAT BELT WARNING LAMP
REMOVAL
(2) Remove instrument cluster. See cluster re-
moval.
(3) Twist lamp socket assembly and remove from
printed circuit board.
(4) Remove bulb from socket.
INSTALLATION
(1) Install bulb into socket.
(2) Install socket assembly into printed circuit
board.
(3) Position cluster into place in panel. See cluster
installation.
(4) Connect battery negative cable.
LAMP BULB REPLACEMENTMESSAGE CENTER
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove instrument cluster bezel assembly. Re-
fer to Instrument Cluster removal.
(3) Twist lamp socket assembly and remove from
printed circuit board.
INSTALLATION
(1) Install bulb into socket assembly.
(2) Install lamp socket assembly into printed cir-
cuit board.
(3) Install Instrument Cluster bezel assembly to
instrument panel. Refer to Instrument Cluster instal-
lation.
(4) Connect negative cable from battery.
FOUR WHEEL DRIVE INDICATOR LAMP
(1) Pull bulb and socket assembly from rear of
housing.
(3) Reverse removal procedures to install.
SPECIFICATIONS
Fuel Gauge Calibration
Mntar Position Resistance
Empty Graduation 90 ohms 3 ohms
Empty Stop Greater than 96.5 ohms
Full Graduation 12 ohm 3 ohms
Full Stop Less than 8 ohms
1/2 45.3 ohms 3 ohms
Temperature Gauge Calibration
Pointer Position Resistance
Cold Graduation 655 ohms
Hot Graduation 64 ohms
Oil Pressure Gauge Calibration
Pointer Position Resistance
Low Graduation 100 ohms
High Graduation 12 ohms
J908E-58

SWITCH AND PANEL COMPONENT S E R V I C E
INDEX
page
Ash Tray 20
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . 20
Four Wheel Drive Indicator 19
F use Block and F l ashers . . . . . . . . . . . . . . . . . . . 19
Glove Box 21
Heater A/ C Control 17
page
Heater Control 16
H ood Rel ease 19
Illumination Bulb Replacement 22
Message Center Modul e . . . . . . . . . . . . . . . . . . . 18
Steering Col umn Lowering and Raising 16
Switches 17
DI SCONNECT NEGATI VE CABLE FEOM
BATTERY I N ENGI NE COMPAETMENT BE-
FORE SERVI CI NG I NSTRUMENT PANEL.
STEERING COLUMN LOWERING AND RAISING
When servicing t he i nst rument panel and t he Low-
ering and Raising of t he steering column is required,
t he following is t he procedure for doing so:
This procedure is not for removi ng and replac-
ing the steering col umn. Refer to Group - 19
Steering of thi s manual for the removal and re-
pl acement procedures.
LOWERING STEERING COLUMN
(2) Remove 3 toe plate nut s and washers (Fig. 1).
(3) Remove 1 toe plate screw.
(4) Remove 4 screws at t achi ng lower steering col-
umn cover and remove cover. The fuse block is at-
tached to t hi s cover and should be supported when
cover is removed.
(5) Spread upper steering column cover out of lock-
ing t angs and slide downward.
(6 ) Disconnect cable from shift indicator bracket.
(7) Remove 2 nut s and washers at t achi ng steering
column bracket to i nst rument panel steering column
support bracket.
(8) Allow column to lower and rest on seat.
STEERING
COLUMN SUPPORT
WASHER A N D NUT
Fig. 1 Steering Column Mounting
RAISING STEERING COLUMN
(1) Raise steering column assembly agai nst t he in-
st rument panel support bracket.
(2) Install 2 steering column bracket washers and
nut s (Finger Tighten Only).
C A U T I O N : C heck that all wiring i s clear and not
pi nched.
(3) Tighten t he 2 bracket nut s to 12 Nnn-(110 in.
lbs.) torque.
(4) Slide toe plate into position, install at t achi ng
screw, tighten to 4 Nm (35 in. lbs.).
(5) Install toe plate nut s and washers and t i ght en
to 23 N*m (200 in. lbs.).
(6 ) Connect cable to shift indicator bracket.
(7) Position upper steering column cover and slide
upward until t angs snap into place.
(8) Install fuse block to cover.
(9) Position lower steering column cover and in-
stall 4 at t achi ng screws.
HEATER CONTROL
REMOVAL
(1) Remove map lamp.
(2) Remove cluster bezel (refer to Cluster Bezel Re-
moval).
(3) Remove 2 control at t achi ng 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 Heat er
A/C Section).
(3) Connect illumination lamp, and wire connec-
tors.
(4) Push control into panel.
(5) Install 2 control mount i ng screws.
(6 ) Install bezel.
HEATER A/C CONTROL
REMOVAL
moval).
(3) Remove 2 control at t achi ng screws.
(4) Pull control rearward.
(5) Disconnect blower switch wiring.
(6) Disconnect wires to pushbut t on switch (three
connectors).
(7) Disconnect illumination l amp.
(8) Disconnect vacuum harness.
(9) Disconnect t emperat ure cable.
(10) Remove control.
INSTALLATION
(1) Position control near panel.
(2) Connect t emperat ure cable (see Group 24 -
Heat i ng and Air Conditioning).
(3) Connect vacuum harness.
(4) Connect illumination lamp.
(5) Attach 3 wire connectors to pushbutton switch.
(6) Connect wires to blower motor switch.
(7) Push control into panel.
(8) Install 2 control mounting screws.
INSTRUMENT
PANEL
SWITCHES
HEADLAMP SWITCH (FIG. 2)
REMOVAL
(1) Remove cluster bezel (refer to Cl ust er Bezel Re-
moval).
(2) Reaching under i nst rument panel, depress knob
and st em release button located on bottom of switch
housing. At the same t i me pull knob and stem as-
sembly out of switch housing located on front of
panel.
(3) Remove power mirror switch knob by pulling
st rai ght off.
(4) Remove bezel.
(5) From front of panel remove spanner nut ,
mount i ng switch to panel.
(6) Reaching under i nst rument panel, lower switch
down far enough to disconnect electrical leads.
(7) Remove switch.
INSTALLATION
(1) Connect all electrical leads to switch.
(2) Guide switch into position in panel , install
spanner nut and tighten securely.
(3) Install bezel.
(4) Install power mirror switch knob.
(5) Insert knob and stem assembly into switch.
AAAP LAMP
BRACKET
HEADLAMP
SWITCH
CLUSTER
ASSEMBLY
HEADLAMP
SWITCH MOUNTING
NUT
CARGO LAMP SWITCH
BEZEL AND APPLIQUE
HEADLAMP
KNOB AND STEM
BRACKET-MAP LAMP MOUNTING
HEADLAMP
SWITCH BEZEL
CLUSTER AAASK
AND LENS J928E-46
Fig. 2 Instrument Panel Switches

Fig. 3 Overdrive Lockout Switch and Message
Center Module
J918E-32
Fig. 4 Message Center Printed Circuit
BoardAutomatic Transmission
INSTALLATION
(1) Position lockout switch into module and push
until retaining tabs lock into place.
(2) Connect switch connector.
(3) Install instrument cluster bezel to panel.
MESSAGE CENTER MODULE (Fig. 3)
REMOVAL
moval).
(3) Reach behind bezel and disconnect lockout
switch (if equipped) and message center connectors.
(4 ) Remove 3 module retaining screws and one clip
and pull module from bezel.
(6 ) Install cluster bezel.
(7) Check operation of switch.
POWER MIRROR SWITCH
Refer to Group 8T - Power Mirrors
CARGO LAMP SWITCH
REMOVAL
(1) Locate chime module. Grasp chime module and
twist it to remove it from the bracket.
(2) Remove wiring connector from cargo lamp
switch.
(3) Depress lock tabs on switch and push it out of
the instrument panel.
INSTALLATION
(1) Hold wiring connector in switch opening.
(2) Push switch on to wiring connector.
(3) Continue to push until switch snaps into place.
(4 ) Install chime module on to bracket.
MAP LAMP SWITCH
REMOVAL
(1) Remove 2 attaching screws.
(2) Drop assembly down and remove wiring con-
nector, then remove map lamp assembly.
INSTALLATION
(1) Connect wiring connector to lamp assembly.
(2) Position map lamp assembly to panel and in-
stall 2 mounting screws.
GLOVE BOX LAMP SWITCH
REMOVAL
(1) Open glove box until stops in bin rest against
instrument panel.
(2) Depress stops to clear instrument panel and
continue pivoting glove box assembly downward.
(3) Disconnect wire to switch.
(4 ) Snap switch out of panel.
INSTALLATION
(1) Snap switch into panel.
(2) Connect wire to switch.
(3) Depress stops and close glove box door.
OVERDRIVE LOCKOUT SWITCH (FIG. 3)
REMOVAL
moval).
(3) Reach behind bezel and disconnect lockout
switch connector.
(4 ) Depress retaining tabs on top and bottom of
switch and pull switch out of module.

MESSAGE CENTER
J918E-33
Fig. 5 Message Center Printed Circuit
BoardManual Transmission
LOW FUEL MODULE >
J918E-34
Fig. 6 Message Center Printed Circuit BoardDiesel
(5) Remove overdrive lockout switch from module.
INSTALLATION
(1) Install overdrive lockout switch into module.
(2) Position module on bezel and install screws and
clip.
(3) Connect lockout switch and message center
connectors.
(4) Install instrument cluster bezel to panel.
FUSE BLOCK AND FLASHERS
FUSE BLOCK
The fuse block is located directly below the steer-
ing column, on the lower steering column cover.
REMOVAL
Push fuse block locking tab on column cover down-
ward and lower fuse block. The following components
plug into the fuse block.
Fuses.
30 amp circuit breakers.
Turn signal flasher.
Horn relay.
Hazard Warning Flasher.
INSTALLATION
(1) Position fuse block to steering column cover.
(2) Push locking tab to lock fuse block in position.
HOOD RELEASE
REMOVAL
(1) Disengage cable from hood latch in engine com-
partment.
(2) Remove 4 screws holding handle assembly to
instrument panel.
(3) Remove assembly by pulling cable rearward
through dash panel grommet.
INSTALLATION
(1) Feed cable assembly forward through dash
panel grommet.
(2) Mount handle assembly to instrument panel
with four screws.
(3) Connect cable to hood latch.
FOUR WHEEL DRIVE INDICATOR
REMOVAL
moval).
(3) Remove 2 screws and remove indicator from be-
zel (Fig. 7).
o
J928E-48
Fig. 7 Four Wheel Drive Indicator Bezel

INSTALLATION
(1) Position indicator to bezel and at t ach with two
screws.
CIGAR LIGHTER (Fig. 8)
REMOVAL
(1) Open ash receiver.
(2) Remove lighter element from shell.
(3) Disconnect wiring.
(4) Turn clamp counterclockwise and remove.
(5) Remove shell t hrough front of housing.
INSTALLATION
(1) Insert shell t hrough front of housing.
(2) Install clamp on shell, t ur n clockwise and
t i ght en securely.
(3) Connect wiring to shell.
(4) Install lighter element.
(5) Install wires and close ash receiver.
ASH TRAY (Fig. 8)
TRAY
REMOVAL
(1) Open ash t ray.
(2) Remove ash t ray bin.
INSTALLATION
(1) Install ash t ray bin.
(2) Push ash t ray inward to closed position.
HOUSING
REMOVAL
(1) Remove ash t ray bin.
(2) Disconnect electrical leads from cigar lighter.
(3) Remove 6 screws ret ai ni ng housing to panel.
(4) Remove cigar lighter from housing.
INSTALLATION
(1) Install cigar lighter in housing.
(2) Connect electrical leads to cigar lighter.
(3) Position housing to panel and install six
mount i ng screws.
(4) Install ash t ray bin.
Fig. 8 Cigar Lighter and Ash Tray

GLOVE BOX (Fig. 9)
BOOH AND BIN ASSEMBLY
REMOVAL
(1) Remove 4 screws t hat ret ai n glove box door as-
sembly to lower reinforcement.
(2) The bin is removed by unsnappi ng bin from
door assembly.
INSTALLATION
(1) Snap bin onto door assembly.
(2) Attach assembly to lower reinforcement with 4
screws.
GLOVE BOM LOCK
REMOVAL
(1) Open glove box door.
(2) Turn lock into locked position and remove key.
(3) Insert a stiff wire in rear slot of lock mecha-
nism and depress ret ai ni ng t umbl er into cylinder.
(4) While holding tumbler down wi t h wire in lock
cylinder, insert key.
(5) Remove wire and pull out lock cylinder.
(6) Remove latch mounting screws and remove as-
sembly.
INSTALLATION
(1) Position latch assembly into place on glove box
door, install mount i ng screws and t i ght en securely.
(2) Depress ret ai ni ng t umbl er into lock cylinder
and insert key.
(3) Position assembly so t hat it will be in the
closed position when installed.
(4) Push lock cylinder into latch assembly, and re-
move key.
CATCH
REMOVAL
(1) Open glove box door.
(2) Remove catch mount i ng screws.
(3) Remove catch.
INSTALLATION
(1) Position catch into place, install mounting
screws and tighten securely.
(2) Close glove box door.
Fig. 9 Giove Box and Bin

ILLUMINATION BULB REPLACEMENT
ASH TRAY ILLUMINATION LAMP
REMOVAL
(1) Open ash receiver and remove bin.
(2) Disconnect wires from cigar lighter.
(3) Remove 6 screws t hat ret ai n assembly to panel.
(4 ) While dropping ash receiver, remove l amp as-
sembly from top of t he housing.
INSTALLATION
(1) Install l amp assembly into top of housing.
(2) Position housing and install 6 mount i ng
screws.
(3) Connect wires to cigar lighter.
(4 ) Install bin and close ash receiver.
MAP LAMP BULB
To replace bulb, snap lens out, replace bulb.
FOUR WHEEL DRIVE INDICATOR
REMOVAL
moval).
(3) Remove bulb and socket.
INSTALLATION
(1) Snap in bulb and socket.
(2) Replace cluster bezel.
HEATER OR HEATER A/C ILLUMINATION
LAMP
REMOVAL
moval).
(3) Remove two control at t achi ng screws.
(4 ) Pull control rearward.
(5) Snap out illumination lamp.
INSTALLATION
(1) Install bulb into socket.
(2) Snap socket into control.
(3) Push control forward and install two at t achi ng
screws.
(4 ) Install cluster bezel.
A U D I O S Y S T E M S
C O N T E N T S
SERVICE PROCEDURES
page
. . 7 TEST PROCEDURES
page
. . 2
GENERAL INFORMATION
For operation of t he factory installed radios, refer
to t he Owner Manual supplied with t he vehicle.
When connecting or disconnecting t he Ignition Off
Draw (IOD) connector, it is i mport ant t hat t he igni-
tion switch be in t he OFF position.
Fai l ure to place t he ignition switch in t he OFF po-
sition can cause t he radio display to become scram-
bled when t he IOD is disconnected. Connecting the
IOD will correct t he scrambled display.
INTERFERENCE ELIMINATION
Many components are used on vehicles equipped
with a radio to suppress radio frequency interference
(static).
A capacitor is mounted inside the generator and
ground st raps are utilized from cab to box and from
the engine to cowl.
The previously mentioned Capacitor and Ground
Straps should be securely mounted to a clean ground
surface to work effectively.
Radio resistance spark plug wires complete t he in-
terference suppression system. Faul t y or deteriorated
spark plug wires should be replaced.
RADIO NOISE DIAGNOSIS
Noise, Static
Hash, Etc.
Check For Noise in the
Following Positions:
1. Accessory (All Electrical
Accessories Off)
2. Engine Running
Is
'Static/NoiseS
Present
'With Ign. Key in Acc.
Y e s \ ^| j Accessories/
Off
No
Refer to
Antenna
Diagnosis
\
f
Stop
No
Is
Static/Noise
Present
With Engine
Running? .
Yes
J928F-3
Check Following:
A. Electric Fuel Pump
B. Ignition System Faults
C. Faulty Ground Connections
D. Faulty Electronic Voltage Reg.
E. Tighten Antenna Mounting Nut
8F - 2 AUDIO SYSTE MS

RADIO CONNECTOR PINS
BLACK
CHRYSLER
A M / F M STEREO
RADIOS
4 S PE A K E R S
GRAY
BLACK
XL
GR AY
0@[3]S[3]@[D
X52 X54
VIEWED
FROM
X58 WI RE
END
X56 E2 Ml
X51 X53 X57 X55 L7 XI 2
A M / F M STEREO
R A D I O S
2 S PE A K E R S
BLACK GR AY
4
BLACK GR AY
[ZlSmEIULIlLT]
X54 X54
VIEWED
FROM
X56 WIRE
END
X56 E2 M l
X53 X53 X55 X55 L7 X12
LEGEND: E2- I LLUMI NATI ON X51-LEFT REAR FEED X55-LEFT DR RETURN
L7- PARK LAMPS X52-RIGHT REAR FEED X56 -RIGHT DR RETURN
M l - BATTERY X53-LEFT DR FEED X57-LEFT REAR RETURN
X12 - ACC/ RUN X54-RIGHT DR FEED X58-RI GHT REAR RETURN
J938F-8
T E S T P R O C E D U R E S
RADIO DIAGNOSIS
Turn Ign. Key
to ACC.
T
Check A M , FM and
Tape Player Operation
NOTE: FOR WI RE COLORS REFER TO
SECTI ON 8W- WI RI NG DI AGRAMS
SPEAKER DIAGNOSIS
Turn Ign. Key
to ACC.
X
Select Known Station
Volume at Listening Level
Adjust Speaker Control (Fader &
Balance) to Check if All Spkrs.
Am Distorted or Inoperative
y r
y
r
Any One Channel
Right or Left
Only One
Speaker
1 r
Replace
Radio
Check Defective Spkr.
Connection, Wiring at
Sack of Radio or Amp
Check Defective Spkr.
Connection, Wiring at
Sack of Radio or Amp
All
Speakers
Without
Sound? ,
Yes
Check Ign. Feed
at Radio
Repair as
Required
Repair as
Required
Yes
Yes
Check for
Short Circuit
To Ground
N o.
Replace
Speaker
Yes
Check for Short
To Ground on Any/
All Speaker Leaas
Stop
Yes Replace
Radio
No
Send Original
Radio
for Service
J928F-10
ANTENNA
TESTING
Antenna performance may be tested by substitut-
ing a known good antenna. Check short or open cir-
cuits with an ohmmeter or continuity light once the
antenna cable is disconnected from the radio as fol-
lows:
(1) Continuity should be observed between the tip
of the mast and radio end pin (Fig. 1).
(2) No continuity or a very high resistance of sev-
eral megohms should be observed between the
ground shell of the connector and radio end pin.
(3) Continuity should be observed between the
ground shell of the connector and the mounting hard-
ware on the fender.
BENCH TEST FOR ANTENNA MALFUNCTION
(1) With test lamp and battery in circuit;
(a) attach one test lead to concentric pin on
lead-in connector
8F - 4 AUDIO SYSTEMS

ANTENNA DIAGNOSIS
Turn Ign. Key to
ACC
Tune to Known
Strong AM Station
f
Check Antenna
Connections
1 1
No
Check for
Reception Using
A Test Antenna
Repair as
Required*
*Be Sure Antenna is
Properly Grounded to Car.
(Poor Grounding of Antenna
May Cause Engine Noise or
Yes Static Especially on AM)
Remove Radio
For Service
Replace or Repair
Defective Antenna
Or Lead in
J928F-4
TIP OF MAST
TEST POINT
RY684
Fig. 1 Antenna Test Points
(b) other test lead to tip of mast (Fig. 2).
The lamp should light indicating Continuity.
(2) Keeping one lead on connector pin, clip other
lead on ant enna body assembly. The l amp should
-TI P OF MAST
RADI O LEAD I N
PR519
Fig. 2 Antenna Bench Test Points
NOT light. If it does, look for a short circuit in t he
body or in t he cable probably at t he connector.
(3) Remove clip lead from connector pin and clip
on outer shell of connector. Connect other clip lead to
ant enna body assembly. The lamp should LIGHT
again. If it does not Light, ant enna shielding has an
open circuit.
Wi ggl e cabl e over i t s ent i r e l engt h t o r eveal in-
t er mi t t ent s hor t or ope n ci r cui t s dur i ng s t eps 1,
2 a n d 3.
REMOVAL
(2) Open glove box door. Depress 2 "stops" on glove
box at center upper area near latch (Fig. 3).
INSTRUMENT PANEL
DEPRESS
TABS
GLOVE
BOX
GLOVE
BOX
DOOR
J928E-51
Fig. 3 Glove Box "Stops"
(3) Reach behind i nst rument panel and unpl ug an-
t enna cable from radio (Fig. 4).
(4) Working t hrough t he glove box opening, pull
ant enna cable from ret ai ner clip (Fig. 5).
(5) Open ri ght door and remove cable grommet
from A pillar (Fig. 6).
(6) Pul l cable from A pillar.
(7) Loosen ant enna mast from ant enna body. Do
not r e move at t hi s t i me.
(8) Loosen cap nut usi ng tool C4816 (Fig. 7).

AUDIO SYSTE MS 8F - 5
RN1005
Fig. 4 Unplugging Antenna Lead from Radio
Fig. 5 Removing Antenna Cable
Fig. 6 Removing Grommet
(9) While holding ant enna mast with one hand, re-
move cap nut with other hand.
(10) Lower ant enna assembly down far enough to
gain access to ant enna body (Fig. 8).
(11) While holding body remove ant enna mast .
(12) Pull ant enna body and cable assembly from
fender area and remove.
(13) Remove adapter on fender.
ADAPTER PR517 A
Fig. 7 Cap Nut and Adapter
Fig. 8 Removing or Installing Antenna Body
INSTALLATION
(1) Route ant enna cable between fender and dash
panel to A pillar area.
(2) Insert ant enna mast t hrough hole in fender and
screw into ant enna body.
(3) Pull assembly up and position into place and
hold.
(4) Install adapter maki ng sure t ab indexes with
opening in fender and ant enna body.
(5) Install cap nut and t i ght en securely with tool
C-4816.
(6) Insert cable t hrough opening in A pillar and
from inside glove box opening pull in far enough to
snap grommet into place.
8F - 6 AUDIO SYSTE MS

(7) Route cable t hrough ret ai ner clip, over to radio,
and plug into back of radio.
(8) Close glove box.
CASSETTE TAPE PLAYER DIAGNOSIS
TAPE PLAYER DIAGNOSIS
Turn Radio On & Insert Tape
Tape
Inoperative
Check Player
For Obstruction
Behind Doors
Poor
Performance
1
Try A
Good
Known
Tape
Yes
Try A Known
Good Tape
Correct As
Required
Yes
Advise Owner
of Worn or
Defective Tape
Yes
Remove Unit
For Repair
Advise Owner
of Worn or
Defective Tape
NO EJECT
Do Not Force Removal
of Jammed Cassette
J928F-5

AUDIO SYSTEMS 8F - 7
SERVICE PROCEDURES
RADIO REPLACEMENT
REMOVAL
C A U T I O N : M ap lamp must be r emoved to prevent
damage to instrument panel.
(2) Remove 2 screws and t he map lamp (if
equipped) (Fig. 9).
(3) Remove 6 screws attaching I/P bezel to t he in-
st rument panel. Be sure t he screw below t he Heat-
er/C control is removed.
Fig. 9 Instrument Cluster Bezel
(4) Remove 2 mounting screws from front of radio
(Fig. 10).
(5) Pull radio out of i nst rument panel and discon-
nect wiring and ant enna.
(6) Remove screw from ground st rap.
RF431
Fig. 10 Radio to Instrument Panel Mounting
INSTALLATION
(1) Install ground st rap.
(2) Install wiring and ant enna.
(3) Insert radio into panel and install mount i ng
screws.
(4) Install i nst rument cluster bezel.
(5) Install map lamp, if equipped.
DOOR MOUNTED SPEAKER
REMOVAL
(1) Remove remote control handle.
(2) Remove window regul at or handle, if equipped.
(3) Remove pull st rap if equipped.
(4) Remove screw at top of armrest .
(5) Using a t ri m stick or other suitable flat tool,
gently pry t ri m panel away from door.
(6) Remove screws holding speaker (Fig. 11).
(7) Disconnect speaker leads.
(8) Remove speaker.
Fig. 11 Door Mounted Speaker
INSTALLATION
(1) Connect leads to speaker.
(2) Position speaker into place, install mount i ng
screws and t i ght en securely.
(3) Install door t ri m panel.
REAR SPEAKER - STANDARD CAB PICKUP
REMOVAL
(1) Remove grille and speaker assembly to pillar
mounting screws (Fig. 12).
(2) Pull speaker and grille away from pillar and
disconnect wiring.
(3) Remove speaker to grille ret ai ni ng nut s (2).
INSTALLATION
(1) Position speaker onto studs of speaker grille
and install nut s.
(2) Install wiring harness connector on speaker.
(3) Position speaker and grille on pillar and install
mounting screws.

Fig. 12 Rear Speakers
REAR SPEAKER - CLUB CAB PICKUP
REMOVAL
(1) Remove two screws from bottom of speaker
housing (Fig. 13).
(2) Lower speaker housing and pull bottom out, al-
lowing ret ai ni ng t ab on top of housing to clear slot.
(3) Disconnect speaker connector and remove
speaker.
INSTALLATION
(1) Install wiring harness connector on speaker.
(2) Install ret ai ni ng t ab into clip.
(3) Install screws on t he bottom of t he speaker
housing.
Fig. 13 Club Cap Speaker Installation
REAR SPEAKER - RAMCHARGER
(1) Remove screws holding t he speaker and grille
assembly to t he mounting plate (Fig. 14).
SPEAKER MOUNTI NG
GRILLE ASSEMBLY
J908F-12
Fig. 14 Ramcharger Rear Speaker
(2) Disconnect speaker connector and remove
speaker.
(3) Remove screws holding speaker to grille and
remove speaker.
(4) To install t he speaker and grille assembly, re-
verse t he removal procedures.

HORNS 8G - 1
H O R N S
C O N T E N T S
SERVICE PROCEDURES
page
page
. . 1
GENERAL INFORMATION plied from the fuse block and grounded in the horn
The horn system consists of a horn switch, horn re- switch. When the horn switch on the steering column
lay (located on the fuse block), horns, and all their is pressed, the ground circuit is completed, energiz-
wiring and connections. The circuit voltage is sup- ing the relay, and supplying power to the horns.
T E S T P R O C E D U R E S
HORNS WILL NOT SOUND
If the horns do not sound, check for a blown horn
fuse in cavity number 4 of the fuse block. If the fuse
is blown, replace it with the same type fuse. If the
horns fail to sound and the newly replaced fuse blows
the horn switch is depressed, check for one of the fol-
lowing:
a short circuit in the horn
the horn wiring between the fuse terminal and the
horn is faulty.
If the fuse is intact, unplug wire connector at horn.
Connect one lead of a test lamp to the wire connector
and the other lead to a good body ground (Fig. 1).
Depress the horn switch. Should test lamp illuminate
the horn is ungrounded or faulty. Ground can be
checked by using a jumper wire between horn
bracket (scratch through paint) and the battery neg-
ative terminal. If the horn still fails to sound with
the ground jumper wire still intact and the horn re-
connected, replace the horn.
If the lamp fails to illuminate, check for a defective
horn relay by substituting a known good horn relay
in the circuit. If the lamp illuminates when depress-
ing the horn switch, the original relay is defective. If
the lamp fails to illuminate with a known good relay,
unplug that relay. Connect a jumper wire from the
battery terminal to the horn terminal on the relay
terminal board. If the lamp, connected in place of the
horns, fails to illuminate, inspect for an open circuit
between the horn fuse and the horn terminal on the
relay. Also check between relay terminal board and
the horn terminals. Should the lamp illuminate, a
defective horn switch or an open circuit in the wiring
between the relay terminal and the horn switch is at
fault.
HORNS SOUND CONTINUOUSLY
Should the horns sound continuously, unplug the
horn relay from the relay connector inside the pas-
HORN TEST LAMP
TO RELAY AND
HORN BUTTON -
TO GOOD BODY GROUND
HORN,
CONNECTOR
PR714
Fig. 1 Testing for Voltage
senger compartment (Fig. 2). Plug in a known good
relay. If the horns stop blowing, relay is defective
and must be replaced. Should the horns still sound,
proceed with Horn Diagnosis Chart.
HORN RELAY
FUSE BLOCK
RB1359
Fig. 2 Horn Relay
Remove steering wheel pad and disconnect wire
from horn switch. Repeat the above test and if the
test lamp still illuminates, wire is shorted and
should be repaired. If test lamp does not illuminate,
horn switch is defective and must be replaced.
8G - 2 HORNS

HORN D O E S N O T
S O U N D
H O R N S O U N D S
I N T E R M I T T E N T L Y
TEST FUSE
H O R N S O U N D S
C O N T I N U O U S L Y
H O R N S WI T C H O R WI R E
T O H O R N S WI T C H
G R O U N D I N G O U T
F U S E B L O WN
R E MO V E H O R N PA D A N D
C HE C K C O N T I N U I T Y BE -
T WE E N S T E E R I N G S HAFT
A N D BO D Y G R O U N D
NOTE: I M M E D I A 1
RELAY A N D Dl
FRO/V
rELY UNPLUG HORN
SCONNECT WI RES
\ HO R N S
USE TEST LIGHT BETWEEN HORN
RELAY SOCKETS t A N D 3
(SEE INSET DI AGRAM)
H O R N CI RCUI T
WI R I N G S HO R T E D
T O G R O U N D
US E TEST LI GHT AT
H O R N S ( D E PR E S S H O R N
BUT T ON) ( FI G. 2)
TEST LIGHT' O N
TEST UGHT "OFF"
TEST LIGHT "OFF"
I N T E R N A L
S HOR T CI RCUI T
I N H O R N
H O R N N O T *
G R O U N D E D
REPLACE H O R N
RELAY WI T H A
K N O WN G O O D O N E
( FI G. 3)
TEST LIGHT "O N "
FAULTY
H O R N RELAY
S HO R T E D
H O R N RELAY
WI R E T O H O R N
BU T T ON S WI T C H
G R O U N D E D O R H O R N
BU T T ON S WI T C H
G R O U N D E D
REFER T O TEST
PR O C E D U R E S
FAULTY H O R N
WR O N G
FUSE S I Z E
TEST LIGHT "O N "
FAULTY O R I G I N A L
RELAY
TEST LIGI HT "OFF"
U N PL U G R E PL A C E ME N T
RELAY F R O M S O C K E T A N D
C O N N E C T A JUMPE R
WI R E BE T WE E N RELAY
S O C K E T 1 A N D 2
S E E I N S E T D I A G R A M
I N S PE C T FOR O P E N
CI RCUI T I N WI R I N G F R O M
FUSE BL OC K T H R O U G H
RELAY BO A R D T O H O R N
T E R MI NAL
FAULTY H O R N S WI T C H
O R WI R I N G BE T WE E N
RELAY T E R MI N A L A N D
H O R N S WI T C H
H O R N
RELAY C O N N E C T O R
ALL M O D E L S
TO H O R N
S WI T C H
TO
H O R N S
TO FUSE
BLOCK
* I T I S I MPO R T A N T THAT H O R N S
BE A D E QU A T E L Y G R O U N D E D . G R O U N D I N G
C A N BE VERI FI ED BY M A K I N G A
T E MPOR A R Y JUMPE R WI R E C O N N E C T I O N
BE T WE E N H O R N BR AC KE T ( S C R A T C H
T HR O U G H PAI NT) A N D THE BATTERY
N E G A T I V E T E R MI N A L .
J918G-5

HORNS 8G - 3
SERVICE PROCEDURES
HORN SWITCH (HORN PAD ASSE MBLY)
REPLACEMENT
REMOVAL
(1) From underside of steering wheel, remove horn
pad mounting screws (Figs. 3 and 4).
(2) Pull pad up from wheel and disconnect electri-
cal leads.
(3) Remove pad.
INSTALLATION
(1) Connect electrical leads to switch t ermi nal on
horn pad.
(2) Position pad into place on steering wheel, install
mounting screws and tighten to 1.5 N*m (15 in. lbs.).
NUT &
WASHER
SOURCE
FOR HORN
RELAY GR OU N D
STEERING
WHEEL
STEERING
SHAFT
COVER
(WITHOUT
SPEED
CONTROL
SWITCHES)
HORN
RELAY
GR OU N D
WI RE
COVER
RETAI NI NG
SCREW
J9119-9
Fig. 3 Standard Steering Wheel
HORN PAD
COLUMN
HORN
LEADS STEERING
WHEEL
J9219-55
Fig. 4 Optional Steering Wheel
HORN REPLACEMENT - GAS ENGINE
The horns are located on either side of t he radiator
support (Fig. 5).
(1) Raise t he hood.
(2) Disconnect t he horn electrical connector.
(3) Remove bolt holding t he horn bracket to the ra-
diator support and remove t he horn.
(4) To install t he horns reverse t he removal proce-
dures. Tighten t he bolts to 200 in. lbs.
HORN
(HI-NOTE)
HORN
(LOW-NOTE)
HORN
MOUNTI NG
BOLTS
J908G-10
Fig. 5 Horn Removal and InstallationGas Engine
HORN REPLACEMENT - DIESEL ENGINE
The horns are located on t he inside of t he left front
fender behi nd t he bat t ery (Fig. 6).
(1) Raise t he hood.
(2) Remove screw and washer holding t he horn
bracket to t he fender.
(3) Lower t he horn and bracket toward the r ear of
t he bat t ery.
(4) Disconnect t he horn electrical connector.
(5) Remove t he horn and bracket assembly by
working it under t he bat t ery t ray brace (Fig. 6 ) .
(6) To i nst al l the horns reverse t he removal proce-
dures.
LEFT
FENDER
HI NOTE
HORN & BRACKET
ASSEMBLY
LOW NOTE
HORN & BRACKET
ASSEMBLY
J908G-11
Fig. 6 Horn Removal and InstallationDiesel Engine

VEHICLE SPEED CONTROL SYSTEM 8H - 1
V E H I C L E S P E E D C O N T R O L S Y S T E M
C O N T E N T S
SERVICE PROCEDURES
page
. 11
TEST PROCEDURES
page
. . 7
GENERAL INFORMATION
The vehicle speed control system (Figs. 1, and 2) is
electrically actuated and vacuum operated. The elec-
tronic control is integrated into the Powertrain Con-
trol Module (PCM). The PCM is located next to the
battery. The controls are located on the steering
wheel and consist of the ON/OFF, RESUME/ACCEL
and SET/DECEL buttons. The system is designed to
operate at speeds between 35 mph (50 km/h) and 85
mph (142 km/h).
WARNING: THE USE OF VEHICLE SPEED CON-
TROL IS NOT RECOMMENDED WHEN DRIVING
CONDITIONS DO NOT PERMIT MAINTAINING A
CONSTANT SPEED, SUCH AS IN HEAVY TRAFFIC
OR ON ROADS THAT ARE WINDING, ICY, SNOW
COVERED, OR SLIPPERY.
CABLE BRACKET
TO ACTIVATE: By pushing the ON/OFF button
to the depressed latched position, ON, the speed con-
trol function is now ready for use.
TO DEACTIVATE: A soft tap of the brake pedal,
normal brake use or clutch pedal use while the sys-
tem is engaged will disengage speed control without
erasing memory. A sudden increase in engine R.P.M.
may be experienced if the clutch pedal is depressed
while the speed control system is engaged. Pushing
the ON/OFF button to the unlatched position or
turning off the ignition erases the memory.
TO SET SPEED: When the vehicle has reached
the desired speed push the SET/DECEL button to en-
gage system which will then automatically maintain
the desired speed.
TO DECELERATE: When speed control is en-
gaged, holding the SET/DECEL button depressed al-
lows the vehicle to coast to a lower speed setting.
SPEED CONTROL
SERVO AND BRACKET
SPEED
CONTROL
CABLE
CABLE
VIEW IN DIRECTION R R A f K F T
OF AR R OW Z
B R A C K E T J928H-16
Fig. 1 Speed Control System3.9L/5.2L/5.9L Gas EngineTypical
8H - 2 VEHICLE SPEED CONTROL SYSTEM

TO RESUME: After disengaging t he speed control
system by tapping t he brake or clutch pedal, push
t he RESUME/ACCEL but t on to r et ur n vehicle to t he
previously set speed.
TO ACCELERATE: While speed control is en-
gaged, hold t he RESUME/ACCEL but t on depressed
and release at a new desired speed. This will allow
t he vehicle to continuously accelerate and set at a
higher speed setting.
TAP- UP: When t he speed control system is en-
gaged, tapping t he RESUME/ACCEL but t on will in-
crease t he speed setting by 2 mph (3 km/h). The
system will respond to multiple tap-ups.
TO ACCELERATE for PASSI NG: Depress t he
accelerator as you would normally. When t he pedal
is released t he vehicle will r et ur n to t he speed set-
t i ng in memory.
SERVO C ONNE C T OR J918H-20
Fig. 2 Speed Control System Diesel Engine
GAS ENGINE
w a r n i n g s t h e u s i of T HE S PE E D c o n t r o l
i s N O T r e c o mme n d e d w h e n D R I V I N G
C O N D I T I O N S D O n o t PE R M I T ma i n t a i n i n g
A c o n s t a n t S PE E D , S U C H A S H E A V Y
T R A F F I C r o n R O A D S T HA T A R E WI N D I N G ,
I C Y , S N O W C O V E R E D O R S L I PPE R Y*
START E N GI N E
r
AC C E L E R AT E V E HI CLE
T O DE S I R E D S PE E D
S PE E D C O N T R O L
E N G A G E S WH E N
mmm is S T A R T E D
PU S H ON/ OFF BU T T ON
TO " O N " PO S I T I O N .
E
FAULTY
ELECTRI CAL C I R C UI T *
S PE E D C O N T R O L E N G A G E S
WI T H O U T P U S H I N G THE
"S E T / D E C E L " BU T T O N
PU S H A N D RELEASE
"S E T / DE C E L ' ' BU T T O N
FAULTY ELECTRI CAL CI RCUI T*
DEFECTI VE S E R V O
i
R E M O V E F O O T F R O M
A C C E L E R A T O R . S PE E D
S HO U L D BE C ON T R OL L E D
T
1
i 1 *
N O WE E D CONTROL WH E N
S E T / D E C E L BUTTON IS
PR E S S E D A N D RELEASED
H U N T I N G S U R G E O R
S PE E D V A R I A T I O N S
A T LOW S PE E D S
E XC E S S I V E S A G
ON HI L L S O R
I N T R A I L E R T O WI N G
SPEED S E T T I N G A F T E R
LOCK-IN, T O O H I G H
C3t L O W
4
*
FUSE BL O WN
L O C K - U P
T O R QU E C O N V E R T E R
R O U G H N E S S
E N G I N E
PE R F O R M A N C E
V A C U U M L E A K
#
f
t
f
N O V A C U U M A T
S E R V O
A M PL I F I C A T I O N
O F E N G I N E
S U R G E
V A C U U M
LE AK
1
f it t
t
S PE E D C O N T R O L
THROTTLE C A BL E
D I S C O N N E C T E D
EXCESSIVE L O A D MAY
R E QUI R E M A N U A L
A S S I S T A N C E O N HI LLS
DEFECTI VE
CABLE
i f
f
*
I MPR O PE R S T O P L A M P
A N D S PE E D C O N T R O L
S WI T C H A D J U S T M E N T
DEFECTI VE
C A BL E
DEFECTI VE V A C U U M
R E S E R V OI R
( CHE CK V A L V E )
DEFECTI VE
V A C U U M R E S E R V OI R
1
f *
FAULTY ELECTRI CAL
C I R C UI T *
DEFECTI VE
E N G I N E C ONT R OL L E R
* TESTS AND A D J U S T M E N T S ARE DESCRIBED
I N APPROPRIATE S E CTI ON O F SERVICE
M A N U A L .
DEFECTI VE V A C U U M
R E S E R V OI R
J918H-7
GAS ENGINE CONTINUED
UNIT DISENGAGES
O N ROUGH ROAD
IMPROPER
ADJUSTMENT OF STOP
LAMP AND SPEED
CONTROL SWITCH*
FAULTY
ELECTRICAL
CIRCUIT

ENGINE DOES
NOT RETURN TO
NORMAL IDLE
SPEED CONTROL
THROTTLE CABLE
KINKED OR DAMAGED
STANDARD THROTTLE
LINKAGE FAULTS
1
DRIVE VEHICLE OVER
ROUGH ROAD
TAP BRAKE PEDAL
LIGHTLY, SPEED
CONTROL SHOULD
DISENGAGE
SPEED CONTROL
DISENGAGES
PUSH RESUME/ACCEL
SWITCH VEHICLE
SHOULD RESUME
PREVIOUSLY
MEMORIZED SPEED
VEHICLE RESUMES
SPEED
DEPRESS BRAKE
PEDAL, SPEED
CONTROL
SHOULD DISENGAGE
N O SYSTEM
DISENGAGEMENT
WHEN M A K E PEDAL
I S DEPRESSED
DEFECTIVE OR
IMPROPERLY ADJSUTED
STOP LAMP AND
SPEED CONTROL
SWITCH
y f
SPEED CONTROL
THROTTLE CABLE
KINKED OR DAAAAGED
1
FAULTY ELECTRICAL
CIRCUIT*
f
DEFECTIVE SERVO
N O RESUME WHEN
BUTTON IS PRESSED
SPEED CONTROL
DISENGAGES
DEFECTIVE SWITCH
FAULTY ELECTRICAL
CIRCUIT*
NO SYSTEM
DISENGAGE
WHEN BRAKE PEDAL IS
DEPRESSED
SPEED CONTROL
SYSTEM OK
1 f
DEFECTIVE ENGINE
CONTROLLER
1
FAULTY ELECTRICAL
CIRCUIT*
r
STICKY BRAKE SWITCH
RESUM
I S PO
BELOW 2
E SPEED
SSIBLE
10 M.P.H.
y
t
DEFECTIVE DISTANCE
SENSOR
y
f
DEFECTIVE
ENGINE CONTROLLER
J928H-14

^ ^ VEHICLE SPEED CONTROL SYSTEM 8H - I
W ARNI NG: THE USE OF THE SPEED CONTROL
IS NOT RECOMMENDED WH EN DRI VI NG
CONDITIONS DO NOT PERMIT MAI NTAI NI NG
A CONSTANT SPEED, SUCH AS H EAV Y
TRAFFIC OR O N ROADS THAT ARE W I NDI NG,
ICY, SNOW COVERED OR SLIPPERY*
SPEED CONTROL E NGAGE S
WITHOUT PUSH I NG THE
"SET/ DECEL" BUTTON

FAULTY ELECTRICAL CIRCUIT*

DEFECTIVE SERVO
START ENGINE
ACCELERATE VEHICLE
TO DESIRED SPEED
PUSH ON/OFF BUTTON
TO "ON" POSITION.
PUSH AND RELEASE
"SET/DECEL" BUTTON
REMOVE FOOT FROM
ACCELERATOR. SPEED
SHOULD BE CONTROLLED
S P E E D CONTROL
ENGAGES WHEN
ENGINE IS STARTED
FAULTY
ELECTRICAL CIRCUIT*
T
DEFECTIVE SERVO
N O SPEED CONTROL WHEN
SET/DECEL BUTTON I S
PRESSED AN D RELEASED
FUSE BLOWN
NO VACUUM AT
SERVO
T
SPEED CONTROL
THROTTLE CABLE
DISCONNECTED
IMPROPER STOP LAMP
AND SPEED CONTROL
SWITCH ADJUSTMENT
FAULTY ELECTRICAL
CIRCUIT*
T
DEFECTIVE SERVO
DEFECTIVE
VACUUM PUMP
HUNTI NG SURGE OR
SPEED VARI ATI ONS
AT LOW SPEEDS
I
LOCK-UP
TORQUE CONVERTER
ROUGHNESS
AMPLIFICATION
OF ENGINE
SURGE
DEFECTIVE SERVO
DEFECTIVE
CABLE
DEFECTIVE
ENGINE CONTROLLER
EXCESSIVE S A G
O N HILLS OR
I N TRAILER TOWI NG
ENGINE
PERFORAAANCE
VACUUM
LEAK
EXCESSIVE LOAD MAY
REQUIRE M A N U A L
ASSISTANCE ON HILLS
DEFECTIVE
VACUUM PUMP
SPEED SETTING AFTER
LOCK- I N, TOO HI GH
OR TOO LOW
T
VACUUM LEAK
DEFECTIVE SERVO
DEFECTIVE
CABLE
T
DEFECTIVE
VACUUM PUMP
REFER TO GROUP 5 - BRAKES
FOR VACUUM PUMP DIAGNOSIS.
"TEST AN D ADJUSTMENTS ARE DESCRIBED
I N APPROPRIATE SECTION OF SERVICE
MANUAL .
J928H-15
DIESEL ENGINE
- 6 VEHICLE SPEED CONTROL SYSTEM

UNIT DISENGAGES
O N ROUGH ROAD
IMPROPER
ADJUSTMENT OF STOP
LAMP AND SPEED
CONTROL SWITCH*
i
FAULTY
ELECTRICAL
CIRCUIT
ENGINE DOES
NOT RETURN TO
NORMAL IDLE
SPEED CONTROL
THROTTLE CABLE
KINKED OR DAAAAGED
STANDARD THROTTLE
LINKAGE FAULTS
N O RESUME WHEN
BUTTON IS PRESSED
DRIVE VEHICLE OVER
ROUGH ROAD

TAP BRAKE PEDAL
LIGHTLY, SPEED
CONTROL SHOULD
DISENGAGE
SPEED CONTROL
DISENGAGES
PUSH RESUME/ACCEL
SWITCH VEHICLE
SHOULD RESUME
PREVIOUSLY
MEMORIZED SPEED
VEHICLE RESUMES
SPEED
DEPRESS BRAKE
PEDAL, SPEED
CONTROL
SHOULD DISENGAGE
N O SYSTEM
DISENGAGEMENT
WHEN M A K E PEDAL
IS DEPRESSED
DEFECTIVE OR
IMPROPERLY ADJSUTED
STOP LAMP AND
SPEED CONTROL
SWITCH
1 1
SPEED CONTROL
THROTTLE CABLE
KINKED OR DAAAAGED
1
FAULTY ELECTRICAL
CIRCUIT*
1
DEFECTIVE SERVO
SPEED CONTROL
DISENGAGES
DEFECTIVE SWITCH
FAULTY ELECTRICAL
CIRCUIT*
1
NO SYSTEM
DISENGAGE
WHEN BRAKE PEDAL IS
DEPRESSED
SPEED CONTROL
SYSTEM OK
1 r
DEFECTIVE ENGINE
CONTROLLER
* r
FAULTY ELECTRICAL
CIRCUIT*
r
STICKY BRAKE SWITCH
RESUM
I S PO
BELOW*
E SPEED
SSIBLE
10 M.P.H.
1
DEFECTIVE DISTANCE
SENSOR
f
DEFECTIVE
ENGINE CONTROLLER
J928H-14
DIESEL ENGINE CONTINUED

TE S T P ROC E D U RE S
INDEX
page
Checking for Diagnostic Trouble Code 7
Inoperative System 7
Road Test 7
Speed Control Cabl e Adj ustmentDiesel Engine . 9
Speed Control Cabl e Attachment 10
GENERAL INFORMATION
Before st art i ng diagnosis and repair procedures for
a speed control malfunction, verify t hat t he speed
control wire harness is properly connected to all con-
nectors. Refer to Diagnosis Chart.
ROAD TEST
Road test vehicle to verify reports of speed control
system malfunction. The road test should include at-
tention to t he speedometer. Speedometer operation
should be smooth and without flutter at all speeds.
Fl ut t er in t he speedometer indicates a problem
which mi ght cause surgi ng in t he speed control sys-
tem. The cause of any speedometer deficiencies
should be corrected before proceeding.
INOPERATIVE SYSTEM
If road t est verifies a system problem and t he
speedometer operates properly, check for:
loose electrical and vacuum connections at t he
servo.
check for correct installation of t he vacuum check
valve in t he hose from servo to vacuum source (Gas
Engine Only). The word VAC on t he valve must
point toward t he vacuum source.
corrosion t hat should be removed from electrical
terminals and a light coating of Mopar Multi-Pur-
pose Grease, or equivalent, applied.
secure at t achment of both ends of speed control ca-
ble.
CHECKING FOR DIAGNOSTIC TROUBLE CODE
(1) When trying to verify a speed control system
electrical problem, use a DRB II Scan Tool to find
the cause. Refer to Powert rai n Diagnostic Procedures
manual .
If t he DRBII is not available, t he Diagnostic Trou-
ble Code (DTC) may be determined with t he follow-
ing method:
(a) With key inserted in ignition switch, cycle
switch to ON position 3 times. On t hi rd cycle, leave
switch in ON position.
(b) After switch has been cycled 3 times, observe
Malfunction Indicator Lamp (CHECK ENGINE) on
i nst rument cluster. If a DTC is present, t he code
page
Speed Control Cabl e AttachmentServo 10
Stop Lamp Switch Test 9
V acuum Suppl y Test . . . . . . . . . . . . . . . . . . . . . . . 9
Vehicle Speed Control Switch Test . 9
Vehicle Speed Control System Electrical Tests . . . 7
Vehicle Speed Sensor Test 7
will be displayed in a series of flashes represent i ng
digits. Three flashes in rapid succession, a slight
pause, t hen 4 flashes in rapid succession would in-
dicate DTC 34.
(2) If a DTC 34 is observed, perform t he t est s in
t he sections Electrical Tests at Servo and Electrical
Tests at Powert rai n Control Module.
If a DTC 15 is observed, perform t he t est for a
faulty Vehicle Speed Sensor.
(3) If a fault code 11 is observed (Diesel only), per-
form t he t est for a faulty engine speed sensor. Refer
to t he Powert rai n Diagnostics Procedures Manual .
(4) Correct any problems found when performing
these tests and recheck for DTC if changes were
made.
VEHICLE SPEED SENSOR TEST
For t est i ng of t he Vehicle Speed Sensor and related
components refer to t he Powertrain Diagnostic Proce-
dures manual .
VEHICLE SPEED CONTROL SYSTEM ELECTRICAL
TESTS
Vehicle speed control systems may be tested using
two different methods. One involves t he use of t he
DRBII Scan Tool. If this test method is desired,
please refer to t he Powertrain Diagnostic Procedures
manual .
The other t est method uses a voltmeter. The volt-
meter method is described in t he following t est s.
If any information is needed concerning wiring, re-
fer to Group 8W - Wiring Diagrams.
C A U T I O N : When test probi ng for vol tage or conti -
nuity at electrical connect ors, care must be taken
not to damage connector, terminals, or seal s. If
these component s are damaged, intermittent or
complete syst em failure may occur.
ELECTRICAL TESTS AT SERVO
(1) Turn ignition switch to ON position.
(2) Push speed control switch to ON position.
(3) Connect t he negative lead of a voltmeter to a
good chassis ground near t he servo.

(4) Disconnect t he 4-way connector going to t he
servo (Figs. 1 and 2), The blue wire with t he red
t racer of t he mai n harness 4-way connector should
read approximately bat t ery voltage. If not, check for
loose connections, brake switch adjustment or, repair
t he mai n harness as necessary.
(5) Connect a j umper wire between t he male and
female t ermi nal s of t he blue wire wi t h red tracer.
The other 3 male t ermi nal s from t he servo should
show bat t ery voltage. If not, replace t he servo.
(6) Turn ignition OFF. Using an ohmmeter, con-
nect one lead to a good body ground. Touch t he other
lead to t he black (BK) wire t ermi nal in t he 4-way
connector of t he mai n harness. The met er should
show continuity. If not, repair t he ground circuit as
necessary.
A VACUUM
y~ HOSE
J918H-24
Fig. 1 Servo And Harness ConnectorGas
EngineTypical
ELECTRICAL TESTS AT POWERTRAIN
CONTROL MODULE
(1) Unpl ug 60-way connector from Powert rai n Con-
trol Module, located on t he left fender (Fig. 3).
(2) Connect negative lead of voltmeter to a good
body ground near t he module.
(3) For t he following tests, t he ignition switch
must be in t he ON position. Refer to Fig. 4 for con-
troller t ermi nal locations. Touch t he positive lead of
t he voltmeter to t he t ermi nal in cavity number 33.
Wi t h t he speed control switch in t he OFF position,
t he voltmeter should read 0 volts. Wi t h t he speed
control switch in t he ON position, t he voltmeter
should read bat t ery voltage. If not, repai r t he mai n
harness as necessary.
(4) Touch t he positive lead of t he voltmeter to t he
t ermi nal in cavity number 53. As in step (3), t he
J918H-25
Fig. 2 Servo And Harness ConnectorDiesel
Engine
PCM
MOUNTING
BOLTS
PCM CONNECTOR
CONNECTOR MOUNTING
BOLT J9314-165
Fig. 3 Powertrain Control Module and Connector
Location
voltmeter should read 0 volts with t he switch in t he
OFF position and bat t ery voltage with t he switch in
t he ON position.
t ermi nal in cavity number 48. With t he speed control
switch in t he OFF position, t he voltmeter should
read 0 volts. With t he switch in t he ON position, t he
voltmeter should read bat t ery voltage. Pressing t he
SET but t on should cause t he voltmeter to change
rain
o o o o o o o o o o
1 10,
. o o o o o o o o o o
\21 30 .
\] 50
x
O O O O O O O O O O
O O O O O O O O O O ^
11 20
O O O O O O O O O O
51
3 1 1
6 o o o o o o o o o
6 0 y /
Trat r
T J K T
RR8HC7
Fig. 4 Powertrain Control Module 60-Way Connector
Shown from Terminal End
from bat t ery voltage to 0 volts for as long as t he
switch is held. If not, perform t he speed control
switch test. If t he switch is not at fault, t hen check
t he mai n harness and repair as necessary.
t ermi nal in cavity number 50. The voltmeter should
read 0 volts with t he speed control switch in either
t he OFF or ON position. With switch in either RE-
SUME or SET position, t he voltmeter should read
bat t ery voltage. If not, perform t he speed control
switch test. If t he switch is not at fault, t hen check
t he mai n harness and repair as necessary.
t ermi nal in cavity number 49. The voltmeter should
read 0 volts with t he switch in t he OFF position.
With t he switch in t he ON position, t he voltmeter
should read bat t ery voltage. The voltmeter will con-
t i nue to read bat t ery voltage when either t he SET or
RESUME switch is pressed. If not, perform t he speed
control switch test. If t he switch is not at fault, t hen
check t he mai n harness and repair as necessary .
(8) Turn key OFF. Using an ohmmeter, connect
one lead to a good body ground and touch the other
lead to t he t ermi nal in cavity number 29. With t he
brake pedal released, t he meter should show continu-
ity. When t he pedal is depressed, t he met er should
show open circuit.
VEHICLE SPEED CONTROL SWITCH TEST
To check t he switch, remove t he switch from its
mount i ng position. Use an ohmmeter and refer to t he
Switch Continuity Chart to determine if continuity is
correct. If t here is no continuity at any one of t he
switch positions, replace t he switch.
STOP LAMP SWITCH TEST
(1) Disconnect connector at stop lamp switch. Us-
ing an ohmmeter, continuity may be checked at
switch side of connector as follows (Fig. 5):
(a) Wi t h brake pedal released, t here should be:
continuity between black (BK) and white with
pink tracer (WT/PK) wires
continuity between yellow with red tracer (YL/RD)
and dark blue with red tracer (DB/RD) wires
No continuity between pink (PK) and white (WT)
wires.
SPEED CONTROL SWITCH CONTINUITY
CHART
C O N N E C T O R TERMINAL E N D
JE El
SWITCH
S PE E D C O N T R O L S WI T C H
C O N T I N U I T Y
SWI TCH! rea? !^ CONTI NUI TY BETWEEN
OFF PIN 1 A N D PIN 4
O N
PIN 1 A N D PIN 4
PIN 1 A N D PIN 2
PIN 2 A N D PIN 4
O N A N D SET PIN 1 A N D PIN 2
O N A N D RESUME PIN 1 A N D PIN 3
J928H-4
(b) With brake pedal depressed, t here should be:
continuity between pink (PK) and whi t e (WT)
wires.
No continuity between black (BK) and whi t e with
pink tracer (WT/PK) wires.
No continuity between yellow with red t racer (YL/
RD) and dark blue with red tracer (DB/RD) wires.
(2) If the above results are not obtained, t he stop
lamp switch is defective or out of adjustment.
Stop lamp switch adjustment is detailed in Group 5 -
Brakes.
VACUUM SUPPLY TEST
(1) Disconnect vacuum hose at t he servo and in-
stall a vacuum gauge in the hose (Fig. 6).
(2) St art engine and observe gauge at idle. Vac-
uum gauge should read at least t en inches of mer-
cury.
(3) If vacuum does not meet t hi s requirement,
check for vacuum leaks or poor engine performance.
SPEED CONTROL CABLE ADJUSTMENT-DI ESEL
ENGINE
(1) The gap between t he end of t he slot on t he ca-
ble and the bellcrank pin must be as small as possi-
ble (0 to 1mm) without moving t he throttle. If gap is
not correct, remove adjustment clip. Push protective

18PK
ADJUSTMENT CLIP PULLED
OUT OF SLOT
18WT
STOP LAMP
SWITCH WI TH
SPEED CONTROL
J938H-9
Fig. 5 Stop Lamp Switch Connector
Fig. 6 Vacuum Gauge Test
sleeve into housing to decrease gap or pull sleeve out
of housing to increase gap (Fig. 7).
(2) Install adjustment clip.
SPEED CONTROL CABLE ATTACHMENT
DIESEL ENGINE
(1) The clevis of t he speed control cable is ret ai ned
to t he bellcrank by a washer and hai rpi n clip.
-TfiROTTLE/SPEED CONTROL
CABLE BRACKET
RR8HC22
Fig. 7 Adjustment Clip Pulled Out of Slot to Move
Sleeve
(2) Visual inspection will verify t hat t he cable is
securely attached. If t he cable is not attached, t he
speed control system will be inoperative. Refer to Ca-
ble Adjustment.
GAS ENGINE
The clevis of t he speed control cable is retained to
t he t hrot t l e body lever by slipping t he clevis into t he
slot on t he lever. Visual inspection will verify t hat
t he cable is securely attached. If t he cable is not at-
tached, t he speed control system will be inoperative.
SPEED CONTROL CABLE ATTACHMENT-SERVO
The speed control cable is attached to t he servo
wi t h a wire clip (Fig. 8). A check should be made to
verify t hat t he clip is in place. If t he clip is missing
t he speed control system will be inoperative.
HAI RPI N CLIP
/ J918H-9
Fig. 8 Speed Control Cable Attachment at Servo

SERVICE PROCEDURES
INDEX
page
Ser vo Throttle Cabl e Assembl yDi esel E ngi ne . . 12
Ser vo Throttle Cabl e Assembl yGas Engi ne . . . 11
Ser vo Unit 11
Speed Control Switch Replacement 12
page
Speed Control V acuum Reservoir Repl acementGas
Engi ne 12
V acuum PumpDi esel Engi ne . 12
SERVO UNIT
REMOVAL
(1) Disconnect vacuum hose at servo.
(2) Disconnect electrical connector at servo.
(3) Remove 2 nut s from servo mount i ng bracket.
(4 ) Pull servo away from mount i ng bracket.
(5) Remove and discard push nut s on servo studs.
(6 ) Pull speed control cable away from servo to ex-
pose cable ret ai ni ng clip.
(7) Remove clip at t achi ng cable to servo.
INSTALLATION
(1) Block t hrot t l e to full open position (gas engine),
pivot bellcrank full rearward (diesel engine), and
align hole in cable sleeve wi t h hole in servo pin. In-
stall ret ai ni ng clip.
(2) Insert servo studs t hrough holes in t he cable.
(3) Install new push nut s on t he servo studs.
(4 ) Insert servo studs t hrough holes in servo
mounting bracket. One s t ud mount s r es er voi r .
(5) Install t he 2 at t achi ng nut s and t i ght en to 6
N*m (50 in. lbs.).
(6 ) Connect vacuum hose to servo.
(7) Connect t he electrical connector to servo termi-
nals.
SERVO THROTTLE CABLE ASSE M BLY - GAS
ENGINE
REMOVAL
(1) Remove ai r cleaner.
(2) Using finger pressure only, remove speed con-
trol cable connector at bell crank by PUSHING con-
nector off t he bell crank (Fig. 1). DO NOT t ry to pull
connector off perpendicular to t he bell crank.
(3) Squeeze t abs on speed control cable and push
out of locking plate.
(4 ) Remove 2 nut s from servo mount i ng bracket.
(5) Pul l servo away from mounting bracket.
(7) Pull speed control cable away from servo to ex-
Fig. 1 Remove Bell Crank Connector Typical
(9) Disconnect cable at servo and remove cable as-
sembly.
INSTALLATION
(1) Locate cable t hrough servo mount i ng bracket.
(2) Connect cable sleeve to servo stud, align holes,
and install hai rpi n clip.
(3) Insert servo studs t hrough holes in cable.
(4 ) Install new push nut s on servo studs.
(5) Insert servo studs t hrough holes in bracket. In-
stall nut washers and torque to 6 Nnn (50 in. lbs.).
(6 ) Route cable from servo, t hrough cable support
bracket, and install cable on nail head stud.
(7) Install ai r cleaner.

SERVO THROTTLE CABLE ASSE MBLYDI E SE L
ENGINE
REMOVAL
(1) Remove hairpin clip and washer ret ai ni ng ca-
bles on bellcrank. Remove servo t hrot t l e cable from
bellcrank.
(2) Remove servo t hrot t l e cable from cable support
bracket.
(3) Remove 2 nut s from servo mount i ng bracket.
(4) Pull servo away from mount i ng bracket.
(6) Pull speed control cable away from servo to ex-
(8) Disconnect cable at servo and remove cable as-
sembly.
INSTALLATION
(1) Locate cable t hrough servo mount i ng bracket.
(2) Connect cable sleeve to servo stud, align holes,
and install hai rpi n clip.
(3) Insert servo studs t hrough holes in cable.
(4) Install new push nut s on servo studs.
(5) Insert servo studs t hrough holes in bracket. In-
stall nut washers and torque to 6 N*m (50 in. lbs.).
(6) Route cable from servo, to cable support
bracket,
(7) Install cable end on bellcrank rod.
(8) Adjust cable as described under speed control
cable adjustment.
(9) Install washer and hai rpi n clip on end of bell-
crank rod.
SPEED CONTROL SWITCH REPLACEMENT
(2) From underside of steering wheel, remove horn
pad mount i ng screws (Fig. 2).
(3) Pull pad up from wheel and disconnect electri-
cal leads.
(4) Remove pad.
(5) Unpl ug 4-way electrical connector from clock-
spring.
(6) Remove 4 screws holding switches and remove
switches (Fig. 3)
(7) Install new switches with 4 screws.
(8) Connect 4-way electrical connector from clock-
spring to switches.
(9) Connect electrical leads to horn pad.
(10) Install horn pad with 3 screws.
HORN PAD
Fig. 2 Sport Steering Wheel
CLOCKSPRING
Fig. 3 Speed Control Switches
SPEED CONTROL VACUUM RESERVOIR
RE PLACE ME NT- GAS ENGINE
REMOVAL
(1) Disconnect all hoses.
(2) Remove nut s and slide vacuum reservoir off
studs.
INSTALLATION
(1) Install vacuum reservoir onto bracket studs.
(2) Install nut washers and torque to 6 Nr n (50 in.
lbs.).
(3) Connect vacuum hoses.
VACUUM PUMP- D I E SE L ENGINE
Refer to Group 5 - Brakes for removal and instal-
lation of t he vacuum pump.
TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 1
CONTENTS
page page
GENERAL INFORMATION 1 MULTIFUNCTION SWITCH TESTING
MULTIFUNCTION SWITCH SERVICE PROCEDURES 2
PROCEDURES 3
GENERAL INFORMATION
TURN SIGNALS
DESCRIPTION
With t he ignition key ON and t he multi-function
lever in its UP or DOWN position, current flows
t hrough the:
t ur n signal flasher canister
Turn/Hazard switch
t ur n indicator l amp
front and rear bulbs.
The selected t ur n signal indicator wi t h front and
rear t ur n signal bulbs will flash.
DIAGNOSIS
High generator output voltage can burn out
lamps rapidly.
(1) Remove and inspect fuse in cavity #9 of fuse
block. Replace if necessary. The fuse block is behind
t he lower i nst rument panel cover under steering
wheel.
(2) Turn key to ACCY. There should be bat t ery
voltage at t he fuse side of t he t ur n signal flasher
(bottom terminal). If not, repair open circuit in wir-
ing between fuse and flasher.
(3) Replace Turn Fl asher with 2 l amp 12 volt rat ed
flasher t hat is know to be good. The l amps should
flash. If not, replace wi t h original flasher and go to
next step.
(4) Measure voltage at t he Turn/Hazard switch
connector cavity #17. Meter should read bat t ery volt-
age. If OK, replace Turn/Hazard switch assembly. If
not, repai r open circuit in wi ri ng between flasher
and Turn/Hazard switch connector.
HAZARD WARNING SYSTEM
DESCRIPTION
With t he hazard switch OUT, current flows
t hrough t he
hazard flasher canister
hazard switch
two front t ur n signal bulbs
two rear t ur n signal bulbs
both indicator bulbs.
All of t he t ur n lamps and both indicators will
flash.
DIAGNOSIS
Hazard switch in ON. The park and stop lamps
should light. If not replace t he 20 amp fuse in fuse
block cavity #13.
(1) Measure voltage at t he fuse side of t he flasher
(side t ermi nal ). Meter should read bat t ery voltage. If
not, repair open circuit in wiring to fuse.
(2) Replace Hazard flasher with known good
flasher. Lamps should flash. If not, replace wi t h orig-
inal flasher and go to next step.
(3) Measure voltage at t he Turn/Hazard switch
connector cavity #13. Meter should read bat t ery volt-
age. If not, repai r open circuit in wiring to hazard
flasher.
TURN SIGNAL AND HAZARD WARNING FLASHER
LOCATION
The t ur n signal and hazard warni ng flasher are
both located on t he fuse block (Fig. 1). The fuse block
is on t he lower i nst rument panel cover under t he
steering column.
TURN SIGNALS AND HAZARD WARNING FLASHER
8J - 2 TURN SIGNALS AND HAZARD WARNING FLASHER

FUSE
BLOCK
INSTRUMENT
PANEL
REAR VIEW
HAZ ARD
WA R N I N G
FLASHER
VI EW IN DIRECTION
OF AR R OW
RR8JC10
Fig. 1 Turn Signal and Hazard Warning Flashers
M U L T I F U N C T I O N SWITCH TESTI NG PROCEDURES
The multifunction switch contains electrical cir-
cuitry for:
t ur n signal
hazard warni ng
headl amp beam select
headl amp optical horn
windshield wiper
pulse wipe
windshield washer switching.
This integrated switch assembly is mounted to t he
left-hand side of t he steering column. Should any
function of t he switch fail, t he entire switch assem-
bly must be replaced.
To test t he switch:
(2) Remove upper and lower column covers to gain
access to t he switch connector.
(3) Remove switch connector (Figs. 2 and 3).
Fig. 2 Multifunction Switch Connector Fig. 3 Steering Column Connectors

TURN SIGNALS AND HAZ ARD WARNING FLASHER 8J - 3
(4) Using an ohmmeter, t est for continuity (no re-
sistance) between t he t ermi nal s of t he switdh as
shown i n t he following continuity chart (Pig. 4).
VIEW FROM TERMINAL CASE
S WI T C H PO S I T I O N S
T U R N S I G N A L HA Z A R D WA R N I N G C ON T I N U I T Y BETWEEN
NEUTRAL OFF 12 AND 14 AND 15
LEFT
LEFT
LEFT
OFF
OFF
OFF
15 AND 16 AND 17
12 AND 14
22 AND 23 WITH OPTIONAL CORNER LAMPS
RIGHT
RIGHT
RIGHT
OFF
OFF
OFF
11 AND 12 AND 17
14 AND 15
23 AND 24 WITH OPTIONAL CORNER LAMPS
NEUTRAL ON 11 AND 12 AND 13 AND 15 AND 16
908J-4
Fig. 4 Turn Signal and Hazard Switch Continuity Chart
M U L T I F U N C T I O N S WI T C H S E R V I C E P R O C E D U R E S
REMOVAL
(2) Remove tilt lever (Tilt column only).
(3) Remove both upper and lower steering column
covers.
(4) Remove multifunction switch t amper proof
mounting screws (tamper proof torx bit Snap On
TTXR20B2 or equivalent required).
(5) Gently pull switch away from column. Loosen
connector screw. The screw will remai n in the con-
nector.
(6) Remove wiring connector from multifunction
switch (Fig. 5).
INSTALLATION
(1) Install wiring connector to switch and t i ght en
connector ret ai ni ng screw to 17 in. lbs.
(2) Mount multifunction switch to column and
torque ret ai ni ng screws to 17 in. lbs.
(3) Install steering column covers. Torque retain-
ing screws to 17 in. lbs.
(4) Install tilt lever (tilt column only).
(5) Install negative cable to bat t ery.
(6) Check all functions of switch for proper opera-
tion.
HAZARD WARNING
908J-9
Fig. 5 Muitifunction Switch

WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 1
WI N D S H I E L D WI P E R A N D W A S H E R S Y S T E M S
C O N T E N T S
page
INTERMITTENT WINDSHIELD WIPER FUNCTION
AND SWITCH TESTING PROCEDURES 6
TWO SPEED WINDSHIELD WIPER MOTOR AND
SWITCH TESTING PROCEDURES 1
GENERAL INFORMATION
The windshield wipers can be operated with t he
windshield wiper switch only when t he ignition
switch is in t he ACCESSORY or RUN position. A
fuse located in t he fuse block protects t he circuitry of
t he wiper system and t he vehicle.
The same motor is used for st andard and intermit-
t ent wipe systems.
The wiper motor has permanent magnet fields. The
speeds are determined by current flow to t he appro-
priate set of brushes.
The i nt ermi t t ent wipe system in addition to low
page
WINDSHIELD WASHERS . . 10
WINDSHIELD WIPER SYSTEM SERVICE
PROCEDURES 7
and high speed, has a delay mode. The delay mode
has a range of 2 to 15 seconds. This is accomplished
by a variable resistor in the wiper switch and is con-
trolled electrically by a control module.
The wiper system completes the wipe cycle when
t he switch is t urned OFF. The blades park in t he
lowest portion of the wipe pat t ern.
Depressing t he washer knob while t he system is in
t he OFF position,
t urns t he wiper motor on
allows t he motor to operate through 3-4 wipe cy-
cles and t hen t ur n OFF.
TWO SPEED WI NDSH I E LD WIPER MOTOR A N D SWI TCH TE STI NG PROCEDURES
INDEX
page
Multifunction (Two Speed Wiper) Switch Testing
Procedures 4
TWO SPEED WIPER MOTOR TESTING
PROCEDURES
The following is a list of general wiper motor sys-
t em problems. It contains t he tests t hat are to be per-
formed to locate the faulty part, and t he corrective
action to be t aken. The same motor is used for stan-
dard and optional systems. If the malfunction in-
volves only t he Delay mode, switch, or wiring, refer
to t he Int ermi t t ent Windshield Wiper Motor and
Switch Service Procedures.
CONDITION
Motor will not run i n any swi tch position.
PROCEDURE
(1) Check for a blown fuse in the fuse block.
(a) If fuse is good, proceed to step No. 2.
(b) If fuse is defective, replace and check motor
operation in all switch positions.
(c) If motor is still inoperative and the fuse does
not blow, proceed to step No. 2.
page
Two Speed Wiper Motor Testing Procedures 1
(d) If replacement fuse blows, proceed to step No.
5.
(2) Place switch in low speed position.
(3) Listen to motor. If you cannot hear it runni ng,
proceed to step No. 4. If you hear it runni ng, check
motor output shaft. If output shaft is not t urni ng, re-
place motor assembly. If it is t urni ng, crank arm or
drive link is not properly connected. Replace worn
part s and/or properly connect drive link to t he motor
output shaft.
(4) Connect a voltmeter between motor t ermi nal
"L" and ground strap (Fig. 1). If t here is no voltage
or very little voltage (less t han one volt) present,
move negative test lead from t he ground st rap to bat-
tery negative terminal.
(a) If an increase in voltage is noticed, t he prob-
lem is a bad ground circuit. Make sure t he motor
mounting is free of paint and t hat nut s or bolts are
tight.
8K - 2 WINDSHIELD WIPER AND WASHER SYSTEMS
M O T O R R U N S
B L A D E S D O
N O T P A R K

M O T O R S T O P S
I N A N Y
POSITION
W H E N S WI T C H
I S T U R N E D
"OF F "
3
I M O T O R R U N S |
B U T O U T P U T
C R A N K D O E S
N O T T U R N
B L A D E S S L A P
A G A I N S T
WI N D S H I I L D
M O U L D I N G S
I O N D R Y G L A S S
M O T O R S T O P S !
B L A D E S D O
N O T P A R K
P R O P E R L Y
M O T O R WI L L
N O T S T O P
I W H E N S WI T C H |
I S T U R N E D
" O F F "
X
LINKAGE NOT
FASTENED
PROPERLY TO
MOTOR OUTPUT
SHAFT
J
ARMS LOOSE
ON PIVOT SHAFT
B L A D E S
C H A T T E R
FOREIGN
SUBSTANCE SUCH
AS BODY POLISH
ON GLASS OR
BLADES
OUTPUT
SHAFT
STATIONARY
T
REPLACE
MOTOR
JE
OUTPUT
SHAFT
ROTATES
t
LOOSE
MOTOR
CRANK
BAD
LINKAGE
CONNECTION
ARMS LOOSE
ON PIVOT SHAFT
TWISTED ARM
HOLDS BLADE AT
WRONG ANGLE
TO GLASS
1 _ _
REPLACE
MOTOR
FUSE
BLOWS
f
CHECK
WIRING
CHECK
SWITCH
RF80B
WINDSHIELD WIPER AND WASHER SYSTE MS 8K - 3
VOLTMETER
TERMI NAL "L"
G R O U N D J928K-13
Fig. 1 Voltmeter Between Terminal "L" and Ground
(b) If t here is still no indication of voltage, t he
problem is an open circuit in t he wiring harness or
wiper switch.
(c) If no noticeable increase (greater t han 3 volts)
in voltage is observed, t he problem is a faulty mo-
tor assembly.
(5) Disconnect motor wiring connector and replace
fuse.
(a) If fuse does not blow, motor is defective.
(b) If fuse blows, switch or wiring is at fault.
CONDITION
Motor runs sl owl y at all speeds.
PROCEDURE
(1) Disconnect wiring harness connector at motor.
Remove wiper arms and blades. Connect an ammet er
between bat t ery and t ermi nal "L" on motor (Fig. 2).
TERMI NAL
"L
AMMETER
WIPER
MOTOR
J928K-14
Fig. 2 Ammeter Between Terminal "L" and Battery
(a) If motor runs and average ammet er readi ng
is more t han 6 amps, proceed to step 2.
(b) If motor runs and average ammet er reading
is less t han 6 amps, proceed to step 3.
(2) Check to see if wiper linkage or pivots are
binding or caught. Disconnect drive link from motor.
(a) If motor now runs and draws less t han 3
amps, repair linkage system.
(b) If motor continues to draw more t han 3 amps,
replace motor assembly.
(3) Check motor wi ri ng harness for shorting be-
tween high and low speed wires as follows:
(a) Connect a voltmeter or t est lamp to motor
ground strap.
(b) Set wiper switch to LOW position.
(c) Connect other lead of voltmeter (test lamp) to
t ermi nal "H" of the wiring harness.
(d) If voltage is present, t here is a short in t he
wiring or wiper switch. If no voltage is present pro-
ceed to step (e).
(e) Set wiper switch to HIGH position.
(f) Move voltmeter (test lamp) lead from termi-
nal "H" to t ermi nal "L" of the wiring harness.
(g) If voltage is present, t here is a short in t he
wiring or wiper switch.
CONDITION
Motor will run at hi gh speed, but not at l ow
speed. Motor will run at l ow speed, but not at
hi gh speed.
PROCEDURE
(1) If motor will not r un on high speed, put switch
in HIGH position and connect a t est lamp between
motor t ermi nal "H" and ground (Fig. 3).
TERMI NAL
"H"
TEST
LAMP
WIPER
MOTOR
J928K-15
Fig. 3 Test Lamp Between Terminal "H" and
Ground
If motor will not r un on low speed, put switch in
LOW position and connect a test lamp between motor
t ermi nal "L" and ground.
(2) If test lamp does not light at motor t ermi nal ,
t here is an open in wi ri ng or switch. If test lamp
lights at motor t ermi nal , replace motor assembly.
CONDITION
Motor will keep runni ng wi th swi tch in OFF
position.
8K - 4 WINDSHIELD WIPER AND WASHER SYSTE MS

PROCEDURE
(1) Remove wiring harness. Connect j umper from
Terminal P2 to t ermi nal "L" of wiper motor (Fig, 4).
TERMINALS
Fig. 4 Om Jumper Wire Between Terminal "P2" and
"L". One Jumper Wire Between Terminal "P1" and
"B+"
(2) Connect second j umper from t ermi nal "PI " to
battery. If motor r uns to PARK position and stops,
wiper switch is faulty. If motor keeps runni ng and
does not park, replace motor assembly.
CONDITION
Motor will stop wherever it i s, when col umn
swi tch i s p u t in OFF posi t i on. (Wi pers do not
conti nue runni ng t o PARK position).
PROCEDURE
(1) Remove motor wiring connector and clean ter-
minals. Reconnect connector and test motor. If prob-
lem persists, proceed to step No. 2.
(2) Put wiper switch to OFF and ignition switch to
ACC position. Disconnect motor wiring connector.
Connect a voltmeter or t est l amp to t he motor
ground strap. Connect t he other lead to t ermi nal
"PI " of wiring connector.
(a) If voltage is not present, check for an open
circuit in t he wi ri ng harness or wiper control
switch or fuse.
(b) If voltage is present, proceed to step (3).
(3) Remove wiper motor from vehicle and connect
an ohmmet er or continuity t est er between t ermi nal s
"L" and "P2" (Fig. 5).
(a) If t here is continuity between these t ermi -
nals, t he problem is a defective motor.
Fig. 5 Ohmmeter Between Terminal "L" and "P2"
(b) If t here is no continuity, t he problem is an
open circuit in t he wiper control switch or wiring
harness.
MULTIFUNCTION (TWO SPEED WIPER) SWITCH
TESTING PROCEDURES
The multifunction switch contains circuitry for:
t ur n signal
hazard warni ng
headl amp beam select
headl amp optical horn
windshield wiper
pulse wipe
and windshield washer switching.
This i nt egrat ed switch assembly is mounted to t he
left-hand side of t he steering column. Should any
function of t he switch fail, t he entire switch assem-
bly must be replaced.
To test t he switch:
(2) Remove tilt lever (Tilt column only).
(3) Remove upper and lower column covers to gai n
access to t he switch connector (Fig. 6 ) .
(4) Remove lower fixed column cover.
(5) Loosen steering column upper bracket nut s. Do
Not remove nut s.
(6 ) Move upper fixed column cover to gain access
to rear of multifunction switch.
(7) Remove switch connector (Figs. 7 and 8) .
(8) Usi ng an ohmmeter, t est for continuity (no re-
sistance) between t he t ermi nal s of t he switch as
shown in t he following continuity chart (Fig. 9) .
(9) Refer to Service Procedures for assembly.
WINDSHIELD WIPER AND WASHER SYSTE MS 8K -
UPPER SHROUD GROUND
CLIP
UPPER
FIXED SHROUD
SUPPORT BRACKET
STUD
NUT WASHER
LOWER
SHROUD
LOWER
FIXED
SHROUD
J9119- 22
Fig. 6 Steering Column Covers
S T E E R I N G
C O L U M N
A S S Y.
J918J-1
T U R N S I G N A L
MULTI S WI T C H A N D
F U N C T I O N LEVER
S WI T C H
C O N N E C T O R
Fig. 7 Multifunction Switch Connector
K E Y- I N S WI T C H &
H A L O L I GHT
M U L T I F U N C T I O N
S WI T C H
I G N I T I O N
S WI T C H
T U R N S I G N A L
S WI T C H & L E V E R
S PE E D
C O N T R O L J918J-2
Fig. 8 Steering Column Connectors
M U L T I F U N C T I O N S WI T C H PI N S
T W O S PE E D WI P E R S WI T C H
C O N T I N U I T Y C H A R T
S WI T C H
PO S I T I O N
C O N T I N U I T Y
BE T WE E N
OFF & PA R K PI N 1 & PI N 2
L O W PI N 1 & PI N 4
HI G H PI N 4 & PI N 5
WA S H PI N 3 & PI N 4
J918K-5
Fig. 9 Standard Two Speed Wipe Switch Continuity
Chart

I N T E R M I T T E N T WI N D S H I E L D WI P E R F U N C T I O N A N D S WI T C H T E S T I N G
P R O C E D U R E S
INTERMITTENT WIPER FUNCTION TESTING
PROCEDURES
The i nt ermi t t ent wipe and st andard two speed mo-
tors are identical. Refer to previous sections for diag-
nosis of system problems which do not involve t he
DELAY function. If problem occurs only in t he DE-
LAY mode, t he following tests are to be performed.
These tests involve disconnecting t he i nt ermi t t ent
wipe control uni t which can be found on t he steering
column support bracket (Fig. 2).
CONDITION
Excessi ve del ay (more than 30 seconds) or in-
adequate variation i n delay.
PROCEDURE
Variations in delay should be as follows:
(1) Mi ni mum delay (delay control to extreme coun-
terclockwise position before first detent) 1/2 to 2 sec-
onds.
(2) Maxi mum delay (delay control to extreme
clockwise position before off detent) 10 to 30 seconds.
(3) If t here is excessive delay or no variations in
delay proceed to i nt ermi t t ent wipe switch test.
CONDITION
In DELAY mode wi pers run conti nual l y when
was h i s operated but do not provi de an extra
wi pe when the was h control i s rel eased.
PROCEDURE
Replace t he control unit.
CONDITION '
Wipers start erratically duri ng DELAY mode.
PROCEDURE
(1) Verify t hat t he ground connection at t he in-
st rument panel is maki ng good connection (free from
paint) and is tight.
(2) Verify t hat t he motor ground st rap is maki ng
good contact and t hat t he motor mount i ng bolts are
tight.
(3) Verify t hat t he wiring ground connections for
t he i nt ermi t t ent wipe control uni t and t he wiper
switch are tight.
(4) If condition is not corrected, replace control
unit.
MULTIFUNCTION (INTERMITTENT WIPER) SWITCH
TESTING PROCEDURES
Refer to Multifunction (Two Speed Wiper) Switch
Testing Procedures using t he following continuity
chart.
i
24 23 22 21 20 19
17 16 15 14 /V~\M3 12 11 10
9 8
7 6
V
5^4 3 .
2 1
EZJ CZ3 CZ3 C3
Jr
L
JT
MULTI FUNCTI ON SWI TCH PI NS
SWITCH
POSITION
CONTINUITY
BETWEEN
OFF PI N 6 AND PI N 7
DELAY
PI N 8 AND PI N 9
PI N 2 AND PI N 4
PI N 1 AND PI N 2
PI N 1 AND PI N 4
LOW PI N 4 AND PI N 6
HI GH PI N 4 AND PI N 5
WASH PI N 3 AND PI N 4
* RESI STANCE AT AAAXI MUM DELAY POSI TI ON SHOULD BE
BETWEEN 270, 000 OHMS AND 330, 000 OHMS.
RESI STANCE AT MI NI MUM DELAY POSI TI ON SHOULD BE
ZERO WI TH OHMMETERSET ON HI GH OHM SCALE.
918J-4
Fig. 11ntermittent Wipe Switch Continuity Chart
INTERMITTENT WIPE MODULE LOCATION
The i nt ermi t t ent wipe module is located to t he
ri ght of t he steering column on t he back side of t he
i nst rument panel (Fig. 2).
BUZZER
MODULE
INTERMITTENT
WIPE MODULE
Fig. 2 Intermittent Wipe Module Location

WI N D S H I E L D WI P E R S Y S T E M S E R V I C E P R O C E D U R E S
INDEX
page
Installation 9
Linkage Replacement (Fig. 6 ) 8
Wiper Arm Replacement 7
Wiper Blade Element Change 7
WIPER BLADES
Wiper blades exposed to t he weat her for a long pe-
riod of time tend to lose t hei r wiping effectiveness.
Periodic cleaning of t he wiper blade is suggested to
remove t he accumulation of salt and road film. The
wiper blades, arms and windshield should be cleaned
with a sponge or cloth and a mild detergent or nona-
brasive cleaner. If t he blades continue to st reak or
smear, they should be replaced.
WIPER BLADE ELEMENT CHANGE
There are two types of wiper blade assemblies. The
assemblies are identified as "Type A" (Fig. 1) and
"Type B" (Figs. 2 and 3).
Fig. 1 Removing Blade and Wiping Element from
Blade Assembly Type'A"
Fig. 2 Removing Blade from Arm Type "B"
(1) Turn wiper switch ON, position blades to a con-
venient place by t ur ni ng t he ignition switch ON and
OFF.
(2) Lift wiper ar m to raise blade off glass.
(3) Remove blade assembly from ar m and wiping
element from blade, depending on type, as follows:
page
Wiper Blades 7
Wiper Motor Replacement . . . . . . . . . . . . . . . . . . . 8
Wiper Switch Replacement . . . . . . . . . . . . . . . . . . 9
TYPE A To remove blade assembly from arm,
insert a small screwdriver blade into release slot of
wiper blade and pry slightly upward (Fig. 1).
To remove wiping element from blade assembly,
pinch lock on end of blade assembly and wi t hdraw
wiping element (blade) out of claws.
Check each release point for positive locking when
installing blade element and blade assembly.
Type BTo remove blade, lift up on release t ab on
center bridge pivot (Fig. 2).
Lift lock t ab on one of end l i nks and squeeze link
to remove from center bridge. Slide end link off ele-
ment and slide element from claws of other link (Fig,
3).
LIFT RELEASE TAB END LINK RH526
Fig. 3 Removing Wiping Element From Blade
Assembly Type "B"
Check each release point for positive locking when
installing blade element and blade assembly.
WIPER ARM REPLACEMENT
REMOVAL
(1) Lift t he arm to permit t he latch (Fig. 4 ) to be
pulled out to t he holding position and remove t he
arm from t he pivot using a rocking motion.
Fig. 4 Removing Wiper Arm
8K - 8 WINDSHIELD WIPER AND WASHER SYSTE MS
C A U T I O N : The use of a screwdriver or other pryi ng
tool to remove an arm may distort it. T hi s distortion
coul d allow the arm to come off the pivot shaft, re-
gar dl ess of how carefully it is installed.
INSTALLATION
With wiper motor in park position, mount arms on
pivot shafts. Choose a serration engagement which
locates blades so t hat distance between t he intersec-
tion of ar m and t he blade and t he weat herst ri p is as
shown in Fig. 5.
ADJUST WIPER ARM SO TIP OF
BLADE IS ABOVE THE WEATHERSTRIP
IN PARK POSITION AS SHOWN J908K-34
Fig. 5 Adjusting Wiper Arms
WIPER MOTOR REPLACEMENT
REMOVAL
(2) Disconnect wires from wiper motor.
(3) Remove motor mount i ng screws.
(4) Lower motor down far enough to gain access to
crank ar m to drive link ret ai ner bushing.
(5) Remove crank ar m from drive link by prying
ret ai ner bushi ng from crank ar m pin with a suitable
size screwdriver.
(6) Remove motor.
(7) Remove nut at t achi ng crank ar m to motor
drive shaft.
(8) Remove crank arm.
INSTALLATION
(1) Position crank ar m on motor drive shaft, mak-
ing sure slot is indexed properly. Install mount i ng
nut and t i ght en to 11 Nm (95 in. lbs.) torque.
(2) Install crank ar m pin in drive link ret ai ner
bushi ng by snapping together with channel lock pli-
ers.
(3) Position motor into place, install mount i ng
screws, and t i ght en to 6 Nm (55 in. lbs.) torque.
(4) Connect wires to wiper motor.
(5) Connect bat t ery cable.
LINKAGE REPLACEMENT (Fig. 8)
CRANK ARM
REMOVAL
(1) Remove wiper motor as previously described.
(2) Remove nut at t achi ng crank ar m to motor
drive shaft.
(3) Remove crank arm.
INSTALLATION
(1) Position crank ar m on motor drive shaft, mak-
ing sure slot is indexed properly. Install mount i ng
nut and t i ght en to 11 N*m (95 in. lbs.) torque.
(2) Install wiper motor.
DRIVE LINK ASSEMBLY LEFT PIVOT
ASSEMBLY
REMOVAL
(1) Remove wiper arms.
(2) Remove screws at t achi ng louvered cowl cover
to cowl panel.
(3) Remove cowl cover by pulling forward wi t h a
slight upward movement.
(4) Reach t hrough access hole and remove drive
link from ri ght pivot by prying ret ai ner bushi ng
from pivot pin with a suitable size screwdriver.
(5) Remove crank arm from drive link by prying
ret ai ner bushing from crank ar m pin wi t h a suitable
size screwdriver.
(6) Remove left pivot mount i ng screws and let
pivot hang loose.
(7) Working t hrough access holes remove drive
links and left pivot as an assembly.
(8) Remove drive link from left pivot by prying re-
t ai ner bushing from pivot pin wi t h a suitable size
screwdriver.
INSTALLATION
(1) Install left pivot pin in drive link ret ai ner
ers.
(2) Maneuver drive links and pivot assembly
t hrough access hole and position into place.
(3) Position left pivot into place, install mount i ng
screws and t i ght en to 11 N*m (95 in. lbs.) torque.
(4) Install crank arm pin in drive link ret ai ner
ers.
(5) Install ri ght pivot pin in drive link ret ai ner
ers.
(6) Position cowl cover into place, install mount i ng
(7) Install wiper arms, refer to wiper ar m adjust-
ment procedure.
WINDSHIELD WIPER AND WASHER SYSTE MS 8K - S
BLADE PIVOT ASSEMBLY
WIPER MOTOR RK755
Fig. 6 Wiper Linkage
RIGHT PIVOT ASSEMBLY
REMOVAL
(1) Remove wiper arms.
(2) Remove screws at t achi ng louvered cowl cover
to dash panel.
(3) Remove cowl cover by pulling forward wi t h a
slight upward movement.
(4 ) Reach t hrough access hole and remove drive
link from ri ght pivot by prying ret ai ner bushi ng
from pivot pin wi t h a suitable size screwdriver.
(5) Remove ri ght pivot mount i ng screws.
(6) Remove pivot t hrough access hole.
INSTALLATION
(1) Position pivot into place, install mount i ng
screws, and t i ght en to 11 N*m (95 in. lbs.) torque.
(2) Install ri ght pivot pin in drive link ret ai ner
bushing by snapping together with channel lock pli-
ers.
(3) Position cowl cover into place, install mount i ng
(4 ) Install wiper arms.
WIPER SWITCH REPLACEMENT
(2) Remove t i l t lever (Tilt column only).
(3) Remove both upper and lower steering column
covers.
(4 ) Remove multifunction switch t amper proof
mount i ng screws.
(5) Gently pull switch away from column. Loosen
connector screw. The screw will remai n in t he con-
nector.
(6) Remove wiring connector from multifunction
switch (Fig. 7).
H A Z A R D W A R N I N G
B U T T O N
WI N D S H I E L D WA S H E R
B U T T O N
WI N D S H I E L D WI PE R
C O N T R O L
M U L T I - F U N C T I O N
S WI T C H
908J-9
Fig. 7 Multifunction Switch
INSTALLATION
(1) Install wiring connector to switch and t i ght en
connector ret ai ni ng screw to 2 Nnn (17 in. lbs.).

(2) Mount multifunction switch to column and (4) Install tilt lever (tilt column only),
torque ret ai ni ng screws to 2 Nm (17 in. lbs.). (5) Install bat t ery cable.
(3) Install steering column covers. Torque retain- (6) Check all functions of switch for proper opera-
ing screws to 2 Nm (17 in. lbs.). tion.
WINDSHIELD WASHERS
GENERAL INFORMATION
All models are equipped with electric operated
windshield washer pumps.
The electric pump assembly is mounted directly to
t he reservoir. A permanent l y lubricated sealed motor
is coupled to a rotor type pump. Fluid, gravity fed
from the reservoir, is forced by t he pump t hrough
rubber hoses to t he nozzles which direct t he streams
to t he windshield.
These vehicles are equipped with special plastic
washer nozzles (Fig. 1). Because they are inserted di-
rectly into t he cowl panel, t here is no adjustment re-
quired.
Fig. 1 Windshield Washer System
WINDSHIELD WASHER PUMP REPLACEMENT (Fig.
2)
REMOVAL
(1) Remove liquid from reservoir.
(2) Remove reservoir mounting screws and remove
reservoir and pump assembly.
(3) Disconnect electrical lead and rubber hose from
bottom of pump.
(4) Using an extension and deep well socket, reach
t hrough reservoir filler neck, and remove pump
mount i ng nut and plastic washer.
(5) Remove pump from bottom reservoir.
(6) Remove rubber grommet from reservoir and
throw away.
Fig. 2 Washer Pump
INSTALLATION
(1) Install new rubber grommet into place in bot-
tom of reservoir.
(2) Position pump into place in reservoir. Install
plastic washer t hen mounting nut , and t i ght en to 3
Nm (25 in. lbs.) torque. Do not overtighten.
(3) Connect electrical leads and hose to pump.
(4) Position reservoir into place, install mounting
(5) Fill reservoir with water and/or washer fluid,
inspect for leaks and test system.

WINDSHIELD WASHER DIAGNOSIS
WA S H E R D O E S
N O T
O PE R A T E PR O PE R L Y
T
P U M P M O T O R
D O E S N O T R U N
L OOS E WI R I N G ,
TE RMI NALS , C OR R ODE D
TERMI NALS
X
BR OKE N WI R E S
POOR G R O U N D
FAULTY SWI TCH
FAULTY MOTOR
P U M P M O T O R
R U N S
T

P U M P R U N S -
P U M P N O T
P U M P I N G FL UI D
N O FLUID I N
RESERVOI R
NOZ Z LE JET UNDER
C O WL PANEL
NOZ Z LE JETS
PLUGGE D
BR O K E N OR
L OOS E HOS E
FAULTY PUMP
M O T O R R U N S
PU M P P U M P I N G
F L U I D
S YS T E M O PE R A T E S
I NT E R MI T T E NT L Y
LOOSE WI R I N G
X
FAULTY SWI TCH
t
FAULTY MOTOR
S YS T E M O PE R A T E S
WI T H O U T
I N T E R R U PT I O N
I A T E S I
T I
I O N j
S YS T E M O U T PU T
L O W
NOZ Z LES
A I ME D LOW
PI NCHE D OR
LEAKY HOS E S
X
LEAKY OR RESTRICTED
PLASTIC HOS E
C ON N E C T OR
X
POOR ELECTRICAL
DEFECTIVE MOTOR
J908K-27

L A M P S
LAMPS 8L - 1
C O N T E N T S
page page
BULB APPLICATION 11 EXTERIOR LAMPS SERVICE PROCEDURES . . . 3
EXTERIOR LAMPS 1 INTERIOR LAMPS 10
E X T E R I O R L A M P S
GENERAL INFORMATION
Each vehicle is equipped wi t h various l amp assem-
blies. A good ground is necessary for proper lighting
operation.
When changing lamp bul bs check t he socket for
corrosion. Clean corrosion wi t h a wire brush. Coat
the inside of t he socket lightly with Mopar Multi-
Purpose Grease or equivalent.
DIAGNOSTIC PROCEDURES
Always begin any diagnosis by testing all of the
fuses and circuit breakers in t he system. Refer to
Group 8W, Wiring Di agrams.
Conventional and halogen headl amps are inter-
changeable. It is recommended t hat t hey not be in-
termixed on a given vehicle.
MULTI-FUNCTION SWITCH TESTING PROCEDURES
The multi-function switch contains electrical cir-
cuitry for:
Headl amp Dimmer Switch
Passing Lights
Turn Signals
Hazard Warni ng
Windshield Wiper
Pulse Wiper
Windshield Washer
HE A D L A MPS HI M
E N G I N E I D L I N G
O R I G N I T I O N OFF
TEST CHARGING
SYSTEM
H E A D L A M P D I A G N O S I S
SEALED BEAM
O R BUL B BU R N S
OUT FREQUENTLY
][
TEST CHARGING
SYSTEM
HE A D L A MPS D I M
E N G I N E R U N N I N G
A BO V E I DLE
][
TEST CHARGING
SYSTEM
HE A D L A MPS
R A N D O M FLASH
[
HE A D L A MPS
WI L L NOT LI GHT
POORLY GROUNDED
HEADLAMP
CIRCUIT
LOOSE CONNECTION
IN HEADLAMP
CIRCUIT
HIGH RESISTANCE
IN HEADLAMP
CIRCUIT
LOOSE CONNECTION
IN HEADLAMP
CIRCUIT
HIGH RESISTANCE
IN HEADLAMP
CIRCUIT
LOOSE CONNECTION
IN HEADLAMP
CIRCUIT
OPEN OR CORRODED
CONTACT IN
HEADLAMP SWITCH
CRACKED LENS ON
HALOGEN SEALED
BEAM ONLY
FAULTY SEALED
BEAMS OR BULBS
OPEN OR CORRODED
CONTACT IN DIMMER
SWITCH
FAULTY SEALED
BEAMS OR BULBS
FAULTY SEALED
BEAMS OR BULBS
RR8LD21
8L - 2 LAMPS

This switch is mounted to t he left hand side of t he
steering column. Should any function of t he switch
fail, t he entire switch must be replaced.
SWITCH TEST
(2) Remove tilt lever.
(3) Remove upper and lower column covers to gain
access to t he switch connector (Fig. 1).
(4) Remove lower fixed column cover.
(5) Loosen steering column upper bracket nut s. Do
not remove nuts.
(6) Move upper fixed column cover to gain access
to rear of multi-function switch.
(7) Remove switch connector (Figs. 2 and 3).
(8) Use an ohmmeter to test for continuity. Check
between t he t ermi nal s of t he switch as shown in t he
continuity chart (Fig. 4).
(9) Refer to Service Procedures for assembly.
UPPER S HR O U D G R O U N D
CLIP
UPPER
FIXED S HR O U D
SUPPORT BRACKET
LOWER
S HR O U D
LOWER
FIXED
S HR O U D
J9119- 22
Fig. 1 Steering Column Covers
STEERI NG
C OL UMN
ASSY.
J918J-1
TURN S I GNAL
MULT I SWI TCH A N D
* FUNCTI ON LEVER
SWI TCH
C ONNE C T OR
Fig. 2 Multi-function Switch Connector
KEY-IN SWI TCH &
HALO LIGHT
MULTI FUNCTI ON
SWI TCH
I GNI T I ON
SWI TCH
TURN S I GNAL
SWI TCH & LEVER
SPEED
CONTROL J918J- 2
Fig. 3 Steering Column Connectors
24 23 22 21 20 19 18
EZJ C=3 C=3 E = 3 CZZJ E = 3 E = 3
17 16 15 14 13 12 11 10
a a a
8 = 3
( ( ) )
1 = 3 1 = 3 1 = 3
9 8 7 6 \ 5 _ y 4 3 2 1
VIEW FROM TERMINAL SIDE
S WI T C H P O S I T I O N
C O N T I N U I T Y B E T WE E N
LOW BEAM
HIGH BEAM
OPTICAL HORN
18 AND 19
19 A N D 20
20 A N D 21
908J-5
Fig. 4 Beam Select Switch Continuity Chart

LAMPS 8L - 3
EXTERIOR LAMPS SERWICE PROCEDURES
INDEX
page
Cargo Lamp 7
Cl earance Lamps for Dual Wheel Model . . . . . . . . 5
Daytime Running Light Module ( Canada Only) . . . 8
Front Park and Turn Signal Lamp Bulb 4
H eadl amp Adjustment Usi ng Alignment Screen . . . 3
H eadl amp Alignment 3
H eadl amp Alignment Preparation 3
page
H eadl amp Switch 4
License Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Seal ed Beam Replacement 4
Si de Marker Lamp and Bulb . 5
Tail, Stop, Turn Si gnal , Rear Si de Marker and
Back- Up Lamps 5
Underhood Lamp 8
HEADLAMP ALIGNMENT
Headl amps can be aligned using the screen method
provided in this section. Alignment Tool C4466-A or
equivalent can also be used. Refer to instructions
provided with t he tool for proper procedures. The
pr ef er r ed he a dl a mp al i gnment set t i ng i s 0 for
the left/ ri ght adj us t ment and 1"down for the up/
down adj us t ment .
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Correct defective components t hat could hinder
proper headl amp alignment.
(3) Verify proper tire inflation.
(4) Clean headl amp lenses.
(5) Verify t hat luggage area is not heavily loaded.
(6) Fuel t ank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over t he fuel t ank for each estimated
gallon of missing fuel.
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
l ar to a flat wall 7.62 meters (25 ft) away from front
of headlamp lens.
(2) If necessary, tape a line on t he floor 7.62
meters (25 ft) away from and parallel to t he wall.
CENTER OF
VEHICLE TO
CENTER OF
HEADLAMP
LENS
VEHICLE
CENTERLINE"
LOW BEAM HOT
SPOT AR E A
FLOOR TO
CENTER OF
HEADLAMP
LENS
PREFERRED
HOT SPOT
LOCATI ON
7.62 METERS
(25 FEET)
FRONT OF
HEADLAMP
938L-25X
Fig. 1 Headlamp Alignment Screen Typical
8L - 4 LAMPS

(3) Up 1.27 met ers (5 feet) from t he floor, tape a
line on t he wall at t he centerline of t he vehicle.
Sight along the centerline of t he vehicle (from rear of
vehicle forward) to verify accuracy of t he line place-
ment.
(4) Rock vehicle side-to-side t hree times to allow
suspension to stabilize.
(5) Jounce front suspension t hree times by pushing
downward on front bumper and releasing.
(6) Measure t he distance from t he center of head-
lamp lens to t he floor. Transfer measurement to t he
alignment screen (with tape). Use this line for up/
down adjustment reference.
(7) Measure distance from t he centerline of t he ve-
hicle to t he center of each headl amp being aligned.
Transfer measurement s to screen (with tape) to each
side of vehicle centerline. Use these lines for left/
ri ght adjustment reference.
HEADLAMP ADJUSTMENT
A properly aimed low beam headl amp will project
top edge of high intensity pat t ern on screen from 50
mm (2 in.) above to 50 mm (2 in.) below headl amp
centerline. The side-to-side outboard edge of high in-
tensity pat t ern should be from 50 mm (2 in.) left to
50 mm (2 in.) ri ght of headl amp centerline (Fig. 1).
The preferred h e a d l a mp al i gnment i s 0 for the
up/ down adj us t ment and 1" down for the left/
right adj us t ment . The high beam pat t ern should be
correct when t he iow beams are aligned properly
(Fig. 2).
To adjust headl amp aim, rot at e alignment screws
to achieve t he specified high intensity pat t ern.
1. HORI Z ONTAL ADJ. SCREW - RH
2. VERTICAL ADJ. SCREW
3. HORI Z ONTAL ADJ. SCREW - LH
J908L-24
Fig. 2 Sealed Beam Headlamp Alignment
SEALED BEAM REPLACEMENT
(1) Remove t he headl amp bezel (Fig. 3).
(2) Remove four screws from ret ai ni ng ri ng (Fig.
4).
(3) Separate sealed beam from seat and disconnect
from the socket.
To install, reverse t he removal procedures.
HEADLAMP
BEZEL
: ') J918L-29
Fig. 3 Headlamp Bezel
RETAI NI NG
RI NG
SCREWS
J918L-28
Fig. 4 Sealed Beam Replacement
HEADLAMP SWITCH
To remove or replace t he headlamp switch see in-
structions in Group 8E - Inst rument Panel and
Gauges.
FRONT PARK AND TURN SIGNAL LAMP BULB
(1) Remove 2 screws securing t he Park/ Turn signal
lamp (Fig. 5)
(2) Twist out lamp socket from back of lamp hous-
ing.
(3) Replace bulb.
To install, reverse removal procedures.

LAMPS 8L - 5
J918L-27
Fig. 5 Park and Turn Signal Lamp
SIDE MARKER LAMP AND BULB
(1) From inside engine compartment, twist out
socket from back of housing.
(2) Remove nut s at t achi ng lamp to fender.
(3) Lift lamp away from outside of fender.
To install, reverse t he removal procedures.
TAI L, STOP, TURN SIGNAL, REAR SIDE MARKER
AND BACK-UP LAMPS
SWEPTLINE MODELS
REMOVAL
(1) Remove screws and remove l amp assembly.
(2) Twist out socket.
INSTALLATION
(1) Twist in socket.
(2) Position t he lamp and install screws.
CAB CHASSIS MODELS
REMOVAL
(1) Remove 4 screws holding lens to lamp.
(2) Twist out bulb.
INSTALLATION
(1) Install bulb.
(2) Position lens and install screws.
SPORT UTILITY MODELS
REMOVAL
(1) Remove screws and remove lamp assembly.
(2) Twist out socket.
(3) Replace bulb.
Fig. 6 Tail, Stop, Turn Signal, Rear Side Marker and
Back-Up Lamp
LAMP
ASSEMBLY PR1086
Fig. 7 Tail, Stop, Turn Signal, and Back-Up Lamp
INSTALLATION
(1) Twist in socket.
(2) Position t he lamp and install screws.
CLEARANCE LAMPS FOR DUAL WHEEL MODEL
WHEEL FLARE AND TAILGATE CLEARANCE
LAMPS
To change bulb, remove lamp as follows:
(1) Pry out ret ai ni ng clamps.
(2) Pull lens away from mount i ng plate.
8L - 6 LAMPS

ASSEMBLY * J908L-6 3
Fig. 8 Tail, Stop, Turn Signal, Rear Side Marker and
Back-Up Lamp
(3) Disconnect electrical connector from bulb and
lens assembly (Figs. 9 and 10).
(4) Connect electrical connector to new lamp and
snap into housing.
J908L-73
Fig. 9 Wheel Flare Clearance Lamp
CAB CLEARANCE LAMPS
To change bulb, remove l amp as follows:
(1) Remove mount i ng screws (Fig. 11).
(2) Slide lens down and out of housing.
(3) Twist out socket and replace bulb.
Fig. 10 Rear Clearance Lamps

LAMPS 8L - 7
(4) To install, reverse procedures. Make sure t he
grounding eyelet is under a mount i ng screw.
Fig. 11 Cab Clearance Lamps
CARGO LAMP
STANDARD CAB
(1) Remove two mount i ng screws.
(2) Pull assembly out and disconnect wiring con-
nector.
(3) To install, reverse t he procedures.
J908 L- 59.
Fig. 12 Cargo LampStandard Cab
CLUB CAB
(1) Remove two mount i ng screws.
(2) Pull assembly out and disconnect wiring con-
nectors.
(3) To install, reverse t he procedures.
LICENSE LAMP
STANDARD BUMPER
(1) Remove rear license plate.
(2) Remove 2 lamp mounting screws.
(3) Remove lamp assembly.
(4) Remove 2 screws at t achi ng l amp lens to hous-
ing.
Fig. 14 License Plate Lamp - Standard Rear Bumper
STEP BUMPER
(1) Remove 2 lamp assembly mount i ng screws
(Fig. 15)
(2) Remove l amp from bumper.
(3) Disconnect wire connector.
(4) Remove lens from lamp.
(5) Twist out bulb.
(6) To install, reverse t he removal procedures.
WITHOUT REAR BUMPER
(1) Remove screws holding lamp assembly to li-
cense bracket (Fig. 16).
(2) Disconnect electrical connector and remove
lamp assembly.
(3) Install new lamp assembly with screws and
connect electrical connector.
8L - 8 LAMPS
CONNECTOR
CUP
FRONT
LAMP ASSEMBLY
LI CENSE PLATE
SCREW
LAMP ASSEMBLY
LI CENSE PLATE
RR8LD24
Fig. 15 License Plate Lamps - Step Bumper
TO TAI L, STOP,
TURN SI G. AND BACK UP LAMPS
LI CENSE PLATE LI CENSE PLATE LAMP AND
LAMP CONNECTOR BRACKET ASSEMBLY J908L-74
Fig. 16 License Plate Lamp Without Rear Bumper
UNDERHOOD LAMP
When equipped, t he underhood lamp is installed on
t he hood left, rear i nner panel (Fig, 17). The lamp is
illuminated when t he hood is opened (Fig. 18).
UNDERHOOD LAMP BULB REPLACEMENT
REMOVAL
(1) Disconnect t he wire connector from t he under-
hood lamp (Fig. 17).
(2) Rotate t he bulb counter-clockwise. Remove it
from t he lamp base socket (Fig. 18).
INSTALLATION
(1) Insert t he replacement bulb in t he lamp base
socket. Rotate it clockwise.
(2) Connect t he wire connector to t he l amp (Fig.
17).
UNDERHOOD LAMP REPLACEMENT
REMOVAL
(1) Disconnect t he wire connector from t he l amp
(Fig. 17).
(2) Rotate t he bulb counter-clockwise. Remove it
from t he lamp base socket (Fig. 18).
(3) Remove t he screw t hat at t aches t he lamp re-
flector and support bracket to t he hood i nner panel
(Fig. 17).
(4) Remove t he lamp from t he hood i nner panel.
INSTALLATION
(1) Position t he underhood l amp on t he hood i nner
panel.
(2) Install t he screw t hrough t he l amp and into t he
hood panel (Fig. 17). Tighten t he screw securely.
(3) Insert a replacement bulb in t he l amp base
socket (Fig. 18). Rotate it clockwise.
(4) Connect t he wire connector to t he lamp (Fig.
17).
HOOD
J9223-446
Fig. 17 Underhood Lamp
DAYTIME RUNNING LIGHT MODULE (CANADA
ONLY)
The headlamps on vehicles sold in Canada will il-
l umi nat e when t he ignition is ON. The module also
receives a signal from t he distance sensor. This pro-
SUPPORT
BRACKET
RETAI NER LI QUI D
TAB SWI TCH
ENCLOSURE
WI RE HARNESS
CONNECTOR
\
1
d
1
^ 1l
L /
CMD>
LAMP
REFLECTOR BULB (105) BASE J
9281
"
1
Fig. 18 Underhood Lamp Components
LAMPS 8L - 9
vides a constant Lights On condition while t he vehi-
cle is rolling. The lamps i l l umi nat e at less t han 50%
of normal intensity.
The Daytime Runni ng Light Module is located on
t he ri ght inner fender (Fig. 19).
(1) Remove t he bolt holding the module and
bracket to t he vehicle.
(2) Disconnect t he electrical connector.
(3) To install t he module, reverse the removal pro-
cedures.
Fig. 19 Daytime Running Light Module
8L - 10 LAMPS

INTERIOR
DOME LAMP
STANDARD CAB
(1) Remove two screws and lens.
(2) Twist bulb to remove.
LENS
SCREW J908L-65
Fig. 1 Dome Lamp (Standard Cab)
EXTENDED CAB
(1) Squeeze t he front and rear of t he lens together
and pull down to remove (Fig. 2).
(2) Pull bulb down to remove from socket.
SPORT UTILITY
(2) Pull bulb down to remove from socket.
READING LAMP (SPORT UTILITY)
J908L-66
Fig. 2 Dome Lamp (Extended Cab)
LAMPS
LENS J918L-30
Fig. 3 Dome Lamp (Sport Utility)
(2) Remove 2 screws holding t he dome and readi ng
l amp assembly to t he mounting bracket.
(3) Lower t he assembly.
(4) Remove t he bulb.
ROOF
MOUNTING
SCREW J918L-31
Fig. 4 Reading Lamp

LAMPS 8L - 11
BULB APPLICATION
GENERAL INFORMATION
The following Bulb Application Table lists t he
lamp title on t he left side of t he column and part
number on t he right.
C A U T I O N : D o not use bul bs that have a hi gher can-
dle power than the bulb listed in the Bul b Appl i ca-
tion Tabl e. D amage to l amp can result.
EXTERIOR LAMPS
Auxiliary Tur n Signal (Snow Plow) 2057
Auxiliary Headl amps (Snow Plow) .6054
Back-up....................... .......1156
Cargo Lamp. . 922
Clearance Lamps 194
Front Side Marker 168
Headlamp/Sealed Beam .6052
License Pl at e 168
Park/ Turn Signal 2057
TaiyStop/Turn Signal ...2057
INTERIOR LAMPS
DIMMER CONTROLLED LAMPS
Service procedures for most of t he lamps in t he in-
st rument panel are located in Group 8E, Inst rument
Panel and Gauges. Some components have lamps
t hat can only be serviced by an Authorized Service
Center (ASC). These components must be removed
from t he vehicle for service. Contact local dealer for
location of nearest ASC.
A/C Heat er Control 158
Ash Receiver ..158
Gear Shift Selector...........................................PC194
Heat er Control 158
Inst rument Cl ust er. . PC 194
Radio ASC
Snow Plow Control .158
INDICATOR LAMPS
Service procedures for most of t he lamps in t he in-
st r ument panel, and switches are located in Group
8E, Inst rument Panel and Gauges.
Anti-lock Brake PC194
Brake Warni ng PC194
Check Engi ne PC194
Engi ne Oil Pressure 158
Fast en Seat Belts.. PC 194
Four Wheel Drive ....158
Hazard Fl asher 194
High Beam PC194
Low Fuel....... JPC194
Mai nt enance Required PC 194
Transmission Temperature ..PC 194
Turn Signal PC194
NON-DIMMING LAMPS
Service procedures for most of t he lamps in t he fol-
lowing list can be found in Group 23, Body.
Dome 1004
Engi ne Compartment ...105
Glove Compartment.... 1891
Ignition Lock ASC
Reading Lamp 912

REAR WINDOW DEFOGGER 8N - 1
R E A R WI N D O W D E F O G G E R
CONTENTS
page
REPAIR PROCEDURES (GRID LINES,
TERMINALS, AND PIGTAILS) 3
GENERAL INFORMATION
The electrically heated rear window defogger is
available on Ramcharger wi t h sunscreen glass only.
The system consists of a r ear window wi t h two ver-
tical bus bars and a series of electrically connected
grid lines baked on t he inside surface.
Circuit protection for t he heat ed grid circuit is pro-
vided by a 18 gauge fusible link wire located in t he
engine compartment. The relay circuit is protected
by a 20 amp fuse, located in t he fuse block.
When t he rear window defogger switch is placed in
the ON position, current is directed to rear window
grid lines. The heated grid lines in t ur n heat t he
rear window to clear t he surface of fog or snow.
CAUTI ON ; Gri d lines can be damaged or scraped
off with shar p i nstruments. Care shoul d be taken in
page
TEST PROCEDURES 1
cl eani ng the g l a s s or removi ng foreign materials,
decal s or sti ckers. Normal g l a s s cleaning sol vent s
or hot water used with r ags or toweling i s recom-
mended.
SYSTEM DESCRIPTION
CONTROL SWITCH/TIMER RELAY MODULE
The control switch and t i mer relay are i nt egrat ed
into a single panel mounted assembly. Actuating t he
switch energizes the electronic timing circuit. Thi s
allows current to flow t hrough t he grid system for
approximately 10 mi nut es, or unt i l either t he control
switch or ignition is t urned off. An indicating l amp
illuminates a lens inlaid in t he control switch.
TEST PROCEDURES
SYSTEM TEST
Electrically heated rear window defogger operation
can be checked in-vehicle in t he following manner:
(1) Turn t he ignition ON.
(2) Turn rear window defogger control switch ON.
(3) Monitor vehicle voltmeter. Wi t h t he control
switch ON, a distinct needle deflection should be
noted.
(4) The rear window defogger operation can be
checked by feeling t he glass. A distinct difference in
t emperat ure between t he grid lines and adjacent
clear glass can be detected in 3 to 4 mi nut es of oper-
ation.
(5) Contact negative lead of a DC voltmeter (Fig.
1), to t ermi nal "B" (passenger side). Contact positive
lead to t ermi nal " A " (driver side). The voltmeter
should read 10-14 volts.
Only steps (3) and (4) or (5) above will confirm sys-
tem operation. Indicator light illumination means
t hat t here is power available at t he out put of t he re-
lay only, and does not verify system operation.
If r ear window defogger does not operate, t he prob-
lem should be isolated in t he following manner:
(1) Confirm t hat ignition switch is ON.
VOLTMETER
Fig. 1 Grid Line Test
(2) Ensure t hat heat ed r ear window feed wire is
connected to t ermi nal or pigtail and t hat ground wire
is in fact grounded.
(3) Ensure t hat fuse is operational and all electri-
cal connections are secure.
When above steps have been completed and t he
system is still inoperative, one or more of t he follow-
ing is defective:
(a) Control switch/timer relay module.
8N - 2 REAR WINDOW DEFOGGER

(b) Rear window grid lines (all grid lines would
have to be broken) or one of t he feed wires are not
connected for t he system to be inoperative.
The following paragraphs outline component check-
out procedures.
If t ur ni ng t he switch ON produces severe voltmeter
deflection, t he circuit should be closely checked for a
shorting condition.
If system operation has been verified but indicator
bulb does not light, check and replace bulb.
For detailed wiring information, refer to Group 8W
- Wiring Di agrams.
REAR WINDOW GRID LINES TEST
Horizontal grid lines and vertical bus bar lines
printed and baked on inside surface of rear window
glass (Fig. 1) comprise an electrical parallel circuit.
The electrically conductive lines are made of a silver-
ceramic mat eri al . When baked onto glass t hey be-
come bonded to t he glass and are highly resi st ant to
abrasion. It is possible, however, t hat a break may
exist or occur in an individual grid line resul t i ng in
no current flow t hrough t he line. To detect breaks in
grid lines, t he following procedure is required:
(1) Turn ignition on and push control switch to
ON. Indicator light should come on.
(2) Contact negative lead of a DC voltmeter, to
vertical bus bar connecting grid lines on passenger
side of vehicle (point A of Fig. 1). Contact positive
lead of voltmeter, to vertical bus bar on driver side of
vehicle (point B of Fig. 1). Voltmeter should read
10-14 volts.
(3) Wi t h negative lead of voltmeter, contact a good
body ground point. Voltage readi ng should not
change. A different readi ng indicates a poor ground
connection.
(4) Connect negative lead of voltmeter to Point A
on passenger side bus bar and touch each grid line at
Mid-Point wi t h positive lead. A readi ng of approxi-
mately 6 volts indicates a line is good. A readi ng of 0
volts indicates a break in line between Mid-Point C
and Point B. A readi ng of 10-14 volts indicates a
break between Mid-Point C and ground Point A.
Move toward break and voltage will change as soon
as break is crossed.
CONTROL SWITCH/TIMER MODULE TEST
Control switch/timer relay module may be tested
in-vehicle or bench tested. In vehicle t est i ng is ac-
complished in t he following manner:
(1) Remove switch from i nst rument panel (refer to
Control Switch Replacement) and leave switch con-
nector plugged in.
(2) Tur n ignition ON.
(3) Usi ng a DC voltmeter, check voltage at t ermi -
nal s B, I and L (Figs. 2 and 3). Terminals B and I
should confirm a voltage of 10 to 14 volts to ground.
Termi nal L should confirm 0 volts to ground. When
t ermi nal s B and I show no voltage, trace circuit up-
st ream of switch/relay module for cause:
wiring cut
fusible link faulty
circuit breaker inoperative
bulkhead connection bad, etc.
If t ermi nal L indicates voltage, place switch in
OFF position. If voltage at L is still indicated or in-
dicator lamp remai ns on, switch/relay module should
be replaced.
"X I FUSE #14 rr~
P 3 AAAP P
FUSE #3
20 AAAP
BATTERY
HEATED REAR
WI NDOW DEFOGGER
SWI TCH
( I NSTRUMENT PANEL)
ON/ OFF
ILLUMINATION
LAMP
fez TI MER
L.E.I
INDICATOR
LIGHT
--
18 GAUGE
FUSI BLE
LI NK
I GNI TI ON
POWER MI DPOI NT "C"
CONNECTOR ( TYPI CAL)
POI NT "A"
POI NT"B" GROUND
CONNECTOR
REAR WI NDOW GRI D LI NE STRUCTURE
Fig. 2 Systems Electrical Circuit
J928N- 5
(4) If t he relay checks out to t hi s point, momen-
tarily operate switch to ON position. The indicator
l amp should come on and remai n on for approxi-
mately 10 mi nut es. Termi nal L should confirm volt-
age. If t he indicator l amp fails to light or voltage at
t ermi nal L is not confirmed t he switch/relay module
should be replaced.
Bench checking of t he relay may be accomplished
in t he following manner. By following t he in-vehicle
procedure except Step 2: With a DC power supply,
apply 12 volts to t ermi nal B and I and ground termi-
nal G.
e , REAR WINDOW DEFOGGER 8N - 3
L - TO BACK GLASS
B - HI GH AMP SUPPLY
I - I GNI TI ON
G - GROUND
S - ILLUMINATION LIGHT
RELAY-TIMER
SWITCH ASSEMBLY
J908N-8
Fig. 3 Rear Window Defogger Switch, Timer, Relay
Connector
REPAIR PROCEDURES (GRID LINES, TERMINALS* AND PIGTAILS)
The repair of grid lines or t he t ermi nal is possible
using t he MOPAR Repair Kit No. 4267922 or equiv-
alent.
W ARN I N G: RE PAI R K I T M AY C A US E SK I N OR E Y E
I RRI TATI ON .
CON TAI N S E POX Y RE SI N AN D AM I N E TY PE
H ARD E N E R, H ARM F UL IF SW AL L OW E D . AV OI D
CON TACT W I TH SK I N AN D E Y E S . F OR SK I N , W A S H
AF F E CTE D A RE A S W I TH S OA P AN D W ATE R. D O
N OT TAK E I N TE RN AL L Y . I F TAK E N I N TE RN AL L Y ,
I N D UCE V OM I TI N G; C AL L A PH Y SI CI AN I M M E D I -
ATE L Y . IF I N CON TACT W I TH E Y E S, F L USH W I TH
PL E N TY OF W ATE R. USE W I TH AD E Q UATE V E N TI -
LATI ON . D O N OT US E N E AR F I RE OR F L AM E .
CON TE N TS CON TAI N 3 % F L AM M ABL E SOL V E N TS.
K E E P OUT OF RE AC H OF CH I L D RE N .
(1) Mask repair area so conductive epoxy can be
extended onto t he line or t he bus bar (Fig. 4).
(2) Follow instructions in repai r ki t for prepari ng
damaged area.
(3) Remove package separator clamp and mix plas-
tic conductive epoxy thoroughly. Fold in half and cut
center corner to dispense epoxy.
(4) For grid line, mar k off area to be repaired wi t h
maski ng tape or a t empl at e (Fig. 4).
(5) Apply epoxy t hrough slit in maski ng t ape.
Overlap both ends of t he break by at least 19mm
(0.75 in).
(6) For a t ermi nal or pigtail replacement, mask ad-
jacent areas so epoxy can be extended onto line as
BREAK GRI D LINE
MASKING TAPE PR1509A
Fig. 4 Grid Line Repair (Typical)
well as bus bar. Apply a t hi n layer of epoxy to area
where t ermi nal was fastened and to adjacent line.
(7) Apply a t hi n layer of conductive epoxy on ter-
mi nal and place t ermi nal on desired location. To pre-
vent t ermi nal from moving while t he epoxy is curing,
it must be wedged or clamped.
(8) Carefully remove maski ng tape from grid line.
C A U T I O N : D o not allow the g l a s s surf ace to exceed
400F, g l a s s may fracture.
(9) Allow epoxy to cure 24 hours at room tempera-
t ure or use heat gun with a 260-371C (500-700F)
range for 15 mi nut es. Hold gun approximately
254mm (10 inches) from repaired area.
(10) After conductive epoxy is properly cured re-
move wedge from t ermi nal and check out operation
of rear window defogger. Do not at t ach connectors
unt i l curing is complete.
81 - 4 REAR WINDOW DEFOGGER

SERVICE PROCEDURES
HEATED REAR WINDOW CONTROL SWITCH
REPLACEMENT
REMOVAL
(1) Locate chime module. Grasp chime module and
twist it to remove it from t he bracket.
(2) Squeeze rear window defogger switch ret ai ni ng
t angs and pull switch from rear of bezel.
(3) Remove connector from switch.
INSTALLATION
(1) Connect electrical connector to switch.
(2) Insert switch into bezel maki ng sure ret ai ni ng
t angs lock into position.
(3) Install chime module on to bracket.

POWER DOOR LOCKS 8P - 1
P O WE R D O O R L O C K S
C O N T E N T S
SERVICE PROCEDURES
page
page
. . 1
equipped, can be
by operating the
GENERAL INFORMATION
Both doors, when electrically
locked or unlocked electrically
switch on a door panel.
Both doors can be locked or unlocked mechanically
with t he locking knob regardless of electrical locking
and unlocking actuation.
TEST PROCEDURES
The ri ght and left front door on all vehicles can be
locked or unlocked mechanically from t he outside
wi t h t he key or electrically as described above. The
left door can also be unlocked by actuation of t he in-
side remote door handle.
FUSE TEST
Locate t he fuse in fuse cavity number 6 on t he fuse
block. If fuse is blown, replace it. If fuse blows agai n
refer to Switch Test and Voltage Test procedures to
find t he short circuit.
SWITCH TEST
For switch testing, remove t he switch from its
mounting location. Using an ohmmeter, refer to (Fig.
1) to determine if continuity is correct in t he Lock
and Unlock switch positions. If these results are not
obtained, replace t he switch.

3
SWITCH
POSI TI ON
CONTINUITY
BO WE I N
OFF
PI NS 1 & 4
PI NS 2 & 5
LOCK
PI NS 2 & 3
PI NS 1 & 4
UNLOCK
PINS 3 &4
PI NS 2 &5
PIN IDENTIFICATION
PIN SIDE OF SWITCH
Fig. 1 Door Lock Switch Continuity
VOLTAGE TEST
The following wiring test sequence determines
whet her or not voltage is continuous t hrough t he
body harness to switch.
After removing switch from t ri m panel for testing
purposes, carefully separate multiple t ermi nal block
on wiring harness from switch body. Connect one
lead of test light to black wire t ermi nal and touch
ot her test light lead to red wire t ermi nal . If t he test
l i ght comes on, t he wiring circuit between t he bat-
t ery and switch is functional. If light does not come
on, check 20 amp fuse or for a broken wire.
ELECTRIC MOTOR TEST
Make certain bat t ery is in normal condition before
circuits are tested.
To determine which motor is defective, check each
individual door switch for lock and unlock or discon-
nect t he motors, one at a time, t hen operate t he door
lock switch. In t he event t hat none of t he motors
work, t he problem may be caused by a shorted motor.
Disconnecting t he defective motor will allow t he
ot her to work.
To test an individual door lock motor, disconnect
t he wire connector at t he motor. Apply 12 volts
across t he motor t ermi nal s to check its operation in
one direction. Reverse t he polarity to check t he oper-
ation in t he other direction. If t he motor works,
check t he wire harness for broken wires or bad con-
nections. If t he motor does not work, replace it.
Should t he motor malfunction be t he result of bro-
ken wiring or an i nt ernal open circuit, it should have
no effect on t he operation of t he other motor.
8P - 2 POWER DOOR LOCKS

SERVICE PROCEDURES
DOOR LOCK MOTOR REPLACEMENT
REMOVAL
(1) Remove remote control handl e (Fig. 2).
TRIM
PANEL
TRIM PANEL
CLIPS (6)
REMOTE
C ON T R OL
HANDLE
SCREW
TRIM PANEL
CLIPS
J908P-12
Fig. 2 Door Trim Panel
(2) Remove power window/lock switch by inserting
a st andard blade screwdriver into notch on forward
end of switch housing and push to depress locking
t ab. Pull out and forward to remove switch bezel
from door panel.
(3) Remove 2 screws at bottom front and rear of
t ri m panel.
(4) Remove screw behind remote handle.
(5) Using a device such as a t ri m stick, pry t ri 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 mount i ng bracket screws and
remove motor assembly from mounting.
D O O R LOCK
M O T O R
J918P-9
Fig. 3 Door Lock Motor Replacement
INSTALLATION
(1) At t ach motor mount i ng bracket to door inside
panel and install 2 screws.
(2) Connect link to motor rod and connect wires.
(3) Reset watershield at lower rear corner of door.
(4) Install door t ri m panel.
(5) Install door panel at t achi ng screws.
(6) Install remote control handle.
(7) Install power window/lock switch.

POWER WINDOWS 8S - 1
P O W E R W I N D O W S
C O N T E N T S
page
GENERAL INFORMATION
Power window motors are of t he per manent mag-
net type. A positive and negative bat t ery connection
to either of t he two motor t ermi nal s will cause t he
motor to rot at e in one direction. Reversing current
t hrough t hese same two connections will cause t he
motor to rot at e in t he opposite direction.
Both motors are grounded t hrough t he mast er
switch by a black wire attached to a ground stud.
The stud is located on t he back of t he i nst r ument
panel, on t he ri ght side of t he steering column.
It is necessary t hat t he window be free to slide up
page
TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . 1
and down in t he glass channels or tubes and t racks.
If t he window is not free to move up and down, t he
window motor will not be able to move t he glass.
To determine if t he glass is free, disconnect t he
electric window regulator lift ar m sliders from t he
glass lift channels. Slide t he window up and down by
hand.
A less positive method is to shake t he glass i n t he
door, (with glass positioned between t he up and down
stop positions). If t he glass will move slightly from
side to side, front to rear, and up and down, t he win-
dow is probably not bound t i ght in t he t racks.
TEST PROCEDURES
SWITCH VOLTAGE TEST
The following wiring test sequence det ermi nes
whet her or not voltage is continuous t hrough t he
body harness to switch.
(1) Remove power window/lock switch by i nsert i ng
end of switch housing. Push screwdriver to depress
locking t ab. Pul l bezel out and forward to remove
from door panel.
(2) Carefully separat e multiple t ermi nal block on
wiring harness from switch body.
(3) Connect one lead of t est light to black (BK)
wire t ermi nal . Touch other t est light lead to t an (TN)
wire t ermi nal . If test light comes on, t he wi ri ng cir-
cuit between t he bat t ery and switch is functional. If
light does not come on, check 30 amp circuit breaker,
or for a broken wire or poor ground.
CIRCUIT BREAKER TEST
Locate t he circuit breaker in fuse cavity number 12
on fuse block. Pull out slightly but be sure t hat cir-
cuit breaker t ermi nal s still contact t ermi nal s i n fuse
block. Connect ground wire of voltmeter to a good
ground. Wi t h probe of voltmeter positive wire, check
both t ermi nal s of circuit breaker for bat t ery voltage.
If only one t ermi nal checks at bat t ery voltage, circuit
breaker is defective and must be replaced. If nei t her
t ermi nal shows bat t ery voltage, check for open or
shorted circuit to circuit breaker.
SWITCH TEST
For switch testing, remove t he switch from its
mount i ng location. Using an ohmmeter, refer to Figs.
1 and 2 to determine if continuity is correct in t he
UP and DOWN switch positions. If continuity is cor-
rect perform window lift motor test.
WINDOW MOTOR TEST
(1) Connect positive lead (from a test battery) to
either of t he two motor t ermi nal s.
(2) Connect negative lead (from t est battery) to re-
mai ni ng motor t ermi nal .
(3) The motor should now rot at e in one direction to
either move window up or down.
(a) If window happens to already be in full UP
position and motor is connected to rot at e in UP di-
rection, no movement will be observed.
8S - 2 POWER WINDOWS

P OW E R W I N D O W S Y S f E M D I A G N O S I S
SY STE M OPE RATE S
BUT GL A S S
TRAVEL IS COCKED
OR INCOMPLETE
I
MANUALLY
C H E C K TRAV E L
OF GL A S S
I
GLASS TRAVEL
OKAY
REMOVE MOTOR
FROM REGULATOR
ASSEMBLY
REPLACE
ARM & SECTOR
PORTION OF
REGULATOR
I
REASSEMBLE
REGULATOR
REINSTALL
REGULATOR
INTO DOOR
IF PROBLEM
STILL EXISTS
CORRECT GLASS
GUI DANCE
PROBLEM
SYSTEM
DOES NOT
OPERATE
CHECK
SYSTEM
OPERATION
SYSTEM
OPERATES
CORRECTLY
CHECK FOR
12 VOLTS AT
MOTOR
TERMINAL
I
N O VOLTAGE
CHECK WI RI NG
AND/ OR SWITCHES
VOLTAGE OKAY
REMOVE
REGULATOR
FROM DOOR
GLASS MOVES
FREELY
CHECK FOR
BI NDI NG OF GLASS
GUI DANCE SYSTEM
* COUNTERBALANCE SPRI NG
MUST BE REMOVED BEFORE
REMOVI NG MOTOR FROM
REGULATOR. IF NOT,
INJURY MAY RESULT
BENCH TEST
REGULATOR
ASSEMBLY
REMOVE
MOTOR FROM
REGULATOR*
I
SYSTEM BI NDI NG
CORRECT
BI NDI NG
CONDI TI ON
REGULATOR
OPERATES
CORRECTLY
REGULATOR
DOES NOT
OPERATE
I
REINSTALL
REGULATOR
INTO DOOR
CHECK
ARM & SECTOR
ASSEMBLY FOR
FREE MOVEMENT,
MI S S I NG AND/ OR
DAMAGED
GEAR TEETH,
MI S S I NG OR DAMAGED
ROLLER,
OR BENT ARM
ANY OF THESE
CONDI TI ONS EXIST
REPLACE
ARM & SECTOR
ASSEMBLY
PI NI ON DOES NOT
ROTATE
REMOVE GEAR & PI NI ON
A N D EXAMINE FOR
MI S S I NG AND/ OR
DAMAGED GEAR TEETH
APPLY VOLTAGE TO
MOTOR AND CHECK
FOR PI NI ON
ROTATION
NONE OF THESE
CONDI TI ONS EXIST
PI NI ON ROTATES
CORRECTLY
REASSEMBLE
REGULATOR A N D
INSTALL INTO DOOR
MI S S I NG AND/ OR
DAMAGED GEAR TEETH
REPLACE
GEAR & PI NI ON
ASSEMBLY
GEAR & PI NI ON
ASSEMBLY
TEETH CHECK
OKAY
REASSEMBLE
REGULATOR
ASSEMBLY
ARMATURE SHAFT
DOES NOT ROTATE
REPLACE MOTOR
WITH
GEAR & PI NI ON
REMOVED
APPLY VOLTAGE TO
MOTOR TERMINAL
A N D CHECK FOR
ARMATURE
SHAFT ROTATION
I
ARMATURE SHAFT
ROTATES
CORRECTLY
J918S-7

POWER WINDOWS 8S - 3
FROM PIN SIDE OF SWITCH
MASTER WI NDOW LIFT SWITCH
SWITCH
POSI TI ON
CONTI NUI TY
BETWEEN
OFF
PI NS 1 & 2
PI NS 2 & 3
PI NS 2 &4
PI NS 2 & 6
DRIVER'S
M P
PI NS 3 & 5
PI NS 2 & 6
PASSENGER'S
PI NS 1 & 5
PI NS 2 &4
DRIVER'S
PI NS 5 & 6
PI NS 2 & 3
TOWN
PASSENGER'S
PI NS 1 & 2
PI NS 4 & 5
898S-11
Fig. 1 Master Window Lift Switch Continuity
(b) Likewise, motor connected to DOWN direc-
tion rotation, no movement will be observed if win-
dow is already in full down position.
PIN IDENTIFICATION S HO WN
FROM PI N SIDE OF SWITCH
SWITCH CONTINUITY
POSI TI ON BETWEEN
PI NS 1 & 4
OFF
PI NS 2 & 5
PI NS 3 & 4
UP
PI NS 2 & 5
PI NS 2 & 3
D O WN
PI NS 1 & 4
898S-12
Fig. 2 Passenger's Door Mounted Switch Continuity
(4) Reverse bat t ery leads (opposite to steps 1 and
2) and window should now move. If window does not
move, remove motor. Refer to Service Procedures for
motor removal from vehicle for bench test.
If window moved completely up or down, motor
should be reversed one more time (reverse leads from
step 4) to complete a full window travel inspection.
SERVICE PROCEDURES
GEAR AND PINION REPLACEMENT AND
LUBRICATION
If gear and pinion assembly are replaced in gear
box, lubrication of gear box, gear pinion and seal is
necessary.
In t he event t here is no lubricant in gear box, fill
with MOPAR, multi-mileage lubricant or equivalent.
Apply a liberal amount of lubricant to inside area of
seal and sealing surface at center area of gear and
pinion coupling. Also lubricate center housing shaft
and worm gear.
REGULATOR AND MOTOR ASSE MBLY
REMOVAL
To repai r or inspect t he entire electric window reg-
ulator, remove from door as follows:
(1) Remove remote control handle (Fig. 3).
(2) Remove power window/lock switch by inserting
end of switch housing. Push screwdriver to depress
locking t ab. Pull bezel out and forward to remove
from door panel.
(3) Remove screws at bottom front and rear of t ri m
panel.
(4) Remove screw behind remote handl e.
(5) Using a device such as a t ri m stick, pry t ri m
panel away from door around perimeter and remove
t ri m panel.
(6) Roll door watershield away from bottom of door
to reveal inside panel access opening.
(7) Remove speaker if equipped.
(8) Lower glass to full down position.
(9) Disconnect wi ri ng connectors from motor.
8S - 4 POWER WINDOWS

(10) Remove i nner weat herst ri p being careful not
to scratch t he belt-line paint.
(11) Free t he clip on t he i nner section of t he
weat herst ri p wi t h a wire hook or suitable tool.
(12) Pull back upper glass r un 8 to 20-25 cm (10
inches).
(13) Remove upper and lower vent wing at t achi ng
screws.
(14) Remove vent wing, being careful to avoid
pai nt damage from glass lower pivot adjusting
screws.
(15) Remove down stop bumper bracket (Fig. 4).
Fig. 4 Electric Window Regulator Mounting
(16) Disengage glass from regulator ar ms and
lower to door bottom.
(17) Remove regul at or mount i ng screws.
(18) Remove regul at or t hrough large access hole.
BENCH REPAIR
If entire regulator is not being replaced, repair as
follows:
(1) Remove regulator as previously described.
W ARN I N G: S TE PS (2) AN D (3) A RE V E RY I M POR-
TAN T. IF N OT D ON E BE F ORE M OTOR RE M OV AL
I N J URY M AY RE SUL T.
(2) Secure regulator in vise to prevent sector gear
from rotating.
(3) Remove counter balance spring. (Must be done
for safety before removing motor).
(4) Remove 3 motor at t achi ng screws and remove
motor (Fig. 5).
Fig. 5 Motor Attaching Screws
(5) Inspect regulator for:
(a) Sector gear t eet h must not be broken or se-
verely worn.
(b) All rivets and sliders must be securely at-
tached.
(c) Par t s must not be bent or cracked.
(d) Sector gear must rotate freely.
(e) Perform window lift motor test as described
above.
(6) Install motor and at t ach with t hree motor at-
t achi ng screws.
(7) Install counter balance spring.
INSTALLATION
(1) Insert upper regulator arm into door mounted
channel.
(2) Mount regulator to door panel with 1/4-20
screws torqued to 11 N*m (105 in. lbs.).
(3) Slide glass onto regulator arms and into rear
glass run.

POWER WINDOWS 88 -
(4) Connect motor electrical connector.
(5) Install plastic nut and "U" nut on vent wing
assembly.
(6) Install vent wi ng assembly into door.
(7) Install upper and lower vent wing at t achment
screws.
(8) Move glass r un back to vent wing by placing
run adjacent to door channel and press into channel
using wide blade screwdriver or similar tool. Press in
both inside corners to ensure hidden lip engages in
channel.
(9) Inst al l belt weat herst ri p by aligning clips to
holes in door and press in.
(10) Raise or lower vent to mai nt ai n a 1.6mm (.06
in.) fore-aft glass free-play t hen with glass up,
t i ght en upper screws.
(11) Hold vent against glass (glass down) and
t i ght en lower screws.
(12) Raise glass to full up position.
(13) Install speaker if equipped.
(14) Install down stop bumper.
(15) Install watershield and t ri m panel.
P O W E R M I R R O R S
C O N T E N T S
page
GENERAL INFORMATION
Electrically-operated remote control mi rrors are
available as an option on D-body vehicles. The mir-
rors are controlled by a single switch assembly lo-
cated on t he i nst rument panel to t he ri ght of t he
headlamp switch (Fig. 1).
D-body vehicles use a toggle-type switch. The
switch is rot at ed clockwise (Right mirror) or counter-
clockwise (Left mirror) for mirror selection. The
switch is moved UP, DOWN, RIGHT, or LEFT for
mirror movement direction.
The motors which operate t he mirrors are part of
t he mirror assembly and cannot be serviced sepa-
rately.
page
TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 1
Fig. 1 Power Mirror and Headlamp Switches
TEST PROCEDURES
MIRROR MOTOR TEST PROCEDURE
(1) Remove power mirror switch from mount i ng
position (refer to Service Procedures).
(2) Disconnect wiring harness at switch connector.
(3) Use 2 j umper wires. Connect one to a 12-volt
source, and t he other to a good body ground. Refer to
t he MIRROR TEST CHART for wire hookups at t he
switch connector (harness side, not switch side),
(4) If results shown in chart are not obtained,
check for broken or shorted circuit, or replace mi rror
assembly as necessary.
MIRROR TEST CHART
12 V ol t s G r ound
M I R R O R R E A C T I O N
12 V ol t s G r ound R i ght Left
Yl/BK 1 WT/BK UP
YL WT UP
WT/BK YL/BK D O WN
WT YL D O WN
WT/BK DB/WT RIGHT
WT DB
RIGHT
DB/WT WT/BK LEFT
DB WT LEFT
J908K-22
8T - 2 POWER MI RRORS

MIRROR SWITCH TEST PROCEDURE
(1) Remove power mirror switch from mount i ng
position (refer to Service Procedures).
(2) Disconnect wiring harness at switch connector.
(3) Test for continuity (no resistance) between t he
t ermi nal s of t he switch as shown in t he MIRROR
SWITCH CONTINUITY CHART.
(4) If results shown in t he chart are not obtained,
replace t he switch.
MIRROR SWITCH CONTINUITY CHART
M I R R O R S E L E C T O R K N O B I N " L " P O S I T I O N
M o v e Lever C ont i nui t y Bet ween
WT and BK
YL and PK and YL/BK and PK
WT and PK,
DB/WT and BK and DB & BK
YL/BK and BK, YL and BK
WT and PK
WT and BK, DB/WT and PK
DB and PK
M I R R O R S E L E C T O R K N O B I N " R " P O S I T I O N
M o v e Lever C ont i nui t y Bet ween
WT/BK and BK, YL and PK
YL/BK and PK

WT/BK and PK, DB and BK
DB/WT and BK
WT/BK and PK, YL and BK
YL/BK and BK

WT/BK and BK, DB and PK
DB/WT and PK
J928T-6
S E R V I C E P R O C E D U R E S
MIRROR SWITCH REMOVAL AND INSTALLATION
(2) Remove 2 screws holding map l amp and re-
move map lamp.
(3) Remove 6 screws which at t ach i nst rument clus-
t er bezel to i nst rument panel (Fig. 2). Make sure t he
screw below t he Heater/C control is removed.
INSTRUMENT
Fig. 2 Instrument Cluster Bezel
(4) Place column shift lever in Position 1.
(5) Remove bezel by pulling top edge rearward to
clear brow. Disengage at t achi ng clips around bottom
of bezel and complete removal of bezel.
(6) If t he bezel has a four wheel drive indicator, re-
move bulb socket as bezel is removed.
(7) Disconnect message center wires.
(8) Remove i nst rument cluster bezel assembly.
(9) Pull headl amp switch to ON position.
(10) Reach under i nst rument panel and depress
but t on on side of switch while pulling stem out.
(11) Remove switch bezel ret ai ni ng screws and pull
bezel out of i nst rument panel (Fig. 1).
(12) Pul l harness out t hrough opening in instru-
ment panel and disconnect mirror switch connector.
(13) Remove 2 switch mounting-plate-to-bezel re-
t ai ni ng screws.
(14) Remove switch-to-mounting-plate nut .
For Installation, reverse removal procedures.
MIRROR ASSEMBLY REMOVAL AND
INSTALLATION
(1) Remove remote control handl e (Fig. 3).
(2) Remove power window/lock switch by i nsert i ng
end of switch housing and push to depress locking
t ab. Pull out and forward to remove switch bezel
from door panel.

POWER MI RRORS 8T - 3
(3) Remove 2 screws at bottom front and rear of
t ri m panel.
(4) Remove screw behind remote handl e.
(5) Usi ng a device such as a t ri m stick, pry t ri m
panel away from door around perimeter.
(6) Roll door watershield away from lower r ear cor-
ner of door to reveal inside panel access opening.
(7) Reach inside door and disconnect mi rror wiring
at connector.
Spray grommet on mounti ng bracket cover
with si l i cone to avoi d grommet comi ng off when
cover is moved up on mirror stem.
(8) Remove mirror mount i ng bracket cover (1
screw) and slide up on mirror st em (Fig. 4).
Fig. 4 Power Mirror Replacement
(9) Remove 3 mirror mount i ng bracket nut s.
(10) Pull mirror loose from door, and feed wiring
harness out t hrough hole in outer door panel.
For Installation, reverse Removal procedure.
- CHIME/BUZ Z ER WARNING SYSTEMS 8U - 1
C H I M E / B U Z Z E R WA R N I N G S Y S T E M S
C O N T E N T S
page
DIAGNOSIS
GENERAL INFORMATION
page
1 KEY-IN SWITCH REPLACEMENT 3
1 OPERATION 1
GENERAL INFORMATION
The buzzer module is located to t he ri ght of t he
steering column (Fig. 1). The buzzer sounds an audi-
ble warni ng tone in any of t he following conditions:
Vehicle lights are ON when t he driver' s door is
opened.
The key is in t he ignition and t he driver' s door is
open.
The ignition is switched ON and t he driver' s seat
belt is not buckled. Buzzer will qui t after 4 to 8 sec-
onds. In addition to the buzzer, a seat belt light in-
dicator t ur ns on as a reminder to fasten seat belt.
BUZZER
MODULE
INTERMITTENT
WIPE MODULE
Fig, 1 Buzzer Module Location
OPERATION
Bat t ery voltage for module operation is supplied to
two pins. Battery voltage is present at pin 7 at all
times (Figs. 2 and 3). Pi n 1 receives voltage when
the ignition switch is t urned ON.
SEA T BELT WARNING
To sound t he seat belt warning, t he module needs:
bat t ery voltage at t he ignition switch input (Pin 1)
a ground at t he seat belt switch.
a ground at Pin 3 to activate t he timer.
This occurs when t he seat belt switch is closed be-
cause t he driver' s seat belt is not buckled. The "fas-
ten belt" light will also t ur n on along with t he
warni ng sound.
KEY IN IGNITION
To sound t he "key in ignition" al arm, t he module
needs:
t he ignition key warni ng switch must be closed
t he driver' s door j amb switch must be closed.
These conditions ground pin 6 of t he module. These
switches are closed when t he driver' s door is open
and t he key is in t he ignition.
LIGHTS ON
To sound t he "lights on" warning, t he module
needs:
t he headl amp switch must be closed
*> t he driver' s door j amb switch must be closed.
These conditions ground pin 6 of t he module. These
switches are closed when t he driver' s door is open
and t he headl amp switch is on.
DIAGNOSIS
If t he buzzer uni t does not operate as described,
check t he two fuses for pins 1 and 7 (Figs. 2, 3 and 4)
and replace as required. If t he fuses are not defec-
tive, perform t he following tests to determine if t he
problem is in t he module or in t he wiring. Using a
flat blade screwdriver, release the locking plastic clip
while carefully pulling out the module. Plug in a
known good module and check its operation. If t he
problem is not corrected by replacing t he module, re-
move t he module and continue as follows:
VOLTAGE TESTS
Ignition in run, measure bet ween the following
pins and vehi cl e ground.
Measure voltage at buzzer module connector pin 1.
Meter should read bat t ery voltage. If not, repair open
to ignition switch.
Turn ignition off and remove key from igni-
tion.
Measure voltage at buzzer module connector pin 7.
Meter should read bat t ery voltage. If not, repair open
to fuse. Bat t ery voltage is present at Pi n 7 at all
times regardless of key position.
8U - 2 CHIME/BUZ Z ER WARNING SYSTEMS

TERMI NAL 7
TO B +
TERMINAL 6
TO DOOR SWITCH
KEY I N SWITCH A N D
HEADLAMP O N
SWITCH
!cO=f Mi cK *h\
C Z 3 EZZ3 EZI 1
TERMI NAL 4
TO SEAT BELT
BUCKLE SWITCH
TERMI NAL 1
TO I GNI TI ON
SWITCH
TERMI NAL 3
TO G R O U N D
TERMI NAL 2
TO SEAT BELT
WA R N I N G LIGHT J928U-12
Fig. 2 Buzzer Module Connector Terminal
IdentificationFront View
LI GHTS- ON/ KEY- I N- I GNI TI ON
WAR NI NG
BATTERY ( + )
IS SI S K|
I GNI TI ON SEAT BELT
WA R N I N G LIGHT
G R O U N D
SEAT BELT
SWITCH
J928U-9
Fig. 3 Buzzer Module Terminal IdentificationFront
View
RESISTANCE TESTS
C A U T I O N : Before maki ng resi stance measurement s,
turn ignition swi tch O F F and di sconnect negative
cabl e from battery to avoi d damagi ng ohmmeter.
Measure bet ween the fol l owi ng pi ns and vehi-
cle ground.
Buzzer module connector pin 2. Meter should read
almost zero ohms (bulb filament). If not, replace seat
belt indicator bulb.
Buzzer module connector pin 3. Meter should read
zero ohms. If not, repai r open to ground.
Buzzer module connector pin 4. Drivers seat belt
not buckled. Meter should read zero ohms. If not, re-
pair open to ground (or buckle switch may be defec-
tive). Meter should read open circuit if drivers seat
belt is buckled. If not, repai r short to ground (or
buckle switch may be defective).
Buzzer module connector pin 6 . Open driver' s door,
key in ignition, (in OFF position). Meter should read
zero ohms. If not, repair open to ground.
Buzzer/chime module connector pin 6. Open driv-
er' s door, headl amp switch on, met er should read
zero ohms. If not, repair open to ground.
ri D O O R S W
7 (SHOWN DOOR CLOSED)
r F Y < ; w M UGHTS SW
( SH OWN KEW/ f(SHOWN^JGHTS OFF)
#5
-^^Y BELT(I)
SW LAMP JL
SEAT BELT S W
/. ( SH OWN
- BUCKLED)
I GN SW
(SHOWN I GN OFF)
PIN VIEW (SAME AS REAR SIDE [WIRE SIDE]
CONNECTOR VIEW)
X = Do Not Care
FUNCTION DESCRIPTION I GN.
SEAT
BELT
DRIVER'S
DOOR
KEY
HEAD
LAMPS
Seat
Belt
Reminder
4 to 8 Second
Tone and
Lamp Output
^ O n
O P
Not
Bckld
X X X
Seat
Belt
Reminder
4 to 8 Second
Lamp Output
Only
^ O n
Of P
Bckld X
X X
Key and
Head Lamp
Reminder*
Continuous,
Steady
Tone
X X Open
In X
Key and
Head Lamp
Reminder*
Continuous,
Steady
Tone
X X Open
X On
*On some vehicles, the key switch opens when the ignition is
switched on.
J928U-8
Fig. 4 Buzzer Module Schematic
o o o o
4 3 2 1
WI RE
CAVI TY APPLI CATI ON
CONTINUITY
BETWEEN
1
2
H d o lamp
Halo lamp
1 & 2 Almost zero ohms
(bulb filament)
3
4
Key-in warning switch
Key-in warning switch
3 & 4 with key in ignition
J918M-3
Fig. 5 Halo Lamp And Key-In Warning Switch
Continuity Chart

CHIME/BUZ Z ER WARNING SYSTE MS 8U - 3
KEY-IN SWITCH REPLACEMENT
REMOVAL
(2) Tilt column onlyremove tilt lever (counter-
clockwise).
(3) Carefully remove both upper and lower steer-
ing column covers. Requires removal of 3 screws
(torx T-20).
(4) Remove 3 ignition switch mounting screws
(tamper proof torx bit Snap On TTXR15A2 or equiv-
alent required) (Fig. 6).
STEERING
COLUMN
I GNI TI ON
SWITCH
908D-14
Fig. 6 Ignition Switch Screw Removal
(5) Gently pull switch away from column. Release
2 connector locks on 7 t ermi nal wiring connector,
t hen remove connector from ignition switch.
(6) Release connector lock on 4 t ermi nal Key In
and Halo light connector t hen remove connector from
ignition switch (Fig. 7).
KEY-IN SWI TCH &
HALO LIGHT
MULTI FUNCTI ON
SWI TCH
I GNI T I ON
SWI TCH
TURN S I GN A L
SWI TCH & LEVER
SPEED
CONTROL
J918J- 2
Fig. 7 Key In Switch And Halo Lamp Connector
(7) Remove key cylinder from ignition switch as
follows:
(a) Insert key in ignition switch and move switch
to Lock position.
(b) Use a small screw driver to depress key cyl-
inder ret ai ni ng pin flush with key cylinder surface
(Fig. 8).
I GNI TI ON SWITCH
MO U N T I N G
SCREWS (3)
STEERI NG
C OL UMN
I GNI TI ON
SWITCH
938 D-1
Fig. 8 Key Cylinder Pin
(c) Rotate key clockwise to Off position. The key
cylinder should now be unseat ed from ignition
switch assembly.
C A U T I O N : D o not try to remove key cylinder at thi s
time.
(d) The key cylinder is unseated and t he key cyl-
inder bezel should be about 1/8 inch above ignition
switch halo light ri ng (Fig. 9). Rotate key counter-
clockwise to Lock position and remove key.
KEY CYLINDER
BEZEL
HALO LIGHT
RI NG 908D-16
Fig. 9 Unseated Key Cylinder
8U - 4 CHIME/BUZZER WARNING SYSTE MS

(e) Remove key cylinder (Fig, 10).
Fig. 10 Key Cylinder Removal
INSTALLATION
(1) Install 2 wiring connectors to t he switch. Make
sure t hat switch locking t abs are fully seated in t he
wiring connectors.
(2) Mount ignition switch to column with 3 screws.
When equipped with column shift:
t he shifter must be in Par k position
t he park lock dowel pin on t he ignition switch as-
sembly must engage with column park lock slider
linkage (Figs. 11 and 12).
Verify ignition switch is in lock position (flag is
parallel with ignition switch terminals). Apply a
daub of grease to flag and pin. Position park lock
link and slider to mid-travel. Position ignition switch
against lock housing face, maki ng sure pin is in-
serted into park lock link contour slot. Torque retain-
ing screws to 2 N*m (17 in. lbs.).
(3) Assemble cover to t he column with 3 screws.
Torque screws to 2 N*m (17 in. lbs.).
(4) Tilt column onlyinstall tilt lever (clockwise).
(5) Install negative cable to bat t ery.
(6) Install key cylinder as follows:
908D-18
Fig. 11 Ignition SwitchView From Column
Fig. 12 Ignition Switch Mounting Pad
(a) Wi t h key cylinder and ignition in t he Lock
position, gently insert key cylinder into t he igni-
tion switch assembly until it bottoms.
(b) Insert key, while gently pushing on key cyl-
inder inward toward t he ignition switch, rotate key
clockwise to t he Run position.
(7) Check for proper operation of push-to-lock, halo
lighting, Accessory, Lock, Off, Run, Start, Column
Lock and Shift Lock (if applicable).

WIRING DIAGRAMS 8W - 1
CONTENTS
page page
COMPONENT IDENTIFICATION . . . . . . . . . . . . . 9 SPLICE LOCATIONS 29
GENERAL INFORMATION 1 WIRING DIAGRAMS AD-BODY 37
GENERAL INFORMATION
INDEX
page
Circuit Identification 2
Component Identification 3
Connectors 3
Fusible Links 3
H arness Repair 3
Locating A Syst em or Component 2
page
Secondary Ignition Wiring 1
Spl ice Locations 3
Symbol s and F uses 5
Troubleshooting Wiring Probl ems 3
Wire Code Identification 2
Wiring Diagram Sheet s and Index es 1
The wiring diagrams contain the latest information
available at time of publication. Throughout out this
group references may be made to a particular vehicle
by letter or number designation. A chart showing the
breakdown of these designations is included in the
Introduction Section of this service manual.
SECONDARY IGNITION WIRING
Secondary ignition wiring is shown in Figures 1
and 2. For information on ignition systems or distrib-
utor operation refer to Group 8D Ignition Systems.
SPARK PLUGS
RIGHT BANK
3.9L SIX-CYLINDER ENGINE
DISTRIBUTORCLOCKWISE ROTATION
FIRING ORDER 1-6 -5-4-3-2
RN755
Fig. 1 Secondary Ignition Wiring 3.9L Engine
WIRING DIAGRAM SHEETS AND INDEXES
The wiring diagram sheets are organized so that
systems relating to the basic vehicle and all of its op-
tions are shown. Add-on or non-factory options are
SPARK PLUGS
LEFT BANK
EIGHT CYLINDER DISTRIBUTOR-CLOCKWISE ROTATION
FOR 318 AND 360 CUBIC INCH ENGINES
FIRING ORDER-1-8^-3-63-7-2 RP899
Fig. 2 Secondary Ignition Wiring 5.2L and 5.9L
Engine
not covered. The diagram pages are identified by a
sheet number which is located at the lower right or
left hand corner of each sheet. Page numbers at the
top of each page do not appl y to di agram sheets.
Diagram sheets show all information relating to
the system. This includes feeds, grounds, switch in-
ternal circuity, connectors, splices, and pin identifica-
tion for controllers and modules.
In certain instances a wire may be referenced to
another sheet. When this happens, the wire will be
identified as to where it is going.
The index used for the diagrams is located at the
beginning of the diagrams. It covers all systems
shown in the diagrams and is in alphabetical order.
WIRING DIAGRAMS
8W - 2 WIRING DIAGRAMS

WIRE CODE IDENTIFICATION
Each wire shown in t he di agrams contains a code
(Fig. 3) which identifies the mai n circuit, part of t he
mai n circuit, gauge of wire, and color. The color is
shown as a two letter code which can be identified by
referring to t he Wire Color Code Chart (Fig. 4). If
t he wire has a tracer and it is a st andard color an
asterisk will follow t he mai n wire color. If t he tracer
is non-standard t he mai n wire color will have a slash
(/) after it followed by t he tracer color.
18 LB/YL*
COLOR OF WIRE
(Light Blue with Yellow Tracer)
. G A U G E OF WIRE
(18 Gauge)
PART OF AAAIN CIRCUIT
(Varies Depending on Equipment)
AAAIN CIRCUIT IDENTIFICATION
918W-16
Fig. 3 Wire Color Code Identification
CIRCUIT IDENTIFICATION
All circuits in t he di agrams use an alpha/numeric
code to identify the, wire and its function. To identify
which circuit code applies to a system, refer to t he
Circuit Identification Code Chart . This chart shows
t he mai n circuits only and does not show t he second-
ary codes t hat may apply to some models.
COLOR
CODE
C OL OR
S T A N D A R D
TRACER
COLOR
COLOR
CODE
COLOR
S T A N D A R D
TRACER
CODE
BL BLUE WT OR ORANGE BK
BK BLACK WT PK PINK BK OR WT
BR BROWN WT RD RED WT
DB DARK
BLUE
WT TN TAN WT
D G DARK
GREEN
WT VT VIOLET WT
GY GRAY BK WT WHITE BK
LB LIGHT
BLUE
BK YL YELLOW BK
LG LIGHT
GREEN
BK
*
WITH TRACER
918W-136
Fig. 4 Wire Color Code Chart
LOCATING A SYSTEM OR COMPONENT
To locate a system or component in t he diagrams,
refer to t he alphabetical index at t he front of t he di-
agrams. Determine t he di agram sheet number. Sheet
numbers are located at t he lower ri ght or left hand
corner of each sheet. Page numbers at the top of
t he pa ge do not appl y to di a gr a m sheets.
The diagram index identifies t he mai n system and
all components t hat rel at e to t hat system. There are
also sections of t he index t hat identify specific com-
ponents only (for example modules, lamps, etc.). Re-
M A I N C I R C U I T I D E N T I F I C A T I O N
C I R C U I T D E S C R I PT I O N C I R C U I T D E S C R I PT I O N
A Battery Feed: Fused and Unfused P Power Assist System: Locks, Mirrors
B A BS System Q Power Assist System: Windows
C Air Conditioning System
R Airbag System
D CCD (+), CCD (-) S Air Suspension, Automatic Load Leveling
E Interior Lamp Illumination T Electronic Automatic Transaxle
F Battery Feed: Fused and Unfused V Windshield Wipers and Washers,
G Sensors, Sending Units, Switches Vehicle Speed Control System
K Powertrain Central Module W Power Assist System: Windows
L Exterior Lighting, Stop Lamp Switch X Horn, Radio, Radio Speakers, Power Locks
M Interior Lamps Z Ground Circuits: Includes power and signal Interior Lamps
grounds for PCM
938W- 17

fer to a components name in t he index if you are
unclear as to what a system may be called.
Diagram pages are arranged st art i ng wi t h t he bat-
tery and fuses. Then working into charging, st art i ng,
and ignition systems. After t hi s t hey st ar t at t he
front of t he vehicle and work to r ear of t he vehicle.
The di agrams end with connector identification
pages.
COMPONENT IDENTIFICATION
To find a components actual location on the vehicle
refer to the wiring and components section index. This
section shows the wire harness routing and the compo-
nents location in the vehicle. When using this section
refer to the wiring diagrams for the general location of
the component. Then use the component identification
index to locate the proper figure number.
SPLICE LOCATIONS
Splices are indicated in t he wiring di agrams by a
diamond with splice circuit code wi t hi n it (Fig. 5 ex-
ample 1). If t here is more t han one splice per circuit
splice code a small box will be connected to t he dia-
mond wi t h t he splice number in it (Fig. 5 example 2).
To locate a splice in t he wire harness det ermi ne
t he splice number from t he wiring di agrams, t hen re-
fer to t he splice location index. This section shows
t he general location of t he splice in t he harness.
EXAMPLE 1 EXAMPLE 2
918W-18
Fig. 5 Wiring Splice Examples
CONNECTORS
The connectors shown in the diagram are viewed from
the terminal end unless otherwise specified. For view-
ing bulkhead and engine controller connectors refer to
the back of the wiring diagrams. This area shows major
connectors for pin and cavity identification.
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems t here are
six steps which can aid in t he procedure. The steps
are listed and explained below.
(1) Verify t he problem.
(2) Verify any related symptoms. Perform opera-
tional checks on components in t he same circuit as
t he problem area. Refer to t he wiring di agram fuse
application chart for circuit information.
(3) Analyze t he symptoms. Use t he wiring dia-
grams to determine what t he circuit is doing, where
t he problem most likely is occurring and where t he
diagnosis will continue.
(4) Isolate t he problem area.
(5) Repair t he problem.
(6) Verify proper operation. For t hi s step check for
proper operation of all i t ems on the circuit repaired.
Refer to t he wiring di agram fuse application chart.
FUSIBLE LINKS
Vehicle wi ri ng harnesses ar e equipped wi t h fusible
links. For protection agai nst harness damage in t he
event of a short. Fusible l i nks are color coded as to
wire gauge size. Refer to t he fusible link chart for
color and gauge identification (Fig. 6).
Wi r e and G a u g e Col or C ode Col or
12 G a. BK Black
14 G a . RD Red
16 G a . DB Dark Blue
18 G a . G Y Gray
20 G a. OR Orange
22 G a . WT White
918W-19
Fig. 6 Fusible Link Chart
H ARNESS REPAIR
FUSIBLE LINK REPLACEMENT
C A U T I O N : D o not replace bl own fusi bl e l i nks with a
st andard wire. Onl y use f usi bl e type wire with hyp-
al on i nsul ati on or damage to the electrical syst em
coul d occur. A l s o make sure correct ga uge of wir-
i ng i s used. Refer to the wiring di agr ams for proper
gauge and col or.
When a fusible link blows it is i mport ant to find
out what t he problem is. They are placed in t he elec-
trical system for protection agai nst shorts to ground
t hat can be caused by a component or various wiring
failures. Do not just repl ace the fusible link to
correct the problem.
When diagnosing a faulty fusible link it is impor-
t ant to check t he wire carefully. In some instances
t he link may be blown and it will not show through
t he insulation, t he wire should be checked over its
entire length for i nt ernal breaks.
(2) Cut out t he blown portion of t he fusible link.
(3) Strip 1 inch of insulation from each end of t he
existing fusible link.
(4) Place a piece of heat shri nk t ubi ng over one
side of t he fusible link. Make sure t he t ubi ng will be
long enough to cover and seal t he entire repai r area.
(5) Cut a replacement piece of fusible link approx-
imately two inches longer t han t he piece removed.
(6) Remove one inch of insulation from each end of
t he replacement fusible link.
(7) Spread t he st rands of wire apart on each of t he
exposed wires (Fig. 7 example 1).
(8) Push t he two ends of t he wire together unt i l
t he st rands of wire are close to t he insulation (Fig. 7
example 2).
(9) Twist t he wires together (Fig. 7 example 3).
(10) Solder t he wires together using rosin core type
solder only. Do not us e aci d cor e t ype sol der .
(11) Center t he heat shri nk t ubi ng over t he joint
and heat using a heat gun. Heat t he joint unt i l t he
t ubi ng is t i ght l y sealed and sealant comes out of both
ends of t he tubing.
(12) Secure t he fusible link to t he existing ones to
prevent chafing or damage to t he insulation.
(13) Connect bat t ery and test all affected systems.
Fig. 7 Wire Repair
918W-20
WIRING REPAIR
When replacing or repai ri ng a wire, it is i mport ant
t hat t he correct gauge be used as shown in t he wir-
ing di agrams. The wires must also be held securely
in place to prevent damage to t he insulation.
(2) Remove 1 inch of insulation from each end the
wire.
side of t he wire. Make sure t he t ubi ng will be long
enough to cover and seal t he entire repai r area.
(4) Spread t he st rands of t he wire apart on each
part of t he exposed wires (Fig. 7 example 1).
(5) Push t he two ends of wire together unt i l t he
st rands of wire are close to t he insulation (Fig. 7 ex-
ample 2).
(6) Twist t he wires together (Fig. 7 example 3).
(7) Solder t he connection together using rosin core
type solder only. Do not us e aci d cor e sol der .
and heat using a heat gun. Heat t he joint until t he
t ubi ng is tightly sealed and seal ant comes out of both
(9) Secure t he wire to t he existing ones to prevent
chafing or damage to t he insulation.
CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect t he connector t hat is to be repaired
from its mat i ng half.
(3) Remove connector locking wedge (Fig. 8).
C ON N E C T OR
CONNECTOR L OC K I N G
W E D G E TAB
9 2 8 W - 1 4 3
Fig. 8 Connector Locking Wedge Tab
(4) Position t he connector locking finger away from
t he t ermi nal . Pull on t he wire to remove t he termi-
nal from t he connector (Fig. 9).
(5) Reset t he t ermi nal locking t ang, if it has one.
(6) Insert t he removed wire in t he same cavity on
t he repair connector.
(7) Repeat steps four t hr u six for each wire in t he
connector. Check t hat all wires are inserted into t he
proper cavities. For connector pin out identification
refer to t he wiring diagrams.
(8) Insert t he connector locking wedge into t he re-
paired connector.
(9) Connect connector to its mat i ng half.
CONNECTOR AND TERMINAL ASSEMBLY
REPLACEMENT
(1) Disconnect Battery.
(2) Disconnect t he connector being repaired form
its mat i ng half.
(3) Cut off t he existing wire connector directly be-
hi nd t he insulator and remove six inches of t ape
from t he harness.
(4) Stagger cut all wires on t he harness side about
1/2 inch apart (Fig. 10).
(5) Remove 1 inch of insulation from each wire on
t he harness side.
WIRING DIAGRAMS SW - 5
CONNECTOR
LOCKI NG WEDGE
CONNE CTOR LOCK I NG
FINGER
If 928W-144
Fig. 9 Connector Locking Finger and Locking Wedge
(6) Stagger cut t he mat chi ng wires on t he repair
connector assembly in t he opposite order as was done
on the harness side of t he repair. Allow ext ra length
for soldered connections. Check t hat t he overall
length is the same as t he original (Fig. 10).
REPAIR SI DE STAGER CUTS
WI RES
HARNESS WI RES 928W-145
Fig. 10 Stagger Cutting Wires
(7) Remove 1 inch of insulation from each wire.
enough to cover and seal t he entire repair area.
(10) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 exam-
ple 2).
(11) Twist the wires together (Fig. 7 example 3).
(12) Solder t he connection together using rosin
core type solder only. Do not use aci d core solder.
(13) Center t he heat shri nk tubing over the joint
and heat using a heat gun. Heat t he joint until t he
tubing is tightly sealed and sealant comes out of both
(14) Repeat steps 8 t hr u 13 for each wire.
(15) Re-tape t he wire harness st art i ng 1-1/2 inches
behind t he connector and 2 inches past the repair.
(16) Reconnect t he repaired connector.
(17) Connect bat t ery and t est all affected systems.
TERMINAL REPLACEMENT
(1) Disconnect bat t ery.
(2) Disconnect t he connector being repaired form
its mat i ng half.
(3) Remove connector locking wedge (Fig. 8).
(4) Position t he connector locking finger away from
t he t ermi nal . Pul l on t he wire to remove t he termi-
nal from t he connector (Fig. 9).
(5) Cut t he wire 6 inches from t he back of t he con-
nector.
(6) Remove 1 inch of insulation from the wire on
t he harness side.
(7) Select a wire from the t ermi nal repair assem-
bly t hat best mat ches t he color wire being repaired.
(8) Cut t he repai r wire to t he proper length and re-
move 1 inch of insulation.
(9) Place a piece of heat shri nk t ubi ng over one of
enough to cover and seal t he entire repair area.
(11) Push t he two ends of wire together unt i l t he
st rands of wire are close to t he insulation (Fig. 7 ex-
ample 2).
(12) Twist the wires together (Fig. 7 example 3).
(13) Solder t he connection together using rosin
core type solder only. Do not use acid core solder.
and heat using a heat gun. Heat t he joint unt i l t he
t ubi ng is tightly sealed and sealant comes out of both
(15) Insert t he repaired wire into t he connector.
(16) Install the connector locking wedge and recon-
nect t he connector to its mat i ng half.
(17) Re-tape t he wire harness st art i ng 1-1/2 inches
behind the connector and 2 inches past t he repair.
SYMBOLS AND FUSES
Various symbols are used t hroughout wiring dia-
grams. These symbols can be identified by referring
to symbol identification chart (Fig. 11).
For fuse block and relay bank information refer to
(Fig. 12).
C A U T I O N : When repl aci ng a bl own f use, it i s impor-
tant to replace it with a f use havi ng the correct am-
perage rating. The use of a f use with a rating other
than indicated may result in a danger ous electrical
overl oad. If a proper rated f use cont i nues to bl ow, it
indicates a probl em that shoul d be corrected.

LEGEND OF SYMBOLS USED ON WIRING DIAGRAMS
+
POSITIVE CONNECTOR

NEGATIVE > MALE CONNECTOR
_L_
GROUND > FEMALE CONNECTOR
FUSE
S
DENOTES WIRE CONTINUES ELSEWHERE
GANG FUSES WITH BUSS BAR
DENOTES WIRE GOES TO ONE OF TWO
CIRCUITS
CIRCUIT BREAKER SPLICE
CAPACITOR
<3>
2
i
SPLICE IDENTIFICATION
A
OHMS c f t P
THERMAL ELEMENT
RESISTOR | TIMER | TIMER
VARIABLE RESISTOR
1 ^ ^ ^ |
'YY Y
1
MULTIPLE CONNECTOR
SERIES RESISTOR
o-l
WI RI NG WITH
OPTIONAL
WI RI NG WITHOUT
COIL
Y
"Y" WI NDI NGS
o
STEP UP COIL
BB-BB
DIGITAL READOUT
OPEN CONTACT - 0 - SINGLE FILAMENT LAMP
M
K
#
CLOSED CONTACT
-(5-
DUAL FILAMENT LAMP
CLOSED SWITCH LE.D. - LIGHT EMITTING DIODE
OPEN SWITCH
^
THERMISTOR
CLOSED GANGED SWITCH GAUGE
mi
OPEN GANGED SWITCH SENSOR
TWO POLE SINGLE THROW SWITCH FUEL INJECTOR
PRESSURE SWITCH
E
| #36 DENOTES WIRE GOES THROUGH
BULKHEAD DISCONNECT
3i
SOLENOID SWITCH
#
" S T R G
C O L U M N
DENOTES WIRE GOES THROUGH
STEERING COLUMN CONNECTOR
f r t
MERCURY SWITCH
| PANEL J
DENOTES WIRE GOES THROUGH
INSTRUMENT PANEL CONNECTOR
H-
DIODE OR RECTIFIER j E N G |
DENOTES WIRE GOES THROUGH GROMMET
TO ENGI NE COMPARTMENT
BY-DIRECTIONAL Z ENER DIODE DENOTES WIRE GOES THROUGH GROMMET
- o -
MOTOR HEATED GRID ELEMENTS
0
ARMATURE AND BRUSHES
908W-191
Fig. 11 Symbol identification
CAVITY
FUSE/
COLOR
ITEMS FUSED CAVITY
FUSE/
COLOR
ITEMS FUSED
10
11
12
13
2 A M P
G Y
VEHICLE SPEED CONTROL
5 A M P
TN
G A U G E S , BRAKE WA R N I N G LAMP, SEAT BELT WA R N I N G
LAMP, BUZ Z ER, LOW OIL LAMP, CHECK E NGI NE LAMP,
ANTI -LOCK LAMP, TAILGATE OPEN LAMP, 4WD LAMP,
O / D MODULE, LOW FUEL LAMP, WAIT TO START LAMP
WATER-IN-FUEL LAMP
14
3 A MP
VT
20 A M P
YL
BACK-UP LAMP, HEATED REAR WI N D O W
15
10 A M P
RD
ILLUMINATION LAMPS, A/C HEATER LAMP, ASH
RECEIVER LAMP, RADI O LAMP, TRANSMI SSI ON
OVERDRIVE SWITCH LAMP, TACHOMETER LAMP,
HEATED REAR WI N D O W SWITCH LAMP.
RADI O A N D CLOCK ME MOR Y, POWER MI RRORS, GLOVE
BOX LAMP, DOME LAMP, RE ADI NG LAMP, M A P LAMP,
C A R G O LAMP, I GNI TI ON SWITCH LAMP, UNDERHOOD
LAMP
20 A M P
YL
FUSE CAVITY #14, TAIL LAMPS, PAR KI NG LAMPS, SIDE
AAARKER LAMPS, LICENSE LAMPS, FRONT A N D REAR
CLEARANCE LAMPS, R ADI O INTENSITY, HORNS
20 A M P
YL
STOP LAMPS, KEY-I N & HEADLAMP O N BUZ Z ER, RWAL
MODULE
30 A M P
CIRCUIT
BREAKER
TURN
SI GNAL
FLASHER
20 A M P
YL
POWER DOOR LOCKS
15 A M P
BL
CI GAR LIGHTER
10 A M P
RD
RADI O A N D CLOCK
20 A M P
YL
TURN SI GNALS, TACHOMETER PROVI SI ON,
RWAL MODULE
20 A M P
YL
WI NDSHI ELD WIPERS
30 A M P
LG
A/C - HEATER BLOWER MOTOR
30 A M P
C/BRKR
POWER WI N D OWS
20 A M P
YL
HAZ AR D FLASHER
A MPS FUSE COLOR
2 G Y GR AY
3 VT VIOLET
5 TN TAN
10 RD RED
15 BL BLUE
20 YL YELLOW
30 LG LIGHT GREEN
HAZ ARD
FLASHER
J938W-94
Fig. 12 Fuse Block and Relay Bank
COMPONENT IDENTIFICATION
INDEX
Caption Fig.
A/C-Heater Wiring 15
Cab Wiring (Extended Cab) 8
Cab Wiring (Standard Cab) 7
Door Wiring (Body Side) 10
Door Wiring 9
Engine Compartment Wiring 3.9L, 5 .2L, and 5.9L Gas
Engines .17
Engine Compartment Wiring 5.9L Diesel Engine . 18
Engine Wiring 3.9L MPI Engine 23
Engine Wiring 5.2L and 5.9L MPI Engine 24
Engine Wiring 5.9L Diesel Engine 25
Four Wheel Drive Wiring .20
Frame Wiring 2
Instrument Panel Wiring (Right Side) 13
Caption Fig^
Instrument Panel Wiring 12
Interior Wiring (Sport Utility) 6
Liftgate Wiring (Sport Utility) . . . . . . 4
Rear Clearance Lamp Wiring 3
Roof Wiring (Sport Utility) 5
Starter Wiring 19
Steering Column Wiring . 11
Stop Lamp Switch Wiring . 14
Tail Lamp Wiring 1
Transmission Wiring (Diesel Engine) . .22
Transmission Wiring (Gas Engines) 21
Underhood Lamp Wiring . .16
B A C K - U P
LAMP J928W-169
Fig. 1 Tail Lamp Wiring
J908W-82
Fig. 2 Frame Wiring
J908W-84
G R O U N D
Fig. 4 L i f t g a t e Wiring (Sport Utility)
WIRING DI AGfi Al S 8W - 13
T O FRONT
D O M E LAMP
TO
VIEW
REAR DOME
LAMP
TO
ROOF
WI RI NG
SPEAKER
VI EWX
J 908W- 85
Fig. 5 Roof Wiring (Sport Utility)
TO
LIFTGATE
G R O U N D
TO DOME
LAMP
TO BODY
WI R I NG
TO REAR
SPEAKER
TO SEAT
BELT
WI RI NG
J928W-170
Fig. 6 Interior Wiring (Sport Utility)
Fig. 7 Cab Wiring (Standard Cab)
TO
M A I N
HARNESS
POWER
WI N D O W
M O T O R
SPEAKER
Fig. 9 Door Wiring
DOOR SWITCH
CONNECTORS
POWER
WI N D O W
MOTOR
CONNECTOR
2
CD
>
3
TO SPEAKER
VIEW IN DIRECTION
OF ARROW Z
TO POWER
MIRROR
TO DOOR
SWITCHES
TO
SPEAKER
VI EW I N DIRECTION OF ARROW
XWI T H POWER MIRRORS
J908W-88
T O D O O R
WI R I NG
T O
POWER
MI RRORS
T O
REAR
SPEAKERS
T O I NSTRUMENT PANEL
WI R I NG
T O
D O O R
WI R I NG
J908W-89
Fig. 10 Door Wiring (Body Side)
KEY
CYLINDER
HALO LAMP
CONNECTOR
I GNI TI ON
SWITCH
TO VEHICLE SPEED
CONTROL
SWI TCH
SEE VI EW Z
MULTI-FUNCTION
SWI TCH
CONNECTOR
TO
I NSTRUMENT
PANEL WI R I N G
WI R I NG
TROUGH
TO FOG LAMP
WI R I N G J938W-95
Fig. 11 Steering Column Wiring
CLUTCH PEDAL POSI TI ON
SWITCH
TO RADI O
TO M A P LP , T Q R , G H T
TO ME S S AGE CENTER \ \ DOOR WI R I NG
TO A/ C- HTR WR G
TO HTR SW L P'
(2-WAY C O N N )
1
TO PRINTED
CIRCUIT BOARD
TO REAR
SPEAKERS
TO BODY WI R I NG
LIFTGATE AJAR
LAMP
VI EW N
(CLUTCH PEDAL POSI TI ON SWITCH)
CLUTCH
PEDAL
TO R ADI O
TO CI GAR LIGHTER
TO CHASSI S
C O N N (R.W.A.L.;
TO LEFT DOOR
SWITCH
I NSTRUMENT
PANEL
INTERMITTENT
WIPER CONTROL
TO STOP LAMP & BRAKE SW
(DIESEL)
TO TRANSMI SSI ON
OVERDRIVE
SWITCH
TO ME S S AGE CENTER
4WD
INDICATOR
VI EW I N DI RECTI ON
OF ARROW S
VI EW P
(R.W.A.L. DATA LINK CONNECTOR)
VI EW I N DIRECTION
OF ARROW R
25
n
o
>
a
>
2
m
J938W-96
Fig. 12 instrument Panel Wiring
RIGHT DOOR SWITCH
HEATER/AC
BLOWER MOTOR
RESISTOR
I NSTRUMENT
PANEL HARNESS
GLOVE BOX
LAMP A N D SWITCH
*REAR WHEEL ANTI-LOCK
DATA LINK CONNECTOR
' T O REAR WHEEL ANTI -LOCK
BRAKE CONTROL MODULE
R.W.A.L.
CONTROL
VI EW I N DIRECTION
OF AR R OW Z
I NSTRUMENT PANEL RIGHT SIDE
Fig. 13 Instrument Panel Wiring (Right Side)
J938W-97
PARK
BRAKE
SWI TCH
STEERI NG
C O L U M N
SUPPORT
C O N N E C T O R
PARK
BRAKE
LEVER
STOP LAMP
SWI TCH
J908W-92
Fig. 14 Stop Lamp Switch Wiring

TRANSMI SSI ON
OVERDRIVE
MODULE
TRANSMISSION OVERDRIVE
SWITCH (GAS)
A / C -
HEATER
MODE SWITCH
TO TRANSMI SSI ON
OVERDRIVE
SWITCH (DIESEL)
J938W-98
Fig. 15 A/C-Heater Wiring
Fig.-16 Underhood Lamp Wiring
WI NDSHI ELD
WIPER MOTOR
TO RIGHT
HEADLAMP
PARK/ TURN
S I GNAL LAMP
TO FUSIBLE LINK
CIRCUITS
TO VEHICLE SPEED
CONTROL SEE VI EW Z
EEMC
RELAY
LEFT HEADLAMP
G R O U N D
ENGI NE
STARTER
A/C RELAY
COMPRESSOR
CLUTCH RELAY AUTOMATI C SHUT
D O WN RELAY
FUEL PUMP
RELAY
BULKHEAD
DI SCONNECT
A/C
LOW PRESSURE
SWITCH
SIDE MARKER
LAMP
TO UNDERHOOD
LAMP WI R I NG
VEHICLE
SPEED CONTROL
SERVO
POWERTRAIN
CONTROL
MODULE
A / C
CYCLI NG
SWITCH
TO BLOWER MTR &
WI NDSHI ELD
WASHER MTR
VI EW I N DIRECTION
OF ARROW Z
VI EW I N DIRECTION
OF ARROW W
a
o
>
o
30
>
2
m
J938W-99
Fig. 17 Engine Compartment Wiring 3.9L, 5.2L, and 5.9L Gas Engines
BLOWER
M O T O R
T O U N D E R H O O D L A M P AI R
HEATER
WI N D S HI E L D
WASHER M O T O R
T O WI N D S HI E L D
WI PER M O T O R
T O R I GHT
HE A D L A M P
PA R K / T U R N
S I G N A L
L A M P
BE Y O N D THI S PO I N T
SEE V I E W Z
DAT A LI NK
C O N N E C T O R
SI DE MAR KE R L A M P
A / C L O W
PRESSURE
S WI T C H
BU L K HE A D
D I S C O N N E C T
FUSIBLE
LI NKS
PO WE R T R A I N
C O N T R O L
M O D U L E
A I R HEATER
RELAYS
T O VEHI CLE
SPEED C O N T R O L
A / C C Y C L I N G
S WI T C H
V I E W I N DI R E C T I ON
O F A R R O W W
V I E W I N D I R E C T I ON
O F A R R O W Z
J 938W- 10 0
Fig. 18 Engine Compartment Wiring 5.9L Diesel Engine
J938W-101
Fig. 19 Starter Wiring
Fig. 20 Four Wheel Drive Wiring
CRANK SH AF T
POSITION SE NSOR
TO CRANK SH AF T POSITION
(SEE V I E W X)
VEHICLE
SPEED
SE NSOR
CONVERTER
CLUTCH
SOLE NOI D
TO VEHICLE SPEED
SENSOR BEYOND
THIS POINT
SEE MAIN VIEW
TO HEATED OXYGEN
SENSOR
(SEE VIEW X)
V I EW A
4 X 4 TRANSFER CASE
(TYPICAL)
VEHICLE
SPEED
SE NSOR
1
>
a
so
>
w
J938W-102
Fig. 21 Transmission Wiring (Gas Engines)
2
FUEL
INJECTOR #6
FUEL
INJECTOR #4
FUEL
INJECTOR #2
BEYOND THIS POI NT
SEE VI EW Z
EGR S OL E NOI D/
TRANSDUCER
ASSEMBLY
A / C COMPRESSOR
CLUTCH
GENERATOR G R O U N D
POWER STEERING
PUMP
AAAP
SENSOR
THROTTLE EVAP/
POSITION PURGE
(SENSOR) SOLENOI D
IDLE AI R
CONTROL
MOTOR
TO A / C
COMPRESSOR CLUTCH
DISTRIBUTOR
I GNI TI ON COIL
ENGI NE
COOLANT
TEMPERATURE
ENGI NE COOLANT SENSOR (PCM)
TEMPERATURE
SENSOR (GAUGE)
ENGI NE OIL
PRESSURE
S E NDI NG UNI T/
SWITCH
DISTRIBUTOR
C O N N E R
, N J E C T O R # 1
INJECTOR # 3
VI EW I N DIRECTION
OF ARROW 1
FUEL
INJECTOR #5
TO
' TRANS MI S S I ON
WI RI NG
J938W-85
INS
m
a
o
>
o
>
2
m
Fig. 23 Engine Wiring 3.9L MPI Engine
FUEL
INJECTOR #8
FUEL
INJECTOR #4
FUEL
INJECTOR #2
EGR
SOLENOID/
TRANSDUCER
DISTRIBUTOR
IGNITION
COIL
THROTTLE
BODY
CHARGE AIR
TEMPERATURE SENSOR
BEYOND THIS POINT
SEE VIEW, Z
TO A/ C
COMPRESSOR CLUTCH
^ DI STRI BUTOR
GENERATOR
GROUND
POWER
STEERING
PUMP
ENGINE OIL
PRESSURE SENDING
UNIT/SWITCH
VIEW IN DIRECTION
OF ARROW Y
TO TRANSMISSION
WIRING
THROTTLE
POSITION
(SENSOR)
IDLE AIR
CONTROL MOTOR
GENERATOR
ENGINE COOLANT
TEMPERATURE SENSOR
(PCM)
ENGINE
COOLANT
TEMPERATURE
SENSOR (GAUGE)
MAP
SENSOR
FUEL
INJECTOR #3
\
EVAP/PURGE
SOLENOID
FUEL
INJECTOR #7
FUEL
INJECTOR. #5
FUEL
INJECTOR #1
A/ C CLUTCH
VIEW IN DIRECTION
OF ARROW Z
J938W-86
Fig. 24 Engine Wiring 5.2L and 5.9L MPI Engine
o
>
30
>
2
w
oo
! \ 3
VIEW IN DIRECTION VIEW IN DIRECTION
OF ARROW Z ~ OF ARROW X J938W-104
Fig. 25 Engine Wiring 5.9L Diesel Engine
S P L I C E L O C A T I O N S
Splice Number Fig^
AO Diesel Engine 6
AO Gas Engine 5
A3 4
A4 4
A21 Diesel Engine 6
A21 Gas Engine 9
A21-1 Gas Engine 5
A21 - 2 Diesel Engine 6
A21 - 3 Diesel Engine 6
A14 2 Gas Engine 9
A14 2-1 Gas Engine 9
C4 8
C7 8
E2 4
F21 7
F35 7
G5 4
G7 5
G7-1 Diesel Engine 6
G7-1 Gas Engine 9
K4 Gas Engine 9
K4 -1 Gas Engine 9
K 6 Gas Engine 9
K7 Gas Engine 9
L1 3
L1 Sport Utility 3
L6 Club Cab 1
L7 Diesel Engine 6
L7-1 4
L7-2 3
L7-2 Sport Utility 3
L7-3 3
L7-4 3
L7-5 3
L50 4
M1 4
M1 - 1 Sport Utility 1
Splice Number Fit^
M2 4
M2- 1 Sport Utility 1
P33 1
P34 1
T4 1 Gas Engine 9
V 6 4
X 2 Diesel Engine 6
X 2 Gas Engine 5
X 2- 1 2
X 2- 4 3
X 2- 5 3
X 2- 6 3
X 2- 7 2
X 53 4
X 54 4
Z1-1 4
Z 1 - 2 4
Z 1 - 3 4
Z1-4 Diesel Engine 6
Z1-4 Gas Engine 5
Z 1 - 5 Diesel Engine 6
Z 1 - 5 Gas Engine 5
Z1-6 Diesel Engine 6
Z1-6 Gas Engine 5
Z1-7 3
Z1-7 Sport Utility 3
Z1-8 3
Z1-8 Sport Utility 3
Z 1 - 9 7
Z1-10 7
Z 1- 11 1
Z11 Diesel Engine 6
Z12 Gas Engine 9
Z 1 2- 1 Gas Engine 5
Z 12- 1 Diesel Engine 6
Z 1 2- 2 Diesel Engine 6
Fig. 2 Rear End Splices
Fig. 4 Instrument Panel Splices
Fig. 8 Heater-A/C Splices
Fig. 9 Engine Splices 3.9L, 5.2L, and 5.9L Engines
WI R I N G D I A G R A M S A D - B O D Y
INDEX
Wiring Diagram Name Sheet Number
A/ C Heater System with Diesel Engine . . . . . . . . . . . . .6 9, 70
Blower Motor . .6 9
Compressor .70
Cycling Switch .70
Diodes 70
Fuse 6 9
Low Pressure Switch 70
Resistor . 6 9
Switch-Blower . 6 9
Vacuum Control Switch .6 9
Wide Open Throttle Cut-Out Relay 70
A/ C Heater System with Gas Engine .6 7, 6 8
Blower Motor .6 7
Compressor .6 8
Cycling Switch 6 8
Low Pressure Switch .6 8
Diodes . .6 8
Fuse . .6 7
Resistor 6 7
Switch-Blower 6 7
Vacuum Control Switch .6 7
Wide Open Throttle Cutout Relay 6 8
Air Heater Relay Diesel Engine .21
Air Intake Heater Diesel Engine 22
Anti-Lock Rear Brake System with Diesel Engine . . . . . .33, 34
Brake Warning Lamp Switch 34
Data Link Connector 33
Duel Solenoid Hydraulic Valve 34
Electronic Vacuum Sensor .34
Fuse 33
Module .33
Park Brake Switch .33
Resistor 34
Rolls Test Connector 33
Sensor 34
Stop Lamp 34
Anti-Lock Rear Brake System with Gas Engine .31 , 32
Brake Warning Lamp Switch .32
Data Link Connector . .31
Dual Solenoid Hydraulic Valve 32
Fuse 31
Module 31
Park Brake Switch .31
Resistor 32
Sensor 32
Stop Lamp Switch 32
Back-Up Lamp Switch with Diesel Engine .7
Back-Up Lamp Switch with Gas Engine .9
Battery . 1 , 3, 5
Brake Warning Indicator Lamp (Diesel Engine) .57
Brake Warning Indicator Lamp (Gas Engine) 58
Brake Warning Indicator Lamp Switch (Diesel Engine) . . . .34
Brake Warning Indicator Lamp Switch (Gas Engine) 32
Bulkhead Disconnect 50-Way .8 5, 8 6
Buzzer-Combined Headlamp, Key In, and Seat Belt . . . .27 , 28
Bypass Jumper (Clutch Pedal Position) 8
Cargo Lamp .4 9, 50
Cargo Lamp Switch 4 9
Charging System with Diesel Engine . . . . . . . . . . . . . . .5, 6
Battery 5
Generator . .6
Charging System with Gas Engine .3, 4
Battery 3
Generator , . .4
Cigar Lighter, Ash & Glove Box Lamps 52
Circuit Breakers
Power Windows 2, 71
Clearance Lamps Duel Rear Wheels . .4 1 , 4 3
Clearance Lamps Roof Mounted 4 0
Clockspring 30, 36 , 38
Clutch Pedal Position Switch .8
Cold Start Advance Motor 24
Compressor, A/ C 6 8 , 7 0
Data Link Connector 1 7 , 23, 31 , 33
Data Link Connectors
Rear Wheel Anti-Lock Diesel Engine .33
Rear Wheel Anti-Lock Gas Engine 31
Daytime Running Light Module 4 6
Diesel Control System . 21 , 22, 23, 24 , 25, 26
Air Heater Relay . .21
Air Intake Heater 21
Automatic Shut Down Relay 22
Cold Start 24
Crankshaft Position Sensor . .25
Data Link Connector . .23
Engine Coolant Temp Switch .26
Fuel Heater 24
Fuel Solenoid 24
Intake Air Temp Sensor 25
Powertrain Control Module 21 , 22, 23, 25, 26
Resistor .24
Thermo Switch 24
Throttle Position (Sensor) 26
Transmission Thermo Switch . . .26
Vehicle Speed Sensor 25, 26
Water in Fuel Sensor .25
Dimmer Switch-Headlamp . .4 7
Diode 6 8, 70
Diode and Mold Assembly 51
Dome and Cargo Lamp 50
Door Jamb Switches 4 9
Left Switch .4 9
Right Switch 4 9
Dual Solenoid Hydraulic Valve .32
E MCC System (3-Speed) . .11

E MCC Relay 11
E MCC Solenoid 11
Ground 11
E MCC Relay with Gas Engine 11, 16
E MCC Solenoid with Gas Engine 1 1 , 1 2
Engine Oil Pressure Sending Unit .27, 28
Engine Starter Motor 7, 9
Engine Starter Relay .7, 9
Engine Starter System 1, 7, 8, 9
Back-Up Lamp Switch .7, 9
Bypass Jumper (Clutch Pedal Position) 8
Clutch Pedal Position Switch 8
Fuse . 7, 9
Motor 7, 9
Park/Neutral Position Switch . .7, 9
Relay 7, 9
Engine Temp Sending Unit . .27, 28
Flasher-Hazard Warning .56
Flasher-Turn Signal 56
Four Wheel Drive Indicator Lamp 13
Front End Lighting . . .4 3, 4 4
Front End Lighting (Canada) 4 5, 4 6
Fuel Gauge 8 1 , 8 2
Fuel Tank Gauge Level Sending Unit Diesel Engine 77
Fuel Tank Gauge Level Sending Unit with Gas Engine 78
Fuel Heater Diesel Engine 24
Fuel Solenoid Diesel Engine .24
Fuse Application Chart 1,2
Fuse Block Module and Relay Bank 82
Fuses
Fuse 1 2, 36
Fuse 2 . . . . . . . . . 2, 1 0, 1 2, 1 3, 1 4 , 58 , 7 7 , 7 8
Fuse 3 2, 7 , 9, 1 0, 39
Fuse 4 1, 30, 4 7
Fuse 5 1, 77, 78
Fuse 6 . . . . . . .1 , 7 3
Fuse 7 1, 10, 52
Fuse 8 . 2, 1 0, 6 1 , 6 3
Fuse 9 . 2, 1 0, 31 , 33, 56
Fuse 10 . 2, 1 0, 54 , 55
Fuse 11 2, 1 0, 6 6 , 6 7 , 6 9
Fuse 12 2, 1 0, 7 1
Fuse 13 1,56
Fuse 14 1 , 4 7 , 52, 6 1 , 6 3
Fuse 15 1 , 4 9, 51 , 52, 6 1 , 6 3, 7 5
Fusible Links 1 , 2, 3, 4 , 5, 6 , 21
Gas Engine Wiring Connector 89
Gauge-Fuel .77, 78
Generator .4 , 6
Glove Box Lamp Switch 52
Hazard Warning System . .56
Headlamp Dimmer Switch 4 7
Headlamp Switch 1,4 7
Headlamp Switch Controlled Interior Lamps
Headlamps 4 3, 4 4 ,
Heated Rear Window (Sport Utility)
Heater Motor Resistor
Heater System
Horn System 30
Identification Lamps-Dual Rear Wheels 4 1 , 4 2
Identification Lamps-Roof Mounted . 4 0
Ignition Coil .16
Ignition Switch .2, 1 0
Ignition Switch System 10
Ignition System (Gas Engine) . . . . . . . . . .1 5, 1 6 , 1 7 , 1 8 , 1 9, 20
Automatic Shut Down Relay .16
Camshaft Position Sensor 20
Crankshaft Position Sensor .18
Data Link Connector * . . .17
Engine Coolant Temp Sensor 20
EV AP Purge Solenoid 16
Ex haust Gas Recirculation Solenoid 16
Fuel Pump Relay .16
Heated Ox ygen Sensor . . . 17
Idle Air Control Motor .19
Ignition Coil .15
Injectors .15
Intake Air Temp Sensor . .20
Map Sensor . .20
Powertrain Control Module .1 5, 1 6 , 1 7 , 1 8 , 1 9, 20
Throttle Position (Sensor) .18
Vehicle Speed Sensor .20
Ignition Time Delay Relay 4 9
Injectors .15
Intermittent Wiper System .53, 54
Control Unit .54
Intermittent Windshield Wiper Motor 54
Windshield Washer Pump Motor 53
Wiper Switch 53
Key-In Switch 4 9
Key-In Warning Buzzer 77, 78
Lamps
Air-Conditioning and Heater Switch Lamp 4 8
Ash Receiver .4 8, 52
Back-Up Lamps . . . . . . 7 9, 8 0, 8 1
Cargo Lamp . .4 9, 50
Clearance Lamps-Dual Rear Wheels .4 1 , 4 2
Clearance Lamps Roof Mounted .4 0
Cluster Illumination Lamps . .57 , 58 , 59
Dome Lamp 50, 51
Four Wheel Drive Indicator .13
Glove Box Lamp 52
Headlamp-Left 4 3, 4 5
Headlamp-Right 4 4 , 4 6
Headlamp Switch Controlled Interior Lamps . 4 8
Heater Switch Lamp .4 8
High Beam Indicator Lamp .59
Identification Lamp . .4 0, 4 1
Ignition Switch Lamp .4 9
Instrument Panel Illumination Lamps . .57 , 58 , 59
License Lamp . . . 80
. .4 8 Low Engine Oil Pressure Lamp 59
4 5, 4 6 Map Lamp 4 9
. .39 Parking Lamp-Left Front 4 3, 4 5
6 6 , 6 7 Parking Lamp-Right Front 4 4 , 4 6
. .6 6 Rear End Lighting System .7 9, 8 0, 8 1
Service Reminder Lamp .58
Side Marker Lamp Left Front 4 3, 4 5
Side Marker Lamp Right Front . .4 4 , 4 6
Stop Lamp-Left Rear 79,81
Stop Lamp-Right Rear 80, 81
Tachometer .4 8
Tail Lamp-Left Rear .79, 81
Tail Lamp-Right Rear 80, 81
Turn Signal Indicator Lamps .7 9, 8 0, 8 1
Turn Signal Lamp-Left Front 4 3, 4 5
Turn Signal Lamp-Right Front 4 4 , 4 6
Turn Signal Lamp-Left Rear .79, 81
Turn Signal Lamp-Right Rear 80, 81
Underhood Lamp 29
Left Printed Circuit Board .59
Left Printed Circuit Board Connector 6 0
Liftgate Ajar Switch 51
Map Lamp and Cargo Lamps .4 9
Message Center (Diesel Engine) 57
Message Center (Gas Engine) .58
Modules
Daytime Running Lamp . .4 6
Intermittent Wiper .54
Key -In 77,78
Seat Belt Warning 77, 78
Motors
Blower-A/C with Diesel Engine .6 9
Blower-A/C with Gas Engine 6 7
Blower-Heater .6 6
Engine Starter with Diesel Engine . .7
Engine Starter with Gas Engine 9
Heater Blower 6 6 , 6 7
Idle Air Control . . . . . . . . . . . . . . . . . . . . . . . .19
Intermittent Windshield Wiper 54
Power Door Lock-Left .73
Power Door Lock-Right 74
Power Mirror Left 75
Power Mirror Right .76
Power Window-Left 71
Power Window-Right .72
Windshield Washer Pump 53
Neutral/Park Position Switch with Diesel Engine 7
Neutral/Park Position Switch with Gas Engine 9
Oil Pressure Sending Unit with Diesel Engine 27
Oil Pressure Sending Unit with Gas Engine 28
Oil Pressure Switch with Diesel Engine 27
Oil Pressure & Temperature System (Diesel) 27
Oil Pressure & Temperature System (Gas) . 28
Oil Pressure Warning Lamp -59
Parking Brake Switch .31 , 33
Power Door Lock System . . 73, 74
Left Door Motor . .73
Left Door Switch . 73
Right Door Motor . -74
Right Door Switch 74
Power Mirrors 75, 76
Fuse 75
Left Motor 75
Right Motor 76
Switch 76
Powertrain Control Module . . . . . . . . . 1 1 , 1 2, 1 4 , 1 5, 1 6 , 1 7 , 1 8 ,
1 9, 20, 21 , 22, 23, 24 , 35, 37
Powertrain Control Module Connector .83, 84
Power Window System 7 1 , 7 2
Circuit Breaker 71
Left Door Switch 71
Left Motor 71
Right Door Switch 72
Right Motor 72
Printed Circuit Board Connectors 6 0
Radio-4 Speakers 6 1 , 6 2, 6 3, 6 4
Radio-2 Speakers 6 5
Rear Lighting System 79, 80
Rear Wheel Anti-Lock Brake System (Diesel) 33, 34
Data Link Connector 33
Electronic Vacuum Sensor 34
Fuse .33
Module 33
Park Brake Switch 33
Rolls Test Connector .33
Resistor .34
Sensor . .34
Stop Lamp Switch . .34
Rear Wheel Anti-Lock Brake System (Gas) . .31 , 32
Data Link Connector .31
Fuse 31
Module 31
Park Brake Switch 31
Resistor 32
Sensor 32
Stop Lamp Switch 32
Relays
Air Heater (Diesel Engine) .21
Automatic Shut Down with Diesel Engine 22
Automatic Shut Down with Gas Engine 16
E MCC Relay 11
Engine Starter Relay .7, 9
Fuel Pump 16
Horn 30
Ignition Lamp Time Delay 4 9
Wide Open Throttle Cut-Out Diesel Engine 70
Wide Open Throttle Cut-Out Gas Engine 6 8
Resistor 24 , 32, 34 , 36 , 38
Right Printed Circuit Board 59
Right Printed Circuit Board Connector 6 0
Rolls Test Connector .31 , 33
Seat Belt Warning System 77, 78
Sending Units
Fuel Gauge-Diesel Engine 77
Fuel Gauge-Gas Engine 78
Oil-Diesel Engine 27
Oil-Gas Engine 28
Temperature-Diesel Engine . . . . , 27
Temperature-Gas Engine . .28
Sensors
Camshaft Position . . .20
Crankshaft Position . . .1 8, 25
Engine Coolant Temperature 20
Electronic Vacuum-Diesel Engine . .34
Heated Ox ygen 17
Intake Air Temperature 25
Map 20
Rear Wheel Anti-Lock Brake 32, 34
Throttle Position with Diesel Engine 26
Vehicle Speed .20, 25
Water In Fuel-Diesel Engine 25
Solenoids
E MCC Solenoid 1 1 , 12
EV AP Purge with Gas Ignition .16
Ex haust Gas Recirculating Gas Engine .16
Fuel .24
Transmission Overdrive 1 2, 1 4
Speakers 6 2, 6 4
Splices
Splice AO 1 , 2, 4 , 6
Splice A3 30, 4 7
Splice A4 39
Splice A21 1 6 , 23
Splice A21 - 1 . .6 8
Splice A21-2 24
Splice A21 - 3 21
Splice A1 4 2 .15
Splice A142-1 15
Splice C4 .6 7, 6 9
Splice C7 .6 7, 6 9
Splice E2 . 4 8 , 52, 6 1 , 6 3, 6 5
Splice F21 . , 71
Splice F35 73
Splice G5 1 2, 1 3, 1 4 , 58 , 7 7 , 7 8
Splice G7 . . . . . . . . . . . .1 9, 25
Splice G7-1 . . .20
Splice K4 20, 26
Splice K4 -1 . . . . . . . . . ; . 18, 20
Splice K6 , 20
Splice K7 .20
Splice L1 .79
Splice L6 . .50
Splice L7 4 3, 4 5
Splice L7-1 4 0, 4 1 , 4 7 , 6 1 , 6 3, 6 5
Splice L7-2 .4 1 , 79
Splice L7- 3 .4 1
Splice L7-4 4 1
Splice L7- 5 .4 1
Splice L50 . . . . . . . . . . . . . . . . . . . 32, 34 , 36 , 38 , 56
Splice M1 4 9, 51 , 52, 6 1 , 6 3, 6 5, 7 5
Splice M1 - 1 51
Splice M2 . .4 9
Splice M2- 1 .51
Splice P33 . 74
Splice P34 . . . . .74
Splice T4 1 . . . . . . . . . . . . . . .9
Splice V6 . . .54 , 55
Splice X 2 . .30
Splice X 2- 1 . . . . .79, 81
Splice X 2- 4 4 1
Splice X 2- 5 .4 1
Splice X 2- 6 . . . . .4 1
Splice X 2- 7 80, 81
Splice X 53 .6 5
Splice X 54 . . . . . . . . . . . . 6 5
Splice Z1-1 .4 8
Splice Z1-2 4 8 , 52
Splice Z1-3 . . 4 8
Splice Z1-4 . . . .4 4 , 4 6
Splice Z1-5 . . . . . . . . . -4 3, 4 5
Splice Z 1 - 6 1 1 , 23
Splice Z1-7 . .4 1 , 79
Splice Z1-8 77, 78
Splice Z 1 - 9 . . . . . . . . . . . . . . .71 , 73, 75
Splice Z1-10 . 7 1 , 7 3
Splice Z1-11 .77, 78
Splice Z11 23
Splice Z12 ' 17
Splice Z12-1 1 7, 23
Steering Column Connector . 87, 88
Stereo Radio 6 1 , 6 3, 6 5
Stop Lamp Switch 32, 34
Stop/Turn System .56
Switches
A/ C Low Pressure with Gas Engine 6 7
A/ C Low Pressure with Diesel Engine 70
A/ C Heater Blower with Diesel Engine 6 9
A/ C Heater Blower with Gas Engine 6 7
A/ C Vacuum with Diesel Engine 6 9
A/ C Vacuum with Gas Engine 6 7
Automatic Transmission Neutral Start with Diesel Engine . .7
Automatic Transmission Neutral Start with Gas Engine . . .9
Back-Up Lamp .7, 9
Brake Warning Lamp Diesel Engine 34
Brake Warning Lamp Gas Engine . .32
Cargo Lamp 4 9
Clutch 8
Clutch Cycling . . . .6 8, 70
Dimmer-Headlamp 4 7
Dome Lamp-Front . .50
Dome Lamp-Rear 50
Door Jamb . 4 9
Engine Coolant Temp .26
Four Wheel Drive 13
Front Axle 13
Glove Box Lamp . .52
Hazard Warning .56
Headlamp 1,4 7
Heated Rear Window 39
Heater . . .6 6 , 6 7
Horn .30
Ignition 2, 10
WIRING DIAGRAMS SW - 4 1
Wiring Diagram Name _ Sheet Number
Illumination Lamps-Instrument Panel . . . . . . . . . . . .12, 14
Intermittent Wiper . . . . . . . . . . . . . . . . . . . . . . . . . .53
Key-In . . . . . . . .49
Liftgate Ajar . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Park Brake .31 , 33
Power Door Lock-Left . . . . . . . . . . . . . . . . . . . . . . . .73
Power Door Lock-Right .74
Power Mirrors .75, 76
Power Window-Left 71
Power Window-Right . .72
Seat Belt Warning with Diesel Engine 77
Seal Belt Warning with Gas Engine .78
Speed Control . . . . . . . . . . . , 32, 36 , 38
Standard Windshield Wiper . .55
Stop Lamp .32, 34 , 36 , 38
Transfer Case Switch . 13
Transmission Thermo . . . . . . . . . . . . . . . . . . . . . . . .24
Turn Signal .56
Windshield Washer Intermittent Wiper . .53
Windshield Washer-Standard .55
Windshield Wiper-Intermittent 53
Stereo Radio-4 Speakers .6 1 , 6 2, 6 3, 6 4
Fuse .6 1 , 6 3
Speaker-Left . . . . . . . . . . . . . . . . . . . . . 6 2, 6 4
Speaker-Right . .6 2, 6 4
Stereo Radio-Dual Speakers .6 5
Temperature Sending with Diesel Engine . .27
Temperature Sending Unit with Gas Engine . . . . . . . . . . .28
Trailer Tow Wiring 81
Transmission Overdrive Solenoid . . . . . . . . . . . . . . . .1 2, 1 4
Transmission Overdrive System 12, 14
Wiring Diagram Name ^ Sheet Number
2-Speed Wiper Motor 55
Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . .55
Switch 55
Turn Signal System . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Flasher 56
Fuse .56
Lamps-Front 4 3, 4 4 , 4 5, 4 6
Lamps-Rear . 79, 80, 81
Switch Control 56
Underhood Lamp 29
Valve Hydraulic, Dual Solenoid .32, 34
Vehicle Speed Control (Diesel) .37, 38
Clockspring 4 2
Connector .37
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Lamp Switch . . .38
Resistor .38
Servo .37
Vehicle Speed Control (Gas) .35, 36
Clockspring 36
Connector .35
Fuse . . . . . . . . . 36
Lamp Switch .36
Resistor .36
Servo . 35
Vehicle Speed Sensor .20, 25, 26
Wide Open Throttle Cutout Relay . .6 8, 70
Windshield Wiper-intermittent . . . . . . . . . . . . . .53, 54
Windshield Wiper-Standard 55
8W - 4 2 WIRING DIAGRAMS
- J _ E N G I N E
= GROUND
BODY
GROUND
BA T T E R Y
- A 15 22WT-
^ F U S I B L E L I N K
( 2 2 WT )
( L E F T FRONT WHE E L HOU S E )
F U S I B L E L I N K
( 18G Y )
A l l
6BK / G Y
F U S I B L E L I N K
{ 10 0 0 ) 5 0 / 12 0 AMP
A15
16PK
13#-ZI
L 9
18BK
WT
i
HAZ AR D
F L A S HE R
S H 5 6
I T-
F U S E #13
20 AMP
O
F U S E #4
| ft 20 AMP
F 33
18PK
RD
A3
12RD
WT
A3
12RD
WT
4-
C HA R G I N G
S YS T E M
S H 3 , 4, 5 . 6
F U S E # 6
20 AMP
F U S E # 5
J1| 20 AMP
F 33
18PK
RD
HORNS
S H 30
POWER DOOR L O C K S
S H 73
C I R C U I T
BR E A K E R
HE ADL AMP
V Wf S WI T C H
E I
18TN
S H 47
- L 2
HE A D L A MPS
D I MME R
S WI T C H
S H 47
F 32
18PK
DB
I
S T O P L A MPS
S H 79, 80
K E Y - I N I
HE ADL AMP ON
BU Z Z E R
S H 77. 78
R E AR WHEEL
A N T I - L O C K
S H 31. 33
F U S E #15
10 AMP
L7 18B K / Y L -
3
F U S E #14
D
3 A MP
E 2
2 0 0 R
X
C L U S T E R L A MPS
S H 5 9
R A D I O L A MPS
S H 61 . 63 . 65
A / C AND HE AT E R
CONTROL LAMP
S H 48
A S H R E C E I V E R LAMP
S H 48
TACHOME TE R LAMP
S H 48
T R A N S M I S S I O N O V E R D R I V E I N D I C A T O R LAMP
S H 12
HE AT E D R E AR WINDOW
S WI T C H LAMP
S H 39
PA R K I N G L A MPS
S H 43 . 44. 45 , 46
T A I L L A MPS
S H 79. 80
L I C E N S E LAMP
S H 80
FRONT S I D E MARKER
L A MPS
S H 43 . 44. 45 . 46
R A D I O D I S PL A Y I N T E N S I T Y
S H 61 . 63 . 65
C L E A R A N C E AND
I D E N T I F I C A T I O N L A M PS
S H 40 . 41
UNDERHOOD LAMP
S H 2 9
GLOV E BOX L AMP
S H 5 2
R A D I O E L E C T R O N I C S
S H 61 . 63 . 65
MAP LAMP
S H 49
I G N I T I O N
S WI T C H LAMP
S H 49
DOME LAMP
S H 5 0 . 5 1
CARGO L A MPS
S H 49. 5 0
POWER M I R R O R S
S H 75
A31 14BK / WT -
7 * 3
L I F U S E # 7
2 h - i 15 AMP
F 30
16RD
TN
1
C I G A R L I G H T E R
S H 5 2
AD 1
FUSE APPLICATION CHART J 938W- U
WIRING DIAGRAMS 8W - 4 3
F U S I BL E LI NK
(18GY)
12BK/RD
FUS I BL E LI NK
(20 0 R)
(LEFT FRONT
WHEELHOUSE)
HEATED
REAR WINDOW
SH 39
FUS I BL E LI NK
(20 0 R)
(LEFT FRONT
WHEELHOUSE)
I A2 2 12BK/0 R
I T
1 30 AMPS
J
C I R C UI T
,
h
BREAKER
P CAVI TY #12
-A22 12BK/ 0 R-
RUN ONLY
I GN I T I ON
SWITCH
SH 10
A31
14BK/WT
RUN AND ACC
F21
12TN
POWER WINDOW
SH 71
FUSE #11
30 AMP
CI
12DG
A / C AND HEATER
BLOWER MOTOR
SH 66. 67. 69
S FUSE #10
10
*ZJ
20 AMP
O
FUSE #8
310 AMP
-A41 14YL-
ENGI NE
STARTER
SYSTEM
SH 7. 8. 9
A21
14DB
FUSE #1
3 2 AMP
RUN AND START
V34
20WT/RD
A2 I
14DB
VEHI CLE
SPEED CONTROL
(GAS)
SH 36
VEHI CLE
SPEED CONTROL
( D I E S E L )
SH 38
FUSE # 3
20 AMP
F20
18WT
BACK-UP LAMP
SH 79. 80
HEATER REAR
WINDOW
SH 39
G5
20DB/WT
TO 4tART
D
FUSE # 2
3 5 AMP
LAMP
LOW
FUSE #9
120 AMP
V6
18DB
WI NDSHI ELD
WIPER
SYSTEM
SH 5 4. 5 5
RADI O AND CLOCK
SH 61. 63. 65
L5
18RD
i
TURN SI GNAL
FLASHER
SH 56
TACHOMETER
PR OV I S I ONS
SH 48
REAR WHEEL
ANTI - LOCK
MODULE
SH 31. 33
AUTOMATIC
SHUT DOWN
RELAY
SH 16.22
TRANSMI SSI ON
OVERDRI VE
SOLENOI DS
SH 12.14
FUEL PUMP RELAY
SH 16
GENERATOR
SH 4
VACUUM SENSOR
SH 34
AI R SWI TCHI NG
SOLENOI DS
SH 16
PMC
SH 16
AI R HEATER
CONTROLLER
SH 21
WOT RELAY
SH 68. 70
A / C
ELECTRONI C
CYCLI NG
SWITCH
SH 68. 70
3. R . L . MODULE
SH 46
EMCC RELAY
SH 11
FUEL HEATER
AND PUMP
SH 24
WAIT TO START
SH 57
FUEL LAMP
SH 57
GAUGES
SH 59
BRAKE LAMP
SH 5 7. 5 8
SEAT BELT LAMP
AND BUZ Z ER
SH 77 78
WATER I N FUEL LAMP
SH 57
4 WHEEL DRI V E
I NDI CATOR LAMP
SH 13
LOW ENGI NE OI L LAMP
SH 59
MALFUNCTION
I NDI CATOR LAMP
SH 59
ANTI - LOCK LAMP
SH 57 58
LI FTGATE OPEN LAMP
SH 58
TRANSMI SSI ON
CONTROL MODULE
SH 12.14
S E R V I C E REMINDER
I NDI CATOR LAMP
SH 58
J938W-11
FUSE APPLICATION CHART
AD 2
TO ENGI NE
STARTER
r
MOTOR r
( S E E SH 9)
- Al 6RD-
BLACK R E D ^
Ai 6BK
A2
10BK
BATTERY
(LEFT FRONT
OF E NGI NE )
BODY
GROUND
(LEFT YOKE
FRONT OF
BATTERY)
ENGI NE
GROUND
(LEFT FRONT
OF ENGI NE)
BLACK
(REAR OF
BATTERY)
F U S I BL E LI NK
(HYPALON WI RE)
TO HAZ ARD
FLASHER
( S E E SH 5 6)
(REAR OF BATTERY)
BLACK
TO FUSE #15
( S E E SH 49)
AND
TO
<8>
S PL I C E
[SPORT U T I L I T Y ONLY)
( S E E SH 39)
AO
6BK
I . O . D .
CONNECTOR
NATURAL
(FRONT LEFT
S I D E S HI E L D )
AO 6BK-
A4 18GY
TO ENGI NE
STARTER
K
MOTOR r
( S E E SH 9)
FUS I BL E LI NK
(HYPALON WI RE)
-AOA 12RD-
AD 3
CH ARGI NG SY STE M WI TH
GAS E N GI N E S
J938W-11

WIRING DIAGRAMS 8W - 4 S
Zl 6BK/WT
BLACK -
GROUND
(REAR OF E NGI NE )
TO
POWERTRAIN
CONTROL .
MODULE 1 1 (PCM I l ) r
CAVI TY 20
( S E E SH 19)
A l l
6BK
-K20 18DG
S PL I C E
( S E E SH 15)
A142 18DB
yr - BL A C K
_
90A ONLY-
35 / 75 . 40 / 90 AND 5 0 / 12 0 GENERATOR
(RI GHT S I D E FORWARD OF ENGI NE)
A l l
6BK
(RI GHT FENDER S I D E S HI E L D )
A l l
6BK
F U S I BL E LI NK
(HYPALON WI RE)
A l l
10DG A2 200R
. TO WIDE OPEN
C26 14BR 1 THROTTLE RELAY
( S E E SH 68)
50
A2 12PK/BK A2 12PK/BK
FUS I BL E LI NK
(HYPALON WI RE)
Al 200R
FUS I BL E LI NK
(HYPALON WI RE)
4 9
m
Al 12RD - Al 12RD-
TO I GN I T I ON
SWITCH
( S E E SH 10)
A14 22WT
k % A 1 C D n
>T0 FUEL PUMP RELAY
- A M 16RD 1 (
SEE SH 16
)
- ^T O <A 3> S PL I C E
( S E E SH 47)
AOA 12RD A3 18GY A3 12RD/WT A3 12RD/WT-
1
J938W-11
CH ARGI NG SY STE M WI TH
GAS E N GI N E S
AD 4
8W - 4 6 WIRING DIAGRAMS
( REAR OF BATTERY)
BLACK
AO 6 BK
BATTERY
( LE F T FRONT
OF E NGI NE )
ENGINE
GROUND
~ ( LE F T FRONT
BODY OF E NGI NE )
GROUND
( LE F T YOKE
FRONT OF
BATTERY)
Al
2 / 0 RD
Al 2 / 0 RD-
I A4 1 4 BK / RD -
TO F USE # 15
( SE E SH 4 9)
A3
14PK
Al
2 / 0 RD
TO HAZARD
r
F LASH ER y
( SE E SH 56 )
23
I . O. D .
CONNECTOR
NATURAL
(FRONT LE F T
SI D E SH I E LD )
A15 16 PK
- T4 0 14 BR
A15 1 6 PK -
T4 0 1 4 BR-
- A1 5 22WT
TO E NGI NE STARTER
MOTOR
( SE E SH 7 )
-BLACK
( REAR OF BATTERY)
TO E NGI NE STARTER
RELAY
( SE E SH 7 ) F USI BLE LI NK
(HYPALON WI RE )
AD 5
CHARGING SYSTEM WITH DIESEL
5.9L ENGINE
J938M-11
TO POWERTRAIN
CONTROL MODULE I I
(PCM I I )
( S E E SH 21)
K20
18DG
Z l 6BK/WT-
GROUND
(ON ENGI NE)
A l l
i ! B 6BK
K20 18DG
ffl A142 18DB-
(RI GHT S I D E
A M 2 OF I NTAKE)
16DG
OR
TO AUTOMATIC SHUT
DOWN RELAY
( S E E SH 22)
mm
flTTTTf
c
CTTTTT}
D
mm
t t t
"K >nrTTH >
J
t t t
5 0 / 120 GENERATOR
(RI GHT S I D E FORWARD OF ENGI NE)
BLACK
A l l
6BK
(RI GHT FENDER S I D E S HI E L D )
FUS I BL E LI NK
(HYPALON WI RE)
AOA 12RD
FUS I BL E LI NK
HYPALON WI RE)
A2 200R
C26 14BR
50
TO ENGI NE
? STARTER
< T O WIDE
1
f
J ^
l
c
h
J n \
-J OPEN THROTTLE ( S E E SH 7)
RELAY
( S E E SH 70 )
Al 20 0 R-
F U S I BL E L I N K -
(HYPALON WI RE)
A2 12PK/ BK-
- A l 1 2 R D
A2 12PK/BK
- A l 12RD
49
-A14 22WT-
A14 16RD
-A14 16RD-
A3 18GY- A3 12RD/WT A3 12RD/WT-
TO I GN I T I ON
SWITCH
( S E E SH 10)
TO AUTOMATIC
SHUT DOWN
RELAY
( S E E SH 22)
TO PCM I I
CAVI TY3
( S E E SH 22)
T 0 <( A3>S PL I C E
( S E E SH 47)
J938 W - 1 1
CH ARGI NG SY STE M WI TH D I E SE L
5 . 9 L E N GI N E AD 6
8W - 4 8 WIRING-DIAGRAMS
ENGINE
STARTER
RELAY
( LE F T SI D E
SH I E LD )
TO CHARGING
SYSTEM
(SEE SH 5 , 6 )
TO
\ v
A 9 1 u n Q
f I GNI TI ON

A 2 1 1 4 0 8
5 SWITCH
(SEE SH 10)
ENGI NE
STARTER MOTOR
(LEFT LOWER
REAR OF E NGI NE )
AD 7 5 . 3 L D I E S E L E N G I N E S T A R T E R S Y S T E M J 938 W - 1 1
TO I GNI TI ON
SWITCH
( SE E SH 10)
A4 1 1 6 Y L - S2 1 1 4 Y L/ BK
31
MANUAL
TRANSMI SSI ON
BLACK
J
18BK
C L U K H
18BK
PEDAL POSI TI ON
( SWI TCH )
(ON CLUTCH ROD)
BYPASS JUMPER
( TAPED TO WIRE H ARNE SS)
SWITCH CLOSE S WHEN
CLUTCH I S DE PRE SSE D
J938 W- 1 1
5 . 9 L D I E SE L E N GI N E STARTE R SY STE M
AD 8
E N GI N E
STARTE R
RE LAY
( LE F T SI D E
SH I E L D )
T4 0
1 4 BR
A4 1 1 6 Y L
TO CH ARGI N G
SY STE M
SE E SH 3 )
- T4 1 1 8 BR/ Y L
F 2 0 18WT
T4 1 1 8 BR/ Y L
L I 1 8 V T/ BK
PARK / N E UTRAL
POSI TI ON AND
BACK - UP SW I TCH
( ON TRAN SM I SSI ON )
\
\ MANUAL TRAN SM I SSI ON
\ BA C K - U P LAMP SW I TCH
\ ( ON TRAN SM I SSI ON )
\
\
T4 1
1 8 BR
YL
r ~ Z 1 1 8 B K -
- T4 1 1 8 BR/ Y L-
1 4
: |ENG|
TO
POW E RTRAI N
CONTROL
MODULE I I
( PCM I I )
( AUTO/ TRAN S)
CAV I TY 3 0
( SE E SH 1 9 )
T4 1
2 0 BR
YL
T4 1 1 8 BR/ Y L
! |
- jt '
__._-._j
1
- - [ b i -
MANUAL TRAN S ONLY
Z l 1 4 BK
H E N Gh
Z l
1 4 BK
TO A/ C
COMPRE SSOR
CLUTCH
( SE E SH 6 8 )
T0 < Z 1 > 4 1 S PL I C E
( SE E SH 4 4 . 4 6 )
L I 1 8 V T/ BK -
F USE #3
( 2 0 AMP)
F 2 0
18WT
TO
H E ATE D RE AR
WINDOW SW I TCH
( SE E SH 3 9 )
TO BACK - UP LAM PS
( SE E SH 7 9 )
TO
) _
A
2 i 1 4 D B( I GN I TI ON
R
SW I TCH
E N GI N E
STARTE R MOTOR
( LE F T LOWER
RE AR OF E N GI N E )
AD 9
( SE E SH 1 0 )
GAS E N GI N E S
STARTE R SY STE M
J 9 3 8 W - 1 1
TO CHARGING
SYSTEM
( SE E SH 4 , 6 )
T
Al
12RD
4 9
TO HEATED REAR
WINDOW SWITCH Y-
( SE E SH 39)
I GNI TI ON SWITCH
(ON STE E RI NG COLUMN)
F20 18WT-
F USE # 3
( 20 AMP)
A21 14 DB-( -
FUSE #2
( 5 AMP)
Al 12RD
TO
ENGINE ,
STARTER Y-
SYSTEM
( SE E SH 8 , 9 )
- A4 1 14 YL-
50
- A2 1 2PK / BK
GROUND
(THRU STE E RI NG
COLUMN
A2 ATTACHMENT)
12PK
BK
X
TO CHARGING
SYSTEM
( SE E SH 4 , 6 )
- F 20 18WT
TO BACK - UP
LAMP SWITCH
( SE E SH 7 , 9 )
> - G5 20DB/ W T- TO < G5 > SPLI CE
( SE E SH 5 8 )
14 DB TO < A21> 1
OR
SPLI CE
( SE E SH 6 8 )
GAS
T0< A21 ,
SPLI CE
( SE E SH 23)
D I E SE L
F USE #11
( 30 AMP)
TO
AI R CONDI TI ONI NG
AND HEATER F EED
( SE E SH 6 6 , 6 7 , 6 9 )
1 2BK / 0R
F USE #1 2
( 30 AMP
CI RCUI T
BRE AK E R)
CI 12DG-
F21 1 2 TN -
TO
< POWER
^ W I N D OW S
( SE E SH 7 1 )
Gi l 20WT/ BK
Gi l 20WT/ BK -
2 0 PK / BK -
A4 1 14 YL
A21 14 DB
Gi l 20WT/ BK
Gi l 20WT/ BK
A2 1 2PK / BK
A22 1 2BK / 0R
A3 ! 14 BK/ WT
Al 12RD
FUSE #7
( 1 5 AMP)
FUSE #8
( 1 0 AMP)
F30
16RD
TN
X 12
20RD
WT
F USE #9
( 20 AMP)
F USE #1 0
( 20 AMP)
18DB5
18DB-5
14 RD
TO MESSAGE
CENTER
( SE E SH 57)
D I E SE L ONLY
TO WIPER
SYSTE MS
( SE E SH 5 4 , 5 5 )
TO
BRAKE WARNING
LAMP SWITCH
( SE E SH 31 )
( GAS E NGI NE )
Gi l
20WT
BK
TO
MESSAGE
CENTER
( SE E SH 5 8 )
(GAS E NGI NE )
TO CIGAR LI GH TER
( SE E SH 52)
TO RADIO TO TURN SI GNAL
( SE E SH SYSTEM
6 1 . 6 3 . 6 5 ) ( SE E SH 56 )
TO R. W . A. L .
MODULE
( SE E SH 3 1 , 3 3 )
J938 W- 1 1
I GN I TI ON SW I TCH AD 10

Z l 16BK-
EMCC
RELAY
(LEFT SI DE
DASH PANEL)
RIGHT
HEADLAMP
GROUND
(CENTER DASH
PANEL)
-411 18BK-
Z l TO TRANSFER
18.BK CASE SWITCH
( S E E SH 13)
Z l 14BK
T0<Z124j SPLICE
(SEE SH 44.46)
EMCC
SOLENOID
(3 SPEED AUTO-TRANS)
(MOUNTED ON TRANSMISSION
LEFT SI DE)
T22
T22 HOB
14DB WT
WT
AD 1 1
EMCC SY STE M
3 - SPE E D AUTOMATI C TRAN SM I SSI ON
J938W-11
- A2 1 1 4 DB
TO I GNI T I ON
SWITCH TRANSMI SSI ON
( S E E SH 1 0 ) CONTROL
SWITCH
FUSE # 2
(5 AMP)
6 5
2 0 D B
E 2
2 0 0 R
i
TO
ILLUM
w
j
/ r
/
/
S PL I C E /
( S E E SH 48) /
6
( S E E SH 5 8 ) < G5
- 6 5 20DB/WT-
(RI GHT OF
STEERI NG
COLUMN ON
I / P)
T6 20 0 R/WT-
T61 2 0 BK/ 0 R"
T6 20 0 R/WT-
T61 2 0 BK / 0 R -
Z l 18BK-
L _
3 _
Z l 18BK-
-G5 20DB/WT
2 4
TO S PL I C E
( S E E SH 48)
T61
20BK
OR
E2 200R
1 8
- UNG} -
. , j
POWERTRAIN 10
CONTROL
MODULE I I 37
(PCM I I )
CONNECTOR
( S E E SH 84)
5 5
T6 20 0 R/WT-
T61 2 0 BK/ 0 R -
54 - K 5 4 2 0 0 R/ BK-
T0 < A2 1 > S PL I C E
T60 \S
200R ( S E E SH 16)
LG
44
T6
200R
WT
17
(ON TRAN SM I SSI ON )
EMCC SOLENOI D
K54 20 QR/BK
A21 14DB
-A21 14DB-
A21 14DB
-T60 20 0 R/LG
J
3 . 9 L T R A N S M I S S I O N
TR
O
A
V
N
EB
n
5
-
9 L E N G I N E S
o v e r d r i v e s y s t e m
( ON TSSSION) ( A U T O / T R A N S M I S S I O N )
J 9 3 8 W - H G A S M P I E N G I N E S
- T6 0 2 0 0 R/ L G
TRAN SM I SSI ON -
OV E RD RI V E
SOL E N OI D
A D 1 2

TO I GNI TI ON
f
SWITCH r
( SE E SH 10)
A21 H OB-
i t
\\
G5 2008/ WT
( SE E SH 58 )
FUSE # 2
( 5 AMP)
G5
20DB
WT
TRANSFER
CASE
SWITCH
( D I E SE L
E NGI NE )
205 TRANSFER
CASE
TRANSFER
CASE
SWITCH
(GAS E NGI NE )
205 TRANSFER
CASE
FRONT
AX LE
SWITCH
r
DO
3
TO
REAR WHEEL <
ANTI - LOCK MODULE^
( SE E SH 3 1 , 3 3 )
r
3
"31
3
BLACK
(REAR OF
E NGI NE '
X 4 20LG/ BR
- Z 1 2 1 8 BK / TN
BLACK
ON TRANSFER
CASE )
V~X4 20LG/ BR
Z l 18BK
BLACK
(ON TRANSFER
CASE )
X 4 20LG/ BR
- Z l 1SBK
24 1 TRANSFER
CASE
( LE F T SI D E
FRONT AX LE )
Gl
20DG
GY
Gl 20DG/ GY -
r X4 20LG/ BR -
D I E SE L
TO
SPLI CE
( SE E SH 24 )
X4
20LG
BR
BLACK
( LE F T SI D E
DASH PANEL)
FOUR WHEEL
DRI V E INDICATOR
LAMP
4 0
GAS ENGINE
TO
/ V E H I C L E SPE E D
> CONTROL SERVO
( SE E SH 35 )
Z l
18BK
1
TO < Z 1 ^ 6 l SPLI CE
( SE E SH 11)
(GAS ONLY)
AD 13
4 WHEEL D RI V E I NDI CATOR LAMP jsasu-n

- A21 14 DB ( f
TO I GNI TI ON
SWITCH
t
TRANSMI SSI ON
( SE E SH 10) CONTROL
SWITCH
F USE #2
( 5 AMP)
0 Q
V ' >S
( SE E SH 5 8 ) < G5
G5
20DB
WT
- G5 20DB/ WT-
( RI GH T OF
STE E RI NG
COLUMN ON
I / P)
T6 200R/ WT-
T6 1 2 0 BK / 0 R-
T6 200R/ WT-
T6 1 2 0 BK / 0 R-
3rJi
Z l 18BK -
Z l 1 8BK -
-G5 20DB/ WT
24
TO < Z 1 ^ 1 | SPLI CE
( SE E SH 4 8 )
T6 1
20BK
OR
c o
c o
c)_p
I i
POWERTRAIN
CONTROL 10
MODULE I I
q 7
(PCM I I )
J /
CONNECTOR
( SE E SH 8 3)
55
T6 200R/ WT-
T6 1 2 0 BK / 0 R-
44
T6
200R
WT
T6 0
200R
LG
TO < A21>21 SPLI CE
( SE E SH 24 )
J938 W - 1 1
- A21 1 4 DB-
DARK GRAY
REAR OF E NGI NE )
T6 0 2 00R/ LG
T R A N S M I S S I O N
OV E R D R I V E SYSTEM
D I E S E L E N G I N E S (PCM
TRAN SMI SSI ON -
OV E RDRI V E
SOLE NOI D
II)
AD 14

I G N I T I O N
C O I L
( ON E N G I N E )
16 15 14 13 38 5 8 17 18
I N J I N J I N J I N J I N J I N J I N J I N J
#1 Ml #3 #4 # 5 # 6 Ul #8
PO WE R T R A I N CONTROL MODULE I I ( PC M I I )
19
I G N I T I O N
C O I L
D R I V E R
5 7
AS D
B +
CONNECTOR ( S E E S H 84)
( L E F T F E N D E R S I D E S H I E L D )
AD 15
I GN I TI ON SY STE M
GAS MF I E N GI N E S
J 938W- 11

A21 H OB
A1 4 1 6 RD -
TO
S PL I C E
( SE E SH 6 8 )
A2 1 M OB
1 - \ E NG f-
- A1 4 2 1 6 0 G/ 0 R
A1 4 2 1 6 D G/ 0 R-
A1 4 2 1 6 D G/ 0 R
TL
TO H E ATE D
OX Y GE N SE N SORS
( SE E SH 1 7 )
A1 4 A1 4
1 6 RD 1 6 RD
K51
A1 4 2 2 0 0 B
1 6 DG
Y L
_ OR
AUTOMATI C
SH UT DOWN
RE LAY
( LE F T S I D E SH I E L D )
- K 5 1 2 0 D 8 / Y L "
K 5 1 2 0 D B/ Y L
K 5 1
2 0 D B
YL
F UE L PUMP
RE LAY
( LE F T S I D E
SH I E L D )
F T O F UE L PUMP
^ ( SE E SH 7 8 )
TO CH ARGI N G
SY STE M
( SE E SH 4 )
A H 1 6 RD -
[ENGT

A2 1
1 4 DB
A2 1 H OB
A2 1 H OB
A H
1 6 RD
K 5 1
2 0 D B
YL
TO DATA L I N K
S CONNE CTOR
( SE E SH 1 7 )
TO
TRAN SM I SSI ON
OV E RD RI V E
SOL E N OI D
( SE E SH 1 2 )
A2 1
H D B
K 5 2
2 0 PK
BK
E V AP
PURGE SOL E N OI D K 3 5
( LE F T RE AR 2 0 GY
OF E N GI N E ) YL
E GR SOL E N OI D
( RI GH T RE AR
OF E N GI N E )
3 5 1
9 5 2
35
BATTE RY ASD I GN I TI ON E V AP E GR
RE LAY F E E D PURGE
SOL E N OI D
SOL E N OI D
SOL E N OI D
POW E RTRAI N CONTROL MODULE I I ( PCM I I ) CONNE CTOR ( SE E SH 8 4 )
J 938H - 11
( LE F T F E N D E R S I D E S I E L D )
I G N I T I O N S YS TE M
GAS MFI E N G I N E S AD 16

18 WT -
18 GY
rff]TH-
M
2 0 B K / L B -
45 5 2 5
DATA S I G N A L DATA
L I N K GROUND L I N K
R E C E I V E T R A N S M I T
I
1 1 I 2
I
POWER
GROUND
2 3 41
HE A T E D
OXYGE N
S E N S O R
AD 17
GAS MFI E N G I N E S J 9 3 8W- U
K4
2 0 B K / L B j
K4 18BK / L B
TO V E H I C L E
S PE E D
S E N S O R
( S E E S H 2 0 )
TO E N G I N E
WI R I N G
S P L I C E < K 4>
( S E E S H 2 0 )
C R A N K S HA F T
P O S I T I O N
S E N S O R
R I G HT
REAR OF
E N G I N E )
TO
S P L I C E
[ S E E S H 2 0 )
K2 4
18GY
BK
T HR OT T L E
P O S I T I O N
( S E N S O R )
( ON T HR OT T L E
BO D Y)
T 0 < K 6
S P L I C E
( S E E S H 2 0 )
rtM-
- K B 2 0 V T / WT -
- K 4 1 8B K / L B -
TO
<8>
x
S P L I C E
( S E E S H 2 0 )
TO A / C AND
HE A T E R S YS T E M
( S E E S H 68)
K2 2
180 R
DB
- [ E N G h
2 5
[FNG]
C 2 0
18BR
C 13
2 0 DB
OR
24 22 27 34
R E F . TP(S) A / C W. O . T .
PI C K U P C Y C L I N G R E L A Y
S WI T C H
J938U- 11
GAS MFI E N G I N E S AD 18
I DLE AI R
CONTROL MOTOR
GRAY
nrrrrnrj
pnrn
(ON THROTTLE
BODY)
4 3 2 1
K59
18VT
BK
59
I AC
TO
S PL I C E
(SEE SH 9)
T
T41
18BR
YL
K40
18BR
WT
i
K60
18YL
BK
K39
18GY
RD
. 1 n
las
2 3 ^ 4
G3 2 0 BK / PK
1
TO PRI NTED
C I R C UI T BOARD
CONNECTOR
( S E E SH 60 )
G7
20WT
OR
TO DAYTIME
RUNNING LAMP
MODULE
(CANADA ONLY)
( S E E SH 46)
G7
20WT
OR
G7
<8>-\
2 0 WT / 0 R ~H>
G3
20BK
PK
38
13
G7
20WT
OR
43
TO
MESSAGE CENTER
S E R V I C E
REMINDER
I NDI CATOR
( S E E SH 5 8)
G24
22 GY
PK
42
G3
20BK
PK
- {ENGf-
TO
CHARGING
SYSTEM
( S E E SH 4)
T
K20
18DG
'T
G24
20GY
PK
33
;HENG}~
24
[ETTGI
G7 20WT/0R
G3
20BK
PK
G24
20GY
PK
30
PARK/
NEUTRAL
SWITCH
40 60 39 20 32
I AC I AC I AC GENERATOR MI L
F I E L D
POWERTRAIN CONTROL MODULE I I (PCM I I ]
56
S R I
CONNECTOR ( S E E SH 84)
(LEFT FENDER S I D E S HI E L D )
AD 19
I GN I TI ON SY STE M
GAS MF I E N GI N E
J 938W- 11

I N T A K E A I R
TEMPERATURE
SENSOR
2 1
CH ARGE
AI R
TE MP
2
E CT
4 4
CMP
7
8 V OLT
I N PUT
4
SE N SOR
RE TURN
6
5 V OLT
SUPPLY
4 7
V E H I CL E
SPE E D
SE N SOR
1
MAP
SE N SOR
POW E RTRAI N CONTROL MODULE I I ( PCM I I )
CONNE CTOR ( SE E SH 8 4 )
J 938H - 11
GAS MFI E N G I N E AD 20

f - A 8 12 BK dp) BATTERY (OTJ A5 1 2 B K f
j \ ^ PO S I T I V E J
TO W. O. T .
RELAY Y
( S E E SH 70 )
A8
6BK F U S I BL E LI NK
A21 160B
(LEFT
FENDER
S I D E
S HI E L D )
AI R
HEATER
RELAY
(LEFT
FENDER
S I D E
S HI E L D )
A7
6BK
"-no)
ten-
AI R
I NTAKE
HEATER
(ON I NTAKE
UNDER I NLET
PI PE )
TO ENGI NE
STARTER
RELAY
( S E E SH 7)
T
T41
20BR
YL
JL
1
S21
18YL
BK
A21 M D B
T0 <^2!)
" S PL I C E
( S E E SH 23)
TO CHARGING
SYSTEM
( S E E SH 6)
K20
18DG
30
PARK/NEUTRAL
PO S I T I O N (SWI TCH)
16
HEATER
#1 RELAY
20
GENERATOR
F I E L D
15
HEATER
#2 RELAY
I GN I T I ON
FEED
POWERTRAIN CONTROL MODULE I I (PCM I I ) CONNECTOR ( S E E SH 83)
AD 21 D I E SE L CONTROL SY STE M
J938W-11
TO CLUSTER
MALFUNCTION
INDICATOR LAMP
( SE E SH 6 0)
Al 4 2 A1 4 2
16DG 16DG
OR OR
TO TACHOMETER
PROV I SI ONS
( SE E SH 4 8 )
L . _ , . I
TO F USI BLE LI NK
( SE E SH 6 )
A21 14 DB
AUTOMATIC
SHUT DOWN
RELAY
( LE F T SI D E
SH I E LD )
A14
16RD
TO GENERATOR
( SE E SH 6 )
G3
20BK
PK
G21
20GY
LB
A1 4 2
16DG
OR
K 51 A1 4 2
20DB 16DG
YL OR
16
A14
16RD
G3
20BK
PK
G21
20GY
LB
51 57 3 32 4 3
A . S . D . A . S . D . BATTERY MI L TACH
RELAY BATTERY FEED
POWERTRAIN CONTROL MODULE I I (PCM I I ) CONNECTOR ( SE E SH 8 3)
J 938W- 11
D I E S E L CONTROL SYSTEM AD 22
TO D A Y T I M E
R U N N I N G L I G H T S
MODULE C A 2 1 140R
S E E S H 46)
l 4 U K
TO A / C
E L E C T R O N I C
C Y C L I N G ^ A 2 1 h o b
S WI T C H
( S E E S H 70 )
TO M E S S A G E
C E NT E R ( D I E S E L )
( S E E S H 5 7)
BL AC K
TO I G N I T I O N
A21 1 4 DB- 4 , S WI T C H
^ ( S E E S H 10 )
RED
BLOWER MOTOR f-
( S E E S H 6 6 . 6 9 T
TO < Z 1 ^ 4 l S P L I C E 5"
( S E E S H 44, 46)
Z l 14BK
Z l 14BK
R I G HT
HE ADL AMP
GROUND
( R I G HT S I D E
S H I E L D )
( R E A R OF E N G I N E )
A2 1 14DB
Z 12 14BK / T N
TO A / C
C OMPR E S S OR
71 1 4B K - C,
C L U T C H
v
Z l j ( S E E S H 70 )
<
T 0
Z l 1 8B K - A UNDERHOOD
LAMP
( S E E S H 2 9)
TO VACUUM
S E N S O R
( S E E S H 34)
A21 1408
TO L E F T
HE ADL AMP GROUND
( S E E S H 43, 45 )
G86
20 DG
WT
G85
2 0 T N
OR
11
TO D A Y T I M E
R U N N I N G L I G H T S
MODULE
( S E E S H 46)
Z l l
18BK
WT
20
E 5 K 31
2 0 DG 2 0 BK
WT PK
DATA L I N K
CONNECTOR
( R I G H T
RE AR OF
E N G I N E
C OMPAR T ME NT )
020
2 0 L G
5 6 5 4
WA I T - T O - WA T E R - I N -
S T A R T LAMP F U E L LAMP
PO WE R T R A I N CONT ROL MODULE I I ( PC M I I )
11
POWER
GROUND
12
POWER
GROUND
45 2 5 5
DATA L I N K DATA L I N K S I G N A L
R E C E I V E T R A N S M I T GROUND
CONNECTOR
( S E E S H 83)
J 938W- 11

A21 14 DB
A21 H O B
TO
TRANSMI SSI ON
4 OV ERDRI V E
>
SOLE NOI D
(SEE SH 14)
TO TRANSF ER
CASE SWITCH
( SEE SH 13)
Z12 1 8 BK / TN '
T41 1 8 BR/ Y Li
TO E NGI NE
STARTE R RELAY
(MANUAL TRANS ONLY)
A 2
i
( SEE SH 7) H OB
FUEL
HEATER
(ON TOP OF
FUEL WATER
SEPARATOR)
BLACK
I 1
THERMO
SWITCH
A21
14 DB
FUEL
SOLE NOI D
( LE F T FRONT
OF E NGI NE )
A21
18BL
EIZZll
COLD START
ADVANCE
( K . S. B MOTOR)
(ON PUMP)
(FRONT OF
E NGI NE )
J 938W- 11 D I E SE L CONTROL SY STE M AD 24

WATE R- 1 N- F UE L SENSOR
( I N FUEL F I LTE R)
V E H I CLE
SPEED SENSOR
(ON REAR
OF TRANSMI SSI ON
MANUAL TRANSMI SSI ON
AND 205
TRANSFER CASE
CRANKSHAFT POSI TI ON
SENSOR
FRONT
OF
E NGI NE )
INTAK E AI R
TEMPERATURE
SENSOR
I N INTAKE
LEFT SI D E )
TO LEFT
PRI NTE D CI RCUI T
BOARD CONNECTOR
[SE E SH 6 0)
TO DAYTIME
RUNNING LIGH T
MODULE
(CANADA ONLY)
( SE E SH 4 6 )
47 7 2 1 21
24
28
V E H I CLE 8 VOLT ECT WATER - 1 N - INTAKE
CKP THERMO
SPE E D SENSOR INPUT SENSOR FUEL AI R TEMP
PI CK - UP SWITCH
PI CK - UP SENSOR CONNECTOR
POWERTRAIN CONTROL MODULE I I (PCM I I )
( SE E SH 83)
J 938H - 11
E N GI N E COOLANT
TE MPE RATURE
SW I TCH
TRAN SM I SSI ON
TH E RMO SW I TCH
( L E F T
S I D E RE AR
OF E N GI N E
BLOCK )
- K 4 1 8 BK / L B
- K 4 1 8 BK / L B
- K 4 1 8 BK / L B
- K 4 2 0 BK / L B
K 2 2 0 TN / BK
- T2 5 2 0 L G/ RD
L
- h - - K 4 4 2 0 TN / Y L
K 4 2 0 BK / L B ^-fl f
G7 20WT / OR
A
\ B L A C K
/ ( LE F T RE AR OF E N GI N E )
O o oo O
O 9 9 9 O
V E H I CL E SPE E D
SE N SOR
( ON RE AR OF
TRAN SM I SSI ON )
AUTOMATI C TRAN S
2 W . D . ONLY
K 2 2
1 8 0R
DB
TO A/ C SY STE M
( SE E SH 7 0 )
K4
1 8 BK
LB
K 6
20V T
WT
C 1 3
2 0 D B
OR
C2 0
1 8 BR
2 2 4 6
T . P . ( S . ) SE N SOR 5 V OLT
RE TURN SUPPLY
POW E RTRAI N CONTROL MODULE I I ( PCM I I )
34 27
W . O. T. A/ C
RE LAY COMPRE SSOR
CLUTCH
CONNE CTOR ( SE E SH 8 3 )
( LE F T F E N D E R S I D E SH I E L D )
J 9 3 8 W - 1 1
D I E SE L CONTROL SY STE M AD 26
TO LEFT
PRI NTE D CI RCUI T
BOARD CONNECTOR
( SE E SH 6 0)
8 5 4 3 2
GRAY
17
G20 20V T/ Y L G20 20V T/ Y L
18
G6 20GY- - 6 6 20GY-
BLACK
19
G6 0 20GY / Y L G60 20GY / Y L
TO RIGHT
PRI NTE D CI RCUI T
BOARD CONNECTOR
( SE E SH 6 0)
BLACK
(REAR OF ENGINE
LEFT SI D E )
G60
20GY
YL
G60 2 0 GY / Y L-
ENGINE
OI L PRE SSURE
SE NDI NG UNIT
AND SWITCH
G20
20VT
YL
G6
20GY
G6 20GY-
( LE F T SI D E
OF BLOCK
CENTER)
G60 2 0 GY / Y L -
G6 20GY-
ENGINE
TEMPERATURE
SENDI NG UNIT
( LEF T REAR
OF CYLI NDE R
HEAD)
AD 2 7
OI L PRE SSURE AND TE MPE RATURE
SY STE M FOR D I E SE L E N GI N E jsaew-n
WIRING DIAGRAMS 8W - 6 S
BLACK
GRAY
TO RIGHT
PRI NTE D CI RCUI T
BOARD CONNECTOR
( SE E SH 6 0 '
19
G60
20GY
YL
G6
20GY
15 16
ENG y v ENG
G60
20GY
YL
G6
20GY
TO LEFT
PRI NTE D CI RCUI T
BOARD CONNECTOR
( SE E SH 6 0)
17
G20
20VT
YL
26
ENG h
G20
ENGI NE
OI L PRE SSURE
SE NDI NG UNIT
AND SWITCH
(REAR OF
INTAK E MANIFOLD
CENTER)
ENGINE
TEMPERATURE
SE NDI NG UNIT
( RIGH T SI D E
FRONT OF
E NGI NE )
OI L PRE SSURE AND TE MPE RATURE SY STE M
FOR E LE CTRON I C
U9 3 8 W - H F UE L I NUE CTI ON I GN I TI ON
AD 2 8

33
(LEFT S I D E
OF STEERI NG
COLUMN
Ml 18BK/TN - Ml 18PK
BLACK
TO BOOY
WI RI NG
( S E E SH 5 0 )
(RI GHT S I D E
COWL PANEL)
BLACK
Z l 1BK
GAS
D I E S E L
Ml
18PK
TO <Z 1> 4| S PL I C E
( S E E SH 4 4 , 4 6 )
TO <M^> S PL I C E
( S E E SH 49)
T 0 <Z 1> 6| S PL I C E
( S E E SH 23)
Z l 18BK
Ml 18PK
UNDERHOOD LI GHT
(CENTER OF
HOOD INNER PANEL)
MERCURY
SWITCH
AD 29 UNDERHOOD LAMP
J938W-11
TO F USI BLE
LI NK
( SE E SH 4 , 6 )
: X2
SPLI CE
( SE E SH 4 7)
F USE #4
( 20 AMP)
F33
18PK
RD
F33
18PK
RD
HORN RELAY
[ON FUSE BLOCK )
( SE E SH 8 2)
TO HEADLAMP
SWITCH
( SE E SH 4 7 )
LOW NOTE)
HORN
( H I GH NOTE)
HORN
( LE F T SI D E
OF RADIATOR
SUPPORT)
( GAS)
( LE F T SI D E
SH I E LD ( D I E SE L)
BLACK
X2 1 8DG/ RD
( RI GH T SI D E
OF RADIATOR
SUPPORT)
( GAS)
( LE F T SI D E
SH I E LD
( D I E SE L)
BLACK
X2
18DG
RD
NOTE: HORNS ON D I E SE L
ARE ON LEFT SI D E
NEAR BATTERY
32
X2
18DG
RD
X3 2 0BK / RD
CLOCK SPRI NG
OR
HORN RI NG
( I N COLUMN)
( I N STE E RI NG COLUMN)
HORN
SWITCH
STE E RI NG COLUMN
GROUND
(THROUGH CENTER SH AF T)
J938 W - 1 1 HORN SY STE M
AD 30
TO
TURN SI GNAL
FLASHER
r
( S E E SH 5 6) Y L5 18R0
FEED 3
I S O SOLENOI D 1
DUMP SOLENOI D 8
RESET 11
4WD SWITCH 4
RWAL
SENSOR \
3
REAR WHEEL
ANTI - LOCK
CONTROL MODULE
(BEHI ND I / P
RI GHT S I D E )
BRAKE
SWITCH
BRAKE
I AMP
DATALI NK
GROUND ~~y
10 12 6
\
--
- L5 14RD
TO
~ - A 3 1 1 4B K / W Tj gj j } { J " J -
( S E E SH 10)
FUSE #9
(20 AMP)
G i l
20WT
BK
B10 1 16LG/ BK-
-yy
-B10 8 14WT/BR-
B i l l 1 8L B -
--
Gl 20 DG/GY
B113 18RD/VT
B114 8WT/VT
TO
<
4WD I NDI CATOR
") LAMP SWITCH
( S E E SH 13)
TWI STED PAI R
ROLLS TEST CONNECTOR *
( I N PLANT USE ONLY) \
pa
3 D
D
3 D
2J3
B114 18WT/VT
--
L50 18WT/TN -
F32 20 PK/ DB
G9 20 GY/BK -
B102 180R
^ A N T I - L O C K LAMP
I GN FEED
G i l 20WT/BK
B112 18BK/WT
12 18BK/LG
TO
I NTERMI TTENT
WIPER MODULE
( S E E SH 5 4)
GRAY
L50 18WT/TN
G i l 20WT/BK
G9 20 GY/BK
Gl 2QDG/GY
L5 14RD
B102 180R
B101 16LG/BK
- B113 18RD/VT
- B114 18WT/VT
-B112 18BK/WT
- B i l l 18LB
-12 18BK/LG
F32 20 PK/ DB
B10 8 14WT/BR
BLACK
2 3 ^ 4 5 6
TO
MESSAGE
CENTER
r Q
SEE SH 58 )
2
g
Y
DATA LI NK
CONNECTOR
(LOWER RI GHT
S I D E COWL)
G i l
20WT
BK
TO
I GN I T I ON
SWITCH
( S E E SH 10)
(ON PARK
BRAKE
LEVER)
PARK BRAKE
SWITCH
AD 31
RE AR WHEEL ANT I - LOCK BRAK E SY STE M
( GAS E N GI N E )
J938W-11
( RI GH T OF
STE E RI N G
BLACK
( LE F T RE AR
F RAME RAI L )
RE SE T SW I TCH
DUMP SOL
#-
/
YYTP i
I SO SOL
DUAL SOL E N OI D
H Y D RAUL I C V ALV E
BRAK E W ARNI NG
LAMP SW I TCH
; L E F T F RONT
F RAME RAI L )
TO H AZ ARD
L5 0 1 8 W T/ TN ( F L ASH E R SW I TCH
( SE E SH 5 6 )
R. W . A . L . SE N SOR
( I N RE AR D I F F E RE N TI AL )
TO
POW E RTRAI N
CONTROL
MODULE I I
CAV I TY 29
( SE E SH 3 5 )
O
STOP LAMP AND V E H I CL E
SPE E D CONTROL SW I TCH
W I TH SPE E D CONTROL
STOP LAMP SW I TCH
WI TH OUT V E H I CL E
SPE E D CONTROL
J 9 3 8 W - 1 1
RE AR WHEEL AN TI - LOCK BRAK E SY STE M
( GAS E N GI N E )
AD 32
SW - 74 WIRING DIAGRAMS
TO
TURN SI GNAL
FLASH ER
f
( SE E SH 56 ) y L5 18R0
F EED 3
I SO SOLE NOI D 1
DUMP SOLE NOI D 8
RE SE T 11
4WD SWITCH 4
.14
4 3
RWAL
SENSOR
<
REAR WHEEL
ANTI - LOCK
CONTROL MODULE
( BE H I ND I / P
RIGH T SI D E )
BRAKE
SWITCH
BRAKE
LAMP
DATALI NK
GROUND
10 12
7
5>
- L5 14 RD
A31 14 BK/WT
TO
J I GNI TI ON
> SWITCH
( SE E SH 10)
F USE #9
' 2 0 AMP)
8 1 01 1 6 LG/ BK
B1 08 14 WT/BR
Bi l l 18LB
Gl 20DG/ GY
B1 1 3 1 8 RD/ V T
TO
<
4WD I NDI CATOR
- } LAMP SWITCH
( SE E SH 13)
--
- B1 1 4 18WT/VT
TWISTED PAI R
ROLLS TEST CONNECTOR m
( I N PLANT USE ONLY) %
B1 1 4 18WT/VT
L50 18WT/ TN
F 32 2 0PK / DB
Gi l 2 0W T/ BK -
B1 02 180R
- A N TI LOCK LAMP
BRAKE LAMP
G9 2 0GY / BK -
Bl 1 2 18BK/WT
Z2 1 8 BK / LG
TO
I NTE RMI TTE NT
WIPER MODULE
( SE E SH 54 )
-GRAY
L50 18WT/ TN
Gi l 20WT/ BK
G9 20GY/ BK
Gl 20DG/ GY
L5 14 RD
B1 02 180R
B1 01 1 6 LG/ BK
to (g)S
- B1 1 3 1 8 RD/ V T
- B1 1 4 18WT/VT
- B1 1 2 18BK/ WT
Bi l l 18LB
- Z 2 1 8 BK / LG
F 32 2 0PK / DB
B1 08 14 WT/ BR
BLACK
DATA LI NK
CONNECTOR
(LOWER RIGH T
SI D E COWL)
TO
MESSAGE
CENTER
( D I E SE L)
( SE E SH 5 7 )
Gi l 20WT/ BK -
(ON PARK
BRAKE
LE V E R)
PARK BRAKE
SWITCH
AD 3 3
RE AR WHEEL ANT I --LOCK BRAK E SY STE M
( D I E SE L E N GI N E )
J 938 W - 1 1
Z 8 18GY
PA N E L GROUND
Z 0 9 18G Y / BK
B i l l 18L B -
_rrrRv_ (
R I G H T 0 F
~
LL1
U) | S T E E R I N G COLUMN)
( L E F T REAR
FRAME R A I L )
BL AC K
B10 8 14WT / BR -j=rf
B10 1 1 6 L G/ BK
- BL A C K 18BK-
G11 18WT / BK
R E S E T S WI T C H
DUMP
I S O SOL
BR A K E WAR NI NG
L AMP S WI T C H
( L E F T FRONT
FR AME R A I L )
DUAL S O L E N O I D
HY D R A U L I C V A L V E
GRAY
G i l
20WT
BK
BL U E
( L E F T S I D E - U N D E R I N S T R / P A N E L )

L 5 0 18WT / T N
F 32 2 0 PK / D B
TO
BU Z Z E R
( S E E S H 77)
GROUND
S P L I C E
( S E E S H 48)
B l 1 3 18R D / V T
B114 18WT / V T
TO
HAZ ARD
L 5 0 18WT / T N ? F L A S HE R
^ S WI T C H
( S E E S H 5 6)
( T A PE D TO HA R N E S S
NE AR C ON N E C T OR )
8113 B l 14
18RD 18RD
VT VT
F 32 18PK / D B
Z l 18BK
150 2 0 WT / T N
Z l 2 0 BK
V40 18WT / PK
TO
DATA L I N K
CONNECTOR
( S E E S H 2 3)
R E S I S T O R
41
2 0 PK
18WT
V 40
18WT
PK
i
TO PO WE R T R A I N
CONTROL MODULE I I
C A V I T Y 2 9
( S E E S H 37)
T WI S T E D
P A I R
BL A C K
STOP LAMP SW I TCH
( LE F T F E N D E R
S I D E SH I E L D )
R E A R W H E E L
ANT I - LOCK BRAK E SY STE M
U938w-ii ( D I E SE L E N GI N E )
R . W. A . L . S E N S O R
( I N R E AR D I F F E R E N T I A L )
AD 34

ON / OF F 49
SE T 48
RE SUME 5 0
BRAK E
SE N SE 29
VACUUM 3 3
POW E RTRAI N
CONTROL
MODULE I I
( PCM I I )
V E NT 5 3
CONNE CTOR
( SE E SH 84)
- - V 3 2 2 0 YL / RD -
~ V 3 1 2 0 BR/ RD -
- V 3 3 2 0 W T/ LG
2 8
[eng]
) >
- V 4 0 18WT/PK-
- V 3 6 2 0 TN / RD -
TO TRAN SF E R
CASE SW I TCH
( SE E SH 1 3 )
TO < Z ^ ] SPLI CE
( SE E SH 1 1 )
31
- { E N G} - :
V 3 5 2 0 L G/ RD
3 0
- { E N G} - :
Z l 2 0 BK
V 3 0
2 0 D B
RD
V 3 6
2 0TN
RD
V 3 5
2 0 LG
RD
D I RE CT-
7
CON N E CTI ON
12
[ENG]
29
HENGV-
V 3 2
2 0 Y L
RD
2 7
- [ E N G] -
V 3 1 2 0 BR/ RD
V 3 3 2 0 W T/ LG-
V 3 0 2 0 D B/ RD -
TO RE AR WH EEL
AN TI - L OCK
CONTROL MODULE
( SE E SH 3 1 )
TO SE AT BE LT
F
W ARNI NG SY STE M y
( SE E SH 7 8 )
F USE D BATTE RY
F E E D
- F 3 2 2 0 PK / D B
- F 3 2 1 8 PK / D B
V 4 0 1 8 W T/ PK
V E H I CL E SPE E D CONTROL SE RV O
( UNDE R BATTE RY TRAY )
AD 35
V E H I CLE
GAS E N GI N E S
SPE E D CONTROL SY STE M J938W-11
TO I G N I T I O N f
S WI T C H >
( S E E SH 10 )
S T OP LAMP AND V E H I C L E S PE E D
CONTROL S WI T C H WI T H
V E H I C L E S PE E D CONTROL
J 938W- 11
GAS E N GI N E S
V E H I CLE SPE E D CONTROL SY STE M
S WI T C H
( I N S T E E R I N G WHE E L )
AD 36

ON/OFF 49
SET 48
RESUME 50
BRAKE
SENSE 29
VACUUM 33
POWERTRAIN
CONTROL MODULE I I
(PCM I I )
VENT 53
CONNECTOR
( S E E SH 83)
- V32 2 0 YL / R D-
- V31 2 0 BR / R D-
- V33 20 WT/LG-
TO < Z Q5 l S PL I C E y
( S E E SH 43, 45 )
Z l 20BK
V40 18WT/PK-
V36 2 0 TN/ RD-
V35 20 LG/ RD
V31 2 0 BR / R D
V33 20 WT/LG-
V30 2 0 DB/ R D-
TO REAR WHEEL
ANTI - LOCK
CONTROL MODULE
( S E E SH 33)
TO SEAT BELT
f
WARNING S Y S T E M r
( S E E SH 77)
FUSED BATTERY
FEED
-F32 18PK/ DB
-F32 18PK/ DB-
V40 18WT/PK
DI RECT
CONNECTION
TO SERVO
VEHI CLE SPEED CONTROL SERVO
AD 37
5 . 9 L D I E SE L E N GI N E
V E H I CLE SPE E D CONTROL SY STE M J 938W- 11
TO I G N I T I O N f
S WI T C H y
( S E E S H 10 )
S T OP L AMP AND V E H I C L E S PE E D
CONTROL S WI T C H WI T H
J 938W- 11
5 . 9L D I E S E L E N GI N E
V E HI C L E S PE E D CONTROL SYSTEM
S WI T C H
( I N S T E E R I N G WHE E L )
AD 38

F USE * 3
[20 AMP
TO BACK - UP LAMP
SWITCH
SEE SH 9)
TO I GNI TI ON
SWITCH JA21 14 DB-< <
( SE E SH ior
A4
12BK
Z l
20BK
nnn
rvm 1 Jl T7< 1 j
CIS
1 2BK / 0R
F 20 E2
18WT 220R
SPLI CE
( SE E SH 48)
T0 < E 2 > SPLICE J -
( SE E SH 48)
( I LLUM LAMP F EED)
ON (jz
OFF OF
MECH ANICAL-
OF F / ON SWITCH
HEATED REAR
WINDOW DEFOGGER
SWITCH
( INSTRUMENT
PANEL)
L . E . D
TIMER
BLACK
CIS 1 2BK / WT-
E2
220R
Z l
20BK
F20
18WT
e-
A4 1 2BK / RD
CIS
12BK
WT
BLACK
( LE F T ' C' PI L L AR)
( LE F T SI D E
K I CK PANEL)
TO
F USI BLE
LI NK
( SE E SH 3)
A4
12BK
RD
48
A4
12BK
RD
TO FUSE BLOCK
F USE #1 5
( SE E SH 49)
, E LE CTRI CALLY H E ATE D RE AR WINDOW
AD 39 ( SPORT UTI L I TY ) vJ938w~n

TO
HEADLAMP
SWITCH
(SEE SH 47)
L7 18BK/ YL
S PL I C E
( S E E SH 47)
L7 18BK/YL
L7 18BK/YL
BLACK
Onj ) - L 7 18BK/YL
(LEFT S I D E OF
INSTRUMENT PANEL)
BLACK
cur
(AT LAMP)
L7 18BK
CLEARANCE
LAMP
L7
18BK
YL
L7
18BK
YL
L7
18BK
YL
L7
18BK
YL
BLACK
CDX
(AT LAMP)
-BLACK
an:
[AT LAMP)
-BLACK
an
(AT LAMP)
-BLACK
an
(AT LAMP)
L7 18BK-
L7 18BK-
I DE NT I FI C AT I ON
LAMP
I DE NT I FI C AT I ON
LAMP
L7 18BK-
I DE NT I F I C AT I ON
LAMP
L7 18BK-
CLEARANCE
LAMP
J938W-11
FRONT CLE ARANCE AND I D E N TI F I CATI ON
LAMPS ( ROOF )
AD 40
- L7 1 8 BK / Y L
- L7 1 8 BK / Y L
CLEARANCE
LAMP
I D E N TI F I CATI ON
LAMP
LAMP
LAMP
CLEARANCE
LAMP
X2 18GY-
X2 18GY-
L7 1 8 BK / Y L -
L7 1 8 BK / Y L
AD 41
CLEARANCE AND I D E N T I F I C A T I O N LAMPS
(DUAL REAR WHEELS)
J938 W - 1 1

J 9 3 8W- H
X2
1 6 GY
X2
18GY
BL A C K
( R E A R - U N D E R BO O Y
L E F T S I D E )
- X2 18GY-
L 7 18B K / Y L
- L 7 16BK -
X2 16G Y-
an
an:
L 7 16BK -
X2 16G Y-
L7 16BK -
- X2 16G Y-
L 7 16BK -
X2 16G Y-
BL A C K
( R E A R - U N D E R BO D Y
R I G HT S I D E )
L E F T FE NDE R
C L E A R A N C E
L A MPS
arr-7^f\
an:
am
an:
R I G HT FE NDE R
C L E A R A N C E
L A MPS
an-y^TN
an:-
FENDER CLEARANCE LAMPS
(DUAL REAR WHEELS) AD 42
BLACK
TO RIGHT
PRI NTE O CI RCUI T
BOARD CONNECTOR
G34 ( SE E SH 6 0)
16RD
GY
TO DIMMER SWITCH
( SE E SH 4 7 )
TO TURN
SI GNAL SYSTEM
( SE E SH 56 )
T0 < L 7 j T| SPLI CE 5 L7 1 8 BK / Y L-
( SE E SH 4 7 )
LEF T
HEADLAMP
LEF T SI D E
MARKER LAMP
LEFT PARK
AND TURN
SI GNAL LAMP
L4 16 VT/WT
- L3 1 4 RD/ 0R-
L6 0 18TN
L6 0 1 8TN-
- L6 1 1 8 LG-
- L6 1 1 8 LG-
2 6
L3 1 4 RD/ 0R
L7
I 8 BK
YL
L7
18BK
YL
L4 16 VT/WT
Z l 22BK
21
GAS
L6 1
18LG
L3 1 4 RD/ 0R -
L7 1 8 BK / Y L-
5 < Z 1
1
L 4 1 6 V T/ WT-
TO
n t r r r
, V E H I CLE SPE E D
D I E SE L CONTROL SERVO
( SE E SH 37 )
( D I E SE L ONLY)
i
Z l
20BK
L7
18BK
YL
Z l 1 8BK -
L6 1 18LG
L7 1 8 BK / Y L
L7 1 8 BK / Y L
L7
18BK
YL
Z l Z l
18BK 18BK
N8>
LEFT
HEADLAMP
GROUND
( LE F T FENDER
SI D E SH I E LD )
Z12
14 BK
TN
[LEFT REAR RADIATOR
YOKE PANE L)
(GAS ENGI NE ONLY)
TO
SPLI CE
( SE E SH 1 7 ) ( GAS ENGINE ONLY)
( SE E SH 2 3 ) ( D I E SE L ENGINE ONLY)
AD 43 FRONT END L I G HT I N G
J 938W- 11

L6 0
18TN
L6 0
18TN
22
- L 3 1 4 RD/ 0R
L7
18BK
YL
Z l
22BK
L6 0
18TN
Z l 14 BK
Zl 14BK
TO
SPLI CE
( SE E SH 2 3 )
( D I E SE L ENGI NE ONLY)
Z l 18BK-
TO
RIGHT HEADLAMP
GROUND
(CENTER DASH
PANEL)
SPLI CE
( SE E SH 11)
(GAS ENGI NE ONLY)
Z l 22BK
L4 16 VT/ WT-
L3 1 4 RD/ 0R
3
d
RIGHT
HEADLAMP
Z l 14 BK
Z l 14 BK
f
TO ENGINE WI RI NG
- j ( SE E SH 9)
(GAS ENGINE ONLY)
TO BLOWER MOTOR
A ( SE E SH 6 6 , 6 7 )
(GAS ENGINE ONLY)
RIGHT SI D E
MARKER LAMP
RIGH T PARK
AND TURN
SI GNAL LAMP
TO
UNDERHOOD
LAMP
( SE E SH 2 9 )
( GAS ENGI NE ONLY)
( RI GH T REAR
RADIATOR YOKE)
(GAS ENGINE ONLY)
- 1 8TN-
J 9 3 8 W - 1 1 FRONT END LI GH TI N G AD 44
-G34 1 6 RD/ GY -
BLACK
Q>
V
Q <n>
TO RIGHT
PRI NTE D CI RCUI T
BOARD CONNECTOR
( SE E SH 6 0)
TO DIMMER SWITCH
( SE E SH 47)
TO TURN
SI GNAL SYSTEM
( SE E SH 56 )
L4 16 VT/WT
-L3 1 4 RD/ 0R-
LEFT
HEADLAMP
LEFT SI D E
MARKER LAMP
LEF T PARK
AND TURN
SI GNAL LAMP
5-
- L6 0 18TN
L6 0 18TN-
-L6 1 1 8 LG-
- L6 1 1 8LG-
TO< L7 > T | SPLI CE 5 L7 1 8 BK / Y L-
( SE E SH 4 7 ) |
26
L3 1 4 RD/ 0R
L7
18BK
YL
L7
18BK
YL
L4 16 VT/WT
Z l 22BK
21
GAS
I
L3 1 4 RD / OR-
L7 1 8 BK / Y L-
- L 4 1 6 V T/ WT-
L6 1 j |
5
< Z 1
k ^
n T F
.
F 1
V E H I CLE SPEED
l D I E SE L CONTROL SERVO
! ( SE E SH 37 )
D I E SE L ONLY)
i
Z l
20BK
18LG
L7
18BK
YL
Z l 18BK-
L6 1 18LG
L7 1 8 BK / Y L
L7 1 8 BK / Y L
I
i
L7
18BK
YL
Z l
18BK
LEF T
HEADLAMP
GROUND
( LE F T FENDER
SI D E SH I E LD )
Z12
14 BK
TN
( LEFT REAR RADIATOR
YOKE PANEL)
(GAS ENGI NE ONLY)
TO < Z12>1
S P L I C E
( S E E S H 17) ( G A S E N G I N E ON L Y) 4
( S E E S H 2 3 ) ( D I E S E L E N G I N E ON L Y)
AD 45
FRONT END L I G HT I N G (CANADA) Jsaew-n
TO HEADLAMP.
SWITCH >
( S E E SH 47
v
LEFT PARK
AND TURN
SI GNAL LAMP
TO BLOWER
MOTOR
( S E E SH 66, 67)
(GAS ENGI NE)
RI GHT
HEADLAMP
GROUND
(CENTER
DASH P A N E L ) =
J938W-11
S PL I C E
( S E E SH 23)
( D I E S E L ENGI NE)
S PL I C E
( S E E SH 11)
(GAS ENGI NE)
FRONT END LI GH TI N G ( CANADA) AD 4 6
. _ fTO F USI BLE
A3 12RD/WT5 LI NK
j ( SE E SH 4 , 6 )
FUSE #14
( 3 AMP)
,616 2 0 BK / LB
JG16 2 0 BK / LB
G26 20LB
G26 20LB
I F 33 1 8 PK / RD
M2 20YL
L2 14 LG
jD cb B3
H , P< A
^ BlLH A3 12RD/WT
L7 1 8 BK / Y L
AD 4 7
TO DAYTI ME
RUNNING LAMP,
MODULE f - L 2 0 20LG/ WT-
(Janada
H
oJEJ) h e a d l a m p s w i t c h
J 938W- 11

TO
T R A N S M I S S I O N V
O V E R D R I V E
CONTROL
S WI T C H
( S E E S H 12 )
TO
O V E R D R I V E
CONTROL
S WI T C H
( S E E S H 12 ) G A S
( S E E S H M ) D I E S E L
Z l 18BK
E 2 2 0 0 R
E 2 2 0 0 R
2 0 0 R
Z l
18BK
TO S E A T
X BE L T S WI T C H
^ ( S E E S H 7 7 , 7 6 )
TO R I G HT
PR I N T E D
C I R C U I T BOARD
CONNECTOR
( S E E S H 60 )
BL A C K
- Z l 2 2 BK
f T O K E Y - I N LAMP
> ( S E E S H 49)
TO C H A S S I S
{ WI R I N G
^ ( S E E S H 41, 79)
TO CARGO LAMP
j S WI T C H
( S E E S H 49)
Z l 12BK
TO HE A T E D R E AR
WINDOW S WI T C H
( S E E S H 39)
( S PO R T U T I L I T Y ONL Y)
TO
R A D I O
[ S E E S H
61 , 63 , 65 )
P R O V I S I O N FOR
TACHOMETER
( N E A R F U S E
BL O C K )
( O I E S E L )
BL A C K
TO PCM I I
( S E E S H 2 2 )
TO TURN
S I G N A L
F L A S HE R
( S E E S H 5 6)
BL AC K
- J M O
TO M E S S A G E
C E NT E R
( D I E S E L )
( S E E S H 5 7)
GROUND
TO BR A K E
S WI T C H ( S E E
S H 3 2 . 3 4,
36, 38)
J 9 3 8W- U
TO MAP LAMP
AND R E A D I N G
( S E E S H 49)
TO POWER DOOR L O C K S
( S E E S H 73)
TO POWER M I R R O R S
( S E E S H 75 )
TO POWER WI NDOWS
( S E E S H 71)
A / C AND
HE AT E R
S WI T C H
LAMP
TO I N T E R M I T T E N T
WI PE R MODULE
( S E E S H 5 3 )
TO C I G A R
L I G H T E R
( S E E S H 5 2 )
TO A / C AND
HE AT E R WI R I N G
( S E E S H 67, 69 )
TO GLOV E
BOX LAMP
( S E E S H 5 2 )
TO HE AT E O
R E AR WI NDOW
( S E E S H 39)
S PO R T U T I L I T Y
ON L Y)
H E ADLAMP SW I TCH CONTROLLE D
I N TE RI OR LI GH TI N G
AD 4 8
TO C O M BI N E D
BU Z Z E R
( S E E S H 77, 78)
L 30 18BR / Y L
Z l 2 0 BK
Ml 18PK
BL U E
AD 4 9 MAP LAMP AND CARGO LAMP msu-n
T 0 <Z Q> 1 ll S P L I C E
( S E E S H 77. 78)
CARGO
LAMP
Z l
18BK
L 30
180 R
VT
CARGO
L AMPS
DOME
LAMP
18BK 18BK
DOME
LAMP
r i
M2 Ml
18BK 18BK
YL PK
BL AC K
NEAR L A MP)
V Y
L 6 L 6
180 R 180 R
VT VT
BLACK
( NE AR L AMP)
fcLJSL
( L E F T S I D E
OF S T E E R I N G
COLUMN)
BL AC K
M2 18BK / Y L -
Ml 18BK / PK
BL AC K
S T A N D A R D \
CAB \
/ C L UB CAB
M2 2 0 Y L -
Mi 18PK
L 30 18BR / Y L
Ml 18PK
TO UNDERHOOD
4 LAMP
>
( S E E S H 2 9)
BL A C K
M2 2 0 YL ^
TO BODY WI R I N G
( S PO R T U T I L I T Y ON L Y)
( S E E S H 5 1)
J 938W- 11 DOME LAMP AND CARGO LAMP
AD 50
BW - 92 WIRING DIAGRAMS

TO
BA T T E R Y F E E D
( S E E S H 3 . 5 K
A4 12 B K / R D -
BL AC K
R E AR DOME LAMP
TO M E S S A G E
C E N T E R 4f O
( S E E S H 5 8) 5 0
- M l 2 0 PK -
F U S E # 15
( 10 A M PS )
( S E E S H 49)
G78 2 0 T N / BK
GR E E N
( L E F T ' B ' P I L L A R )
M2 18BK / Y L
M2 18BK / Y L
Ml 18PK / PK
FRONT D O M E /
R E A D I N G LAMP
BL A C K
C3
3 ^ - @ Z >
BL A C K -
( UNDE R BU L K HE A D J
C ONNE C T OR )
L I F T G A T E
AJAR S WI T C H
( L I F T G A T E L A T C H)
M2 G78
18BK 18TN
YL BK
TO UNDERHOOD
LAMP
( S E E S H 2 9)
D I O D E AND
MOLD A S S E M BL Y
( L E F T ' C P I L L A R )
M4 18T N / BK
Z l 12BK
BOOY
GROUND
( L E F T R E AR
' C P I L L A R )
BL AC K
( L E F T ' C
P I L L A R )
AD 51
LI F TGATE AJAR WARNI NG SY STE M AND RE AR
DOME LAMPS ( SPORT UTI L I TY ONLY) JSMI MI

TO <
BATTERY FEED V
( SE E SH 3 . 5 )
A4 1 2BK / RD
GLOVE
BOX LAMP
AND
SWITCH
CIGAR
LIGH TER
n n t n t
U U 1
(CENTER OF
INSTRUMENT
PANEL)
BLACK
TO HEADLAMP
SWITCH
( SE E SH 4 7 )
TO I GNI TI ON
SWITCH
( SE E SH 10)
J938 W - 1 1
CI GAR L I GH TE R, ASH RE CE I V E R LAMP
AND GLOVE BOX LAMP
AD 52

-V10 20BR-
V10 20BR
Z l 20BK
-yy
WI NDSHI ELD WASHER
PUMP MOTOR
(UNDER WI NDSHI ELD
WASHER RESERVOI R)
Z l 20BK
' TO BLOWER MOTOR
( S E E SH 66. 67, 69)
29
V10 18BR-
V10 20BR-
3
)>V6 18DB-
)>V8 18VT-
I NTERMI TTENT
WIPER SWITCH
"ON STEERI NG
COLUMN)
V9 18WT/BK
)X"V3 18BR/WT
V 4 18RD/YL
))V7 18DG/WT
' 18DG/YL
STEERI NG COLUMN
CONNECTOR
( S E E SH 87)
V3 18BR/WT-
V17 18DG/ YL
Z l 12BK-
V I O 18BR-
- V 8 18VT-
V9 18WT/BK-
V7 18DG/WT-
Z 2 18BK/ LG-
V6 18DB
V3 18BR/WT-
-V4 18RD/ YL-
-JTO <Jlj2
AD 53
S PL I C E
PANEL GROUND ( S E E SH 48)
(RI GHT OF
STEERI NG COLUMN)
I N TE RMI TTE N T W I PE R SY STE M
J938W-11
V 8 18V T -
V7 18D G / WT -
12 1 8B K / L G -
V 6 18D B-
V9 18WT / BK -
NOT U S E D ON 2 S PE E D
WI PE R S YS T E M
- V 17 18D G / Y L
-12 18BK / L G
- V 5 18DG
- V 10 18BR
I 5,_ 1
V17 18D G / Y L
I N T E R M I T T E N T WI PE R
7 CONTROL U N I T
2 8 1 6 3 4 5
(MOUNTED ON BR A C K E T
UNDER S T E E R I N G
COLUMN)
TO I G N I T I O N
S WI T C H
( S E E S H 10 )
- V 1 0 18BR
- V 8 18VT
V 9 18WT / BK
V 7 18DG/ WT
12 18BK / L G
V 6 18DB
V3 18BR / WT
4 18R D / Y L
1
I N T E R M I T T E N T WI N D S H I E L D
WI PE R MOTOR
( I N PL E N U M - L E F T S I D E )
t=C4V3 18BR / WT
K)=t~V6 18DB
NC4V5 18D G / YL
K M- V 4 18R D / Y L
PARK
S WI T C H
J 938W- 11
I NTE RMI TTE NT W I PE R SY STE M AD 54
WI N D S H I E L D WI PE R S WI T C H ( F 0 R __C O N N E C T O R - S E E S H 88)
LO
W PARK ft
w
_
HI TV HI
TO A / C
8LOWER MOTOR
( S E E S H 66.
67. 69)
AD 5 5 W I N D SH I E LD W I PE R SY STE M
J 938W- 11
F U S E # 9
( 2 0 AMP)
TURN S I G N A L
F L A S HE R
(MOUNTED ON
R E L AY BA N K )
( S E E S H 82 )
L19 18PK
A 31 1 4B K / WT ( TO I G N I T I O N
S WI T C H
( S E E S H 10 )
TO REAR WHEEL
A N T I - L O C K
( R WAL ) MODULE
( S E E S H 31 , 33)
A15 16PK
A15
16PK
2 3
L 5 14R D-
TO C HA R G I N G
S YS T E M
( S E E S H 3. 5 )
F U S E # 1 3
( 2 0 AMP)
TO TACHOMETER
_T PR O V I S I O N
> ( S E E S H 48)
L 19 18PK
HAZ AR D WAR NI NG
F L A S HE R
MOUNTED ON
R E L A Y BA N K )
S E E S H 82 )
TO BR A K E
S WI T C H
S E E S H 36, 38)
L 5 0
18WT
TN
L 5 0 18WT / T N L 5 0 18WT / T N
GRAY
CL50
HAZ ARD F L A S HE R
S WI T C H
CONNECTOR
( S E E S H 87, 88)
TO RE AR WHEEL
< A N T I - L O C K
i ( R WAL ) MODULE
( S E E S H 3 2 . 3 4)
L 61
18LG
L 61 18LG
11
- L 6 G 18T N-
TO
RE AR L I G H T I N G
( S E E S H 79)
TURN S I G N A L
S WI T C H
( ON S T E E R I N G COLUMN)
L6 3 18D G / R D
L 62 18BR / R D
, 0 0 0 /
4 5 6
TO L E F T PR I N T E D
C I R C U I T BOARD
CONNECTOR
( S E E S H 60 )
21
22
- L 61 18L G - 5
L S I 18LG -
L 60 18TN5
L 60 18T N ^
TO
FRONT END
L I G H T I N G
( S E E S H
43. 45 )
L 60
18TN TO R I G HT
PR I N T E D C I R C U I T
BOARD CONNECTOR
( S E E S H 60 )
BL A C K
d 9 3 8 w- n STOP/ TURN AND HAZARD F LASH E R SY STE MS AD 56
G85 20TN/ 0R W ATE R- I N- F UE L
( SE E SH 23)
G9 20GY/ BK REAR WHEEL
ANTI - LOCK BRAKE MODULE
( SE E SH 33)
G9 20GY/ BK PARK BRAKE WARNING SWITCH
( SE E SH 33
G14 2 0PK / BK TO I GNI TI ON SWITCH GROUND
BULB TE ST)
( SE E SH 10)
Gi l 20WT/ BK BRAKE WARNING SWITCH
AND VACUUM SWITCH
( SE E SH 33)
Gi l 20WT/ BK REAR WHEEL
ANTI - LOCK BRAKE MODULE
( SE E SH 33)
G86 20DG/WT W AI T- TO- START SWITCH
( SE E SH 23)
B1 02 180R ANTI - LOCK MODULE
( SE E SH 33)
G5 20DB/ WT I GNI TI ON- 1 2 V FEED
( SE E SH 58 )
Z l 22BK GROUND - < Z 1 > 1 | SPL I C E
SE E SH 4 8 )
G40 2 0LB/ BK FUEL TANK
LOW FUEL SWITCH
( SE E SH 7 7 )
AD 57 ME SSAGE CE NTE R ( D I E SE L )
J 938 W - 1 1

DIODE-
BRAKE LAMP
GATE OPEN LAMP
SERVICE REMINDER
INDICATOR LAMP
REAR WHEEL
ANT1-LOCK LAMP
TO
O V E R D R I V E CONT ROL
S WI T C H ( D I E S E L ONLY
( S E E S H 14)
I
I
I
I
G5
2 0 DB
WT
TO FOUR
WHEEL D R I V E
I N D I C A T O R LAMP
( S E E S H 13)
i ,
- BL A C K
G5 2 0 D B/ WT
TO R I G HT
BOARD CONNE CTOR
( S E E S H 60 )
TO
O V E R D R I V E S WI T C H
( S E E S H 12 )
( G A S O N L Y)
GRAY
G5 2 0 D B/ WT
G i l 2 0 WT / BK
S E E S H 10 )
G i l 2 0 WT/ BK~
B10 2 180 R
BL A C K
TO I G N I T I O N S WI T C H GROUND
TO R E AR
WHEEL A N T I - L O C K
MODULE
( S E E S H 31)
TO
C O M BI N E D
BU Z Z E R
( S E E S H 77, 78)
G24 2 2 G Y / PK S E R V I C E R E M I N D E R
I N D I C A T O R ( S E E S H 19)
G78 2 0 T N / BK GATE OPE N LAMP
( S E E S H 5 1)
G9 2 0 G Y / BK TO RE AR WHEEL A N T I - L O C K
MODULE ( S E E S H 31)
G9 2 0 G Y / BK TO BR A K E LAMP WAR NI NG
S WI T C H ( S E E S H 31)
TO L E F T
BOARD CONNECTOR
( S E E S H 60 )
A2 1 14D B-
F U S E # 2
( 5 AMP)
TO I G N I T I O N
S WI T C H
( S E E S H 10 )
J 938W- 11
ME SSAGE CE NTE R ( GAS) AD 58
I LLUMI NATI ON LAMP
V OLTME TE R
LE F T TURN SIGNAL LAMP
SEAT BELT WARNING LAMP
NOT USE D
LOW E N G I N E
O I L PR E S S U R E
LAMP
RIGHT TURN SIGNAL LAMP
LOW E N G I N E
O I L PR E S S U R E
GAUGE
E N G I N E COOLANT
T E MPE R A T U R E GAUGE
ILLUMINATION LAMP
M A L F U N C T I O N
I N D I C A T O R
LAMP
V E H I C L E S PE E D S E N S O R
( E L E C T R I C S PE E D O M E T E R )
H I G H - BE A M
I N D I C A T O R LAMP
ILLUMINATION LAMP
F UE L GAUGE
AD 59
CLUSTE R- PRI N TE D CI RCUI T BOARD
J 938W- 11
G20 2 0 V T / Y L
E N G I N E COOLANT
T E MPE R A T U R E GAUGE S E N D I N G U N I T
( S E E S H 2 7, 2 8)
L 61 18LG L E F T TURN S I G N A L LAMP
( S E E S H 5 6)
G7 2 0 WT / 0 R V E H I C L E S PE E D S E N S O R
( S E E S H 19, 2 5 )
GRAY
G13 2 0 D B/ R D S E A T BE L T WAR NI NG L AMP S WI T C H
( S E E S H 77, 78)
G3 2 0 BK / PK M A L F U N C T I O N I N D I C A T O R L A MP)
( S E E S H 5 8)
G5 2 0 D B/ WT I G N I T I O N F E E D - 1 2 V O L T S
( S E E S H 5 8)
L E F T CONNECTOR
BL AC K
E 2 2 0 0 R I L L U M I N A T I O N LAMP F E E D
( S E E S H 48)
Z l 2 0 BK GROUND
( S E E S H 48)
G4 2 0 DB F U E L GAUGE S E N D I N G U N I T
( S E E S H 77, 78)
G6 20 GY E N G I N E O I L PR E S S U R E LAMP S WI T C H
( S E E S H 2 7, 2 8)
G5 2 0 D B/ WT I G N I T I O N F E E D - 12 V O L T S
( S E E S H 5 8, 77, 78)
G34 16R D / G Y H I G H - BE A M I N D I C A T O R LAMP
( S E E S H 43, 45 )
L 60 18TN R I G HT TURN S I G N A L LAMP
( S E E S H 5 6)
G60 2 0 G Y / Y L E N G I N E O I L PR E S S U R E GUAGE
S E N D I N G U N I T
( S E E S H 2 7, 2 8)
R I G HT CONNECTOR
J 93 8w- i i PRI N TE D CI RCUI T BOARD CONNECTORS AD 6 0

BL A C K
TO
HE ADLAMP
S WI T C H
[ S E E S H 47
3
TO I G N I T I O N
S WI T C H
( S E E S H 10 )
T
A31
14BK
WT
TO
BATTEF
F E E D
( S E E S H 3 , 5
s
F U S E # 8
^ ( 10 AMP)
q oc
Y
N
S E E
X12 2 0 R D / WT |
Ml 2 0 PK
GR AY-
BE HI N D
R A D I O )
X5 6 18D B/ R D
X5 5 18BR / R D
X5 8 18D B/ 0 R
X5 7 18BR / L B
- X 5 4 18VT
- X5 3 18DG
- X5 2 18DB/ WT -
- X 5 1 18BR / Y L
GRAY
BL AC K
[ aTl
FOR 2 S PE A K E R S
WI R I N G
( S E E S H 65 )
S T E R E O R A D I O
AD 61
S TE RE O R A D I O - 4 S PE A K E R S
J 938W- 11

L E F T
REAR
S PE A K E R
X5 1 1 8B R / Y L -
X5 7 1 8B R / L B -
X5 6 18D B/ R D
X5 5 18BR / R D
- X5 8 18D B/ 0 R
X5 7 18BR / L B
X5 4 18VT
X5 3 18DG
X5 2 18DB/ WT
X5 1 18B R / Y L -
X5 2 18DB/ WT
- X5 8 18D B/ 0 R
(BELOW BU L K HE A D Lb dl
C ON N E C T OR )
GR E E N
X5 6 18D B/ R D
- X5 3 18DG-
X5 5
18BR
RD
R I G HT
REAR
S PE A K E R
BL A C K -
(COWL T O P-
R I G HT S I D E )
L E F T FRONT
DOOR S PE A K E R
R I G HT FRONT
DOOR S PE A K E R
J 938W- 11
STE RE O RAD I O- 4 SPE AK E RS AD 6 2
BW - 104 WIRING DIAGRAMS

BLACK
TO
HE ADLAMP
S WI T C H
( S E E S H 47)
TO I G N I T I O N
S WI T C H
( S E E S H 10 )
T
A31
14BK
WT
F U S E # 8
- ( 10 AMP)
qoc | T 7
TO
BA T T E R Y
F U S E # 14
( 3 AMP)
F E E D
( S E E S H 3, 5
( S E E S H 48) \
X12 2 0 R D / WT
Ml 2 0 PK
E 2
2 0 0 R
GR AY-
( BE H I N D
R A D I O )

X5 6 18D B/ R D
X5 5 18BR / R D
X5 8 18D B/ 0 R
X5 7 18BR / L B
- X 5 4 18VT
- X5 3 18DG
- X5 2 18DB/ WT -
- X 5 1 18BR / Y L
GRAY
BL AC K
[ T
FOR 2 S PE A K E R S
WI R I N G
( S E E S H 65 )
AD 6 3
STE RE O RAD I O- 4 SPE AK E RS
( SPORT UTI L I TY ) J 938W- 11
LEFT
REAR
SPEAKER
+
+
P
3
r -
X5 6 18D B/ R D
X5 5 18BR / R D
X5 8 18D B/ 0 R
X5 7 18BR / L B
X5 4 18VT
X5 3 18DG
X5 2 18DB/ WT
X5 1 18BR / Y L
+
9
+
R I G HT
REAR
S PE A K E R
- X5 8 18D B/ 0 R
X5 2 18DB/ WT
- X5 7 18BR / L B
( L E F T ' B ' P I L L A R )
X5 2 18DB/ WT
X5 8 18D B/ 0 R
GR E E N
L E F T FRONT
DOOR S PE A K E R
R I G HT FRONT
DOOR S PE A K E R
J 938W- 11
STE RE O RAD I O- 4 SPE AK E RS
( SPORT UTI L I TY ) AD 64

( S E E S H 49)
AD 65 S TE RE O R A D I O - D U A L S PE A K E R S Jaasw-

TO
I G N I T I O N c
S WI T C H Y
( S E E S H 10 )
A22 12 BK / 0 R
C I 12DG
F U S E #11
( 30 AMP)
HE ATE R BLOWER
MOTOR
( R I G HT S I D E
DAS H PA N E L )
TO
WI N D S H I E L D
WASHER V
MOTOR
( S E E S H 5 3, 5 5 )
S P L I C E S P L I C E
( S E E S H 2 3) ( S E E S H 44, 46)
( D I E S E L ON L Y) ( G A S ON L Y)
J 938W- 11
H E ATE R AD 6 6

N A T U R A L -
C5 16LG
F U S E #1 1
( 30 AMP)
C6 14L B- - | 7 ][7 }- C 3 12WT/DG
C7 12DG[5] [2] C4 12TN
TO I G N I T I O N
SWITCH S
( S E E S H 10
v
HE AT E R BLOWER
MOTOR
( R I G H T S I D E
D A S H PA N E L )
S P L I C E
( S E E S H 4 4 , 4 6 )
TO WASHER
MOTOR
( S E E S H 5 3, 5 5
AD 6 7
A/ C AND H E ATE R
GAS E N GI N E S
J 938W- 11

COMPRESSOR
(RI GHT S I D E
FORWARD OF
ENGI NE)
C9
18BK
C2
18BK
TO ENGI NE
STARTER
RELAY
( S E E SH 9)
I
I
I
!
Z l
18BK
C26 14BR-
A21 14DB-
ca h d b / b k ^ 3 E 5 | H
C13 20 DB/0 R J
^MANUAL TRANS
ONLY
BLACK
(LEFT OF
COMPRESSOR)
Z l 14BK-
\ TO POWERTRAIN
\ CONTROL MODULE I I
\ CAVI TY 27,34
BI - D I R E C T I O N A L
Z ENER DI ODE
TO I GN I T I ON
SWITCH
( S E E SH 10)
:-4ENG]~ 2
TO FUS I BL E
LI NK
(SEE SH 4)
( S E E SH 18)
Z l
14BK
TO
EMCC RELAY
( S E E SH 11)
A21 14DB
I A 2 1 14DB
34
: - [ E N G | ~
T 0 <Z 1> 4| S PL I C E
( S E E SH 44.46)
TO<A21> S PL I C E
( S E E SH 16)
C21 18DB/0 R
-C3 14DB/BK
r
TO DAYTIME
A21 14DB ) RUNNING LI GHTS
MODULE
( S E E SH 46)
A21 14DB
WIDE OPEN
THROTTLE
CUTOUT
RELAY
(LEFT FENDER
S I D E S HI E L D '
C21 18DB/0 R ~<f
A / C LOW
PRESSURE SWITCH
(RI GHT FENDER
S I D E S HI E L D)
A21 14DB
PROBE
= 3 :
(RI GHT
S I D E
S HI E L D)
A / C
CYCLI NG
SWITCH
C2 18DB/WT-
A21 14DB-
C20 18BR-
C20 18BR-
J938W-11
A/ C AND H E ATE R-
GAS E N GI N E S AD 6 8

NAT URAL
"^V[T[V-C5 16LG
C6 14LB-{T][T}---C3 12 WT / DG
C7 12DG[] [2] C4 12TN
F U S E #11
30 AMP
TO I G N I T I O N
S WI T C H
( S E E S H 10 )
HE AT E R BLOWER
MOTOR
( R I G H T S I D E
D A S H PA N E L )
S P L I C E
( S E E S H 2 3)
TO WASHER
MOTOR
( S E E S H 5 3. 5 5 )
AD 6 9
A/ C AND H E ATE R-
D I E SE L E N GI N E S
J 938W- 11
COMPRESSOR
(RI GHT S I D E
FORWARD OF
E NGI NE ) i
C26 14BR-
A21 14DB-
C 3
i4DB/BK-ffi^]QLJ
I 86K
18BK
(LEFT OF
COMPRESSOR)
Z l
18BK
(RI GHT FENDER
C13 2 0 DB/ 0 R -
TO F U S I BL E
LI NK $-
(SEE SH 6 )
\ TO POWERTRAIN
\ CONTROL MODULE I I
\ CAVI TY 27, 34
\ ( S E E SH 26)
r
\
\
\
T
C20
18BR
BI - D I R E C T I O N A L
Z ENER DI ODE
WIDE OPEN
THROTTLE
CUTOUT
RELAY
(LEFT FENDER
C13 14DB/BK
Z l
14BK
TO
S PL I C E
( S E E SH 23)
C21 18DB/0 R
TO<A21> S PL I C E
( S E E SH 23)
S PL I C E
( S E E SH 21)
A / C LOW
PRESSURE SWITCH
(RI GHT FENDER
A21 14DB
PROBE
(RI GHT
S I D E
S HI E L D )
A / C
CYCLI NG
SWITCH
C2 18DB/0 R-
A21 14DB-
C20 18BR-
C20 18BR-
J 938W- H
A / C AND HE AT E R -
D I E S E L E N G I N E S AD 70
LEFT DOOR
B +
POLARI TY
LB
WT
BR/WT
VT/WT
TN
B -
POLARI TY
WT
LB
VT/WT
BR/WT
BK
WINDOW AND MOVEMENT
LEFT FRONT UP
LEFT FRONT DOWN
RIGHT FRONT UP
RI GHT FRONT DOWN
FEED AND GROUND
Ql l 14LB
Q21 14WT-
A Aflk
4 W ^ V
] 4 * \
6
21 14BK
Q16 14BR/WT
Q26 14VT/WT
F21 14TN
UP
FORWARD-
CONNECTOR GAGE LEFT FRONT DOOR
MASTER SWITCH
TO I GN I T I ON 11
SWITCH 1 2 B K / 0 R ~
( S E E SH 10)
1
DN
)
UP

14VTi
14DG-
LEFT DOOR
WINDOW L I F T MOTOR
DOWN
7 XX
- -0 26 14VT/WT
LEFT DOOR
WINDOW SWITCH
AD 71 POWER WINDOW SY STE M
J938W-11
RI GHT DOOR
B +
POLARI TY
B ~
POLARI TY
VT BR
BR VT
VT/WT BR/WT
BR/WT VT/WT
TN
WINDOW MOVEMENT AND SWITCH
DOWN FROM DOOR SWITCH
UP FROM DOOR SWITCH
DOWN FROM MASTER SWITCH
UP FROM MASTER SWITCH
FEED
RED
Q26A 14VT-
Q26 14VT/WT-
1
.
FORWARD I N CAR
-Q16 14BR/WT
- F2 1 12TN
-Q16A 14BR
UP
RIGHT FRONT WINDOW L I FT SWITCH CONNECTOR
1
1
DN
)
UP
L i
14 VT
14DG
RED
(AT MOTOR)
RI GHT DOOR
WINDOW L I F T MOTOR
BLACK
OVER HEATER
OR A / C UNI T)
Q16A 14BR
Q26 14VT/WT
016 14BR/WT
F21 12TN
Q26A 14VT
SWITCH
(VI EW FROM
TERMI NAL END)
J938W-11
POWER WINDOW SY STE M AD 7 2
TO <g> S P L I C E
( S E E S H 47)
A3 12 R D/ WT
F U S E # 6
( 2 0 AMP)
F 35 16RD 3 Z l 12 BK-
TO POWER
WI NDOWS 5 Z l 16BK .
( S E E S H 71)
Z l
16BK
10 <Z 1
F 35
16RD
Z l
16BK
i LK
Ml
UNLK
F 35 16R0 G=
v 0:
BL A C K
( BE H I N D
R A D I O )
-5 TO < Z 1 ^ 3 ] S P L I C E
( S E E S H 48)
L E F T DOOR S WI T C H CONNECTOR
' L E F T FRONT
DOOR S WI T C H
( V I E W FROM
T E R M I N A L E N D )
1^F 35 16RD
1
TO POWER
M I R R O R S WI T C H
( S E E S H 75 )
P37 160 R / V T
( L O C K )
Z l 16BK
r - G R A Y
Z l 16BK
F 35 16RD
( F E E D )
P36 16PK / V T
( U N L O C K )
FORWARD
T E R M I N A L END
UP
P36 16PK / V T
P35 160 R / V T
P34 16PK / BK
P33 160 R / BK
F 3 5 16RD
P36
16PK
VT
L E F T FRONT
DOOR MOTOR
R I G HT DOOR
COWL TOP
D I S C O N N E C T
( OV E R HE AT E R
OR A / C U N I T )
F 35 16R D -
P36 16PK / V T
P35 160 R / V T
P33 160 R / BK
P34 16PK / BK
AD 73 POWER DOOR LOCKS
J 938W- 11

RI GH T DOOR SW I TCH CONNE CTOR
P3 3 1 6 0 R/ BK
( LOCK )
P3 5 1 6 0 R/ V T
] E
FORWARD
TE RMI N AL E ND
- BL UE
P3 6 1 6 PK / V T
F 3 5 1 6 RD
P3 4 1 BPK / BK
( UN LOCK )
t UP
y- '
RI GH T F RON T D OOR
S W I TC H /
( V I E W F ROM /
TE RM I N A L E N D ) /
B L A C K ^ fTOPl /
VLK
P3 6 P3 4
1 6 PK 1 6 PK
V T BK
F 3 5 1 6 RD -
P3 6 1 6 PK / V T - J
P35 1 6 0 R/ V T -
P3 3 1 6 0 R/ BK -
P3 4 1 6 P K / B K
J 9 3 8 W - 1 1
P3 4
1 6 PK
BK
F 3 5
1 6 RD
P3 5
1 6 0 R
V T
P3 3 1 6 0 R/ BK -
P3 4 1 6 PK / BK
POWER DOOR LOCK S
RI GH T F RONT
DOOR MOTOR
^ LK X \ U N
L K
t o
AD 74
BLACK
P75 18DB/WT
P71 18YL
P73 18YL/PK
S23
18DB
S l l
18WT
S13
18YL
LT
HORIZ ONTAL
RT
UP DN
VERTI CAL
P74 18DB
Z l 12BK'
Ml 18PK
BLACK
(RI GHT OF
STEERI NG
COLUMN)
P72 18YL/ BK-
- P70 18WT -
Z l
12BK Ml 20PK
Ml
18PK
S l l
18DG
.Ml
( S E E SH 49)
P74 20 DB/WT
P72 2 0 Y L -
Ml Z l
20PK 12BK
TO
BATTERY FEED
( S E E SH 3. 5 )
LEFT MIRROR
MOTORS
T
FUSE #15
(10 AMP)
A4 14BK/RD
TO <ZJS] S PL I C E
( S E E SH 48)
AD 75 POWER MI R R OR S
J 938W- 11
G R A Y
P 7 4 1 8D B
P 7 0 1 8WT
P 7 2 1 8 Y L / 8 K
C O WL R I G H T T O P
B L A C K
S24
18DB
l T
H O R I Z O N T A L
R T
o
U P
V
" ' O N
V E R T I C A L
R I G H T M I R R O R
M O T O R S
S 1 2
18WT
S 1 2
1 8 0 G
PO WE R M I R R O R S WI T C H
Z l
20BK
DN
IIS
P71 2 0 Y L / B K -
P 7 3 20WT
r
# K E #
II T
P 7 0 2 0 W T / B K
P 7 2 2 0 Y L -
L H #
up I i
is A #
U P L T -
O P
L E F T
M I R R O R
# G M
U P ( A )
L E F T
M I R R O R
L T ( D)
R I G H T
M I R R O R
RT( B)
D N ( C )
V I E W O F S W I T C H I N D E X I N G
F R O M F R O N T O F S WI T C H
R I G H T
M I R R O R
P 7 5 2 0 D B
P 7 4 2 0 D B / W T
r
# P J #
# R
# C
R T
PO WE R M I R R O R S WI T C H F U N C T I O N
L E V E R
P O S I T I O N
C I R C U I T
M I R R O R
D I R E C T I O N
A S K . T L . P B U P
B N G . V P . R C R I G H T
C S D . T E . P H D O WN
D N A . V M . R J L E F T
J 938W- 11
POWER MI RRORS AD 76

SPLI CE
TO I GNI TI ON
SWITCH
( SE E SH 10
F 32 1 8 PK / DB
F 32 1 8 PK / DB
G26 20LB
IcQa ch c O,
p n i
^ cjâ cQa cBn\
G10 20LG/ RD
G10 20LG/ RD
Z l 20BK -
SPLI CE
( SE E SH 47)
G5 20DB/ WT
G13 20DB/ RD
HEADLAMP K E Y - I N
SEAT BELT
COMBINED BUZZER
( RIGH T OF STE E RI NG COLUMN)
TO RIGHT
PRI NTE D CI RCUI T
BOARD CONNECTOR
( SE E SH 6 0)
BLACK
G5 20DB/ WT G5 20DB/ WT-
( SE E SH 58 )
G10
20LG
RD
Z l
20BK
TO STOP
j LAMP SWITCH
( SE E SH 3 4 , 3 7 )
TO HEADLAMP
{ SWITCH
( SE E SH 4 7 . 4 9 )
TO LEF T
PRI NTE D
CI RCUI T
BOARD
CONNECTOR
( SE E SH 6 0)
G13 20DB/ RD
TO MESSAGE
CENTER
( D I E SE L)
( SE E SH 57 )
TZ7
n
era
c
c
QC
at
BLACK BLACK
-G10 1 8 LG/ RD
( LE F T BASE OF
STE E RI NG COLUMN
DD
DP
DD
G40 2 0LB/ BK
/ ( LE F T SI D E
UNDER I / P)
I
DD
DD
3 GROUND
SPLI CE
[SE E SH 4 8 )
G4 1 8 DB/ Y L-
Z l 16 BK
Z l
16GY
BK
TO <Z 1>71 GROUND
SPLI CE
( SE E SH 7 9)
\
5 21 1 6 BK - H T
A6 1
16DG
BK
b o c
bo}
((ppoc ?o))
Z l 1 8 BK $
SEAT BELT
SWITCH
( I N SEAT
BELT BUCK LE)
TO CARGO LAMP
[SE E SH 5 0 )
5
T0
<B]
GROUND
SPLI CE
( SE E SH 4 8 )
FUEL TANK LE V E L GAUGE
SE NDI NG UNIT WITH
LOW FUEL
LAMP SWITCH
AD 77
D I E SE L F UE L TANK GAUGE
AND SE AT BE LT WARNING SY STE M
J 938 W - 1 1
TO I G N I T I O N
S WI T C H
( S E E S H 10 )
t
1
A 2 1 H O B
TO <A21> 1| S P L I C E
( S E E S H 68)
r
A2 1
H O B
47
F32 1 8P K / D B ,
F32 18PK / D B
G2 6 2 0 L B
lcL
iCZD
G10 20 L G / R D -
G10 20 L G / R D -
Z l 2 0 BK-
~1
G5 2 0 D B/ WT
G13 2 0 D B/ R D
TO
F U S E # 5
[20 AMP)
S P L I C E
( S E E S H 47)
HE ADLAMP K E Y - I N
S E AT BE L T
C O MBI N E D BU Z Z E R
\ F 32
\ 18PK
R I G HT OF S T E E R I N G COLUMN \ DB
TO R I G HT
BOARD CONNECTOR
( S E E S H 60 )
( S E E S H 5 8)
BL AC K
G5 2 0 D B/ WT G5 2 0 D B/ WT -
G10
2 0 L G
Z l
2 0 BK
F32
18PK
DB
G26
2 0 L B
TO S T OP
- \ LAMP S WI T C H
( S E E SH 32 , 35 )
< TO HE ADLAMP
S S WI T C H
( S E E SH 47)
GRAY
TO L E F T
PR I N T E D
C I R C U I T
BOARD
CONNECTOR
( S E E S H 60 )
G13 2 0 D B/ R D
, TO FUE L PUMP
H i 4 1 16D G / BK - A MOTOR F E E D
( S E E S H 16)
G10
Z l ( L E F T BA S E OF
18BK S T E E R I N G COLUMN) ^
I , 18BK
Z l
8BK
( AT S E A T ^ 18LG
B E L T
> 18BK
^ B L U E
r ( L E F T S I D E UNDER
I N S T R / P A N E L )
G4 18D B/ Y L -
TO < Z 1 > 3 GROUND
S P L I C E
[ S E E SH 48)
Z l 16BK
XL
Z l
16GY
BK
TO <Z 1> 7| G R O U N D
S P L I C E
( S E E S H 79)
\ z ^
2 0
5~Z l 16BK - H T
A61
16DG
BK
4 o o o d
) c
F.
it JJ
Z l
18BK
Z 1> 11
S E AT BE L T
S WI T C H
( I N S E A T
BE L T BU C K L E )
7 1 1 f t R
. f TO CARGO LAMP
- Z l 1 8B K ^ ( S E E S H 5 0 )
-5 TO < Z ^ T] GROUND
S P L I C E
( S E E S H 48)
F U E L TANK MODULE
J 938W- 11
E LE CTRON I C F UE L I N J E CTI ON TANK GAUGE
AND SE AT BE LT WARNING SY STE M
AD 7 8
TO TRANSMI SSI ON
WI RI NG r
( SE E SH 7 D I E SE L ) J
( SE E SH 9 GAS)
TO< L7 ^ T] SPLI CE
( SE E SH 4 7) S
TO TURN
SI GNAL SWITCH
( SE E SH 56 )
T 0 < Z 1 > 3 [ S PL I C E
( SE E SH 4 8 )
SPORT
UTI LI TY
LEFT
TAI L.
STOP i
TURN X 2
SI GNAL 18GY
LAMP
LEFT
BACK - UP
LAMP
CAB I
CH ASSI S
SWEPT-
LI N E
BOX
LEF T
TAI L.
STOP I
TURN
SI GNAL
LAMP -
LEFT
BACK - UP
LAMP
LEF T
TAI L,
STOP I
TURN
Y 9
SI GNAL , ppv
LAMP
1 8
f
Y
LEF T
BACK - UP
LAMP
BLUE
( LE F T SI D E UNDER I / P)
TO < Z 1 > 81 S P L I C E
( SE E SH 7 7 . 7 8 )
B2 1 8 V T/ BK
AD 7 9 RE AR LI GH TI N G
J 938W- 11
H4 18BK -
( L E F T R E A R /
FRAME R A I L ) /
BL A C K '
L 7
1 8 BK
YL
Z l 18BK
1
L I 18V T / BK -
H4 18BK
X2 18GY
18BK / Y L
L7 18B K / Y L -
H4 1 8B K
BL A C K -
( C E N T E R OF R E AR BU MPE R )
L 7 18B K / Y L -
BL AC K
X2 18GY
- L 7 18BK
BL AC K
L 62 18B R / R D
Z l 18BK
L I C E N S E
LAMP
WI THOUT
BUMPER
L I C E N S E
LAMP
L I C E N S E
LAMP
S T E P
BUMPE R
L I C E N S E
LAMP
^ S T A N D A R D
BUMPE R
R I G HT
T A I L .
S T OP I
X2 TURN
18GY S I G N A L
LAMP
B2 18V T / BK -
R I G HT
BA C K - U P
LAMP
R I G HT
T A I L .
S T OP I
TURN
S I G N A L
LAMP
R I G HT
BA C K - U P
LAMP
R I G HT
T A I L .
S T OP I
TURN
S I G N A L
LAMP
R I G HT
BA C K - U P
LAMP
S POR T
U T I L I T Y
C A B I
C H A S S I S
S WE PT -
L I N E
BOX
J 938W- 11
RE AR LI GH TI N G AD 8 0
PART OF
CH ASSI S WIRING
( SE E SH 80)
Z l 18BK-
f ~ L7 1 8 BK / Y L
5~L62 1 8 BR/ RD
5L1 1 8 V T/ BK -
1
OO
- L 7 1 8 BK / Y L-
-D7 1 8 BK / LG
X2 18GY-
X2 18GY-
RIGHT
TAI L, STOP &
TURN SI GNAL
LAMP
X2 18GY
B2 1 8 V T/ BK -
RIGHT
BACK - UP
LAMP
J2-SL
OOh
OQ
L6 2
18BR
R0
NOTE - I NSE RT TRAI LE R
TOW WI RI NG BETWEEN
CH ASSI S I TAI L LAMP
WI RI NG AS SHOWN, AND
MAKE CONNECTION TO TRAI LE R
CONNECTOR AS RE Q UI RE D.
L7 1 8 BK / Y L-
Z l
18BK
LI
18VT
BK
L2
18BR
YL
Zl
18BK
LEF T
TAI L, STOP ft
TURN SI GNAL
LAMP
LEF T
BACK - UP
LAMP
- LI 1 8 BK BACK - UP LAMPS
- Zl 1 8 WT BODY GROUND
6 2 18DG RIGHT STOP ft TURN
SI GNAL LAMP
r
7 1 P Y
. LEFT STOP ft TURN
L6 3 18YL SI GNAL LAMP
L7 18BR-
TAI L I
RUNNING LAMPS
WIRE ENDS SEALED AND
UNTERMI NATED, PROV I SI ONS
FOR TRAI LE R CONNECTOR
L7 18BK/YL5
Zl 1 8 B K ^
LI 18V T/ BK -J
L6 3 18DG/RD-5
PART OF
CH ASSI S WI RI NG
( SE E SH 7 9)
B2 1 8 V T/ BK
AD 81
TRAI LE R TOW W I RI N G
J938 W - 1 1

F33
F33
E l 18TN
18PK/RD
1 8 PK / RD
BLUE DOT
TURN SI GNAL
FLASH ER
( SE E SH 56 )
L6 1 8 RD/ BK
L5 18RD
_ L5 18RD
V34 20WT/RD
A21 14 DB
F20 18WT
F20 18WT
G5 20DB/ WT
A3 12RD/WT
F 35 16 RD
F 32
A31
1 8 PK / DB
14 BK/WT
GREEN DOT
F21
E2 200R
F30 1 6 RD/ TN
A4 1 2BK / RD
A4 1 2BK / RD
Ml 20PK
X 12 20RD/ WT
L5 18RD
L5 14RD
V34 20WT/ RD
12TN
L1 9 18PK
HAZARD
L9 18BK/ WT
X3 2 0BK / RD
F 33 1 8 PK / RD
X2 1 8 DG/ RD_
A15 16 PK
A22 1 2BK / 0R
V6 18DB
V6 18DB
HAZARD
FLASH ER
( SE E SH 56 )
HORN
RELAY
( SE E SH 30)
FUSE NO. AMPS COLOR SHEET
1 2 GRAY 2 , 3 6 , 3 8
2 5 TAN 2 , 1 0, 1 2 . 1 3 , 1 4 , 5 8 , 7 7 , 7 8
3 20 YELLOW 2 . 7 , 9 , 1 0 , 3 9
4 20 YELLOW 1 . 3 0 . 4 7
5 20 YELLOW 1 . 7 7 . 7 8
6 20 YELLOW 1 , 7 3
7 15 LT BLUE 1 , 1 0 . 5 2
8 10 RED 2 , 1 0 , 6 1 . 6 3 . 6 5
9 20 YELLOW 2 . 1 0 , 3 1 . 3 3 . 5 6
10 20 YELLOW 2 . 1 0 . 5 4 . 5 5
11 30 GREEN 2 . 1 0 . 6 6 , 6 7 . 6 9
12 30 CI RCUI T BREAKER SI LV E R CAN 2 , 1 0 , 7 1
13 20 YELLOW 1 , 56
14 3 V I OLE T 1 . 4 7 , 5 2 . 6 1 . 6 3 , 6 5
15 10 RED 1 , 4 9 , 5 1 . 5 2 , 6 1 , 6 3 , 6 5 , 7 5
J 9 3 8W- H F USE BLOCK MODULE AND RE LAY BANK AD 82

\j i i i i i i i i 1 I r 11 I I i I i M ig
VIEWED FROM WIRE
END OF CONNECTOR
^ AUTO TRANSMI SSI ON ONLY
CAV I GNI TI ON SYSTEM CI RCUI TS SHEET
K 32 20WT/ BK
WATER IN FUEL SENSOR
25
2 K2 20TN/ BK ENGI NE COOLANT TEMP SENSOR 25
3 A H i oRD DI RECT BATTERY FEED 22
4
K4 1 8 BK / LB SENSOR RETURN 26
5 Z l l 16 BK/WT SI GNAL GROUND 23
e !<6 20VT/WT 5 VOLT SUPPLY 26
"7
/ K44 1 0TN/ YL
8 VOLT INPUT
25
8
9
JA21 HO B
I GNI T I ON FEED
21
10 76 20 OR/WT TRANSMI SSI ON OD CONTROL 14
11 Z 12 1 8 BK / TN POWER GROUND 23
12
Z 12 1 8 BK / TN POWER GROUND 23
13

14
_ _ _

J.5 S22 1 8 0R/ BK HEATER Ul RELAY 21
16 S21 1 8 Y L/ BK
HEATER #1 RELAY
21
17
--

18

19
20 K20 18DG GENERATOR F I E LD DRI VER 20
21 I K 2 1 1 8 BK / RD TRANSMI SSI ON OD LOCKOUT SOLENO 0 25
22 K22 1 8 0R/ DB THROTTLE POSI TI ON ( SE NSOR) 26
23

24
K24 1 8GY/ BK REFERENCE PI CKUP 25
25 021 20PK DATA LI NK TRANSMIT 23
26

27 J C20 18BR A/ C COMPRESSOR CLUTCH INPUT 26
28 T25 20 LG/RD TRANSMI SSI ON THERMO SWITCH 25
29 V40 18WT/PK BRAKE SENSE 37
30 rTTF 1 8 BR/ Y L "
PARK/ NEUTRAL POSI TI ON SWITCH 21
31
32 G3 2 0BK / PK MALFUNCTION INDICATOR LAMP 22
33 V36 20TN/ RD V E H I CLE SPE E D CONTROL VACUUM 37
34 CI 3 20DB/ 0R W. O. T . CUTOUT RELAY 26
35
.
36
37 T6 1 2 0BK / 0R TRANSMI SSI ON OD LAMP SI GNAL 14
38

39
40
4 1
42
4 3 G21 20GY / LB TACHOMETER PROV I SI ONS 22
44

45 D20 20LG DATA LI NK RE CE I V E 23
46
47 G7 20WT/OR V E H I CLE SPE E D SENSOR PI CK UP 25
48 V31 2 0BR/ RD V E H I CLE SPE E D CONTROL- SET 37
4 9 V32 2 0Y L/ RD V E H I CLE SPE E D CONTROL- ON/ OF F 37
50
V33 20WT/LG V E H I CLE SPE E D CONTROL-RESUME 37
5 i
K51 20 DB/ YL
AUTOMATIC SHUT-DOWN RELAY 22
52

53 V35 20 LG/RD V E H I CLE SPE E D CONTROL-VENT 37
54 K 31 2 0BK / PK W ATE R- I N- F UE L LAMP 23
5
r
: T6 0 2 0 0 R/ LG TRANSMISSION OD SOLENOID 14
56 E5 20DG/WT W AI T- TO- START LAMP 23
57 A142 16DG/0R A. S. D . - BATTE RY SE NSE 22
50

53
60
.
AD 83
POWERTRAIN CONTROL MODULE I I
(PCM I I ) CONNECTOR ( 5 . 9 L D I E SE L E NGI NE )
J 9
38w - n
5 . 2 L 5 . 9L E N G I N E
V I E WE D FROM WI R E
END OF CONNECTOR
POWERTRAIN CON
J 9 3 8W- H (PCM I I ) CONNECTOR
CAV IGNITION S YS T E M C I R C U I T S S HE E T
1
K l 200G/RD
MAP S E N S O R 20
2"-1 K2 2 0 T N / BK
E N G I N E COOLANT TEMPERATURE SENSOR 20
3
A14 IBRD
D I R E C T BA T T E R Y 16
4
K4 18BK / L B S E N S O R R E T UR N 20
5
Z l l 16BK/ WT S I G N A L GROUND 17
6 K6 2 0 V T / WT
5 VOLT S U PPL Y 20
7 K7 180R
8 VOLT I N PU T 20
8

9 A21 14DB
I G N I T I O N F E E D 16
10
T6 200R/WT
T R A N S M I S S I O N OD CONTROL 12
11 Z12 18BK / T N
POWER GROUND 17
12 Z12 18BK / T N
POWER GROUND 17
13 | K l 4 18L B/ BR I N J E C T O R D R I V E R 4 15
14
K 13 18YL / WT I N J E C T O R D R I V E R 3 15
15
K12 18TN
I N J E C T O R D R I V E R 2 15
16
17"
K l 1 18WT / DB I N J E C T O R D R I V E R 1 15 16
17" K17 18D B/ T N I N J E C T O R D R I V E R 7 15
18 K18 18RD/YL
19 K 19 18GY
I G N I T I O N C O I L D R I V E R 15
20 K20 18DG
GE NE R AT OR F I E L D D R I V E R 19
21 K21 18BK/RD
TB S U R F A C E TEMP S E N S O R 20
22 K22 180R/DB
T HR OT T L E P O S I T I O N ( S E N S O R ) 18
23 K141 18TN/ WT
HE A T E D OXYGE N S E N S O R ( 5 . 9 L HD) 17
24
K24 18GY/BK R E F E R E N C E PI C K U P 18
2 5
021 20PK
DATA L I N K T R A N S M I T 17
26

27 C20 18BR
A / C C Y C L I N G S WI T C H I NPUT 18
28

_
29 V40 18WT / PK
BR A K E S E N S E 35
30 T41 20BR/YL
PA R K / N E U T R A L PO S I T I O N S WI T C H 19
31

32 G3 2 0BK / PK
M A L U N C T I O N I N D I C A T O R LAMP 19
33 V 3 6 2 0 T M / R D V E H I C L E S PE E D C ONT R OL - V AC UUM 35
34 C 13 2 0 D B/ O R W. O . T . CUTOUT R E L A Y 18
35
K35 20GY/YL EGR S O L E N O I D 16
36

37 TBI 2 0 BK / 0 R
T R A N S M I S S I O N OD LAMP S I G N A L 12
38 K15 18PK/BK
39
"40
K 3 9 18G Y / R D I D L E A I R CONTROL MOTOR 19 39
"40
K40 18BR / WT
I D L E A I R CONTROL MOTOR 19
4 1
K41 18BK/DG
HE A T E D OXYGE N S E N S O R 17
42
43
42
43

44 K44 18GY
C AMS HAFT P O S I T I O N S E N S E 20
45 0 2 0 2 0 LG DATA L I N K R E C E I V E 17
4 6

4 7 G7 2 0 WT / OR V E H I C L E S PE E D S E N S O R PI C K U P 20
48 V31 20BR/RD
V E H I C L E S PE E D C O N T R O L - S E T 35
49 V32 20YL/RD
V E H I C L E S PE E D C O N T R O L - O N / O F F 35
50
Y33 2 0 WT / L G
V E H I C L E S PE E D C O N T R O L - R E S U M E 35
5 1
K51 2 0 D B/ Y L
A U T O MA T I C S HUT - DOWN R E L A Y 16
52
K52 20PK/BK
E V A P/ PU R G E S O L E N O I D 16
5 3
V35 20LG/RD
V E H I C L E S PE E D C O N T R O L - V E N T 35
54 K54 200R/BK
EMCC S O L E N O I D 11. 12
5 5
T60 200R/LG
T R A N S M I S S I O N OD S O L E N O I D 12
5G
G24 20GY/PK
S E R V I C E R E M I N D E R I N D I C A T O R LAMP 13
57
A142 16DG/0R
A . S . D . - BA T T E R Y S E N S E 15
58 K16 18LG/ BK
5 9
K59 18VT/ BK
60 K60 18Y L / BK
TROL MODULE I I
( GAS MF I E N GI N E S)
A D
84
SMALL
INDEX
50 49 48 47 46 45
44 43 42 41 40 39 38 37 36 35
34 33 32

31 30 29
28 27 26

25 24 23
22 21 20

19 18 17
16 15 14 13 12 11 10 9 8 7
6 5 4 3 2 1
LARGE
INDEX
TERMINAL END
OF DISCONNECT
ENGINE COMPARTMENT
CAV I TY
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
4 0
4 1
4 2
4 3
44
4 5
4 6
47
4 8
50
ENGINE COMPARTMENT CI RCUI TS
A3 12RD/WT
C7 1 2BK / TN
A1 4 1 1 6 DG/ BK
L4 16 VT/WT
L3 1 4 RD/ 0R
V30 20DB/ RD
V31 20BR/ RD
V33 20WT/ LG
V32 2 0Y L/ RD
E5 20DG/WT
G34 1 6 RD/ GY
L20 14 LG/WT
G21 20GY / LB
G20 20V T/ Y L
G6 20GY
G60 20GY / Y L
G85 20TN/ OR
L6 1 18LG
L6 0 18TN
A15 16 PK
T6 1 2 0BK / 0R
LI 1 8 V T/ BK
L7 1 8 BK / Y L
F 20 18WT
V10 20BR
A4 1 16 YL
X2 1 8DG/ RD
Ml 1 8 BK / TN
Gi l 20WT/ BK
V5 1 8DG/ YL
V6 18DB
C21 1 8 DB/ 0R
G3 2 0BK / PK
X4 20LG/ BR
V4 0 18WT/PK
G24 20GY/ PK
G7 2GWT/0R
T6 200R/ WT
V3 18BR/WT
V4 1 8 RD/ Y L
A21 14 DB
A4 1 2BK / RD
Al 12RD
A2 1 2PK / BK
HEADLAMP SWITCH
A/ C AND HEATER BLOWER MOTOR
FUEL PUMP FEED (GAS ONLY)
HEADLAMP LOW BEAM ( 2 W I RE S)
HEADLAMP HIGH BEAM ( 2 W I RE S)
V E H I CLE SPEED CONTROL
WAIT TO START LAMP ( D I E SE L Q N LY r
HIGH BEAM INDICATOR LAMP
HIGH BEAM FEED
TACHOMETER SI GNAL ( D I E SE L)
ENGINE COOLANT TEMPERATURE SE NDI NG UNIT
ENGINE OI L PRE SSURE SWITCH
ENGINE OI L PRE SSURE SE NDI NG UNIT
WATE R- I N FUEL LAMP ( D I E SE L)
LEFT TURN SI GNAL LAMP
RIGHT TURN SI GNAL LAMP
BATTERY- H AZ ARD FLASH ER
TRANSMI SSI ON OV ERDRI V E INDICATOR LAMP
BACK - UP LAMPS
PARK I NG LAMPS ( 2 W I RE S)
BACK - UP LAMP SWITCH
WI NDSH I E LD WASHER MOTOR
ENGINE STARTER RELAY - 1 GN I TI ON
HORN
UNDERHOOD LAMP
E LE CTRI C VACUUM SENSOR ( D I E SE L) ( 2 W I RE S)
WI NDSH I E LD WIPER MOTOR
AI R CONDI TI ONI NG DAMPED PRE SSURE SWITCH
MALFUNCTION I NDI CATOR LAMP
4 WHEEL DRI V E SWITCH
BRAKE SENSOR
SRI LAMP (GAS ENGI NE ONLY)
V E H I CLE SPEED SENSOR
TRANSMI SSI ON OV E RDRI V E
SPLI CE - I GN I TI ON RUN CI RCUI T
I GNI TI ON OFF DRAW
I GNI TI ON SWITCH
I GNI TI ON SWITCH
AD 8 5 50- W AY BULK H E AD DI SCONNE CT
J938 W - 1 1

C A V I T Y I N S T R U ME N T PA N E L C I R C U I T S
1
10
11
12
13
14
15
16
17
18
19
20
21
22
2 3
24
25
26
27
2 8
2 9
30
31
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
5 0
A3 12 R D/ WT
C7 12 BK / T N
A61 16D G / BK
L4 16V T / WT
L 3 16R D / 0 R
V30 2 0 D B/ R D
V31 2 0 B R / R D
V33 2 0 WT / L G
V32 2 0 Y L / R D
V32 2 0 Y L / R D
G86 2 0 D G/ WT
G34 16R D / G Y
L 2 0 2 0 L G / WT
G21 2 0 G Y / L B
G20 18V T / Y L
G6 20 GY
G60 2 0 G Y / Y L
G85 2 0 T N / 0 R
L 61 18L G
L 61 18LG
L 60 18TN
L 60 18TN
A15 16PK
T61 2 0 BK / O R
L I 18V T / BK
L7 18BK / Y L
F2 0 18WT
V10 2 0 BR
A41 14YL
S 2 1 14Y L / BK
X2 18D G / R 0
Ml 18PK
G i l 2 0 WT / BK
V5 18DG
V6 18DB
C2 18D B/ Y L
G3 2 0 BK / PK
Gl 2 0 D G / G Y
V40 18WT / PK
G24 2 2 G Y / PK
G7 2 0 WT / 0 R
T6 2 0 0 R / WT
V3 18BR / WT
V4 18R D / Y L
A21 14DB
A21 14DB
A4 12 BK / R D
A l 12RD
A2 12 PK / BK
A / C AND HE AT E R BLOWER MOTOR
FUE L PUMP F E E D ( G A S ONL Y)
HE ADL AMP- L OW BEAM
H E A D L A M P- H I G H BEAM
WAI T TO S T A R T LAMP ( D I E S E L ON L Y)
HI G H BEAM I N D I C A T O R LAMP
HI G H BEAM F E E D ( D . R . L . MODUL E )
TACHOMETER ( D I E S E L )
ECT S E N D / U N I T OR S WI T C H
E N G I N E O I L PR E S S U R E LAMP
E N G I N E O I L PR E S S U R E G A U G E - S E N D U N I T
WATER I N F U E L LAMP ( D I E S E L )
L E F T FRONT TURN S I G N A L LAMP
R I G HT FRONT TURN S I G N A L LAMP
HAZ AR D F L A S HE R
T R A N S M I S S I O N O V E R D R I V E I N D I C A T O R LAMP
BA C K - U P L A MPS
PA R K I N G L A MPS
BA C K - U P LAMP F E E D
WI N D S H I E L D WASHER MOTOR
I G N I T I O N S T A R T
I G N I T I O N S T A R T ( D I E S E L )
HORNS
UNDERHOOD LAMP
E L E C T R I C VACUUM S E N S OR ( D I E S E L )
WI N D S H I E L D WI PE R S WI T C H
WI N D S H I E L D WI PE R S WI T C H
A / C C OMPR E S S OR C L UT C H
M A L F U N C T I O N I N D I C A T O R
4 WHEEL D R I V E S WI T C H
BR A K E S E N S OR
S R I LAMP ( G A S E N G I N E ONL Y)
V E H I C L E S PE E D S E N S OR ( 2 WI R E S )
T R A N S M I S S I O N O V E R D R I V E S WI T C H
WI N D S H I E L D WI PE R LOW S PE E D
WI N D S H I E L D WI PE R HI G H S PE E D
I G N I T I O N - R U N I S T A R T
I G N I T I O N S WI T C H ( B l )
I G N I T I O N S WI T C H ( B3)
S HE E T NO
4, 6. 3 0 , 47
66, 67, 68
78
43 , 45 , 47
36, 38
2 3
43, 46
46, 47
22
2 7, 2 8
2 3
43 . 45 , 5 6
43 , 45 . 5 6
3 , 5 , 5 6
12 , 14
7. 79
43 , 45 , 47
7. 9
5 3. 5 5
8, 9
30
2 9
34
5 4, 5 5
67, 69
19, 2 2
13
32 , 34, 36, 38
19
19, 2 5
12 , 14
5 4. 5 5
10 , 2 3. 77, 78
3 . 5 . 3 9
4, 6. 1 0
4. 6. 1 0
T E R M I N A L END
OF D I S C O N N E C T
ff p
45
46 47 48 49 50
35 36 37 38 39 40 41 42 43 44
29 30 31

32 33 34
23 24 25

26 27 28
17 18 19

20 21 22
7 8 9 10 11 12 13 14 15 16
1
^ 1.
2 3 4 5 &
J *j
L A R GE
I N D E X
I N S T R U ME N T PA N E L
J 938W- 11
50- W AY BULK H E AD DI SCONNE CT AD 8 6

10 11 12 13 14 15 16 17
18 19 20
21
22 23
24
STEERI NG COLUMN INSULATOR
AS VIEWED FROM WIRE END
CAV C I R C UI T DE S CRI PTI ON SHEET
1 V9 18WT/BK I NTERMI TTENT WIPER MODULE
2 V8 18VT I NTERMI TTENT WIPER MODULE
3 V10 20BR WI NDSHI ELD WASHER MOTOR
4 V6 18DB WIPER SWITCH FEED
5 V4 18RD/YL WIPER MOTOR-HI GH SPEED
53
6
V3 18BR/WT WIPER MOTOR-LOW SPEED
6
V3A 18BR/WT WIPER SWITCH
7 V7 18DG/WT I NTERMI TTENT WIPER MODULE
8 V17 18DG/YL I NTERMI TTENT WIPER MODULE
9 V3A 18BR/WT WIPER SWITCH
10

11 L60 18TN RI GHT FRONT TURN SI GNAL
12 L62 18BR/RD RI GHT REAR TURN SI GNAL
13 L19 18PK HAZ ARD FLASHER FEED
14 L50 18WT/TN STOP LAMP FEED
56
15 L63 18DG/RD LEFT REAR TURN SI GNAL
16 L61 18LG LEFT FRONT TURN SI GNAL
17 L6 18RD/WT TURN SI GNAL FLASHER FEED
18 L4 14VT/WT LOW BEAM-HEADLAMPS
19 L2 14LG HEADLAMP FEED
47
20 L3 14RD/0 R HI GH BEAM-HEADLAMPS
47
21 L20 14LG/WT HEADLAMP-OPT HORN FEED
22

23
24

-
AD 87
S T E E R I N G COLUMN CONNECTOR
WI TH I NT E R MI T T E NT WI PE R S ( PU L S E WI PE )
J 9 3 8 W
.
n

1
1 2 3 4 5 6 7 8 9 1 2 3
( \
\ )
7 8 9
10 11 12 13
( \
\ )
14 15 16 17
18 19 20
^- -
21
22 23 24
S T E E R I N G COLUMN I N S U L A T O R
AS V I E WE D FROM WI R E END
CAV C I R C U I T D E S C R I PT I O N S HE E T
1
V3 18BR / WT WI PE R MOTOR- LOW S PE E D
5 5
2 V5 18DG WI PE R - PA R K
5 5
3 V10 20 BR WASHER MOTOR
5 5
4 V6 18DB WI P E R - I G N I T I O N F E E D
5 5
5 V4 18R D / Y L WI PE R M O T O R - HI G H S PE E D
5 5
6
7
8

9
10
11 L 60 18TN R I G HT FRONT TURN S I G N A L
5 6
12 L 62 18BR / R D R I G HT R E AR TURN S I G N A L
5 6
13 L 19 18PK HAZ ARD F L A S HE R F E E D
5 6
14 L 5 0 18WT/ TN S T OP LAMP F E E D
5 6
15 L 63 18D G / R D L E F T REAR TURN S I G N A L
5 6
16 L 61 18LG L E F T FRONT TURN S I G N A L
5 6
17 L6 18R D/ WT TURN S I G N A L - F L A S H E R F E E D
5 6
18 L4 14V T/ WT LOW BE A M - HE A D L A M PS
47
19 L2 14LG HE ADL AMP F E E D
47
20 L 3 14R D / O R HI G H BE A M - HE A D L A M PS
47
21 L 2 0 14LG/ WT HE A D L A M P- O PT HORN F E E D
47
22
23
24
J 938H - 11
STE E RI N G COLUMN CONNECTOR
WITH 2 SPE E D W I PE RS
AD 88

1 2 3
A
4 5 6 7 8
/
\
9 10 11
/
\
12 13 14 15 16
/
\
17 18 19 20 21
u
22 23 24 25 26
u
27 28 29 30 31
u
32 33 34
u
35 36 37 38 39
u
4 0 4 1 4 2
u
VIEW FROM WIRE END
HEADLAMP I DASH
WI RI NG
CAV I GNI TI ON SYSTEM CI RCUI TS SHEET NO
1 A21 14 DB I GNI TI ON FEED 16
2 Z l 14 BK GROUND 9 . 6 8
3
4 LI 1 8 V T/ BK BACK - UP LAMPS 9
5 K54 2 00R/ BK EMCC SOLE NOI D 11
6 A1 4 1 1 6 DG/ BK FUEL PUMP 16
7 C20 18BR A/ C COMPRESSOR CLUTCH 18
8 G3 2 0BK / PK MALFUNCTION INDICATOR LAMP 19
9 A14 16 RD BATTERY FEED 16
10
11 Z l l 16 BK/ WT SI GNAL GROUND 17
12 V4 0 18WT/ PK BRAKE SI GNAL 35
13 Z12 1 6 BK / TN POWER GROUND 17
14 T4 1 1 8 BR/ Y L ENGINE STARTER RELAY COI L 9
15 G60 20GY / Y L ENGINE OI L PRE SSURE SE ND/ UNI T 28
16 G6 20GY ENGI NE OI L PRE SSURE SWITCH 28
17 T6 200R/ WT TRANSMI SSI ON OD OV E RRI DE 12
18 T6 1 2 0BK / 0R TRANSMI SSI ON OD LAMP SI GNAL 12
19
20 F20 18WT BACK - UP LAMP SWITCH 9
21
22 T22 14 DB/WT EMCC 11
23
24 G24 20GY / PK SRI LAMP 19
25 C13 2 0DB/ 0R A/ C COMPRESSOR CLUTCH RELAY 18
26 G20 2 0V T/ Y L ECT SE ND/ UNI T 28
27 V 31 2 0BR/ RD V E H I CLE SPEED CONTROL- SET 35
28 V32 2 0 Y L/ RD V E H I CLE SPE E D CONTROL- OF F / ON 35
29 V33 20WT/ LG V E H I CLE SPEED CONTROL- RESUME 35
30 V35 20LG/ RD V E H I CLE SPEED CONTROL- VENT 35
31 V36 20TN/ RD V E H I CLE SPEED CONTROL- VACUUM 35
32
33 G7 20WT/ 0R V E H I CLE SPEED SENSOR 19
34 C3 1 4 DB/ BK A/ C COMPRESSOR CLUTCH FEED 6 8
35
36
37
38
39
4 0
4 1
4 2
&
GjCUQjQ
UXJUXj
O
" I T
mJKXTV
ENGI NE WI RI NG
- ENG
AD 8 9 GAS E N GI N E W I RI N G CONNECTOR
J 938 W - 1 1

E N G I N E S
ENGINES 9 - 1
C O N T E N T S
page page
3.9L ENGINE SERVICE PROCEDURES 17 5.9L ENGINE SERVICE PROCEDURES 77
5.2L ENGINE SERVICE PROCEDURES 47 ENGINE DIAGNOSIS 5
5.9L (DIESEL) ENGINE SERVICE PROCEDURES . 107 STANDARD SERVICE PROCEDURES 1
S T A N D A R D S E R V I C E P R O C E D U R E S
INDEX
page
Engi ne Performance 2
Form-ln-Place Gaskets 1
H oning Cylinder Bores 2
FORM-IN-PLACE GASKETS
There are several places where form-in-place gas-
ket s are used on t he engine. DO NOT us e form-in-
pl ace gas ket mat er i al unl ess speci fi ed. Care must
be t aken when applying form-in-place gaskets. Bead
size, continuity and location are of great importance.
Too t hi n a bead can result in leakage while too much
can result in spill-over. A continuous bead of t he
proper width is essential to obtain a leak-free joint.
Two types of form-in-place gasket mat eri al s are
used in t he engine area (Mopar Silicone Rubber Ad-
hesive Seal ant and Mopar Gasket Maker). Each have
different properties and cannot be used interchange-
ably.
MOPAR SILICONE RUBBER ADHESIWE
SEALANT
Mopar Silicone Rubber Adhesive Sealant, normally
black in color, is available in 3 ounce tubes. Moisture
in t he air causes the sealant mat eri al to cure. This
mat eri al is normally used on flexible met al flanges.
It has a shelf life of 1 year and will not properly cure
if over aged. Always inspect t he package for t he ex-
piration dat e before use.
MOPAR GASKET MAKER
Mopar Gasket Maker, normally red in color, is
available in 6 cc tubes. This anaerobic type gasket
mat eri al cures in t he absence of air when squeezed
between smooth machined metallic surfaces. It will
not cure if left in t he uncovered tube. DO NOT use
on flexible metal flanges.
page
Hydrostatic Lock 4
Measuring with Plastigage 3
Repair Damaged or Worn Threads . 4
SURFACE PREPARA TION
Part s assembled with form-in-place gaskets may be
disassembled without unusual effort. In some in-
stances, it may be necessary to lightly t ap t he part
with a mallet or other suitable tool to break t he seal
between t he mat i ng surfaces. A flat gasket scraper
may also be lightly tapped into t he joint but care
must be t aken not to damage t he mat i ng surfaces.
Scrape or wire brush all gasket surfaces to remove
all loose mat eri al . Inspect stamped part s to ensure
gasket rails are flat. Fl at t en rails with a hammer on
a flat plate, if required. Gasket surfaces must be free
of oil and dirt. Make sure t he old gasket mat eri al is
removed from blind at t achi ng holes.
GASKET APPLICATION
Assembling part s using a form-in-place gasket re-
quires care.
Mopar Silicone Rubber Adhesive Seal ant should be
applied in a continuous bead approximately 3 mm
(0.12 inch) in diameter. All mounting holes must be
circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4
inch) drop is placed in t he center of t he gasket con-
tact area. Uncured seal ant may be removed with a
shop towel. Components should be torqued in place
while t he seal ant is still wet to t he touch (within 10
minutes). The use of a locating dowel is recom-
mended during assembly to prevent smearing t he
mat eri al off location.
Mopar Gasket Maker should be applied sparingly
to one gasket surface. The sealant diameter should
be 1.Q0 mm (0.04 inch) or less. Be certain the mate-
9 - 2 ENGINES
rial surrounds each mounting hole. Excess mat eri al
can easily be wiped off. Components should be
torqued in place within 15 minutes. The use of a lo-
cating dowel is recommended duri ng assembly to pre-
vent smeari ng t he mat eri al off location.
ENGINE PERFORMANCE
To provide best vehicle performance and lowest ve-
hicle emissions, it is most i mport ant t hat t he tune-up
be done accurately. Use t he specifications listed on
t he Vehicle Emission Control Information label
found on t he engine compartment hood.
(1) Test cranki ng amperage draw (refer to Group
8B, Battery/Starter/Generator Service for t he proper
procedures).
(2) Tighten t he i nt ake manifold bolts (refer to
Group 11, Exhaust System and Int ake Manifold for
t he proper specifications).
(3) Perform cylinder compression test:
(a) Check engine oil level and add oil, if neces-
sary.
(b) Drive t he vehicle unt i l engine reaches normal
operating t emperat ure.
(c) Select a route free from traffic and other
forms of congestion, observe all traffic laws and
briskly accelerate t hrough t he gears several times.
The higher engine speed may help clean out valve
seat deposits which can prevent accurate compres-
sion readings.
C A U T I O N : D O N O T overspeed the engi ne.
(d) Remove all spark plugs from engine. As
spark plugs are being removed, check electrodes for
abnormal firing indicators - fouled, hot, oily, etc.
Record cylinder number of spark plug for future
reference.
(e) Disconnect coil wire from distributor and se-
cure to good ground to prevent a spark from start-
ing a fire.
(f) Be sure throttle blades are fully open duri ng
t he compression check.
(g) Insert compression gage adaptor into t he
No. l spark plug hole. Crank engine until maxi-
mum pressure is reached on gauge. Record this
pressure as No. l cylinder pressure.
(h) Repeat Step 3g for all remai ni ng cylinders.
(i) Compression should not be less t han 689 kPa
(100 psi) and not vary more t han 172 kPa (25 psi)
from cylinder to cylinder.
(j) If cylinder(s) have abnormally low compres-
sion pressures, repeat steps 3a t hrough 3h.
(k) If t he same cylinder(s) repeat an abnormally
low reading, it could indicate t he existence of a
problem in t he cylinder.
The recommended compressi on pressures are
to be used onl y as a gui de to di agnosi ng engi ne
probl ems. An engi ne shoul d NOT be di sassem-
bl ed to determine the cause of l ow compressi on
unl ess some malfunction is present.
(4) Clean or replace spark plugs as necessary. Ad-
j ust gap (refer to Group 8D, Ignition System for gap
adjustment and torque).
(5) Test resistance of spark plug cables (refer to
Group 8D, Ignition System.
(6) Inspect t he pri mary wire. Test coil output volt-
age, pri mary and secondary resistance. Replace part s
as necessary (refer to Group 8D, Ignition System and
make necessary adjustment).
(7) Set ignition t i mi ng to specifications (refer to
Specification Label on engine compartment hood).
(8) Perform a combustion analysis.
(9) Test fuel pump for pressure and vacuum (refer
to Group 14, Fuel System for t he proper specifica-
tions).
(10) Inspect air filter element (refer to Group 0,
Lubrication and Maintenance for t he proper proce-
dure).
(11) Inspect crankcase ventilation system (refer to
Group 0, Lubrication and Maintenance for t he proper
procedure).
(12) For emission controls refer to Group 25, Emis-
sion Controls System for service procedures.
(13) Inspect and adjust accessory belt drives (refer
to Group 7, Cooling System for t he proper adjust-
ments).
(14) Road test vehicle as a final test.
H0NIN6 CYLINDER BORES
Before honing, stuff plenty of clean shop towels un-
der t he bores and over t he crankshaft to keep abra-
sive mat eri al s from ent eri ng t he crankshaft area.
(1) Used carefully, t he Cylinder Bore Sizing Hone
C-823 equipped with 220 grit stones, is t he best tool
for t hi s job. In addition to deglazing, it will reduce
t aper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and mai nt ai n t he required lim-
its.
C A U T I O N : D O N O T use rigid type hones to remove
cylinder wall gl aze.
(2) Deglazing of t he cylinder walls may be done if
t he cylinder bore is st rai ght and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). 20-60 strokes, de-
pending on t he bore condition, will be sufficient to
provide a satisfactory surface. Using honing oil
C-3501-3880 or a light honing oil available from ma-
jor oil distributors.
C A U T I O N : D O N O T us e engi ne or t r ansmi ssi on oil,
mineral spi ri ts or kerosene.

ENGINES 9 - 3
(3) Honing should be done by moving t he hone up
and down fast enough to get a Crosshatch pattern.
The hone marks should INTERSECT at 50 to 60 for
proper seating of rings (Fig. 1).
Fig. 1 Cylinder Bore Crosshatch Pattern
(4) A controlled hone motor speed b e t w e e n 200 and
300 RPM is necessary to o b t a i n t he proper C r o s s h a t c h
angle. The number of up and down strokes per
mi nut e can be regulated to get t he desired 50 to 60
angle. Fast er up and down strokes increase t he cross-
hat ch angle.
(5) After honing, it is necessary t hat t he block be
cleaned to remove all traces of abrasive. Use a brush
to wash part s with a solution of hot wat er and deter-
gent. Dry part s thoroughly. Use a clean, white, lint-
free cloth to check t hat t he bore is clean. Oil t he
bores after cleaning to prevent rust i ng.
MEASURING WITH PLASTIGAGE
CRANKSHAFT MAIN BEARING CLEARANCE
Engine crankshaft beari ng clearances can be deter-
mined by use of Plastigage, or equivalent. The fol-
lowing is t he recommended procedures for t he use of
Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) The total clearance of t he mai n bearings can
only be determined by removing t he weight of t he
crankshaft. This can be accomplished by either of
two methods:
METHOD - 1 ( PREFERRED) Shi m t he bear-
ings adjacent to t he beari ng to be checked. This will
remove t he clearance between upper bearing shell
and t he crankshaft. Place a mi ni mum of 0.254 mm
(0.010 inch) shim between t he beari ng shell and t he
adjacent bearing cap. Tighten t he bolts to 18 N*m (13
ft. lbs.) torque.
ALL ENGINESWhen checking No. l mai n bear-
ing; shim No.2 mai n bearing.
ALL ENGI NES- Whe n checking No.2 mai n bear-
ing; shim No. l and No.3 mai n bearing.
ALL ENGI NES- Whe n checking No.3 mai n bear-
ing; shim No.2 and No.4 mai n bearing.
5.2L, 5.9L AND 5.9L (DIESEL) EN-
GINESWhen checking No.4 main bearing; shim
No.3 and No.5 mai n bearing.
3.9L ENGINEWhen checking No.4 mai n bear-
ing; shim No.3 mai n bearing.
5.2L AND 5.9L ENGINESWhen checking No.5
mai n bearing; shim No.4 mai n bearing.
5.9L (DIESEL) ENGI NE- Wh e n checking No.5
mai n bearing; shim No.4 and No.6 main bearing.
mai n bearing; shim No.5 and No.7 mai n bearing.
mai n bearing; shim No.6 mai n bearing.
Remove all shi ms before assembl i ng engine.
METHOD - 2 (ALTERNATIVE)The weight of
the crankshaft is supported by a jack under t he coun-
terweight adjacent to t he bearing being checked.
(3) Place a piece of Plastigage across the entire
width of t he beari ng cap shell (Fig. 2). Position t he
Plastigage approximately 6.35 mm (1/4 inch) off cen-
ter and away from t he oil holes. In addition, suspect
areas can be checked by placing t he Plastigage in
t hat area. Ti ght en t he beari ng cap bolts of t he bear-
ing being checked to 115 Nm (85 ft. lbs.) torque. DO
NOT rotate the crankshaft or the Pl asti gage may
be smeared, gi vi ng i naccurate results.
Fig. 2 Placement of Plastigage in Bearing Shell
(4) Remove t he bearing cap and compare t he width
of t he flattened Plastigage with the scale provided on
t he package (Fig. 3). Plastigage generally comes in 2
scales (one scale is in inches and t he other is a met-
ric scale). Locate t he band closest to t he same width.
This band shows t he amount of clearance. Differ-
ences in readings between t he ends indicate t he
amount of t aper present. Record all readings t aken
(refer to Engine Specifications).
(5) Plastigage is available in a variety of clearance
ranges. The 0.025-0.076 mm (0.001-0.003 inch) range
is usually t he most appropriate for checking engine
bearing clearances.
9 - 4 ENGINES

RN861
Fig. 3 Clearance Measurement
CONNECTING ROD BEARING CLEARANCE
Engi ne connecting rod beari ng clearances can be
determined by use of Plastigage, or equivalent. The
following is t he recommended procedures for t he use
of Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across t he entire
width of t he bearing cap shell (Fig. 2). Position t he
Plastigage approximately 6.35 mm (1/4 inch) off cen-
t er and away from t he oil holes. In addition, suspect
areas can be checked by placing t he Plastigage in t he
suspect area.
(3) The crankshaft must be t urned unt i l t he con-
necting rod to be checked st art s moving toward t he
top of t he engine. Only t hen should t he rod cap wi t h
Plastigage in place be assembled. Tighten t he rod
cap nut to 61 Nnn (45 ft. lbs.) torque. DO NOT r o-
t at e t he cr anks haf t or t he Pl as t i gage ma y be
s me a r e d, gi vi ng i na c c ur a t e r es ul t s .
(4) Remove t he beari ng cap and compare t he width
of t he flattened Plastigage with t he scale provided on
t he package (Fig. 3). Plastigage generally comes in 2
scales (one scale is in inches and t he other is a met-
ric scale). Locate t he band closest to t he same width.
This band shows t he amount of clearance. Differ-
ences in readings between t he ends indicate t he
amount of t aper present. Record all readings t aken
(refer to Engi ne Specifications).
(5) Plastigage is available in a variety of clearance
ranges. The 0.025-0.076 mm (0.001-0.003 inch) range
is usually t he most appropriate for checking engine
beari ng clearances.
REPAIR DAMAGED OR WORN THREADS
Damaged or worn t hreads can be repaired. Essen-
tially, t hi s repai r consists of:
Drilling out worn or damaged t hreads.
Tapping t he hole with a special Heli-Coil Tap, or
equivalent.
Installing an insert into t he tapped hole.
This brings t he hole back to its original t hread
size.
C A U T I O N : Be sure that the tapped hol es maintain
the original center line.
Heli-Coil tools and inserts are readily available
from automotive part s jobbers.
HYDROSTATIC LOCK
When an engine is suspected of hydrostatic lock
(regardless of what caused t he problem), follow t he
steps below.
(1) Perform t he Fuel Pressure Release Procedure
(refer to Group 14, Fuel System).
(2) Disconnect t he negative cable from t he battery.
(3) Inspect air cleaner, induction system and in-
t ake manifold to ensure system is dry and clear of
foreign mat eri al .
(4) Place a shop towel around t he spark plugs to
catch any fluid t hat may possibly be under pressure
in t he cylinder head. Remove t he plugs from t he en-
gine.
C A U T I O N : D O N O T use the starter motor to rotate
the crankshaft. Severe damage coul d occur.
(5) With all spark plugs removed, rotate t he crank-
shaft using a breaker bar and socket.
(6) Identify t he fluid in t he cylinders (i.e. coolant,
fuel, oil, etc.).
(7) Make sure all fluid has been removed from t he
cylinders.
(8) Repair engine or components as necessary to
prevent t hi s problem from occurring again.
(9) Squirt engine oil into t he cylinders to lubricate
t he walls. This will prevent damage on rest art .
(10) Install new spark plugs. Tighten t he spark
plugs to 41 N
#
m (30 ft. lbs.) torque.
(11) Drai n engine oil. Remove and discard t he oil
filter.
(12) Install t he drai n plug. Tighten t he plug to 34
(13) Install a new oil filter.
(14) Fill engine crankcase with t he specified
amount and grade of oil (refer to Group 0, Lubrica-
tion and Maintenance).
(15) Connect t he negative cable to t he battery.
(16) St art t he engine and check for any leaks.

ENGINES 9 - S
ENGINE DI AGNOSI S
Engi ne diagnosis is helpful in determining t he
causes of malfunctions not detected and remedied by
routine tune-ups.
These malfunctions may be classified as either per-
formance (e.g., engine idles rough and stalls) or me-
chanical (e.g., a st range noise).
Refer to t he Service DiagnosisPerformance chart
and t he Service DiagnosisMechanical chart for pos-
sible causes and corrections of malfunctions. Refer to
Group 1 4 , Fuel System for t he fuel system diagnosis.
SERWIGE DIAGNOSIS (GASOLINE ENGINES) - PERFORMANCE
CONDITION POSSI BL E C A U S E S CORRECTION
ENGINE WILL NOT START 1. Weak battery.
2. Corroded or loose battery
connections.
3. Faulty starter.
4 . Moisture on ignition wires and
distributor cap.
5. Faulty ignition cables.
6. Faulty coil or control unit.
7. Incorrect spark plug gap.
8. Incorrect ignition timing.
9. Dirt or water in fuel system.
10. Faulty fuel pump.
1. Test battery specific gravity. Charge or replace as necessary.
2. Clean and tighten battery connections. Apply a coat of light
mineral grease to the terminals.
3. Refer to Group 8A, Battery/Starter/Charging System
Diagnostics.
4. Wipe wires and cap clean and dry.
5. Replace any cracked or shorted cables.
6. Test and replace, if necessary (refer to Group 8D, Ignition
System).
7. Set gap (refer to Group 8D, Ignition System).
8. Refer to Group 8D, Ignition System.
9. Clean system and replace fuel filter.
10. Install new fuel pump (refer to Group 14, Fuel System).
ENGINE STALLS OR
ROUGH IDLE
1. Idle speed set too low.
2. Idle mixture too lean or too rich.
3. Leak in intake manifold.
4. Worn or burned distributor rotor.
5. Incorrect ignition wiring.
6. Faulty coil.
7. EGR valve leaking.
1. Refer to Group 14, Fuel System.
2. Refer to Group 14, Fuel System.
3. Inspect intake manifold gasket and vacuum hoses. Replace, if
necessary (refer to Group 11, Exhaust System & Intake
Manifold).
4 . Install new distributor rotor.
5. Install correct wiring.
6. Test and replace, if necessary (refer to Group 8D, Ignition
System).
7. Test and replace, if necessary (refer to Group 25, Emissions
Control System).
J9309-105
9 - 6 ENGINES
SERVICE DIAGNOSIS (GASOLINE ENGINES) PERFORMANCE (CONT.)
1 CON D I TI ON POSSI BL E CAUSE S ^ C O R R E C T I O N
1 ENGINE LOSS OF POWER 1. Incorrect ignition timing.
3. Worn distributor shaft.
4 . Dirty or incorrectly gapped spark
plugs.
6. Faulty fuel pump.
7. Incorrect valve timing.
8. Blown cylinder head gasket.
9. Low compression.
10. Burned, warped or pitted valves.
11. Plugged or restricted exhaust
system.
12. Faulty ignition cables.
13. Faulty coil.
2. install new distributor rotor.
3. Remove and repair distributor (refer to Group 8D, Ignition
System).
4. Clean plugs and set gap (refer to Group 8D, Ignition System).
6. Install new fuel pump.
7. Correct valve timing.
8. Install new cylinder head gasket.
9. Test compression of each cylinder.
10. Install new valves.
11. Install new parts, as necessary.
12. Replace any cracked or shorted cables.
13. Test and replace, as necessary (refer to Group 8D, Ignition
System).
ENGINE MISSES ON
ACCELERATION
1. Dirty or gap set too wide in spark
plug.
3. Dirt in fuel system.
4. Burned, warped or pitted valves.
5. Faulty coil.
1. Clean spark plugs and set gap (refer to Group 8D, Ignition
System).
3. Clean fuel system.
4. Install new valves.
5. Test and replace, if necessary, (refer to Group 8D, Ignition
System).
ENGINE MISSES AT HIGH
SPEED
1. Dirty or gap set too wide in spark
plug.
2. Worn distributor shaft.
4. Faulty coil.
6. Dirty injector in throttle body.
1. Clean spark plugs and set gap (refer to Group 8D, Ignition
System).
2. Remove and repair distributor (refer to Group 8D, Ignition
System).
3. Install new distributor rotor.
4 . Test and replace, as necessary (refer to Group 8D, Ignition
System).
6. Clean injector.
J9309-106

ENGINES 9 - 7
SERVICE DIAGNOSIS (GASOLINE ENGINES) - MECHANICAL
C O N D I T I O N PSSSI1LI C A U S I S CORRE CTI ON
NOI SY VALVES 1. High or low oil level in
crankcase.
2. Thin or diluted oil.
3. Low oil pressure.
4. Dirt in tappets/lash adjusters.
5. Bent push rods.
6. Worn rocker arms.
7. Worn tappets/lash adjusters.
8. Worn valve guides.
9. Excessive runout of valve seats on
valve faces.
1. Check for correct oil level (refer to Group 0, Lubrication and
Maintenance).
2. Change oil (refer to Group 0, Lubrication and Maintenance).
3. Check engine oil level.
4. Clean hydraulic tappets/hydraulic lash adjusters.
5. Install new push rods.
6. Inspect oil supply to rocker arms.
7. Install new hydraulic tappets/hydraulic lash adjusters.
8. Ream and install new valves with oversize stems.
9. Grind valve seats and valves.
C ONNE C T I NG ROD
NOI SE
1. Insufficient oil supply.
4. Excessive bearing clearance.
5. Connecting rod journal out-of-
round.
6. Misaligned connecting rods.
1. Check engine oil level (refer to Group 0, Lubrication and
Maintenance).
2. Check engine oil level. Inspect oil pump relief valve and spring.
3. Change oil to correct viscosity.
4. Measure bearings for correct clearance. Repair as necessary,
5. Replace crankshaft or grind journals.
6. Replace bent connecting rods.
M A I N BEARING NOI S E 1. Insufficient oil supply.
2 Low oil pressure.
5. Excessive end play.
6. Crankshaft journal out-of-round,
worn,
7. Loose flywheel or torque
converter.
1. Check engine oil level (refer to Group 0, Lubrication and
Maintenance).
2. Check engine oil level. Inspect oil pump relief valve and spring.
4. Measure bearings for correct clearance. Repair as necessary.
5. Check No. 3 main bearing for wear on flanges.
6. Grind journals or replace crankshaft.
7. Tighten to correct torque.
OIL PRESSURE DROP 1. Low oil level.
2. Faulty oil pressure sending unit.
4. Clogged oil filter.
5 Worn parts in oil pump.
8. Oil pump relief valve stuck.
9. Oil pump suction tube loose, bent
or cracked.
10. Oil pump cover warped or
cracked.
1. Check engine oil level.
2. Install new sending unit.
3. Check sending unit and check main bearing oil clearance.
4. Install new oil filter.
5. Replace worn parts or pump.
7. Measure bearings for correct clearance.
8. Remove valve and inspect, clean and install.
9. Remove oil pan and install new tube, if necessary.
10. Install new oil pump.
OIL LEAKS 1. Misaligned or deteriorated
gaskets.
2. Loose fastener, broken or porous
metal part.
1. Replace the gasket.
2. Tighten, repair or replace the part.
OIL PUMPI NG AT RI NGS ;
SPARK PLUGS FOULI NG
1. Worn, scuffed or broken rings.
2. Carbon in oil ring slot.
3. Rings fitted too tightly in grooves.
4. Worn valve guides.
5. Leaking intake gasket.
6. Leaking valve guide seals.
7. Dislodged valve guide seals.
1. Hone cylinder bores and install new rings.
2. Install new rings.
3. Remove the rings. Check grooves. If grooves are not proper
width, replace piston.
4. Ream guides and replace valves with oversize valves and seals.
5. Replace gasket and tighten intake manifold to proper torque.
6. Replace seals.
7. Seat valve guide seals or replace, as needed.
J9209-58
9 - 8 ENGINES

SERVICE DIAGNOSIS (DIESEL ENGINE) - PERFORMANCE
CONDI TI ON POSSIBLE CAUSES C O t i E C T I O N
ENGINE WILL NOT
C R ANK OR C R A N K S
SLOWLY
Starting motor operating, but
not cranking the engine.
Crankshaft rotation restricted.
Starting circuit connections
loose or corroded.
Neutral safety switch or starter
relay inoperative.
Battery charge low.
No voltage to starter solenoid.
Solenoid or starting motor
inoperative.
Remove the starter motor. Check for broken flywheel teeth or
a broken starting motor spring.
Rotate the engine to check for rotational resistance.
Clean and tighten connections.
Check starter relay for supply voltage and proper operation of
neutral safety. Replace defective parts.
Check battery voltage. Replace battery if a charge cannot be
held.
Check voltage to solenoid. If necessary, replace the solenoid.
Replace starter motor.
ENGINE CRANKS,
BUT WILL NOT
STARTNO SMOKE
FROM EXHAUST
No fuel in supply tank.
Electrical fuel shutdown not
open.
Air intake or exhaust plugged.
Fuel filter plugged.
Injection pump not getting fuel
or fuel is aerated.
Worn or inoperative injection
pump.
Internal pump timing incorrect.
Camshaft out of time.
Fill fuel supply.
Check for loose wires and verify that the valve is functioning.
Check to be sure manual shutoff lever is in the run position.
Remove the obstruction.
Drain fuel/water separator and replace fuel filter.
Check fuel flow/bleed fuel system.
Visually check fuel delivery with an externally connected
injector to one of the pump outlets. Replace the pump if fuel
is not being delivered.
Time the pump (refer to Group 14, Fuel System).
Check/correct gear train timing alignment.
ENGINE HARD TO
START, OR WILL
NOT S TARTS MOKE
FROM EXHAUST
Incorrect starting procedure.
Cranking speed too slow.
Cold starting aids not working
or are needed.
Intake heater system not
working.
Insufficient intake air.
Air in the fuel system or the
fuel supply is inadequate.
The manual fuel shutoff control must be in the run position.
(a) Verify that the transmission is not engaged.
(b) Check the battery, starting motor and look for loose or
corroded wiring connections.
(c) Rotate the engine with a barring tool (Snap-On Tool SP371,
MTE No. 3377462, or equivalent) to check for internal
rotational resistance.
Verify the aids are operating. Repair/replace inoperative
parts.
Verify system is working. Repair/replace inoperative parts.
Inspect or replace filter and check for obstructions to the air
supply tube.
Check the flow through the filter and bleed the system. Locate
and eliminate the air source.
J9109-232

ENGINES 9 - 9
SERVICE DIAGNOSIS (DIESEL ENGINE) PERFORMANCE (CONT.)
CONDI TI ON POSSIBLE CAUSES CORRECTION
ENGINE HARD TO
START, OR WILL
NOT STARTSMOKE
FROM EXHAUST
(Cont'd)
Fuel pump Inoperative.
Injection pump throttle linkage
loose or damaged.
Contaminated fuel.
Worn or inoperative injection
pump.
Injection pump out of time.
Valves incorrectly adjusted.
One or more injectors worn or
not operating properly.
Disconnect fuel line and verify fuel delivery. If needed replace
pump.
Visually check the linkage. Tighten/replace linkage.
Verify by operating the engine with clean fuel from a
temporary tank. Check for presence of gasoline. Drain and
flush fuel supply tanks. Replace fuel/water separator filter.
Visually check fuel delivery with an externally connected
injector to one of the pump outlets. Replace the pump if fuel is
not being delivered.
Check/time the pump (refer to Group 14, Fuel System).
Adjust valves.
Check/replace bad improperly operating injectors.
ENGINE STARTS,
BUT WILL NOT
KEEP RUNNI NG
Idle speed too low for the
accessories.
Intake air or exhaust system
restricted.
Air in the fuel system or the
fuel supply is inadequate.
Fuel waxing due to extremely
cold weather.
Contaminated fuel.
Adjust the idle speed.
Visually check for exhaust restriction and inspect the air intake.
Repair/replace restricting parts.
Verify by inspecting the fuel filter. Clean the system and use
climatized fuel. Replace fuel/water separator filter. Check fuel
heater for proper operation.
Verify by operating the engine with clean fuel from a temporary
supply tank. Check for presence of gasoline. Replace fuel/water
separator filter.
SURGING (SPEED
CHANGE)
If the condition occurs at idle,
the idle speed is set too low for
the accessories.
High pressure fuel leak.
One or more injectors worn or
not operating properly.
Improperly operating injection
pump.
Adjust the idle.
Inspect/correct leaks in the high pressure lines. Fittings and
delivery valve sealing washers.
Check/replace the inoperative injectors.
Replace the injection pump.
ROUGH IDLE
(IRREGULARLY FIRING
OR ENGINE SHAKING)
Cold engine.
Idle speed too low for the
accessories.
Engine mounts damaged or
loose.
Refer to troubleshooting logic for intake manifold heater system
(see Group 11, Exhaust System & Intake Manifold)
Adjust idle speed.
Repair or replace mounts.
J9109-233
9 - 10 ENGINES _

C O N D I T I O N possmu CLOSES CORRECTI ON
ROUGH IDLE
(IRREGULARLY FI RI NG
OR ENGI NE SHAKI NG)
(Cont'd)
High pressure fuel leaks.
Air In the fuel system.
Correct leaks in the high pressure lines, fittings or delivery
valves.
Bleed the fuel system and eliminate the source of the air.
Sticking needle valve in an
injector.
Check and replace the injector with the sticking needle valve.
E NGI NE RUNS ROUGH
OR MI SFI RI NG
Fuel injection lines leaking. Correct leaks in the high pressure lines, fittings, injector sealing
washers or delivery valves.
Air in the fuel or the fuel
supply is inadequate.
Contaminated fuel. Verify by operating the engine with clean fuel from a temporary
supply tank. Check for presence of gasoline. Replace fuel/water
separator filter.
Incorrect valve adjustment. Check for a bent push rod and adjust valves. Replace push rod,
if necessary.
Injection pump timing incorrect. Check/time pump (refer to Group 14, Fuel System).
Improperly operating injectors. Replace inoperative injectors.
Defective injection pump
(delivery valves).
Replace injection pump.
Camshaft out of time. Check/correct gear train timing alignment.
Damaged camshaft or tappets. Inspect camshaft valve lift. Replace camshaft and tappets.
E NGI NE RPM WILL NOT
REACH RATED SPEED
Engine overloaded. Verify high idle speed without load. Investigate operation to be
sure correct gear is being used.
Improperly operating
tachometer.
Verify engine speed with hand tachometercorrect as required.
Throttle linkage worn or
incorrectly adjusted.
Adjust linkage for stop-to-stop fuel control lever travel. Replace
linkage if necessary.
Partially engaged mechanical
shutdown lever.
Adjust and place shutdown lever in the run position.
Inadequate fuel supply. Check the fuel flow through the system to locate the reason for
inadequate fuel supplycorrect as required.
pump.
LOW POWER
Fuel control lever not moving to
full throttle.
Check/correct for stop-to-stop travel.
Mechanical/shutdown lever
partially engaged.
Check to see if the shutdown lever is in run position.
High oil level. Check/correct oil level.
Engine overloaded. Check for added loading from accessories or driven units, brakes
dragging and other changes in vehicle loading. Repair/replace as
needed.
J9109-264

ENGINES 9 - 11
SERVICE DIAGNOSIS (DIESEL ENGINE) - PERFORMANCE (CONT.)
LOW POWER
(Cont'd)
SJow throttle response, leaking
air fuel control tube or
improperly operating control
in the pump.
Tighten the fittings. Replace the pump if the controls are not
functioning.
Incorrect external injection
pump timing.
Verify that injection pump timing marks are aligned (see Group
14, Fuel System).
Inadequate intake air flow. Inspect/replace air cleaner element. Look for other restrictions.
High pressure fuel leak. Inspect/correct leaks in the high pressure lines, fittings injector
sealing washers or delivery valve seals.
Inadequate fuel supply. Check the flow through the filter to locate the source of the
restriction.
High fuel temperature. Verify that fuel heater is off during warm weather. Check for a
restricted fuel drain manifold. Repair/replace as needed.
Poor quality fuel or fuel
contaminated with gasoline.
Verify by operating from a temporary tank with good fuel.
Check for presence of gasoline. Replace fuel/water separator
filter.
Air leak between the turbo-
charger and the intake
manifold.
Check/correct leaks in the air crossover tube, hoses, gaskets,
and around mounting capscrews or through holes in the manifold
cover.
Exhaust leak at the manifold
or turbocharger.
Check/correct leaks in the manifold or turbocharger gaskets.
If manifold is cracked, replace manifold.
Improperly operating turbo-
charger.
Inspect/replace turbocharger.
Valve clearance incorrect. Check/adjust valves.
Injection pump improperly
operating.
Check/time pump (refer to Group 14, Fuel System).
Worn or improperly operating
injectors.
Check/replace injectors.
pump.
Excessive exhaust restriction. Check/correct the restriction in the exhaust system.
EXCESSIVE EXHAUST
SMOKE
Engine running too cold (white
smoke).
Refer to troubleshooting logic for coolant temperature below
normal (refer to Group 7, Cooling System). Inspect intake
manifold heater/KSB valve for proper operation.
Inadequate intake air. Inspect/change air cleaner. Look for other restriction.
Air leak between turbocharger
and intake manifold.
Check/correct leaks in the air crossover tube, hoses, gaskets,
mounting capscrews or through holes in the manifold cover.
Exhaust leak at the manifold
or turbocharger.
Check/correct leaks in the manifold or turbocharger gaskets.
If cracked replace manifold.
turbocharger.
Inspect/replace turbocharger.
J9209-57
9 - 12 ENGINES

C O N D I T I O N POS S I BL E C A U S E S C OR R E C T I ON
EXCESSIVE EXHAUST
SMOKE (Cont'd)
More than one sealing washer
under an injector.
Check and remove extra washer.
Improperly operating injectors. Check and replace inoperative injectors.
Improperly operating or over-
fueled injection pump.
Piston rings not sealing
(blue smoke).
Perform blow-by check. Correct as required.
ENGINE WILL NOT
SHUT-OFF
Fuel shutoff valve inoperative.
Engine running on fumes drawn
into the air intake.
Stop the engine mechanically with lever on the fuel pump.
Check/replace sealing washer, piston and spring.
Check the air intake ducts for the source of the fumes.
WAR NI NG: In ease of engine runaway due to flammable fumes
from gasoline spills or turbocharger oil leaks being sucked into the
engine, shut off engine ignition switch first then use a CO* or dry
chemical type fire extinguisher and direct the spray under the front
bumper to remove oxygen supply. The engine air intake is on the
passenger side behind the bumper. The fire extinguisher must bo
directed at this location for emergency shutdown conditions.
COOLANT TEMPERA-
TURE ABOVE NORMAL
Low coolant level. (a) Check coolant level. Add coolant, if necessary.
(b) Locate and correct the source of the coolant leak. Refer to
troubleshooting logic for coolant loss.
Incorrect/improperly operating
pressure cap.
Replace cap with the correct rating for the system.
High lube oil level. Check/drain oil to correct level.
Loose drive belt on water
pump/fan.
Check/replace belt or belt tensioner.
Inadequate air flow to the
radiator.
Check/repair radiator core, fan shroud and fan clutch as
required.
Radiator fins plugged. Blow debris from fins.
Collapsed radiator hose. Replace the hose.
Improperly operating tempera-
ture sensor/gauge.
Verify that the gauge and temperature sensor are accurate.
Replace gauge/sensor, if bad.
Improperly operating, incorrect
or no thermostat.
Check and replace the thermostat.
Air in the cooling system. (a) Make sure the fill rate is not being exceeded and the correct
vented thermostat is installed.
(b) Check for loose hose clamps. Tighten if loose.
(c) If aeration continued, check for a compression leak through
the head gasket.
Inoperative water pump. Check and replace the water pump.
incorrect injection pump timing. Verify pump timing marks are aligned. Check/time the injector
pump (refer to Group 7, Cooling System).
J9209-56
SERVICE DIAGNOSIS (DIESEL ENGINE) - PERFORMANCE (CONT.)

ENGINES 9 - 13
CONDI TI ON POSSIBLE CAUSES COfiiiECTION
COOLANT TEMPERA-
TURE ABOVE NORMAL
(Cont'd)
Overfueled injection pump.
Plugged cooling passages in
radiator, head, head gasket or
block.
Engine overloaded.
Replace the injection pump.
Flush the system and fill with clean coolant.
Verify that the engine load rating is not being exceeded.
COOLANT TEMPERA-
TURE BELOW NORMAL
Too much air flow across the
radiator.
Incorrect thermostat, broken
thermostat jiggle pin or
contamination in thermostat.
Temperature sensor or gauge
inoperative.
Coolant not flowing by
temperature sensor.
Check/repair viscous fan as required.
Check and replace thermostat.
Verify that the gauge and sensor are accurate. If not, replace
gauge/sensor.
Check and clean coolant passages.
J9109-254
9 - 14 ENGINES
SERVICE DIAGNOSIS (DIESEL ENGINE) MECHANICAL
CONDI TI ON
r
POSSIBLE C A U S E S
CORRECTION
LUBRICATING OIL
PRESSURE LOW
Low oil level. (a) Check and fill with clean engine oil.
(b) Check for a severe external oil leak that could reduce the
pressure.
Oil viscosity thin, diluted or
wrong specification.
Verify the correct oil is being used. Check for oil dilution. Refer
to Contaminated Lube Oil (Engine DiagnosisMechanical).
Improperly operating pressure
switch/gauge.
Verify the pressure switch is functioning correctly. If not,
replace switch/gauge.
Relief valve stuck open. Check/replace valve.
Plugged oil filter. Change oil filter. Oil filter change interval may need to be
revised.
If cooler was replaced, shipping
plugs left in cooler.
Check/remove shipping plugs.
If pump replaced, four cylinder
oil pump installed in a six
cylinder engine.
Verify that the correct pump is installed. If not, install an oil
pump for a six cylinder engine.
Loose or missing cup plugs. Check and replace cup plugs.
Worn oil pump. Check and replace oil pump.
Suction tube loose or seal
leaking.
Check and replace seal.
Loose main bearing cap. Check and install new bearings and tighten cap to proper torque.
Worn bearings or wrong
bearings installed.
inspect and replace connecting rod or main bearings. Check and
replace piston cooling nozzles.
J9109-237
ENGINES 9 - 15
C O N D I T I O N POSSI BLE C AUS E S CORRECTI ON
LUBRI CATI NG OIL
PRESSURE TOO HI GH
Pressure switch/gauge not
operating properly.
Verify the pressure switch is functioning correctly. If not,
replace switch/gauge.
Engine running too cold. Refer to Coolant Temperature Below Normal (Engine Diagnosis-
Performance)
Oil viscosity too thick. Make sure the correct oil Is being used. Refer to Group O,
Lubrication and Maintenance.
Oil pressure regulator valve
stuck closed or binding.
Check and replace valve, and/or oil cooler cover.
LUBRI CATI NG OIL LOSS External leaks. Visually inspect for oil leaks. Repair as required.
Crankcase being overfilled. Verify that the correct dipstick is being used.
incorrect oil specification or
viscosity.
(a) Make sure the correct oil is being used.
(b) Look for reduced viscosity from dilution with fuel.
(c) Review/reduce the oil change intervals.
Oil cooler leak. Check and replace the oil cooler.
High blow-by forcing oil out
the breather.
Check the breather tube area for signs of oil loss. Perform the
required repairs.
Turbocharger leaking oil to the
air intake.
Inspect the air ducts for evidence of oil transfer.
Repair as required.
Worn valve seals. Inspect and replace the valve seals.
Piston rings not sealing (oil
being consumed by the engine).
Perform blow-by check. Repair as required.
COMPRESSI ON
KNOCKS
Air in the fuel system.
Poor quality fuel.
Bleed the fuel system (refer to Group 14, Fuel System).
Verify by operating from a temporary tank with good fuel. Clean
and flush the fuel supply tanks. Replace fuel/water separator
filter.
Engine overloaded. Verify that engine load rating is not being exceeded.
Incorrect injection pump timing. Check and time injection pump (refer to Group 14, Fuel System).
Improperly operating injectors. Check and replace inoperative injectors.
J9109-266
SERVICE DIAGNOSIS (DIESEL ENGINE) - MECHANICAL (CONT.)
9 - 16 ENGINES

EXCESSIVE VIBRATION Loose or broken engine mounts. Replace engine mounts.
Damaged fan or improperly
operating accessories.
Check and replace the vibrating components.
Improperly operating vibration
clamper.
Inspect/replace the vibration damper.
Improperly operating fan hub. Inspect/replace the fan hub.
Worn or damaged alternator
bearing.
Check/replace the alternator.
Flywheel housing misaligned. Check/correct flywheel alignment.
Loose or broken power
component.
Inspect the crankshaft and rods for damage that causes an
unbalance. Repair/replace as required.
Worn or unbalanced driveline
components.
Check/repair driveline components.
EXCESSIVE ENGINE
NOISES
Drive belt squeal, insufficient
tension or abnormally high
loading.
Check the tensioner and inspect the drive belt. Make sure water
pump, tensioner pulley, fan hub and alternator turn freely.
Intake air or exhaust leaks. Refer to Excessive Exhaust Smoke (Engine Diagnosis
Performance).
Excessive valve lash Adjust valves. Make sure the push rods are not bent and rocker
levers or adjusting screws are not severely worn. Replace bent
or severely worn pads.
Turbocharger noise. Check turbocharger impeller and turbine wheel for housing
contact. Repair/replace as required.
Gear train noise. Visually inspect and measure gear backlash. Replace gears as
required.
Power function knock. Check/replace rod and main bearings.
ALTERNATOR NOT
CHARGI NG OR IN-
SUFFICIENT CHARGI NG
Loose or corroded battery
connections.
Alternator belt slipping.
Clean/tighten battery connection.
Check/replace belt tensioner. Check/replace belt.
Alternator pulley loose on
shaft.
Tighten pulley.
alternator.
Check/replace alternator.
J9109-253
SERVICE DIAGNOSIS (DIESEL ENGINE) - MECHANICAL (CONT.)

3.9L ENGINE 9 - 17
3 . 9 L ENGINE SERVICE PROCEDURES
INDEX
page
Camshaft 31
Crankshaft 38
Crankshaft Mai n Beari ngs 39
Crankshaft Rear Oil Seal s . 40
Cylinder Block 4 1
Cylinder H ead Cover . , 21
Cylinder H eads . 2 2
Distributor 3 3
Engine Assembl y . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine Front Mounts 17
Engine Rear Mount 18
Front Crankshaft Oil Seal Replacement . . . . . . . . 31
GENERAL INFORMATION
The 3.9 Liter (238 CID) six-cylinder engine is a
V-Type, lightweight, single cam, overhead valve en-
gine with hydraulic roller tappets (Fig. 1).
Engine Type 90 V-6 OH V
Bore and Stroke 99.3 x 84 .0 mm (3.91 x 3. 31 in.)
Displacement 3.9L (238 cu. in.)
Compression Ratio 9.1: 1
Torque 305 N-m (225 ft. lbs.) @ 3,200 rpm
Firing Order.... 1-6-5-4-3-2
Lubrication Pressure Feed-Full Flow Filtration
Engine Oil Capacity 3.8L (4.0 Qts) with Filter
Cooling System Liquid Cooled-Forced Circulation
Cooling Capacity 14.3L (15.1 Qts)
Cylinder Block Cast Iron
Crankshaft Nodular Iron
Cylinder Head Cast Iron
Combustion Chambers "Fast Burn" Design
Camshaft Nodular Cast Iron
Pistons Aluminum Alloy w/Strut
Connecting Rods Forged Steel
J9309-29
Fig. 1 Engine Description
This engine is designed for unleaded fuel.
Engine lubrication system consists of a rotor type
oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,
3, 5 on t he left bank and 2, 4, 6 on t he ri ght bank.
The firing order is 1-6-5-4-3-2 (Fig. 2).
The engine serial number is stamped into a ma-
chined pad located on t he left, front corner of t he cyl-
inder block. When component part replacement is
necessary, use t he engine type and serial number for
reference (Fig. 3).
page
Hydraulic Tappets 27
Oil Pan 34
Oil Pump 34
Piston / Connecting Rod Assembl y 36
Rocker Ar ms 21
Specifications3.9L Engi ne 4 3
Timing Chai n Cover 29
Valve Stem Seal / Spring Replacement . . . . . . . . 27
Valve Timing 28
V al ves / Valve Spri ngs 25
Vibration Damper 29
J 9309- 26
Fig. 2 Firing Order
i M 3.9L T x x x x X X X X X X X X
X = Last Digit of Model Year
M = Plant - M Mound Road
S Sabillo
T Trenton
K Toluca
3.9L = Engine Displacement
T = Usage - T Truck
XXXX = Month/Day
XXXXXXXX - Serial Code - Last 8 Digits of VI N No.
J9209-72
Fig. 3 Engine identification Number
ENGINE FRONT MOUNTS
REMOVAL
(1) Disconnect the negative cable from t he bat t ery.
9 - 18 3.9L ENGINE

(2) Raise hood and position fan to assure clearance
for radiator top t ank and hose.
C A U T I ON : D O N O T lift the engi ne by the intake
mani fol d.
(3) Install engine lifting fixture.
(5) Remove bolts and nut s from insulators (Figs. 4
and 5).
ATTACHI NG
BOLT
ATTACHI NG
NUT
BRACKET
INSULATOR
ATTACHI NG
BOLT
FRAME
SIDE
INSULATOR?
(RIGHT SIDE)
(LEFT SIDE)
J9109-238
Fig. 4 Engine Front Mounts2WD Vehicles
ATTACHI NG
NUT
FRAME
SIDE
INSULATOR
BRACKET
STUD
NUT
STUD
NUT
ATTACHI NG
BOLT
INSULATOR
BACKI NG.
PLATE
ATTACHI NG
NUT
BRACKET
STUD
NUT
FRONT
BRACKET
STUD
NUT
ATTACHI NG
NUT
FRAME
s , d e
(RIGHT SIDE)
J9109-239
Fig. 5 Engine Front Mounts4WD Vehicles
(6) Raise engine with lifting fixture only far
enough to remove insulators.
(7) If necessary, remove t he bracket from t he block
(Figs. 4 and 5).
(8) If necessary, remove t he front bracket (4WD)
from t he crossmember (Fig. 5).
INSTALLATION
(1) If removed, position t he front bracket (4WD) to
t he crossmember (Fig. 5). Install t he at t achi ng nut s
and t i ght en to 41 Nm (30 ft. lbs.) torque.
(2) If removed, position t he bracket to t he block
(Figs. 4 and 5). Install t he bolts and t i ght en to 41
(3) With engine raised SLIGHTLY, install insula-
tors on front bracket (Figs. 4 and 5).
(4) Lower engine with lifting fixture while guiding
insulator studs into brackets.
(5) Install at t achi ng bolts and nut s (Figs. 4 and 5).
Tighten t he at t achi ng bolts and nut s to 41 Nm (30
ft. lbs.) torque,
(6) Install insulator stud nut s and washers.
Tighten t he stud nut s to 102 Nm (75 ft. lbs.) torque.
(8) Remove lifting fixture.
ENGINE REAR MOUNT
REMOVAL-2WD
(2) Position a transmission jack in place.
(3) Remove rear mount insulator through-bolt and
nut (Fig. 6).
(4) Raise rear of transmission and engine
SLIGHTLY.
(5) Remove t he flange nut s from t he frame cross-
member support bracket (Fig. 6).
(6) Raise rear of transmission enough to provide
insulator to crossmember clearance. Remove t he in-
sulator and t he crossmember support bracket. Re-
move t he flange nut s and separate t he insulator from
t he support bracket (Fig. 6).
(7) If necessary, remove t he at t achi ng bolts hold-
ing t he transmission support bracket to t he t ransmi s-
sion (Fig. 6).
INSTALLA TION-2WD
(1) If removed, position t he transmission support
bracket to t he transmission. Install t he at t achi ng
bolts and t i ght en to 68 N*m (50 ft. lbs.) torque.
(2) Position insulator in transmission support
bracket. Install through-bolt.
(3) Be sure insulator is secured in a LEVEL posi-
tion relative to transmission rear support bracket.
Tighten t he through-bolt nut to 68 N*m (50 ft. lbs.)
torque.
(4) Position t he crossmember support bracket onto
t he insulator (Fig. 6). Install t he insulator flange
nut(s) and t i ght en to 41 Nnn (30 ft. lbs.) torque.
(5) Using t he transmission jack, lower t he insula-
tor and crossmember support bracket onto t he cross-
member (Fig. 6).
(6) Tighten t he crossmember flange nut s to 41 Nnn
(7) Remove t he transmission jack.
HE MO VAL4 WD
3.9L ENGINE 9 - 19
I NSULATOR
TRANSMISSION
ATTACHING
BOLT
TRANSMI SSI ON
THROUGH
BOLT
TRANSMI SSI ON
SUPPORT BRACKET
I NSULATOR
CROSSMEMBER
SUPPORT BRACKET
CROSSMEMBER
FLANGE NUTS
TRANSMISSION
SUPPORT BRACKET
A ATTACHI NG
^ BOLT
J9109-241
(2) Remove t he skid plate (if equipped) from t he
rear crossmember and transmission crossmember
(Fig. 7).
(3) Position transmission jack under transmission
and raise rear of transmission and engine
SLIGHTLY.
(4) AUTOMATIC TRANSMISSIONRemove
t he nut s and bolts holding t he transmission support
spacer to t he insulator mount i ng plate (Fig. 8). Re-
move t he bolts and nut s holding t he engine rear sup-
port plate to t he insulator mount i ng plate (Fig. 8).
(5) MANUAL TRANSMISSIONRemove t he
nut s and bolts holding the insulator mounting plate
to t he transfer case (Fig. 9).
(6) Remove insulator mount i ng bolts, spacers,
washers and upper/lower insulators (Figs. 8 and 9).
Fig. 6 Rear Engine Support2WD
(7) Remove t he insulator mounting plate (Figs. 8
and 9).
TRANSFER
CASE
ENGI NE REAR
SUPPORT
PLATE
EXTENSI ON
ASSEMBLY
TRANSMI SSI ON
SUPPORT
SPACER
^SPACER
fjy. ^ UPPER
Î NSULATOR
I NSULATOR
MOUNTI NG
PLATE
LOWER
I NSULATOR
RAI L ASSEMBLY J91 09- 24 3
PU873
Fig. 8 Rear Engine Support4WD with Automatic
Transmission
Fig. 7 Skid Plate
TRANSFER
CASE
INSULATOR
M O U N T I N G
PLATE
NUT(B
RAIL
ASSEMBLY
SPACER
UPPER
INSULATOR
N UT
L OW E R
INSULATOR
J9109-242
Fig. 9 Rear Engine Support4WD with Manual
Transmission
(8) If necessary, remove t he transmission support
spacer (automatic transmission) from t he extension
assembly (Fig. 8).
(9) If necessary, remove t he engine rear support
plate (automatic transmission) from t he transfer case
(Fig. 8).
INSTALLATION-4WD
(1) If removed, position t he engine rear support
plate (automatic transmission) to t he transfer case
(Fig. 8). Install t he bolts and t i ght en to 41 N-m (30
ft. lbs.) torque.
spacer (automatic transmission) to t he extension as-
sembly (Fig. 8). Install t he bolts and t i ght en to 68
(3) Install insulator mount i ng plate, mount i ng
bolts, spacers, washers and upper/lower insulators to
the rail assembly (Figs. 8 and 9). Tighten t he mount-
ing nut s to 204 N*m (150 ft. lbs.) torque.
(4) AUTOMATI C TRANSMI SSI ON- Al i gn t he
engine rear support plate and t he transmission sup-
port spacer to t he insulator mount i ng plate (Fig. 8).
Lower t he engine and transmission onto t he insula-
tor mount i ng plate and install t he bolts. Tighten t he
transmission support spacer nut s to 204 N-m (150 ft.
lbs.) torque. Tighten t he engine rear support pl at e
bolts to 41 N-m (30 ft. lbs.) torque.
(5) MANUAL TRANSMISSIONAl i gn t he
transfer case to t he i nsul at or mounting plate and
lower t he engine and transmission. Install t he bolts
and t i ght en t he nut s (Fig. 9 - nut A) to 204 N-m (150
ft. lbs.) torque. Install t he bolts and t i ght en t he nut s
(Fig. 9 - nut B) to 41 N-m (30 ft. lbs.) torque.
(6) Install t he skid plate.
(7) Lower the vehicle.
ENGINE ASSEMBLY
REMOVAL
(1) Scribe hood hinge outlines on hood. Remove t he
hood.
(2) Remove t he battery.
(3) Drai n cooling system (refer to Group 7, Cooling
System for t he proper procedure).
(4) Remove t he air cleaner.
(5) Disconnect t he radi at or and heat er hoses. Re-
move radiator (refer to Group 7, Cooling System).
(6) Set fan shroud aside.
(7) Remove t he vacuum lines.
(8) Remove t he distributor cap and wiring.
(9) Disconnect t he accelerator linkage.
(10) Remove MPI t hrot t l e body.
(11) Disconnect the fuel lines.
(12) Disconnect t he st art er wires.
(13) Disconnect t he oil pressure wire.
(14) Discharge t he air conditioning system, if
equipped (refer to Group 24, Heat i ng and Air Condi-
tioning for service procedures).
(15) Disconnect t he air conditioning hoses.
(16) Disconnect t he power steering hoses, if
equipped.
(17) Remove st art er motor (refer to Group 8B, Bat-
tery/Starter/Generator Service).
(18) Remove t he generator (refer to Group 8B, Bat-
(19) Raise and support t he vehicle on a hoist.
(20) Disconnect exhaust pipe at manifold.
(21) AUTOMATI C TRANSMI SSI ON:
(a) Support transmission. This will assure t hat
t he torque converter will remai n in proper position
in t he transmission housing.
(b) Remove bell housing bolts and inspection
plate.
(c) Attach a C-clamp on front bottom of t rans-
mission torque converter housing to prevent torque
converter from falling out.
(d) Remove torque converter drive plate bolts
from torque converter drive plate. Mark converter
and drive plate to aid in assembly.
(22) MANUAL TRANSMI SSI ON:
(a) Support transmission.
(b) Disconnect clutch release mechanism and re-
move transmission to clutch housing bolts.
C A U T I O N : D O N OT lift the engi ne by the intake
mani fol d.
(23) Install an engine lifting fixture.
(24) Remove engine front mount bolts.

3.9L ENGINE 9 - 21
(26) On automatic transmission vehicles, discon-
nect t he engine from the torque converter drive
plate. On manual transmission vehicles, move engine
forward until drive pinion shaft clears t he clutch
disc. Remove engine from engine compartment.
(27) Install engine assembly on engine repair
stand.
INSTALLATION
(1) Remove engine from t he repair stand and posi-
tion in t he engine compartment.
(2) Install engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4 ) AUTOMATI C TRANSMI SSI ON:
(a) Position t he torque converter and drive plate.
Install torque converter drive plate bolts. Tighten
t he bolts to 31 Nnn (270 in. lbs.) torque.
(b) Install t he engine front mounts.
(c) Install bell housing bolts. Tighten t he bolts to
(d) Remove C-clamp.
(e) Install t he inspection plate.
(a) Position t he drive pinion shaft to t he clutch
disc.
(b) Connect t he clutch release mechanism and
install t he transmission to clutch bolts. Tighten t he
(c) Install t he engine front mounts.
(6) Remove transmission support.
(7) Install exhaust pipe to manifold.
(9) Remove engine lifting fixture.
(10) Install t he generator (refer to Group 8B, Bat-
(11) Install st art er motor (refer to Group 8B, Bat-
(12) Connect power steering hoses, if equipped.
(13) Connect air conditioning hoses.
(14) Evacuate and charge t he air conditioning sys-
tem, if equipped (refer to Group 24, Heat er and Air
Conditioning for service procedures).
(15) Using a new gasket, install MPI t hrot t l e body.
Tighten t he throttle body bolts to 23 N-m (200 in.
lbs.) torque.
(16) Connect t he accelerator linkage.
(17) Connect t he st art er wires.
(18) Connect t he oil pressure wire.
(19) Install t he distributor cap and wiring.
(20) Connect t he vacuum lines.
(21) Connect t he fuel lines.
(22) Install t he radiator (refer to Group 7, Cooling
System). Connect t he radiator hoses and heat er
hoses.
(23) Install fan shroud in position.
(24) Fill cooling system (refer to Group 7, Cooling
System for t he proper procedures).
(25) Install t he air cleaner.
(26) Install t he battery.
(27) Warm engine and adjust.
(28) Install hood and line up with t he scribe
marks.
(29) Road test vehicle.
CYLINDER HEAD COVER
A steel backed silicon gasket is used with t he cyl-
inder head cover (Fig. 1). This gasket can be used
again.
CYLINDER HEAD
COVER GASKET \
J 9209- 104
Fig. 1 Cylinder Head Cover Gasket
REMOVAL
(1) Disconnect t he negative cable from t he bat t ery.
(2) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(3) Remove cylinder head cover and gasket. The
gasket may be used again.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check t he gasket for use in "head cover installation.
If damaged, use a new gasket.
INSTALLATION
(1) The cylinder head cover gasket can be used
again. Install t he gasket onto t he head rail.
(2) Position t he cylinder head cover onto t he gas-
ket. Tighten t he bolts to 11 N-m (95 in. lbs.) torque.
(3) Install closed crankcase ventilation system and
evaporation control system.
(4) Connect t he negative cable to t he bat t ery.
ROCKER ARMS
REMOVAL
(1) Disconnect spark plug wires by pulling on t he
boot straight out in line with plug.
(2) Remove cylinder head cover and gasket.
(3) Remove the rocker arm bolts and pivots (Fig.
2). Place them on a bench in the same order as re-
moved.
(4) Remove the push rods and place them on a
bench in the same order as removed.
ROCKER
ARMS
J9209-6 6
Fig. 2 Rocker Arms
INSTALLATION
(1) Rotate the crankshaft until the "V6" mark
lines up with the TDC mark on the timing chain
case cover. This mark is located 147 ATDC from the
No. l firing position.
C A U T I O N : D O N O T rotate or crank the engi ne dur-
ing or immediately after rocker arm installation. Al -
low the hydraulic roller tappets adequate time to
bleed down (about 5 mi nutes).
(2) Install the push rods in the same order as re-
moved.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
to 28 N*m (21 ft. lbs.) torque.
(4) Install cylinder head cover.
(5) Connect spark plug wires.
CYLINDER HEADS
The alloy cast iron cylinder heads (Fig. 3) are held
in place by 8 bolts. The spark plugs are located in
the peak of the wedge between the valves.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (refer to Group 7, Cooling
System for the proper procedures).
(3) Remove the heat shields (Fig. 4).
SPARK SPARK INTAKE
PLUGS PLUG VALVE
EXHAUST INTAKE EXHAUST
VALVE VALVES VALVES J9309-35
Fig. 3 Cylinder Head Assembly
Fig. 4 Exhaust Manifold Heat Shields
(4) Remove the intake manifold-to-generator
bracket support rod. Remove the generator.
(5) Remove closed crankcase ventilation system.
(6) Disconnect the evaporation control system.
(7) Remove the air cleaner.
(9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove the return spring.
(11) Remove distributor cap and wires.
(12) Disconnect the coil wires.
(13) Disconnect heat indicator sending unit wire.
(14) Disconnect heater hoses and bypass hose.
(15) Remove cylinder head covers and gaskets.
(16) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(17) Remove exhaust manifolds.
(18) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.

3.9L ENGINE 9 - 23
(19) Remove t he head bolts from each cylinder
head and remove cylinder heads. Discard t he cylin-
der head gasket.
(20) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if t her e is
any reason to suspect leakage. If out-of-flatness ex-
ceeds 0.00075 mm/mm (0.00075 inch/inch) t i mes t he
span length in any direction, either replace head or
lightly machine the head surface.
FOR EXAMPLE:A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 x 0,00075 (12 x 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept-
able.
The cylinder head surface finish should be 1.78-
3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
(1) Apply Perfect Sealant No.5, or equivalent, to
both sides of t he gasket (Fig. 5).
PERFECT SEALANT NO. 5 PERFECT SEALANT N O. 5
Fig. 5 Sealant Location on Cylinder Head Gasket
(2) Position t he new cylinder head gasket s onto t he
cylinder block.
(3) Position t he cylinder heads onto head gasket s
and cylinder block.
(4) St art i ng at top center, tighten all cylinder head
bolts, in sequence, to 68 Nm (50 ft. lbs.) torque (Fig.
6). Repeat procedure, t i ght en all cylinder head bolts
to 143 Nm (105 ft. lbs.) torque. Repeat procedure to
confirm t hat all bolts are at 143 N*m (105 ft. lbs.)
torque.
C A U T I O N : When tightening the rocker arm bol t s,
Fig. 6 Cylinder Head Bolt Tightening Sequence
make sure the pi st on in that cylinder is N O T at
T D C . Cont act between the val ves and pi ston coul d
occur.
(5) Install push rods and rocker arm assemblies i n
their original position. Tighten t he bolts to 28 Nnn
(6) Place the 4 plastic locator dowels into t he holes
in t he block Fig. 7).
(7) Apply Mopar Silicone Rubber Adhesive Seal-
ant, or equivalent, to t he four corner joints. An ex-
cessive amount of seal ant is not required to ensure a
leak proof seal. However, an excessive amount of
sealant may reduce t he effectiveness of the flange
gasket. The sealant should be slightly higher t han
t he cross-over gaskets, approx. 5 mm (0.2 in).
(8) Install t he front and rear cross-over gaskets
onto t he dowels (Fig. 7).
FRONT CROSS-OVER GASKET
REAR CROSS-OVER GASKET J9209-99
Fig. 7 Cross-Over Gaskets and Locator Dowels
(9) Install t he flange gaskets. Be sure t hat t he ver-
tical port alignment t ab is rest i ng on t he deck face of
t he block. Also t he horizontal al i gnment t abs must
be in position with t he mat i ng cylinder head gasket
t abs (Fig. 8). The words MANIFOLD SIDE should be
visible on t he center of each flange gasket.
FLANGE GASKET
\
INTAKE
AAANIFOLD
CYLINDER
HEAD GASKET
J9209-101
Fig. 8 Intake Manifold Flange Gasket Alignment
(10) Carefully lower i nt ake manifold into position
on t he cylinder block and cylinder heads. Use t he
al i gnment dowels in t he cross-over gasket s to posi-
tion t he i nt ake manifold. After i nt ake manifold is in
place, inspect to make sure seals are in place.
(11) The following torque sequence duplicates t he
expected results of t he aut omat ed assembly system
(Fig. 9).
Step 1- Ti ght en bolts 1 and 2 to 8 N-m (72 in. lbs.)
torque. Tighten in al t ernat i ng steps 1.4 N-m (12 in.
lbs.) torque at a time.
Step 2Tighten bolts 3 t hrough 12, in sequence,
to 8 N-m (72 in. lbs.) torque.
Step 3Check t hat all bolts are t i ght en to 8 N-m
Step 4Tighten all bolts, in sequence, to 16 N-m
Step 5Check t hat all bolts are tighten to 16 N-m
(12) Install exhaust manifolds. Tighten t he bolts
and nut s to 34 N-m (25 ft. lbs.) torque.
FRONT OF ENGINE
J9209-59
Fig. 9 Intake Manifold Bolt Tightening Sequence
(13) Adjust spark plugs to specifications (refer to
Group 8D, Ignition System). Install t he plugs and
t i ght en to 41 N-m (30 ft. lbs.) torque.
(14) Install coil wires.
(15) Connect heat indicator sending uni t wire.
(16) Connect t he heat er hoses and bypass hose.
(17) Install distributor cap and wires.
(18) Hook up t he r et ur n spring.
(19) Connect t he accelerator linkage and if so
equipped, t he speed control and transmission kick-
down cables.
(20) Install t he fuel lines.
(21) Install t he generator and drive belt. Tighten
generator mounting bolt to 41 N-m (30 ft. lbs.)
torque. Tighten t he adjusting st rap bolt to 23 N-m
(200 in. lbs.) torque. Refer to Group 7, Cooling Sys-
t em for adjusting t he belt tension.
(22) Install t he i nt ake manifold-to-generator
bracket support rod. Tighten t he bolts.
(23) Place t he cylinder head cover gaskets in posi-
tion and install cylinder head covers. Tighten t he
bolts to 11 N-m (95 in. lbs.) torque.
(24) Install closed crankcase ventilation system.
(25) Connect t he evaporation control system.
(27) Install t he heat shields. Tighten t he bolts to
System for proper procedure).

3.9L ENGINE 9 - 25
VALVES / VALVE SPRINGS
The valves are arranged in-line and inclined 18.
The rocker pivot support and the valve guides are
cast integral with the heads.
This procedure requires the removal of the cylinder
head.
REMOVAL
(1) Remove the cylinder head.
(2) Compress valve springs using Valve Spring
Compressor Tool MD-998772A.
(3) Remove valve retaining locks, valve spring re-
tainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location.
VALVE CLEANING
Clean valves thoroughly. Discard burned, warped
and cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VALVE INSPECTION
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
Measure valve stem guide clearance as follows:
(a) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 10). The special
sleeve places the valve at the correct height for
checking with a dial indicator.
Fig. 10 Positioning Valve with Tool C-3973
(b) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 11).
(c) Move valve to and from the indicator. The to-
tal dial indicator reading should not exceed 0.432
mm (0.017 inch). Ream the guides for valves with
oversize stems if dial indicator reading is excessive
or if the stems are scuffed or scored.
Service valves with oversize stems are available
(Fig. 12).
Slowly turn reamer by hand and clean guide thor-
oughly before installing new valve. Re a m the val ve
gui des from s t a nda r d t o 0.381 mm (0,015 inch).
Fig. 11 Measuring Valve Guide Wear
Reamer O / S Valve Guide Size
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316 -0.317 in.)
0.381 mm 8.331 -8. 357 mm
(0.015 in.) (0.328-0.329 in.)
J9309-30
Fig. 12 Reamer Sizes
Use a 2 step procedure so the val ve gui des are
reamed true i n relation to the val ve seat:
Step 1- Ream to 0.0763 mm (0.003 inch).
REFACING VALVES / VALVE SEATS
The intake and exhaust valves have a 43-1/4 to
43-3/4 face angle and a 44-1/4 to 44-3/4 seat angle
(Fig. 13).
VALES
Inspect the remaining margin after the valves are
refaced (Fig. 14). Valves with less than 1.190 mm
(0.047 inch) margin should be discarded.
VALVE SEATS
C A U T I O N : D O N OT un- shr oud val ves during valve
seat refacing (Fi g. 15).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be ob-
tained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch) total indicator reading.
A - SEAT WIDTH - INTAKE 1.016 - 1.524 mm (0.040 - 0.060 in.)
EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
B - FACE ANGLE (INTAKE & EXHAUST) 4374- 43
3
A
C - SEAT ANGLE (INTAKE & EXHAUST) 4474- 44%
D - CONTACT SURFACE
J9309-95
Fig. 13 Valve Face and Seat Angles
i
INTAKE
VALVE
\ MARGIN / "
>FACE'
STEM"
VALVE SPRING
RETAINER LOCK
GROOVE
EXHAUST
VALVE
J9209- 127
Fig. 14 Intake and Exhaust Valves
(3) Inspect t he valve seat wi t h Prussi an blue to de-
t ermi ne where t he valve contacts t he seat. To do
this, coat valve seat LIGHTLY with Prussi an blue
t hen set valve in place. Rotate t he valve wi t h light
pressure. If t he blue is transferred to t he center of
valve face, contact is satisfactory. If t he blue is t rans-
ferred to t he top edge of valve face, lower valve seat
with a 15stone. If t he blue is transferred to bottom
edge of valve face raise valve seat wi t h a 60stone.
(4) When seat is properly positioned t he width of
i nt ake seats should be 1.016-1.524 mm (0.040-0.060
inch). The width of t he exhaust seats should be
1.524-2.032 mm (0.060-0.080 inch).
Fig. 15 Refacing Valve Seats
VALVE SPRING INSPECTION
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example t he compression length of
t he spring to be tested is 1-5/16 inch. Turn table of
Valve Spring Tester Tool C-647 unt i l surface is in
line with t he 1-5/16 inch mark on t he threaded stud.
Be sure t he zero mar k is to t he front (Fig. 16). Place
spring over stud on t he table and lift compressing le-
ver to set tone device. Pull on torque wrench until
ping is heard. Take readi ng on torque wrench at this
i nst ant . Multiply t hi s readi ng by 2. This will give
t he spring load at t est length. Fractional measure-
ment s are indicated on t he table for finer adjust-
ment s. Refer to specifications to obtain specified
hei ght and allowable tensions. Discard t he springs
t hat do not meet specifications.
SPECIAL
TOOL C-647
9209-37
Fig. 16 Testing Valve Spring for Compressed
Length with Tool C-647
INSTALLATION
(1) Coat valve stems with lubrication oil and insert
t hem in cylinder head.

3.9L ENGINE 9 - 27
(2) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(3) Install new seals on all valve guides. Install
valve springs and valve ret ai ners.
(4) Compress valve springs wi t h Valve Spring
Compressor Tool MD-998772A, install locks and re-
lease tool. If valves and/or seats are ground, measure
the installed height of springs. Make sure t he mea-
surement is t aken from bottom of spring seat in cyl-
inder head to t he bottom surface of spring ret ai ner. If
spacers are installed, measure from t he top of spacer.
If hei ght is greater t han 42.86 mm (1-11/16 inches),
install a 1.587 mm (1/16 inch) spacer in head coun-
terbore. This should bri ng spring hei ght back to nor-
mal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
VALVE STEM SEAL / SPRING REPLACEMENT
This procedure is done wi t h t he cylinder head in-
stalled.
(1) Set engine basic t i mi ng to TDC and remove air
cleaner.
(2) Remove cylinder head covers and spark plugs.
(3) Remove coil wire from distributor and secure to
good ground to prevent engine from st art i ng.
(4) Using suitable socket and flex handl e at crank-
shaft ret ai ni ng bolt, t ur n engine so t he No. l piston is
at Top Dead Center on t he compression stroke.
(5) Remove rocker arms.
(6) With air hose attached to an adapter installed
in No. l spark plug hole, apply 620-689 kPa (90-100
psi) air pressure.
(7) Using Valve Spring Compressor Tool
MD-998772A, compress valve spring and remove re-
t ai ner valve locks and valve spring.
(8) Install seals on t he exhaust valve stem and po-
sition down against valve guides.
(9) The i nt ake valve stem seals should be pushed
firmly and squarely over t he valve guide using t he
valve stem as a guide. DO NOT force seal against
top of guide. When installing t he valve ret ai ner
locks, compress t he spring only enough to install t he
locks.
(10) Follow t he same procedure on t he remai ni ng 5
cylinders using t he firing sequence 1-6-5-4-3-2. Make
sure piston in cylinder is at TDC on t he valve spring
t hat is being removed.
(11) Remove adapt er from t he No. l spark plug
hole.
(12) Install rocker arms.
(13) Install covers and coil wire to distributor.
(14) Install air cleaner.
HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor-
rect tappet noise, check t he oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at
t he pressure sending unit. The pressure should be be-
tween 207-552 kPa (30-80 psi) at 3,000 RPM.
Check t he oil level after t he engine reaches normal
operating t emperat ure. Allow 5 minutes to stabilize
oil level, check dipstick.
The oil level in the pan should never be above t he
FULL mar k or below t he ADD OIL mark on dipstick.
Ei t her of these 2 conditions could be responsible for
noisy tappets.
OIL LEWEL
HIGH
If oil level is above t he FULL mark, it is possible
for t he connecting rods to dip into t he oil. With t he
engine runni ng, this condition could create foam in
the oil pan. Foam in oil pan would be fed to t he hy-
draulic t appet s by t he oil pump causing t hem to lose
length and allow valves to seat noisily.
LOW
Low oil level may allow oil pump to t ake in air.
When ai r is fed to t he tappets, they lose l engt h
which allows valves to seat noisily. Any leaks on in-
t ake side of oil pump t hrough which air can be
drawn will create t he same tappet action. Check t he
lubrication system from t he intake strainer to t he
pump cover, including t he relief valve ret ai ner cap.
When t appet noise is due to aeration, it may be in-
t ermi t t ent or constant, and usually more t han 1 t ap-
pet will be noisy. When oil level and leaks have been
corrected, operate t he engine at fast idle. Run engine
for a sufficient time to allow all of the air inside t he
tappets to be bled out.
TAPPET NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate en-
gine at idle wi t h cylinder head covers removed.
(2) Feel each valve spring or rocker ar m to detect
noisy tappet. The noisy tappet will cause t he affected
spring and/or rocker ar m to vibrate or feel rough in
operation.
Worn val ve gui des or cocked spri ngs are some-
times mi staken for noi sy tappets. If such is the
case, noi se may be dampened by appl yi ng side
thrust on the val ve spring. If noi se is not appre-
ciably reduced, it can be assumed the noi se i s in
the tappet. Inspect the rocker arm push rod
sockets and push rod ends for wear.
(3) Valve t appet noise ranges from light noise to a
heavy click. A light noise is usually caused by exces-
sive leak down around t he uni t plunger or by the
plunger partially sticking in the tappet body cylin-
der. The t appet should be replaced. A heavy click is
caused by a t appet check valve not seating or by for-
eign particles becoming wedged between t he plunger
and t he t appet body. This will cause t he pl unger to
stick in t he down position. This heavy click will be
9 - 28 3.9L ENGINE

accompanied by excessive clearance between t he
valve stem and rocker ar m as valve closes. In either
case, tappet assembly should be removed for inspec-
tion and cleaning.
The valve t rai n generates a noise very much like a
light tappet noise duri ng normal operation. Care
must be t aken to ensure t hat tappets are maki ng t he
noise. In general, if more t han one tappet seems to
be noisy, its probably not t he tappets.
REMOVAL
(2) Remove cylinder head cover.
(3) Remove rocker assembly and push rods. Iden-
tify push rods to ensure installation in original loca-
tion.
(4) Remove i nt ake manifold.
(5) Remove yoke ret ai ner and aligning yokes.
(6) Slide Hydraulic Tappet Remover/Installer Tool
C-4129- A t hrough opening in cylinder head and seat
tool firmly in t he head of tappet.
(7) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed, identify tappets to
ensure installation in original location.
(8) If t he t appet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream t he bore to
next oversize. Replace with oversize tappet.
C A U T I O N : The pl unger and tappet bodi es are not
interchangeable. The pl unger and val ve must al-
ways be fitted to the original body. It i s advi sabl e to
work on one tappet at a time to avoi d mi xi ng of
parts. Mi xed parts are not compati bl e. D O N OT di s-
assembl e a tappet on a dirty work bench.
DISASSEMBLE
(1) Pry out plunger ret ai ner spring clip (Fig. 17).
(2) Clean varni sh deposits from inside of tappet
body above plunger cap.
(3) Invert t appet body and remove plunger cap,
plunger, check valve, check valve spring, check valve
ret ai ner and plunger spring (Fig. 17). Check valve
could be flat or ball.
ASSEMBLE
(1) Clean all tappet part s in a solvent t hat will re-
move all varni sh and carbon.
(2) Replace tappets t hat are unfit for further ser-
vice with new assemblies.
(3) If plunger shows signs of scoring or wear, in-
stall a new t appet assembly. If valve is pitted, or
valve seat on end of plunger is prevented from seat-
ing, install a new t appet assembly.
(4) Assemble t appet s (Fig. 17).
INSTALLATION
(1) Lubricate t appet s.
PLUNGER
SPRING
CHECK
BALL
PLUNGER
RETAINER
SPRING CLIP
ROLLER
TAPPET
BODY
RETAINER
I
PLUNGER
CHECK VALVE
SPRING
PLUNGER
CAP J9109-220
Fig. 17 Hydraulic Tappet Assembly
(2) Install tappets and push rods in t hei r original
positions. Ensure t hat t he oil feed hole in t he side of
t he t appet body faces up (away from t he crankshaft).
(3) Install aligning yokes with ARROW toward
camshaft.
(4) Install yoke retainer. Tighten t he bolts to 23
N*m (200 in. lbs.) torque. Install i nt ake manifold.
(5) Install push rods in original positions.
(8) St art and operate engine. Warm up to normal
C A U T I O N : To prevent damage to valve mechani sm,
engi ne must not be run above fast idle until all hy-
draulic tappets have filled with oil and have become
quiet.
VALVE TIMING
(1) Turn crankshaft until t he No.6 exhaust valve
is closing and No.6 i nt ake valve is opening.
(2) Insert a 6.350 mm (1/4 inch) spacer between
rocker ar m pad and stem tip of No. l i nt ake valve.
Allow spring load to bleed tappet down giving in ef-
fect a solid tappet.
(3) Install a dial indicator so plunger contacts
valve spring ret ai ner as nearly perpendicular as pos-
sible. Zero t he indicator.
(4) Rotate t he crankshaft clockwise (normal run-
ni ng direction) until t he valve has lifted 0.254 mm
(0.010 inch). The timing of t he crankshaft should
now read from 10 before top dead center to 2 after
top dead center. Remove spacer.
C A U T I O N : D O N OT turn crankshaft any further
cl ockwi se a s val ve spri ng mi ght bottom and result
in ser i ous damage.
(5) If reading is not within specified limits:
(a) Check sprocket index marks.
(b) Inspect t i mi ng chain for wear.
(c) Check accuracy of DC mar k on t i mi ng indica-
tor.

3.9L ENGINE I - 21
VIBRATION DAMPER
REMOVAL
(1) Disconnect t he negative cable from t he battery,
(2) Remove fan shroud ret ai ner bolts and set
shroud back over engine.
(3) Remove t he cooling system fan.
(4) Remove t he serpentine belt (refer to Group 7,
Cooling System).
(5) Remove t he vibration damper pulley.
(6) Remove vibration damper bolt and washer from
end of crankshaft.
(7) Install bar and screw from Puller Tool Set
C- 36 88. Install 2 bolts with washers t hrough t he
puller tool and into t he vibration damper (Fig. 1).
(8) Pull vibration damper off of t he crankshaft.
J9209-81
Fig. 1 Vibration Damper Assembly
INSTALLATION
(1) Position t he vibration damper onto t he crank-
shaft.
(2) Place installing tool, par t of Puller Tool Set
C-3688 in position and press t he vibration damper
onto t he crankshaft (Fig. 2).
Fig. 2 Installing Vibration Damper
(3) Install t he crankshaft bolt and washer. Tighten
t he bolt to 183 N*m (135 ft. lbs.) torque.
(4) Install t he crankshaft pulley. Tighten t he pul-
ley bolts to 23 N*m (200 in. lbs.) torque.
(5) Install t he serpentine belt (refer to Group 7,
Cooling System).
(6) Install t he cooling system fan. Tighten t he
bolts to 23 N*m (17 ft. lbs.) torque.
(7) Position t he fan shroud and install t he bolts.
Tighten t he ret ai ner bolts to 11 N*m (95 in. lbs.)
torque.
TIMING CHAIN COVER
REMOVAL
System).
Cooling System).
(4) Remove water pump (refer to Group 7, Cooling
System).
(5) Remove power steering pump (refer to Group
19, Steering).
(6 ) Remove vibration damper.
(7) Remove fuel lines (refer to Group 14, Fuel Sys-
tem).
(8) Loosen oil pan bolts and remove t he front bolt
at each side.
(9) Remove t he cover bolts.
(10) Remove chain case cover and gasket using ex-
t reme caution to avoid damagi ng oil pan gasket.
(11) Place a suitable tool behind t he lips of t he oil
seal to pry t he oil seal outward. Be careful not to
damage t he crankshaft seal surface of cover (Fig. 3).
Fig. 3 Removal of Front Crankshaft Oil Seal
TIMING CHAIN STRETCH
(1) Place a scale next to t he t i mi ng chain so t hat
any movement of t he chain may be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket at t achi ng bolt. Apply torque in t he di-
rection of crankshaft rotation to t ake up slack; 41
N
#
m (30 ft. lbs.) torque wi t h cylinder head installed
or 20 Nm (15 ft. lbs.) torque with cylinder head re-
moved. With a torque applied to t he camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block t he crankshaft to
prevent rotation.
(3) Hold a scale with dimensional readi ng even
wi t h t he edge of a chain link. Wi t h cylinder heads
installed, apply 14 N*m (30 ft. lbs.) torque in t he re-
verse direction. With t he cylinder heads removed, ap-
i - 30 3.9L ENGINE
J9209-130
Fig. 4 Measuring Timing Chain Wear and Stretch
ply 20 N*m (15 ft. lbs.) torque in t he reverse direc-
tion. Note t he amount of chain movement (Fig. 4).
(4) Install a new t i mi ng chain, if its movement ex-
ceeds 3.175 mm (1/8 inch).
(5) If chain is not satisfactory, remove camshaft
sprocket at t achi ng bolt and remove t i mi ng chain
with crankshaft and camshaft sprockets.
(6) Place both camshaft sprocket and crankshaft
sprocket on t he bench wi t h t i mi ng mar ks on exact
i magi nary center line t hrough both camshaft and
crankshaft bores.
(7) Place t i mi ng chain around both sprockets.
(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets t i ght
against t he chain in position as described).
(10) Slide both sprockets evenly over t hei r respec-
tive shafts and use a straightedge to check al i gnment
of t i mi ng marks (Fig. 5).
TIMING
MARKS
J 9209- 129
Fig. 5 Alignment of Timing Marks
(11) Install t he camshaft bolt. Tighten t he bolt to
68 Nnn (50 ft. lbs.) torque.
(12) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
t hr ust plate and up to 0.254 mm (0.010 inch) with a
used t hr ust plate. If not wi t hi n these limits install a
new t hr ust plate.
CLEANING
Be sure mat i ng surfaces of chain case cover and
cylinder block are clean and free from burrs.
INSTALLATION
(1) Using a new cover gasket, carefully install
chain case cover to avoid damagi ng oil pan gasket.
Use a small amount of Mopar Silicone Rubber Adhe-
sive Sealant, or equivalent, at t he joint between tim-
ing chain cover gasket and t he oil pan gasket. Finger
t i ght en t he t i mi ng chain cover bolts at t hi s time.
(2) Place t he smaller diameter of t he oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat
t he oil seal in t he groove of t he tool.
(3) Position t he seal and tool onto t he crankshaft
(Fig. 7).
CRANKSHAFT >
FRONT OIL
SEAL
INSTALL THIS
END INTO
SPECIAL TOOL
6 6 35
J9309-44
Fig. 6 Placing Oil Seal on Installation Tool 6635
SPECIAL TOOL \ \ OIL
SEAL
TI MI NG'
CHAI N
COVER J9309-45-
Fig. 7 Position Tool and Seal onto Crankshaft

3.9L ENGINE 9 - 31
(4) Usi ng t he vibration damper bolt, t i ght en t he
bolt to draw t he seal into position on t he crankshaft
(Fig. 8).
J9309-46
Fig. 8 installing Oil Seal
(5) Ti ght en chain case cover bolts to 41 N-m (30 ft.
lbs.) torque. Tighten oil pan bolts to 24 N*m (215 in.
lbs.) torque.
(6) Remove t he vibration damper bolt and seal in-
stallation tool.
(7) Inst al l vibration damper.
(8) Instajl fuel lines (refer to Group 14, Fuel Sys-
tem).
(9) Install wat er pump and housing assembly us-
ing new gasket s (refer to Group 7, Cooling System).
Tighten bolts to 41 N-m (30 ft. lbs.) torque.
(10) Inst al l power steering pump (refer to Group
19, Steering).
Cooling System).
(12) Inst al l t he cooling system fan. Tighten t he
Tighten t he bolts to 11 N-m (95 in. lbs.) torque.
FRONT CRANKSHAFT OIL SEAL REPLACEMENT
The oil seal can be replaced without removing t he
t i mi ng chain cover provided t he cover is not mis-
aligned.
(2) Remove vibration damper.
(3) If front seal is suspected of leaking, check front
oil seal al i gnment to crankshaft. The seal installa-
tion/alignment tool 6635, should fit wi t h mi ni mum
interference. If tool does not fit, t he cover must be re-
moved and installed properly.
damage t he crankshaft seal surface of cover.
(Fig. 7).
(7) Using t he vibration damper bolt, tighten t he
(Fig. 8).
stallation tool.
(9) Install t he vibration damper.
(10) Connect the negative cable to t he battery.
CAMSHAFT
This procedure requires t hat t he engine is removed
from t he vehicle..
The camshaft has an integral oil pump and distrib-
utor drive gear (Fig. 9).
CHAIN
SPROCKET
Fig. 9 Camshaft and Sprocket Assembly
REMOVAL
(2) Remove cylinder head covers.
(3) Remove t i mi ng case cover and t i mi ng chain.
(5) Remove push rods and tappets; identify each
par t so it can be installed in t he original location.
(6) Remove distributor and lift out t he oil pump
and distributor drive shaft.
(7) Remove camshaft t hr ust plate; note location of
oil t ab (Fig. 10).
(8) Install a long bolt into front of camshaft to fa-
cilitate removal of t he camshaft. Remove camshaft,
being careful not to damage cam beari ngs with t he
cam lobes.
RE MO VAL-BEA RING
(1) With engine completely disassembled, drive out
rear cam beari ng core hole plug.
(2) Install proper size adapt ers and horseshoe
washers (part of Camshaft Beari ng Remover/Installer
9 - 32 3.9L ENGINE

Fig, 10 timing Chain Oil Tab installation
Fig, 11 Camshaft Bearings Removal and Installation
with Tool C-3132-A
Tool C-3132-A) at back of each beari ng shell. Drive
out beari ng shells (Fig. 11).
INSTALLA TION BEARING
(1) Install new camshaft bearings wi t h Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
t he new camshaft beari ng shell over proper adapter.
(2) Position rear beari ng in t he tool. Install horse-
shoe lock and by reversing removal procedure, care-
fully drive beari ng shell into place.
(3) Install remai ni ng bearings in t he same man-
ner. Beari ngs must be carefully aligned to bri ng oil
holes into full register with oil passages from t he
mai n bearing. If t he camshaft beari ng shell oil holes
are not in exact alignment, remove and install t hem
correctly. Install a new core hole plug at t he rear of
camshaft. Be s ur e t hi s pl ug does not l eak.
INSTALLATION
(1) Lubricate camshaft lobes and camshaft beari ng
journals and insert t he camshaft to wi t hi n 51 mm (2
inches) of its final position in cylinder block.
Whenever an engi ne h a s be e n r ebui l t , a ne w
cams haf t and/ or ne w t a ppe t s i nst al l ed, a dd 1
pi nt of Mopa r Cr a nkc a s e Condi t i oner , or equi v-
al ent . The oil mi xt ur e s houl d be left i n engi ne
for a mi ni mum of 805 k m (500 mi l es). Dr ai n a t
t he next nor ma l oil change.
(2) Install Camshaft Gear Installer Tool C-3509
with tongue back of distributor drive gear (Fig. 12).
Fig. 12 Camshaft Holding Tool C-3509 (Installed
Position)
(3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out t he welch
plug in rear of cylinder block. Tool shoul d remai n
installed until the camshaft and crankshaft
sprockets and timing chai n have been installed.
(4) Install camshaft t hr ust plate and chain oil t ab.
Make sure tang enters l ower right hol e in thrust
plate. Tighten bolts to 24 N*m (210 in. lbs.) torque.
Top edge of t ab should be flat against t hrust plate in
order to catch oil for chain lubrication.
sprocket on t he bench with t i mi ng mar ks on exact
crankshaft bores.
( 7) Turn crankshaft and camshaft to line up with
shaft sprocket.
(8) Lift sprockets and chain (keep sprockets tight
agai nst t he chain in position as described).
tive shafts and use a straightedge to check alignment
of t i mi ng mar ks (Fig. 13).
(10) Install t he camshaft bolt/cup washer. Tighten
bolt to 68 N*m (50 ft. lbs.) torque.
(11) Measure camshaft end play. Refer to Specifi-
cations for proper clearance. If not within limits in-
stall a new t hr ust plate.

3.9L ENGINE 9 - 33
(12) Each tappet reused must be installed in t he
same position from which it was removed. Wh e n
camshaf t Is r e p l a c e d , al l of t h e t a p p e t s mu s t b e
r epl aced.
DISTRIBUTOR
REMOVAL
Refer to Group 8D, Ignition Systems for t he proper
procedure.
REMOVAL-DRIVE SHAFT BUSHING
(1) Insert Distributor Drive Shaft Bushing Puller
Tool C-3052 into old bushing and t hread down unt i l
a t i ght fit is obtained (Fig. 14).
(2) Hold puller screw and t i ght en puller n u t unt i l
bushing is removed.
Fig. 14 Distributor Driveshaft Bushing Removal
INSTALLATION-DRIVE SHAFT BUSHING
(1) Slide new bushi ng over burni shi ng end of Dis-
tributor Drive Shaft Bushing Driver/Burnisher Tool
C-3053. Insert t he tool and bushi ng into t he bore.
(2) Drive bushi ng and tool into position, using a
hammer (Fig. 15).
(3) As t he burni sher is pulled t hrough t he bushing,
t he bushi ng is expanded tight in t he block and bur-
nished to correct size (Fig. 16). DO NOT r e a m t hi s
bus hi ng.
DISTRIBUTOR TIMING
Before installing t he distributor and oil pump drive
shaft, t i me engine as follows:
Fig. 16 Burnishing Distributor Driveshaft Bushing
(1) Rotate crankshaft unt i l No. l cylinder is at top
dead center on t he firing stroke.
(2) When in this position, t he t i mi ng mark on vi-
bration damper should be under "0" on the t i mi ng in-
dicator.
(3) Coat shaft and drive gear with engine oil. In-
stall t he shaft so t hat after t he gear spirals into
place, it will index wi t h t he oil pump shaft. The slot
on top of drive gear should be aligned towards left
front i nt ake manifold at t achi ng bolt hole (Fig. 17).
INSTALLATION
procedure.
Fig. 17 Position of Installed Distributor Drive Gear
OIL PAN
REMOVAL
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drai n engine oil.
(5) Remove exhaust pipe.
(6) Remove left engine to transmission st rut .
(7) Remove oil pan and one-piece gasket.
CLEANING
Clean t he block and pan gasket surfaces.
Trim or remove excess sealant film in t he rear
mai n cap oil pan gasket groove. DO NOT r emove
t he s eal ant i nsi de t he r e a r ma i n c a p sl ot s.
If present, t ri m excess sealant from inside t he en-
gine.
Clean oil pan in solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly in clean sol-
vent. Inspect condition of screen.
INSPECTION
Inspect oil drai n plug and plug hole for stripped or
damaged t hreads. Repair as necessary.
Inspect oil pan mount i ng flange for bends or distor-
tion. St rai ght en flange, if necessary.
INSTALLATION
(1) Fabricate 4 al i gnment dowels from 1 1/2 x 5/16
inch bolts. Cut t he head off t he bolts and cut a slot
into t he top of t he dowel. This will allow easier in-
stallation and removal with a screwdriver (Fig. 1).
1
1
/ 2 " x 5/16 " BOLT
, DOWEL
SLOT J9209-106
Fig. 1 Fabrication of Alignment Dowels
(2) Install t he dowels in t he cylinder block (Fig. 2).
(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in t he corner of t he
cap and t he cylinder block.
(4) Slide t he one-piece gasket over t he dowels and
onto t he block.
(5) Position t he oil pan over t he dowels and onto
t he gasket.
(6) Install t he oil pan bolts. Tighten t he bolts to 23
N-m (200 in. lbs.) torque.
Fig. 2 Position of Dowels in Cylinder Block
(7) Remove t he dowels. Install t he remai ni ng oil
pan bolts. Tighten these bolts to 23 N-m (200 in. lbs.)
torque.
(8) Install t he drain plug. Tighten drai n plug to 34
(9) Install t he engine to transmission st rut .
(10) Install exhaust pipe.
(11) Lower vehicle.
(12) Install dipstick.
(14) Fill crankcase with oil to proper level.
OIL PU1 P
REMOVAL
(1) Remove t he oil pan.
(2) Remove t he oil pump from rear mai n beari ng
cap.
DISASSEMBLE
(1) Remove t he relief valve as follows:
(a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into t he relief valve ret ai ner cap and in-
sert a self-threading sheet met al screw into cap.
(b) Clamp screw into a vise and while supporting
oil pump, remove cap by tapping pump body using
a soft hammer. Discard ret ai ner cap and remove
spring and relief valve (Fig. 3).
(2) Remove oil pump cover (Fig. 4).
(3) Remove pump outer rotor and i nner rotor with
shaft (Fig. 4).
(4) Wash all part s in a suitable solvent and inspect
carefully for damage or wear.
OI L PUMP ASSEMBLY
SPRI NG
RELIEF VALVE
RETAINER CAP
COTTER PI N
RH174
Fig. 3 Oil Pressure Relief Valve
I NNER ROTOR
A N D SHAFT
DISTRIBUTOR DRIVESHAFT
m m
(REFERENCE)
COTTER PIN
RELIEF VALVE
LARGE CHAMFERED
EDGE
SPRI NG
RETAINER
CAP
RY10B
Fig. 4 Oil Pump
INSPECTION
Mating surface of t he oil pump cover should be
smooth. Replace pump assembly if cover is scratched
or grooved.
Lay a straightedge across t he pump cover surface
(Fig. 5). If a 0.038 mm (0.0015 inch) feeler gauge can
be inserted between cover and straightedge, pump
assembly should be replaced.
STRAIGHT EDGE>
COVER
RH175
Fig. 5 Checking Oil Pump Cover Flatness
Measure thickness and diameter of outer rotor. If
outer rotor thickness measures 20.9 mm (0.825 inch)
or less or if the di amet er is 62.7 mm (2.469 inches) or
less, replace out er rotor (Fig. 6).
RH176
Fig. 6 Measuring Outer Rotor Thickness
If i nner rotor measures 20.9 mm (0.825 inch) or
less, replace i nner rotor and shaft assembly (Fig. 7).
RH177
. Fig. 7 Measuring Inner Rotor Thickness
Slide outer rotor into pump body. Press rotor to t he
side with your fingers and measure clearance be-
tween rotor and pump body (Fig. 8). If clearance is
0.356 mm (0.014 inch) or more, replace oil pump as-
sembly.
FEELER GUAGE
OUTER ROTOR
RH178
PUMP BODY
Fig. 8 Measuring Outer Rotor Clearance in Housing
9 - 36 3.9L ENGINE

Install inner rotor and shaft into pump body. If
clearance between inner and outer rotors is 0.203
mm (0.008 inch) or more, replace shaft and both ro-
tors (Fig. 9).
OUTER
ROTOR
INNER
ROTOR
RH179
Fig. 9 Measuring Clearance Between Rotors
Place a straightedge across t he face of t he pump,
between bolt holes. If a feeler gauge of 0,102 mm
(0.004 inch) or more can be inserted between rotors
and t he straightedge, replace pump assembly (Fig.
10).
Fig. 10 Measuring Clearance Over Rotors
Inspect oil pressure relief valve pl unger for scoring
and free operation in its bore. Small mar ks may be
removed with 400-grit wet or dry sandpaper.
The relief valve spring has a free l engt h of approx-
imately 49.5 mm (1.95 inches). The spring should
t est between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 inches). Replace spring t hat fails
to meet these specifications (Fig. 11).
If oil pressure was low and pump is wi t hi n specifi-
cations, inspect for worn engine bearings or other
reasons for oil pressure loss.
ASSEMBLE
(1) Install pump rotors and shaft, using new part s
as required.
RN98
Fig. 11 Proper Installation of Retainer Cap
(2) Position t he oil pump cover onto t he pump
body. Tighten cover bolts to 11 N-m (95 in. lbs.)
torque.
(3) Install t he relief valve and spring. Insert t he
cotter pin.
(4) Tap on a new ret ai ner cap.
(5) Pri me oil pump before installation by filling ro-
tor cavity with engine oil.
INSTALLATION
(1) Install oil pump. Duri ng installation slowly ro-
t at e pump body to ensure driveshaft-to-pump rotor
shaft engagement.
(2) Hold t he oil pump base flush against mat i ng
surface on No.4 mai n bearing cap. Finger t i ght en
pump at t achi ng bolts. Tighten at t achi ng bolts to 41
(3) Install t he oil pan.
PISTON / CONNECTING ROD ASSEMBLY
The pistons are elliptically t urned so t hat t he di-
amet er at t he pin boss is less t han its diameter
across t he t hr ust face. This allows for expansion un-
der normal operating conditions. Under operating
t emperat ures, expansion forces t he pin bosses away
from each other, causing t he piston to assume a more
nearly round shape.
All pistons are machined to t he same weight, re-
gardless of size, to mai nt ai n piston balance.
The piston pin rot at es in t he piston only and is re-
tained by t he press interference fit of t he piston pin
in t he connecting rod.
REMOVAL
(1) Remove t he engine from t he vehicle.
(2) Remove t he cylinder head.
(4) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block. Be sure to keep tops of pistons covered
duri ng t hi s operation.
(5) Be sure t he connecting rod and connecting rod
cap are identified with t he cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston
and connecting rod assemblies from t he engine, ro-
t at e crankshaft so t hat t he connecting rod is centered
in cylinder bore and at BDC. Be careful not to ni ck
crankshaft journal s.
(7) After removal, install beari ng cap on t he mat-
ing rod.
INSPECTION
Check t he crankshaft connecting rod j ournal for ex-
cessive wear, t aper and scoring.
Check t he cylinder block bore for out-of-round,
taper, scoring and scuffing.
Check t he pistons for t aper and elliptical shape be-
fore t hey are fitted into t he cylinder bore (Fig. 12).
DIAMETER (D)
SHOULD BE
0.0000-0.0152 mm
(0.0000-0.0006 in.)
LARGER THAN (C).
98.704-98.831 mm
-(3.886-3.891 i n. ) -
98.577-98.704 mm-
(3.881-3.886 in.)
(a) Measure piston ri ng gap 2 inches from bot-
tom of cylinder bore. An inverted piston can be
used to push t he rings down to ensure positioning
rings squarely in t he cylinder bore before measur-
ing.
(b) Insert feeler gauge in t he gap. The top com-
pression ri ng gap should be between 0.254-0.508
mm (0.010-0.020 inch). The second compression
ri ng gap should be between 0.508-0.762 mm (0.020-
0.030 inch). The oil ri ng gap should be 0.254-1.270
mm (0.010-0.050 inch).
(c) Rings wi t h insufficient end gap may be prop-
erly filled to t he correct dimension. Rings with ex-
cess gaps should not be used.
(2) Install ri ngs and confirm ri ng side clearance:
(a) Install oil rings being careful not to nick or
scratch t he piston.
(b) Install t he compression rings usi ng Installa-
tion Tool C-4184. The top compression may be in-
stalled with either side up. The second compression
ri ng must be installed with t he identification mark
face up (toward top of piston) and t he chamfer
should face down. An identification mar k on the
ri ng is a drill point, a stamped l et t er "O", an oval
depression or t he word TOP.
(c) Measure side clearance between piston ring
and ri ng land (Fig. 13). Clearance should be 0.038-
0.076 mm (0.0015-0.0030 inch) for t he compression
rings. The steel rail oil ri ng should be free in
groove, but should not exceed 0.203 mm (0.0080
inch) side clearance.
FEELER GAUGE
ELLIPTICAL SHAPE OF THE PISTON
SKIRT SHOULD BE 0.254-0.304 mm
(0.010-0.012 in.) LESS AT DIAMETER
(A) THAN ACROSS THE THRUST
FACES AT DIAMETER (B).
J9309-9
Fig. 12 Piston Measurements
FITTING PISTONS
Piston and cylinder wall must be clean and dry.
Specified clearance between t he piston and t he cylin-
der wall is 0.013-0.038 mm (0.0005-0.0015 inch).
Piston diameter should be measured at t he top of
skirt, 90 to piston pin axis. Cylinder bores should be
measured halfway down t he cylinder bore and t rans-
verse to t he engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room t emperat ure, 21C (70F).
FITTING RINGS
(1) Measurement of end gaps:
J9209- 136
Fig. 13 Measuring Piston Ring Side Clearance
(d) Pistons with insufficient or excessive side
clearance should be replaced.
(3) Orient t he rings:
(a) Arrange top compression ri ng 90 counter-
clockwise from t he oil ri ng rai l gap (Fig. 14).
(b) Arrange second compression ri ng 90 clock-
wise from t he oil ring rail gap (Fig. 14).
9 - 38 3.9L ENGINE

OIL RI NG
SPACE R GAP
TOP
COM PRE SSI ON
RI NG GAP
SE CON D
COM PRE SSI ON
RI NG GAP
OIL RI NG RAi L
GAP (TOP)
OIL RI NG RAI L
GAP ( BOTTOM) J9309- 8 0
Fig. 14 Proper Ring Installation
CONNECTING ROD BEARINGS
Fi t all rods on a bank unt i l completed. DO NOT al-
t er nat e from one bank to another, because connect-
ing rods and pistons are not interchangeable from
one bank to another.
The beari ng caps are not interchangeable and
should be marked at removal to ensure correct as-
sembly.
Each beari ng cap has a small V-groove across t he
part i ng face. When installing t he lower beari ng
shell, make certain t hat t he V-groove in t he shell is
in line wi t h t he V-groove in t he cap. This provides
lubrication of t he cylinder wall in t he opposite bank.
The beari ng shells must be installed so t hat t he
t angs are in t he machined grooves in t he rods and
caps.
Limits of t aper or out-of-round on any crankshaft
j ournal s should be held to 0.025 mm (0.001 inch).
Bearings are available in 0.025 mm (0.001 inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under-
size. Install the beari ngs in pairs. DO NOT use a
new beari ng half wi th an ol d beari ng half. DO
NOT file the rods or beari ng caps.
INSTALLATION
(1) Be sure t hat compression ri ng gaps are stag-
gered so t hat nei t her is in-line with oil ri ng rai l gap.
(2) Before installing t he ri ng compressor, make
sure t he oil ri ng expander ends are but t ed and t he
rail gaps located properly (Fig. 14).
(3) Immerse t he piston head and rings in clean en-
gine oil. Slide Piston Ring Compressor Tool C-385
over t he piston and t i ght en with t he special wrench
(part of Tool C-385). Be sure posi ti on of ri ngs does
not change duri ng this operation.
(4) Install connecting rod bolt protectors on rod
bolts, t he long protector should be installed on t he
numbered side of t he connecting rod.
(5) Rotate crankshaft so t hat the connecting rod
j ournal is on t he center of the cylinder bore. Be sure
connecting rod and cylinder bore number are t he
same. Insert rod and piston into cylinder bore and
guide rod over t he crankshaft journal.
(6) Tap t he piston down in cylinder bore, using a
hammer handle. At t he same time, guide connecting
rod into position on crankshaft journal.
(7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft j ournal fillet.
(8) Install rod caps. Be sure connecting rod, con-
necting rod cap and cylinder bore number are t he
same. Install nut s on cleaned and oiled rod bolts and
t i ght en nut s to 61 Nm (45 ft. lbs.) torque.
(10) Install t he cylinder head.
(11) Install t he engine into t he vehicle.
CRANKSHAFT
A crankshaft which has undersize journals will be
stamped with 1/4 inch letters near t he notch of t he
No.6 crankshaft counterweight (Fig. 15).
FOR EXAMPLE:R2 stamped on t he No.6 crank-
shaft counterweight indicates t hat t he No.2 rod jour-
nal is 0.025 mm (0.001 in) undersize. M4 indicates
t hat t he No.4 mai n j ournal is 0.025 mm (0.001 in)
undersize. R3 M2 indicates t hat t he No.3 rod j ournal
and t he No.2 mai n j ournal are 0.025 mm (0.001 in)
undersize.
U nder si ze J our nal I denti fi cati on Stamp
ROD - 0.025mm (0.001 in.) Rl-R2-R3-Etc.
MAIN - 0.025mm (0.001 in.) M1- M2 - M3 or M4
STEEL STAMP I DENTI FI CATI ON
R (ROD) A N D / O R M (MAI N) FOLLOWED
BY THE R O D OR M A I N NUMBER
Fig. 15 Location of Crankshaft Identification
When a crankshaft is replaced, all mai n and con-
necting rod bearings should be replaced with new
bearings. Therefore, selective fitting of t he bearings
is not required when a crankshaft and bearings are
replaced.
REMOVAL
(1) Remove the oil pan.

3.9L ENGINE 9 - 39
(2) Remove t he oil pump from t he rear mai n bear-
i ng cap.
( 8 ) Identify beari ng caps before removal. Remove
beari ng caps and bearings one at a time.
(4) Lift t he crankshaft out of t he block.
(5) Remove and discard t he crankshaft rear oil
seals.
(6 ) Remove and discard t he front crankshaft oil
seal.
INSPECTION OF JOURNALS
The crankshaft connecting rod and mai n j ournal s
should be checked for excessive wear, t aper and scor-
ing. The maxi mum taper or out-of-round on any
crankshaft j ournal is 0.025 mm (0.001 inch).
Journal grinding should not exceed 0.305 mm
(0.012 inch) under t he st andard journal diameter. DO
NOT grind t hr ust faces of No.3 mai n bearing. DO
NOT nick crank pin or beari ng fillets. After grind-
ing, remove rough edges from crankshaft oil holes
and clean out all oil passages.
C A U T I O N : After any journal gri nd, it i s important
that the final paper or cloth pol i sh be in the same
direction a s the engi ne rotates.
INSTALLATION
(1) Lightly oil t he new upper seal lips wi t h engine
oil.
(2) Install t he new upper rear bearing oil seal wi t h
t he yellow pai nt facing towards t he rear of t he en-
gine.
(3) Position t he crankshaft into the cylinder block.
(4) Lightly oil t he new lower seal lips wi t h engine
oil.
(5) Install t he new lower rear bearing oil seal into
t he beari ng cap with t he yellow paint facing towards
t he rear of t he engine.
(6) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of t he rear mai n beari ng cap
(Fig. 16). Do not over apply sealant or allow t he seal-
ant to contact t he rubber seal. Assemble beari ng cap
to cylinder block immediately after seal ant applica-
tion.
(7) To align t he beari ng cap, use cap slot, align-
ment dowel and cap bolts. Do not remove excess ma-
terial after assembly. Do not strike rear cap more
t han 2 times for proper engagement.
(8) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and al t ernat el y
t i ght en to 115 Nm (85 ft. lbs.) torque.
(9) Install oil pump.
ant, or equivalent, at beari ng cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap-
BEARING CAP J9309-72
Fig. 16 Sealant Application to Bearing Cap
ply enough sealant until a small amount is squeezed
out. Withdraw nozzle and wipe excess sealant off t he
oil pan seal groove.
(11) Install new front crankshaft oil seal.
(12) Immediately install t he oil pan.
MOPAR SILICONE SEALANT
RUBBER ADHESIVE APPLIED
Fig. 17 Apply Sealant to Bearing Cap to Block Joint
CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower beari ng halves are NOT inter-
changeable. Lower mai n beari ng halves of No. l and
3 are interchangeable.
Upper and lower No.2 beari ng halves are flanged
to carry t he crankshaft t hr ust loads. They are NOT
interchangeable with any other beari ng halves in t he
engine (Fig. 18). Beari ng shells are available in stan-
dard and t he following undersizes: 0.25 mm (0.001
inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
Never install an undersize beari ng t hat will reduce
clearance below specifications.
REMOVAL
S - 40 3.9L ENGINE
3 9
Fig. 18 Main Bearing identification
ing cap.
(3) Identify beari ng caps before removal. Remove
beari ng caps one at a time.
(4) Remove upper half of beari ng by i nsert i ng
Crankshaft Mai n Beari ng Remover/Installer Tool
C-3059 into t he oil hole of crankshaft (Fig. 19).
(5) Slowly rot at e crankshaft clockwise, forcing out
upper half of beari ng shell.
Fig. 19 Upper Main Bearing Removal and
installation with Tool C-3059
INSTALLATION
Only one mai n beari ng should be selectively fitted
while all other mai n beari ng caps are properly tight-
ened. All beari ng capbolts removed duri ng service
procedures are to be cleaned and oiled before instal-
lation.
When installing a new upper beari ng shell, slightly
chamfer t he sharp edges from t he plain side.
(1) St ar t beari ng in place, and insert Crankshaft
Main Beari ng Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 19).
(2) Slowly rot at e crankshaft counterclockwise slid-
ing t he beari ng into position. Remove Tool C-3059.
(3) Install t he bearing caps. Clean and oil t he
bolts. Tighten t he capbolts to 115 N*m (85 ft. lbs.)
torque.
(4) Install t he oil pump.
CRANKSHAFT REAR OIL SEALS
The service seal is a 2 piece, viton seal. The upper
seal half can be installed with crankshaft removed
from engine or with crankshaft installed. When a
new upper seal is installed, install a new lower seal.
The lower seal half can only be installed wi t h t he
rear mai n beari ng cap removed.
UPPER SEAL REPLACEMENT (CRANKSHAFT
REMOVED)
(1) Remove t he crankshaft. Discard t he old upper
seal.
(2) Lightly oil t he new upper seal lips with engine
oil.
(3) Install t he new upper rear beari ng oil seal wi t h
gine.
(4) Position t he crankshaft into t he cylinder block.
(5) Lightly oil t he new lower seal lips wi t h engine
oil.
(6) Install t he new lower rear beari ng oil seal into
t he beari ng cap with t he yellow pai nt facing towards
(Fig. 16). Do not over apply seal ant or allow t he seal-
tion.
t eri al after assembly. Do not strike rear cap more
(9) Clean and oil all cap bolts. Install all mai n
beari ng caps. Install all cap bolts and al t ernat el y
t i ght en to 115 N*m (85 ft. lbs.) torque.
ant , or equivalent, at beari ng cap to block joint to
out. Wi t hdraw nozzle and wipe excess seal ant off t he
INSTALLED)
ing cap.

3.9L ENGINE 9 - 4 1
(3) Remove t he rear mai n beari ng cap. Remove
and discard the old lower oil seal.
(4) Carefully remove and discard t he old upper oil
seal.
oil. To allow ease of installation of t he seal, loosen at
least t he 2 main beari ng caps forward of t he r ear
bearing cap.
(6) Rotate t he new upper seal into t he cylinder
block being careful not to shave or cut t he outer sur-
face of t he seal. To assure proper installation, use t he
installation tool provided with t he kit. Install t he
new seal with t he yellow pai nt facing towards t he
rear of t he engine.
the beari ng cap with t he yellow pai nt facing towards
the rear of t he engine.
equivalent, on each side of t he rear mai n bearing cap
ant to contact t he rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica-
tion. Be sure the yellow paint faces toward t he rear
of t he engine.
terial after assembly. Do not st ri ke rear cap more
t han 2 t i mes for proper engagement.
(10) Install t he rear mai n beari ng cap with cleaned
and oiled cap bolts. Alternately t i ght en ALL cap
ant, or equivalent, at bearing cap to block joint to
ply enough sealant unt i l a small amount is squeezed
LOWER SEAL REPLACEMENT
ing cap.
(3) Remove t he r ear mai n beari ng cap and discard
t he old lower seal.
(4) Carefully install a new upper seal (refer to Up-
per Seal Replacement - Crankshaft Installed proce-
dure above).
(5) Lightly oil t he new lower seal lips with engine
oil.
(6) Install a new lower seal in beari ng cap wi t h
yellow pai nt facing t he rear of engine.
equivalent, on each side of the rear mai n beari ng cap
tion.
(9) Install t he r ear mai n beari ng cap with cleaned
and oiled cap bolts. Alternately t i ght en t he cap bolts
to 115 Nnn (85 ft. lbs.) torque.
ply enough seal ant unt i l a small amount is squeezed
out. Wi t hdraw nozzle and wipe excess sealant off t he
CYLINDER BLOCK
Remove t he engine assembly from t he vehicle.
DISASSEMBLE
(3) Remove t he piston/connecting rod assembly.
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Exami ne block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and t aper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and ri ngs fitted if:
The cylinder bores show more t han 0.127 mm
(0.005 inch) out-of-round.
The cylinder bores show a taper of more t han
0.254 mm (0.010 inch).
The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely co-
ordinated with t he fitting of pistons and rings so
specified clearances may be maintained.
Refer to St andard Service Procedures in t he begin-
ni ng of this Group for t he proper honing of cylinder
bores.
OIL LINE PLUG
The oil line plug is located in t he vertical passage
at t he rear of t he block between t he Oil-To-Filter and
Oil-From-Filter passages (Fig. 20). Improper installa-
tion or plug missing could cause erratic, low or no oil
pressure.
(1) Remove oil pressure sending uni t from back of
block.
(2) Insert a 3.175 mm (1/8 inch) finish wire or
equivalent into passage.
(3) Plug should be 192.0 to 195.2 mm (7-1/2 to
7-11/16 inches) from machined surface of block (Fig.
20). If plug is too high, use a suitable flat dowel drift
to position properly.
RIGHT OIL GALLERY
CYLINDER
BLOCK
PLUG
OIL FROM FILTER
TO SYSTEM
OIL TO FILTER
CRANKSHAFT FROM OIL PUMP
J 9209- 147
Fig. 20 Oil Line Plug
(4) If plug is off position, remove oil pan and rear
mai n beari ng cap. Use suitable flat dowel to remove
plug. Coat outside di amet er of new plug with Mopar
(stud and beari ng mount adhesive), or equivalent.
Pl ug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16
inches) from bottom of t he block.
(5) Assemble engine and check oil pressure.
ENGINE CORE, OIL AND CAMSHAFT PLUGS
Engi ne core plugs have been pressed into t he oil
galleries behind t he camshaft t hr ust plate (Fig. 21).
This will reduce i nt ernal leakage and help mai nt ai n
higher oil pressure at idle.
REMOWAL
(1) Usi ng a bl unt tool such as a drift or a screw-
driver and a hammer, st ri ke t he bottom edge of t he
cup plug (Fig. 22).
(2) With t he cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig.
22).
CLEANING *
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Make certain t he new plug is cleaned of all oil or
grease.
RH157
Fig. 21 Location of Cup Plugs in Oil Galleries
Jr
CYLINDER
^ BLOCK
/
S E C O N D
REMOVE PLUG
WI TH PLIERS
FIRST
STRIKE HERE
WI TH HAMME R
DRIFT
9209-41
Fig. 22 Core Hole Plug Removal
INSTALLATION
(1) Coat edges of plug and core hole with Mopar
Gasket Maker, or equivalent.
C A U T I O N : D O N OT drive cup pl ug into the cast i ng
a s restricted cool ant flow can result and cause se-
ri ous engi ne probl ems.
(2) Using proper drive plug, drive plug into hole.
The sharp edge of t he plug should be at least 0.50
mm (0.020 inch) inside t he lead-in chamfer.
It is not necessary to wait for curing of t he sealant.
The cooling system can be filled and t he vehicle
placed in service immediately.
ASSEMBLE
(1) Install t he piston/connecting rod assembly.
SPECIFICATIONS3.9L ENGINE
ENGINE SPECIFICATIONS
C a ms h a f t
Bearing Diameter
No. 1 50.800- 50.825 mm
(2.000-2.001 in)
No. 2 . . . 50.394 - 50.4 1 9 mm
(1.984 -1.985 in)
No. 3 4 9.6 06 - 4 9.6 32 mm
(1.953-1.954 in)
No. 4 39.6 88-39.713 mm
(1.56 25-1.56 35 in)
Diametrical Clearance 0.0254 - 0.076 2 mm
(0.001-0.003 in)
Max. Allowable 0.127 mm
(0.005 in)
End Play 0.051-0.254 mm
(0.002-0.010 in)
Bearing Journal Diameter
No. 1 . . . . 50.74 9-50.775 mm
(1.998-1.999 in)
No. 2 50.34 3- 50.36 8 mm
(1.982-1.983 in)
No. 3 4 9.555- 4 9.581 mm
(1.951-1.952 in)
No. 4 . . . . 39.6 37- 39.6 6 2 mm
(1.56 05-1.56 15 in)
C onnect i ng R ods
Bearing Clearance 0.0127-0.0559 mm
( 0.0005-0.0022 in)
Piston Pin Bore Diameter 24 .94 0- 24 .978 mm
(0.9819-0.9834 in)
Side Clearance (Two Rods) 0.152-0.356 mm
(0.006 -0.014 in)
Total Weight (Less Bearing) 7 26 grams
(25.6 1 oz)
C r ankshaf t
Connect Rod Journal
Diameter 53.950- 53.975 mm
(2.124 -2.125 in)
Out-of-Round (Max.) . 0.0254 mm
(0.001 in)
Taper (Max.) 0.0254 mm
(0.001 in)
Diametrical Clearance
No. 1 0.0127-0.0381 mm
(0.0005-0.0015 in)
Nos. 2, 3, and 4 0.0127-0.0508 mm
( 0.0005-0.0020 in)
Max. Allowable (Nos. 2, 3, & 4) . . . 0.06 35 mm
(0.0025 in)
End Play 0.051-0.178 mm
( 0.002-0.007 in)
Max. Allowable . 0.254 mm
(0.010 in)
Main Bearing Journals
Diameter 6 3.4 87- 6 3.51 3 mm
( 2.4 995- 2.5005 in)
Out-of-Round (Max.) . 0.0254 mm
(0.001 in)
(0.001 in)
C yl i nder Bl ock
Cylinder Bore
Diameter . 99.31 4 - 99.36 5 mm
(3.910-3.912 in)
Out-of-Round (Max.) 0.127 mm
(0.005 in)
Taper (Max.) . 0.254 mm
(0.010 in)
Oversize (Max.) . 1.016 mm
(0.04 0 in)
Distributor Lower Drive Shaft
Bushing (Press Fit in Block) . . . . 0.0127- 0.3556 mm
(0.0005-0.014 0 in)
Shaft-to-Bushing Clearance 0.01 78- 0.06 86 mm
( 0.0007- 0.0027 in)
Tappet Bore Diameter 22.99- 23.01 mm
( 0.9051-0.9059 in)
C yl i nder H e a d
Compression Pressure 6 89 kPa
(100 psi)
Gasket Thickness (Compressed) 1.206 5 mm
(0.04 75 in)
Valve Seat
Angle 4 4 .25 - 4 4 . 7 5
Runout (Max.) 0.076 2 mm
(0.003 in)
Width (Finish) - Intake 1.016-1.542mm
( 0.04 0-0.06 0 in)
Width (Finish) - Exhaust. 1.524 -2.032 mm
( 0.06 0-0.080 in)
Hydr aul i c T appet s
Body Diameter . . 22.94 9- 22.96 2 mm
( 0.9035- 0.904 0 in)
Clearance in Block. . 0.0279-0.06 10 mm
(0.0011-0.0024 in)
Dry Lash 1.524 -5.334 mm
(0.06 0-0.210 in)
Push Rod Length 172.57-173.08 mm
(6 .794 -6 .814 in)
J9309- 96
ENGINE SPECIFICATIONS (CONT.f
O i l Pump
Clearance Over Rotors ( M a x . ) . . . . . 0.1016 mm
(0.004 in)
Cover Out-of-Flat (Max.) 0.0381 mm
(0.0015 in)
Inner Rotor Thickness (Min.) . . . . . . 20.955 mm
(0.825 in)
Outer Rotor
Clearance (Max.) 0.3556 mm
(0.014 in)
Diameter (Min.) 62.7126 mm
(2.469 in)
Thickness (Min.) . . . . . . . . . . 20.955 mm
(0.825 in)
Tip Clearance Between Rotors (Max). . 0.2032 mm
(0.008 in)
Oi l Pr essur e
At Curb Idle Speed* 41.4 kPa
(6 psi)
At 3000 rpm 207-552 kPa
(30-80 psi)
Oil Pressure Switch
Actuating Pressure (Min.) . . . 34.5-48.3 kPa
(5-7 psi)
* C A U T I O N : If pressure is Z E RO at curb idle,
D O NOT run engine at 3,000 rpm.
Oi l Filter
Bypass Valve Setting . 62-103 kPa
(9-15 psi)
Pi st ons
Clearance at Top of Skirt 0.0127-0.0381 mm
(0.0005-0.0015 in)
Land Clearance (Diametrical) 0.635-1.016 mm
(0.025-0.040 in)
Piston Length 86.360 mm
(3.40 in)
Piston Ring Groove Depth
Nos. 1 and 2 4.572-4.826 mm
(0.180-0.190 in)
No. 3 3.810-4.064 mm
(0.150-0.160 in)
Weight 592.6-596.6 grams
(20.90-21.04 oz)
Pi st on Pi ns
Clearance
In Piston 0.00635-0.01905 mm
(0.00025-0.00075 in)
In Rod (Interference) 0.0178-0.0356 mm
(0.0007-0.0014 in)
Diameter. 24.996-25.001 mm
(0.9841-0.9843 in)
End Pl ay. . N O N E
Length 75.946-76.454 mm
(2.990-3.010 in)
Pi st on R i n g s
Ring Gap
Compression Rings 0.254-0.508 mm
(0.010-0.020 in)
Oil Control (Steel Rails) 0.254-1.270 mm
(0.010-0.050 in)
Ring Side Clearance
(0.0015-0.0030 in)
Oil Ring (Steel Rails) 0.06-0.21 mm
(0.002-0.008 in)
Ring Width
(0.0776-0.0783 in)
Oil Ring (Steel Rails) 3.848-3.975 mm
(0.1515-0.1565 in)
V al ves
Face Angle 43.25 - 43.75
Head Diameter
Intake 48.666 mm
(1.916 in)
Exhaust 41.250 mm
(1.624 in)
Length (Overall)
Intake 124.28-125.92 mm
(4.893-4.918 in)
Exhaust 124.64-125.27 mm
(4.907-4.932 in)
Lift (Zero Lash) 10.973 mm
(0.432 in)
Stem Diameter 7.899-7.925 mm
(0.311-0.312 in)
Stem-to-Guide Clearance 0.0254-0.0762 mm
(0.001-0.003 in)
Max. Allowable (Rocking Method). . 0.4318 mm
(0.017 in)
Guide Bore Diameter (Std) 7.950-7.976 mm
(0.313-0.314 in)
J9309-32
ENGINE SPECIFICATIONS (CONT.)
Valve Spr i ngs
Free L engt h ( A p p r o x . ) 49.962 mm
(1.967 in)
S p r i n g T ensi on @ 4 1.6 6 mm = 378 N
( V al ve C l o s e d ) (@ 1.64 in = 85 l bs)
S p r i n g Tensi on @ 30.89 mm = 890 N
( V al ve O p e n ) (@ 1.212 in = 200 l bs)
N u mb e r of C oi l s 6.8
I nst al l ed H e i g h t . 41.66 mm
( S pr i ng S e a t to Ret ai ner) (1.64 in)
Wi r e D i amet er 4 .50 mm
(0.177 in)
V al ve T i mi ng
E xhaust V al ve
C l o s e s ( AT C ) 16
Opens (BBC) 52
Duration 24 8
Intake Valve
C l o s e s ( A B C ) 50
Opens (BTC) . . 10
Duration 24 0
Valve Overlap 26
J9309- 33
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
CON D I TI ON I D E N T I F I C A T I O N L O C A T I O N O F I D E N T I F I C A T I O N
CRANKSHAFT JOURNALS
(UNDERSIZE)
0 . 0 2 5 4 mm ( 0 . 0 0 1 in.)
R o r M
M - 2 - 3 etc. (indicating no. 2 a n d 3 mai n bear i ng
journal)
a n d / o r
R-l - 4 etc. (indicating no. 1 a nd 4 connecti ng rod
journal)
Steel st amped (near notch) on no. 6 crankshaft
counterweight.
H Y D R A U L I C T A PPE T S
(OVERSIZE)
0 . 2 0 32 mm ( 0 . 0 0 8 in.)
D i amond- shaped st amp
T op p a d - front of engi ne a n d flat gr ound on
outside surface of each O / S tappet bore.
V A L V E S T E M S (OVERSIZE)
0 . 12 7 mm ( 0 . 0 0 5 in.)
X Mi l l ed pa d adj acent to two t apped holes
( 3/ 8 in.) on each end of cylinder head.
J930 9-81
9 - 46 3.9L ENGINE
D E SCRI PTI ON T O R QU E D E S C R I PT I O N TORQ UE
Adjusting Strap Bolt..... 23 N-m (200 in. lbs.)
Camshaft Bolt 68 N-m (50 ft. lbs.j
Camshaft Thrust Plate Bolts 24 N-m (210 in. lbs.)
Chain Case Cover Bolts 41 N-m (30 ft. lbs.)
Connecting Rod Cap Bolts 61 N*m (45 ft. lbs.)
Crankshaft Main Bearing Cap Bolts 115 N-m (85 ft. lbs.}
Cylinder Head Bolts
1st Step . 68 N-m (50 ft. lbs.)
2nd Step ............................................. 143 N-m (105 ft. lbs.)
Cylinder Head Cover Bolts 11 N-m (95 in. lbs.)
Exhaust ManifoId-to-Cylinder
Head Bolts/Nuts 34 N-m (25 ft. lbs.)
Front Insulator Attaching
Bolts (2WD)... 41 N-m (30 ft. lbs.)
Front Insulator Stud Nuts 102 N-m (75 ft. lbs.)
Front Mount Adaptor-to-Block Bolts.. 41 N-m (30 ft. lbs.)
Front Mount Bracket-to-
Crossmember Bolts ( 4 WD) . 41 N-m (30 ft. lbs.)
Generator Mounting Bolt 41 N-m (30 ft. lbs.)
Intake Manifold Bolts Refer to Procedure in
Service Manual.
Oil Pan Bolts 23 N-m (200 in. lbs.)
Oil Pan Drain Plug 34 N-m (25 ft. lbs.)
Oil Pump Attaching Bolts 41 N-m (30 ft. lbs.)
Oil Pump Cover Bolts 11 N-m (95 in. lbs.)
Rear Insulalor-to-Bracket
Through-Bolt (2WD) 6 8 N-rn (50 ft. lbs.)
Rear Insuiator-to-Crossmember
Support Bracket Nut (2WDJ .. 41 N-m (30 ft. lbs.
Rear Insulator Mounting Plate-to-
Rail Assembly Nuts (4WD) ...................... 41 N-m (30 ft. lbs.
Rear Support Bracket-to-Crossmember
Flange Nuts.... 41 N-m (30 ft. lbs.
Rear Support Plate-to-lnsulator
Mounting Plate Bolts (4WD) 4 1 N-m (30 ft. lbs.
Rear Support Plate-to-Transfer
Case Bolts 41 N-m (30 ft. lbs.
Rocker Arm Bolts 23 N-m (200 in. lbs.
Spark Plugs....... 4 1 N-m (30 ft. lbs.
Sfarfer Counting Bolts. 68 N-m (50 ft. lbs.
Throttle Body Bolts (MPI) 23 N-m (200 in. lbs.
Torque Converter Drive Plate Bolts 31 N-m (270 in. lbs.
Transfer Case-to-Insulator
Mounting Plate Nuts.............. 204 N-m (150 ft. lbs.
Transmission Support Bracket
Bolts (2WD) 68 N-m (50 ft. lbs.
Transmission Support Spacer
Bolts (4 WD). 6 8 N-m (50 ft. lbs.
Transmission Support Spacer-to-
Insulator Mounting Plate Nuts (4WD) .... 204 N-m (150 ft. lbs.
Vibration Damper Retainer Bolt................ 183 N-m (135 ft. lbs.
Water Pump-to-Chain Case
Cover Bolt... 41 N-m (30 ft. lbs.)
J9309-S8
5.2L ENGINE 9 - 47
S.2L E N GI N E SERVICE PROCEDURES
INDEX
page
Camshaft . , . 6 1
Crankshaft 6 8
Crankshaft Mai n Beari ngs 6 9
Crankshaft Rear Oil Seal s . . . . . . . . . . . . . . 70
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Cylinder H ead Cover . . . . 51
Cylinder H eads 52
Distributor 6 2
Engi ne Assembl y . 50
Engi ne Front Mounts 4 7
Engi ne Rear Mount . . . . . . . . . . . . . . . 4 8
Front Crankshaft Oil Seal Replacement . . 6 1
GENERAL INFORMATION
The 5.2 Liter (318 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve en-
gine with hydraulic roller tappets (Fig. J).
Engine Type .... 90 V-8 OH V
Bore and Stroke ..... 99.3 x 84 .0 mm (3.91 x 3.31 in.)
Displacement................ 5.2L( 318cu. in.)
Compression Ratio ....... . 9.1:1
Torque .. 379 N-m (280 ft. lbs.) @ 3,200 rpm
Firing Order .... 1-8-4-3-6-5-7-2
Lubrication ....... Pressure Feed-Full Flow Filtration
Engine Oil Capacity...... 4.7L (5.0 Qts) with Filter
Cooling System ...... Liquid Cooled-Forced Circulation
Cooling Capacity.......... 16 .1L(17.0Qts)
Ramcharger 15.6L (16 .5 Qts)
Cylinder Block , Cast Iron
Crankshaft Nodular Iron
Cylinder Head .............. Cast Iron
Combustion Chambers .. Wedge-High Swirl Valve Shrouding
Pistons Aluminum Alloy w/Strut
Connecting Rods........... Forged Steel
J9309-4 1
The cylinders are numbered from front to rear; 1
?
3, 5, 7 on t he left bank and 2, 4, 6, 8 on t he ri ght
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 2) .
reference (Fig. 3).
page
General Information . . . . . . . . . . . . . . . . . . . . . . . 4 7
Oil Pan . 6 3
Oil Pump . 6 4
Piston / Connecting Rod Assembl y 6 6
Rocker Ar ms 51
Specifications5.2L Engi ne 7 3
Timing Chai n Cover . . . . . . . . . . . . . . . . 59
Valve Stem Shield / Spring Replacement 56
Valve Timing . 58
V al ves / V al ve Spri ngs 54
Vibration Damper . . 58
J908D-49
Fig. 2 Firing Order
X M 5.2L T XXXX XXXXXXXX
X ~ Last Digit of Model Year
S Saltillo
T Trenton
K Toluca
T = Usage - T Truck
XXXX = Month/Day
XXXXXXXX = Serial Code - Last 8 Digits of V IN No.
J9209-73
Fig. 3 Engine Identification Number
ENGINE FRONT MOUNTS
REMOVAL
9 48 5.2L ENGINE

CAUTI ON ; D O N OT lift the engi ne by the intake
mani fol d.
(4) Remove nuts from brackets and insulators (Fig.
4).
(5) Raise engine with lifting fixture only far
SCREW < > SCREW <1j>
FRONT
LOCATING PIN
" ON LEFT SIDE
ONLY
USE FRONT HOLES
FOR INSULATOR MTG,
2-WHEEL DRIVE
TIGHTENING TORQUE
75 FT. LBS. (102 N-m)
<B> 65 FT. LBS. (88 N.m)
<> 30 FT. LBS. (41 N-m)
NUT
WASHER
BRACKET'
INSULATOR <
LEFTSIDE
4-WHEEL DRIVE
FRAME SHOWN
INSULATOR
BRACKET
(FRONT ENG
SUPPORT)
Fig. 4 Engine Front Mounts
(Fig. 4).
(7) If necessary, remove t he front engine support
bracket (Fig. 4).
INSTALLATION
(1) If removed, install t he front engine support
bracket. Tighten t he bolts to 41 N-m (30 ft. lbs.)
torque.
(2) If removed, position t he bracket to t he block.
Install t he screws and t i ght en screw A to 102 N-m
(75 ft. lbs.) torque. Tighten screw B to 88 N-m (65 ft.
lbs.) torque.
(3) With engine raised slightly, install insulators.
(4) Lower engine wi t h lifting fixture while guiding
insulator studs into at t achi ng holes in crossmember
and bracket s (Fig. 4).
(5) Tighten at t achi ng insulator nut s to 102 N-m
ENGINE REAR MOUNT
REMOVAL-2WD
(1) Raise vehicle on a hoist.
(2) Position a transmission jack under the t rans-
mission and raise rear of transmission and engine
SLIGHTLY.
(3) Remove rear mount through-bolt from frame
crossmember (sport utility) or from t he transmission
support bracket (Fig. 5).
(4) Remove the flange nut s from the crossmember
sulator flange nut s and remove the insulator (Fig. 5).
sion (Fig. 5).
INSTALLATION-2WD
bracket to the transmission (Fig. 5). Install t he at-
taching bolts and tighten to 68 N-m (50 ft. lbs.)
torque.
Tighten t he through-bolt nut to 68 N-m (50 ft. lbs.)
torque.
t he insulator (Fig. 5). Install t he flange nut(s) and
member (Fig. 5).
(6) Tighten t he crossmember flange nut s to 41 N-
REMOVAL-4WD
(Fig. 6 ) .
SLIGHTLY.
(4) AUTOMATI C TRANSMI SSI ON- Remove
spacer to t he insulator mounting plate (Fig. 7). Re-
move t he bolts and nut s holding t he engine rear sup-
port plate to t he insulator mounting plate (Fig. 7).

5.21 ENGINE 9 - 49
TRANSMISSION
SUPPORT
BRACKET
TRANSMISSION
TRANSMISSION
SUPPORT
BRACKET
INSULATOR
CROSSMEMBER
(SPORT UTILITY)
J9109-240
l ^ ^ ^ U . T R A N S F E R J C A S E .
S K I D R A T l f ~
l ! pW ; ; ^
n i

p
ATTACHI NG BOLTS 1|BS^
I D P L A T E |
Fig. 5 Rear Engine
iSKID PLATE
I ATTACHING BOLTS
PU873
Fig. 6 Skid Plate
(5) MANUAL TRANSMI SSI ON- Remove t he
nut s and bolts holding the insulator mount i ng plate
(6) Remove insulator mount i ng bolts, spacers,
(7) Remove t he insulator mount i ng plate (Figs. 7
and 8).
spacer (automatic transmission) from the extension
assembly (Fig. 7).
bracket (automatic transmission) from t he transfer
case (Fig. 7).
Supports2WD
mSYALLATION-4WD
(1) If removed, position t he engine rear support
bracket (automatic transmission) to t he transfer case
(Fig. 7). Install t he bolts and tighten to 41 N-m (30
ft. lbs.) torque.
sembly (Fig. 7). Install the bolts and t i ght en to 68
(3) Install insulator mounting plate, mounting
t he rail assembly (Figs. 7 and 8). Tighten t he mount-
ing bolt nut s to 204 N-m (150 ft. lbs.) torque.
(4) AUTOMATI C TRANSMISSIONAl i gn t he
engine rear support plate and the transmission sup-
port spacer to t he insulator mounting plate (Fig. 7).
tor mount i ng pl at e and install t he bolts. Tighten t he
transmission support spacer nut s to 204 N-m (150 ft.
lbs.) torque. Tighten t he engine rear support plate to
(5) MANUAL TRANSMISSIONAl i gn t he
transfer case to t he insulator mounting plate and
lower t he engine and transmission. Install the bolts
and t i ght en t he nut s (Fig. 8 - nut A) to 204 N-m (150
ft. lbs.) torque. Install t he bolts and t i ght en t he nut s
(Fig. 8 - nut B) to 41 N-m (30 ft. lbs.) torque.
TRANSFER
CASE
TRANSFER
CASE
ENGINE REAR
SUPPORT
PLATE
EXTENSION
ASSEMBLY
TRANSMISSION
SUPPORT
SPACER
SPACER
UPPER
INSULATOR
INSULATOR
MOUNTING
PLATE
LOWER
INSULATOR
fT^RAIL
J9109-244
Fig, 7 Rear Engine Support4WD with Automatic
Transmission
ENGINE ASSE MBLY
REMOVAL
hood.
(2) Remove t he bat t ery.
(4) Remove t he ai r cleaner.
move radi at or (refer to Group 7, Cooling System).
(11) Disconnect t he fuel lines.
(15) Disconnect t he ai r conditioning hoses.
equipped.
INSULATOR
MOUNTING
PLATE
SPACER
UPPER
L\ f INSULATOR
N U T
RAIL
ASSEMBLY
LOWER
INSULATOR
l 6
f f
RAIL I
J9109-245
Transmission
(21) AUTOMATIC TRANSMISSION:
plate.
(22) MANUAL TRANSMISSION;
CAUTI ON :
mani fol d.
D O N O T lift the engi ne by the intake

5.2L ENGINE 9 - 51
nect the engine from t he torque converter drive
forward unt i l drive pinion shaft clears t he clutch
stand.
INSTALLATION
(1) Remove engine from t he repair st and and posi-
(2) Install an engine support fixture.
the bolts to 31 N-m (270 in. lbs.) torque.
(b) Install t he engine front mounts.
(d) Remove C-clamp.
(e) Install t he inspection plate.
disc.
(c) Install t he engine front mounts.
tery/Starter/ Generator Service).
(11) Install t he st art er motor (refer to Group 8B,
Battery/Starter/Generator Service).
(12) Connect power steering hoses, if so equipped.
(15) Using a new gasket, install MPI throttle body.
Tighten t he t hrot t l e body bolts to 23 N-m (200 in.
lbs.) torque.
(21) Connect t he fuel lines,
(22) Install t he radi at or (refer to Group 7, Cooling
System). Connect the radi at or hoses and heat er
hoses.
(25) Install the ai r cleaner.
(26) Install the bat t ery.
(28) Install hood and line up wi t h t he scribe
marks.
CY LI i i E R HEAD COVER
A steel backed silicon gasket is used with t he cyl-
again.
CYLINDER HEAD
J9209-105
REMOVAL
CLEANING
INSPECTION
Inspect cover for distortion and st rai ght en, if nec-
essary.
Check the gasket for use in head cover installation.
INSTALLATION
ket. Tighten t he bolts to 11 N-m (95 in. lbs.) torque.
ROCKER ARMS
REMOVAL
(1) Disconnect spark plug wires by pulling on t he
boot st rai ght out in line with plug.
9 - 52 5.2L ENGINE

(3) Remove the rocker arm bolts and pivots (Fig,
2). Place t hem on a bench in t he same order as re-
moved.
(4) Remove t he push rods and place t hem on a
bench in t he same order as removed.
ROCKER CYLINDER
J9209-65
Fig. 2 Rocker Arms
INSTALLATION
(1) Rotate t he crankshaft until t he "V8" mar k
lines up with t he TDC mar k on t he t i mi ng chain
case cover. This mar k is located 147 ATDC from t he
C A U T I O N : D O NOT rotate or crank the engi ne dur-
ing or immediately after rocker arm installation. Al -
low the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(2) Install t he push rods in t he same order as re-
moved.
(3) Install rocker arm and pivot assemblies in t he
same order as removed. Tighten t he rocker ar m bolts
CYLINDER HEADS
the peak of the wedge between t he valves.
The 5.2L cylinder head is identified by t he foundry
mar k NH.
REMOVAL
(3) Remove t he heat shields (Fig. 4).
(4) Remove t he i nt ake manifold-to-generator
bracket support rod. Remove t he generator.
(6) Disconnect t he evaporation control system.
(7) Remove the air cleaner.
down cables.
EXHAUST SPARK EXHAUST SPARK EXHAUST
VALVE PLUGS VALVES PLUGS VALVE
INTAKE INTAKE
VALVES VALVES J9309-37
(10) Remove t he ret urn spring.
(12) Disconnect t he coil wires.
(13) Disconnect heat indicator sending uni t wire.
(14) Disconnect heat er hoses and bypass hose.
(16) Remove i nt ake manifold and throttle body as
an assembly. Discard t he flange side gaskets and t he
(18) Remove rocker ar m assemblies and push rods.
der head gasket.
CLEANING
heads.
usi ng a suitable solvent.

5.2L ENGINE 9 - 53
INSPECTION
Inspect all surfaces with a straightedge if there is
ceeds 0.00075 mm/ mm (0.00075 inch/inch) t i mes t he
span length in inches in any direction, ei t her replace
head or lightly machine t he head surface.
FOR EXAMPLE: A 305 mm (12 inch) span is
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
able.
INSTALLATION
(1) Apply Perfect Sealant No.5, or equivalent, to
(2) Position t he new cylinder head gaskets onto t he
cylinder block.
(3) Position t he cylinder heads onto head gaskets
and cylinder block.
(4) St art i ng at top center, t i ght en all cylinder head
bolts, in sequence, to 68 Nm (50 ft. lbs.) torque (Fig.
6). Repeat procedure, tighten all cylinder head bolts
to 143 Nm (105 ft. lbs.) torque. Repeat procedure to
confirm t hat all bolts are at 143 N-m (105 ft. lbs.)
torque.
C A U T I O N : When tightening the rocker arm bol ts,
make sure the pi ston in that cylinder i s N O T at
occur.
(5) Install push rods and rocker ar m assemblies in
t hei r original position. Tighten t he bolts to 28 Nm
(6) Place t he 4 plastic locator dowels into t he holes
ant , or equivalent, to t he four corner joints. An ex-
cessive amount of seal ant is not required to ensure a
seal ant may reduce the effectiveness of the flange
gasket. The seal ant should be slightly higher t han
(8) Install the front and rear cross-over gaskets
tical port alignment t ab is resting on t he deck face of
the block. Also t he horizontal al i gnment tabs must
be in position wi t h t he mat i ng cylinder head gasket
FLANGE GASKET
X
Fig. 8 intake Manifold Flange Gasket Alignment
al i gnment dowels in t he cross-over gaskets to posi-
expected results of t he aut omat ed assembly system
(Fig. 9).
J9209-60
Step 1Tighten bolts 1 t hrough 4, in sequence, to
8 N-m (72 in. lbs.) torque. Tighten in al t ernat i ng
steps 1.4 N-m (12 in. lbs.) torque at a time.
(18) Hook up t he ret urn spring.
down cables.
generator mount i ng bolt to 41 N-m (30 ft. lbs.)
tem for adjusting t he belt tension.
(22) Install t he i nt ake manifold-to-generator
(26) Install the air cleaner.
VALVES / VALVE SPRI NGS
The rocker pivot support and t he valve guides are
cast integral with t he heads.
This procedure requires t he removal of t he cylinder
head.
REMOVAL
(3) Remove valve ret ai ni ng locks, valve spring re-
t ai ners, valve stem seals and valve springs.
valve stem lock grooves to prevent damage to t he
valve guides. Identify valves to ensure installation in
original location.
VALVE CLEANING
and cracked valves.
Remove carbon and varni sh deposits from inside of
VAL VE INSPECTION
0.051 mm (0.002 inch), replace t he valve.

5.2L ENGINE I - 55
Fig. 10 Positioning Valve with Tool C-3973
sleeve places t he valve at t he correct hei ght for
checking with a dial indicator.
(b) Attach Dial Indicator Tool C-3339 to cylinder
head and set it at ri ght angle of valve stem being
measured (Fig. 11).
(c) Move valve to and from t he indicator. The to-
t al dial indicator readi ng should not exceed 0. 432
mm (0. 017 inch). Ream t he guides for valves with
or if t he stems are scuffed or scored.
(Fig. 12).
0.076 mm 8.026 - 8.052 mm
(0.003 in.)
( 0.31 6 - 0.31 7i n.)
0.381 mm 8.331 - 8.357 mm
(0.015 In.)
( 0. 328 - 0. 329 In.)
J9309-30
Sl owl y t u r n r e a me r by h a n d a n d cl ean gui de t hor -
oughl y before i ns t al l i ng ne w val ve. R e a m t he val ve
g u i d e s f r o m s t a n d a r d t o 0, 381 m m ( 0. 015 I n c h ) .
Us e a 2 s t e p p r o c e d u r e s o t h e v a l v e g u i d e s a r e
r e a me d t r u e i n r e l a t i o n t o t h e v a l v e s e a t :
Step 1- Re a m to 0.0763 mm (0.003 inch),
Step 2Ream, to 0.381 mm (0.015 inch).
REFACING VAL WES / WAL WE SEATS
The i nt ake and exhaust valves have a 43-1/4 to
(Fi g. 13).
CONTACT
A - SEAT WIDTH - INTAKE 1.0 16-1.5 24 mm (0.040 - 0.060 in.)
EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
B - FACE ANGLE (INTAKE & EXHAUST) 437.- 4 3
3
/ /
C - SEAT ANGLE (INTAKE & EXHAUST) 4 4 7/ - 4 4 7/
D - CONTACT SURFACE
J9309-95
VALVES
Inspect t he remai ni ng margi n after t he valves are
refaced (Fig. 14). Valves with less t han 1.190 mm
(0.047 inch) margi n should be discarded.
VALVE SEATS
C A U T I O N : D O N O T un- shroud val ves dur i ng val ve
seat refacing (Fi g. 15).
(1) When refacing valve seats, it is important t hat
t he correct size valve guide pilot be used for reseat-
ing stones. A t r ue and complete surface must be ob-
tained.
(2) Measure t he concentricity of valve seat usi ng a
(3) Inspect t he valve seat with Prussi an blue to de-
t ermi ne where t he valve contacts t he seat. To do
t hi s, coat valve seat LIGHTLY with Prussi an blue
t hen set valve in place. Rotate t he valve wi t h light
9 - 56 5.2L ENGINE

VALVE SPRI NG
RETAINER LOCK
GROOVE
EXHAUST
VALVE
J9209-127
t he spring load at test length. Fractional measure-
ments. Refer to specifications to obtain specified
height and allowable tensions. Discard t he springs
SPECIAL
TOOL C-647
Fig. 14 Intake and Exhaust Valves
Fig. 15 Refacing Valve Seats
wi t h a 15 stone. If t he blue is transferred to bottom
edge of valve face raise valve seat with a 60 stone.
1.524-2.032 mm (0.060-0.080 inch).
WALVE SPRING INSPECTION
t he spring to be tested is 1-5/16 inch. Turn table of
line with t he 1-5/16 inch mar k on t he threaded stud.
ver to set tone device. Pull on torque wrench unt i l
ping is heard. Take readi ng on torque wrench at t hi s
i nst ant . Multiply t hi s readi ng by 2. This will give
^ 9209-37
Fig. 16 Testing Valve Spring for Compressed
INSTALLATION
head.
(4) Compress valve springs with Valve Spring
t he installed hei ght of springs. Make sure t he mea-
inder head to t he bottom surface of spring ret ai ner. If
If height is great er t han 42.86 mm (1-11/16 inches),
install a 1.587 mm (1/16 inch) spacer in head coun-
terbore. This should bri ng spring height back to nor-
mal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
VALVE STEM SHIELD / SPRING REPLACEMENT
#
This procedure is done with t he cylinder head in-
stalled.
(1) Set engine basic t i mi ng to Top Dead Center
(TDC) and remove air cleaner.
good ground to prevent engine from st art i ng.
(4) Using suitable socket and flex handl e at crank-
at TDC on t he compression stroke.

5.2L ENGINE 9 - 57
(6) Wi t h ai r hose attached to an adapt er installed
psi) air pressure.
(7) Usi ng Valve Spring Compressor Tool
tainer valve locks and valve spring.
(8) Install seals on t he exhaust valve stem and po-
sition down agai nst valve guides.
firmly and squarely over t he valve guide using t he
valve stem as a guide. DO NOT force seal agai nst
locks, compress t he spring only enough to install t he
locks.
cylinders usi ng t he firing sequence 1-8-4-3-6-5-7-2.
Make sure piston in cylinder is at TDC on t he valve
spring t hat is being removed.
(11) Remove adapter from t he No.l spark plug
hole.
HYDRAULIC TAPPETS
Before disassembling any part of t he engine to cor-
rect tappet noise, check t he oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at
the pressure sending unit. The pressure should be be-
operating t emperat ure. Allow 5 mi nut es to stabilize
The oil level in t he pan should never be above t he
FULL mar k or below t he ADD OIL mar k on dipstick.
Ei t her of these 2 conditions could be responsible for
noisy tappets.
OIL LEWEL
HIGH
If oil level is above t he FULL mark, it is possible
engine runni ng t hi s condition could create foam in
t he oil pan. Foam in oil pan would be fed to t he hy-
draulic tappets by the oil pump causing t hem to lose
LOW
When air is fed to t he tappets, they lose length
which allows valves to seat noisily. Any leaks on in-
t ake side of oil pump through which ai r can be
drawn will create t he same tappet action. Check t he
lubrication system from t he i nt ake st rai ner to t he
pump cover, including t he relief valve ret ai ner cap.
When tappet noise is due to aeration, it may be in-
t ermi t t ent or constant, and usually more t han 1 tap-
pet will be noisy. When oil level and l eaks have been
corrected, operate t he engine at fast idle. Run engine
for a sufficient time to allow all of t he air inside t he
tappets to be bled out.
(1) To determine source of tappet noise, operate en-
gine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect
noisy tappet. The noisy t appet will cause t he affected
spring and/or rocker arm to vibrate or feel rough in
operation.
Worn val ve gui des or cocked spri ngs are some-
ti mes mi staken for noi sy tappets. If such is the
case, noi se may be dampened by appl yi ng side
thrust on the valve spring. If noi se is not appre-
ci abl y reduced, it can be assumed the noi se is in
the tappet. Inspect the rocker arm push rod
sockets and push rod ends for wear.
(3) Valve t appet noise ranges from light noise to a
sive leak-down around t he uni t plunger or by the
plunger partially sticking in t he t appet body cylin-
der. The tappet should be replaced. A heavy click is
caused by a t appet check valve not seating or by for-
and t he t appet body. This will cause t he plunger to
accompanied by excessive clearance between the
valve stem and rocker arm as valve closes. In either
tion and cleaning.
The valve t r ai n generates a noise very much like a
light tappet noise during normal operation. Care
must be t aken to ensure t hat tappets are maki ng the
noise. In general, if more t han one t appet seems to
be noisy, its probably not t he tappets.
REMOVAL
tify push rods to ensure installation in original loca-
tion.
C-4129-A t hrough opening in cylinder head and seat
(7) Pull t appet out of bore with a twisting motion.
If all tappets are to be removed, identify t appet s to
(8) If t he tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream t he bore to
CAUTI ON: Th plunger and tappet bodies are not
interchangeable. The plunger and valve must al-
ways be fitted to the original body. It is advisable to
work on one tappet at a time to avoid mix ing of
parts. Mix ed parts are not compatible. DO NOT dis-
assemble a tappet on a dirty work bench,
DISASSEMBLE
(2) Clean varni sh deposits from inside of tappet
(3) Invert t appet body and remove plunger cap,
ret ai ner and plunger spring (Fig. 17). Check valve
ASSEMBLE
(1) Clean all t appet part s in a solvent t hat will re-
(2) Replace t appet s t hat are unfit for further ser-
vice with new assemblies.
ing, install a new t appet assembly.
(4) Assemble t appet s (Fig. 17).
PLUNGER
CHECK
BALL
PLUNGER
RETAINER
SPRING CLIP
ROLLER
TAPPET
BODY
RETAINER
I
PLUNGER
CHECK VALVE
SPRING
PLUNGER
CAP J9109-220
INSTALLATION
(1) Lubricate tappets.
(2) Install t appet s and push rods in t hei r original
positions. Ensure t hat t he oil feed hole in t he side of
(3) Install aligning yokes with ARROW toward
camshaft.
(4) Install yoke ret ai ner. Tighten t he bolts to 23
Nm (200 in. lbs.) torque. Install i nt ake manifold.
(5) Install push rods in original positions.
(6) Install rocker arm.
(7) Inst al l cylinder head cover.
(8) St art and operate engine. War m up to normal
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all hy-
draulic tappets have filled with oil and have become
quiet.
VALVE TIMING
(1) Turn crankshaft unt i l t he No.6 exhaust valve
is closing and No.6 i nt ake valve is opening.
Allow spring load to bleed tappet down giving in ef-
sible. Zero t he indicator.
(0.010 inch). The t i mi ng of t he crankshaft should
CAUTI ON: DO NOT turn crankshaft any further
clockwise as valve spring might bottom and result
in serious damage.
tor.
VIBRATION DAMPER
REMOVAL
(3) Remove the cooling system fan.
Cooling System).
end of crankshaft.
C-3688. Install 2 bolts with washers t hrough t he
J9209-81

5.2L ENGINE 9 - 59
INSTALLATION
(1) Position the vibration damper onto t he crank-
shaft.
(2) Place installing tool, part of Pul l er Tool Set
t he bolt to 183 N*m (135 ft. lbs.) torque.
ley bolts to 23 Ni n (200 in. lbs.) torque.
Cooling System).
(6) Install t he cooling system fan. Ti ght en t he
Tighten t he ret ai ner bolts to 11 Nm (95 in. lbs.)
torque.
TIMING CHAIN COVER
REMOVAL
(1) Disconnect the negative cable from t he bat t ery.
System).
Cooling System).
(4) Remove water pump (refer to Group 7, Cooling
System).
19, Steering).
tem).
(8) Loosen oil pan bolts and remove t he front bolt
at each side.
t reme caution to avoid damaging oil pan gasket.
Nm (30 ft. lbs.) torque wi t h cylinder head installed
or 20 Nm (15 ft. lbs.) torque with cylinder head re-
move. It may be necessary to block t he crankshaft to
prevent rotation.
(3) Hold a scale wi t h dimensional reading even
with t he edge of a chain link. Wi t h cylinder heads
installed, apply 14 Nnn (30 ft. lbs.) torque in t he re-
verse direction. With t he cylinder heads removed, ap-
ply 20 Nm (15 ft. lbs.) torque in t he reverse
direction. Note t he amount of chain movement (Fig.
4).
with crankshaft and camshaft sprockets.
sprocket on t he bench wi t h t i mi ng marks on exact
imaginary center line t hrough both camshaft and
crankshaft bores.
(7) Place timing chain around both sprockets.
9 - 60 5.2L ENGINE
shaft sprocket.
T I M I N G
M A R K S
J 9209- 129
be 0.051-0.152 mm (0.002-0.006 inch) with a new
t hrust plate and up to 0.254 mm (0.010 inch) with a
new t hr ust plate.
CLEANING
INSTALLATION
(1) Using a new cover gasket, carefully install
ing chain cover gasket and t he oil pan gasket. Fi nger
t i ght en t he t i mi ng chain cover bolts at this time.
(2) Place t he smaller di amet er of t he oil seal over
(Fig. 7) .
(4) Using t he vibration damper bolt, t i ght en t he
(Fig. 8).
(5) Tighten chain case cover bolts to 41 Nnn (30 ft.
lbs.) torque. Tighten oil pan bolts to 24 Nnn (215 in.
lbs.) torque.
stallation tool.
(7) Install vibration damper.
(8) Install fuel lines (refer to Group 14, Fuel Sys-
tem).
CRANKSHAFT
k
FRONT OIL
SEAL
INSTALL THIS
END INTO
SPECIAL TOOL
6635
J9309-44
SPECIAL TOOL \ | OIL
SEAL
TIMING
CHAI N
COVER J9309-45*-
ing new gaskets (refer to Group 7, Cooling System).
Tighten bolts to 41 Nnn (30 ft. lbs.) torque.
(10) Install power steering pump (refer to Group
19, Steering).
Cooling System).
Tighten t he bolts to 11 Nnn (95 in. lbs.) torque.

J9309-46
Fig. 8 Installing Oil Seal
The oil seal can be replaced wi t hout removing t he
t i mi ng chain cover provided t he cover is not mis-
aligned.
oil seal alignment to crankshaft. The seal installa-
tion/alignment tool 6635, should fit with mi ni mum
(5) Place the smaller diameter of t he oil seal over
(Fig. 7).
bolt to draw the seal into position on t he crankshaft
(Fig. 8).
stallation tool.
CAMSHAFT
from t he vehicle.
5.2L ENGINE 9 - 61
J9309-71
REMOVAL
(3) Remove t i mi ng case cover and t i mi ng chain.
(4 ) Remove rocker arms.
(5) Remove push rods and tappets. Identify each
part so it can be installed in its original location.
(6 ) Remove distributor and lift out the oil pump
(7) Remove camshaft t hrust plate, note location of
oil t ab (Fig. 10).
Fig. 10 Timing Chain Oil Tab Installation
being careful not to damage cam bearings with t he
cam lobes.
REMOVAL-BEARING
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
9 - 62 5.2L ENGINE
Fig, 11 Camshaft Bearings Removal and installation
with Tool C-3132-A
Tool C-3132-A) at back of each beari ng shell. Drive
INSTALL A TION- BEARING
(1) Install new camshaft bearings with Camshaft
Beari ng Remover/Installer Tool C-3132-A by sliding
fully drive beari ng shell into place.
ner. Bearings must be carefully aligned to bri ng oil
camshaft. Be sure this pl ug does not leak.
INSTALLATION
j ournal s and insert t he camshaft to wi t hi n 51 mm (2
Whenever an engi ne has been rebuilt, a new
camshaft and/or new tappets installed, add 1
pint of Mopar Crankcase Conditioner, or equiv-
alent. The oil mixture shoul d be left in engi ne
for a mi ni mum of 805 km (500 miles). Drai n at
the next normal oil change.
Position)

(10) Install t he camshaft bolt/cup washer. Tighten
bolt to 68 Nm (50 ft. lbs.) torque.
cations for proper clearance. If not within limits in-
stall a new t hrust plate.
(12) Each tappet reused must be installed in t he
same position from which it was removed. When
camshaft is repl aced, all of the tappets must be
repl aced.
DISTRIBUTOR
REMOVAL
procedure.
Tool C-3052 into old bushi ng and t hread down unt i l
plug in rear of cylinder block Tool shoul d remai n
(4 ) Install camshaft t hr ust plate and chain oil t ab.
plate. Tighten bolts to 24 N*m (210 in. lbs.) torque.
sprocket on t he bench with t i mi ng marks on exact
crankshaft bores.
keyway location in
crankshaft sprocket and in camshaft sprocket.
agai nst t he chain in position as described).

5.2L ENGINE I - 63
Fig. 14 Distributor Driveshaft Bushing Removal
(2) Hold puller screw and tighten puller nut unt i l
bushing is removed.
INSTALLA TION-DRIVE SHAFT BUSHING
tributor Drive Shaft Bushi ng Driver/Burnisher Tool
C-3053. Insert t he tool and bushi ng into t he bore.
hammer (Fig. 15).
Fig. 15 Distributor Driveshaft Bushing Installation
(3) As t he burnisher is pulled t hrough t he bushing,
t he bushing is expanded t i ght in t he block and bur-
nished to correct size (Fig. 16). DO NOT ream this
bushing.
DISTRIBUTOR TIMING
shaft, time engine as follows:
(1) Rotate crankshaft unt i l No. l cylinder is at top
(2) When in t hi s position, t he t i mi ng mar k on vi-
brat i on damper should be under "0" on the t i mi ng in-
dicator.
place, it will index with t he oil pump shaft. The slot
in top of drive gear should be aligned towards left
Fig. 17 Position or Installed Distributor Drive Gear
INSTALLATION
procedure.
OIL PAN
REMOVAL
(3) Raise vehicle.
(6) Remove left engine to transmission strut.
CLEANING
Tri m or remove excess sealant film in t he rear
mai n cap oil pan gasket groove. DO NOT remove
the seal ant i nsi de the rear mai n cap slots.
gine.
cloth.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged t hreads. Repair as necessary.
Inspect oil pan mount i ng flange for bends or distor-
INSTALLATION
(1) Fabricate 4 al i gnment dowels from 1 1/2 x 5/16
inch bolts. Cut t he head off t he bolts and cut a slot
9 - 64 5.2L ENGINE

VI2' x 5/16 " BOLT
DOWE L
SLOT
J9209-106
DOWE L
DOWE L
J9309- 7 9
Fig. 2 Position of Dowels in Cylinder Block
Adhesive Sealant, or equivalent in t he corner of t he
cap and t he cylinder block.
onto t he block.
t he gasket.
(6) Install t he oil pan bolts. Tighten t he bolts to 24
pan bolts. Tighten these bolts to 24 Nm (215 in. lbs.)
torque.
(8) Install t he drai n plug. Ti ght en drai n plug to 34
Nm (25 ft. lbs.) torque.
(11) Lower vehicle.
(13) Fill crankcase with oil to proper level.
OIL PUMP
REMOVAL
cap.
DISASSEMBLE
(1) Remove the relief valve as follows:
sert a self-threading sheet met al screw.
OIL PUMP ASSEMBLY
SPRING
RELIEF VALVE
' RETAINER CAP
COTTER PIN
RH174
(3) Remove pump outer rotor and i nner rotor with
shaft (Fig. 4).
INNER ROTOR DISTRIBUTOR DRIVESHAFT
AND SHAFT
m m
(REFERENCE)
COTTER PIN
LARGE CHAMFERED
EDGE
Fig. 4 Oil Pump
SPRING
RETAINER
CAP
RY10B
5.2L ENGINE S - 6 5
INSPECTION
Mat i ng surface of t he oil pump cover should be
smooth. Replace pump assembly if cover is scratched
or grooved.
be inserted between cover and straightedge, pump
Measure thickness and diameter of OUTER rotor.
If outer rotor thickness measures 20.9 mm (0.825
inch) or less or if t he diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 6).
less, replace i nner rotor and shaft assembly (Fig. 7) .
sembly.
Install i nner rotor and shaft into pump body. If
clearance between i nner and outer rotors is 0.203
tors (Fig. 9).
Place a straightedge across t he face of the pump,
between bolt holes. If a feeler gauge of 0.102 mm
Fig. 7 Measuring Inner Rotor Thickness
OUTER
ROTOR
INNER
ROTOR
RH179
and the straightedge, replace pump assembly (Fig.
10).
Inspect oil pressure relief valve pl unger for scoring
and free operation in its bore. Small mar ks may be
The relief valve spring has a free l engt h of approx-
test between 19.5 and 20.5 pounds when compressed
i - 68 5.2L ENGINE
RH 1 80
Fig. 10 Measuring Clearance Over Rotors
If oil pressure was low and pump is within specifi-
N
BV y%L RETAINER CAP
COTTER KEY
CHAMFER
RN 9 8
Fig. 11 Proper Installation of Retainer Cap
ASSEMBLE
as required.
body. Tighten cover bolts to 11 Nm (95 in. lbs.)
torque.
cotter pin.
(4) Tap on a new ret ai ner cap.
tor cavity wi t h engine oil.
INSTALLATION
shaft engagement.
(2) Hold t he oil pump base flush agai nst mat i ng
surface on No.4 mai n beari ng cap. Finger t i ght en
pump at t achi ng bolts. Tighten at t achi ng bolts to 41
amet er at t he pin boss is less t han its diameter
nearly round shape.
The piston pin rotates in t he piston only and is re-
tained by t he press interference fit of t he piston pin
REMOVAL
(4) Remove top ridge of cylinder bores with a reli-
inder block. Re sure to keep tops of pistons covered
duri ng t hi s operation.
(5) Be sure t he connecting rod and connecting rod
in cylinder bore and at BDC. Be car ef ul not t o ni ck
cr anks haf t j our na l s .
(7) After removal, install bearing cap on t he mat-
ing rod.
INSPECTION
cessive wear, t aper and scoring.
fore they are fitted into t he cylinder bore (Fig. 12).
FITTING PISTONS*
der wall is 0.013-0.038 mm (0.0005-0.0015 inch).
FITTING RINGS

5.2L ENGINE I - 67
DIAMETER (D)
SHOULD BE
0.0000-0.0152 mm
(0.0000-0.0006 in.)
LARGER THAN (C).
98.704-98.831 mm
(3.886-3.891 in.)-
FEELER GAUGE
62.230 mm
(2.45 in.)
1
26.543 mm
(1.045 in.)
c
J9309-9
rings squarely in t he cylinder bore before measur-
ing.
(b) Insert feeler gauge in t he gap. The top com-
pression ri ng gap should be between 0.254-0.508
mm (0.010-0.020 inch). The second compression
ring gap should be between 0.508-0.762 mm (0.020-
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be prop-
erly filled to the correct dimension. Rings wi t h ex-
(2) Install rings and confirm ri ng side clearance:
(b) Install t he compression rings using Installa-
stalled wi t h either side up. The second compression
ring must be installed wi t h t he identification mar k
should face down. An identification mar k on t he
ring is a drill point, a stamped letter "O", an oval
(c) Measure side clearance between piston ri ng
rings. The steel rai l oil ring should be free in
(3) Arrange ring gaps 90 apart as shown in Fig.
RI NG
GROOVE
J9209- 136
OIL RI NG
SPACE R GAP
TOP
COM PRE SSI ON
RI NG GAP
SE CON D
COM PRE SSI ON
RI NG GAP
OIL RI NG RAI L
GAP (TOP)
OIL RI NG RAI L
GAP ( BOTTOM)
J9309- 80
14.
Fit all rods on a bank unt i l completed. DO NOT al-
t ernat e from one bank to another, because connect-
sembly.
Each beari ng cap has a small V-groove across t he
part i ng face. When installing t he lower bearing
in line with t he V-groove in t he cap. This provides
lubrication of t he cylinder wall in t he opposite bank.
The beari ng shells must be installed so t hat t he
caps.
journals should be held to 0.025 mm (0.001 inch).
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
size. Install the beari ngs i n pairs. DO NOT use a
new beari ng half wi th an ol d beari ng half. DO
9 - 68 5.2L ENGINE

INSTALLATION
gered so t hat nei t her is in-line with oil ri ng rail gap.
sure t he oil ri ng expander ends are but t ed and t he
over t he piston and t i ght en with t he special wrench
(part of Tool C-385). Be sure posi ti on of ri ngs does
not change duri ng this operation.
(5) Rotate crankshaft so t hat t he connecting rod
j ournal is on t he center of t he cylinder bore. Be sure
guide rod over t he crankshaft j ournal .
hammer handl e. At t he same t i me, guide connecting
rod into position on crankshaft j ournal .
of t he connecting rod bore must be installed toward
(8) Install rod caps. Be sure connecting rod, con-
necting rod cap and cylinder bore number are t he
same. Install nut s on cleaned and oiled rod bolts and
t i ght en nut s to 61 Nm (45 ft. lbs.) torque.
CRANKSHAFT
A crankshaft which has undersize j ournal s will be
stamped wi t h 1/4 inch letters on t he milled flat on
t he No.8 crankshaft counterweight (Fig. 15).
F O R EXAMPLE: R2 stamped on t he No.8 crank-
and t he No.2 mai n j ournal are 0.025 mm (0.Q01 in)
undersize.
necting rod bearings should be replaced wi t h new
bearings. Therefore, selective fitting of t he bearings
replaced.
REMOVAL
ing cap.
beari ng caps and beari ngs one at a time.
Undersize Journal
Identification Stamp
0.025 mm (0.001 in.) (Rod) R1-R2-R3 or R4
0.025 mm (0.001 in.) (Main) M1-M2-M3-M4 or M5
#8 CRANKSHAFT
COUNTERWEIGHT
(ROD)
(MAIN)
f\
J 920 9- 13 8
Fig. 15 Location of Crankshaft Identification
seals.
(6) Remove and discard t he front crankshaft oil
seal.
The crankshaft connecting rod and mai n journals
ing. The maxi mum t aper or out-of-round on any
Journal grinding should not exceed 0.305 mm
(0.012 inch) under t he st andard j ournal diameter. DO
NOT grind t hr ust faces of No.3 mai n bearing. DO
NOT nick crank pin or beari ng fillets. After grind-
INSTALLATION
oil.
(2) Install the new upper rear bearing oil seal with
gine.
oil.
t he bearing cap with t he yellow paint facing towards
(6 ) Apply 5 mm (0.20 in) drop of Loctite 515, or
tion.
5.2L ENGINE 9 - 6 9
BE A R I N G C A P J930 9- 72
bearing caps. Install all cap bolts and alternately
t i ght en to 115 Nnn (85 ft. lbs.) torque.
MOPAR SILICONE SEALANT
RUBBER ADHESIVE APPLIED
changeable. Lower mai n bearing halves of No.2 and
Upper and lower No.3 beari ng hal ves ar e flanged
i nt erchangeabl e with any other beari ng hal ves in t he
engine (Fig. 18). Bearing shells are available in stan-
dard and t he following under sizes: 0.25 mm (0.001
Never install an undersize beari ng t hat will reduce
Fig. 18 Main Bearing Identification
REMOVAL
ing cap.
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
upper half of bearing shell.
Installation with Tool C-3059
INSTALLATION
while all other mai n bearing caps are properly tight-
ened. All bearing capbolts removed during service
lation.
(1) St art beari ng in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
(2) Slowly rotate crankshaft counterclockwise slid-
(3) Install t he beari ng cap. Clean and oil t he bolts.
Tighten t he capbolts to 115 Nm (85 ft. lbs.) torque.
seal half can be installed with crankshaft removed
The lower seal half can only be installed with t he
REMOVED)
(1) Remove t he crankshaft.
oil.
(3) Install t he new upper rear beari ng oil seal with
gine.
oil.
t he bearing cap with t he yellow pai nt facing towards
the rear of t he engine.
equivalent, on each side of t he rear mai n bearing cap
tion.
INSTALLED)
(1) Remove the oil pan.
ing cap.
(3) Remove t he rear mai n bearing cap. Remove
and discard the old lower oil seal.
( 4) Carefully remove and discard t he old upper oil
seal.
least t he 2 main bearing caps forward of t he rear
beari ng cap.
t he beari ng cap with the yellow paint facing towards
tion. Be sure t he yellow pai nt faces toward t he rear
of t he engine.
(9) To align t he bearing cap, use cap slot, align-
(10) Install the rear mai n beari ng cap with cleaned
ply enough seal ant until a small amount is squeezed
ing cap.
(3) Remove t he rear mai n beari ng cap and discard

5.2L ENGINE 9 - 71
per Seal Replacement - Crankshaft I ns t a l l e d proce-
dure above).
(5) Lightly oil the new l ower seal lips w i t h engine
oil.
yellow pai nt facing t he rear of engine.
(7) Apply 5 m m (0.20 in) drop of Loctite 5 15 , or
tion.
(8) T o align t he bearing cap, use cap slot, align-
ment dowel and cap bolts. D o not r emove excess ma-
terial after assembly. D o not strike r ear cap more
(9) Install t he rear mai n bearing cap w i t h cl eaned
to 115 N-m (85 ft. lbs.) torque*.
(11) Apply M o p a r Silicone Rubber Adhesive S e a l -
CYLINDER BLOCK
DISASSEMBLE
(3) R e mo v e t he piston/connecting rod assembly.
CLEANING
Clean cylinder block thoroughly and check ail core
INSPECTION
Exami ne bl ock for cracks or fractures.
The cylinder walls s houl d be checked for out-of-
bound a n d taper with C y l i n d e r Bore Indicator Tool
C -119. T h e cylinder block should be bored a n d honed
with new pistons a n d rings fitted if:
T he cylinder bores show more t han 0 .127 mm
(0. 005 inch) out-of-round.
0. 254 mm (0. 010 inch).
The cylinder walls ar e badly scuffed or scored.
Boring and h o n i n g operation should be closely co-
ordinated with t he fitting of pistons and rings so
specified clearances ma y be ma i nt a i ne d.
ning of t hi s G r o u p for t he proper h o n i n g of cylinder
bores.
OIL LINE PLUG
The oi l l i ne plug is located i n t he vertical passage
at t he r ear of t he bl ock bet ween t he Oil-To-Filter and
Oil-From-Filter passages (Fig, 20). Improper installa-
tion or plug missing could cause errat i c, low or no oil
pressure.
block.
(3) Pl ug should be 192.0 to 195.2 mm (7-1/2 to
20). If plug is too hi gh, use a suitable flat dowel drift
RIGHT OIL GALLERY
CRANKSHAFT FROM OIL PUMP J9209-147
Fig, 20 Oil Line Plug
(4) If plug is off location, remove oil pan and rear
mai n bearing cap. Use suitable flat dowel to remove
plug. Coat outside diameter of plug with Mopar (stud
and bearing mount adhesive), or equivalent. Pl ug
should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 inches)
from bottom of the block.
Engine core plugs have been pressed into the oil
This w i l l reduce i nt ernal leakage and help mai nt ai n
REMOVAL
(1) Using a bl unt tool such as a drift or a screw-
driver and a hammer, strike t he bottom edge of t he
cup plug (Fig. 22).
9 - 72 5.2L ENGINE
(2) With t he cup plug rotated, grasp firmly with
22).
CLEANING
grease.
CYLINDER
" BLOCK ' /
DRIFT 9209-41
INSTALLATION
C A U T I O N : DO NOT drive cup plug into the casting
as restricted coolant flow can result and cause se-
rious engine problems.
ASSEMBLE
C a ms h a f t
Bearing Diameter
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 50.800-50.825 mm
(2.000-2.001 in)
No. 2 . . . 50.394-50.419 mm
(1.984-1.985 in)
No. 3. . 50.013-50.038 mm
(1.969-1.970 in)
No. 4 . . . . . . . . . . . . . . . . . . . . 49.606-49.632 mm
(1.953-1.954 in)
No. 5 39.688-39.713 mm
(1.5625-1.5635 in)
Diametrical Clearance 0.0254-0.0762 mm
(0.001-0.003 in)
(0.005 in)
End Play. . . . . . 0.051-0.254 mm
(0.002-0.010 in)
Bearing Journal Diameter
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 50.749-50.775 mm
(1.998-1.999 in)
No. 2 50.343-50.368 mm
(1.982-1.983 in)
No. 3 . . . 49.962-49.987 mm
(1.967-1.968 in)
No. 4. . . . . . . . . . . . . . . . . . . . 49.555-49.581 mm
(1.951-1.952 in)
No. 5 39.637-39.662 mm
(1.5605-1.5615 in)
C onnect i ng R ods
Bearing Clearance 0.0127-0.0559 mm
(0.0005-0.0022 in)
Piston Pin Bore Diameter . 24.966-24.978 mm
(0.9829-0.9834 in)
Side Clearance (Two Rods) . . . . . . . . . 0.152-0.356 mm
(0.006-0.014 in)
Total Weight (Less Bearing) . . . . . . . . . 726 grams
(25.61 oz)
C r a nk s ha f t
Connect Rod Journal
Diameter . . . . . . . 53.950-53.975 mm
(2.124-2.125 in)
Out-of-Round (Max.) . . . . . . . . . . . . 0.0254 mm
(0.001 in)
Taper (Max.) . . . . . . . . . . 0.0254 mm
(0.001 in)
No. 1 0.0127-0.0381 mm
(0.0005-0.0015 in)
Nos. 2, 3, 4 and 5 . . . . . . . . . . . . . 0.0127-0.0508 mm
(0.0005-0.0020 in)
Max. Allowable (Nos. 2, 3,4&5) 0.0635 mm
(0.0025 in)
End Play 0.051-0.178 mm
(0.002-0.007 in)
(0.010 in)
Diameter . . . . . . . . . . . . . . . . . . . . . 63.487-63.513 mm
(2.4995-2.5005 in)
(0.001 in)
(0.001 in)
C yl i nder Bl ock
Cylinder Bore
Diameter 99.314-99.365 mm
(3.910-3.912 in)
Out-of-Round (Max.) . . . . . . . . . . . . 0.127 mm
(0.005 in)
(0.010 in)
Oversize (Max.) . . . . . . . . . . . . . . . . 1.016 mm
(0.040 in)
Bushing (Press Fit in Block) 0.0127-0.3556 mm
(0.0005-0.0140 in)
Shaft-to-Bushing Clearance . . . . . . . . 0.0178-0.0686 mm
(0.0007-0.0027 in)
Tappet Bore Diameter . . . . . . . . . 22.99-23.01 mm
(0.9051-0.9059 in)
C yl i nder H e ad
Compression Pressure 689 kPa
(100 psi)
Gasket Thickness (Compressed) . . . . . . 1.2065 mm
(0.0475 in)
Valve Seat
Angle. . . . . 44.25 - 44.75
Runout (Max.) . . . . . . . . . . . . . 0.0762 mm
(0.003 in)
Width (Finish) - Intake 1.016-1.524 mm
(0.040-0.060 in)
Width (Finish) - Exhaust. . . . . . . . . . 1.524-2.032 mm
(0.060-0.080 in)
Hydr aul i c T appet s
Body Diameter 22.949-22.962 mm
(0.9035-0.9040 in)
Clearance in Block . 0.0279-0.0610 mm
(0.0011-0.0024 in)
Dry Lash 1.524-5.334 mm
(0.060-0.210 in)
Push Rod Length . . . . . . . . . . . . . 172.57-173.08 mm
(6.794-6.814 in)
J9309-97
ENGINE SPECIFICATIONS (CONT*)
Oi l Pump
Clearance Over Rotors ( M a x . ) . . . . . 0.1016 mm
(0.004 in)
Cover Out-of-Flat ( Max . ) . . . . . 0.0381 mm
(0.0015 in)
Inner Rotor Thickness (Min.) 20.955 mm
(0.825 in)
Outer Rotor
Clearance ( M a x . ) . . . . . . . . . . . . . 0.3556 mm
(0.014 in)
Diameter (Min.) 6 2.71 26 mm
(2.4 6 9 in)
Thickness (Min.) 20.955 mm
(0.825 in)
Tip Clearance Between Rotors (Max ). . 0.2032 mm
(0.008 in)
Oi l Pr es s ur e
At Curb Idle Speed* 4 1.4 kPa
(6 psi)
At 3000 rpm 207- 552 kPa
(30-80 psi)
Oil Pressure Switch
Actuating Pressure (Min.) . 34 .5- 4 8.3 kPa
(5-7 psi)
* CAUTI ON : If pressure is Z E RO at curb idle,
D O NOT run engine at 3, 000 rpm.
Oi l Fil ter
Bypass Valve Setting . . . . . . . . . . . . 6 2-103 kPa
(9-15 psi)
Pi st ons
Clearance at Top of Skirt . . . . 0.0127-0.0381 mm
(0.0005-0.0015 in)
Land Clearance (Diametrical) . . . . . 0.6 35-1.016 mm
( 0.025-0.04 0 in)
Piston Length . . . . . . . . . . . . . . . . . 86 .36 0 mm
(3.4 0 in)
Nos. 1 and 2 4 .57 2- 4 .8 26 mm
(0.180-0.190 in)
No. 3 3.810-4 .06 4 mm
(0.150-0.16 0 in)
Weight 592.6 - 596 .6 grams
(20.90-21.04 oz)
Pi st on Pi ns
Clearance
In Piston . 0.006 35- 0.01905 mm
( 0.00025-0.00075 in)
In Rod (interference) . . . . . . . . . . 0.0178-0.0356 mm
(0.0007-0.0014 in)
Diameter. 24 .996 - 25.001 mm
(0.984 1-0.984 3 in)
End Play N O N E
Length 75.94 6 - 76 .4 54 mm
(2.990-3.010 in)
Pi st on Ri ngs
Ring Gap
Compression Rings . 0.254 - 0.508 mm
(0.010-0.020 in)
Oil Control (Steel Rails) . 0.254 -1.270 mm
(0.010-0.050 in)
Ring Side Clearance
Compression Rings 0.038- 0.076 mm
(0.0015-0.0030 in)
Oil Ring (Steel Rails) . . . . . . . . . . 0.06 - 0.21 mm
( 0.002-0.008 in)
Ring Width
( 0.0776 - 0.0783 in)
Oil Ring (Steel Rails) 3.84 8- 3.975 mm
(0.1515-0.156 5 in)
Vhrs
Face Angle 4 3.25 - 4 3.75
Head Diameter
Intake . . . . . . . . . . . . . . . . . . . . . 4 8 . 6 6 6 mm
(1.916 in)
Exhaust 4 1.250 mm
(1.6 24 in)
Length (Overall)
Intake . 124 .28-125.92 mm
(4 .893-4 .918 in)
Exhaust . 124 .6 4 -125.27 mm
( 4 .907-4 .932 in)
Lift (Z ero Lash) 10.973 mm
(0.4 32 in)
Stem Diameter 7.899- 7.925 mm
(0.311-0.312 in)
Stem-to-Guide Cl e ar anc e . . . . . . . . . 0.0254 - 0.076 2 mm
(0.001-0.003 in)
Max . Allowable (Rocking Method). . 0.4 318 mm
(0.017 in)
Guide Bore Diameter (Std) 7.950- 7.976 mm
(0.313-0.314 in)
J9309-32
ENGINE SPECIFICATIONS (CONT,)
V al ve S p r i n g s
Free Length (Approx .) 4 9.96 2 mm
(1.96 7 in)
Spring Tension . @ 4 1.6 6 mm = 378 N
(Valve Closed) (@ 1.64 in . 85 lbs)
Spring Tension . @ 30.89 mm = 890 N
(Valve Open) (@ 1.212 in = 200 lbs)
Number of Coils . . . . . . . . . . . . . . . 6 .8
Installed Height 4 1.6 6 mm
(Spring Seat to Retainer) (1.64 in)
Wire Diameter . 4 .50 mm
(0.177 in)
V al ve T i mi ng
Exhaust Valve
Closes (ATC) 16
Opens (BBC) 52
Duration 24 8
Intake Valve
Closes (ABC) 50
Opens (BTC) . 10
Duration . 24 0
Valve Overlap . . . 26
J9309- 33
C O N D I T I O N I D E N T I F I C A T I O N L O C A T I O N O F I D E N T I F I C A T I O N
CRANKSHAFT JOURNALS
(UNDERSIZE)
0.0254 mm (0.001 in.)
RorM
M-2-3 etc. (indicating no. 2 and 3 main bearing
journal)
and/or
R-l-4 etc. (indicating no. 1 and 4 connecting rod
journal)
Milled flat on no. 8 crankshaft counterweight.
HYDRAULIC TAPPETS
(OVERSIZE)
0.2032 mm (0.008 in.)
Diamond-shaped stamp top pad - front of
engine and flat ground on outside surface of
each O/S tappet bore.
VALVE STEMS (OVERSIZE)
0.127 mm (0.005 in.)
X Milled pad adjacent to two tapped holes
( 3/ 8 in.) on each end of cylinder head.
J9309-82
DESCRI PTI ON T O R QU E D E S C R I PT I O N T O R QU E
Adjusting Strap Bolt... 23 N-m (200 in. lbs.)
Camshaft Bolt 68 N-m (50 ft. lbs.)
Camshaft Thrust Plate Bolts........................ 24 N-m (210 in. lbs.)
Connecting Rod Cap Bolts 61 N-m (45 ft. lbs.)
Crankshaft Main Bearing Cap Bolts 115 N-m (85 ft. lbs.)
Cylinder Head Bolts
1st Step 68 N-m (50 ft. lbs.)
2nd Step 143 N-m (105 ft. lbs.)
Cylinder Head Cover Bolts 11 N-m (95 in. lbs.)
Exhaust Manifold-to-Cylinder
Bolts (2WD).. 41 N-m (30 ft. lbs.)
Front Mount Adaptor-to-Block Bolts 41 N-m (30 ft. lbs.)
Crossmember Bolts (4WD) 41 N-m (30 ft. lbs.)
Service Manual.
Oil Pump Cover Bolts.. 11 N-m (95 in. lbs.)
Rear Insulator-to-Bracket
Through-Bolt (2WD)................................. 68 N-m (50 ft. lbs.
Rear Insulator-to-Crossmember
Support Bracket Nut (2WD) 41 N-m (30 ft. lbs.
Rear Insulator Mounting Plate-to-
Rail Assembly Nuts (4WD) 41 N-m (30 ft. lbs.
Flange Nuts 41 N-m (30 ft. lbs.
Mounting Plate Bolts (4WD) 41 N-m (30 ft. lbs.
Spark Plugs.... 41 N-m (30 ft. lbs.
Starter Mounting Bolts 68 N-m (50 ft. lbs.
Throttle Body Bolts (MPI)... 23 N-m (200 in. lbs.
Transfer Case-to-Insulator
Mounting Plate Nuts.... 204 N-m (150 ft. lbs.
Bolts (2WD).... 68 N-m (50 ft. lbs.
Insulator Mounting Plate Nuts (4WD) .... 204 N-m (150 ft. lbs.
Vibration Damper Retainer Bolt 183 N-m (135 ft. lbs.
Cover Bolt 41 N-m (30 ft. Ibs.j
J9309-98
5 . 9 L ENGINE SERVICE PROCEDURES
INDEX
page
Camshaft 91
Crankshaft 98
Crankshaft Mai n Beari ngs 99
Crankshaft Rear Oil Seal s 100
Cylinder Block 101
Cylinder H ead Cover 81
Cylinder H eads 82
Distributor 92
Engine Assembl y 80
Engine Front Mounts 77
Engine Rear Mount 78
Front Crankshaft Oil Seal Replacement 91
page
Oil Pan 93
Oil Pump . 94
Piston / Connecting Rod Assembl y 96
Rocker Ar ms 81
Specifications5.9L Engine 103
Timing Chai n Cover 89
V al ve Stem Shield / Spring Replacement 86
Val ve Timing . 88
V al ves / V al ve Spri ngs 84
Vibration Damper 88
GENERAL INFORMATION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve en-
gine with hydraulic roller tappets (Fig. 1).
Engine Type .90 V-8 OHV
Bore and Stroke 101.6 x 90.9 mm (4.00 x 3.58 in.)
Compression Ratio 9.1:1
Torque 441 N-m (325 ft. lbs.) @ 3,200 rpm
(Heavy Duty). 448 N-m (330 ft. lbs.) @ 2,800 rpm
Firing Order 1-8-4-3-6-5-7-2
Lubrication . . . . . . Pressure Feed - Full Flow Filtration
Engine Oil Capacity .4.7L (5.0 Qts) w/filter
Cooling System . . . Liquid Cooled - Forced Circulation
Cooling Capacity . . . . . . . 14.7L (15.5 Qts)
Ramcharger (4WD) 14.2L (15.0 Qts)
Cylinder Block Cast Iron
Crankshaft - Nodular Iron
Cylinder Head . Cast Iron
Combustion Chambers Wedge-High Swirl Valve
Shrouding
Pistons Cast Aluminum Alloy
J9309-99
3, 5, 7 on t he left bank and 2, 4, 6, 8 on t he ri ght
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 2).
reference (Fig. 3).
o
FRONT
OF
E N G I N E
CLOCKWI SE ROTATION
1-8-4-3-6-5-7-2
J908D-49
Fig. 2 Firing Order
X M 5.9L T XXXX XXXXXXXX
X = Last Digit of Model Year
S Saltillo
T Trenton
K Toluca
T = Usage - T Truck
XXXX = Month/Day
XXXXXXXX = Serial Code - Last 8 Digits of VIN No.
J9209-74
Fig. 3 Engine identification Number
ENGINE FRONT MOUNTS
REMOVAL
for radi at or top t ank and hose.
9 - 78 5.9L ENGINE

CAUTION: D O NOT lift the engi ne by the intake
mani fol d.
(4) Remove nut s from brackets and insulators (Fig,
4 ) .
(5) Raise engine wi t h lifting fixture only far
SCREW < > SCREW <B>
FRONT
#C3p LOCATING PIN
- - - SIDE
ONLY
I NSULATORS ^
4-WHEEL DRIVE
FRAME SHOWN
INSULATOR
BRACKET
(FRONT ENG
SUPPORT)
USE FR ONT HOLES
FOR I NS UL AT OR M T G .
2-WHEEL DRIVE
TIGHTENING TORQUE
75 FT. LBS.
(102 N-m)
65 FT. LBS. (38 Hw)
<) 30 FT. LBS. (41 N-m)
RIGHT SIDE
4-WHEEL
DRIVE
LEFT SIDE
2-WHEEL
DRIVE
RR09B145
Fig. 4 Engine Front Mounts
(Fig. 4).
(7) If necessary, remove t he front engine support
bracket (Fig. 4).
INSTALLATION
(1) If removed, install t he front engine support
bracket. Tighten t he bolts to 41 N-m (30 ft. lbs.)
torque.
(2) If removed, position t he bracket to t he block.
Install t he screws and t i ght en screw A to 102 Nr n
(75 ft. lbs.) torque. Tighten screw B to 88 N-m (65 ft.
lbs.) torque.
(3) With engine raised slightly, install insulators.
(4) Lower engine with lifting fixture while guiding
insulator studs into at t achi ng holes in crossmember
and brackets (Fig. 4).
(5) Tighten at t achi ng insulator nut s to 102 N-m
engine r e a r MOUNT
REMCYAL-2WD
(2) Position a transmission jack under t he t rans-
mission and raise rear of transmission and engine
SLIGHTLY.
(3) Remove rear mount through-bolt from frame
crossmember (sport utility) or from t he transmission
(4) Remove the flange nut s from t he crossmember
sulator flange nut s and remove t he insulator (Fig. 5).
sion (Fig. 5).
INSTALLATION-2WD
bracket to t he transmission (Fig. 5). Install t he at-
t achi ng bolts and t i ght en to 68 N-m (50 ft. lbs.)
torque.
Tighten t he through-bolt nut to 68 N-m (50 ft. lbs.)
torque.
t he insulator (Fig. 5). Install t he flange nut(s) and
member (Fig. 5).
(6) Tighten t he crossmember flange nut s to 41 N-
REMOVAL-4WD
(Fig. 6).
SLIGHTLY.
(4) AUTOMATIC TRANSMISSION- Remove
spacer to t he insulator mounting plate (Fig. 7). Re-
move t he bolts and nut s holding t he engine r ear sup-
port pl at e to t he insulator mounting plate (Fig. 7).
TRANSMI SSI ON
SUPPORT
BRACKET
TRANSMISSION
TRANSMISSION
SUPPORT
BRACKET
INSULATOR
CROSSMEMBER
(SPORT UTILITY)
J9109-240
j TRANSFER CASE f | |
SKID PLATE l l l l p i f c i ^ ^
ATTACHING BOLTS pt l l l l SK i P PLATE f
FIG, 5 REAR ENGINE
iSKID PLATE
I ATTACHING BOLTSlt
PU873
FIG. 6 SKID PLATE
( 5) MANUAL TRANSMISSIONRemove t he
nut s and bolts holding the insulator mount i ng pl at e
(6) Remove insulator mounting bolts, spacers,
(7) Remove t he insulator mounting plate (Figs. 7
and 8).
spacer (automatic transmission) from the extension
assembly (Fig. 7).
bracket (automatic transmission) from t he transfer
case (Fig. 7).
Supporis-2WD
SNSTALLA TION-4 WD
(1) If removed, position the engine rear support
bracket (automatic transmission) to t he transfer case
(Fig. 7). Install t he bolts and t i ght en to 41 Nm (30
ft. lbs.) torque.
(2) If removed, position the transmission support
sembly (Fig. 1). Install t he bolts and t i ght en to 68
(3) Install insulator mount i ng plate, mounting
the rail assembly (Figs. 7 and 8). Tighten t he mount-
ing bolt nut s to 204 N*m (150 ft. lbs.) torque.
( 4) AUTOMATIC TRANSMISSIONAlign t he
engine rear support plate and t he transmission sup-
port spacer to t he insulator mount i ng plate (Fig. 7).
tor mount i ng plate and install t he bolts. Tighten t he
transmission support spacer nut s to 204 N*m (150 ft.
lbs.) torque. Tighten t he engine rear support plate to
(5) MANUAL TRANSMISSIONAlign the
transfer case to t he insulator mount i ng plate and
lower t he engine and transmission. Install t he bolts
and tighten t he nut s (Fig. 8 - nut A) to 204 N-m (150
ft. lbs.) torque. Install t he bolts and tighten t he nut s
(Fig. 8 - nut B) to 41 N-m (30 ft. lbs.) torque
(6) Install the skid plate.
9 - 80 5.9L ENGINE

TRANSFER
CASE
TRANSFER
CASE
ENGI NE REAR
SUPPORT
PLATE
INSULATOR
MOUNT I NG
PLATE
LOWER
INSULATOR
\7" RAIL 1
J91 09- 24 4
Fig. 7 Rear Engine Support4WD with Automatic
Transmission
ENGINE ASSEMBLY
REMOVAL
hood.
(2) Remove t he bat t ery.
move radiator (refer to Group 7, Cooling System).
(15) Disconnect t he air conditioning hoses.
equipped.
INSULATOR
MOUNT I NG
PLATE
SPACER
UPPER
INSULATOR
N U T
LOWER
INSULATOR
J91 09- 24 5
Transmission
plate.
(22) MANUAL TRANSMI SSI ON;
CAUTI ON :
mani fol d.
D O N O T lift the engi ne by the intake

5.9L ENGINE 9 - 8 1
nect the engine from t he torque converter drive
forward unt i l drive pinion shaft clears t he clutch
stand.
INSTALLATION
(1) Remove engine from the repai r st and and posi-
(2) Install an engine support fixture.
t he bolts to 31 Nnn (270 in. lbs.) torque.
(b) Install t he engine front mount s.
(d) Remove C-clamp.
(e) Install t he inspection pl at e.
(5) MANUAL TRANSMISSION:
disc.
(c) Install t he engine front mount s.
(11) Install t he st art er motor (refer to Group 8B,
Battery/Starter/Generator Service).
(12) Connect power steering hoses, if so equipped.
(15) Using a new gasket, install MPI t hrot t l e body.
Tighten t he t hrot t l e body bolts to 23 Nnn (200 in.
lbs.) torque.
(21) Connect t he fuel lines.
(22) Install t he radiator (refer to Group 7, Cooling
System). Connect the radiator hoses and heat er
hoses.
(25) Install t he ai r cleaner.
(26) Install t he bat t ery.
(28) Install hood and line up with the scribe
marks.
CYLINDER HEAD COVER
A steel backed silicon gasket is used with the cyl-
again.
CYLINDER HEAD
J9209-105
REMOVAL
CLEANING
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
INSTALLATION
ket. Tighten t he bolts to 11 Nnn (95 in. lbs.) torque.
ROCKER ARMS
REMOVAL
(1) Disconnect spark plug wires by pulling on the
boot st rai ght out in line with plug.
9 - 82 5.9L ENGINE

(3) Remove t he rocker arm bolts and pivots (Fig.
2). Place t hem on a bench in t he same order as re-
moved.
(4) Remove t he push rods and place t hem on a
bench in t he same order as removed.
ROCKER CYLINDER
J9209-65
Fig. 2 Rocker Arms
INSTALLATION
(1) Rotate t he crankshaft unt i l t he "V8" mar k
lines up wi t h t he TDC mar k on t he t i mi ng chain
case cover. This mar k is located 147 ATDC from t he
C A U T I O N : D O N O T rotate or crank the engi ne dur-
i ng or immediately after rocker arm installation. Al -
l ow the hydraul i c roller tappets adequate time to
bleed down (about 5 minutes).
(2) Install t he push rods in t he same order as re-
moved.
(3) Install rocker ar m and pivot assemblies in t he
same order as removed. Tighten t he rocker ar m bolts
CYLINDER HEADS
t he peak of t he wedge between t he valves.
The 5.9L cylinder head is identified by t he foundry
mar k CF.
REMOVAL
(3) Remove t he heat shields (Fig. 4).
(4) Remove t he i nt ake manifold-to-generator
bracket support rod. Remove t he generator.
(6) Disconnect t he evaporation control system.
equipped, t he speed control and t ransmi ssi on kick-
down cables.
EXHAUST SPARK EXHAUST SPARK EXHAUST
VALVE PLUGS VALVES PLUGS VALVE
INTAKE INTAKE
VALVES VALVES J9309-37
(10) Remove t he r et ur n spring.
(13) Disconnect heat indicator sending uni t wire.
(14) Disconnect heat er hoses and bypass hose.
(16) Remove i nt ake manifold and t hrot t l e body as
an assembly. Discard t he flange side gaskets and t he
(18) Remove rocker arm assemblies and push rods.
der head gasket.
CLEANING
heads.
usi ng a suitable solvent.

I J L ENGINE 9 - 83
INSPECTION
Inspect all surfaces wi t h a straightedge if t here is
ceeds 0.00075 mm/ mm (0.00075 inch/inch) times t he
span length in inches i n any direction, either replace
head or lightly machi ne t he head surface.
FOR EXAMPLE: A 305 mm (12 inch) span is
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
able.
INSTALLATION
(1) Apply Perfect Seal ant No.5, or equivalent, to
(2) Position t he new cylinder head gaskets onto t he
cylinder block.
(3) Position t he cylinder heads onto head gaskets
and cylinder block.
(4) St art i ng at top center, t i ght en all cylinder head
bolts, in sequence, to 68 N-m (50 ft. lbs.) torque (Fig.
6). Repeat procedure, t i ght en all cylinder head bolts
to 143 N-m (105 ft. lbs.) torque. Repeat procedure to
confirm t hat all bolts are at 143 N-m (105 ft. lbs.)
torque.
C A U T I O N : When tightening the rocker arm bol ts,
make sure the pi ston in that cylinder i s N OT at
occur.
(5) Install push rods and rocker arm assemblies in
t hei r original position. Tighten t he bolts to 28 N-m
cessive amount of sealant is not required to ensure a
sealant may reduce t he effectiveness of t he flange
gasket. The sealant should be slightly highe^ t han
the cross-over gaskets, approx. 5 mm (0.2 in).
(8) Install t he front and rear cross-over gaskets
tical port al i gnment tab is resting on the deck face of
t he block. Also the horizontal alignment t abs must
be in position with t he mat i ng cylinder head gasket
FLANGE GASKET
al i gnment dowels i n t he cross-over gaskets to posi-
expected results of t he automated assembly system
(Fig. 9).
J9209-60
8 N-m (72 in. lbs.) torque. Tighten in al t ernat i ng
steps 1.4 N-m (12 in. lbs.) torque at a t i me.
Step 3-Check t hat all bolts are t i ght en to 8 N-m
(18) Hook up t he r et ur n spring.
down cables.
generator mount i ng bolt to 41 N-m (30 ft. lbs.)
(200 In. lbs.) torque. Refer to Group 7, Cooling Sys-
t em for adjusting t he belt tension.
(22) Install the i nt ake manifold-to-generator
ALES / WALWE SPRI l i S
The rocker pivot support and t he valve guides are
cast integral wi t h t he heads.
This procedure requires t he removal of t he cylinder
head.
REMOVAL
(3) Remove valve ret ai ni ng locks, valve spring re-
t ai ners, valve stem seals and valve springs.
valve stem lock grooves to prevent damage to t he
valve guides. Identify valves to ensure Installation in
original location,
VALVE CLEANING
and cracked valves.
Remove carbon and varni sh deposits from Inside of
VALVE INSPECTION
0.051 mm (0.002 Inch), replace t he valve.

5.9L ENGINE 9 - 85
sleeve places t he valve at t he correct height for
checking wi t h a dial indicator.
(c) Move valve to and from t he indicator. The to-
t al dial indicator reading should not exceed 0.432
mm (0.017 inch). Ream t he guides for valves with
or if t he stems are scuffed or scored.
(Fig. 12).
0.076 mm 8.026 - 8.052 mm
(0.003 in.) ( 0. 31 6 - 0. 31 7 in.)
0.381 mm 8.331 - 8.357 mm
(0.015 in.) ( 0. 328 - 0. 329 in.)
J9309-30
Slowly t ur n reamer by hand and clean guide thor-
oughly before installing new valve. Ream the val ve
gui des from standard to 0.381 mm (0.015 inch).
Use a 2 step procedure so the val ve gui des are
reamed true in relation to the val ve seat:
Step 2 - Re a m to 0.381 mm (0.015 inch).
REFACING VALVES / VALVE SEATS
The intake and exhaust valves have a 43-1/4 to
(Fig. 13).
CONTACT
A - SEAT WIDTH - INTAKE 1.016-1.524 mm (0.040 - 0.060 in.)
EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
B - FACE ANGLE (INTAKE & EXHAUST) 4374-43
3
/
4
C - SEAT ANGLE (INTAKE & EXHAUST) 447/ - 44

3
A
D - CONTACT SURFACE
J9309-95
VALVES
Inspect t he remai ni ng margi n after t he valves are
refaced (Fig. 14). Valves with less t han 1.190 mm
(0.047 inch) margi n should be discarded.
VALVE SEATS
CAUTI ON : D O N OT un- shroud val ves duri ng val ve
seat refacing (Fig. 15).
(1) When refacing valve seats, it is i mport ant t hat
t he correct size valve guide pilot be used for reseat-
ing stones. A t rue and complete surface must be ob-
tained.
(2) Measure the concentricity of valve seat using a
(3) Inspect t he valve seat with Prussi an blue to de-
t ermi ne where the valve contacts t he seat. To do
this, coat valve seat LIGHTLY wi t h Prussi an blue
t hen set valve in place. Rotate t he valve with light
9 86 5.9L ENGINE

INTAKE
VALVE
\ MARGI N /
>
\ A C E ^
* STEM *
VALVE SPRING
RETAINER LOCK
GROOVE
EXHAUST
VALVE
J9209-127
Fig. 14 intake and Exhaust Waives
REFACI NG STONE
MUST NOT CUT
VALVE SHROUD
Fig. 15 Refacing Waive Seats
with a 15 stone. If t he blue is transferred to bottom
edge of valve face raise valve seat with a 60 stone.
1.524-2.032 mm (0.060-0.080 inch).
VALVE SPRING INSPECTION
t he spring to be tested is 1-5/16 inch. Turn t abl e of
line with t he 1-5/16 inch mar k on t he t hreaded stud.
ver to set tone device. Pull on torque wrench unt i l
ping is heard. Take readi ng on torque wrench at t hi s
i nst ant . Multiply t hi s reading by 2. This will give
t he spring load at test length. Fractional measure-
ment s. Refer to specifications to obtain specified
height and allowable tensions. Discard t he springs
SPECIAL
TOOL C-647
9209-37
Fig. 16 Testing Waive Spring for Compressed
INSTALLATION
head.
(4) Compress valve springs with Valve Spring
t he installed height of springs. Make sure t he mea-
inder head to t he bottom surface of spring retainer. If
If hei ght is great er t han 42.86 mm (1-11/16 inches),
i nst al l a 1.587 mm (1/16 inch) spacer in head coun-
terbore. This should bring spring height back to nor-
mal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
ALE STEM SHIELD / SPRING REPLACEMENT
This procedure is done with t he cylinder head in-
stalled.
(1) Set engine basic t i mi ng to Top Dead Center
(TDC) and remove air cleaner.
good ground to prevent engine from starting.
(4) Using suitable socket and flex handle at crank-
at TDC on t he compression stroke.

5.9L ENGINE 9 - 87
(6) Wi t h ai r hose attached to an adapt er installed
psi) air pressure.
(7) Usi ng Valve Spring Compressor Tool
t ai ner valve locks and valve spring.
(8) Install seals on t he exhaust valve st em and po-
sition down against valve guides.
firmly and squarely over t he valve guide usi ng t he
valve stem as a guide. DO NOT force seal agai nst
locks, compress t he spring only enough to i nst al l t he
locks.
cylinders using t he firing sequence 1-8-4-3-6-5-7-2.
Make sure piston in cylinder is at TDC on t he valve
spring t hat is being removed.
(11) Remove adapt er from t he No. l spark plug
hole.
HYDRAULIC TAPPETS
Before disassembling any par t of t he engine to cor-
rect t appet noise, check t he oil pressure. If vehicle
has no oil pressure gauge, Install a reliable gauge at
t he pressure sending unit. The pressure should be be-
operating t emperat ure. Allow 5 mi nut es to stabilize
The oil level in t he pan should never be above t he
FULL mar k or below t he ADD OIL mar k on dipstick.
Ei t her of t hese 2 conditions could be responsible for
noisy tappets.
OIL LEVEL
HIGH
If oil level Is above t he FULL mark, It is possible
engine runni ng t hi s condition could create foam in
t he oil pan. Foam in oil pan would be fed to t he hy-
draulic t appet s by t he oil pump causing t hem to lose
LOW
When air is fed to t he tappets, causes t hem to lose
length and allows valves to seat noisily. Any leaks
on i nt ake side of oil pump t hrough which ai r can be
drawn will create t he same t appet action. When t ap-
pet noise is due to aeration, it may be i nt ermi t t ent or
constant, and usually more t han 1 tappet will be
noisy. When oil level and leaks have been corrected,
engine should be operated at fast idle for sufficient
time. This allows all of t he air inside of t he tappets
to be bled out.
(1) To determine source of t appet noise, operate en-
gine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect
noisy tappet. The noisy tappet will cause the affected
spring and/or rocker arm to vi brat e or feel rough in
operation.
Wor n val ve gui des or cocked s pr i ngs a r e some-
t i mes mi s t aken for n o i s y t a p p e t s . If s uch i s t he
case, noi se ma y be d a mp e n e d by appl yi ng si de
t hr us t on t h e v a l v e s pr i ng. If noi s e i s not a ppr e -
ci abl y r educed, it c a n be a s s u me d t he noi se Is i n
t he t appet . I ns pect t h e r oc ke r a r m pus h r od
s ocket s a n d p u s h r od e nds for wear .
(3) Valve tappet noise ranges from light noise to a
sive leak-down around t he uni t plunger or by t he
plunger partially sticking in t he t appet body cylin-
der. The tappet should be replaced. A heavy click is
caused by a tappet check valve not seating or by for-
and t he tappet body. This will cause t he plunger to
accompanied by excessive clearance between t he
valve stem and rocker arm as valve closes. In either
tion and cleaning.
The valve t rai n generates a noise very much like a
light tappet noise during normal operation. Care
must be t aken to ensure t hat t appet s are maki ng t he
noise. In general, if more t han one tappet seems to
be noisy, its probably not t he t appet s.
REMOVAL
tify push rods to ensure Installation in original loca-
tion.
(4) Remove Intake manifold.
C-4129-A t hrough opening in cylinder head and seat
(7) Pull tappet out of bore with a twisting motion.
If all t appet s are to be removed, identify tappets to
(8) If t he t appet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, r eam t he bore to
9 - 88 5.9L ENGINE

CAUTI ON : The pl unger and tappet bodi es are not
interchangeable, . The pl unger and val ve must al-
w ays be fitted to the original body, It i s advi sabl e to
work on one tappet at a time to avoi d mi x i ng of
parts. Mi x ed parts are not compati bl e. D O N OT di s-
assembl e a tappet on a dirty wor k benc h.
DISASSEMBLE
(2) Clean varni sh deposits from inside of t appet
(3) Invert tappet body and remove plunger cap,
ret ai ner and plunger spring (Fig, 17). Check valve
ASSEMBLE
(1) Clean all t appet part s in a solvent t hat will re-
(2) Replace t appet s t hat are unfit for further ser-
vice wi t h new assemblies.
ing, install a new tappet assembly.
(4) Assemble tappets (Fig. 17).
SPi I NG CAP J9109-220
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and push rods in t hei r original
positions. Ensure t hat t he oil feed hole In t he side of
(3) Install rocker ar m and shaft assembly.
(4) Install vent cover.
(5) Install distributor, st art engine and reset tim-
ing.
CAUTI ON : To prevent damage to val ve mec hani sm,
engi ne must not be r un above fast idle until all hy-
draulic tappets have filled with oil and have bec ome
quiet.
ALE TIMING
(1) Turn crankshaft unt i l t he No.6 exhaust valve
is closing and No.6 i nt ake valve Is opening.
Allow spring load to bleed t appet down giving in ef-
sible. Zero t he Indicator.
(0.034 inch). The t i mi ng of t he crankshaft should
CAUTI ON : D O N OT turn crankshaft any further
cl ockwi se a s val ve spri ng mi ght bottom and result
in ser i ous damage.
tor. -
IBRATI0N PAMPER
REMOVAL
(3) Remove t he cooling system fan.
Cooling System).
end of crankshaft.
C-3688. Install 2 bolts with washers t hrough t he
J9209-81
INSTALLATION
(1) Position t he vibration damper onto t he crank-
shaft.

5.9L ENGINE 9 - 89
(2) Place installing tool, par t of Puller Tool Set
t he bolt to 183 N-m (135 ft. lbs.) torque.
ley bolts to 23 N-m (200 In. lbs.) torque.
Cooling System).
Tighten t he ret ai ner bolts to 11 N-m (95 in. lbs.)
torque.
TIMING CHAIN COWER
REMOVAL
System).
Cooling System).
(4) Remove wat er pump (refer to Group 7, Cooling
System).
19, Steering).
tem).
(8) Loosen oil pan bolts and remove the front bolt
at each side.
t reme caution to avoid damagi ng oil pan gasket.
N-m (30 ft, lbs.) torque with cylinder head installed
or 20 N-m (15 ft. lbs.) torque with cylinder head re-
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale wi t h dimensional reading even
wi t h t he edge of a chain link. Wi t h cylinder heads
installed, apply 14 N-m (30 ft. lbs.) torque In t he re-
verse direction. With the cylinder heads removed, ap-
ply 20 N-m (15 ft. lbs.) torque In t he reverse
direction. Note t he amount of chain movement (Fig.
4).
with crankshaft and camshaft sprockets,
crankshaft bores.
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
9 - 90 5.9L ENGINE

of t i mi ng mar ks (Fig. 5).
TIMING
MARKS
J9209- 1 29
be 0.051-0.152 mm (0.002-0.006 inch) wi t h a new
t hrust plate and up to 0.254 mm (0.010 inch) with a
new t hr ust pl at e.
CLEANING
INSTALLATION
(1) Usi ng a new cover gasket, carefully install
ing chain cover gasket and t he oil pan gasket. Fi nger
t i ght en t he t i mi ng chain cover bolts at this time.
CRANKSHAFT.
FRONT OIL
SEAL
INSTALL THIS
END INTO
SPECIAL TOOL
6635
J9309-44
(Fig. 7).
SPECIAL TOOL OIL
SEAL
TI MI NG'
CHAI N
COVER J930 9- 45 -
(Fig. 8).
J9309-46
Fig. 8 Installing Oil Seal
(5) Tighten chain case cover bolts to 41 N-m (30 ft.
lbs.) torque. Tighten oil pan bolts to 24 Nm (215 in.
lbs.) torque.
stallation tool.
(7) Install vibration damper.
(8) Install fuel lines (refer to Group 14, Fuel Sys-
tem).
ing new gasket s (refer to Group 7, Cooling System).
Tighten bolts to 41 N-m (30 ft. lbs.) torque.
(10) Install power st eeri ng pump (refer to Group
19, Steering).
Cooling System).
(13) Position the fan shroud and install t he bolts.
The oil seal can be replaced without removing t he
timing chain cover provided t he cover is not mis-
aligned.
oil seal alignment to crankshaft. The seal installa-
tion/alignment tool 6635, should fit wi t h mi ni mum
(Fig. 7).
(Fig. 8).
stallation tool.
(10) Connect the negative cable to t he bat t ery.
CAMSHAFT
from the vehicle.
REMOVAL
(3) Remove timing case cover and t i mi ng chain.
(5) Remove push rods and tappets. Identify each
part so it can be installed in its original location.
THRUST
PLATE
OIL PUMP A N D
DISTRIBUTOR DRI VE
GEAR INTEGRAL
WITH CAMSHAFT
CAMSHAFT SPROCKET
J8309-71
(6) Remove distributor and lift out t he oil pump
(7) Remove camshaft t hr ust plate, note location of
oil t ab (Fig. 10).
THRUST PLATE
REAR SIDE
J9209-132
Fig. 10 Timing Chain Oil Tab Installation
being careful not to damage cam bearings with t he
cam lobes.
REMOVAL-BEARING
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
Tool C-3132-A) at back of each bearing shell. Drive
INSTALLATION-BEARING
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
9 - 92 5.9L ENGINE

Fig. 11 Camshaft Bearings Removal and Installation
with Tool C-3132-A
fully drive bearing shell into place.
ner. Bearings must be carefully aligned to bring oil
camshaft. Be sure this pl ug does not leak.
INSTALLATION
journals and insert t he camshaft to within 51 mm (2
Whenever an engi ne has been rebuilt, a new
camshaft and/or new tappets installed, add 1
pint of Mopar Crankcase Conditioner, or equiv-
alent. The oil mixture shoul d be left in engi ne
for a mi ni mum of 805 km (500 miles). Drain at
the next normal oil change.
Position)
plug in rear of cylinder block. Tool shoul d remai n
(4) Install camshaft t hr ust plate and chain oil t ab.
plate. Tighten bolts to 24 N-m (210 in. lbs.) torque.
imaginary center line t hrough both camshaft and
crankshaft bores.
shaft sprocket.
against the chain in position as described).
(10) Install the camshaft bolt/cup washer. Tighten
bolt to 68 N-m (50 ft. lbs.) torque.
cations for proper clearance. If not within limits, in-
stall a new t hr ust plate.
(12) Each t appet reused must be installed in t he
same position from which it was removed. When
camshaft is repl aced, all of the tappets must be
repl aced.
DISTRIBUTOR
REMOVAL
procedure.
Tool C-3052 into old bushing and t hread down unt i l
(2) Hold puller screw and t i ght en puller nut until
bushi ng is removed.
INSTALLATION-DRIVE SHAFT BUSHING
t ri but or Drive Shaft Bushing Driver/Burnisher Tool
C-3053. Insert t he tool and bushing into t he bore.

5.9L ENGINE 9 - 93
Fig. 14 Removing Distributor Driveshaft Bushing
hammer (Fig. 15).
Fig. 15 Distributor Driveshaft Bushing Installation
(3) As t he burni sher is pulled t hrough the bushing,
t he bushi ng is expanded tight in t he block and bur-
nished to correct size (Fig. 16). DO NOT ream thi s
bus hi ng.
DISTRIBUTOR TIMING
shaft, t i me engine as follows:
(1) Rotate crankshaft until No. l cylinder is at top
(2) When in t hi s position, t he t i mi ng mark on vi-
bration damper should be under "0" on the t i mi ng in-
dicator.
place, it will index with t he oil pump shaft. The slot
Fig. 17 Position of Installed Distributor Drive Gear
on top of drive gear should be aligned towards left
INSTALLATION
procedure.
OIL PAN
REMOVAL
(1) Disconnect the negative cable from t he battery.
(3) Raise vehicle.
(6) Remove left engine to transmission st rut .
CLEANING
Trim or remove excess sealant film in t he rear
mai n cap oil pan gasket groove. DO NOT remove
the seal ant inside the rear mai n cap slots.
gine.
cloth.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor-
INSTALLATION
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
inch bolts. Cut the head off t he bolts and cut a slot
Adhesive Sealant, or equivalent in t he corner of the
cap and the cylinder block.
- 17 " x 5 / 16" BOLT
D OWE L
E
SLOT
J 92 0 9- 10 6
DOWE L ^ ^ ^ ^ DOWE L
J9309- 7 9
F/ g. 2 Position of Dowels in Cylinder Block
onto t he block.
t he gasket.
(6) Install t he oil pan bolts. Ti ght en t he bolts to 24
pan bolts. Tighten these bolts to 24 Nmi (215 in. lbs.)
torque.
(8) Install t he drain plug. Tighten drai n plug to 34
(11) Lower vehicle.
(13) Fill crankcase wi t h oil to proper level.
OIL PU1 P
REMOVAL
cap.
DISASSEMBLE
(1) Remove t he relief valve as follows:
sert a self-threading sheet met al screw.
OIL PUMP ASSEMBLY
SPRING
COTTER PIN
RELIEF VALVE
' RETAINER CAP
RH 174
(3) Discard oil seal ring.
(4) Remove pump rotors and shaft (Fig. 4).
INNER ROTOR
AND SHAFT
DISTRIBUTOR DRIVESHAFT
BODY (REFERENCE)
COTTER PIN
LARGE CHAMFERED
EDGE
SPRING
RETAINER
CAP
RY10B
Fig. 4 Oil Pump
INSPECTION
Mat i ng surface of t he oil pump cover should be
smooth. Replace pump assembly If cover is scratched
or grooved.

5.9L ENGINE 9 - 95
be inserted between cover and st rai ght edge, pump
Measure thickness and diameter of OUTER rotor.
If outer rotor thickness measures 20.9 mm (0.825
inch) or less or if t he diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 6).
less, replace i nner rotor and shaft assembly (Fig. 7).
Fig. 7 Measuring Inner Rotor Thickness
sembly.
Install inner rotor and shaft into pump body. If
clearance between i nner and outer rotors is 0.203
tors (Fig. 9).
OUTER
ROTOR
INNER
ROTOR
RH179
Place a straightedge across t he face of t he pump,
between bolt holes. If a feeler gauge of 0.102 mm
and t he straightedge, replace pump assembly (Fig.
10).
Inspect oil pressure relief valve plunger for scoring
and free operation in its bore. Small marks may be
The relief valve spring has a free length of approx-
test between 19.5 and 20.5 pounds when compressed
If oil pressure was low and pump is within specifi-
9 - 96 5.9L ENGINE

Fig. 11 Proper installation of Retainer Cap
ASSEMBLE
as required.
body. Tighten cover bolts to 11 N-m (95 in. lbs.)
torque.
cotter pin.
(4 ) Tap on a new ret ai ner cap.
tor cavity with engine oil.
INSTALLATION
shaft engagement.
(2) Hold t he oil pump base flush against mat i ng
surface on No.4 mai n beari ng cap. Finger t i ght en
pump at t achi ng bolts. Tighten at t achi ng bolts to 4 1
amet er at t he pin boss Is less t han its diameter
nearly round shape.
The piston pin rotates in t he piston only and is re-
t ai ned by t he press interference fit of t he piston pin
REMOVAL
(4 ) Remove top ridge of cylinder bores with are li-
inder block. Be sure to keep tops of pistons covered
duri ng this operation.
(5) Be sure the connecting rod and connecting rod
in cylinder bore and at BDC. Be car ef ul not t o ni ck
cr anks haf t j our nal s .
(7) After removal, install beari ng cap on t he mat-
ing rod.
INSPECTION
cessive wear, taper and scoring.
fore they are fitted into t he cylinder bore (Fig. 12).
FITTING PISTONS
der wall is 0.013-0.038 mm ( 0.0005- 0.001 5 inch).
FITTING RINGS
ri ngs squarely in t he cylinder bore before measur-
ing.
(b) Insert feeler stock in t he gap. The compres-
sion ri ng gap should be between 0.254 - 0.508 mm

5.9L ENGINE 9 - 97
DIAMETER (D)
SHOULD BE
0.0000-0.0152 mm
(0.0000-0.0006 in.
LARGER THAN (C)
98.704-98.831 mm
(3.886-3.891 in.]
FEELER GAUGE
H - c
-#-D
J9309-9
(0.010-0.020 inch). The second compression ri ng
gap should be between 0.508-0.762 mm (0.020-
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be prop-
erly filled to t he correct dimension. Rings with ex-
(2) Install rings and confirm ri ng side clearance:
(b) Install t he compression ri ngs using Installa-
stalled with either side up. The second compression
ring must be installed with t he identification mark
should face down. An identification mar k on the
ri ng is a drill point, a stamped l et t er "O", an oval
(c) Measure side clearance between piston ring
rings. The steel rail oil ring should be free in
(3) Arrange ri ng gaps 90 apart as shown in Fig.
14.
Fi t all rods on a bank until completed. DO NOT al-
t ernat e from one bank to another, because connect-
GROOVE
J9209- 136
OIL RI NG
SPACE R GAP
TOP
COM PRE SSI ON
RI NG GAP
SE CON D
COM PRE SSI ON
RI N G GAP
OIL RI N G RAIL
GAP (TOP)
OIL RI NG RAI L
GAP ( BOTTOM)
J9309- 8 0
sembly.
Each beari ng cap has a small V-groove across the
part i ng face. When installing t he lower beari ng
in line with t he V-groove in t he cap. This provides
lubrication of t he cylinder wall in the opposite bank.
The bearing shells must be installed so t hat the
caps.
j ournal s should be held to 0.025 mm (0.001 inch).
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
size. Install the beari ngs i n pairs. DO NOT use a
new beari ng half wi th an old beari ng half. DO
INSTALLATION
gered so t hat nei t her is in line wi t h oil ri ng rai l gap.
sure t he oil ring expander ends are butted and t he
over t he piston and t i ght en wi t h t h e special wrench
(part of Tool C-385). Be s u r e p o s i t i o n of r i n g s d o e s
not c ha nge d u r i n g t h i s o p e r a t i o n .
(5) Rotate crankshaft so t hat t he connecting rod
j ournal is on t he center of t he cylinder bore. Be sure
guide rod over t he crankshaft journal.
hammer handle. At t he same time, guide connecting
rod into position on crankshaft journal.
of t he connecting rod bore must be Installed toward
(8) Install rod caps. Install nut s on cleaned and
oiled rod bolts and t i ght en nut s t o 61 N*m (45 ft. lbs.)
torque.
(11) Install t he engine Into t he vehicle.
CRANKSHAFT
A crankshaft which has undersize j ournal s will be
stamped with 1/4 inch letters on t he milled flat on
t he No.3 crankshaft counterweight (Fig. 15).
FOR EXAMPLE: R2 stamped on t he No.3 crank-
and t he No.2 mai n j ournal are 0.025 mm (0.001 In)
undersize.
necting rod beari ngs should be replaced wi t h new
bearings. Therefore, selective fitting of t he beari ngs
replaced.
REMOVAL
ing cap.
bearing caps and bearings one at a time.
seals.
(6) Remove and discard t he front crankshaft oil
seal.
Undersize Journal
Identification Stamp
0.025 mm (0.001 inch) (Rod)
0.025 mm (0.001 inch) (Main)
R1-R2-R3 or R4
M1-AA2-M3-AA4 or AA5
V/ L E TTE RS/ R - l - 2 > (ROD)
VM- WHMAI N)
J9309-52
Fig. 15 Location of Crankshaft identification
The crankshaft connecting rod and mai n j ournal s
ing. The maxi mum t aper or out-of-round on any
Jour nal grinding should not exceed 0.305 mm
(0.012 inch) under t he st andard j ournal diameter. DO
NOT grind t hrust faces of No.3 mai n bearing. DO
NOT nick crank pin or bearing fillets. After grind-
INSTALLATION
oil.
(2) Install t he new upper rear beari ng oil seal with
gine.
oil.
tion.

5.9L ENGINE 9 - 99
BE ARI NG CAP J9309-72
(12) Immediately i nst al l t he oil pan.
MOPAR SI LI CONE SEALANT
RUBBER ADHESI VE APPLIED
changeable. Lower mai n beari ng halves of No.2 and
Upper and lower No.3 beari ng halves are flanged
interchangeable wi t h any other beari ng halves in the
engine (Fig. 18). Beari ng shells ar e available in stan-
dard and t he following undersizes: 0.25 mm (0.001
Never i nst al l an undersize bearing t hat will reduce
Fig. 18 Main Bearing Identification
REMOVAL
ing cap.
(3) Identify bearing caps before removal. Remove
beari ng caps one at a time.
(4) Remove upper half of bearing by i nsert i ng
Crankshaft Main Bearing Remover/Installer Tool
upper half of bearing shell.
Installation with Tool C-3059
INSTALLATION
while all other mai n bearing caps are properly tight-
ened. All beari ng capbolts removed duri ng service
lation.
9 - 100 5.9L ENGINE

(1) St art beari ng in place, and i nsert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
(2) Slowly rot at e crankshaft counterclockwise slid-
(3) Install t he beari ng cap. Clean and oil t he bolts.
Tighten t he capbolts to 115 N m (85 ft. lbs.) torque.
seal half can be installed wi t h crankshaft removed
The lower seal half can only be installed with t he
REMOVED)
(1) Remove t he crankshaft.
oil.
(3) Install t he new upper rear beari ng oil seal wi t h
gine.
oil.
tion.
t eri al after assembly. Do not st ri ke rear cap more
t i ght en to 115 N t h (85 ft. lbs.) torque.
INSTALLED)
ing cap.
(3) Remove t he rear mai n beari ng cap. Remove
and discard t he old lower oil seal.
(4) Carefully remove and discard t he old upper oil
seal.
least t he 2 mai n bearing caps forward of t he rear
bearing cap.
t he bearing cap wi t h t he yellow pai nt facing towards
tion. Be sure t he yellow pai nt faces toward t he rear
of t he engine.
(9) To align t he bearing cap, use cap slot, align-
(10) Install t he rear mai n beari ng cap with cleaned
out. Withdraw nozzle and wipe excess seal ant off t he
ing cap.
(3) Remove t he rear mai n beari ng cap and discard
per Seal Replacement - Crankshaft Installed proce-
dure above).
oil.
yellow pai nt facing t he r ear of engine.

5.9L ENGINE 9 - 101
tion.
(9) Install t he rear mai n bearing cap with cleaned
(12) Immediately install the oil pan.
CYLINDER BLOCK
DISASSEMBLE
(3) Remove t he piston/connecting rod assembly.
CLEANING
Clean cylinder block thoroughly and check all core
INSPECTION
Exami ne block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and t aper with Cylinder Bore Indicator Tool
C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
The cylinder bores show more t han 0.127 mm
(0.005 inch) out-of-round.
0.254 mm (0.010 inch).
The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely co-
ordinated wi t h t he fitting of pistons and rings so
specified clearances may be maintained.
ning of t hi s Group for t he proper honing of cylinder
bores.
OIL LINE PLUG
The oil line plug is located in t he vertical passage
at t he rear of t he block between t he Oil-To-Filter and
Oil-From-Filter passages (Fig. 20). Improper installa-
tion or plug missing could cause erratic, low or no oil
pressure.
block.
(3) Pl ug should be 190.0 to 195.2 mm (7-1/2 to
20). If plug is too high, use a suitable flat dowel drift
RIGHT OIL GALLERY
J9109-229
Fig. 20 Oil Line Plug
(4) If plug is off position, remove oil pan and rear
mai n beari ng cap. Use suitable flat dowel to remove
plug. Coat outside diameter of plug, with Mopar (stud
and beari ng mount adhesive), or equivalent. Pl ug
should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 inches)
from bottom of the block.
Engine core plugs have been pressed into t he oil
This will reduce i nt ernal leakage and help mai nt ai n
RE10 AL
(1) Usi ng a bl unt tool such as a drift or a screw-
driver and a hammer, strike t he bottom edge of t he
cup plug (Fig. 22).
(2) Wi t h t he cup plug rotated, grasp firmly with
22).
CLEANING
grease.
INSTALLATION
9 - 102 5.9L ENGINE ^ ^ ^
CAUTION: DO NOT drive cup pl ug into the cast i ng
a s restricted cool ant flow can result and cause se-
ri ous engi ne probl ems.
CYLINDER
ASSEMBLE
5.9L ENGINE 9 - 103
EmmmE SPECIFICATIONS
Camshaft
Bearing Diameter
N o
i 50.800 - 50.825 mm
" " (2.000 - 2.001 in)
N o
2 50. 394 - 50. 4 1 9 mm
' ( 1 .984 - 1.985 in)
N o
3 50.013 - 50.038 mm
( 1 .96 9- 1 970 in)
No 4 4 9.6 06 - 4 9.6 32 mm
(1.953 - 1.954 in)
No 5 ................ 39.6 83 - 39. 7 1 3 mm
( 1 .56 25- 1.5635 in)
Diametrical Clearance 0.0254 - 0.076 2 mm
(0.001 - 0.003 in)
Max . Allowable . 0.127 mm
(0.005 in)
End p|
a y
0.051 - 0.254 mm
( 0.002- 0.01 0 in)
Bearinq Journal Diameter
N o
i 50.74 9 - 50.775 mm
( 1 .998- 1.999 in)
No 2 50.34 3 - 50.36 8 mm
( 1 .982- 1.983 in)
No 3 . .............. 4 9.96 2 - 4 9.987 mm
( 1 .96 7- 1.968 in)
No 4 . 4 9. 555- 4 9. 58 1 mm
(1.951 - 1 952 in)
No 5 39.6 37 - 39.6 6 2 mm
( 1 .56 05- 1.5615 in)
Connecting Rods
Bearing Clearance 0.0127 - 0.0559 mm
(0.0005 - 0.0022 in)
Piston Pin Bore Diameter 24 .96 6 - 24 .978 mm
(0.9829 - 0.9834 in)
Side Clearance (Two Rods) ......................... 0.152 - 0.356 mm
( 0.006 - 0.01 4 in)
Total Weight (Less Bearing) . ... 758 grams
(25.74 oz)
Crankshaft
Connecting Rod Journal
Diameter . 53.950 - 53.975 mm
(2.124 - 2.125 in)
(0.001 in)
Taper (Max.) ... 0.0254 mm
(0.001 in)
No 1 ... ........ 0.0127 - 0.0381 mm
( 0.0005- 0.001 5 in)
Max Allowable (No.l) - 0.0381 mm
(0.0015 in)
Nos.2, 3, 4 and 5 0.0127 - 0.0508 mm
(0.0005 - 0.0020 in)
Max . Allowable (Nos.2, 3, 4 & 5) ...... - 0.06 35 mm
(0.0025 in)
End Play 0.051 - 0.1 7 8 mm
(0.002 - 0.007 in)
Max . Allowable 0.254 mm
(0.010 in)
Diameter 71.36 1 - 71.387 mm
( 2.8095- 2.8105 in)
(0.001 in)
Taper (Max.) .., 0.0254 mm
(0.001 in)
Cylinder Block
Cylinder Bore
Diameter , 101.6 0 - 101.6 5 mm
(4 .000 - 4 .002 in)
Out-of-Round (Max.) ........... 0.127 mm
(0.005 in)
(0.010 in)
Bushing (Press Fit in Block) 0.0127 - 0.3556 mm
( 0.0005- 0.01 4 0 in)
Shaft-to-Bushing Clearance 0.0178 - 0.06 86 mm
(0.0007 - 0,0027 in)
Tappet Bore Diameter .............. 22.99 - 23.01 mm
(0.9051 - 0.9059 in)
Cylinder Head
Compression Pressure 6 89 kPa
(100 psi)
Gasket Thickness (Compressed) 1.2065 mm
(0.04 75 In)
Valve Seat
Angle . 44.25 - 4 4 .7 5
Runout (Max.) ....................... 0.076 2 mm
(0.003 in)
Width (Finish) - Intake 1.016-1.524 mm
( 0, 04 0-0.06 0 in)
Width (Finish) - Exhaust 1.524-2.032 mm
(0.060-0.080 in)
Hydraulic Tappets
Body Diameter 22.94 9 - 22.96 2 mm
(0.9035 - 0.904 0 in)
Clearance in Block 0.0279 - 0.06 10 mm
(0.0011 - 0.0024 in)
Dry Lash . 1.524 - 5.334 mm
( 0. 06 0- 02 1 0 in)
Push Rod Length 190.6 3 - 191.14 mm
(7.505 - 7.525 in)
J9309-102
9 - 104 5.9L ENGINE

ENGINE SPECIFICATIONS (CONT)
Oil P u m p
Clearance over Rotors (Max.) 0.1016 mm
(0.004 in)
Cover Out-of-Flat (Max.) 0.0381 mm
(0.0015 in)
Inner Rotor Thickness (Min.) 20.955 mm
(0.825 in)
Outer Rotor
Clearance (Max.) 0.3556 mm
(0.014 in)
Diameter (Min.) 62.7126 mm
(2.469 in)
Thickness (Min.) 20.955 mm
(0.825 in)
Tip Clearance between Rotors (Max.) 0.2032 mm
(0.008 in)
Oil Pressure
At Curb Idle Speed * 41.4 kPa
(6 psi)
At 3000 rpm 207 - 552 kPa
(30 - 80 psi)
Switch Actuating Pressure (Min.) 34.5 - 48.3 kPa
(5-7 psi)
* CAUTION: If pressure is ZERO at curb idle, DO NOT
run engine at 3,000 rpm.
Oil Filter
Bypass Valve Setting 62 -103 kPa
(9-15 psi)
Pistons
Clearance at Top of Skirt 0.0127 - 0.0381 mm
(0.0005-0.0015 in)
Land Clearance (Diametrical) 0.508 - 0.660 mm
(0.020 - 0.026 in)
Piston Length 81.03 mm
(3.19 in)
Nos.l and 2 4.761 -4.912 mm
(0.187-0.193 in)
No.3 3.996-4.177 mm
(0.157-0.164 in)
Weight 582 - 586 grams
(20.53 - 20.67 oz)
Piston Pins
Clearance In Piston 0.006 - 0.019 mm
(0.00023 - 0.00074 in)
Diameter 25.007 - 25.015 mm
(0.9845 - 0.9848 in)
End Play NONE
Length 67.8 - 68.3 mm
(2.67 - 2.69 in)
Piston Rings
Ring Gap
Compression Ring (Top) 0.30 - 0.55 mm
(0.012-0.022 in)
Compression Rings (2nd) 0.55 - 0.80 mm
(0.022 - 0.031 in)
Oil Control (Steel Rails) 0.381 - 1.397 mm
(0.015-0.055 in)
Ring Side Clearance
Compression Rings 0.040 - 0.085 mm
(0.0016-0.0033 in)
Oil Ring (Steel Rails) 0.05 - 0.21 mm
(0.002 - 0.008 in)
Ring Width
Compression Rings 1.530 - 1.555 mm
(0.060 - 0.061 in)
Oil Ring (Steel Rails) - Max 0.447 - 0.473 mm
(0.018-0.019 in)
Valves
Face Angle 43.25 - 43.75
Head Diameter
Intake 47.752 mm
(1.88 in)
Exhaust 41.072 mm
(1.617 in)
Length (Overall)
Intake 126.21 - 126.85 mm
(4.969 - 4.994 in)
Exhaust 126.44 - 127.30 mm
(4.978-5.012 in)
Lift (Zero Lash) 10.414 mm
(0.410 in)
Stem Diameter
Intake 9.449 - 9.474 mm
(0.372 - 0.373 in)
Exhaust 9.423 - 9.449 mm
(0.371 - 0.372 in)
Stem-to-Guide Clearance
Intake 0.0254 - 0.0762 mm
(0.001 - 0.003 in)
Exhaust 0.0508-0.1016 mm
(0.002 - 0.004 in)
Max. Allowable (Rocking Method) 0.4318 mm
(0.017 in)
Guide Bore Diameter (Std) 9.500 - 9.525 mm
(0.374 - 0.375 in)
J9309-103
5.9L ENGINE 9 - 105
ENGINE SPECIFICATIONS (CONT.J
V al ve Spr i ngs
Free Length ( Ap p r o x . ) . . . . . . . . . . . 49.962 mm
f1.96 7 in)
Spring Tension . . . . . . . . . . . . . . . . @ 4 1.6 6 mm = 378 N
(Valve Closed) (@ 1.64 in 85 lbs)
Spring Tension @ 30.89 mm = 890 N
(Valve Open) (@ 1.212 in = 200 lbs)
Number of Coils . . . . . . . . . . . . . . . 6 .8
Installed Height 4 1.6 6 mm
(Spring Seat to Retainer) (1.64 in)
Wire Diameter . . . . . . . . . . . . . . . . 4.50 mm
(0.177 in)
V al ve Timing
Exhaust Valve
Closes (ATC) . . . . . . . . . . . . . 16
Opens (BBC) . . . . . . . . . . . . . . . . . . . . . . . . . 52
Duration 24 8
Intake Valve
Closes (ABC) 50
Opens (BTC) 10
Duration . . . . . . . . . . . . . . . . . 24 0
Valve Ov e r l a p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
J9309- 33
CONDI TI ON I DENTI FI CATI ON LOCATI ON OF I DENTI FI CATI ON
0.025 mm (0.001 inch)
U/ S Crankshaft
R o r M
M-2-3 etc. (Indicating No. 2 & 3 main
bearing journal)
and/or
R-l-4 etc. (Indicating No. 1 & 4 connecting
rod journal)
Milled flat on number three crankshaft
counterweight
0.508 mm (0.020 inch)
O / S Cylinder Bores
A Following engine serial number.
0.203 mm (0.008 inch)
O / S Tappets

3/8" diamond-shaped stamp Top pad Front
of engine and flat ground on outside surface of
each O / S tappet bore.
0.127 mm (0.005 inch)
O / S Valve Stems
X Milled pad adjacent to two 3/8" tapped holes
on each end of cylinder head.
J9209-120
D E S C R I PT I O N TORQUE D E S C R I PT I O N TORQ UE
Adjusting Strap Bolt 23 N-m (200 in. lbs.)
Camshaft Bolt 68 N-m (50 ft. lbs.)
Camshaft Thrust Plate Bolts 24 N-m (210 in. lbs.)
Connecting Rod Cap Bolts.. 61 N-m (45 ft. lbs.)
Crankshaft Main Bearing Cap Bolts 115 N-m (85 ft. lbs.)
Cylinder Head Bolts
1st Step 68 N-m (50 ft. lbs.)
2nd Step 143 N-m (105 ft. lbs.)
Cylinder Head Cover Bolts .......................... 11 N-m (95 in. lbs.)
Bolts (2WD) 41 N-m (30 ft. lbs.)
Front Mount Adaptor-to-Block Bolts 41 N-m (30 ft. lbs.)
Crossmember Bolts (4WD) 41 N-m (30 ft. lbs.)
Service Manual.
Oil Pump Cover Bolts 11 N-m (95 in. lbs.)
Rear Insulator-to-Bracket
Through-Bolt (2WD) 68 N-m (50 ft. lbs.
Rear Insulator-to-Crossmember
Support Bracket Nut (2WD) 41 N-m (30 ft. lbs.
Rear Insulator Mounting Plate-fo-
Rail Assembly Nuts (4WD) 41 N-m (30 ft. lbs.
Flange Nuts 41 N-m (30 ft. lbs.
Mounting Plate Bolts (4WD) 41 N-m (30 ft. lbs.
Spark Plugs....... 41 N-m (30 ft. lbs.
Starter Mounting Bolts. 68 N-m (50 ft. lbs.
Throttle Body Bolts (MPI) 23 N-m (200 in. lbs.
Transfer Case-to-lnsulator
Mounting Plate Nuts... 204 N-m (150 ft. lbs.
insulator Mounting Plate Nuts (4WD) .... 204 N-m (150 ft. lbs.
Vibration Damper Retainer Bolt 183 N-m (135 ft. lbs.
Cover Bolt 41 N-m (30 ft. lbs.)
J930 9- 98

5.9L (DIESEL) ENGINE 9 - 107
5 . 9 L (DIESEL) E N G I N E SERVICE P R O C E D U R E S
INDEX
page
Camshaft 1 2 7
Crankshaft 1 38
Cylinder Block 1 29
Cylinder H ead 1 1 3
Engine Assembl y . 109
Engine Front Mounts (Insulators / Brackets) . . . 107
Engine Rear Support 1 08
Gear H ousing / Cover 1 22
Oil Cooler Element / Gasket . 1 4 9
Oil Filter 1 4 8
page
Oil Filter Bypass Valve . 1 4 8
Oil Pan / Suction Tube 1 4 6
Oil Pressure Regulator Valve / Spring 1 4 8
Oil Pump 1 4 6
Piston / Connecting Rod Assembl y 1 34
Rocker Levers / Push Rods 1 1 2
Specifications5.9L Diesel E ngi nes 151
Tappet 1 25
Timing Pin 1 23
Valve Cl earance Adjustment . . . . . . . . . . . . . . . 121
V al ves and V al ve Spri ngs 1 1 6
GENERAL INFORMATION
The 5.9 Liter (359 CID) six-cylinder diesel engine
is an In-line valve-in head type (Fig. 1).
Fig. 1 Diesel Engine Description
This engine is designed for No.2 Diesel Fuel. Only
use No. l Diesel Fuel where extended arctic condi-
tions exist (below -23C or -10F).
Engine lubrication system consists of a gerotor
type oil pump and a full flow oil filter with a bypass
valve.
2, 3, 4, 5 and 6. The firing order is 1-5-3-6-2-4 (Fig.
2).
J898D-10
Fig. 2 Firing Order
The engine dat a plate is located on t he driver side
of t he engine forward of t he fuel injection pump.
ENGINE FRONT MOUNTS (INSULATORS /
BRACKETS)
REMOVAL
(2) Raise vehicle on a hoist. Support t he engine.
(3) Remove t he through-bolts and nut s from t he
bracket (Fig. 3).
(4) Remove t he nut s from insulator studs (Fig. 3).
(5) Raise engine with a lifting fixture only far
enough to remove the insulators and brackets. Mark
t he locating pin position.
(6) Remove t he engine mounting brackets from t he
engine block.
Engine Type In-line 6 (Diesel-Turbo)
Bore and Stroke 102.0 x 120.0 mm
(4.02x4.72 in.)
Compression Ratio 17.5:1
Torque 542 N-m (400 ft. lbs.)
@ 1,750 rpm
Firing Order 1-5-3-6-2-4
Lubrication Pressure Feed - Full Flow
Filtration w/Bypass Filter
Engine Oil Capacity 11.4L (12.0 Qts) w/Filter
Cooling System Liquid Cooled - Forced
Circulation
Cooling Capacity
Manual Trans 15.2L (16.0 Qts)
Automatic Trans 16.2L (17.0 Qts)
Recovery Bottle 0.95L(1.0Qts)
Cylinder Block.... Cast Iron
Crankshaft Induction Hardened
Forged Steel
Cylinder Head Cast Iron
Combustion Chambers High Swirl Bowl
Camshaft.... Chilled Cast Iron
Pistons Cast Aluminum
J9209-48
9 - 108 .9L (DIESEL) ENGINE

J9109-12
Fig. 3 Engine Front Mount
INSTALLATION
(1) Install t he engine mount i ng bracket s to t he
block, if removed (Fig. 3). Ti ght en t he bolts to 60
(2) Wi t h t he engine raised slightly, install t he in-
sulators using t he locating pin. Ti ght en t he nut s to
(3) Install t he bracket onto t he insulator and
t i ght en t he nut to 109 Nnn (80 ft. lbs.) torque.
(4) Lower engine wi t h lifting fixture while guiding
i nsul at or studs into at t achi ng holes in crossmember
and brackets.
(5) Ti ght en at t achi ng nut s and bolts to specified
torques (Fig. 3).
ENGINE REAR SUPPORT
REMOVAL-2WD
(2) Position a transmission jack under t he t rans-
mission.
(3) Remove t he through-bolt from t he t ransmi ssi on
support bracket/insulator (Fig. 4).
(4) Raise t he transmission SLIGHTLY.
(5) Remove t he insulator nut s (Fig. 4).
(6) Remove t he transmission blocker bracket nut s
and remove t he bracket (Fig. 4).
(7) Remove t he insulator/crossmember bracket
nut s and remove t he bracket (Fig. 4).
INSULATOR
TRANSMISSION
BLOCKER
BRACKET
TRANSMISSION
SUPPORT
BRACKET
INSULATOR/
CROSSMEMBER
BRACKET
CROSSMEMBER
J9109-149
Fig. 4 Rear Engine Support2WD
INSTALLA TION-2WD
(1) Install t he insulator/crossmember bracket to
t he crossmember. Tighten t he nut s to 41 N-m (30 ft.
lbs.) torque.
(2) Install t he transmission blocker bracket to t he
crossmember and t he insulator/crossmember bracket
(Fig. 4). Tighten t he nut s to 41 N-m (30 ft. lbs.)
torque.
(3) Install t he insulator to t he crossmember and
t he insulator/crossmember bracket (Fig. 4). Tighten
t he nut s to 41 N-m (30 ft. lbs.) torque.
(4) Lower t he transmission unt i l t he insulator is
lined up with t he transmission support bracket.
(5) Install t he through-bolt and t i ght en t he nut to
REMOVAL-4WD
(Fig. 5).
SKID PLATE ^ M A T T A C H I N G BOLTSl
. M I M I N G
PU873
Fig. 5 Skid Plate
(3) Position a transmission j ack under t he t rans-
mission.
(4) Remove t he nut s from t he transfer case to plate
bolts and from t he transfer case to st rut bolts (Fig.
6).

(5) Raise the rear of t he transmission and engine
SLIGHTLY.
(6 ) Remove t he mounting bolts and nut s. Remove
the washers, sleeves and insulators (Fig. 6).
(7) The pl at e and st rut will be removed as a unit.
Remove t he bolts, washers and nut s (Fig. 6).
J9109-150
Fig. 6 Rear Engine Mount4WD
INSTALL A TION4 WD
(1) Assemble t he plate and t he st rut (Fig. 6).
Tighten t he nut s to 240 N-m (150 ft. lbs.) torque.
(2) Install t he plate and st rut assembly to t he rai l
with t he insulators, sleeves, washers and mount i ng
bolts (Fig. 6). Tighten t he nut s to 240 N-m (150 ft.
lbs.) torque.
(3) Lower t he rear of t he engine and transmission
until t he transfer case aligns with t he holes in t he
plate and t he st rut .
(4) Install t he nut s to t he transfer case to pl at e
bolts and to t he transfer case to st rut bolts (Fig. 6).
Tighten t he nut s to 240 N-m (150 ft. lbs.) torque.
ENGINE ASSE MBLY
REMOVAL
(1) Disconnect t he electrical connection into t he
hood. Scribe t he hood hinge bolt locations and re-
move t he hood (Fig. 7).
(2) Disconnect t he bat t ery cables and remove t he
battery.
(3) Drai n t he coolant from t he cooling system (re-
fer to Group 7, Cooling System for t he proper proce-
Fig. 7 Scribe Hood Hinge
dures). DO NOT waste reusable coolant. If t he
solution is clean, drai n t he coolant into a clean con-
t ai ner for reuse.
(4) Disconnect t he radiator hoses. Remove t he fan
shroud, fan/fan clutch assembly and radiator (refer to
Group 7, Cooling Systems for t he proper procedures).
(5) Disconnect t he heat er hoses at t he dash panel
and at the wat er valve (Fig. 8).
Fig. 8 Heater Hoses
(6) Disconnect t he air inlet tube from t he turbo-
charger (Fig. 9) and t he air i nt ake housing. Remove
t he tube.
(7) Remove t he exhaust pipe from t he turbocharger
outlet flange (Fig. 9).
(8) Disconnect t he intercooler inlet duct from t he
turbocharger and t he intercooler (Fig. 10). Remove
t he inlet duct.
(9) Disconnect t he intercooler outlet duct from t he
ai r inlet housing and t he intercooler (Fig. 10). Re-
move t he outlet duct.
9 - 119 5.9L (DIESEL) ENGINE
Fig. 10 intercooler Ducts
(10) Remove t he drive belt. Disconnect t he genera-
tor ground wire. Remove t he generator and set aside
(Fig. 11).
(11) Remove t he A/ 0 compressor and set aside. The
A/C compressor i s located below t he generator.
(12) Disconnect t he accelerator linkage, t he speed
control linkage and t he t hrot t l e valve linkage (Fig.
12).
(13) Raise and support the vehicle on a hoist.
(14 ) Drai n t he engine lubricating oil. Dispose of
t he oil according to all applicable regulations.
(15) Disconnect t he exhaust pipe steady rest clamp
and remove.
(16) Disconnect t he st art er connections (Fig. 13).
(17) Disconnect t he transmission cooler lines.
(a) Remove torque converter bolt access cover.

Fig, 11 Generator Removal
Fig. 12 Accelerator/Speed Control/Throttle Valve
Linkage
(b) M a r k torque converter and drive plate for as-
sembly al i gnment. Note t hat bolt hol es in crank-
shaft flange, drive plate and torque converter all
have one offset hole.
(c) Rotate crankshaft in clockwise direction unt i l
converter bolts are accessible. Then remove bolts
one at a time. Rotate crankshaft with socket
wrench on damper pulley bolt.
(d) Support t he transmission.
(e) Remove bell housing bolts and inspection
pl at e.
(19) MANUAL TRANSMISSION:
Refer to Group 21, Transmissions for t he G360
Manual Transmission Removal procedure.
(21) Disconnect t he power steering lines.
- 5.9L (DIESEL) ENGINE 9 - 111
J 9109- 1 1 3
Fig. 13 Starter Connections
(22) Disconnect t he vacuum pump lines.
( 23) Disconnect all electrical connections from t he
engine. Put t ags on the connections to identify t hei r
locations.
(24) Disconnect the fuel lines to t he lift pump and
fuel ret urn. Use t ags to identify t he lines (Fig. 14).
Fig. 14 Lift Pump and Fuel Lines
(25) Put a cover or tape over all engine openings.
(26) Make sure t hat t he lifting bracket s are
mounted with t he eye up. If not, remove t he bracket
and install in t he proper position. Tighten t he lifting
bracket bolts to 77 Nm (57 ft. lbs.) torque.
(27) Use t he lifting brackets to apply tension to
t he engine. Remove t he engine mount through-bolts
from t he cylinder block mount i ng bracket.
C A U T I O N : When removi ng the engi ne, take care not
to damage the wiper motor and vol tage regulator
mounted on the dash panel (Fi g. 15).
(28) Lift t he engine out of t he vehicle (Fig. 16).
(29) Install t he engine on a suitable stand.
(30) Remove all accessories and brackets not previ-
ously removed for use with t he replacement engine.
Fig. 15 Wiper Motor/Voltage Regulator
ENGI NE
/ HOIST
Ml
J9109-H
Fig. 16 Lifting Engine from Vehicle
INSTALLATION
(1) If removed, install and t i ght en t he rear engine
lifting bracket to 77 N-m (57 ft. lbs.) torque. DO
NOT exceed t hi s torque valve.
(2) Check t he dat a plate to verify t hat t he replace-
ment engine is t he same model and rat i ng as t he en-
gine t hat was removed.
( 3) Install all accessories and brackets t hat had
been removed from t he previous engine.
(4) Use t he lifting bracket s to lift t he engine off of
t he stand.

(5) Position t he engine in t he chassis and install
t he t hrough bolt. Tighten t he t hrough bolt nut to 41
(6) Ma ke s ur e t he lifting br a c ke t s a r e mount e d
wi t h t he eye down.
(7) Remove t he covers or t ape covering t he engine
openings.
(8) Connect t he fuel lines to t he lift pump and fuel
ret urn.
(9) Connect all electrical connections.
(10) Connect t he power steering lines.
C A U T I O N : If new flex plate i s installed, remove
fl ashi ng from the engi ne back plate at the 5 and 7
o' cl ock posi t i ons.
(a) Rotate converter unt i l al i gnment mar k on t he
converter is aligned wi t h mar k on drive plate. Off-
set holes in plate are next to 1/8 inch hole in i nner
circle of drive plate.
(b) Install bell housing bolts. Tighten t he bolts to
(c) With t he torque converter plate aligned to t he
torque converter, install and t i ght en t he bolts to 31
(d) Install t he converter housing access plate.
(e) Remove t he transmission support.
Refer to Group 21, Transmissions for t he G360
Manual Transmission Installation procedure.
(14) Connect t he ground cable and t i ght en t he nut
to 22 N-m (16 ft. lbs.) torque. Connect t he solenoid
cable and t i ght en t he nut to 5 N-m (44 in. lbs.)
torque.
(15) Connect t he transmission cooler lines.
(16) Install t he exhaust pipe to t he exhaust sys-
tem.
(18) Install t he A/C compressor and t i ght en t he
bolts to 47 N-m (35 ft. lbs.) torque. If removed, con-
nect t he clutch electrical wire.
(19) Install t he generator. Tighten t he upper
mount i ng bolts to 24 N-m (18 ft. lbs.) torque. Now
t i ght en t he lower mount i ng bolts to 43 N-m (32 ft.
lbs.) torque. Connect all wires.
(20) Install t he radiator, fan/fan clutch assembly
and fan shroud (refer to Group 7, Cooling Systems
for t he proper procedures). Connect t he radi at or
hoses.
(21) Position t he intercooler inlet duct to t he t ur-
bocharger and t he intercooler. Wi t h t he clamps in po-
sition, t i ght en t he clamp nut to 8 N-m (72 in. lbs.)
torque.
(22) Position t he intercooler outlet duct to t he air
inlet housing and t he intercooler. With t he clamps in
position, t i ght en the clamp nut to 8 N-m (72 in. lbs.)
torque.
(23) Connect t he air i nt ake t ube to t he turbo-
charger inlet flange and t he air cleaner housing.
Tighten t he clamps to 8 N-m (72 in. lbs.) torque.
(24) Install t he exhaust pipe to t he turbocharger.
Tighten t he steady rest clamp to 8 N-m (72 in. lbs.)
torque.
(25) Make sure t he air i nt ake and exhaust pipe
connections are t i ght and free of leaks.
(26) Fill t he engine with t he required amount of
clean engine lubricating oil (refer to Group 0, Lubri-
cation and Maintenance).
(27) Fill t he cooling system with a mi xt ure of 50%
wat er and 50% ethylene-glycol base antifreeze (refer
Group 7, Cooling System for t he proper procedure).
(28) Install t he bat t ery and connect t he bat t ery ca-
bles.
(29) Check t he oil level after t he engine has r un
for 2 or 3 minutes. Oil held in t he oil filter and oil
passages will cause t he oil level in t he pan to be
lower.
(30) Operate t he engine at idle for 5 to 10 mi nut es
and check for leaks and loose part s.
ROCKER LEVERS / POSH RODS
REMOVAL
(1) Remove t he valve covers (Fig. 1).
(2) Loosen t he adjusting screw locknuts. Loosen
t he adjusting screws unt i l they stop (Fig. 2).

(3) Remove t he bolts from t he rocker lever pedes-
tals. Remove t he pedestals and rocker lever assem-
blies (Fig. 2).
(4 ) Remove t he push rods.
LOCK NUT ADJ USTI NG
J 91 09- 31
Fig. 2 Location of Rocker Lever Components
DISASSEMBLEROCKER LEVERS
(1) Remove t he ret ai ni ng ri ngs and t hrust washers
(Fig. 2) .
(2) Remove t he rocker levers (Fig. 2) . DO NOT dis-
assemble t he rocker lever shaft and pedestal. The
pedestal and shaft must be replaced as an assembly.
(3) Remove t he locknut and adjusting screw (Fig.
2).
(4 ) Clean all part s in a strong solution of l aundry
detergent in hot water.
(5) Use compressed air to dry t he part s after rins-
ing in clean hot water. The pedestals are made from
powdered met al and may continue to show wetness
after they have been cleaned and dried.
(6) Inspect for excessive wear in t he bore and t he
contact surface for t he valve stem.
(7) Measure t he rocker lever bore diameter. The
maxi mum diameter is 19.05 mm (0.75 inch). Replace
if out of limits.
(8) Inspect t he pedestal and shaft.
(9) Measure t he shaft diameter. The mi ni mum di-
amet er is 18.94 mm ( 0.74 6 inch). Replace if out of
limits.
ASSEMBLE-ROCKER LEVERS
(1) Install t he adjusting screw and locknut.
(2) Lubricate t he shaft wi t h clean engine oil. Be
sure to assemble t he i nt ake and exhaust rocker le-
vers in t he correct location.
(3) Position t he levers on t he rocker shaft. Install
t he t hrust washers.
(4 ) Clean t he push rods in t he hot soapy water.
(5) Inspect t he push rod ball and socket for signs of
scoring or cracks where t he ball and t he socket are
pressed into t he tube.
(6) Check t he push rods for roundness and
straightness.
(7) Install t he push rods into the sockets of t he
valve tappets. Lubricate t he push rod sockets wi t h
clean engine oil.
(8) Make sure t he rocker lever adjusting screws
are completely backed out.
INSTALLATION
(1) Make sure t he dowel rings in t he pedestals are
installed into t he dowel bores in t he cylinder head.
(2) If t he push rod is holding pedestal off head, bar
t he engine unt i l t he pedestal will set on the head
surface without interference.
(3) Use clean engine oil to lubricate t he cylinder
head bolt t hreads and under t he bolt heads.
(4) Install t he long bolts (12 mm) into the rocker
lever pedestals. Tighten t he bolts as follows:
Step 1Tighten t he bolts, in sequence (Fig. 3) , to
90 Nm (6 6 ft. lbs.) torque. Check the torque. If lower
t han 90 Nm ( 6 6 ft. lbs.), t i ght en to this torque.
Step 2Tighten t he bolts, in sequence (Fig. 3) , to
120 N-m (89 ft. lbs.) torque. Check t he torque. If
lower t han 120 N-m (89 ft. lbs.), t i ght en to t hi s
torque.
Step 3Tighten t he bolts, in sequence (Fig. 3) , an
additional 90.
C=J FRONT
J 91 09- 32
Fig. 3 Rocker Lever (Head Boits) Tightening
Sequence
(5) Tighten t he 8 mm bolts to 24 Nnn (18 ft. lbs.)
torque.
(6 ) Install t he valve cover. Tighten t he valve cover
bolt to 24 Nnn (18 ft. lbs.) torque.
CYLINDER HEAD
These cylinder heads can only be used on engines
with an intercooler. DO NOT interchange with ear-
lier models.
REMOVAL
(1) Drai n t he coolant. DO NOT waste reusable
coolant. If t he solution is clean, drain t he coolant
into a clean container for reuse.
(2) Drai n t he engine oil. Dispose of t he used oil
properly.
Fig. 4 Exhaust Manifold
(6) Remove t he fuel lines and injector nozzles (re-
fer to Group 14, Fuel System).
(7) Remove t he valve covers (Fig. 5).
Fig. 5 Valve Cover
(8) Remove t he rocker levers and push rods.
(9) Remove t he fuel/water separator filter (Fig. 6).
Refer to Group 14, Fuel System, for t he proper pro-
cedures.
(10) If t he engine is hot, remove t he cylinder head
bolts in t he sequence shown in Fig. 7. . The removal
sequence is not i mport ant if t he engine is cold. There
are 3 sizes of head bolts. Note t he position of each
bolt for future installation.
(11) Remove t he cylinder head and gasket from t he
cylinder block.

Fig. 6 Fuel/Water Separator Filter
J9109-36
Fig. 7 Cylinder Head Bolt Removal
SequenceCylinder Head Hot
INSPECTION
Remove t he cup plugs and inspect t he coolant pas-
sages. A large build up of rust and lime will require
removal of t he cylinder block for cleaning in a hot
t ank.
Inspect t he cylinder bores for damage or excessive
wear. Rotate t he crankshaft so t he piston is at Bot-
tom Dead Center (BDC) to inspect t he bores.
Measure t he cylinder bores (Fig. 8). DO NOT pro-
ceed with in-chassis repair if t he bores are damaged
or worn beyond t he limits (refer to Cylinder Bore Re-
pair - Cylinder Block).
Check t he top surface for damage caused by t he
cylinder head gasket leaking between cylinders.
Inspect t he block and head surface for nicks, ero-
sion, etc.
Check the head distortion (Fig. 9). The distortion of
t he combustion deck face is not to exceed 0.010 mm
(0.0004 inch) in any 50.8 mm (2.00 inch) diameter.
Overall variation end to end or side to side 0.30 mm
(0.012 inch).
(3) Disconnect t he radiator and heat er hoses (refer
to Group 7, Cooling System).
(4) Remove t he turbocharger.
(5) Remove t he exhaust manifold (Fig. 4).
* ^ ^ ^ 5 . I L (DIESEL) ENGINE 9 - 115
MIN. 102.0 mm (4.0157 inch)
MAX. 102.1 16 mm (4.0203 inch)
Out-of-Round 0.038 mm (0.0015 inch)
Taper 0.76 mm (0.003 inch)
Oversize pistons and rings are
available for bored cylinder blocks.
J9109-75
Fig. 8 Cylinder Bore Diameter
DO NOT proceed with t he in-chassis overhaul if
t he cylinder head or block surface is damaged or not
flat (within specifications).
Fig. 9 Cylinder Head Combustion Deck Face
Measurement
REFACING HEAD SURFACE
The cylinder head combustion deck may be refaced
in whatever increments necessary to clean up t he
surface and mai nt ai n t he surface finish and flatness
tolerances. The combined total of stock removed must
not exceed 1.00 mm (0.03937 inch). The amount of
stock removed each time must be steel stamped
above combustion deck edge, on t he lower ri ght hand
corner of t he rear face (Fig. 10). Check valve protru-
sion after head surface refacing.
Surface finish requi rement s are 1.5-3.2 microme-
ters (60-126 microinch).
CLEANING
Clean t he carbon from t he injector nozzle seat with
a nylon or brass brush.
Scrape t he gasket residue from all gasket surfaces.
REFERENCE
STOCK TOTAL (MAX.)
1.00 mm (0.03937 inch)
REFERENCE HEIGHT (MIN.)
94.00 0.25 mm
(3.7008 0.0010 inch)
SURFACE FINISH
1.5 to 3.2 micrometers
(60 to 128 microinches)
J9109-134
Fig. 10 Cylinder Head Stock Removal
Wash the cylinder head in hot soapy wat er solution
(88C or 140F).
After rinsing, use compressed air to dry t he cylin-
der head.
Polish t he gasket surface with 400 grid paper. Use
an orbital sander or sanding block to mai nt ai n a flat
surface.
INSTALLATION
(1) The cylinder block and head must be clean and
dry.
(2) Position t he gasket onto the dowels (Fig. 11).
Make sure t he gasket is correctly aligned with t he
holes in t he cylinder block.
(3) Carefully put t he cylinder head onto t he gasket
and cylinder block. Make sure t he cylinder head is
installed onto t he dowels in t he cylinder block (Fig.
11).
(4) Install t he push rods and rocker levers.
(5) Use clean engine oil to lubricate t he cylinder
head bolt t hreads and under t he bolt heads.
(6) The cylinder head bolts are 3 different sizes. In-
stall t he bolts in t he proper hole. Tighten t he bolts as
follows:
Step 1Tighten all bolts, in sequence (Fig. 12), to
90 N
#
m (66 ft. lbs.) torque. Check t he torque. If lower
t han 90 N*m (66 ft. lbs.), tighten to t hi s torque.
Step 2Tighten all long 12 mm bolts (Nos. 4, 5,
12, 13, 20 and 21), in sequence (Fig. 12), to 120 N*m
(89 ft. lbs.) torque. Check t he torque. If lower t han
120 Nm (89 ft. lbs.), t i ght en to this torque.
Step 3 Tighten all bolts, in sequence (Fig. 12), an
additional 90.

CYLINDER HEAD
Fig. 11 Cylinder Head/Gasket Alignment
J9109-36
Fig. 12 Cylinder Head Tightening Sequence
(7) Be sure to lubricate t he push rod sockets wi t h
clean engine oil.
(8) Install t he rocker lever pedestal bolts and
(9) Adjust t he valve clearance.
(10) Install t he valve covers. Tighten t he bolts to
24 N*m (18 ft. lbs.) torque.
(11) Install t he injector nozzles and fuel lines (refer
to Group 14, Fuel System).
(12) Install t he fuel filter (refer to Group 14, Fuel
(13) Install t he exhaust manifold (refer to Group
11, Exhaust System and Int ake Manifold).
(14) Install t he turbocharger.
(15) Connect t he radi at or and heat er hoses.
(16) Fill t he engine wi t h new coolant or t he clean
drained coolant (refer to Group 7, Cooling System for
t he proper procedure).
(17) Fill t he engine with clean lubricating oil (re-
fer to Group 0, Lubrication and Maintenance).
VALVES AND VALVE SPRINGS
REMOWAL
(2) Mark t he valves to identify t hei r position.
(3) Compress t he valve spring and remove t he
valve stem collets (Fig. 1).
(4) Release valve spring and remove t he ret ai ner
and spring (Fig. 1).
(5) Remove t he remai ni ng collets, ret ai ners,
springs and valves. Keep t he valves in a labeled
rack.
(6) Remove t he valve stem seals (Fig. 1).
-38
Fig. 1 Valve Removal
WALVES
Before cleaning, note t he valve number. Clean t he
valve heads with a soft wire wheel. Mark t he valve
wi t h t he numbet* noted above.
Polish t he valve stems with crocus cloth.
Inspect for abnormal wear on t he valve heads and
stems. Replace badly worn valves.
Check for bent valves. Replace bent valves.
Measure t he valve stem diameter (Fig. 2). The
valve st em diameter should be 7.935-7.960 mm
(0.3126-0.3134 inch). If out of limits, replace t he
valve. Mark t he new valves with t he replacement lo-
cation.
Ik 1
MEASURE AT THESE POINTS
Fig. 2 Measure Valve Stem Diameter

Inspect t he end of t he valve stem for flatness.
If required, resurface t he valve end.
VALVE GRINDING
The valve seat angle should be 30 (Intake Valve)
and 45 (Exhaust Valve) - (Fig. 3).
INTAKE EXHAUST
J910 9-41
^ 00 ^
Fig. 3 Valve Seat Angle
Measure t he ri m thickness (Fig. 4). The mi ni mum
valve ri m thickness is 0.79 mm (0.031 inch).
VALVE RIM
THI CKNESS
J9109-146
Fig. 4 Valve Rim Thickness
Grind t he face of valves to be reused.
Check t he valve stem tip for flatness. If required,
re-surface t he tip.
VALWE GUIDES
INSPECTION
Inspect t he valve guides for scuffing or scoring.
Measure t he valve guide bore (Fig. 5). The bore di-
amet er should be 8.019-8.089 mm (0.3157-0.3185
inch).
If t he valve guide bores are larger t han t he worn
limit, t he cylinder head must be machined for service
valve guides. New valve guides must be reamed to
size after t hey are installed.
If t he cylinder head needs service valve guides and
valve seat inserts, t he valve guides should be in-
stalled first.
N E W DIAMETER LIMITS
8.019-8.029 mm (0.3157-0.3165 inch)
WO R N LIMIT
8.090 mm (0.3185 inch)
J9109-135
Fig. 5 Valve Guide Bore
INSTALLATION
THIN WALL- SERVI CE GUIDES
Machine t he cylinder head valve guide bores to
11.125 0. 013 mm (0.4380 0.0005 inch) in diame-
t er (Fig. 6).
Service valve guides must be centered with valve
seats within 0.35 mm (0.01378 inch) diameter. They
must also be square with t he combustion face within
0.10 mm (0.004 inch) at 50.0 mm (1.9685 inch) ra-
dius.
Lubricate t he valve guides with oil and press t he
guides flush to the bottom of t he bosses.
Trim off the top of t he valve guides flush to top of
guide bosses, if necessary.
Machine the valve guide bores to 8.029 0.010 mm
(0.3161 0.0004 inch) - (Fig. 6).
The valve guide bore must be centered with t he
valve seat within 0.35 mm (0.0138 inch) diameter. It
also must be square with t he combustion face within
0.010 mm (0.0004 inch) at 50.0 mm (2.0 inch) radius.
THICK WALL- SERVI CE GUIDES
Machine t he cylinder head valve guide bores to
14.000 0.013 mm (0.5512 0.0005 inch) diameter
(Fig. 7).
Valve guides must be centered with valve seats
within 0.35 mm (0.01378 inch) diameter. Valve
guides must also be square with t he combustion face
within 0.10 mm (0.004 inch) at 50.0 mm (2.0 inch)
radius.
Lubricate t he valve guides with oil and press in
t he guides to 12.25 0.50 mm (0.4823 0.020 inch)
protrusion above t he cylinder head.
Ream t he bores to 8.029 0.010 mm (0.3161
0.0004 inch) - (Fig. 7).
i - 118 5.9L (DIESEL) ENGINE
VALVE GUI DE BORES
EXHAUST
CYLINDER
HEAD
INTAKE
CYLINDER HEAD VALVE GUI DE BORES
11.125 0.013 mm (0.438 0.0005 in)
VALVE GUI DE BORES
8.029 0.010 mm (0.3161 0.0004 in)
J9109-136
Fig. 6 Service Valve GuidesThin Wall
VALVE GUI DE BORES
CYLINDER
HEAD
EXHAUST
INTAKE
14.000 0.013 mm (0.5512 0.0005 in)
VALVE GUI DE BORES
8.029 0.010 mm (0.3161 0.0004 in)
J9109-137
Fig. 7 Service Valve GuidesThick Wall
VALVE SPRINGS
Measure t he valve spring length. The approximate
free l engt h is 55.63 mm (2.190 inch) with t he maxi-
mum inclination of 1.0 mm (0.039 inch).
Measure t he valve spring force. 289.32 N (65 lbs.)
is t he mi ni mum acceptable load required to compress
t he spring to a hei ght of 49.25 mm (1.94 inch).
If t he valve spring does not meet t he limits above,
replace t he spring.
VALVE SEATS
INSPECTION
Cylinder head with integral valve seats can be
ground only once. Previously ground integral seats
must be replaced with service seats.
One X stamped into t he head casting identify seats
t hat have been ground previously (Fig. 8).
Two X's stamped on t he head indicate service seats
have been installed (Fig. 8). Service seats can be
ground.
SERVICE SEATS
INSTALLED
n o
REGROUND
INTEGRAL
VALVE SEAT
J9109-138
Fig. 8 Reworked Cylinder Head SeatsStamped
Identification
On t he integral seat head, if 0.254 mm (0.010 inch)
or more has been removed from t he head combustion
surface, service seats must be installed.
To determine if t he head has been previously re-
surfaced, before calculating valve depth, process as
follows:
(1) Check t he rear lower ri ght corner of t he head
for a st ampi ng t hat would indicate previous resurfac-
ing (e.g. .003).
(2) To verify t he information, or if no amount is in-
dicated, measure t he head height (Fig. 9).
(3) If t he head height is 94.75 mm (3.730 inch) or
great er, t he valve seats may be ground, if they have
not been ground previously.
CYLINDER
HEAD
HEIGHT
J9109-139
Fig. 9 Cylinder Head Height

INTEGRAL VALWE SEAT GRINDING
After resurfacing t he valves and det ermi ni ng t hat
all valves meet specifications, install t he valves in
their designated locations and measure valve depth
(Fig. 10). The valve depth is t he distance from t he
valve face to t he head deck. Record t he dept h of each
valve.
CYLINDER
HEAD DECK
GRI ND TO 15
VALVE
DEPTH
J9109-140
Fig. 10 Valve Depth
Grind t he valve seats to remove scores, scratches
and burns. The seat angle should beIntake 30 and
Exhaust 45.
Install t he valves in t hei r respective bores and
measure t he depth again (Fig. 10). Record t he depth
of each valve.
The grinding depth is t he difference between t he
measurement before grinding and t he measurement
after grinding. The grinding depth maxi mum limit
(integral seats only) is 0.254 mm (0.010 inch). Ser-
vice valve seats are available for over limit integral
valve seats.
Identify ground valve seats by st ampi ng t he cylin-
der head.
Install t he valves in their designated locations and
measure t he depth of each. The valve depth limit (In-
t egral and Inserted Seats) is 0.99 mm to 1.52 mm
(0.039 inch to 0.060 inch). Replace t he valve if t he
depth is over t hi s limit.
Apply a light coat of valve lapping compound to
each valve and lap each valve to its mat i ng seat.
Remove t he valves and clean lapping compound
from t he valves and seats.
Measure t he valve seat width indicated by t he lap-
ping surface. The valve seat width limit is 1.50-2.00
mm (0.060-0.080 inch).
If required, grind t he areas with a 60 stone and a
15 stone to center t he seat on t he valve face. Main-
t ai n t he valve seat width limits (Fig. 11).
SERVICE VALVE SEAT INSTALLATION
Inspect t he valve guide bores as described in t he
valve guide section of t hi s manual . If it is necessary
to install valve guides, install t he guides before in-
stalling t he service seats.
J9109-141
Fig. 11 Grind Valve Seat
Replacement valve seat inserts must be installed if
t he valve seats have been ground previously. The il-
l ust rat ed marks indicate valve seats have been
ground previously.
Machine t he cylinder head to install t he service
valve seats (Figs. 12 and 13).
COMBUSTI ON
FACE
VALVE
SEAT
DEPTH
VALVE SEAT DEPTH
10.40 0.10 mm (0.4094 0.004 inch)
VALVE SEAT WIDTH
47.0 0.013 mm (1.8504 0.0005 in)
MAXI MUM RADI US
0.40 mm (0.0157 inch) MAX.
SURFACE FINISH
3.2 micrometers (128.0 microinch)
J9109-142
Fig. 12 Machining for Service Valve SeatsIntake
Valve
Press service seats into t he machined pockets.
St ake t he valve seats into the pockets.

COMBUSTI ON
FACE
VALVE
SEAT
DEPTH
'///
A
I
V
1
VALVE SEAT DEPTH
10.20 0.10 mm (0.4015 0.004 inch)
VALVE SEAT WIDTH
43.65 0.013 mm (1.7185 0.0005 in)
MAXI MUM RADI US
0.40 mm (0.0157 inch) MAX.
SURFACE FINISH
3.2 micrometers (128.0 microinch)
J9109-143
Fig. 13 Machining for Service Valve SeatsExhaust
Valve
SERVICE VALVE SEAT GRINDING
Install t he valves in t hei r designated location and
measure t he valve depth. The valve depth is t he dis-
tance from t he valve face to t he head deck.
Record t he depth of each valve (Fig. 14). The depth
is 0.99-1.52 mm (0.039-0.060 inch).
Grind t he valve seats to remove scores, scratches
and burns. The valve seat angle is 30 (Intake) and
45 (Exhaust).
Install t he valves in t hei r respective bores and
measure t he depth agai n (Fig. 14). The valve depth
limit is 0.99-1.52 mm (0.039-0.060 inch). Replace t he
valve if t he depth is over t he limit.
Apply a light coat of valve lapping compound to
each valve and lap each valve to its companion seat.
Remove t he valves and clean t he lapping compound
from t he valve and seats.
Measure t he valve seat width indicated by t he
lapped surface (Fig. 15). The width limits are 1.5-2.0
mm (0.060-0.080 inch). If required, grind lower area
with 60 stone and upper area with 15 stone (Fig.
15). Be sure to center t he seat on t he valve face.
Mai nt ai n t he valve seat within limits.
M I N . - 0. 990 mm ( 0.039 inch)
M AX . - 1.520 mm ( 0.06 0 inch)
J 91 09- 4 4
Fig. 14 Valve Depth with Seat Insert
M I N I M UM
1 . 5 mm
( 0.06 0 inch)
M AX I M UM
2.0 mm
( 0.08 0 inch)
J 9 1 09 - 4 5
Fig. 15 Valve Seat Width
SERVICE VALVE SEAT REPLACEMENT
To replace service seat inserts, machine t he insert
in t he same manner as if machining out t he i nt ernal
seat. Hold t he same tolerances and follow t he same
installation procedures.
INSTALLATION
(1) Clean all cylinder head components before as-
sembling.
(2) Install t he valve stem seals (Fig. 16). The in-
t ake and exhaust valve seals are t he same.
(3) Lubricate t he stems with SAE 90W oil before
installing t he valves. Install t he valves in t he same
positions as removed.
(4) Compress t he valve spring after installing t he
spring and ret ai ner (Fig. 17).
(5) Install new valve collets and release t he spring
tension (Fig. 17).
W ARN I N G: W E AR PROTE CTI V E E Q UI PM E N T AN D
D O N OT STAN D I N LI N E W I TH TH E VALVE STEM
W H E N TAPPI N G TH E V AL V E S.

Fig. 17 Valve, Valve Spring and Collet Installation
(6) Tap t he ends of t he valve stems with a mallet
to verify t he collets are seated.
(8) Check t he valve clearance adjustment.
VALVE CLEARANCE ADJUSTMENT
Use t he t i mi ng pin to locate Top Dead Center
(TDC) for cylinder No. l (Fig. 18). The t i mi ng pin is
located at t he back of t he gear housing and below t he
injection pump. Be sure to disengage t he t i mi ng pin
after locating top dead center.
Adjust t he valves when t he engine is cold, below
60C (140F).
STEP 1
Adjust t he clearance for t he valves shown in Fig.
19. The valve lash adjustment is 0.254 mm (0.010
inch) for t he i nt ake valve. The valve lash adjustment
is 0.508 mm (0.020 inch) for t he exhaust valve.
Tighten t he valve adjusting nut s to 24 N*m (18 ft.
lbs.) torque.
Be sure t i mi ng pin is disengaged before rot at i ng
t he crankshaft. Mark t he pulley and rot at e t he
crankshaft 360.
5 J L (DIESEL) ENGINE 9 - 121
Fig. 18 Locating TDC using Timing Pin
I = INTAKE E = EXHAUST
E I E I E I

J9109-34 FRONT mz>
Fig. 19 Adjust Valve ClearanceStep 1
STEP 2
Adjust t he clearance for t he valves shown in Fig.
20. The valve l ash adjustment is 0.254 mm (0.010
inch) for t he i nt ake valve. The valve lash adjustment
is 0.508 mm (0.020 inch) for t he exhaust valve.
I = INTAKE E = EXHAUST
E l I E I E

J9109-35 FRONT
Fig. 20 Adjust Valve ClearanceStep 2

GEAR HOUSING / COVER
GEAR HOUSING
REMOVAL
(1) Remove t he engine assembly from t he vehicle.
(2) Remove t he front end components and t he gear
housing cover (refer to Gear Housing Cover Removal
for t he proper procedures).
(3) Remove t he following:
Camshaft
Gear driven accessories
Fuel injection pump (refer to Group 14, Fuel Sys-
tem)
Fan hub assembly (refer to Group 7, Cooling Sys-
tem)
(4) Remove t he gear housing and gasket (Fig. 1).
(5) Clean t he gasket mat eri al from t he cylinder
block.
Fig. 1 Gear Housing/Gasket
INSTALLATION
(1) Install a new gasket and t he gear housing.
(2) Install t he camshaft. Make sure t he al i gnment
mar ks on t he camshaft and crankshaft gears are
aligned (Fig. 2),
(3) If a new housing is installed, t he t i mi ng pin as-
sembly must be accurately located.
(4) Install t he following:
Fan hub assembly (refer to Group 7, Cooling Sys-
tem)
Fuel injection pump (refer to Group 14, Fuel Sys-
tem)
Gear driven accessories
(5) Inst al l t he gear housing cover (refer to Gear
Housing Cover Installation for t he proper proce-
dures).
(6) Inst al l t he front end components.
(7) Install t he engine assembly into t he vehicle.
J9109-104
Fig. 2 Camshaft/Crankshaft Gear Alignment
GEAR HOUSING COVER
REMOVAL
(1) Remove fan drive assembly.
(2) Remove t he fan belt (Fig. 3).
(3) Remove belt tensioner (Fig. 3).
Fig. 3 Drive Belt Installation
(4) Remove oil fill t ube and adaptor (Fig. 4).
- 1 5 8
Fig. 4 Oil Fill Tube

(6) Remove t he bolts t hat hold t he gear cover to
the gear housing.
(7) Gently pry t he cover away from t he housing,
t aki ng care not to mar t he gasket surfaces (Fig. 5).
(8) Clean t he old gasket residue from t he back of
the gear cover and front of t he gear housing.
Fig. 5 Gear Housing and Cover
INSTALLATION
(1) Lubricate t he front gear t rai n with clean en-
gine oil.
(2) Thoroughly clean t he front seal area of t he
crankshaft. The seal lip and t he sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks.
(3) Install t he gear housing cover and a new gas-
ket.
(4) Install t he bolts but DO NOT t i ght en t hem at
this time.
(5) Use t he alignment/installation tool from t he
seal kit to align t he cover to t he crankshaft (Fig. 6).
(6) Tighten t he gear housing cover bolts to 24 N*m
Fig. 6 Alignment/Installation Tool
(7) Remove t he alignment/installation tool. Always
use a seal pilot when you install a seal.
(8) Apply a bead of Loctite 277 to t he outside di-
ameter of t he seal. Install t he pilot from t he seal ki t
onto t he crankshaft. Install t he seal onto t he pilot
and st art into t he gear housing cover. Remove t he pi-
lot.
(9) Use t he alignment/installation tool and a plas-
tic hammer to install t he seal to t he correct depth.
To prevent damage to t he seal carrier, hi t the align-
ment/installation tool alternately at t he 12, 3, 6 and
9 o'clock positions.
(10) Install t he oil fill tube and mount i ng bolts.
(11) Install t he vibration damper. DO NOT t i ght en
t he bolts to t he correct torque valve at t hi s time.
(12) Install t he belt tensioner. Ti ght en t he mount-
ing bolts to 43 Nnn (32 ft. lbs.) torque.
(13) Raise t he belt tensioner to i nst al l t he belt.
(14) Tighten t he vibration damper bolts to 125
N*m (92 ft. lbs.) torque. Use an engine barri ng tool to
keep t he engine from rot at i ng duri ng t i ght eni ng op-
eration.
TIMING PIN
TIMING PIN REPLACEMENT
The t i mi ng pin can be replaced wi t hout removing
t he assembly from t he gear housing.
(1) Remove t he t i mi ng pin by prying t he ret ai ni ng
ri ng out wi t h a small screwdriver. Replace t he re-
t ai ni ng ri ng if it is damaged during removal.
(2) If t i mi ng pin assembly is removed from gear
housing, it must be precisely reset to obtain exact
TDC.
(3) Install a new O-Ring, lubricate t he pin and po-
sition in t he housing (Fig. 7). Install t he new retain-
ing ri ng to 1.5 mm (0.059 inch).
Fig. 7 Engine Timing Pin Location
TIMING PIN HOUSING ASSEMBLY/ GASKET
REMOVAL
(1) Locate TDC for cylinder No. l .
(2) Remove t he t i mi ng pin housing assembly and
gasket.
(3) Clean any gasket mat eri al from t he gear hous-
Fig. 8 Fabricated Wire Pointer
(5) Rotate t he crankshaft one-quarter rotation in
t he opposite direction of engine rotation (counter-
clockwise).
(6) Tighten t he No. l cylinder exhaust valve adjust-
ing screw two complete t urns. Tighten t he locknut.
CAUTION; U se extreme care that the pi ston does
not push agai nst the exhaust val ve with s o much
force that it bends the push rod (Fi g. 9).
(7) Rotate t he crankshaft slowly in t he direction of
engine rotation unt i l t he piston touches t he exhaust
valve (Fig. 9).
(8) Mark t he vibration damper corresponding to
t he wire pointer (Fig. 9).
(9) Rotate t he crankshaft in t he opposite direction
unt i l t he piston touches t he valve (Fig. 10). Make
sure t hat t he piston touches t he valve with approxi-
mately t he same amount of force as in t he previous
step (Fig. 10).
(10) Mark t he vibration damper agai n (Fig. 10).
(11) Measure t he distance and mar k t he pulley at
one-half t hat distance between t he two mar ks. This

Fig. 9 Locate and Mark Vibration DamperFirst
Mark
Fig. 10 Mark Vibration DamperSecond Mark
Fig. 11 Location of Top Dead Center (TDC)
mar k is t he TDC mark (Fig. 11).
(12) Completely loosen t he No. l cylinder exhaust
valve adjusting screw.
(13) Rotate t he crankshaft with Cummi ns Barri ng
Tool 3377371 approximately 180 in t he direction of
engine rotation unt i l t he pointer is aligned with t he
TDC mark. Look t hrough t he back side of t he gear
housing for t he t i mi ng pin hole in t he camshaft gear.
ing and from t he t i mi ng pin housing assembly.
INSTALLATION (CYLINDER HEAD ON)
The location of t he t i mi ng pin assembly on t he
gear housing is critical for correct engine adjustment.
Follow t hi s procedure to install t he assembly so t hat
it corresponds to TDC for cylinder No. l .
(1) Look t hrough t he hole in t he gear housing and
rot at e t he engine unt i l t he hole in t he cam gear can
be seen.
(2) Adjust t he No. l cylinder exhaust rocker lever
to have zero (0) valve clearance.
(3) Remove t he injector nozzles from all of t he cyl-
inders. This step is i mport ant to vent t he cylinders so
t he crankshaft can be rotated smoothly to locate TDC
for cylinder No. l .
(4) Temporarily install the vibration damper. Fab-
ricate and install a wire pointer (Fig. 8).

5 J L (DIESEL) ENGINE 9 - 125
(14) Reset the valves on No. l cylinder and install
valve cover.
(15) Install timing pi n housing assembly and a
new gasket.
(16) Apply a coat of Loctite 59241 Liquid Teflon, or
equivalent to the t hreads of t he Torx head bolts.
(17) Hold the t i mi ng pin in t he hole to align t he
housing and install the Torx head bolts. Tighten t he
Torx bolts to 5 Nm (44 in. lbs.) torque.
(18) Install the injectors and bleed t he fuel system
(refer to Group 14, Fuel System).
INSTALLATION (CYLINDER HEAD OFF)
The t i mi ng pin assembly is precisely located on t he
gear housing to correspond to TDC for Cylinder No. l .
The t i mi ng pin assembly must be relocated if t he
gear housing is interchanged.
(1) Temporarily install the vibration damper and a
fabricated wire pointer (Fig. 12). Put a flat washer
between t he pointer and gear housing to prevent
damage to t he gear housing.
(2) Fabricate a steel plate (Fig. 13).
Fig. 12 Fabricated Wire Pointer
Fig. 13 Fabricated Steel Plate
(3) Use two flywheel housing bolts to assemble t he
pl at e over No. l cylinder (Fig. 14).
Fig. 14 Fabricated Plate Location on No.1 Cylinder
(4) Rotate t he crankshaft in t he direction of rota-
tion unt i l the piston contacts t he plate.
(5) Mark t he vibration damper (Fig. 11).
(6) Rotate t he engine in t he opposite direction un-
til t he piston contacts t he plate.
(7) Mark t he vibration damper (Fig. 11).
(8) Mark t he vibration damper for TDC. TDC will
be one-half t he distance between t he first two marks
(Fig. 11).
(9) Remove the plate and rot at e t he engine in t he
direction of rotation unt i l t he pointer aligns with t he
TDC mark.
(10) Look for the t i mi ng pin hole in t he camshaft
gear. If it is not visible, rot at e t he crankshaft one
complete rotation. Align t he pointer with t he TDC
mark.
(11) Install t he t i mi ng pin housing assembly with
a new gasket.
(12) Apply a coat of Loctite 59241 liquid teflon, or
equivalent to t he t hreads of t he torx head bolts.
(13) Push t he pin into t he hole in t he cam gear to
align t he t i mi ng pin housing.
(14) Hold t he pin in while t i ght eni ng t he torx head
bolts to 5 Nnn (44 in. lbs.) torque. Be sure t i mi ng pin
is disengaged before rot at i ng t he engine.
(15) Remove t he vibration damper and wire
pointer.
TAPPET
REMOVAL
(1) Remove t he camshaft.
(2) Insert a trough t he full length of t he cam bore
(Fig. 1). Cummins Tappet Changi ng Tool 3822513 is
available for this job.
(3) Make sure t he t rough is positioned so it will
catch t he tappet when t he wooden dowel is removed.
(4) Identify t he location of each tappet as it is re-
moved. The tappets must be installed in t hei r origi-
nal locations.

(5) Only remove one t appet at a time. Remove t he
rubber band from t he two companion tappets, secur-
ing t he tappet not to be removed with t he rubber
band.
(6) Pull t he wooden dowel from t he tappet bore al-
lowing t he tappet to fall into t he trough (Fig. 1).
(7) Normally t he t appet will fall over when it
drops into t he trough. Use a flashlight to determine
this. If t he tappet does not fall over, shake t he
t rough gently to get it to do so.
(8) Special care should be t aken, when removing
t he No.6 cylinder tappets. DO NOT knock or shake
t he t appet over t he end barri er of t he trough.
(9) Carefully pull t he t rough and tappet from t he
cam bore and remove t he tappet. Repeat t he process
unt i l all tappets are removed.
Fig. 1 Tappet Removal using a Trough
INSPECTION
Inspect t he tappet socket, st em and face for exces-
sive wear, cracks and other damage (Fig. 2).
The mi ni mum tappet stem di amet er is 15.925 mm
(0.627 inch) - (Fig. 2). If t he t appet is out of limits,
replace t he tappet.
NORMAL
WEAR
STEM DIAMETER-
ABNORMAL
WEAR
J9109-152
Fig. 2 Tappet Inspection
INSTALLATION
(1) Insert t he trough t he full length of t he cam
bore.
(2) Feed t he installation tool down t he tappet bore
and into t he trough (Fig. 3).
J9109-153
Fig. 3 Tappet Installation Tool
(3) Feed t he installation tool cord t hrough t he cam
bores. Carefully pull t he trough and installation tool
out t he front. The barri er at t he rear of t he trough
will assure t he tool will be pulled out with it.
(4) Lubricate t he tappets with Lubriplate 105, or
equivalent.
(5) Insert t he installation tool into t he tappet (Fig.
4). To aid in removing t he installation tool after t he
t appet s is installed, work t he tool in and out of t he
t appet several times before installing t he tappets.
(6) Place t he t appet and tool in t he trough and
slide t he t rough back into t he cam bore (Fig. 4).
J9109-155'
Fig. 4 Insert Installation Tool into Tappet
(7) Pull t he tool/tappet through t he cam bore and
up into t he t appet bore (Fig. 5).
(8) Difficulty could be experienced in getting t he
t appet to make t he bend from t he trough up to t he
t appet bore (due to t he webbing of t he block). If t hi s
occurs, pull t he trough out enough to allow t he t ap-

Fig. 5 Pull Tappet/Tool into Position
pet to drop down and align itself. Now pull t he tap-
pet up into t he bore carefully.
(9) After t he t appet has been pulled up into posi-
tion, slide t he trough back into t he cam bore and ro-
t at e it 1/2 t urn. This will position t he round side of
t he t rough up, which will hold t he t appet in place.
(10) Remove t he installation tool from t he tappet.
(11) Install a wooden dowel into t he top of t he tap-
pet and secure it with a rubber band.
(12) Repeat t hi s process unt i l all t appet s have been
installed.
(13) Install t he camshaft.
CAMSHAFT
REMOVAL
(1) Remove t he following part s:
Valve covers
Rocker lever assemblies
Push rods
Drive belt
Fan hub assembly
Vibration damper
Gear housing cover
Lift pump
(2) Insert t he dowels through t he push t ube holes
and into t he top of each tappet. When properly in-
stalled, t he dowels can be used to pull t he tappets up
(Fig. 6).
(3) Pull t he tappets up and wrap a rubber band
around t he top of t he dowel rods (Fig. 6). This will
prevent t he t appet s from dropping down.
(4) Rotate t he crankshaft to align t he crankshaft
to camshaft t i mi ng marks (Fig. 7).
(5) Remove t he bolts from t he t hr ust plate (Fig. 8)
(6) Remove t he camshaft, gear and t hr ust plate.
INSPECTION
Inspect t he lift pump lobe, valve lobes and bearing
j ournal s for wear, cracking, pi t t i ng and other dam-
age.
DOWEL TOOL
Fig. 6 Holding Tappets in Place (Cummins Tool
3822513)
J9109-51
Fig. 7 Align Crankshaft to Camshaft
Fig. 8 Thrust Plate Bolt Location
Clean t he camshaft and gear with solvent and a
lint free cloth.
Inspect t he gear t eet h for wear and damage. Look
for cracks at t he root of t he teeth.
Measure t he beari ng journals, lift pump lobe and
valve lobes (Fig. 9).

CAMSH AF T
J OURNAL
CAMSH AF T J OURNAL DI AMETER ( MI N.
53.962 mm (2.1245 inch)
V ALV E LOBE HEIGHT (MIN..)
INTAK E - 47.040 mm (1.852 inch)
EX H AUST - 46.770 mm (1.841 inch)
LIFT PUMP LOBE DIAMETER ( MI N.)
35.500 mm (1.398 inch)
J9109-53
Fig. 9 Bearing Journal/Valve Lobe Measurements
CAMSHAFT BUSHING-REPLACEMENT
(1) Measure t he diameter of each bore. (The limit
for t he bushing in t he No. l bore is t he same as for
t he other bores without bushings). The limit of t he
inside diameter is 54.133 mm (2.1312 inch). If t he
camshaft bore for t he first cam bushi ng is worn be-
yond t he limit, install a new service bushing. Inspect
t he rest of t he camshaft bores for damage or exces-
sive wear.
(2) If t he bores without a bushi ng are worn beyond
t he limit, t he engine must be removed for machi ni ng
and installation of service bushings. If badly worn,
replace t he cylinder block.
(3) Remove t he bushi ng from t he No. l bore, usi ng
a universal cam bushi ng tool.
(4) Mark t he cylinder block so you can align t he
oil hole in t he cylinder block with t he oil hole in t he
bushing.
(5) Use a universal cam bushi ng installation tool
and install t he bushi ng so t hat it is even with t he
front face of t he cylinder block. The oil hole must .be
aligned. A 3.2 mm (0.128 inch) di amet er rod must be
able to pass t hrough t he hole (Fig. 10).
(6) Measure t he installed bushing. The limit of t he
inside diameter is 54.133 mm (2.1312 inch).
CAMSHAFT GEAR-REPLACEMENT
(1) Press t he camshaft out of t he gear.
J9109-54
Fig. 10 Oil Hole Alignment
(2) Remove all burrs and smooth any rough sur-
faces caused by removing t he gear.
(3) Install t he camshaft key.
(4) Lubricate t he camshaft surface with Lubriplate
105, or equivalent.
(5) Heat t he gear in an oven at 121C (250F) for
45 minutes.
WA R N I N G : WE A R PR O T E C T I V E G L O V E S T O H A N -
D L E T HE HOT G E A R .
(6) Install t he gear with t he t i mi ng mar ks visible.
Be sure t he gear is seated against t he camshaft
shoulder.
(7) If t he camshaft is not to be used immediately,
lubricate t he lobes and j ournal s to prevent rust.
INSTALLATION
(1) Apply a coat of Lubriplate 105 to t he camshaft
bores.
(2) Lubricate t he camshaft lobes, journals and
t hr ust washer with Lubriplate 105, or equivalent.
C A U T I O N : When installing the camshaf t , D O N O T
push it in farther than it will g o with the thrust
washer in place. Pushi ng it too far can di sl odge the
pl ug in the rear of the camshaf t bore and cause an
oil leak.
(3) Install t he camshaft/thrust washer. Align t he
t i mi ng marks as illustrated (Fig. 11).
(4) Install t he t hrust washer bolts and t i ght en to
(5) Verify t he camshaft has t he correct amount of
backlash and end clearance (Fig. 12).
(6) Install t he following parts:
Lift pump
Gear housing cover
Vibration damper
Fan hub assembly
Drive belt
Push rods
Rocker lever assemblies
Valve covers
(7) Install t he engine in t he vehicle.

BACKLASH - 0. 080-0. 330 mm
(0.003-0.013 inch)
CLEARANCE - 0. 152-0. 254 mm
(0.006-0.010 inch)
Fig. 12 Camshaft Backlash and End Clearance
(8) Operate t he engine at idle for five to t en min-
utes and check for leaks and loose part s.
CYLINDER BLOCK
REMOVAL
(2) Remove t he cylinder head from t he block.
(3) Remove t he camshaft.
(4) Remove t he piston/connecting rod assemblies.
INSPECTION
Measure t he combustion deck face usi ng a st rai ght
edge and a feeler gauge (Fig. 1). The distortion of the
combustion deck face is not to exceed 0.010 mm
(0.0004 inch) in any 50.00 mm (2.0 inch) diameter.
Overall variation end to end or side to side is 0.075
mm (0.003 inch).
If t he surface exceeds t he limit, refer to Cylinder
Block Refacing.
Fig. 1 Combustion Deck Face Measurement
Inspect t he cylinder bores for damage or excessive
wear.
Measure t he cylinder bores (Fig. 2). If t he cylinder
bores exceeds t he limit, refer to Cylinder Bore Re-
pair.
MIN. 102.0 mm (4.0157 inch)
MAX. 102.1 16 mm (4.0203 inch)
Out-of-Round 0.038 mm (0.0015 inch)
Taper 0.0 76 mm (0.003 inch)
Oversize pistons and rings are
available for bored cylinder blocks.
J9209- 1 6 7
Fig. 2 Cylinder Bore Diameter
Inspect t he camshaft bores for scoring or excessive
wear.
Measure t he camshaft bores (Fig. 3). Limit for t he
No. l bore applies to t he ID of t he bushing.
If a bore exceeds t he limit, refer to Camshaft Bore
Repair.
Inspect t he t appet bores for scoring or excessive
wear (Fig. 4).
If out of limits, replace t he cylinder block.
CYLINDER BORESDE-GLAZE
(1) New piston rings may not seat in glazed cylin-
der bores.
(2) De-glazing gives t he bore t he correct surface
finish required to seat t he rings. The size of t he bore
is not changed by proper de-glazing.

CAMSHAFT BORE DIAMETER
MAX. 5 4. 133 mm ( 2 . 1312 inch)
J9109-78
Fig. 3 Camshaft Bores
BORE DIAMETER
MAX. 16.055 mm (0.632 inch)
J9109-79
Fig. 4 Tappet Bore Diameter
(3) Cover t he lube holes in t he top of t he block
with waterproof tape.
(4) A correctly honed surface will have a cross-
hat ch appearance with t he lines at 15 to 25 angles
(Fig. 5 ). For t he rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones.
(5) Use a drill, a fine grit Flexi-hone and a mix-
t ure of equal part s of mi neral spirits and SAE 30W
engine oil to de-glaze t he bores.
(6) The Crosshatch angle is a function of drill speed
and how fast t he hone is moved vertically (Fig. 6).
TOP OF BLOCK
Fig. 5 Cylinder Bore Crosshatch Pattern
(7) Vertical strokes MUST be smooth continuous
passes along t he full length of t he bore (Fig. 6).
1 STROKE ( f +| ) / PER SECOND
Fig. 6 De-Glazing Drill Speed and Vertical Speed
(8) Inspect t he bore after 10 strokes.
(9) Use a strong solution of hot wat er and l aundry
detergent to clean t he bores. Clean t he cylinder bores
immediately after de-glazing.
(10) Rinse t he bores unt i l t he detergent is removed
and blow t he block dry with compressed air.
(11) Check t he bore cleanliness by wiping with a
white, lint free, lightly oiled cloth. If grit residue is
still present, repeat t he cleaning process unt i l all res-
idue is removed. Wash t he bores and t he complete
block assembly with solvent and dry with compressed
air.
(12) Be sure to remove t he t ape covering t he lube
holes after t he cleaning process is complete.
CYLINDER BLOCK REFACING
(1) The combustion deck can be refaced twice. The
first reface should be 0.15 mm (0.0059 inch). If addi-
tional refacing is required, an additional 0.35 mm
(0.0138 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 7).
(2) The upper ri ght corner of t he rear face of t he
block must be stamped with a X when t he block is
refaced to 0.15 mm (0.0059 inch). A second X must

1st REFACE 0.15 mm (0.0058 inch)
2nd REFACE 0.35 mm (0.0138 inch)

Total 0.50 mm (0.0197 inch)
Standard 323.00 mm 0.10 mn i
(12.7165 inch 0.0039 inch)
1st RE FACE 322.85 mm 0.10 mm
(12.7106 inch 0.0039 inch)
2nd REFACE 322.50 mm 0.10 mn i
(12.6968 inch 0.0039 inch)
J9109-118
Fig. 7 Refacing Dimensions of the Cylinder Block
1st REFACE X
2nd REFACE XX
J9109-116
Fig. 8 Stamp Block after Reface
be stamped beside t he first when t he block is refaced
to 0.50 mm (0.0197 inch) - (Fig. 8).
(3) Consult t he par t s catalog for t he proper head
gaskets which must be used with refaced blocks to
ensure proper piston-to-valve clearance (Fig. 9).
CYLINDER BORE REPAIR
Cylinder bore(s) can be repaired by one of two
methods:
Method 1:Over boring and using oversize pistons
and rings.
GASKET
FOR
0.15 mm
(0.0058 inch)
REFACE
GASKET
FOR
0.50 mm
(0.0197 inch)
REFACE
Fig. 9 Proper Head Gasket
Method 2:Boring and installing a repai r sleeve
to l et ur n t he bore to st andard dimensions.
METHOD 1 - 0WERS1 Z E BORE
Oversize pistons and ri ngs are available in two
sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393
inch).
Any combination of standard, 0.50 mm (0.0197
inch) or 1.00 mm (0.0393 inch) overbore may be used
in t he same engine.
If more t han 1.00 mm (0.0393 inch) overbore is
needed, a repai r sleeve can be installed (refer to
Method 2Repair Sleeve).
Cylinder block bores may be bored twice before use
of a repai r sleeve is required (Fig. 10). The first bore
is 0.50 mm (0.0197 inch) oversize. The second bore is
1.00 mm (0.0393 inch) oversize.
After boring to size, use a honing stone to chamfer
t he edge of t he bore (Fig. 10).
A correctly honed surface will have a C r o s s h a t c h
appearance with t he lines at 15 to 25 angles with
t he top of t he cylinder block (Fig. 11). For t he rough
hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
A maxi mum of 1.2 micrometer (48 microinch) sur-
face finish must be obtained.
After finish honing is complete, immediately clean
t he cylinder bores with a strong solution of l aundry
detergent and hot water.
After rinsing, blow t he block dry.
Check t he bore cleanliness by wiping wi t h a white,
lint-free, lightly-oiled cloth. There should be no grit
residue present.
If t he block is not to be used ri ght away, coat i t
with a rust-preventing compound.
METHOD 2REPAIR SLEEWE
If more t han a 1.00 mm (0.03937 inch) di amet er
oversize bore is required, t he block must be bored
and a repai r sleeve installed.
BORI NG A N D
HO N I N G DIAMETERS
BORI NG DIAMETER DI ME NS I ON
1st REBORE - 102.469 mm
(4.0342 inch)
2nd REBORE - 102.969 mm
(4.0539 inch)
HO N I N G DIAMETER DI ME NS I ONS
STANDARD 102.020 0.020 mm
(4.0165 0.0008 inch)
1st REBORE 102.520 0.020 mm
(4.0362 0.0008 inch)
2nd REBORE 103.020 0.020 mm
(4.0559 0.0008 inch)
CHAMFER DI ME NS I ONS
Approx. 1.25 mm (0.049 inch)
by 15
J9109-119
Fig. 10 Cylinder Bore Dimensions
TOP OF BLOCK
Fig. 11 Crosshatch Pattern of Repaired Sleeve(s)
Bore t he block cylinder bore to 104.500-104.515
mm (4.1142-4.1148 inch) - (Fig. 12).
Repair sleeves can be replaced by using a boring
bar to bore out t he old sleeve. DO NOT cut t he cyl-
inder bore beyond t he oversize limit.
BORE DIAMETER
BLOCK REBORE FOR REPAIR SLEEVE
BORE DIA. - 104.500 +0.015 mm
(4.1142 +0.0006 inch)
STEP DIM. - 6.35 mm (0.25 inch)
J9109-120
Fig. 12 Block Bore for Repair Sleeve Dimensions
After machining t he block for t he new repai r
sleeve, thoroughly clean t he bore of all met al chips,
debris and oil residue before installing t he sleeve.
Cool t he repair sleeve(s) to a t emperat ure of -12C
(10F) or below for a mi ni mum of one hour. Be ready
to install t he sleeve immediately after removing it
from t he freezer.
Apply a coat of Loctite 620, or equivalent to t he
bore t hat is to be sleeved.
Wear protective gloves to push t he cold sleeve into
t he bore as far as possible.
Using a sleeve driver, drive t he sleeve downward
unt i l it contacts t he step at t he bottom of t he bore
(Fig. 13).
J9109-121
Fig. 13 Sleeve Installation

5 9L (DIESEL) ENGINE 9 - 133
A sleeve driver can be constructed as follows (Fig. 14).
DRIVE - ALUMI NUM
HANDLE - STEEL
A = 127 mm (5 inch)
B = 38 mm (1.5 inch)
C = 6.35 mm (0.25 inch)
D = 25.4 mm (1 inch)
E = 101 mm (3.976 inch)
F = 107.343 mm (4.226 inch)
J9109-122
Fig. 14 Sleeve Driver Construction
Set up a boring bar and machine t he sleeve to
101.956 mm (4.014 inch) - (Fig. 15).
After removing the boring bar, use a honing stone to
chamfer the corner of the repair sleeve(s) - (Fig. 15).
SLEEVE DIAMETER - 101.956 mm
(4.014 inch)
SLEEVE PROTRUSION
MI N . - FLUSH WITH BLOCK
MAX. - 0.050 mm (0.0019 inch)
SLEEVE CHAMFER
APPROX. 1.25 mm (0,049 inch)
BY 15
J9109-123
Fig. 15 Sleeve Machining Dimensions
A correctly h o n e d surface w i l l h a v e a C r o s s h a t c h
appearance w i t h t he l i n e s at 15 t o 25 angles w i t h
t he top of t he c y l i n d e r block. For t h e r o u g h hone, u s e
80 g r i t h o n i n g stones. To finish h o n e , u s e 280 g r i t
h o n i n g stones.
Finished bore inside dimension is 102.020 0.020
mm (4.0165 0. 0008 inch).
A maxi mum of 1.2 micrometer (48 microinch) sur-
face finish must be obtained.
After finish honi ng is complete, immediately clean
t he cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry wi t h compressed
air.
Wipe t he bore wi t h a white, lint-free, lightly oiled
cloth. Make sure t here is no grit residue present.
Apply a rust-preventing compound if t he block will
not be used immediately.
A st andard diameter piston and a piston ri ng set
must be used with a sleeved cylinder bore.
CAM BORE REPAIR
The front cam bushi ng bore can be bored to 57.740
Mm 0.018 mm (2.273 inch 0.0007 inch) oversize.
DO NOT bore t he i nt ermedi at e or rear cam bore to
t he front cam bore oversize dimensions. Intermediate
and rear cam bores may be bored to 57.240 mm
0. 018 mm (2.253 inch 0.0007 inch) oversize.
A surface finish of 2.3 micrometers (92 microinch)
must be maintained. Not more t han 20% of an area
of any one bore may be 3.2 micrometers (126 micro-
inch).
Camshaft bores can be repaired individually. It is
not necessary to repai r undamaged cam bores in or-
der to repair individually damaged cam bores. The
st andard front bushi ng cannot be used to repair in-
t ermedi at e or rear bores.
Install all cam bushings flush or below t he front
cam bore surface. The oil hole must align to allow a
3.2 mm (0.125 inch) rod to pass t hrough freely (Fig.
16).
Fig. 16 Oil Hole Alignment
CUP PLUG-REPLACEMENT
(1) Remove t he cup plugs from t he oil passages
(Fig. 17).
(2) Apply a bead of Loctite 277 around t he outside
diameter of t he oil passage cup plugs.
(3) Drive t he cup plugs in unt i l t hey bottom in t he
bore (Fig. 17).

(4) Fill t he engine with oil. Run t he engine and
check for leaks.
(5) Stop t he engine and check t he oil level wi t h t he
dipstick.
CUP PLUG
J9109-30
Fig. 17 Cup Plug Locations in Cylinder Block
INSTALLATION
(1) Install t he cylinder head onto t he block.
The turbocharged intercooler piston has a Ni-Resist
insert wi t h a keystone profile for t he top compression
ring. The new piston has a new design bowl and a 7
mm longer piston pin. These pistons can not be in-
terchanged wi t h earlier models.
REMOVAL
(2) Remove t he cylinder head from t he block.
(3) Remove t he oil pan and suction pump.
(4) If t he cylinder bores have ridges, use a ridge
reamer to cut t he ridge from t he top of t he cylinder
bore before removing t he piston. Make sure t he ridge
reamer does not make a deep cut into t he bore. DO
NOT remove more met al t han is necessary to remove
t he ridge.
(5) If cylinders have ridges, t he cylinders are over-
size and will need boring.
(6) Use a hammer and a steel st amp to mar k t he
cylinder number onto each connecting rod cap. Mark
t he cylinder number onto t he top of each piston.
(7) Remove t he connecting rod bolts and rod caps.
Use care so t he cylinder bores and connecting rods
are not damaged.
(8) Use a hammer handl e or similar object to push
t he piston and connecting rod t hrough t he cylinder
bore.
(9) Store t he piston/rod assemblies in a rack.
DISASSEMBLE
(1) Remove t he ret ai ner ri ngs from t he piston (Fig.
1).
(2) Remove t he piston pin. Heat i ng t he piston is
not required.
(3) Remove t he piston rings (Fig. 1).
RETAINER
RING
CON N E CTI N G
ROD
PI STON
PISTON
RIN
RETAINER
RING
J9109-62
Fig. 1 Retainer Rings
CLEANING
CAUTION: DO NOT use bead blast to clean the pis-
tons. DO N O T clean the pistons and rods in an acid
tank.
Soak t he pistons in cold part s cleaner. Soaking t he
pistons overnight will usually loosen t he carbon de-
posits.
Wash t he pistons and rods in a strong solution of
l aundry detergent and hot water.
Clean t he remai ni ng deposits from t he ri ng grooves
with t he square end of a broken ring. DO NOT use a
ri ng groove cleaner and be sure not to scratch t he
ri ng sealing surface in t he piston groove.
Wash t he pistons again in a detergent solution or
solvent.
Rinse t he pistons. Use compressed ai r to dry.
INSPECTION
Inspect t he rod j ournal s for deep scratches, indica-
tion of overheating and other damage.
Inspect t he pistons for damage and excessive wear.
Check top of t he piston, ri ng grooves, ski rt and pin
bore.
Measure t he piston ski rt diameter (Fig. 2). If t he
piston is out of limits, replace t he piston.
The upper groove only needs to be inspected for
damage.
Use a new piston ri ng to measure t he clearance in
t he i nt ermedi at e ri ng groove (Fig. 3). If t he clearance
of t he i nt ermedi at e ri ng exceeds 0.152 mm (0.006
inch), replace t he piston.
Use a new oil ri ng to measure t he clearance in t he
oil groove (Fig. 3). If t he clearance exceeds 0.127 mm
(0.005 inch), replace t he piston.

- j ^
u m m 1 1 / 2 i n c h )
MIN. DIAMETER
101.823 mm
4. 0088 inch
J 9 1 09 - 6 3
Fig. 2 Piston Skirt Diameter
PISTON
PIN
FEELER GAUGE
J910<
PISTON
J9109-64
Fig. 3 Intermediate and Oil Ring Clearances
Measure t he pin bore (Fig. 4). The maxi mum diam-
eter is 40.025 mm (1.5756 inch). If t he bore is over
limits, replace t he piston,
PISTON
J 9 1 09 - 6 5
Fig. 4 Piston Pin Bore
Inspect t he piston pin for nicks, gouges and exces-
sive wear.
Measure t he pin diameter (Fig. 5). The mi ni mum
di amet er is 39.990 mm (1.5744 inch). If t he diameter
is out of limits, replace t he pin.
Inspect t he rod for damage and wear. The I-Beam
section of t he connecting rod cannot have dents or
other damage. Damage to t hi s par t can cause stress
risers which will progress to breakage.
-66
Fig. 5 Piston Pin Diameter
Measure t he connecting rod pin bore (Fig. 6). The
maxi mum di amet er is 40.092 mm (1.5784 inch). If
out of limits, replace t he connecting rod.
CONNECTING
Fig. 6 Connecting Rod Pin Bore
CONNECTING ROD BEARING / CRANKSHAFT
JOURNAL CLEARANCE
Measure the connecting rod bore with t he bearings
installed and t he bolts tightened to 100 N*m (73 ft.
lbs.) torque.
Record t he smaller diameter.
Measure t he di amet er of t he rod j ournal at t he lo-
cation shown (Fig. 7). Calculate t he average diame-
t er for each side of t he j ournal .
The clearance is t he difference between t he con-
necting rod bore (smallest diameter) and t he average
diameter for each side of t he crankshaft journal.
If t he crankshaft is within limits, replace t he bear-
ing. If t he crankshaft is out of limits, grind t he
crankshaft to t he next smaller size and use oversize
rod bearings.
ASSEMBLE
(1) Be sure t he FRONT mar ki ng on t he piston and
t he numbers on t he rod and cap are oriented (Fig. 8).

MIN. 68.962 mm (2.715 inch)
MAX. 69. 013 mm (2.717 inch)
Out-of-Round - Max.
0.050 mm (0.002 inch)
Taper - Max.
0.013 mm (0.0005 inch)
Bearing Clearance - Max.
0.089 mm (0.0035 inch)
J9109-91
Fig. 7 Connecting Rod Journal Diameter Limits
Install t he ret ai ni ng ri ng into t he pin groove on t he
FRONT side of t he piston.
Fig. 8 Proper Markings on the Piston and
Connecting Rod
(2) Lubricate t he pin and bore with engine oil.
(3) Install t he piston pin in t he opposite side of t he
installed ret ai ni ng pin. Pistons do not require heat -
ing to install t he pin, however, t he piston does need
to be at room t emperat ure or above.
(4) Det ermi ne t he piston diameter and obtain t he
appropriate ri ng set. The piston ri ngs can be identi-
fied as shown in Fig. 9.
TOP RING
INTERMEDIATE
RING
OIL CONTROL
RING
TOP
J9109-69
Fig. 9 Piston Ring Identification
(5) Position each ri ng in t he cylinder and use a
piston to square it with t he bore at a depth of 89.0
mm (3.5 inch) - (Fig. 10).
(6) Use a feeler gauge to measure t he piston ri ng
gap (Fig. 11).
Fig. 10 Position of Ring in Cylinder Bore
MINIMUM MAXIMUM
TOP
0.400 mm
(0. 0160 inch)
0.700 mm
(0.0275 inch)
INTERMEDIATE
0.250 mm
(0.0100 inch)
0.550 mm
(0.0215 inch)
OIL CONTROL
0.250 mm
(0.0100 inch)
0.550 mm
(0.0215 inch)
J9109-71
Fig. 11 Piston Ring Gap

(7) The top surface of all of t he rings are identified
with t he word TOP or t he supplier' s MARK. Assem-
ble t he ri ngs with t he word TOP or t he supplier' s
MARK up.
(8) Position t he oil ri ng expander in t he oil control
ring groove (bottom groove).
(9) Install t he oil control ring with t he end gap
OPPOSITE t he ends on t he expander (Fig. 12).
OIL CONTROL
RING
PISTON
EXPANDER
J9109-72
Fig. 12 Oil Control Ring/Expander Location in
Groove
(10) Install t he i nt ermedi at e piston ri ng in t he sec-
ond groove (Fig. 13).
(11) Install t he top piston ri ng in t he top groove
(Fig. 13).
PISTON RING
INSTALLATION
TOOL
J9109-74
Fig. 13 Piston Ring Installation Tool
(12) Position t he rings as shown in Fig. 14.
(13) Install t he original bearings as removed or in-
stall new bearings. If new bearings are used, be sure
to obtain t he proper beari ng clearance (Fig. 15).
(14) DO NOT lubricate t he side of t he beari ng t hat
is against t he connecting rod or cap. Apply a coat of
Lubriplate 105, or equivalent to t he new upper and
lower connecting rod bearings.
INSTALLATION
(1) Lubricate t he cylinder bore with clean engine
oil.
(2) Generously lubricate t he rings and piston
ski rt s with clean engine oil.
(3) Compress t he rings using a piston ri ng com-
TOP
RING
INTERMEDIATE
RING
OIL CONTROL
RI N G
J9109-73
Fig. 14 Piston Ring Positioning
STANDARD
J9109-82
OVERSIZE
0.250 mm (.0098 in.
0.500 mm (.0197 in.
0.750 mm (.0295 in.
1.000 mm (.0394 in.
Fig. 15 Connecting Rod Bearing Size Location
pressor tool (Fig. 16). If using a strap-type ri ng com-
pressor, make sure t he inside end of t he st rap does
not hook on a ring gap and break t he ring.
PISTON
RING
COMPRESSOR TOOL
J9109-83
Fig. 16 Piston Ring Compressor Tool
(4) Bar t he crankshaft so t he rod j ournal for t he
piston to be installed is at BDC (Bottom Dead Cen-
ter) - (Fig. 17).
(5) Be sure t he FRONT marki ng on t he piston and
t he numbers on tlie rod and cap are oriented as illus-
trated.
(6) Position t he piston and rod assembly into t he
cylinder bore with t he word FRONT on t he piston to-
wards t he front of t he cylinder block. Use care when
you install t he piston and connecting rod so t he cyl-
inder bore is not damaged.
(7) Push t he piston into t he bore until t he top of
t he piston is approximately 50 mm (2 inch) below t he
J9109-84
Fig. 17 Piston/Rod Assembly at BDC
top of t he block. Carefully pull t he connecting rod
onto t he crankshaft journal.
(8) Use clean engine oil to lubricate t he t hreads
and under t he heads of t he connecting rod bolts.
(9) The 4 digit number stamped on t he rod cap at
t he part i ng line must match and be installed towards
t he oil cooler side of t he engine (Fig. 18).
O
o
--.
f ' - \
ro o
O

"k
J9109-85
Fig. 18 Correct Rod Cap Installation
(10) Install t he rod cap and bolts to t he connecting
rod. Tighten t he connecting rod and bolt evenly in 3
steps.
Tighten t he bolts to 35 Nun (26 ft. lbs.) torque.
(11) The crankshaft must rotate freely. Check for
freedom of rotation as t he caps are installed. If t he
crankshaft does not rotate freely, check t he installa-
tion of t he rod beari ng and t he beari ng size.
(12) Measure t he side clearance between t he con-
necting rod and t he crankshaft (Fig. 19). DO NOT
measure t he clearance between t he cap and crank-
shaft.
(13) Install t he suction tube and oil pan.
(14) Install t he cylinder head onto t he block.
SI DE CLE ARANCE LIMITS
MIN.
MAX.
0.100 mm
0.300 mm
(0.004 inch)
(0.012 inch)
Fig. 19 Side Clearance between Connecting Rod/
Crankshaft
CRANKSHAFT
REMOVAL
(1) Remove t he rear crankshaft seal housing.
(2) Remove t he gear housing.
(3) Rotate t he engine to a horizontal position and
remove t he mai n bearing bolts.
(4) The mai n beari ng caps should be numbered. If
t hey are not, be sure to mark them, beginning with
number one at t he front and ending with number
seven at t he rear (Fig. 1).
MAIN
BEARING
CAP
J9109-87
Fig. 1 Numbering Main Bearing Caps
C A U T I O N : D O N OT pry on the main caps to free
them from the cylinder block.
(5) Use two of t he mai n beari ng cap bolts to "wig-
gle" t he mai n cap loose, being careful not to damage
t he bolt t hreads (Fig. 2). Remove t he caps.
W ARN I N G: USE A H OI ST TO AV OI D INJURY.
(6) Lift t he crankshaft and gear from t he cylinder
block (Fig. 3).

5 .9L (DIESEL) ENGINE 9 - 139
Fig. 2 Main Beating Cap Removal
CAUTI ON : Cr ankshaft must be lifted straight off the
bear i ngs to prevent damage to the thrust bear i ngs.
Fig. 3 Lifting Crankshaft out of Cylinder Block
(7) Remove t he mai n bearings from t he block and
t he mai n caps.
(8) Remove t he piston cooling nozzles by using a
3/16 inch pin punch to push t hem out (Fig. 4).
Fig. 4 Piston Cooling Nozzles
Clean t he crankshaft oil galley holes with a nylon
brush.
Rinse in clean solvent and dry with compressed air.
Inspect t he front and rear seal contact areas of t he
crankshaft for scratches or grooving.
The service seal ki t will position t he seal slightly
deeper into t he seal bore so it will contact the crank-
shaft at a different location. If t hi s has already been
done and t he crankshaft has two worn areas, install
a wear sleeve to provide a new contact surface for
t he seal.
Inspect t he rod and mai n j ournal for deep scores,
signs of overheating and other abnormal marks.
CRANKSHAFT REWORK
Crankshaft mai n and rod j ournal s may be ground
in increments of 0.25 mm (0.0098 inch) up to a total
of 1.00 mm (0.0394 inch).
The only exception is t he mai n j ournal t hr ust
width surface. This j ournal must be ground in incre-
ment s of 0.50 mm (0.0197 inch) up to a total of 1.00
mm (0.0394 inch). The t hr ust surface is located on
t he No.6 mai n bearing. When the t hr ust surface re-
quires grinding, the mai n j ournal must be ground to
t he same undersize dimension.
MAIN JOURNAL
All mai n j ournal s are to be ground in t he opposite
direction of engine rotation (clockwise as viewed
from t he front of crankshaft). Polish t he journals in
t he same direction as engine rotation.
The mai n bearing grinding specifications are
shown in Fig. 5.
STANDARD MAI N JOURNAL DIAMETER
83.000 +0.013 mm
(3.2677 0.0005 inch)
W ORN MAI N JOURNAL DIAMETER LIMIT
82.962 (3.2662 inch)
UNDERSIZES REGRIND TO
0.25 mm
(0.0098 inch)
82.750 0.013 mm
(3.2579 0.0005 inch)
0.50 mm
(0.0197 inch)
82.500 +0.013 mm
(3.2480 +0.0005 inch)
0.75 mm
(0.0295 inch)
82.250 +0.013 mm
(3.2381 0.0005 inch)
1.00 mm
(0.0394 inch)
82.000 +0.013 mm
(3.2283 0.0005 inch)
OUT-OF ROUND & TAPER (MAX.)
0.005 mm (0.0002 inch)
ALL MAI N JOURNALS ARE TO BE PARALLEL
TO THE FRONT AND REAR MAI NS WITHIN:
0.030 mm (0.001 inch)
J9109-125
Fig. 5 Crankshaft Main Journal Dimensions
Thrust journals can be ground in t he same incre-
ment s and using t he same specifications as all other
mai n journals. The mai n j ournal radi us may be
ground using either t he preferred or t he al t ernat i ve

procedure providing t he t hr ust surface width is not
being ground. The preferred procedure must be used
when t he mai n beari ng t hr ust width surface is
ground. When t he t hr ust surface width requires
grinding, t he mai n j ournal must be ground to t he
same undersize dimension (Fig. 6).
THRUST JOURNAL WIDTH
37.500 0.025 mm
(1.4764 0.001 inch)
UNDERSIZES REGRIND WIDTH TO
0.50 mm 38.000 0.025 mm
(0.0197 inch) (1.4961 0.001 inch
1.00 mm 38.500 0.025 mm
(0.0394 inch) (1.5158 0.001 inch)
J9109-127
Fig. 6 Crankshaft Thrust Journal Width Dimensions
The t hr ust surface is to be ground on center wi t hi n
0.10 mm (0.004 inch). It also must be perpendicular
to t he front and rear mai ns wi t hi n 0.0015 mm
(0.00006 inch) per radi al inch on t he t hr ust area
(Fig. 7). The surface finish requi rement is 0.04 mi-
crometer (16.0 microinch).
JOURNAL
J9109-128
Fig. 7 Crankshaft Thrust Surface
PREFERRED PROCEDURE:
Smoothly blend a 4.20 0. 020 mm (0.1654 0. 0008
inch) radi us to t he ground di amet ers (Fig. 8).
C A U T I O N : D O N O T use the Alternative Procedure
when the thrust surface width i s gr ound.
ALTERNATIVE PROCEDURE:
Smoothly blend a 1.25 0. 020 mm (0.0492 0. 0008
inch) radi us to t he ground di amet ers (Fig. 9).
ROD JOURNAL
All rod j ournal s are to be ground in t he opposite di-
rection of engine rotation (clockwise as viewed from
ORI GI NAL RADI US
JOURNAL SURFACE

SURFACE FINISH
0.8 micrometer (32.0 microinch)
for a minimum of 45 into the
fillet beyond journal surface
for remainder of fillet

J9109-129
Fig. 8 Grind Crankshaft Main JournalPreferred
Method
t he front of crankshaft). Polish t he j ournal s in t he
same direction as engine rotation.
The rod beari ng grinding specifications are shown
in Fig. 10.
PREFERRED PROCEDURE:
Smoothly blend a 4.00 0.020 (0.1575 0.0008
inch) radi us to t he ground diameters and side faces
(Fig. 11).
ALTERNATIVE PROCEDURE:
Smoothly blend a 1.25 0.020 mm (0.0492 0. 0008
inch) radi us to t he ground j ournal s (Fig. 12).
CRANKSHAFT FRONT SEAL
REMOVAL
(1) Remove t he drive belt.
(2) Remove t he vibration damper.
(3) Drill two 1/Sth inch holes into t he seal face,
180 apart .
(4) Use a slide hammer tool with a #10 met al
screw. Pull al t ernat i ng from side-to-side unt i l t he
seal is free.
INSTALLATION
(1) The sealing surface on t he crankshaft must be
free from all oil residue to prevent seal leaks.
5-9L (DIESEL) ENGINE 9 - 14 1
ORI GI NAL RADI US
N E W UNDERCUT RADI US
JOURNAL SURFACE
ORI GI NAL RADIUS
NE W UNDERCUT RADI USs
SURFACE FINISH
for a minimum of 4 5 into the
(D 1.6 micrometer (64.0 microinch)
WIDTH OF REGRIND/UNDERCUT RADI US
3 4 . 5 0.025 mm (1.358 0.001 in)
JOURNAL SURFACE
J9109-130
Fig. 9 Grind Crankshaft Main JournalAlternative
Method
STANDARD ROD JOURNAL DIAMETER
69.000 +0.013 mm
(2.7165 0.0005 inch)
WORN ROD JOURNAL DIAMETER LIMIT
68.962 (2.7150 inch)
UNDERSIZES REGRIND TO
0.25 mm
(0.0098 inch)
68.750 +0.013 mm
(2.7067 0.0005 inch)
0.50 mm
(0.0197 inch)
68.500 +0.013 mm
(2.6969 0.0005 inch)
0.75 mm
(0.0295 inch)
68.250 +0.013 mm
(2.6870 0.0005 inch)
1.00 mm
(0.0394 inch)
68.000 +0.013 mm
(2.6772 0.0005 inch)
OUT-OF ROUND & TAPER (MAX.)
0.005 mm (0.0002 inch)
ALL MAIN JOURNALS ARE TO BE PARALLEL
TO THE FRONT AND REAR MAINS WITHIN:
0.030 mm (0.001 inch)
J9109-126
Fig. 10 Crankshaft Rod Journal Dimensions
(2) If t he gear cover was replaced, use t he align-
ment tool from t he seal ki t to make sure t he cover is
aligned with t he crankshaft.
SURFACE FINISH
for a minimum of 45 into the
CD

J9109-131
Fig. 11 Crankshaft Rod Journal GrindPreferred
Method
(3) Apply a bead of Loctite 277 to t he outside di-
ameter of the seal.
(4) Install t he pilot from t he seal kit onto t he
crankshaft.
(5) Install t he seal onto t he pilot and st art it into
t he gear housing cover seal bore.
(6) Remove t he pilot.
(7) Use t he alignment/installation tool and a plas-
tic hammer to install t he seal to t he correct depth.
(8) Install t he vibration damper, but DO NOT
tighten t he damper bolt unt i l t he belt is installed.
(9) Install t he drive belt.
(10) Tighten t he vibration damper bolts to 125
Nun (92 ft. lbs.) torque. Use t he engine barri ng tool
to keep t he engine from rot at i ng duri ng torquing op-
eration.
CRANKSHAFT REAR SEAL HOUSING AND
SEAL
REMOVAL
(1) Remove t he rear seal housing and gasket (Fig.
13).
(2) Support t he seal area of t he rear seal housing
and press/drive out t he seal usi ng a hammer and a
pin pinch.
(3) Clean t he rear seal housing.

ORIGINAL RADIUS
SURFACE FINISH
for a minimum of 45into the
^ fillet beyond journal surface
v/ 1.6 micrometer (64.0 microinch)
^ for remainder of fillet
v) 0.4 micrometer (16.0 microinch)
WIDTH OF REGRIND/UNDERCUT RADIUS
34.79 0.025 mm (1.369 0.001 in)
J9109-132
Fig. 12 Grind Crankshaft Rod JournalAlternative
Method
Fig. 13 Crankshaft Rear Seal Housing/Gasket
INSTALLATION
(1) Clean and dry t he r ear crankshaft sealing sur-
face. The seal lip and t he sealing surface on t he
crankshaft must be free from all oil residue to pre-
vent seal leaks.
(2) Assemble t he rear seal housing and gasket to
t he cylinder block wi t h t he bolts.
(3) Align t he seal housing to t he crankshaft wi t h
t he al i gnment tool provided in t he seal ki t (Fig. 14).
Make sure t he seal housing is level with both sides
of t he block oil pan rail. Tighten t he bolts to 9 N*m
(4) Remove t he alignment tool and t ri m t he gasket
even with t he oil pan mount i ng surface (Fig. 14).
Fig. 14 Crankshaft Rear Seal Housing Alignment
Tool
(5) The rubber O.D. rear crankshaft seals are lu-
bricated with soapy water. Seals without rubber O.D.
use Loctite 277, or equivalent.
(6) Install t he seal pilot (provided with t he replace-
ment kit) onto t he crankshaft. Push t he seal onto t he
crankshaft (Fig. 15).
(7) Remove t he seal pilot.
Fig. 15 Crankshaft Rear Seal Pilot
(8) Use al i gnment and installation tool packaged
in t he seal ki t (Fig. 16). Alternately, drive t he seal at
t he 12, 3, 6 and 9 o'clock positions to prevent bend-
ing t he seal carrier during installation.

ALIGNMENT AND \
INSTALLATION TOOL
J9109-102
Fig. 16 Crankshaft Rear Seal Alignment/Installation
Tool
CRANKSHAFT REAR SEAL
RE MOV AL
(1) Remove the transmission (refer to Group 21,
Transmission for the proper procedure).
(2) Remove the clutch cover.
(3) Remove the clutch plate.
(4) Remove the flywheel.
(5) Drill holes 180 apart into the seal. Be careful
not to get the drill against the crankshaft.
(6) Install #10 sheet metal screws in the drilled
holes and remove the rear seal with a slide hammer
(Fig. 17).
NO. 10
SCREW
\W
CRANKSHAFT
J9109-60
Fig. 17 Crankshaft Rear Seal Removal
I NSTALLATI ON
C A U T I O N : The seal lip and the seal i ng surface on
the crankshaft must be free from all oil residue to
prevent seal l eaks.
The crankshaft and seal must be dry when the seal
is installed.
(1) Install the seal pilot, provided in the replace-
ment kit, on the crankshaft. Push the seal on the pi-
lot and crankshaft.
(2) Remove the seal pilot.
(3) Seal O.D. lubricant/sealant:
Rubber O.D, rear crankshaft seals are lubricated
with soapy water.
Seals without rubber O.D. use Loctite 277 or
equivalent sealant.
(4) Use the alignment tool to install the seal to the
correct depth in the housing. Use a hammer to drive
the seal into the housing until the alignment tool
stops against the housing (Fig. 18).
(5) Hit the tool at the 12, 3, 6 and 9 o'clock posi-
tions to drive the seal evenly and prevent bending
the seal housing.
ALIGNMENT
TOOL-
J9109-6T
Fig. 18 Seal Installation using Alignment Tool
FLYWHEEL RING GEAR
RE M OV AL
(1) Remove the transmission.
(2) Remove the clutch cover.
(3) Remove the clutch plate.
(4) Remove the flywheel.
W ARN I N G: W E AR E Y E PROTE CTI ON W H E N Y OU
D RI V E TH E GE AR F ROM TH E F L Y W H E E L . D O N OT
USE A STE E L D RI F T PI N .
(5) Use a drift pin to drive the ring gear from the
flywheel (Fig. 19). Strike the gear at several points
around the wheel until it is off.
(6) Heat the new ring for 20 minutes in an oven
preheated to 127C (250F).
W ARN I N G: W E AR PROTE CTI V E GL OV E S W H E N
Y OU I N STAL L TH E H E ATE D GE AR.
(7) Install the gear. The gear must be installed so
the bevel on the teeth is towards the crankshaft side
of the flywheel (Fig. 19).

DIAL
INDICATOR
CYLI NDE R
BLOCK
GASKET
J910 9-97
Fig. 26 Position of Dial Indicator
CRANKSHAFT
END
CLE ARANCE
CRANKSHAFT
GEAR
MIN.
MAX.
0 . 1 3 0 mm
0.300 mm
(0M5 inch)
(0.012 inch)
J 91 09- 98
Fig. 27 Crankshaft End Clearance
OIL PAN / SUCTION TU1E
REMOVAL
(1) Remove t he engine from t he vehicle and mount
on an engine stand.
WA R N I N G : HOT O I L C A N C A U S E PE R S O N A L IN-
J URY .
(2) Drai n t he used engine oil. Dispose of t he used
oil properly.
(3) Remove t he oil pan and gasket (Fig. 1). Be sure
to connect t he support bracket.
(4) If required, remove t he suction t ube and gasket
(Fig. 1).
INSTALLATION
(1) Clean t he sealing surface.
(2) Install t he suction t ube and gasket. Tighten t he
bolts to 24 Ni n (18 ft. lbs.) torque.
(3) Fill t he joint between t he pan rail/gear housing
and pan rail/rear cover with sealant. Use Three Bond
1207-C, or equivalent.
SUCTI ON
TUBE
J9109-19
Fig. 1 Oil Pan, Suction Tube and Gasket
(4) Install t he pan and gasket (Fig. 1). Tighten t he
(5) Install t he drain plug with a new sealing
washer and t i ght en to 80 Nnn (60 ft. lbs.) torque.
(7) Fill t he engine with clean lubrication oil (refer
to Group 0, Lubrication and Maintenance). Run t he
engine and check for leaks.
(8) Stop t he engine and let it set for five mi nut es.
Check t he oil level, and add oil if needed.
OIL PUMP
The non-intercooled turbocharged engine oil pumps
can not be used on intercooled engines.
REMOVAL
(1) Remove t he radiator (refer to Group 7, Cooling
(2) Loosen t he crankshaft vibration damper and re-
move t he drive belt.
(3) Remove t he fan clutch assembly.
(4) Remove t he fan hub.
(5) Remove t he oil fill tube.
(6) Remove t he crankshaft vibration damper.
(7) Remove t he gear housing cover.
(8) Remove t he four mounting bolts and pull t he
pump from t he bore in t he cylinder block (Fig. 2).
CLEAN AND INSPECT
Visually inspect t he lube pump gears for chips,
cracks or excessive wear.
Remove t he back plate (Fig. 3).
Mark TOP on t he gerotor pl anet ary using a felt tip
pen (Fig. 3).
Remove t he gerotor pl anet ary (Fig. 3).


Fig. 2 Oil Pump Removal
J9109-20
OIL PUMP
BACK PLATE
GEROTOR
GEROTOR
PLANETARY.
J9109-156
Fig. 3 Gerotor Planetary and Gerotor
Inspect for excessive wear or damage.
Clean all part s in solvent and dry with compressed
air.
Inspect t he pump housing and gerotor drive for
damaged and excessive wear.
Install t he gerotor pl anet ary in t he original posi-
tion. The chamfer must be on t he O.D. and down.
Measure t he tip clearance (Fig. 4). Maximum clear-
ance is 0.1778 mm (0.007 inch). If t he oil pump is out
of limits, replace t he pump.
FEELER
GAUGE
J9109-21
Measure t he clearance of the gerotor drive/gerotor
pl anet ary to port plate (Fig. 5). Maxi mum clearance
is 0.127 mm (0.005 inch). If t he oil pump is out of
limits, replace t he pump.
PORT
PLATE
GEROTOR
J91 09- 22
Fig. 5 Gerotor to Port Plate Clearance
Measure t he clearance of t he gerotor planetary to
t he body bore (Fig. 6). Maxi mum clearance is 0.381
mm (0.015 inch). If the oil pump is out of limits, re-
place the pump.
BODY
BORE
GEROTOR
PLANETARY
J91 09- 23
Fig. 6 Gerotor Planetary to Body Bore Clearance
Measure t he gears backlash (Fig. 7). The limits of
a used pump is 0.080-0.380 mm (0.003-0.015 inch). If
t he backlash is out of limits, replace t he oil pump.
Install the back plate.
OIL PUMP
DRIVE
GEAR
IDLER GEAR
BACKLASH
BACKLASH
J9109-24
Fig. 4 Tip Clearance
Fig. 7 Measure Gear Backlash
INSTALLATION
(1) Lubricate t he pump with clean engine oil. Fill-
ing t he pump with clean engine oil duri ng installa-
tion will help to prime t he pump at engine st art up.

Make sure t he idler gear pin is installed in t he lo-
cating bore in t he cylinder block.
(2) Install t he pump. Tighten t he oil pump mount-
ing bolts in two steps and in t he sequence shown
(Fig. 2).
Step 1Tighten to 5 Nm (44 in. lbs.) torque.
Step 2- Ti ght e n to 24 N*m (18 ft. lbs.) torque.
(3) The back plate on t he pump seats agai nst t he
bottom of t he bore in t he cylinder block. When t he
pump is correctly installed, t he flange on t he pump
will not touch t he cylinder block.
(4) Measure t he idler gear to pump drive gear
backlash and t he idler gear to crankshaft gear back-
lash (Fig. 8). The backlash should be 0.080-0.330 mm
(0.003-0.013 inch). If t he backlash is out of limits, re-
place t he oil pump drive gear and t he idler gear.
(5) If t he adjoining gear moves when you measure
t he backlash, t he reading will be incorrect.
Fig. 8 idler Gear to Pump Drive Gear and
Crankshaft Gear Backlash
OIL FILTER
When replacing t he oil filter, Chrysler Corporation
recommends use of t he replacement filter specified in
your Operator' s Manual .
C A U T I O N : The internal filtering medi um of some fil-
ters has been known to disintegrate. Debri s from
failed filters may pl ug the pi st on oil cool i ng noz-
zl es, resulting in scuffed pi st ons and eventual en-
gi ne failure.
REMOVAL
W ARN I N G: H OT OI L C AN C A US E PE RSON AL I N-
J URY .
(1) Operate t he engine unt i l t he wat er tempera-
t ure reaches 60C (140F). Shut t he engine off.
(2) Use a container t hat can hold at least 14 liters
(15 quart s) to hold t he used oil. Remove t he oil drai n
plug and drai n t he used engine oil into t he container.
(3) Always check t he condition of t he used oil. This
can give you an indication of some engine problems
t hat mi ght exist.
Thin, black oil indicates fuel dilution.
Milky discoloration indicates coolant dilution.
(4) Clean t he area around t he lubricating oil filter
head. Remove t he filter using a 90-95 mm filter
wrench.
(5) Clean t he gasket surface of t he filter head. The
filter canister O-Ring seal can stick on t he filter
head. Make sure it is removed.
INSTALLATION
(1) Fill t he oil filter element with clean oil before
installation. Use t he same type oil t hat will be used
in t he engine.
(2) Apply a light film of lubricating oil to t he seal-
ing surface before installing t he filter.
C A U T I O N : Mechani cal over-tightening may distort
the threads or damage the filter element seal .
(3) Install t he filter as specified by t he filter man-
ufacturer.
(4) Clean t he drai n plug and t he sealing surface of
t he pan. Check t he condition of t he t hreads and seal-
ing surface on t he oil pan and drai n plug.
(5) Install the drain plug using a new sealing washer.
Tighten the plug to 80 N-m (60 ft. lbs.) torque.
(6) Use only High-Quality Multi-Viscosity lubricat-
ing oil in t he Cummi ns Turbo Diesel engine. Choose
t he correct oil for the operating conditions outlined
in Group 0, Lubrication and Maintenance.
(7) Fill t he enginfe with t he correct grade of new
oil. The engine capacity is i 0. 4 liters (11 quarts) in
t he crankcase and 0.95 liters (1 quart) in t he lubri-
cating oil filter.
(8) Start the engine and operate it at idle for several
minutes. Check for leaks at the filter and drain plug.
(9) Stop t he engine. Wait approximately 5 mi nut es
to let t he oil in t he upper part s of t he engine to drain
back to t he oil pan. Check t he oil level again. Add oil
as necessary to bri ng t he level to t he "H" (High)
mar k on t he dipstick.
OIL FILTER BYPASS VALWE
REMOVAL
(1) Remove t he oil cooler cover (Fig. 9).
(2) Remove t he valve from t he cooler cover (Fig. 9).
INSTALLATION
(1) Drive t he new valve in unt i l it bottoms agai nst
t he step in t he bypass valve bore (Fig. 10).
(2) Install t he oil cooler cover.
OIL PRESSURE REGULATOR VALVE / SPRING
When oil pressure from t he oil pump exceeds 448
kPa (65 psi), t he regulator valve opens to allow oil to
drai n back into t he pan.
FILTER BYPASS-
VALVE
OIL COOLER COVER
Fig. 9 Removing Filter Bypass Valve
n
J9109-16
FILTER
BYPASS
VALVE
OIL COOLER
COVER
J9109-15
Fig. 10 Installing New Filter Bypass Valve
REMOVAL
(1) Remove t he threaded plug, gasket, spring and
valve (Fig. 11).
(2) Check t he spring for height and load limita-
tions (Fig. 12). Replace the spring if out of limits.
OIL
FILTER
PLUG GASKET
SPRI NG
J9109-14
Fig. 11 Oil Pressure Regulator
VALVE OPEN
HEIGHT: 39.98mm (1.574 inch)
LOAD: 91 N (20.5 lb)
ASSEMBLED
HEIGHT: 44.98mm (1.77 inch)
LOAD: 60 N (13.5 lb)
J9109-13
Fig. 12 Oil Pressure Regulator Spring Check
INSTALLATION
(1) Clean and inspect t he plunger, bore and seat
before assembly. The plunger must move freely in
t he valve bore.
(2) Install t he valve, spring, gasket and plug.
Tighten t he plug to 80 N*m (60 ft. lbs.) torque.
OIL COOLER ELEMENT / GASKET
The non-intercooled turbocharged engine filter
head/coolers can not be used on intercooled engines.
REMOVAL
(1) Drain the cooling system (refer to Group 7,
Cooling System for t he proper procedures).
(2) Remove t he oil filter.
(3) Clean around t he oil cooler cover.
(4) Disconnect t he turbocharger supply line (Fig.
13).
J9109-17
Fig. 13 Turbocharger Supply Line
(5) Remove t he oil cooler cover, gaskets and cooler
element.
Clean t he sealing surfaces.
Apply 483 kPa (70 psi) air pressure to t he element
to check for leaks. If t he element leaks, replace t he
element.

INSTALLATION
(1) If a new oil cooler is being installed, remove
t he shipping plugs (Fig. 14).
(2) Assemble t he oil cooler, gaskets and t he cover
(Fig. 14). Tighten t he bolts to 24 N-m (18 ft. lbs.)
torque.
(3) Connect t he turbocharger oil supply line.
Tighten t he nut to 15 N-m (11 ft. lbs.) torque.
(4) Fill t he filter with clean lubricating oil and ap-
ply a light coat of oil to t he sealing gasket. Install
t he oil filter.
(5) Fill t he coolant system and operate t he engine
to check for leaks. Stop t he engine and check t he
coolant and oil level.
SHI PPI NG
PLUG J9109-18
Fig. 14 Oil Cooler
SPECIFICATIONS5.9L DIESEL ENGINES
VALVE TRAI N
Valve Clearance
Intake .0.25 mm (0.010 inch)
0.51 mm (0.020 inch)
Valve Guide Diameter
Minimum 8.019 mm (0.3157 inch)
Maximum . 8 . 08 9 mm ( 0.3185 inch)
Valve Stem Diameter
7.935 mm (0.3126 inch)
Maximum 7.96 0 mm (0.3134 inch)
Valve Seat Angle
Intake Valve 3 0
Exhaust Valve 4 5
Valve Depth (Installed)
Minimum . . . . . . . . . . . 0.99 mm (0.039 inch)
Maximum 1.52 mm (0.06 0 inch)
Valve Spring
Free Standing Length 55.6 3 mm (2.19 inch)
Inclination (Max.) , 1.00 mm (0.039 inch)
Minimum Load 4 9.25 mm (1.94 inch)
289.32 N (6 5 lbs.)
Valve Rim Thickness (Min.) 0.79 mm (0.031 inch)
Valve Seat Width
Minimum 1.50 mm (0.06 b inch)
Maximum . 2.00 mm ( 0.080 inch)
CYLINDER HEAD
Cylinder Head Flatness
Max. Overall 0.030 mm (0.012 inch)
Max. Variation within 0.01 mm (0.0004 inch) in any
50.8 mm ( 2.0 inch) diameter area.
GE A R T R AI N
Gear Backlash (all gears) 0.08- 0.33 mm (0.003-0.013 inch)
Camshaft End Clearance 0.152-0.254 mm (0.006 -0.010 inch)
C AMS HAFT
Journal Diameter (Min.) 53.96 2 mm (2.124 5 inch)
Valve Lobes (Min. Diameter at Peak of Lobe)
Intake . . . . 4 7.04 0 mm ( 1.852 inch)
Exhaust 4 6 .770 mm ( 1.84 1 inch)
Lift Pump Lobe (Min. Diameter at Peak of Lobe) 35.50 mm (1.398 inch)
TAPPETS
Sfem Diameter (Min.) 15.925 mm (0.6 27 inch)
ROCKERLEVER
Rocker Lever Bore (Max.) 19.05 mm (0.75 inch)
Shaft Diameter (Min.) 18.94 mm ( 0.74 6 inch)
CYLI NDER TORES
Cylinder Bore Diameter (Max.) 102.116 mm (4 .0203 inch)
Out of Round (Max.) . .0.038 mm (0.0015 inch)
Taper (Max.) 0.076 mm (0.003 inch)
C ON N E C T I N G ROD
Pin Bore Diameter (Max.) . 4 0.053 mm (1.576 9 inch)
Side Clearance 0.10-0.30 mm (0.004 -0.012 inch)
J9109-246
ENGINE SPECIFICATIONS (CONT.)
PISTONS
Skirt Diameter (Min.)
Nominal . . . . . . . 101.880 mm (4.0110 inch)
Worn Limits 101.823 mm (4.0088 inch)
Pin Bore Diameter (Max.) 40.025 mm (1.5758 inch)
Ring Groove (Max.)
Intermediate Groove 0.15 mm (0.006 inch)
Oil Control Groove 0.13 mm
(0.005 inch)
Piston Pin Diameter (Min.) 39.99 mm (1.5744 inch)
Ring End Gap
Top Ring 0.40-0.70 mm (0.016-0.0275 inch)
Intermediate Ring . . .0.25-0.55 mm (0.010-0.0215 inch)
Oil Control Ring 0.25-0.55 mm (0.010-0.0215 inch)
C R A N K S H A F T
Main Bearing Journal Diameter
Standard 82.962 mm (3.2662 inch)
Machined 0.25 mm .82.712 mm (3.2564 inch)
Machined 0.50 mm 82.462 mm (3.2465 inch)
Out of Round (Max.) 0.050 mm (0.002 inch)
Taper (Max.) 0.013 mm (0.0005 inch)
Oil Clearance (Max.) . . . . . . .0.119 mm (0.0047 inch)
End Clearance . .0.13-0.30 mm (0.005-0.012 inch)
Connecting Rod Journal
Standard .68.962 mm (2.7150 inch)
Out of Round (Max.) 0.050 mm (0.002 inch)
Taper (Max.) .0.013 mm (0.0005 inch)
Oil Clearance (Max.) 0.089 mm (0.0035 inch)
CYLI NDER B L O C K
Top Surface Flatness
(Max. Overall Variation) 0.075 mm (0.003 inch)
Max. Variation any 50 mm
(2 inch) Diameter Area 0.010 mm (0.0004 inch)
Refacing Combustion Deck
First Reface 0.15 mm (0.0058 inch)
Second Reface 0.35 mm (0.0138 inch)
Total .0.50 mm (0.0197 inch)
Surface Finish 1.5-3.2 micrometers (60-126 microinch)
Main Bearing Bore Diameter (Max.)
with bearing installed . .83.106 mm (3.2719 inch)
Camshaft Bore Diameter (Max.)
#1 w / o Bushing 57.258 mm (2.2543 inch)
#1 with Bushing .54.133 mm (2.1312 inch)
#2 thru #7 54.133 mm (2.1312 inch)
Tappet Bore Diameter (Max.) 16.055 mm (0.632 inch)
O I L P U M P
Tip Clearance (Max.) 0.1778 mm (0.007 inch)
Gerotor Drive/Planetary to Port Plate Clearance (Max.) . .0.127 mm (0.005 inch)
Gerotor Planetary to Body Bore Clearance (Max.) .0.381 mm (0.015 inch)
Gear Backlash (Used Pump) 0.08-0.38 mm (0.003-0.015 inch)
J9109-247
5.9L (DIESEL) ENGINE 9 - 1 5 3
COMPONENT
Air Fuel Control Banjo Screw (In Pump) . . . .
Air Fuel Control Fitting (In Head)
Alternator Ground Cable Mounting to Block
Alternator Mounting to Water Pump Inlet ..
Alternator Pulley
Alternator Support (Upper)
Battery Cable (Negative) Mounting to Block ,
Belt Tensioner Mounting
Block Heater Mounting
Cab Heater Hose Clamp
Cab Heater Tubing Clamp Mount i ng.......
Camshaft Thrust Plate
Clutch Cover Mounting to Flywheel . . .
Connecting Rod (Alternately tighten in 3 steps)
Step 1
Step 2
Step 3 .
Cooling Fan Mounting to Fan Clutch
Crossover Clamp (Air)
Cylinder Head Mounting Bolts
1. All Bol t s. . . .
2. Long Bolts . . . . . . . . .
3. Tighten All Bolts An Additional
Exhaust Manifold
Exhaust Outlet Pipe - V Band Clamp
Exhaust Pipe Clamp Mounting
Exhaust Pipe Steady Rest Mounting to Trans .
Fan Clutch Mounting/Fan Hub (L Hand Threads)..
Fan Hub Bracket Mounting
Fan Hub Bearing Retaining Capscrew
Fan Pulley to Fan Hub
Fan Pulley Crankshaft .
Fan Shroud Mounting Nuts
Flywheel Bolts
Flywheel Housing - Adaptor
Front Engine Mount Isolator Mounting to Mount..
Front Engine Mount Through Bolt
Front Engine Mount to Block
Front Oil Filler Pipe - Access Cover
Fuel Banjo Screw (In Fuel Pump)
Fuel Banjo Screw (In Head)
Fuel Banjo Screw (In Injector)
Fuel Filter
Fuel Heater Assembly Mounting
Fuel Heater Ground Mounting to Intake Manifold
Fuel Link Fitting (High Pressure)
Fuel Low Pressure Supply
Fuel Pump Drive Gear (With Pump Unlocked)
Fuel Pump Lock (Bosch)
TORQUE
12 N-m
9 ft. lbs.
8 N-m
6 ft. lbs.
24 N-m
18 ft. lbs.
41 N*m 30 ft. lbs.
80 N-m
60 ft. lbs.
24 N-m
18 ft. lbs.
77 N-m
57 ft. lbs.
43 N-m
32 ft. lbs.
12 N-m
9 ft. lbs.
4 N-m
(35 in. lbs.)
24 N-m 18 ft. lbs.
24 N-m
18 ft. lbs.
23 N-m
17 ft. lbs.
35 N-m
26 ft. lbs.
70 N-m
51 ft. lbs.
100 N-m
73 ft. lbs.
20 N-m
15 ft. lbs.
5 N-m
(44 in. lbs.)
90 N-m
66 ft. lbs.
120 N-m
89 ft. lbs.
90
43 N-m
32 ft. lbs.
8 N-m
(72 in. lbs.)
27 N-m 20 ft. lbs.
68 N-m
50 ft. lbs.
57 N-m
42 ft. lbs.
24 N-m
18 ft. lbs.
77 N-m
57 ft. lbs.
9 N-m
7 ft. lbs.
9 N-m
7 ft. lbs.
11 N-m (95 in. lbs.)
137 N-m
101 ft. lbs.
60 N-m
44 ft. lbs.
109 N-m 80 ft. lbs.
41 N-m
30 ft. lbs.
60 N-m
44 ft. lbs.
Hand Tighten
32 N-m 24 ft. lbs.
24 N-m
18 ft. lbs.
8 N-m
6 ft. lbs.
Vi Turn after contact
32 N-m
24 ft. lbs.
12 N-m
9 ft. lbs.
24 N-m
18 ft. lbs.
24 N-m
18 ft. lbs.
65 N-m
48 ft. lbs.
30 N-m 22 ft. lbs.
J9109-261
TORQUE SPECIFICATIONS (CONT.J
C O MPO N E N T
TORQUE
Fuel Pump Mounting Nut ..
Fuel Pump Solenoid
Fuel Pump Support Bracket
Fuel Pump Unlock (Bosch) .
Fuel Vent Screw (In Banjo) .
Gear Cover
Gear Housing-to-Block
Injector Retaining Nut.
Intake Manifold Cover
Intercooler Attaching Bolts
Intercooler Duct Clamp Nuts.
Lift Pump Mounting
Lifting Bracket (Rear) ..
Main Bearing Cap Bolts. Step!.
Step 2.
Steo3.
Oil Cooler Assembly
Oil Fill Tube Bracket
Oil Filter
Oil Pan Drain Plug
Oil Pan Mount i ng. . . . . . . . .
Oil Pressure Regulator Plug
Oil Pressure Sender/Switch
Oil Pump Mounting
Oil Suction Tube (Flange) ..
Oil Suction Tube Brace
Power Steering Pump to Vacuum Pump Mounting
Radiator Hose Clamp - Upper
Radiator Mounting Nuts
Rear Seal Mounting
Refrigerant Compressor Lines - Flange Mounting
Refrigerant Compressor Mounting
Rocker Lever Nut
Rocker Support
Starter Mounting
Starter Battery (Positive) Cable Nut
Starter Solenoid Nut
Tappet Cover/Fuel Drain Line Supports
Thermistor ,
Thermostat Housing
Throttle Bracket Mounting to Mounting Bracket.
Throttle Rod Mounting to Throttle Lever Nut . . .
Timing Pin Flange Mounting
Torque Converter Access Cover Plate Mounting
Transfer Case Linkage Bracket Mounting/Trans
Transfer Case Mounting to Transmission . .
24 N- m
18 ft. lbs.
43 N- m
32 ft. lbs.
24 N- m
18 ft. lbs.
13 N- m
10 ft. lbs.
8 N- m 6 ft. lbs.
24 N- m
18 ft. lbs.
24 N- m 18 ft. lbs.
60 N- m
44 ft. lbs.
24 N- m 18 ft. lbs.
2 N- m
(17 in. lbs.)
8 N- m
(72 in. lbs.)
24 N- m
18 ft. lbs.
77 N- m 57 ft. lbs.
60 N- m
45 ft. lbs.
119 N- m 88 ft. lbs.
176 N- m 129 ft. lbs.
24 N- m
18 ft. lbs.
43 N- m
32 ft. lbs.
Turn after contact
80 N- m
60 ft. lbs.
24 N- m
18 ft. lbs.
80 N- m
60 ft. lbs.
16 N- m
12 ft. lbs.
24 N- m
18 ft. lbs.
24 N- m 18 ft. lbs.
24 N- m
18 ft. lbs.
24 N- m
18 ft. lbs.
4 N- m
(35 in. lbs.)
11 N- m (95 in. lbs.)
9 N- m
7 ft. lbs.
20 N- m
15 ft. lbs.
47 N- m
35 ft. lbs.
24 N- m 18 ft. lbs.
24 N- m
18 ft. lbs.
43 N- m
32 ft. lbs.
22 N- m
16 ft. lbs.
5 N- m (44 in. lbs.)
24 N- m
18 ft. lbs.
24 N- m
18 ft. lbs.
24 N- m
18 ft. lbs.
24 N- m
18 ft. lbs.
10 N- m 73 ft. lbs.
5 N- m
(44 in. lbs.)
4 N- m
(35 in. lbs.)
41 N- m
30 ft. lbs.
47 N- m
35 ft. lbs.
J9109-262
TORQUE SPECIFICATIONS (CONT.)
COMPONENT
TORQUE
24 N-m 18 ft. lbs.
Trans Kickdown Cable Bracket Mounting/Trans 68 N-m 50 ft. lbs.
68 N-m 50 ft. lbs.
68 N-m 50 ft. lbs.
41 N-m 30 ft. lbs.
54 N-m 40 ft. lbs.
Transmission Oil Cooler Line F l ange. . . . . . . . . . . . . . . . . . . . . . . . . 6 N-m (50 in. lbs.)
Transmission Oil to Air Cooler Hose Clamps 2 N-m (18 in. lbs.)
Transmission to Clutch Housing Mounting 47 N-m 35 ft. lbs.
Transmission Torque Converter Mounting 47 N-m 35 ft. lbs.
Turbine Housing 11 N-m 8 ft. lbs.
Turbo Compressor Housing Clamp 8.5 N-m (75 in. lbs.)
Turbo Mounting Nut 32 N-m 24 ft. lbs.
Turbo Oil Drain Tube 24 N-m 18 ft. lbs.
Turbo Oil Supply (Both Ends) . 15 N-m 11 ft. lbs.
Vacuum Pump Mounting
9 N-m
7 ft. lbs.
Vacuum Pump to Gear Housing Mounting 77 N-m 57 ft. lbs.
Valve Cover. 24 N-m 18 ft. lbs.
Vibration Damper Mounting 125 N-m 92 ft. lbs.
Water Hose Clamps
4 N-m
(35 in. lbs.)
Water Inlet Connection 43 N-m 32 ft. lbs.
Water Pump Mounting 24 N-m 18 ft. lbs.
Water Temperature Sensor 50 N-m 37 ft. lbs.
J9109-263
EXHAUST SYSTEM AND INTAKE MANIFOLD 1 1 - 1
C O N T E N T S
page
EXHAUST SYSTEM DIAGNOSIS 3
SERVICE PROCEDURES (DIESEL ENGINES) . 17
page
SERVICE PROCEDURES (GASOLINE ENGINES) . 4
SPECIFICATIONS 27
EXHAUST SYSTEM
The gasoline engine exhaust system consists of en-
gine exhaust manifolds, exhaust pipe(s), catalytic
converter(s), extension pipe(s), exhaust heat shields,
muffler(s) and exhaust tailpipe (Fig. 1).
The diesel engine exhaust system consists of an en-
gine exhaust manifold, turbocharger, exhaust pipe,
extension pipe, muffler and exhaust tailpipe (Fig. 2).
The engine exhaust manifolds on gasoline engines
are equipped with ball flange outlets to assure a
t i ght seal and st rai n free connections.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If t he sys-
t em contacts any body panel, it may amplify objec-
tionable noises from t he engine or body.
When inspecting an exhaust system, critically in-
spect for cracked or loose joints, stripped screw or
bolt t hreads, corrosion damage and worn, cracked or
broken hangers. Replace all components t hat are
badly corroded or damaged. DO NOT at t empt to re-
pair.
When replacement is required, use original equip-
ment part s (or t hei r equivalent). This will assure
proper alignment and provide acceptable exhaust
noise levels.
C A U T I O N : A voi d application of rust prevention
compounds or undercoati ng materials to exhaust
syst em floor pan exhaust heat shi el ds. Li ght overs-
pray near the edges i s permitted. Appl i cati on of
coati ng will result in excessi ve floor pan tempera-
tures and objectionable f umes.
CATALYTIC CONVERTER (GASOLINE ENGINES)
The stainless steel catalytic converter body is de-
signed to last t he life of t he vehicle. Excessive heat
can resul t in bulging or other distortion, but exces-
sive heat will not be t he fault of t he converter. If un-
burned fuel ent ers t he converter, overheating may
occur. If a converter is heat-damaged, correct t he
cause of t he damage at t he same t i me t he converter
is replaced. Also, inspect all other components of t he
exhaust system for heat damage.
Unleaded gasoline must be used to avoid contami-
nat i ng the catalyst core.
EXHAUST HEAT SHIELDS (GASOLINE ENGINES)
Exhaust heat shields are needed to protect both t he
vehicle and t he environment from t he high tempera-
t ures developed by t he catalytic converter. The com-
bustion reaction facilitated by t he catalyst releases
additional heat in t he exhaust system. Under severe
operating conditions, t he t emperat ure increases in
t he area of t he reactor. Such conditions can exist
when t he engine misfires or otherwise does not oper-
at e at peak efficiency. DO NOT remove spark plug
wires from plugs or by any other means short out
cylinders. Fai l ure of t he catalytic converter can occur
due to a t emperat ure increase caused by unburned
fuel passing t hrough t he converter.
Do not allow t he engine to operate at fast idle for
extended periods (over 5 minutes). This condition
may result in excessive t emperat ures in the exhaust
system and on t he floor pan.
EXHAUST GAS RECIRCULATION
(EGR)(GASOLINE ENGINES)
To assist in t he control of oxides of nitrogen (NOx)
in engine exhaust, all engines are equipped wi t h an
exhaust gas recirculation system. The use of exhaust
gas to dilute incoming air/fuel mi xt ures lowers peak
flame t emperat ures during combustion, t hus limiting
t he formation of NOx.
Exhaust gases are t aken from openings in t he ex-
haust gas crossover passage in t he i nt ake manifold.
Refer to Group 25, Emission Control Systems for
complete description, diagnosis and service proce-
dures of the exhaust gas recirculation system and
components.
TURBOCHARGER (5.9L DIESEL ENGINE)
A turbocharger is used to force more air into t he
engine cylinders. Exhaust gas energy is used to t ur n
E X H A U S T S Y S T E M A N D I N T A K E M A N I F O L D
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD
EXHAUST
J9011-41
Fig. 1 Exhaust SystemGasoline Engines (Typical)
t he t urbi ne wheel and shaft. At t he other end of t he
shaft is t he compressor wheel. The compressor wheel
draws ai r in and forces it into t he engine cylinders
t hrough t he i nt ake manifold.
Supplying Increased air flow to the engine pro-
vides:
Improved engine performance
Lower exhaust smoke density
Improved operating economy
Altitude compensation
Noise reduction.
EXHAUST
PIPE
MUFFLER TAIL PIPE
J91U-42
Fig. 2 Exhaust SystemDiesel Engines (Typical)
EXHAUST SYSTEM DIAGNOSIS
C O N D I T I O N PO S S I BL E C A U S E C O R R E C T I O N
EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints.
2. Burned or blown out muffler.
3. Burned or rusted out exhaust pipe.
4. Exhaust pipe leaking at manifold flange.
5. Exhaust manifold cracked or broken.
6. Leak between manifold and cylinder head.
7. Restriction in muffler or tail pipe.
1. Tighten clamps at leaking joints.
2. Replace muffler assembly. Check
exhaust system.
3. Replace exhaust pipe.
4 . Tighten connection attaching nuts.
5. Replace exhaust manifold.
6. Tighten exhaust manifold to cylinder
head stud nuts or bolts.
7. Remove restriction, if possible.
Replace muffler or tail pipe, as
necessary.
LEAKING EXHAUST GASES 1. Leaks at pipe joints.
2. Damaged or improperly installed gaskets.
1. Tighten clamps at leaking joints.
2. Replace gaskets, as necessary.
ENGINE HARD TO WARM UP
OR WILL NOT RETURN TO
NORMAL IDLE
1. Thermostat broken.
2. Blocked crossover passage in intake
manifold.
1. Replace thermostat.
2. Remove restriction or replace intake
manifold.
J9311-10

S E R V I C E PROCEDURES (GASOLINE ENGINES)
INDEX
page
Catalytic Converters 4
Engine Ex haust Manifold : . . . . 1 5
Ex haust Heat Shi el ds 5
Ex haust Pipe 4
page
Ex haust Tailpipe . 5
Intake Manifold 13
Mufflers 4
EXHAUST PIPE
Refer to Figs. 1, 4, 5 and 6 for t he following proce-
dure.
REMOVAL
(2) Apply penet rat i ng oil to bolts and clamp nut s.
(3) Remove clamps, supports and bolts from ex-
haust pipe.
(4) Remove t he exhaust pipe.
(5) Clean ends of pipes to assure mat i ng of all
part s.
(6) Discard rusted clamps, broken or worn supports
and at t achi ng part s. Replace a component with orig-
inal equipment part s, or equivalent. This will assure
proper al i gnment with other part s in t he system and
provide acceptable exhaust noise levels.
INSTALLATION
(1) Assemble exhaust pipe, supports and clamps
loosely to permit proper al i gnment of all part s.
(2) Position t he exhaust pipe for proper clearance
with underbody part s.
(3) On models using ball-type connections, alter-
nately t i ght en bolts to assure flanges are even and
parallel.
(4) Tighten all clamp nut s, bolts and support
bracket nuts/bolts to t he proper torques (Refer to
Figs. 1, 4, 5 and 6).
(6) St art t he engine and check for leaks.
CATALYTIC CONVERTERS
Refer to Figs. 1, 4, 5 and 6 for t he following proce-
dure.
REMOVAL
(3) Remove clamps, isolators and bolts.
(4) Remove t he catalytic converter.
(5) Clean ends of pipes and muffler to assure mat-
ing of all part s.
(6) Discard rust ed clamps, broken or worn isola-
tors, supports and at t achi ng part s. Replace a compo-
nent with original equipment part s, or equivalent.
This will assure proper alignment with other part s in
t he system and provide acceptable exhaust noise lev-
els.
INSTALLATION
(1) Assemble converter, isolators and clamps
loosely to permit proper alignment of all part s.
(2) Position t he converter for proper clearance with
exhaust heat shields and underbody part s.
Figs. 1, 4, 5 and 6).
MUFFLERS
Refer to Figs. 1, 2, 4, 5, 6 and 7 for t he following
procedure.
REMOVAL
(4) Remove t he muffler.
ing of all part s.
(6) Discard rusted clamps, broken or worn isola-
nent with original equipment part s, or equivalent.
This will assure proper alignment with other part s in
t he system and provide acceptable exhaust noise lev-
els.
INSTALLATION
(1) Assemble muffler, isolators and clamps loosely
to permi t proper alignment of all part s.
(2) Position t he muffler for proper clearance with
t he underbody part s.
Figs. 1, 2, 4, 5, 6 and 7).

EXHAUST TAILPIPE
Refer to Figs. 2, 4, 5, and 7 for t he following pro-
cedure.
REMOVAL
(4) Remove t he exhaust tailpipe.
ing of all part s.
(6) Discard rusted clamps, broken or worn isola-
nent with original equi pment part s, or equivalent.
This will assure proper al i gnment with other parts in
the system and provide acceptable exhaust noise lev-
els.
INSTALLATION
(1) Assemble exhaust tailpipe, isolators and clamps
loosely to permi t proper alignment of all part s.
(2) Position t he exhaust tailpipe for proper clear-
ance with t he underbody part s.
(3) Tighten all clamp nuts, bolts and support
Figs. 2, 4, 5 and 7).
(5) St ar t t he engine and check for leaks.
EXHAUST HEAT SHIELDS
Refer to Figs. 3, 4 and 8 for t he following proce-
dure.
REMOVAL
(2) Remove t he nut s or bolts holding the exhaust
heat shield to t he floor pan, crossmember or bracket.
(3) Slide t he shield out around t he exhaust system.
INSTALLATION
(1) Position t he exhaust heat shield to t he floor
pan, crossmember or bracket and install the nut s or
bolts.
(2) Tighten t he nut s and bolts to the proper torque
(refer to Figs. 3, 4 and 8).
i
11 - 6 EXHAUST SYSTEM AI D INTAKE MANIFOLD

HOLE LOCATION FOR SUPPORT
(4 WHEEL DRIVE)
REAR
CONVERTER
PIPE
( 115" WHEELBASE1
(131" WHEELBASE)
5.9L ENGINES
HANGER
ASSEMBLY
CONVERTER
PIPE
INSULATOR
MUFFLER
3.9L AND 5.2L ENGINES
J 9211- 16
Fig. 1 Single Exhaust SystemLight Duty Trucks (1 of 3)

INSULATOR
FRAME
SIDE RAIL
3.9L AND 5.2L
ENGINES
TAIL PIPE
TAIL PIPE
TAIL PIPE
EXTENSION
5.9L ENGINES
HANGER
ASSEMBLY
TAIL
PIPE
FRAME SIDE RAIL
INSULATOR
3.9L AND 5.2L
ENGINES J9211-17
Fig. 2 Single Exhaust SystemLight Duty Trucks (2 of 3)
Fig. 3 Single Exhaust System (Exhaust Heat Shields)Light Duty Trucks (3 of 3)

RETAINER
135" & 159" WHEELBASE
BRAKE
LINE
FRONT
SUSPENSI ON
CROSSMEMBER
BRAKE
LINE
SHIELD
(2 WHEEL DRIVE)
12.7 4.8 M M
(0.50 0.19 INCH)
TYPICAL SLIP JOINT
(MUST BE FULLY ENGAGED)
TIGHTENING TORQUE
2 6 N-m ( 1 9 FT. LBS.)
4 3 N-m ( 32 FT. LBS.)
2 3 N-m ( 200 I N. LBS.)
1 4 N-m ( 1 25 I N. LBS.)
5 4 N-m ( 4 0 FT. LBS.)
J 9 2 1 1 - 1 9
Fig. 4 Dual Exhaust System (5.9L Engines)Heavy Duty Trucks (1 of 2)
EXHAUST
PIPE
BRACE
MA N U A L TRANS.
EXHAUST
PIPE
BRACE
AUTO TRANS.
BRACKET
ISOLATORS
MUFFLER
PIPE
FRAMERAIL
131 " WHEELBASE
135" WHEELBASE
FRAMERAIL
\
135" WHEELBASE
131" WHEELBASE
ISOLATORS
159" WHEELBASE
MUFFLER
PIPE
131 " & 135" WHEELBASE
FRAMERAIL
BRACKET
CONVERTER
PIPE
FRAMERAIL
TIGHTENING TORQUE
23 N-m (200 IN. LBS.)
14 N-m (125 IN. LBS.)
28 N-m (250 IN. LBS.)
J9211-20
Fig. 5 Dual Exhaust System (5.9L Engines)Heavy Duty Trucks (2 of 2)
EXHAUST SYSTEM AND INTAKE MANIFOLD 1 1 - 1 1
RETAINER CATALYTIC
CONVERTER
PIPE
HEAT
SHIELD
FRAMERAIL
J9211-22
Fig. 6 Sport Utility Exhaust System (1 of 3)
11- 12 EXHAUST SYSTEM AND INTAKE MANIFOLD

Fig. 7 Sport Utility Exhaust System (2 of 3)

EXHAUST SYSTEM AND INTAKE MANIFOLD 11- 13
TIGHTENING TORQUE
23 N-m (200 I N. LBS.)
7 N-m (65 I N. LBS.)
5 N-m (40 I N. LBS.)
HEAT
SHIELD
CATALYTIC
CONVERTER
LOWER HEAT SHIELD
HEAT
SHIELD
UPPER
H E AT SHIELD
CROSSMEMBER
SKID PLATE
UPPER HEAT SHIELD
(6 I N. RAI L)
C ONE D WASHER
UPPER HEAT SHIELD
(7 I N. RAIL)
J9211-21
Fig. 8 Sport Utility Exhaust SystemExhaust Heat Shields (3 of 3)
INTAKE MANIFOLD
The al umi num i nt ake manifold is a single plane
design with equal length runners. The manifold is
sealed by flange side gaskets with front and rear
cross-over gaskets. The i nt ake manifold has i nt ernal
EGR.
REMOVAL
(2) Drai n t he cooling system (refer to Group 7,
Cooling System for t he proper procedures).
(3) Remove t he generator.
(4) Remove t he ai r cleaner.
(6) Disconnect t he accelerator linkage and if so
down cables.
(7) Remove t he r et ur n spring.
(8) Remove t he distributor cap and wires.
(10) Disconnect t he heat indicator sending uni t
wire.
(11) Disconnect t he heat er hoses and bypass hose.
(12) Remove t he closed crankcase ventilation and
evaporation control systems.
(13) Remove i nt ake manifold bolts.
(14) Lift t he i nt ake manifold and throttle body out
of t he engine compart ment as an assembly.
(15) Remove and discard t he flange side gaskets
and t he front and r ear cross-over gaskets.
(16) Remove t he t hrot t l e body bolts and lift t he
t hrot t l e body off t he i nt ake manifold (Fig. 9). Discard
t he gasket.
(17) Remove t he pl enum pan as follows:
THROTTLE
BODY (MPI)
J9209-68
Fig. 9 Throttle Body AssemblyMPI
(a) Turn t he i nt ake manifold upside down. Sup-
port t he manifold.
(b) Remove the bolts and lift t he pan off t he
manifold. Discard t he gasket.
CLEANING
Clean manifold in solvent and blow dry wi t h com-
pressed air.
using a suitable solvent.

The pl enum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mat i ng surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) Install t he plenum pan, if removed, as follows:
(a) Turn t he i nt ake manifold upside down. Sup-
port t he manifold.
(b) Place a new plenum pan gasket onto t he seal
rai l of t he i nt ake manifold. Position t he pan over
t he gasket. Align all t he gasket and pan holes with
t he i nt ake manifold.
(c) Hand st art all bolts.
(d) Tighten t he bolts, in sequence (Fig. 10), as
follows:
V- 6 V- 8
Fig. 10 Plenum Pan Bolt Tightening Sequence
Step 1- Ti ght en bolts to 2.7 N*m (24 in. lbs.)
torque.
Step 2- Ti ght e n bolts to 5.4 Nm (48 in. lbs.)
torque.
Step 3- Ti ght e n bolts to 9.5 Nnn (84 in. lbs.)
torque.
Step 4Check t hat all bolts are t i ght en to 9.5 Nm
(2) Using a new gasket, install t he t hrot t l e body
onto t he i nt ake manifold. Tighten t he bolts to 23
Nun (200 in. lbs.) torque.
(4) Apply MOPAR Silicone Rubber Adhesive Seal-
cessive amount of sealant is not required to ensure a
sealant may reduce t he effectiveness of t he flange
gasket. The sealant should be slightly higher t han
(5) Install the front and rear cross-over gaskets
\
Fig 11 Cross-Over Gaskets and Locator Dowels
(6) Install t he flange gaskets. Ensure t hat t he ver-
tical port alignment t ab is rest i ng on t he deck face of
t he block. Also t he horizontal alignment t abs must
be in position with the mat i ng cylinder head gasket
t abs (Fig. 12). The words MANIFOLD SIDE should
be visible on t he center of each flange gasket.
alignment dowels in t he cross-over gaskets to posi-
(8) Install t he i nt ake manifold bolts and t i ght en as
follows:
V-6 ENGINE(Fi g. 13)
Step 1- Ti ght en bolts 1 and 2 to 8 Nun (72 in. lbs.)
torque. Tighten in al t ernat i ng steps 1.4 Nun (12 in.
lbs.) torque at a time.
to 8 Nun (72 in. lbs.) torque.
Step 3Check t hat all bolts are t i ght en to 8 Nun
Step 4Tighten all bolts, in sequence, to 16 Nun
Step 5Check t hat all bolts are t i ght en to 16 Nun
EXHAUST SYSTEM AND INTAKE MANIFOLD 11- 15
FLANGE GASKET
\
o
o
CYLINDER
HEAD GASKET
J9209- 1 01

INTAKE
MANI FOLD
FRONT OF E NGI NE
J9209- 59
Fig. 13 Intake Manifold Bolt Tightening
Sequence3.9L Engines
V-8 ENGINE(Fig* 14)
8 Nun (72 in. lbs.) torque. Tighten in al t ernat i ng
steps 1.4 Nun (12 in. lbs.) torque at a time.
FRONT
OF ENGINE
J9209- 6 0
Fig. 14 Intake Manifold Bolt Tightening
Sequence5.2L Engines
to 8 Nun (72 in. lbs.) torque.
Step 3Check t hat all bolts are tighten to 8 Nun
Step 4Tighten all bolts, in sequence, to 16 Nun
Step 5Check t hat all bolts ar e t i ght en to 16 Nun
(9) Install closed crankcase ventilation and evapo-
rat i on control systems.
(10) Connect t he coil wires.
(11) Connect the heat indicator sending uni t wire.
(12) Connect the heat er hoses and bypass hose.
(14) Hook up t he ret urn spring.
down cables.
(16) Install t he fuel lines,
generator mounting bolt to 41 Nun (30 ft. lbs.)
torque. Tighten t he adjusting st rap bolt to 23 Nun
t em for t he proper adjusting of belt tension.
(18) Install t he ai r cleaner.
ENGINE EXHAUST MANIFOLD
Engi ne exhaust manifolds are LOG type with port-
ing for air injection into t he LOG.
REMOVAL
(3) Remove t he bolts and nut s at t achi ng t he ex-
haust pipe to t he engine exhaust manifold.
(5) Remove t he exhaust heat shields.

(6) Remove bolts, nut s and washers at t achi ng
manifold to cylinder head.
(7) Remove manifold from t he cylinder head.
CLEANING
Clean mat i ng surfaces on cylinder head and mani -
fold. Wash wi t h solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks.
Inspect mat i ng surfaces of manifold for flatness
with a st rai ght edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
C A U T I O N : If the studs came out with the nuts when
removing the engine ex haust 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 t he engine exhaust manifolds on t he
two studs located on t he cylinder head. Install coni-
cal washers and nut s on these studs (Fig. 15 or 16).
(2) Install two bolts and conical washers at t he in-
ner ends of t he engine exhaust manifold outboard
arms. Install two bolts WITHOUT washers on t he
center ar m of engine exhaust manifold (Fig. 15 or
16). St art i ng at t he center ar m and working outward,
t i ght en t he bolts and nut s to 34 N t h (25 ft. lbs.)
torque.
(3) Install t he exhaust heat shields.
(5) Assemble exhaust pipe to manifold and secure
with bolts, nut s and ret ai ners. Tighten t he bolts and
nut s to 26 N - m (19 ft. lbs.) torque.
Fig. 15 Engine Exhaust Manifold Installation3.9L
Engine
J9311-11
Fig. 16 Engine Exhaust Manifold Installation5.2U
5.9L Engines

EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 17
8ERY1CE PROCEDURES ( DI E SE L E N GI N E S)
INDEX
page
Charge Air Cooler (Intercooler) 25
Engine Ex haust Manifold 1 8
Ex haust Pipe 17
Ex haust Tailpipe 18
EXHAUST PIPE
REMOVAL
(1) Remove t he clamp t hat holds t he front exhaust
pipe clamp to t he turbocharger (Fig. 1).
Fig. 1 Exhaust Pipe to Turbocharger Clamp
(3) Remove t he bolt from t he exhaust pipe support
st rap (Fig. 2) .
(4 ) Remove t he clamp nut s (Fig. 2) .
(5) Separate t he exhaust pipe from t he front ex-
haust extension pipe (Fig. 2) .
TURBOCHARGER WELD FRONT EXHAUST
CLAMP JOINT PIPE
SUPPORT STRAP PIPE
J 9 1 1 M
Fig. 2 Front Exhaust Pipe Mounting and Clamps
page
Intake Manifold Cover / Air Intake Heater 19
Muffler and Ex tension Pi pes 17
Turbocharger 21
INSTALLATION
(1) Align t he front exhaust pipe with t he front ex-
haust extension pipe and t he turbocharger exhaust
outlet.
(2) Install t he exhaust pipe support st rap. Tighten
the nut to 4 1 Nun (30 ft. lbs.) torque.
(3) Install t he exhaust pipe support clamps and
nuts. Tighten the nut s to 54 Nun (4 0 ft. lbs.) torque.
(5) Install t he turbocharger clamp and t i ght en t he
screw to 8 Nun (74 in. lbs.) torque (Fig. 2) .
MUFFLER AND EXTENSION PIPES
Rear extension pipes are used on t he 1 35 inch, 14 9
inch and 1 59 inch wheelbase vehicles.
REMOVAL
(2) Remove t he clamps and nut s from t he front ex-
tension pipe. Remove t he clamps and nut s from t he
rear extension pipe or from t he muffler rear exten-
sion pipe (Fig. 3).
Fig. 3 Muffler and Extension Pipe(s)
1 1 - 1 8 EXHAUST SYSTEM AND INTAKE MANIFOLD
MUFFLER REAR
SUPPORT BRACKET
MUFFLER FRONT
SUPPORT BRACKET
159" W. B. ) - 2 REQUIRED
MUFFLER
INSULATOR
FRAME
RAIL
/
SHOULDER
BOLT
MUFFLER
INSULATOR
MUFFLER FRONT
SUPPORT BRACKET
(131", 135" & 149" W.B.]
1 REQUIRED
SHOULDER BOLTS J9211-26
Fig. 4 Muffler Front/Rear Support Brackets
(3) Remove t he shoulder bolts from t he muffler
front and rear support bracket s (Fig. 4).
(4) Separat e t he extension(s) and t he muffler from
t he exhaust tailpipe and t he front exhaust pipe.
(5) If required, remove t he muffler support bracket
from t he frame rai l (Fig. 4).
INSTALLATION
(1) If removed, install t he muffler support bracket
to t he frame rail. Tighten t he bolts to 28 Nun (250
in. lbs.) torque.
(2) Align t he extension(s) and t he muffler wi t h t he
front exhaust pipe and t he exhaust tailpipe.
(3) Install t he shoulder bolts t hrough t he insula-
tors and into t he muffler front and rear support
brackets (Fig. 4). Tighten t he bolts to 28 N-m (250
in. lbs.) torque.
(4) Position t he clamps onto t he front exhaust ex-
tension pipe. Tighten t he nut s to 54 Nun (40 ft. lbs.)
torque.
(5) Position t he clamps onto t he rear exhaust ex-
tension pipe or onto t he muffler rear extension pipe.
Tighten t he nut s to 54 Nun (40 ft. lbs.) torque.
EXHAUST TAILPIPE
REMOVAL
(2) Remove t he clamp from t he pipe (Fig. 5).
(3) Remove t he bolt from t he exhaust tailpipe
bracket.
(4) Separat e t he exhaust tailpipe from t he rear ex-
tension pipe or from t he muffler rear extension pipe.
(5) If required, remove t he exhaust tailpipe
bracket from t he frame rai l (Fig. 5).
TAIL PIPE
BRACKET J9211-25
Fig. 5 Exhaust Tailpipe
INSTALLATION
(1) If removed, install t he exhaust tailpipe bracket
to t he frame rail. Tighten t he bolts to 23 Nun (200
in. lbs.) torque.
(2) Position t he exhaust tailpipe into t he rear ex-
tension pipe or t he muffler rear extension pipe.
(3) Install t he bolt into t he exhaust tailpipe
bracket. Tighten t he bolt to 23 Nun (200 in lbs.)
torque.
(4) Position t he clamp onto t he exhaust tailpipe.
ENGINE EXHAUST MANIFOLD
REMOVAL
(1) Disconnect t he air i nt ake and exhaust pipes
(Fig. 6).
(2) Disconnect t he turbocharger oil supply line and
t he oil drai n t ube from t he turbocharger (Fig. 7).
(3) Disconnect t he charge air cooler (intercooler)
inlet duct from t he turbocharger (Fig. 7).
(4) Remove t he turbocharger and gasket.
(5) Remove t he cab heat er supply and r et ur n lines.
(6) Remove t he engine exhaust manifold and gas-
ket s (Fig. 8).
(7) Clean t he sealing surfaces.
INSTALLATION
(1) Install t he engine exhaust manifold and gas-
kets. Tighten t he exhaust manifold bolts in sequence
to 43 Nun (32 ft. lbs.) torque (Fig. 9).
(2) Install t he turbocharger. Tighten t he turbo-
charger mount i ng nut s to 32 Nun (24 ft. lbs.) torque.
EXHAUST
MANI FOLD
GASKET
J9111-52
Fig. 6 Air intake Pipe, Exhaust Pipe and
Turbocharger
, t i l l
TURBOCHARGER,
OI L SUPPLY
UNE
^ J91 1 1 - 53
Fig. 7 OH Supply Line and Charge Air Cooler
(intercooler) inlet Duct
(3) Position t he charge air cooler (intercooler) inlet
duct to t he turbocharger. With t he clamp in position,
t i ght en t he clamp nut to 8 Nun (72 in. lbs.) torque.
(4) Position t he air i nt ake pipe and t he exhaust
pipe onto t he turbocharger. Ti ght en t he clamps to 8
Nun (74 in. lbs.) torque.
(5) Install t he oil drain t ube and oil supply line to
t he turbocharger. Tighten t he drai n t ube bolts to 24
J9111-5
Fig. 8 Engine Exhaust Manifold and Gaskets
EXHAUST
M A N I F O L D ^ ^ ^ ^
GASKET
J9111-6
Fig. 9 Engine Exhaust Manifold Bolt Tightening
Sequence
Nun (18 ft. lbs.) torque. Tighten t he oil supply line
fitting nut to 15 Nun (11 ft. lbs.) torque.
(6) Connect t he cab heat er supply and r et ur n lines.
Tighten t he line nut s to 24 Nun (18 ft. lbs.) torque.
(7) Operate t he engine to check for leaks.
INTAKE MANIFOLD COVER / AIR INTAKE HEATER
REMOVAL
(1) Remove t he charge air cooler (intercooler) out-
let duct from t he air inlet t ube (Fig. 10).
(2) Remove t he high pressure fuel lines.
(3) Disconnect and remove the air i nt ake heat er
ground wire (Fig. 10).
(4) Disconnect t he ai r i nt ake heat er power supply
lines (Fig. 11). Remove t he air i nt ake heat er and
gaskets (Fig. 11). Clean t he mounting surface of t he
i nt ake manifold cover.
(5) Disconnect t he charge air t emperat ure sensor
from t he i nt ake manifold cover (Fig. 12).
(6) Disconnect t he air t emperat ure switch from t he
i nt ake manifold cover (Fig. 12).
1 1 - 2 0 EXHAUST SYSTEM AND INTAKE MANIFOLD
AIR INLET
I NTERCOOLER/
OUTLET DUCT
X^l /J9111-54.
Fig. 10 Air Inlet Tube and Heater Ground Wire
J9111-51
Fig. 11 Air Intake Heater
(7) Disconnect t he fuel heat er ground wire from in-
t ake manifold cover (Fig. 13).
(8) Remove t he manifold i nt ake cover and gasket
(Fig. 13). Keep t he gasket mat eri al and any other
mat eri al out of t he ai r i nt ake.
(9) Clean t he sealing surface.
INSTALLATION
(1) Using a new gasket, install t he i nt ake manifold
cover.
(2) Install t he fuel heat er ground wire. Tighten t he
bolt to 12 Nun (110 in. lbs.) torque.
(3) Connect t he air t emperat ure switch to t he in-
t ake manifold cover.
(4) Connect t he charge ai r t emperat ure sensor to
t he i nt ake manifold cover.
AIR
TEMPERATURE
SWITCH
(KSB SOLENOID)
J9114-235
Fig. 12 Charge Air Temperature Sensor and Air
Temperature Switch
AAANIFOLD
INTAKE
COVER
FUEL HEATER
G R O U N D WIRE
J9111-50
Fig. 13 Manifold Intake Cover and Fuel Heater
Ground Wire
(5) Some of t he i nt ake manifold bolt holes are
drilled t hrough and must be sealed. Apply liquid te-
flon sealant to t he bolts. Install t he i nt ake manifold
cover bolts. Tighten t he bolts to 24 Nun (18 ft. lbs.)
torque.
(6) Install a new gasket between t he air i nt ake
heat er and t he i nt ake manifold cover. Install a new
gasket on top of t he air i nt ake heater.
(7) Install t he air inlet tube. Tighten t he air inlet
t ube bolts to 24 Nun (18 ft. lbs.) torque.
(8) Connect t he i nt ake manifold heat er ground
wire.
(9) Install and t i ght en t he air i nt ake heat er power
supply nut s to 14 Nun (10 ft. lbs.) torque.
(10) Position t he charge air cooler (intercooler) out-
let duct onto t he air inlet tube. Tighten t he charge
air cooler (intercooler) outlet duct clamps to 8 Nun
(11) Install and bleed t he high pressure fuel lines.
Tighten t he high pressure fuel line nut s to 24 Nun

TURBOCHARGER
REMOVAL
(2) Disconnect t he air i nt ake pipe and exhaust pipe
(Fig. 14).
Fig. 14 Air Intake Pipe, Exhaust Pipe and
Turbocharger
(3) Remove t he oil drai n tube bolts.
(4) Remove t he oil supply line (Fig. 15).
(5) Disconnect t he charge air cooler (intercooler)
inlet duct from t he turbocharger (Fig. 15).
(6) Remove t he turbocharger mount i ng nut s and
the turbocharger.
(7) If t he turbocharger is not to be installed imme-
diately, cover t he opening to prevent mat eri al from
entering into t he manifold.
(8) Clean and inspect t he sealing surface.
DISASSEMBLY
(1) Scribe t he housing so they can be assembled in
t he same position.
(2) Clamp t he turbocharger in a bench vise.
(3) Remove t he compressor housing V-Band clamps
(Fig. 16).
(4) Remove t he compressor housing and inspect for
impeller contact (Fig. 16).
(5) Remove t he square cut O-ring (Fig. 16).
(6) Remove t he impeller nut (Fig. 16). Turn t he
impeller nut to the ri ght to loosen. The nut and shaft
have left hand t hreads.
(7) Remove t he impeller and inspect t he blades for
damage. The wheel and shaft assembly is balanced
as a unit. If t he impeller is damaged t he complete as-
sembly must be replaced.
Fig. 16 Compressor Housing and Impeller
(8) Remove t he diffuser bolts and lockplate (Fig.
17).
(9) Remove t he diffuser and discard t he O-ring
(Fig. 18).
(10) Remove t he oil slinger and discard t he piston
ri ng (Fig. 18).
(11) Inspect for cracks and excessive wear.
(12) Remove t he oil baffle (Fig. 19).
(13) Remove t he t hr ust bearing and ret ai ner
screws (Fig. 19). Do not reuse t he t hrust bearing.
(14) Remove t he t hr ust collar (Fig. 19).
(15) Inspect t he collar for excessive wear.
(16) Remove t he t urbi ne housing lock plates and
clamp plates (Fig. 20).
(17) Remove t he beari ng housing (Fig. 20).

DIFFUSER
TURBINE
HOUS I NG
O- RI NG
BEARI NG
HOUS I NG
LOCKPLATE
J9111-9
Fig. 17 Diffuser and Lockplate
OIL
SLINGER
MO
Fig. 18 Diffuser, O-Ring and Oil Slinger
THRUST
COLLAR
OIL
BAFFLE
J9111-11
Fig. 19 Oil Baffle, Thrust Bearing and Collar
(18) Remove t he t urbi ne shaft and heat shield
(Fig. 21).
(19) Inspect t he t urbi ne blades and t he shaft for
excessive wear.
LOCK
PLATE
J9111-12
Fig. 20 Turbine Housing Lock Plates and Clamp
Plates
TURBINE WHEEL
SHAFT
PISTON RI NG
TYPE SEAL
J9111-13
HEAT
SHIELD
Fig. 21 Turbine Wheel Shaft and Heat Shield
(20) Remove and discard t he piston ri ng type seal
(Fig. 21).
C A U T I O N : The wheel and shaft assembl y i s bal-
anced a s a unit. If the turbine bl ades or shaft are
damaged, the complete assembl y must be replaced.
(21) Remove and discard t he outer ret ai ner rings
(Fig. 22).
(22) Remove and discard t he turbocharger shaft
beari ngs (Fig. 22).
(23) Remove and discard t he i nner snap ri ngs (Fig.
22).
CLEANING
Use a stiff bristle nylon brush and solvent to clean
all part s. Do not use a wire brush on t he compressor
wheel. Do not bead blast t he part s.
Remove t he carbon build up from t he housing with
a scraper and a 240 grit emery cloth.
Polish t he beari ng surfaces with crocus and kero-
sene or diesel fuel.
After rinsing in clean solvent, use compressed air
to dry t he part s.
INSPECTION
In addition to t he inspection specified duri ng disas-
sembly, inspect all part s after cleaning.
HEAT SHIELD
OUTER RETAINER
RI NGS
BREAKI NG,
HOUS I NG
J9111-18
Fig. 24 Turbine Shaft/Heat Shield to Bearing
Housing
I NNER
RETAI NI NG
RI NGS
I NNER
RETAI NI NG
RI NG
J9111-14
Fig. 22 Snap Rings and Shaft Bearing
Measure t he shaft bearing diameter (Fig. 23). The
mi ni mum diameter should be 10.97 mm (0.432 inch).
SHAFT BEARI NG
DIAMETER
Fig. 25 Beveled Face of Inner Retainer Ring
J911M6
OUTER
RETAI NI NG
RI NG
J9111-15
Fig. 23 Shaft Bearing Diameter
ASSEMBLE
The balance mar ks must be aligned to make sure
t he wheel and shaft assembly is balanced.
(1) Install t he piston ring and lubricate t he groove
with engine oil.
(2) Install t he heat shield (Fig. 24).
(3) Clamp a socket in a soft jawed vice and posi-
tion t he shaft in t he socket.
(4) Install t he inner retainer rings. The beveled
face must be towards the bearing (Fig. 25).
(5) Lubricate t he turbocharger bearing with engine
oil and install t he bearings in t he housing.
(6) Install t he outer retainer ring. The beveled face
must be towards t he bearings (Fig. 26).
(7) Assemble t he turbine shaft and heat shield to
t he beari ng housing. Rotating the housing as you
press downward will assist in properly seating t he
piston ring.
OUTER
RETAI NI NG
RI NG
J9111-17
Fig. 26 Beveled Face of Outer Retainer Ring
(8) Install t he t hrust collar. Align t he balance
mark with the balance mar k on t he shaft. Mark t he
top surface with a marker pen so alignment can be
verified after installing t he t hr ust bearing.
(9) Lubricate t he t hrust beari ng with engine oil
and install it on t he housing. Tighten t he torx bolts
to 4.5 Nm (40 in. lbs.) torque.
(10) Install t he oil baffle. Check t he balance mar k
alignment.
(11) Install t he piston ri ng type seal on t he oil
slinger (Fig. 27).
Fig. 27 Piston Ring Type Seal
(12) Mark t he top surface of t he oil slinger line
with t he balance mark.
(13) Lubricate t he oil slinger with engine oil and
install it into t he diffuser.
(14) Install t he O-ring into t he diffuser.
(15) Install t he diffuser. Align t he balance mar ks
on t he shaft and t he oil slinger (Fig. 28).
Fig. 28 Align Balance MarksShaft and Oil Slinger
(16) Align t he balance mar k and install t he impel-
ler (Fig. 29). Be careful not to move t he beari ng
housing.
(17) Do not allow t he impeller to t ur n when in-
stalling t he nut . The impeller nut and t he shaft have
LEFT hand t hreads. Tighten t he nut to 14 N-m (129
in. lbs.) torque.
(18) Install t he beari ng housing assembly into t he
t urbi ne housing (Fig. 30).
(19) Align t he scribe mar ks (Fig. 30).
(20) Apply anti-seize compound to t he bolt t hreads.
(21) Install t he clamp plates, lock plates and bolts
(Fig. 31). Ti ght en t he bolts to 11.3 N-m (100 in. lbs.)
torque.
Fig. 29 Align Balance MarksImpeller
Fig. 30 Bearing Housing Assembly/Turbine Housing
Fig. 31 Install Clamp Plates/Lock Plates
(22) Install t he lock plates and bolts into t he dif-
fuser (Fig. 32).
(23) After t i ght eni ng t he bolts to 5.7 N-m (50 in.
lbs.) torque, bend t he lockplate t abs to lock t he bolts.
Be sure t he scribe mar ks are aligned.

Fig. 32 Diffuser and Lockpiate
(24) Measure t he end play (Fig. 33). For turbo-
charger with a serial number before 840638 t he end
play should be 0.102-0.152 mm (0.004-0.006 inch).
For turbocharger with a serial number of 840638 and
after t he end play should be 0.026-0.076 mm (0.001-
0.003 inch).
(25) Measure radial clearance of t he shaft (Fig.
33). The clearance should be 0.300-0.460 mm (0.012-
0.018 inch).
Fig. 33 End Play/Radial Clearance of Shaft
(26) Install t he square cut O-ring.
(27) Be sure t he scribe mar ks are aligned. Install
t he compressor housing and V-Band clamp. Apply
anti-seize compound to the V-Band bolt threads.
Tighten t he clamp to 8 N-m (72 in. lbs.) torque. Tap
against t he clamp on 4 places around its circumfer-
ence. Again t i ght en t he clamp to 8 N-m (72 in. lbs.)
torque.
INSTALLATION
(1) Install a new gasket and apply anti-seize com-
pound to t he mounting studs.
(2) Install t he turbocharger. Tighten the turbo-
charger mounting nut s to 32 N-m (24 ft. lbs.) torque.
(3) Use a new gasket and connect t he drain line.
Tighten t he drain line connection bolts to 24 N-m (18
ft. lbs.) torque.
(4) New turbocharger must be pre-lubricated with
clean engine lubricating oil before st art up. Pour
50-60 cc (2-3 ounces) of oil into supply fitting.
WA R N I N G : D O N OT U S E Y O U R F I N G E R T O T U R N
T HE T U R BI N E WH E E L .
(5) Rotate t he t urbi ne wheel to allow oil to enter
t he turbocharger.
(6) Install t he oil supply line. Tighten the oil sup-
ply line fitting nut to 15 N-m (11 ft. lbs.) torque.
(7) Position t he Charge air cooler (intercooler) in-
let duct to t he turbocharger. With t he clamp in posi-
tion, t i ght en t he clamp nut to 8 N-m (72 in. lbs.)
torque.
(8) Position t he air i nt ake pipe and the exhaust
pipe onto the turbocharger. Tighten t he clamps to 8
(10) Operate t he engine and check for leaks.
CHARGE AIR COOLER (INTERCOOLER)
Int ake air is drawn t hrough t he air cleaner and
into t he turbocharger compressor housing. Pressur-
ized air from t he turbocharger t hen flows forward
t hrough t he charge ai r cooler (intercooler) located in
front of the radiator. From t he charge air cooler (in-
tercooler) the ai r flows back into t he i nt ake manifold.
The charge air cooler (intercooler) is a heat ex-
changer t hat uses air flow to dissipate heat from t he
i nt ake air. As t he turbocharger increases air pres-
sure, t he air t emperat ure increases. Lowering t he in-
t ake air t emperat ure increases engine efficiency and
power.
REMOVAL
WA R N I N G : IF T HE E N G I N E WA S J U S T T U R N E D
O F F , T HE I N T A K E A N D O U T L E T D U C T S M A Y B E
HOT .
(1) Remove t he grille (refer to Group 23, Body for
(2) Remove t he front support bracket (Fig. 34).
(3) If the vehicle is equipped with air conditioning,
remove t he condenser as follows:
(a) Discharge t he air conditioning system (refer
to Group 24, Heat i ng and Air Conditioning for t he
proper procedures).
(b) Remove t he bolt from t he sealing plate (Fig.
34).
(c) Remove t he nut s holding t he condenser to t he
charge air cooler (intercooler) (Fig. 34). Lift t he

condenser and sealing plate assembly away from
t he charge air cooler (intercooler).
Fig. 34 Condenser and Charge Air Cooler
(Intercooler)
(4) Remove t he inlet and outlet ducts from t he
charge air cooler (intercooler)(Fig. 35).
(5) Remove t he charge air cooler (intercooler) bolts.
Pivot t he charge air cooler (intercooler) forward and
up to remove.
INSTALLATION
(1) Position t he charge air cooler (inter-
cooler)(Fig. 34). Install t he bolts and t i ght en to 2
Fig. 35 Charge Air Cooler (Intercooler) Ducts
(2) Install t he inlet and outlet ducts to t he charge
ai r cooler (intercooler)(Fig. 35). With t he clamps in
position, t i ght en t he clamp nut to 8 N-m (72 in. lbs.)
torque.
(3) If t he vehicle is equipped wi t h air conditioning,
install t he condenser as follows:
(a) Position t he condenser and sealing plate as-
sembly onto t he charge air cooler (intercooler)
studs. Install t he nut s and tighten.
(b) Connect t he halves of t he sealing plate (Fig.
34). Install t he bolt and tighten.
(c) Charge t he air conditioning system (refer to
Group 24, Heat i ng and Air Conditioning for t he
proper procedures).
(4) Install t he front support bracket (Fig. 34). In-
stall and t i ght en t he bolts.
(5) Install t he grille (refer to Group 23, Body for

EXHAUST SYSTEM AND INTAKE MANIFOLD 11- 2 7
TURBOCHARGER SPECIFICATIONS
C O M PO N E N T D I M E N S I O N S
Air Intake Restrictions 635 mm Water (25 in. Water) Max.
Turbo Radial Clearance 0.300-0.460 mm (0.012-0.018 inch)
Turbo Rotor Assembly End Play
Before S/N 840638 0.102-0.152 mm (0.004-0.006 inch)
S/N 840638 AND AFTER . 0.026-0.076 mm (0.001-0.003 inch)
Turbo Shaft Bearing Diameter 10.97 (0.432 inch)
J9111-26

D E S C R I PT I O N T O R QU E DESCRIPTION T O R QU E
Adjusting Strop Bolt 23 N-m (200 in. lbs.)
Air Heater Power Supply Nuts 14 N-m (10 ft. lbs.)
Cab Heater Supply/Return Line Nuts 24 N-m (18 ft. lbs.)
Catalytic Converter-to-Muffler
Clamp Nuts 43 N-m (32 ft. lbs.)
Head Bolts (5.9L Diesel) 4 3 N-m (32 ft. lbs.)
Exhaust Pipe-to-Catalytic
Converter Clamp Nuts 43 N-m (32 ft. lbs.)
Exhaust Pipe-to-Exhaust
Manifold Bolts/Nuts 26 N-m (19 ft. lbs.)
Fuel Heater Ground Bolt . 12 N-m (110 in. lbs.)
Fuel Line Nuts 24 N-m (18ft. lbs.)
Intake ManiFolcf Capbolts Refer to Procedure i n
Service Manual.
Intake Manifold Cover Bolts 24 N-m (18 ft. lbs.)
Intercooler Attaching Bolts............................. 2 N-m (17 in. lbs.)
Intercooler Duct Clamp Nuts 8 N-m (72 in. lbs.)
Muffler-to-Tail Pipe Clamp Nuts 43 N-m (32 ft. lbs.)
Plenum Pan Bolts (3.9L & 5.2L)
1st Step 2.7 N-m (24 in. lbs.)
2nd Step 5.4 N-m (48 in. lbs.)
3rd Step 9.5 N-m (84 in. lbs.)
Throttle Body (MPI) Bolts 23 N-m (200 in. lbs.)
Throttle Control Bracket
Mounting Bolts 24 N-m (18 ft. lbs.)
Thrust Bearing Torx Bolts............................ 4.5 N-m (40 in. lbs.)
Turbocharger Bearing Housing/
Diffuser Bolts 5.7 N-m (50 in. lbs.)
Turbocharger Bearing Housing/
Turbine Housing Bolts 11.3 N-m (100 in. lbs.)
Turbocharger Impeller Nut 14 N-m (129 in. lbs.)
Turbocharger Mounting Nuts 32 N-m (24 ft. lbs.)
Turbocharger Oil Drain Tube Bolts... 24 N-m (18 ft. lbs.)
Turbocharger Oil Supply Line Fitting Nut.. 15 N-m (11 ft. lbs.)
Turbocharger V-Band Clamp 8.5 N-m (75 in. lbs.)
J9311-12
FRAME AND BUMPERS 13 - 1
CONTENTS
page page
ATTACHED COMPONENTS .
B B
.
B
.
B
. 30 FRAME 20
BUMPERS 1 SNOW PLOW 3
BUMPERS
FRONT BUMPER
REMOVAL/DISASSEMBLY
(1) Support bumper.
(2) Remove bumper nut s and bolts from t he
bumper brackets.
(3) Remove support and bumper from vehicle.
(4) Remove nut s and bolts, and bumper brackets
from frame rails.
INSTALLATION
(1) Position t he bumper brackets on t he frame
rails. Install bolts and nut s. Tighten to 68 Nnn (50 ft.
lbs) torque.
(2) Position and support t he bumper at t he front of
t he vehicle. Align bumper bolt holes with bracket
holes.
(3) Insert bumper bolts in brackets. Install nut s.
Verify t he bumper is aligned with grille and fenders.
Tighten nut s to 41 N*m (30 ft. lbs.) torque.
REAR BUMPER
TEMPORARY BUMPER
REMOVAL
(1) Support bumper.
(2) Remove bumper bracket nut s and bolts from
t he frame rails.
(3) Remove support and remove bumper from t he
vehicle.
STANDARD BUMPER
REMOVAL
(1) Support t he bumper,
(2) Remove bumper nut s and bolts from t he frame
side rai l s and bumper brackets.
(3) Remove support and bumper from vehicle.
(4) Remove nut s and bolts, and remove bumper
bracket s from bumper.
BOLT FRAME
RAIL
NUT-LOCK
NUT
BUMPER
BRACKET
J9123-326
Fig. 1 Front Bumper
INSTALLATION
(1) Position t he bumper brackets on t he bumper
with t he bolt holes aligned. Install t he bolts and
nut s. Tighten to 41 Nm (30 ft. lbs.) torque.
(2) Position and support t he bumper at t he rear of
t he vehicle. Align t he bumper bracket bolt holes with
t he frame side rail holes.
(3) Insert bumper bracket bolts in t he brackets and
t he frame side rails. Install nut s. Verify bumper is
aligned with t he rear corner panels. Tighten t he nut s
(4) Remove t he support from t he bumper.
BUMPER FILLER PANEL-RAMCHARGER
REMOVAL
(1) Remove the filler panel screws from t he rear
cross sill.
F R A M E A N D B U M P E R S
13 - 2 FRAME AND BUMPERS

Fig. 2 Standard Rear Bumper
(2) Remove t he filler panel from t he rear cross sill
and rear bumper.
INSTALLATION
(1) Position t he filler panel lip under t he rear
bumper. Position t he flange against t he r ear cross
sill.
(2) Align t he filler panel flange screw holes with
t he sill holes. Install t he screws. Tighten t he screws
until t he heads are seated.
TO SILL BUMPE R J 912 3- 361
Fig. 3 Bumper Filler Panel
STEP BUMPER
REMOVAL
(1) Remove t he wire harness clip ret ai ners. Discon-
nect t he bulb sockets from each license pl at e lamp.
Detach t he wire harness from t he step bumper (Fig.
4).
(2) Support t he step bumper.
(3) Remove t he nut s and bolts t hat at t ach each
bumper support bracket and brace to t he frame rails
(Fig. 5) .
(4) Lower t he bumper and remove as a unit.
(5) Remove t he bracket and brace bolts to t he
bumper. Remove t he brackets and braces from t he
bumper (Fig. 5).
INSTALLATION
(1) Attach brackets and braces to t he bumper with
t he bolts and nut s. Tighten t he support bracket nut s
to 68 N*m (50 ft. lbs.) torque. Tighten t he brace nut s
to 41 Nm (30 ft. lbs.) torque.
(2) Position step bumper assembly to t he rear of
t he vehicle.
(3) Align t he support bracket and brace holes with
t he holes in t he frame rails. Install t he bracket at-
taching bolts and nut s.
(4) Ensure t hat t he bumper is correctly aligned
wi t h t he cargo box rear corner panels. Tighten to 68
(5) Connect t he license plate lamp bulb sockets to
t he lamps. Attach t he wire harness to t he bumper
with t he clip ret ai ners (Fig. 4).
(6) Remove t he support from t he bumper.
LOCATOR LAMP
CLIP WI RE
BUMPER SCREW J9123429
Fig. 4 License Plate Lamp Wire Harness
Fig. 5 Rear Step Bumper

SNOW PLOW
NDEX
page
Power Angling Cylinder Service 16
Power Unit . . 13
Snow Plow Control Module 17
Snow Plow Frame 16
SERVICE INFORMATION
A snow plow is optionally available for 4WD Ram
Truck and Ramcharger vehicles. The primary me-
chanical components are illustrated in Figure 1.
LIFT AR M
RUNNERS J9001-2
Fig. 1 Snow Plow Components
COMPONENT DESCRIPTION
The pri mary snow plow components are described
within t he following list:
Mol dboard Snow blade constructed from high
tensile steel
Trip spri ngs Allow the moldboard to t i l t for-
ward and slide over obstructions without losing t he
snow load
Sector Used for positioning t he moldboard
st rai ght ahead or angling it to t he ri ght or left
page
Snow Plow Malfunction Di agnosi s and Tests 4
Snow Plow Pivot Bracket 16
Snow Plow Wiring Di agrams 4
Syst em Description and Operation 3
Sector shear pi n Self-locking pin t hat locks
the moldboard in either a st rai ght ahead or an an-
gled plowing position
If the bl ade i mpacts obstructions, the pin will
shear to protect the snow pl ow and the vehi cl e
from damage. The pin i s not used wi th power
angl e pl owi ng.
Power angl i ng cyl i nders Enabl e t he operator
to move t he moldboard either st rai ght ahead or to
t he side
Hi nge pi ns Allows t he A-Frame to pivot up
and down. The pins act as at t achi ng points.
Cutting edge Replaceable blade edge extends
the life of t he blade
Runners Adjustable runners ret ai n t he cutting
edge at t he proper hei ght
Sno-Flo pai nt Specially developed high-
visibility, yellow pai nt provides fast, smooth snow-
rolling action
Hydraul i c pump and motor (Electro-Touch )
Hydraulically raises, lowers and angles the snow
plow
A-frame Provides t he means for attaching t he
snow plow to t he vehicle
Lift arm Raises and lowers t he snow plow.
SYSTEM DESCRIPTION AND OPERATION
HYDRAULIC CYLINDER AND MOTOR
The hydraulic cylinder and motor uni t is designed
to raise, lower and angle t he blade.
The power uni t is a hi gh torque, 12-volt motor t hat
is coupled to a gear-type hydraulic pump.
The toggle switches operate t he solenoid valves.
The following components control t he snow plow
blade positioning:
Solenoid valves designated A,B, and C
Mechanical hydraulic check valves
Pilot check valve
Crossover relief valve
SOLENOID fELEGTRO'MEGHANIGALj VALVES
Three solenoid valves are used for snow plow con-
trol. Each valve is comprised of two components:
Cartridge Comprised of a valve and a solenoid.

Coil The electrical component t hat ret ract s t he
cartridge solenoid.
With power applied, t he solenoid ret ract s and pulls
t he poppet valve into t he OPEN position.
When power is t urned off, t he spring forces t he so-
lenoid back to its normal, CLOSED position.
SOLE NOI D V ALV E A
The solenoid valve A cartridge contains a poppet
valve. This valve is normally de-energized in t he
CLOSED position. When closed, t he valve ret ai ns
pressure in t he lift cylinder. When it is energized
(valve opened), it allows t he fluid to flow from t he
lift cylinder back to t he reservoir. This enables t he
plow blade to lower via gravity.
Solenoid valve A is designed to remai n energized
(valve open) duri ng plowing to provide a floating
blade position. This ensures t hat t he plow blade is
guided up-down by t he surface deviations.
SOLE NOI D V ALV E B
The solenoid valve B cartridge contains a spool
valve. This valve is normally in t he de-energized
CLOSED position. This allows t he fluid to flow to t he
C solenoid. In t he energized OPEN position, t he fluid
is diverted to t he lift cylinder. This causes t he plow
blade to be raised.
SOLE N OI D V ALV E C
The solenoid valve C cartridge contains a spool
valve t hat is normally in t he de-energized CLOSED
position. This allows t he fluid to flow to t he right-
side power angling cylinder. This angles t he blade to
t he left. At t he same time, it allows t he fluid from
t he ret ract i ng left-side power angling cylinder to re-
t ur n to t he pump reservoir.
Energizing t he solenoid valve will route fluid to
t he left side angl i ng cylinder. This angles t he plow
blade to t he right. Also, t he fluid is forced from t he
ret ract i ng ri ght side cylinder. It flows t hrough t he C
cartridge valve and ret urns to t he pump reservoir.
MECHANICAL HYDRAULIC VALVES
The mechanical hydraulic valves all have t he same
function: t hey control t he direction of t he hydraulic
fluid flow.
CH E CK V ALV E S
Check valves allow fluid to flow freely in one direc-
tion while preventing fluid from flowing in t he oppo-
site direction.
A pump check valve is used to prevent fluid from
leaking back t hrough t he pump to t he reservoir.
Two additional check valves are necessary because
solenoid valves B and C have some leakage.
One check valve is located between solenoid valve
B and t he lift cylinder. It prevents fluid in t he lift
cylinder from l eaki ng back t hrough solenoid valve B.
If fluid leaks back, it could angle t he blade to t he
left. This would force fluid t hrough solenoid valve C
into t he ri ght side cylinder.
The other check valve is located between valve B
and valve C. It prevents fluid from being forced
t hrough solenoid valve B.
PILOT CHECK VALVE
A pilot check valve has a piston in addition to a
ball seat and spring. A pilot check valve is located
between solenoid valve C and t he reservoir. It has
two functions:
Prevent s t he hydraulic fluid in either angling cyl-
inder from leaking back to t he reservoir.
Allows t he hydraulic fluid from a ret ract i ng an-
gling cylinder to r et ur n to t he reservoir.
The valve action is done by fluid moving t he pis-
ton, which forces t he check ball off its seat.
CROSSOVER RELIEF VALVE
This valve protects against damage by a sudden
impact against t he end of t he blade. This will cause
high hydraulic pressure to accumulate in one of t he
angling cylinders.
The hydraulic pressure increases enough to open
t he crossover relief valve. The valve allows t he
highly pressurized hydraulic fluid to flow to t he
other cylinder. This cushions t he impact and changes
t he position of t he blade.
SYSTEM OPERATION
Refer to Figures 2 t hrough 5 for voltage application
and hydraulic fluid flow for each snow plow function.
Each figure shows t he components t hat are actuated
for each function.
SNOW PLOW WIRING DIAGRAMS
Refer to Figures 6, 7 and 8 for wiring diagrams.
Refer to Specifications chart at t he end of t hi s
group.
SNOW PLOW MALFUNCTION DIAGNOSIS AND
TESTS
Refer to t he charts and illustrations for proper di-
agnosis.
SOLENOID VALVE COIL FUNCTIONAL TEST
Test t he coils for proper operation, according to t he
following procedure.
(1) Hold a screwdriver blade about 1/8 inch above
t he nut on t he coil to be tested.
(2) Have a helper operate t he control switch t hat
energizes t he applicable coil.
C A U T I O N : D o not connect an ohmmeter to a coil
when it i s appl i ed. T hi s can cause internal damage
to the ohmmeter.
(3) If t he coil is working, t he electromagnetic ac-
tion will pull t he screwdriver down to t he ret ai ni ng
nut . If t hi s does not occur, use an ohmmeter to check
t he coil for continuity.
FRAME AND BUMPERS 13 -
T AN-
BLACK*
-o
ORANGE WITH
WHITE
TRACER
SWITCH
I
RAISE
| A N D j
! LOWER
x
RED-
6 o
SWITCH
O
I GNI TI ON SWITCH
ANGLE
TAN
LIGHT
' GREEN
ORANGE
WITH
WHITE TRACER
FUSE
+
BATTERY
o
SOLENOI D SWITCH
MOTOR
ENERGIZ ED: MOTOR A N D "B" COIL
PRESSURE RELIEF "
B
" SOLENOI D
JUL.
' C " SOLENOI D
ANGL I NG CYLINDER
CSSE] OPERATI NG PRESSURE
EXHAUST
INTAKE OR DRAI N
METERED FLOW
RB525
Fig. 2 Raise BladeVoltage Application & Hydraulic Fluid Flow
- 6 FRAME AND BUMPERS

SWITCH
TAN
ORANGE
WITH
WHITE
TRACER
RED
N
6 o
I GNI TI ON SWITCH
_ L _
ANGLE
ORANGE WITH
WHITE TRACER
L f
FUSE
LIGHT GREEN
u==c
SOLENOI D SWITCH
>+
BATTERY
o
ENERGIZ ED: "A " COIL
C" SOLENOI D
POWER
ANGL I NG
CYLINDER
LOWER A N D FLOAT
(FORCE APPLIED AGAI NST LIFT RAM)
OPERATI NG PRESSURE
EXHAUST
INTAKE OR DRAI N
METERED FLOW
RB526
Fig. 3 Lower & Float BladeVoltage Application & Hydraulic Fluid Flow
IGNITION SWITCH
L
BLACK
mm OPERATING PRESSURE
EXHAUST
^SS3 INTAKE OR DRAI N
METERED FLOW
RB527
Fig, 4 Angle Blade Right-Voltage Application & Hydraulic Fluid Flow
TAN
I GNI TI ON SWITCH
BLACK
WSSm OPERATI NG PRESSURE
mm EXHAUST
ESBS3 INTAKE OR DRAIN
METERED FLOW
J9001-1
Fig. 5 Angle Blade LeftVoltage Application & Hydraulic Fluid Flow

FRAME AND 1 UMPE RS - 1 3 - S
SNOW PLOW DIAGNOSIS
Condition Possible Coys Cor r ect i on
PLOW BLADE WILL NOT LIFT OR
LIFTS SLOWLY
PLOW BLADE WI LL NOT ANGLE RIGHT-
MOTOR I S OPE RATI ONAL
PLOW BLADE WILL NOT ANGLE LEFT-
MOTOR I S OPERATIONAL
PLOW BLADE WILL NOT ANGLE-
MOTOR I S OPERATIONAL
PLOW WILL NOT REMAI N I N
ANGLED POSITION
MOTOR DOES NOT OPERATE
PLOW BLADE WILL NOT LOWER
PLOW BLADE CREEPS DOWNWARD
PLOW BLADE WILL NOT
CLEAN SURFACE
BLADE WILL NOT FOLLOW
SURFACE DEVIATIONS
SNOW STICKS TO FACE
OF BLADE
(n) Low hydraulic fluid level.
(b) Discharged battery.
(c) Leaking or open "A" cartridge.
(d) No voltage at "B" coil.
(e) Inoperative "B" coil.
(f) Malfunctioning motor.
(g) Malfunctioning pump.
(a) Improper coupler engagement.
(b) Mechanical bind or interference.
(c) Malfunctioning coupler.
(d) No voltage at "C" coil.
(e) Inoperative "C" coil.
(f) Inoperative "C" cartridge.
(c) Malfunctioning coupler.
(d) Leaking or open crossover relief
valve.
(c) Leaking or open crossover relief
valve.
(a) Air in cylinders and hoses.
(b) Leaking "C" cartridge O-ring seals.
(c) Leaking or open pilot check valve.
(d) Leaking crossover relief valve.
(e) Crossover relief valve opening
pressure too low.
(a) Discharged or defective battery.
(b) Loose or corroded electrical
connections.
(c) Inoperative solenoid switch.
(d) Malfunctioning control switch.
(e) Malfunctioning motor.
(a) No voltage at "A" coil.
(b) "A" cartridge jammed in closed
position.
(c) Inoperative "A" coil.
(a) Leaking "A" cartridge.
(b) Leaking "A" cartridge O-ring seal.
(c) Leaking B-Check Valve.
(d) Leaking Ram Packing Cup.
(e) Leaking O-ring seal at bottom of
cylinder.
(a) Runner height incorrect.
(b) Cutting edge unevenly worn.
(a) Not in "Lower Float Position".
(b) Insufficient slack in lift chain.
(a) Sno-Flo paint worn off.
(a) Add fluid to proper level.
(b) Recharge battery.
(c) Clean or replace "A" cartridge.
(d) Locate malfunction and repair.
(e) Replace "B" coil.
(f) Repair or replace motor.
(g) Replace pump.
(a) Engage coupler properly.
(b) Eliminate mechanical bind or
interference.
(c) Repair or replace coupler.
(d) Locate malfunction and repair.
(e) Replace "C" coil.
(f) Clean or replace "C" cartridge.
interference.
(c) Repair or replace coupler.
(d) Clean or replace crossover relief
valve.
interference.
(c) Clean or replace crossover relief
valve.
(a) Purge cylinders and hoses.
(b) Replace O-ring seals.
(c) Clean or replace pilot check valve.
(d) Clean or replace crossover relief
valve.
(e) Replace crossover relief valve.
(a) Recharge or replace battery.
(b) Clean and tighten electrical
connections.
(c) Replace solenoid switch.
(d) Replace control switch.
(e) Repair or replace motor.
(a) Locate malfunction and repair.
(b) Clean or replace "A" cartridge.
(c) Replace "A" coil.
(a) Clean or replace "A" cartridge.
(b) Replace O-ring seal.
(c) Clean or replace Pump Check Valve.
(d) Replace Ram Packing Cup.
(e) Replace O-ring seal.
(a) Adjust runners.
(b) Replace.
(a) Position switch at "Lower Float"
(b) Adjust lift chain.
(a) Refinish.
J9001-3
TO TURN
SI GNAL FLASHER <
(SEE SHEET 27)
y -Dl 18RD/YL*
FUSE #5
(20 AMP)
Dl
18RD
YL*
-Dl 18RD/YL*
-Dl 18RD/YL*-
Dl 18RD/YL*
TO R.W.A.L.
j MODULE
(SEE SH 51, 53)
BLACK
TO
IGNITION
SWITCH
(SEE SH 10)
-SP4 18WT/BR*
PLOW
CONTROL
SWITCH
UP & DOWN L.
- S P4 18WT/BR*-
-SP4 18WT/BR*-
PLOW
CONTROL
SWITCH
LEFT TO
RIGHT
-SP4 18WT/BR*
-Dl 18RD/YL*-
TRANSMISSION OIL
TEMPERATURE LAMP
-SP4 18WT/BR*-
-SP4 18WT/BR*
-SP4 18WT/BR*
-SP1 18WT/BK* I
Dl 18RD/YL*
-SP3 18 WT/RD*
-SP3 18WT/RD*-
-SP1 18WT/BK*-
SP4 18WT/BR* I
SP4 18WT/BR* !
-SP4 18WT/BR* j
Dl 18RD/YL*
-SP5 18WT/LG* I
-SP5 18WT/LG*-
-T2 18LG/RD*-
8901-3
Fig. 6 Snow Plow Control Wiring Diagram
S N OW PLOW D OWN
SOLENOI D (FRONT
S N O W PLOW FRAME)
S N O W PLOW
RIGHT SOLENOI D
(FRONT S N OW
PLOW FRAME)
TRANSMI SSI ON OIL
TEMPERATURE LAMP
TRANSMI SSI ON OIL
TEMPERATURE SWITCH
(RIGHT SIDE
BELOW RADIATOR)
8901-4
Fig. 7 Snow Plow Control Wiring Diagram (Cont'd)
TO FRONT
END WIRING
(SEE SH 21)
T T
1 8 B K
18BK
YL*
TO HEADLAMP Jr
SWITCH
-L2 14LG
TO FRONT
END WI RI NG
(SEE SH 22)
BLACK
(RIGHT
SIDE
RADIATOR
YOKE
PANEL)
BLACK
(RIGHT
' UPPER
SNOW
PLOW
FRAME)
BLACK
LEFT AUXILIARY
PARK A N D TURN
SI GNAL LAMP
LEFT AUXILIARY
HEADLAMP
RIGHT AUXILIARY
HEADLAMP
RIGHT AUXILIARY
PARK A N D TURN
SI GNAL LAMP
8901-2
Fig. 8 Snow Plow Auxiliary Lighting Wiring Diagram

POWER UNIT
DISASSEMBL Y/INSPECTION
(1) Remove the drai n plug (Fig. 9). Drain t he unit.
(2) Extend t he r am and piston rod completely.
Drain t he remai ni ng oil from t he cylinder.
(3) Remove t he cover locknuts (Fig. 9). Remove t he
cover.
(4) Inspect the casting for damage and cracks. In-
spect t he seal for cuts (Fig. 9).
(5) Remove t he r am and t he piston. Inspect t he ny-
lon sleeve, t he piston, and t he piston follower for ex-
cessive wear (Fig. 10).
(6) Inspect the cylinder for pi t t i ng and scoring in
the bore (Fig. 10).
(7) Inspect the r am for nicks, scratches, and corro-
sion (Fig. 10).
(8) Inspect the piston packing cup for wear (Fig.
10).
(9) Clean and inspect t he base strainer.
(10) Replace all t he O-ring seals during assembly.
(11) Loosen t he motor bolts. Do not remove t he
bolts from t he motor. Retain t he motor end pl at e dur-
ing removal. Temporarily install two 1/4-20 nut s on
t he motor bolts to ret ai n t he motor intact.
Both Prestolite and Ameri can Bosch motors
are used in snow pl ow power units. A Prestolite
motor can be identified by a domed top cover
and the trade name stamped on the body. Amer-
i can Bosch motors have a flat top cover and no
identifying name or marks.
(12) Remove t he pump drive shaft seal.
(13) Verify the seal kit components are correct for
t he unit.
(14) Dip t he new seal in oil. Install it over t he
pump shaft with t he seal lip facing down.
(15) Position t he seal in t he pump housing slightly
below t he boss face.
(16) Remove solenoid valve A coil from t he base.
Test it for continuity. The normal coil DC resistance
is 9.0 ohms 10%.
(17) Remove solenoid valve A cartridge with a 1
and 1/8-inch diameter deep socket wrench. Inspect
for external damage.
(18) Remove the filters. Clean t he screens with
cleaning solvent and compressed air. Discard t he
O-ring seals and t he nylon ret ai ni ng rings.
(19) Remove t he pump housing (Fig. 9). Remove
t he insert valve, t he ball, t he spring, and t he re-
t ai ner from t he pump housing (Fig. 11). Inspect all
t he components for damage and contamination. Dis-
card t he O-ring seals.
(20) Remove t he socket-head screws. Remove t he
valve block from t he pump housing (Fig. 9). Discard
t he O-ring seals.
(21) Remove solenoid valve B with special tool
J-25399 (Fig. 9).
(22) Remove t he ball and spring from the valve
block (Fig. 9). Clean t he solenoid valve. Inspect it for
external damage.
(23) Disassemble t he three-way valve (Fig. 9). Dis-
card the O-ring seal.
(24) Remove and clean solenoid valve C wi t h spe-
cial tool J-25399 (Fig. 9). Inspect t he solenoid valve
for ext ernal damage.
(25) Disassemble t he four-way valve (Fig. 12). Dis-
card t he O-ring seals (Fig. 12).
(26) Test solenoid valve B and C coils for electrical
continuity. The normal coil DC resistance is 3.7
ohms.
(27) Remove t he pilot check valve plug, the spring
and t he ball from t he bottom of t he valve block.
(28) Inspect t he spring for damage and t he ball
seat for nicks.
(29) Remove t he acorn nut for access to t he cross-
over valve components (Fig. 9).
(30) Remove t he crossover valve components (Fig.
13). Inspect for ext ernal damage. Discard the O-ring
seals.
(31) Clean t he block with compressed air to re-
move all foreign mat eri al .
ASSEMBLY
Verify t hat all components are thoroughly clean
and free of foreign mat eri al . Use replacement gas-
ket s and seals duri ng assembly. Petroleum jelly
should used for installing t he rubber O-ring seals.
(1) Install t he crossover valve components in t he
valve block with replacement O-ring seals (Fig. 13)
(2) Install t he ball, spring and pressure plug with
a replacement O-ring seal in the bottom of t he valve
block (Fig. 13)
(3) Assemble solenoid valve C with replacement
O-ring seals and nylon ret ai ner rings (Fig. 12).
(4) Install solenoid valve C with Tool J-25399 (Fig.
9).
(5) Assemble solenoid valve B with replacement
O-ring seals.
(6) Install t he ball, spring and solenoid valve B
wi t h Tool J-25399 (Fig. 9).
(7) Install t he valve block and t he replacement
O-ring seals on t he pump base.
(8) Install t he ret ai ner, t he spring, t he ball, t he in-
sert valve and t he pump housing with replacement
O-ring seals (Fig. 11). Tighten the pump housing
base nut s to 11.3 N*m (100 in. lbs.) torque.
(9) Install t he filters and t he plugs with replace-
ment O-ring seals (Fig. 9).
(10) Install solenoid valve A cartridge in t he pump
base wi t h replacement O-ring seals (Fig. 9).
(11) Install solenoid valve A coil (Fig. 9).
(12) Install t he motor on t he pump housing (Fig.
9). Engage t he gear shaft t ang with t he notch in t he
motor output shaft. Tighten t he motor housing cap-
screws to 5 N
#
(13) Install t he r am and piston with replacement
O-ring seals (Fig. 9).
(14) Position t he cover on t he reservoir. Secure it
with locknuts (Fig. 9). Tighten t he locknuts to 11.3
Nr n (100 in. lbs.) torque.
14 FRAME AND BUMPERS

RB530
Fig. 9 Power UnitExploded View
LEGEND FOR FIG. 9
1. Plastic Washer
2. Locknut
3. Pressure Relief Valve
4. Filler Plug
5. Cover arid Seal
6 . O-Rirtg Seal
7. Sleeve
8. Washer
9. Ram
10. Piston
11. Packing Cup
12. Piston Follower
13. Locknut
14. Motor
15. Shaft Seat
I f. ' i mp Housing
V/.
p
cppet
18. Spring
19. Guide
20. Retainer
21. Setscrew
22. Aluminum Washer
23. Jamnut
24. Acorn N ut
25. Stud
26. Brass Washer
27. 2-Way Solenoid
28. 2-Way Coil
29. 2-Way Valve
30. Ease and Strainer
COVER
ASSEMBLY
TANK
RESERVOIR
CYLINDER
I
3
PISTON LOCKNUT
I
i
O- RI NG
RAM
S PACKINC
WASHER
CUP
PISTON
FOLLOWER
RB531
Fig. 10 Lift Cylinder Components
BASE
O- RI NG
RETAINER
SPRI NG
NSERT
VALVE
O- RI NG
31. Valve Block
32. Socket Head Cap Screw
33. Filter
34. Plug
35. Strainer
36. Check Valve Retainer
37. Ball
38. Insert Valve
39. Cylinder Tank
40. Cylinder
41. 4-Way Solenoid
42. 4-Way Valve
43. 4-Way Coil
44. 3-Way Solenoid
45. 3-Way Valve
46. 3-Way Coil
47. Cap Plug
48. Check Spring
49. Cylinder Tank
50. Val ve Block
5 1. Cage
52. O- Ring Seal / Gl i de Ring
53. Crossover Valve
54. Pilot Check Valve
55. Spacer
56. Disc
57. Adjustment Screw
59. Drain Plug
J9001-6
BRASS NUT
COIL
O- RI NGS
SNAP RI NG
O- RI NGS
O- RI NG
NOTE: NYLON WASHERS
A N D O- RI NGS SHOULD
TAPER DOWN TO VALVE SHAPE
FROM VALVE DOWN.
LOCK NUT
VALVE CARTRIDGE
SPRI NG
PLUNGER
VALVE
NYLON WASHER
NYLON WASHER
NYLON WASHER
RB533
Fig. 12 Solenoid Valve C/Four-Way Valve-Exploded
View
RB532
Fig. 11 Insert Valve Exploded View
13 - 16 FRAME AND i UMPE RS

RB534
Fig. 13 Crossover Relief ValveDisassembled
POWER ANGLING CYLINDER SERVICE
If angling cylinder fluid leakage occurs, t he cause
could be a loose gland nut (Fig. 14). Tighten t he
gland nut .
CAUTI ON : Over- ti ghteni ng the gl and nut can l ock
the cylinder. Leakage will not c ease immediatel y be-
cause fluid has accumul at ed between the packi ng
and the gland nut. If the l eakage persi st s, repl ace
the rod packi ng ( F i g. 1 4 ) ,
SNOW PLOW FRAME
REMOVAL
(1) Support t he snow plow frame.
(2) Eemove t he nut s and bolts t hat at t ach t he
bumper brackets to t he snow plow frame (Fig. 15).
(3) Remove t he nut s and bolts t hat at t ach t he sup-
port st raps to t he snow plow frame (Fig. 15).
(4) Remove t he nut s, washers and bolts t hat at t ach
t he snow plow frame to t he vehicle frame side rails
and front crossmember (Fig. 15).
(5) Remove t he snow plow frame and support from
t he front of t he vehicle frame (Fig. 15).
INSTALLATION
(1) Position and support t he snow plow frame at
t he front of t he vehicle frame with t he bolt holes
aligned (Fig. 15).
(2) Install t he snow plow frame at t achi ng bolts,
washers and nut s finger-tight (Fig. 15).
(3) Install t he support st rap at t achi ng bolts and
nut s finger-tight (Fig. 15).
(4) Install t he bumper bracket at t achi ng bolts and
nut s finger-tight (Fig. 15).
(5) Ti ght en all t he at t achi ng nut s to 68 N*m (50 ft.
lbs.) torque.
(6) Remove t he support from under t he snow plow
frame.
SNOW PLOW PIVOT BRACKET
REMOVAL
(1) Support t he snow plow pivot bracket.
(2) Remove t he nut s and bolts t hat at t ach t he sup-
port st raps to t he pivot bracket (Fig. 15).
Fig. 14 Angling CylinderExploded View

Fig. 15 Snow Plow Frame Removal/Installation
(3) Remove t he nut s, washers and bolts t hat at t ach
t he pivot bracket to the vehicle frame side rai l s (Fig.
16).
(4) Remove t he pivot bracket from t he vehicle
frame rails (Fig. 16).
INSTALLATION
(1) Position and support the pivot bracket at t he
vehicle frame rai l s with t he bolt holes aligned (Fig.
16).
(2) Install t he pivot bracket at t achi ng bolts, wash-
ers and nut s finger-tight (Fig. 16).
(3) Install t he support strap at t achi ng bolts and
nut s (Fig. 15). Tighten t he nut s to 68 N*m (50 ft.
lbs.) torque.
(4) Tighten t he pivot bracket attaching nut s to 68
Nrni (50 ft. lbs.) torque.
(5) Remove t he support from under t he pivot
bracket.
SNOW PLOW CONTROL MODULE
FRAME FRAME
REMO VAUDISASSEMBL Y
(1) Remove the screws and module ret ai ners from
t he i nst rument panel (Fig. 17).
(2) Remove t he control module from t he instru-
ment panel (Fig. 17).
(3) Remove t he module housing at t achi ng screws
(Fig. 18).
(4) Separat e t he switch cover from t he housing
(Fig. 18).
J9101-1
Fig. 16 Snow Plow Pivot Bracket
Removal/Installation
(5) Detach t he lamp holders from t he switch cover.
Disconnect t he wire harness connectors from t he
switches (Fig. 18).
(6) Remove t he nut , ri ng washer and loekwasher
from each toggle switch (Fig. 18).
(7) Remove t he toggle switches from t he switch
cover (Fig. 18).
(8) Carefully pry t he auxiliary headl amp switch
outward from t he switch cover face. Remove it from
t he switch cover (Fig. 18).
(1) Insert t he auxiliary headl amp switch in t he
switch cover opening. Carefully push i nward unt i l it
is completely seated against t he cover face (Fig. 18).
(2) Position t he toggle switches in t he switch cover
openings. Install t he lockwashers, ri ng washers and
nut s (Fig. 18). Tighten t he nut s wi t h 5 Nnn (45 in.
lbs.) torque.
(3) Insert t he l amp holders in t he switch cover
openings. Connect t he wire harness connectors to t he
switches (Fig. 18).
(4) Mate t he switch cover with t he module hous-
ing. Install t he housing at t achi ng screws (Fig. 18).
Tighten t he screws until t he screw heads are seated
agai nst t he housing.
(5) Position t he control module on t he i nst rument
panel with t he slots aligned wi t h t he holes. Install
t he ret ai ners and screws (Fig. 17). Tighten t he
screws unt i l t he module is tightly attached to t he in-
st rument panel.
INSTRUMENT
PANEL
WI RE
HARNESS
AUXILLARY
HEADLAMP
SWITCH
BLADE
RAISE/LOWER
SWITCH
RETAINER
SWITCH
COVER A N D BEZEL
HOUS I NG
BLADE
ANGLE
SWITCH
J9123-424
Fig. 17 Snow Plow Control Module Removal/
Installation
BLADE SWITCH
ANGLE COVER
SWITCH
AUXILIARY
HEADLAMP
SWITCH
TRANS OIL
TEMP LAMP
(AUTO TRANS)
TO AUXILLARY
H/LAMP SWITCH
WI RE
HARNESS
RI NG
WASHER
LOCKWASHER
HOUS I NG
SCREW
NUT
'I LLUMI NATI ON*
LAMP' \
BLADE
RAISE/LOWER
SWITCH
TO SNO- PLOW CONTROL
SWITCH
(ANGLE)
TO S N O PLW CONTROL SWITCH
(RAISE/LOWER) J9123-425
Fig. 18 Snow Plow Control Module Disassembled

SNOW PLOW SPECIFICATIONS
ELECTRICAL SPECIFICATIONS
MOTOR SPECIFICATIONS
American Bosch M0 S S 1M6A
No load (motor not attached to pump) operation:
C A U T I O N : D o not o p e r a t e motor cont i nuousl y for mor e
t han 30 seconds.
A p p l i e d V ol t a ge 12 V ol t s D C
Max. Current 24 A mp e r e s
S peed (Min.) 5900 r p m
Wi t h load ( pump oper at i ng) :
C A U T I O N : Do not operate motor cont i nuousl y for more
than 5 seconds.
Applied Voltage 12 Volts DC
Max. Current 230 Amperes
Prestolite MGL4105
No load (motor not attached to pump) operation:
CAUTION: Do not operate motor continuously for more
than 30 seconds.
Speed (Min.) 10,000 rpm
Under Load (pump operating):
CAUTION: Do not operate motor continuously for more
than 5 seconds.
Applied Voltage - 12 Volts DC
HYDRAULIC SPECIFICATIONS
PUMP
m
Pressure Output (pump relief valve opening pressure
1650 50 psi
CROSSOVER RELIEF VALVE
SOLENOID VALVES A . B, AND C SPECIFICATIONS
A Coll
Current 0.83 Amperes
Nominal resistance (one ohmmeter probe to coil wire, other
to metal coil cover)9.0 10% ohms.
i and C Colls
Current 1.24 Amperes
to metaT coil cover)-3.5 10% ohms.
SOLENOID SWITCH
Applied Voltage 12 Volts D C
to metal foot)2.65-4.5 ohms.
HYDRAULIC FLUID CAPACITY
NOTE: 1 Quart = 32 Fluid Ounces
A Reservoir and Pump
Hoses & 1-1/2 x 10 Cylinders
Total
B Reservoir and Pump
Hoses & 1-1/2 x 12 Cylinders
Total
C Reservoir and Pump
Hoses & 2 x 12 Cylinders
Total
28 oz.
16 oz.
1 qt., 12 oz.
(44 oz.)
28 oz.
19 oz.
1 qt., 15 oz.
(47 oz.)
1 qt., 4.5 oz.
(36.5 oz.)
28 oz.
2 qt., 5 oz.
(64.5 oz.)
Opening Pressure 3800 400 psi
J9001-4
13 - 20 FRAME AND IUMPERS

FRAME
INDEX
page
Frame Inspection/ Measurements 25
Frame Repair 29
General Information
page
. . 20
GENERAL INFORMATION
DESIGN
Ram Truck, Chassis Cab and Ramcharger vehicles
have a ladder-type frame (Fig. 1) t hat has:
A box-section front,
A dropped center
Open-channel side rails and crossmembers.
REAR
SPRI NG REAR
REAR SPRI NG
^CROSSMEMBER FRONT
.CROSSMEMBER
ENGI NE
FRONT SUPPORT
CROSSMEMBER
REAR
SHOCK
ABSORBER
CROSSMEMBER
MID-FRAME
CROSSMEMBER
ENGI NE/ TRANSMI SSI ON
REAR
SUPPORT
CROSSMEMBER
FRONT
CROSSMEMBER
J9113-20
Fig. 1 Ram Truck, Chassis Cab and Ramcharger
Frame
The frame crossmembers are attached to t he side
rai l s by ei t her rivets or bolts to form a ladder-shaped
frame (Fig. 1). The cab is attached to t he front of t he
frame wi t h holddowns. The holddowns are comprised
of bolts, insulators, spacers and brackets. The cargo
box is attached to t he rear of t he frame wi t h screws.
Ram Chassis Cabs and Ram Trucks with 8-foot
cargo boxes are equipped with frames t hat have
adapters attached to t he top of t he frame rails (Fig.
2).
FRONT BODY-TO-
FRAME ADAPTER
REAR
BODY-TO-FRAME
ADAPTER
BOLT
BOLT
> KAC
MODEL 64 CAB A N D
CHASSI S VEHICLES
NUT
REAR
BODY-TO-
FRAME ADAPTER
BOLT
FRONT
BODY-TO-x\
FRAME ADAPTER
NUT
NUT
BOLT
NUT
MODEL 63 CAB A N D CHASSI S
A N D 8-FT CARGO BOX VEHICLES J9113-14
Fig. 2 Ram Chassis Cab & Truck (8-Ft Cargo Box)
Adapters
The frames used with 2 W D vehicles (Figs. 3 and 4 )
are designed for independent front suspension. The
front suspension crossmember is riveted to and a
part of t he frame. The engine mount s are welded to
t he crossmember and riveted to t he side rails. The
rear suspension brackets are riveted to t he side rails.
The frame used for 4 W D vehicles (Figs. 5 and 6 )
are basically t he same as t he 2 W D vehicle versions.
The difference is t he front crossmember is replaced
wi t h a smaller engine mount crossmember.
MID FRAME CROSSMEMBER
(EXTRA) (159"-165" W.B.)
ENGINE/SUSPENSION FRONT
SUPPORT CROSSMEMBER
ALL FASTENERS ARE
RIVETS EXCEPT AS NOTED
PU892C
30
>
O
m
30
OS
I
Fig. 3 AD1, 2 & 3 Frame Structure
Fig. 4 AD4 Frame Structure
RI VETS EXCEPT A S N O T E D
PU893B
Fig. 5 ADS, 6 & 7 Frame Structure
FUNCTION
The frame is t he foundation and t he st ruct ural cen-
ter of t he vehicle. The pri mary function of a frame is
to provide support and at t achment locations:
For all t he chassis/drivetrain components
For the cab/body
For the vehicle payload
While limiting deflections and t wi st i ng of t he
frame members.
The frame mai nt ai ns t he correct relationship and
alignment of t he powertrain. This relationship and
alignment ensures normal operation of t he attached
units.
CONSTRUCTION MATERIAL
High-strength, carbon steel with a mi ni mum yield
strength of 32,000 psi is used to construct frame side
rails. A frame made of 32,000 psi mi ni mum yield
strength steel has, in reality, a range of 32,000 to
44,000 psi yield st rengt h.
For 4WD vehicle applications, t he frame side rai l s
reinforcements are constructed of t he same high-
strength, carbon steel as t he side rails.
BENDING RESISTANCE
A frame reacts to its load and t he road surface de-
viations by deflecting and twisting. The pri mary de-
flecting frame members are the side rails. Resistance
to frame twist is provided by t he crossmembers.
FRAME INSPECTION/MEASUREMENTS
INSPECTION
Inspect t he frame members for visible damage and
metal deformations. Inspect all riveted, bolted and
welded connections for looseness and/or missing
hardware.
All damaged areas must be repaired and/or t he
frame members replaced, as necessary.
MEASUREMENTS
Measure t he frame for mis-alignment wi t h t he cab/
body and cargo box attached to t he frame. Figures 7,
8, 9 provide t he frame alignment reference dimen-
sions.
The following information applies to all measure-
ments.
(1) Place t he vehicle on a level surface.
(2) If t he vehicle is loaded, verify t he vehicle does
not exceed t he gross vehicle weight rat i ng (GVWR).
Verify t he load is distributed in t he vehicle as evenly
as possible. For bet t er measurement results, remove
t he cargo/payload from t he vehicle.
(3) Measure t he t i re inflation pressures. Adjust as
necessary.
HORIZ ONTAL/DIAGONAL FRAME MEASUREMENTS
Determine t he frame horizontal, according to the
following procedure.
(1) Select several reference points along one frame
side rail, preferably at t he crossmember junctions.
(2) Transfer these reference points to t he surface/
floor. Paper sheets can be attached to t he surface be-
low t he reference points.
(3) Locate t he same reference points on t he other
frame side rail. Transfer t hem to t he surface/floor.
(4) Move t he vehicle away. Measure between all
t he reference points diagonally from and parallel to
t he side rails (Fig. 10). The corresponding measure-
ment s should not differ by more t han 6 mm (1/4 in).
(5) Measure the distance between t he two front
reference points. Measure t he distance between the
two rear reference points. Divide each distance in
half and indicate t he two half-way points on t he sur-
face/floor. Designate t he front point as 1 and t he rear
point as 2 (Fig. 10).
(6) Place a chalk-line between points 1 and 2 (Fig.
10) and snap t he string.
(7) Determine how close t he center line is to t he
diagonal intersection points in Figure 10.
(8) The mar ks on t he floor will show t he amount of
frame misalignment.
(9) The reference point transferred from one side
rai l should be within 3 mm (1/8 in) of t he opposite
reference point.
(10) Frame bow to t he side should not exceed 3
mm per 2540 mm (1/8 inch per 100 inches) in frame
length.
(11) The overall width of t he frame should not
vary more t han 3 mm (1/8 in).
(12) Repeat steps (1) t hrough (11) after straighten-
ing the frame.
Refer to Fi gures 7, 8, and 9 for frame horizon-
tal alignment reference di mensi ons.
TWIST AND PARALLEL FRAME MEASUREMENTS
Determine t he amount of frame twist using t he fol-
lowing procedure.
(1) Mark t he vertical reference points under t he
frame side rai l s at 305-mm (12-in) intervals. St art at
t he rear frame crossmember.
(2) Measure t he distance up from a level surface/
floor to each corresponding reference point.
(3) The distance to a reference point under one
side rail should be a maxi mum of 3 mm (1/8 in) dif-
ference t han t he opposite side rail.
Refer to Fi gures 7, 8 and 9 for frame vertical
alignment reference di mensi ons.
T O OU T S I D E O F M E TA L
I N S I D E O F M E T A L
37.68
CENTERLINE OF FRONT WHEELS 750 DIAMETER GAUGE HOLE
5.55
REAR OVERHANG
'SEE SPECIFICATIONS"
Fig. 7 Frame DimensionsAD1, 2 & 3
m m
RN888
Fig. 10 Frame Horizontal Aligi
FRAME REPAIR
GENERAL INFORMATION
Frames t hat are either bent or twisted can be
straightened by application of heat, The t emperat ure
must not exceed 566C/1050F (a dull red glow). Ex-
cessive heat will decrease t he strength of the met al .
This will result in a weakened frame.
Damaged frame side rails, crossmembers, and
brackets are repaired either by st rai ght eni ng t hem
or by replacement.
Welding joints between t he frame side rails and
crossmembers are not recommended.
FRAME MEMBER STRAIGHTENING
A st rai ght eni ng repair process should be limited to
frame members t hat are not severely damaged. The
hardware t hat is used to join t he frame members
should conform to t he same specifications as t he orig-
inals.
FRAME MEMBER REPLACEMENT
Frame member replacement is recommended if t he
shape is not recognizable.
FRAME MEMBER REPAIRS
DRILLING HOLES
Holes should not be drilled in frame side rail
flanges. This will reduce t he frame st rengt h.
ent Reference PointsTypical
WELDING
It is recommended t hat electric welding equipment
be used to weld frame side rails and crossmembers.
This method i mpart s heat only to a small area.
A damaged frame member should be examined for
hairline cracks. Repair frame member cracks accord-
ing to the following procedure.
(1) Stop-drill a hole at each end of t he crack with a
3-mm (1/8-in) diameter drill bit.
(2) V-groove the crack to allow good weld penetra-
tion.
(3) Weld t he crack.
(4) Grind t he weld surface area smooth. Install a
reinforcement section at t he welded area.
The flanges on reinforcement channel , shoul d
not exceed the wi dth of the si de rail flanges.
This will avoi d the necessi ty of wel di ng al ong
the outer edge of the side rail flanges. Longitu-
dinal wel ds are acceptabl e. Transverse wel ds
must be avoi ded.
FRAME REPAIR HARDWARE
Bolts, nut s and rivets can be used to repair frames.
When it is necessary to use a bolt for a rivet, install
t he next-larger-size diameter bolt. This will prevent
t he bolt from loosening. Ream the hole to fit t he bolt.
Conical-type lockwashers are preferred over t he
split-ring type lockwashers.Grade-3 bolts (or less)
shoul d not be used. Tightening bolts/nuts with t he
correct torque is mandat ory to prevent t hem from
loosening.
REINFORCEMENT SECTIONS
A reinforcement section must overlap beyond t he
repair area. A reinforcement section can be cut from
channel steel, angle steel, or flat stock steel. Com-
mon carbon steel t hat is equal in thickness to t he
frame member is acceptable.
ATTACHED COMPONENTS
SKID PLATES
TRANSFER CASE SKID PL ATF 4 WD
VEHICLES
REMOVAL
(1) Position a support under t he skid plate.
(2) Remove t he bolts t hat at t ach t he skid plate to
the frame crossmember. Remove t he bolts for t he
crossmember support to t he frame rail.
(3) Remove t he crossmember support and t he skid
plate.
INSTALLATION
(1) Position and support t he skid plate and t he
crossmember support at t he frame rail. Align t he
bolt holes.
(2) Insert t he bolts t hrough t he frame crossmember
and frame rail. Install t he nut s. Tighten to 23 N*m
(3) Remove t he support from under t he skid plate.
Fig. 1 Transfer Case Skid Plate4WD Vehicles
FUEL TANK SKID PLATE-4WD VEHICLES
REMOVAL
(1) Position a support under t he fuel t ank skid
plate.
(2) Remove t he nut s and bolts t hat at t ach t he skid
plate to t he frame rails, rear crossmember and t he
support bracket.
(3) Remove t he skid plate from t he fuel t ank and
t he vehicle.
INSTALLATION
(1) Position and support t he skid plate under t he
fuel t ank. Insert t he studs in t he support bracket.
(2) Install t he nut s to at t ach t he skid plate to t he
support bracket. Install t he bolts at t he rear cross-
member. Install t he bolts at t he frame side rails.
Tighten t he nut s and bolts to 23 N*m (200 in. lbs.)
torque.
(3) Remove t he support from under t he skid plate.
FRAME FRAME
Fig. 2 Fuel Tank Skid Plate-4WD Vehicles
SPARE TIRE/WHEEL CARRIER
REMOVAL
(1) Remove t he nut and insert from t he support
rod.
(2) Lower t he hanger and remove t he spare tire/
wheel from t he underside of t he frame crossmember.
(3) Remove t he ret ai ni ng nut , lockwasher and
hanger from t he left frame rail.
(4) Refer to removal procedures for installation.
BOLT BOLT FRAME
Fig. 3 Spare The/Wheel Carrier
1
PIVOT BOL T ADJUSTMENT
(1) Refer to the Pivot Bolt Height chart and deter-
mine the l engt h of dimension A for t he pivot bolt.
PIVOT BOLT HEIGHT
PIVOT BOLT HEIGHT
RIM SIZE TIRE SIZE BOLT HEIGHT
15 x 6.5 P195/75R-15 4.0"
P205/75R-15 4 . 0"
P235/ 75R- 1 5X L 5.0"
15 x 7.0 P235/75R-15XL 5 . 2 "
10R-15LT-B 5. 6 2"
16 x 6.0 7.50-16 SINGLE & DUAL 6.75"
LT215/85R-16 SINGLE 4 . 5"
LT215/85R-16 DUAL 5.0"
LT235/85R-16 5.0"
16.5 x 6.0 8.00-16.5 SINGLE 4 . 1 2 "
8.00-16.5 DUAL 5. 0"
16.5 x 6.75 8.75-16.5 5.0"
NOTE: 7.50 x 16 TIRE SHOULD
BE INSTALLED IN A DISH
UP POSITION ONLY
(2) Loosen t he pivot bolt nut and adjust dimension
A to required length.
INSTALLATION
(1) Position t he hanger under t he frame side rails
and insert t he pivot bolt in t he frame rail hole.
(2) Install t he lockwasher and t he nut on t he pivot
bolt. Tighten t he nut to 61 N*m (45 ft. lbs).
(3) Position t he spare tire/wheel on t he hanger.
Raise t he hanger and insert t he support rod in t he
hole.
(4) Install t he washer,nut and i nsert on t he sup-
port rod. Tighten t he nut to 11 Nnn (95 in. lbs.).
CAB
REMOVAL
The cab is attached to t he frame with holddowns
(Figs. 4 and 5). The cab can be removed for repair or
service. Refer to the associated component procedure
when necessary.
(1) Disconnect t he bat t ery cables from t he termi-
nals. Remove t he bat t ery from t he t ray.
(2) Disconnect t he wire harness connectors from
t he engine components. Disconnect from t he frame.
(3) Disconnect the parki ng brake cable and t he
brake lines.
(4) Disconnect t he engine controls.
(5) Disconnect t he heat er and A/C hoses.
(6) Disconnect t he cable from t he st art er motor.
(7) Disconnect t he transmission and transfer case
(if equipped) shift linkage.
(8) Disconnect t he t ubi ng from t he clutch mast er
cylinder (if equipped).
(9) Disconnect t he steering shaft from t he steering
gear.
(10) Disconnect all remai ni ng connections between
t he cab and t he frame components.
(11) Remove t he r est r ai nt cable from t he cab.
(12) Remove t he cab front holddown nut s and
washers (Fig. 4). The nut s are accessible at t he front,
underside of t he cab.
(13) Remove t he cab holddown bolts (Fig. 5). The
bolts are accessible from t he underside of t he cab.
(14) Separate and remove t he cab from t he frame.
BOLT
Fig. 4 Front Cab Holddown
CAB FRONT DOWN HOLD CAB REAR DOWN HOLD
J9113-18
Fig. 5 Cab HolddownsTypical
r
INSTALLATION
(1) Verify t he insulators and spacers are positioned
on t he frame holddown brackets (Figs. 4 and 5).
(2) Position t he cab on t he frame.
(3) Install t he cab holddown nut s and bolts (Figs. 4
and 5). Tighten t he nut s to 68 N-m (50 ft. lbs.)
torque. Tighten t he bolts to 81 Nnn (60 ft. lbs.)
torque.
(4) Position t he rest rai nt cable ends on t he cab
rear seat belt anchor bolts. Install t he ret ai ni ng nut s.
Tighten t he nut s to 45 N-m. (33 ft. lbs.) torque.
(5) Connect t he steering shaft to t he steering gear.
(6) Connect t he t ubi ng to t he clutch mast er cylin-
der (if equipped).
(7) Connect t he transmission and transfer case (if
equipped) shift linkage.
(8) Connect t he cable to t he st art er motor.
(9) Connect t he heat er and A/C hoses.
(10) Connect t he engine controls.
(11) Connect t he parki ng brake cable and t he
brake lines.
(12) Connect t he wire harness connectors to t he
engine components and to t he frame.
(13) Connect all remai ni ng items between t he cab
and t he frame components.
(14) Install t he bat t ery in t he t ray. Connect t he ca-
bles to t he t ermi nal s.
(15) Inspect t he installation of t he cab on t he
frame and verify t hat :
All connecting hardware is tightened
All fluids and lubricants are full
All electrical, engine, drivetrain and chassis com-
ponents are operational.
CARGO BOX
REMOVAL
The cargo box is attached to t he rear frame struc-
t ure with holddown bolts (Fig. 6). The box can be re-
moved for repai r or service access. Refer to t he
associated component procedures when necessary.
(1) Disconnect t he bat t ery cables from t he t ermi -
nals.
(2) Disconnect t he rear lamp wire harness connec-
tors.
(3) Support t he exhaust pipe. Disconnect t he sup-
port hanger from t he cargo box.
(4) Loosen t he clamps. Disconnect t he fuel and
vent hoses from t he nozzle tubes (Fig. 7).
(5) Remove t he cargo box holddown bolts (Fig. 6).
The bolts are accessible from t he underside of t he
cargo box.
(6) Identify, mar k and ret ai n t he spacers (if used)
for i nst al l at i on reference.
(7) Remove t he cargo box from t he frame (Fig. 6).
CARGO CARGO BOX
FWD HOS E CLAMP J9123-551
Fig. 7 Fuel & Vent Hoses
INSTALLATION
(1) Position cargo box on t he frame (Fig. 6).
(2) Insert t he spacers. Install t he holddown bolts
(Fig. 6). Tighten t he bolts to 47 Nnn (35 ft. lbs.)
torque.
(3) Connect t he fuel and vent hoses to t he nozzle
tubes (Fig. 7). Tighten t he fuel hose clamp screw to 3
Nnn (20 in. lbs.) torque. Tighten t he vent hose clamp
screw to 2 Nnn (14 in. lbs.) torque.
(4) Connect t he tail pipe to t he hanger on t he
cargo box. Remove t he support.
(5) Connect rear lamp wire harness connectors.
(6) Connect t he bat t ery cables to t he t ermi nal s.
(7) Inspect t he installation of t he cargo box on t he
frame and verify t hat :
All connecting hardware is tightened
All electrical system components are operational

FUEL SYSTEM 14 - 1
F U E L S Y S T E M
page
ACCELERATOR PEDAL AND THROTTLE
CABLE ................ 25
DIESEL FUEL INJECTION-COMPONENT
DESCRIPTION/SYSTEM OPERATION 76
DIESEL FUEL INJECTION- GENERAL
DIAGNOSIS 88
DIESEL FUEL I NJE CTI ON- SE RV I CE
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . 106
FUEL DELIVERY SY STE M- E X CE PT DIESEL . . 3
FUEL DE LI V E RY - DI E SE L ENGINE 15
FUEL TANKS . . . . 20
page
MULTI-PORT FUEL INJECTION ( M PI ) -
COMPONENT DESCRIPTION/SYSTEM
OPERATION- EX CEPT DIESEL 29
COMPONENT REMOV AL/ INSTALLATION-
EXCEPT DIESEL 64
GENERAL DI AGNOSI S- E X CE PT DIESEL . . . 4 3
SERVICE ADJUSTME NTS- DI E SE L 122
SPECIFICATIONS 123
by t he particular vehicle namepl at e. A chart showing
a breakdown of t he alphabetical designations is in-
cluded in the Introduction section at t he beginning of
this manual .
The 5.9L (V-8) gas powered engine will be referred
to in t hi s group as ei t her the: LDC (Light Duty Cy-
cle) or HDC (Heavy Duty Cycle) engine. The HDC
engine can be easily identified by t he use of an en-
gine mounted air injection pump. The 3.9L/5.2L/5.9L
LDC engine will not use an air injection pump.
This Fuel System group will cover all fuel system
components for t he 3.9L (V-6), 5.2L (V-8), 5.9L LDC
(V-8), 5.9L HDC (V-8) and 5.9L (in-line six cylinder)
diesel engines.
The Fuel System consists of: t he fuel t ank, an
electric (fuel t ank mounted) fuel pump and fuel fil-
ter. It also consists of fuel tubes/lines/hoses, vacuum
hoses, throttle body and fuel injector(s).
The Fuel Delivery System consists of: the electric
fuel pump, fuel filter, fuel tubes/lines/hoses, fuel rail,
fuel injectors and fuel pressure regulator.
A Fuel Return System is used on all vehicles (all
engines) except t he 5.9L (V-8) gas powered engine.
On t hi s engine, a returnless type fuel system is
used. The fuel ret urn system consists of fuel tubes/
lines and hoses t hat route fuel back to t he fuel t ank.
The Fuel Tank Assembl y consists of: t he fuel
t ank, filler tube, fuel gauge sending unit/electric fuel
pump module, a pressure relief/rollover valve and a
pressure-vacuum filler cap.
Also to be considered par t of t he fuel system is t he
Evaporati on Control System. This is designed to
reduce t he emission of fuel vapors into t he atmo-
sphere. The description and function of t he Evapora-
tive Control System is found in Group 25, Emission
Control Systems.
FUEL USAGE STATE ME NT- GAS ENGINES
Your vehicle was designed to meet all emission
regulations and provide excellent fuel economy using
high quality unleaded gasoline. Only use unleaded
gasolines havi ng a mi ni mum posted octane of 87.
If your vehicle develops occasional light spark
knock (ping) at low engine speeds, this is not harm-
ful. However, conti nued heavy knock at hi gh
speeds can cause damage and shoul d be re-
ported to your deal er immediately. Engi ne dam-
age as a result of heavy knock operation may not be
covered by t he new vehicle warrant y.
In addition to using unleaded gasoline with t he
proper octane rat i ng, those that contain deter-
gents, corrosi on and stability additives are rec-
ommended. Using gasolines t hat have these
additives will help improve fuel economy, reduce
emissions and mai nt ai n vehicle performance. Gener-
ally, premi um unleaded gasolines contain more addi-
tive t han regul ar unleaded gasolines.
Poor quality gasol i ne can cause problems such as
hard st art i ng, stalling and stumble. If you experience
these problems, use anot her brand of gasoline before
considering service for t he vehicle.
14 - 2 FUEL SYSTEM

GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
mat eri al s t hat contain oxygen such as alcohol, MTBE
and ETBE. The type and amount of oxygenate used
in t he blend is important. The following are gener-
ally used in gasoline blends:
E TH ANOL
Et hanol (Ethyl or Grain Alcohol) properly blended,
is used as a mi xt ure of 10 percent ethanol and 90
percent gasoline. Gasol i ne wi t h et hanol ma y be
us e d i n your vehi cl e.
ME TH ANOL
CAUTI ON : D O N OT US E GASOL I N E S CON TAI N I N G
M E TH AN OL . Use of methanol/gasoline blends may re-
sult in starting and driveability problems. In addition,
damage may be done to critical fuel system compo-
nents.
Methanol (Methyl or Wood Alcohol) is used in a va-
riety of concentrations blended with unleaded gaso-
line. You may encounter fuels containing 3 percent
or more met hanol along with other alcohols called co-
solvents.
Problems t hat are t he result of using methanol/gas-
oline blends are not t he responsibility of Chrysler
Corporation. They may not be covered by t he vehicle
warrant y.
MTBE / E TBE
Gasoline and MTBE (Methyl Tertiary Butyl Et her)
blends are a mi xt ure of unleaded gasoline and up to
15 percent M TBE . Gasoline and E TBE (Ethyl Ter-
t i ary Butyl Et her) are blends of gasoline and up to
17 percent ETBE. Gasoline blended with MTBE or
ETBE may be used in your vehicle.
CLE AN AIR GASOLINE
Many gasolines are now being blended t hat con-
t ri but e to cleaner air, especially in those areas of t he
country where air pollution levels are high. These
new blends provide a cleaner burni ng fuel and some
are referred to as Ref or mul at ed Gasol i ne.
In areas of t he country where carbon monoxide lev-
els are high, gasolines are being t reat ed wi t h oxy-
genated mat eri al s such as MTBE, ETBE and
ethanol.
Chrysler Corporation supports these efforts toward
cleaner air and recommends t hat you use these gas-
olines as they become available.
FUEL REQUI REMENTS-DI ESEL ENGINE
Use good quality diesel fuel from a reputable sup-
plier in your Chrysler Corporation vehicle. For most
year-round service, number 2 (two) diesel fuel meet-
ing ASTM specification D-975 will provide good per-
formance. If t he vehicle is exposed to extreme cold
(below -18C - 0F), or for any reason is required to
operate at colder t han normal conditions for pro-
longed periods, t hen dilution of t he 2D fuel with 50
percent kerosine or number I D diesel fuel will pro-
vide better protection from fuel gelling or wax-plug-
ging of t he fuel filters. Diesel fuel is seldom
completely free of water. To prevent fuel system
trouble, including fuel t ube (line) freezing in winter,
drai n t he accumulated wat er using t he drai n pro-
vided. If you buy good quality fuel and follow t he
cold weat her advice above, fuel conditioners should
not be required in your vehicle.

FUEL SYSTEM 14 3
FUEL DELIVERY SY STE M- E X CE PT DIESEL
INDEX
page
Fuel Filter3.9L/5.2L Gas E ngi ne . . . . . . . . . . . . 10
Fuel Filter5.9L Gas Engi ne 11
Fuel Pressure Leak Down Test3.9L/ 5.2L Engine . 8
Fuel Pressure Leak Down Test5.9L Engine . . . . 9
Fuel Pump Capacity TestAll Gas E ngi nes . . . . . 8
Fuel Pump Control . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Pump Modul e3.9L/ 5.2L E ngi nes 3
GENERAL INFORMATION
Two different types of fuel delivery/fuel ret urn sys-
tems are used. The system used with t he 3.9L/5.2L
engine will route excess fuel pressure back to t he
fuel t ank t hrough a fuel r et ur n line. The system used
with the 5.9L engine will not have a separate fuel re-
t ur n line. This system will be referred to as a re-
turnless type. The fuel pump module used wi t h t he
5.9L engine will contain a combination fuel pressure
regulator and fuel filter. Refer to t he following Fuel
Pump Module for additional information or, refer to
the Multi-Port Fuel Injection sections of t hi s Fuel
System group.
A separate frame mounted fuel filter will not be
used with any 5.9L gas powered engine.
FUEL PUMP M0 DULE- 3.9L/5 .2L ENGINES
The fuel pump module on vehicles equipped with
3.9L/5.2L engines is installed in t he top of t he fuel
t ank (Fig. 1). The fuel pump module contains t he fol-
lowing components (Fig. 2):
Fuel pump
Fuel pump reservoir
A separate i n-t ank fuel filter
Pressure relief/rollover valve
PRESSURE RELIEF/ PUMP/GAUGE
Fig. 1 Top View of Fuel Pump Module3.9U5.2L
Engine
page
Fuel Pump Modul e5.9L Engine . . . . . . . . . . . . . 3
Fuel Syst em Pressure Rel ease . . . . . . . . . . . . . . . 5
Fuel Syst em Pressure Test3.9L/ 5.2L E ngi ne . . . 5
Fuel Syst em Pressure Test5.9L Engi ne 7
Fuel Tubes/ Li nes/ H oses and Cl amps . . . . . . . . . . 11
Q ui ck- Connect Fittings 11
Fuel pump gauge sending unit
Fuel supply and ret urn tube connections
J9114-147
Fig. 2 Fuel Pump Module ComponentsTypical
FUEL PUMP MODULE5.9L ENGINE
The fuel pump module on vehicles equipped wi t h a
5.9L gas powered engine is installed in t he top of t he
fuel t ank (Fig. 3). The fuel pump module contains
t he following components (Fig. 2):
Fuel filter/fuel pressure regulator
Fuel pump
Fuel pump reservoir
A separat e in-tank fuel filter
Fuel pump gauge sending uni t
Fuel supply t ube connection
1 4 - 4 FUEL SYSTEM

Fig. 3 Top View of Fuel Pump Module5.9L Engine
FUEL PUMP
The fuel pump used in t hi s system has a perma-
nent magnet electric motor. The pump is part of t he
fuel pump module (Fig. 2). The fuel pump module is
suspended in fuel in t he fuel t ank. Fuel is drawn in
t hrough a filter and pushed t hrough t he electric mo-
tor to t he outlet. The pump contains a check valve.
This valve is located near t he pump outlet. It re-
stricts fuel movement in either direction to mai nt ai n
fuel supply line pressure when t he pump is not oper-
ational. Voltage to operate t he pump is supplied
t hrough the auto shut down (ASD) and fuel pump re-
lays.
WA R N I N G : T HE F U E L S Y S T E M I S U N D E R A C O N -
S T A N T P R E S S U R E ( E V E N WI T H T HE E N G I N E OFF) .
B E F O R E S E R V I C I N G T HE F U E L PU M P, F U E L
T U B E S ( L I N E S ) , F U E L F I L T E R , O R F U E L INJEC-
TOR^) , T HE F U E L S Y S T E M P R E S S U R E M U S T BE
R E L E A S E D .
FUEL PUMP REPLACEMENT
The fuel pump is not serviceable. If t he fuel pump
needs replacement, t he complete fuel pump module
must be replaced. Perform t he Fuel System Pressure
Release procedure before servicing t he fuel pump.
FUEL PUMP MODULE REMOVAL
B E F O R E S E R V I C I N G THE F U E L PU M P M O D U L E ,
T HE F U E L S Y S T E M P R E S S U R E M U S T B E R E -
L E A S E D .
C A U T I O N : Whenever the fuel pump modul e i s ser-
vi ced, the locknut and gasket must be replaced.
(1) Drain t he fuel t ank. Refer to Draining Fuel
Tank in t he Fuel Tank section of this group.
(2) Remove fuel t ank. Refer to t he Fuel Tank sec-
tion of this group.
(3) The fuel pump module locknut is threaded onto
t he fuel t ank. Remove t he fuel pump module locknut
(Figs. 1 or 3). The fuel pump module will spring up
when t he locknut is removed.
(4 ) Remove module from fuel t ank.
DI S AS S E MBLY- FUEL GAUGE SENDING UNIT
(1) Remove sending uni t mounting screws (Fig. 4).
(2) Mark t he sending uni t electrical wires before
FUEL G A U G E TABS
I N-TANK
FUEL FILTER J9114-146
Fig. 4 Module ServiceTypical
removal for correct installation. Carefully disconnect
electrical wires from sending unit. Remove sending
unit.
(3) Reverse order of removal for installation.
IN-TANK FUEL FILTER
The in-tank filter is attached to t he bottom of t he
fuel pump module (Fig. 4).
(1) Pry t he mount i ng tabs back and remove t he in-
t ank fuel filter.
(2) Install new fuel filter into ret ai ni ng tabs.
FUEL PUMP MODULE INSTALLATION
C A U T I O N : Whenever the fuel pump modul e i s ser-
vi ced, the locknut and gasket must be replaced.
(1) Using a new gasket, position fuel pump module
into opening in fuel t ank.
(2) Position new locknut over top of fuel pump
module.
(3) Tighten locknut.
(4) Install fuel t ank. Refer to Fuel Tank Installa-
tion in t hi s section.

FUEL SYSTEM 1 4- 5
FUEL PUMP CONTROL
The powertrain control module (PCM) computer en-
ergizes t he fuel pump t hrough t he automatic shut
down (ASD) and fuel pump relays. Battery voltage is
applied to t he relay from t he ignition switch. The coil
in t he relay is energized when a ground is provided
by t he PCM. The relays are located in t he engine
compartment (Fig. 5).
DATA UNK CONTROL
Fig. 5 Fuel Pump and ASD Relays
FUEL SYSTEM PRESSURE RELEASE
ALL GAS ENGINES
The fuel system is under constant fuel pressure
(even with t he engine off).
WARNING: BECAUSE THE FUEL SYSTEM IS UN-
DER CONSTANT FUEL PRESSURE, THIS PRES-
SURE MUST BE RELEASED BEFORE SERVICING
ANY FUEL SUPPLY OR FUEL RETURN SYSTEM
COMPONENT. THIS DOES NOT APPLY TO THROT-
TLE BODY REMOVAL.
(2) Remove t he fuel t ank filler tube cap to release
fuel t ank pressure.
(3) Remove protective cap from pressure test port
on t he fuel rai l (Figs. 6, 7 or 8).
WARNING: DO NOT ALLOW FUEL TO SPILL ONTO
THE ENGINE INTAKE OR EXHAUST MANIFOLDS.
PLACE SHOP TOWELS UNDER AND AROUND THE
PRESSURE PORT TO ABSORB FUEL WHEN THE
PRESSURE IS RELEASED FROM THE FUEL RAIL.
WARNING: WEAR PROPER EYE PROTECTION
WHEN RELEASING FUEL SYSTEM PRESSURE.
(4) Obtain t he fuel pressure gauge/hose assembly
from fuel pressure gauge tool set 5069. Remove t he
gauge from t he hose.
CONNECTOR HOSES J9214-27
Fig. 7 Fuel Pressure Test Port5.2L (V-8) Engine
(5) Place one end of hose (gauge end) into an ap-
proved gasoline container.
(6) Place a shop towel under t he test port.
(7) To release fuel pressure, screw t he other end of
hose onto t he fuel pressure test port.
(8) After fuel pressure has been released, remove
t he hose from t he test port.
(9) Install protective cap to fuel test port.
FUEL SYSTEM PRESSURE TEST-3.9L/5 .2L
ENGINE
Fuel systems on vehicles equipped with a 3.9L or
1 4 - 6 FUEL SYSTEM

I l / / / / /
PROTECTIVE CAP
AND TEST PORT
J 9314- 168
Fig. 8 Fuel Pressure Test Port5.9L (V-8) Engine
5.2L engine are equipped with a vacuum assisted
fuel pressure regulator (Figs. 6 or 7). With engine at
idle speed, system fuel pressure should be approxi-
mately 214 kPa (31 psi) wi t h t he vacuum line con-
nected to t he regulator. With t he vacuum line
disconnected from t he regulator, fuel pressure should
be approximately 269 kPa (39 psi). This is 55-69 kPa
(8-10 psi) higher.
(1) Remove t he protective cap at t he fuel rai l (Figs.
6 or 7). Connect t he 0-414 kPa (0-60 psi) fuel pres-
sure gauge (from Gauge Set 5069) to t est port pres-
sure fitting on fuel rail (Fig. 9).
FUEL PRESSURE
TEST G A U G E
J921 4 - 28
Fig. 9 Fuel Pressure Test Typical
(2) Note pressure gauge reading. Fuel pressure
should be approximately 214 kPa (31 psi) at idle.
(3) Disconnect vacuum line at fuel pressure regu-
lator (Figs. 6 or 7). Note gauge reading. Wi t h vac-
uum line disconnected, fuel pressure should rise to
approximately 269 kPa (39 psi).
Fuel pressure should be approximately 55-69 kPa
(8-10 psi) higher with vacuum line removed from
regulator. If not, inspect pressure regulator vacuum
line for leaks, ki nks or blockage. If vacuum line
checks OK and fuel pressure does not rise approxi-
mately 8-10 psi after disconnecting vacuum line, re-
place fuel pressure regulator.
The fuel pressure regulator is not adj ust abl e.
(4) If fuel pressure exceeds 45 psi, check fuel re-
t ur n line for ki nks or obstructions.
If t he previous tests checked good, fuel pump pres-
sure is correct. If pump pressure was low, proceed as
follows:
(5) Release fuel system pressure. Refer to t he pre-
vious Fuel Pressure Release Procedure in t hi s group.
(6) Disconnect t he 5/16 inch fuel r et ur n line quick-
connect fitting (Fig. 10) on fuel rai l near fuel pres-
sure regulator. Connect Fuel Line (Tube) Pressure
Test Adapter Tool number 6539 (5/16 in.) between
t he disconnected fuel r et ur n t ube and fuel rail (Fig.
11).
FUEL TUBE REMOVAL
QUI CK CONNE CT
FITTING
PUSH
INSTALLATION
X
PUSH-
/
PUSH
PLASTIC
RETAINER
J9314-100
Fig. 10 Removing Quick-Connect Fitting
WA R N I N G : T HE F U E L S Y S T E M P R E S S U R E I N T HE
F O L L O WI N G T E S T M A Y E XC E E D 100 PS I . B E F O R E
S T A R T I N G T E S T , V E R I F Y G O O D C O N N E C T I O N S A T
E N D S O F A D A PT E R T O O L 6539. B E S U R E T O O L I S
L O C K E D O N T O F U E L R A I L A N D F U E L R E T U R N
L I N E . PU L L F I R M L Y O N E N D S O F T O O L T O V E R -
I FY.
(7) To activate t he fuel pump and pressurize the
system, obtain t he DRB II scan tool. Refer to t he ap-

FUEL SYSTEM 14 - 7
Fig. 1"f Adapter ToolTypical Connection
propriate Powertrain Diagnostic Procedures service
manual for DRB II operation.
(8) MOMENTARI LY pinch t he rubber hose por-
tion of adapter tool 6539. Pressure should rise to ap-
proximately 75 psi within two (2) seconds. DO NOT
pinch hose for longer t han five seconds.
If fuel pump pressure rises to approximately 75 psi
within two seconds, pump is operat i ng at its maxi-
mum and is correct.
If fuel pump pressure does not rise to approxi-
mately 75 psi within two seconds, proceed as follows:
(9) Release fuel system pressure. Refer to t he pre-
vious Fuel Pressure Release Procedure in t hi s group.
(11) Disconnect fuel supply line at i nl et (fuel t ank
side) of fuel filter. Connect Fuel Line (Tube) Pressure
Test Adapter Tool number 6631 (3/8 in.) between fuel
filter and fuel supply line.
WA R N I N G : T HE F U E L S Y S T E M P R E S S U R E I N T HE
F O L L O WI N G T E S T M A Y E XC E E D 100 PS I . B E F O R E
S T A R T I N G T E S T , V E R I F Y G O O D C O N N E C T I O N S A T
E N D S O F A D A PT E R T O O L 6631. B E S U R E T O O L I S
L O C K E D O N T O F U E L F I L T E R A N D F U E L S U PPL Y
L I N E . PU L L F I R M L Y O N E N D S O F T O O L T O V E R -
I FY.
(12) To activate t he fuel pump and pressurize t he
system, obtain the DRB II scan tool. Refer to t he ap-
propriate Powert rai n Diagnostic Procedures service
MOMENTARI LY pinch the rubber hose portion of
adapt er tool 6631. Pressure should rise to approxi-
mat el y 75 psi within two (2) seconds. DO NOT pinch
hose for longer t han five seconds.
If fuel pump pressure now rises to approximately
75 psi wi t hi n two seconds, but this pressure could not
be met at t he fuel rail, check for a plugged or re-
stricted fuel filter. Also check t he fuel supply line be-
tween fuel filter and fuel rai l for kinks or
obstructions. Proceed to t he Fuel Pump Capacity
Test.
FUEL SYSTEM PRESSURE TEST5.9L ENGINE
Fuel systems on vehicles equipped wi t h a 5.9L en-
gine are equipped wi t h a fuel t ank module mounted,
combination fuel filter/fuel pressure regulator (Fig.
12). The fuel pressure regul at or is not controlled by
engine vacuum.
ROLLOVER V ALV E J 9314- 167
Fig. 12 Fuel Filter/Fuel Pressure Regulator5.9L
Engine
With engine at idle speed, system fuel pressure
should be approximately 241-310 kPa (35-45 psi).
(1) Remove t he protective cap at t he fuel rail (Fig.
13). Connect t he 0-414 kPa (0-60 psi) fuel pressure
gauge (from Gauge Set 5069) to t est port pressure fit-
t i ng on fuel rai l (Fig. 14).
Fig. 13 Fuel Pressure Test Port5.9L Engines
(2) Note pressure gauge reading. Fuel pressure
should be approximately 241-310 kPa (35-45 psi) at
idle.
Fig. 14 Fuel Pressure TestTypical
(3) If pressure is at O psi, connect DRB II scan tool
and refer to operating instructions in t he appropriate
Powertrain Diagnostics Procedures service manual .
If operating pressure is above 4 5 psi, fuel pump is
OK. Replace fuel filter/fuel pressure regulator assem-
bly.
FUEL PUMP CAPACITY T E S T - AL L GAS ENGINES
Before performing this test, verify fuel pump pres-
sure by performing t he previous tests.
(1) Release t he fuel system pressure from fuel sys-
tem. Refer to t he previous Fuel Pressure Release
Procedure in t hi s group.
(2) Disconnect t he fuel supply line at fuel rail near
pressure regulator.
(3) Connect Fuel Line (Tube) Pressure Test
Adapter Tool number 6631 (3/8 in.) into t he discon-
nected fuel supply line (tube). Insert t he other end of
Adapter Tool 6631 into an approved gasoline con-
tainer.
(4 ) To activate t he fuel pump and pressurize t he
system, obtain t he DRB II scan tool. Refer to t he ap-
propriate Powert rai n Diagnostic Procedures service
(5) 3.9L/5.2L Engi nes : A good fuel pump will de-
liver approximately 1 liter of fuel per mi nut e. 5.9L
Engi nes : A good fuel pump will deliver approxi-
mately 2 liters of fuel per mi nut e.
FUEL PRESSURE LEAK DOWN TE ST- 3 JL/ 5.2L
ENGINE
ENGINE OFF
Abnormally long periods of cranki ng to rest art a
hot engine t hat has been shut down for a short pe-
riod of time may be caused by:
Fuel pressure bleeding past t he fuel pressure reg-
ulator.
Fuel pressure bleeding past t he check valve in t he
outlet end of t he fuel t ank mounted fuel pump.
(1) Remove protective cap at fuel rail test port
(Figs. 15 or 16). With t he engine off, connect an ac-
curate 0-689 kPa (0-100 psi) fuel gauge to t he pres-
sure test port fitting on t he fuel rail. The fitting on
t he pressure tester must be in good condition and
free of any leaks before performing this test.
PRESSURE REGULATOR
Fig. 16 Fuel Pressure Test Port5.2L Engine

FUEL SYSTEM 14 - 9
(2) St art t he vehicle and let engine idle. Check
fuel pressure reading on gauge. Fuel pressure should
be wi t hi n specifications. Refer to t he previous Fuel
System Pressure Tests.
(3) Shut engine off. Observe and record fuel pres-
sure readi ng on gauge. Leave fuel pressure gauge
connected. Allow engine to set for 30 mi nut es and
then compare the fuel pressure readi ng on t he gauge
with t he reading t aken when engine was shut down.
A pressure drop of up to 138 kPa (20 psi) wi t hi n 30
mi nut es is within specifications.
(4) If the fuel pressure drop is within specifica-
tions, t he fuel pump outlet check valve and fuel pres-
sure regulator are both operating normally.
(5) If fuel pressure drop is great er t han 138 kPa
(20 psi), it must be determined if t hi s drop is being
caused by (in-tank mounted) fuel pump outlet check
valve or fuel pressure regulator. Proceed to next step.
(6) Release the fuel system pressure from fuel sys-
tem. Refer to t he previous Fuel Pressure Release
Procedure in this group.
(7) Disconnect both fuel tubes (lines) at fuel rai l
near fuel pressure regulator.
Adapter Tool number 6631 (3/8 in.) between t he dis-
connected fuel supply line and fuel rail (Fig. 17).
connected fuel ret urn line and fuel rail (Fig. 17).
Fig. 17 Adapter ToolsTypical Connections
(10) St art engine. Observe and record fuel system
pressure.
(11) Shut engine off.
(12) Clamp off t he rubber hose portion of adapt er
tool number 6539 connected to t he fuel r et ur n line.
Allow engine to set for 30 mi nut es. If pressure has
dropped more t han 138 kPa (20 psi) in 30 mi nut es,
pressure is bleeding past t he (in-tank mounted) fuel
pump outlet check valve. Replace Fuel Pump Module
assembly. Refer to Fuel Pump Module removal and
i nst al l at i on in t hi s group. If pressure drop is wi t hi n
specifications, proceed to next step.
(13) Clamp off t he rubber hose portion of adapt er
tool number 6631 connected to t he fuel supply line.
Allow engine to set for 30 mi nut es. If pressure has
dropped more t han 138 kPa (20 psi) in 30 mi nut es,
pressure is bleeding past t he fuel pressure regulator.
Replace fuel pressure regulator. Refer to Fuel Pres-
sure Regulator removal and installation in t he Com-
ponent Removal/Installation section of this group.
FUEL PRESSURE LEAK DOWN TEST5.9L
ENGINE
ENGINE OFF
Abnormally long periods of cranking to rest art a
hot engine t hat has been shut down for a short pe-
riod of t i me may be caused by:
Fuel pressure bleeding past a fuel injector.
Fuel pressure bleeding past the check valve in t he
fuel filter/fuel pressure regulator.
(1) Disconnect t he fuel inlet tube at fuel rail (Fig.
18). This is done by pushing on plastic part of quick-
connect fitting on t ube (Fig. 19).
Fig. 18 Fuel Pressure Test Port5.9L Engines
connected fuel t ube and fuel rail.
(3) Connect t he 0-414 kPa (0-60 psi) fuel pressure
test gauge (from Gauge Set 5069) to t he test port on
tool 6631. The fi t t i ngs on bot h t ool s mus t be i n
good condi t i on a n d free from a ny smal l l eaks
bef or e per f or mi ng t he pr oceedi ng t est ,
(4) St art engine and bring to normal operating
t emperat ure.
(5) Observe t est gauge. Normal operating pressure
should be 241-310 kPa (35-45 psi).
(7) Pressure should not fall below 24 psi for five
mi nut es.
FUEL TUBE REMOVAL
QUICK CONNECT
FITTING
PUSH
PUSH
PUSH
INSTALLATION
X
PUSH
/
PUSH
PLASTIC
RETAINER
J 9314- 10 0
Fig. 19 Removing/Installing Quick-Connect Fitting
(8) If pressure falls below 24 psi, it must deter-
mined if a fuel injector, t he fuel module mounted fuel
pressure regulator or a fuel tube/line is leaking.
(9) Again, st art engine and bri ng to normal oper-
at i ng t emperat ure.
(11) Checki ng for fuel injector l eakage: Clamp
off t he rubber hose portion of tool 6539 between t he
disconnected fuel tube (line) and test port inlet. If
pressure now holds at or above 24 psi, a fuel injector
or t he fuel rail is leaking.
Checki ng for fuel pressure regulator or fuel
tube l eakage: Clamp off t he rubber hose portion of
tool 6539 between t he fuel rail and test port inlet. If
pressure now holds at or above 24 psi, a leak can be
found at a fuel tube/line. If no leaks are found at fuel
tubes, replace t he fuel filter/fuel pressure regulator.
MECHANICAL MALFUNCTIONS
Mechanical malfunctions are more difficult to diag-
nose wi t h t hi s system. The powertrain control mod-
ule (PCM) has been programmed to compensate for
some mechanical malfunctions such as incorrect cam
timing, vacuum leaks, etc. If engine performance
problems are encountered and a diagnostic trouble
code (DTC) is not displayed, t he problem may be me-
chanical r at her t han electronic.
FUEL F I LTE R- 3. 9L/ 5. 2L GAS ENGINE
For diesel engines, refer to Fuel/Water Separator
Filter in t he Diesel Fuel InjectionService Proce-
dures section of t hi s group.
REMOVAL
WA R N I N G : THE F U E L S Y S T E M I S U N D E R A C O N -
S T A N T P R E S S U R E (EVEN WITH THE E N G I N E OFF).
BEFORE S E R V I C I N G THE FUEL FILTER, THE FUEL
SYSTEM P R E S S U R E MUST BE RELEASED.
The fuel filter is located under t he vehicle and near
t he fuel t ank. It is mounted to t he frame rail (Fig.
20) .
(1) Perform Fuel System Pressure Release proce-
dure.
(4) Remove and discard both fuel hose-to-fuel filter
hose clamps.
(5) Wrap a shop towel around hoses to absorb fuel.
Remove hoses at filter.
(6) Remove filter from frame.
FUEL HOSES
HOSE
CLAMPS
. FILTER MOUNT I NG
BOLT
FUEL
FILTER
J921 4 - 6 8
Fig. 20 Fuel Filter3.9U5.2L Engine
INSTALLATION
C A U T I O N : The t ubes/ hoses used on fuel injected
vehi cl es are of a speci al constructi on. T hi s i s due
to the higher fuel pr essur es and the possi bi l i ty of
contami nated fuel in this syst em. If it i s necessar y
to replace these t ubes/ hoses, onl y t ubes/ hoses
marked E F M / E F I may be used.
C A U T I O N : The hose cl amps used on fuel injected
vehi cl es are of a speci al rolled edge constructi on to
prevent the edge of the cl amp from cutting into the
hose. Onl y these rolled edge type cl amps may be
used in this syst em. All other t ypes of cl amps may
cut into the hoses and cause hi gh pressure fuel
l eaks.
(1) Install fuel filter to frame rail. Tighten mount-
ing bolt to 8 Nm (75 in. lbs.) torque.
(2) Install new original equipment clamps to fuel
hoses.

FUEL SYSTEM 14- 11
(3) Install hoses to filter. Tighten clamps to 1 N*m
(4) Lower vehicle.
(6) St ar t engine and check for leaks.
FUEL FILTER5.9L GAS ENGINE
For diesel engines, refer to Fuel/Water Separator
Filter i n t he Diesel Fuel InjectionService Proce-
dures section of this group.
The fuel filter and fuel pressure regulator (Fig. 21)
are one non-repairable component. For service, refer
to Fuel Filter/Fuel Pressure Regulator. This can be
found i n the Multi-Port Fuel Injection (MPI)Com-
ponent Removal/Installation section of this group.
ROLLOVER VALVE J931 4 - 1 6 7
Fig. 21 Fuel Filter/Fuel Pressure Regulator5.9L
Engine
FUEL TUBES/ LINES/ HOSES AND CLAMPS
Also refer to Quick-Connect Fi t t i ngs in t hi s sec-
tion.
B E F O R E S E R V I C I N G A N Y F U E L S Y S T E M H O S E S ,
F I T T I N G S O R L I N E S , T HE F U E L S Y S T E M P R E S -
S U R E M U S T B E R E L E A S E D - R E F E R T O T HE F U E L
P R E S S U R E R E L E A S E PR O C E D U R E I N T HI S
G R O U P.
Inspect all hose connections such as clamps, cou-
plings and fittings to make sure they are secure and
leaks are not present. The component should be re-
placed immediately if t here is any evidence of degra-
dation t hat could result in failure.
Avoid contact of any fuel tubes/hoses with other ve-
hicle components t hat could cause abrasions or scuff-
ing. Be sure t hat t he plastic fuel tubes are properly
routed to prevent pinching and to avoid heat sources.
C A U T I O N : The t ubes/ hoses used on fuel injected
vehi cl es are of a speci al constructi on. T hi s i s due
to the hi gher fuel pressures and the possi bi l i ty of
contami nated fuel in thi s syst em. If it i s necessar y
to replace these t ubes/ hoses, onl y t ubes/ hoses
marked E F M / E F I may be used.
C A U T I O N : The hose cl amps used on fuel injected
vehi cl es are of a speci al rolled edge const ruct i on to
prevent the edge of the cl amp from cutting into the
hose. Onl y these rolled edge type cl amps may be
used in thi s syst em. All other types of cl amps may
cut into the hoses and cause hi gh pressure fuel
l eaks.
Use new original equipment type hose clamps.
Tighten hose clamps to 1 N*m (10 in. lbs.) torque.
QUICK-CONNECT FITTINGS
Also refer to t he previous Fuel Tubes/Lines/Hoses
and Clamps.
Two different types of Quick-Connect fittings are
used at several fuel system connections. One type of
fitting will be referred to as a Tab Type Fi t t i ng. The
other will be referred to as a Plastic Ring Type fit-
ting.
C A U T I O N : Qui ck- connect fittings are not servi ced
separately. D o not attempt to repair damaged qui ck-
connect fittings or fuel tubes. Repl ace the compl ete
fuel tube/ qui ck- connect fitting assembl y.
TAB TYPE FITTING
This fitting is equipped with a ret ai ner t ab (Figs.
22 or 23) t hat must be released prior to disconnecting
t he fitting from t he fuel tube. This type of fitting can
be disassembled either manual l y or with a st rai ght
blade screwdriver.
TUBE E N D TAB J9114 -16 7
Fig. 22 Tab Type Fitting
14 - 12 FUEL SYSTEM

PULL TAB
RETAINER TAB RETAINER TAB BENT
I N OR I GI NAL UPRIGHT D O WN FOR
POSI TI ON REMOVAL J9114-168
Fig. 23 Retainer Tabs
MANUAL DI SASSEMBLY
W ARNI NG: RE LE ASE F UE L SY STE M PRE SSURE
BE F ORE DI SCONNE CTI NG A Q UI CK - CONNE CT FIT-
TI NG. RE F E R TO TH E F UE L PRE SSURE RE LE ASE
PROCE D URE .
(1) Disconnect negative cable from t he bat t ery,
(2) Perform t he Fuel Pressure Release Procedure.
Refer to t he Fuel Pressure Release Procedure in t hi s
section.
(3) Bend t he ret ai ner t ab downward (Fig. 23).
CAUTI ON: If the retainer tab on the removable pull
tab is not bent down prior to disconnecting quick-
connect fitting, the connector could be damaged.
(4) While pushi ng upward on t he bottom side of
t he pull t ab, release t he ret ai ner legs by pulling
t hem away from each other (Fig. 24).
(5) Raise t he pull t ab unt i l t he hooks on t he re-
t ai ner legs clear t he stop on t he fuel t ube fitting
(Fig. 25).
PULL
Fig. 24 Separating Retainer Legs
Fig. 25 Manually Disconnecting Fitting
(6) Pull t he fuel t ube out of quick-connect fitting
(Fig. 26).
(7) Inspect t he quick-connect fitting body and re-
t ai ner for damage. Replace as necessary.
FUEL QUI CK C ONNE C T
TUBE FITTING
STOP J9114-171
Fig. 26 Fuel Tube and Fitting
(8) Prior to connecting t he fuel tube to quick-con-
nect fitting, check condition of t ube and clean t he
fuel t ube and fitting wi t h a lint-free cloth. Lubricate
it with clean engine oil.
(9) Insert t he fuel tube into quick-connect fitting
unt i l stop on fuel t ube rests agai nst back of fitting.
Push ret ai ner down unt i l it locks in place. Pull back
on fuel t ube and fitting to be sure of a complete con-
nection.
DI SASSEMBLY WITH SCREWDRIVER
W ARNI NG: RE LE ASE F UE L SY STE M PRE SSURE
BE F ORE DI SCONNE CTI NG A Q UI CK - CONNE CT FIT-
TI NG. RE F E R TO TH E F UE L PRE SSURE RE LE ASE
PROCE D URE .

FUEL SYSTEM 14 - 13
(1) Disconnect negative cable from t he bat t ery.
section.
(3) Bend t he ret ai ner t ab downward.
CAUTI ON : If the retainer tab on the removabl e pull
tab i s not bent down prior to di sconnect i ng the
qui ck- connect fitting, the connect or coul d be dam-
aged.
(4) Insert screwdriver tip between connector body
and ret ai ner pull t ab (Fig. 27).
RETAINER SCREWDRI VER
J9114- 172
J9114 -181
Fig. 29 Disconnecting Fitting
(9) Prior to connecting fuel t ube to quick-connect
fitting, check condition of t ube and clean t he fuel
t ube and fitting with a lint-free cloth. Lubricate it
wi t h clean engine oil.
(10) Insert fuel tube into quick-connect fitting un-
til stop on fuel tube rest s agai nst back of fitting.
Push ret ai ner down unt i l it locks in place. Pull back
on fuel t ube and fitting to be sure of a complete con-
nection.
PLASTIC RING TYPE FITTING
Fig. 27 Disassembly with Screwdriver
(5) Turn screwdriver 90 degrees to lift ret ai ner up
(Fig. 28).
RETAINER
PULL TAB
SCREWDRI VER
J91 1 4 - 1 73
Fig. 28 Releasing Retainer
(6) Raise t he pull t ab unt i l t he hooks on t he re-
t ai ner legs clear t he stop on t he fuel t ube fitting
(Fig. 29).
(7) Pull fuel t ube out of quick-connect fitting.
(8) Inspect fitting body and ret ai ner for damage.
Replace as necessary.
W ARN I N G: RE L E A S E F UE L SY STE M PRE S S URE
BE F ORE D I SCON N E CTI N G A Q UI CK - CON N E CT F I T-
TI N G. RE F E R TO TH E F UE L PRE S S U RE RE L E A S E
PROC E D URE .
This type of fitting contains non-serviceable sealed
O-rings.
(1) Disconnect negative cable from t he battery.
section.
(3) To release t he fuel tube from t he fitting, push
in on t he tube while pushi ng t he spring loaded plas-
tic ret ai ner ring into t he fitting (Fig. 30). With t he
plastic ri ng depressed, pull t he t ube from fitting. Af-
t er disconnection, t he plastic ret ai ner ri ng will re-
mai n on t he fitting.
(4) Inspect fitting connector body and plastic re-
t ai ner ri ng (Fig. 30) for damage. Replace as neces-
sary.
(5) Prior to connecting fuel t ube to quick-connect
fitting, check condition of tube and clean t he fuel
t ube and fitting with a lint-free cloth. Lubricate it
wi t h clean engine oil.
(6) Insert t he fuel t ube into quick-connect fitting
(Fig. 30) unt i l a click is felt. Pul l back on fuel tube
and fitting to be sure of a complete connection.
14 - 14 FUEL SYSTEM
FUEL TUBE REMOVAL
QUI CK C ONNE C T
FITTING
PUSH
INSTALLATION
^ PUSH -
/
PLASTIC
RETAINER J93U- 10 0
Fig. 30 Plastic Ring Type Fitting
PUSH
FUEL DELIVERYDIESEL ENGI NE
INDEX
page
Fuel Gauge Sendi ng Unit Module 15
Manual Shut Down Lever . . 17
page
Mechanical Lift Pump 1 5
Quick Connect FittingsEx cept Chassi s
Fuel Tubes 17
GENERAL INFORMATION
The fuel system of t he 5.9L turbo-diesel engine
consists of the:
Fuel t ank
Low and hi gh pressure fuel supply lines
Mechanical lift pump
Fuel/water separator filter
Fuel heat er
Fuel injection pump
Fuel injectors
Fuel r et ur n lines
For information regarding fuel requi rement s of t he
5.9L turbo diesel engine, refer to t he Fuel Require-
mentsDiesel Engines paragraph at t he front of t hi s
group.
MECHANICAL LIFT PUMP
The mechanical lift pump is located on t he left side
of the engine cylinder block. The lift pump is driven
by an eccentric on t he camshaft t hat actuates a
spring loaded lever in t he pump (Fig. 1). The lever is
connected to t he pump diaphragm. When t he eccen-
tric on t he camshaft pushes t he lever upward, the le-
ver in t ur n pulls t he diaphragm to its extended
position. Fuel is drawn into t he pump chamber
through t he inlet check valve. When t he pump gath-
ers more fuel in t he fuel chamber t han t he engine
can consume, t he outlet check valve is held closed.
The fuel gathered in lift pump chamber prevents t he
diaphragm from relaxing. The lever will continue to
move up and down on t he shaft connecting it to t he
diaphragm. However, t he lever is prevented from op-
erating t he diaphragm unt i l the check valve again
opens to expel fuel from t he pump chamber. This pro-
cess continues as long as t he engine is runni ng.
Minimum lift pump output pressure is 21 Kpa (3
psi). Lift pump output volume is 0.75 liters (0.70 U.S.
quarts) per 30 seconds of engine cranking.
The lift pump housing has a weep hole at t he bot-
tom of t he casing (Fig. 1). If t he di aphragm rupt ures,
fuel will exit out of t he weep hole and t he pump
must be replaced. The lift pump is not serviceable
and must be replaced as a complete assembly.
C A U T I O N : Do not operate the engi ne if the fuel sup-
ply line has a restriction of more than 95 M M Hg
( 3.75 in Hg) .
Fig. 1 Lift Pump
The lift pump has a manual lever.(Fig. 2). The le-
ver is located on t he lower ri ght side of t he pump
housing. The purpose of t he lever is to prime t he fuel
system and bleed air from t he system if t he vehicle
has run out of fuel. To prime t he system up to t he
injector pump, raise and lower t he lever until resis-
tance is felt. During vehicle operation t he pump le-
ver must be in t he up position.
J9114-3
Fig. 2 Lift Pump Manual Lever
FUEL GAUGE SENDING UNIT MODULE
The fuel gauge sending uni t module is installed in
t he top of t he fuel t ank (Fig. 3). The fuel gauge send-
ing unit module contains t he following components
(Fig. 4).
1 4 - 1 6 FUEL SYSTEM

Fuel t ank reservoir
Separate in-tank fuel filter
Fuel gauge sending uni t
Fuel filler vent
Fig. 3 Top View of Fuel Gauge Sending Unit
J9114-229
Fig. 4 Fuel Gauge Sending Unit Module--Diesel
Engine
REMOVAL
C A U T I O N : W henever t he fuel modul e i s ser vi c ed,
the l ocknut (collar) and gasket must be r epl aced.
(1) Drain t he fuel t ank. Eefer to Drai ni ng Fuel
Tank in t he Fuel Tank section of t hi s group.
(2) Remove fuel t ank. Refer to Fuel Tanks in t hi s
group.
(3) The fuel module locknut (collar) is threaded
onto t he fuel t ank. Remove t he fuel module locknut
(Fig. 3) . The fuel module will spring up when t he
locknut is removed.
(4) Remove module from fuel t ank.
DISASSEMBLY
FUEL GAUGE SENDING UNIT
(1) Remove sending uni t mount i ng screws (Fig. 5).
(2) Mark t he sending uni t electrical wires for cor-
FUEL G A U G E TABS
I N-TANK
FUEL FILTER J9114-146
Fig. 5 Fuel Gauge Sending Unit and In-Tank Filter
Service
rect installation when t he new uni t is installed.
Carefully disconnect electrical wires from sending
unit. Remove sending unit.
(3) Reverse order of removal for installation.
IN-TANK FUEL FILTER
C A U T I O N : The diesel in-tank fuel filter i s si mi l ar in
appearance to filter used with gasol i ne engi nes ex-
cept for col or. The in-tank filter must be replaced
with filter intended for diesel vehi cl es.
The in-tank filter is attached to t he bottom of t he
fuel module (Fig. 5).
(1) Pry t he mount i ng tabs back and remove t he in-
t ank fuel filter.
(2) Install new fuel filter into ret ai ni ng t abs.
FUEL GAUGE SENDING UNIT MODULE
INSTALLATION
C A U T I O N : Whenever the fuel modul e i s servi ced,
the locknut and gasket must be replaced.

FUEL SYSTEM 14- 17
(1) Using a new gasket, position fuel module into
opening in fuel t ank.
(2) Position new locknut over top of fuel module.
(3) Tighten locknut.
tion in this section.
MANUAL SHUT DOWN LEER
The injection pump has a manual shut down lever
(Fig. 6). In an emergency, t he engine can be shut
down by t urni ng the lever forward.
Fig. 6 Manual Shut Down Lever
QUICK CONNECT FITTINGS-EXCEPT CHASSIS
FUEL TUBES
Quick Connect fittings are used at several fuel sys-
t em connections (Fig. 7). The fittings have a ret ai ner
t ab. The retainer must be released before disconnect-
ing the fittings from t he fuel t ube (Fig. 8).
Fig. 7 Quick Connect Fittings
DISASSEMBLY
Quick Connect fittings can be disassembled either
manual l y or with a st rai ght blade screwdriver.
PULL TAB
RETAINER TAB RETAINER TAB BENT
I N ORIGINAL UPRIGHT DOWN FOR
POSITION REMOVAL J9114-168
Fig. 8 Retainer Tabs
MANUAL DI SASSEMBLY
C A U T I O N : If retainer tab on removable pull tab i s
not bent down before di sconnect i ng qui ck connect
fitting, connect or coul d be damaged.
PULL
Fig. 9 Separating Retainer Legs
(2) While pushi ng upward on t he bottom side of
t he pull t ab, release t he ret ai ner legs by pulling
t hem away from each ot her (Fig. 10).
(3) Raise t he pull t ab unt i l hooks on the ret ai ner
legs clear t he stop on t he fuel tube fitting (Fig. 10).
(4) Pull fuel t ube out of connector (Fig. 11).
(5) Inspect connector body and ret ai ner for dam-
age. Replace as necessary.
Before connecting t he fuel tube to t he quick con-
nect fitting, clean t he fuel tube fitting. Lubricate t he
fitting wi t h clean engine oil.
(6) Insert fuel t ube into quick connect fitting until
stop on fuel tube rests agai nst back of fitting. Push
14 - 18 FUEL SYSTEM

RETAINER
CLEAR OF
FUEL TUBE
FUEL TUBE
RETAINER
PULL
TAB
SCREWDRI VER
ff
\
t
i i i i l i l
J9114-170
Fig. 10 Manually Disconnecting Quick Connect
Fitting
FUEL
TUBE
QUI CK C ONNE C T
FITTING
RETAINER
PULL TAB
J9114-172
Fig. 12 Disassembly with Screwdriver
SCREWDRI VER
FUEL
TUBE
STOP J9114-171
Fig. 11 Fuel Tube and Quick Connect Fitting
ret ai ner down unt i l it locks in place. Pull back on
fuel t ube and fitting to be sure of a complete connec-
tion.
DI SASSEMBLY WITH SCREWDRIVER
CAUTI ON: If the retainer tab on the removable pull
tab is not bent down before disconnecting the
qui ck connect fitting, the connector coul d be dam-
aged.
(2) Insert screwdriver tip between connector body
and ret ai ner pull t ab (Fig. 12).
(3) Turn screwdriver 90 degrees to lift ret ai ner up
(Fig. 13).
(4) Raise pull t ab unt i l hooks on t he ret ai ner legs
clear t he stop on t he fuel t ube fitting (Fig. 14).
(5) Pull fuel tube out of connector (Fig. 11).
(6) Inspect connector body and ret ai ner for dam-
age. Replace as necessary.
J9114-173
Fig. 13 Releasing Retainer
RETAINER ^SCREWDRI VER
J9114-181
Fig. 14 Disconnecting Quick-Connect Fitting
Before connecting fuel tube to quick connect fit-
ting, clean t he fuel tube fitting. Then lubricate t he
fitting with clean engine oil.

FUEL SYSTEM 14 - 19
(7) Insert fuel t ube into quick connect fitting until
stop on fuel tube rests agai nst back of fitting. Push
ret ai ner down until it locks in place. Pull back on
fuel t ube and fitting to be sure of a complete connec-
tion.
CHASSIS FUEL TUBE QUICK-CONNECT
FITTINGS
Quick-connect fuel tube fittings are used at t he
ends of t he chassis fuel t ubes (lines) (Fig. 15). The
fitting consists of O-rings and a plastic release collar
to disconnect t he fitting from t he fuel tube.
QUI CK-CONNECT
FITTING
FUEL
J9014-187
Fig. 15 Quick-Connect FittingChassis Fuel Tubes
At t he end of t he fuel tube fitting is a raised shoul-
der. When t he fuel t ube is installed into t he quick-
connect fitting, t he shoulder is locked in place by
t angs inside t he fitting (Fig. 16). After t he t ube is in-
stalled into t he fitting, Verify t hat connection is se-
cure by firmly pulling back on fuel tube (Fig. 17).
The tube should be locked in place.
To disconnect t he fitting from t he fuel tube, pull
t he release collar back into t he fitting. Then slide t he
fitting off t he fuel t ube (Fig. 18).
QUI CK CONNECT
COLLAR
, w r L C
J9014-188
Fig. 16 Quick-Connect Fitting AssemblyChassis
Fuel Tubes
FUEL
TUBE
QUI CK-CONNECT
FITTING J9014-189
Fig. 17 Assembled Quick-Connect FittingChassis
Fuel Tubes
Fig. 18 Quick-Connect Fitting
Disassembly Chassis Fuel Tubes

F UE L TANKS
INDEX
page
Fuel Gauge Sendi ng Unit 24
Fuel Pump 22
Fuel Reservoir 23
Fuel Tank Filler Tube Cap 20
Fuel Tank Pressure Relief/Rollover Val ve . . . . . . 24
GENERAL INFORMATION
All Dodge Trucks pass a full 360 degree rollover with-
out fuel leakage. To accomplish this, fuel and vapor
flow controls are required for all fuel tank connections.
All models have a pressure relief/rollover valve
mounted in the top of the fuel tank. On vehicles
equipped with a return line from fuel pump to fuel
tank, a one-way check valve is used to provide required
protection. In addition to the valve, improved flow con-
trol is used in the fuel pump. Fuel flow is controlled if
pump is subjected to higher than normal pressure dur-
ing rollover. For the same reason, a fuel tank filler tube
cap (gas cap) with higher pressure setting is used to
control fuel flow on vehicles with side fill.
An evaporation control system is used to reduce
emissions of fuel vapors into atmosphere by evapora-
tion and to reduce unburned hydrocarbons emitted
by vehicle engine. When fuel evaporates from fuel
t ank, vapors pass t hrough vent hoses or tubes to a
charcoal canister. The are temporarily held in t he
canister. When t he engine is runni ng, t he vapors are
drawn into i nt ake manifold. Refer to Group 25,
Emission Control System for additional information.
Inspect all hose connections to make sure t hey are
secure and not leaking. Hoses should be replaced im-
mediately if t here is any evidence of degradation
t hat could result in failure.
Avoid contact with clamps or other components
t hat cause abrasions or scuffing. Be sure t hat t he
rubber hoses are properly routed to prevent pinching
and to avoid heat sources.
The hoses used on fuel injected vehicles are of a
special construction due to hi gher fuel pressures in-
volved in system. If hoses need replacement, only use
hoses marked EFM/EFI.
The hose clamps used on fuel injected vehicles have
a special rolled edge construction. This prevent s t he
edge of t he clamp from cut t i ng into t he hose. Only
these rolled edge type clamps may be used on t hi s
system. Other clamps may cut into t he hoses. This
could cause hi gh pressure fuel leaks.
NO-LEAD FUEL TANK FILLER TUBE
All catalyst equipped vehicles have a special fuel
t ank filler tube. The fuel filler opening is smaller in
page
Fuel Tank Ski d Plate . 20
Fuel Tanks 21
Heat Shi el ds 21
No- Lead Fuel Tank Filler Tube 20
diameter t han those used for non-catalyst vehicles to
permit ent ry of only t he smaller no-lead fuel nozzles.
A deflector is installed in t he fuel filler opening. The
deflector is opened by t he no-lead fuel nozzle.
The fuel filler t ube on these models has a one-way
ball check valve. The valve is designed to prevent
fuel back splash which may occur while filling t he
t ank.
A label is attached to i nst rument panel under fuel
gauge t hat reads UNLEADED FUEL ONLY as a re-
minder to driver. A similar label is located near fuel
t ank filler.
FUEL TANK FILLER TUBE CAP
The loss of any fuel or vapor out of filler neck is
prevented by t he use of a pressure-vacuum fuel t ank
filler t ube cap. Relief valves inside cap will release
only under significant pressure of 6.58 to 8.44 kPa
(1.95 to 2.5 psi). The vacuum release for all gas caps
is between .97 and 2.0 kPa (.14 and .29 psi). This cap
must be replaced by a similar uni t if replacement is
necessary. This is in order for t he system to remai n
effective.
C A U T I O N : R emove fuel tank filler tube cap before
servi ci ng any fuel syst em component . T hi s i s done
to help relieve tank pressure.
FUEL TANK CAPACITIES
TANK: LITERS GALLONS
Standard 83.0 22
Optional 114 30
Ramcharger 120.9 34
Nominal refill capacities are shown. A variation may be observed
from vehicle to vehicle due to manufacturing tolerances and refill
procedures.
J9014-182
FUEL TANK SKID PLATE
A protective met al skid plate is available for t he
Ramcharger thirty-four (34) gallon fuel t ank (Fig. 1).
The plate is mounted to t he frame rails and to brack-
ets attached to frame crossmembers.

FUEL SYSTEM 1 4 - 2 1
FRAME RAIL
SKI D PLATE
RN869
Fig. 1 Fuel Tank Skid Plate
HEAT SH IELDS
The sheet metal heat shields must be removed
when servicing fuel t ank, fuel tubes/lines or vapor
vent line. It is very important that these heat
shields be reinstalled after service. They are used
to protect lines and t ank from heat of exhaust sys-
tem. See Group 11 in t hi s manual for proper instal-
lation.
FUEL TANKS
DRAINING FUEL TANK
(1) Remove fuel t ank filler t ube cap to release fuel
t ank pressure.
(2) Perform Fuel System Pressure Release proce-
dure as described in t hi s group.
(4) Drai n fuel into an approved portable holding
t ank or a properly labeled gasoline safety container.
If fuel pump operates, fuel can be drained t hrough
fuel supply hose. The DRB II scan tool can be used to
operate t he electric fuel pump (gas engines only).
If pump does not operate, but fuel level in fuel
t ank is below fuel filler hose, fuel can be siphoned
through fuel filler hose. The hose will have to be dis-
connected from filler neck.
If fuel t ank is full and fuel pump does not operate,
drain fuel from filler neck. Support fuel t ank with a
transmission jack. Loosen fuel t ank mount i ng st raps
with passenger side fuel st rap loosened slightly more
t han driver side strap. Lower t he t ank slightly.
Loosen t he filler neck-to-filler hose clamp. Slide
clamp back on hose. Wrap shop towels around fuel
filler hose to absorb any spilled fuel. Disconnect filler
hose from filler neck. Drai n fuel t ank t hrough filler
hose.
REMOVAL-MID-FRAME MOUNTED TANKS
(1) Drai n fuel t ank. Refer to Drai ni ng Fuel Tank
in this group.
(3) Remove fuel t ank filler tube cap.
(4) Pump all fuel from fuel t ank into an approved
portable holding t ank. If t hi s equipment is not avail-
able, disconnect fuel tube (line) and drain t ank dry
into a properly identified Gasoline safety container.
Refer to Drai ni ng Fuel Tank.
(5) Raise vehicle on hoist. Disconnect all vent
hoses and filler hose (Figs. 2 and 3).
PRESSURE RELIEF/
F U E L F , L T E R
J9014-191
Fig. 2 Hose ConnectionsMid-Frame Mounted Fuel
TanksTypical
(6) Place a transmission jack under t he center of
t he fuel t ank. Apply a slight amount of pressure to
fuel t ank with transmission jack.
WA R N I N G : WR A P S H O P T O WE L S A R O U N D H O S E S
T O C A T C H A N Y G A S O L I N E S PI L L A G E .
(7) Remove fuel t ank mount i ng st rap nut s at t he
crossmembers (Fig. 4). Lower fuel t ank enough to
permit fuel gauge wire and fuel t ubes to be discon-
nected from fuel pump module at top of fuel t ank.
Disconnect fuel tubes from fuel pump module (Fig.
5). Refer to Quick-Connect Fi t t i ngs in t he Fuel De-
livery sections of this group.
(8) Lower fuel t ank.
INSTALLA TIONMID-FRAME MOUNTED
TANKS
(1) Place fuel t ank on top of transmission jack.
Raise t ank unt i l fuel supply t ube, r et ur n tube and
pump/gauge sending uni t connector can be connected
to fuel pump module. Refer to Quick-Connect Fit-
tings in t he Fuel Delivery sections of this group.
(2) Raise t ank into position under frame cross-
members and connect t he two end mount i ng straps.
Remove transmission jack. Tighten all straps firmly.
Do not over t i ght en ret ai ni ng st rap nut s.
14 - 22 FUEL SYSTEM

CLAMP
(2)
VIEW IN DIRECTION
OF ARROW Z
CLAMP
(20 I NCH-POUNDS)
RB1362A
Fig. 3 Fuel Tank Filler Tube Connections-
(3) Connect vent hoses.
(4) Connect fuel t ube (line) if it was disconnected
to drai n t ank.
(5) Refill fuel t ank and inspect all hoses and lines
for leaks. Connect bat t ery cable to bat t ery.
RE MO VA LRAMCHARGER MODELS
(1) Drai n fuel t ank. Refer to Drai ni ng Fuel Tank
in t hi s section.
(3) Remove fuel t ank filler t ube cap to release fuel
t ank pressure.
(4) Pump all fuel from fuel t ank into an approved
portable holding t ank. If t hi s equipment is not avail-
able, disconnect t he fuel t ube (line) and drai n t ank
dry into a properly identified Gasoline safety con-
tainer.
(6) Place transmission jack under center of t ank
and apply slight pressure. Disconnect t he t ank
mount i ng st raps J-bolts and remove ret ai ni ng st raps
(Fig. 6).
(7) Lower fuel t ank enough to permi t fuel gauge
wire and fuel t ubes to be disconnected from fuel
pump module. The fuel pump module is located at
top of fuel t ank. Disconnect fuel tubes from fuel
pump module on top of t ank (Fig. 7). Refer to Quick-
Connect Fi t t i ngs in t he Fuel Delivery sections of t hi s
group.
-Mid-Frame Mounted Fuel TanksTypical
(8) Remove fuel t ank filler tube hose and fill vent
hose from t ank (Figs. 7 and 8).
(9) Lower t he fuel t ank.
INSTALLATION
(1) Position t ank on transmission jack.
(2) Raise t ank until fuel supply tube, r et ur n t ube
and pump/gauge sending uni t connector can be con-
nected to fuel pump module. Refer to Quick-Connect
Fi t t i ngs in t he Fuel Delivery sections of t hi s group.
(3) Raise t ank into position.
(4) Install t ank mounting straps. Connect J-bolts
and t i ght en nut s as shown in Fig. 7.
(5) Remove jack.
(6) Connect t ank filler t ube and all vent hoses. In-
stall new hose clamps and t i ght en securely.
(7) Fill fuel t ank and inspect all hoses and lines
for leaks.
FUEL PUMP
REMOVAL/INSTALLA TION
Gas Engines: Refer to Fuel Pump Module in t he
Fuel Delivery System section of t hi s group.
Diesel Engines: Refer to Mechanical Lift Pump in
t he Diesel section of this Group.

FUEL SYSTEM 14 - 23
USED WITH
7-INCH RAIL
TI GHTENI NG TORQUE
A 30 FT LBS (41 N-m)
B TIGHTEN TO SECURE TANK
C 100 I N LBS (11 N-m)
REAR
STRAP
VIEW I N CIRCLE Z
(30 G A L TANK)
PRESSURE RELIEF/
ROLLOVER VALVE
LOCKNUT
Fig. 4 Mid-Frame Mounted Fuel Tank Removal/InstallationTypical
PU M P/ G A U G E
S E NDI NG
UNIT
ELECTRICAL
CONNECTOR
FUEL
SUPPLY
TUBE
FUEL
RETURN
TUBE
J9114-232
J9014-183
NUT (2)
ASSEMBLY
(200 I NCH-POUNDS)
Fig. 5 Fuel Pump Module ConnectionsTypical
FUEL RESERVOIR
The fuel reservoir (Fig. 9) is par t of t he lower end
of t he fuel pump module. The purpose of t he reser-
voir is to provide fuel at t he pump i nt ake duri ng all
driving conditions. This is especially those times
TIGHTEN NUT TO
END OF THREAD
O N STUD
VIEW A -
STRAP ADJUSTMENT J9014-184
Fig. 6 Ramcharger Fuel Tank Removal/Installation
FUEL TANK
Ô U N T WG ASSEMBLY
ol KAP5>
14 - 24 FUEL SYSTEM

FUEL TUBES
TO FILLER
N E C K
J9014-185
Fig. 7 Fuel Tube ConnectionsRamcharger
CLAMP
J9014-186
Fig. 8 Fuel Tank Tube Connections
when low fuel levels are present. The fuel r et ur n line
directs fuel into t he reservoir.
FUEL
HOUS I NG J9114-162
Fig. 9 Fuel Reservoir HousingTypical
FUEL GAUGE SENDING UNIT
The fuel gauge sending uni t is attached to t he fuel
pump module. Refer to Fuel Delivery System in t hi s
group for fuel gauge sending uni t service.
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
The fuel t anks of all vehicles have a pressure re-
lief/rollover valve. The valves relieve fuel t ank pres-
sure and prevent fuel flow t hrough fuel t ank vent
hoses duri ng rollover. All vehicles pass a full 360 de-
gree rollover without fuel leakage.
The pressure relief/rollover valve (Fig. 5) is
mounted at top of fuel pump module.
REMOVAL
(1) Remove fuel t ank. Refer to Fuel Tanks section
in t hi s group.
(2) Wedge t he blade of a st rai ght screwdriver be-
tween rubber grommet and fuel t ank where support
rib is located. Do not wedge bet ween val ve and
grommet or damage to val ve may result upon re-
moval .
(3) Use a second screwdriver as a support to pry
valve and grommet assembly from t ank.
(4) To remove grommet from valve, place valve up-
ri ght on a flat surface. Push down on t he grommet.
Peel t he grommet off t he valve.
INSTALLATION
(1) Install rubber grommet in fuel t ank and work
it around t he curled lip.
(2) Lubricate grommet with power steering fluid
and push valve downward into grommet. Twist valve
unt i l properly positioned.
tion.
ACCELERATOR PEDAL AND THROTTLE CABLE
INDEX
page
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . 25
GENERAL INFORMATION
All gas powered models have torsion ret urn springs
on t he throttle body. Models equipped wi t h a manual
transmission have an additional pedal ret urn spring
(Fig. 1). These springs give positive throttle ret urn
and lower throttle pedal efforts while meet i ng safety
requirements.
Fig. 1 Throttle Body Return SpringManual
TransmissionExcept Diesel
ACCELERATOR PEDAL
C A U T I O N : Be careful not to damage or kink the ca-
ble core wire (within the cabl e sheat hi ng) while ser-
vi ci ng accelerator pedal or cabl es.
REMOVAL
(1) From inside t he vehicle, hold up accelerator
pedal. Remove plastic cable ret ai ner and t hrot t l e ca-
ble core wire from upper end of pedal arm (Fig. 2).
The plastic cable ret ai ner snaps into pedal arm.
(2) Remove 2 accelerator pedal/bracket nut s (Fig.
2) and remove pedal/bracket assembly from vehicle.
INSTALLATION
(1) Position pedal/bracket assembly over t he two
dash panel mount i ng studs and install ret ai ni ng
nuts.
(2) Tighten nut s to 7 N*m (6 5 in. lbs.) torque.
(3) From inside t he vehicle, hold up t he accelerator
pedal. Install t he t hrot t l e cable core wire and plastic
cable ret ai ner into t he upper end of t he pedal arm.
page
Throttle Cabl eEx cept Diesel . . . . . . . . . . . . . . . 25
Throttle Linkage Adj ustmentDiesel Engine . . . . 26
PI NCH
SI DES
PEDAL J9314-103
Fig. 2 Accelerator PedalRemoval or Installation
The plastic ret ai ner is snapped into t he pedal arm.
When installing t he plastic ret ai ner to t he accelera-
tor pedal arm, note t he index t ab on t he pedal ar m
(Fig. 3). Align t he index slot (Fig. 3) on t he plastic
cable ret ai ner to t hi s index t ab.
THROTTLE CABLE - E X CE PT DIESEL
CAUTI ON : Be careful not to damage or kink the ca-
ble core wire (within the cabl e sheathi ng) while ser-
vi ci ng accel erator pedal or cabl es.
REMOVAL
(1) From inside t he vehicle, hold up accelerator
pedal. Remove plastic cable ret ai ner and t hrot t l e ca-
ble core wire from upper end of pedal arm (Fig. 2) .
Plastic cable ret ai ner snaps into pedal arm.
(2) Remove t he cable core wire at t he pedal arm.
14 - 26 FUEL SYSTEM

I NDEX
SLOT
INDEX TAB
PEDAL
A R M
CABLE
RETAINER J9314-104
Fig. 3 Index Tab and Slot
(3) From inside t he vehicle, pinch both sides of t he
cable housing ret ai ner at t he dash panel (Fig. 2). Re-
move cable housing from dash panel and pull into
t he engine compartment.
(4) Remove t he air cleaner housing.
(5) Remove t he throttle cable ball end socket at
t hrot t l e body linkage (Fig. 4) (snaps off).
(6) Remove cable housing at t hrot t l e body mount-
ing bracket by pressing forward on release t ab wi t h a
small screwdriver (Fig. 5). To prevent cabl e hous-
i ng breakage, press on the tab onl y enough to
rel ease the cabl e from the bracket. Lift t he cable
housing st rai ght up from bracket while pressing on
release t ab. Remove cable housing.
(7) Disconnect cable from radi at or fan shroud rout-
ing clip.
(8) Remove cable from vehicle.
TRANS.
CONTROL
CABLE
CABLE
END
SPEED
CONTROL
CABLE
THROTTLE
CONTROL CABLE
Fig. 4 Throttle CableExcept DieselTypical
INSTALLATION
(1) Connect cable end to t hrot t l e body linkage ball
(snaps on). Connect cable to t hrot t l e body bracket ,
(push down and lock). Connect cable to fan shroud
clip.
^ ^ J 9 3 1 4 - 1 0 5
Fig. 5 Cable Release TabExcept DieselTypical
(2) Install t he remai ni ng cable housing end into
t he dash panel opening (snaps into position).
(3) Install t he ball end of t he cable wire t hrough
t he hole in t he pedal arm. Install t he plastic cable re-
tainer. The plastic ret ai ner is snapped into t he pedal
arm. When installing t he ret ai ner to t he accelerator
pedal arm, note t he index t ab on t he pedal arm (Fig.
3). Align t he index slot (Fig. 3) on the plastic re-
t ai ner to this index t ab.
THROTTLE LINKAGE ADJUSTMENT-DIESEL
ENGINE
The t hrot t l e linkage between t he t hrot t l e cam and
fuel pump lever is adjustable. Adjust linkage to be
sure of full t ravel of t hrot t l e lever.
C A U T I O N : Before adjusti ng injection pump throttle
l i nkage, verify that engi ne i s set at correct low idle
speed. Refer to L ow I dle S peed Setting in the S er-
vice Adj ust ment sDi esel secti on of this gr oup.
(1) Disconnect t hrot t l e cable from ball stud on
t hrot t l e cam (Fig. 6).
THROTTLE
LEVER
BALL
STUD
BREAKOVER
S PRI NG
THROTTLE.
CABLE ^J9114
r
207
Fig. 6 Throttle Cable and Bali Stud-Diesel

FUEL SYSTEM 14 - 27
(2) Insert a 0.50 mm (0.020 inch) feeler gauge be-
tween throttle cam and cam stop (Fig. 7).
BALL
STUD
J9114-206
Fig. 7 Throttle Cam and Cam StopDiesel
(3) Verify t hat injection pump throttle lever is con-
tacting the low idle speed stop screw (Fig. 6).
(4) Verify t hat t he spring load breakover lever has
moved off t he stop and is agai nst breakover spring
(Fig. 8).
BREAKOVER
SPRI NG
J9114-208
Fig. 8 Correct Breakover Spring PositionDiesel
(5) If throttle lever does not contact idle stop screw
and breakover spring is not agai nst stop (Fig. 9), t he
throttle actuation rod must be adjusted.
(6) One of t he t hrot t l e actuation rod lock nut s is a
left hand t hread. An L is marked on the flat of rod to
identify which locking nut has left hand t hread (Fig.
10).
(7) Hold t he actuation rod on the flat and loosen
locking nut s.
' BREAKOVER
S PR I NG
J9114-209
Fig. 9 Incorrect Breakover Spring PositionDiesel
THROTTLE
ACTUATION
ROD
L I NDI CATI NG
LEFT HA N D
THREAD NUT
J9114-210
Fig. 10 Throttle Actuation RodDiesel
(8) The throttle actuation rod can be rotated to in-
crease or decrease adjustment (Fig. 10).
(9) Adjust t he throttle actuation rod unt i l :
The t hrot t l e lever contacts idle stop screw.
The spring loaded breakover lever has moved off
t he stop and is against breakover spring (Fig. 8).
(10) Tighten locking nut s.
(11) Remove t he feeler gauge.
(12) Connect throttle cable to ball stud on t hrot t l e
cam.
(13) With engine off, operate t he t hrot t l e from ac-
celerator pedal and check for throttle lever breakover
in both idle and full positions (Fig. 11).
(14) Check engine rpm at low idle speed and at
full throttle. Check with t he air conditioning on and
transmission in drive (automatic transmission). Be
sure t hat t he parki ng brake is set. If engine will not
meet full throttle limit and low pressure fuel system
and injectors are functioning correctly, remove injec-
tion pump for service.
Fig. 11 Checking For BreakoverDiesel
LOW IDLE STOP SPEED-DIESEL
Transmi ssi on M i n i mu m RPM
Automatic 700 RPM
Manual 750 RPM
J9114-212
FULL THROTTLE STOP SPEED-DIESEL
Mi ni mum RPM M a x i mu m RPM
2825 RPM 2925 RPM
J9114-213

MULTI-PORT FUEL INJECTION (MPI)-COMPONENT DESCRIPTION/SYSTEM
OPERATION-EXCEPT DIESEL
INDEX
page
Air Conditioning ( A/ C) Clutch Rel ay- Per n Output . 35
Air Conditioning ( A/ C) Cont r ol sPCM Input . . . . 31
Auto Shut Down ( ASD) Re l a y - PC M Output . . . . 36
Automatic Shut Down ( ASD ) S e n s e - PC M Input . 31
Battery V ol t age - PCM Input 32
Brake Swi t c h - PCM Input 32
Camshaft Position Sens or PCM Input 32
Charge Air Temperature Sens or PCM Input . . . 32
Crankshaft Position Se n s o r - PC M Input . . . . . . . 32
Electric Ex haust Gas Recirculation Transducer
( E E T) Sol e noi d - PCM Output . . . . . . . . . . 36
Engine Coolant Temperature Sens or PCM Input . 33
E V AP Canister Purge Sol enoi dPCM Output . . . 37
Fuel I nj ec t or s- PCM Output 37
Fuel Pressure Regulator 4 1
Fuel Rail 4 1
Generator F i e l d - PCM Output 36
Generator L a mp - PC M Output 36
Idle Air Control ( IAC) M o t o r - PCM Output . . . . . . 36
Ignition Circuit Se ns e PCM Input 33
GENERAL INFORMATION
All gas powered engines are equipped wi t h sequen-
tial Multi-Port Fuel Injection (MPI). The MPI system
(Fig. 1) provides precise air/fuel ratios for all driving
conditions.
The Powertrain Control Module (PCM) operates
the fuel system. The PCM was formerly referred to
as t he SBEC or engine controller. The PCM is a pre-
programmed, dual microprocessor digital computer.
It regul at es ignition timing, air-fuel ratio, emission
control devices, charging system, speed control, air
conditioning compressor clutch engagement and idle
speed. The PCM can adapt its programmi ng to meet
changing operating conditions.
Powertrai n Control Module (PCM) Inputs rep-
resent t he i nst ant aneous engine operating conditions.
Air-fuel mi xt ure and ignition timing calibrations for
various driving and atmospheric conditions are pre-
programmed into t he PCM. The PCM monitors and
analyzes various inputs. It t hen computes engine fuel
and ignition t i mi ng requi rement s based on these in-
puts. Fuel delivery control and ignition t i mi ng will
t hen be adjusted accordingly.
Other i nput s to t he PCM are provided by t he brake
light switch, air conditioning select switch and t he
speed control switches. All inputs to t he PCM are
converted into signals.
Electrically operated fuel injectors spray fuel in
precise metered amount s into t he i nt ake port directly
above t he i nt ake valve. The injectors are fired in a
specific sequence by t he PCM. The PCM mai nt ai ns
page
Ignition Co i l - PCM Output 37
Malfunction Indicator LampPCM Output 37
Manifold Absolute Pressure ( MAP) Se n s o r -
PCM Input 33
Open Loop/ Cl osed Loop Modes of Operation . . . 38
Overdrive/Override Switch 34
Ox ygen ( 0
2
) Sens or PCM Input 33
Park/Neutral Swi t chPCM Input 34
Power Ground 34
SCI Re c e i v e - PCM Input . 34
SCI Tr ans mi t - PCM Output 37
Sensor Return PCM Input 35
Shift I ndi c at or - PCM Output 38
Speed Cont r ol - PCM Input 34
Speed Cont r ol - PCM Output 38
SRI L a mp - PC M Output 36
TachometerPCM Output 38
Throttle Body 4 0
Throttle Position Sensor ( TPS ) - PC M Input 35
Vehicle Speed Se n s o r - PC M Input 35
an air/fuel ratio of 14.7 to 1 by constantly adjusting
injector pulse width. Injector pulse width is t he
length of t i me t hat t he injector opens and sprays fuel
into t he chamber. The PCM adjusts injector pulse
width by opening and closing t he ground pat h to t he
injector.
Manifold absolute pressure (air density) and engine
rpm (speed) are t he pri mary i nput s t hat determine
fuel injector pulse width. The PCM also monitors
other inputs when adjusting air-fuel ratio.
Inputs That Effect Fuel Injector Pul se Width:
Exhaust gas oxygen content
Coolant t emperat ure
Manifold absolute pressure (MAP)
Engine speed
Throttle position
Battery voltage
Air conditioning selection
Transmission gear selection (auto, trans. )
Speed control
The powertrain control module (PCM) adjusts igni-
tion t i mi ng by controlling ignition coil operation. The
ignition coil receives bat t ery voltage when t he igni-
tion key is in t he r un or st art er (crank) position. The
PCM provides a ground for t he ignition coil. The coil
discharges when t he PCM supplies a ground. By
switching t he ground pat h on and off, t he PCM reg-
ulates ignition timing.
The sensors and switches t hat provide inputs to t he
powertrain control module (PCM) comprise t he En-
14 - 30 FUEL SYSTEM
I N PUTS OUTPUTS
POWERTRAIN CONTROL
MODULE
DRB II
SCAN TOOL
SPEED
CONTROL
BRAKE
SWI TCH
A/ C LOW
PRESSURE CUTOFF
SWITCH VEHICLE
SPEED SENSOR
PARK/NEUTRAL
SWI TCH
TORQUE CONVERTER
CLUTCH SOLENOID
MALFUNCTION
INDICATOR
LAMP
m HEATED i
* O XY G E N S E NS OR
ENGI NE
COOLANT yy BATTERY
TEMPERATURE
SENSOR MAP SENSOR
i r
CHARGE AIR
TEMPERATURE
SENSOR
AI R CHARGE
TEMPERATURE
SENSOR
DISTRIBUTOR
WITH CAMSHAFT r
POSITION
SENSOR (|
TACHOMETER
A/C CLUTCH
RELAY
AUTO SHUTDOWN
RELAY
OVERDRI VE
S OL E NOI D
IDLE AIR
CONTROL MOTOR
SPEED
CONTROL
SHIFT
INDICATOR
LAMP
EMI SSI ON
CONTROL SOLENOI DS
I GNI TI ON COIL
OVERDRI VE
OVERRI DE
SWI TCH
A S D
S E NS E FUEL
INJECTORS
PARK THROTTLE
SOLENOID
GENERATOR
CRANKSHAFT
POSI TI ON
FUEL
PUMP
RELAY
J9314-117
Fig. 1 Multi-Port Fuel Injection ComponentsExcept Diesel
gine Control System. It is also comprised of t he PCM
Outputs (engine control devices t hat t he are operated
by t he PCM).
SYSTEM DIAGNOSIS
The powertrain control module (PCM) tests many
of its own i nput and out put circuits. If a diagnostic
trouble code (DTC) is found in a major system, t hi s
information is stored in t he PCM memory. Refer to
On-Board Diagnostics in t he Multi-Port Fuel Injec-
tionGeneral DiagnosisExcept Diesel section of
t hi s group for DTC information.
The Powert rai n Control Module (PCM) (Fig. 2) op-
erat es t he fuel system. The PCM was formerly re-
ferred to as t he SBEC or engine controller. The PCM
is a pre-programmed, dual microprocessor digital
computer. It regul at es ignition timing, air-fuel ratio,
emission control devices, charging system, speed con-
trol, air conditioning compressor clutch engagement
TORQUE CONVERTER
CLUTCH RELAY
AUTO SHUTDOWN RELAY
FUEL PUMP RELAY
DATA UNK
CONNECTOR
POWERTRAIN
CONTROL
MODULE J9314-164
Fig. 2 Powertrain Control Module (PCM) Location
and idle speed. The PCM can adapt its programmi ng
to meet changing operating conditions.
The PCM receives input signals from various
switches and sensors. Based on these inputs, t he
PCM regul at es various engine and vehicle operations

FUEL SYSTEM 14- 31
through different system components. These compo-
nent s are referred to as Powert rai n Control Module
(PCM) Outputs. The sensors and switches t hat pro-
vide i nput s to t he PCM are considered Powertrain
Control Module (PCM) Inputs.
The PCM adjusts ignition t i mi ng based upon in-
puts it receives from sensors t hat react to: engine
rpm, manifold absolute pressure, engi ne coolant tem-
perat ure, throttle position, t ransmi ssi on gear selec-
tion (automatic transmission), vehicle speed and t he
brake switch.
The PCM adjusts idle speed based on inputs it re-
ceives from sensors t hat react to: t hrot t l e position,
vehicle speed, transmission gear selection, engine
coolant t emperat ure and from i nput s it receives from
the air conditioning clutch switch and brake switch.
Based on inputs t hat it receives, t he PCM adjusts
ignition coil dwell. The PCM also adjusts the gener-
ator charge rat e t hrough control of t he generator
field and provides speed control operation.
Powertrai n Control Module (PCM) Inputs:
Generator output
A/C request (if equipped with factory A/C)
A/C select (if equipped with factory A/C)
Auto shut down (ASD) sense
Charge ai r t emperat ure sensor
Bat t ery voltage
Brake switch
Engi ne coolant t emperat ure sensor
Crankshaft position sensor
Ignition circuit sense (ignition switch in r un posi-
tion)
Manifold absolute pressure (MAP) sensor
Overdrive/override switch
Oxygen sensor(s)
Park/ neut ral switch (auto, t rans, only)
SCI receive (DRB II connection)
Speed control resume switch
Speed control set switch
Speed control on/off switch
Camshaft position sensor signal
Throttle position sensor
Vehicle speed sensor
Sensor r et ur n
Power ground
Signal ground
Powertrai n Control Module (PCM) Outputs:
A/C clutch relay
Idle air control (IAC) motor
Auto shut down (ASD) relay
Generator field
Malfunction indicator lamp
Service reminder indicator lamp
EGR valve control solenoid
Fuel injectors
Fuel pump relay
Ignition coil
EVAP canister purge solenoid
SCI t r ansmi t (DRB II connection)
Shift indicator l amp (manual transmission only)
Speed control vacuum solenoid
Speed control vent solenoid
Tachometer (on i nst r ument panel, if equipped)
The powertrain control module (PCM) contains a
voltage convertor. Thi s converts bat t ery voltage to a
regulated 8.0 volts. It is used to power t he crankshaft
position sensor and camshaft position sensor. The
PCM also provides a five (5) volt supply for t he man-
ifold absolute pressure (MAP) sensor and throttle po-
sition sensor (TPS).
AIR CONDITIONING (A/C) CONTROLS- PCM INPUT
The A/C control system information applies to fac-
tory installed air conditioning uni t s.
A/C SELECT SI GNAL: When t he A/C switch is
in t he ON position and t he A/C low pressure switch
is closed, an i nput signal is sent to t he powertrain
control module (PCM). The signal informs t he PCM
t hat t he A/C has been selected. The PCM adjusts idle
speed to a pre-programmed rpm through t he idle air
control (IAC) motor to compensate for increased en-
gine load.
A/C REQUEST SI GNAL: Once A/C has been se-
lected, t he powertrain control module (PCM) receives
t he A/C request signal from t he evaporator switch.
The i nput indicates t hat t he evaporator t emperat ure
is in t he proper range for A/C application. The PCM
uses t hi s input to cycle t he A/C compressor clutch
(through t he A/C relay). It will also determine t he
correct engine idle speed t hrough t he idle air control
(IAC) motor position.
If t he A/C low pressure switch opens (indicating a
low refrigerant level), t he PCM will not receive an
A/C select signal. The PCM will t hen remove t he
ground from t he A/C relay. This will deactivate t he
A/C compressor clutch.
If t he evaporator switch opens, (indicating t hat
evaporator is not in proper t emperat ure range), t he
PCM will not receive t he A/C request signal. The
PCM will t hen remove t he ground from t he A/C re-
lay, deactivating t he A/C compressor clutch.
AUTOMATIC SHUT DOWN (ASD) S E N S E - PC M
INPUT
A 12 volt signal at t hi s i nput indicates to t he PCM
t hat t he ASD has been activated. The ASD relay is
located in t he engine compartment (Fig. 2). It is used
to connect t he oxygen sensor(s) heat er element, igni-
tion coil, generator field winding and fuel injectors to
12 volt + power supply.
This i nput is used only to sense t hat t he ASD relay
is energized. If t he powertrain control module (PCM)
does not see 12 volts at t hi s i nput when t he ASD
should be activated, it will set a diagnostic trouble
code (DTC).
14 - 32 FUEL SYSTEM

BATTERY VOLTAGEPCM INPUT
The bat t ery voltage input provides power to t he
powertrain control module (PCM). It also informs t he
PCM what voltage level is supplied to t he ignition
coil and fuel injectors.
If battery voltage is low, the PCM will increase injec-
tor pulse width (period of time t hat the injector is ener-
gized). This is done to compensate for the reduced flow
through injector caused by the lowered voltage.
BRAKE S WI T C H- PC M INPUT
When t he brake light switch is activated, t he pow-
ert rai n control module (PCM) receives an i nput indi-
cating t hat t he brakes are being applied. After
receiving this input, t he PCM mai nt ai ns idle speed
to a scheduled rpm t hrough control of t he idle air
control (IAC) motor. The brake switch i nput is also
used to operate t he speed control system.
CAMSHAFT POSITION SENSORPCM INPUT
A sync signal is provide by the camshaft position sen-
sor located in the ignition distributor (Fig. 3) . The sync
signal from this sensor works in conjunction with the
crankshaft position sensor to provide the powertrain
control module (PCM) with inputs. This is done to es-
tablish and maintain correct injector firing order.
Refer to Camshaft Position Sensor in Group 8D, Ig-
nition System for more information.
Fig. 3 Camshaft Position Sensor
CHARGE AIR TEMPERATURE SENSOR-PCM
INPUT
The i nt ake manifold charge air t emperat ure sensor
is installed in t he i nt ake manifold with t he sensor el-
ement extending into t he air st ream (Fig. 4). The
sensor provides an input voltage to t he powertrain
control module (PCM) indicating i nt ake manifold air
t emperat ure. The i nput is used along wi t h i nput s
from other sensors to determine injector pulse width.
As t he t emperat ure of the air-fuel st ream in t he
manifold varies, t he sensor resistance changes. This
results in a different input voltage to t he PCM.
Fig. 4 Charge Air Temperature SensorTypical
CRANKSHAFT POSITION SENSOR-PCM INPUT
This sensor is a hall effect device t hat detects
notches in t he flywheel (manual transmission), or
flexplate (automatic transmission).
This sensor is used to indicate to t he powertrain
control module (PCM) t hat a spark and or fuel injec-
tion event is to be required. The output from this
sensor, in conjunction with t he camshaft position
sensor signal, is used to differentiate between fuel in-
jection and spark events. It is also used to synchro-
nize t he fuel injectors with t hei r respective cylinders.
The sensor is bolted to t he cylinder block near t he
rear of t he ri ght cylinder head (Fig. 5).

FUEL SYSTEM 14 - 33
Refer to Group 8D, Ignition System for more crank-
shaft position sensor information.
The engine will not operate if t he PCM does not re-
ENGINE COOLANT TEMPERATURE S E N S O R - PC M
INPUT
The engine coolant t emperat ure sensor is installed
next to the t hermost at housing (Fig. 6 ) and protrudes
into t he wat er jacket. The sensor provides an i nput
voltage to t he powertrain control module (PCM) re-
lating coolant t emperat ure. The PCM uses this i nput
along with inputs from other sensors to determine in-
jector pulse width and ignition timing. As coolant
t emperat ure varies, t he coolant t emperat ure sensor
resistance will change. This change in resistance re-
sults i n a different i nput voltage to t he PCM.
When the engine is cold, t he PCM will operate in
Open Loop cycle. It will demand slightly richer air-
fuel mi xt ures and higher idle speeds. This is done
until normal operating t emperat ures are reached.
Fig. 6 Coolant Temperature Sensor Typical
IGNITION CIRCUIT SE N SE - PCM INPUT
The ignition circuit sense i nput tells t he power-
t rai n control module (PCM) t he ignition switch has
energized the ignition circuit. Refer to t he wiring di-
agrams for circuit information.
MANIFOLD ABSOLUTE PRESSURE (MAP)
S E N S O R - PC M INPUT
The MAP sensor reacts to absolute pressure in t he
i nt ake manifold. It provides an i nput voltage to t he
powertrain control module (PCM). As engine load
changes, manifold pressure varies. The change in
manifold pressure causes MAP sensor voltage to
change. The change in MAP sensor voltage resul t s in
a different i nput voltage to t he PCM. The i nput volt-
age level supplies t he PCM with information about
ambient barometric pressure duri ng engine start-up
(cranking) and engine load while t he engine is run-
ning. The PCM uses this i nput along with i nput s
from other sensors to adjust air-fuel mi xt ure.
The MAP sensor is mounted on t he side of t he en-
gine t hrot t l e body (Fig. 7). The sensor is connected to
t he t hrot t l e body wi t h a rubber L-shaped fitting.
MANI FOL D ABSOLUTE
Sensor Typical
OXYGEN ( 0
2
) SE NSORPCM INPUT
3.9L/5.2L/S9L LDC ENGINE
The single 0
2
sensor on the 3.9L, 5.2L or 5.9L light
duty cycle (LDC) engine is located in t he exhaust
down pipe (Fig. 8). It provides an i nput voltage to t he
powertrain control module (PCM) rel at i ng t he oxy-
gen content of t he exhaust gas. The PCM uses t hi s
information to fine t une the air-fuel ratio by adjust-
ing injector pulse width.
The 0
2
sensor produces voltages from 0 to 1 volt.
This voltage will depend upon t he oxygen content of
t he exhaust gas in t he exhaust manifold. When a
large amount of oxygen is present (caused by a l ean
air-fuel mixture), t he sensor produces a low voltage.
When t here is a lesser amount present (rich air-fuel
mixture) it produces a higher voltage. By monitoring
t he oxygen content and converting it to electrical
voltage, t he sensor acts as a rich-lean switch.
The oxygen sensor is equipped with a heat i ng ele-
ment t hat keeps t he sensor at proper operating tem-
perat ure duri ng all operating modes. Mai nt ai ni ng
correct sensor t emperat ure at all t i mes allows t he
system to ent er into closed loop operation sooner.
In Closed Loop operation, t he powertrain control
module (PCM) monitors t he 0
2
sensor input (along
with other inputs). It t hen adjusts t he injector pulse
14 - 34 FUEL SYSTEM
width accordingly. Duri ng Open Loop operation, t he
PCM ignores t he 0
2
sensor i nput and adjusts injector
pulse width to a preprogrammed value (based on
other sensor inputs).
EXHAUST
PIPE J9214-5
Fig. 8 Oxygen Sensor Location3.9L/5.2L/5.9L LDC
Engine
5,9L HDC ENGINE
Dual 0
2
sensors are used on t he 5.9L heavy duty
cycle (HDC) engine (Fig. 9). Each sensor will monitor
t he oxygen content in each exhaust downpipe. The
left sensor monitors t he odd numbered cylinders (1-3-
5-7). The ri ght sensor monitors t he even numbered
cylinders (2-4-6-8),
For sensor operational information, refer to t he
paragraphs in t he previous 3.9L/5.2/5.9L LDC oxygen
sensor section.
Fig. 9 Oxygen Sensor Location5.9L HDC Engine
OVERDRIVE/OWERRIDE SWITCH
On vehicles equipped with overdrive, t he power-
t r ai n control module (PCM) regulates t he 3-4 over-
drive up-shift and down-shift t hrough t he overdrive
solenoid. An override switch is located on t he instru-
ment panel .
The overdrive/override switch is normally closed. It
opens when t he operator presses t he switch. The
transmission will not enter overdrive when t he oper-
ator presses t he override switch. The transmission
downshifts if t he operator presses t he override switch
while in overdrive.
The overdrive switch circuit contains two other
switches: A transmission thermo-switch and a cool-
ant t emperat ure switch. When either switch opens,
t he transmission will not shift into overdrive, or
downshift (if already in overdrive).
Refer to Group 21 for more information.
PARK/NEUTRAL S WI T C H- PC M INPUT
The park/ neut ral switch is located on t he t ransmi s-
sion housing and provides an i nput to t he powertrain
control module (PCM). This will indicate t hat t he au-
tomatic transmission is in Park, Neut ral or a drive
gear selection. This i nput is used to determine idle
speed (varying wi t h gear selection), fuel injector
pulse width and ignition t i mi ng advance. Refer to
Group 21, Transmissions, for testing, replacement
and adjustment information.
POWER GROUND
The power ground is used to control ground circuits
for t he following powertrain control module (PCM)
loads:
Generator field winding
8 volt (PCM) power supply
Fuel injectors
Ignition coil
SCI RECEI VE- PCM INPUT
SCI Receive is t he serial dat a communication re-
ceive circuit for t he DRB II scan tool. The powertrain
control module (PCM) receives dat a from t he DRB II
t hrough t he SCI Receive circuit.
SPEED CONTROL- PCM INPUT
The speed control system provides t hree separate
i nput s to t he powertrain control module (PCM); On/
Off, Set and Resume. The On/Off i nput informs t he
PCM t hat t he speed control system has been acti-
vated. The Set i nput informs t he PCM t hat a fixed
vehicle speed has been selected. The Resume i nput
indicates to t he PCM t hat t he previous fixed speed is
requested.
The speed control operating range is from 50 km/h
to 142 km/h (35 to 85 mph). Input s t hat effect speed
control operation are:
Park/ neut ral switch
Refer to Group 8H for further speed control infor-
mation.

FUEL SYSTEM 14 - 35
SENSOR RETURNPCM INPUT
Sensor Ret urn provides a low noise ground refer-
ence for all system sensors.
THROTTLE POSITION SENSOR ( T PS ) - PC M INPUT
The t hrot t l e position sensor (TPS) is mounted on
t he t hrot t l e body (Fig. 10). The TPS is a variable re-
sistor t hat provides the powertrain control module
(PCM) with an input signal (voltage) t hat represents
throttle blade position. The sensor is connected to t he
t hrot t l e blade shaft. As t he position of t he t hrot t l e
blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to t he
TPS. The TPS output voltage (input signal to t he
PCM) represents t he t hrot t l e blade position. The
PCM receives an input signal voltage from t he TPS.
This will vary in an approximate range of from 1
volt at mi ni mum t hrot t l e opening (idle), to 4 volts at
wide open t hrot t l e. Along wi t h inputs from other sen-
sors, t he PCM uses t he TPS input to determine cur-
rent engine operating conditions. In response to
engine operating conditions, t he PCM will adjust fuel
injector pulse width and ignition timing.
MANI FOLD ABSOLUTE
Fig. 10 Throttle Position SensorTypical
VEHICLE SPEED SE NSORPCM INPUT
The speed sensor (Fig. 11) is located in t he exten-
sion housing of t he transmission (2WD) or on t he
transfer case extension housing (4WD). The sensor
input is used by t he powertrain control module
(PCM) to determine vehicle speed and distance trav-
eled.
The speed sensor generates 8 pulses per sensor rev-
olution. These signals, in conjunction with a closed
t hrot t l e signal from t he throttle position sensor, indi-
cate a closed t hrot t l e deceleration to t he PCM. When
t he vehicle is stopped at idle, a closed t hrot t l e signal
is received by t he PCM (but a speed sensor signal is
not received).
Under deceleration conditions, t he PCM adjusts t he
idle air control (IAC) motor to mai nt ai n a desired
MAP value. Under idle conditions, t he PCM adjusts
t he IAC motor to mai nt ai n a desired engine speed.
Fig. 11 Vehicle Speed SensorTypical
AIR CONDITIONING (A/C) CLUTCH RELAYPCM
OUTPUT
The powertrain control module (PCM) activates t he
A/C compressor through t he A/C clutch relay. The
PCM regulates A/C compressor operation by switch-
i ng t he ground circuit for t he A/C clutch relay on
and off. The relay is located in t he engine compart-
ment (Fig. 12).
DATA LINK CONTROL
Fig. 12 Relay Location
When t he PCM receives a request for A/C from A/C
evaporator switch, it will adjust idle air control (IAC)
motor position. This is done to increase idle speed.
The PCM will t hen activate t he A/C clutch t hrough
t he A/C clutch relay. The PCM adjusts idle air con-
trol (IAC) stepper motor position to compensate for
increased engine load from t he A/C compressor.
By switching t he ground pat h for t he relay on and
off, t he PCM is able to cycle t he A/C compressor
clutch. This is based on changes in engine operating
conditions. If, duri ng A/C operation, t he PCM senses
low idle speeds or a wide open t hrot t l e condition, it
will de-energize t he relay. This prevents A/C clutch
engagement. The relay will remai n de-energized un-
til t he idle speed increases or t he wide open t hrot t l e
condition exceeds 15 seconds or no longer exists. The
PCM will also de-energize t he relay if coolant tem-
perat ure exceeds 125C (257F).
IDLE AIR CONTROL (IAC) MOT OR - PC M OUTPUT
The IAC motor is mounted to t he back of t he throt-
tle body (Fig. 13) and is controlled by t he powertrain
control module (PCM).
AAANIFOLD ABSOLUTE
PRESSURE SENSOR
MOUNT I NG SCREWS
MAP SENSOR
THROTTLE
POSITION
SENSOR J9314-86
Fig. 13 IAC MotorTypical
The t hrot t l e body has an air control passage t hat
provides air for t he engine at idle (the t hrot t l e plate
is closed). The IAC motor pintle protrudes into t he
ai r control passage (Fig. 14) and regulates air flow
t hrough it. Based on various sensor inputs, t he pow-
ert rai n control module (PCM) adjusts engine idle
speed by moving t he IAC motor pintle in and out of
t he air control passage. The IAC motor is positioned
when t he ignition key is t urned to t he On position.
A (factory adjusted) set screw is used to mechani-
cally limit t he position of t he throttle body t hrot t l e
plate. Never attempt to adjust the engi ne idle
speed usi ng thi s screw. All idle speed functions are
controlled by t he PCM.
RUBBER FITTING
J9314-87
Fig. 14 Throttle Body Air Control Passage
AUTO SHUT DOWN (ASD) RELAYPCM OUTPUT
The ASD relay is located in t he engine compart-
ment (Fig. 12).
The ASD supplies bat t ery voltage to t he fuel pump,
fuel injector, ignition coil, generator field winding
and oxygen ( 0
2
) sensor(s) heat i ng element. The
ground circuit for t he coil in t he ASD relay is con-
trolled by t he powertrain control module (PCM). The
PCM operates t he relay by switching t he ground cir-
cuit on and off.
The fuel pump relay is controlled by t he PCM
t hrough same circuit t hat t he ASD relay is con-
trolled.
GENERATOR F I E LD - PCM OUTPUT
The powertrain control module (PCM) regul at es
t he charging system voltage within a range of 12.9 to
15.0 volts. Refer to Group 8A for charging system in-
formation.
GENERATOR LAM P- PCM OUTPUT
If t he powertrain control module (PCM) senses a
low charging condition in t he charging system, it
will i l l umi nat e t he generator lamp on t he i nst rument
panel. For example, during low idle with all accesso-
ries t urned on, t he light may momentarily go on.
Once t he PCM corrects idle speed to a hi gher rpm,
t he light will go out. Refer to Group 8A for charging
system information.
ELECTRIC EXHAUST GAS RECIRCULATION
TRANSDUCER (EET) S0 LE N 0 I D - PCM OUTPUT
Refer to Group 25, Emission Control System for in-
formation. See Electric Exhaust Gas Recirculation
Transducer (EET) Solenoid.
SRI LAM P- PCM OUTPUT
The i nst rument panel mounted service reminder
indicator (SRI) lamp was formerly referred to as t he
emission mai nt enance reminder (EMR) lamp. It is

FUEL SYSTEM 14 - 37
used only on vehicles equipped with t he 5.9L heavy
duty cycle (HDC) engine. Refer to Group 25, Emis-
sion Control System for information.
EVAP CANISTER PURGE S OLE NOI D- PCM
OUTPUT
Refer to Group 25, Emission Control System. See
EVAP Canister Purge Solenoid.
FUEL I NJECTORS- PCM OUTPUT
The fuel injectors are attached to t he fuel rai l (Fig.
15). 3.9L engines use six injectors. 5.2L and 5.9L en-
gines use eight injectors.
The nozzle ends of t he injectors are positioned into
openings in t he i nt ake manifold j ust above t he in-
t ake valve ports of the cylinder head. The engine
wiring harness connector for each fuel injector is
equipped with an attached numerical t ag (INJ 1, I NJ
2 etc.). This is used to identify each fuel injector with
its respective cylinder number.
The injectors are energized individually in a se-
quential order by t he powertrain control module
(PCM). The PCM will adjust injector pulse width by
switching t he ground pat h to each individual injector
on and off. Injector pulse width is t he period of t i me
t hat t he injector is energized. The PCM will adjust
injector pulse width based on various i nput s it re-
ceives.
During st art up, bat t ery voltage is supplied to t he
injectors t hrough t he ASD relay. When t he engine is
operating, voltage is supplied by t he charging sys-
tem. The PCM determines injector pulse width based
on various inputs.
FUEL
INJECTOR J9214-30
Fig. 15 Fuel injectorsTypical
MALFUNCTION INDICATOR LAM P- PCM OUTPUT
The malfunction indicator lamp (formerly referred
to as t he check engine lamp) illuminates at t he bot-
tom of t he i nst rument panel each t i me t he ignition
key is turned on. It will stay on for t hree seconds as
a bulb test.
If t he powertrain control module (PCM) receives an
incorrect signal, or no signal from cert ai n sensors or
emission related systems, t he lamp is t urned on. This
is a warni ng t hat t he PCM has recorded a system or
sensor malfunction. In some cases, when a problem is
declared, the PCM will go into a limp-in mode. This
is an at t empt to keep t he system operating. It signals
an immediate need for service.
The lamp can also be used to display a diagnostic
trouble code (DTC). Cycle t he ignition switch On-Off-
On-Off-On within t hree seconds and any codes stored
in t he PCM memory will be displayed. This is done
in a series of flashes representing digits. Refer to On-
Board Diagnostics in t he General Diagnosis section
of t hi s group for more information.
IGNITION COI L- PCM OUTPUT
System voltage is supplied to t he ignition coil pos-
itive terminal. The powertrain control module (PCM)
operates the ignition coil. Base (initial) ignition
t i mi ng i s not adj us t abl e. The PCM adjusts ignition
t i mi ng to meet changing engine operating conditions.
The ignition coil is located near t he front of t he
ri ght cylinder head (Fig. 16 or 17).
Refer to Group 8D, Ignition System for additional
information.
Fig. 16 Ignition Coii-3.9U5.2U5.9L LDC-Gas
Engine
SCI TRANSMITPCM OUTPUT
SCI Transmi t is t he serial dat a communication
t ransmi t circuit for t he DRB II scan tool. The power-
t rai n control module (PCM) t ransmi t s dat a to t he
DRB II t hrough t he SCI Transmi t circuit.
14 - 38 FUEL SYSTEM

SHIFT I NDI CATOR- PCM OUTPUT
Vehicles equipped with manual transmissions have
an Up-Shift indicator l amp. The lamp is controlled
by t he powertrain control module (PCM). The l amp
illuminates on t he i nst rument panel to indicate when
t he driver should shift to t he next highest gear for
best fuel economy. The PCM will t ur n t he lamp off
after 3 to 5 seconds if t he shift of gears is not per-
formed. The up-shift light will remai n off unt i l vehi-
cle stops accelerating and is brought back to range of
up-shift light operation. This will also happen if ve-
hicle is shifted into fifth gear.
The indicator lamp is normally illuminated when
t he ignition switch is t urned on and it is t urned off
when t he engine is st art ed up. Wi t h t he engine run-
ning, t he lamp is t urned on/off depending upon en-
gine speed and load.
SPEED CONTROL- PCM OUTPUT
Speed control operation is regulated by t he power-
t rai n control module (PCM). The PCM controls t he
vacuum to t he t hrot t l e act uat or t hrough t he speed
control vacuum and vent solenoids. Refer to Group
8H for Speed Control Information.
TACHOMETERPCM OUTPUT
The powertrain control module (PCM) supplies en-
gine rpm values to t he i nst rument cluster tachome-
ter. Refer to Group 8E for tachometer information.
OPEN LOOP/CLOSED LOOP MODES OF
OPERATION
As input signals to t he powertrain control module
(PCM) change, t he PCM adjusts its response to t he
output devices. For example, t he PCM must calculate
different injector pulse width and ignition t i mi ng for
idle t han it does for wide open t hrot t l e (WOT). There
are several different modes of operation t hat deter-
mine how t he PCM responds to t he various i nput sig-
nals.
MODES
Open Loop
Closed Loop
Duri ng Open Loop modes, t he powertrain control
module (PCM) receives i nput signals and responds
only according to preset PCM programming. Input
from t he oxygen ( 0
2
) sensor(s) is not monitored dur-
ing Open Loop modes.
Duri ng Closed Loop modes, the PCM will monitor
t he oxygen ( 0
2
) sensor input. This input indicates to
t he PCM whet her or not t he calculated injector pulse
width resul t s in t he ideal air-fuel ratio. This ratio is
14.7 part s air-to-1 part fuel. By monitoring t he ex-
haust oxygen content t hrough t he 0
2
sensor, t he
PCM can fine t une t he injector pulse width. This is
done to achieve optimum fuel economy combined
with low emission engine performance.
The fuel injection system has the following modes
of operation:
Ignition switch ON
Engi ne st art -up (crank)
Engi ne warm-up
Idle
Cruise
Acceleration
Deceleration
Wide open t hrot t l e (WOT)
Ignition switch OFF
The ignition switch On, engine start-up (crank),
engine warm-up, acceleration, deceleration and wide
open t hrot t l e modes are Open Loop modes. The idle
and cruise modes, (with t he engine at operating tem-
perat ure) are Closed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
This is an Open Loop mode. When t he fuel system
is activated by t he ignition switch, t he following ac-
tions occur:
The powertrain control module (PCM) pre-posi-
tions t he idle air control (IAC) motor.
The PCM determines atmospheric air pressure
from t he MAP sensor input to determine basic fuel
strategy.
The PCM monitors t he engine coolant t emperat ure
sensor input. The PCM modifies fuel strategy based
on t hi s input.
Int ake manifold charge air t emperat ure sensor in-
put is monitored.
Throttle position sensor (TPS) is monitored.
The auto shut down (ASD) relay is energized by
t he PCM for approximately t hree seconds.
The fuel pump is energized through t he fuel pump
relay by t he PCM. The fuel pump will operate for ap-
proximately one second unless t he engine is operat-
ing or t he st art er motor is engaged.
The 0
2
sensor(s) heat er element is energized
t hrough t he fuel pump relay. The 0
2
sensor(s) input

FUEL SYSTEM 14 - 39
is not used by t he PCM to calibrate air-fuel ratio
during t hi s mode of operation,
The up-shift indicator light is i l l umi nat ed (manual
transmission only).
ENGINE START-UP MODE
This is an Open Loop mode. The following actions
occur when t he st art er motor is engaged.
The powertrain control module (PCM) receives in-
puts from:
Bat t ery voltage
Int ake manifold charge air t emperat ure sensor
Throttle position sensor (TPS)
St art er motor relay
Camshaft position sensor signal
The PCM monitors t he crankshaft position sensor.
If t he PCM does not receive a crankshaft position
sensor signal within 3 seconds of cranki ng t he en-
gine, it will shut down t he fuel injection system.
The fuel pump is activated by t he PCM t hrough
t he fuel pump relay.
Voltage is applied to t he fuel injectors with t he
PCM. The PCM will t hen control t he injection se-
quence and injector pulse width by t ur ni ng t he
ground circuit to each individual injector on and off.
The PCM determines t he proper ignition t i mi ng ac-
cording to input received from t he crankshaft posi-
tion sensor.
ENGINE WARM-UP MODE
This is an Open Loop mode. Duri ng engine warm-
up, t he powertrain control module (PCM) receives in-
puts from:
Bat t ery voltage
Engine coolant t emperat ure sensor
Camshaft position sensor signal (in t he distributor)
Park/ Neut ral switch (gear indicator signalauto,
t rans, only)
Air conditioning select signal (if equipped)
Air conditioning request signal (if equipped)
Based on these i nput s t he following occurs:
Voltage is applied to t he fuel injectors wi t h t he
powertrain control module (PCM). The PCM will
t hen control t he injection sequence and injector pulse
width by t urni ng t he ground circuit to each individ-
ual injector on and off.
The PCM adjusts engine idle speed t hrough t he
idle air control (IAC) motor and adjusts ignition tim-
ing.
The PCM operates the A/C compressor clutch
t hrough the clutch relay. Thi s is done if A/C has
been selected by t he vehicle operator and requested
by t he A/C t hermost at .
If t he vehicle has a manual transmission, t he up-
shift light is operated by the PCM.
When engine has reached operating t emperat ure,
the PCM will begin monitoring 0
2
sensor(s) input.
The system will t hen leave t he warm-up mode and
go into closed loop operation.
IDLE MODE
When t he engine is at operating t emperat ure, t hi s
is a Closed Loop mode. At idle speed, the powertrain
control module (PCM) receives i nput s from:
Battery voltage
Camshaft position sensor signal (in the distributor)
Battery voltage
Park/ Neut ral switch (gear indicator signalAuto,
t rans, only)
Oxygen sensor
Based on these inputs, the following occurs:
Voltage is applied to t he fuel injectors wi t h t he
t hen control injection sequence and injector pulse
width by t ur ni ng the ground circuit to each individ-
The PCM monitors t he 0
2
sensor(s) input and ad-
j ust s air-fuel rat i o by varying injector pulse width. It
also adjusts engine idle speed t hrough the idle air
control (IAC) motor.
The PCM adjusts ignition t i mi ng by increasing
and decreasing spark advance.
The PCM operates t he A/C compressor clutch
t hrough t he clutch relay. This happens if A/C has
by t he A/C t hermost at .
CRUISE MODE
is a Closed Loop mode. At cruising speed, t he power-
t rai n control module (PCM) receives inputs from:
Battery voltage
14 - 40 FUEL SYSTEM

Park/ Neut ral switch (gear indicator signalauto,
t rans, only)
Oxygen ( 0
2
) sensor(s)
Based on these inputs, t he following occurs:
PCM. The PCM will t hen adjust t he injector pulse
width by t ur ni ng t he ground circuit to each individ-
The PCM monitors t he 0
2
sensor(s) i nput and ad-
j ust s air-fuel ratio. It also adjusts engine idle speed
t hrough t he idle air control (IAC) motor.
The PCM adjusts ignition t i mi ng by t ur ni ng t he
ground pat h to t he coil on and off.
The PCM operates t he A/C compressor clutch
t hrough t he clutch relay. This happens if A/C has
by t he A/C thermostat.
ACCELERATION MODE
This is an Open Loop mode. The powertrain control
module (PCM) recognizes an abrupt increase in
t hrot t l e position or MAP pressure as a demand for
increased engine output and vehicle acceleration.
The PCM increases injector pulse width in response
to increased t hrot t l e opening.
DECELERATION MODE
is an Open Loop mode. Duri ng hard deceleration, t he
powertrain control module (PCM) receives t he follow-
ing inputs.
Bat t ery voltage
Park/ Neut ral switch (gear indicator signal auto,
t rans, only)
If t he vehicle is under hard deceleration with t he
proper rpm and closed t hrot t l e conditions, t he PCM
will ignore t he oxygen sensor i nput signal. The PCM
will ent er a fuel cut-off strategy in which it will not
supply bat t ery voltage to t he injectors. If a hard de-
celeration does not exist, t he PCM will det ermi ne t he
proper injector pulse width and continue injection.
Based on t he above inputs, t he PCM will adjust en-
gine idle speed t hrough t he idle air control (IAC) mo-
tor.
The PCM adjusts ignition t i mi ng by t ur ni ng t he
The PCM opens t he ground circuit to t he A/C
clutch relay to disengage t he A/C compressor clutch.
This is done unt i l t he vehicle is no longer under de-
celeration (if t he A/C system is operating).
WIDE OPEN THROTTLE MODE
This is an Open Loop mode. During wide open
throttle operation, t he powertrain control module
(PCM) receives t he following inputs.
Battery voltage
During wide open t hrot t l e conditions, t he following
occurs:
t hen control t he injection sequence and injector pulse
width by t urni ng t he ground circuit to each individ-
ual injector on and off. The PCM ignores t he oxygen
sensor i nput signal and provides a predetermined
amount of additional fuel. This is done by adjusting
injector pulse width.
The PCM adjusts ignition t i mi ng by t urni ng t he
The PCM opens t he ground circuit to t he A/C
clutch relay to disengage t he A/C compressor clutch.
This will be done for approximately 15 seconds (if t he
air conditioning system is operating).
If t he vehicle has a manual transmission, t he up-
shift light is operated by t he PCM.
IGNITION SWITCH OFF MODE
When ignition switch is t urned to OFF position,
t he PCM stops operating t he injectors, ignition coil,
ASD relay and fuel pump relay.
THROTTLE BODY
Filtered air from t he air cleaner enters t he i nt ake
manifold t hrough t he t hrot t l e body (Fig. 18). Fuel
does not enter t he i nt ake manifold t hrough t he throt-
tle body. Fuel is sprayed into t he manifold by t he
fuel injectors. The t hrot t l e body is mounted on t he
i nt ake manifold. It contains an air control passage
(Fig. 19) controlled by an idle air control (IAC) mo-
tor. The air control passage is used to supply air for
idle conditions. A t hrot t l e valve (plate) is used to
supply air for above idle conditions.
The t hrot t l e position sensor (TPS), idle air control
(IAC) motor and manifold absolute pressure sensor
(MAP) are attached to t he t hrot t l e body. The acceler-
ator pedal cable, speed control cable and t ransmi s-
sion control cable (when equipped) are connected to
t he t hrot t l e arm.
cally limit t he position of t he t hrot t l e body t hrot t l e
plate. Never attempt to adjust the engi ne idle
speed usi ng this screw. All idle speed functions are
controlled by t he PCM.

FUEL SYSTEM 14 - 4 1
THROTTLE
BODY
FUEL RAIL
CONNECTI NG
HOSES
THROTTLE BODY
MOU N T I N G BOLTS J9214-31
Fig. 18 Throttle Body
MOUNT I NG SCREWS
MAP SENSOR
RUBBER FITTING
J9314-87
Fig. 19 Air Control Passage
FUEL RAIL
The fuel rail supplies fuel to t he injectors and is
mounted to t he i nt ake manifold (Fig. 20). On vehi-
cles equipped with a 3.9L or 5.2L engine, t he fuel
pressure regulator is attached to t he rail and t he fuel
pressure test port is integral with t he rail. On vehi-
cles equipped with a 5.9L engine, t he fuel pressure
regulator is not par t of t he fuel rail. It is located on
t he fuel t ank mounted fuel pump module. The fuel
rail is not repairable.
FUEL PRESSURE REGULATOR
3.9L/5.2L
On vehicles equipped with a 3.9L or 5.2L engine,
t he fuel pressure regul at or is integral with t he fuel
rail.
J9214-32
Fig. 20 Fuel RailTypical
Re gul a t or Oper at i on: The fuel pressure regulator
is a mechanical device t hat is not controlled by t he
powertrain control module (PCM).
The fuel pressure regulator used is a vacuum bal-
anced, nonadjustable type. The regulator is mounted
on t he out put end of t he fuel rai l and is connected to
i nt ake manifold vacuum (Figs. 21 or 22). The fuel re-
t ur n t ube (to t he fuel t ank) is connected to t he fuel
pressure regulator.
M A P
SENSOR
d o c c
E L
PRESSURE REGULATOR
VACUUM LINE
REGULATOR
PROTECTIVE CAP
\
J9214-26
Fig. 21 Fuel Pressure Regulator3.9L Engine
The regulator is calibrated to mai nt ai n fuel system
operating pressure at approximately 214 kPa (31
psi). This is with vacuum applied while t he engine is
at idle. Fuel pressure will be 55-69 kPa (8-10 psi)
higher if vacuum is not applied to t he regulator.
The pressure regulator contains a diaphragm, cali-
brated spring and a fuel r et ur n valve. Fuel pressure
operates on one side of t he regulator, while spring
V A C U U M
LI NE
PROTECTIVE C AP
I NT E R NAL
FUEL FILTER
FUEL
PRESSURE
RE GULATOR FUEL RAI L
C O N N E C T O R HOSES J9214-27
pressure and i nt ake manifold vacuum operate on t he
other side. Spring pressure on one side of t he dia-
phragm t ri es to force t he r et ur n valve closed. Fuel
pressure on other side of diaphragm, with assistance
from manifold vacuum on spring side of diaphragm,
act agai nst spring pressure to open t he r et ur n valve.
System fuel pressure is t he amount of fuel pressure
required to force agai nst spring pressure and unseat
t he r et ur n valve.
Without vacuum applied to t he spring side of t he
regulator, t he spring is calibrated to open t he fuel re-
t ur n outlet. This happens when t he pressure differen-
tial between t he fuel injectors and t he i nt ake
manifold reaches approximately 269 kPa (39 psi).
Since manifold vacuum varies with engine operating
conditions, t he amount of vacuum applied to t he
spring side of t he di aphragm varies. For t hi s reason,
fuel pressure varies, depending upon i nt ake manifold
vacuum. Wi t h low vacuum, such as duri ng wide open
t hrot t l e conditions, mi ni mal vacuum assistance is
available. Full spring pressure is exerted to seal t he
fuel outlet. This causes t he system pressure to in-
crease. Wi t h high vacuum, such as at engine idle or
duri ng vehicle deceleration, fuel pressure on one side
of t he di aphragm is balanced by i nt ake manifold
pressure. This is done on t he spring side of t he dia-
phragm and results in lower system fuel pressure.
5.9L ENGINE
On vehicles equipped with a 5.9L engine, t he fuel
filter and fuel pressure regulator are one combined
part (Fig. 23). The fuel filter/fuel pressure regul at or
is located on t he top of t he fuel pump module (Fig.
24). It is pressed into a rubber grommet on module
(Fig. 23).
Re gul a t or Oper at i on: The fuel pressure regul at or
RUBBER
G R O M M E T
AT PUMP
MO D U L E
FUEL FILTER/FUEL
PRESSURE REGULATOR
CALI BRATED
S PR I NGS
X EXCESS FUEL BACK
T O T A N K
FUEL I NLET J 9314- 170
Fig. 23 Side ViewFilter/Regulator5.9L Engine
L OC KNUT FUEL SUPPLY
TUBE
FUEL FILTER/
FUEL PRESSURE
REGULATOR
PU M P/ G A U G E
ELEC. C O N N E C T I O N
PRESSURE RELIEF/ , I I
ROLLOVER VALVE J9314-167
Fig. 24 Filter/Regulator Location5.9L Engine
is a mechanical device t hat is not controlled by t he
powertrain control module (PCM).
The regulator is calibrated to mai nt ai n fuel system
operating pressure at approximately 241-310 kPa
(35-45 psi).
The regulator contains a diaphragm, calibrated
springs and a fuel ret urn valve. The i nt ernal fuel fil-
t er (Fig. 23) is part of t he assembly.
Fuel is supplied by t he electric fuel pump t hrough
an opening tube at t he bottom of filter/regulator (Fig.
23). The calibrated pressure regulator allows a con-
st ant fuel system operating pressure of approxi-
mat el y 241-310 kPa (35-45 psi). Fuel flows t hrough
regulator and fuel filter and on to fuel injectors at
engine.
If t he fuel pressure at regulator exceeds approxi-
mat el y 45 psi, an i nt ernal di aphragm closes and ex-
cess fuel pressure is routed back into pump module
and ret urned to fuel t ank (Fig. 23).
MULTI-PORT FUEL INJECTION (MPI)GENERAL DIAGNOSISEXCEPT DIESEL
INDEX
page
Camshaft Position Sensor Testing . . . . . . . . . . . . 52
Charge Air Temperature Sensor Test 52
Coolant Temperature Sensor Test 52
Crankshaft Position Sensor Test 54
Diagnostic Trouble Code ( DTC) 6 0
D RB II Sc an Tool . . . . . . . . . . . . . . . . . . . . . . . . 6 0
Fuel Injector Test 57
Fuel Pump Pressure Test 57
Idle Air Control ( I AC) Motor Test 55
Manifold Absolute Pressure ( MAP) Sensor Test . 53
page
On- Boar d Diagnostics ( OBD) 59
Ox ygen ( 0
2
) Sensor Heating Element Test 54
Powertrain Control Modul e ( PCM) 6 0- W ay
Connector . 4 7
Rel aysOperation/ Testing 56
Starter Motor Rel ay Test 57
Syst em Schematics . 4 7
Throttle Position Sensor ( TPS) Test 54
Visual Inspection 4 3
VISUAL INSPECTION
A visual inspection for loose, disconnected, or incor-
rectly routed wires and hoses should be made. This
should be done before at t empt i ng to diagnose or ser-
vice t he fuel injection system. A visual check will
help spot these faults and save unnecessary t est and
diagnostic time. A thorough visual inspection will in-
clude the following checks:
(1) Verify t hat t he 60-way connector is fully in-
serted into t he connector of t he powertrain control
module (PCM) (Fig. 1). Verify t hat t he connector
mounting screw is tightened to 4 N
#
m (35 in. lbs.)
torque.
PCM
M O U N T I N G
BOLTS
PCM CONNECTOR
CONNECTOR MO U N T I N G
BOLT J9314-165
Fig. 1 Powertrain Control Module (PCM)
(2) Inspect t he bat t ery cable connections. Be sure
t hat they are clean and tight.
(3) Inspect fuel pump relay and air conditioning
compressor clutch relay (if equipped). Inspect t he
ASD relay connections. Inspect st art er motor relay
connections. Inspect relays for signs of physical dam-
age and corrosion. The relays are located in t he en-
gine compartment (Fig. 2).
TORQUE CONVERTER
CLUTCH RELAY
AUTO SHUTDOWN RELAY
FUEL PUMP RELAY
POWERTRAIN
DATA UNK CONTROL
(4) Inspect ignition coil connections. Verify t hat
coil secondary cable is firmly connected to coil (Fig. 3
or 4 ) .
| X
COIL
frCONNECTOR J9214-7
Fig. 3 Ignition Coil3.9U5.2L/5.9L LDC-Gas Engine
14 - 44 FUEL SYSTEM

Fig. 4 ignition Coil5.9L HDC-Gas Engine
(5) Verify t hat distributor cap is correctly attached
to distributor. Be sure t hat spark plug cables are
firmly connected to t he distributor cap and t he spark
plugs are in t hei r correct firing order. Be sure t hat
coil cable is firmly connected to distributor cap and
coil. Be sure t hat camshaft position sensor wire con-
nector (at t he distributor) is firmly connected to har-
ness connector. Inspect spark plug condition. Refer to
Group 8D, Ignition. Connect vehicle to an oscillo-
scope and inspect spark events for fouled or damaged
spark plugs or cables.
(6) Verify t hat generator output wire, generator
connector and ground wire are firmly connected to
t he generator.
(7) Inspect t he system body grounds for loose or
dirty connections. Refer to Group 8, Wiring for
ground locations.
(8) Verify positive crankcase ventilation (PCV)
valve operation. Refer to Group 25, Emission Control
System for additional information. Verify PCV valve
hose is firmly connected to PCV valve and manifold
(Fig. 5).
Fig. 5 PCV Valve Hose ConnectionsTypical
(9) On 3.9L and 5.2L engines, verify t hat vacuum
hose is firmly connected to fuel pressure regulator
and manifold fitting (Figs. 6 or 7).
Fig. 7 Pressure Regulator Vacuum Hose5.2L
Engine
(10) Inspect fuel* t ube quick-connect fitting-to-fuel
rai l connections.
(11) Verify t hat hose connections to all ports of
vacuum fittings on i nt ake manifold are t i ght and not
leaking.

(12) Inspect accelerator cable, transmission throt-
tle cable (if equipped) and cruise control cable con-
nections (if equipped). Check t hei r connections to t he
throttle ar m of throttle body for any bi ndi ng or re-
strictions (Fig. 8).
Fig. 8 Throttle Body CablesTypical
(13) If equipped with vacuum brake booster, verify
t hat vacuum booster hose is firmly connected to fit-
ting on i nt ake manifold. Also check connection to
brake vacuum booster.
(14) Inspect t he air cleaner inlet and ai r filter ele-
ment for dirt or restrictions.
(15) Inspect radiator grille area, radi at or fins and
air conditioning condenser for restrictions.
(16) Verify t hat t he i nt ake manifold charge air
t emperat ure sensor wire connector is firmly con-
nected to harness connector (Figs. 9 or 10).
Fig. 9 Air Temperature Sensor3.9L (V-6) Engine
(17) Verify t hat MAP sensor electrical connector is
firmly connected to MAP sensor (Fig. 11). Also verify
t hat rubber L-shaped fitting from MAP sensor to t he
throttle body is firmly connected (Fig. 12).
(18) Verify t hat fuel injector wire harness connec-
tors are firmly connected to injectors in t he correct
Fig. 10 Air Temperature Sensor5.2U5.9L (V-8)
Engines
MANI FOLD ABSOLUTE
Fig. 11 MAP SensorTypical
order. Each harness connector is numerically tagged
with t he injector number (INJ 1, I NJ 2 etc.) of its
corresponding fuel injector and cylinder number.
(19) Verify harness connectors are firmly con-
nected to idle air control (IAC) motor, throttle posi-
tion sensor (TPS) and manifold absolute pressure
(MAP) sensor (Fig. 11).
(20) Verify t hat wire harness connector is firmly
connected to t he engine coolant t emperat ure sensor
(Fig. 13).
(22) Verify t hat oxygen sensor wire connector (or
connectors) are firmly connected to t he sensor (or
sensors). Inspect sensor(s) and connector(s) for dam-
age (Figs. 14 or 15).
14 - 46 FUEL SYSTEM
Fig. 12 Rubber L-Shaped FittingMAP Sensor-to-
Throttie Body
Fig. 13 Engine Coolant Temperature
Sensor Typical
EXHAUST ~~
PIPE J9214-5
Fig. 14 Single Oxygen Sensor Location-3.9U5.2L/
5.9L LDC Engine
(23) Inspect for pinched or l eaki ng fuel tubes. In-
spect for pinched, cracked or leaking fuel hoses.

Fig. 15 Dual Oxygen Sensor Location5.9L HDC
Engine
(24) Inspect for exhaust system restrictions such as
pinched exhaust pipes, collapsed muffler or plugged
catalytic convertor.
(25) If equipped with automatic transmission, ver-
ify t hat electrical harness is firmly connected to
park/ neut ral switch. Refer to Automatic Transmis-
sion section of Group 21.
(26) Verify t hat t he harness connector is firmly
connected to t he vehicle speed sensor (Fig. 16).
Fig. 16 Vehicle Speed Sensor Typical
(27) Verify t hat fuel pump/gauge sender uni t wire
connector is firmly connected to harness connector.
(28) Inspect fuel hoses at fuel pump/gauge sender
uni t for cracks or leaks.
(29) Inspect transmission torque convertor housing
(automatic transmission) or clutch housing (manual
transmission) for damage to t i mi ng ring on drive
plate/flywheel.
(30) Verify t hat bat t ery cable and solenoid feed
wire connections to t he st art er solenoid are t i ght and
clean. Inspect for chaffed wires or wires rubbing up
agai nst other components.

FUEL SYSTEM 14- 47
POWERTRAIN CONTROL MODULE (PCM) 60-WAY
CONNECTOR
Terminal identification and specific circuit applica-
tions are shown in t he PCM connector chart (Fig.
17). Also refer to Group 8W, Wi ri ng Diagrams.
SYSTEM SCHEMATICS
Fuel system schematics for fuel injected engines
are shown in figures 18, 19 and 20.
C AV
WI R E
C O L O R
D E S C R I PT I O N C AV
WI R E
C O L O R
1 DG/RD* MAP SENSOR 37 BK/OR OVERDRIVE LAMP
2 TN/BK* ENGINE COOLANT TEMPERATURE SENSOR 38 PK/BK INJECTOR DRIVE #5
3 RD/WT DIRECT BATTERY 39 GY/RD IAC MOTOR #4
4 BK/LB* SENSOR RETURN 40 BR/WT IAC MOTOR #2
5 BK/WT SIGNAL GROUND 41 BK/DG* OXYGEN SENSOR SIGNAL
6 VT/WT 5-VOLT OUTPUT (MAP AND TPS) 42
7 OR 8-VOLT OUTPUT (DISTRIBUTOR PICK-UP) 43 GY/LB* TACHOMETER SIGNAL OUTPUT (VEHICLES W/TACHOMETER)
8 44 GY CAMSHAFT POSITION SENSE
9 DB J2-IGNITION FEED 45 LG SCI RECIEVE
10 R/WT OVERDRIVE OVERRIDE 46 CCD (-)
11 BK/TN POWER GROUND 47 WT/OR* SPEED SENSOR SIGNAL
12 BK/TN POWER GROUND 48 BR/RD* SPEED CONTROL SET SWITCH
13 LB/BR INJECTOR DRIVER #4 49 YL/RD* SPEED CONTROL ON/OFF SWITCH
14 YL/WT INJECTOR DRIVER #3 50 WT/LG* SPEED CONTROL RESUME SWITCH
15 TN INJECTOR DRIVER #2 51 DB/YL* AUTO SHUTDOWN (ASD) RELAY - RETURN
16 WT/DB* INJECTOR DRIVER #1 52 PK/BK EVAP CANISTER PURGE SOLENOID
17 DB/TN INJECTOR DRIVER #7 (V-8 ONLY) 53 LG/RD* SPEED CONTROL VENT SOLENOID
18 DB/GY INJECTOR DRIVER #8 (V-8 ONLY) 54 OR/BK* SHIFT INDICATOR LIGHT (MANUAL TRANSMISSION ONLY)
19 BK/GY* IGNITION COIL DRIVER 54 OR/BK* CONVERTOR CLUTCH SOLENOID (AUTO TRANSMISSION)
20 DG GENERATOR FIELD CONTROL 55 OR/WT OVERDRIVE SOLENOID (AUTO TRANSMISSION ONLY)
21 BK/RD CHARGE TEMPERATURE SENSOR 56 GY/PK SRI LAMP (5.9L HDC ENGINE)
22 OR/DB* THROTTLE POSITION SENSOR (TPS) 57 DG/OR ASD SENSE
23 TN/WT OXYGEN SENSOR SIGNAL (5.9L HDC ENGINE) 58 LG/BK INJECTOR DRIVER #6
24 GY/BK IGNITION (CAMSHAFT POSITION SENSOR) 59 VT/BK IAC MOTOR #1
25 PK , SCI TRANSMIT 60 YL/BK* IAC MOTOR #3
26 CCD (-:-) WIRE COLOR CODES LB LIGHT BLUE V T V I O L E T
27 BR A/C SWITCH SENSE BK BLACK LG LIGHT GREEN W T WHITE
28 VT A/C SELECT BR BROWN OR ORANGE YL YELLOW
29 WT/PK* BRAKE SWITCH - DB DARK BLUE PK PINK
*
WITH TRACER
30 BY/YL* PARK/NEUTRAL SWITCH DG DARK GREEN RD RED
31 GY GRAY TN TAN
32 BK/PK* MALFUNCTION INDICATOR LAMP
33 TN/RD* SPEED CONTROL VACUUM SOLENOID
CONNECTOR
34 DB/OR* A/C CLUTCH RELAY
TERMINAL
|(pcKX>coooop
0
ffoj' ooooooooooj j
35 GY/YL* EGR SOLENOID SHOWN
W'41 30 50M#5l31 604
%\ o o o o o o o o o o o o o o o o o o o o j
36 J9314-171
Fig. 17 PCM ConnectorGas Powered Engines

TH ROTTL E
POSI TI ON
SE N SOR
C O
Fig. 18 System Schematic3.9L (V-6) Engine
C O
CJ1
m
r-
co
- <
CO
J 9 3 1 4 - 1 2 0
Fig. IS System Schematic5.2U5.9L LDC (V-8) Engine
-<
m
J9314-172
Fig. 20 System Schematic-SSL HDC (V-8) Engine
14- 5 2 FUEL SYSTEM

CAMSHAFT POSITION SENSOR TESTING
Refer to Group 8D, Ignition Systems for testing.
COOLANT TEMPERATURE SENSOR TEST
To perform a complete test of t he engine coolant
t emperat ure sensor and its circuitry, refer to DRB II
tester and appropriate Powert rai n Diagnostics Proce-
dures manual . To test t he sensor only, refer to t he
following:
(1) Disconnect wire harness connector from coolant
t emperat ure sensor (Fig. 21).
Engi nes wi t h ai r condi t i oni ng; When removing
the connector from sensor, do not pull directly on
long). Place t he hook part of tool under t he connector
for removal. The connector is snapped onto t he sen-
sor. It is not equipped with a lock type t ab.
Fig. 21 Engine Coolant Temperature
Sensor Typical
(2) Test t he resistance of t he sensor wi t h a high in-
put impedance (digital) volt-ohmmeter. The resis-
tance (as measured across t he sensor terminals)
should be less t han 1340 ohms with t he engine
warm. Refer to t he Coolant Temperat ure sensor/
Charge Air Temperat ure sensor resistance chart. Re-
place t he sensor if it is not wi t hi n t he range of
resistance specified in t he chart.
(3) Test continuity of t he wire harness. Do t hi s be-
tween t he powertrain control module (PCM) wire
harness connector t ermi nal 2 and t he sensor connec-
tor t ermi nal . Also test continuity of wire harness ter-
mi nal 4 to t he sensor connector t ermi nal . Repair t he
wire harness if an open circuit is indicated.
(4) After tests are completed, connect electrical
connector to sensor. The sensor connector is symmet-
rical (not indexed). It can be installed to t he sensor
in either direction.
SENSOR RESISTANCE (OHMS)-COOLANT
TEMPERATURE SENSOR/CHARGE AIR
TEMPERATURE SENSOR
T E MPE RAT URE R E S I S T ANC E ( O HM S )
C F M I N M A X
- 40 - 40 291,490 381,710
- 2 0 - 4 85 , 85 0 10 8,390
- 10 14 49, 2 5 0 61,430
0 32 2 9, 330 35 , 990
10 5 0 17,990 21,810
2 0 68 11,370 13,610
25 77 9,120 10 ,880
30 86 7, 370 8,75 0
40 104 4, 90 0 5 , 75 0
5 0 122 3,330 3, 880
60 140 2,310 2 , 670
70 158 1,630 1,870
80 176 1,170 1,340
90 194 860 970
10 0 212 640 72 0
n o 2 30 480 5 40
120 2 48 370 410
J928D-4
CHARGE AIR TEMPERATURE SENSOR TEST
To perform a complete test of t he i nt ake manifold
charge air t emperat ure sensor and its circuitry, refer
to DRB II tester and appropriate Powertrain Diag-
nostics Procedures manual . To test t he sensor only,
refer to t he following:
charge air t emperat ure sensor (Fig. 22).
Fig. 22 Charge Air Temperature SensorTypical
(2) Test t he resistance of t he sensor with an i nput
impedance (digital) volt-ohmmeter. The resistance
(as measured across t he sensor terminals) should be
less t han 1340 ohms wi t h t he engine warm. Refer to
t he Coolant Temperat ure sensor/Charge Air Temper-

at ure sensor resistance chart. Replace t he sensor if it
is not wi t hi n the range of resistance specified in the
chart.
(3) Test t he resistance of t he wire harness. Do t hi s
between t he powertrain control module (PCM) wire
harness connector t ermi nal 21 and the sensor connec-
tor t ermi nal . Also check between t ermi nal 4 to t he
sensor connector t ermi nal . Repair t he wi re harness
as necessary if t he resistance is greater t han 1 ohm.
TEST
To perform a complete test of MAP sensor (Fig. 23)
and its circuitry, refer to DRB II tester and appropri-
ate Powert rai n Diagnostics Procedures manual . To
test t he MAP sensor only, refer to t he following:
(1) Inspect the rubber L-shaped fitting from t he
MAP sensor to t he throttle body (Fig. 24). Repair as
necessary.
MANI FOLD ABSOLUTE
Sensor Typical
C A U T I O N : When testing the M A P sensor , be sure
that the har ness wi res are not damaged by the test
meter pr obes.
(2) Test t he MAP sensor output voltage at t he
MAP sensor connector between t ermi nal s A and B
(Fig. 25). Wi t h t he ignition switch ON and t he en-
gine OFF, output voltage should be 4-to-5 volts. The
voltage should drop to 1.5-to-2.1 volts wi t h a hot,
neut ral idle speed condition.
(3) Test powertrain control module (PCM) pin-1 for
t he same voltage described above to verify t he wire
harness condition. Repair as necessary.
Fig. 24 Rubber L-Shaped FittingMAP Sensor-to-
Throttle Body
A . Ground
B. Output Voltage
C . 5 Volts
J8914-91
Fig. 25 MAP Sensor Connector TerminalsTypical
(4 ) Test MAP sensor supply voltage at sensor con-
nector between t ermi nal s A and C (Fig. 25) with t he
ignition ON. The voltage should be approximately 5
volts (0.5V). Five volts (0.5V) should also be at
t ermi nal 6 of t he powertrain control module (PCM)
wire harness connector. Repair or replace t he wire
harness as necessary.
(5) Test t he MAP sensor ground circuit at sensor
connector t ermi nal A (Fig. 25) and PCM connector
terminal/pin-4. Repair t he wire harness if necessary.
(6) Test t he MAP sensor ground circuit at t he
PCM connector between terminal/pin-4 and t ermi nal /
pin-11 with an ohmmeter. If t he ohmmet er indicates
an open circuit, inspect for a defective sensor ground
connection. Refer to Group 8W, Wiring Di agrams for
location of this connection. If t he ground connection

is good, replace t he PCM. If terminal/pin-4 has a
short circuit to 12 volts +, correct t hi s condition be-
fore replacing t he PCM.
CRANKSHAFT POSITION SENSOR TEST
To perform a complete test of t hi s sensor (Fig. 26)
and its circuitry, refer to t he DRB II t est er and ap-
propriate Powert rai n Diagnostics Procedures manual .
To t est t he sensor only, refer to t he following:
(1) Near t he rear of t he ri ght cylinder head, dis-
connect t he sensor pigtail harness connector from t he
mai n wiring harness.
Fig. 26 Crankshaft Position Sensor Typical
(2) Place an ohmmeter across t ermi nal s B and C
(Fig. 27). Ohmmet er should be set to lK-to-lOK scale
for t hi s test. The met er readi ng should be open (no
resistance). Replace sensor if a low resistance is indi-
cated.
VI EW LOOKI NG I NTO
CPS WI R I N G CONNECTOR
Fig. 27 Sensor Wiring Connector
THROTTLE POSITION SENSOR (TPS) TEST
To perform a complete t est of t he TPS and its cir-
cuitry, refer to t he DRB II t est er and appropriate
Powert rai n Diagnostics Procedures manual . To test
t he TPS only, refer to t he following:
The TPS can be tested with a digital voltmeter.
The center t ermi nal of t he TPS is t he output termi-
nal (Fig. 28).
AAANIFOLD ABSOLUTE
Fig. 28 Throttle Position Sensor (TPS)
Connector Typical
With t he ignition key in t he ON position, check t he
TPS output voltage at t he center t ermi nal wire of t he
connector. Check t hi s at idle (throttle plate closed)
and at wide open throttle (WOT). At idle, TPS output
voltage should must be great er t han 200 millivolts.
At wide open throttle, TPS output voltage must be
less t han 4.8 volts. The output voltage should in-
crease gradually as t he t hrot t l e plate is slowly
opened from idle to WOT.
OXYGEN ( 0
2
) SENSOR HEATING ELEMENT TEST
To perform a complete test of single or dual 0
2
sen-
sor(s) and circuitry, refer to DRB II t est er and appro-
pri at e Powertrain Diagnostics Procedures manual . To
t est t he 0
2
sensor only, refer to t he following:
On 3.9L/5.2L/5.9L LDC engines, t he single 0
2
sen-
sor is located on t he ri ght exhaust down pipe (Fig.
29). On 5.9L HDC engines, t he dual 0
2
sensors are
located on each (left and right) exhaust down pipe
(Fig. 29).
The 0
2
heat i ng element can be tested wi t h an ohm-
met er as follows:
Disconnect t he 0
2
sensor connector. Connect t he
ohmmeter test leads across t he whi t e wire t ermi nal s
of t he sensor connector. Resistance should be be-
tween 5 and 7 ohms. Replace t he sensor if t he ohm-
met er displays an infinity (open) reading.

FUEL SYSTEM 14 - 55
Fig. 30 Dual Oxygen Sensors5.9L HDC Engine
IDLE AIR CONTROL (IAC) MOTOR TEST
To perform a complete test of IAC motor (Fig. 81)
and its circuitry, refer to DRB II scan tool and appro-
priate Powert rai n Diagnostics Procedures manual . To
test t he IAC motor only, special IAC motor exerciser
tool number 7558 (Fig. 32) may be used.
C A U T I O N : Proper safet y pr ecaut i ons must be taken
when t est i ng the I AC motor,
Set t he parki ng brake and block t he drive wheels
Route all tester cables away from t he cooling fans,
drive belt, pulleys and exhaust components
Provide proper ventilation while operating t he en-
gine
Always ret urn t he engine idle speed to normal be-
fore disconnecting t he exerciser tool
(1) Wi t h t he ignition OFF, disconnect t he IAC mo-
tor wire connector at t hrot t l e body (Fig. 31).
(2) Pl ug t he exerciser tool (7558) harness connector
into t he IAC motor (Fig. 32).
MANI FOLD ABSOLUTE
Fig. 31 IAC MotorTypical
Fig. 32 IAC Motor Testing Typical
(3) Connect t he red clip of exerciser tool (7558) to
bat t ery positive t ermi nal . Connect t he black clip to
negative bat t ery t ermi nal . The red light on t he exer-
ciser tool will be illuminated when t he exerciser is
properly connected to battery.
(4) St art engine.
When t he switch is in t he HIGH or LOW position,
t he light on t he exerciser tool will flash. This indi-
cates t hat voltage pulses are being sent to t he IAC
stepper motor.
14 - 56 FUEL SYSTEM

(5) Move t he switch to t he HIGH position. The en-
gine speed should increase. Move t he switch to t he
LOW position. The engine speed should decrease.
(a) If t he engine speed changes while using t he
exerciser tool, t he IAC motor is functioning prop-
erly. Disconnect t he exerciser tool and connect t he
IAC stepper motor wire connector to t he stepper
motor.
(b) If t he engine speed does not change, t ur n t he
ignition OFF and proceed to step (6). Do not discon-
nect exerciser from t he IAC stepper motor.
(6) Remove t he IAC stepper motor from t he throt-
tle body.
C A U T I O N : When checki ng I A C motor operation with
the motor removed from the throttle body, do not
extend the pintle (Fi g. 33) more than 6.35 mm (.250
in). If the pintle is ex tended more than this amount, it
may separate from the I AC stepper motor. The I AC mo-
tor must be replaced if the pintle separates from the
motor.
WIRE HARNESS
PINTLE J9314-116
Fig. 33 IAC Stepper Motor PintleTypical
(7) Wi t h t he ignition OFF, cycle t he exerciser tool
switch between t he HIGH and LOW positions. Ob-
serve t he pintle. The pintle should move in-and-out
of t he motor.
(a) If t he pintle does not move, replace t he IAC
motor. St ar t t he engine and t est t he replacement
motor operation as described in step (5).
(b) If t he pintle operates properly, check t he IAC
motor bore in t he t hrot t l e body bore for blockage
and clean as necessary. Install t he IAC motor and
retest. If blockage is not found, refer to t he DRB II
scan tool and t he appropriate Powert rai n Diagnos-
tics Procedures service manual .
RELAYSOPERATION/TESTING
OPERATION
The fol l owi ng operati ons/ tests appl y to these
rel ays only: Automatic Shut Down (ASD) and Fuel
Pump. For operations/tests on all other relays, refer
to t he appropriate section of t hi s service manual .
These relays are located in t he engine compart-
ment (Fig. 34).
DATA LINK CONTROL
The relay t ermi nal numbers from (Fig. 35) can be
found on t he bottom of t he relay.
Termi nal number 30 is connected to bat t ery volt-
age and can be switched or B+ (hot) at all times.
The center t ermi nal number 87A is connected (a
circuit is formed) to t ermi nal 30 in t he de-energized
(normally OFF) position.
Termi nal number 87 is connected (a circuit is
formed) to t ermi nal 30 in t he energized (ON) posi-
tion. Termi nal number 87 t hen supplies bat t ery volt-
age to t he component being operated.
Termi nal number 86 is connected to a switched
( + ) power source.
Termi nal number 85 is grounded by t he power-
t r ai n control module (PCM).
TESTING
(1) Remove relay before testing.
(2) Using an ohmmeter, perform a resistance test
between t ermi nal s 85 and 86. Resistance value
(ohms) should be 75 5 ohms for resistor equipped
relays.
(3) Connect t he ohmmeter between t ermi nal s num-
ber 87A and 30. Continuity should be present at t hi s
time.
(4) Connect t he ohmmeter between t ermi nal s num-
ber 87 and 30. Continuity should not be present at
t hi s time.
(5) Use a set of j umper wires (16 gauge or small-
er). Connect one j umper wire between t ermi nal num-
ber 85 (on t he relay) to t he ground side (-) of a 12
Volt power source.
(6) At t ach t he other j umper wire to t he positive
side ( + ) of a 12V power source. Do not connect t hi s
j umper wire to relay at t hi s time.

BOTTOM V I E W
OF RELAY
RELAY
CONNECTOR
DE-ENERGI Z ED
RELAY
ENERGI Z ED
RELAY
9 2 1 4 - 1 5 7
Fig. 35 Relay Terminals
CAUTI ON : D O N OT AL L OW TH E OH M M E TE R TO
CON TACT TE RM I N AL S 8 5 OR 8 6 D URI N G TH E SE
TE STS. D AM AGE TO OH M M E TE R M AY RE SUL T.
(7) Attach t he other j umper wire (12V +) to termi-
nal number 86. This will activate t he relay. Continu-
ity should now be present between t ermi nal s number
87 and 30. Continuity should not be present between
t ermi nal s number 87A and 30.
(8) Disconnect j umper wires from relay and 12
Volt power source.
If continuity or resistance tests did not pass, re-
place relay. If tests passed, refer to Group 8W, Wir-
ing Diagrams for (fuel system) relay wiring
schematics and for additional circuit information.
STARTER MOTOR RELAY TEST
Refer to Group 8A, Battery/Starting/Charging Sys-
t em Diagnostics, for st art er motor relay testing.
FUEL INJECTOR TEST
Disconnect t he fuel injector wire harness connector
from t he injector (Fig. 36). Place an ohmmeter across
t he injector t ermi nal s. Resistance reading should be
approximately 14.5 ohms 1.2 ohms at 20C (68F).
Proceed to following Fuel Injector diagnosis chart.
FUEL INJECTOR
HARNESS CONNECTORS
FUEL
INJECTOR
J9214-30
Fig. 36 Fuel Injector Wiring Connector Typical
FUEL PUMP PRESSURE TEST
Refer to Fuel Pump Pressure Test in the Fuel De-
livery System section of t hi s group.
14 - 58 FUEL SYSTEM

INJECTOR DIAGNOSIS-VEHICLE RUNS ROUGH AND/OR HAS A MISS
DO PRELIMINARY INSPECTION OF
DISTRIBUTOR CAP, IGNITION
CABLES SPARK PLUGS, AND
CHECK FOR VACUUM LEAKS.
START VEHICLE, PULL THE
ELECTRICAL CONNECTORS OFF
THE INJECTORS ONE AT A TIME
TO DETERMINE WHI C H CYLINDER
IS NOT FI RI NG.
REPLACE THE INJECTOR
- N O
CHECK POWER FEED AND
GROUND CIRCUITS BETWEEN
POWERTRAIN CONTROL MODULE
A N D THE INJECTOR CONNECTOR.
REFER TO WI RI NG SCHEMATIC
FOR COLOR CODES A N D PIN
TERMINAL NUMBERS.
- N O -
YES
TEST THE VEHICLE WITH THE DRB II
S C AN TOOL
N O
REPAIR OR REPLACE THE WI R I N G
HARNESS A S NECESSARY.
REPLACE INJECTOR IF VISUALLY
PLUGGED AT INJECTOR FUEL
INLET.
REPLACE FUEL RAIL IF VISUALLY
PLUGGED OR RESTRICTED AT
INJECTOR DELIVERY COUPLI NG.
- N O
REPLACE INJECTOR
N O -
TEST THE INJECTOR RESISTANCE
U S I N G A N OHMMETER AC R OS S
THE INJECTOR TERMI NALS WI TH
THE INJECTOR CONNECTOR
REMOVED.
PLACE A 12 VOLT TEST LAMP
AC R OS S THE INJECTOR
ELECTRICAL CONNECTOR
TERMI NALS. OBSERVE THE TEST
LAMP WHILE C R ANKI NG THE
ENGI NE.
CIRCUIT IS OK. CHECK FOR FUEL
DELIVERY AT SUSPECT INJECTOR
BY R E MOV I NG THE INJECTOR
FROM THE RAIL A N D OBSERVI NG
FOR FUEL A N D / O R RESTRICTIONS
I N THE RAIL OR INJECTOR FUEL
INLET.
WI TH INJECTOR REMOVED FROM
THE FUEL RAIL, CONNECT A 12V
SOURCE TO ONE TERMI NAL O N
THE INJECTOR CONNECTOR A N D
A GR OU N D WIRE TO THE OTHER
TERMI NAL. THE INJECTOR
SHOULD "CLI CK" EACH TIME THE
GR OU N D WIRE IS CONNECTED
A N D DI SCONNECTED TO THE
TERMI NAL.
J9314-114

FUEL SYSTEM 14 - 59
fill DHADn HIAf5MflCTipQ /f|Rn\
The powertrain control module (PCM) has been
programmed to monitor many different circuits of t he
fuel injection system. If a problem is sensed in a
monitored circuit often enough to indicate an actual
problem, a diagnostic trouble code (DTC) is stored.
The DTC will be stored in t he PCM memory for
eventual display to t he service technician. If t he
problem is repaired or ceases to exist, t he PCM can-
cels t he DTC after 51 engine starts.
Cert ai n criteria must be met for a diagnostic trou-
ble code (DTC) to be entered into PCM memory. The
criteria may be a specific range of engine rpm, en-
gine t emperat ure and/or i nput voltage to t he PCM.
It is possible t hat a DTC for a monitored circuit
may not be entered into memory even t hough a mal-
function has occurred. This may happen because one
of t he DTC criteria for t he circuit has not been met.
Example: assume t hat one of the criteria for t he
MAP sensor circuit is t hat t he engine must be oper-
ating between 750 and 2000 rpm to be monitored for
a DTC. If t he MAP sensor output circuit shorts to
ground when t he engine rpm is above 2400 rpm, a 0
volt i nput will be seen by t he PCM. A DTC will not
be entered into memory because t he condition does
not occur wi t hi n t he specified rpm range.
A DTC indicates t hat t he powertrain control mod-
ule (PCM) has recognized an abnormal signal in a
circuit or t he system. A DTC may indicate t he result
of a failure, but never identify t he failed component
directly.
There are several operating conditions t hat t he
PCM does not monitor and set a DTC for. Refer to
t he following Monitored Circuits and Non-Monitored
Circuits in t hi s section.
MONITORED CIRCUITS
The powertrain control module (PCM) can detect
certain problems in t he fuel injection system.
Open or Shorted Circuit - The PCM can deter-
mine if sensor output (which is the input to PCM) is
within proper range. It also determines if t he circuit
is open or shorted.
Output Devi ce Current Fl ow - The PCM senses
whet her t he output devices are hooked up.
If t here is a problem with the circuit, t he PCM
senses whet her t he circuit is open, shorted to ground
(-), or shorted to ( + ) voltage.
Oxygen Sensor - The PCM can determine if t he
oxygen sensor is switching between rich and lean.
This is, once t he system has entered Closed Loop. Re-
fer to Open Loop/Closed Loop Modes Of Operation in
t he Component Description/System Operation section
for an explanation of Closed (or Open) Loop opera-
tion.
NON-MONITORED CIRCUITS
The PCM does not monitor the following circuits,
systems or conditions t hat could have malfunctions
t hat result in driveability problems. A diagnostic
trouble code (DTC) may not be displayed for these
conditions.
Fuel Pressure: Fuel pressure is controlled by t he
vacuum assisted fuel pressure regulator. The PCM
cannot detect a clogged fuel pump inlet filter, clogged
in-line fuel filter, or a pinched fuel supply or ret urn
line. However, these could resul t i n a rich or lean
condition causing an oxygen sensor DTC to be stored
in t he PCM.
Secondary Ignition Circuit: The PCM cannot de-
tect an inoperative ignition coil, fouled or worn spark
plugs, ignition cross firing, or open circuited spark
plug cables.
Engi ne Timing: The PCM cannot detect an incor-
rectly indexed timing chain, camshaft sprocket or
crankshaft sprocket. The PCM also cannot detect an
incorrectly indexed distributor. However, these could
result in a rich or lean condition causing an oxygen
sensor DTC to be stored in t he PCM.
Cylinder Compression: The PCM cannot detect
uneven, low, or high engine cylinder compression.
Exhaust System: The PCM cannot detect a
plugged, restricted or leaking exhaust system.
Fuel Injector Malfunctions: The PCM cannot de-
t ermi ne if t he fuel injector is clogged, or t he wrong
injector is installed. However, these could result in a
rich or lean condition causing an oxygen sensor DTC
to be stored in t he PCM.
Excessi ve Oil Consumption: Although t he PCM
monitors exhaust st ream oxygen content t hrough ox-
ygen sensor (closed loop), it cannot det ermi ne exces-
sive oil consumption.
Throttle Body Air Flow: The PCM cannot detect
a clogged or restricted air cleaner inlet or air filter
element.
Evaporati ve System: The PCM will not detect a
restricted, plugged or loaded EVAP canister.
Vacuum Assist: Leaks or restrictions in t he vac-
uum circuits of vacuum assisted engine control sys-
t em devices are not monitored by t he PCM. However,
a vacuum leak at the MAP sensor will be monitored
and a diagnostic trouble code (DTC) will be gener-
ated by t he PCM.
Powertrai n Control Modul e (PCM) System
Ground: The PCM cannot det ermi ne a poor system
ground. However, a DTC may be generated as a re-
sult of this condition.
Powertrai n Control Modul e (PCM) Connector
Engagement: The PCM cannot determine spread or
damaged connector pins. However, a DTC may be
generated as a result of this condition.
14 - SO FUEL SYSTEM

HIGH AND LOW LIMITS
The powertrain control module (PCM) compares in-
put signal voltages from each i nput device. It will es-
tablish high and low limits t hat are programmed
into it for t hat device. If t he i nput voltage is not
wi t hi n specifications and other diagnostic trouble
code (DTC) criteria are met, a DTC will be stored in
memory. Other DTC criteria mi ght include engine
rpm limits or input voltages from other sensors or
switches. The other inputs mi ght have to be sensed
by t he PCM when it senses a high or low i nput volt-
age from t he control system device in question.
ACCESSING DIAGNOSTIC TROUBLE CODES
A stored diagnostic trouble code (DTC) can be dis-
played by cycling t he ignition key On-Off-On-Off-On
wi t hi n t hree seconds and observing t he malfunction
indicator lamp. This lamp was formerly referred to
as t he check engine lamp. The l amp is located on t he
i nst rument panel.
They can also be displayed t hrough t he use of t he
Diagnostic Readout Box II (DRB II scan tool). The
DRB II connects to t he dat a link connector in t he ve-
hicle (Fig. 37). For operation of t he DRB II, refer to
t he appropriate Powert rai n Diagnostic Procedures
service manual .
TORQUE CONVERTER
CLUTCH RELAY
A / C CLUTCH RELAY . STARTER RELAY
AUTO SHUTDOWN RELAY
FUEL PUMP RELAY
POWERTRAIN
DATA LINK CONTROL
Fig. 37 Data Link Connector LocationTypical
EX AMPLES
If t he lamp flashes 4 times, pauses and flashes 1
more time, a diagnostic trouble code (DTC) number
41 is indicated.
more times, a diagnostic trouble code (DTC) number
46 is indicated.
Refer to t he Diagnostic Trouble Code (DTC) charts
for DTC identification.
If t he problem is repaired or ceases to exist, t he
powertrain control module (PCM) cancels t he DTC
after 51 engine st art s.
Diagnostic trouble codes indicate t he results of a
failure, but never identify t he failed component di-
rectly.
The circuits of t he dat a link connector are shown
in (Fig. 38).
J9214-20
D-1 G R O U N D
D-2 Im/c
D-3 S CI T R A N S
D-4 S CI RECEI VE
D-5 I GN I T I ON
D-6 N O T USED
Fig. 38 Data Link Connector Schematic
ERASING TROUBLE CODES
The DRB II scan tool must be used to erase a di-
agnostic trouble code (DTC). Refer to t he appropriate
Powert rai n Diagnostic Procedures service manual for
operation of t he DRB II scan tool.
DRB II SCAN TOOL
For operation of t he DRB II scan tool, refer to t he
appropriate Powertrain Diagnostic Procedures ser-
vice manual .
DIAGNOSTIC TROUBLE CODE (DTC)
On t he following pages, a list of diagnostic trouble
codes is provided for all gas powered engines. A DTC
indicates t hat the powertrain control module (PCM)
has recognized an abnormal signal in a circuit or t he
system. A DTC may indicate t he result of a failure,
but never identify t he failed component directly.

FUEL SYSTEM 14- 61
DIAGNOSTIC TROUBLE CODE {DTC) DESCRIPTION
Diagnostic
Trouble Code
DRB II Display Description of Trouble Code Condition
11 No Crank Reference
Signal at PCM
No distributor reference signal detected during engine cranking.
13+ * * No Change in AAAP
From Start to Run
No variation in MAP sensor signal is detected.
No difference is recognized between the engine MAP reading and
the barometric pressure reading at start up.
14 + * * MAP Voltage Too Low
or
MAP Voltage Too High
MAP sensor input below minimum acceptable voltage.
MAP sensor input above maximum acceptable voltage.
15* * No Vehicle Speed
Sensor Signal
No speed sensor signal detected during road load conditions.
17 Engine is Cold Too Long Engine coolant temperature remains below normal operating temperatures
during vehicle travel (thermostat).
2 1 * * O2 Signal Stays at
Center
or
Oo Signal Shorted to
Voltage
Neither rich or lean condition is detected from the oxygen sensor input.
Oxygen sensor input voltage maintained above normal operating range.
22+ * * ECT Sensor
Voltage Too Low
or
ECT Sensor
Voltage Too High
Coolant temperature sensor input below the minimum acceptable voltage.
Coolant temperature sensor input above the maximum acceptable voltage.
23 Charge Air Temperature
Sensor Voltage High
or
Charge Air Temperature
Sensor Voltage Low
Charge Air Temperature Sensor input above/below acceptable minimum.
24 + * * Throttle Position
Sensor Voltage High
or
Throttle Position
Sensor Voltage Low
Throttle position sensor (TPS) input above the maximum acceptable voltage.
Throttle position sensor (TPS) input below the minimum acceptable voltage.
** Check Engine Lamp ON (California only)
+ Check Engine Lamp ON
J9314-126

DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTION-CONTINUED
Diagnostic
Trouble Code
DRB If Display Description of Trouble Code Condition
25**
Idle Air Control
Motor Circuits
(ISC Actuator)
A shorted condition detected in one or more of the idle air control
actuator circuits.
27+** Control Circuit Injector output driver does not respond properly to the control signal.
31** EVAP Purge
Solenoid Circuit
An open or shorted condition detected in the purge solenoid circuit.
32**
EGR System Failure An open or shorted condition detected in the EGR solenoid circuit.
Required change in air-fuel ratio not detected during diagnostic test
(California emissions packages only).
33 A/C Clutch Relay
Circuit
An open or shorted condition detected in the A/C clutch relay circuit.
34 Speed Control
Solenoid Circuits
An open or shorted condition detected in the speed control vacuum or
vent solenoid circuits.
37
Torque Converter
Clutch Solenoid
Circuit (CKT)
An open or shorted condition detected in the torque converter clutch
solenoid circuit (vehicles with automatic transmissions only).
41+**
Generator Field Not
Switching Properly
Generator field not switching properly.
42 Auto Shutdown Relay
Control Circuit
or
No ASD Relay Voltage
Sense at Controller
An open or short condition detected in the auto shutdown relay circuit.
No ASD voltage sensed at PCM.
** Check Engine Lamp ON (California only)
+ Check Engine Lamp ON J9314-127

FUEL SYSTEM 14 - 63
DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTION-CONTINUED
D i agnost i c
T roubl e
C o d e
D RB 11 D i s pl ay D escr i pt i on of T r oubl e C ode C ondi t i on
4 4 Battery Temperature
Voltage
Battery temperature sensor volts out of limit.
4 5 Overdrive Solenoid An open or shorted condition detected in overdrive solenoid circuit.
4 6 + * * Charging System
Voltage Too High
Charging system voltage too high.
4 7 + * * Charging System
Voltage Too Low
Charging system voltage too low.
5 1 * * 0
2
Signal Stays
Below Center (Lean)
or
Additive Adaptive
Memory at Rich Limit
0
2
sensor signal stays lean.
Additive adaptive memory at rich limit.
5 2 * * 0
2
Signal Stays
Above Center (Rich)
or
Additive Adaptive
Memory at Lean Limit
0
2
sensor signal stays rich.
Additive adaptive memory at lean limit.
53 Internal PCM Failure Internal failure in the PCM {Powertrain Control Module)
54 Sync Pick-up Signal N o fuel sync signal detected during crankshaft rotation.
55 N A Completion of trouble code display on the Malfunction Indicator (MIL) lamp.
6 2 PCM Failure
SRI Miles Not Stored
PCM (Powertrain Control Module) failure - SRI miles not stored.
6 3 PCM Failure
EEprom Write Denied
PCM (Powertrain Control Module) failure - EEprom write denied.
+Check Engine Lamp ON **Check Engine Lamp ON (California only)
J 931 4 - 1 7 7
MULTI - PORT FUEL INJECTION ( M P I ) - C O M P O N E N T
REMOVAL/INSTALLATION EXCEPT DIESEL
INDEX
page
Accelerator Pedal and Throttle Cabl e . 64
Air Conditioning ( A/ C) Clutch Rel ay 64
Air Filter/Filter H ousi ng 64
Automatic Shut Down ( ASD) Rel ay . 64
Brake Switch 64
Camshaft Position Sensor . . . . . . . . . . . . . . . . . . 64
Charge Air Temperature Sensor 64
Engi ne Coolant Temperature Sensor 65
E V AP Canister Purge Sol enoid 65
Fuel Filter 65
Fuel Filter/Fuel Pressure Regulator5.9L Engine . 65
Fuel Injector(S) 67
Fuel Pressure Regulator 67
Fuel Pump Modul e 68
Fuel Pump Rel ay 68
ACCELERATOR PEDAL AND THROTTLE CABLE
Refer to t he Accelerator Pedal and Throttle Cable
section of t hi s group for removal/installation proce-
dures.
AIR CONDITIONING (A/C) CLUTCH RELAY
The A/C clutch relay is located in t he engine com-
part ment (Fig. 1).
DATA LINK CONTROL
AIR FILTER/FILTER HOUSING
Refer to Air Filter/Filter HousingGas Engi nes in
Group 25, Emission Control System for removal/in-
stallation procedures.
ment (Fig. 1).
page
Fuel Rail 69
Fuel Syst em Pressure Rel ease Procedure . . . . . . 71
Fuel Tank Pressure Relief/Rollover Val ve 71
Fuel Tanks 71
Fuel Tubes/ Li nes/ H oses and Cl amps 71
Idle Air Control ( IAC) Motor 71
Ignition Coil 71
Intake Manifold 71
Manifold Absolute Pressure ( MAP) Sensor 71
Ox ygen ( 0
2
) Sensor 72
Park/Neutral Switch . 73
Powertrain Control Module ( PCM) 73
Q uick-Connect Fittings 73
Throttle Body 73
Throttle Position Sensor ( TPS) . . . . . . 74
Vehicle Speed Sensor 75
BRAKE SWITCH
Refer to Group 5, Brakes for removal/installation
procedures.
For removal/installation procedures, refer to Group
8D, Ignition System. See Camshaft Position Sensor.
CHARGE AIR TEMPERATURE SENSOR
The i nt ake manifold charge air t emperat ure sensor
is located in t he front/side of t he i nt ake manifold
(Fig. 2 or 3).
REMOVAL
(1) Remove air cleaner assembly.
(2) Disconnect electrical connector at sensor (Figs.
2 or 3).
INSTALLATION
(1) Install sensor to i nt ake manifold. Tighten to 28
Refer to Group 8D, Ignition System for removal/in-
Fig. 2 Ait Temperature Sensor3.9L (-6) Engine
Fig. 3 Air Temperature Sensor5.2U5.9L (V-8)
Engines
REMOVAL
W ARN I N G: H OT, PRE SSURI Z E D COOL AN T C AN
C AUSE I N J URY BY SCAL D I N G- COOL I N G SY STE M
M UST BE PARTI AL L Y D RAI N E D BE F ORE RE M OV -
I N G TH E COOL AN T TE M PE RATURE SE N SOR. RE -
F E R TO GROUP 7, COOL I N G.
(1) Partially drai n cooling system. Refer to Group
7, Cooling.
(2) Disconnect electrical connector from sensor
(Fig. 4).
Engi nes wi t h ai r condi t i oni ng: When removing
t he connector from sensor, do not pull directly on
long). Place t he hook part of tool under t he connector
for removal. The connector is snapped onto t he sen-
sor. It is not equipped wi t h a lock type t ab.
INSTALLATION
(1) Install sensor.
(2) Ti ght en to 11 Nnn (8 ft. lbs.) torque.
The sensor connector is symmetrical (not indexed).
It can be installed to t he sensor in either direction.
(4) Replace any lost engine coolant. Refer to Group
7, Cooling System.
EAP CANISTER PURGE SOLENOID
Refer to Group 25, Emission Control System for re-
moval/installation procedures.
FUEL FILTER
3.9L/5.21. ENGINE
The fuel filter on vehicles equipped wi t h a 3.9L
(V-6) or a 5.2L (V-8) engine is mounted to t he frame
rail. Refer to t he Fuel Delivery System section of this
group for removal/installation procedures.
5.91 ENGINE
On vehicles equipped wi t h t he 5.9L (V-8) engine,
t he fuel filter and fuel pressure regulator are one
combined part . Refer to t he following Fuel Filter/
Fuel Pressure Regulator5.9L Engine for removal
and installation procedures.
FUEL FILTER/FUEL PRESSURE REGULATOR5JL
ENGINE
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE, EVEN WITH ENGINE OFF. BE-
FORE SERVICING THE FUEL FILTER/FUEL
PRESSURE REGULATOR, THE FUEL SYSTEM
PRESSURE MUST BE RELEASED.
Refer to Fuel System Pressure Release in t he Fuel
Delivery System section of t hi s group.
14 - 66 FUEL SYSTEM
REMOVAL
The fuel filter/fuel pressure regul at or is located on
t he top of fuel pump module (Fig. 5).
ROLLOVER VALVE J9314-167
Fig. 5 Filter/Regulator Location5.9L Engine
Fuel pump module removal is not necessary.
(1) Drain fuel t ank and remove t ank. Refer to Fuel
Tanks in t hi s group.
(2) The fuel filter/regulator is pressed into a rub-
ber grommet. Remove by twisting and pulling
st rai ght up (Fig. 6).
CAUTI ON ; D o not pull the filter/regulator more than
three i nches from the fuel pump modul e. D amage to
the coiled fuel tube (line) may result.
Fig. 6 Filter/Regulator Removal and
Installation5.9L Engine
(3) Remove t he snap ri ng ret ai ni ng t he convoluted
tube (cover) to t he filter/regulator (Fig. 7). Slide t he
plastic t ube down t he fuel tube to clear t he fuel t ube
clamp.
(4) Gently cut t he old fuel t ube (line) clamp (Fig.
8) t aki ng care not to damage t he plastic fuel t ube.
Remove and discard t he old fuel t ube clamp.
Fig. 7 Plastic Tube and Snap Ring
Fig. 8 Fuel Tube and Clamp
(5) Remove t he plastic fuel tube from t he filter/reg-
ulator by gently pulling downward. Remove filter/
regulator from fuel pump module.
INSTALLATION
(1) Install a new clamp over t he plastic fuel tube.
(2) Install filter/regulator to fuel tube. Rotate t he
filter/regulator in t he fuel t ube unt i l it is in t he 10
o'clock position.
(3) Tighten clamp to fuel tube (line) using special
Hose Clamp Pliers number C-4124 or equivalent
(Fig. 9). Do not use conventional side cutters to
t i ght en t hi s type of clamp.
(4) Slide t he convoluted plastic t ube (cover) up to
t he bottom of filter/regulator and install snap ri ng
(Fig. 7).
(5) Press t he filter/regulator (by hand) into t he
rubber grommet. Position t he filter to t he 10 o'clock
position.
(6) Install fuel t ank. Refer to Fuel Tanks in t hi s
group.

FUEL SYSTEM 14- 67
Fig. 9 Tightening Fuel Tube Clamp
FUEL INJECTOR(S)
W ARN I N G; THE F UE L SYSTEM IS UN D E R A C ON -
STAN T PRE S S URE ( E V E N WITH TH E E N GI N E
TURN E D OF F ) . BE F ORE SE RV I CI N G TH E F UE L I N-
J E C TOR^ ) , THE F UE L SYSTEM PRE S S URE M UST
BE RE L E ASE D .
To release fuel pressure, refer to t he Fuel Delivery
System section of t hi s group. See Fuel System Pres-
sure Release.
To remove one or more fuel injectors, t he fuel rail
assembly must be removed from engine.
REMOVAL
(1) Remove ai r cleaner assembly.
(2) Remove fuel rail assembly. Refer to Fuel Rail
removal in t hi s section.
(3) Remove t he clip(s) ret ai ni ng the injector(s) to
fuel rail (Fig. 10).
CUP
Fig. 10 Fuel Injector and Retaining Clip
(4) Remove injector(s) from fuel rail.
INSTALLATION
(1) Apply a small amount of engine oil to each fuel
injector O-ring. This will help in fuel rail installa-
tion.
(2) Install injector(s) and injector clip(s) to fuel
rail.
(3) Install fuel rail assembly. Refer to Fuel Rail in-
stallation.
(5) St art engine and check for leaks.
W ARN I N G: TH E F UE L SY STE M I S UN D E R A C ON -
STAN T PRE S S U RE ( E V E N W I TH TH E E N GI N E
TURN E D OF F ) . BE F ORE SE RV I CI N G TH E F UE L
PRE S S URE RE GUL ATOR, TH E F UE L SY STE M
PRE S S URE M UST BE RE L E ASE D .
System section of this group. See Fuel System Pres-
sure Release.
RE MOV AL3JL (V-6 ) ENGINE
The pressure regulator is located (mounted horizon-
tally) in t he fuel rail assembly near t he dash panel
(Fig. 11). It is held to t he fuel rail with a snap ri ng
(Fig. 12).
(1) Perform t he fuel pressure release procedure.
(3) Remove t he vacuum line from t he pressure reg-
ulator.
14 - 68 FUEL SYSTEM

S NAP
RI NG
SNAP RING
PLIERS
VACUUM
LINE
PROTECTIVE CAP
FUEL
PRESSURE
REGULATOR,
FUEL RAIL
J9214-47
Fig. 12 Regulator Snap Ring3.9L Engine
(4) Using a pair of 90 degree snap-ring pliers, re-
move t he snap-ring (Fig. 12) from pressure regulator.
A small hand held mirror will aid in removal of t hi s
snap-ring.
(5) Remove pressure regulator from fuel rail.
INSTALLATION3.9L ENGINE
(1) Install new O-ring seals to pressure regulator.
(2) Install pressure regulator to fuel rail. The vac-
uum nipple on t he regulator must be pointed st rai ght
up.
(3) Install snap-ring. Be sure snap-ring is seated.
(4) Install vacuum line to pressure regulator.
RE M OV AL - 5 . 2 1 (-8) ENGINE
The pressure regulator is located (mounted verti-
cally) in t he fuel rai l assembly near t he dash panel
(Fig. 13). It is Jield to t he fuel rail wi t h a clamp and
bolt (Fig. 14).
(3) Remove t he vacuum line from t he pressure reg-
ulator.
(4) Remove t he clamp bolt and regulator ret ai ni ng
clamp from fuel rail.
(5) Remove pressure regulator from fuel rail.
INSTALLATION5.2L ENGINE
(1) Install new O-ring seals to pressure regulator.
(2) Install pressure regulator to fuel rail.
(3) Install ret ai ni ng clamp and clamp bolt.
(4) Install vacuum line to pressure regulator.
(6) St ar t engine and check for leaks.
REMOVAL/I NSTALLATI ONiJL (V-8) ENGINE
On vehicles equipped wi t h t he 5.9L (V-8) engine,
t he fuel filter and fuel pressure regulator are one
FUEL
PRESSURE
REGULATOR
FUEL RAIL
FUEL
PRESSURE
REGULATOR
MOUNTING
BOLT
REGULATOR
MOUNTING
CLAMP
J9214-48
Fig. 14 Pressure Regulator Mounting5.2L Engine
combined part . Refer to Fuel Filter/Fuel Pressure
Regulator5.9L Engine for removal and installation
procedures.
FUEL PUMP MODULE
Refer to t he Fuel Delivery System section of t hi s
FUEL PUMP RELAY
The Fuel Pump relay is located in t he engine com-
part ment (Fig. 1).
FUEL RAIL
W ARN I N G: T HE F UE L SY STE M I S UN D E R A C O N -
STAN T PRE S S URE ( E V E N WI T H TH E E N GI N E
TURN E D OF F ) . BE F ORE SE RV I CI N G T H E F UE L
RAI L A S S E M BL Y , TH E F UE L SY STE M PRE S S U RE
M U S T BE RE L E ASE D .
System section of t hi s group. See Fuel Syst em Pres-
sure Release.
C A U T I O N : The left and right fuel rails are replaced
a s an assembl y. Do not attempt to separate the rail
hal ves at the connecti ng hose( s) (Fi g. 15). Due to
the desi gn of these connecti ng hose( s) , they do not
use any cl amps. Never attempt to install a cl ampi ng
device of any kind to the hose( s) . When removi ng
the fuel rail assembl y for any r eason, be careful not
to bend or kink the connecti ng hose( s) .
FUEL RAIL
CONNECTI NG
HOSES
AI R C ONDI T I ONI NG
/ COMPRESSOR SUPPORT BRACKET
MO U N T I N G BOLTS ' " J9214-49
Fig. 16 A/C Compressor Support Bracket Typical
FUEL
RAIL
FUEL INJECTOR
HARNESS CONNECTORS
J9214-32
Fig. 15 Fuel Rail Assembly Typical
REMOVAL
(1) Remove negative bat t ery cable at bat t ery.
(2) Remove air cleaner.
group.
(4) Remove throttle body from i nt ake manifold. Re-
fer to Throttle Body removal in t hi s group.
(5) If equipped with air conditioning, remove t he
A/C compressor-to-intake manifold support bracket
(three bolts) (Fig. 16).
(6) Disconnect electrical connectors at all fuel in-
jectors (Fig. 17). The factory fuel injection wiring
harness is numerically tagged (INJ 1, I NJ 2, etc.) for
injector position identification.
(7) If equipped with a 3.9L or 5.2L engine, remove
vacuum line at fuel pressure regulator (Fig. 18).
(8) 3.9L (V-6) engine only: Disconnect electrical
connector at i nt ake manifold charge air t emperat ure
sensor. Do not remove sensor.
' FUEL
INJECTOR J9214-30
Fig. 17 Fuel Injector ConnectorsTypical
(9) Remove EVAP canister purge solenoid/bracket
assembly (Fig. 19) from i nt ake manifold (one nut on
3.9L, one bolt on 5.2L/5.9L).
(10) Disconnect fuel tube(s) (lines) at rear of fuel
rail. Refer to Fuel Tubes/Lines/Hoses and Clamps in
t he Fuel Delivery System section of t hi s group.
(11) Remove t he remai ni ng fuel rail mount i ng
bolts (Fig. 20).
(12) Gently rock and pull t he left fuel rail unt i l
t he fuel injectors j ust st ar t to clear t he i nt ake mani -
fold. Gently rock and pull t he r i ght fuel rail unt i l
t he fuel injectors j ust st art to clear t he i nt ake mani -
fold. Repeat this procedure (left/right) until all fuel
injectors have cleared t he i nt ake manifold.
(13) Remove fuel rail (with injectors attached)
from engine.
14 - 70 FUEL SYSTEM

CANI STER PURGE
SOLENOI D/BRACKET
VACUUM
CONNECTOR
J9214-50
Fig. 19 EVAP Canister Purge Solenoid
(14) Remove t he clip(s) ret ai ni ng t he injector(s) to
fuel rai l (Fig. 21).
INSTALLATION
(1) Apply a small amount of engine oil to each fuel
injector O-ring. This will help in fuel rail installa-
tion.
(2) Install injector(s) and injector clip(s) to fuel
rail.
(3) Position t he fuel rail/fuel injector assembly to
t he injector openings on t he i nt ake manifold.
(4) Guide each injector into t he i nt ake manifold.
Be careful not to t ear t he injector O-ring.
(5) Push t he r i ght fuel rai l down unt i l fuel injec-
tors have bottomed on injector shoulder. Push t he
left fuel rai l down unt i l fuel injectors have bottomed
on injector shoulder.
INJECTOR
J9214-24
Fig. 21 Fuel Injector ClipTypical
(6) Install fuel rail mount i ng bolts.
(7) Install EVAP canister purge solenoid to i nt ake
manifold.
(8) Connect electrical connector to i nt ake manifold
charge air t emperat ure sensor.
(9) Connect wiring to all fuel injectors. The injec-
tor wiring harness is numerically tagged.
(10) Install t he A/C support bracket (if equipped).
(11) Install throttle body to i nt ake manifold. Refer
to Throttle Body installation in t hi s section of t he
group.
(12) If equipped, install vacuum line to fuel pres-
sure regulator.
(13) Install fuel tube(s) (lines) at rear of fuel rail.
Refer to Fuel Tubes/Lines/Hoses and Clamps in t he
Fuel Delivery System section of t hi s group.

FUEL SYSTEM 14- 71
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
S T A N T P R E S S U R E ( E V E N WI T H T HE E N G I N E
T U R N E D OFF) . B E F O R E S E R V I C I N G T HE F U E L
PU M P, F U E L L I N E S ( T U BE S ) , F U E L F I L T E R , O R
F U E L I N J E C T O R ( S ) , T HE F U E L S Y S T E M P R E S S U R E
M U S T B E R E L E A S E D .
System section of t hi s group. See Fuel System Pres-
sure Release Procedure.
FUEL TANKS
Refer to t he Fuel Tank section of t hi s group for re-
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
Refer to the Fuel Tank section of t hi s group for re-
FUEL TUBES/LINES/HOSES AND CLAMPS
Refer to Fuel Tubes/Lines/Hoses and Clamps in t he
Fuel Delivery System section of t hi s group for remov-
al/installation procedures.
Also refer to Quick-Connect Fi t t i ngs in t he Fuel
Delivery System section of t hi s group for removal/in-
IDLE AIR CONTROL (IAC) MOTOR
The IAC motor is located on t he back of t he throt-
tle body (Fig. 22).
MANI FOLD ABSOLUTE
Fig. 22 idle Air Control MotorTypical
REMOVAL
(1) Remove ai r cleaner assembly.
(2) Disconnect electrical connector from IAC motor.
(3) Remove two mount i ng bolts (screws) (Fig. 23).
J9214-23
Fig. 23 Mounting Bolts (Screws)IAC Motor
(4) Remove IAC motor from throttle body.
INSTALLATION
(1) Install IAC motor to throttle body.
(2) Install and t i ght en two mounting bolts (screws)
to 7 Nm (60 in. lbs.) torque.
(4) Install air cleaner assembly.
IGNITION COIL
Refer to Group 8D, Ignition Systems for removal/
installation procedures.
INTAKE MANIFOLD
Refer to Group 11, Exhaust System and Int ake
Manifold for removal/installation procedures.
The MAP sensor is located on t he front of t he
t hrot t l e body (Fig. 24). An L-shaped rubber fitting is
used to connect t he MAP sensor to throttle body (Fig.
25).
REMOVAL
The t hrot t l e body must be removed from t he i nt ake
manifold for MAP sensor removal.
(1) Remove air cleaner assembly.
(2) Remove t hrot t l e body. Refer to Throttle Body
removal in t hi s section.
(3) Remove two MAP sensor mount i ng bolts
(screws) (Fig. 24).
(4) While removing MAP sensor, slide t he vacuum
rubber L-shaped fitting (Fig. 25) from t he t hrot t l e
body.
(5) Remove rubber L-shaped fitting from MAP sen-
sor.
14 - 72 FUEL SYSTEM

MANI FOLD ABSOLUTE
Fig. 24 MAP Sensor Typical
Fig. 25 MAP Sensor L-Shaped Rubber Fitting
INSTALLATION
(1) Install rubber L-shaped fitting to MAP sensor.
(2) Position sensor to t hrot t l e body while guiding
rubber fitting over t hrot t l e body vacuum nipple.
(3) Install MAP sensor mount i ng bolts (screws).
Tighten screws to 3 Nm (25 in. lbs.) torque.
(4) Install t hrot t l e body. Refer to Throttle Body in-
stallation in t hi s section.
OXYGEN ( 0
2
) SENSOR
On 3.9L/5.2L/5.9L LDC engines, t he single 0
2
sen-
sor is located on t he ri ght exhaust down pipe (Fig.
26). On 5.9L HDC engines, t he dual 0
2
sensors are
located on each (left and right) exhaust down pipe
(Fig. 27).
Fig. 27 Dual Oxygen Sensors5.9L HDC Engine
REMOVAL
W ARN I N G: TH E E X H AUST M AN I F OL D B E C O M E S
V E R Y H OT D U R I N G E N G I N E O PE R A T I O N . A L L O W
E N G I N E T O C O O L B E F O R E R E M O V I N G O XY G E N
S E N S OR.
(2) Disconnect t he wire connector from t he 0
2
sen-
sor.
C A U T I O N : When di sconnect i ng the sensor electrical
connector, do not pull directly on wire goi ng into
sensor .
(3) Remove t he 0
2
sensor from t he exhaust mani -
fold.
INSTALLATION
Threads of new oxygen sensors are factory coated
wi t h anti-seize compound to aid in removal. DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor.

FUEL SYSTEM 14- 73
(1) Install t he 0
2
sensor into t he exhaust manifold.
Tighten to 30 N*m (22 ft. lbs.) torque.
(2) Connect t he 0
2
sensor wire connector.
PARK/NEUTRAL SWITCH
Refer to Group 21, Transmission and Transfer Case
for removal/installation procedures.
The powertrain control module (PCM) is located in
the engine compartment behind t he bat t ery (Fig. 28).
REMOVAL
DATA LINK CONTROL
(1) Disconnect negative bat t ery cable at battery.
(2) Carefully remove 60-way wiring connector from
PCM (one screw) (Fig. 29).
PCM
MO U N T I N G
PCM CONNECTOR
CONNECTOR M O U N T I N G
BOLT J9314-165
(3) Remove t hree mounting bolts (Fig. 29).
INSTALLATION
(1) Install PCM to inner fender.
(2) Check inside of 60-way wiring harness connec-
tor for bent pins or corrosion. Repair as necessary.
(3) Install 60-way connector to PCM. Ti ght en
mount i ng screw to 4 N
e
m (35 in. lbs.), torque.
(4) Install bat t ery cable to bat t ery.
QUICK-CONNECT FITTINGS
THROTTLE BODY
cally limit t he position of t he t hrot t l e body t hrot t l e
plate. Never a t t e mpt t o adj ust t he engi ne i dl e
s peed us i ng t hi s scr ew. All idle speed functions are
controlled by t he powertrain control module (PCM).
REMOVAL
(2) Disconnect throttle body electrical connectors
at MAP sensor, IAC motor and TPS (Fig. 30).
MANI FOL D ABSOLUTE
Fig. 30 Sensor Electrical ConnectorsTypical
(3) Remove vacuum line at t hrot t l e body.
(4) Remove (unsnap) all control cables from throt-
tle body (lever) arm. Refer to t he Accelerator Pedal
and Throttle Cable section of t hi s group for addi-
tional information.
(5) Remove four throttle body mount i ng bolts (Fig.
31).
(6) Remove t hrot t l e body from i nt ake manifold.
14 - 74 FUEL SYSTEM

THROTTLE
THROTTLE BODY
MO U N T I N G BOLTS J9214-31
Fig. 31 Throttle Body Mounting BoltsTypical
(7) Discard old throttle body-to-intake manifold
gasket.
INSTALLATION
(1) Clean t he mat i ng surfaces of t he t hrot t l e body
and t he i nt ake manifold.
(2) Install new t hrot t l e body-to-intake manifold
gasket.
(3) Install t hrot t l e body to i nt ake manifold.
(4) Install four mount i ng bolts. Ti ght en bolts to 23
Nm (200 in. lbs.) torque.
(5) Install control cables.
(6) Install vacuum line to t hrot t l e body.
(7) Install electrical connectors.
REMOVAL
The TPS is located on t he side of t he t hrot t l e body
(Fig. 30).
(1) Remove air i nt ake t ube at t hrot t l e body.
(2) Disconnect TPS electrical connector.
(3) Remove two TPS mount i ng screws (Fig. 32).
(4) Remove TPS from t hrot t l e body.
INSTALLATION
The t hrot t l e shaft end of t he t hrot t l e body slides
into a socket in the TPS (Fig. 33). The TPS must be
installed so t hat it can be rotated a few degrees. If
t he sensor will not rotate, install t he sensor with t he
t hrot t l e shaft on t he other side of t he socket t angs.
The TPS will be under slight tension when rotated.
(1) Install t he TPS and two ret ai ni ng screws.
(2) Tighten screws to 7 Nm (60 in. lbs.) torque.
THROTTLE
Fig. 32 TPS Mounting Screws
THROTTLE THROTTLE
BODY POSI TI ON
THROTTLE SOCKET LOCATI NG
SHAFT TANGS J9214-52
Fig. 33 TPS InstallationTypical
(3) Manually operate t he t hrot t l e control lever by
hand to check for any binding of t he TPS.
(4) Connect TPS electrical connector to TPS.
(5) Install air i nt ake tube.

FUEL SYSTEM 14- 75
VEHICLE SPEED SENSOR
The vehicle speed sensor (Fig. 34) is located on t he
extension housing of t he transmission on 2WD mod-
els. It is located on t he transfer case on 4WD models.
REMOVAL
Fig. 34 Vehicle Speed Sensor LocationTypical
(2) Disconnect t he electrical connector from t he
sensor.
(3) Remove (unscrew) t he speedometer cable (if
equipped) from t he sensor (Fig. 35).
(4) Loosen t he sensor mounting nut (Fig. 35).
Fig. 35 Sensor and ComponentsTypical
(5) Remove the sensor.
INSTALLATION
(1) Install new sensor into speedometer adapter.
(2) Tighten sensor mount i ng nut.
(4) Connect t he speedometer cable (if equipped).
D I E SE L FUEL I NJ E CTI ONCOMPONE NT DE SCRI PTI ON/ SYSTE M OPERATI ON
NDEX
page
Air Conditioning (A/C) Clutch Re l ay - PCM Output . 81
Air Conditioning ( A/ C) Cont r ol s - PCM Input . . . . 77
Air Intake Heater Rel aysPCM Output . . . . . . . . 81
Auto Shut Down ( ASD ) Re l a y - PC M Output . . . . 8 2
Automatic Shut Down ( ASD) S e n s e - PC M input . 7 8
Battery V ol t age - PCM Input 7 8
Brake Swi t chPCM Input . . . . . . . 78
Charge Air Temperature Sens or PCM Input . . . 7 8
Engi ne Speed Sens or PCM Input . . . . . . . . . . . 7 8
Fuel Drain Manifold 8 3
Fuel Heater 8 3
Fuel Injection Pump 8 3
Fuel Injectors 8 4
Fuel Sol enoid 84
Fuel/ Water Separator Filter . . . . . . . . . . . . . . . . . 84
Generator F i e l d - PCM Output . 81
H igh Pressure Fuel Lines 8 5
Ignition Se n s e PCM Input 7 8
K SB Sol enoid . . . . . . . 8 5
Malfunction Indicator LampPCM Output . . . . . . 8 2
Manual Shut Down Lever . . . . . . . . . . . . . . . . . . 85
GENERAL INFORMATION
The fuel system of t he 5.9L (in-line six-cylinder)
turbo-diesel engine (Fig. 1) consists of t he following
components:
Fuel t ank
Low and high pressure fuel supply lines
Mechanical lift pump
Fuel/water separator filter
Fuel heat er
Fuel injection pump
Fuel injectors
Fuel r et ur n lines
For information regarding fuel requi rement s of t he
5.9L turbo-diesel engine, refer to t he Fuel Require-
mentsDiesel Engines paragraph at t he front of t hi s
group.
Although various components, relays and switches
are operated by t he powertrain control module
(PCM), t he diesel fuel injection system (Fig. 1) is not
directly regulated by t he PCM. Refer to t he proceed-
ing Powert rai n Control Module section for additional
information.
SYSTEM DIAGNOSIS
The PCM tests many of its own i nput and out put
circuits. If a diagnostic trouble code (DTC) is found
in a major system, this information is stored in t he
PCM memory. Refer to On-Board Diagnostics in t he
Diesel Fuel InjectionGeneral Diagnosis section of
page
Mechanical Lift Pump 8 6
Overdrive Indicator LampPCM Output . . . . . . . 8 2
Overdrive Sol e noi d - PCM Output . . . . . . . . . . . . 8 2
Overdrive/Override Swi t chPCM Input . . . . . . . . 7 9
Park/Neutral Swi t c h - PCM Input 7 9
Power Gr o u n d - PCM Input . 7 9
Powertrain Control Module ( PCM) 7 6
SCI Re c e i v e - PCM Input . . 8 0
SCI Tr ans mi t - PCM Output . . . 8 2
Sensor Re t ur n- PCM Input . . . . . . . . . . . . . . . . . 8 0
Signal Gr o u n d - PCM Input . 8 0
Speed Cont r ol - PCM Input 8 0
Speed Cont r ol - PCM Output 8 2
Syst em Di agnosi s 7 6
Syst em Operation 8 6
Tac homet er - PCM Output 8 2
Throttle Position Sensor ( TPS) - PC M Input 80
Vehicle Speed Se n s o r - PC M Input 80
Wait-To-Start L a mp - PC M Output 8 2
Water-ln-Fuel L a mp - PC M Output 8 3
Water-ln-Fuel Se n s o r - PC M input 80
t hi s group for DTC information. The DRB II scan
tool can be used to access t he DTC messages stored
in t he PCM memory.
The powertrain control module (PCM) (Fig. 2) was
formerly referred to as t he SBEC or engine control-
ler. The PCM is a pre-programmed, dual micropro-
cessor digital computer.
hi nd t he bat t ery and under t he left front fender (Fig.
2).
The PCM contains a voltage convertor, which con-
verts bat t ery voltage to a regulated 8.0 volts. This is
used to power t he engine speed sensor. The PCM also
provides a 5 volt supply for t he throttle position sen-
sor (TPS). The TPS is not used if equipped with a
manual transmission.
Various sensors, switches and relays provide t he
i nput s necessary for operation of t he PCM.
The PCM I nput s a r e from:
9 Air conditioning control switch
Automatic shut down (ASD) sense circuit
Bat t ery voltage
Brake light switch
Charge air t emperat ure sensor
Coolant t emperat ure sensor (Auto, t rans, only)
Engine speed sensor
Ignition
Overdrive/override switch
Park/ neut ral switch (Auto, t rans, only)

FUEL FROM SUPPLY TANK
LIFT PUMP
LOW PRESSURE SUPPLY LINE
FUEL/WATER SEPARATOR FILTER
4A. FUEL HEATER
4B. FUEL/WATER DRAI N VALVE
W.I .F. (WATER I N FUEL) SENSOR
CHARGE AIR TEMP. SENSOR
BLEED SCREW
LOW PRESSURE SUPPLY LINE
INJECTION PUMP
TURBO BOOST CONTROL LINE
POWERTRAI N CONTROL MODULE
FUEL DRAI N MANI FOLD
(RETURN FUEL TO TANK)
HI GH PRESSURE LINES
INJECTORS
KSB SOLENOI D
MANUAL SHUT D O WN LEVER
TDC TI MI NG PIN
AIR TEMP. SWITCH
NOTE: #10 CONTROLS INTAKE HEATER,
KSB VALVE, FUEL HEATER, WIF SENSOR
J9314-179
Fig. 1 Diesel Fuel System Components
TORQUE CONVERTER
CLUTCH RELAY
AUTO SHUTDOWN RELAY
FUEL PUMP RELAY
DATA UNK
CONNECTOR
POWERTRAIN
CONTROL
MODULE J9314-164
Power ground
SCI receive (DRB II connection)
Sensor r et ur n
Signal ground
Speed control switch
Throttle position sensor (Auto, t rans, only)
Transmission thermo-switch (Auto, t rans, only)
Water-in-fuel sensor
Based on these i nput s, t he PCM regul at es various
engine and vehicle operations t hrough different sys-
tem components. These are called PCM outputs.
PCM outputs are to the:
A/C compressor clutch relay
Air i nt ake heat er relays
Generator field control
ASD relay
Malfunction indicator l amp
Overdrive indicator l amp
Overdrive solenoid
SCI t ransmi t
Speed control functions
Tachometer (if equipped)
Water-in-fuel indicator lamp
Wait-to-start indicator l amp
AIR CONDITIONING (A/C) CONTROLS- PCM INPUT
The A/C control system information applies to fac-
tory installed air conditioning uni t s only.
A/C REQUEST SIGNAL
Once A/C has been selected, t he PCM receives t he
A/C request signal from t he evaporator switch. The
input indicates t hat t he evaporator t emperat ure is in
t he proper range for A/C application. The PCM uses
this i nput to cycle t he A/C compressor clutch
(through t he A/C relay).
14- 78 FUEL SYSTEM

If t he A/C low pressure switch opens (indicating a
low refrigerant level), t he PCM will not receive an
A/C select signal. The PCM will t hen remove t he
ground from t he A/C relay. This will deactivate t he
A/C compressor clutch.
If evaporator switch opens, (indicating t hat evapo-
rat or is not in proper t emperat ure range), PCM will
not receive t he A/C request signal. The PCM will
t hen remove t he ground from t he A/C relay, deacti-
vat i ng t he A/C compressor clutch.
AUTOMATIC SHUT DOWN (ASD) S E N S E - PC M
INPUT
A 12 volt signal at t hi s i nput indicates to t he PCM
t hat t he ASD has been activated. The ASD relay is
located in t he engine compartment (Fig. 3) . It is used
to power a circuit to t he generator field winding.
TORQUE CONVERTER
CLUTCH RELAY
A/ C CLUTCH RELAY . STARTER RELAY
AUTO SHUTDOWN RELAY
FUEL PUMP RELAY
DATA LINK
CONNECTOR
POWERTRAIN
CONTROL
MODULE J 9 31 4 - 1 6 4
Fig. 3 Relay LocationTypical
BATTERY VOLTAGE-PC! INPUT
The bat t ery i nput provides power to operate t he
PCM. Bat t ery voltage is needed to keep PCM mem-
ory alive. The memory stores diagnostic trouble code
(DTC) messages and t he mi ni mum TPS value from
t he previous key-on,
BRAKE S WI T C H- PC M INPUT
If t he PCM receives a brake switch i nput while t he
speed control system is on, it will disable speed con-
trol.
CHARGE AIR TEMPERATURE SENSORPCM
INPUT
The charge ai r t emperat ure sensor is located on top
of t he i nt ake manifold (Fig. 4). It provides an i nput
to t he PCM t hat indicates air t emperat ure in t he
manifold. Based on t he charge air t emperat ure input,
t he PCM det ermi nes if and how long to energize t he
ai r i nt ake heat ers. Refer to Air Int ake Heat ers in
t hi s section.
AIR
TEMPERATURE
SWITCH
(KSB SOLENOID)
j 91 1 4 - 2 35
Fig. 4 Charge Air Temperature Sensor
ENGINE SPEED S E N S O R - PC M INPUT
The engine speed sensor (sometimes referred to as
t he crankshaft position sensor) is mounted to t he
front of engine (Fig. 5). It generates an rpm signal to
t he PCM. The engine speed sensor i nput is used
along with t he vehicle speed sensor and t hrot t l e po-
sition sensor inputs to determine when to shift t he
aut omat i c transmission into and out of overdrive.
The speed sensor signal is also used as an i nput for
t he ASD relay (for control of generator field), vehicle
speed control and i nst rument panel mounted tachom-
eter.
SENSOR MOUNT I NG BOLTS
VI BRATI ON
DAMPER
J9214-69
Fig. 5 Engine Speed Sensor
IGNITION S E N S E - PC M INPUT
The ignition circuit (J2) sense input informs t he
PCM t hat t he ignition switch is in t he r un position.

FUEL SYSTEM 14- 79
OVERDRIVE/OVERRIDE S WI T C H- PC M INPUT
The overdrive/override switch is not used wi t h
manual transmissions.
On vehicles equipped wi t h overdrive, t he PCM reg-
ulates t he 3-4 overdrive upshift and downshift
through the overdrive solenoid. An override switch is
located on t he i nst rument panel .
The overdrive/override switch is a momentary con-
tact switch. The switch contacts are normally open.
When t he switch is activated, t he PCM will receive a
ground signal. The t ransmi ssi on will not ent er over-
drive when t he operator presses t he override switch.
The transmission downshifts if t he operator presses
t he override switch while i n overdrive.
COOLANT TEMPERATURE SENSOR
The coolant t emperat ure sensor is not used with
The coolant t emperat ure sensor (Fig. 6) monitors
engine coolant t emperat ure. Thi s input is used to in-
hibit transmission upshift into overdrive when t he
engine coolant t emperat ure is below 16 degrees C (60
degrees F).
Fig. 6 Coolant Temperature Sensor
TRANSMISSION THERMO-SWITCH
The transmission thermo-switch is not used with
The transmission thermo-switch opens when t he
transmission fluid t emperat ure is above 134C
(273F). When t he thermo-switch opens, t he t rans-
mission will not shift into overdrive. The t ransmi s-
sion downshifts if it is in overdrive when the thermo-
switch opens. Once t he thermo-switch opens, it will
not close until transmission fluid t emperat ure drops
to 116C (240F). The switch is located in the t rans-
mission-to-radiator cooling line (Fig. 7).
PARK/NEUTRAL S WI T C H- PC M INPUT
The park/ neut ral switch (Fig. 8) is located on the
automatic transmission housing. It provides an input
THERMO SWITCH J9214-62
Fig. 7 Transmission Thermo-SwitchTypical
to t he PCM. The i nput indicates if t he aut omat i c
transmission is in park, neut ral or a drive gear se-
lection.
If transmission is in overdrive and operator shifts
vehicle into neut ral , t he overdrive solenoid will be
de-energized. Normal PCM operation will resume
when t he transmission is shifted back into drive po-
sition.
The PCM uses t he park/ neut ral switch input when
det ermi ni ng speed control strategy. The PCM will
disable t he speed control if t he operator shifts t he
transmission into neut ral . The speed control will
have to be reset once t he vehicle is placed back into
drive.
The park/ neut ral switch is sometimes referred to as
t he neut ral safety switch. Refer to Group 21 Trans-
missions for adjustment, replacement and test infor-
mation.
Fig. 8 Park/Neutral SwitchTypical
POWER GROUND- PCM INPUT
Provides a common ground for power devices (sole-
noid and relay).
14 - 80 FUEL SYSTEM

SCI RE CE I V E - PCM INPUT
The serial communication interface (SCI) receive
and t ransmi t outputs allow t he PCM to communicate
with t he DRB II scan tool.
SENSOR R E T UR N- PC M INPUT
Sensor r et ur n provides a low noise ground refer-
ence for all system sensors.
SIGNAL GR OUND- PC M INPUT
Provides a common ground for t he input signals.
SPEED CONTROL- PCM INPUT
The PCM regul at es t he speed control system based
on i nput s it receives. The speed control operating
range is from 35 to 85 mph. Input s t hat effect speed
control operation are:
Park/ neut ral switch
Engi ne speed sensor
Brake switch
THROTTLE POSITION SENSOR (TPS) PCM INPUT
The t hrot t l e position sensor is not used with man-
ual transmissions.
The t hrot t l e position sensor (TPS) is mounted on
t he top of t he fuel injection pump (Fig. 9). The TPS
provides an i nput to t he PCM. It senses how far t he
t hrot t l e is open (past t he idle position). The PCM
uses t he TPS input, along with vehicle speed sensor
and engine speed sensor i nput s to determine 3-4 up-
shift (overdrive) and 4-3 downshift.
The TPS is a potentiometer. The PCM supplies 5
volts to t he sensor. TPS output to t he PCM varies
from approximately 1.0 volt at idle to 3.5 volts at
wide open t hrot t l e (WOT).
T \
J9114-237
Fig. 9 Throttle Position Sensor
VEHICLE SPEED S E N S O R - PC M INPUT
The vehicle speed sensor (Fig. 10) is located in t he
extension housing of t he transmission (2WD) or on
the transfer case extension housing (4WD). A signal
is sent from t hi s sensor, along with signals from both
t he TPS and t he engine speed sensor, to t he PCM.
The PCM will t hen use this information to determine
when to shift into and out of overdrive.
The speed sensor is also used in determining speed
control set, decelerate, accelerate, maxi mum set
speed (85 mph) and mi ni mum set speed (35 mph) op-
erations.
VEHICLE
SPEED
SENSOR
Fig. 10 Vehicle Speed SensorTypical Location
WATER-IN-FUEL S E N S O R - PC M INPUT
The water-in-fuel (WIF) sensor is located at t he
bottom of t he fuel/water separator filter (Fig. 11).
The sensor sends an input to t he PCM when it senses
wat er in t he fuel. The PCM looks at t he water-in-fuel
sensor signal when t he ignition key is put in t he ON
position. It also monitors t he input at t he end of t he
i nt ake heat er post-heat cycle.
The PCM t ur ns t he water-in-fuel indicator lamp to
t he ON position if wat er is detected in t he fuel. The
water-in-fuel indicator lamp is located in t he instru-
ment panel.
J91 14-85
Fig. 11 Water-in-Fuel Sensor

AIR CONDITIONING (A/C) CLUTCH RELAYPCM
OUTPUT
The PCM activates t he A/C compressor through t he
A/C clutch relay. The PCM regulates A/C compressor
operation by switching t he ground circuit for t he A/C
clutch relay on and off. The relay is located in t he
engine compartment (Fig. 3).
By switching t he ground pat h for t he relay on and
off, t he PCM is able to cycle t he A/C compressor
clutch. This is based on changes in engine operating
conditions. If, duri ng A/C operation, t he PCM senses
a low idle speed, it will de-energize t he relay. This
prevents A/C clutch engagement. The relay will re-
mai n de-energized unt i l t he idle speed increases.
GENERATOR FI E L D- PC M OUTPUT
The PCM regul at es t he charging system voltage
within a range of 12.9 to 15.0 volts. It will control
ASD relay operation. The input (through the PCM)
for t he ASD relay comes from t he engine speed sen-
sor.
When engine r unni ng speed is above 384 rpm, a
signal is sent from t he PCM to engage t he ASD re-
lay. This supplies t he necessary generator field wind-
ing control. When rpm drops below 320, t he signal to
the ASD relay is stopped. Refer to Group 8A, for
charging system information.
AIR INTAKE HEATER R E L AYS - PC M OUTPUT
The PCM operates t he air i nt ake heat ers t hrough
t he air i nt ake heat er relays (Fig. 12). The relays may
be energized before and after cranking, depending
upon i nt ake manifold air t emperat ure. The PCM
monitors i nt ake manifold air t emperat ure t hrough
t he charge air t emperat ure sensor. Refer to Air In-
t ake Heat ers in t hi s section.
The relays are not energized during engine crank-
ing. When they are energized they make a clicking
noise.
C A U T I O N : D o not energize the air intake heater re-
l ays more than once per 15 mi nutes. If the relays
are cycl ed and the key i s turned off and then turned
back on, the engi ne coul d be damaged. Wait 15
mi nutes before turning the key back to the O N po-
si ti on.
AIR INTAKE HEATER
When energized, t he air i nt ake heat ers warm in-
coming air as it ent ers t he i nt ake manifold. The air
i nt ake heat ers (Fig. 13) are energized by t he PCM
t hrough t he air i nt ake heat er relays. Int ake manifold
air t emperat ure determines when t he heat ers are en-
ergized. They may be energized before cranki ng and
after cranking, or both. Refer to Pre-Heat Cycle and
Post-Heat Cycle. The heat ers are not energized dur-
ing cranking.
HEATER
RELAYS
WELL J9114-67
Fig. 12 Air Intake Heater Relays
Fig. 13 Air Intake HeatersTypical
PREHEAT CYCLE
The PCM powers up when t he ignition key is
t urned to the On position. If i nt ake manifold ai r tem-
perat ure is 15C (59F) or below, t he i nt ake heat ers
are energized and t he wait-to-start light is illumi-
nated. The heat ers are energized for a specific
amount of time. This is based on t he i nt ake manifold
air t emperat ure. Refer to t he Air Int ake Heat er Cy-
cle Chart .
Once t he heat ers have cycled, the wait-to-start
light goes out. While t he engine is cranked, t he heat-
ers are not energized.
POST-HEAT CYCLE
After engine has been started, t he post-heat cycle
will begin if i nt ake manifold air t emperat ure was
15C (59F) or below when ignition switch was
t urned on. Depending upon i nt ake manifold temper-
at ure, either: both heat ers are energized, or t hey are
cycled on and off (when one is energized, t he other is
not). The time t he heat ers are energized depends
upon i nt ake manifold air t emperat ure. Refer to t he
Air Int ake Heat er Cycle Chart.
14 - 82 FUEL 'SYSTEM . ~
INTAKE HEATER CYCLE CHART
I nt ak e
f eat per af wr e
Preheat Cycle Time
I gnition ley O N
Engine Not Running
Pestheat Cycle
I gnition Key O N
Snglne Running
Above 15 C
(59 F)
0 Seconds No
-8C(18F)to
15C (59 F)
10 Seconds Yes
- 17C( 1 F)
-9 C(]6 F)
15 Seconds Yes
2dC(-15F)
to-18C(0 F)
17.5 Seconds Yes
Below-26 C
(-15 *F)
20 Seconds Yes
J9114 -239
AUTO SHUT DOWN (ASD) R E L AY- PC M OUTPUT
ment (Fig. 14).
TORQUE CONVERTER
CLUTCH RELAY
AUTO SHUTDOWN RELAY
FUEL PUMP RELAY
DATA LINK
CONNECTOR
POWERTRAIN
CONTROL
MODULE J9314-164
Fig. 14 Relay LocationTypical
The ASD relay supplies bat t ery voltage to t he gen-
erat or field winding to provide regulation of t he
charging system. The ground circuit for t he ASD re-
lay is controlled by t he PCM. The PCM operates t he
relay by switching t he ground circuit on and off.
MALFUNCTION INDICATOR L A M P- PC M OUTPUT
The malfunction indicator lamp (formerly referred
to as t he check engine lamp) i l l umi nat es at t he bot-
tom of t he i nst rument panel each t i me t he ignition
key is t urned on. It will stay on for t hree seconds as
a bulb test.
If t he powertrain control module (PCM) receives an
incorrect signal, or no signal from certain sensors or
emission related systems, t he lamp is t urned on. This
is a warni ng t hat t he PCM has recorded a system or
sensor malfunction. In some cases, when a problem is
declared, t he PCM will go into a limp-in mode. This
is an at t empt to keep t he system operating. It signals
an immediate need for service.
The lamp can also be used to display a diagnostic
trouble code (DTC). Cycle t he ignition switch On-Off-
On-Off-On within t hree seconds and any codes stored
in t he PCM memory will be displayed. This is done
in a series of flashes representing digits. Refer to On-
Board Diagnostics in t he General Diagnosis section
of this group for more information.
OVERDRIVE INDICATOR L A M P- PC M OUTPUT
Indicates t he st at e of t he overdrive defeat switch
on t he i nst rument panel.
OVERDRIVE S 0 L E N 0 I D - PC M OUTPUT
The overdrive solenoid is used on vehicles t hat
have an automatic transmission. The solenoid is op-
erated by t he PCM. It controls shifting in and out of
overdrive t hrough t he overdrive solenoid. Refer to
Group 21 for overdrive solenoid service.
SCI TRANSMITPCM OUTPUT
SCI Transmi t is t he serial dat a communication
t ransmi t circuit for t he DRB II scan tool. The PCM
t ransmi t s dat a to t he DRB II through t he SCI Trans-
mi t circuit.
SPEED C 0 NT R 0 L - PC M OUTPUT
The speed control vacuum and vent solenoids are
operated by t he PCM. The vacuum solenoid main-
t ai ns vacuum at a required pressure to resume, set
or accelerate t he speed control system. The vent so-
lenoid allows vacuum to bleed off during decelera-
tion, when t he brakes are applied, or t he
transmission is shifted into park or neut ral .
TACHOMETER-PCM OUTPUT
This output generates t he necessary signal needed
to operate a dealer installed tachometer (if equipped).
The i nput for t hi s signal is from t he engine speed
sensor.
WAIT-TO-START L A M P- PC M OUTPUT
The wait-to-start lamp is t urned on and off by t he
PCM based on t he charge air t emperat ure sensor in-
put.
The light is t urned on when t he ignition is first ac-
tivated. It will remai n on for two seconds as a bulb
test. If t he PCM reads i nt ake manifold air tempera-
t ure below 15C (59F), it will t ur n t he wait-to-start
light on for t he i nt ake heat er preheat cycle. The
light stays on until t he preheat cycle is over.
The wait-to-start light will flash on and off if t he
charge air t emperat ure sensor input to t he PCM is

FUEL SYSTEM 14 - 83
below mi ni mum value or above maxi mum value. The
PCM stores a DTC when these conditions occur.
WATER-IN-FUEL L A M P- PC M OUTPUT
The water-in-fuel l amp is t urned on and off by t he
PCM. The lamp is t urned on by t he PCM when it re-
ceives an i nput from t he water-in-fuel sensor. The
sensor sends an input to t he PCM when it detects
wat er in t he fuel/water separator filter.
FUEL DRAIN MANIFOLD
Some fuel is continually vented from t he injection
pump to cool t he pump and t he fuel injectors. Duri ng
injection, a small amount of fuel
flows past t he injector nozzle and is not injected
into t he combustion chamber. This fuel, along wi t h
the fuel vented from t he injection pump, drai ns into
t he fuel drai n manifold (Fig. 15). Fuel in t he drai n
manifold is routed back to t he fuel t ank.
Fig. 15 Fuel Drain Manifold
FUEL HEATER
The 5.9L turbo-diesel engine has a fuel heat er to
prevent t he fuel from waxing in t he fuel/water sepa-
rator. The fuel heat er is located in the top of t he fil-
ter/separator adapter (Fig. 16).
The heat er has a built in monitor t hat senses fuel
t emperat ure. Voltage to operate t he fuel heat er is
supplied t hrough t he ignition switch. The heat er op-
erat i ng range is from 6 - 13.5C (43 - 53F).
FUEL INJECTION PUiVSP
The injection pump is a Bosch VE Distributor type
(Fig. 17). The injection pump is driven by t he engine
camshaft. A gear on t he end of t he pump shaft
meshes with t he camshaft gear. The pump is timed
to t he engine. Fuel injection occurs near the end of
t he compression stroke for each cylinder. Refer to In-
jection Pump Removal and Installation in t he Diesel
Service Procedures section of this group for injection
pump t i mi ng procedures.
Fig. 16 Fuel Heater
Fig. 17 Injection Pump
The injection pump varies injector t i mi ng to corre-
spond with changing engine speed. As engine speed
increases, t he i nt ernal pump pressure increases. Fuel
flows t hrough an orifice in t he advance mechanism
piston (Fig. 18). The piston is opposed by a spring.
The spring regulates injection pump t i mi ng advance.
As pump pressure increases, t he piston moves
against t he spring, advancing injection timing. The
spring holds t he advance mechani sm in t he st art i ng
position during cranking and idle.
The mechanical lift pump delivers fuel under a low
pressure of 21-35 kPa (3-5 psi) to t he injection pump
t hrough t he fuel/water separator filter. The injection
pump supplies high pressure fuel of approximately
59,000 kPa (8,000 psi) to each injector in precise me-
tered amounts at the correct time.
The injection pump contains t he KSB (cold start)
solenoid, fuel solenoid, turbo boost control line and
manual shut down valve.
PISTON
ORIFICE
J9114-33
Fig. 18 injection Pump Timing Advance Mechanism
FUEL INJECTORS
The fuel injectors are mounted on t he left side of
the cylinder head (Fig. 19). The injectors are con-
nected to t he fuel injection pump by t he high pres-
sure fuel lines.
HIGH
PRESSURE
FUEL LINE
(6)
J9114-74 =
Fig. 19 Fuel Injectors
The injectors consist of t he nozzle holder, O-ring
wat er seal, shims, spring, needle valve and nozzle
(Fig. 20). Fuel ent ers t he injector at t he fuel inlet
(top of injector) and is routed, to t he needle valve
bore. When fuel pressure rises to approximately
24,445 kPa (3550 psi), t he needle valve spring ten-
sion is overcome. The needle valve rises and fuel
flows t hrough t he spray holes in t he nozzle tip into
t he combustion chamber. The pressure required to
lift t he needle valve is t he operating pressure set-
ting, sometimes referred to as t he POP pressure set-
ting.
Fuel pressure in t he injector circuit decreases after
injection. The injector needle valve is immediately
closed by t he needle valve spring and fuel flow into
t he combustion chamber is stopped. Exhaust gases
are prevented from ent eri ng t he injector nozzle by
t he needle valve.
HIGH
PRESSURE
FUEL FROM
INJECTION
PUMP
J91 14-82
Fig. 20 Fuel Injector Operation
FUEL SOLENOID
The fuel solenoid (Fig. 21) is mounted on t he injec-
tor pump. When energized, t he solenoid allows fuel
to reach t he high pressure chamber of t he injection
pump.
FUEL
SOLENOID
Fig. 21 Fuel Solenoid
Bat t ery voltage is supplied to t he solenoid when
t he ignition key is in t he ON position. When ener-
gized, t he solenoid pulls a plunger off its seat allow-
ing fuel to flow to t he hi gh pressure head of t he
injection pump. When t he ignition key is t urned to
t he OFF position, t he solenoid is not energized and
t he plunger blocks t he flow of fuel to high pressure
chamber.
A mi ni mum of t en volts is required to allow t he so-
lenoid to lift t he plunger off its seat. A mi ni mum of
six volts is required to hold t he plunger in t he open
position.
The fuel/water separator filter protects t he injec-
tion pump by removing wat er and cont ami nant s from
t he fuel. The separator filter construction allows fuel

FUEL SYSTEM 14- 85
to pass t hrough it, but prevents moisture (water)
from doing so. Moisture collects at t he bottom of t he
separator filter.
WA R N I N G : E XT I N G U I S H A L L S M O K I N G M A T E R I -
A L S B E F O R E D R A I N I N G T HE F U E L / WA T E R S E PA -
R A T O R F I L T E R .
There is a drain at the bottom of t he separator fil-
t er (Fig. 16). Place a drain pan under t he drai n t ube.
With the engi ne not running, push up on t he drai n
to remove t he wat er from t he separat or filter. Hold
t he drai n open unt i l all wat er and cont ami nant s
have been removed and clean fuel exits t he drain.
Dispose of mi xt ure in drain pan according to applica-
ble regulations.
Refer to t he mai nt enance schedules in Group 0 in
this manual for t he recommended fuel/water separa-
tor filter replacement intervals.
KSB SOLENOID
The KSB solenoid is not an output of t he PCM. The
solenoid is located on t he injector pump (Fig. 22). It
contains a valve t hat controls vent i ng of t he injection
pump i nt ernal pressure regulator. When voltage is
supplied to t he solenoid, it closes off t he vent circuit
in t he injection pump. When t he vent circuit is closed
off, i nt ernal pump pressure increases and injection
t i mi ng advances. The KSB solenoid allows t he injec-
tion pump t i mi ng to reach full advance sooner.
When t he KSB solenoid is energized, i nt ernal
pump pressure reaches 8 bars (116 psi). When t he so-
lenoid is not energized, i nt ernal pump pressure
should be approximately 4 bars (58 psi).
The KSB solenoid circuit contains an air tempera-
t ure switch. Battery voltage is supplied to t he sole-
noid t hrough t he ignition switch.
The air t emperat ure switch is mount ed on t he in-
t ake manifold next to the charge ai r t emperat ure
sensor (Fig. 23). The air t emperat ure switch is open
at or above 32C (90F).
Fig. 22 KSB Solenoid Typical
Fig. 23 Air Temperature Switch
MANUAL SHUT DOWN LEVER
The injection pump has a manual shut down lever
(Fig. 24). In an emergency, t he engine can be shut
down by t urni ng t he lever counterclockwise.
Fig. 24 Manual Shut Down Lever
HIGH PRESSURE FUEL LINES
C A U T I O N : Hi gh pressure fuel lines must be held se-
curely in place in the hol ders. The lines cannot con-
tact each other or other component s. D o not
attempt to weld hi gh pressure fuel lines or to repair
lines that are damaged. Onl y use the recommended
lines when replacement of hi gh pressure fuel line i s
necessary.
High pressure fuel lines deliver fuel under pressure
of approximately 59,000 kPa (8,000 psi) from t he in-
jection pump to t he fuel injectors. The lines expand
and contract from t he high pressure fuel pulses gen-
erated duri ng t he injection process. All high pressure
fuel lines are of t he same length and inside diameter.
Correct high pressure fuel line usage and installation
is critical to smooth engine operation.
WA R N I N G : U S E E XT R E M E C A U T I O N WH E N I N-
S PE C T I N G F O R HI G H P R E S S U R E F U E L L E A K S . I N -
S PE C T F O R HI G H P R E S S U R E F U E L L E A K S WI T H A
S H E E T O F C A R D B O A R D . HI G H F U E L I N J E C T I O N
P R E S S U R E C A N C A U S E PE R S O N A L I N J U R Y I F
C O N T A C T I S M A D E WI T H T HE S K I N .
The mechanical lift pump is located on the left side of
the engine cylinder block. The lift pump is driven by an
eccentric on the camshaft t hat actuates a spring loaded
lever in the pump (Fig. 25). The lever is connected to
the pump diaphragm. When the eccentric on the cam-
shaft pushes the lever upward, the lever in t urn pulls
the diaphragm to its extended position. With the lever
in the extended position, fuel is drawn into the pump
chamber through the inlet check valve. When the pump
gathers more fuel in the fuel chamber than the engine
can consume, the outlet check valve is held closed. Fuel
gathered in lift pump chamber prevents the diaphragm
from relaxing. The lever will continue to move up and
down on the shaft connecting it to the diaphragm. How-
ever, it is prevented from operating the diaphragm until
the check valve again opens and the fuel in the pump
chamber is expelled. This process continues as long as
the engine is running.
Mi ni mum lift pump out put pressure is 21 Kpa (3
psi). Lift pump out put volume is 0.75 liters (0.70 U.S.
quarts) per 30 seconds of engine cranking.
Fig. 25 Lift Pump
The lift pump housing has a weep hole at t he bot-
tom of t he casing (Fig. 25). If t he di aphragm rup-
t ures, fuel will exit out of t he weep hole and t he
pump must be replaced. The lift pump is not service-
able and must be replaced as a complete assembly.
CAUTION: D o not operate the engi ne if the fuel s up-
pl y line has a restriction of mor e than 95 M M H g
(3.75 in Hg).
The lift pump has a manual lever (Fig. 26). The le-
ver is located on t he lower ri ght side of t he pump
housing. The purpose of t he lever is to prime t he fuel
system and bleed ai r from t he system if t he vehicle
has r un out of fuel. Raise and lower t he lever unt i l
resistance is felt to prime the system up to t he injec-
tor pump. Dur i ng vehi cl e oper at i on t he p u mp le-
ver mus t be i n t he u p posi t i on.
FUEL
PUMP
MANUAL J K T /
LEVER - .
L
J * y ^ " ^ ^
J9114-3
Fig. 26 Lift Pump Manual Lever
SYSTEM OPERATION
IGNITION SWITCH ON
When t he ignition switch is put in t he ON (run)
position, t he following occurs:
The PCM receives an ignition sense input. It t hen
powers up. Bat t ery voltage is supplied t hrough t he
bat t ery voltage input.
The wait-to-start lamp and the water-in-fuel lamp
are turned on by the PCM for 2.8 seconds as a bulb test.
The PCM monitors t he charge air t emperat ure
sensor input. If manifold air t emperat ure is at or be-
low 15C (59F), t he PCM will st art t he air i nt ake
heat er preheat cycle. It will energize t he i nt ake heat-
ers by grounding t he air i nt ake heat er relays. The
PCM will t ur n t he wait-to-start light on unt i l t he
preheat cycle is over. If PCM receives a crank signal
from engine speed sensor before preheat cycle is over,
it will abort preheat cycle.
The PCM monitors engine speed. When t he engine
speed is above 384 rpm, t he PCM determines t hat
t he engine is runni ng.
The PCM will t ur n on t he water-in-fuel l amp if a
signal is received from t he water-in-fuel sensor.
ENGINE START-UP
When t he ignition key is put in t he st art position,
t he following occurs:
The PCM receives a crank signal i nput from t he
engine speed sensor.
The ai r i nt ake heat ers are not energized duri ng
cranking.

FUEL SYSTEM 14 - 87
ENGINE WARM-UP
The PCM may start the air intake heater post-heat
cycle depending on intake air temperature. If manifold
air temperature was at or below 15C (59F) when the
ignition switch was turned on, the cycle is started.
If i nt ake manifold air t emperat ure is below 32C
(90F), the KSB solenoid will be energized t hrough
t he ai r t emperat ure switch. The solenoid remai ns en-
ergized until t he air t emperat ure switch opens. The
switch opens when i nt ake manifold air t emperat ure
is above 32C (90F).
If t he coolant t emperat ure is below 16C (60 F),
t he transmission will not be allowed to enter over-
drive (automatic transmission).
The PCM will t ur n on t he water-in-fuel lamp if a
CRUISE OR IDLE
The PCM monitors i nt ake manifold air tempera-
t ure t hrough t he charge t emperat ure sensor input.
t he air t emperat ure switch. The solenoid remai ns en-
is above 32C (90F).
The air i nt ake heat er post-heat cycle will be com-
pleted, if it is not already over.
The vehicle speed sensor, engine speed sensor and
t hrot t l e position sensor i nput s are used to control
transmission overdrive operation.
If t he coolant t emperat ure is below 16 C (60 F),
If t he transmission thermo-switch is open, t he
transmission will not be allowed to ent er into over-
drive (automatic transmission). If t he switch opens
when t he vehicle is in overdrive, t he transmission
will be downshifted. The transmission thermo-switch
opens at 134C (273F).
The thermo-switch will close once t he transmission
fluid t emperat ure drops to 116C (240F).
ACCELERATION
t he transmission will not be allowed to ent er over-
is above 32C (90F).
If t he transmission thermo-switch is open, the
transmission will not be allowed to ent er into over-
drive (automatic transmission). If t he switch opens
when t he vehicle is in overdrive, t he transmission
will be downshifted. The transmission thermo-switch
opens at 134C (273F). The thermo-switch will close
once t he transmission fluid t emperat ure drops to
116C (240F).
The PCM will t ur n on t he water-in-fuel l amp if a
If t he speed control system resume/accelerate func-
tion is being used, t he PCM will only allow t he vehi-
cle to accelerate at a predetermined rat e. If a speed
control has been set and t he resume/accelerate but-
ton is moment ari l y pushed in, t he PCM will increase
vehicle speed by two miles per hour.
If t he brakes are applied, t he PCM will disable t he
speed control.
DECELERATION
If the transmission thermo-switch is open, the trans-
mission will not be allowed to enter into overdrive (au-
tomatic transmission). If the switch opens when the
vehicle is in overdrive, the transmission will be down-
shifted. The transmission thermo-switch opens at 134C
(273F). The thermo-switch will close once the transmis-
sion fluid temperature drops to 116C (240F).
(90F), t he KSB solenoid will be energized t hrough
ergized unt i l t he air t emperat ure switch opens. The
is above 32C (90F).
If t he speed control system coast/set function is be-
ing used, t he PCM will only allow t he vehicle to de-
celerate at a predetermined rat e. If t he coast/set
switch is pushed while t he system is operating, t he
PCM will set speed control to t he r at e the vehicle is
t ravel i ng at when t he switch is released.
If t he brakes are applied, t he PCM will disable t he
speed control.
IGNITION SWITCH OFF
When t he ignition switch is t urned to t he off posi-
tion, t he PCM still receives bat t ery voltage t hrough
t he bat t ery input. Bat t ery voltage is needed to keep
PCM memory alive. The PCM memory stores diag-
nostic trouble code (DTC) messages and t he mini-
mum TPS value from t he previous key-on.
DIESEL FUEL INJECTIONGENERAL DIAGNOSIS
INDEX
page
Air in Fuel Syst em 90
Air Intake Heater . 90
Diagnostic Trouble Code ( DTC) . 95
D RB II Sc an Tool 95
Engi ne Speed Sensor 91
Fuel Heater 91
Fuel Injection Pump 91
Fuel Injectors 92
Fuel Suppl y Restrictions 92
page
Fuel/Water Separator Filter 92
High Pressure Fuel Line Restrictions 93
K SB Sol enoid . 93
Mechanical Lift Pump 93
On- Board Diagnostics ( OBD) 94
System Schemati cs5.9L Diesel Engine . . . . . . . 95
Throttle Position Sensor Test 94
Visual Inspection 8 8
VISUAL INSPECTION
A visual inspection for loose, disconnected, or incor-
rectly routed wires and hoses should be made before
at t empt i ng to diagnose or service t he fuel injection
system. A visual check will help find these condi-
tions. It also saves unnecessary test and diagnostic
time. A thorough visual inspection of t he fuel injec-
tion system includes t he following checks:
(1) Be sure t hat t he bat t ery connections are t i ght
and not corroded (Fig. 1).
POSITIVE
v^3t ^TERMINAL
J91 14
QUICK
DISCONNECT
PCM
MOUNTING
BOLTS
PCM CONNECTOR
CONNECTOR MOUNTING
BOLT J9314-165
HEATER
RELAYS
Fig. 1 Battery Connections
(2) Be sure t hat t he 60-way connector is fully en-
gaged with t he PC M . Verify t hat t he connector
mount i ng screw is t i ght (Fig. 2) .
(3) Be sure t hat t he electrical connections at t he
air i nt ake heat er relays (Fig. 3) are t i ght and not
corroded.
(4 ) Inspect t he st art er motor and st art er solenoid
connections for t i ght ness and corrosion (Fig. 4 ) .
(5) Verify t hat t he electrical connectors are con-
nected to t he charge air t emperat ure sensor and ai r
t emperat ure switch. Inspect t he connectors for corro-
sion or damaged wires (Fig. 5) .
(6) Verify t hat t he electrical connector is connected
to t he ai r t emperat ure switch (Fig. 5) .
WHEEL ^
WELL J9114-67
Fig. 3 Air Intake Heater Relays
Fig. 4 Starter Motor ConnectionsTypical
Fig. 5 Charge Air Temperature Sensor and Air
Temperature Switch
(7) Verify t hat t he Water-in-Fuel (WIF) sensor
electrical connector is connected to t he sensor (Fig.
6). Inspect t he connector for corrosion or damaged
wires.
Fig. 6 Water-in-Fuel (WIF) Sensor
(8) Place a drain pan under t he drain t ube (Fig. 6).
With the engi ne not operating, hold t he drai n open
unt i l all water and contaminants have been removed
and clean fuel exits t he drain. Dispose of mi xt ure in
drai n pan according to applicable regulations.
(9) Verify t hat t he electrical connector is connected
to t he fuel solenoid on t he injection pump (Fig. 7). In-
spect t he connector for corrosion or damage.
(10) Verify t hat t he electrical connector is con-
nected to t he KSB solenoid on t he injection pump
(Fig. 7). Inspect t he connector for corrosion or dam-
age.
Fig. 8 Air Intake Heater
(12) Inspect t he t hrot t l e linkage and accelerator
linkage for binding (Fig. 9).
(13) Be sure t hat t he t hrot t l e ret urn spring is con-
nected.
(14) Inspect all fuel lines for signs of leakage.
(15) Be sure t hat t he ground cable connection at
t he front of t he cylinder head is tight and free of cor-
rosion.
14 - 90 FUEL SYSTEM
Fig. 10 Air Filter ElementDiesel
(17) Be sure t hat t he turbocharger output hose is
connected to t he charge air cooler (intercooler) inlet
tube. Verify t hat t he charge air cooler output hose is
connected to t he cooler and t he i nt ake manifold (Fig.
11).
(18) Be sure t hat t he vacuum pump-to-brake
booster hose is connected and not damaged.
(19) Be sure t hat t he accessory drive belt is not
damaged or slipping.
AIR IN FUEL SYSTEM
Air will ent er t he fuel system whenever fuel supply
lines, separator filters, injection pump, hi gh pressure
lines or injectors are removed or disconnected. Air
trapped in t he fuel system can result in hard start-
ing, a rough runni ng engine, engine misfire, low
power, excessive smoke and fuel knock. After service
is performed, air must be bled from t he system before
st art i ng t he engine.

Fig. 11 Charge Air Cooler (Intercooler)
Inspect t he fuel system from t he lift pump to t he
injectors for loose connections. Leaking fuel is an in-
dicator of loose connections or defective seals. Air can
also enter t he fuel system between t he fuel t ank and
t he lift pump. Inspect t he fuel t ank and fuel lines for
damage t hat might allow air into t he system.
AIR INTAKE HEATER
PREHEAT/POST-HEAT CYCLE
The PCM provides a ground pat h for t he air i nt ake
heat er relays. The ground pat h is provided if i nt ake
manifold t emperat ure is below 16C (60F) when t he
ignition key is in t he ON position. When t he ground
is provided, t he i nt ake heat ers are energized to st art
t he preheat cycle.
The preheat cycle can be tested with a voltmeter or
test light. If t he i nt ake manifold t emperat ure is
above 16C (60F), t he wait-to-start light will not
come on and t he air i nt ake heat ers will not be ener-
gized.
l ays more than once per 15 mi nutes. If the relays
are cycl ed, the key turned off and then turned back
on, the engi ne coul d be damaged. Wait 15 mi nutes
before turning the key back to the O N posi ti on.
(1) With t he engine not runni ng and ambient air
t emperat ure below 16C (60F), t ur n t he ignition key
to t he ON position.
(2) The wait-to-start light will come on and t he air
i nt ake heat er relays should click on signaling t he
st art of t he preheat cycle.
(3) Check for battery voltage at both i nt ake ai r
heat er t ermi nal s. The he a t e r s will onl y be ener -
gi zed for 10 to 20 s econds . Refer to t he Preheat
Cycle Time Interval Chart.
PREHEAT CYCLE TIME INTERVAL
SENSOR MOUNT I NG BOLTS
I ntake
Mani fol d
t emperat ure
Preheat Cycle Time
I gnition Key O N
Engine Net R unni ng
Pestheat Cycle
I gnition K ey ON
Ingin Running
Above 15 C
(59 F)
0 Seconds No
-8C{18F)*o
15C(59 F)
10 Seconds Yes
-17C{1 F)
9C(16F)
15 Seconds Yes
-26C(-15F)
fo-18C (0 F)
17.5 Seconds Yes
Below -26 C
(15T)
20 Seconds Yes
J9114-239
AIR INTAKE HEATER TEST
(2) Note wire positions on heat er t ermi nal s for as-
sembly. Disconnect wires from heater.
(3) Use an ohmmeter to test resistance from each
heat er t ermi nal to ground. The resistance should be
zero (0). If t he resistance is not to specifications, in-
spect for corroded or dirty connections. Clean or re-
pair t he connections and retest before replacing
heat ers.
ENGINE SPEED SENSOR
t he crankshaft position sensor) is located on t he front
of engine (Fig. 12).
To perform a complete test of t he engine speed sen-
sor and its circuitry, refer to t he DRB II scan tool.
Also refer to t he appropriate Powertrain Diagnostics
Procedures manual .
FUEL HEATER
A malfunctioning fuel heat er can cause a wax
build-up in t he fuel/water separator (Fig. 13). Wax
build-up in t he fuel/water separator can cause engine
st art i ng problems and prevent t he engine from rev-
ving up. It can also cause miss fire under load and
blue or white fog like exhaust.
Voltage to operate t he fuel heat er is supplied
through t he ignition switch. The heat er operating
range is from 6 - 13.5C (43 - 53). A mi ni mum of 7
VIBRATION
DAMPER
J921 4 - 6 9
volts is required to operate t he fuel heater. The re-
sistance value of t he heat er uni t is 2.5 - 3.0 ohms.
. * r r , ,
J911 4 - 84
Fig. 13 Fuel Heater
FUEL INJECTION PUMP
The fuel solenoid is t he only serviceable component
of t he fuel injection pump. The injection pump is
not to be servi ced or the warranty may be
voided. If the injection pump requires service,
the compl ete assembl y must be repl aced.
Incorrect injection pump t i mi ng can cause poor per-
formance, excessive smoke and emissions and poor
fuel economy. Refer to t he 5.9L Diesel Service Proce-
dures section of this manual for injection pump tim-
ing.
14- 92 FUEL SYSTEM

A broken injection pump t i mi ng mechanism spring
will cause t he t i mi ng to be fully advanced resulting
in torque loss, a fuel knock and possible engine over-
heating.
An improperly operating KSB (cold start) solenoid
will cause white smoke duri ng engine warm-up. The
KSB solenoid is not serviceable.
A defective or non-adjustable fuel injection pump
can cause st art i ng problems or prevent t he engine
from revving up. It can also cause:
Engine surge at idle
Rough idle (warm engine)
Engine miss under load
Low power
Excessive fuel consumption
Poor performance
Low power
Black smoke from t he exhaust
Blue or white fog like exhaust
Incorrect idle or maxi mum speed
A worn fuel injection pump plunger can effect fuel
pressure and t he amount of fuel injected. This results
in reduced engine power. In most cases, if t he injec-
tion pump is delivering fuel from one outlet, it will
deliver fuel from all outlets. If t he i nt ernal plunger
is defective, t he fuel injection pump must be re-
placed.
Engine power is also effected by t he governor set-
t i ng and performance. Do not attempt to adjust the
governor. If the governor seal s on the external
adjustment screw are broken, the fuel rate may
be out of adjustment. The warranty of the injec-
tion pump and the engi ne may be voi d if the
seal s have been tampered wi th or removed.
FUEL INJECTORS
A leaking fuel injector can cause fuel knock, poor
performance, black smoke, poor fuel economy and
rough engine idle. If t he fuel injector needle valve
does not operate properly, t he engine may misfire
and produce low power.
A leak in t he injection pump-to-injector high pres-
sure fuel line can cause many of t he same symptoms
as a malfunctioning injector. Inspect for a leak in t he
high pressure lines before checking for a malfunc-
tioning fuel injector.
W ARN I N G: TH E I N J E CTI ON PUM P SUPPL I E S H I GH
P R E S S U R E F U E L O F A PPR O XI M A T E L Y 59,000 K PA
(8,000 PSI ) TO E AC H I N D I V I D UAL I N J E CTOR
TH ROUGH TH E H I GH PRE S S U RE L I N E S. F UE L UN -
D E R TH I S AM OUN T OF PRE S S URE C AN PE N E -
TRATE TH E SK I N AN D C A US E PE RSON AL I N J URY ,
W E AR SAF E TY GOGGL E S AN D AD E Q UATE PRO-
TE CTI V E CL OTH I N G. AV OI D CON TACT W I TH F UE L
S PRA Y W H E N BL E E D I N G H I GH PRE S S U RE F UE L
L I N E S.
W ARN I N G: DO N OT BL E E D AI R F ROM TH E F UE L
SY STE M OF A H OT E N GI N E . D O N OT AL L OW F UE L
TO S PRA Y ON TO TH E E X H AUST M AN I F OL D W H E N
BL E E D I N G AI R F ROM TH E F UE L SY STE M .
To determine which fuel injector is malfunctioning,
r un t he engine and loosen t he high pressure fuel line
nut at t he injector. Listen for a change in engine
speed (Fig. 14). Tighten t he line nut . If engine speed
drops, t he injector was operating normally. If engine
speed remai ns t he same, t he injector is malfunction-
ing. Test all injectors in t he same manner one at a
time.
Fig. 14 Inspecting Injector Operation
Once an injector has been found to be malfunction-
ing, remove it from t he engine and replace it. Refer
to Diesel Engine Service Procedures for injector re-
moval and installation.
FUEL SUPPLY RESTRICTIONS
C A U T I O N : D o not operate the engi ne if the fuel s up-
ply line has a restriction of more than 12.7 kPa (3.75
in Hg) . Refer to Lift Pump Test.
Fuel supply line restrictions can cause st art i ng
problems and prevent t he engine from revving up.
The st art i ng problems include; engine miss under
load, low power and blue or white fog like exhaust.
Test all fuel supply lines for restrictions or blockage.
Fl ush or replace as necessary. Bleed t he fuel system
of air once a fuel supply line has been replaced.
A blocked or clogged fuel/water separator filter can
cause st art i ng problems and prevent t he engine from
revving up. It can also cause engine miss under load,
low power and blue or white fog like exhaust.
The maxi mum allowable fuel pressure drop across
t he fuel/water filter separator is 21 kPa (3 psi).

There is a drain at t he bottom of t he separator fil-
t er (Fig. 13). Place a drai n pan under t he drain tube.
Wi t h t he engi ne not r unni ng, hold t he drain open
until all water and cont ami nant s have been removed
and clean fuel exits t he drain. Dispose of mi xt ure in
drain pan according to applicable regulations.
If excess water gat hers in separator/filter in a short
time, the fuel t ank must be removed, drained and
cleaned.
HIGH PRESSURE FUEL LINE RESTRICTIONS
High pressure fuel line leaks can cause st art i ng
problems, poor engine performance and engine miss
under load. Restricted high pressure lines can cause
st art i ng problems, poor engine performance, engine
miss under load and black smoke from exhaust.
W ARN I N G: USE E X TRE M E CAUTI ON W H E N I N-
SPE CTI N G F OR H I GH PRE S S U RE F UE L L E AK S. I N-
SPE C T F OR HI GH PRE S S U RE F UE L L E A K S W I TH A
S H E E T O F C ARD BOARD . H I GH F UE L I N J E CTI ON
PRE S S URE C AN C A US E PE RSON AL I N J URY IF
C O N T A C T I S M A D E WI T H T HE S K I N .
St art the engine. Move t he cardboard over t he high
pressure fuel lines and check for fuel spray onto t he
cardboard. If a high pressure line connection is leak-
ing, bleed t he system and t i ght en t he connection. Re-
fer to t he 5.9L Diesel Service Procedures section for
air bleeding procedures. Replace damaged, restricted
or leaking high pressure fuel lines with the correct
replacement line.
C A U T I O N : The hi gh pressure fuel lines must be
cl amped securely in place in the hol ders. The lines
cannot contact each other or other component s. D o
not attempt to weld hi gh pressure fuel lines or to
repair lines that are damaged. Onl y use the recom-
mended lines when replacement of hi gh pressure
fuel line i s necessary.
KSB SOLENOID
The KSB solenoid will click when it is energized
and de-energized.
If t he solenoid does not click when 12 volts is sup-
plied to it, replace t he solenoid.
An improperly operating lift pump can cause low
engine power. Inspect t he fuel supply line to t he
pump for restrictions, ki nks or leaks. Fuel leaking
from t he weep hole (Fig. 15) in t he pump casing in-
dicates a leaking pump diaphragm. The lift pump is
not repairable and must be replaced as an assembly.
C A U T I O N : D o not operate the fuel syst em with a
suct i on restriction of more than 95 MM Hg (3.75
inch Hg) . Refer to Lift Pump Test.
Fig. 15 Lift Pump
Low lift pump output can be caused by a worn ec-
centric on t he engine camshaft. A properly operating
lift pump will pump a mi ni mum volume of 0.75 liter
(0.70 U.S. quart) of fuel in 30 seconds at engine
cranking speed.
The maxi mum allowable pressure drop across t he
fuel filter is 21 Kpa (3 psi). As the filter removes
contaminants in t he fuel, t he pressure drop across
the fuel separator filter will increase. Frequent re-
placement of t he separator filter can indicate a worn
lift pump. Refer to t he Maintenance Schedule at t he
front of t hi s manual for recommended replacement
intervals.
LIFT PUMP TEST
(1) Disconnect fuel inlet tube at t he lift pump.
(2) Install T-fitting between disconnected fitting
and lift pump inlet. Connect vacuum gauge to T-fit-
ting.
W ARN I N G: USE E X TRE M E CAUTI ON W H E N E N -
GI N E I S OPE RATI N G. D O N OT STAN D I N D I RE CT
LI N E W I TH F AN . D O N OT PUT H AN D S N E AR PUL-
L E Y S, BE L TS OR F AN . D O N OT W E AR L OOSE
CLOTH I N G.
The vacuum gauge will not indicate a vacuum un-
til t he lift pump begins to operate at full capacity.
(3) Operate engine at approximately 1500 rpm for
30 seconds. Vacuum should not exceed 12.7 kPa (3.75
in. Hg).
(4) If vacuum exceeds 12.7 kPa (3.75 in. Hg) check
fuel tube for restriction. A partially clogged i n-t ank
fuel filter can also cause excess vacuum.
14 - 94 FUEL SYSTEM

THROTTLE POSITION SENSOR TEST
CAUTI ON ; Before checki ng the TPS, the throttle
l i nkage must be checked for correct adjustment.
The throttle lever must contact the low idle speed
screw. The throttle lever must reach breakover when
the throttle is wide open. Refer to the Accelerator Pedal
and Throttle Cabl e section of Group 14 , Fuel Syst ems.
The t hrot t l e position sensor (TPS) can be tested
with t he DRB II or a digital voltmeter (Fig. 16). The
center t ermi nal of t he TPS is t he output t ermi nal .
J9114-244
Fig. 16 Throttle Position Sensor (TPS) Testing
Tur n t he ignition key to t he On position. Check
TPS out put voltage at t he center t ermi nal wire of t he
connector. Measure t he voltage at idle (throttle lever
contacting low idle speed screw) and at wide open
t hrot t l e ( W OT) . At idle TPS output voltage should be
approximately 1 volt. At wide open t hrot t l e, t he TPS
output voltage must be 2.25 to 2.75 volts higher t han
t he readi ng at idle. The output voltage should in-
crease gradually as t he t hrot t l e lever is slowly
opened from idle to WOT. If t he TPS is not wi t hi n
t he proper range, adjust t he sensor. Refer to t he Die-
sel Fuel InjectionService Procedures section of this
group.
ON-BOARD DIAGNOSTICS (OBD)
The powertrain control module (PCM) has been
programmed to monitor many different circuits. If a
problem is sensed in a monitored circuit often
enough to indicate an actual problem, a diagnostic
trouble code (DTC) is stored. The DTC will be stored
in t he PCM memory for eventual display to t he ser-
vice technician. If t he problem is repaired or ceases
to exist, t he PCM cancels t he DTC after 51 engine
st art s.
Cert ai n criteria must be met for a diagnostic trou-
ble code (DTC) to be entered into PCM memory. The
criteria may be a specific range of engine rpm, en-
gine t emperat ure and/or i nput voltage to t he PCM.
It is possible t hat a DTC for a monitored circuit
may not be entered into memory even though a mal-
function has occurred. This may happen because one
of t he DTC criteria for t he circuit has not been met.
ACCESSING DIAGNOSTIC TROUBLE CODES
A stored diagnostic trouble code (DTC) can be dis-
played by cycling t he ignition key On-Off-On-Off-On
within t hree seconds and observing t he malfunction
indicator lamp. This lamp was formerly referred to
as t he check engine lamp. The lamp is located on t he
i nst rument panel.
They can also be displayed t hrough t he use of t he
Diagnostic Readout Box II (DRB II scan tool). The
DRB II connects to t he dat a link connector in t he en-
gine compartment. For operation of t he DRB II, refer
to t he appropriate Powertrain Diagnostic Procedures
service manual .
EXAMPLES
more time, a diagnostic trouble code (DTC) number
41 is indicated.
more times, a diagnostic trouble code (DTC) number
46 is indicated.
Refet* to t he Diagnostic Trouble Code (DTC) charts
for DTC identification.
If t he problem is repaired or ceases to exist, t he
powertrain control module (PCM) cancels t he DTC
after 51 engine st art s.
Diagnostic trouble codes indicate t he results of a
failure, but never identify t he failed component di-
rectly.
The circuits of t he dat a link connector are shown
in (Fig. 17).
J9214-20
D-1
1
G R O U N D
D-2 N / C
D-3 S C I T R A N S
D-4 S C I RECEI VE
D-5
I GN I T I ON
D-6 N O T US E D
Fig. 17 Data Link Connector Schematic
ERASING TROUBLE CODES
The DRB II scan tool must be used to erase a di-
agnostic trouble code (DTC). Refer to t he appropriate
Powertrain Diagnostic Procedures service manual for
operation of t he DRB II scan tool.

FUEL SYSTEM 14 - 95
DRB II SCAN TOOL
For operation of t he DRB II scan tool, refer to t he
appropriate Powert rai n Diagnostic Procedures ser-
vice manual .
DIAGNOSTIC TROUBLE CODE (DTC)
On t he following pages, a list of diagnostic trouble
codes is provided for t he diesel engine. A DTC indi-
cates t hat the powertrain control module (PCM) has
recognized an abnormal signal in a circuit or t he sys-
tem. A DTC may indicate t he result of a failure, but
never identify t he failed component directly.
SYSTEM SCHEMATICS5.9L DIESEL ENGINE
Refer to t he following system schematic for t he
5.9L diesel engine.
5.9L DIESEL DIAGNOSTIC TROUBLE CODES (DTC)
Faul t C ode D R BI I D i s p l a y D escr i pt i on of Faul t C ondi t i on
11 No Reference Signal
During Cranking
15 No Vehicle Speed
Signal
22 Coolant Sensor Voltage
Too Low
or
Coolant Sensor Voltage
Too High
23 Charge Air Temperature
Sensor Voltage High
or
Charge Air Temperature
Sensor Voltage Low
24* TPS Voltage High
or
TPS Voltage Low
33 A/C Clutch Relay Circuit
34 Speed Control
Solenoid Circuits
41 Generator Field Not
Switching Properly
42 Auto Shutdown Relay
Control Circuit
or
No ASD Relay Voltage
Sense at PCM
No reference signal from Engine Speed Sensor.
No speed sensor signal detected during road load conditions.
Coolant temperature sensor input below the minimum acceptable voltage.
Coolant temperature sensor input above the maximum acceptable voltage.
Charge Air Temperature Sensor input above/below acceptable minimum.
Throttle position sensor (TPS) input above the maximum acceptable voltage.
Throttle position sensor (TPS) input below the minimum acceptable voltage.
An open or shorted condition detected in the A/C clutch relay circuit.
An open or shorted condition detected in the speed control vacuum or vent
solenoid circuits.
Generator field not switching properly.
An open or short condition detected in the auto shutdown relay circuit.
No ASD voltage sensed at PCM.
*Automatic Transmission Only
J9314-182
FUEL SYSTEM 14 - 97
59L DIESEL DIAGNOSTIC TROUBLE CODES {DTC}-CONTINUED
Faul t C ode DRBII Di spl ay D escr i pt i on of Fault Condi t i on
45* Overdrive Solenoid
46 Charging System
Voltage Too High
47 Charging System
Voltage Too Low
53 Internal PCM Failure
62 PCM Failure
SRI Miles Not Stored
63 PCM Failure
EEprom Write Denied
An open or shorted condition detected in overdrive solenoid circuit.
Charging system voltage too high.
Charging system voltage too low.
Internal failure in the PCM.
PCM failure - SRI miles not stored.
PCM failure - EEprom write denied.
*Automatic Transmission Only
J9314-183
OVERDRIVE/ OVER-RIDE
SWITCH
(AUTO ONLY)
CO
oo
c/3
- <
L STARJ E RJ ^ _ j
J9314-184
5 . 9 1 . DIESEL SYSTEM SCHEMATIC

C A V
WI R E
C O L O R
D E S C R I PT I O N C A V
WI R E
C O L O R
1 WT/BK WATER-IN-FUEL SENSOR 37 OVERDRIVE LAMP SIGNAL
2 TN/BK COOLANT SENSOR (AUTOMATIC TRANSMISSION ONLY) 38
3 RD BATTERY 39
4 BK/LB* SENSOR RETURN 40
5 BK/WT SIGNAL GROUND 41
6 VT/WT* 5 VOLT SUPPLY 42
7 TN/YL 8 VOLT INPUT 43 GR/LB TACHOMETER
8 44
9 DB IGNITION SENSE 45 LG DATA LINK RECIEVE
10 RD/WT* OVERDRIVE OVERRIDE 46
11 BK/TN POWER GROUND 47 WT/OR* VEHICLE SENSOR
12 BK/TN POWER GROUND 48 BR/RD* SPEED CONTROL COAST/SET SWITCH
13 49 YL/RD* SPEED CONTROL ON/OFF SWITCH
14 50 WT/LG* SPEED CONTROL RESUME/ACCEL SWITCH
15 OR/BK* HEATER #2 RELAY 51 DB/YL ASD RELAY
16 YL/BK HEATER #1 RELAY 52
17 53 LG/RD* SPEED CONTROL VENT SOLENOID
18 54 BK/PK* WATER-IN-FUEL LAMP
19 55 OR/LG* OVERDRIVE SOLENOID
20 DG GENERATOR FIELD 56 DG/WT WAIT-TO-START LAMP
21 BK/RD CHARGE (INTAKE) AIR TEMPERATURE SENSOR 57 DG/OR ASD SENSE
22 OR/DB* THROTTLE POSITION SENSOR 58
23 59
24 GY/BK REFERENCE PICKUP 60
25 PK DATA LINK TRANSMIT WIRE COLOR CODES LB LIGHT BLUE VT VIOLET
26 BK BLACK LG LIGHT GREEN WT WHITE
27 BR A/C CLUTCH REQUEST BR BROWN OR ORANGE YL YELLOW
28 LG/RD THERMO SWITCH DB DARK BLUE PK PINK
*
WITH TRACER
29 WT/PK* BRAKE SWITCH DG DARK GREEN RD RED
30 BR/YL* PARK/NEUTRAL SWITCH GY GRAY TN TAN
31
ruin
32 BK/PK* MALFUNCTION INDICATOR LAMP n
33 TN/RD* SPEED CONTROL VACUUM SOLENOID CONNECTOR J / / 0 0 0 O O O O O O O 1 1
HI 1 7 3 4 5 6 7 8 9 10 J/ ^"* \ \
Hi oooooooooo (1 O j ]
VlX 21 22 23 24 25 26 27 28 29 30 \ V ~V / /
oooooooooo \ \
II 12 13 14 15 16 17 18 19 20 \ \
34 DB/OR WIDE OPEN THROTTLE (A/C)
TERMINAL
J / / 0 0 0 O O O O O O O 1 1
HI 1 7 3 4 5 6 7 8 9 10 J/ ^"* \ \
Hi oooooooooo (1 O j ]
VlX 21 22 23 24 25 26 27 28 29 30 \ V ~V / /
oooooooooo) }
31 32 33 34 35 36 37 38 39 40 1JU
35 SHOWN
\ \ \ 41 42 43 44 45 46 47 48 49 SO 1 ^m^^ |
oooooooooo 1 1
oooooooooo J / /
36
Li
J9314-185
PC M CONNECTOR CAVITY DESCRIPTION
1 4 - 1 0 0 FUEL SYSTEM

DIESEL FUEL INJECTION SYSTEM DIAGNOSIS
SYMPTOM CAUSE ACTION
Starting problem Improper fuel Drain fuel tank, flush system, fill with proper
fuel. Change filter
Empty fuel tank or fuel tank vent blocked Fill tank, bleed system, check tank vent
Air in fuel system Bleed fuel system
Voltage not supplied to fuel solenoid or
fuel solenoid inoperative
Correct voltage supply problem or
replace solenoid
Clogged fuel filter Replace fuel filter
Restricted or blocked fuel supply lines Remove restriction or replace lines
Leaking injection lines, damaged lines or
loose connections
Replace damaged lines or tighten
connections as necessary.
Bleed fuel system
Wax buildup in fuel filter (cold weather
only)
Replace fuel filter, use recommended
diesel fuel
Incorrect injection pump to engine timing Adjust injection pump timing
Malfunctioning air heating system Repair air heating system
Injection sequence does not correspond
with firing order
Install fuel injection lines in correct order
Malfunctioning KSB valve Replace injection pump
Low or uneven engine compression Repair as necessary
Restricted or blocked fuel injection lines Remove restriction or replace lines
Fuel injection pump malfunction or
not adjustable
Replace fuel injection pump
Engine Surge at idle
Low idle speed
Adjust idle speed J9H4-22

FUEL SYSTEM 14 - 101
DIESEL FUEL INJECTION SYSTEM DIAGNOSIS-CONTINUED
Engine surges at idle Fuel injection pump malfunction or
not adjustable
Rough idle when engine I s warm Improper fuel
Air in fuel system
Drain fuel tank, flush system, fill with
proper fuel
Bleed fuel system
Low idle speed Adjust idle speed
Injection pump rear support bracket loose Repair as necessary
Restricted or damaged injector nozzle Repair or replace as necessary
with firing order
Install injection lines in correct order
Fuel injection pump malfunctioning
or not adjustable
Engine mines under lead Improper fuel Drain fuel tank, flush system, fill with
proper fuel
Restricted or blocked fuel injection lines Remove restrictions or replace lines
Restricted or blocked fuel supply lines Remove restrictions or replace lines
loose connection
Bleed fuel system.
1
J9114-23
14 - 102 FUEL SYSTEM

SYMPTOM CAUSI ACTION
l upi n* mimes under I m4 Incorrect injection pump timing Adjust injection pump timing
Restricted or damaged injector nozzle Replace or repair as necessary
Restricted or blocked fuel injection lines Install fittings proper positions
Fuel Injection pump malfunction or
not adjustable
l e w power Improper fuel Drain fuel tank, flush system, fill with
proper fuel
Control lever not going to full throttle
position
Adjust throttle linkage
Intercooler internally blocked or leaking Check pressure drop across intercooler.
If pressure drop is more than 4 in. Hg, clean
or replace as necessary.
Injection pump overflow fitting switched with
inlet fitting
Install fittings in proper positions
loose connections
Bleed fuel system
Clogged or restricted air filter Remove restrictions or replace filter if
necessary
Air fuel control tube broken or leaking Repair or replace as necessary
Low manifold pressure Check and repair turbocharger operation.
Check intercooler and air pipes for blockage
with firing order
Install fuel injection lines in correct
order
Incorrect injection pump to engine timing Check injection pump to engine timing
not adjustable
J9114-253
FUEL SYSTEM 1 4 - 1 0 3
S YM PT O M CAUS E A C T I ON
Excessive fuel consumption improper diesel fuel Use correct fuel for conditions. Refer to
owner's manual
Incorrect injection pump timing Adjust injection pump timing
Clogged or restricted air filter Remove restrictions or replace air filter if
necessary
with firing order
install fuel injection lines in correct order
If pressure drop is more than 4 in. Hg,
clean or replace as necessary
Low idle misadjusted Adjust idle stop screw
Malfunctioning KSB valve Replace injection pump
Incorrect injection pump to engine timing Adjust injection pump to engine timing
not adjustable
Unabie to shut engine off Voltage to fuel solenoid interrupted or fuel
solenoid inoperative
Correct voltage supply problem or replace
solenoid
Either poor performance, black
m o k e or l ow power
Improper fuel Drain fuel tank, flush system, fill with
proper fuel for conditions. Refer to owner's
manual
Clogged or restricted air filter Remove restrictions or replace filter if
necessary
Air fuel control tube leaking or broken Repair or replace as necessary
Low manifold pressure Check and repair turbocharger operation
with firing order
Install fuel injection lines in correct order

J9114-255
1 4 - 1 0 4 FUEL SYSTEM

Either poor performance,
black smoke or low power
Injection pump to engine timing
not adjustable
Check injection pump to engine timing
White or blue fog-like exhaust
in full-load range
Improper fuel Drain fuel tank, flush system, fill with proper
fuel, change filter
Restricted or blocked fuel injection lines Remove restriction or replace lines
Restricted or blocked fuel supply lines Remove restriction or replace lines
only)
Replace fuel filter, use recommended i
diesel fuel. Inspect fuel heater
electrical connector for damage.
Injection pump overflow fitting switched
with inlet fitting
Install fittings in proper positions
not adjustable
Incorrect lale speed Low idle misadjusted Adjust idle stop screw
not adjustable
Engine does not rev up Improper fuel Drain fuel tank, flush system, fill with proper
fuel, change filter
Empty fuel tank or fuel tank
vent blocked
Fill tank, bleed system, check
tank vent
J9114-26
Engine does not rev up Control lever not going to full throttle
position
Adjust throttle linkage
only)
Inspect fuel heater electrical connector
for damage. Replace fuel filter, use
recommended diesel fuel.
Injection pump overflow fitting switched
with inlet fitting
Install fittings in proper sequence
not adjustable
Replace injection pump
Infection pump runs hot Overflow blocked Clean overflow orifice or replace fitting
J9114-254
14 - 106 FUEL SY STE i
DIESEL FUEL I N J E C T I O N - S E R V I C E PROCEDURES
INDEX
page
Air Bleed Procedure 106
Air Fuel Control Tube 107
Air Intake Heater 107
Engine Speed Sensor 108
Fuel Drain Manifold 109
Fuel Heater . 110
Fuel Injection Pump 110
Fuel Injection Pump Suppl y Line 114
Fuel Injectors 114
AIR BLEED PROCEDURE
A certain amount of air becomes trapped in t he
fuel system when fuel system components are ser-
viced or replaced. Bleed t he system after fuel system
service according to t he following procedures.
W ARN I N G: D O N OT BL E E D AI R F ROM TH E F UE L
SY STE M OF A H OT E N GI N E . D O N OT AL L OW F UE L
TO S PRA Y ON TO TH E E X H AUST M AN I F OL D W H E N
BL E E D I N G AI R F ROM TH E F UE L SY STE M .
MANUAL BLEEDING
Some air enters t he fuel system when t he filters or
injection pump supply line are changed. This small
amount of air is vented automatically from t he injec-
tion pump t hrough t he fuel drain manifold. This is if
t he filter was changed according to instructions.
The system will have to be bleed manual l y if:
The fuel filter is not filled before installation
Injection pump is replaced
High pressure fuel line connections are loosened or
lines replaced
Initial engine start-up or start-up after an ex-
tended period of no engine operation.
(1) Open t he low pressure bleed screw (Fig. 1).
(2) Operate t he hand lever on t he mechanical lift
pump unt i l t he fuel exiting t he low pressure bleed
screw is free of air.
If t he manual lever feels as if it is not pumping, ro-
t at e (crank) t he engine approximately 90 degrees.
Continue pumpi ng until air is removed.
(3) Tighten low pressure bleed screw to 8 Nm (6
ft. lbs.) torque.
CAUTI ON : The manual lever must be returned to
the l ock posi ti on ( up) after pri mi ng.
INJECTION PUMP
W ARN I N G: TH E E N GI N E M AY START W H E N
C RAN K I N G TO BL E E D AI R F ROM TH E I N J E CTI ON
page
Fuel/Water Separator Filter . . . . . . . . . . . . . . . . 1 1 5
High Pressure Fuel Lines 116
Injection Timing 117
K SB Solenoid 1 1 8
Mechanical Lift Pump 119
Powertrain Control Module ( PCM) 1 08
Throttle Position Sensor ( TPS) 119
Water-ln-Fuel Sensor 121
Fig. 1 Low Pressure Bleed Screw
PUM P. PL AC E TH E TRAN SM I SSI ON IN N E UTRAL
OR PARK AN D SE T PARK I N G BRA K E BE F ORE E N -
GAGI N G TH E STARTE R M OTOR.
CAUTI ON : D o not engage the starter motor for more
than 30 s ec ond s at a time. Al l ow two mi nutes be-
tween cr anki ng interval s.
Crank t he engine for 30 seconds at a time to allow
air trapped in t he injection pump to vent out t he
drain manifold. Observe t he previous WARNING and
CAUTION.
W ARN I N G: TH E I N J E CTI ON PUM P SUPPL I E S H I GH
PRE S S U RE F UE L OF APPROX I M ATE L Y 59,000 K PA
( 8, 000 PSI ) TO E AC H I N D I V I D UAL I N J E CTOR
TH ROUGH TH E H I GH PRE S S U RE L I N E S. F UE L UN -
D E R TH I S AM OUN T OF PRE S S URE C AN PE N E -
TRATE TH E SK I N AN D C A US E PE RSON AL I N J URY .
W E AR SAF E TY GOGGL E S AN D AD E Q UATE PRO-
TE CTI V E CLOTH I N G AN D AV OI D CON TACT W I TH
F UE L S PRA Y W H E N BL E E D I N G H I GH PRE S S URE
F UE L L I N E S.

WARNING; DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
Bleed air from one injector at time.
(1) Loosen t he high pressure fuel line fitting at t he
injector (Fig. 2).
Fig. 2 Bleeding High Pressure Fuel Lines
(2) Crank t he engine unt i l all ai r is bleed from t he
line. Do not ope r a t e t he s t a r t e r mot or for l onger
t ha n 30 s econds . Wai t t wo mi nut es be t we e n
c r a nki ng i nt er val s .
(3) St art t he engine and bleed one injector at a
time unt i l t he engine r uns smoothly.
AIR FUEL CONTROL TUBE
REMOWAL
(1) Disconnect tube from fuel injection pump (Fig.
3).
Fig. 3 Air Fuel Control Tube Removal/Installation
(2) Disconnect tube from i nt ake manifold.
(3) Remove tube. Discard seals.
INSTALLATION
(1) Connect t ube to i nt ake manifold. Tighten fit-
t i ng to 8 Nnn (6 ft. lbs.) torque.
(2) Connect t ube to injection pump using new
seals. Tighten fitting screw to 12 Nnn (9 ft. lbs.)
torque.
AIR INTAKE HEATER
(2) Disconnect t he t hrot t l e rod from t he throttle le-
ver on t he injection pump.
(3) Disconnect electrical connections air i nt ake
heat ers (Fig. 4).
Fig. 4 Air Intake HeatersTypical
(4) Remove t he t hrot t l e bracket (Fig. 5).
Fig. 5 Throttle BracketTypical
(5) Loosen clamps securing air t he crossover t ube
hose to t he turbo-charger.
(6) Remove ai r crossover t ube mounting screws.
(7) Remove ai r crossover tube.
(8) Remove ai r i nt ake heat er.
(9) Clean ai r i nt ake heater-to-intake manifold
mat i ng surfaces.
(10) Install air i nt ake heat er (with new gasket) in
reverse order of removal.
AIR INTAKE HE A TER RELA YS
(2) Disconnect electrical connections from relays
(Fig. 6).
HEATER
RELAYS
WHEEL..
WELL J9114- 67
Fig. 6 Air intake Heater RelaysTypical
(3) Remove relay mount i ng screws. Remove relays.
(4) Install relays in reverse order of removal.
POWERTRAIN CONTROL MODULE ( PCI )
REMOWAL
hind t he bat t ery and under t he left front fender (Fig.
7).
TORQUE CONVERTER
CLUTCH RELAY
A/ C CLUTCH RELAY STARTER RELAY
AUTO SHUTDOWN RELAY
FUEL PUMP RELAY
DATA LINK
CONNECTOR
POWERTRAIN
CONTROL
MODULE J9314-164
(1) Disconnect t he negative bat t ery cable at bat-
tery.
(2) Remove bat t ery holddown clamps.
(3) Position bat t ery to gain access to PCM,
(4) Remove 60-way electrical connector from t he
PCM (one screw) (Fig. 8).
PCM
MOUNTING
BOLTS
PCM CONNECTOR
CONNECTOR MOUNTING
BOLT J9314-165
Fig. 8 PCM Mounting
(5) Remove t he t hree PCM-to-mounting bracket
bolts (Fig. 8). Do not remove t he PCM mount i ng
bracket from t he fender.
INSTALLATION
(1) Check pins in 60-way PCM connector for dam-
age. Repair as necessary.
(2) Position PCM and install mount i ng bolts.
Ti ght en bolts to 4 N*m (35 in. lbs.) torque.
(3) Connect 60-way electrical connector to t he
PCM. Tighten connector mount i ng screw to 4 N
#
m
(4) Install bat t ery.
ENGINE SPEED SENSOR
t he crankshaft position sensor) is located on t he front
of engine (Fig. 9). Two spacers located behind t he
sensor are used to position sensor over t he vibration
damper.
REMOWAL
Before removing t he sensor, note t he position and
rout i ng of t he sensor wiring harness. This routing
must be mai nt ai ned to prevent wiring from contact-
ing belt or pulleys.
(1) Disconnect t he speed sensor pigtail harness
from t he mai n engine wiring harness near t he front/
top of engine.
(2) Remove t he clip bolts from t he sensor pigtail
wi ri ng harness.
(3) Remove t he two speed sensor mount i ng nut s
(Fig. 9).
SENSOR MOUNTING BOLTS
VIBRATION
DAMPER
J9214-69
(4) Remove t he speed sensor and its two mounting
spacers from t he vehicle.
INST ALL A TION/ADJUSTMENT
The engine speed sensor uses a slotted hole on one
side (Fig. 10) to adjust its depth. A brass (non-mag-
netic) feeler gauge must be used to adjust t he sensor.
Fig. 10 Engine Speed SensorInstallation
Sensor-to-vibration damper air gap is: 1.25 MM
(.049 in.) mi ni mum to 1.30 MM (.051 in.) maximum.
(2) Position speed sensor, its two mount i ng spacers
and two mount i ng nut s to t he engine. Install mount-
ing nut s finger tight.
(3) Route sensor wi ri ng harness behind engine pul-
leys. Install and t i ght en wiring harness clip bolts.
(4) Place t he feeler gauge between t he sensor and
t he vibration dampener.
(5) Gently seat (push down) t he sensor unt i l it con-
t act s t he feeler gauge. Be sure the sensor is not
near either of the notches (Fig. 9) on the vibra-
ti on da mpe r . If sensor is adj us t ed at or near
t hese notches, it will be damaged when engi ne i s
started.
(6) Tighten sensor mount i ng nut s to 24 N
#
m (18 ft.
lbs.) torque.
(7) Remove feeler gauge.
(8) Connect t he sensor electrical connector to t he
mai n engine wiring harness.
FUEL DRAIN MANIFOLD
REMOVAL
(1) Remove t he fuel drain manifold holddown
clamp mount i ng screws (Fig. 11).
DRAIN
MANIFOLD
J9114-43
Fig. 11 Fuel Drain Manifold
(2) Remove injection pump vent capscrew (Fig. 11).
(3) Remove fuel drain manifold fitting screws and
washers at each fuel injector (Fig. 12).
INJECTOR
DRAIN MANIFOLD
FITTING
SCREW
J9114-44
Fig. 12 Fuel Drain Fitting Screws
(4) Disconnect drain line T-fittings.
SENSOR J9114-39
(5) Remove t he filter adapt er from t he fuel heat er
(Fig. 14).
(6) Remove fuel heat er.
(7) Remove seals from fuel heat er. Clean t he fuel
heat er and cylinder block mat i ng surfaces.
INSTALLATION
(1) Install new seals in fuel heat er and adapter.
(2) Install fuel heat er and adapter. Tighten
adapt er to 32 Nr n (24 ft. lbs.) torque.
(3) Apply a light film of clean engine oil to sealing
surface of WIF sensor.
(4) Install WIF sensor into new fuel/water separa-
tor filter.
(5) Fill separator filter wi t h clean fresh fuel.

Fig. 14 Fuel Heater Removal/Installation
surface of separator filter.
(7) Install a new square cut O-ring to t he filter
connector on t he bottom of t he fuel heater.
(8) Install separator filter. Tighten separator filter
one half t ur n after it makes contact.
(9) Connect electrical connector to WIF sensor and
Fuel Heater.
FUEL INJECTION PUMP
REMOVAL
(2) Disconnect t hrot t l e linkage.
(3) Remove throttle bracket (Fig. 15).
Fig. 15 Throttle Bracket
(4) Remove injection pump supply line. Refer to
Fuel Injection Pump Supply Line.
(5) Remove high pressure fuel lines. Refer to High
Pressure Lines.
(6) Disconnect electrical connector from fuel sole-
noid.
(7) Disconnect electrical connector from KSB Sole-
noid.
INSTALLATION
(1) Using new seals on all fittings, assemble fuel
drain manifold in reverse order of disassembly.
(2) Tighten drai n manifold fitting screws at t he in-
jectors to 8 N
#
(3) Tighten drain manifold holddown clamp screws
(4) Tighten injection pump capscrew to 32 N
#
m (24
ft. lbs.) torque.
FUEL HEATER
The fuel heat er is located above t he fuel/water sep-
arat or filter (Fig. 13).
REMOVAL
(1) Thoroughly clean t he area around t he separa-
tor filter before service is performed.
(2) Disconnect t he water-in-fuel (WIF) sensor elec-
trical connector (Fig. 13).
(3) Remove t he fuel/water separator filter. Refer to
Fuel/Water Separator Filter removal and installation
in t hi s group.
(4) Disconnect electrical connector from t he fuel
heat er (Fig. 13).

(8) Remove t he air control tube (Fig. 16).
(9) Remove fuel pump vent line and capscrew (Fig.
16).
Fig. 16 Fuel Solenoid, Air Control Tube, Pump Vent
Line
The control lever is indexed to t he shaft duri ng cal-
ibration. Do not remove the control l ever from in-
jecti on pump.
(10) Remove bolt at t achi ng t he injection pump sup-
port bracket to t he vacuum pump. Remove t he upper
and lower bolts attaching t he support bracket to t he
engine block. Loosen t he middle bolt and pivot t he
bracket towards t he rear of t he engine (Fig. 17).
Fig. 17 Injection Pump Support Bracket
(11) Remove oil fill t ube bracket mounting screw
(Fig. 18).
(12) Remove oil fill t ube from and adapter from
front cover.
C A U T I O N : If gear retainer nut or washer dr ops into
gear housi ng, cover must be removed to retrieve
them before engi ne i s started.
Fig. 18 Oil Fill Tube and Bracket
(13) Place a shop towel below t he ret ai ner nut in
t he gear housing cover opening to prevent t he nut or
washer from falling into t he gear housing. Remove
t he gear ret ai ni ng nut and washer.
The engine can be rotated wi t h a barri ng tool such
as Snap-On No. SP371, MTE No. 3377462 (Cummins
Tool Division), or an equivalent.
(14) Insert t he barri ng tool into t he flywheel hous-
i ng opening. The opening is located in r ear flange of
t he engine, on t he exhaust manifold side (Fig. 19).
Fig. 19 Rotating Engine with Barring Tool
(15) Rotate engine wi t h t he barri ng tool unt i l t he
fuel injection pump key-way is in t he position shown
in Fig. 20.
The engine has a t i mi ng pin (Fig. 21). The pin en-
gages a hole in t he camshaft gear when cylinder No.
1 is at TDC on t he compression stroke.
C A U T I O N : Duri ng engine assembl y by the manuf ac-
turer, the timing pin i s posi ti oned to cor r espond
with the compr essi on stroke T D C posi t i on of cyl i n-
der number one. If the timing pin or gear housi ng i s
removed, the timing pi n location will not be correct
when reinstalled.
J9114-57
Fig. 21 Timing PinCylinder No. 1
(16) Locate TDC position (compression stroke) for
No. 1 cylinder by slowly rot at i ng t he engine wi t h t he
barri ng tool while lightly pushi ng in on t he t i mi ng
pin. Stop when t he t i mi ng pin engages t he index hole
in t he camshaft gear.
(17) Disengage t he t i mi ng pin from t he camshaft
gear.
Check t he t i mi ng mar ks on t he flange of t he injec-
tion pump (Fig. 22). Each pump and engine have
uni que marks. It is not possible to exchange pumps
and use t he same mar ks for al i gnment .
The injection pump has a lockscrew. The lockscrew
is used to hold t he injection pump shaft in place once
TDC has been located. New and rebuilt injection
pumps should be received wi t h t he shaft locked in
place by t he lockscrew.
(18) Loosen t he injection pump shaft lockscrew. It
is located below t he injection pump mount i ng nut .
Remove washer from injection pump (Fig. 23). At t ach
washer to injection pump wi t h wire t ag for use dur-
ing installation.
(19) Tighten lockscrew.
J9114-58
Fig. 22 Injection Pump Timing Marks
Fig. 23 Injection Pump Shaft LockScrew and
Washer
(20) Use a T-bar puller to separate t he gear from
t he pump shaft. Use M8 X 1.24 MM (metric) screws
to at t ach T-bar to shaft. Pull t he injection pump gear
forward unt i l it separates from t he injection pump
shaft (Fig. 24). The injection pump gear cannot be re-
moved from t he engine t hrough t he oil fill opening in
t he t i mi ng case cover.
C A U T I O N : D o not allow the drive gear keyway to
drop into the gear housi ng cover when removi ng
the pump.
(21) Remove t he injection pump mount i ng nut s.
(22) Remove injection pump. Clean gasket surfaces
on block and injection pump.
INSTALLATION
Before installing t he injection pump, be sure t hat
No. 1 cylinder is at No. 1 position.
No. 1 cylinder by slowly rot at i ng t he engine with t he

Fig. 24 Separating Pump Gear from injection Pump
Shaft
in the camshaft gear.
(2) Disengage the t i mi ng pin from t he camshaft
gear.
(3) Install a new injection pump gasket.
The shaft of a new or reconditioned pump is locked
in place. The key is positioned to align with the drive
gear slot when cylinder No. 1 is at TDC on t he com-
pression stroke.
CAUTI ON : Be sure that the injection pump shaft
keyway does not fall into the gear housi ng when
installing the injection pump. The keyway must be
removed if it fal l s into the gear housi ng.
(4) Install t he injection pump. Fi nger t i ght en t he
mounting nut s. The pump must be able to move in
t he slot.
(5) Remove t he T-bar from t he injection pump
gear.
(6) Install pump drive shaft gear ret ai ni ng nut and
spring washer. The injection pump will rotate
slightly if t he pump mounting nut s were installed
finger t i ght and t he crankshaft does not move.
(7) Tighten injection pump drive shaft gear retain-
ing nut to 15-20 N t h (11-15 ft. lbs.) torque. Do not
over tighten. This i s not the final tightening
t or que .
(8) If installing original injection pump, rotate
pump to align t i mi ng marks. If installing a new or
rebuilt pump without a timing mark, t ake up gear
lash by rot at i ng pump counterclockwise towards cyl-
inder head.
(9) Tighten injection pump mount i ng nut s to 24
If installing a new or rebuilt pump, permanent l y
mar k t he injection pump flange in line with t he
mar k on t he gear housing (Fig. 25).
Fig. 25 Marking New or Rebuilt Injection Pump
New and rebuilt injection pumps should be re-
ceived with t he shaft locked in place by t he lock-
screw.
(10) Loosen injection pump lockscrew and install
washer under lockscrew (Fig. 26). Tighten lockscrew
Fig. 26 Installing Lockscrew Washer
(11) Install injection pump support bracket wi th
mounting screws finger tight. Using following t he
sequence, t i ght en mount i ng screws to 24 Nnn (18 ft.
lbs.) torque.
Tighten bracket to vacuum pump screw.
Tighten bracket to block mounting screws.
Tighten bracket to injection pump mounting
screws.
Tighten t hrot t l e support bracket mount i ng screws.
(12) Tighten injection pump drive shaft gear re-
t ai ni ng nut to 65 N*m (48 ft. lbs.) torque.
(13) Install oil filler assembly to gear housing.
Tighten clamp screw to 43 Nnn (32 ft. lbs.) torque.
(14) Install high pressure fuel lines. Refer to High
Pressure Lines. Tighten hi gh pressure fuel lines to

(15) Install fuel injection pump supply line. Refer
to Fuel Injection Pump Supply Line.
(16) Connect electrical connector to fuel solenoid.
(17) Connect electrical connector to KSB solenoid.
(18) Install fuel pump vent line and capscrew.
(19) Install air fuel control tube.
(20) Install throttle bracket (Fig. 15). Tighten
mounting bolts to 24 Nm (18 ft. lbs.) torque.
(21) Install throttle linkage. When connecting the
cable to the control lever, adjust the length so the le-
ver has stop-to-stop movement. Refer to Accelerator
Pedal and Throttle Controls section of Group 14,
Fuel Systems.
(22) Install and adjust throttle position sensor. Re-
fer to Service Adjustments.
(23) Bleed air from fuel system. Refer to High
Pressure Fuel Lines in the Air Bleeding portion of
the Diesel Fuel Injection section of Group 14, Fuel
Systems.
(24) Adjust the low idle speed if required. Refer to
Service Adjustments near the end of this group.
(25) Inspect throttle linkage to be sure that the
control lever breaks over the full throttle position.
Adjust as necessary. Refer to Accelerator Pedal and
Throttle Cable section of Group 14, Fuel Systems.
FUEL INJECTION PUMP SUPPLY LINE
REMOVAL
(2) Disconnect supply line at fuel/water separator
filter (Fig. 27).
Fig. 27 Supply Line to Separator Filter Connection
(3) Do not al l ow the injection pump inlet fit-
ting to move when l ooseni ng suppl y line. Use
t wo wrenches when removi ng line. Disconnect
supply line from injection pump (Fig. 28).
INSTALLATION
(1) Install low pressure fuel supply line in reverse
order of removal.
Fig. 28 Supply Line to Injection Pump Connection
(2) Tighten the supply line connections to 24 Nnn
(3) Manually bleed the system of air. Refer to
Manual Bleeding in this section.
FUEL INJECTORS
REMOVAL
(2) Remove throttle linkage.
(3) Remove high pressure fuel lines. Refer to High
Pressure Fuel Lines in this section.
(4) Remove the fuel drain manifold. Refer to Fuel
Drain Manifold in this section.
(5) Thoroughly clean the area around the injector.
C A U T I O N : U se a deep well socket to remove the
fuel injector (Fi g. 29).
(6) Remove injector (Cummins injector nozzle
puller tool 3823276 or an equivalent). Discard copper
seal.
Fig. 29 Fuel Injector Removal/Installation
(7) Clean injector nozzle bore wi t h wire brush
(Cummins tool number 3822509 or equivalentFig.
30).
Fig. 30 Cleaning Cylinder Head Injector Bore
INSTALLATION
(1) Install new copper seal on injector (Fig. 31).
J9114 -50
Fig. 31 Injector Seal
(2) Apply a coating of anti-seize compound to t he
t hreads of t he injector holddown nut and between t he
top of t he nut and injector body.
C A U T I O N : Align the tab on the side the injector
with the notch in the cylinder head injector bore
(Fig. 32).
(3) Install injector.
(4) Tighten injector nut to 60 Nm (44 ft. lbs.)
torque.
(5) Position O-ring into groove on injector.
(6) Connect fuel drai n manifold. Refer to Fuel
Drai n Manifold in t hi s section.
(7) Connect hi gh pressure fuel lines. Refer to High
Pressure Fuel Lines in this section.
(8) Install t hrot t l e linkage.
Fig. 32 Injector Installation
(10) Bleed air from t he high pressure lines. Refer
to High Pressure Lines in t he Air Bleeding section.
REMOVAL
(1) Disconnect electrical connector from water-in-
fuel (WIF) sensor at t he bottom of t he separator filter
(Fig. 33).
C A U T I O N : When removing the fuel/water separator
filter, be sure that the fuel heater electrical connec-
tor is not turned against the engi ne. The connector
coul d be opened or damaged.
(2) Remove fuel/water separator filter. The fuel
heat er assembly should not move when removing or
installing t he fuel/water separator.
(3) Remove t he square cut O-ring from t he filter
connector at t he bottom of t he fuel heat er (Fig. 34).
(4) Drai n t he fuel/water separator filter. Remove
t he water-in-fuel sensor, O-ring and fuel/water drain
valve assembly from separator filter (Fig. 34).
14 116 FUEL SYSTEM
Fig. 34 WIF Sensor, Drain Valve Assembly
INSTALLATION
(1) Install new O-ring on WIF sensor.
(2) Install WIF sensor into new separator filter.
If t he new fuel/water separator filter is not filled
with clean fuel before it is installed, manual air
bleeding of t he fuel system may be necessary.
(3) Fill separator filter with clean fuel.
(4) Apply a light film of clean unused engine oil to
t he separator filter seal.
connector on t he bottom of t he fuel heater.
C A U T I O N : When installing the Fuel/Water separator
filter, be sure that the fuel heater electrical connec-
tor i s not turned agai nst the engi ne. The connector
coul d be damaged or opened.
one half t ur n after it makes contact.
(7) Connect electrical connector to WIF sensor.
All high pressure fuel lines are of t he same l engt h
and inside diameter. Correct high pressure fuel line
usage and installation is critical to smooth engine
operation.
C A U T I O N : The hi gh pressure fuel lines must be
cl amped securel y in pl ace in the hol ders. The lines
cannot contact each other or other component s. D o
not attempt to weld hi gh pressure fuel l i nes or to
repair lines that are damaged. Onl y use the recom-
mended lines when replacement of hi gh pressure
fuel line i s necessar y.
REMOVAL
(2) Remove t hrot t l e linkage.
(3) Remove injection pump bracket (Fig. 35).
Fig. 35 Injection Pump Bracket Typical
(4) Disconnect high pressure lines from fuel injec-
tors.
(5) Remove high pressure line holders mount i ng
screws.
C A U T I O N : Be sure that the hi gh pressure fuel lines
are installed in the same order that they were re-
moved. Prevent the injection pump delivery valve
hol ders from turning when removi ng or installing
hi gh pressure lines from injection pump (Fi g. 36).
Fig. 36 Injection Valve Holder
(6) Disconnect high pressure lines from fuel injec-
tion pump. Remove high pressure lines.
INSTALLATION
(1) Install high pressure fuel lines in t he correct
order and positioned in holders.
(2) Tighten high pressure fuel line connections.
(3) Tighten holder screws to 24 N-m (18 ft. lbs.)
torque.
(4) Install injection pump bracket. Tighten mount-
ing screws to 24 N*m (18 ft. lbs.) torque.

(5) Bleed air from the fuel system. Refer to High
Pressure Fuel Lines in the Air Bleeding portion of
this section.
INJECTION TIMING
If incorrect injection timing is suspected, injection
pump-to-engine timing or injection pump timing may
be the cause. Check injection pump timing before
checking injection pump-to-engine timing.
INJECTION PUMP TIMING
CAUTION; W hen setti ng inj ection pump ti mi ng, re-
fer to the engi ne identification plate attached to the
timing c ase fl ange for the correct speci fi cati on ( F i g.
37).
Fig. 37 Engine identification Plate
The engine can be rotated with a barring tool such
The engine has a timing pin (Fig. 38). The pin en-
gages a hole in the camshaft gear when cylinder No.
1 is at TDC on the compression stroke.
J9114-57
Fig. 38 Timing PinCylinder No. 1
CAUTI ON : Dur i ng engi ne assembl y by the manufac-
turer, the timing pi n i s posi t i oned to c or r espond
with the c ompr essi on stroke TD C posi t i on of cyl i n-
der number one. If the timing pi n or gear housi ng i s
r emoved, the ti mi ng pin l ocation will not be correct
when reinstal l ed.
cylinder number one by slowly rotating the engine
with the barring tool while lightly pushing in on the
timing pin. Stop when the timing pin engages the in-
dex hole in the camshaft gear.
(2) Once TDC has been located, pull the timing pin
out of the camshaft gear to the normal run position.
(3) Remove plug and copper washer from the rear
of the injection pump (Fig. 39).
PLUG J9114-63
Fig. 39 Timing Indicator Plug
Dial gauges and dial gauge holders used to check
injection pump timing are commercially available.
Snap-On dial gauge and gauge holder YA83300,
MTE (Cummins Tool Division) dial gauge 3377259
and dial gauge holder 2066 or an equivalent can be
used. Whichever dial gauge is used, note the range of
gauge and also what one revolution of needle travel
equals. On gauge shown in Fig. 40, one revolution of
the needle equals 0.50 MM.
It may be necessary to remove one or more high
pressure fuel line(s) from the pump to install the
gauge (Fig. 40). If a high pressure fuel line is re-
moved, the system must be bled of air after reinstall-
ing the fuel line. Refer to High Pressure Fuel Lines
in the Air Bleeding portion of the Diesel Fuel Injec-
tion section of Group 14, Fuel Systems.
(4) Install the gauge holder and gauge in the injec-
tion pump (Fig. 40). Be sure gauge travel is at least
2.0 MM.
The engine can be rotated with a barring tool such
(5) Insert barring tool into the flywheel housing
opening. The opening is located in the rear flange of

J9114-64
Fig. 40 Checking injection Pump Timing
t he engine, on t he exhaust manifold side (Fig. 4 1 ) .
Fig. 41 Rotating Engine with Barring Tool
( 6 ) Rotate t he engine in t he direction opposite en-
gine rotation unt i l t he needle on t he dial gauge stops
moving. Adjust t he face of t he gauge to read zero at
t he needle.
(7) Rotate t he engine (in normal direction) back to
TDC on t he No. 1 cylinder compression stroke.
CAUTI ON : The dial gauge needl e shoul d move
smoot hl y when the engi ne i s rotated. If the needl e
j umps or bounc es, repl ace the inj ection pump.
( 8 ) Taki ng note of dial gauge t ravel (number of
revolutions), rot at e t he engine in t he normal direc-
tion unt i l cylinder No. 1 is agai n at TDC on t he com-
pression stroke. Use t he t i mi ng pin to locate TDC.
The readi ng on t he dial gauge when t he t i mi ng pin
indicates TDC is t he amount of pl unger lift t he pump
has at t hat point. Refer to t he specification on t he
engine identification pl at e for t he correct amount of
lift. The injection pump is properly t i med when t he
correct amount of plunger lift is obtained at TDC
(TDC pin engages hole in camshaft gear). Set t i mi ng
to 1 . 2 5 MM lift.
( 9 ) If t he injection pump does not have t he correct
lift, rot at e t he injection pump on t he mount i ng studs
while noting t he readi ng on t he dial gauge. Rotate
t he pump to obtain t he correct amount of injection
pump plunger lift.
( 1 0 ) Tighten mount i ng stud nut s to 2 4 N*m ( 1 8 ft.
lbs.) torque.
( 1 1 ) Remove dial gauge and holder.
( 1 2 ) If removed, install hi gh pressure fuel lines.
( 1 3 ) Install plug tod washer into injection pump.
Tighten plug to 1 0 Nnn ( 7 ft. lbs.) torque.
( 1 4 ) If hi gh pressure fuel lines were removed,
bleed ai r from t he fuel system. Refer to High Pres-
sure Fuel Lines in t he Air Bleeding section.
INJECTION PVMP*>TO*ENGINE TIMING
( 1 ) Wi t h t he gear housing cover off, be sure t hat
t he crankshaft gear and camshaft gear are correctly
timed. Correct as necessary. Refer to Group 9 , En-
gines.
The engine can be rotated with a barri ng tool such
as Snap-On No. S P 3 7 1 , MTE N o . 3 3 7 7 4 6 2 (Cummins
The engine has a t i mi ng pin (Fig. 3 8 ) . The pin en-
gages a hole in t he camshaft gear when cylinder No.
1 is at TDC on t he compression stroke.
CAUTI ON ; Dur i ng engi ne assembl y by the manufac-
turer, the ti mi ng pi n i s posi t i oned to c or r espond
with the c ompr essi on st roke TD C posi ti on of cyl i n-
der number one. If the ti mi ng pi n or gear housi ng i s
r emoved, the ti mi ng pi n l ocation will not be correct
when reinstal l ed.
( 2 ) Locate TDC position (compression stroke) for
No. 1 cylinder by slowly rot at i ng t he engine wi t h t he
in t he camshaft gear.
( 3 ) Once TDC has been located, pull t he t i mi ng pin
out of t he camshaft gear to t he normal r un position.
( 4 ) With t he gear housing cover off, inspect t he
al i gnment of t he t i mi ng mar ks on t he camshaft gear
and injection pump gear. The letter E on t he injec-
tion pump gear should be aligned wi t h t he mar k on
t he camshaft gear (Fig. 4 2 ) .
( 5 ) If necessary check and adjust injection pump
timing. Refer to Injection Pump Timing.
KSB SOLENOID
REMOVAL
The KSB Solenoid is not serviceable. It must be re-
placed as a complete unit.

Fig. 42 Injection Pump-to-Engine Timing
(1) Disconnect electrical connector from KSB sole-
noid (Fig. 4 3 ) .
(2) Remove KSB solenoid.
Ai r does not ha ve t o be Med from t he fuel in-
j ect i on p u mp a n d fuel s ys t em aft er r e pl a c i ng t he
KSB sol enoi d.
Fig. 43 KSB SolenoidRemoval/installation
INSTALLATION
(1) Install t he KSB solenoid in t he injection pump.
Ti ght en t he solenoid to 43 N*m (32 ft. lbs) torque.
(2) Connect harness connector to KSB solenoid.
The lift pump is attached to t he drivers side of t he
engine block towards t he rear of t he engine (Fig. 44).
REMOVAL
(2) Disconnect low pressure fuel lines from pump
(Fig. 44).
(3) Remove lift pump mount i ng screws.
(4) Clean mat i ng surfaces on lift pump and engine
block.
Fig. 44 Lift Pump Removal/Installation
INSTALLATION
(1) Install lift pump wi t h new gasket. Tighten
mount i ng screws to 24 N
#
(2) Install low pressure fuel lines.
(3) Manually bleed t he system of air. Refer to
Manual Bleeding in t hi s section.
The TPS is used on vehicles equipped wi t h an au-
tomatic transmission only. The TPS is adjustable and
mus t be adjusted after installation.
REMOVAL
(1) Remove t he electrical connector from t he TPS
(Fig. 45).
Fig. 45 Throttle Position Sensor
(2) Remove the two TPS mount i ng screws. Do not
remove t he TPS mount i ng bracket screws from t he
injection pump. Lift t he TPS st rai ght up for removal.
(3) If t he nylon adapter (Fig. 46) has remained on
t he TPS mounting bracket after removal of TPS, it
must also be removed. To remove adapter, slightly
14- 12 0 FUEL SYSTEM

move t he t hrot t l e lever (by hand) from t he idle posi-
tion and lift adapt er for removal.
Fig. 46 Nylon AdaptorTPS to Injector Pump
INSTALLATION
The bottom of t he nylon adapter (on t he TPS) has a
hex head. The hex head on t hi s adapt er fits into a
hex opening in t he injection pump t hrot t l e shaft (Fig.
47).
(1) Install t he nylon adapt er to t he TPS mount i ng
bracket. The t ang on t he nylon adapter (Fig. 48)
should be wi t hi n t he notch area on t he TPS mount-
ing bracket (Fig. 48). If adapter will not drop into
hex opening on injector pump, open t he t hrot t l e
slightly. This will cause t he t hrot t l e shaft to rot at e
and allow t he adapter to be positioned.
CAUTI ON: Do not allow the tang on the nylon
adapter to be outside of notch area on T PS mount-
ing bracket (Fig. 48). Damage to adapter and im-
proper T PS operation will occur.
Fig. 47 Throttle Position Sensor Installation
The hex drive on t he TPS nylon adapt er should be
flush wi t h t he top of t he t hrot t l e lever hex opening
or j ust above it.
TPS MO U N T I N G
BRACKET
T ANG NYLON ADAPTOR
Fig. 48 Positioning Nylon Adapter
(2) Position t he TPS to nylon adapter. Refer to t he
previous CAUTION.
(3) The TPS is spring loaded. After positioning t he
TPS on t he adapter, be certain to rot at e t he TPS in a
clockwise direction to allow installation of its two
mount i ng screws.
(4) Install and t i ght en both TPS mount i ng screws.
If t he TPS bracket mount i ng screws were removed,
t i ght en t hem to 7 Nm (60 in. lbs.) torque.
(5) Connect t he electrical connector to t he TPS.
(6) Adjust t he TPS. Refer to t he following Adjust-
ment procedure.
ADJUSTMENT
CAUTI ON: Before adjusting the T PS , the throttle
linkage must be checked for correct adjustment.
The throttle lever must contact the low idle speed
screw. The throttle lever must reach breakover
when the throttle is wide open. Refer to the Accel-
erator Pedal and Throttle Cable section of Group
14, Fuel Systems.
A digital voltmeter (Fig. 49) or t he DRB II scan
tool is needed to adjust t he t hrot t l e position sensor.
(1) Tur n t he ignition key to t he On position.
(2) Connect t he negative probe of t he voltmeter to
a good ground source such as t he negative post of t he
battery.
(3) Probe t he t hrot t l e position sensor output wire
at t he TPS electrical connector. The center wire on
t he connector is t he output circuit.

Fig. 49 Throttle Position Sensor (TPS) Testing
(4) Wi t h t he fuel injection pump t hrot t l e lever con-
tacting t he low idle speed screw (Fig. 50), TPS output
should be 1 volt or slightly above. If not, t he TPS
must be adjusted.
(5) The TPS nylon adapter (Fig. 51) is machined to
accept a 10 MM open end wrench. To adjust, gently
rotate t he nylon adapter with a 10 MM open end
wrench to unt i l correct voltage is obtained.
J9114-261
Fig. 50 Throttle Lever Contacting Low Idle Speed
Screw
(6 ) Open throttle to t he wide open position. The
spring load breakover lever should have moved off
t he stop and rest against t he breakover spring (Fig.
52). If not, t he throttle actuation rod must be ad-
justed before adjusting TPS. Refer to Accelerator
Pedal and Throttle Cable section of Group 14, Fuel
Systems.
(7) With throttle held in wide open position, check
TPS output voltage. It should be 2.25 to 2.75 volts
higher t han t he output voltage is at closed t hrot t l e
position. If not, gently rot at e nylon adapt er to obtain
correct voltage.
Fig. 51 Adjusting Throttle Position Sensor
Fig. 52 Correct Breakover Spring Position
WATER-IN-FUEL SENSOR
REMOVAL
(1) Remove fuel/water separator filter. Refer to Fu-
el/Water Separator Filter Removal.
(2) Remove t he square cut O-ring from t he filter
connector at t he bottom of t he fuel heat er (Fig. 53).
(3) Drain t he fuel/water separator filter. Remove
t he water-in-fuel sensor, O-ring and fuel/water drain
valve assembly from separator filter (Fig. 53).
INSTALLATION
surface of WIF sensor.
(2) Install WIF sensor into new fuel/water separa-
tor filter.
(3) Fill separator filter wi t h clean fresh fuel.
surface of separator filter.
connector on the bottom of t he fuel heater.

one half turn after it makes contact.
(7) Connect electrical connector to WIF sensor and
fuel heater.
GENERAL INFORMATION
The low idle speed adjustment is the only adjust-
ment that can be made to the injection pump. The
fuel solenoid is the only component that can be ser-
viced on the injection pump. Refer to Service Proce-
dures section for fuel solenoid service. All other
injection pump servi ce must be performed by
authori zed personnel .
LOW IDLE SPEED
Use an optical tachometer such as Snap-on No.
MT139 or MTE (Cummins tool division) No. 3377462
to read engine rpm.
(1) If necessary, adjust low idle speed at the low
idle speed screw (Fig. 54). If the vehicle has an auto-
matic transmission, with the air conditioning on, set
low idle speed to 700 rpm. If the vehicle has a man-
ual transmission, with the air conditioning on, set
low idle speed to 750 rpm.
(2) Loosen idle screw lock nut using Cummins tool
number 3823750 or an equivalent. Adjust idle screw
Fig. 54 Adjusting Low Idle Speed
to obtain specified rpm. Refer to the Specification
section at the end of this group for idle speeds.
S E R V I C E A D J U S T M E N T S D I E S E L

GENERAL INFORMATION
latest information available at t he t i me of publica-
tion. If a nyt hi ng di ffers be t we e n t he speci fi ca-
t i ons f ound on t he Vehi cl e Emi ssi on Cont r ol
I nf or mat i on (VECI) l abel a n d t he fol l owi ng spec-
i fi cat i ons, us e speci f i cat i ons on VECI l abel .
FUEL TANK CAPACITIES
T A N K : LI TERS GALLONS
Standard 83.0 22
Optional 114 30
Ramcharger 120.9 34
Nominal refill capacities are shown. A variation may be observed
from vehicle to vehicle due to manufacturing tolerances and refill
procedures.
FUEL SOLENOID-5.9L DIESEL
J9014-182
Current Draw
2 Amps
Minimum Voltage
10 Volts
Operating Voltage
12 Volts
Resistance 6.9-7.9 Ohms
J9114-214
ENGINE SPEED5.9L DIESEL
Full Throttle Stop Speed (No Load) 2925 RPM (Max)
Full Throttle Stop Speed (No Load) 2824 RPM (Min)
Low Idle Stop Speed (A/C OnAuto Trans) 700 RPM
Low Idle Stop Speed (A/C OnMan Trans) 750 RPM
J9114-215
FUEL SYSTEM5*9L DIESEL
Fuel Pressure Drop Across Filter 21 kPa (3 psi) Max
Fuel Return Line Restrictions 20.4 in. Hg. Max
Injector Operating Pressure (Pop Off Pressure) 3550 psi
Mechanical Lift Pump Inlet Restriction 3.75 in. Hg. Max
Mechanical Lift Pump Output (Flow) 0.75 L (0.70 qt) per 30 seconds Max
Mechanical Lift Pump Output (Pressure) 21-35 kPa (3-5 psi)
J91 1 4 - 21 6
14- 12 4 FUEL SYSTEM
TORQUE-EXCEPT DIESEL
Accelerator Pedal Bracket
Mounting Nuts . 7 N m (55 in. lbs.)
Coolant Temperature Sensor . . 11 N m (8 ft. lbs.)
Crankshaft Position Sensor
Mounting Bolts . 8 N m (70 in. lbs.)
Fuel Filter Mounting Bolts . . . . 8 N- m (75 in. lbs.)
Fuel Hose (Tube) Clamps . . . . 1 N- m (10 in. lbs.)
IAC Motor-To-Throttle Body . . . 7 N- m (6 0 in. lbs.)
Intake Manifold Charge
(6 0 in. lbs.)
Air Temperature Sensor . . . . 28 N m (20 ft. lbs.)
MAP Sensor Mounting Screws. . 3 N m (25 in. lbs.)
Oxygen Sensor . 30 N m (22 ft. lbs.)
PCM 60-Way Connector
Mounting Screw . 4 N m (35 in. lbs.)
Throttle Body Mounting Bolts. . . 23 N m (200 in. lbs.)
Throttle Position Sensor
Mounting Bolts . . . . . . . . . . 7 N m (60 in. lbs.)
_ _ FUEL SYSTEM 14 - 125
C omponent N - m ft. l bs. / I n. l bs.
Air Fuel Control Tube 12 N-m 9 ft. lbs.
Fuel Line Clamp to Intake Manifold Mounting Screws 24 N-m 18 ft. lbs.
Fuel Line Fittings at InjectorHigh Pressure 24 N-m 18ft. lbs.
Fuel Line Fittings at Injection PumpHigh Pressure 24 N-m 18ft. lbs.
Fuel Solenoid 43 Nm 32 ft. lbs.
Injection Pump Mounting Nuts 24 N-m 18ft. lbs.
Injection Pump Lockscrew (Locked Position) 30 Nm 22 ft. lbs.
Injection Pump Lockscrew (Unlocked Position) 13 Nm 10ft. lbs.
Injection Pump Gear Retaining Nut 65 Nm 48 ft. lbs.
* Injection Pump Support Bracket 24 Nm 18 ft. lbs.
Injection Pump Timing Plug 10Nm 7.5 ft. lbs.
Injector Drain Screw 8 N-m 6 ft. lbs.
Injector Retainer Nut 60 Nm 44 ft. lbs.
Low Pressure Bleed Screw on Filter Head 8 Nm 6 ft. lbs.
Mechanical Lift Pump Mounting Screws 24 Nm 18ft. lbs.
Throttle Linkage Rod Lock Nuts 9 N-m 7 ft. lbs.
Throttle Control Bracket Mounting Screws 24 Nm 18 ft. lbs.
Throttle Rod to Throttle Rod Ball Stud Nut 10 Nm 7.5 ft. lbs.
* Mounting bolts must be tightened in specified sequence. J9114-205
TORQUE5.9L DIESEL
PROPELLER SHAFTS 1 6- 1
P R O P E L L E R S H A F T S
C O N T E N T S
page
GENERAL INFORMATION 1 TORQUE SPECIFICATIONS
PROPELLER SHAFT REPLACEMENT 8 UNIVERSAL JOINT REPLACEMENT
SERVICE DIAGNOSIS/PROCEDURES 3
page
15
10
PROPELLER SHAFTS
The basic function of a propeller shaft is to t rans-
mit power from one point to another. The shaft is de-
signed to send torque t hrough an angle from t he
transmission (transfer case on 4WD vehicles) to t he
axle (Fig. 1).
The propeller shaft must operate through con-
st ant l y changing relative angles between t he t rans-
mission and axle. It also must be capable of changing
length while t ransmi t t i ng torque. The axle rides sus-
pended by springs in a floating motion. This means
t he propeller shaft must contract, expand and change
operating angles. This is accomplished t hrough uni -
versal joints. The U-joints permit t he propeller shaft
to operate at different angles. The slip joints (or
yokes) permi t contraction or expansion.
Tubul ar propeller shafts are balanced by t he man-
ufacturer wi t h weights spot welded to t he tube.
The propeller shaft is designed and built with t he
yoke lugs in line with each other. This is called phas-
ing. This design produces t he smoothest runni ng con-
dition. An out of phase shaft can cause a vibration.
Before undercoati ng a vehicle, the propeller
shaft and the U-joints shoul d be covered. This
SLI P YOKE BOOT
FRONT
PROPELLER
SHAFT
REAR
PROPELLER SHAFT
Fig. 1 Front and Rear Propeller Shafts (4 WD)
J9216-23
1 6- 2 PROPELLER SHAFTS

will prevent the undercoati ng from causi ng an
unbal anced condi ti on and vibration.
CAUTION: Use ex act replacement hardware for at-
tachi ng the propeller shaf t s. E xact replacement will
ensure safe operation. The specified torque must
al ways be applied when tightening the fasteners.
UNIVERSAL JOINTS
The front prop shaft uses t he 7260 series universal
joint. The r ear prop shaft uses t he 7290 series uni-
versal joint on all but t he Dana 70 axle. The 1410 se-
ries is used with t he Dana 70 axle.
Two different types of universal joints systems are
used:
Single cardan universal joint (Fig. 2)
Double cardan universal joint (Fig. 3)
LUBRICATION
The slip yoke on t he front shaft is equipped with a
zerk type lubrication fitting. Use a multi-purpose
NLGI Grade 2 EP lubricant. Refer to Group 0, Lubri-
cation and Maintenance for additional information.
The factory installed U-joints are lubricated for t he
life of t he vehicle and do not need re-lubrication. All
RETAINER J9216-20
Fig. 2 Single Cardan Universal Joint (Typical)
U-joints should be inspected for leakage and damage
each t i me t he vehicle is serviced. If seal leakage or
damage exists, t he U-joint should be replaced.
1. LINK YOKE
2. SOCKET SPRI NG
3. SOCKET BALL RETAINER
4. THRUST WASHER
5. NEEDLE BEARI NGS
6. SEAL
7. BEARI NG CAP
8. REAR SPIDER
9. SOCKET YOKE
10. SOCKET BALL
11. FRONT SPIDER
12. NEEDLE BEARI NGS
13. THRUST WASHER
14. DRIVE SHAFT YOKE
15. RETAI NI NG CLIP
Fig. 3 Double Cardan (CV) Universal Joint

PROPELLER SHAFTS 16 - 3
S E R V I C E DI AGNOSI S/ PROCEDURES
INDEX
page page
Precautions . 3 Universal Joint Angl e Measurement . . . . . . . . . . . . 4
Runout 4 Vibration 3
Unbalance 3
PRECAUTIONS
Propeller shafts are balanced by t he manufacturer
to prevent vibration. Before undercoating a vehicle,
t he propeller shaft and the U-joints should be cov-
ered. This will prevent t he undercoating from caus-
ing an unbalanced condition and vibration.
Use exact replacement hardware for at t achi ng t he
propeller shafts. Exact replacement will ensure safe
operation. The specified torque must always be ap-
plied when t i ght eni ng t he fasteners.
VIBRATION
Tires t hat are out-of-round or wheels t hat are un-
balanced will cause a low frequency vibration. Refer
to Group 22, Tires And Wheels for service informa-
tion.
Brake drums t hat are unbalanced will cause harsh,
low frequency vibration. Refer to Group 5, Brakes for
service information.
Driveline vibration can also result from loose or
damaged engine mount s. Refer to Group 21, Trans-
missions for additional information.
Propeller shaft vibration will increase as t he vehi-
cle speed is increased. A vibration t hat occurs within
a specific speed range is not caused by propeller
shaft unbalance. Defective U-joints or an incorrect
propeller shaft angle are usually t he cause.
UNBALANCE
If propeller shaft unbalance is suspected, it can be
verified wi t h the following procedure.
Removi ng and re-indexing the propeller shaft
180 may eliminate some vibrations.
(2) Clean all foreign mat eri al from propeller shaft
and U-joints.
(3) Inspect propeller shaft for missing balance
weights, broken welds, and bent areas. If the pro-
peller shaft is bent, it must be repl aced.
(4) Ensure t he U-joints are not worn and are prop-
erly installed.
(5) Check t he U-joint clamp screws torque.
(6) Remove wheels and tires. Install wheel lug
nut s to ret ai n brake drums in place.
(7) Mark and number t he shaft at four positions
90 apart , six inches from t he yoke weld end.
DRIVELINE VIBRATION
D r i ve C ondi t i on Possi bl e C a u s e C or r ect i on
PROPiLLlR S HA F T a. Undercoating or other foreign material
on shaft.
b. Loose U-joint clamp screws.
c. Loose or bent U-joint yoke or excessive
runout.
d. Incorrect drive line angularity.
e. Rear spring center bolt not in seat.
f. Worn U-joint bearings.
g. Propeller shaft damaged (bent tube) or
out of balance.
h. Broken rear spring.
i. Excessive runout or unbalanced
condition.
j . Excessive drive pinion gear shaft yoke
runout.
a. Clean exterior of shaft and wash with
solvent.
b. Tighten screws properly.
c. Install replacement yoke.
d. Correct angularity
e. Loosen spring U-bolts and seat center
bolts.
f. Replace U-joint.
g. Install replacement propeller shaft.
h. Replace rear spring.
i. Reindex propeller shaft 180, test and
correct as necessary.
j . Reindex propeller shaft 180 and
evaluate.
UNIVERSAL J O I N T NOISE a. U-joint clamp screws loose.
b. Lack of lubrication.
a. Tighten screws with specified torque.
b. Replace U-joint.
J9216-7
1 6 - 4 PROPELLER SHAFTS

(8) Run and accelerate t he vehicle unt i l vibration
occurs. Note t he intensity and speed t he vibration oc-
curred. Stop t he engine.
(9) Install a screw clamp at posi t i on I (Fig. 1).
Fig. 1 Clamp Screw At Position 1
(10) St art t he engine and re-check for vibration. If
t here is little or no change in vibration, move t he
clamp to one of t he other t hree positions. Repeat t he
vibration test.
(11) If t here is no difference, t he vibration may not
be caused by propeller shaft unbalance.
(12) If t he vibration decreased, install a second
clamp (Fig. 2) and repeat t he vibration test.
Fig. 2 Two Clamp Screws At The Same Position
(13) If vibration increased, separat e t he clamp
screws (1/4 inch above and 1/4 inch below t he mark).
Repeat t he vibration t est (Fig. 3).
(14) Increase distance between t he clamp screws.
Repeat t he t est unt i l t he amount of vibration is at
t he lowest level. Bend t he slack end of t he clamps so
t he screws will not loosen.
(15) Install t he wheel and t i re. Remove supports
and lower t he vehicle.
RF4B9
Fig. 3 Clamp Screws Separated
(16) If t he amount of vibration remai ns unaccept-
able, apply procedures at t he front end of propeller
shaft.
RUNOUT
(1) Remove dirt, rust, paint, and undercoating
from t he propeller shaft surface. Areas where t he
dial indicator will contact t he shaft must be clean.
(2) The dial indicator must be installed perpendic-
ul ar to t he shaft surface.
(3) Measure runout at t he center and ends.
(4) Refer to Runout Specifications chart.
(5) Replace t he propeller shaft if t he runout ex-
ceeds t he limit.
RUNOUT SPECIFICATIONS
Front of shaft 0.010 in. (0.25 mm)
Center of shaft . 0.015 in. (0.38 mm)
Rear of shaft . 0. 010 in. (0.25 mm)
NOTE: Measure front/rear runout approximately 3 inches
(76 mm) from the weld seam at each end of the shaft tube
for tube lengths over 30 inches. Under 30 inches the max.
runout is 0.20 inch for full length of the tube.
J9116-15
UNIVERSAL JOINT ANGLE MEASUREMENT
INFORMATION
When two shafts intersect, t he bend t hat is formed
is called t he working angle. The larger t he angle, t he
larger t he amount of acceleration and deceleration of
t he joint. This speeding up and slowing down of t he
joint must be cancelled. This will produce a smooth
power flow. This is done t hrough phasing and proper
universal joint working angles.

PROPELLER SHAFTS 1 6- 5
A propeller shaft is properly phased when t he yoke
ends are on t he same plane or in line. A twisted
shaft will throw t he yokes out of phase and cause a
noticeable vibration.
When t aki ng universal joint angle measurement s
or checking phasing with two piece shafts, consider
each shaft separately. On 4WD vehicles, t he front
shaft input (pinion shaft) angle has priority over t he
caster angle.
Ideally t he driveline system should have:
Angl es that are in equal or opposi te wi thi n 1
degree of each other
Have a 3 degree maxi mum operati ng angl e
Have at l east a 1/2 degree conti nuous operat-
i ng (propeller shaft) angle
Engine speed (R.P.M.) is t he mai n factor t hough in
determining maxi mum allowable operating angles.
As a guide to maxi mum normal operating angles re-
fer to t he chart listed (Fig. 4).
PR OPE L L E R S HAFT M A X * NORMAL
RP*JVi*
OPERATI NG ANGLES
5000 3
4500 3
4000 4
3500 5
3000 5
2500 7
2000 8
1500 11
J9316-4
Fig. 4 Maximum Angles and R.P.M.
INSPECTION
Before measuri ng universal joint angl es, the
fol l owi ng must done.
Inflate all tires to correct pressure.
Check angl es in the same l oaded or unl oaded
condi ti on as when the vibration occurred. Prop
shaft angl es will change accordi ng to the
amount of l oad i n the vehicle. Al ways check an-
gl es in l oaded and unl oaded conditions.
Check t he condition of all suspension components
and verify all fasteners are torqued to specifications.
Check t he condition of t he engine and t ransmi s-
sion mount s and verify all fasteners are torqued to
specifications.
MEASUREMENT
To accurately check driveline alignment, raise and
support t he vehicle at t he axles as level as possible.
Allow t he wheels and propeller shaft to t urn. Remove
any ext ernal beari ng snap rings (if equipped) from
uni versal joint so protractor base sits flat.
(1) Rotate t he shaft until transmission/transfer
case output yoke beari ng is facing downward.
Al ways make measurements from front to
rear.
(2) Place Inclinometer on yoke beari ng (A) parallel
to t he shaft (Fig. 5). Center bubble in sight glass and
record measurement .
This measurement will gi ve you the transmis-
si on or OUTPUT YOKE ANGLE (A).
Fig. 5 Front (Output) Angle Measurement (A)
(3) Rotate propeller shaft 90 degrees. Place Incli-
nometer on yoke bearing parallel to t he shaft (Fig.
6). Center bubble in sight glass and record measure-
ment. This measurement can also be t aken at t he
rear end of t he shaft.
This measurement will gi ve you the PROPEL-
LER SHAFT ANGLE (C).
J9216-9
Fig. 6 Propeller Shaft Angle Measurement (C)
16 - 6 PROPELLER SHAFTS

(4) Subtract smaller figure from larger ( C mi nus
A) to obtain transmission OUTPUT OPERATING
ANGLE.
(5) Rotate propeller shaft 90 degrees and place In-
clinometer on pinion yoke beari ng parallel to t he
shaft (Fig. 7). Center bubble in sight glass and record
measurement.
Thi s me a s ur e me nt will gi ve you t he pi ni on
shaft or I NPUT YOKE ANGLE (B).
(6) Subtract smaller figure from larger (C mi nus
B) to obtain axle INPUT OPERATING ANGLE.
Refer to rules given below and t he example in (Fig.
8) for additional information.
Good cancellation of u-joint operating angles (with-
in 1)
Operating angles less t han 3
At least 1/2 of one degree continuous operating
(propeller shaft) angle
7663
( J- 234 98A) J921 6 - 1 2
Fig. 7 Rear (input) Angle Measurement (B)
Horizontal Level
(A) Output Yoke = 3.0 4.9 (B) Axle Input Yoke = 3.2
Q r
4.9
(C) Prop. Shaft = 4.9
r
-3. 0 (C) Prop. Shaft = 4.9 -3.2
Transmission Output 1.9 Axle Input 1.7
Operating Angle Operating Angle
Trans. Output Operating Angle 1.9
Axle Input Operating Angle -1.7
Amount of U-Joint Cancellation 0.2
Fig. 8 Universal Joint Angle Example
J9316-3

ADJUSTMENT AT AXLE WITH LEAF SPRINGS
Adjust t he pinion shaft angle at t he springs with
tapered shims (Fig. 9). Install t apered shims between
the springs and axle pad to correct t he angle. Refer
to Group 3, Rear Suspension and Axle for additional
information.
Fig. 9 Angle Adjustment at Leaf Springs
ADJUSTMENT AT CENTER BEARING WITH
TWO-PIECE SHAFT
Drive away shudder is t he vibration t hat occurs at
first acceleration from a stop. Shudder vibration usu-
ally peaks at t he engines highest t orque output.
Shudder is a symptom associated on vehicles using a
two-piece prop shaft. Shudder can be decreased by
lowering t he center beari ng in 1/4 inch increments
with shim stock or fabricated plates (Fig. 10). Pl at e
stock must be used to mai nt ai n compression of t he
rubber insulator around t he bearing. Do not use
washers. Replace t he original bolts with t he appro-
priate increased l engt h bolts.
J9316-25
Fig. 10 Angle Adjustment at Center Bearing
1 6- 8 PROPELLER SHAFTS

P R O P E L L E R S H A F T R E P L A C E M E N T
PRECAUTIONS
Use exact replacement hardware for at t achi ng t he
propeller shafts. Exact replacement will ensure safe
operation. The specified torque must always be ap-
plied when t i ght eni ng t he fasteners.
Mark t he propeller shaft yoke and axle or t rans-
mission yoke before service (Fig. 1). This will assure
correct phasing and eliminate possible vibration.
REFERENCE MA R K S
J9316-2
Fig. 1 Reference Marks on Yokes
C A U T I O N : D o not allow the propeller shaft to drop
or hang from either universal joint duri ng removal .
Attach it to the vehicle undersi de with wire to pre-
vent damage to the universal joints.
C A U T I O N : Protect the machi ned, external surface of
the sl i p yoke from damage after propeller shaft re-
moval . If damaged, the t r ansmi ssi on extensi on seal
coul d be damaged.
FRONT
REMOVAL
(1) Shift t he t ransmi ssi on and transfer case (if ap-
plicable) to t hei r Neut ral positions. Raise t he vehicle.
Remove skid plates (if equipped) from frame, refer to
Group 13, Frames.
(2) Scribe al i gnment mar ks on t he yokes at t he
transfer case. Place mar ks at t he pinion shaft and at
each end of t he propeller shaft. These mar ks will be
used for installation reference (Fig. 2).
(3) Remove t he U-joint st rap bolts at t he pinion
shaft yoke.
(4) Remove bolts from transfer case yoke and re-
move t he propeller shaft.
TRANSFER
Fig. 2 Front Propeller Shaft
INSTALLATION
(1) Position t he propeller shaft with t he yoke ref-
erence mar ks aligned. Install t he propeller shaft
(Fig. 2) .
Repl acement U-joint straps and bolts must be
installed.
(2) Tighten t he U-joint st rap bolts at t he pinion
shaft to;
Gasoline engines to 19 N*m (14 ft. lbs.) torque.
Diesel engines to 29 N*rri (21 ft. lbs.) torque.
Tighten t he transfer case bolts to 88 Nnn (65 ft.
lbs.) torque.
(3) Install skid plates (if equipped), refer to Group
13, Frames. Lower t he vehicle.
REAR
REMOVAL
(1) Shift t he transmission and transfer case (if ap-
(2) Scribe al i gnment mar ks at t he pinion yoke and
at each end of t he propeller shaft.
(3) Remove t he U-joint strap bolts at t he pinion
shaft yoke (and transfer case).
(4) Slide t he slip yoke off of t he transmission/
transfer case output shaft and remove t he propeller
shaft (Fig. 3).

PROPELLER SHAFTS 1 6 - 9
SLI DI NG
SCRE W
19 N-m
(14 ft-lbs). CLAMP J9216-6
Fig. 3 Rear Propeller Shaft
INSTALLATION
(1) Slide t he slip yoke on t he transmission/transfer
case output shaft. Align t he installation reference
marks at t he axle yoke and install t he propeller
shaft (Fig. 3).
Repl acement U-j oi nt s t r a ps a n d bol t s mus t be
i nst al l ed.
(2) Tighten t he U-joint st rap bolts to 19 Nnn (14 ft.
lbs.) torque.
RE AR- TW O PIECE
REMOVAL
(1) Shift t he transmission and transfer case (if ap-
(2) Scribe alignment mar ks at t he pinion yoke and
at each end of t he propeller shaft.
(3) Remove t he universal joint st rap bolts at t he
pinion shaft yoke.
(4) Scribe al i gnment mar ks at t he frame cross-
member for reference. Remove t he bolts t hat at t ach
t he center beari ng to t he support bracket (Fig. 4).
Fig. 4 Center Bearing Support
(5) Slide t he slip yoke off of t he transmission/
transfer case output shaft and remove t he propeller
shaft.
INSTALLATION
(1) Slide t he slip yoke on t he transmission/transfer
case out put shaft. Align t he installation reference
mar ks at t he axle yoke. Install the propeller shaft.
(2) Align and install t he center bearing to t he sup-
port bracket. Install t he bolts and t i ght en to 68 Nnn
Re pl a c e me nt U-joint s t r a ps a nd bol t s mus t be
i nst al l ed.
(3) Tighten t he U-joint st rap bolts to;
Gasoline engine to 19 Nnn (14 ft. lbs.) torque.
Diesel engine to 34 Nnn (25 ft. lbs.) torque.
1 6 - 1 0 PROPELLER SHAFTS

UNIVERSAL JOINT REPLACEMENT
PRECAUTIONS
It is very i mport ant to put reference mar ks on t he
yokes before removal or component service (Fig. 1).
This will ensure correct phasing.
REFERENCE MAR KS
J9316-2
Fig. 1 Reference Marks on Yokes
SINGLE CARDAN
REMO VAL/DISASSEMBL Y
Single cardan universal joints are not serviceable.
If worn or leaking, they must be replaced as a unit.
(1) Remove t he propeller shaft. Refer to Propeller
Shaft Replacement in this group.
(2) Pai nt or score al i gnment marks on the
yokes and propeller shaft for installation refer-
ence.
(3) Using a soft drift, t ap t he outside of t he bear-
ing assembly to loosen snap ring.
(4) Remove snap rings from both sides of yoke
(Fig. 2).
(5) Set the yoke in an arbor press or vise with a large
socket beneath it. Position the yoke with the lube fit-
ting pointing up (if equipped). Place a smaller socket on
the upper bearing assembly and press it through to re-
lease the lower bearing assembly (Fig. 3).
J9316-19
Fig. 2 Remove Snap Ring
J9316-2V
Fig. 3 Press Out Bearing
(6) If the bearing assembly will not pull out by hand
after pressing, tap the base of the lug near it to dis-
lodge.
(7) To remove t he opposite bearing, t ur n t he yoke
over and st rai ght en t he cross in t he open hole. Then
carefully press t he end of t he cross until t he remai n-
ing bearing can be removed (Fig. 4).
CAUTI ON : If the c r os s or bearing assembl y are
cocked when bei ng pr essed, the bearing assembl y
will scor e the wal l s of the yoke bore and ruin the
yoke.
(1) Clean all t he universal joint yoke bores wi t h
cleaning solvent and a wire brush.
(2) Inspect t he yokes for distortion, cracks and
worn beari ng assembly bores.
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to aid in installation.
(2) Position t he cross in t he yoke with its lube fit-
t i ng (if equipped) pointing up (Fig. 5).
(3) Place a beari ng assembly over t he t runni on
and align it with t he cross hole (Fig. 6). Keep t he

BEARING
J9316-24
Fig. 4 Press Out Remaining Bearing
CROSS
J931 6 - 22
Fig. 5 Install Cross In Yoke
needle bearings upright in the bearing assembly. A
needle roller lying at the bottom will prevent proper
assembly.
(4) Press the bearing assembly into the cross hole
enough to install a snap ring. Install a snap ring.
(5) Repeat steps 3 and 4 to install the opposite
bearing assembly. If the joint is stiff, strike the yoke
with a soft hammer to seat tjie needle bearings. In-
stall a snap ring.
(6) Add grease to lube fitting (if equipped).
(7) Install the propeller shaft. Refer to Propeller
DOUBLE CARDAN (CV)
REMOVAL/DISASSEMBL Y
Single cardan universal joints are not serviceable.
If worn or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller
(2) Pai nt or score al i gnment marks on the
yokes and propeller shaft for installation refer-
ence.
(3) Remove all the bearing assembly snap rings
(Fig. 7).
J931 6 - 5
Fig. 7 Remove Snap Rings
16 - 12 PROPELLER SHAFTS

(4) Press t he bearing assembly partially from t he
outboard side of t he center yoke, enough to grasp by
vise j aws (Fig. 8) . Be sure to remove any lube fittings
t hat may interfere with removal.
f ^
J9316-6
Fig. 8 Press Out Bearing
(5) Grasp t he protruding beari ng by vise j aws. Tap
t he t ube yoke with a mallet and drift to dislodge
from t he yoke (Fig. 9).
J9316-7
Fig. 9 Remove Bearing From Yoke
(6) Flip assembly and repeat steps 4 and 5 for re-
moving t he opposite side bearing. This will t hen al-
low removal of t he cross centering ki t assembly and
spring (Fig. 10).
J9316-8
Fig. 10 Remove Centering Kit
(7) Press t he remai ni ng beari ng assemblies out t he
other cross as described above to complete t he disas-
sembly.
(1) Clean all t he U-joint yoke bores wi t h cleaning
solvent and a wire brush.
(2) Inspect t he yokes for distortion, cracks and
worn beari ng assembly bores.
ASSEMBLY/INSTALLATION
Duri ng installation, ensure that the spi ders
and yokes are al i gned to the reference marks.
(1) Fi t a cross into t he t ube yoke (Fig. 11).
J9316-9
Fig. 11 Install Cross In Yoke

(2) Place a beari ng assembly in a t ube yoke hole
and over a t runni on. Keep the needle beari ngs up-
ri ght in t he bearing assembly (Fig. 12). A needle
roller lying at t he bottom will prevent proper assem-
bly. Be sure to remove any lube fittings t hat may in-
terfere with removal.
Fig. 12 Install Bearing Assembly
(3) Press t he beari ng assembly in place and install
a snap ri ng (Fig. 13).
Fig. 13 Press in Bearing Assembly
(4) Flip t he t ube yoke and beari ng assembly instal-
lation on t he opposite t runni on. Inst al l a snap r i ng
(Fig. 14).
J9316-12
Fig. 14 Press In Bearing Assembly
(5) Fi t t he center yoke on t he remai ni ng two t r un-
nions and press beari ng assemblies in place, both
sides (Fig. 15). Install a snap ring.
J9316-13
Fig. 15 Install Center Yoke
16- 14 PROPELLER SHAFTS
(6) Install t he centering ki t assembly inside t he
center yoke maki ng sure t he spring is in place (Fig.
16). Align t he lube fitting on t he centering ki t with
t he lube fitting on t he installed cross.
J9316-14
Fig. 16 Instail Centering Kit
(7) Place two beari ng assemblies on t he remai ni ng
cross (opposite sides). Fi t t he open t runni ons into t he
center yoke holes and t he beari ng assemblies into
t he centering ki t (Fig, 17). Align t he lube fitting on
t he cross wi t h t he other two lube fittings.
J9316-15
Fig. 17 Install Remaining Cross
(8) Press t he remai ni ng two beari ng assemblies
into place and install snap rings (Fig. 18).
I
1
J9316-16
Fig. 18 Press In Bearing Assembly
(9) Tap t he snap rings to allow t hem to set into t he
grooves (Fig. 19).
J9316-17
Fig. 19 Seat Snap Rings In Groove
(10) Check for proper assembly. Flex t he CV joint
beyond center, it should snap over-center in both di-
rections when correctly assembled (Fig. 20).
(11) Add grease to all t hree l ube fittings.
(12) Install t he propeller shaft. Refer to Propeller
J9316-18
Fig. 20 Check Assembly
PR O PE L L E R S HA F T S A N D U - J O I N T S
Center Bearing to Support
Bracket (Two Piece Shaft) 68 N-m (50 ft. lbs.)
Double Cardan to Transfer
Case Yoke Bolts 88 N-m (65 ft. lbs.)
Prop Shaft to Axle Yoke
Screws (Gas Engine) 19 N-m (14 ft. lbs.)
Prop Shaft to Axle Yoke
Screws (Diesel Engine) 29 N-m (21 ft. lbs.)
J9216-24

S T E E R I N G
STEERING 1 9 - 1
CONTENTS
page
POWER STEERING PUMP 11
POWER STEERING SYSTEM DIAGNOSIS . . . . . 2
RECIRCULATING BALL POWER STEERING GEAR . 20
page
STEERING COLUMN 3 i
STEERING LINKAGE 17
GENERAL INFORMATION
STEERING SYSTEM COMPONENTS
Dodge Tr ucks use a power assisted recirculating-
ball t ype s t eer i ng ge a r (Fig. 1). The ge a r i s used wi t h
four wheel dr i ve a nd t wo wheel drive vehi cl es.
Power s t eer i ng s ys t ems us e;
St eer i ng gear
Steering linkage
Pressure and ret urn fluid hoses and fittings
Belt driven hydraulic steering pump with fl ui d
reservoir
J921 9- 6 5
Fig. 1 Power Steering Systems
The steering linkage consists of a pi t man arm,
idler arm, tie rods, and center link. Adjustment
sleeves are used on t he tie rods for toe and steering
wheel alignment. For additional wheel alignment in-
formation refer to Group 2, Front Suspension.
RECIRCULA TING-BALL POWER STEERING
GEARS
The recirculating ball system acts as a rolling
t hread between t he worm shaft and rack piston. The
worm shaft is supported by a t hr ust bearing at t he
lower end and a beari ng assembly at t he upper end.
When t he worm shaft is t urned t he rack piston
moves. The rack piston t eet h mesh with t he pi t man
(sector) shaft. Turni ng t he worm shaft t ur ns t he pit-
man shaft, which t ur ns the steering linkage.
The steering gears can be adjusted and i nt ernal l y
serviced.
An identification code on the upper adjustment
cover designates t he ratio.
Code XS designates 13-16:1 ratio used in Dodge
Ram Truck vehicles
POWER STEERING PUMP
Hydraulic pressure is provided by a belt driven
power steering pump. The power steering pump is a
constant flow rat e and displacement, vane-type
pump. The i nt ernal part s t hat are inside t he housing
operate submerged in fluid. The flow control orifice is
part of t he pressure line union. The pressure relief
valve inside t he flow control valve limits t he pump
pressure.
The power steering pump is connected to t he steer-
ing gear via t he pressure hose and t he ret urn hose.
The pump shaft has a pressed-on pulley t hat is belt
driven by t he crankshaft pulley.
Trailer tow option vehicles are equipped with a
power steering pump oil cooler. The oil cooler is
mounted to t he engine block under t he steering
pump cast al umi num mount i ng bracket.
The power steering pump on t he DODGE TURBO
DI ESEL engine is bolted onto t he rear of t he vac-
uum pump. The pump is driven by t he accessory
drive t hrough a common shaft.
19 - 2 STEERING

Dodge Ra m T r u c k p o w e r s t e e r i n g p u m p s a r e
not i nt er changeabl e wi t h p u m p s i n s t a l l e d i n
ot her vehi cl es.
The Saginaw P-Series pump (Fig. 2) is used in
Dodge Ram Truck vehicles.
STEERING COLUMNS
Two general types of steering columns are installed
on Dodge Ram Truck vehicles: a fixed, non-tilt col-
umn and a tilt column.
The ignition key/lock cylinder and t he ignition
switch are located in t he steering column. When in
t he LOCK position, t he ignition switch and t he steer-
ing shaft cannot be operated. The lock mechanism
also prevents operation of t he automatic t rans, gear
shift mechanism.
The i nt ermedi at e shaft is attached to t he gear and
column shaft with universal joints.
POWER STEERING
PUMP PRESSURE TEST
The following procedure can be used to test t he op-
eration of t he power steering system on t he vehicle.
(1) Check belt tension and adjust as necessary.
(2) Disconnect high pressure hose at gear or pump.
Use a container for dripping fluid.
(3) Connect Gauge C-3309-E to both hoses using
adapt er fitting (Fig. 1). Connect spare pressure hose
to gear or pump.
SPECIAL
1 Pressure Hose to Steering Gear
2 Shut-Off Valve
3 Pressure Hose From Pump J92 19- 44
Fig. 1 Pressure Test Gauge
(4) Open t he t est valve completely.
(5) St art engine and let idle.
(6) Check fluid level, add fluid as necessary.
Fig. 2 Saginaw P-Series Pump
Both types of steering columns have anti-theft pro-
visions. They are energy-absorbing (collapse from im-
pact in t he event of a front-end collision).
S Y S T E M D I A G N O S I S
(7) Gauge should read below 862 kPa (125 psi), if
above, inspect t he hoses for restrictions and repair as
necessary. The initial pressure should be in t he
range of 345-552 kPa (50-80 psi).
C A U T I O N : The fol l owi ng test procedure i nvol ves
testing maximum pump pressure output and flow
control val ve operation. D o not leave val ve cl osed
for more than five seconds a s the pump coul d be
damaged.
(8) Close valve fully t hree times and record high-
est pressure indicated each time. All three readi ngs
must be above specifications and wi thi n 345 kPa
(50 psi) of each other.
9 Pressures above specifications but not within 345
kPa (50 psi) of each other, replace pump.
Pressures within 345 kPa (50 psi) of each other
but below specifications, replace pump.
C A U T I O N : D o not force the pump to operate agai nst
the st ops for more than 2 to 4 seconds at a time be-
cause, pump damage will result.
(9) Open t he test valve, t ur n steering wheel ex-
t reme left and ri ght positions against t he stops.
Record t he highest indicated pressure at each posi-
tion. Compare readings to specifications. If highest
output pressures are not t he same against either
stop, t he gear is leaking internally and must be re-
paired.
The steering pump relief pressure for all en-
gi nes is 1400 p.s.i. 50.

STEERING 19 - 3
PUMP LEAKAGE DIAGNOSIS
9119-1
19 - 4 STEERING
POWER STEERING SYSTEM DIAGNOSIS
P U M P NOISI
There is some noise in all power steering systems. One of the most common is a hissing sound evident at standstill parking. Hiss is
a high frequency noise similar to that experienced while slowly closing a water tap. The noise is present in every valve and results
from high velocity fluid passing valve orifice edges. There is no relationship between this noise and performance of the steering.
Hiss may be expected when steering wheel is at end of travel or when slowly turning at standstill.
C O N D I T I O N P O S S I B U C A U S I CORRI Cri ON
OBJECTIONALH ISSOR
WHISTLE
1. Noisy valve in gear 1. Check for proper seal between steering
column coupling and dash seal.
Ensure steering column lower coupling
has no metal-to-metal contact
within the coupling by performing an
electrical continuity check. (Remove
coupling for check.)
If hiss is still extremely objectionable,
replace steering gear.
RATTLE OR CLUNK 1 . Gear loose on front crossmember
2. Crossmember-to-frame bolts or studs loose
3. Tie rod looseness (outer or inner)
4. Pressure hose touching other parts of vehicle
5. Noise internal to gear
1 . Check gear-to-crossmember mounting
bolts. Tighten to specification.
2. Torque bolts and studs to specifications.
3. Check tie rod pivot points for wear.
Replace if necessary.
4 . Adjust hose to proper position by
loosening, repositioning, and retightening
fitting. Do not bend tubing.
5. Replace gear.
CHIRP OR SQUEAL (IN
THE AREA OF PUMP)
PARTICULARLY
NOTICEABLE AT FULL
WHEEL TRAVEL AN D
DURING STANDSTILL
PARKING
1 . Loose belt 1 . Adjust belt tension to specification.
9119-2

STEERING 1 9 - 5
P U M P G R O WL
Pump growl results from the development of high pressure fluid flow. Normally this noise should not be high enough to be
objectionable. Abnormal situations, such as a low oil level causing aeration or hoses touching the vehicle body, can create a noise
level that could bring complaints.
C O N D I T I O N PO S S I BL E C A U S E C O R R E C T I O N
WHINE OR GROWL
(PUMP NOISE)
1. Low fluid level
2. Hose touching vehicle body or frame
3. Extreme wear of pump internal parts
1. Fill to proper level and perform leakage
diagnosis. (Recheck after system is free
of aeration.)
2. Reposition hose. Replace hose if tube
ends are bent.
3. Replace pump and flush system.
SUCKING AIR SOUND 1. Loose return line clamp
2. Missing O-ring on hose connection
3. Low fluid level
4. Air leak between reservoir and pump
1. Tighten or replace clamp.
2. Inspect connection and replace o-ring as
required.
diagnosis.
4. Inspect and replace reservoir as required.
SQUEAK OR RUB SOUND 1. Sound from steering column
2. Sound internal to steering gear
1. Check for squeak in steering column.
Inspect for contact between shroud
intermediate shaft, column, and wheel.
(Realign if necessary.)
2. Replace gear.
SCRUBBING/KNOCKING 1. Incorrect tire size
2. Check clearance between tires and other
vehicle components, through full travel
3. Check for interference between steering gear
and other components
4. Incorrect gear supplied
1. Verify tire size is the same as originally
supplied.
2. Correct as necessary.
3. Correct as necessary.
4. Replace gear.
9119-3
19 - 6 STEERING

B I N D S S T I C K S S E I Z E D
CON D I TI ON POSSI BL E CAUSE CORRE CTI ON
CATCHES, STICKS IN
CERTAIN POSITIONS OR
DIFFICULT TO TURN
1. Low fluid level
2. Tires not properly inflated
3. Lack of lube in ball joints
4. Lack of lube in outer tie rod ends
5. Loose pump belt
6. Faulty pump flow control (Verify cause using
Pump Test Procedure)
7. Excessive friction in steering column or
intermediate shaft
8. Steering column coupling binding
9. Excessive friction in gear
diagnosis.
2. Inflate tires to proper pressure.
3. Lubricate where possible.
4. Lubricate where possible.
5. Tighten or replace belt.
6. Replace pump.
7. Correct condition. (See Steering Column
Service Procedure.)
8. Realign as necessary.
9. Replace gear.
S H A K E S H U D D E R V I BRATI ON
CON D I TI ON PO S S I BL E C A U S E CORRE CTI ON
VIBRATION OF THE
STEERING WHEEL AN D /
OR DASH DURING DRY
PARK OR LOW SPEED
STEERING MANEUV ERS
1. Air in the power steering system
3. Excessive engine vibration
4. Faulty accessory drive belt tensioner.
(Poly-V belt systems only)
5. Overcharged air conditioner
1. Steering shudder can be expected in new
vehicles and vehicles with recent steering
system repairs. Shudder should improve
after the vehicle has been driven several
weeks.
3. Make sure that engine is running properly.
4. Check dynamic belt tensioner for
abnormal vibration. (See Drive Belt
Adjustments.)
5. Check air conditioning pump head
pressure. (See Air Conditioning
Refrigerant System Diagnosis.)
9119-4

STEERING 19 - 7
L OW A S S I S T , N O A S S I S T , O R H ARD S T E E R I N G
CONDITION POS S I BL E CAUS E CORRE CTI ON
STIFF, HARD TO TURN,
SURGES, MOMENTARY
INCREASE IN EFFORT
W H E N TURNING
2. Low fluid level
3. Loose belt
2. Add power steering fluid as required and
perform leakage diagnosis.
3. Tighten or replace belt.
4. Lack of ball joint lubrication 4. Lubricate or replace as required.
5. Low pressure pump (Verify using Pump Test
Procedure)
5. Verify cause using Pump Test Procedure.
Replace pump if necessary.
6. High internal leak gear 6. Check steering system using test
procedure. If steering gear is at fault,
replace steering gear.
PO O R R E T U R N T O CENTER
C O N D I T I O N POS S I BL E CAUS E C O R R E C T I O N
STEERING WHEEL DOES
NOT WANT TO RETURN
TO CENTER POSITION
2. Improper front wheel alignment
3. Lack of lubrication in ball joint
2. Check and adjust as necessary.
3. Replace as required or lubricate.
4. Steering column U-joints misaligned 4. Realign steering column U-joints.
5. Mispositioned dash cover 5. Reposition dash cover.
To evaluate items 6 and 7, disconnect the
intermediate steering shaft. Turn the steering
wheel and listen for internal rubbing in
column.
6. Steering wheel rubbing 6. Adjust covers.
7. Tight steering shaft bearings 7. Replace bearings.
8. Excessive friction coupling universal joint 8. Replace U-joints.
9. High friction in the steering gear 9. Replace steering gear.
91195
19 - 8 STEERING
L OOSE STE E RI N G
CON D I TI ON POSSI BL E CAUSE C O R R E C T I O N
EXCESSIVE WHEEL
KICKBACK OR TOO
MUCH STEERING WHEEL
PLAY
1 . Air in system
2. Gear loose on crossmember
3. Worn/broken intermediate shaft
4. Free play in steering column
5. Loose ball joints
6. Front wheel bearings loose or worn
7. Loose outer tie rod ends
8. Loose inner tie rod ends
9. Defective steering gear rotary valve
1 . Add fluid.
2. Check gear to crossmember mounting
bolts. Tighten to specification,
3. Check for worn universal joint ond broken
isolator. Replace intermediate shaft if
worn.
4. Check and replace as required.
6 . Tighten hub nut or replace with new parts
as necessary.
8. Replace gear.
9. Replace gear.
V E H I CLE L E AD S TO TH E SI D E
CON D I TI ON POSSI BL E CAUSE CORRE CTI ON
WHEEL DOE S NOT
W ANT TO RETURN TO
CENTER POSITION
1. Radial tire lead
2. Front end misaligned
3. Wheel braking
4. Unbalanced steering gear valve. (If this is the
cause, the steering efforts will be very light in
direction of lead and heavier in the opposite
direction)
1 . Rotate tires as recommended in Tire
Service.
2. Align front end as recommended in
Wheel Alignment Service Procedure.
3. Check for dragging brakes as directed in
Brake Service Procedure.
4. Checking for pull with outer tie rod end
disconnected. If verified, replace gear.
9119-6

STEERING 1 9 - 9
F L U I D L E A K
CONDITION POSSIBLE CAUSE CORRECTION
LOW FLUID LEVEL WITH:
NO VISIBLE SIGNS OF
LEAKS ON THE
STEERING GEAR,
PUMP, ON FLOOR, OR
ANYWHERE ELSE
LOW FLUID LEVEL WITH:
VISIBLE LEAK ON
STEERING GEAR,
PUMP, FLOOR, OR
ANYWHERE ELSE
1. Overfilled reservoir
2. Hose connections at pump or gear
3. Pump or gear leak
1. Adjust fill level.
2. Check for loose fittings and tighten to
specifications. If fittings are tight, examine
for damaged or missing O-ring and
replace as required.
3. Identify location of leak and repair or
replace as indicated in Power Steering
Pump and/or Gear sections of this
service manual.
FOAMY OR MI LKY FLUID
CONDITION POSSI BLE CAUSE CORRECTION
AERATION AND
OVERFLOW OF FLUID
1. Air leaks
2. Low fluid level
3. Cracked pump housing
4. Water contamination
1. Check for air leak as described under
sucking air and correct.
2. Extremely cold temperatures may cause
system aeration if the oil level is low.
Add fluid as required.
3. Remove pump from vehicle and separate
reservoir from housing. Check expansion
plug and housing for cracks. Replace
pump as required.
4. Drain and refill fluid if there is evidence
of contamination.
9119-7
19 - 10 STEERING

GEAR LEAKAGE DIAGNOSIS
1 . S I D E C O V E R L E A K - T O R Q U E S I D E
C O V E R B O L T S T O 6 0 N TTI ( 4 5 F T .
L BS . ) . R E P L A C E T H E S I D E C O V E R
S E A L I F T H E L E A K A G E PE R S I S T S .
2 . A D J U S T E R P L U G S E A L - R E P L A C E
T H E A D J U S T E R P L U G S E A L S .
3 . PRESSURE LINE FITTING - TOR-
QUE THE HOSE FITTING NUT TO
2 7 N.m ( 2 0 FT. LBS.). IF LEAKAGE
PERSISTS, REPLACE THE SEAL.
4. PITMAN SHAFT SEALS - REPLACE
THE SEALS.
5 . T O P C O V E R S E A L - R E P L A C E T H E
S E A L .
J 9 2 1 9 - 2 9

STEERING 19 - 11
P O WE R S T E E R I N G P U M P
INDEX
page
Power Steering H ose 11
Power Steering PumpInitial Operation 1 5
Pump Pulley 1 5
Pump Repl acementDiesel Engine 12
SERVICE INFORMATION
The power steering pump i nt ernal components are
not serviced or adjusted. If a malfunction or an inter-
nal fluid leak occurs, t he complete uni t must be re-
placed.
POWER STEERING HOSE
Max. cool, vehicles are equipped with a power
steering auxiliary fin oil cooler. The oil cooler is
mounted to t he engine block under t he steering
pump (Fig. 2).
Cap hose open ends and pump/steering gear fit-
tings to prevent entry of foreign mat eri al .
WARNING; POWER STEERING F LUI D ( AN D PUM P
COMPONENTS) AN D TH E E X H AUST SY STE M C AN
BE EXTREMELY H OT IF TH E E N GI N E H AS BE E N
R E C E N T L Y O PE R A T I N G . D O N OT START TH E E N -
GINE WI T H A N Y L O O S E O R D I S C O N N E C T E D
HOSES. DO N OT AL L OW TH E H OS E S TO TOUCH A
HOT EXHAUST M AN I F OL D OR TH E CATAL Y TI C
CONVERTER.
REMOWAL
(1) Remove fasteners from hose ret ai ni ng brackets
at all locations.
(2) Disconnect pressure and ret urn hose from t he
steering gear. Drai n t he fluid from pump and reser-
voir (Fig. 1, 2).
(3) If applicable, remove cooler bracket fasteners
from block.
(4) Disconnect pressure and r et ur n hose from t he
pump. Remove hoses from vehicle (Fig. 1, 2).
INSTALLATION
(1) Wipe hose ends, pump and gear unions clean.
(2) Connect hose at steering gear and pump. Route
hose while avoiding extreme bends or ki nks. The
hos e mu s t be ke pt a wa y f r om exhaus t syst em
component s . Do not distort hose t ube ends by bend-
ing, ki nki ng or over tightening.
(3) Tighten cooler bracket fasteners to 41 Nm (30
ft. lbs.) torque (Fig. 1, 2).
(4) When used, t he protective foam sleeves must be
properly positioned on t he hose to prevent chafing.
page
Pump Repl acementGasol ine Engi ne . . . . . . . . . 14
Pump Reservoir 15
Service Information . . . . . . . . . . . . . . . . . . . . . . . 11
Fig. 1 Power Steering Hose Diesel Engine
SCREW
Fig. 2 Power Steering Hose V/6, V/8
19 - 12 STEERING

(5) Tighten fittings at pump and gear to 35 Nnn
(6 ) Install clamps on r et ur n hose on gear and
pump.
(7) After installation, inspect and test for fluid
leaks.
PUMP REPLACEMENTDIESEL ENGINE
REMOVAL
(1) Place a drai n pan under t he power steering
pump.
(2) Disconnect and cap t he vacuum and steering
pump hoses.
(3) Disconnect t he electrical connector on t he oil
pressure sender uni t (Fig. 3). Remove sender uni t
from engine block and plug hole in block.
PUMP ENGI NE BLOCK
Fig. 3 Oil Pressure Sending Unit
(4) Disconnect and cap t he oil feed line from t he
bottom of t he vacuum pump (Fig. 4).
(5) Remove t he lower bolt t hat at t aches t he vacu-
um/steering pump assembly to t he engine block. Re-
move t he nut from t he steering pump at t achi ng
bracket (Fig. 4).
(6 ) Remove upper bolt from t he pump assembly
(Fig. 5). Remove t he assembly from t he engine (Fig.
6).
(7) Remove t he gasket from t he mount i ng surfaces
on engine block and pump assembly.
(8) Drai n t he fluid from t he steering pump.
(9) Remove t he steering pump to vacuum pump
bracket at t achi ng nut s (Fig. 7).
(10) Slide t he steering pump from t he bracket. Use
care not to damage t he i nt ernal oil seal in t he vac-
uum pump (Fig. 8).
Fig. 4 Oil Feed Line Removal/Installation
Fig. 5 Pump Assembly Upper Bolt
(11) Remove t he two pump body spacers (Fig. 8),
for pump installation.
INSTALLATION
(1) Install t he two pump body spacers (Fig. 8).
(2) Rotate t he drive gear unt i l t he steering pump
and vacuum pump drive dogs align. Install t he steer-
ing pump onto t he vacuum pump bracket. Use care
to avoid damagi ng t he oil seal in t he vacuum pump
duri ng installation. The st eer i ng p u mp hous i ng

STEERING 19 - 13
Fig. 6 Pump Assembly Removal/Installation
PUMP
Jf 119-78
Fig. 7 Bracket Nut Removal/Installation
a n d s pa c e r s mus t mat e compl et el y wi t h t he vac-
uum p u mp b r a c k e t (Fig. 9).
(3) Install t he t hree (3) vacuum pump bracket to
steering pump nut s. Tighten to 24 Nm (18 Ft . lbs.)
torque.
(4) Position a new gasket on t he vacuum pump as-
sembly, use sealer if necessary to retain the gasket.
(5) Align and install t he pump assembly on t he en-
gine. Ensure t he steering pump stud is inserted into
PUMP BRACKET
SPACERS J9119-69
Fig. 8 Steering Pump Removal/Installation
Fig. 9 Steering/Vacuum Pump Assembly
t he block bracket. Tighten t he pump-to-engine block
at t achi ng bolts to 77 N*m (57 ft. lbs.) torque.
(6) Install t he steering pump to at t achi ng bracket
nut and t i ght en to 24 N*m (18 ft. lbs.) torque.
(7) Remove plug and install t he oil pressure send-
ing uni t and electrical connector.
(8) Install t he oil feed line to t he vacuum pump.
Tighten t he oil line connection to 7 Nm (60 in. lbs./
5 ft. lbs.) torque.
19 - 14 STEERING

(9) Install t he fluid hoses to t he power steering
pump, Tighten t he pressure fitting at t he pump to 30
(10) Install and clamp t he hose on t he vacuum
pump.
(11) Fill t he reservoir wi t h power steering fluid
only. If necessary, refer to P u mp I ni t i al Oper at i on
for detailed instructions.
(12) St art and r un t he engine. Check t he operation
of t he brakes, if necessary refer to Group 5, Brakes
for additional information.
PUMP REPLACEMENTGASOLINE ENGINE
REMOVAL
W ARN I N G: D O N OT RE M OV E TH E W ATE R PUM P
COOL AN T TUBE UN L E S S TH E COOL AN T SY STE M
H AS BE E N D E PRE SSUR1 Z E D AN D D RAI N E D *
W ARN I N G: D O N OT ATTE M PT TO RE M OV E TH E
PUM P W I TH OUT RE M OV I N G TH E BE L T F I RST. TH E
AUTOM ATI C TE N SI ON E R I S UN D E R A H I GH
SPRI N G L OAD .
(1) Remove t he serpentine drive belt. Rotate ten-
sioner clock-wise and hold in place, and remove belt
(Fig. 10).
Fig. 10 Serpentine Belt Removal/Installation
(2) Clamp t he fluid r et ur n hose and disconnect t he
hoses from t he power steering pump. Cap t he fit-
tings.
(3) Remove bat t ery ground cable and nut at stud.
Unt hread stud from cylinder head, do not remove
from bracket. Loosen upper bracket bolt. Remove t he
lower bracket to engine block bolts. Pivot t he pump
assembly past t he coolant tube. Remove the upper
stud. Remove upper bolt from cylinder head. The
steering pump and mounting bracket will be re-
moved from engine as an assembly.
(4) Remove t he pump pulley, refer to t he procedure
below. This will allow access to the pump at t achi ng
screws.
(5) Remove t he bracket to pump at t achi ng screws
(Fig. 11).
Fig. 11 Pump Removal/Installation
INSTALLATION
(1) Install t he bracket to pump mounting screws
(Fig. 11). Tighten to 54 N-m (40 ft. lbs.).
(2) Install t he pump pulley, refer to t he procedure
below.
(3) Position t he steering pump (with pulley) and
mount i ng bracket on t he engine block (Fig. 11). In-
stall t he upper stud and bolt in bracket. Pivot t he
pump down past t he coolant tube. Install t he lower
bolts in bracket (Fig. 11).
(4) Install t he bracket to engine block at t achi ng
bolts (Fig. 11). Tighten t he bolts and nut to 41 N*m
(30 ft. lbs.).
(5) Connect t he fluid hoses to t he pump.
(6) Install t he serpentine drive belt. Rotate ten-
sioner clock-wise and hold in place, slip t he belt over
t he pulleys. Refer to Group 7, Cooling for belt rout-
ing.
CAUTI ON : D o not use automatic t r ansmi ssi on fluid
to fill the reservoir.
(7) Fill t he reservoir with power steering fluid
only. If necessary, refer to P u mp I ni t i al Oper at i on
for detailed instructions.
# _ ,
Fig. 12 Pulley Removal (Typical)
Do not hammer on pul l ey because t hi s will
damage it a n d the pump.
(2) Replace pulley if bent, cracked, or loose.
INSTALLATION
(1) Install t he pulley with Installer C-4063-A (Fig.
13). Do not use t he tool adapters.
(2) Ensure t hat t he tool and t he pulley remai n
aligned with t he pump shaft. Prevent t he pulley from
being cocked on t he shaft.
(3) Force pulley flush with t he end of t he shaft.
With Serpentine Belts; Run engine unt i l warm (5
min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise is increases, press on 1.0 mm (0.040 in.). Be
careful that pul l ey does not contact mounti ng
bol t s.
PUMP RESERVOIR
REMOVAL
Di scard all O-ring seal s during di sassembl y,
they are not re-usable.
(1) Remove t he filler cap and drain t he fluid from
reservoir before removing part s.
(2) Remove mounting studs and pressure fitting
(Fig. 14). Rock reservoir by hand or use a soft face
mallet to remove.
STEERING 1 9 - 1 5
Fig. 13 Pulley Installation (Typical)
(3) Remove O-ring seals from housing and reser-
voir (Fig. 14).
(4) Remove flow control valve and spring from
housing.
INSTALLATION
Clean all parts before installation. Lubricate
new O-ring seal s wi th MOPAR Power Steering
Fl ui d or an equi val ent product.
(1) Install flow control valve and spring (Fig. 15).
(2) Install new O-ring seals in housing (Fig. 15).
Tighten mount i ng studs to 48 Nm (35 ft. lbs.)
torque.
(3) Install fitting in flow control valve bore.
Tighten t he fitting to 75 N-m (55 ft. lbs.) torque.
POWER STEERING PUMP-INITIAL OPERATION
C A U T I O N : The fluid level shoul d be checked with
engi ne off to prevent injury from movi ng compo-
nents. U se only M O PA R Power Steering Fluid. D o
not use automatic t r ansmi ssi on fluid. D o not over-
fill.
Wipe filler cap clean, t hen check t he fluid level.
The dipstick should indicate FULL COLD when t he
fluid is at normal t emperat ure.
(1) Fill t he pump fluid reservoir to t he proper level
and let t he fluid settle for at least two (2) minutes.
(2) St art t he engine and let r un for a few seconds.
The t ur n t he engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until t he fluid level remai ns constant after run-
ni ng t he engine.
(4) Raise t he front wheels off the ground.
PUMP PULLEY
REMOVAL
(1) Remove t he pulley wi t h Puller C-4333 (Fig.
12).
19 - 16 STEERING

EXPANSI ON PLUG - D O N O T RE MOV E ;
IF DEFORMED OR DI SLODGED,
REPLACE HOUSI NG
RESERVOIR
HOUSI NG
CAP
SEAL
FI TTI NG
75 N-m
( 5 5 FT. LBS.) 9119-9
(5) St art t he engine. Slowly t ur n
wheel ri ght and left, lightly contacting t he wheel
stops.
(6) Add power steering fluid if necessary.
(7) Lower t he vehicle and t ur n t he steering wheel
slowly from lock to lock.
(8) Stop t he engine. Check t he fluid level and refill
as required.
(9) If t he fluid is extremely foamy, allow t he vehi-
cle to st and a few mi nut es and repeat t he above pro-
cedure.
Fig. 14 Pump and Reservoir
t he steering
VALVE A N D
SPRI NG
J8919-101
Fig. 15 Flow Control Valve/Spring Installation

STEERING 19 - 17
STEERING L I N K A G E
SERVICE INFORMATION
The tie-rod end ball stud seals should be inspected
during all oil changes.
A damaged ball stud seal requires removal of t he
seal. Inspect t he tie-rod end ball st ud at t he t hroat
opening. Check for lubricant loss, contamination, ball
stud wear or corrosion. If these conditions exist, re-
place t he tie-rod. A replacement seal can be installed
if lubricant is in good condition. Otherwise, a com-
plete replacement tie-rod end should be installed. Lu-
bricate t he tie-rod end with MOPAR Multi-Mileage
Lubricant, or equivalent.
Use Pul l er C-3894-A for tie rod removal. Fail-
ure to use this tool coul d damage the tie rod and
seal (Fig. 1).
Fig. 1 Ball Stud Removal
STEERING LINKAGE2WD
REMOWAL
(1) Remove the cotter pin and nut from t he tie-rod.
(2) Remove the tie-rod end ball studs from steering
knuckle arms (Fig. 1 and 2),
Use care to avoi d damagi ng the seal s.
(2) Remove inner tie-rod ends (Fig. 1 and 2) from
center link.
(3) Remove idler ar m ball stud from center link
(Fig. 2). Remove idler ar m bolts from frame side rail
(Fig. 2).
(4) Remove pi t man ar m ball stud from center link.
(5) Mark t he pi t man ar m and shaft positions for
reference. Remove pi t man arm with Puller C-4150
(Fig. 3).
INSTALLATION
Replace all damaged or worn steering linkage com-
ponents.
(1) Position idler ar m on t he frame side rail. In-
stall bolts/nuts and t i ght en to 88 N-m (65 ft. lbs.)
torque.
IDLER
AR M
DUTY
TIE ROD J9119-6 6
Fig. 2 Steering Linkage2WD Vehicles
Fig. 3 Pitman Arm Removal
(2) Center steering gear to alignment mar ks and
install pi t man arm.
(3) Install the washer and ret ai ni ng nut on t he pit-
man shaft. Tighten t he nut to 251 N-m (185 ft. lbs.)
torque.
(4) Install center link to ball studs (Fig. 2). Install
and t i ght en ret ai ni ng nut s to 88 N-m (65 ft. lbs.)
torque. Install new cotter pins.
19 - 18 STEERING

CAUTI ON: It i s possi bl e to install the cent er link r e -
versed position. Thi s wi l l resul t i n i n c o r r e c t geome-
try and interferences duri ng vehicle jounce. Viewed
from t h e front of the vehicle, the c e n t e r l i nk ends
s h o u l d turn upwar d. V i ewed from the si de of the v e -
hicle, the ends shoul d t u r n toward the front of t h e
vehicle. The t i e- r od ball s t u d s e n t e r t h e center link
bores from the rear.
(5) Install tie-rod ends into center link (Fig. 2).
Tighten t he nut s to 54 Nm (40 ft. lbs.) torque. In-
stall new cotter pins.
(6) Insert tie-rod ends into steering knuckle ar m
(7) Remove t he supports and lower t he vehicle to
t he surface. Adjust t he wheel toe position (refer to
t he Alignment Specifications chart within Group 2,
Front Suspension).
Posi ti on the cl amp on the sl eeve so retai ni ng
bolt is l ocated on the bottom side of the sl eeve.
(8) After adjustment, t i ght en t he tie-rod adjust-
ment sleeve clamp bolt;
St andard Duty 25.4 N-m (225 in. lbs.) torque
Heavy Du t y - 34 N-m (25 ft. lbs.) torque
STEERING LINKAGE4 WD VEHICLES
Use Pul l er C-4150 to remove a drag link or pit-
man arm. Failure to use this tool coul d cause
damage to the seal s (Fig. 4).
TOOL C-4150
R H 4 0 4
Fig. 4 Drag-Link Removal
REMOVAL
(1) Remove drag link tie-rod end ball studs from
steering ar m and pi t man ar m (Fig. 4 and 5).
Use care to avoi d damagi ng the seals.
(2) Remove t he steering arm nut s and washers
(Fig. 6). Tap t he steering arm to loosen it from t he
knuckl e. Pry t he steering arm upward and remove.
STEERING NUT
LINK FITTING J9119-12
Fig. 5 Drag Link
Fig. 6 Steering Arm Removal Model 44 Axle
(3) Mark t he pi t man arm and shaft positions for
reference. Remove t he nut and washer from t he pit-
man arm. Remove t he pi t man ar m with Puller
C-4150 (Fig. 7).
(4) Remove t he cotter pin and nut from t he tie-rod.
(5) Remove t he tie-rod end ball studs from steering
knuckl e arms (Fig. 1 and 2).
Use care to avoi d damagi ng the seal s.
INSTALLATION
Replace all damaged or worn steering linkage com-
ponents.
(1) Center steering gear to alignment mar ks and
install pi t man arm.
(2) Install t he washer and ret ai ni ng nut on t he pit-
man shaft. Tighten t he nut to 251 N-m (185 ft. lbs.)
torque.
(3) Position t he steering ar m on t he knuckle. In-
stall t he washers and at t achi ng nut s. Tighten t he
nut s to 122 N-m (90 ft. lbs.).

STEERING 19 - 19
(4) Connect t he drag-link ball studs to the steering
knuckle arm and pi t man arm (Fig. 8). Install t he re-
t ai ni ng nut s and tighten to 81 Nm (60 ft. lbs.)
POINT J9102-62
Fig. 8 Correct Drag Link installation
(5) Insert tie-rod ends into steering knuckle arm
(6) Remove the supports and lower t he vehicle to
t he surface. Adjust t he wheel toe position (refer to
t he Alignment Specifications chart within Group 2,
Front Suspension).
Posi ti on the cl amp on the sl eeve so retaining
bolt is l ocated on the bottom side of the sleeve.
(7) After adjustment, t i ght en t he tie-rod adjust-
ment sleeve clamp bolt to 34-41 N-m (25-30 ft. lbs.)
torque.
1 9 - 2 0 STEERING

RECIRCULATING BALL POWER STEERI NG GEAR
INDEX
page
Adjuster Plug Assembl y Replacement 26
Check Valve Replacement 32
Gear Di sassembl y Information 23
H ousing E nd Plug 25
Pitman Shaft and Si de Cover Replacement 25
Pitman Shaft Seal s in Car Replacement . . . . . 20
page
Pitman Shaft Seal s and Bearing Replacement . . . 31
Rack Piston and Worm Shaft Replacement . . . . . 29
Steering Gear Adj ustments 22
Steering Gear Replacement 32
Val ve Replacement 27
SERVICE INFORMATION
A recirculating-ball steering gear is used wi t h t he
power (assisted) steering system. The power steering
gear can be adjusted and i nt ernal l y serviced.
PITMAN SHAFT SEALS - IN CAR REPLACEMENT
REMOVAL
(1) Remove pi t man ar m from gear. Refer to Pit-
man Arm Removal in Steering Linkage.
(2) Clean exposed end of pi t man shaft and housing.
Use a wire brush to clean t he shaft splines.
(3) Remove ret ai ni ng ri ng wi t h snap ri ng pliers
(Fig. 1).
RETAINING RI NG
BACKUP WASHER
DOUBLE-UP SEAL
BACKUP WASHER
SINGLE-LIP SEAL
NEEDLE BEARI NG
J8919-39
Fig. 1 Pitman Shaft Seals
C A U T I O N : U se care not to scor e the housi ng bore
when pryi ng out seal s and washer s.
(4) Remove backup washer and double lip seal
with screwdriver.
St ar t t he engi ne and t ur n t he steering wheel fully
to t he LEFT to force out t he seals and washers.
Stop t he engine.
(5) Remove backup washer and single lip seal wi t h
screwdriver.
(6 ) Inspect t he housing for burrs and remove if
necessary. Inspect t he pi t man shaft seal surface for
roughness and pitting. If pitted replace shaft.
INSTALLATION
(1) Install single lip seal with Installer or a suit-
able size deep socket (Fig. 2) .
SPECIAL TOOL
C4171
TOP OF TOOL
FLUSH WITH
HOUSI NG
SPECIAL TOOL
G4328
J9119-42
Fig. 2 Pitman Shaft Seal Installation
(2) Coat t he double lip seal and washer with
grease.
(3) Install t he backup washer.
(4) Install t he double lip seal.
(6 ) Install t he ret ai ner ring with snap ri ng pliers.
(7) Center t he steering gear.
(8) Install t he pi t man arm. Refer to Pi t man Arm
Installation in Steering Linkage.
(9) Add power steering fluid. Refer to Power Steer-
ing Initial Operation.
19 - 22 STEERING
WORM THRUST BEARING PRELOAD
ADJUSTMENT
(1) Remove adjuster plug locknut (Fig. 4).
Fig. 4 Loosening the Adjuster Plug Locknut
(2) Turn t he adjuster in with Spanner Wrench
C-4381. Tighten t he plug and t hr ust beari ng in t he
housing unt i l firmly bottomed in housing.
(3) Place an index mar k on t he housing even with
one of t he holes in adjuster plug (Fig. 5).
(4) Measure back (counterclockwise) 13 mm (0.50
in) and mar k housing (Fig. 6).
(5) Rotate adjustment cap back (counterclockwise)
with spanner wrench unt i l hole is aligned with t he
second mark (Fig. 7).
(6) Install and t i ght en locknut to 109 N-m (80 ft.
lbs.) torque. Be sure adjustment cap does not t ur n
while t i ght eni ng t he locknut.
OVER-CENTER ADJUSTMENT
(1) Rotate t he stub shaft from stop to stop and
count t he number of t ur ns.
(2) St art i ng at either stop t ur n t he stub shaft back
1/2 t he total number of t ur ns. This is t he center of
t he gear travel (Fig. 8).

J8919-58
Fig. 5 Alignment Marking On Housing
Fig. 6 Remarking The Housing
(3) Turn t he pi t man shaft adjuster screw back
(COUNTERCLOCKWISE) unt i l extended, t hen t ur n
back in (CLOCKWISE) one full t urn.
(4) Place t he torque wrench in t he vertical position
on t he stub shaft. Rotate t he wrench 45 degrees each
side of t he center and record t he highest rotational
torque on center (Fig. 9).
(5) Turn t he adjuster in until torque to t ur n stub
shaft is 0.6 to 1.2 N-m (6.0 to 10.0 in. lbs.) more t han
readi ng in Step 4 .
(6) Prevent t he adjuster screw from t urni ng while
t i ght eni ng adjuster lock nut . Tighten t he adjuster
lock nut to 49 N-m (36 ft. lbs.).
STEERING GEAR ADJUSTMENTS
SERVICE INFORMATION
Adjusting the steering gear in t he vehicle is NOT
recommended. Remove t he gear from t he vehicle
(Fig. 3) and mount in a vise. Drai n t he power steer-
ing fluid and make t he following adjustments in this
order:
FIRST - worm t hr ust beari ng preload
SECOND - over-center preload adjustment

FIRST
MARK
J9219-30
Fig. 7 Aligning To The Second Mark
GEAR DISASSEMBLY INFORMATION
C A U T I O N : C l eanl i ness is extremely important when
repairing a power steering gear. Keep the bench,
t ool s and component s cl ean at all ti mes. Thor-
oughl y clean the exterior of the gear with cl eani ng
sol vent before di sassembl y. Drai n a s much of the
fluid a s possi bl e. U se protective vi se j aws at all
times when cl ampi ng component s. During a s s e m-
bly, lubricate all component s with power steering
fluid except when instructed otherwise (Fi g. 10).
STEERING 19 - 23
Fig. 8 Steering Gear Centered
Fig. 9 Checking Over-center Rotation Torque
TO
4^
m
r n
z
o
1 - HOUSING, STEERING GEAR
2 - RACE, THRUST BEARING (WORM)
3 - BEARING ASSY., ROLLER THRUST (WORM)
4 - RACE, THRUST BEARING (WORM)
5 - WORM, STEERING
6 - SEAL "O" R I NG (STUB SHAFT)
7 - SHAFT, STUB
8 - SPOOL, VALVE
9 - SEAL, "O" RING (SPOOL)
10 - BODY, VALVE
11 - RING, VALVE BODY (3)
12 - SEAL, "O" RI NG (VALVE BODY) (3)
13 - RETAINER, BEARI NG (ADJUSTER)
14 - SPACER, THRUST BEARI NG
15 - RACE, UPPER THRUST BEARI NG (SMALL)
16 - BE ARI NG, UPPER THRUST
17 - RACE, UPPER THRUST BEARI NG (LARGE)
18 - SEAL, "O" RI NG (ADJUSTER)
19 - PLUG, ADJUSTER
20 - BE ARI NG, NEEDLE
21 - SEAL, STUB SHAFT
22 - SEAL, STUB SHAFT DUST
23 - R I NG, RETAI NI NG
24 - NUT, ADJUSTER PLUG LOCK
25 - BEARI NG AS S Y. , NEEDLE (PI TMAN SHAFT)
26 - SEAL, PI TMAN SHAFT (SI NGLE LIP)
27 - WASHER, SEAL BACK-UP (PI TMAN SHAFT)
28 - SEAL, PITAAAN SHAFT (DOUBLE LIP)
29 - WASHER, SEAL BACK-UP (PI TMAN SHAFT)
30 - R I NG, RETAI NI NG (PI TMAN SHAFT SEAL)
31 - WASHER, PI TMAN SHAFT LOCK
32 - NUT, PI TMAN SHAFT
33 - NUT, RACK PI STON
34 - BALL
35 - GUI DE, BALL RETURN (2)
36 - CLAMP, BALL RETURN GUI DE
37 - SCREW AS S Y. , LOCKWASHER & (2)
38 - PLUG, RACK PISTON
39 - SEAL, "O" RI NG (RACK PISTON)
40 - R I NG, RACK PISTON
41 - SEAL, "O" R I NG (HOUSI NG END PLUG)
42 - PLUG, HOUS I NG END
43 - R I NG, RETAI NI NG (HOUSI NG END PLUG)
44 - GEAR AS S Y. , PI TMAN SHAFT
45 - SEAL AS S Y. , GASKET
46 - COVER AS S Y. , HOUS I NG SIDE
47 - BOLT, HEX. HEAD (SIDE COVER) (4 )
48 - NUT, LASH ADJUSTER
J9219-64
Fig. 10 Power Steering Gear

STEERING 19 - 25
PITMAN SHAFT AND SIDE COVER REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in t hi s section.
(2) Remove pi t man ar m from steering gear. Refer
to Pi t man Arm Removal in t he Steering Linkage sec-
tion.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
Clean exposed end of pi t man shaft and housing.
Clean pi t man shaft spline with a wire brush.
(1) Remove preload adjuster nut.
(2) Rotate stub shaft wi t h socket to center gear.
Remove side cover bolts.
(3) Remove side cover, gasket and pi t man shaft as
an assembly.
(4) Remove pi t man shaft from t he side cover (Fig.
11).
Fig. 11 Side Cover and Pitman Shaft
ASSEMBLE
(1) Install pi t man shaft to side cover by screwing
shaft in unt i l it fully seat s to side cover.
(2) Install preload adjuster nut. Do not tighten
nut until after pitman shaft adjustment has been
made.
(3) Install gasket to side cover and bend t abs
around edges of side cover.
(4) Install pi t man shaft assembly and side cover to
housing.
(5) Install side cover bolts and t i ght en to 60 Nm
(44 ft. lbs.).
(6) Adjust pi t man shaft, refer to Over-Center Ad-
j ust ment .
INSTALL
(1) Install steering gear. Refer to Power St eeri ng
Gear Replacement in t hi s section.
(2) Install pi t man ar m onto steering gear. Refer to
Steering Li nkage in t hi s group.
HOUSING END PLUG
REMOVE
(2) Remove pi t man ar m from steering gear. Refer
to Steering Linkage in t hi s group.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
Rotate st ub shaft back and forth to drai n fluid.
(1) Rotate ret ai ni ng ri ng until one end is under
t he hole in t he housing. Unseat and force ri ng from
groove (Fig. 12).
Fig. 12 End Plug Retaining Ring
(2) Rotate stub shaft slowly COUNTER-CLOCK-
WISE to remove end plug out from housing (Fig. 13).
19 - 2 6 STEERING

CAUTI ON : D o not turn st ub shaft any further than
necessar y. The recircul ating bal l s will dr op out of
the rack pi st on circuit and fall i nsi de the rack pi s-
ton chamber .
(3) Remove O-ring seal (Fig. 13).
HOUSING END PLUG
O-RING SEAL
HOUSING END PLUG
RETAINING RING J9319- 30
Fig. 13 End Plug Components
ASSEMBLE
Lubricate O-ring seal with power steering fluid.
(1) Install O-ring into housing.
(2) Install plug, t ap lightly with a plastic mallet to
seat it.
(3) Install ret ai ni ng ri ng with open end 25 mm (1
inch) from access hole (Fig. 14).
Fig. 14 Installing The Retaining Ring
(2) Install pi t man arm onto steering gear. Refer to
Steering Linkage in this group.
ADJUSTER PLUG ASSEMBLY REPLACEMENT
REMOWE
DISASSEMBLE
(1) Remove adjuster plug lock nut from housing.
(2) Remove adjuster plug from housing with Span-
ner Wrench C-4381 (Fig. 15).
SPECIAL TOOL
C-4381 OR J-7624
Fig. 15 Remove/Install Adjustment Plug
(3) Remove t hrust washer bearing ret ai ner from
adjuster plug with screwdriver (Fig. 16).
BEARING RETAINER
Fig. 16 Remove Retainer
INSTALL
(1) Install steering gear. Refer to Power Steering
(4) Remove beari ng spacer, races and t hrust bear-
ing (Fig. 17).
RETAINING
SNAP RING
f
STUB SHAFT
DUST SEAL
LARGE
THRUST
WASHER
SMALL
THRUST WASHER
NEEDLE
BEARI NG
ADJUSTMENT
CAP
SPACER
RETAINING
RI NG
J8919-42
Fig. 17 Adjustment Plug (Cap) Components
(5) Remove O-ring seal.
(6) Remove ret ai ni ng snap ring.
(7) Remove needle bearing, dust seal and lip seal
with an appropriate tool (Fig. 18).
NEEDLE
BEARI NG
REMOVAL
T OOL
J8919-43
Fig. 18 Needle Bearing Removal
ASSEMBLE
C A U T I O N : Needle bearing must be installed with
identification on beari ng faci ng tool to prevent dam-
age to beari ng.
(1) Install needle bearing into adjuster plug with
an appropriate tool.
(2) Install lip seal and dust seal into adjuster plug
with an appropriate tool.
(3) Install ret ai ner snap ring.
(4) Install O-ring seal to adjuster plug.
(5) Install large bearing race, t hr ust beari ng, small
beari ng race and bearing spacer to adjuster plug.
(6) Install t hrust washer beari ng ret ai ner to ad-
j ust er plug (Fig. 19).
NEEDLE
BEARI NG
PUNCH
SEAL
RETAINER
ADJUSTER PLUG
J9219-10
Fig. 19 Install Retainer
C A U T I O N : When installing adjuster pl ug,
shoul d be taken N OT to cut the seal s.
care
(7) Install adjuster plug into housing with Spanner
Wrench C-4381.
(8) Adjust bearing preload, refer to Thrust Bearing
Preload Adjustment.
(9) Install adjuster plug lock nut , and using a
punch (drift) in a notch, t i ght en securely (Fig. 20).
Hol d adjuster pl ug to mai ntai n al i gnment of the
marks.
(10) Adjust pi t man shaft. Refer to Over-Center Ad-
j ust ment .
INSTALL
(1.) Install steering gear. Refer to Power Steering
VALVE REPLACEMENT
REMOVE
Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove adjuster plug, refer to Adjuster Plug
Assembly Replacement.
19 - 28 STEERING
Fig. 20 Tighten Lock Nut
(2) Remove stub shaft and valve assembly (Fig.
GEAR, MAKE SURE ANGLE OF
THRUST RACES ARE AS S HOWN. J9319-32
Fig. 21 Bearing, Worm and Valve Assembly
(3) Remove stub shaft from valve assembly, if nec-
essary.
Tap stub shaft lightly on a block of wood to loosen
shaft cap.
Pull cap and valve body and disengage stub shaft
pin from hole in valve body (Fig. 22).
(4) Remove valve assembly if necessary.
Remove valve spool by pulling and rot at i ng from
valve body (Fig. 23).
Remove valve spool O-ring seal.
Remove valve body teflon rings and O-ring seals
(Fig. 24).
J9319-36
Fig. 22 Remove and Install Stub Shaft
Fig. 23 Remove and Install Spool
ASSEMBLE
(1) Install valve spool O-ring seal to valve spool.
(2) Lubricate valve spool and O-ring seal with
power steering fluid.
(3) Install valve spool to valve body by pushi ng
and rot at i ng. Hole in valve spool for stub pin must
be accessible from opposite end of valve body.
(4) Assemble stub shaft to valve spool, if necessary
and insert pin (Fig. 25).
Notch in stub shaft cap MUST fully engage valve
body pin and seat against valve body shoulder.
(5) Install O-ring seals and teflon rings to valve
body.
(6) Lubricate O-ring seals and teflon rings with
power steering fluid.

STEERING 19 - 29
RACK PISTON AND WORM SHAFT REPLACEMENT
J8919-48
Fig. 24 Remove and install Valve Seals
NOTCH IN CAP
VALVE BODY PIN
liHiiiiiim
J 9319- 38
Fig. 25 Stub Shaft Installation
(7) Install stub shaft and valve assembly to worm
shaft. Line up worm shaft to slot in t he valve assem-
bly.
(8) Adjust Thrust Bearing Preload Adjustment and
Over-Center Adjustment. Refer to Steering Gear Ad-
j ust ment s in this section.
REMOVE
(1) Remove steering gear from vehicle. Refer
Power Steering Gear Replacement in this section.
to
DISASSEMBLE
(1) Remove pi t man shaft and side cover. Refer to
Side Cover and Pi t man Shaft Replacement i n this
section.
(2) Remove housing plug end. Refer to Housing
End Pl ug Replacement in this section.
(3) Turn stub shaft COUNTERCLOCKWISE until
t he rack piston begins to come out of t he housing.
(4) Remove rack piston plug (Fig. 26).
EXTENSION END PLUG
RACK
PISTON
J 9219- 9
Fig. 26 Remove and Install Rack Piston End Plug
(5) Insert Arbor C-4175 into bore of rack piston
(Fig. 27). Hold tool t i ght l y against worm shaft while
t urni ng t he stub shaft COUNTERCLOCKWISE.
The rack piston will be forced onto t he tool and
hold t he rack piston balls in place.
(6) Remove t he rack piston, rack balls, and tool to-
gether from housing.
(7) Remove valve. Refer to Valve Replacement in
this section.
(8) Remove worm shaft.
(9) Remove t hrust beari ng and races.
(10) Remove tool from rack piston.
(11) Remove rack piston balls.
(12) Remove screws, clamp and ball guide.
(13) Remove teflon ri ng and O-ring seal (Fig. 28).
CLEAN AND INSPECTION
(1) Wash all components in clean solvent and dry
with compressed air.
INSTALL
1 1 - 3 0 STEERING
Fig. 27 Remove and install Rack Piston
J92T9-12
Fig. 28 Remove and Install Seal on Rack Piston
(2) Check for scores, nicks or burrs on t he rack pis-
ton finished surface. Slight wear is normal on t he
worm gear surfaces.
ASSEMBLE
(1) Install O-ring seal and teflon ri ng and lubricate
wi t h power steering fluid.
(2) Install worm shaft to rack piston outside of
housing. Fully seat worm shaft to rack piston. Align
worm shaft spiral groove wi t h rack piston ball guide
hole (Fig. 29).
WARNING: MAKE SURE AL L RACK PISTON BALLS
ARE REINSTALLED I N THE RACK PI STON. IM-
PROPER INSTALLATION MAY RESULT IN PER-
SONAL INJURY.
The r e a r e 24 bal l s i n t he r a c k pi s t on ci r cui t , 12
a r e Ma c k a n d 12 a r e si l ver ( Chr ome) . The bl a c k
w
INSTALL BALLS I N THIS HOLE
WHI LE SLOWLY ROTATI NG
WO R M COUNTERCLOCKWI SE
J 9319- 39
Fig. 29 Installing Balls in Rack Piston
rack pi ston balls are smaller than the silver
bal l s. THE BLACK AND SI LVEE BALLS MUST
BE I NSTALLED ALT1ENATELY I NTO THE
RACK PI STON AND BALL GUI DE. Thi s pr oce-
dur e will mai ntai n worm shaft preload.
(3) Lubricate and install rack piston balls t hrough
r et ur n guide hole while t urni ng worm shaft COUN-
TERCLOCKWISE.
(4) Install remai ni ng balls to guide using grease or
petroleum jelly at each end to hold in place (Fig. 30).
(5) Install guide onto rack piston and ret urn with
GUI DE
BALLS J 9319- 40
Fig. 30 Balls in the Return Guide
clamp and screws. Tighten screws to 58 N
#
m (43 in.
lbs.) torque.
(6) Insert Arbor C-4175 into bore of rack piston.
Hold tool tightly agai nst worm shaft while t urni ng
t he stub shaft COUNTERCLOCKWISE.

STEERING 19 - 31
The rack piston will be forced onto t he tool and
hold t he rack piston balls in place.
(7) Install t he races and t hr ust beari ng to worm
shaft (Fig. 31).
WORM SHAFT THRUST RACES
MAKE SURE ANGLE OF THRUST
RACES ARE AS S HOWN
J9319-41
Fig. 31 Worm Shaft and Bearing
(8) Install worm shaft to housing.
(9) Install valve. Refer to Valve Replacement in
t hi s section.
(10) Install rack piston to worm shaft from tool,
compress seals.
Hold Arbor tightly against worm shaft and t ur n
stub shaft CLOCKWISE unt i l rack piston is seated
on worm shaft.
W ARN I N G: M AK E S URE AL L RAC K PI STON BAL L S
A RE RE I N STAL L E D I N TH E RAC K PI STON . I M-
PROPE R I N STALLATI ON M AY RE SUL T I N PE R-
SON AL I N J URY .
(11) Install rack piston plug and t i ght en to 150
(12) Install housing end plug. Refer to Housing
End Pl ug Replacement in this section.
(13) Install pi t man shaft and side cover. Refer to
Side Cover and Pi t man Shaft Replacement in this
section.
(14) Adjust steering gear. Refer to Steering Gear
Adjustments in t hi s section.
PITMAN SHAFT SE ALS AND BEARING
REPLACEMENT
REMOVE
(1) Remove st eeri ng gear from vehicle. Refer to
DISASSEMBLE
(1) Remove pi t man arm from gear. Refer to Pit-
man Arm Removal in Steering Linkage.
(2) Clean exposed end of pi t man shaft and housing.
Use a wire brush to clean t he shaft splines.
(3) Remove ret ai ni ng r i ng wi t h snap ri ng pliers
(Fig. 32).
RETAINING RING
BACKUP WASHER
DOUBLE-UP SEAL
BACKUP WASHER
SINGLE-LIP SEAL
NEEDLE BEARING
J8919-39
Fig. 32 Pitman Shaft Seals
C A U T I O N : U se care not to scor e the housi ng bore
when prying out seal s and washer s.
(4) Remove backup washer and double lip seal
with screwdriver.
(5) Remove backup washer and single lip seal with
screwdriver.
(6) Inspect t he housing for bur r s and remove if
necessary.
(7) Remove needle beari ng from side cover area of
housing (Fig. 33).
ASSEMBLE
(1) Install needle beari ng into housing (Fig. 34).
(2) Install single lip seal with Installer or a suit-
able size socket (Fig. 35).
(3) Coat t he double lip seal and washer wi t h
grease.
(5) Install t he double lip seal.
INSTALL
Gear Replacement in this section.
19 - 32 STEERING
REMOVER SIDE COVER
AREA
SPECIAL TOOL
C-4171
J9319-42
Fig. 33 Needle Bearing Removal
SPECIAL TOOL
C-4171
WHEN TOOL
BOTTOMS ON
HOUSING, BEARING IS
FULLY INSTALLED
SPECIAL TOOL
C-4178
DO NOT
BOTTOM BEARING
IN HOUSING
\ J9119-4
Fig. 34 Pitman Shaft Bearing Installation
(7) Install t he ret ai ner ri ng wi t h snap ri ng pliers.
(8) Install t he pi t man shaft and side cover. Refer
to Side Cover and Pi t man Shaft Replacement in t hi s
section.
TOP OF TOOL
FLUSH WITH
HOUSING
SPECIAL TOOL
C4328
J9119-42
Fig. 35 Pitman Shaft Seal Installation
CHECK VALVE REPLACEMENT
REMOVE
DISASSEMBLE
C A U T I O N : Use care not to damage the threads of
the housi ng when prying out check valve.
(1) Remove valve by prying from housing wi t h a
small screwdriver.
ASSEMBLE
(1) Install t he valve into t he housing wi t h a 3/8-
inch diameter piece of t ubi ng 100 mm (4 inches)
long.
INSTALL
STEERING GEAR REPLACEMENT
REMOVAL
(1) Place t he front wheels in a st rai ght -ahead posi-
tion.
(2) Disconnect and cap t he fluid hoses from steer-
ing gear.
(3) Remove t he coupler roll pin and disconnect at
t he steering gear (Fig. 36).
(4) Mark t he pi t man shaft and pi t man ar m for in-
stallation reference. Remove t he pi t man ar m from
t he shaft wi t h Puller C-4150 (Fig. 37).
(6) Remove t he steering gear ret ai ni ng bolts and
INSTALL
(1) Inst al l steering gear. Refer to Power St eeri ng

STEERING 1 1 - 3 3
Fig. 36 Column Shaft Removal
nut s. Remove t he steering gear from t he vehicle (Fig.
38, 39).
9 2WD vehicles; remove t he steering gear ret ai ni ng
bolts from t he frame rai l and remove t he gear (Fig.
40).
4WD vehicles; remove t he steering gear and rein-
forcement bracket from t he frame rail. Remove t he
gear from t he reinforcement bracket (Fig. 39).
INSTALLATION
(1) Align t he column coupler shaft to steering
gear. Install t he roll pin in shaft coupling (Fig. 38).
(2) Position t he steering gear on t he frame rail and
install t he bolts (Fig. 38, 39). Tighten t he bolts to
2WD vehicles; position t he steering gear at t he
frame rail. Install and t i ght en t he at t achi ng bolts
SCREW REI NFORCEMENT
Fig. 38 Steering Gear Removal/Installation (2WD)
Fig. 39 Steering Gear Removal/Installation (4 WD)
finger-tight (Fig. 38). Center t he steering gear and
align t he steering column shaft and t he stub shaft.
4WD vehicles; install t he steering gear to t he
frame reinforcement bracket (Fig. 39). Tighten t he
screws to 176 Nm (130 ft. lbs.) torque. Install t he as-
sembly as above, finger tight.
A special knurled shoulder bolt is used for t he
lower bracket to frame bolt. The bolt is available for
service to el i mi nat e bracket shift t hat produces an off
center condition. The t i ght fit between t he frame and
bracket will eliminate any movement between t he
two part s.
(3) Re-position gear at frame to eliminate any
binding, t i ght en at t achi ng bolts/nuts;
2WD vehicles; t i ght en gear to frame bolts to 136
19 - 34 STEERING

4WD vehicles; tighten gear frame reinforcement
bracket to frame bolts/nuts to 223 N-m (165 ft. lbs.)
torque.
(4) Align and install the pitman arm.
(5) Install the washer and retaining nut on the pit-
man shaft. Tighten the nut to 251 N-m (185 ft. lbs.)
torque.
(6) Connect fluid hoses to steering gear, tighten to
28 N-m (21 ft. lbs.). Add fluid, refer to Power Steer-
ing Pump Initial Operation.
POWER STEERING GEAR SPECIFICATIONS
Steering Gear Type . . . . . . . . . . . . . Recirculating ball with
hydraulic assist.
Ratio Code (Top of Gear)
BH,NZ 14:1
BF, XS 13-16:1
Steering Gear Hydraulic Fluid Use Mopar Power
Steering Fluid, or equivalent.
Steering Gear Lubricants Lubricate pitman shaft
seals, bearings races, and rack
piston recirculating balls with
petroleum jelly. Lubricate all other
parts with power steering fluid.
Steering Gear Adjustments:
Wormshaft Bearing Preload Torque 0.45-1.13 Nm
(4 to 10 in-lbs)
Pitman Shaft Overcenter Drag Torque:
New Gear
(less than 400 miles/640 km) . . . . . . . . . 0.45-0.90 Nm
(4 to 8 in-lbs) in addition to wormshaft
bearing preload but not to exceed
combined total of 2 Nm (18 in-lbs).
Used Gear
(over 400 miles/640 km) 0.5-0.6 Nm (4 to 5 in-lbs)
in addition to wormshaft bearing
preload but not to exeed
combined total of 2 N-m (18 in-lbs).
C a ut i on: Gears must be adjusted exactly as outlined in
Steering Gear Adjustments-On Bench. Failure to
adhere to the recommended procedures may result
in gear damage or improper steering response.
J9219-36

STEERING 19 - 3 i
STEERI NG COLUMN
SERVICE INFORMATION
The Acustar columns ( Fi g. l ) have been designed to
be serviced as an assembly; less wiring, switches,
shrouds, steering wheel, etc. Also most steering col-
umn components can be serviced without removing
the column from t he vehicle. For additional informa-
tion refer to Group 8H, Electrical.
C A U T I O N : Bumpi ng, jolting and hammeri ng on the
steering column shaft and gear shift tube must be
avoi ded during all servi ce procedures.
C A U T I O N : Di sconnect negative (ground) cable f rom
the battery before servi ci ng any component on the
column.
C A U T I O N : D o not attempt to remove the pi ns to di s-
sembl e the tilting mechani sm. D amage will occur.
Safety goggl es shoul d be worn at all ti mes
when i nvol ved wi th steering col umn service.
STEERING WHEEL
REMOWAL
(1) Make sure t he front wheels are in t he straight
ahead position.
(2) Disconnect t he negative (ground) cable from
t he bat t ery.
(3) Remove the horn pad components (Fig. 2).
(4) Remove t he steering wheel ret ai ni ng nut . Score
or pai nt alignment mar ks on t he column shaft and
steering wheel (if none exist) for installation refer-
ence.
HORN PAD
Fig. 2 Horn Pad Removal/installation
STEERING TILT UPPER PANEL TOE COUPLER ROLL
Fig. 1 Acustar Steering Column
1 9 - 3 6 STEERING

(5) Remove t he steering wheel with Puller
C-3428-B (Fig. 3). Do not h a mme r or j ol t t he
steeri ng col umn or shaft duri ng r emoval of t he
wheel .
SPECI AL
TOOL
C- 3428- B
STEERI NG
WHEEL J9219-56
Fig. 3 Steering Wheel Removal
INSTALLATION
(1) Install t he steering wheel wi t h t he scored
mar ks or mast er splines aligned.
(2) Pull t he speed control wires t hrough t he lower,
larger hole in t he steering wheel. Pull t he horn wire
t hrough t he smaller hole at t he top. Ensure the
wi res a r e NOT pi nched.
(3) Install t he ret ai ni ng nut and t i ght en to 61 Nm
(45 ft. lbs.) torque. Force the s t eer i ng wheel down
on the shaft wi th the r et ai ni ng nut only. Do not
hammer or shock the col umn wi th sudden im-
pact to install the wheel .
(4) Connect t he wire feed to t he horn buttons.
(5) Connect t he wire feeds to t he speed control
switch (Fig. 2).
(6) Connect t he bat t ery ground (negative) cable.
CLOCKSPRING
REMOVAL
(1) Place t he front wheels in t he st rai ght ahead po-
sition before st art i ng t he repair.
(2) Disconnect bat t ery negative cable and isolate.
(3) Remove t he steering wheel, refer to Steering
Wheel Removal.
(4) Remove upper and lower steering column
shrouds to gain access to t he clockspring wiring.
(5) Release wire connector at clockspring.
(6) Pull clockspring assembly from column by lift-
ing locking fingers as necessary. The clockspring
cannot be repaired, and must be replaced if faulty.
INSTALLATION
(1) Snap clockspring assembly onto column. If
clockspring is not properly positioned, follow t he cen-
t eri ng procedures before installing steering wheel.
(2) Connect t he wire connector to t he clockspring.
W ARN I N G: E N SURE C L OC K SPRI N G W I RE C ON -
N E CTI ON I S C OM PL E TE L Y SE ATE D . TH E L ATCH -
I NG CLI P A RM S M UST BE PROPE RL Y E N GAGE D
ON TH E M OD UL E .
(3) Install upper and lower steering column
shrouds. Be sure wiring is inside of shrouds and not
pinched.
(4) Install t he steering wheel and air bag module,
refer to Steering Wheel Installation.
CENTERING PROCEDURE
If t he rot at i ng tape within t he clockspring is not
positioned properly, t he clockspring may fail duri ng
use. The following procedures MUST BE USED to
center t he clockspring.
(1) Place t he front wheels in t he st rai ght ahead po-
sition before st art i ng t he procedure.
(2) Depress t he 2 locking t abs to disengage t he
locking mechanism (Fig. 4).
Fig. 4 Clockspring (Auto-Locking)
(3) Keeping t he mechanism disengaged, rotate t he
clockspring rotor in t he CLOCKWISE DIRECTION
to t he end of t he travel. Do not apply excessive
torque.

STEERING 19 37
(4) From t he end of travel, rot at e t he rotor 2 1/2
full t ur ns in t he COUNTER CLOCKWISE direction.
The horn wire should end up at t he top and t he squib
wire at t he bottom (Fig. 4).
(5) Install t he steering wheel, refer to Steering
Wheel Installation.
COLUMN REMOVAL/INSTALLATION
steering col umn shaft and gear shift tube must be
avoi ded duri ng all servi ce procedures.
REMOVAL
(1) Make sure t he front wheels are in t he s t r ai ght
a he a d position.
(2) Disconnect t he negative (ground) cable from
the bat t ery.
(3) Remove steering wheel from column, refer to
Steering Wheel-Removal.
(4) For vehicles equipped with a column shift, dis-
connect t he link rod by prying it out of t he grommet
in t he shift lever (Fig. 5).
DASH
" PANEL
SCREW
SPRI NG
PI N
PRYING TOOL
RN829
Fig. 5 Link Rod Removal
(5) Pai nt installation alignment mar ks on t he col-
umn shaft-to-coupler. This will aid in column shaft to
wheel alignment. Remove t he steering column shaft-
to-coupler screws (Fig. 6).
(6) Remove t he dash panel column and fuse block
cover (Fig. 7).
(7) For column shift vehicles, make sure shift lever
is i n Park position and remove PRNDL driver cable.
(8) Remove tilt lever (if equipped) from column.
(9) Remove t he upper and lower lock housing
shroud (Fig. 1). Remove the lower fixed shroud.
(10) Remove t he t ur n signal multi-function switch
wi t h a 7mm socket (Fig. 8).
(11) Loosen t he upper Support Bracket nut s to al-
low some slack. This will aid in removal of t he upper
fixed shroud.
(12) Remove t he electrical connections from Key-in
light, Main Ignition Switch, Horn connection or
Cl ock Spring (Speed Cont r ol ) (Fig. 9).
STEERI NG
GEAR
STEERI NG
COLUMN
WASHER
N U T
R
J?N" J9119-15
Fig. 6 Coupler Screw Removal
STEERING
COLUMN
COVERS
J908K-33
Fig. 7 Steering Column Cover
STEERI NG
COLUMN
ASSY.
J918J-1
MULTI
^FUNCTI ON
SWI TCH
CONNECTOR
TURN SI GNAL
SWI TCH AND
LEVER
Fig. 8 Multi-function Switch Wiring
(13) Remove t he wiring harness from t he column
by prying out t he plastic ret ai ner buttons (Fig. 8).
(14) Remove t he lower dash panel and support
bracket standoff fasteners (Fig. 1).
(15) Remove t he column out t hrough t he passenger
19 - 38 STEERING
KE Y- I N S WI T C H & MULTI F U N C T I O N
SWITCH CONTROL J918J- 2
Fig. 9 Steering Column Wiring
compartment. Use care to avoid damagi ng t he pai nt
or t ri m.
INSTALLATION
steering col umn shaft and gear shift tube must be
avoi ded duri ng all servi ce procedures.
(1) Column shift vehicles, install a new grommet
(Fig. 10). Use MOPAR Multipurpose Lubricant, or
equivalent, to aid installation of t he grommet. A
new grommet shoul d be used when ever the rod
is di sconnected from the lever.
D I R E C T I O N O F I NS T AL L AT I ON
RN830
Fig. 10 Grommet Installation
(2) Install t he ground clip on t he left spacer slot
(Fig. 11).
(3) Remove t he shipping lock pin (Fig. 1), if neces-
sary.
(4) Install column t hrough floor pan.
(5) Position t he column bracket shear pins on t he
at t achi ng studs. Install, but l oose assembl e t he two
upper bracket washers and nut s.
(6) Wi t h t he front wheels in t he st rai ght -ahead po-
sition. Align t he steering column shaft-to-coupler
screws (Fig. 6). Tighten t he screws to 22.5 N*m (200
in. lbs.) torque.
RN832
Fig. 11 Ground Clip & Spacer Installation
(7) Clip t he wiring harness on t he steering column.
Connect t he multi-function switch wiring and t i ght en
with 7mm socket (Fig. 8).
(8) Install t he upper fixed shroud.
(9) Be sure both breakaway capsules are fully
seated in t he slots in t he column support bracket.
Tighten t he two upper bracket nut s to 12 N-m (105
in. lbs.) torque.
(10) Tighten t he toe plate to floor pan at t achi ng
nut s to 22.5 N-m (200 in. lbs.) torque.
(11) Install t he wiring connections to t he column
(Fig. 10). Install t he lower fixed shroud.
(12) Column shift vehicles, install t he PRNDL
driver cable.
(13) Install t he lock housing shrouds. Install t he
tilt lever (if equipped).
(14) Install t he lower dash panel column cover
(Fig. 7).
(15) Install steering wheel on column, refer to
Steering Wheel-Installation.
(16) Column shift vehicles, connect t he shift link
rod to t he transmission shift lever. Use MOPAR
Multipurpose Lubricant, or an equivalent product, to
aid t he installation.
(17) Check operation of t he transmission shift link-
age and adjust as necessary. Refer to Group 21,
Transmission for t he shift linkage adjustment.
(18) Connect t he bat t ery ground (negative) cable.
COLUMN COMPONENT SERVICE
The Acustar tilt and st andard columns (Fig.l) have
been designed to be serviced as an assembly; less
wiring, switches, shrouds, steering wheel, etc. Most
steering column components can be serviced without
removing t he column from t he vehicle. For additional
information, refer to Group 8H, Electrical.
(1) The gear shift lever (if equipped) can be ser-
viced. Use a drift and a suitable size socket to drive
out t he pin (Fig. 12).
(2) The PRNDL driver can be removed by drilling
out t he rivets. Use care from bending when install-

STEERING 1 9 - 3 9
Fig. 14 Do Not Remove Retainer
1 9 - 4 0 STEERING

TORQUE SPECI FI CATI ONS
STEERING COLUMN STEERING LINKAGE
Description Torque
Steering Wheel to Shaft
Retaining Nut 61 Nm (45 ft. lbs.)
Coupler Bolt 47 Nm (35 ft. lbs.)
Upper Column Bracket
Support Nuts 12N*m(105in. lbs.)
Toe Plate Attaching
Bolts/Nuts 23 Nm (200 in. lbs.)
J9319-61
STEERING GEAR
DESCRIPTION TORQUE
Adjustment Cap Locknut 108 Nm (80 ft. lbs.)
Adjustment Screw Locknut.... 27 Nm (20 ft. lbs.)
Gear to Frame Bolts (2WD) 136 Nm (100 ft. lbs.)
Gear to Frame Bracket (4WD) 176 Nm (130 ft. lbs.)
Gear Frame Bracket to Frame (4WD)... 223 N*m (165 ft. lbs.)
Gear to Frame Bolts (4WD) 203 N*m (150 ft. lbs.)
High Pressure Fluid Line. 35 N*m (25 ft. lbs.)
Intermediate Shaft Pinch
Bolt (Upper and Lower) 47 Nm (35 ft. lbs.)
Pitman Shaft Nut 251 Nm (185 ft. lbs.)
Return Pressure Fluid Line 35 N*m (25 ft. lbs.)
Return Guide Clamp Bolt 5 N*m (4 ft. lbs.)
Rack-Piston Plug 102 Nm (75 ft. lbs.)
Side Cover Bolts 61 N*m (45 ft. lbs.)
J9219-90
DESCRIPTION TORQUE
Center Link to Ball Stud Nuts...,
Drag Link Ball Stud Nuts (4WD-AII)
Idler Arm to Frame Bolts...
Pitman Shaft Nut
Nuts (4WD-Model 44)
Tie-Rod Clamp Nut (Standard
Duty 2WD)....
Tie-Rod Clamp Nut (Heavy Duty 2WD) .
Tie-Rod Clamp Nut (4WD)
tie-Rod End to Center Link Nut.
Tie-Rod End Nut to Steering
Knuckle Arm (2WD). .
Tie-Rod End Nut to Steering
Knuckle Arm (4WD)
88 Nm (65 ft. lbs.)
81 Nm (60 ft. lbs.)
88 N*m (65 ft. lbs.)
251 NTn(185ft. lbs.)
122 N*m (90 ft. lbs.)
25 N^m (225 in. lbs.)
34 Nm (25 ft. lbs.)
34-41 Nm
(25-30 ft. lbs.)
54 Nm (40 ft. lbs.)
54 N*m (40 ft. lbs.)
61 Nm(45ft. lbs.)
J9219-91
STEERING PUMP
DESCRIPTION TORQUE
Flow Control Valve
High Pressure Fluid Line
Oil Cooler to Block Screws
Pump Bracket to Engine
(3.9 and 5.2 L)..
Pump to Bracket (3.9 and 5.2 L)....
Pump to Front Bracket Bolt (5.9 L).
Pump to Rear Bracket Nut (5.9 L)
Pump to Vacuum Pump Nuts
(Diesel Engine)
Pump Assembly to Engine
Block (Diesel Engine)
Pump to Support Bracket Nut
(Diesel Engine)
Remote Reservoir to Acc,
Drive Bracket (5.9 L)
Reservoir to Body Bolts
75 Nm (55 ft. lbs.)
35 N*m (25 ft. lbs.)
41 N*m (30 ft. lbs.)
41 N*m (30 ft. lbs.)
54 Nm (40 ft. lbs.)
41 N*m (30 ft. lbs.)
54 N*m (40 ft. lbs.)
24 Nm (18 ft. lbs.)
77 N*m (57 ft. lbs.)
24 N T H (18 ft. lbs.)
23 N*m (200 in. lbs.)
48 Nm (35 ft. lbs.)
J9219-92
TRANSMISSION AND TRANSFER CASE 21 - 1
CONTENTS
page
AUTOMATIC TRANSMI SSI 0N- 32RH / 36 RH /
37RH/4 2RH/4 6 RH 73
G360 MANUAL TRANSMISSION 46
6360 TRANSMISSION OVERHAUL . . . . . . . . . . 53
NP2Q5 TRANSFER CASE . . . . . . . . . . . . . . . . 34 2
page
NP24 1 TRANSFER CASE 350
NV4 500 MANUAL TRANSMISSION 1
NV4 500 TRANSMISSION OVERHAUL . . . . . . . . . 6
TRANSMISSION/ TRANSFER CASE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 36 4
NV4 300 MANUAL TRANSMISSION
INDEX
page
Gear Ratios 1
Recommended LubricantCapacityFill Level . . . 1
Shift Pattern 1
Transmi ssi on Di agnosi s 2
page
Transmi ssi on Identification 1
Transmi ssi on Installation2-Wheel Drive 4
Transmi ssi on Installation4-Wheel Drive . . . . . . . . 5
Transmi ssi on Removal 2-Wheel Drive 3
Transmi ssi on Removal 4- Wheel Drive 4
GENERAL INFORMATION
The NV4500 is a five-speed, constant mesh manual
transmission (Fig. 1). All gear ranges including re-
verse are synchronized. Fifth gear is an overdrive
range wi t h a ratio of 0.74:1. The transmission has a
cast iron gear case and al umi num shift cover.
The NV4500 is a top loader style transmission. The
shift lever is located in t he shift cover and operates
t he shift forks and rai l s directly. The shift forks and
rails are all located wi t hi n t he al umi num cover
which is bolted to t he top of t he gear case.
A reverse gear inhibitor mechanism prevents re-
verse gear engagement when shifting into forward
gear ranges. The inhibitor mechanism is located in
t he shift cover.
Tapered roller beari ngs support t he drive gear,
mainshaft and countershaft in t he gear case. Pilot
roller bearings in t he drive gear hub support the for-
ward end of t he mainshaft. The mainshaft gears are
all supported on caged type roller bearings. Drive
gear t hr ust reaction is controlled by a needle type
t hrust bearing. The beari ng is located at t he forward
end of t he mainshaft.
TRANSMISSION IDENTIFICATION
The NV4500 transmission identification t ag is at-
tached to t he driver side PTO cover (Fig. 2).
The t ag provides t he transmission model number,
build dat e and par t number. Be sure to reinstall t he
I.D. t ag if removed during service. The information
on t he t ag is essential to correct part s ordering.
RECOMMENDED LUBRI CANT- CAPACI TY- F I LL
LEVEL
Recommended lubricant for t he NV4500 is Castrol
Syntorq. This is a SAE 75W-90 synthetic gear lubri-
cant wi t h an API grade rat i ng of GL 4. Syntorq is
t he onl y lubricant recommended for use in NV4500
transmissions.
Dry fill lubricant capacity is approximately 3.78 li-
t ers (8 pints).
Correct lubricant fill level is to t he bottom edge of
t he fill plug hole (Fig. 3). Check fill level only when
t he transmission is level.
GEAR RATIOS
NV4500 gear ratios are:
Fi rst gear: 5.61:1
Second gear: 3.04:1
Third gear: 1.67:1
Fourt h gear: 1.00:1
Fifth gear: 0.74:1
Reverse gear: 5.61:1
SHIFT PATTERN
The NV4500 shift pat t ern is in a modified H pat-
t ern (Fig. 4). Overdrive fifth and reverse gears are in
line and outboard of t he first t hrough fourth gear po-
sitions.
T R A N S M I S S I O N A N D T R A N S F E R C A S E
21 - 2 NV4500 MANUAL TRANSMISSION

2WD
VERSION
4WD
VERSION
J9221-15
Fig. 1 NV4500 Manual Transmission
TRANSMISSION DIAGNOSIS
COMMON PROBLEM CAUSES
The majority of transmission malfunctions are a re-
sult of:
insufficient lubricant
incorrect lubricant
misassembled or damaged i nt ernal components
improper operation.
mon causes of hard shifting. If hard shifting is also
accompanied by gear clash, synchronizer clutch and
stop rings, or mainshaft gear t eet h may be worn or
damaged.
Hard shifting may also be caused by a loose, or
misaligned shift cover, or alignment dowels. Worn, or
damaged shift cover components will also cause har d
shifting. Any of t he foregoing faults will cause com-
ponent bind and high shift efforts.
Misassembled synchro components will also cause
shift problems. Incorrectly installed synchro sleeves,
st rut s, or springs will all cause shift problems.
HARD SHIFTING
A low lubricant level, loose or worn shift lever, or
loose, damaged shift housing components are com-

NV4500 MANUAL TRANSMISSION 21 - 3
PTO
COVER
J9221-14
Fig. 2 NV4500 identification Tag Location
DRAIN
PLUG J9221-80
Fig. 3 NV4500 Drain And Fill Plug Locations
o 0
0 0
J9221-13
Fig. 4 NV4500 Shitt Pattern
NOISY OPERATION
Transmission noise is most often a result of worn
or damaged components. Chipped, broken gear or
synchronizer t eet h and brinnelled, spalled beari ngs
all cause noise.
Abnormal wear and damage to internal compo-
nent s is frequently t he end result of insufficient lu-
bricant, non-recommended lubricants, or improper
operation.
SLIPS OUT OF GEAR
Transmission disengagement may be caused by
misaligned or damaged shift components, or worn
t eet h on t he mainshaft gears or synchro components.
Incorrect assembly will also contribute to gear disen-
gagement.
LOW LUBRICANT LEWEL
Insufficient transmission lubricant is usually t he
result of leaks, or inaccurate fluid level check or re-
fill method.
Leaks will be evident by t he presence of gear oil
around t he leak point. If leakage is not evident, t he
condition is probably t he result of an underfill condi-
tion.
If air powered lubrication equipment is used to fill
a transmission, be sure t he equi pment is properly
calibrated. Equipment out of calibration can lead to
an underfill condition.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash and noise.
A damaged pilot beari ng will cause noise. If bear-
ing damage is severe, drive gear mi sal i gnment and
hard shifting can also occur.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
Damaged or worn clutch hydraulic components, or
leaks in t he fluid lines or cylinders will cause hard
shifting and gear clash. Fai l ure of one of t he clutch
hydraulic cylinders can result in incomplete clutch
release or engagement.
Verify t hat clutch components are all in good con-
dition before removing t he transmission for repair.
TRANSMI SSI ON REMOVAL2-WHEEL DRIVE
(2) Shift transmission into Neut ral .
(3) Remove screws at t achi ng shift boot to floorpan.
Then slide boot upward on lever.
(4) Loosen nut t hat secures shift lever on t ransmi s-
sion st ub lever. Then remove shift lever from stub le-
ver.
(6) Mark propeller shaft and axle yokes for align-
ment reference. Use paint, scriber, or chalk to mark
yokes.
(7) Remove U-joint clamp st rap screws and remove
clamps.
(8) Remove propeller shaft.
(9) Disconnect and remove exhaust system Y-pipe.
(10) Disconnect wires at speed sensor and backup
light switch.
(11) Support engine with adjustable safety stand
and wood block.
21 - 4 NV4500 MANUAL TRANSMISSION
(12) If transmission is to be disassembled for re-
pair, remove drain plug and drai n lubricant from
transmission.
(13) move bolts/nuts at t achi ng transmission to rear
mount.
(14) Support transmission with a transmission
jack. Secure transmission to jack with safety chains.
(15) Remove rear crossmember,
(16) Remove bolts at t achi ng clutch slave cylinder
to clutch housing. Then move cylinder aside for
working clearance.
(17) Remove transmission harness wires from clips
on transmission shift cover.
(18) Remove bolts at t achi ng transmission to clutch
housing.
(19) Slide transmission and jack rearward unt i l
drive gear clears clutch housing.
(20) Lower transmission jack and remove t rans-
mission from under vehicle.
(21) If transmission will be overhauled, clean
transmission exterior with solvent or with st eam
gun.
TRANSMISSION INSTALLATION2-WHEEL DRIVE
(1) Apply light coat of Mopar hi gh t emperat ure
beari ng grease to contact surfaces of following com-
ponents:
drive gear splines and pilot beari ng hub
release bearing slide surface of front ret ai ner
pilot beari ng
release bearing bore
release fork
release fork ball stud
propeller shaft slip yoke
(2) Fill transmission with recommended lubricant.
Correct fill level is bottom edge of fill plug hole.
(3) Mount transmission on jack and position t rans-
mission under vehicle.
(4) Raise transmission unt i l drive gear is centered
in release bearing and clutch disc hub.
(5) Move transmission forward and st art drive gear
in release bearing, clutch disc and pilot bushing.
(6) Work transmission forward unt i l seated agai nst
clutch housing. Do not allow transmission to remai n
unsupported after drive gear has entered clutch disc.
(7) Install and t i ght en transmission-to-clutch hous-
ing bolts to 108 N*m (80 ft. lbs.) torque.
(8) Install clutch slave cylinder.
(9) Connect speed sensor and backup light switch
wires.
(10) Position transmission harness wires in clips
on shift cover.
(11) Install transmission mount on transmission or
rear crossmember.
(12) Install rear crossmember.
(13) Remove transmission jack and engine support
fixture.
(14) Align and connect propeller shaft.
(15) Fill transmission with required lubricant, if
necessary.
(16) Lower vehicle.
(17) Install shift lever on transmission stub lever.
(18) Install shift boot and bezel.
(19) Connect bat t ery negative cable.
TRANSMISSION REMOVAL4-WHEEL DRIVE
(2) Shift transmission into Neut ral .
(3) Remove shift lever boot and bezel.
(4) Loosen nut at t achi ng shift lever to t ransmi s-
sion stub lever and remove shift lever from stub le-
ver.
(5) Raise- vehicle.
(6) Remove skid plate if equipped.
(7) If transmission will be disassembled for repair,
remove drain plug and drain lubricant from t rans-
mission.
(8) Mark propeller shafts and yokes for assembly
reference.
(9) Disconnect propeller shafts and remove propel-
ler shafts.
(10) Disconnect and remove exhaust system
Y-pipe. Then disconnect and lower remai ni ng ex-
haust pipes for clearance as necessary.
(11) Support engine with adjustable safety stand.
(12) Disconnect speed sensor wires and disconnect
speedometer cable, if equipped.
(13) Disconnect backup light switch wires.
(14) Disconnect transfer case shift linkage at
transfer case range lever.
(15) Remove bolts/nuts at t achi ng transmission to
rear support.
(16) Remove crossmember bolts/nuts and remove
crossmember.
(17) Support transfer case with transmission jack.
Secure transfer case to jack with safety chains.
(18) Remove transfer case at t achi ng nut s.
(19) Move transfer case rearward unt i l input gear
clears transmission mainshaft.
(20) Lower transfer case assembly and move it
from under vehicle.
(21) If transmission is being removed for repair,
remove drai n plug and drain lubricant from t rans-
mission.
(22) Support transmission with transmission jack.
Secure transmission to jack with safety chains.
(23) Remove transmission harness from ret ai ni ng
clips on transmission shift cover.
(24) Remove bolts/nuts at t achi ng transmission
mount to rear crossmember.
(25) Remove rear crossmember.
(26) Remove clutch slave cylinder splash shield, if
equipped.
(27) Loosen clutch slave cylinder at t achi ng nut s
unt i l cylinder piston rod is clear of release lever.
This reduces pressure on lever and release bearing
1 . NW4500 MANUAL TRANSMISSION 21 - 5
maki ng transmission removal/installation easier.
Cylinder does not have to be removed completely.
(28) Remove bolts at t achi ng t ransmi ssi on to clutch
housing.
(29) Move transmission rearward unt i l drive pin-
ion clears clutch disc and release beari ng.
(30) Lower transmission and remove i t from under
vehicle.
(31) If transmission will be overhauled, thoroughly
clean transmission exterior with solvent or steam
gun.
TRANSMISSION INSTALLATION-4-WHEEL DRIVE
(1) Apply light coat of Mopar hi gh t emperat ure
bearing grease to contact surfaces of following com-
ponents:
drive gear splines and pilot beari ng hub
release beari ng slide surface of front ret ai ner
pilot beari ng
release beari ng bore
release fork
(2) Fill transmission with recommended lubricant.
Correct level is to bottom edge of fill plug hole.
(3) Mount transmission on jack and position t rans-
mission under vehicle. Secure transmission to jack
with safety chains.
(4) Raise transmission unt i l drive gear is centered
in release beari ng and clutch disc hub.
(5) Move transmission forward and st art drive gear
in release beari ng and clutch disc.
(6) Work transmission forward unt i l seated agai nst
clutch housing. Do not allow transmission to remai n
unsupported after drive gear has entered clutch disc.
ing bolts to 108 N*m (80 ft. lbs.) torque.
(8) Connect speed sensor and backup light switch
wires.
(9) Position t ransmi ssi on harness wires i n clips on
shift cover.
(10) Tighten slave cylinder at t achi ng nut s and in-
stall slave cylinder shield, if equipped.
(11) Install t ransmi ssi on mount on transmission or
rear crossmember.
(13) Remove t ransmi ssi on j ack and engine support
fixture.
(14) Install transfer case on transmission jack. Se-
cure transfer case to jack wi t h safety chains.
(15) Install new gasket on transmission adapter, or
coat adapter sealing surface with Mopar Gasket
Maker, or silicone adhesive sealer.
(16) Raise jack and align transfer case i nput gear
with transmission mainshaft.
(17) Move transfer case forward and seat it on
adapter.
(18) Install and t i ght en transfer case at t achi ng
nut s to 47 Nm (35 ft. lbs.) torque.
(19) Connect transfer case shift lever to range le-
ver on transfer case.
(20) Align and connect propeller shafts. Tighten
U-joint clamp st rap bolts to 19 N*m (170 in. lbs.)
torque.
(21) Check lubricant levels in transmission and
transfer case. Add lubricant if necessary.
(22) Install transfer case skid plate and crossmem-
ber. Tighten at t achi ng bolts/nuts to 41 Nm (30 ft.
lbs.) torque.
(23) Install exhaust system components.
(24) Lower vehicle.
(25) Install transmission shift lever, boot and be-
zel.
21 - i NV4500 TRANSMI SSI ON OVERHAUL
NV4 500 TRAN SM I SSI ON OVERHAUL
INDEX
page
Shift Cover Service . . . . . . . . . . . . . . . . . . . . . . . 4 3
Transmi ssi on Assembl y and Adjustment . . . . . . . 26
TRANSMI SSI ON DI SASSEMBLY
SHIFT COVER REMOVAL
(1) Remove shift cover bolts (Fig. 1).
Fig. 1 Shift Cower Bolt Removal/installation
(2) Loosen shift cover with pry tool. To avoid dam-
aging cover seal surface, insert pry tool only in slots
provided in cover (Fig. 2) .
SHIFT
COVER
SLOT
Fig. 2 Loosening Shift Cover
(3) Raise cover enough to disengage it from align-
ment dowels in gear case (Fig. 3).
(4) Raise front of shift cover and lift cover up and
off gear case (Fig. 3).
page
Transmi ssi on Cleaning and Inspection . . . . . . . . . 21
Transmi ssi on Di sassembl y 6
(5) Set cover assembly aside for inspection. If cover
components are damaged, refer to shift cover service
information.
SHIFT
COVER
Fig. 3 Shift Cover Removal/installation
EXTENSION/ADAPTER HOUSING REMOVAL
(1) Remove bolts attaching extension/adapter hous-
ing to gear case (Fig. 4 ) . Use 10 mm, 12 point socket
to remove housing bolts. Loosen bolts 4-5 threads
with socket and ratchet first. An air wrench can then
be used to complete removal but only after bolts are
loose.
C A U T I O N : Spl i ne head bol ts are used to attach the
extensi on or adapter housi ng to the gear case. The
bolt spl i nes are easily damaged if the wrong tool i s
used to l oosen and remove them. U se a 10 mm, 12
point socket or box end wrench onl y.
(2) Remove extension/adapter housing (Fig. 5). Tap
housing with rubber mallet to loosen it. Then break
sealer bead with putty knife and work housing off
alignment dowels with two pry tools. One alignment
dowel is in case. Other dowel is in housing.
(3) Remove spline seal from end of mainshaft (Fig.
6). The seal can be reused or di scarded as de-
sired. The seal is not an essenti al part and can
be reused or di scarded as desired. The seal is
mai nl y used to prevent lubricant l oss duri ng
shi ppi ng and does not have to be repl aced if
damaged.
NV4500 TRANSMI SSI ON OVERHAUL 21 - 7
EXTENSI ON
HO U S I N G
SPLINE
HEAD
BOLTS (8)
J9221-84
Fig. 4 Extension/Adapter Housing Bolts
EXTENSI ON
HO U S I N G
GEAR
CASE
J9221-85
Fig. 5 Extension/Adapter Housing
MAI NS HAFT RUBBER
SPLINE
SEAL
J 92 2 1- 86
Fig. 6 Mainshaft Spline Seal
(4) On 2-wheel drive models, remove extension
housing seal (Fig. 7). Seal can be removed by collaps-
ing one side with punch t hen prying seal out wi t h
suitable tool.
(5) Note that 4-wheel drive adapter housi ng
does not have a seal (Fig. 8).
2-WHEEL-DRI VE
EXTENSI ON
HO U S I N G
SEAL
J 92 2 1- 87
Fig. 7 Extension Housing And Seal (2-Wheel Drive
Models)
4-WHEEL-DRI VE
ADAPTER
HO U S I N G
J 92 2 1- 88
Fig. 8 Adapter Housing (4-Wheel Drive Models)
MAINSHAFT AND COUNTERSHAFT FIFTH
GEAR REMOWAL
The fifth gear components can be removed in-
dividually or as an assembl y. If the fifth gear
components are only bei ng removed for access
to another component, remove them as an as-
sembly. However, if any of the fifth gear compo-
nents require service, remove them individually.
Procedures for both removal methods are pro-
vi ded bel ow.
Removing Countershaft Fifth Gear Components As Assembly
(1) Remove snap ri ng t hat secures fifth speed
clutch gear on countershaft (Fig. 9).
(2) Remove roll pins t hat secure countershaft fifth
gear shift fork to shift rai l with pin punch (Fig. 10).
Roll pins are dri ven out from bottom of fork and
not from top.
21 - 8 NV4500 TRANSMI SSI ON OVERHAUL ^ _ _ _ _ - #
CLUTCH
GEAR J 92 2 1- 89
Fig. 9 Removing Countershaft Fifth Speed Clutch
Gear Snap Ring
FIFTH GEAR
SHIFT FORK J 9221 - 94
Fig. 10 Removing Fifth Gear Shift Fork Roil Pins
(3) Remove shift fork and fifth gear components as
assembly. Rotate mainshaft as needed to allow coun-
tershaft fifth gear to clear mainshaft fifth gear.
Removing Countershaft Fifth Gear Components Individually
(1) Remove snap ri ng t hat secures fifth speed
clutch gear on countershaft (Fig. 9).
(2) Remove countershaft fifth speed clutch gear,
stop ri ng and beari ng spacer (Fig. 11).
(3) Remove t hree st rut s and st rut springs from
countershaft fifth gear hub and sleeve (Fig. 11).
(4) Remove mainshaft fifth gear nut and washer as
follows:
(a) Install Nut Wrench 6443 on fifth gear nut
(Fig. 12). Note t hat wrench only fits one way on
nut . Be sure wrench is fully engaged in nut slots
and is not cocked.
(b) On 2-wheel drive models, install Socket
Wrench 6441 on mainshaft splines. On 4-wheel
drive models, install Socket Wrench 6442 on mai n-
shaft splines. Then install breaker bar in socket
wrench (Fig. 13). Wedge breaker bar handl e
J 9221 - 90 GEAR
Fig. 11 Removing Countershaft Fifth Gear Synchro
Components
agai nst workbench. Purpose of socket wrench and
breaker bar is to prevent mainshaft from t ur ni ng
while nut is loosened.
(c) Position small end of Nut Wrench 6443 at ap-
proximately 10 o'clock position (Fig. 12).
(d) Strike small end of Nut Wrench 6443 wi t h
heavy copper hammer to break nut loose. Nut is se-
cured by interference fit t hread plus Loctite adhe-
sive and will require several firm blows to loosen it
(nut torque is in 300 ft. lb. range).
(e) Once nut is loose, it can be removed by hold-
ing nut wrench with breaker bar and rot at i ng out-
put shaft with socket wrench and ratchet.
(f) Remove fifth gear nut and coned washer from
shaft (Fig. 14). Note position of washer for assem-
bly reference (coned side of washer faces rear).
SPECIAL STRIKE
NUT J 9221 - 91
Fig. 12 installing Nut Wrench On Mainshaft Fifth
Gear
NV4 500 TRANSMISSION OVERHAUL 21 - I
SPECIAL FIFTH
RATCHET
WR E N C H J 92 2 1- 92
Fig. 13 Removing Mainshaft Fifth Gear Nut From
Shaft Threads
FIFTH NUT
Fig. 14 Mainshaft Fifth Gear Nut And Washer
Removal
(5) Remove roll pins t hat secure countershaft fifth
gear shift fork to shift rai l wi t h pin punch (Fig. 10).
Rol l pi ns a r e dr i ven o u t from b o t t o m of f or k a n d
not from t op.
(6) Remove fifth gear shift fork and sleeve as as-
sembly (Fig. 15). Remove fork by t appi ng it off rail
with plastic mallet. Leave sl eeve engaged i n f or k
or not e posi t i on of sl eeve for as s embl y refer-
ence.
(7) Remove countershaft fifth gear and hub assem-
bly (Fig. 16).
(8) Remove countershaft fifth gear needle bearing
assemblies (Fig. 17).
(9) Remove cone shaped rear beari ng t hr ust
washer from end of countershaft (Fig. 18). Note posi-
tion of washer for assembly reference. Also note t hat
PLASTIC FIFTH
Fig. 15 Fifth Gear Shift Fork And Sleeve Removal
Fig. 16 Removing Countershaft Fifth Gear And
Synchro Hub Assembly
washer bore has notch for locating pin.
(10) Remove and ret ai n t hrust washer locating pin
from countershaft (Fig. 19).
Fig. 17 Countershaft Fifth Gear Needle Bearing
Removal
21 - 10 NV4500 TRANSMISSION OVERHAUL
SPECIAL TOOL
645 9
SPECIAL TOOLS
6444- 3 (3 REQD.)
THRUST
WASHER
PIN
THRUST
WASHER
(CONE SHAPED)
J9221-98
J9221-100
Fig. 18 Countershaft Rear Bearing Thrust Washer
Removal
(11) Remove mainshaft fifth gear with Puller Tool
Set 6444 as follows:
(a) Position first Puller J aw 6459 on gear (Fig.
19).
nr m
Fig. 20 Seating Puller Flange In First Puller Jaw
SPECIAL TOOL
6 4 4 4 - 8
J9221-101
Fig. 21 Installing Retaining Collar Over Puller Jaws
SPECIAL TOOL
6444- 8
1 MAINSHAFT
J9221-99
Fig. 19 Installing First Puller Jaw On Mainshaft Fifth
Gear
(b) Assemble Puller Fl ange 6444-1 and Puller
Rods 6444-3 (Fig. 2 0 ) .
(c) Slide assembled puller flange and rods onto
output shaft. Then seat flange in notch of puller
j aw (Fig. 20) .
(d) Position second Puller J aw 6459 on gear and
in notch of puller flange (Fig. 21).
(e) Slide Ret ai ni ng Collar 6444-8 over puller
j aws to hold t hem in place (Fig. 21).
(f) Install Puller and Bolt 6444 on puller rods.
Then secure puller to rods with ret ai ni ng nut s (Fig.
22).
SPECIAL TOOL
645 9
SPECIAL TOOL
6444
MAINSHAFT
SPECIAL TOOL
6444- 3
HOLDING
WRENCH
J9221-190
Fig. 22 Removing Fifth Gear From Mainshaft Splines
(g) Ti ght en puller bolt to remove gear from shaft
splines (Fig. 22).

NV4500 TRANSMISSION OVERHAUL 21 - 11
(12) Remove bolts at t achi ng mainshaft rear bear-
ing pl at e to gear case and remove fifth gear, plate,
end play shims and beari ng cup (Fig. 28),
. MAI NSH AF T REAR
BE ARI NG CUP
BE ARI NG
SH I MS
BE ARI NG
PLATE
FIFTH GE AR
J 9221- 102
Fig. 23 Removing Mainshaft Fifth Gear, Bearing
Plate, Bearing Shims And Rear Bearing Cup
FRONT RETAINER REMOWAL AND
DISASSEMBLY
(1) Remove front ret ai ner bolts (Fig. 24).
FRONT BEARING
RETAINER
J 9221- 103
Fig. 24 Removing Front Bearing Retainer Bolts
(2) Remove front ret ai ner by lightly t appi ng it
back and forth with plastic mallet to loosen it. Then
rock ret ai ner back and forth by hand to work it out
of gear case. Note t hat ret ai ner flange extends into
and is fairly snug fit in case bore.
(3) Remove seal from front ret ai ner (Fig. 25). Use
small chisel to collapse one side of seal t hen pry it
out with suitable tool.
(4) Remove bearing cup from front retainer as fol-
lows:
(a) Assemble Puller Flange 6444-1 and Puller
Rods 6444-6 (Fig. 26).
(b) Insert Puller Jaws 6453-1 in puller flange
(Fig. 26). Narrow lip of puller jaws will go under
beari ng cup.
(c) Install assembled tools in front retainer (Fig.
27). Be sure puller jaws are seated under bearing cup.
(d) Place Insert Tool 6453-2 in center of puller
jaws (Fig. 27). Insert tool is used to hold puller
jaws in place.
FRONT BEARING
RETAINER
SEAL
Fig. 25 Removing Bearing Retainer Seal
SPECIAL
TOOL
6 4 53- 1
SPECIAL
TOOL
6444-4
SPECIAL
TOOL
6 4 4 4 - 1
J 9221 - 1 7 8 X
Fig. 26 Assembling Puller Rods, Flange And Jaws
SPECIAL
TOOL
6 4 5 3
SPECIAL
TOOL
6 4 53- 2
FRONT
RETAINER J 9221 - 1 7 9
Fig. 27 Installing Puller Tools In Front Retainer
2 1 - 1 2 NV45Q0 TRANSMISSION OVERHAUL

(e) Install Puller 6444 on puller rods (Fig. 28).
Then install ret ai ni ng nut s on puller rods.
(f) Tighten puller bolt to draw beari ng cup out of
ret ai ner (Fig. 28). Use holding wrench on puller
and t ur n puller bolt with adjustable wrench.
TIGHTENING
WRENCH
HOLDING
WRENCH
SPECIAL
TOOL
6453-2
FRONT
RETAINER J92 2 M80
Fig. 28 Removing Bearing Cup From Front Retainer
DRIVE GEAR REMOVAL AND DISASSEMBLY
(1) Remove drive gear. Tilt gear downward and out
of case (Fig. 29).
(2) Remove pilot beari ng from drive gear (Fig. 30).
(3) Remove bearing from drive gear as follows:
J9221-105
DRIVE GEAR
MAI NSHAFT
PILOT BEARI NG
J9221-106
Fig. 30 Pilot Bearing Removal/Installation
(a) Note t hat puller tool assembly and setup is
similar to t hat used for removing fifth gear from
mainshaft (Figs. 19-23).
(b) Assemble Puller Fl ange 6444-1 and Puller
Rods 6444-4. Then position first Puller Jaw 6447
on gear (Fig. 31).
(c) Slide assembled puller flange and rod tools
onto output shaft. Then seat flange in notch of
puller j aw (Fig. 31).
(d) Position second Puller J aw 6447 on gear and
in notch of puller flange (Fig. 31).
SPECIAL TOOL
6444
DRIVE GEAR
SPECIAL
TOOL
6 4 4 4 - 1
SPECIAL
TOOLS
6444-6 (3)
SPECIAL TOOLS
6447 (2)
Fig. 29 Drive Gear Removal
SPECIAL TOOL
6444-8
J9221-115X
Fig. 31 Removing Front Bearing From Drive Gear
+
MAINSHAFT AND GEARTRAIN REMOVAL
(1) Remove countershaft rear bearing plate (Fig.
32).
Fig. 32 Removing Countershaft Rear Bearing Plate
(2) Remove countershaft end play shim and rear
bearing cup (Fig. 33).
Fig. 33 Countershaft End Play Shim And Rear
Bearing Cup Removal
(3) Remove reverse idler shaft. Thread a shift
cover bolt into shaft and withdraw shaft from case
(Fig. 34).
(4) Move 1-2 and 3-4 synchro sleeves into Neut ral ,
if necessary.
(5) Remove drive gear t hrust bearing from forward
end of mainshaft (Fig. 35).
(6) Remove fourth speed clutch gear and synchro
stop ring from mainshaft (Fig. 36).
N4S0O TRANSMISSION OVERHAUL 21 - 13
Fig. 34 Removing Reverse Idler Shaft
Fig. 35 Drive Gear Thrust Bearing Removal
Fig. 36 Fourth Speed Clutch Gear Stop Ring
Removal
(7) Roll gear case onto left side (Fig. 37).
(8) Reach into gear case and push reverse idler
gear away from mainshaft gears.
(9) Remove mainshaft assembly as follows (Fig.
37):
(a) Lift front end of mainshaft slightly.
(b) Grasp mainshaft rear splines. Then t ur n
spline end of mainshaft in counterclockwise direc-
tion to rot at e shaft and geart rai n out of case.
(c) Once mainshaft gears roll clear of counter-
shaft gears, shaft and gear assembly can be tilted
outward and removed from gear case (Fig. 37).
jaws to hold t hem in place (Fig. 31).
(f) Install Puller 6444 on puller rods. Then se-
cure puller to rods wi t h ret ai ni ng nut s (Fig. 31).
(g) Tighten puller bolt to remove bearing cone
from drive gear (Fig. 31).
Fig. 37 Mainshaft And Geartrain Removal
(10) Refer to mainshaft disassembly procedures if
any gears or synchro components must be replaced.
REVERSE IDLER GEAR AMD COUNTERSHAFT
REMOVAL/DISASSEMBL
(1) Rotate countershaft outward and push reverse
idler gear away from countershaft and toward front
of case (Fig. 38).
Fig. 38 idler Gear Moved Away From Countershaft
(2) Remove idler gear t hrough drive gear bore at
front of case (Fig. 39).
(3) Keep reverse idler gear bearings and spacer to-
gether for cleaning and inspection (Fig. 40). Insert
idler shaft t hrough gear and bearings to keep t hem
in place.
(4) Remove idler gear t hrust washers from gear
case. Install washers on idler shaft to keep t hem to-
gether for cleaning and inspection.
(5) Remove countershaft r e a r bearing. Shaft can-
not be removed from case unt i l rear beari ng has been
removed. Bearing removal procedure is as follows:
Rods 6444-6 (Fig. 41).

J922M14
Fig. 39 Reverse Idler Gear Removal
REVERSE
BEARI NGS IDLER
Fig. 40 Reverse Idler Gear Components
(b) Position first Puller J aw 6449 on beari ng
cone (Fig. 41).
(c) Seat puller flange in notch of puller j aw j ust
installed on bearing cone (Fig. 41).
(d) Install second Puller J aw 6449 on beari ng
and in notch of puller flange (Fig. 41).
(e) Slide Retaining Collar 6444-8 over puller
jaws to hold t hem in place (Fig. 41). Note t hat re-
t ai ni ng collar has small lip on one end and only
fits one way over jaws.
Fig. 41 Removing Countershaft Rear Bearing

cure puller to rods wi t h ret ai ni ng nut s (Fig. 41).
(g) Tighten puller bolt to remove bearing from
shaft (Fig. 41). If beari ng is exceptionally tight, t ap
end of puller bolt wi t h copper mallet to help loosen
bearing.
(6) Remove beari ng puller tools.
(7) Rotate countershaft out of gear case (Fig. 42).
Fig. 42 Removing Countershaft From Gear Case
(8) Remove countershaft front beari ng as follows:
(a) Assemble Pul l er Flange 6444-1 and Puller
Bolts 6444-6 (Fig. 43).
(b) Position first Puller Jaw 6451 on bearing.
(c) Seat puller flange in notch of puller jaw.
(d) Install second Puller J aw 6451 on beari ng
and in notch of puller flange.
(f) Install Puller Bridge And Bolt Assembly 6444
on puller bolts. Then secure bridge to bolts with re-
t ai ni ng nut s (Fig. 43).
J922M 59X 6444-4
Fig. 43 Removing Countershaft Front Bearing
(g) Tighten puller bolt to remove beari ng from
shaft (Fig. 43). If bearing is exceptionally t i ght , tap
end of puller bolt with mallet to help loosen bear-
ing.
(9) Remove bearing puller tools.
(10) Set countershaft and idler gear aside for
cleaning and inspection.
GEAR CASE DISASSEMBL
(1) Remove countershaft front bearing cap. Use
mal l et or hammer to remove cap from inside case
(Fig. 44).
Fig. 44 Countershaft Front Bearing Cap Removal
(2) Remove countershaft front beari ng cup with
Remover Tool 6454 and Tool Handle C-4171 (Fig.
45).
Fig. 45 Countershaft Front Bearing Cup Removal
(3) Remove roll pin t hat secures shift lug on shift
rai l in case (Fig. 46). A small pin punch can be mod-
ified by put t i ng a slight bend in it to drive pin com-
pletely out of shift rail (Fig. 46).
(4) Remove shift lug rail by tapping it out of case
and shift lug with tapered punch (Fig. 47). Note po-
sition of rai l and lug for assembly reference.
(5) Remove lug rail bushings from gear case with
Special Tool 6456 (Fig. 48).
(6) Unclip and remove magnet from bottom of gear
case (Fig. 49).
21 - 16 NV4 500 TRANSMISSION OVERHAUL
Fig. 46 Removing Shift Lug Roii Pin
Fig. 4? Removing Shift Lug Rali
Fig. 48 Removing Shift Lug Rail Bushings
Fig. 49 Gear Case Magnet Location
c hr o component s can be i nst al l ed b a c k wa r d s .
To avoi d r eas s embl y pr obl ems , ma r k t he s peed
gear s , cl ut ch gear s , s ync hr o hubs , a n d sl eeves
for r ef er ence dur i ng t e a r down. Use pa i nt or a
s cr i ber for ma r ki ng pur pos e s . T h e n s t ack t he
ge a r t r a i n pa r t s i n o r d e r of r emoval . Thi s pr a c -
t i ce wi l l hel p avoi d i ncor r ect as s embl y a n d l ost
t i me.
(1) Remove drive gear t hrust beari ng from end of
mainshaft, if not previously removed.
(2) Remove fourth gear synchro st rut s and springs
from 3-4 hub and sleeve (Fig. 50). Three st rut s and
springs are used. Keep springs and st rut s together
for inspection and cleaning. Store part s in a paper
cup to avoid losing them.
Fig. 50 3-4 Synchro Strut And Spring Removal
(3) Remove 3-4 sleeve from 3-4 synchro hub (Fig.
51).
(4) Remove 3-4 synchro hub from mainshaft
splines with suitable size beari ng splitter, or with
two tapered drifts. Position splitter or drifts between
t hi rd gear stop ri ng to st art moving hub off shaft.
Then complete hub removal by tapping it off shaft
with plastic mallet. Tap hub at 6-8 different points to
remove hub evenly.
MAINSHAFT DISASSEMBLY
No t al l of t h e ma i n s h a f t g e a r a n d s y n c h r o c o m-
p o n e n t s a r e a o n e - wa y fit. S o me g e a r a n d syn-
J 9 2 2 M 1 9
Fig. 51 Removing 3-4 Sieeve From Hub
THIRD
GEAR
NEEDLE
BEARING
ASSEMBLI ES
THIRD
GEAR
THIRD
GEAR
STOP
RING
J 9 2 2 M 2 1
Fig. 53 Third Gear Needle Bearing Removal
S E COND
GE AR THRUST
WASHER
THRUST
WASHER
S NAP R I NG
THIRD GEAR
BEARI NG
SPACER
3-4
S YNCHRO
HUB
J9221 - 1 22
Fig. 54 Bearing Spacer And Snap Ring Location
SECOND
GEAR
J 9 2 2 M 2 0
Fig. 52 Third Gear, Stop Ring And 3-4 Hub Removal
(5) Remove 3-4 synchro hub, third gear stop ri ng
and t hi rd gear (Fig. 52).
(6) Remove t hi rd gear bearing assemblies from
mainshaft (Fig. 53).
(7) Remove t hi rd gear bearing spacer (Fig. 54).
(8) Remove snap ring t hat ret ai ns second gear
t hrust washer on mainshaft (Fig. 54).
(9) Remove second gear t hrust washer (Fig. 55).
Note t hat washer is notched for locating pin.
THRUST
WASHER
SECOND
GEAR
BEARI NG J 9221 - 1 23
Fig. 55 Second Gear Thrust Washer Removal
2 1 - 1 8 NV4500 TRANSMISSION OVERHAUL
Fig. 56 Second Gear Removal
Fig. 57 Second Gear Bearing Removal
Fig. 58 Thrust Washer Locating Pin Removal
(10) Remove second gear (Fig. 56).
(11) Remove second gear beari ng assembly (Fig.
57).

J 9 2 2 M 2 7
Fig. 59 Removing Second Speed Clutch Gear Snap
Ring
Fig. 60 Second Speed Clutch Gear, Clutch Ring And
Stop Ring Removal
(13) Remove snap ring t hat ret ai ns second speed
clutch gear (Fig. 59). Snap ring is seated in main-
shaft synchro hub groove.
(14) Remove second speed clutch gear, synchro
clutch ri ng and synchro stop ring (Fig. 60).
(15) Remove 1-2 synchro hub snap ri ng (Fig. 61).
(16) Mark position of 1-2 synchro sleeve and hub
for assembly reference. Side of hub with flat hub
spring goes toward front (Fig. 62). Note t hat tapered
side of sleeve also goes toward front.
(17) Remove 1-2 synchro sleeve, hub, st rut s and
springs as an assembly (Fig. 62). It is not necessary
to disassemble synchro components unless worn, or
damaged.
(18) Remove first gear synchro stop ri ng and
clutch ri ng (Fig. 63).
(19) Remove first speed clutch gear front snap ri ng
from mainshaft hub (Fig. 64).
(20) Remove first speed clutch gear (Fig. 65).
(12) Remove t hr ust washer locating pin (Fig. 58).
Use needle nose pliers to grip and remove pin.
NV4500 TRANSMI SSI ON OVERHAUL 21 - 19
J9221-129
Fig. 81 Hemming 1-2 Sleeve And Hub Snap Ring
1-2
SLEEVE
AND HUB
(MARK
POSI TI ON FOR
ASSEMBLY
REFERENCE)
HUB SPRI NG
J9221-130
Fig. 62 Removing 1-2 Synchro Sleeve And Hub
FIRST GEAR
CLUTCH RING
FIRST GE AR
STOP RI NG J922M31
Fig. 63 First Gear Stop And Clutch Ring Removal
(21) Remove first speed clutch gear rear snap ring
from mainshaft hub (Fig, 65). It is not really neces-
sary to remove this snap ring unless it, or t he main-
shaft is to be replaced.
( 2 2 ) Remove mainshaft rear beari ng as follows:
FIRST
SPEED
CLUTCH
GEAR
CLUTCH
GEAR
S N A P
R I NG
(FRONT)
J922M32
Fig. 64 First Speed Clutch Gear Front Snap Ring
Removal
CLUTCH GEAR
S NAP RI NG (REAR)
FIRST
SPEED
CLUTCH
GEAR
J9221-133
Fig. 65 First Speed Clutch Gear Removal
Rods 6444-3 (Fig. 66).
(b) Position first Puller Jaw 6445 on bearing
cone (Fig. 66).
(c) Seat Puller Flange 6444-1 in notch of first
puller jaw (Fig. 66).
(d) Install second Puller J aw 6445 on bearing
cone and on puller flange (Fig. 66).
(e) Slide Retaining Collar 6444-8 over puller
cure puller to rods with ret ai ni ng nut s (Fig. 67).
(g) Place holding wrench on hex at top of puller
(Fig. 67). Then t i ght en puller bolt with adjustable
wrench to remove beari ng from shaft (Fig. 67). If
bearing proves difficult to remove, t ap end of puller
bolt with copper hammer after each t ur n of bolt.
This will help loosen beari ng on shaft and ease re-
moval.

Fig. 66 Assembling
SPECIAL
Fig. 67 Removing Mainshaft Rear Bearing
(23) Remove beari ng puller tools.
(24) Remove reverse gear t hr ust washer (Fig. 68).
(25) Remove reverse gear t hr ust washer locating
pin (Fig. 69).
Rear Bearing Puller Tools
REVERSE
GEAR
J922M35
Fig. 68 Reverse Gear Thrust Washer Removal
(26) Remove reverse gear and synchro components
as assembly (Fig. 70). It i s not necessary t o re-
move or di sassembl e synchro components unl ess
they are damaged and need to be repl aced. If
synchro sl eeve or struts require service, mark
posi ti on of sl eeve on hub before removal. Cor-
rect sl eeve posi ti on is important as sl eeve can be
i nstal l ed backwards causi ng shift probl ems.
(27) Remove reverse gear beari ng assembly from

Fig. 69 Removing Thrust Washer Locating Pin
(28) Remove reverse gear synchro stop ring and
clutch gear (Fig. 70).
FIRST REVERSE
Fig. 70 Reverse Gear, Bearing And Stop Ring
Removal
(29) Remove reverse gear beari ng spacer from
(30) Remove first gear snap ri ng (Fig. 71). Tension
of this snap ring is considerable. Heavy duty snap
ring pliers will be required to spread the ri ng far
enough to remove it.
(31) Remove reverse clutch gear (Fig. 72).
(32) Remove first gear from bearing and mainshaft
(Fig. 73).
(33) Remove first gear beari ng from mainshaft
(Fig. 74).
TRANSMISSION CLEANING AND INSPECTION
Clean t he gears, bearings shafts, extension/adapter
housing and gear case wi t h solvent. Dry all part s ex-
cept t he bearings with compressed air. Allow t he
bearings to either air dry or wipe t hem dry with
clean shop towels.
Fig. 71 Reverse Gear Bearing Spacer And First Gear
Snap Ring Removal
J922M5 1
Fig. 72 Removing Reverse Clutch Gear
FIRST
GEAR
J922M52
Fig. 73 Removing First Gear
Inspect t he reverse idler gear, bearings, shaft and
t hrust washers (Fig. 75). Replace t he bearings if t he
rollers are worn, chipped, cracked, flat-spotted, or
21 - 22 IV 4 500 TRANSMISSION OVERHAUL

MAI NS HAFT FIRST
SPACER SHAFT J 92 2 1- 183
Fig. 75 Reverse idler Components
brinnelled. Or if t he beari ng cage is damaged or dis-
torted. Replace t he t hrust washers if cracked,
chipped, or worn. Replace t he gear if t he t eet h are
chipped, cracked or worn thin.
Inspect t he drive gear and bearings (Fig. 76). Mi-
nor scratches and burrs on t he gear surfaces can be
reduced wi t h an oil stone and 400 grit paper wetted
with oil. Replace either beari ng if worn, or damaged.
Replace t he gear if any t eet h, splines, or beari ng sur-
faces are also worn or damaged.
Inspect the front bearing retainer and bearing cup
(Fig. 77). Replace the bearing cup if scored, cracked,
brinnelled, or rough. Check the release bearing slide
surface of the retainer carefully. Minor corrosion, nicks,
or pitting can be smoothed with 400 grit emery and pol-
ished out with crocus cloth. Wet the abrasive paper and
crocus cloth with oil when smoothing/polishing. Replace
the retainer if worn or damaged in any way.
Inspect t he countershaft and beari ngs (Fig. 78). Re-
place t he bearings if worn, rough, flat spotted, or
heat checked. Check t he countershaft gear t eet h
carefully. Small nicks, scratches, or burrs can be re-
MAI NS HAFT FRONT
DRIVE
GEAR J 92 2 1- 181
Fig. 76 Drive Gear Components
BEARI NG OI L FRONT BEARI NG
CUP SEAL RETAINER
Fig. 77 Front Bearing Retainer Components
REAR COUNTERSHAFT FRONT
J 9 2 2 M 84
Fig. 78 Countershaft And Bearings
moved with an oif stone and 400 grit paper wetted
wi t h oil. However, replace t he shaft as an assembly
if t he forward gear is loose, or any of the t eet h are
worn, cracked, broken, or severely chipped.
Be sure to check condition of the countershaft bearing
cups. Replace either bearings cup if worn, or damaged.
NV4 500 TRANSMISSION OVERHAUL 21 - 23
Check condition of the mainshaft. Inspect all the
bearing surfaces, splines and threads. Also check condi-
tion of the snap ring grooves in the hub area and the
speedometer drive gear teeth (Fig. 79). Minor scratches
or burrs can be removed with an oil stone and polished
with crocus cloth. However, replace the shaft if any sur-
faces exhibit considerable wear or damage.
GEAR
CASE
BEARING
SURFACES
HUB BEARING NUT
SURFACES THREADS
SPEEDOMETER
TEETH
SPLINES SPLINES
SPLINES
J 9 2 2 M 85
Fig. 79 Mainshaft Bearing And Spline Surfaces
Check condition of the gear case and extension or
adapter housing (Fig. 80). Be sure the alignment dowels
in the case top surface and in the housing/adapter are
tight and in good condition.
Run a tap through the gear case bolt holes if the
threads need minor cleanup. Helicoil inserts can be
used to repair seriously damaged threaded holes if nec-
essary.
Be sure all case and housing/adapter sealing and
mat i ng surfaces are free of burrs and nicks. This is
especially i mport ant as gaskets are not used in t he
NV4500. Minor nicks and scratches on the sealing
surfaces can be dressed off with a fine tooth file or oil
stone.
Replace t he gear case or housing/adapter if cracked
or broken. Do not at t empt to repair t hi s type of dam-
age by welding or brazing.
Check condition of t he countershaft fifth gear com-
ponents (Fig. 81). This includes t he shift lug and rail
located in t he gear case and the rail bushings.
Inspect the gear and hub assembly. Minor burrs can
be cleaned up with an oil stone. However, the gear and
hub assembly should be replaced if the teeth or splines
are excessively worn, or damaged. The synchro sleeve
should also be replaced if worn or damaged in any way.
Do not reuse synchro struts that are worn, or springs
that are collapsed or severely distorted. Replace worn
distorted synchro parts to avoid shift problems after as-
sembly and installation.
The shift fork should be inspected for evidence of
wear and distortion. Check fit of t he sleeve in the
fork to be sure t he two part s fit and work smoothly.
Replace t he fork if t he roll pin holes are worn over-
EXTENSION
HOUSING
(2-WHEEL DRIVE)
ADAPTER
HOUSING
(4-WHEEL
DRIVE)
J9221-186
Fig. 80 Gear Case And Extension/Adapter Housings
size or damaged. Do not at t empt to salvage a worn
fork. It will cause shift problems l at er on. Replace
t he shift fork roll pins if necessary, or if doubt exists
about t hei r condition.
The bearings should be examined carefully for wear,
roughness, flat spots, pitting, or other damage. Replace
the bearings if necessary.
Inspect t he stop ring and clutch gear, replace ei-
t her part if worn or damaged in any way. Also be
sure replacement part s fit properly before proceeding
with assembly.
Inspect the 1-2 synchro components (Fig. 82). The hub
weights and retainer springs are reusable if in good
condition. However, replace the springs if distorted, or
broken and replace the weights if worn or damaged.
Exami ne t he hub and sleeve for wear or damage.
Replace t he sleeve and hub if t he splines are worn,
chipped or damaged.
Replace t he synchro st rut s if worn, or chipped. Also
replace t he springs if collapsed, distorted, or broken.
Inspect t he mainshaft geart rai n components (Fig.
83). Check t he t eet h on all gears, hubs, clutch gears,
stop ri ngs and clutch rings. The t eet h must be in
good condition and not worn, cracked, or chipped. Re-
place any component t hat exhibits wear or damage.
Exami ne t he synchro stop rings, clutch rings and
clutch gears. Replace any part t hat exhibits wear,
distortion, or damage. Replace the clutch rings if t he
friction mat eri al is burned, flaking off, or worn.
Inspect all of t he t hrust washers and locating pins.
Replace t he pins if bent, or worn. Replace t he wash-
ers if worn, or t he locating pin notches are distorted.
Check condition of t he synchro st rut s and springs.
Replace these part s if worn, cracked, or distorted.
- 24 NV4500 TRANSMISSION OVERHAUL

Fig. 82 1-2 Synchro Components

LEGEND FOR
1. MAINSHAFT
2. FIRST GEAR BEARING
3. FIRST GEAR
4. CLUTCH GEAR
5. SYNCHRO STOP RING
6. FIRST GEAR SNAP RING
7. REVERSE GEAR BEARING SPACER
8. REVERSE GEAR BEARING
9. REVERSE SYNCHRO SLEEVE
10. SYNCHRO STRUTS AND SPRINGS (3 EACH)
1 1 . REVERSE GEARLINES
12. THRUST WASHER
13. THRUST WASHER LOCATING PIN
14. MAINSHAFT REAR BEARING
15. MAINSHAFT REAR BEARING CUP
16. MAINSHAFT END PLAY SHIMS
17. MAINSHAFT REAR BEARING PLATE
18. MAINSHAFT FIFTH GEAR
19. THRUST WASHER
20. FIFTH GEAR NUT
21. MAINSHAFT SPLINE SEAL
22. CLUTCH GEAR SNAP RING
23. FIRST SPEED CLUTCH GEAR
24. FIRST GEAR SYNCHRO CLUTCH RING
FT GEMRTRAIN
25. SYNCHRO HUB SNAP RING
26. FIRST GEAR SYNCHRO STOP RING
27. 1-2 SYNCHRO SLEEVE
29. 1 -2 SYNCHRO HUB (INC. RETAINER SPRINGS AND WEIGHTS)
30. SYNCHRO HUB SNAP RING
31. SECOND GEAR SYNCHRO STOP RING
32. SECOND SPEED CLUTCH GEAR
33. SECOND GEAR SYNCHRO CLUTCH RING
34. CLUTCH GEAR SNAP RING
35. SECOND GEAR BEARING
36. SECOND GEAR
37. THRUST WASHER AND LOCATING PIN
38. THRUST WASHER SNAP RING
39. THIRD GEAR BEARING SPACER
40. THIRD GEAR
41. THIRD GEAR BEARING ASSEMBLIES (2)
42. THIRD GEAR SYNCHRO STOP RING
43. 3-4 SYNCHRO SLEEVE
45. 3-4 SYNCHRO HUB
46. FOURTH GEAR SYNCHRO STOP RING
47. FOURTH SPEED CLUTCH GEAR
48. DRIVE GEAR THRUST BEARING
TRANSMISSION ASSE MBLY AND ADJUSTMENT
Assembly Information
Gaskets are not used in the NV4500 transmis-
sion. Use Mopar Gasket Maker, silicone adhe-
sive/sealer, or Loctite 518 on all gear case and
extensi on housi ng seal i ng surfaces.
Adjustment Specifications
Countershaft End Play: 0.051-0.15 mm (0.002-
0.006 in.)
Mainshaft End Play: 0.051-0.15 mm (0.002-0.006 in.)
Fig. 84 Installing Countershaft Front Bearing Cup
J9321-98
GEAR CASE ASSEMBLY
(1) Install countershaft front bearing cup in case
wi t h Tool Handle C-4171 and Installer Tool 6061-1
or C-4340 (Fig. 84).
(2) Install new bushings in shift lug rail bores
with Tool 6456 (Fig. 85). Seat bushings flush wi t h
bores.
Fig. 85 Installing Shift Lug Rail Bushings
(3) If case magnet was removed, install and secure
magnet in clip at bottom of case (Fig. 86).
Fig. 86 Gear Case Magnet Installation
NV4 50I TRANSMISSION OVERHAUL 21 - 27
COUNTERSHAFT AND REVERSE IDLER GEAR
INSTALLATION
(1) Install front bearing on countershaft with In-
staller Tool 6446 (Fig. 87).
Fig. 87 Countershaft Front Bearing installation
(2) Lubricate countershaft front beari ng cup and
cone with petroleum jelly.
(3) Position gear case on end wi t h rear of case fac-
ing up (Fig. 88).
(4) Install countershaft in gear case (Fig. 88). Do
not install rear bearing on countershaft rear at
this time.
Fig. 88 Positioning Countershaft In Gear Case
(6) Install idler gear front t hr ust washer on boss in
gear case (Fig. 89). Coat t hr ust washer with liberal
quant i t y of petroleum jelly to hold it in place.
POSITION
IDLER
GEAR
Fig. 89 Positioning Idler Gear Front Thrust Washer
In Case
(7) Install reverse idler gear in case (Fig. 90).
(8) Install idler gear rear t hrust washer between
idler gear and case boss (Fig. 90).
REAR
THRUST
Fig. 90 Idler Gear And Thrust Washer Installation
(9) Align idler gear bearings and t hrust washers
with drift.
(10) Install reverse idler shaft (Fig. 91). Be sure
notched end of shaft is facing countershaft as shown.
Use shift cover bolt to hold and insert shaft in case
bore.
(11) Lift countershaft upward and position wood
block between front of shaft and case (Fig. 92).
(12) Install rear beari ng cone on countershaft with
Installer Tool C-4040 or 6446 (Fig. 93).
(13) Remove wood block from under countershaft
and lower countershaft front beari ng into front bear-
ing cup.
(14) Install new front beari ng cap in gear case
(Fig. 94). Apply Mopar silicone adhesive/sealer to
(5) Lubricate reverse idler gear bearings with pe-
troleum jelly and install first bearing, beari ng spacer
and second beari ng (Fig. 89).
21 - 28 N4500 TRANSMISSION OVERHAUL
COUNTERSHAFT SHIFT
COVER
BOLT
REVERSE
IDLER
SHAFT
Fig. 91 Reverse idler Shaft Installation
WOOD,
BLOCK
J9221 - 1 65
COUNTERSHAFT
Fig. 92 Supporting Countershaft With Wood Block
flange and lip of new cap. Then seat cap in case bore
wi t h wood block and mallet.
(15) Lubricate countershaft rear beari ng cup and
cone with petroleum jelly.
(16) Install countershaft rear beari ng cup in gear
case and over rear beari ng (Fig. 95). Tap cup into
place with plastic mallet if necessary.
ADJUSTING COUNTERSHAFT END PLAY
(1) Install countershaft rear beari ng plate (Fig.
96). Be sure plate is seated in notch in reverse idler
shaft before t i ght eni ng beari ng pl at e bolts.
(2) Rotate countershaft 4-5 t i mes to seat bearings.
(3) Mount dial indicator on case. Then position in-
dicator plunger on end of countershaft and zero indi-
cator dial needle (Fig. 97).
COUNTERSHAFT
SPECIAL
TOOL
6446
REAR
BEARING
_ J9221-166
Fig. 93 Installing Countershaft Rear Bearing
FRONT
BEARING
CAP
(SEAT
WI TH
WOOD
BLOCK)
^ , ( / J9221-172
Fig. 94 Countershaft Front Bearing Cap Installation
COUNTERSHAFT
REAR
BEARING
CUP
J9221-167
Fig. 95 Countershaft Rear Bearing Cup Installation
(4) Raise countershaft with screwdriver and note
end play reading on dial indicator. End play should
be 0.051 - 0.15 mm (0.002 - 0.006 in.).
(5) Remove countershaft rear bearing plate.
(6) Select and install end play shim t hat will pro-
vide mi ni mum countershaft end play. Position shim
on rear bearing cup (Fig. 98).
(7) Reinstall countershaft rear bearing plate (Fig.
96). Be sure plate is seated in reverse idler shaft
notch before installing bolts. Also be sure end play

COUNTERSHAFT
REAR
BEARING
PLATE
IDLER
SHAFT
J9221-168
Fig. 96 Countershaft Rear Bearing Plate installation
DIAL
INDICATOR
INDICATOR
MOUNTI NG
ARM
AND
BASE
J922M69
Fig. 97 Measuring Countershaft End Play
REAR
BEARING
CUP
END
PLAY
SHIM
(SELECTIVE)
Fig. 98 Installing Countershaft End Play Shim
shims are still in position before t i ght eni ng bearing
plate bolts.
(8) Apply 1-2 drops Mopar Loc N' Seal or Loctite
242 to t hreads of rear bearing plate bolts. Then in-
stall and t i ght en beari ng plate bolts to 23 Nnn (200
in. lbs.) torque.
SHIFT LUG AND RAIL INSTALLATION
(1) Lubricate shift lug, rail and bushings wi t h Cas-
trol Syntorq.
(2) Insert shift lug rai l part way into case.
(3) Install shift lug on rail. Note position of
(4) Position shift rail so roll pin notches are at ap-
proximately 5 o'clock position (Fig. 99).
(5) Install roll pin t hat secures lug to rail (Fig. 99).
NOTCHES
(FOR 5TH GEAR
SHIFT FORK
ROLL PINS)
LUG
RAIL
SHIFT
LUG
J922M71
Fig. 99 Shift Lug And Rail Installation
MAINSHAFT AND GEARTRAIN ASSEMBLY
C A U T I O N : The reverse, 1-2 and 3-4 synchr o compo-
nents can be assembl ed and installed incorrectly if
care i s not exerci sed. S ome component s can be in-
stalled backwar ds resulting in shift probl ems. Refer
to the assembl y procedures for component identifi-
cation and l ocati on.
(1) Lubricate mainshaft bearing surfaces and all
beari ng assemblies with Castrol Syntorq or wi t h pe-
troleum jelly.
(2) Install first snap ring in rearmost groove of
mainshaft hub (Fig. 100). This snap ri ng locates first
speed clutch gear on shaft. A total of four of these
snap rings are used to secure various components on
t he mainshaft 1-2 synchro hub. The snap rings are
all t he same size and are interchangeable.
(3) Install first gear beari ng assembly on mai n-
shaft (Fig. 100).
(4) If desired, mainshaft can be placed in upri ght
(vertical) position and supported with wood blocks
(Fig. 101). Reverse gear components are easier to in-
stall with shaft upright.
(5) Install first gear and beari ng on shaft (Fig.
101). Clutch hub side of gear faces front of shaft.

SNAP
RING
FIRST
-GEAR
BEARING
MAINSHAFT
SYNCHRO
HUB J 9221 - 1 7 6
Fig. 100 First Gear Bearing and Snap Ring
Installation
(6) Install clutch gear on first gear (Fig. 101). Be
sure clutch gear is seated on shaft splines.
(7) Install first gear snap ri ng (Fig. 101). Use
heavy duty snap ri ng pliers to install t hi s snap ri ng
as ri ng tension is considerable. Do not overspread
snap ring and make sure it is fully seated in
groove. Reverse gear will not fit properl y if snap
ring is not fully seated.
FIRST
GEAR
FIRST
GEAR
SNAP
RING
REVERSE
CLUTCH
GEAR
J 9221 - 1 7 7
Fig. 101 First Gear, Clutch Gear And Snap Ring
Installation
(8) Install stop ri ng on clutch gear (Fig. 102). Be
sure stop ri ng is fully seated on gear taper.
(9) Install reverse gear beari ng spacer on main-
shaft (Fig. 103). Bearing spacer seats agai nst first
gear snap ring.
(10) Install reverse gear beari ng on mainshaft
(Fig. 103).
(11) If reverse gear sleeve and st rut s were disas-
sembled for service, reassemble sleeve, st rut s and
springs as follows:
WO O D BLOCKS
REVERSE GEAR
STOP RI NG
XLUTCH GEAR
-FIRST GEAR
\- - ~ - -
x
J9221-191
i
Fig. 102 Clutch Gear Stop Ring Installation
REVERSE GEAR
BEARI NG
BEARI NG
SPACER
FIRST
GEAR
J9221-192
Fig. 103 Reverse Gear Bearing And Spacer
Installation
C A U T I O N : The reverse sl eeve will fit either way on
the hub. T hi s means the sl eeve can be installed
backwards if care i s not exerci sed. Be sure the ta-
pered si de of the sl eeve f aces rearward after instal-
lation.
(a) Position sleeve on hub so tapered side of
sl eeve faces rearward. Sleeve will fit either way
but will cause shift problems if installed backwards
(Fig. 104).
(b) Rotate sleeve to align t eet h on sleeve and
hub. Sleeve will slide easily into place on hub
when properly aligned.
(c) Install springs in gear hub (Fig. 104). Use pe-
troleum jelly to hold springs in place if desired.
(d) Compress first spring with flat blade screw-
driver and slide st rut into position in hub slot.
Then work spring into seat in st rut with small
hooked tool, or screwdriver.
(e) Install second and t hi rd st rut s in same man-
ner as described in step (d).
(f) Work sleeve upward on hub unt i l st rut s are
centered and seated in sleeve. Sleeve should be in
neut ral position after seating st rut s.

HUB J92 2 M89
Fig. 104 Reverse Gear Synchro Assembly
(12) Install reverse gear and synchro assembly on
mainshaft (Fig. 105). Rotate assembly until stop ring
lugs engage in hub slots and gear drops into fully
seated position.
Fig. 105 Reverse Gear Installation
(13) Install reverse gear thrust washer pin in main-
shaft (Fig. 106). Use needle nose pliers to install pin.
(14) Install reverse gear t hr ust washer (Fig. 107).
Be sure locating pin is seated in t hr ust washer notch.
(15) Install rear beari ng on mainshaft. Use In-
staller Tool 6446 to seat bearing on shaft and against
t hrust washer (Fig. 108). If beari ng is not fully
seated on shaft, seat bearing by tapping inner race
with small brass punch and hammer. Bearing i nner
race should be flush wi t h shaft.
(16) Tur n mainshaft over and place it in horizontal
position on workbench.
(17) Install first speed clutch gear on mainshaft
1-2 synchro hub (Fig. 109). Recessed side of gear
faces front. Be sure gear is seated against snap ri ng
previously installed on hub.
(18) Install snap ri ng on mainshaft 1-2 synchro
NV4 I00 TRANSMISSION OVERHAUL 21 - 31
Fig. 106 Thrust Washer Pin Installation
Fig. 107 Reverse Gear Thrust Washer Installation
Fig. 108 Installing Mainshaft Rear Bearing
hub to secure clutch gear (Fig. 110). Be sure snap
ri ng is fully seated in hub groove and agai nst clutch
gear. Note t hat t hi s is second of four snap rings used
to secure synchro components on shaft hub.
(19) Assemble first speed clutch ri ng and stop ri ng
(Fig. 111).
(20) Install assembled first speed clutch and stop
rings on clutch gear (Fig. 112). Be s ur e tabs on
cl ut ch ri ng are al i gned and seated i n first gear
Fig. 109 installing First Speed Clutch Gear
Fig. 110 installing First Speed Clutch Gear Snap
Ring
Fig. 111 Assembling First Speed Clutch And Stop
Rings
h u b . 1-2 s ync hr o h u b wi l l not s eat pr ope r l y if
cl ut ch r i ng t a b s a r e mi sal i gned.
(21) Support mainshaft in upri ght position (Fig.
113). Remai ni ng gears, snap ri ngs and synchro com-
ponents are easier to install with shaft in upri ght po-
sition. Shaft can be supported in gear case as shown,
or hole can be cut in workbench to support shaft.

Fig. 112 First Speed Clutch And Stop Ring
Installation
MAINSHAFT
GEAR
CASE
J 92 2 1- 2 2 2
Fig. 113 Mainshaft Positioned For Gear And
Synchro Installation
(22) If 1-2 synchro hub and sleeve were disassem-
bled for service, reassemble hub, sleeve, st rut s and
springs as follows:
(a) Install weights in hub (Fig. 114). Use petro-
l eum jelly to hold weights in place if desired.
(b) Install weight ret ai ner springs. Fl at spring
goes at front side of hub (Fig. 115). Be sure re-
t ai ner spring ends are securely engaged in weight
slots as shown.
(c) Place synchro hub on bench so side of hub
wi t h square spring is facing up (Fig. 116).
(d) Align and install sleeve on hub. Be sure ta-
pered side of sleeve faces upward (toward front).
Rotate sleeve until it slides onto hub. Sleeve only

HUB SYNCHRO
Fig. 114 Installing Weights In 1-2 Synchro Hub
J9221 -207
Fig. 115 Installing Weight Retainer Springs In 1-2
Synchro Hub
fits one way and will easily slide onto hub when
long slot in sleeve, aligns with long shoulder on
hub (Fig. 116).
(e) Place wood blocks under hub t hat will raise
hub about 3.5 cm (1-3/8 in.) above surface of work-
bench. Then allow sleeve to drop down on hub (Fig.
117).
(f) Install springs and st rut s in hub (Fig. 117).
Use lots of petroleum jelly to hold t hem in place.
Then compress st rut s with your fingers and move
sleeve upward unt i l st rut s are started in sleeve.
Verify t hat st rut s are engaged in sleeve before pro-
ceeding.
(g) Turn synchro assembly upright. Then move
sleeve into neut ral position on hub and work st rut s
into sleeve at same time. Be sure st rut s are seated
and springs are not displaced during assembly.
Fig. 116 installing 1-2 Synchro Sleeve On Hub
STRUTS AND
SPRINGS (4 EACH) J9221 -209
Fig. 117 Installing 1-2 Synchro Struts And Springs
(23) Install first speed stop ring in 1-2 synchro hub
and sleeve (Fig. 118). Be sure stop ri ng is fully
seated and engaged in hub and sleeve.
Fig. 118 Installing First Speed Stop Ring In Synchro
Hub
(24) Install 1-2 synchro assembly and stop ring on
mainshaft. Rotate sleeve to align it with stop ring lugs
if necessary. Then seat assembly on shaft (Fig, 119).
MAINSHAFT
HUB
SYNCHRO
ASSEMBLY
TAPERED
SIDE
OF
SLEEVE
J9221-211
Fig. 119 1-2 Synchro Installation
(25) Check position of 1-2 and reverse synchro
sleeves. Be sure tapered side of 1-2 sleeve faces front
and tapered side of reverse sleeve faces rear (Fig.
120). Also be sure square spring is visible at forward
side of 1-2 synchro hub. Do not ski p this check as
transmi ssi on will not shift properl y if either syn-
chro sl eeve is installed backwards.
1-2
SLEEVE
TAPER
TO
FRONT
REVERSE
SLEEVE
TAPER
TO
REAR
J9221-216
Fig. 120 Correct Position Of Reverse And 1-2
Synchro Sleeves
(26) Temporarily remove flat weight spring from
front side of 1-2 synchro hub. Removing spring
makes installation of 1-2 hub snap ri ng easier.
(27) Install snap ri ng t hat secures 1-2 synchro on
mainshaft hub (Fig. 121). Be sure snap ri ng is fully
seated in ri ng groove in mainshaft hub. If snap ri ng
will not seat i n groove, round wei ght spring at
rear of 1-2 synchro hub is probabl y not seated i n
recess a t front of first speed cl utch gear. Or first
speed cl utch gear is slightly mi sal i gned. Real i gn
as needed to fully seat snap ring.
SYNCHRO
SNAP
RING
SYNCHRO
ASSEMBLY
J9221-212
Fig. 121 Installing 1-2 Synchro Snap Ring
(28) Reinstall flat weight spring in 1-2 synchro
hub (Fig. 122). Be sure spring ends are securely en-
gaged in weight slots.
FLAT
WEIGHT
SPRING
1-2
SYNCHRO
HUB
f l l ^ \ \ V ^221-213
Fig. 122 Reinstalling Flat Weight Spring
(29) Assemble second speed clutch gear, clutch
ri ng and stop ri ng (Fig. 123).
STOP RING
CLUTCH RING
CLUTCH GEAR
J9221 - 200
Fig. 123 Assembling Second Speed Clutch Gear,
Clutch Ring And Stop Ring
NV450Q TRANSMISSION OVERHAUL 21 - 35
(30) Install assembled second speed clutch gear
and rings on mainshaft and in 1-2 synchro hub (Fig.
124).
Fig. 124 Second Speed Clutch Gear, Clutch Ring
And Stop Ring Installation
(31) Install snap ring t hat secures second speed
clutch gear on mainshaft (Fig. 125). Use narrow
blade screwdriver to work snap ri ng into hub groove
as shown. Be sure snap ring i s fully engaged in
mainshaft groove before proceedi ng. If snap
ring will not fit i n groove, cl utch gear is slightly
misaligned. Or, flat wei ght spri ng at front of 1-2
synchro hub is probabl y not seated i n recess i n
front of second speed cl utch gear.
Fig. 125 Installing Second Speed Clutch Gear Snap
Ring
(32) Install second gear beari ng on mainshaft (Fig.
126).
(33) Install second gear on mainshaft and bearing.
Rotate gear unt i l t abs of second speed clutch ring are
fully seated in t ab slots in gear (Fig. 127).
(34) Install t hrust washer pin in shaft (Fig. 128).
Use needle nose pliers to insert pin in shaft hole.
Fig. 126 Second Gear Bearing Installation
1 SECOND
GEAR
Fig. 127 Second Gear Installation
Fig. 128 Thrust Washer Pin Installation
21 - 36 NV4500 TRANSMISSION OVERHAUL -
SECOND SECOND
J 92 2 1- 2 2 4
Fig. 129 Second Gear Thrust Washer installation
(36) Install second gear t hrust washer snap ri ng
(Fig. 130). Be sure snap ring is fully seated in main-
shaft groove.
(37) Install t hi rd gear bearing spacer on shaft and
seat it agai nst t hr ust washer snap ri ng (Fig. 130).
THRUST
WASHER
SNAP RING
HIRD GEAR
BEARING
SPACER
J922M22
Fig. 130 Installing Snap Ring And Third Gear
Bearing Spacer
(38) Install t hi rd gear bearings on mainshaft (Fig.
131). Upper beari ng should be flush with mainshaft
hub. If upper beari ng is not flush wi th hub, ei-
ther beari ng spacer or snap ring was not in-
stalled. Check and correct if necessary.
(39) Install t hi rd gear over bearings and on mai n-
shaft (Fig. 132).
(40) Install synchro stop ri ng on t hi rd gear (Fig.
133). Be sure stop ri ng is fully seated on gear taper.
(41) If 3-4 synchro was disassembled for service,
reassemble synchro components as follows:
(a) Align and install synchro sleeve on hub (Fig.
134). Front si de of hub has a narrow groove
machi ned i n it.
Fig. 131 Third Gear Bearing Installation
Fig. 132 Third Gear Installation
SYNCHRO THIRD
Fig. 133 Third Gear Stop Ring Installation
(b) Insert all t hree synchro st rut s in slots ma-
chined in sleeve and hub (Fig. 134).
(c) Install and seat synchro springs (Fig. 134).
Use flat blade or phillips screwdriver to compress
springs and seat t hem in st rut s and hub as shown.
(42) Remove mainshaft and geart rai n from gear
case or from workbench.
(43) St art 3-4 synchro assembly on mainshaft. Tap
assembly onto shaft splines unt i l hub is about 3 mm
(1/8 in.) away from t hi rd speed stop ring. Then align
stop ri ng with synchro sleeve and hub and seat syn-
chro assembly with Tool C-4040 (Fig. 135).
(44) Verify t hat 3-4 synchro hub is fully seated on
shaft. Approximately 3 mm (1/8 in.) of shaft spline
should be visible. If hub is not seated, stop ri ng lugs
are misaligned. Rotate ri ng unt i l lugs are fully en-
gaged in 3-4 hub slots.
(35) Install second gear t hr ust washer. Be sure
washer is seated on gear and pin (Fig. 129).

I V 4 500 TRANSMISSION OVERHAUL 21 - 37
Fig 134 3-4 Synchro Assembly
Fig. 135 Seating 3-4 Synchro Assembly On
Mainshaft
(45) Install fourth speed stop ring in 3-4 synchro
sleeve (Fig. 136).
Fig. 136 Fourth Speed Stop Ring Installation
(46) Install fourth speed clutch gear in stop ri ng
(Fig. 137).
MAINSHAFT AND GEARTRAIN INSTALLATION
(1) Position gear case so case opening is facing up
(Fig. 138).
(2) Grip mainshaft at pilot bearing hub and j ust
behind rear bearing. Then lift assembly and guide
rear of shaft through beari ng bore at rear of case.
Fig. 137 Fourth Speed Clutch Gear Installation
(3) Continue holding front of shaft but switch grip
at rear to shaft output splines. Lift mainshaft assem-
bly slightly, align gears and seat assembly in case.
Be sure fourth speed clutch gear and stop ring were
not displaced duri ng installation (Fig. 138).
MAINSHAFT
Fig. 138 Mainshaft And Geartrain Installed In Case
(4) Install drive gear t hrust beari ng on mainshaft
(Fig. 139). Use plenty of petroleum jelly to hold bear-
ing in place.
(5) Check alignment and mesh of mainshaft gears.
If gears are not aligned, roll case on side and realign
shaft and gears in case.
Fig. 139 Drive Gear Thrust Bearing Installation
21 - 38 NV45U0 TRANSMISSION OVERHAUL
DRIVE GEAR AND RETAINER INSTALLATION
(1) Install beari ng on drive gear with Installer
Tool 6448 (Fig. 140).
SPECIAL
-TOOL
6 4 4 8
BEARING
DRIVE GEAR
J9221-204
Fig. 140 installing Front Bearing On Drive Gear
(2) Lubricate pilot bearing with petroleum jelly
and install it in drive gear bore.
(3) Install drive gear on mainshaft. Work gear
rearward unt i l mainshaft hub is fully seated in pilot
bearing.
(4) Install beari ng cup in front ret ai ner with
Driver Handl e C-4171 and Installer C-4308 (Fig.
141).
SPECIAL
TOOL
C-4308
SPECIAL
TOOL
C-4171
WO O D
BLOCKS
RETAINER
J9221-203
Fig. 141 Installing Front Bearing Cup In Retainer
(5) Install new oil seal in front beari ng ret ai ner
with Tool C-4595 or 6052 (Fig. 142). Use one or two
wood blocks to support ret ai ner as shown. Lubricate
seal lip wi t h petroleum jelly after installation.
(6) Clean contact surfaces of gear case and front
beari ng ret ai ner with a wax and grease remover.
(7) Apply Mopar Gasket Maker to flange surface of
front beari ng ret ai ner (Fig. 143).
(8) Inst al l front bearing ret ai ner over drive gear
and st ar t it into case.
WO O D BLOCK
SPECIAL TOOL
6052
RETAINER
J9221-202
Fig. 142 Installing Bearing Retainer Oil Seal
(9) St art front bearing ret ai ner in gear case. Ver-
ify that retainer l ube channel is at top-center (12
O' clock) position (Fig. 143). Adjust ret ai ner posi-
tion before proceeding, if necessary.
LUBE
C HANNE L
(INSTALL AT
12 O' CLOCK
POSI TI ON)
APPLY
GASKET
MAKER
HERE
FRONT
RETAINER
J92 2 1- 2 31
Fig. 143 Location Of Front Retainer Lube Channel
(10) Align front beari ng ret ai ner bolt holes and t ap
ret ai ner into place with plastic mallet. Install and
t i ght en ret ai ner bolts to 30 N-m (265 in. lbs.) torque
(Fig. 144).
FRONT BEARING
RETAINER
9 J9221-103
Fig. 144 Installing Front Bearing Retainer
MAINSHAFT END PLAY ADJUSTMENT
(1) Install mainshaft rear bearing cup in case and
over bearing. Tap beari ng cup into place with plastic
mallet.
(2) Install r ear beari ng plate to hold mainshaft
and rear beari ng in position (Fig. 145). Do not install
any end play shims at this time.
(3) Tighten rear bearing plate bolts securely.
(4) Place gear case in upright position on bench.
Ei t her cut hole in bench to accept drive gear and
front ret ai ner, or use C-clamps to secure t ransmi s-
sion on bench. Do not leave transmission unsup-
ported.
(5) Mount dial indicator on rear of gear case and
position indicator plunger against i nner race of r ear
bearing (Fig. 145).
(6) Move mainshaft forward to remove all play.
Then zero dial indicator.
(7) Move mainshaft upward and observe dial indi-
cator reading. Move mainshaft with pry tool posi-
tioned between drive gear and case.
(8) End play should be 0.051-0.15 mm (0.002-0.006
in.). Select fit shims are available to adjust end play
if necessary.
DIAL
INDICATOR
AND
BASE
REAR
BEARING
(j POSITION
J INDICATOR
(J PLUNGER .
L/L-ON BEARING-
( / INNER RACE
J 92 2 1- 2 32
Fig. 145 Checking Mainshaft End Play
(9) If end play adjustment is required, remove
bearing plate and install necessary shim.
(10) Reinstall rear bearing plate (Fig. 146).
Tighten rear beari ng plate bolts to 23 N*m (200 in.
lbs.) torque. Be sure oil hole in beari ng plate is at
top as shown.
MAINSHAFT FIFTH GEAR INSTALLATION
(1) Install mainshaft fifth gear. Use Installer Tool
6446 to seat gear on shaft (Fig. 147). Gear is seated
when it contacts rear bearing.
(2) Install fifth gear nut washer (Fig. 148). Coned
side of washer faces end of shaft.
(3) Apply 3-4 drops Mopar Lock N' Seal, or Loctite
242 to nut t hreads on mainshaft.
BEARING
PLATE
OIL HOLE
(AT TOP)
MAINSHAFT
REAR
BEARING
PLATE
J 92 2 1- 2 33
Fig. 146 Rear Bearing Plate Installation
MAINSHAFT
FIFTH
GEAR
SPECIAL
TOOL
6446 J 92 2 1- 2 2 0
Fig. 147 Installing Mainshaft Fifth Gear
(4) Install fifth gear nut on mainshaft (Fig. 148).
FIFTH
GEAR
NUT
WASHER
'(CONED)
FIFTH
GEAR
NUT
J9221-93
Fig. 148 Installing Fifth Gear Nut And Washer
(5) Tighten fifth gear nut as much as possible with
Nut Wrench 6443, long handl e ratchet, breaker bar
and Socket Wrench 6441 or 6442 (Fig. 149).
SPECIAL
TOOL
6443
FIFTH
GEAR
NUT
SPECIAL
T OOL
6441
OR
6442
RATCHET
WR E N C H
BREAKER
BAR
J 92 2 1- 92
Fig. 149 Fifth Gear Nut installation
(6) Lock mainshaft gears by shifting all synchro
sleeves into engaged position,
(7) Position Spline Socket Wrench 6441 or 6442 on
mainshaft splines. Then install breaker bar in socket
wrench and wedge bar agai nst workbench.
(8) Tighten fifth gear nut with Nut Wrench 6443
and hi gh capacity torque wrench. Required torque on
nut is 339-475 N*m (250-350 ft. lbs.). Have helper
hold transmission steady if necessary. Nut can also
be tightened by st ri ki ng Wrench 6443 with heavy-
copper mallet t hen checking wi t h torque wrench.
COUNTERSHAFT FIFTH GEAR AND SYNCHRO
INSTALLATION
(1) Install t hr ust washer pin in countershaft (Fig.
150).
0 /
COUNTERSHAFT J 92 2 1- 2 34
Fig. 150 Installing Fifth Gear Thrust Washer Pin
(2) Install t hr ust washer on countershaft. Tur n
washer unt i l pin engages in washer notch (Fig. 151).
Fl at side of washer faces rear and cone side to front
as shown.
J9221-235
Fig. 151 installing Fifth Gear Thrust Washer
(3) Lubricate and install fifth gear bearings on
countershaft (Fig. 152).
(4) Install beari ng spacer on countershaft and seat
it agai nst bearings (Fig. 152). Coat spacer wi t h pe-
troleum jelly to hold it in place.
. BE AR I NG
SPACER
FIFTH
GEAR
BEARI NGS
J 92 2 1- 2 36
Fig. 152 Countershaft Fifth Gear Bearing And
Spacer Installation
(5) Install synchro sleeve on hub of countershaft
fifth gear. Tapered side of sleeve faces front and flat
side faces rear (Fig. 153).
GEAR
S YNC HR O
SLEEVE
COUNTERSHAFT
FIFTH
GEAR
J 92 2 1- 2 37
Fig. 153 Installing Synchro Sleeve On Countershaft
Fifth Gear Hub
(6) Install shift fork in synchro sleeve (Fig. 154).
(7) Install assembled fifth gear, synchro sleeve and
shift fork (Fig. 155). Align fork with shift l ug rai l
and align gear with bearings and countershaft. St art

NV4500 TRANSMISSION OVERHAUL 21 - 4 1
SYNCHRO
' SLEEVE
SHIFT
FORK
V ^ .LS J9221-238
Fig. 154 Installing Fifth Gear Shift Fork In Synchro
Sleeve
components onto shaft and rail. Then t ap gear and
fork into place with plastic or rawhide mallet.
(8) Align roll pin holes in shift fork with notches
in shift lug rail. Then install roll pins from top side
of fork (Fig. 155). Note t hat roll pins are one way fit
due to small shoulder at one end of each pin.
Fig. 155 Installing Assembled Countershaft Fifth
Gear, Shift Fork And Synchro Sleeve
(9) Install synchro st rut s and springs in fifth gear
hub (Fig. 156). Install st rut s in hub slots first. Then
install springs by compressing t hem with screwdriver
and working springs into hub and st rut s.
(10) Assemble and install fifth synchro clutch gear
and stop ri ng in fifth gear hub (Fig. 157). Make sure
both part s are seated in fifth gear hub.
(11) Install clutch gear snap ri ng (Fig. 158).
EXTENSION/ADAPTER HOUSING
INSTALLATION
(1) If extension housing seal needs replacement,
remove it collapsing with a punch and chisel. Then
pry seal out of housing with crowfoot pry bar.
(2) If extension housing bushi ng must be replaced,
collapse old bushi ng with tapered drift (Fig. 159). Po-
sition drift in slot provided at end of housing. Then
t ap drift into slot and against bushi ng to collapse
and remove it.
Fig. 156 installing Fifth Gear Synchro Struts And
Springs
Fig. 157 Fifth Synchro Clutch Gear And Stop Ring
Installation
CLUTCH
GEAR J9221-89
Fig. 158 Installing Fifth Synchro Clutch Snap Ring
(3) Remove any burrs from housing bushi ng bore
with a file and emery cloth.
(4) Install new bushing in extension housing (Fig.
160). Use Tool Handle C-4171 and Installer Tool
SP5559 to install bushing. Note t hat installer tool
SP5559 is part of tool set C-4469.
(5) Install extension housing seal with Tool
C-4660-3 (Fig. 161).
21 - 4 2 NV4500 TRANSMISSION OVERHAUL
TAPERED
PUNCH
SPECIAL TOOL
C-4660-3
BUSHING
EXTENSION
HOUSING
J9221-251
Fig. 159 Removing Extension Housing Bushing
SPECIAL
-TOOL
C-4171
SPECIAL
TOOL
C-4660-3
EXTENSION
HOUSING
J9221-252
Fig. 160 Installing Extension Housing Bushing
(6) Clean mat i ng surfaces of extension/adapter
housing and gear case wi t h a wax and grease re-
mover.
(7) Check al i gnment dowels in gear case and hous-
ing or adapter. Be sure dowels are in position and
seated.
(8) Apply Mopar Gasket Maker to gear case and
housing mat i ng surfaces.
(9) Align and install extension/adapter housing on
gear case (Fig. 162).
(10) Apply Mopar Lock N' Seal or Loctite 242 to
t hreads of extension/adapter housing bolts.
(11) Install and t i ght en housing bolts to 54 N (40
ft. lbs.) torque. Use a twel ve poi nt 10 mm socket,
a ratchet wrench and necessary extensi ons to in-
stall bol ts. Do not use any other type of socket
and do not use an i mpact wrench. Spl i nes on
bolt heads can be damaged if i mpact wrench or
wrong type of socket is used for ti ghteni ng pur-
poses.
J9221-201
EXTENSION HOUSING
Fig. 161 Installing Extension Housing Seal
EXTENSION
HOUSING
GEAR
CASE
J9221-85
Fig. 162 Installing Extension/Adapter Housing
SHIFT COVER INSTALLATION
(1) Clean mat i ng surfaces of shift cover and gear
case wi t h a wax and grease remover.
(2) Apply Mopar Gasket Maker, or Loctite 518 to
sealing surface of shift cover or gear case. Do not
overapply sealer mat eri al . Excess can be squeezed
into gear case and could block lubricant feed holes in
time.
(3) Lubricate synchro sleeves with Castrol Syntorq
gear lubricant. Then apply light coat of petroleum
jelly to shift fork contact surfaces.
(4) Verify t hat 1-2 and 3-4 synchro sleeves are in
neut ral position. Also verify t hat forks in shift cover
are in neut ral position.

NV4500 TRANSMISSION OVERHAUL 21 43
(5) Align and install shift cover (Fig. 163). If cover
will not seat, it is either not aligned on gear case
dowels, or shift forks are not aligned with sleeves
and shift lug.
SHIFT
Fig. 163 Installing Shift Cover Assembly
t hreads of shift cover bolts.
(7) Install and tighten shift cover bolts to 30 Nnn
(8) Install backup light switch and vent in shift
cover. Apply sealer to switch t hreads before installa-
tion and tighten switch to 30 Nnn (265 in. lbs.).
(9) On 2-wheel drive models, install and index
speedometer adapter in extension housing.
(10) Install and t i ght en drai n plug to 40 Nnn (30
ft. lbs.) torque.
(11) Fill transmission to bottom edge of fill plug
hole with Castrol Syntorq gear lubricant.
(12) Install and t i ght en fill plug to 40 N-m (30 ft.
lbs.) torque.
SHIFT COVER SERVICE
The only serviceable shift cover components are:
fifth-reverse shift fork pads
reverse inhibitor
vent components
backup light switch
expansion plugs
shift lever components
The shift cover, shift forks, shift rai l s and detent
components are not serviced individually. The cover
must be replaced as an assembly if t he cover, or any
shift components are worn or damaged.
Shift Cover Inspection
Inspect t he cover and shift components whenever
t he cover is removed from t he gear case. Or, when-
ever diagnosis indicates inspection is necessary.
Check t he forks for wear, distortion, cracks, or be-
ing loose on t he shift rails. Also check fit of t he shift
rai l s in the cover. Replace t he cover assembly if t he
rai l s are loose in t he cover bores.
Inspect and replace t he pads on the fifth-reverse
shift fork if worn. The reverse inhibitor should also
be replaced if worn, or faulty. The expansion plugs at
t he rear of t he cover can be replaced if loose or leak-
ing.
A gasket is not used bet ween the shift cover
and gear case. Use Mopar Gasket Maker, or Loc-
tite 518 to seal the cover.
Procedures for t he serviceable components in t he
shift cover as follows:
Fifth-Reverse Shift Fork Pad Replacement
The plastic shift fork pads are held in place by a
combination of tension and a small locating t ang.
Three pads are used on t he fork (Fig. 164).
The pads can be removed either by hand or with a
narrow blade screwdriver. To remove t he pads by
hand, grasp each pad and tilt it out and off t he fork.
If t he pads prove difficult to remove by hand, insert a
screwdriver blade between t he pad and fork and pry
t he pad off.
Fig. 164 Shift Fork Pad Locations
Reverse Inhibitor Replacement
The reverse inhibitor mechanism should be
checked for wear or damage whenever diagnosis in-
dicates this is necessary.
The inhibitor mechanism is attached to t he cover
with two screws (Fig. 165). Attaching screw torque is
8-14 N-m (75-115 in. lbs.).
Vent Component Replacement
The shift cover vent assembly consists of t he vent
tube, connecting hose, hose clamps, and vent valve
(Fig. 166).
If t he vent t ube is removed for replacement or ser-
vice access, apply Mopar silicone adhesive/sealer to
t he t ube to help secure it in t he cover.
21 - 44 NV450Q TRANSMISSION OVERHAUL
REVERSE
INHIBITOR
J9221-255
Fig. 165 Reverse Inhibitor Mounting
HOSE
VENT
VALVE
VENT
TUBE CLAMP J9221-256
Fig. 166 Shift Cover Vent Components
Backup Light Switch Replacement
The backup light switch is located at t he left (driv-
er) side of t he cover (Fig. 167). The switch plunger is
operated by t he fifth-reverse shift rail.
The switch can be replaced with t he transmission
in, or out of t he vehicle. A gasket may, or may not be
used wi t h t he switch.
Apply sealer to t he switch t hreads before installa-
tion. Ti ght eni ng torque for t he switch is 22-34 N
#
m
(192-300 in. lbs.).
BACKUP
LIGHT
SWITCH
J9221-257
Fig. 167 Backup Light Switch Location
Expansion Plug Replacement
The expansion plugs at t he rear of t he shift rai l
bores (Fig. 168) can be replaced if loose and/or leak-
ing. Replacement procedure is as follows:
(1) Drill 6 mm (1/4 in.) di amet er hole in each plug
to be removed.
(2) Pry plug out of cover wi t h tapered punch.
(3) Clean all chips from shift cover and plug bores.
Then clean plug bores with solvent and dry with
clean shop towel.
(4) Apply small bead of sealer to outer edge of each
new plug. Use Mopar silicone adhesive/sealer, or
equivalent.
(5) Position each new plug in bore and t ap into
place with hammer and suitable size punch or socket.
Shift Lever Replacement
EXPANSION
PLUGS J9221-258
Fig. 168 Expansion Plug Location
(1) If transmission is in vehicle, remove shift lever
extension, upper boot and bezel. If transmission is
out of vehicle, temporarily mount cover on gear case.
(2) Remove shift lever lower boot. Unseat boot
from shift tower and slide it off shift lever.
(3) Unlock shift lever ret ai ner with two long
screwdrivers for leverage. Press lever ret ai ner down-
ward with screwdrivers. Then t ur n ret ai ner counter-
clockwise to release ret ai ner from locking pins in
shift tower (Fig. 169).
RETAINER
Iff^r J9221-253
Fig. 169 Unlocking Shift Lever Retainer

SHIFT SPRI NG RETAINER
LOWER
BOOT
J9221-259
Fig. 170 Shift Lever Components
(5) Lubricate shift lever and ret ai ner contact sur-
faces with petroleum jelly or Castrol Syntorq.
(6) If transmission is out of vehicle, temporarily
mount shift cover on gear case.
(7) Position lever assembly in shift tower.
(8) Lock lever ret ai ner in shift tower with two long
screwdrivers. Use screwdrivers to push and t ur n re-
t ai ner unt i l it engages both locking pins in tower.
(9) Install lower boot on shift lever. Seat boot se-
curely on shift tower.
(10) If transmission is in vehicle, install upper
boot, bezel and shift lever extension.
Shift Cover Replacement
(1) Remove transmission from vehicle.
(2) Remove shift cover bolts (Fig. 171).
Fig. 171 Shift Cover Boit Removal/Installation
(3) Loosen shift cover wi t h pry tool. To avoid dam-
aging cover seal surface, insert pry tool only in slots
provided in cover (Fig. 172).
(4) Raise cover enough to disengage it from align-
ment dowels in gear case (Fig. 173).
(5) Raise front of shift cover and lift cover up and
off gear case (Fig. 173).
(6) Set cover assembly aside for inspection. If cover
components are damaged, refer to shift cover service
information.
NV4 500 TRANSMISSION OVERHAUL 21 - 4 5
SHIFT
COVER
SLOT
SHIFT
Fig. 173 Shift Cover Removal/Installation
(7) Clean mat i ng surfaces of shift cover and gear
case wi t h wax and grease remover.
sealing surface of shift cover or gear case. Do not
overapply sealer mat eri al . Excess can be squeezed
into gear case and could block lubricant feed holes in
time.
(9) Lubricate synchro sleeves with Castrol Syntorq
gear lubricant. Then apply light coat of petroleum
jelly to shift fork contact surfaces.
(10) Verify t hat 1-2 and 3-4 synchro sleeves are in
neut ral position. Also verify t hat forks in shift cover
are in neut ral position.
(11) Align and install shift cover (Fig. 173). If
cover will not seat, it is either not aligned on gear
case dowels, or shift forks are not aligned with
sleeves and shift lug.
t hreads of shift cover bolts.
(13) Install and t i ght en shift cover bolts to 27-31
N*m (216-276 in. lbs.) torque.
(14) Install backup light switch in cover. Apply
sealer to switch t hreads before installation and
t i ght en switch to 22-34 N*m (193-265 in. lbs.).
(15) Install vent assembly, if removed. Apply an
adhesive/sealer to vent tube to help secure it in
cover.
(4) Lift shift lever upward and remove lever, re-
tainer and spring as assembly (Fig. 170).
21 - 46 G360 MANUAL TRANSMISSION
G36 0 MANUAL TRAN SM I SSI ON
INDEX
page
Gear Ratios 46
Recommended Lubricant 4 6
Transmi ssi on Identification 4 6
Transmi ssi on Installation2-Wheel Drive . 50
GENERAL INFORMATION
The Getrag G360 transmission is used exclusively
with t he Cummi ns turbo diesel engine. It is a heavy
duty, 5-speed, fully synchronized manual t ransmi s-
sion (Fig. 1). Fifth gear is an overdrive range with a
ratio of 0.77 to 1.
The G360 is a top loader style transmission (Fig.
1). The shift lever, shift rails and shift forks are
mounted in t he transmission shift cover. The shift le-
ver operates t he shift rails and forks directly.
RECOMMENDED LUBRICANT
Recommended lubricant for t he Getrag G360 t rans-
mission is SAE 5W-30 engine oil. The oil should
meet A.P.I, service classifications SG or SG-CD.
page
Transmi ssi on Installation4 -Wheel Drive . . . . . . . 52
Transmi ssi on Removal 2- Wheel Drive . . . . . . . . 4 7
Transmi ssi on Removal 4 - Wheel Drive 51
Transmi ssi on Serviceability 4 7
Lubricant capacity is 3.3 liters (3.5 qts.). The t rans-
mission drain and fill plugs are both accessible from
t he passenger side of t he transmission case (Fig. 2).
The transmission identification/part number is im-
printed on a metal t ag attached to t he passenger side
of t he case (Fig. 2).
GEAR RATIOS
G360 gear ratios are:
Fi rst gear : 5.531:1
Second gear: 3.017:1
Third gear : 1.60:1
Fourt h gear: 1.00:1
Fig. 1 G360 Manual Transmission
G360 MANUAL TRANSMI SSI ON 21 - 47
on lower boot. Then slide boot upward on lever (Fig.
3).
(3) Remove screws at t achi ng lower boot and plate
assembly to floor pan (Fig. 4).
IDENTIFICATION
PLATE
Fig. 2 G360 identification Plate And Drain/Fill Plug
Locations
Fifth gear : 0.77:1
Reverse : 5.029:1
TRANSMISSION SERVICEABILITY
The G360 transmission can be serviced when nec-
essary. Replacement part s are available for overhaul.
The transmission gear case, r ear retainer, counter
gear and countershaft are not serviceable part s. If
these components become damaged to t he point of re-
placement, t he transmission must be replaced as an
assembly.
(2) Shift transmission into Neut ral and remove
screws at t achi ng shift lever upper boot to met al plate
PLATE
SCREW (4)
LOWER
.BOOT
AND
PLATE
J9121-255
Fig 4 Removing/Installing Lower Boot And Plate
Attaching Screws
(4) Remove shift lever extension by either un-
t hreadi ng, or unbolting it from shift lever (Fig. 5).
LOWER
BOOT AND
PLATE
BOOT
SCREW (4 )
UPPER
BOOT
LOWER
BOOT AND
PLATE J9121-254
J9121-256
Fig. 5 Removing/Installing Shift Lever Extension
(5) Slide lower boot and plate upward and off shift
lever (Fig. 6).
Fig. 3 Removing/Installing Shift Lever Upper Boot
J9121-257
Fig. 6 Removing/Installing Lower Boot And Plate
(6) Remove transmission shift tower boot. Loosen
clamp securing boot to shift tower. Then slide boot
up and off shift lever and shift tower (Fig. 7).
Fig. 7 Removing/Installing Shift Tower Boot
(7) Remove snap ri ng securing shift lever in shift
tower (Fig. 8).
(8) Remove shift lever (Fig. 10). If lever does not
come out readily, press lever downward and quickly
release it two or t hree times. Or lightly t ap side of
lever with plastic mallet to loosen it. Note align-

Fig. 8 Removing Shift Lever Snap Ring
ment slots i n l ever color and pivot ball (Fig. 9).
These slots align wi th shoul der bolts in shift
tower.
Fig. 9 Removing/Installing Shift Lever
(10) Mark propeller shaft U-joints and axle yokes
for assembly al i gnment reference (Fig. 10).
(11) Remove propeller shaft. Remove clamp st rap
bolts at front of shaft first. Remove center beari ng
bracket bolts and support shaft on tool box or stand.
Then remove rear clamp strap bolts and remove
shaft.
(12) Spread clamps t hat secure switch wires to
transmission top cover and remove wires from
clamps. Move wires aside to protect t hem and pro-
vide working clearance.

Fig. 11 Transmission Rear Mount Bolt Locations
(14) Support transmission with transmission jack
(Fig. 12). Secure transmission to jack with safety
chains as shown.
(15) On some models it may be necessary to re-
move screws at t achi ng fuel line clamps to driver side
frame rai l (Fig. 13). Three clamps must be removed
so fuel lines can be moved for access to crossmember
bolts on this side of frame rail.
(16) Remove left and ri ght crossmember-to-frame
braces (Fig. 14) and remove crossmember.
G360 MANUAL TRANSMISSION 21 - 49
Fig, 12 Transmission Supported On Jack
Fig. 13 Removing/installing Fuel Line Clamps
SAFETY

FRAME
RAIL
CROSSMEMBER
DRIVER SIDE
BRACKET
PASSENGER.
SIDE
BRACE
CROSSMEMBER
J9221-65
Fig. 14 Crossmember And Braces
(17) Remove clutch slave cylinder shield (Fig. 15).
SLAVE
CYLINDER
HEAT SHIELD
J9121-269
Fig. 15 Removing/Installing Slave Cylinder Shield
unt i l cylinder piston rod is clear of release lever (Fig.
16). This reduces pressure on lever and release bear-
ing maki ng transmission removal/installation easier.
SLAVE
CYLINDER
PISTON
ROD
CLUTCH
RELEASE
FORK
LOOSEN CYLINDER NUTS
TO RELIEVE TENSION
ON FORK AND BEARING J9121-270
Fig. 16 Loosening Slave Cylinder Nuts
housing and remove transmission. Rock transmission
slightly to help free i nput shaft from clutch disc and
release bearing.
(20) Support engine with wood block and adjust-
able jack stand (Fig. 17).
J9106-22
Fig. 17 Typical Method Of Supporting Engine
TRANSMISSION INSTALLATION2-WHEEL DRIVE
(1) Mount transmission on jack stand. Secure
transmission to jack with safety chains.
beari ng grease to contact surfaces of i nput shaft (Fig.
18) and following components:
C A U T I O N : D o not use an excessi ve amount of
gr ease. E xcessi ve amount s of gr ease coul d result
in gr ease contami nati on of the clutch di sc.
i nput shaft splines and pilot bearing hub
pilot bushi ng
release fork

APPLY LI GHT COAT OF
HI -TEMP GREASE TO THESE
SURF ACES BEFORE INSTALLATION J9106-15
Fig. 18 input Shaft Lubrication Points (Typical)
(3) Align transmission and clutch housing. Move
transmission forward and st ar t input shaft into re-
lease bearing and clutch disc hub. Rotate output
shaft with socket or yoke to align i nput shaft and
clutch disc splines if necessary.
(4) Move transmission forward and seat t ransmi s-
sion against housing.
(5) Install and t i ght en t ransmi ssi on mount i ng
bolts to 68 N-m (50 ft-lbs).
(6) Install rear crossmember and crossmember
brackets. St art all crossmember bolts/nuts before
tightening to final torque of 68 Nm (50 ft-lbs).
(7) Remove transmission jack.
(8) Install screws t hat at t ach fuel line clamps to
driver side frame rail.
(9) Align clutch slave cylinder in housing and
t i ght en cylinder at t achi ng nut s.
(10) Install clutch slave cylinder shield.
(11) Secure backup light and vehicle speed sensor
wires in clips at top of transmission. Route wires
across top of transmission to sensor and switch and
connect wires.
(12) Align and install propeller shaft. Support
shaft on box or stand. Install shaft front U-joint first.
Next, secure center beari ng bracket to frame bracket.
Then install shaft rear U-joint in axle yoke. Final-
tighten U-joint clamp bolts to 19 N
@
m (14 ft-lbs) and
center bearing bracket bolts to 68 Nm (50 ft-lbs).
(13) Lower vehicle.
(14) Lubricate shift lever ball and collar with Mo-
par all purpose grease.
(15) Align notches in shift lever ball and collar
and insert shift lever in shift tower.
(16) Press shift lever and collar downward and in-
stall shift lever snap ring.
(17) Tighten shift lever al i gnment bolts com-
pletely.
(18) Install boot over shift lever and onto shift
tower and tighten boot clamp securely.
(19) Install lower boot and pl at e assembly over
shift lever and onto floorpan. Position plate so large
G360 MANUAL TRANSMI SSI ON 21 - 51
SKI D
PLATE J9121-525
Fig. 19 Transfer Case Skid Plate Mounting
notch is forward t hen install lower boot at t achi ng
screws.
(20) Thread or bolt shift lever extension to shift le-
ver. Slide upper boot down extension. Position boot
on plate and install boot at t achi ng screws.
(21) Install shift knob on extension (if removed).
(2) Remove screws at t achi ng shift lever upper boot
to met al plate on lower boot. Then slide boot upward
on lever (Fig. 3).
(3) Remove screws at t achi ng lower boot and plate
assembly to floor pan (Fig. 4).
(4) Remove shift lever extension by unt hreadi ng it
from shift lever (Fig. 5).
(5) Slide lower boot and plate upward and off shift
lever (Fig. 6).
(6) Remove transmission shift tower boot. Loosen
clamp securing boot to shift tower. Then slide boot
up and off shift lever and shift tower (Fig. 7).
(7) Remove snap ri ng securing shift lever in shift
tower (Fig. 8).
(8) Remove shift lever (Fig. 9). If lever does not
come out readily, press lever downward and quickly
release it two or t hree times. Pressure from spring
under lever should push it out of housing. Note
al i gnment slots i n lever cover and pivot ball
(Fig. 9). These slots align wi th shoul der bolts i n
shift tower.
(10) Mark front and rear propeller shafts for in-
stallation reference (Fig. 10). Then disconnect and re-
move both shafts.
(11) Remove transfer case skid plate and cross-
member (Fig. 19).
21 - 52 G360 MANUAL TRANSMI SSI ON

(12) Disconnect wires at vehicle speed sensor and
backup light switch.
(13) Disconnect transfer case shift lever from lever
on transfer case.
(14) Temporarily support transmission with adjust-
able jack stand. Then support transfer case with
transmission jack.
(15) Remove nut s at t achi ng transfer case to t rans-
mission adapt er and move transfer case away from
transmission rear retainer.
(16) Lower transfer case and move it from under
vehicle. Remove transfer case from transmission jack
and place transfer case on workbench.
Secure transmission to jack with safety chains. Then
remove jack st and previously used to support t rans-
mission.
(18) Spread clamps t hat secure switch wires to
transmission top cover and remove wires from
clamps. Move wires aside to protect t hem and pro-
vide working clearance.
(19) Remove bolts at t achi ng transmission rear
mount to crossmember.
(20) On some models, it is necessary to remove
screws at t achi ng fuel line clamps to driver side
frame rail. Three clamps must be removed to so fuel
lines can be moved for access to crossmember bolts at
t hi s side of frame rail.
(21) Remove left and ri ght crossmember-to-frame
braces and remove crossmember.
(22) Remove clutch slave cylinder shield.
unt i l cylinder piston rod is clear of release lever (Fig.
20). This reduces pressure on lever and release bear-
ing maki ng transmission removal/installation easier.
housing and remove transmission. Rock transmission
slightly to help free i nput shaft from clutch disc and
release beari ng.
(25) Support engine with wood block and anot her
adjustable jack stand.
TRANSMI SSI ON INSTALLATION4-WHEEL DRIVE
(1) Mount transmission on jack stand. Secure
transmission to jack with safety chains.
beari ng grease to contact surfaces of input shaft (Fig.
20) and following components:
C A U T I O N : D o not use excessi ve amount s of gr ease.
T hi s practice coul d result in contami nati on of the
clutch di sc.
i nput shaft splines and pilot beari ng hub
pilot bushi ng
release fork
(3) Align transmission and clutch housing. Move
transmission forward and st art i nput shaft into re-
lease bearing and hub of clutch disc.
(4) Rotate output shaft with socket or yoke to align
i nput shaft and clutch disc splines. If i nput shaft will
not rotate enough in neut ral to align splines, it will
be necessary to shift transmission into t hi rd or
fourth gear with screwdriver.
(5) Seat transmission against clutch housing and
align bolt holes in transmission and housing.
ing bolts to 68 N-m (50 ft. lbs.).
(7) Install rear crossmember and mount. St art all
crossmember bolts/nuts t hen t i ght en t hem to 68 N*m
(8) Remove transmission jack.
(9) Install screws t hat at t ach fuel line clamps to
driver side frame rail.
(10) Align clutch slave cylinder in housing and
t i ght en cylinder at t achi ng nut s.
(11) Install clutch slave cylinder shield.
(12) Secure backup light and vehicle speed sensor
wires in clips at top of transmission. Route wires
across top of transmission to sensor and switch and
connect wires.
(13) Install gasket and transfer case on t ransmi s-
sion rear retainer. Tighten transfer case at t achi ng
nut s to 47 N-m (35 ft. lbs.) torque.
(14) Check transmission and transfer case lubri-
cant levels. Add lubricant if necessary and install fill
plugs.
(15) Connect transfer case shift lever to lever on
transfer case.
(16) Align and install propeller shafts. Tighten
U-joint clamp bolts to 19 N-m (14 ft. lbs.).
(17) Install skid plate and crossmember. Tighten
skid plate and crossmember bolts/nuts to 41 Nm
(18) Lower vehicle.
(19) Shift transmission into neut ral if necessary.
(20) Lubricate shift lever ball and collar with Mo-
par all purpose grease.
(21) Align notches in shift lever ball and collar
and insert shift lever in shift tower.
(22) Press shift lever and collar downward and in-
stall shift lever snap ring.
(23) Install boot over shift lever and onto shift
tower and t i ght en boot clamp securely.
(24) Install lower boot and plate assembly over
shift lever and onto floorpan. Position plate so large
notch is forward t hen install lower boot at t achi ng
screws.
(25) Thread or bolt shift lever extension to shift le-
ver. Slide upper boot down extension. Position boot
on plate and install boot at t achi ng screws.
(26) Install shift knob on extension (if removed).

G360 TRANSMISSION OVERHAUL 21 - 53
G 3 6 0 TRANSMI SSI ON O V E R H A U L
INDEX
page
Transmission Assembl y and Adjustment . . . . . . . 6 3
Transmission Cl eaning and Inspection 59
TRANSMISSION DI SASSEMBLY
SHIFT COVER REMOVAL
(1) Shift transmission into neut ral .
(2) Remove shift cover bolts.
(3) Loosen shift cover with two pry tools. Insert
tools in cover slots and pry cover off alignment dow-
els (Fig. 1). It is i mportant to remove the cover
evenl y to avoi d damage. Do not pry one side
loose then the other. This practice coul d damage
the forks and cover.
SHIFT
COVER
(4) Remove shift cover assembly (Fig. 2). Discard
old shift cover gasket. Note that a gasket was not
used on early producti on transmi ssi ons. It is
recommended that a gasket be used when shift
cover is installed after overhaul .
(5) Set shift cover assembly aside for inspection.
REARING RETAINER AND SHAFT BEARING
RACE REMOVAL
(1) Remove front beari ng ret ai ner bolts and re-
move ret ai ner (Fig. 3). Tap ret ai ner with rubber mal-
let to loosen it if necessary.
(2) On 2-wheel drive models, remove rear beari ng
ret ai ner as follows (Fig. 4):
(a) Remove nut at t achi ng yoke to output.
Torque on nut is quite hi gh. Best way to re-
move nut is wi th 350-400 ft. lb. rated hi gh ca-
pacity i mpact wrench.
(b) Remove yoke from output shaft splines.
page
Transmi ssi on Di sassembl y 53
Fig. 2 Shift Cover Removal/Installation
CHANNELS (4) J9321-268
Fig. 3 Front Bearing Retainer Removal
(c) Remove bolts at t achi ng rear beari ng ret ai ner
to gear case and remove retainer. Use rubber mal-
let to loosen ret ai ner if necessary.
(d) Remove speedometer gear and spacers from
output shaft.
(e) Remove preload shims from rear ret ai ner, or
bearings.
(f) Remove yoke seal from ret ai ner with suitable
pry tool. Do not damage ret ai ner surface while re-
moving seal.
(3) On 4-wheel drive transmission, remove r ear
bearing ret ai ner bolts and remove ret ai ner from gear
case (Fig. 5).
21 - 54 G350 TRANSMISSION OVERHAUL
4-
REAR
BEARING
RETAINER
SPEEDOMETER
GEAR
>YOKE
NUT
YOKE
SPACERS
YOKE
SEAL
J9321-271
Fig. 4 Two Wheel Drive Rear Bearing Retainer And Speedometer Gear Removal
(4 ) On 4 -wheel drive transmission, remove beari ng OUTPUT
preload shims from rear bearing ret ai ner (Fig. 6 ) . On SHAFT
2-wheel drive transmissions, remove shims from re- SHIM
t ai ner and slide output shaft rear beari ng shims off \ ,
shaft.
REAR
BEARING
RETAINER
J9321-270
Fig. 6 Shim Locations In Rear Bearing Retainer
( 5) Remove output shaft and countershaft beari ng
races (Fig. 7 ) . Tap front and rear faces of gear case
with large plastic mallet to loosen and remove races.
Do not strike beari ng races. Tap on case sur-
faces only.
J9321-267
Fig. 5 Four Wheel Drive Rear Bearing Retainer
Removal
G360 TRANSMISSION OVERHAUL 21 - ii
Fig. 7 Shaft Bearing Race Removal
INPUT SHAFT AND OUTPUT SHAFT REMOWAL
(1) Rotate input shaft until flats on shaft clutch
teeth are facing downward toward countershaft (Fig.
8).
Fig. 8 Location Of Input Shaft Clutch Gear Flats
(2) Work input shaft forward until clear of output
shaft.
(3) Remove output shaft and gears as assembly
from case (Fig. 9).
(4) Remove input shaft from case (Fig. 9).
(5) If bearing on input shaft is damaged, press
bearing from shaft. Use hydraulic shop press and
standard bearing splitter type remover tool.
Fig. 9 Output Shaft And Gear Assembly Removal
COUNTER GEAR AND SHAFT REMOWAL
(1) Remove countershaft front bearing cap from
case (Fig. 10). Strike cap with punch to unseat it. Ex-
ercise care as bearing could be damaged if punch
penetrates cap and contacts bearing.
(2) Remove large snap ring retaining counter gear
shaft front bearing race in gear case (Fig. 10).
(3) Remove counter gear shaft front bearing race
from gear case (Fig. 10). If race proves difficult to re-
move, use a slide hammer and blind hole puller tool.
Or, remove rear bearing snap ring and drive counter
gear shaft (and front bearing) out front of case. Pro-
cedure is outlined in following steps.
B E A R I N G
C A P J932 1- 2 74
Fig. 10 Counter Gear Shaft Front Bearing Cap, Snap
Ring And Race Removal
(4) Remove small snap ring retaining rear bearing
on counter gear shaft (Fig. 11).
21 - 56 G360 TRANSMISSION OVERHAUL ^ ^ ^ ^
REAR
BEARING
SNAP
RI NG
C OU N T E R
GE A R
SHAFT
REAR
BEARI NG
J9321-275
Fig. 11 Removing Counter Gear Shaft Front Bearing
Snap Ring
(5) Tap countershaft out of forward end of gear
case (Fig. 12). Use hammer and brass punch to re-
move shaft and front bearing.
(6 ) If countershaft rear beari ng is damaged, re-
move snap ri ng and press beari ng off shaft.
COUNTER
GEAR
SHAFT
AND
FRONT BEARI NG
J9321-276
Fig. 12 Counter Gear Shaft And Front Bearing
Removal
(7) Position gear case in upri ght position (Fig. 13).
(8) Remove counter gear from case as follows:
(a) On transmission with new style gear case,
counter gear can be removed by rot at i ng it past re-
verse idler gear and out of case (Fig. 13).
(b) On transmi ssi on wi t h early style gear
case, it will be necessary to remove reverse
idler gear before counter gear can be removed.
Refer to fol l owi ng Reverse Idler Gear Removal
procedures.
REVERSE IDLER GEAR REMOVAL
Two styles of transmission case were used for t he
G360 transmission. Earl y style cases had a part i al
radi us machined in t he reverse idler area while l at er
style cases had a full radi us. The different machi ni ng
required different methods for removing t he reverse
idler gear and shaft.
On early style gear cases, t he idler gear must be
removed before t he counter gear can be removed.
On new style cases, t he counter gear can be re-
moved with t he idler gear still i n place.
REVERSE
I DLER
GEAR
ROTATE
COUNTER GEAR
PAST I DLER
GEAR AND
OUT OF CASE
J9321-277
Fig. 13 Counter Gear Removal (With New Style Gear
Case)
Reverse Idler Removal (New Style Gear Case)
(1) Remove idler shaft pins (Fig. 14). Use appropri-
at e size pin punch only to remove pins. Discard pins
after removal as they are not reusable.
I DLER
GEAR
PI NS
( REMOVE WI TH
PI N PUNCH ONLY)
REVERSE
I DLER
GEAR
J9321-279
Fig. 14 Location Of Reverse Idler Shaft Pins
(2) Remove bolt t hat aligns and secures idler shaft
in case (Fig. 15). Keep bolt wi th idler gear compo-
nents. Do not i nt er mi x it wi th other fasteners.
G350 TRANSMI SSI ON OVERHAUL 21 - 57
REVERSE
IDLER
SHAFT
BOLT
J9321-278
Fig. 15 Reverse idler Shaft -Bolt Removal
(3) Remove reverse idler shaft (Fig. 16)
REVERSE
IDLER
SHAFT J9321 - 28 0
Fig. 16 Reverse Idler Shaft Removal (New Style
Gear Case)
(4) Remove idler gear, t hr ust washers, bearings
and spacer as assembly (Fig. 17).
IDLER GEAR
THRUST
WASHERS
J 9321 - 28 1
Fig. 17 Reverse Idler Gear Removal (New Style Gear
Case)
Reverse Idler Removal (Early Style Gear Case)
(1) Remove front pin from idler shaft first.
(2) Slide gear and washer forward and remove rear
pin.
(3) Remove bolt securing idler shaft in case.
(4) Slide idler shaft forward and remove gear and
washer from case. Tur n counter gear to help rotate
idler gear out of case.
OUTPUT SHAFT DISASSEMBLY
Do not di sassembl e the 1-2, 3-4 and fifth-re-
verse synchros duri ng overhaul. The component
parts in each synchro are not available sepa-
rately. The synchros are servi ced as assembl i es
only.
C A U T I O N : The output shaft and geartrain are quite
heavy. Have a helper support and hol d the output
shaft and gear assembl y duri ng all pr ess opera-
t i ons. Do not al l ow the shaft and gear assembl y to
fall and strike the s hop floor.
(1) Press fifth gear and r ear bearing off output
shaft. Use st andard beari ng splitter type remover
tool and shop press to remove gear and beari ng (Fig.
18).
REAR
BEARING
STANDARD TYPE
REMOVER TOOL
PRESS
RAM
OUTPUT
SHAFT
Fig. 18 Removing Fifth Gear And Rear Bearing
(2) Remove fifth-reverse snap ri ng and blocker
ri ng (Fig. 19).
(3) Remove two halves of fifth gear beari ng from
output shaft (Fig. 20).

S NAP
RI NG
BLOCKER
RI NG
FIFTH-REVERSE
SYNCHRO
ASSEMBLY J9321-283
Fig. 19 Removing Fifth-Reverse Snap Ring And
Blocker Ring
(4) Remove reverse gear and fifth-reverse synchro
assembly (Fig. 20). Use two large, flat-blade screw-
drivers to pry components up and off mainshaft
splines (Fig. 20). If gear and synchro proves difficult
to remove, use a press and beari ng splitter for re-
moval.
(5) Remove reverse gear beari ng from gear or out-
put shaft.
FIFTH
GEAR
BEARI NG
(2-PIECE)
FIFTH-REVERSE
SYNCHRO
ASSEMBLY
REVERSE
GEAR
PRY>
TOOLS
J9321-284
Fig. 20 Reverse Gear And Fifth-Reverse Synchro
Removal
(6) Remove first gear snap ri ng (Fig. 21).
(7) Remove first gear (Fig. 22). Use shop press and
two press plates to press gear off shaft. Have helper
hold output shaft while removing gear.
(8) Remove first gear beari ng from gear or out put
shaft.
(9) Mark position of 1-2 synchro assembly for in-
stallation reference. Then remove synchro assembly
from out put shaft (Fig. 23).
(10) Remove pilot bearing, 3-4 synchro assembly
and t hi rd gear as a unit. Use suitable size beari ng
splitter type remover tool, press tool and hydraul i c
S NAP
RI NG
FIRST
GEAR
S NAP
RI NG
PLIERS
J9321-285
Fig. 21 First Gear Snap Ring Removal
PRESS
RAM
FIRST
GEAR
PRESS
PLATES
J9321-286
Fig. 22 First Gear Removal
1-2
SYNCHRO
ASSEMBLY
(NOTE POSI TI ON
BEFORE REMOVAL)
J9321-288
Fig. 23 Removing 1-2 Synchro Assembly
shop press to remove these components (Fig. 24). Po-
sition remover tool jaws under t hi r d ge a r for re-
moval purposes. Al so have hel per support and
hol d assembl y during removal.

Fig. 24 Pilot Bearing, 3-4 Synchro And Third Gear
Removal
THRUST
WASHER
J9321-290
Fig. 25 Second Gear Snap Ring Removal
(11) Remove t hi rd gear beari ng from gear or shaft.
(12) Remove second gear snap ring with heavy
duty snap ri ng pliers (Fig. 25). Discard snap ri ng af-
t er removal as it is not reusable.
(13) Remove second gear and t hrust washer from
shaft wi t h hydraulic shop press (Fig. 26). Have
helper hold output shaft while gear and washer are
being removed.
(14) Remove second gear beari ng from gear or
shaft.
FIRST AND SECOND GEAR BLOCKER RING
REMOVAL
The blocker rings on t he first and second gears are
secured to t he gear with roll pins.
The pins can either be removed completely, or sim-
ply tapped inward to allow blocker ring removal. An
appropriate size pin punch and hammer, or locking
pliers are t he only tools required for removal (Fig.
27). Procedure is as follows:
Fig. 26 Second Gear And Thrust Washer Removal
(1) On first gear, t ap pins through blocker ring
and remove ri ng from gear.
(2) On second gear, remove blocker ri ng as follows:
(a) Position gear on workbench so first roll pin to
be removed extends over edge of bench (Fig. 27).
(b) Tap each roll pin about t hree quart ers of way
t hrough blocker ring.
(c) Pry blocker ri ng off gear (Fig. 28). Discard
ri ng if considerable force was required to remove
ri ng from gear.
(d) Remove pins from gear with locking pliers
(Fig. 29).
(3) Discard roll pins after removal. They should
not be reused.
(4) Discard either gear if damaged.
Fig. 27 Unseating Blocker Ring Roll Pins
TRANSMISSION CLEANING AND INSPECTION
Clean t he transmission components with solvent.
Use shop towels to dry bearings and bearing races.
Compressed air can be used to dry t he other t rans-
mission components.
Do not use compressed air to dry the bearings.
This practice can result in abradi ng and brinnel-
ling the beari ng rollers and races.

BLOCKER
Fig. 28 Removing Blocker Ring From Gear
Output Shaft And Gears
Inspect t he shaft and gears for wear, or damage
(Fig. 30). Check for broken, or chipped gear t eet h,
SECOND
GEAR
Fig. 29 Removing Roll Pins From Gear
damaged synchro blocker rings, or worn galled bear-
ings. Discoloration or shiny spots on gear t eet h are a
normal condition and do not indicate a need for re-
placement.
1
I
21 - 62 G360 TRANSMI SSI ON OVERHAUL
Synchronizers And Blocker Rings
LEGEND FOR OUTPUT SHAFT AND
GEARTRAIN
COUNTER
GEAR
8
9
ho
11
12
13
14
15
16
17
18
19
20'
21
22
23'
24
25
'26
27
28
29
Front Bearing
Input Shaft
Blocker Ring (4th Gear)
Output Shan Pilot Bearing
3-4 Synchro Assembly
Blocker Ring (3rd gear)
Third Gear
Third Gear Bearing
Snap Ring
Spacer
Second Gear
Second Gear Blocker Ring And Retaining Pins (3)
Second Gear Bearing
Output Shaft (2WD version shown)
1 -2 Synchro Assembly
First Gear Bearing
First Blocker Ring And Retaining Pins (3)
First Gear
Spacer
Snap Ring
Reverse Gear Bearing
Reverse Gear
Blocker Ring (reverse gear)
Fifth-Reverse Synchro Assembly
Snap Ring
Fifth Gear Bearing (2-piece)
Blocker Ring (fifth gear)
Fifth Gear
Rear Bearing
J9321-305
Inspect t he synchro blocker rings (Fig. 30). Look
for evidence of wear or damage to t he clutch mat eri al
on t he rings. Also check t he rings for cracks. Place
the rings on a flat surface to check for distortion.
The 1-2, 3-4 and fifth-reverse synchro hubs,
sleeves, st rut s and springs are serviced as assem-
blies. If wear or damage is evident, it will be neces-
sary to replace t he complete synchro assembly.
Counter Gear And Shaft
Check t he gear, shaft and bearings for wear or
damage (Fig. 31). Minor nicks or scratches on t he
gear t eet h can be smoothed off with an oilstone. Mi-
nor nicks or scratches on t he shaft can be reduced
and smoothed off wi t h 320/400 grit emery cloth.
The counter gear and shaft are not serviceable
components. If either part is damaged, it will be nec-
essary to replace t he complete transmission assem-
bly.
Reverse Idler Components
The reverse idler components consist of t he gear,
shaft, t hr ust washers, pins, bearings and t he shaft
bolt (Fig. 32).
Clean and inspect t he idler components. Replace
t he gear if any t eet h are chipped, or cracked. Replace
t he shaft and beari ngs if galled, brinnelled, or se-
verely worn. The t hr ust washers can be reused but
only if wear is not excessive and t he washer notches
are in good condition.
Replace t he pins duri ng overhaul. The pins should
not be reused. Also be sure t he shaft bolt and case
REAR
BEARI NG
A N D S NAP
RI NG
COUNTER
GEAR
SHAFT
FRONT
BEARI NG
A N D
S NAP RI NG
J9321-308
Fig. 31 Counter Gear Components
t hreads are in good condition. The case t hreads can
be cleaned up with a t ap, or repaired with Heli-Coil
stainless steel t hread inserts if necessary. Replace
t he bolt if damaged.
THRUST
WASHER
REVERSE
IDLER
GEAR
BEARI NGS
IDLER
SHAFT
SHAFT
BOLT
THRUST
WASHER
SHAFT
PI NS
J9321-309
Fig. 32 Idler Gear Components
Bearings And Races
Inspect each beari ng and race carefully. Check for
such conditions as spalling, wear, cracks, distortion,
or flat spotting of t he rollers and races. Replace any
beari ng or race if doubt exists about its condition.
Seals And Snap Rings
Replace front and rear ret ai ner seals and t he coun-
tershaft front beari ng cap. Do not reuse these part s.

G360 TRANSMI SSI ON OVERHAUL 21 - 63
The ret ai ner seals have a small spring around t he in-
ner part of t he seal. Be sure each seal is installed
with t hi s spring facing t he case interior.
The snap rings should all be replaced. Eeusi ng
snap ri ngs is not recommended.
Shift Cover
Inspect t he shift cover components (Fig. 33). The
only serviceable shift cover components are t he shift
lever, lever ret ai ner ring, snap ring, boot and clamp,
and backup light switch.
If any of t he shift forks, shift rails, or shift rai l de-
t ent part s are worn, or damaged, replace t he shift
cover assembly.
COVER 1-2 3- 4
SHIFT
RAILS J9321-310
Fig. 33 Shift Cover Assembly
TRANSMISSION ASSEMBLY AND ADJUSTMENT
Assembly Information
The only gasket in current G360 transmissions is
t he shift cover gasket. All other sealing surfaces are
to be sealed wi t h a coating of Mopar Gasket Maker,
or Loctite 518.
Pri or producti on G360 transmi ssi ons wi th the
early style gear case, were not equi pped wi th a
shift cover gasket. It is recommended that a gas-
ket be used on these transmi ssi ons during over-
haul or whenever the shift cover is removed
duri ng service. A gasket is available separatel y
or as part of the basi c overhaul kit.
Apply Mopar Lock N' Seal, or Loctite 242 to bolt
t hreads before installation. These products will en-
sure proper fastener retention and sealing.
Lubricate t he transmission components with Mopar
5W-30 engine oil or equivalent, duri ng assembly. Pe-
troleum jelly can be used to hold part s i n place and
prelubricate bearings and seal lips.
Do not use chassi s grease, or similar products
on any component duri ng assembl y. Heavy lu-
bricating grease will pl ug the transmi ssi on oil
passages resulting i n failure.
Preload adjustments are required for the output
shaft and countershaft bearings. Preload is accom-
plished by t he use of select fit shims. An accurate
vernier style depth gauge, depth micrometer, or dial
indicator and suitable mount i ng stand are required
for measurement and adjustment. The procedure is
described i n the Bearing Preload Adjustment section.
ASSEMBLING OUTPUT SHAFT AND
GEARTRAIN
(1) Lubricate mainshaft, gears and synchro compo-
nent s with Mopar 5W-30 engine oil.
(2) Install blocker rings on first and second gears
as follows:
(a) St art roll pins into blocker ri ngs and gears
wi t h hammer (Fig. 34).
(b) Seat roll pins with pin punch (Fig. 35). Be
sure roll pins are seated flush with surface of each
blocker ring. Do not drive pins below surface of
rings.
Fig. 34 Starting Roll Pins In First/Second Gear
Blocker Rings
(3) Install bearing in second gear and install sec-
ond gear on output shaft (Fig. 36).
(4) Install second gear t hr ust washer on output
shaft (Fig. 37). Washer is tight fit on shaft. Heat
washer i n oven or use suitable tool to seat
washer on shaft.If washer is heat ed to ease instal-
lation, heat washer for no more t han 5 mi nut es at
200F.
21 - 64 136 0 TRANSMISSION OVERHAUL

BLOCKER
RING
GEAR
J9321-297
Fig. 35 Seating Roil Pins in First/Second Gear
Blocker Rings
OUTPUT
SHAFT-
SECOND
GEAR
J9321-298
Fig. 36 Second Gear Installation
INSTALLER
TOOL
THRUST
WASHER
SECOND
GEAR
J9321-299
Fig. 37 Second Gear Thrust Washer Installation
(5) Install second gear snap ri ng (Fig. 38). Sn a p
r i ng i s sel ect fit part. Use t hi ckes t s n a p r i ng t ha t
wi l l fit
(6 ) Install beari ng in t hi rd gear. Then install gear
on output shaft (Fig. 39).
(7) Install synchro ri ng in t hi rd gear (Fig. 39).
(8) Install 3-4 synchro assembly on output shaft
(Fig. 40). Side of synchro hub wi th l ong shoul der
goes to front of shaft and fits i nsi de third gear.
Use suitable size pipe style tool to t ap or press syn-
chro assembly into place.
SELECT
FIT
S NAP
RI NG
S E C OND
GEAR
THRUST
WASHER
J9321-300
Fig. 38 Second Gear Snap Ring Installation
BLOCKER
RI NG
THIRD
GEAR
J9321-301
Fig. 39 Third Gear And Blocker Ring Installation
C A U T I O N : Be sure the third gear blocker ring i s
al i gned with the synchr o hub before seati ng the
synchr o assembl y. Failure to al i gn the ring coul d
result in damage to the blocker ring.
THIRD GEAR
BLOCKER
RI NG
SYNCHRO
-INSTALLER
TOOL
3-4 SYNCHRO
ASSEMBLY
J9321-302
Fig. 40 Installing 3-4 Synchro Assembly
(9) Install pilot beari ng on output shaft (Fig. 41).
Heat beari ng in oven to ease installation, or use suit-
able tool to t ap beari ng into place.
(10) Turn output shaft over so rear of shaft is fac-
ing upward.
(11) Install 1-2 synchro assembly (Fig. 42). If new
synchro is bei ng installed, it can be installed ei-

OUTPUT
SHAFT
" PILOT
BEARI NG
J9321-303
Fig. 41 Output Shaft Pilot Bearing Installation
ther way on shaft. If original synchro i s bei ng
reused, install synchro i n same posi ti on as when
removed.
Fig. 42 Installing 1-2 Synchro Assembly
(12) Install first gear bearing on mainshaft (Fig.
43).
FIRST
GEAR
BEARING
J9321-306
Fig. 43 First Gear Bearing Installation
G360 TRANSMISSION OVERHAUL 21 - 6 5
(13) Install first gear on mainshaft (Fig. 44). Work
gear back and forth until blocker ri ng seats in syn-
chro assembly.
Fig. 44 First Gear Installation
(14) Install first gear t hr ust washer (Fig. 45).
Washer is tight fit on shaft. Either heat washer
in oven to ease installation, or use pi pe tool or
brass drift to press washer onto shaft and
agai nst gear.
FIRST
GEAR
Fig. 45 First Gear Thrust Washer Installation
(15) Install first gear snap ri ng (Fig. 46). Do not
overspread snap ring to install it. Al so be sure
snap ring i s fully seated i n shaft groove. Tap ri ng
into place with punch if necessary.
(16) Install bearing in reverse gear.
(17) Install reverse gear on mainshaft (Fig. 47).
(18) Install blocker ri ng in reverse gear (Fig. 47).
(19) Install fifth-reverse synchro assembly (Fig.
48). Be sure reverse gear blocker ri ng is aligned in
synchro before proceeding. Use pipe tool to press syn-
chro into place if necessary.
SELECT
Fig. 46 Installing First Gear Snap Ring
BLOCKER
Fig. 47 Reverse Gear And Blocker Ring Installation
J9321-314
Fig. 48 Fifth-Reverse Synchro Installation
(20) Install fifth-reverse synchro snap ri ng (Fig.
49). Thi s i s a sel ect fit s n a p r i ng. Use t hi ckes t
s n a p r i ng t ha t wi l l fit In shaf t gr oove a n d b e
s ur e s na p r i ng is fully s eat ed i n shaft gr oove.
Move synchro into reverse position for snap ring se-
lection if necessary.
Fig. 49 Fifth-Reverse Synchro Snap Ring
Installation
(21) Install fifth gear bearing halves on output
shaft (Fig. 50). Use petroleum jelly to hold beari ng
halves in place.
(22) Install blocker ri ng in fifth-reverse synchro
sleeve (Fig. 50).
(23) Install fifth gear (Fig. 50).
S YNCHRO SLEEVE J9321-316
Fig. 50 Fifth Gear, Bearings And Blocker Ring
Installation
(24) Install rear beari ng on output shaft (Fig. 51).
Use suitable tool to seat bearing on shaft.
(25) Verify correct gear installation. Refer to in-
stallation sequence shown in Figure 51.
6 36 0 TRANSMISSION OVERHAUL 21 - 6 7
3- 4 THIRD 1-2 SYNCHRO REVERSE FIFTH
SYNCHRO GEAR ASSEMBLY GEAR GEAR
S E C OND FIRST FIFTH-REVERSE
GEAR GEAR SYNCHRO ASSEMBLY J9321-287
Fig. 51 Output Shaft Gea
REVERSE IDLER GEAR INSTALLATION
Different procedures are required for installing the
idler gear in early and new style gear cases.
The idler gear can be installed before installing the
counter gear in a new style gear case. However, the
counter gear must be installed before t he idler gear
in an early style gear case.
Refer to t he appropriate idler gear installation pro-
cedure during reassembly.
Reverse Idler Installation (With New Style Gear Case)
(1) Install reverse idler shaft part way into case
(Fig. 52) .
Fig. 52 Idler Shaft Installed Part Way In Case
fin Installation Sequence
(3) Position t hr ust washer at each end of idler gear
and install gear assembly in case (Fig. 53). Be sure
slots i n thrust washers face outward as idler
gear roll pi ns fit in these slots.
(4) Align idler shaft pin holes and push idler shaft
into place in gear and washers.
IDLER GEAR
Fig. 53 Idler Gear And Thrust Washer Installation
(5) Part i al l y install idler shaft pins. Insert pins
only far enough to hold t hr ust washers in place.
(6) Check idler gear t hr ust washer clearance (Fig.
54) as follows:
(a) Check clearance between each t hrust washer
and idler gear with feeler gauge.
(b) Clearance should be 0.05 - 0.25 mm (0.002 -
0.010 in.).
(2) Install bearings and spacer in reverse idler
gear (Fig. 32). Be sure spacer is installed between
bearings.

(c) If clearance is not within specified limits, re-
move idler gear and replace t hr ust washers. Use
new pins when gear and washers are reinstalled.
THRUST
WASHER
INSERT FEELER
GAUGE HERE
TO CHECK
CLEARANCE
Fig. 54 Checking Idler Gear Thrust Washer
Clearance
(7) Install idler shaft bolt (Fig. 55). Tighten bolt to
54 N*m (40 ft. lbs.) torque.
J9321-317
Fig. 55 Idler Shaft Bolt Installation
(8) Tap idler shaft pins into place (Fig. 56).
J9321-318
Fig. 56 Idler Shaft Pin Installation
REVERSE IDLER INSTALLATION (WITH
EARLY STYLE GEAR CASE)
(1) Install counter gear and shaft in case. Refer to
procedure in t hi s section.
(2) Install idler shaft part way into case from
front.
(3) Assemble and install reverse idler gear and
t hrust washers.
(4) Install rear pin in idler gear and shaft. Then
install front pin.
(5) Check idler gear t hrust washer clearance (Fig.
54) as follows:
(a) Check clearance between each t hrust washer
and idler gear with feeler gauge.
(b) Clearance should be 0.05 - 0.25 mm (0.002 -
0.010 in.).
(6) If clearance is not within specified limits, re-
move idler gear and replace t hrust washers. Use new
pins when gear and washers are reinstalled.
COUNTER GEAR AND SHAFT INSTALLATION
(1) Place gear case in upri ght position. Front bear-
ing ret ai ner/ i nput shaft bore should be facing up
(Fig. 57).
(2) Slide counter gear into position in case (Fig.
57).
(3) Install front beari ng and beari ng snap ri ng on
countershaft (Fig. 57).
(4) Install countershaft in gear and seat shaft front
beari ng in case (Fig. 57).
FRONT
BEARING
COUNTERSHAFT
COUNTER
GEAR
J9321-319
Fig. 57 Countershaft And Gear Installation
(5) Install countershaft front beari ng race in case
and on beari ng (Fig. 58).

Fig. 58 Countershaft Front Bearing Race Installation
(6 ) Install snap ring that retains countershaft front
bearing race in case bore (Fig. 59).
Fig. 59 Front Bearing Race Snap Ring Installation
(7) Install countershaft front bearing cap in case
bore (Fig. 60). Appl y Mopar adhesive/ sealant, or
3M industrial seal ant # 8 0 0 around outer edge of
beari ng cap before installation.
Fig. 60 Countershaft Front Bearing Cap Installation
(8) Install rear bearing on countershaft. Then in-
stall bearing retaining snap ring.
OUTPUT AND INPUT SHAFT INSTALLATION
(1) Install new seal in front bearing retainer (Fig.
61). Use socket or pipe tool to seat seal in retainer.
Be sure seal lip faces i nward t oward case inte-
rior.
(2) Install new front bearing on input shaft if nec-
essary. Use shop press to install bearing.
USE SOCKET
A S INSTALLER
TOOL
SEAL SEATED
I N RETAINER
RETAINER
J9321-327
Fig. 61 Input Shaft Seal Installation
(3) Install input shaft. Rotate shaft so flats on
clutch teeth are facing downward. Then install shaft
in case.
(4) Install output shaft and geartrain assembly in
case (Fig. 62).
Fig. 62 Output Shaft And Geartrain Assembly
Installation
(5) Install front bearing race in gear case.
(6) Apply recommended sealer to front bearing re-
tainer flange surface. Then apply oil to lip of retainer
oil seal.
(7) Install front bearing retainer on case (Fig. 63).
It is not necessary to align retainer i n any spe-
cial posi ti on. Oil channel s and bolt hol es i n re-
tainer are symmetrical and can be installed i n
any posi ti on.
front bearing retainer bolts. Then install and tighten
bolts to 22-30 Nm (16-22 ft. lbs.) torque.
(9) Before proceeding, verify that countershaft
front bearing cap has been installed (Fig. 64).

Fig. 63 Front Bearing Retainer installation
(10) Install output shaft rear beari ng race. Tap
race into position with plastic mallet.
(11) Install countershaft rear beari ng race in case
(Fig. 64). Then position race on beari ng and t ap race
into position with plastic mallet.
Fig. 64 Countershaft Rear Bearing Race Position
OUTPUT SHAFT AND COUNTERSHAFT
BEARING PRELOAD ADJUSTMENT
Beari ng preload adjustment is accomplished by t he
use of shims. The shims are installed in t he shim
bores machined into t he rear ret ai ner.
(1) Place transmission in upri ght position. Use
wood blocks to support transmission on either side of
front bearing ret ai ner.
(2) Tap output shaft and countershaft rear beari ng
races into place. Be sure races are seated on bear-
ings.
(3) Measure distance from top e a c h of rear beari ng
race to case surface wi t h depth gauge (Figs. 65 and
66). Measurement s reflect amount of beari ng race
t hat extends above rear surface of case. Record these
measurement s as they will be needed for shi m selec-
tion.
Fig. 65 Measuring Height Of Output Shaft Rear
Bearing Race
Fig. 66 Measuring Height Of Countershaft Rear
Bearing Race
(4) Measure depth of shim bore in rear ret ai ner
with depth gauge (Figs. 67 and 68). Record t hi s mea-
surement also as it will be needed for shim selection.
Fig. 67 Measuring Depth Of Output Shaft Bearing
Shim Bore (In Rear Retainer)

DEPTH
GAUGE
REAR
RETAINER
COUNTERSHAFT
BEARING
SHIM
BORE
J 9321 - 332
Fig. 68 Measuring Depth Of Countershaft Bearing
Shim Bore (in Rear Retainer)
(5) Select preload shims for shaft bearings as fol-
lows: Subt ract height of bearing from depth of shim
bore. Then add ext ra shim thickness of 0.15 - 0.20
mm ( 0.006 - 0.008 in.) for correct preload.
(6) Assemble and install shim packs in r ear re-
t ai ner (Fig. 69). Use petroleum jelly to hold shim
packs in place duri ng installation. Posi ti on thin
shi ms at rear of pack where they will seat in
rear retai ner shi m bore.
TRANSMISSION FINAL ASSEMBLY
rear ret ai ner flange surface.
OUTPUT
SHAFT
BEARING
SHIMS
COUNTERSHAFT
BEARING
SHIMS
REAR
RETAINER
J 9321 - 325
Fig. 69 Preload Shim Location
(2) On 2-wheel drive transmissions, install new
output shaft seal in ret ai ner. Then install speedome-
t er gear and spacers on output shaft (Fig. 70).
(3) Install rear ret ai ner on gear case. Do not dis-
place preload shims when i nst al l i ng retainer.
(4) Apply Mopar or Loctite t hr ead locker to r ear
ret ai ner bolts. Then install and t i ght en bolts to 22-30
(5) On 2-wheel drive transmissions, lube propeller
shaft yoke seal surface with petroleum jelly or en-
gine oil and install yoke. Then install and t i ght en
new yoke nut to 380 N*m (280 ft. lbs.) torque.
(6) Apply coat of Mopar Perfect Seal, or similar
sealer to new shift cover gasket. Then position gas-
ket on gear case. (Although early production t rans-
REAR
BEARING
RETAINER
SPEEDOMETER
GEAR
YOKE
NUT
YOKE
SPACERS
Fig. 70 Two Wheel Drive Rear Bearing Retainer And Speedometer Gear
J9321-271
21 - 72 G36Q TRANSMI SSI ON OVERHAUL
missions were not originally equipped with a cover
gasket, a gasket should be installed on these t rans-
missions).
(7) Verify t hat synchronizer sleeves are in neut ral
position. Shift cover cannot be installed otherwise.
(8) Install shift cover. Align shift forks with syn-
chro sleeves and alignment dowels and seat cover on
case.
(9) Apply Mopar or Loctite t hread locker to shift
cover bolts. Then install and t i ght en bolts to 22-30
(10) Place transmission in level position and in-
stall drai n plug. Tighten plug to 47 N-m (35 ft. lbs.)
(11) Fill transmission to bottom edge of fill plug
hole with Mopar 5W-30 engine oil.
(12) Install and t i ght en fill plug to 47 N-m (35 ft.
lbs.) torque.
(13) Install backup light switch in shift cover if re-
moved.
(14) Mount transmission on jack for installation in
vehicle.
(15) Secure transmission to jack with safety
chains.
(16) Apply t hi n coat of Mopar hi gh t emperat ure or
multi-purpose grease to pilot hub of i nput shaft.
AUTOMATIC TRANSMISSION32RH/36RH/37RH/42RH/46RH 21 - 73
C O N T E N T S
page
AUTOMATIC TRANSMISSION DIAGNOSIS
AND TESTING 85
AUTOMATIC TRANSMISSION REMOVAL
AND INSTALLATION 142
GENERAL INFORMATION-32RH/36RH/37RH . . . 73
GENERAL I NFORMATI ON-42RH/46RH 78
IN-VEHICLE SERVICE32RH/36RH/37RH/
42RH/46RH 130
page
OVERDRIVE UNIT OVERHAUL42RH/46RH . 324
TRANSMI SSI ON OVERHAUL32RH 152
TRANSMI SSI ON OVERHAUL36RH/37RH . . 192
G E N E R A L I N F O R M A T I O N - 3 2 R H / 3 6 R H / 3 7 R H
INDEX
page
Components Unique to 3 7 RH Diesel
Transmi ssi on 7 6
Description 7 3
Recommended Fluid 76
page
Torque Converter 76
Transmi ssi on Hydraulic Control System 7 6
Transmi ssi on Identification 7 6
DESCRIPTION
Chrysler 32RH/36RH/37RH transmissions are
three speed, fully automatic units with a planetary
gear system (Figs. 1 and 2).
The 32RH transmission is used with 3.9L and 5.2L
engines. The 36RH transmission is used with 5.2IV
5.9L gas engines. The 37RH is used with the 5.9L
Cummins diesel engine.
A U T O M A T I C T R A N S M I S S I O N - 3 2 R H / 3 6 R H / 3 7 R H / 4 2 R H / 4 6 R H
*4
FRONT PLANETARY GEAR SET
FLEXIBLE DRIVE PLATE
Fig. 1 Automatic Transmission-32RH
PR225
21 - 76 AUTOMATIC TRANSMISSION32RH/36RH/37RH/42RH/46RH

TORQUE CONVERTER
A t hree element torque converter is used. The con-
verter used with 32RH and some 36RH t ransmi s-
sions has a modulated converter clutch. The
converter used with 37RH transmissions is not
equipped with a modulated clutch.
The converter used with 1993, 32RH transmissions
is new. The converter hub was changed to accept t he
new style drive flats on t he oil pump inner gear. The
new style converter is not interchangeable with pre-
vious designs.
A 241 or 273 mm (9.5 or 10.75 in.) converter is
used for 3.9L, 5.2L and 5.9L gas engine applications.
A 310 mm (12.2 in.) converter is used for diesel en-
gine applications.
The converter impeller is connected to t he engine
crankshaft through t he front cover which is welded
to t he impeller. The t urbi ne is splined to t he t rans-
mission i nput shaft and t he stator is splined to t he
transmission reaction shaft.
The converter is a welded assembly. It is not a re-
pairable component and is serviced as an assembly.
RECOMMENDED FLUID
The recommended and preferred fluid for Chrysler
automatic transmissions is Mopar ATF Plus, Type
7176. Use Mopar Dexron II only when ATF Pl us is
not readily available.
The transmission part and identification numbers
are stamped on t he left side of t he case j ust above
t he oil pan gasket surface (Fig. 3). Refer to t hi s in-
formation when ordering replacement part s.
PART
NUMBER
BUILD
DATE
SERIAL 19191-909
NUMBER
J V U I z u z
Fig. 3 Transmission Identification Numbers And
Codes
COMPONENTS UNIQUE TO 37RH DIESEL
TRANSMISSION
Planetary Gears
The transmission and overdrive pl anet ary gear car-
riers in t he 37RH are heavy duty components. The
transmission pl anet ary carriers have four pinion
gears. The carrier in t he overdrive compounder has
five pinion gears.
Clutch Packs
Front and rear clutch packs used in t he 37RH con-
t ai n 4 discs and 5 steel plates.
Governor Weight Assembly
The governor weight assembly is made of alloyed
brass. The diesel weight assembly is easily identified
by t he distinctive gold color of t he alloyed mat eri al .
The heavier weight assembly provides t he shift
points needed to offset lower operating speeds of a
diesel engine.
The alloyed weight assembly is unique to t he
37RH. It is not interchangeable with t he weight as-
semblies used in gas engine versions.
TRANSMISSION HYDRAULIC CONTROL SYSTEM
The transmission hydraulic control system provides
fully automatic operation. The system performs five
basic functions, which are:
pressure supply
pressure regulation
flow control
clutch and band application
lubrication.
Pressure Supply
The oil pump develops fluid pressure for clutch/
band application and for lubrication. The pump is
driven by t he torque converter.
Pressure Regulation
The pressure regulator valve mai nt ai ns t ransmi s-
sion line pressure. The amount of pressure developed
is controlled by t hrot t l e pressure. Throttle pressure is
dependent on t he degree of throttle opening. The reg-
ulator valve is located in t he valve body.
The throttle valve determines line pressure and
shift speed. The t hrot t l e valve also controls upshift
and downshift speeds by regul at i ng pressure accord-
ing to t hrot t l e position.
Pressure developed by t he governor valve works
wi t h t hrot t l e pressure to determine shift points. Gov-
ernor pressure is t he speed signal t hat indicates
when a shift should t ake place. In operation, gover-
nor pressure increases at a rat e approximately t he
same as vehicle speed.

AUTOMATIC TRANSMISSION32RH/3SRH/37RH/42RH/48RH 21 - 77
Flow Control And Lubrication
The manual valve is operated by t he gearshift link-
age and provides t he operating range selected by t he
driver.
The 1-2 shift valve provides aut omat i c 1-2 or 2-1
shifts and t he 2-3 shift valve provides automatic 2-3
or 3-2 shifts.
The kickdown valve provides forced 3-2 or 3-1
downshifts depending on vehicle speed. Downshifts
occur when t he throttle is opened beyond downshift
detent position which is j ust before wide open throt-
tle.
The 2-3 valve t hrot t l e pressure plug provides 3-2
downshifts with varying t hrot t l e openings and de-
pending on vehicle speed.
The 1-2 shift control valve t ransmi t s 1-2 shift pres-
sure to t he accumulator piston to control kickdown
band capacity on 1-2 upshifts and 3-2 downshifts.
The limit valve determines maxi mum speed at
which a 3-2 part throttle kickdown can be made.
Some transmissions do not have t he limit valve and
maxi mum speed for a 3-2 kickdown is at t he detent
position.
The shut t l e valve has two functions. Fi rst is fast
front band release and smooth engagement during
"lift foot" 2-3 upshifts. Second is to regul at e front
clutch release and band application duri ng 3-2 down-
shifts.
The converter clutch valve applies t he converter
modulated clutch when supplied with line pressure
t hrough t he converter clutch solenoid. The solenoid is
controlled by and connected to t he powertrain control
module t hrough a connector in t he transmission case.
Electronic control of converter clutch engagement
includes disengagement at closed t hrot t l e duri ng
warmup and duri ng part throttle acceleration. Non-
converter clutch transmissions have a threaded plug
at t he rear of t he transmission case in place of t he
solenoid wiring connector.
The fail safe valve restricts feed to the converter
clutch if front clutch pressure drops. It permits clutch
engagement only in direct (third) gear and provides
fast clutch release duri ng kickdown.
The switch valve directs apply fluid pressure to t he
converter clutch in one position and releases it in t he
opposite position. It also directs oil to t he cooling and
lube circuits. The switch valve regulates oil pressure
to t he torque converter by limiting maxi mum oil
pressure to 130 psi.
Clutch/Band Application
The front/rear clutch pistons and servo pistons are
actuated by line pressure. When line pressure is re-
moved, t he pistons are released by spring tension.
On 2-3 upshifts, t he front servo piston is released
by spring tension and hydraulic pressure. The accu-
mul at or controls hydraulic pressure on t he apply side
of t he front servo duri ng 1-2 upshifts and at all
t hrot t l e openings.
21 - 78 AUTOMATIC TRANSMISSION- 32RH / 36 RH / 37RH / 4 2RH / 4 6 RH
G1NERAL I N F O R M A T I O N 4 2 R H / 4 6 R H
INDEX
page
Components Unique to Diesel V ersion of 4 6 RH . 81
Description 78
Fourth Gear Overdrive Components 81
Fourth Gear Overdrive Operation . 8 2
Gear Ratios 81
page
Hydraulic Controls . 8 3
Recommended Fluid 81
Torque Converter 81
Transmi ssi on Identification . 81
DESCRIPTION
The Chrysler 42RH/46RH are four-speed, auto-
matic transmissions. Fourt h gear is an overdrive
range. The 42RH is used for 3.9L and 5.2L engine
applications. The 46RH is used with 5.2L/5.9L gas
engines. A heavy duty version of t he 46RH is used
with t he 5.9L Cummi ns turbo-diesel engine.
The 42RH/46RH is a dual uni t design. The assem-
bly consists of a t hree speed automatic transmission
with an overdrive uni t attached at t he rear (Figs. 1
and 2). Fi rst t hrough t hi rd gear ranges are provided
by t he clutches, bands, overrunning clutch and plan-
et ary gear set in t he transmission. Fourt h gear range
is provided by t he overdrive unit. Overdrive ratio is
0.69:1.
The overdrive uni t contains an overdrive clutch, di-
rect clutch, pl anet ary gear set and overrunni ng
clutch. The overdrive clutch is applied in fourth gear
only. The direct clutch is applied in all ranges except
fourth gear.
The governor and park lock assemblies are located
inside t he overdrive unit. The uni t must be removed
and disassembled for service access to t he park lock
and governor components.
Fourt h gear is controlled by a manual l y operated
switch in t he i nst rument panel. The switch is in cir-
cuit with t he overdrive solenoid (on t he valve body)
and t he powertrain control module. In the On posi-
tion, current flows t hrough t he switch to t he solenoid
for the 3-4 shift sequence. The transmission must be
in third gear before a 3-4 upshift will occur.
The overdrive solenoid will not be energized and a
3-4 upshift will not occur when t he control switch is
in t he OFF position.
TORQUE
CONVERTER
VALVE
BODY
Fig. 2 46RH Transmission And Overdrive Unit

TORQUE CONVERTER
A t hree element torque converter is used for all ap-
plications. The converter consists of t he impeller, sta-
tor and t urbi ne. The converter also contains an
overrunning clutch and a modulated converter clutch
mechanism.
The converter used with 1993, 42RH transmissions
is new. The converter hub was changed to accept t he
new style drive flats on t he oil pump i nner gear. The
new style converter is not interchangeable with pre-
vious designs.
The converter modulated clutch consists of a slid-
ing clutch piston, clutch springs and t he clutch disc
friction mat eri al . The clutch provides optimum
torque t ransfer and economy when engaged.
The clutch disc is attached to t he converter front
cover. The clutch piston and clutch springs are at-
tached to t he t urbi ne hub. The springs dampen en-
gine firing impulses and loads duri ng t he initial
phase of converter clutch engagement.
Clutch engagement is controlled by t he converter
clutch valve and solenoid. Both are located on t he
transmission valve body. Clutch engagement occurs
in drive range at speeds above approximately 30-35
mph.
The clutch provides reduced engine speed and
greater fuel economy when engaged. Clutch engage-
ment also provides reduced transmission fluid tem-
perat ures.
COMPONENTS UNIQUE TO DIESEL VERSION OF
4 6 RH
Planetary Gears
The t ransmi ssi on and overdrive pl anet ary gear car-
riers in t he diesel version of t he 46RH are heavy
duty components. The transmission pl anet ary carri-
ers have four pinion gears. The carrier in the over-
drive compounder has five pinion gears. The heavy
duty pl anet ary uni t s are unique to t he diesel 46RH.
Clutch Packs
Clutch packs used in t he diesel version of t he
46RH contain t he following number of discs and
plates:
t ransmi ssi on front/rear clutch has 4 discs and 5
steel pl at es
overdrive clutch has 5 discs and 6 steel plates
overdrive direct clutch has 8 discs and 9 steel
plates
Governor Weight Assembly
The governor weight assembly in t he diesel 46RH
is made of alloyed brass. The diesel weight assembly
is easily identified by t he distinctive gold color of t he
alloyed mat eri al . The heavier weight assembly pro-
vides t he shift points needed to offset lower operating
speeds of a diesel engine.
The alloyed weight assembly is uni que to t he diesel
46RH. It is not interchangeable wi t h the weight as-
semblies used in gas engine versions.
Diesel Thermo Switch
Fourt h gear operation in t he diesel 46RH is also
controlled by two t emperat ure sensitive thermo-
switches.
The first thermo-switch is t he engi ne coolant t em-
perat ure switch. This switch prevent s overdrive
fourth gear operation when engine coolant t empera-
t ure is below approximately 65 F.
The second thermo-switch directly monitors t rans-
mission fluid t emperat ure. The switch will ei t her
downshift t he transmission to t hi rd gear, or prevent
a 3-4 upshift when fluid t emperat ure exceeds
270-275 F.
The fluid t emperat ure switch is located in a boss
built into t he cooler outlet line. The boss and switch
are located approximately 2-3 inches from t he outlet
line fitting in t he transmission case.
The engine coolant and fluid t emperat ure switches
are in circuit with t he overdrive control switch in t he
i nst rument panel.
GEAR RATIOS
42RH forward gear ratios are:
Fi rst gear = 2.74:1
Second gear = 1.54:1
Third gear = 1.00:1
Fourt h gear = 0.69:1.
46RH forward gear ratios are:
Fi rst gear = 2.45:1
Second gear = 1.45:1
Third gear = 1.00:1
Fourt h gear = 0.69:1.
RECOMMENDED FLUID
The recommended and preferred fluid for 42RH/
46RH transmissions is Mopar ATF Pl us, type 7176.
Use Mopar Dexron II only when ATF Plus is not
readily available.
The transmission part and identification numbers
and codes are stamped on t he left side of t he case
j ust above t he oil pan gasket surface (Fig. 3).
The first letter/number group is t he assembly part
number. The next number group t he transmission
build date. The last number group is t he t ransmi s-
sion serial number. Refer to t hi s information when
ordering replacement part s.
FOURTH GEAR OVERDRIVE COMPONENTS
42RH/46RH models have t hree transmission shafts.
An i nt ermedi at e shaft is positioned between t he in-
put and out put shafts. The output shaft is in t he
21 - 82 AUTOMATIC TRANSMISSION32RH/ 36 RH/ 37RH/ 4 2RH/ 4 6 RH
PART
NUMBER
BUILD
DATE
SERIAL
NUMBER
The fourth gear shift valves and plugs are located
in t he valve body lower housing. The components in-
clude:
a separate housing for t he overdrive valves and
plugs
an overdrive solenoid
a converter clutch solenoid
a 3-4 shift valve
a 3-4 t i mi ng valve
a 3-4 accumulator
a 3-4 shut t l e valve
an overdrive separator plate.
a boost valve and connecting t ube
J9121-202 FOURTH GEAR OVERDRIVE OPERATION
Fig. 3 Identification Number And Code Location
overdrive unit. The i nt ermedi at e shaft is supported
by t he overdrive piston ret ai ner and piloted in t he
output shaft.
The overdrive piston and ret ai ner are located at
t he rear of t he transmission case. The ret ai ner serves
as both t he rear support and pressure chamber for
t he overdrive piston. The i nt ermedi at e shaft is
splined to t he overdrive direct clutch sliding hub,
pl anet ary assembly and overrunning clutch.
The governor components and speedometer drive
are located on t he output shaft in t he overdrive unit.
Two bearings are used to support t he output shaft. A
longer park rod assembly is also required.
There are no rot at i ng seal ri ngs or pressurized oil
for t he direct clutch. The clutch is applied by spring
pressure and released by movement of t he overdrive
clutch piston duri ng t he 3-4 upshift.
The governor is operated by fluid pressure supplied
t hrough pressure tubes. The tubes are permanent l y
attached to t he governor support. Governor fluid
pressure is t ransmi t t ed t hrough t he i nt ermedi at e
shaft to t he tubes.
Governor pressure and overdrive clutch pressure
taps are provided in t he transmission case for pres-
sure testing purposes.
The overdrive uni t contains a direct clutch, an
overdrive clutch and an overrunning clutch. Fourt h
gear range is provided by an additional pl anet ary
gear set In t he overdrive unit.
The direct clutch is applied by spring pressure. A
high pressure spring rat ed at approximately 830
pounds (5530 kPa) tension, holds t he clutch in en-
gagement. The sun gear, direct clutch sliding hub
and drum are splined to t he annul us gear for direct
drive. For coasting or reverse gear, power flows only
t hrough t he direct clutch.
A t i mi ng valve disengages t he torque converter
clutch prior to a 4-3 downshift. The clutch solenoid,
engagement valve, and t i mi ng valve are actuated in
fourth gear range.
3-4 Shift Sequence
The overdrive clutch is applied in fourth gear only.
The direct clutch is applied in all ranges except
fourth gear.
Fourt h gear overdrive range is electronically con-
trolled and hydraulically activated. Various sensor
i nput s are supplied to t he powertrain control module
to operate t he overdrive solenoid on t he valve body.
The solenoid contains a check ball t hat opens and
closes a vent port in t he 3-4 shift valve feed passage.
The overdrive solenoid (and check ball) are not en-
ergized in first, second, t hi rd or reverse gear. The
vent port remai ns open diverting line pressure from
t he 2-3 shift valve away from t he 3-4 shift valve.
The overdrive switch must be in t he On position to
t r ansmi t signals to t he solenoid. A 3-4 upshift occurs
only when t he overdrive solenoid is energized by an
electrical signal from t he powertrain control module.
The solenoid is energized upon receiving a signal.
This causes t he check ball to close t he vent port.
Closing t he vent port allows line pressure from t he
2-3 shift valve to act directly upon t he 3-4 upshift
valve.
Line pressure acting on t he 3-4 shift valve over-
comes valve spring tension moving t he valve to t he
upshift position. This action exposes t he feed pas-
sages to t he 3-4 t i mi ng valve, 3-4 shut t l e valve, 3-4
accumulator and ultimately to t he overdrive piston.
Line pressure t hrough t he t i mi ng and shut t l e
valves move t he overdrive piston into simultaneous
contact with t he overdrive clutch and t he direct
clutch sliding hub.
The overdrive clutch is engaged and t he direct
clutch is disengaged simultaneously to complete t he
3-4 upshift.
The boost valve provides increased fluid apply pres-
sure to t he overdrive clutch during t he 3-4 upshift
and during fourth gear operation. The amount of
boost is determined by throttle opening and line
pressure.
The overdrive piston engages t he overdrive clutch
by pressing directly against t he clutch pressure

AUTOMATIC TRANSi I SSI O| - 32 RH / 8 i RH / 37 RH / 4 2 RH / 4 i RH 21 - 83
plate. The overdrive clutch also disengages t he direct
clutch during 3-4 upshifts. As fluid pressure extends
t he overdrive piston, t he piston contacts t he direct
clutch hub pressing it rearward. This action com-
presses the direct clutch spring relieving spring load
on t he clutch pack. The clutch is disengaged once
spring load is relieved.
The 3-4 accumulator cushions overdrive clutch en-
gagement to smooth the t ransi t i on into fourth gear.
The accumulator is charged at t he same time as ap-
ply pressure acts against t he overdrive piston.
Converter clutch engagement i n overdrive fourth
gear is controlled by sensor inputs to t he powertrain
control module. In third gear above 25 mph, sensor
i nput s to t he control module t hat determine clutch
engagement and shift timing are:
coolant t emperat ure (verifies mi ni mum of 60 F)
engine speed
vehicle speed
t hrot t l e position
manifold vacuum (MAP sensor)
Gearshift Mechanism
The gear shift mechanism provides t he same shift
positions used with 3-speed Chrysler transmissions
( P- R- N - D - 2- 1) .
The shift into overdrive fourth gear range occurs
only after t he transmission has completed t he shift
into D t hi rd gear range. No further movement of t he
shift mechanism is required to complete t he 3-4 shift.
The fourth gear upshift occurs automatically when
t he overdrive control switch is in t he ON position.
Shift t i mi ng is determined by sensor i nput s to t he
engine controller.
Overdrive Control Switch
The overdrive control switch is located in t he in-
st rument panel. In t he On position, automatic shifts
into fourth gear overdrive will occur. In t he Off posi-
tion, t he switch overrides t he engine controller pre-
vent i ng a shift to overdrive fourth gear range.
The switch has an indicator light t hat illuminates
when overdrive is t urned off. The switch also resets
when t he ignition key is t urned to t he OFF position
so t hat t he automatic overdrive feature is restored.
The use of fault codes is employed to help diagnose
t he electronic components t hat operate t he overdrive
uni t and converter clutch.
HYDRAULIC CONTROLS
The 42REJ/46RH hydraulic control system provides
fully automatic operation. The system performs five
basic functions which are: pressure supply, pressure
regulation, flow control, clutch/band application, and
lubrication.
42RH/46RH system operation is similar to t hat de-
scribed in t he 32RH/36RH/37RH General Informa-
tion section. The mai n difference being fourth gear
operation which is covered here.
Pressure Regulation
The pressure regulator valve mai nt ai ns line pres-
sure. The amount of pressure developed is controlled
by throttle pressure which is dependent on t he de-
gree of t hrot t l e opening. The regulator valve is lo-
cated in t he valve body.
The t hrot t l e valve determines line pressure and
shift speed. Governor pressure increases in propor-
tion to vehicle speed. The t hrot t l e valve controls up-
shift and downshift speeds by regul at i ng pressure
according to t hrot t l e position.
Flow Control And Lubrication
The manual valve is operated by t he gearshift link-
age and provides t he operating range selected by t he
driver.
The 1-2 shift valve provides 1-2 or 2-1 shifts and
t he 2-3 shift valve provides 2-3 or 3-2 shifts.
The kickdown valve provides forced 3-2 or 3-1
downshifts depending on vehicle speed. Downshifts
occur when t he t hrot t l e is opened beyond downshift
detent position which is j ust before wide open throt-
tle.
The 2-3 valve t hrot t l e pressure plug provides 3-2
downshifts at varyi ng t hrot t l e openings depending on
vehicle speed.
The 1-2 shift control valve t ransmi t s 1-2 shift pres-
sure to t he accumulator piston. This controls kick-
down band capacity on 1-2 upshifts and 3-2
downshifts.
The 3-4 shift valve, shut t l e valve, t i mi ng valve and
accumulator are only actuated when the overdrive
solenoid is energized.
The solenoid contains a check ball t hat controls a
vent port to t he 3-4 valve. The check ball either di-
verts line pressure away from or directly to, t he 3-4
shift valve. Energizing t he solenoid causes t he check
ball to close t he vent port allowing line pressure to
act upon t he 3-4 upshift valve.
The limit valve determines maxi mum speed at
which a 3-2 part t hrot t l e kickdown can be made.
Some transmissions do not have t he limit valve and
maxi mum speed for a 3-2 kickdown is at t he detent
position.
The 2-3 shut t l e valve has two functions. Fi rst is
fast front band release and smooth engagement dur-
ing lift-foot 2-3 upshifts. The second is to regulate
front clutch and band application during 3-2 down-
shifts.
The 3-4 shut t l e valve uses a combination of throt-
tle and governor pressure to control t he rat e of over-
drive piston apply and release. This is done to
mai nt ai n shift quality at varyi ng t hrot t l e openings.
21 - 84 AUTOMATIC TRANSMISSION-32RH/36RH/37RH/42RH/46RH

The 3-4 t i mi ng valve is moved by line pressure
coming t hrough t he 3-4 shift valve. The t i mi ng valve
holds t he 2-3 shift valve in an upshift position. The
purpose is to prevent t he 2-3 valve from up or down-
shifting before t he 3-4 valve.
The 3-4 accumulator is mounted on t he overdrive
housing. It performs t he same function as t he 2-3 ac-
cumulator. It is used to smooth engagement duri ng
t he 3-4 shift.
On models with a converter clutch, t he clutch valve
applies t he converter clutch when supplied with line
pressure t hrough t he converter clutch solenoid.
The converter clutch solenoid is mounted on t he
valve body. It is energized by an electrical signal
from t he powertrain control module. Electronic con-
trol of converter clutch engagement includes disen-
gagement at closed t hrot t l e duri ng warmup and
duri ng par t t hrot t l e acceleration.
The switch valve directs apply fluid pressure to t he
lube circuits. The switch valve regul at es oil pressure
Boost Valve Function
The boost valve provides increased fluid apply pres-
sure for converter clutch and overdrive clutch en-
gagement.
The boost valve is connected to t he overdrive clutch
circuit via a t ube connected between t he valve body
upper and lower housings. The valve is connected to
t he converter clutch circuit via t he regulator valve,
switch valve and 3-4 shift and t i mi ng valves.
Hydraulic circuitry for t he boost valve is shown in
t he hydraulic flow di agrams. The di agrams are lo-
cated at t he end of t he transmission diagnosis and
test section.
Duri ng converter clutch engagement in fourth
gear, t he valve supplies full line pressure directly to
t he clutch. The increased pressure available at t he
clutch provides smooth shifting and positive engage-
ment.
The 3-4 upshift causes t he boost valve to increase
line pressure to t he overdrive clutch. Pressure also
increases with t hrot t l e opening. This ensures positive
clutch engagement duri ng periods of high t hrot t l e
opening acceleration.
Converter Clutch Control
The converter clutch valve applies t he converter
clutch when supplied with line pressure t hrough t he
converter clutch solenoid. The solenoid is mounted on
t he valve body and energized by an electrical signal
from t he powertrain control module. Electronic con-
trol of converter clutch operation includes clutch re-
lease at closed t hrot t l e duri ng warmup and duri ng
part t hrot t l e acceleration. The boost valve provides
additional apply pressure for converter clutch appli-
cation.
The switch valve directs fluid apply pressure to t he
lube circuits. The switch valve regulates oil pressure
Clutch/Band Application
The clutch and servo pistons are actuated by line
pressure. When fluid pressure is released, t he pistons
are released by spring pressure.
On 2-3 upshifts, t he front servo piston is released
by spring tension and hydraulic pressure. The accu-
mul at or controls hydraulic pressure on t he apply side
of t he front servo duri ng 1-2 upshifts and all t hrot t l e
openings.
The overdrive direct clutch is applied by spring
pressure. The direct clutch is applied in all ranges
except fourth gear.
The overdrive clutch is applied in fourth gear only.
The clutch is applied by t he overdrive piston which is
actuated by line pressure t hrough t he 3-4 shift valve.

AUTOMATIC TRANSi I SSi Oi - 32RH / 38 RH / 37 RH / 4 2RH / 4eR H 21 - 81
AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING
INDEX
page
Air Testing Clutch and Band Operation 91
Analyzing the Road Test 87
Converter H ousi ng Fluid Leak Di agnosi s . . . . . . . 92
Converter Stall Test 90
Di agnosi s Charts and Hydraulic Flow Di agrams . . 95
Fluid Contamination 86
Fluid Level and Condition 8 5
GENERAL INFORMATION
The diagnosis and t est i ng information in this sec-
tion applies to three and four speed models alike. Di-
agnosis and t est procedures apply to all models
except where indicated. Diagnosis information t hat
only applies to 42RH/46RH models is noted.
Automatic transmission problems can be a result of
poor engine performance, incorrect fluid level, incor-
rect linkage adjustment, band or hydraulic control
pressure adjustments, hydraulic system malfunctions
or electrical/mechanical component malfunctions.
Begin diagnosis by checking t he easily accessible
items such as: fluid level and condition, linkage ad-
j ust ment s and electrical connections on 4-speed mod-
els. A road t est will det ermi ne if further diagnosis is
necessary.
Procedures outlined in t hi s section should be per-
formed in t he following sequence to realize t he most
accurate results:
Prel i mi nary diagnosis
Fluid Level and condition
Linkage Adjustment
Road test
Hydraulic pressure t est
Stall test
Air pressure tests
Leak Tests
Analyze test results and consult diagnosis charts
PRELIMINARY DIAGNOSIS
Two basic procedures are required. One procedure
for vehicles t hat are driveable and an al t ernat e pro-
cedure for disabled vehicles (will not back up or
move forward).
Vehicle Is Driveable
(1) Check fluid level and condition.
(2) Adjust t hrot t l e and gearshift linkage if com-
plaint was based on delayed, erratic, or harsh shifts.
(3) On 4-speed models, check electrical connections
at dash switch and transmission case. Turn control
switch to ON position before proceeding.
(4) Road test and note transmission operating
characteristics.
page
Gearshift Linkage 8 7
Hydraulic Pressure Test 8 8
Overdrive Fourth Gear Electrical Controls . . . . . . 8 6
Preliminary Di agnosi s 8 5
Road Test 8 7
Throttle V al ve Cabl e 8 6
(a) If acceleration is sluggish, or if abnormal
t hrot t l e opening is needed to mai nt ai n normal
speeds with a properly t uned engine, perform a
stall test to check converter clutch operation.
(b) On 42RH/46RH, if fourth gear upshift does
not occur, check overdrive solenoid and switch wir-
ing for opens, shorts, grounds.
(c) If slippage and engine flare is noted, perform
hydraulic pressure test and air pressure test to
check clutch-band-governor operation.
Vehicle Is Disabled
(1) Check fluid level and condition.
(2) Check for broken, disconnected t hrot t l e link-
age.
(3) Check for cracked, leaking cooler lines, or
loose, missing pressure port plugs.
(4) Raise vehicle, st art engine, shift transmission
into gear and note following:
(a) If propeller shafts t ur n but wheels do not,
problem is with differential or axle shafts.
(b) If propeller shafts do not t ur n and t ransmi s-
sion is noisy, stop engine. Remove oil pan, and
check for debris. If pan is clear, remove t ransmi s-
sion and check for damaged drive plate, converter,
oil pump or i nput shaft.
(c) If propeller shafts do not t ur n and t ransmi s-
sion is not
noisy, perform hydraulic pressure t est to deter-
mine if problem is a hydraulic or mechanical.
FLUID LEVEL AND CONDITION
(1) Place vehicle on level surface. This is impor-
t ant for an accurate reading.
(2) Do not check level unt i l fluid is at normal op-
erat i ng t emperat ure of approximately 82C (180F).
This is necessary to avoid false readings which could
produce under or over fill condition,
(3) Fully apply parki ng brakes.
(4) St art and r un engine at curb idle speed. Then
shift transmission t hrough all gear ranges and back
to Neut ral .
(5) Clean top of filler tube and dipstick to keep dirt
out of tube.

(6 ) Remove dipstick a nd check fluid l e ve l as fol-
lows:
(a) Dipstick has t hree fluid level indicating
mar ks which are a MIN dot mark, an OK mar k
and a MAX fill arrow mark:
(b) Correct level is to MAX arrow nar k on dip-
stick. This is correct maxi mum hot fluid level. Ac-
ceptable level is between OK mar k and max arrow
mar k on dipstick.
(c) If level is at, or below MIN level dot on dip-
stick, add only enough fluid to restore correct level.
Mopar ATF Plus, type 7176 is t he preferred fluid.
Mopar Dexron II can be used if ATF Pl us is not
readily available.
C A U T I O N : D o not overfill the t r ansmi ssi on. Overfill-
ing may cause l eakage out the pump vent whi ch
can be mi staken for a pump seal leak. I n addi ti on,
overfilling will al so cause fluid aeration and f oam-
ing a s the excess fluid i s picked up and churned by
the gear train. T hi s will si gni fi cantl y reduce fluid
life.
(7) Check and note fluid condi ti on as follows:
(a) Fluid should be dark to light red in color and
free of particles and sludge.
(b) If fluid is orange, brown, or smells slightly
burned, flow test and reverse flush cooler and lines.
Then change fluid and filter and road t est agai n to
confirm proper operation.
(c) If fluid is black, dark brown, t urned to sludge,
contains extensive amount of met al or friction ma-
t eri al particles, transmission will need overhaul.
Main and auxiliary coolers will have to be flow
tested and reverse flushed as well.
Effects Of Incorrect Fluid Level
A low fluid level allows t he pump to t ake in air
along wi t h t he fluid. Air in the fluid will cause fluid
pressures to be low and develop slower t han normal .
If t he transmission is overfilled, t he gears churn
t he fluid into foam, aerat i ng t he fluid and causing
t he same conditions t hat occur with a low level.
In either case, air bubbles cause fluid overheating,
oxidation and varni sh buildup which interferes wi t h
valve, clutch and servo operation. Foami ng also
causes fluid expansion which can resul t i n fluid over-
flow from t he transmission vent or fill tube. Fluid
overflow can easily be mi st aken for a leak if inspec-
tion is not careful.
FLUID CONTAMINATION
Transmission fluid contamination is generally a re-
sult of:
adding incorrect fluid
failure to clean dipstick and fill t ube when check-
ing level
engine coolant ent eri ng t he fluid
i nt ernal failure t hat generat es debris
overheat t hat generates sludge (fluid breakdown)
failure to reverse flush cooler and lines after re-
pair
failure to replace contaminated converter after re-
pair
The use of non recommended fluids can resul t in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and event ual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill t ube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign mat eri al on t he cap and t ube could fall
into t he t ube if not removed beforehand. Take t he
time to wipe t he cap and t ube clean before withdraw-
ing the dipstick.
Engi ne coolant in t he transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace t he radiator as t he cooler in t he radiator
is not a serviceable part . If coolant has circulated
t hrough t he transmission for some time, an overhaul
may also be necessary; especially if shift problems
had developed.
The transmission cooler and lines should be reverse
flushed whenever a malfunction generates sludge
and/or debris. The torque converter should also be re-
placed at t he same time.
Fai l ure to flush t he cooler and lines will result in
re-contamination and a shop comeback. Fl ushi ng ap-
plies to auxiliary coolers as well. The torque con-
verter should also be replaced whenever a failure
generates sludge and debris. This is necessary be-
cause normal converter flushing procedures will not
remove al of t he cont ami nant s.
OVERDRIVE FOURTH GEAR ELECTRICAL
CONTROLS
The electrical controls governing t he shift into
fourth gear consist of t he control switch on t he in-
st rument panel and t he overdrive solenoid on t he
valve body. The control switch is in circuit with t he
solenoid and must be in t he On position to energize
t he solenoid. The transmission must also have
reached t hi rd gear range before t he shift to fourth
gear will occur.
The control switch, valve body solenoid, case con-
nectors and related wiring can all be tested with a 12
volt test lamp or a mul t i met er. Check continuity of
each component when diagnosis indicates t hi s is nec-
essary.
Switch and solejioid continuity should be checked
whenever t he transmission fails to shift into fourth
gear range.
THROTTLE VALVE CABLE
Throttle valve cable adjustment is i mport ant to
proper operation. This adjustment positions t he
throttle valve which controls shift speed, quality and
part throttle downshift sensitivity.
If cable setting is too short, early shifts and slip-
page between shifts may occur. If the setting is too
long, shifts may be delayed and part t hrot t l e down-
shifts may be very sensitive. Refer to t he In-Vehicle
Service section for adjustment procedure.
GEARSHIFT LINKAGE
Gearshift linkage adjustment is important because
it positions t he valve body manual valve. Incorrect
adjustment will cause creeping in Neut ral , prema-
t ure clutch wear, delayed engagement in any gear, or
a no-start in Par k or Neut r al position.
Proper operation of t he neut ral st art switch will
provide a quick check of linkage adjustment. Refer to
the In-Vehicle Service section for adjustment proce-
dure.
ROAD TEST
Before road testing, be sure t he fluid level and all
linkage adjustments have been checked and adjusted
if necessary.
Observe engine performance during t he road test.
A poorly t uned engine will not allow an accurate
analysis of transmission operation.
Operate t he t ransmi ssi on in all gear ranges. Check
for slippage and shift variations. Note whet her t he
shifts are harsh, spongy, delayed, early, or if part
throttle downshifts are sensitive.
Watch closely for slippage or engine flare which
usually indicates clutch, band or overrunning clutch
problems. If t he condition is advanced, an overhaul
may be necessary to restore normal operation.
A slipping clutch or band can often be determined
by comparing which i nt ernal uni t s are applied in t he
various gear ranges. Refer to t he Elements In Use
Chart s (Figs. 1 and 2) for clutch and band applica-
tion. The chart s provide a basis for analyzing road
test results.
ANALYZ ING THE ROAD TEST
Refer to t he Clutch And Band Application chart s
(Figs. 1 and 2). Then note which elements are ap-
plied in t he various gear ranges.
The rear clutch is applied in all forward ranges (D,
2, 1). The transmission overrunni ng clutch is applied
in first gear (D, 2 and 1 ranges only).
The rear band is applied in 1 and R range only.
The overdrive clutch is applied only in fourth gear
and the overdrive direct clutch and overrunning
clutch are applied in all ranges except fourth gear.
For example: If slippage occurs in first gear in D
and 2 range but not in 1 range, t he transmission
overrunning clutch is slipping. Similarly, if slippage
occurs in t hi rd and fourth gear, t he rear clutch is
slipping. However, if slippage only occurs in fourth
gear, t he overdrive clutch is slipping.
Gearshift Lever Position
D R I V E
E L E M E N T S
P R N D 2 1
D R I V E
E L E M E N T S
1 2 3 1 2
FR ONT
C L UT C H

FRONT
BAND
(KI CKDOWN)

R E A R
C L UT C H
REAR
BAND
(LOW-REV.)

OV E R -
R U N N I N G
C L UT C H

J9021-33
Fig. 1 Clutch And Band Application32RH/36RH/
37RH
Applying t he same method of analysis, note t hat
both clutches are applied in D range t hi rd gear only.
If t he transmission slips in t hi rd gear, ei t her t he
front clutch or t he rear clutch is slipping.
By selecting another gear which does not use both
clutches, t he slipping clutch can be determined. For
example, if t he transmission also slips in Reverse,
t he front clutch is slipping. If t he transmission does
not slip in Reverse, t he rear clutch is slipping.
If slippage occurs duri ng t he 3-4 shift or in fourth
gear, t he overdrive clutch is slipping. Similarly, if
t he direct clutch were to fail, t he transmission would
lose reverse gear and overrun braki ng i n 2 (manual
second gear) position would not occur. If t he t rans-
mission slips in any other two forward gears, t he
transmission front section rear clutch may be slip-
ping.
If t he transmission will not shift into fourth gear,
t he control switch, overdrive solenoid or related wir-
ing may also be t he problem cause.
This process of elimination can be used to deter-
mi ne t he slipping uni t and check operation. Proper
use of t he Clutch and Band Application Chart is t he
key.
Although road test analysis will help determine
t he slipping uni t , t he actual cause of a malfunction
usually cannot be determined until hydraulic and air
pressure t est s are performed. Practically any condi-
tion can be caused by leaking hydraulic circuits or
sticking valves.
Unl ess the condi ti on i s obvi ous, such as no
drive in D range, first ge a r onl y, or no f our t h
gear range, the t r ans mi s s i on s houl d not be dis-
as s embl ed until hydraulic and air pressure tests
have been performed.
S HI F T
LEVER
PO S I T I O N
T R A N S M I S S I O N CLUTCH E S A N D B A N D S
O V E R D R I V E C L U T C HE S
S HI F T
LEVER
PO S I T I O N
F R O N T
C L U T C H
F R O N T
B A N D
R E A R
C L UT C H
R E A R
B A N D
O V E R R U N .
C L UT C H
O V E R D R I V E
C L UT C H
D I R E C T
C L UT C H
O V E R R U N .
C L UT C H
Reverse
X
X
X
Drive Range
First
Second
Third
Fourth
X
X
X
X
X
X
X
X
X
X
X
X
X
X
2-Range:
(Manual
Second):
Second
First
X X
X X
X
X
X
X
1-Range
(Manual
Low):
First X X X X X
J9221-22
Fig. 2 Clutch And Band Application-42RH/46RH
HYDRAULIC PRESSURE TEST \ \\\REAR \\v - LI NE FRONT
' M SERVO \ \ PRESSURE / S' SERVO
PRESSURE TEST PORT LOCATIONS \\\ W \ \ \ PO.
RT
, \ i PORT
There are pressure t est ports at t he accumulator,
front servo, r ear servo and governor. On 42RH/46RH
transmissions, an additional port for overdrive clutch
pressure is provided at t he left-rear of t he case.
Line pressure is checked at t he accumulator port
on t he ri ght side of t he case (Fig. 3). The front servo
pressure port is at t he ri ght side of t he case j ust be-
hind t he filler t ube opening (Fig. 4).
The rear servo pressure port is at t he ri ght r ear of
t he case (Fig. 3). The governor pressure port is at t he
left side of t he extension housing (Fig. 4).
On 42RH/46RH transmissions, t he governor and
overdrive clutch pressure ports are at t he rear of t he
case (Fig. 5).
Hydraulic test pressures range from a low of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at t he r ear servo pressure port in reverse.
Two gauges are needed for t he pressure test. Use
Pressure Gauge C-3292 to check pressure at t he ac-
cumulator, front servo, governor and overdrive pres-
sure ports. Use 300 psi Pressure Gauge C-3293 to
check pressure at t he rear servo. The 300 psi gauge
can also be used to check all other pressures except
governor pressure.
PRESSURE TEST PROCEDURE
Connect a tachometer to t he engine. Position t he
tachometer so it can be observed from under t he ve-
hicle. Raise t he vehicle on hoist t hat will allow t he
wheels to rot at e freely.
F
Fig. 3 Pressure Test Ports At Side Of Case
GOVERNOR
PRESSURE PORT
Fig. 4 Pressure Test Ports At Rear Of Case
Test OneTransmission In 1 Range
Thi s test checks pump output, pressure regula-
tion, and condi ti on of the rear cl utch and rear
servo circuits. Pressure Gauges C-3292 and
C-3293 are required for this test.
(1) Connect 100 psi Gauge C-3292 to accumulator
(line pressure) port and connect 300 psi Gauge

Fig. 5 Pressure Test Port Locations42RH/46RH
C-3293 to rear servo port (Figs. 3, 4). Be sure 300
psi gauge is connected to rear servo port.
(2) Disconnect t hrot t l e and gearshift cable/linkage
at transmission.
(3) St art and r un engine at 1000 rpm.
(4) Move transmission shift lever (on valve body
manual shaft) all way forward into 1 range.
(5) Read pressures on both gauges as transmission
t hrot t l e lever is moved from full forward to full rear-
ward position.
(6) Line pressure should be 54-60 psi (372-414
kPa) with throttle lever forward and gradually in-
crease to 90-96 psi (621-662 kPa) as lever is moved
rearward.
(7) Rear servo pressure should be same as line
pressure within 3 psi.
Test TwoTransmission In 2 Range
Thi s test checks pump output and pressure
regulation. Use 100 psi Gauge C-3292 for this
test.
(1) Connect pressure gauge to accumulator (line
pressure) port (Fig. 3).
(2) St ar t and run engine at 1000 rpm.
(3) Move transmission shift lever (on valve body
manual shaft) one det ent rearward from full forward
position. This is 2 range.
(4) Move transmission t hrot t l e lever from full for-
ward to full rearward position and read pressure at
both gauges.
(5) Line pressure should be 54-60 psi 372-414 kPa)
wi t h t hrot t l e lever forward and gradually increase to
90-96 psi ( 621-662 kPa) as lever is moved rearward.
Test ThreeTransmission In D Range
This test checks pressure regul ati on and con-
dition of the front and rear cl utch circuits. Use
both pressure gauges for thi s test.
(1) Connect gauges to accumulator (line pressure)
and front servo ports (Fig. 3). Ei t her pressure t est
gauge can be used at either port.
(2) St art and r un engine at 1600 rpm for t hi s test.
(3) Move selector lever two det ent s rearward from
full forward position. This is D range.
(4) Read pressures on both gauges as transmission
t hrot t l e lever is moved from full forward to full rear-
ward position.
(5) Line pressure should be 54-60 psi (372-414
kPa) with throttle lever forward and gradually in-
crease as lever is moved rearward.
(6) Front servo is pressurized only i n D range and
should be same as line pressure wi t hi n 3 psi (21 kPa)
up to downshift point.
Test FourTransmission In Reverse
This test checks pump output, pressure regula-
tion and the front cl utch and rear servo circuits.
Use 300 psi Gauge C-3293 for this test.
(1) Connect pressure gauge to r ear servo port
(Figs. 3 and 4).
(2) St art and r un engine at 1600 rpm for test.
(3) Move valve body selector lever four detents
rearward from full forward position. This is Reverse
range.
(4) Move throttle lever fully forward t hen fully
rearward and note gauge readings.
(5) Pressure should be 145 - 175 psi (1000-1207
kPa) with lever forward and increase to 230 - 280 psi
(1586-1931 kPa) as lever is moved rearward.
Test FiveGovernor Pressure
This test checks governor operati on by mea-
suri ng governor pressure response to changes i n
engi ne speed. It i s usual l y not necessary to
check governor operati on unl ess shift speeds
are i ncorrect or if the transmi ssi on will not
downshift. Use 100 psi Gauge C-3293 for this
test.
(1) Position vehicle on hoist t hat will allow rear
wheels to rot at e freely.
(2) Connect pressure gauge to governor pressure
port (Figs. 4 and 5).
(3) St art engine, shift t he transmission into drive
(D) range and apply brakes to prevent rear wheels
from rotating.

(4) Note pressure wi t h engine at curb idle speed
and rear wheels stopped. Pressure should be zero to
1-1/2 psi maxi mum. If pressure exceeds t hi s figure,
governor valve or weights are sticking open.
(5) Slowly increase engine rpm and observe speed-
ometer and pressure t est gauge. Governor pressure
should increase in proportion to indicated vehicle
speed (or approximately 1 psi for every 1 mph).
(6) Pressure rise should be smooth and drop back
to 0 to 1-1/2 psi when wheels are braked to a stop
and engine ret urns to curb idle speed.
(7) Compare resul t s of t he pressure tests with t he
Pressure Test Analysis Chart s (Figs. 6 and 7).
Test Six42RH/46RH Transmission In Overdrive Fourth
Gear
This test checks line pressure at the overdri ve
cl utch in fourth gear range. Use 300 psi Test
Gauge C-3292 for this test.
(1) Raise vehicle and connect t est gauge to over-
drive clutch pressure port (Fig. 5).
(2) Lower vehicle to enough to allow ent ry into
drivers seat. Leave vehicle wheels approximately one
foot off shop floor.
(3) Secure test gauge where it can be viewed from
drivers seat.
(4) Verify t hat overdrive control switch is in ON
position.
(5) St art engine and shift into D range.
(6) Increase engine rpm gradually unt i l 3-4 shift
occurs and note gauge pressure.
(7) Pressure should be 469-496 kPa (68-72 psi)
with closed t hrot t l e and increase to 620-827 kPa (90-
120 psi) at 1/2 to 3/4 t hrot t l e. Note t hat pressure will
increase to 896 kPa (130 psi) or more at full t hrot t l e.
(8) Refer to pressure test chart (Fig. 7) for pressure
diagnosis.
CONVERTER STALL TEST
Stall t est i ng involves det ermi ni ng maxi mum en-
gine rpm obtainable at full t hrot t l e with t he rear
wheels locked and t he transmission in D range. This
test checks t he holding ability of t he converter over-
runni ng clutch and both of t he transmission clutches.
When stall t est i ng is completed, refer to t he Stall
Speed Specifications chart and Stall Speed Diagnosis
guides.
WARNING: NEVER ALLOW ANYONE TO STAND
IN FRONT OF THE VEHICLE DURING A STALL
TEST. ALWAYS BLOCK THE FRONT WHEELS AND
APPLY THE SERVI CE AND PARKING BRAKES
DURING THE TEST.
STALL TEST PROCEDURE
(1) Connect tachometer to engine.
(2) Check and adjust t ransmi ssi on fluid level.
1EST CONDITION INDICATION
Line pressure O K during
any one test
Pump and regulator valve O K
Line Pressure O K in R
but low in D, 2, 1
Leakage in rear dutch area (servo,
dutch seals, governor support
seal rings)
Pressure O K in 1, 2 but
low in D 3 and R
Leakage in front dutch area (servo,
dutch seals, retainer bore, pump
seal rings)
Pressure O K in 2 but low in
R and 1
Leakage in rear servo
Front servo pressure in 2 Leakage in servo; broken servo
ring or cracked servo piston
Pressure low in all positions C ogge d filter, stuck pressure
regulator valve, worn or
defective pump
Governor pressure too high at
idle speed:
Governor valve sticking open
Governor pressure low at all
mph figures
Governor valve sticking dosed
Lubrication pressure low at all
throttle positions
Cl ogged oil cooler or lines, seal
rings leaking, output shaft
plugged with debris, worn
bushings in pump or dutch
retainer J9021-34
Fig. 6 Pressure Test Analysis Chart (32RH/36RH/
37RH)
(3) St art and r un engine unt i l transmission fluid
(4) Block front wheels.
(5) Fully apply service and parki ng brakes.
(6) Open t hrot t l e completely for no more t han five
seconds and record maxi mum engine rpm registered
on tachometer.
C A U T I O N : Stall testing causes a rapid i ncrease in
transmission fluid temperature. D o not hol d the
throttle open any longer than five seconds. If more
than one stall test i s required, run the engi ne at
1000 rpm with the t r ansmi ssi on in Neutral for at
least 20 s e c onds to cool the fluid.
(7) If engine speed exceeds maxi mum shown in
stall speed chart, release accelerator pedal immedi-
ately. This condition indicates transmission clutch
slippage is occurring.
(8) Shift transmission into Neut ral . Operate en-
gine for 20 seconds. Stop engine, shift transmission
into Par k and release brakes.
(9) Stall speeds should be: 1800-2100 rpm with
3.9L engine and 1700-2000 rpm with 5.2L/5.9L en-
gines.
(10) Refer to Stall Test Diagnosis.
TEST CONDITION
Line pressure OK during
any one test
Line Pressure OK in R
but low in D, 2, 1
Pressure Low in D
Fourth Gear Range
Pressure OK in 1, 2 but
low in D3 and R
Pressure OK in 2 but low
in R and 1
Front servo pressure low
in 2
Pressure low in all positions
Governor pressure too high
at idle speed
Governor pressure low
at all mph figures
Lubrication pressure low at
all throttle positions
INDICATION
Pump and regulator valve OK
Leakage in rear clutch area (servo,
clutch seals, governor support
seal rings)
Overdrive clutch piston seal, or
check ball problem
Leakage in front clutch area (servo,
clutch seals, retainer bore, pump
seal rings)
Leakage in rear servo
Leakage in servo; broken servo
ring or cracked servo piston
Clogged filter, stuck regulator
valve, worn or faulty pump,
plugged fluid cooler
Governor valve sticking open
Governor valve sticking closed
Clogged oil cooler or lines, seal
rings leaking, output shaft plugged
with debris, worn bushings in
pump or clutch retainer
J9321-165
Fig. 7 Pressure Test Analysis Chart (42RH/46RH)
STALL TEST DIAGNOSIS
Stall Speed Too High
If stall speed exceeds specifications by more t han
200 rpm, transmission clutch slippage is indicated.
Stall Speed Too Low
Low stall speeds with a properly tuned engine in-
dicate a torque converter overrunning clutch prob-
lem. The condition should be confirmed by road
testing prior to converter replacement.
The converter overrunning clutch is slipping when:
Stall speeds are 250 to 350 rpm below specified min-
i mum and the vehicle operates properly at highway
speeds but has poor low speed acceleration.
Stall Speed Normal
If stall speeds are normal but abnormal t hrot t l e
opening is required to mai nt ai n highway speeds, the
converter overrunning clutch is seized and t he torque
converter must be replaced.
Converter Noise During Test
A whining noise caused by fluid flow is normal
duri ng a stall test. However, loud metallic noises in-
dicate a damaged converter. To confirm t hat noise is
originating from t he converter, operate t he vehicle at
light throttle in Drive and Neut ral on a hoist and lis-
ten for noise coming from t he converter housing.
AIR TESTING CLUTCH AND BAND OPERATION
Air pressure t est i ng can be used to check clutch
and band operation with t he transmission either in
t he vehicle, or on t he work bench as a final check af-
t er overhaul.
Air pressure t est i ng requires t hat t he oil pan and
valve body be removed from t he transmission. The
servo and clutch apply passages are shown in Figure
8.
FRONT SERVO APPLY^
REAR SERVO APPLY
LINE PRESSURE TO
ACCUMULATOR
GOVERNOR
PRESSURE
FRONT
SERVO
RELEASE
PUMP
SUCTI ON
PUMP
PRESSURE
FRONT
CLUTCH
APPLY
REAR
CLUTCH
APPLY
TO TORQUE
CONVERTOR
I
FROM TORQUE
CONVERTER
T O
GOVERNOR TO COOLER ^ H 2 5 2
Fig. 8 Air Pressure Test Passages
Front Clutch Test
Place one or two fingers on t he clutch housing and
apply air pressure t hrough front clutch apply passage
(Fig. 8). Piston movement can be felt and a soft t hud
heard as t he clutch applies.
Rear Clutch Test
Place one or two fingers on t he clutch housing and
apply air pressure t hrough rear clutch apply passage
(Fig. 8). Piston movement can be felt and a soft t hud
heard as t he clutch applies.
Front Servo Test
Apply air pressure to t he front servo apply passage.
The servo rod should extend and cause t he band to
t i ght en around t he drum. Spring tension should re-
lease t he servo when air pressure is removed.

Rear Servo Test
Apply air pressure to t he rear servo apply passage.
The servo rod should extend and cause t he band to
t i ght en around t he drum. Spring tension should re-
lease t he servo when air pressure is removed.
CONVERTER HOUSING FLUID LEAK DIAGNOSIS
When diagnosing converter housing fluid leaks,
two items must be established before repair. First, it
must be verified t hat a leak condition actually exists.
And second, t he t r ue source of t he leak must be de-
termined.
Some suspected converter housing leaks may not
be leaks at all. They may only be t he resul t of resid-
ual fluid in t he converter housing, or excess fluid
spilled during factory fill or refill after repair.
Converter housing leaks have several potential
sources. Through careful observation, a leak source
can be identified before removing t he transmission
for repair.
Pump seal leaks tend to move along t he drive hub
and onto t he rear of t he converter. Pump O-ring or
pump body leaks follow t he same pat h as a seal leak
(Fig. 9).
Pump vent or pump at t achi ng bolt l eaks are gener-
ally deposited on t he inside of t he converter housing
and not on t he converter itself (Fig. 9).
Pump seal or gasket leaks usually t ravel down t he
inside of t he converter housing.
Front band lever pin plug leaks are generally de-
posited on t he housing and not on t he converter.
,j PUMP PUMP PUMP
Fig. 9 Typical Converter Homing Leak Paths
LEAK DIAGNOSIS PROCEDURE
(1) Raise rear of vehicle and allow accumulated
fluid to drai n out of converter housing.
(2) Check and adjust transmission fluid level.
(3) Raise vehicle. Remove converter housing dust
cover and wipe as much fluid as possible from con-
vert er housing.
(4) Fabricate test probe from steel or al umi num
stock (Fig. 10). Then at t ach probe to converter hous-
ing with one a dust shield bolt.
(5) Have helper r un engine at 2500 rpm (with
transmission in Neutral) for two minutes; t hen stop
engine.
(6) Inspect test probe and converter housing. If
leak is evident, note color of fluid. Transmission fluid
is red. Engine oil ranges in color from brown to
green, or to black when oil is dirty.
(7) If probe upper surface is dry, converter and seal
are OK. However, pat h of fluid across probe upper
surface indicates converter or seal leak. Fluid leak-
ing u n d e r probe is coming from pump housing area
(Fig. 11).
(8) Fluid leaking under probe could be from: pump
seal and/or bushing, pump vent, kickdown lever shaft
access plug, pump bolts, or porous spots in pump
body or transmission case (Fig. 11).
(9) If porous spots in transmission case or pump
body are suspected leak source, pressurize t ransmi s-
sion as described in Leak Testing With Air Pressure.
TORQUE CONVERTER LEAK POINTS
SHIELD MATERIAL: 5- 1 / 2" X 1-1/2" X 1/32"
BOLT SHEET METAL RN778
Fig. 10 Leak Test Probe
Fig. 11 Pump Area Inspection Points
Possible sources of converter leaks are:

AUTOMATIC TRANSMI SSI ON- 32RH / 3I RH / 37 RH / 4 2RH / 4 8 RH 21 - 13
Leaks at weld joint around outside diameter weld
(Fig. 12).
Leaks at converter hub weld (Fig. 12).
OUTSIDE
DIAMETER
WELD
TORQUE CONVERTER
HUB WELD
"LUG
STARTER RING GEAR
RH254
Fig. 12 Typical Converter Leak Points
LEAK TESTING WITH AIR PRESSURE
This test involves closing off t he transmission
openings and pressurizing t he transmission to 8 psi
(55 kPa) with air pump tool 7700.
A soapy water solution is applied to suspected leak
points before and duri ng t he pressure test. Leaks will
be indicated by t he presence of air bubbles coming
t hrough the solution.
Some transmission openings such as t he fill tube
and front cooler line fitting can be closed off with a
rubber plug or similar device. Plugs can secured with
wire or duct tape.
The transmission rear output shaft opening is
closed off simply by leaving t he transfer case bolted
in place. However, if t he transfer case has been re-
moved, a shipping plug can used to close off this
opening.
The torque converter hub opening in t he pump and
t he pump vent require special tools to close t hem off.
The converter hub seal cup is made from t hi n wall
tube and a 3.18 mm (1/8 in.) thick disc (Figs. 13, 14).
A ret ai ni ng strap is needed to secure t he seal cup
for testing. The strap can be made from 31.75 mm (1-
1/4 in.) wide stock (Fig. 15).
WELD OR
BRAZE
BREAK EDGE
1/16"
MIN.
MATERIAL: 1-7/8 INCH O.D.
THIN WALLED STEEL TUBING
AND 1/8 INCH STEEL DISC
OUTSIDE OF OPEN
END FOR THIS
DISTANCE ON TUBE
RN779
The st rap at t achi ng hole positions are approximate
only. Measure hole position on the converter housing
before drilling.
The pump vent tool is made from 6.35 mm (1/4 in.)
rod and 4.75 mm (3/16 in.) pl at e (Figs. 16, 17).
The fabricated tools can all be made from mild
steel or al umi num stock.
WELD
OR BRAZE
BREAK EDGE 1/16" MI N.
- - l / 8 "
SEAL THIS END AIR TIGHT
1-3/4"-*-
5 " -
MATERIAL: 1-1/2 INCH O. D. THIN
WALLED STEEL TUBING AND
1/8 INCH STEEL DISC
POLISH
OUTSIDE
OF OPEN
" E N D FOR
THIS DISTANCE
ON TUBE
RN780
Fig. 14 Converter Hub Seal Cup-32RH/42RH
15/ 32 INCH DRILL 4 HOLES
MATERIAL: 1/4 INCH STEEL STOCK
1-1/4 INCH WIDE RN781
Fig. 13 Converter Hub Seal Cup-36RH/46RH
Fig. 15 Seal Cup Retaining Strap
AIR PRESSURE LEAK TEST PROCEDURE
(1) Install vent plug, converter hub seal cup and
cup ret ai ni ng st rap (Fig. 18).
(2) Close off remai ni ng transmission openings with
rubber plugs, or stoppers. Do not cl ose off rear
cool er line fitting as air pump will be attached
to this fitting.
(3) Attach Air Pump 7700 to rear cooler line fit-
ting. Connect length of copper tube to fitting. Then
at t ach air pump hose to tube with hose clamp (Fig.
19).
(4) Apply thick soapy wat er solution to suspected
leak areas.
C A U T I O N : The recommended test pressure i s 8 psi .
The maxi mum allowable test pressure i s 10 psi
(68.9 kPa). D o not exceed specified pressure.
(5) Pressurize transmission to 8 psi (55 kPa) with
t he hand operated air pump.

MATERIAL: 3/16 INCH STEEL STOCK
Fig. 16 Pump Vent Piug-36RH/46RH
13/32" DRILL 2 HOLES
M A T E R I A L : 3/16 INCH STEEL STOCK
K N / a j
Fig. 17 Pump Vent Plug-32RH/42RH
(6) Observe suspected leak areas. Air bubbles ap-
pearing in soapy wat er solution indicate leak points.
(7) Remove test tools and plugs after test comple-
tion and make necessary repairs. Refer to Converter
Housing Area Leak Correction procedure.
CONVERTER HOUSING AREA LEAK
CORRECTION
(1) Remove transmission and remove torque con-
verter.
(2) Tighten front band adjusting screw unt i l band
is t i ght around front clutch ret ai ner. This prevents
front clutch from coming out when oil pump is re-
moved.
(3) Remove oil pump and seal. Inspect pump hous-
ing drainback and vent holes for obstructions. Clear
holes with solvent and wire.
COOLER LINE FITTING RY254
Fig. 19 Pressurizing Transmission
(4) Inspect pump bushing and converter hub. If
bushi ng is scored, replace it. If converter hub is
scored, either polish it with crocus cloth or replace
converter if scoring is severe.
(5) Install new pump seal, O-ring, gasket, and
bushing. Replace oil pump if housing is cracked, po-
rous or damaged in any way.
(6 ) Remove kickdown lever pin access plug. Apply
Mopar silicone sealer, or Permat ex No. 2 to plug
t hreads and t i ght en plug to 17 N*m (150 in. lbs.)
torque.
(7) Adjust front (kickdown) band.
(8) Lubricate pump seal and converter hub with
t ransmi ssi on fluid or petroleum jelly and install con-
verter.
(9) Install transmission.
(10) Install converter housing dust shield
(11) Lower vehicle and refill transmission with
recommended fluid.

AUTOMATIC TRANSMISSION32RH/ 36 RH/ 37RH/ 4 2RH/ 4 6 RH 21 - ii
DIAGNOSIS CHARTS AND HYDRAULIC FLOW
DIAGRAMS
The diagnosis chart s and hydraulic flow di agrams
provide additional reference for transmission diagno-
sis.
The diagnosis chart s provide general information
on a variety of transmission, overdrive uni t and con-
verter clutch fault conditions. The Transmission Uni t
diagnosis chart s apply to all t ransmi ssi on models.
The Overdrive Unit chart s apply to t he four speed
transmissions only.
The hydraulic flow di agrams outline transmission
fluid flow and hydraulic circuitry. The flow diagrams
also provide basic working pressures for t he various
gear ranges.

HAR S H E NGAGE ME NT (FROM
NEUTRAL TO DRI VE OR
REVERSE)
Note: The shift from neutral to
reverse is normally quite firm.
Hydraulic pressure at the rear
servo can approach 300 psi in
reverse gear. Do not confuse a
firm engagement with a truly
harsh engagement
1. Engine idle speed too high
2. Driver "riding" accelerator pedal during shift
3. Throttle cable or linkage misadjusted
4. Band adjustment needed
5 . Loose mounting bolts
6 Worn or damaged U-joints
7. Loose axle pinion nut
8. Hydraulic pressure is incorrect
9. Accumulator piston spring, or seal worn or
damaged
10. Faulty converter clutch (if equipped)
11. Clutch, band, or planetary component is damaged
1. Check/adjust idle speed
2. Advise owner/operator
3. Adjust cable or linkage; setting is either too
long or too short
4 . Adjust front/rear bands
5. Check engine, transmission, propeller shaft,
crossmember, and axle bolt torque; tighten
loose bolts and replace missing bolts
6. Remove propeller shaft and replace U-joints
7. Replace nut and check pinion threads before
installing new nut; replace pinion gear if
threads are damaged
8. Check pressures; remove, overhaul, or adjust
valve body as needed; repair oil pump if
necessary
9. Remove valve body and replace piston,
seal, or spring as needed
10. Replace converter and flush cooler and lines
before installing new converter
11. Remove, disassemble, and repair
transmission as necessary
DELAYED E N GA GE ME N T
(FROM NEUTRAL TO DRI VE
OR REVERSE)
1. Engine idle speed too low
2. Low fluid level
3. Gearshift linkage but of adjustment
4. Rear band out of adjustment
5 . Valve body filter plugged
6. Oil pump gears worn or damaged or pump
body or seal is damaged, allowing pump to
take in air, causing fluid aeration
7. Reaction shaft seal rings worn or broken
8. Governor valve stuck or valve shaft is loose or
damaged
9. Low hydraulic pressure
10. Clutch, band, or servo damage
1. Adjust idle speed
2. Correct level and check for leaks
3. Adjust cable or linkage and repair linkage if
worn or damaged
4. Adjust band
5 . Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary
6. Remove transmission and replace oil pump
7. Remove transmission, remove oil pump, and
replace seal rings
8. Remove and inspect governor components;
replace worn or damaged parts
9. Perform pressure test, remove transmission,
and repair as needed
10. Remove and disassemble transmission and
repair as necessary
J9321-255

Cenoltfeie Possible Caws Cowsci l on
SHIFTS DELAYED OR ERRATIC
(SHIFTS ALSO HARSH AT
TIMES)
1. Low fluid level
2. Throttle linkage out of adjustment
3. Throttle linkage is binding
4. Gearshift linkage out of adjustment
5. Fluid filter partially clogged
6. Air in fluid due to overfill condition or air leakage
into pump suction passages
7. Clutch or servo problem
8. Front band out of adjustment (may cause harsh
1-2 shift)
1. Correct fluid level and check for leaks
2. Adjust linkage as described in service section
3. Disassemble, clean, and adjust linkage; replace
linkage grommets if removed or if worn or
cracked
4. Adjust linkage as described in service section
5. Replace filter. If filter and fluid contained clutch
material or metal particles, an overhaul may be
necessary
6. Drain fluid to correct level if overfilled. If fluid is
highly aerated (full of bubbles and foamy), oil
pump gasket or seal may have failed, or pump
body is porous or cracked
7. Remove valve body and air test clutch, band and
servo operation; disassemble and repair
transmission as needed
8. Adjust band
N O REVERSE (D RANGES OK) 1. Gearshift linkage is either out of adjustment or
damaged
2. Rear band is out of adjustment
3. Valve body malfunction (stuck/damaged manual
valve, regulator valve, or check ball)
4. Rear servo or front clutch malfunction
1. Repair or replace linkage parts as needed
2. Adjust band
3. Remove and service valve body; replace valve
body if any valves or valve bores are worn or
damaged
4. Remove and disassemble transmission; replace
worn, damaged servo and clutch parts as
necessary
HAS FIRST-REVERSE ONLY
(NO 1-2 OR 2-3 UPSHIFT)
1. Governor valve, shaft, weights, or body damaged 1. Remove governor assembly and repair as
necessary
J9121-440

CendSfion Possible Cause Correction
N O DRIVE RANGE
(REVERSE OK)
1 . Gearshift linkage either loose, damaged or out of
adjustment
2. Low fluid level
3. Valve body malfunction (manual valve or shaft
damaged or 1 -2 shift valve stuck)
4. Rear clutch failure
5. Transmission overrunning clutch failure
6. Input shaft seal rings worn or damaged
1. Repair or replace linkage components
2. Correct fluid level and check for leaks
3. Remove and disassemble valve body; replace as
assembly if any valves or bores are damaged
4 . Remove and disassemble transmission and rear
clutch; repair/replace worn, damaged parts as
needed
overrunning clutch
seal rings and any other worn or damaged parts
N O DRIVE OR REVERSE
(VEHICLE WILL NOT MOVE)
1. Low fluid level
2. Gearshift linkage loose, damaged, or misassembled
3. Failure of driveline component, such as U-joint, axle
shaft, transfer case component, etc.
4. Low fluid pressure due to worn or damaged oil
pump
5. Transmission internal component damaged
6. Valve body malfunction (seized valve, damaged
manual lever, valve body screws loose or
overtightened causing distortion and bind)
1 . Add fluid and check for leaks if drive is restored
2. Inspect, adjust, and reassemble linkage as needed;
replace worn, damaged parts
3. Perform preliminary inspection procedure for
vehicle that will not move; refer to procedure in
diagnosis section
4. Perform pressure test to confirm low pressure;
replace pump body and/or gears if necessary
5. Remove and disassemble transmission; repair or
replace failed components as needed
6. Remove, disassemble, and inspect valve body;
replace valve body (as assembly) if any valve or
bore is damaged; clean and reassemble correctly
if all parts are in good condition
J9121-443

AUTOMATIC TRANSMISSION-32RH/36RH/37RH/42RH/46RH 21 - 99
MOVES IN 2ND OR 3RD
GEAR, ABRUPTLY
DOWNSHIFTS TO LOW
1. Governor valve sticking
2. Valve body malfunction
1. Remove, clean, and inspect; replace faulty parts
2. Remove, clean, and inspect; look for stuck
1 -2 valve or governor plug
SLIPS IN LOW GEAR D ONLY,
BUT NOT I N 1 POSITION
1. Overrunning clutch faulty, not holding 1. Replace overrunning clutch
SLIPS IN FORWARD DRIVE
RANGES
1. Low fluid level
2. Air in fluid (fluid is foamy, full of bubbles), shifts are
spongy, caused by air getting into pump suction
passages
3. Gearshift or throttle linkage out of adjustment
4. Low hydraulic pressures due to worn pump,
incorrect control pressure adjustments, valve body
warpage or malfunction, sticking governor, leaking
seal rings, dutch seals leaking, servo leaks, clogged
filter, or cooler lines
5. Accumulator piston cracked, spring broken or
seal worn
6. Clutch or servo malfunction, leaking seals or
worn plates
7. Overrunning clutch worn, not holding (slips in
1 only)
1. Add fluid and check for leaks
2. Check for bad pump gasket or seals, dirt
between pump halves, and loose pump bolts or
defective O-ring at filler tube
3. Adjust linkage
4. Perform hydraulic and air pressure tests to
determine cause
5. Inspect and repair as necessary
6. Air pressure check clutch-servo operation and
repair as required
7. Replace clutch
SLIPS IN REVERSE ONLY 1. Low fluid level
2. Aerated fluid; see Slips in Forward Drive Ranges
3. Gearshift linkage out of adjustment
5. Hydraulic pressure too low due to worn pump, worn
seal rings, clutch or servo seal leakage
6. Worn front clutch, leaking rear servo, or worn
rear band
7. Band-linkage binding
1. Add fluid and check for leaks
2. See Slips in Forward Drive Ranges
3. Adjust linkage
4. Adjust band
5. Perform hydraulic pressure tests to determine
cause
6. Air pressure check clutch-servo operation and
repair as required
7. Inspect and repair as required
J9121-444
2 1- 10 0 AUTOMATIC TRANSMISSION-32RH/36RH/37RH/42RH/46RH

Condition Possi bi e Cause Correction
NO KICKDOWN OR
NORMAL DOWNSHIFT
1. Incorrect throttle linkage or cable adjustment
2. Incorrect gear shift linkage or cable adjustment
3. Front band out of adjustment
4 Hydraulic pressures too high or too low due to
sticking governor, valve body malfunction, or
incorrect hydraulic control pressure adjustments
5. Front servo, band, or linkage malfunction
6 . Clutch or servo malfunction
1. Adjust linkage or cable
3. Adjust band
4 . Perform hydraulic pressure tests to determine
cause and repair as required. Correct valve
body pressure adjustments as required
5 . Air pressure test operation and repair as
necessary
6 . Air pressure test operation and repair as
necessary
STUCK IN LOW GEAR (WILL
NOT UPSHIFT)
1. Gearshift or throttle linkage or cable out of
adjustment
2. Front band out of adjustment
3. Governor valve stuck closed; loose output shaft
support or governor housing bolts, worn pump,
leaking seal rings, or valve body problem (i.e.,
stuck 1-2 shift valve or governor plug)
4 . Clutch or servo malfunction
1. Adjust linkage or cable. Repair linkage of
worn or damaged. Relace damaged cable.
2. Adjust band
3. Check line and governor pressures to
determine cause; correct as required
4 . Air pressure check operation of clutches and
bands; repair faulty component
N O LOW GEAR (MOVES IN
2ND OR 3RD GEAR ONLY)
1 . Governor valve sticking in partially open position
3. Front servo piston cocked in bore
4 . Front band linkage malfunction
5. Incorrect throttle or gearshift linkage or cable
adjustment
1. Remove governor; clean, inspect, and repair
as required
2. Remove, clean, and inspect. Look for sticking
1-2 vafve, 2-3 valve, governor plug, or
broken springs
3. Inspect servo and repair as required
4 . Inspect linkage and look for bind in linkage
J9321-256
+ AUTOMATIC TRANSMISSION32RH/36RH/37RH/42RH/46RH 21 - 101
CREEPS I N NEUTRAL 1. Gearshift linkage out of adjustment
2. Valve body malfunction (warped body, cross
leakage)
3. Clutch dragging
4 . Converter lockup clutch dragging
1. Adjust linkage
2. Perform hydraulic pressure test to determine
cause ana repair as required
3. Air pressure check operation of clutches and
repair as required
4. Oi l pump worn; replace pump
D R A G S O R L OC KS UP 1. Front or rear band out of adjustment
2. Servo band or linkage malfunction (i.e., binding
linkage, warped band, servo piston stuck)
3. Draggi ng clutch (does not release fully)
4. Broken or seized planetary gears
5 . Overrunning clutch worn, broken, or seized
1. Adjust bands
2. Air pressure check servo operation and repair
as required
3. Air pressure check clutch operation and repair
as required
4. Remove, inspect, and repair as required (look
for debris in oil pan)
5. Remove and inspect clutch, repair as required
G R O WL I N G , G R A T I N G , O R
S C R A PI N G N O I S E S
1. Planetary gear set broken or seized
2. Overrunning clutch worn, seized, or broken
3. Oil pump components scored, binding, or broken
4. Output shaft bearing or bushing damaged
5 . Faulty clutch operation
6. Governor support (park gear) binding or seal rings
broken
7. Front and rear bands out of adjustment
1. Check for debris in oil pan and repair as
required
2. Inspect and check for debris in oil pan; repair as
required
3. Remove, inspect, and repair as required
5. Perform air pressure check and repair as
required
7. Adjust bands
BU Z Z I N G N O I S E 1. Low fluid level
2. Air being drawn into pump suction passages
3. Overrunning clutch damaged
4 . Valve body misassembled, bolts loose, weak spring,
or mispositioned valve or check ball
1. A dd fluid and check for leaks
2. Check pump for porous casting, scores on
mating surfaces, and excess rotor clearance;
repair as required
3. Replace clutch
4. Remove, disassemble, inspect valve body;
reassemble correctly if necessary; replace
assembly if valves or springs are damaged
J9121-446
2 1- 10 2 AUTOMATIC
TRANSMISSION32RH/36RH/37RH/42RH/46RH

OIL COMES OUT FILLER TUBE 1. Transmission overfilled 1. Drain fluid to correct level; remove neutral
switch and drain through switch hole with
suction gun
2. Breather vent in oil pump blocked 2. Inspect and clear blockage
3, Fly id cooler or cooler lines plugged 3. Flush cooler and lines
4. Air in fluid (aerated) 4. See "Slips In Forward Drive Ranges"
5. Oil filter clogged 5. Replace filter; determine the reason for clogged
condition and repair
6. tear servo piston or seal failure 6. Check hydraulic pressure at servo in reverse
(will register low or fluctuate rapidly)
7. Valve body switch valve sticking 7. Remove and clean valve
OIL LEAKS (ITEMS LISTED
REPRESENT POSSIBLE LEAK
POINTS AND SHOULD ALL BE
CHECKED)
1. Speedometer adapter
2. Pan gasket
3. Filler tube (where tube enters case)
4. Fluid lines and fittings
5. Valve body manual lever shaft seal
6 . Pressure port plug loose
7. Rear bearing access plate
8. Gasket damaged or bolts are loose
9. Adapter/extension gasket damaged
10. Neutral switch
11. Converter housing area
12. Cooler line fittings and hoses
13. Pump seal
14. Torque converter
1. Replace both adapter seals
2. Tighten pan screws to 150 inch-pounds; if
leaks persist, replace gasket; do not
overtighten screws
3. Replace O-ring seal
4. Tighten fittings; if leaks persist, replace fittings
and lines if necessary
5. Replace shaft seal
6. Tighten to correct torque; replace plug if leak
persists
7. Replace gasket
8. Replace bolts or gasket or tighten bolts
9. Replace gasket
10 . Replace switch and gasket
11. Check for leaks at seal caused by worn seal or
burr on converter hub (cutting seal), worn
bushing, missing oil return, oil in front pump
housing, or hole plugged. Check for leaks past
O-ring seal on pump, or past pump-to-case
bolts; pump housing porous, oil coming out
vent due to overfill or leak past front band shaft
access plug
12. Replace fittings and hoses
13. Replace seal
14. Replace converter
J9121-448

AUTOMATIC TRANSMISSION32RH/36RH/37RH/42RH/46RH 2 1- 10 3
Condi ti on Possible Couso Correction
OV E RHE AT D U R I N G
C O M M E R C I A L OPE R AT I ON
O R WHI LE TRAILER T O WI N G
(FLUID DAR K A N D BURNE D
WI TH S O M E SLUDGE
FOR MAT I ON)
1. Vehicle not properly equipped for trailer towing or
commercial use
2. Vehicle not equipped with auxiliary fluid cooler
3. Extensive idling time or operation in heavy traffic in
hot weather
4. Tow vehicle overloaded (exceeding vehicle tow
capacity)
5. Air flow to auxiliary cooler blocked by snow plow,
front mounted spare tire, bug screen, or similar item
1. Be sure vehicle is equipped with recommended
optional components (i.e., HD springs,
transmission, axle, larger C I D engine, auxiliary
cooler, correct axle ratio, etc.). If vehicle is not so
equipped, it should not be used for severe
service operation
2. Drain fluid, change filter, and install auxiliary
cooler
3. Cut down on idling time; shift into neutral every
so often and run engine at 10 0 0 rpm to help
circulate fluid through cooler
4. Be sure vehicle is properly equipped to handle
load; do not tow Class Ill-type loads with a
vehicle that is only rated for Class 1 or II
operation
5. Remove or reposition item causing air flow
blockage
OV E R HE AT D U R I N G N O R M A L
OPE R A T I ON (FLUID
D I S C OL OR E D , SMELLS
BURNED)
1. Low fluid level
2. Fluid cooler, lines blocked, or cooler cracked (oil in
engine coolant)
3. Switch valve sticking
4. Clutch pack clearance incorrect (too tight)
5 . Bands too tight
2. Flush cooler and lines and replace radiator if
transmission fluid has entered coolant
3. Remove, disassemble, clean valve body
4. Check and correct as required
5. Adjust bands
J9121-45 0

Condition P O M I O S O Ccwse Correction
N O START I N PARK OR
NEUTRAL
1 . Gearshift linkage out of adjustment
2. Neutral switch wire broken or open
3. Faulty neutral switch
4. Valve body manual lever assembly bent, worn,
broken, or not aligned with switch
1 . Adjust linkage
2 . Check continuity with test lamp; repair as
required
3. Refer to service section for test and replacement
procedure
4. inspect lever assembly and replace if damaged
S L U G G I S H AC C E L E R AT I ON AT
L O W SPEEDS O R REQUI RES
EXCESSI VE THROTTLE
O PE N I N G T O M A I N T A I N
HI G HWA Y SPEEDS
1. Poor engine performance
2. Gearshift or throttle linkage out of adjustment
3. Transmission clutches slipping
4. Overrunning clutch in converter not holding
5 . Converter overrunning clutch stuck
1 . Check engine and repair as required
2. Adjust linkage
3. Perform stall test and repair as required
4. Perform stall test and replace converter if clutch
has failed
5. Replace converter
FLUID C O N T A M I N A T E D
( DI S C OL OR E D, FULL OF
S LUDGE A N D / O R METAL
A N D FRI CTI ON MATERI AL
PARTICULAR)
1 . If contamination occurred shortly after overhaul,
fluid cooler and lines were not flushed and flow
rested. This is especially true when original overhaul
was to correct a problem that generated a large
amount of debris, such as a gear failure or a clutch
pack failure
Note: Flushing the cooler and lines is mandatory after
a failure of the converter lockup clutch
2 . Incorrect fluid used in transmission
3. Mai n cooler in radiator is cracked, allowing engine
coolant to enter transmission
4. Severe overload results in overheat, fluid break-
down, and accelerated wear, especially in high
ambient temperatures. Most frequent causes are:
Vehicle is not properly equipped for heavy duty
service
Tow vehicle and boat or trailer are both
overloaded
Trailer or boat are too large for tow vehicle (load
exceeds rated capacity of tow vehicle)
1. If contamination is severe, cooler flushing,
converter replacement, and another overhaul
may be necessary; particularly so if shift
problems were also present
2 . If transmission is operating properly, drain fluid,
reverse flush cooler and lines, and change fluid
and filter. However, if shift problem has
developed, converter replacement and
transmission overhaul may be required
3. Replace radiator (and cooler) and flush lines. If
problem was diagnosed early enough, fluid and
filter change may only be necessary. If
contamination perioa was prolonged, overhaul
and converter replacement may be required
4. Repair transmission, flush cooler, and lines.
Replace converter if necessary. Install auxiliary
cooler if needed. Also install HD cooling system
if needed. If tow vehicle and unit being towed
are both overloaded, the only repair is to reduce
the load to rated limits. However, if trailer or
boat is too large for tow vehicle, the only option
is for the owner to move up to properly-
equipped and load-rated tow vehicle
J 9 1 2 1 - 4 4 9

AUTOMATIC TRANSMISSION32RH/36RH/37RH/42RH/46RH 2 1 - 1 0 5
Condition Possible Co use Correction
N O 3-4 U PS HI F T 1. Fourth gear overdrive switch (on dash) in OFF 1. Turn control switch to O N position
2.
position
Overdrive circuit fuse blown
2. Replace fuse; determine why fuse failed
and repair as necessary (i.e., shorts,
grounds in circuit)
3. Fourth gear overdrive switch shorted, open,
wires loose
3. Repl ace switch if shorted or open and
repair loose or damaged wires
4. Overdrive solenoid or circuit wire loose,
shorted, open
4. Check wires/connections with 12V test lamp
and voltmeter; repair damaged or loose
wires/connections as necessary
5 . Solenoid feed orifice in valve body is blocked 5 . Remove, di sassembl e, clean valve body
thoroughly
6. Fourth gear overdrive solenoid failure 6. Verify solenoid failure with test lamp and
replace solenoid
7. Sensor failure (vehicle speed sensor or coolant
sensor)
7. Test both sensors with test lamp or volt/
ohmmeter and replace faulty sensor
8. Park/neutral switch open or shorted or switch
wire to powertrain control module is damaged
(loss of park/neutral input)
8. Test switch as described in service section
and replace if necessary
9. Powertrain control module faulty 9. Check with D R B I I scan tool and replace if
necessary
10. T.P.S. fault 10. Adjust or replace T.P.S.
11. Transmission fluid temperature sensor fault (if
equipped)
12. Overdrive piston seal failure
13. Wr ong overdrive piston spacer
11. Replace sensor
12. Replace both seals
13. Remove unit, check end play, and install
correct spacer
14. Low hydraulic pressure
14. Pressure test transmission to determine
cause
15. Set-reset module faulty 15. Replace module (if equipped)
S U P S IN OVERDRIVE
FOURTH GEAR
1.
2.
Low fluid level
Overdrive piston or seal malfunction
2. Remove overdrive unit; replace piston seals
if worn; replace piston if da ma ge d, if piston
retainer is damaged, it will be necessary to
remove and disassemble the transmission
3. Overdrive clutch pack wor n 3. Remove overdrive unit and rebuild clutch pack
4. 3-4 shift valve, timing valve, or accumulator
malfunction
4. Remove and overhaul valve body. Replace
accumulator seals. Make sure all valves operate
freely in bores, and do not bind or stick. Make
sure valve body screws are correctly tightened
and separator plates are properly positioned
5 . Overdrive piston retainer bleed orifice blown out 5 . Disassemble transmission, remove retainer,
and replace orifice
6. Overdrive unit thrust bearing failure 6. Di sassembl e overdrive unit and replace
thrust beari ng ( N o. 1 thrust beari ng is
between overdrive piston and clutch hub;
N o. 2 thrust beari ng is between the
planetary gear and the direct clutch spring
plate; N o. 3 thrust beari ng is between
overrunning clutch hub and output shaft)
J9321-252
42RH/46RH OVERDRIVE DIAGNOSIS
2 1- 10 6 AUTOMATIC TRANSMISSION32RH/36RH/37RH/42RH/46RH

D E L A YE D 3-4 U PS HI F T
( S L O W T O E N G A G E )
1. Low fluid level
2. Overdrive solenoid or wiring is faulty
3. Overdrive piston spacer too thin
4. Overdrive clutch pack worn
5 . T.P.S. faulty
6. Overdrive clutch bleed orifice pl ugged
2. Test solenoid and check wiring for l oose/
corroded connections, or shorts/ground; replace
solenoid if faulty and repiar wiring if necessary
3. Remove unit; measure end pl ay and select
proper spacer
4. Remove unit and rebuild clutch pack
5. Replace T.P.S.
6. Di sassembl e transmission and replace orifice
3-4 U PS HI F T O C C U R S BE F O R E
C O M P L E T I O N O F 2- 3 U PS HI F T
1. Overdrive solenoid connector or wiring problem
2. Overdrive solenoid malfunction
3. Cool ant temperature or T.P.S. malfunction
5. Powertrain control module malfunction
1. Test connector and wiring for loose connections,
shorts, or ground, and repair as needed
2. Replace solenoid
3. Test each sensor for continuity, short, gr ound,
and replace as necessary
4. Remove, disassemble, clean, and inspect
valve body components; make sure all valves
and pl ugs slide freely in bores; polish valves
with crocus cloth if needed
3. Test with D R B I I scan tool and replace
controller if faulty
J9321- 25 3
+ AUTOMATIC TRANSMISSION-32RH/36RH/37RH/42RH/46RH 2 1- 10 7
C o n d i t i o n Possible Cause C o r r e c t i o n
N O 4- 3 D O WN S H I F T 1. Circuit wiring and/ or connectors shorted
2. Converter clutch solenoid not venting
3. Overdrive solenoid not venting
4. 3-4 shift, shuttle, timing val ve, or accumulator
malfunction
5 . Powertrain control module malfunction
6. T.P.S. malfunction
7. Sensor or sensor wiring problem
1. Test wiring and connectors, with test l amp
and volt/ohmmeter; repair wiring as
necessary; replace connectors and/or
harnesses as required
2. Remove valve body and replace solenoid if
seized or shorted
3. Remove valve body and replace solenoid if
seized or shorted
4. Remove valve body; remove and disassemble
lower housing and 3-4 accumulator housi ng;
replace seals and clean valves as necessary;
be sure all valves slide freely in bores
5 . Check operation with D R B I I scan tool;
replace controller only if faulty
6. Replace T.P.S.
7. Check coolant and transmission temperature
sensors, speed sensor, and overdrive control
switch
N O 4- 3 D O WN S H I F T WH E N
C O N T R O L S WI T C H I S
T U R N E D OF F
1. Control switch open-shorted
2. Overdrive solenoid wiring or connectors faulty
3. Overdrive or converter clutch solenoid not
venting
4. Powertrain control module malfunction
1. Test and replace switch if faulty
2 . Check solenoid wiring and connections for
shorts/grounds; repair as necessary
3. Test solenoids and replace if seized or shorted
4. Test with D R B I I scan tool; replace module if
faulty
J9321- 25 4
HARSH 1-2, 2-3, OR 3-2
SHIFTS (A500)
1. Lockup solenoid failure 1. Remove valve body and replace solenoid
TORQUE CONVERTER LOCKS
UP I N SECOND AND/ OR
THIRD GEAR (A500)
1. Lockup solenoid, relay, or wiring problem 1. Test solenoid, relay, and wiring for continuity,
shorts, or grounds; replace solenoid and relay if
faulty; repair wiring and connectors as
necessary
NOISY OPERATION IN
FOURTH GEAR ONLY
1. Overdrive clutch discs, plates, or snap rings
damaged
2. Overdrive piston or planetary thrust bearing
brinnelled, installed wrong, or damaged
3. Output shaft bearings brinnelled, scored, damaged
4. Planetary gears worn, chipped, damaged
5. Overdrive unit overrunning clutch rollers rough,
scored, or output bushings are worn
1. Remove unit and rebuild clutch pack
2. Remove and disassemble unit; replace either
thrust bearing if damaged
3. Remove and disassemble unit; replace either
bearing if damaged
4. Remove and overhaul overdrive unit
5. Remove and overhaul overdrive unit
J9121 455
+ AUTOMATIC TRANSMISSION32RH/36RH/37RH/42RH/46RH 21 - 109
NO REVERSE (OR SLIPS IN
REVERSE)
1. Direct clutch spring collapsed or broken
2. Direct clutch pack worn
4. Front clutch malfunction
5. Overdrive thrust bearing failure
1. Remove and disassemble unit; check clutch pack
and replace spring
2. Disassemble unit and rebuild clutch pack
3. Adjust band
4. Air pressure test clutch operation; remove and
rebuild if necessary
5. Disassemble geartrain and replace bearings
NO 1-2 OR 2-3 UPSHIFT (HAS
LOW AND REVERSE ONLY)
1. Governor component loose, worn, or damaged 1. Remove and disassemble unit; replace worn or
damaged governor components as needed
J9121-456
PO S S I B L E C A U S E
FAULTY OIL PUMP X X X X X
STICKING GOVERNOR VALVE X X X
PLUGGED COOLER, LINES OR FITTINGS X X X
VALVE BODY MALFUNCTION X X X X X X X
STUCK SWITCH VALVE X X X X X X
STUCK CONVERTER CLUTCH VALVE X X X
STUCK CONVERTER CLUTCH SOLENOID X X
SOLENOID WIRING DISCONNECTED X
FAILED CONVERTER CLUTCH SOLENOID X
FAILED CONVERTER CLUTCH RELAY X X
FAULTY TORQUE CONVERTER: X X X X X
OUT OF BALANCE X
FAILED CONVERTER CLUTCH X X X
LEAKING TURBINE HUB SEAL X X
ALIGN EXHAUST SYSTEM X X
TUNE ENGINE X X X
FAULTY INPUT SHAFT OR SEAL RING X X
THROTTLE CABLE MISADJUSTED X X
Z
0
o
z
o
C
O
N
V
E
R
T
E
R

C
L
U
T
C
H

W
I
L
L

N
O
T

E
N
G
A
G
E

C
L
U
T
C
H

W
I
L
L

N
O
T

D
I
S
E
N
G
A
G
E

S
T
A
Y
S

E
N
G
A
G
E
D

A
T

T
O
O

L
O
W

A

S
P
E
E
D

I
N

4
t
h

G
E
A
R

L
O
C
K
S

U
P

O
R

D
R
A
G
S

I
N

L
O
W

O
R

S
E
C
O
N
D

S
T
A
L
L
S

O
R

I
S

S
L
U
G
G
I
S
H

I
N

R
E
V
E
R
S
E

C
H
A
T
T
E
R

D
U
R
I
N
G

C
L
U
T
C
H

E
N
G
A
G
E
M
E
N
T
-
(
C
O
L
D
)

V
I
B
R
A
T
I
O
N

O
R

S
H
U
D
D
E
R

D
U
R
I
N
G

C
L
U
T
C
H

E
N
G
A
G
E
M
E
N
T

V
I
B
R
A
T
I
O
N

A
F
T
E
R

C
L
U
T
C
H

E
N
G
A
G
E
M
E
N
T

V
I
B
R
A
T
I
O
N

W
H
E
N

"
R
E
V
V
E
D
"

I
N

N
E
U
T
R
A
L

O
V
E
R
H
E
A
T
I
N
G
:

O
I
L

C
O
M
I
N
G

j

O
U
T

O
F

F
I
L
L

T
U
B
E

O
R

P
U
M
P

S
E
A
L

S
H
U
D
D
E
R

A
F
T
E
R

C
L
U
T
C
H

E
N
G
A
G
E
M
E
N
T

TORQUE CONVERTER CLUTCH DIAGNOSIS
HYDRAULIC FLOW IN D-FIRST GEAR (32RH/36RH/37RH)
GOVERNOR VALVE
r
REAR SERVO
FRONT, SERVO
ÂCCUMULATOR
LOCK-UP ONLY
FRONT
CLUTCH
UBRICATION
SELECTOR LEVER I N
DRIVE (BREAKAWAY)
HALF THROTTLE
U9 0 2 M 6 1
GOVERNOR VALVE
HYDRAULIC FLOW IN DSEGOND GEAR (32RH/36RH/37RH)
FRONT M SERVO REAR SERVO
FRONT CLUTCH
ACCUMULATOR
3 OI L FILTER
LINE 75 PSI
PUMP SUCTION \y>>>\
THROTTLE 40 PSI WMM
GOV E RNOR 6-75 PSI
CONVERTER 5-75 PSI
LUBRICATION 5-30 PSI WMM (j
1-2 SHIFT CONTROL M
25-35 PSI ^ (i
SELECTOR LEVER I N TORQUE C O N V E R T E R - * * !
DRIVE (SECOND) ( |
HALF THROTTLE
TO
LUBRICATION
FRONT
^CLUTCH
LUBRICATION
J9021-162
GOVERNOR VALVE
/
HYDRAULIC FLOW IN D-THIRD GEAR (32RH/36RH/37RH)
REAR CLUTCH J ^ T
X
Î^L FRONT CLUTCH FRONT UJ SERVO
ACCUMULATOR
LOCK-UP ONLY
TO
LUBRICATION
FRONT
CLUTCH
LUBRICATION
J9021-163
HYDRAULIC FLOW IN DTHIRD GEARAFTER CONVERTER CLUTCH ENGAGEMENT (32RH/36RH/37RH)
GOVERNOR VALVE
REAR SERVO
ACCUMULATOR
LOCK-UP ONLY
TO
LUBRICATION
FRONT
.-CLUTCH
IMBRICATION
SELECTOR LEVER IN TORQUE CONVERTER
DRIVE (LOCK-UP)
J90 2M64
GOVERNOR VALVE
y
HYDRAULIC FLOW DURING PART THROTTLE 3-2 KICKDOWN (32RH/36RH/37RH) fs9
ACCUMULATOR
LOCK-UP ONLY
1-2 SHIFT CONTROL
55-70 PS l k%>3
GOVERNOR 6-40 PSI [
SELECTORLEVER IN DRIVE TORQUE CONVERTER-
(PART THROTTLE KICKDOWN)
BELOW 40 M.P.H.
33
G O
33
30
4>
m
30
J9021-165
GOVERNOR VALVE
HYDRAULIC FLOW DURING FULL THROTTLE 3-2 KICKDOWN (32RH/36RH/37RHJ
REAR SERVO I T FRONT SERVO ACCUMULATOR
LOCK-UP ONLY
1-2 SHIFT CONTROL P 5 r ^ r i
55-70 ?$ir///A
GOVERNOR 30-73 PSI f"
SELECTOR LEVER IN DRIVE TORQUE CONVERTER"
(FULL THROTTLE KICKDOWN)
J902M66
GOVERNOR VALVE
HYDRAULIC FLOW IN 2-POSITION MANUAL SECOND (32RH/36RH/37RH)
ro
REAR CLUTCH
REAR SERVO
FRONT CLUTCH
FRONT SERVO
ACCUMULATOR
l / M - l v X ' X v : - : - - I OIL FILTER
FRONT
CLUTCH
UBRICATION
SELECTOR LEVER I N TORQUE CONVERTER*
TWO (MANUAL SECOND) I B U ^ w S S S ^ ^ ^ i
CLOSED THROTTLE J9021-167
O
O
ao
>
oo
00
m
r O
30
c 3
o>
30
30
3^
r o
30
30
r
GOVERNOR VALVE
HYDRAULIC FLOW IN 1-POSITION MANUAL LOW (32RH/36RH/37RHf
REAR SERVO r r % ^ , t m , FRONT SERVO
REAR CLUTCH FRONT CLUTCH
ACCUMULATOR
FRONT
2 CLUTCH
LUBRICATION
SELECTOR LEVER IN
ONE (MANUAL LOW)
CLOSED THROTTLE
^21- 168
G O V E R N O R V A L V E
HYDRAULIC FLOW IN REVERSE32RH/36RH/37RH
REAR C L UT C H
RE AR SERVO
FRONT C L UT C H
FRONT SERVO
AC C UMUL AT OR
FRONT
iCLUTCH
UBRI CATI ON
SELECTOR LEVER
I N REVERSE
HYDRAULIC FLOW IN NEUTRAL (42RH/46RH)
GOVERNOR
HYDRAULIC FLOW IN REVERSE (42RH/46RHJ
ACCUM UL ATOR
J9321-197
IN3
HYDRAULIC FLOW IN MANUAL LOW (42RH/46RH}
F RON T SE RV O
ACCUM UL ATOR
LENE
PRESSURE
( 55- 6 2 psi)
1-2
SHIFT
CONTROL
( 25- 35 pslj
GOVERNOR
PRESSURE
(C-30 psi)
CONVERTER/
LUSE PRESSURE
( 5 - 5 7 psi |
PUMP SUCTION
SE LE CTOR LE V E R I N MANUAL I
F I RST GE AR
( CLOSE D TH ROTTLE J
o
30
>
Z
C O
CO
f
C O
i
as
ac
&3
cn
C
c3
ro
as
ac
as
J 9321 - 1 98
HYDRAULIC FLOW IN MANUAL SECOND (42RH/46RHJ
j LINE PRESSURE j
(55-62 psi)
1-2 SHIFT
CONTROL
(25-35 psi)
GOV E RNOR
PRESSURE
(6-57 psi)
CONVERTER/
| LUBE PRESSURE |
(5-57 psi)
PUMP
SUCTI ON
HYDRAULIC FLOW IN DRIVE FIRST GEAR (42RH/46RH)
J9321-200
HYDRAULIC FLOW IN DRIVE SECOND GEAR (42RH/46RH)

SELECTOR LEVER I N DRIVE (D)
S E C OND GEAR
(PART THROTTLE)
LINE
PRESSURE
(57-94 psi)
GOVERNOR
PRESSURE
(0-57 psi)
1-2 SHIFT
CONTROL
(25-70 psi)
THROTTLE
PRESSURE
(0-94 psi)
COVERTER/
LUBE PRESSURE
(5-57 psi)
PUMP
SUCTION
J9321-201
HYDRAULIC FLOW IN DRIVE THIRD GEAR (42RH/46RH)
HYDRAULIC FLOW IN DRIVE FOURTH GEAR OVERDRIVE (42RH/46RH)
GOV E RN OR
V AL V E
J9321-203 r3
21 - 130 IN-VEHICLE SERVICE-~ 32RH / 36 RH / 37RH / 4 2RH / 4 iRH

IN-VEHICLE SERVICE-32RH/36RH/37RH/42RH/46RH
INDEX
page
Aluminum Thread Repair 14 1
Checking Fluid Level 130
Ex tension H ousi ng Bushi ng and Output Shaft
Bearing Ser v i c e- 3 2 RH / 3 6 RH / 3 7 RH . . . . 135
Ex tension H ousi ng Yoke Seal Replacement . . . . 1 35
Fluid and Filter Change 130
Front Band Adjustment 1 33
Gearshift Linkage Adjustment 130
Governor and Park Gear Service
3 2 RH / 3 6 RH / 3 7 RH 137
Governor and Park Lock Ser vi c e4 2 RH / 4 6 RH . 1 38
CHECKING FLUID LEVEL
(1) Position vehicle on level surface. This is ex-
tremely i mport ant for accurate check.
(2) Apply parki ng brakes and r un engine at curb
idle speed.
(3) Shift transmission moment ari l y into all gear
ranges. Then shift back to Neut ral .
(4 ) Clean top of filler t ube and dipstick (to avoid
dirt entry) and check fluid level. Correct level is as
follows:
(5) Be sure fluid is at normal operating tempera-
t ure (180F). Correct level is between "Maximum
Level Hot" and " A d d " mar ks (crosshatched area) on
dipstick.
(6) If fluid level is low, add only enough fluid to
correct level.
C A U T I O N : D o not overfill the t r ansmi ssi on. Overfill-
ing will force fluid out the pump vent whi ch can be
mi staken for a pump seal leak. Overfilling will al so
cause fluid aeration and foaming when the excess
fluid i s pi cked up and churned by the gear train.
Aeration will reduce fluid life si gni fi cantl y.
FLUID AND FILTER CHANGE
Normal Change Interval
The fluid and filter should be changed (and t he
bands adjusted) at recommended mai nt enance inter-
vals. Or whenever t he t ransmi ssi on has been disas-
sembled for any reason.
Recommended Fluid
The recommended (and preferred) fluid for
Chrysler aut omat i c t ransmi ssi ons is Mopar ATF
Plus, type 7176. Use Mopar Dexron II only when
ATF Pl us is not readily available.
page
Park Lock Ser v i c e- 3 2 RH / 3 6 RH / 3 7 RH . 1 38
Park/Neutral Position Switch 1 34
Rear Band Adjustment 1 33
Speedometer Service 134
Transmi ssi on Cooler Service 14 0
Transmi ssi on Throttle Cabl e Adj ust ment -
Cummi ns Diesel Engi ne 1 32
Transmi ssi on Throttle Cabl e Adj ust ment -
Gas E ngi nes 131
Valve Body Control Pressure Adj ustments . . . . . 1 4 0
Valve Body Service 1 38
Severe Usage Change Interval
Under severe usage, t he fluid and filter should be
changed and t he bands adjusted at 12,000 mile
(19,000 km) intervals.
Severe usage is defined as:
More t han half of vehicle operation occurs in
heavy city traffic during hot weat her at ambi ent
t emperat ures above 90 F.
Vehicle is used for Taxi, Police, Limousine, or sim-
ilar commercial operations.
Vehicle is used for trailer/boat towing or heavy
load haul i ng.
When t he factory fluid is drained, refill t he t rans-
mission with Mopar ATF Plus, type 7176 fluid. Mo-
par Dexron II can be used if ATF Pl us is not readily
available.
FLUID AND FILTER REPLACEMENT
PROCEDURE
(1) Raise vehicle, remove oil pan and drain fluid.
(2) Remove filter screws and remove filter.
(3) Position new filter on valve body and install fil-
t er screws finger tight.
(4) Tighten filter screws to 4 N*m (35 in. lbs.) wi t h
torque wrench.
(5) Position new gasket on oil pan and install pan
on transmission. Tighten pan bolts to 17 Nm (150
in. lbs.) torque.
(6) Lower vehicle and refill transmission with rec-
ommended fluid.
GEARSHIFT LINKAGE ADJUSTMENT
Check linkage adjustment by st art i ng t he engine
in Par k and Neut ral .
Adjustment is OK if t he engine st art s only in par k
and Neut ral .
Adjustment is incorrect if t he engine st art s in one
but not both positions.
If t he engine st art s in any position other t han Par k
or Neut ral , or if t he engine will not st art at all, t he
park/ neut ral position switch may be faulty.

IN-VEHICLE SERVICE-32RH/36RH/37RH/42RH/46RH 21 - 131
Fig. 1 Column Gearshift Linkage
LINKAGE ADJUSTMENT PROCEDURE
Do not at t empt l i n k a g e adj ust ment if any compo-
nent s ar e worn or damaged. If e i t he r l i nkage r od
must be disconnected, t he plastic gr ommet secur-
ing the rod in the torque shaft lever must be re-
placed. Disconnect the rod with a pry tool. Pry
only where the grommet and rod attach and not on
the rod itself. Then cut away the old grommet. Use
pliers to snap the new grommet into the lever and
to snap the rod into the grommet.
(1) Shift transmission into Park.
(2) Raise vehicle.
(3) Check condition of shift rods, control lever,
bushings, washers and torque shaft (Fig. 1). Tighten,
repair, or replace worn or damaged parts.
(4) Loosen shift rod adjusting swivel lock screw. Be
sure swivel turns freely on rod.
(5) Verify that valve body shift control lever is in
Park detent. Move lever fully rearward to check.
(6) Adjust swivel position (on the shift rod) to a ob-
tain free pin fit in torque shaft lever (Fig. 1). Then
tighten swivel lock screw to 10 Nm (90 in. lbs.)
torque.
(7) Check adjustment by starting engine in Park
and Neutral. Engine should start in these positions
only. If engi ne starts i n any position other than
Park or Neutral, adjustment is incorrect or
park/neutral posi ti on swi tch is faulty.
TRANSMISSION THROTTLE CABLE
ADJ USTME NT- GAS ENGINES
(1) Turn ignition key to OFF position.
(2) Remove air cleaner.
(3) Position 2. 8 - 3. 04 mm (0.110 - 0.120 in.) thick
spacer between idle stop and throttle lever on throt-
tle body. Use appropriate thickness feeler gauges, or
shim stock as spacer (Fig. 2).
Fig. 2 Positioning Spacer Between Throttle Stop
And Lever (Gas Engine)
(4) Press cable lock button to release cable (Fig. 3).
21 - 132 IN-VEHICLE SERVICE-32RH/36RH/37RH/42RH/46RH

IDLE STOP
ADJUSTMENT
/
SPACER (USE
H k s
FEELER GAUGES
/o)
OR SHIM STOCK)
\
THROTTLE BODY
LEVER
TRANSMISSION
THROTTLE
CABLE
TORQUE
SHAFT
BRACKET.
CABLE
RETURN
SPRING
^ CABLE
CONDUI T
CABLE ^1
BUTTON
1
CABLE \ >
WIPER
J 932 M 84
Fig. 3 Throttle Cable Attachment At Engine
(Gas Engine)
(5) Pull cable conduit toward rear of vehicle unt i l
wiper is completely retracted into end of conduit fit-
t i ng (Fig. 3). Then release cable lock button.
(6) Raise vehicle for access to transmission t hrot t l e
valve lever (Fig. 4).
(7) Rotate t hrot t l e valve lever toward front of ve-
hicle unt i l rat chet i ng sound (from cable) stops.
C A U T I O N : D o not rotate the throttle val ve lever be-
yond the idle st op. The lever, val ve and manual le-
ver shaft will be damaged if rotated too far.
(8) Remove spacer and check cable adjustment.
Throttle valve lever should begin to move at same
t i me lever on MPI t hrot t l e body moves off idle posi-
tion.
(9) Lower vehicle.
TRANSMI SSI ON THROTTLE CABLE
ADJUSTMENT- CUMMI NS DIESEL ENGINE
A cable is used to operate t he transmission t hrot t l e
valve on models with a Cummi ns diesel engine. Ca-
ble adjustment is controlled by a locking pawl on t he
cable sheat h (Fig. 5).
The rear of t he cable is connected to t he t ransmi s-
sion t hrot t l e valve lever. The forward end of t he ca-
ble is at t ached to a pin on t he engine t hrot t l e cam
RETURN
SPRING /
BRACKET ^
CABLE
BRACKET
THROTTLE
VALVE
LEVER
(ROTATE LEVER
I N DIRECTION
OF ARROW
FOR ADJUSTMENT)
THROTTLE
VALVE
CABLE
J9221-64
Fig. 4 Throttle Cable Attachment At Transmission
(Gas Engine)
(Fig. 6). Rotation of t he t hrot t l e cam (by t he engine
t hrot t l e cable), actuates t he cable and t hrot t l e valve
lever for downshifts.
A 4.57 mm (0.180 in.) diameter gauge is needed
to check and adjust the throttle val ve cabl e on
diesel model s. Use a mi crometer and inside cali-
pers, a drill of the correct diameter, or fabricate
a gauge from metal or al umi num stock.
(1) Run engine unt i l it reaches normal operating
t emperat ure.
(2) Verify t hat engine hot idle speed is within
specifications. Adjust hot idle rpm if necessary.
(3) Check cable adjustment with gauge as follows:
(a) Verify t hat t hrot t l e lever is seated agai nst
low idle stop screw (with accelerator pedal fully re-
leased).
(b) Check clearance between rear of cable actuat-
ing pin and end of slot in t hrot t l e valve cable (Fig.
6).
(c) Clearance should be 4.57 mm (0.180 in.) as
measured with gauge.
(d) If adjustment is OK, no further action is re-
quired. However, if clearance is great er or less
t hen specified, adjust cable as described in follow-
ing steps.

IN-VEHICLE SERV ICE- 32RH / 36 RH / 37RH / 4 2RH / 4 6 RH 21 - 133
(4) Lift and release cable locking pawl (Fig. 7) .
(5) Insert gauge between cable act uat i ng pin and
end of slot in cable.
(6) Slide cable forward or rearward to obtain spec-
ified clearance between pin and cable slot.
(7) Press cable locking pawl downward until it
snaps into locked position.
(8) Check cable adjustment one more t i me before
moving vehicle. This avoids misadjustment caused by
a shift in component position duri ng adjustment pro-
cedure.
THROTTLE TRANSMISSION
CAM THROTTLE
VALVE i j /\&s/,
CABLE
m
ENGINE
THROTTLE
CABLE
CABLE
LOCK
PAWL J9121-533
Fig. 5 Transmission Throttle Cable
AttachmentDiesel Engine
4.57 M M
(0.180 IN.) GAUGE
J9121-534
Fig. 6 Transmission Throttle Cable
AdjustmentDiesel Engine
FRONT BAND ADJUSTMENT
The front (kickdown) band adjusting screw is at t he
left side of the case above t he manual valve and
throttle valve levers (Fig. 8).
(1) Raise vehicle.
(2) Loosen band adjusting screw locknut. Then
back locknut off 4-5 t urns. Also be sure adjusting
screw t ur ns freely in case. Lubricate screw t hreads if
necessary.
(3) Tighten band adjusting screw to 8 Nrm (72 in.
J9121 -535
Fig. 7 Transmission Throttle Cable Locking Pawl
PositionDiesel Engine
lbs.) torque. If Adapter Extensi on C-3705 must be
used to reach adjuster screw, ti ghten screw to
onl y 5 Nm (47-50 in. lbs.) torque.
(4) Back off adjusting screw 2-1/2 t ur ns on all
transmission models.
(5) Hold adjuster screw in position with backup
wrench. Then tighten locknut to 41 Nm (30 ft. lbs.)
torque.
(6) Lower vehicle.
TO COOLER KICKDOWN BAND ADJUSTING SCREW
GEARSHIFT CONTROL LEVER
RH256
Fig. 8 Front (Kickdown) Band Adjustment Screw
Location
REAR BAND ADJUSTMENT
The transmission oil pan must be removed for ac-
cess to the rear band adjusting screw.
(1) Raise vehicle.
(2) Remove transmission oil pan and drain fluid.
(3) Loosen band adjusting screw locknut 5-6 t urns.
Be sure adjusting screw t urns freely in lever. Lubri-
cate screw t hreads if necessary.
(4) Tighten adjusting screw to 8 Nnn (72 in. lbs.)
torque (Fig. 9).
(5) Complete band adjustment as follows:
On 32RH/42RH, back off adjusting screw four
t urns.
21 - 134 IN-WEHiCLE SE Ri CE - 32RH / 3I RH / 37RH / 4 2RH / 4 6 RH

On 36RH/37RH746RH, back off adjusting screw
t wo t urns.
(6) Hold adjusting screw in place with backup
wrench. Then t i ght en locknut to 34 N*m (25 ft. lbs.)
torque.
(7) Position new gasket on oil pan and install pan
on transmission. Ti ght en pan bolts to 17 Nm (13 ft.
lbs.) torque.
(8) Lower vehicle and refill transmission with Mo-
par ATF Pl us, type 7176, or Dexron II fluid.
Fig. Rear Band Adjustment Screw Location
SPEEDOMETER SERVICE
Rear axle gear rat i o and t i re size determine speed-
ometer pinion requi rement s. If t he gear must be re-
placed, refer to t he part s catalogue information for
t he correct pinion.
ADAPTER AND PINION REMOWAL
(1) Raise vehicle.
(2) Disconnect wires from vehicle speed sensor.
(3) Remove speed sensor from speedometer adapt er
(Fig. 10).
SEAL ADAPTER ADAPTER
RETAINING OIL O-RING
SPEED ADAPTER SPEEDOMETER
SENSOR CLAMP ADAPTER J932 M0 0
Fig. 10 Speedometer Components
(4) Check speed sensor mount i ng area in speedom-
et er adapter. If transmission fluid is found in t hi s
area, adapter oil seal is leaking and will have to be
replaced.
(5) Remove bolt and ret ai ner securing pinion gear
adapt er to extension housing.
(6) Carefully work adapter and gear out of hous-
ing.
(7) Remove and discard adapter O-ring (Fig. 10).
(8) Remove adapter oil seal if necessary. St art new
seal in adapter by hand. Then press seal into adapt er
wi t h Installer Tool C-4004 unt i l tool bottoms (Fig.
10).
ADAPTER AND PINION INSTALLATION AND
ADJUSTMENT
C A U T I O N : Before installing the pi ni on and adapter
assembl y, make sure the adapter fl ange and fl ange
seat in the housi ng are perfectly cl ean. Dirt or for-
ei gn material on these sur f aces will cause mi sal i gn-
ment resulting in pinion gear damage.
(1) Thoroughly clean adapter flange and flange
seat in extension housing.
(2) Lubricate adapter oil seal and O-ring with
transmission fluid.
(3) Count number of t eet h on pinion gear before
installing gear in adapter.
(4) Note range numbers on adapt er face (Fig. 11).
These numbers correspond to number of t eet h on pin-
ion.
(5) Install adapter in extension housing.
(6) Rotate adapter until required range numbers
are at six o-clock position (Fig. 12). Be sure adapter
range numbers correspond to number of t eet h on pin-
ion.
(7) Seat adapter in housing.
(8) Install adapter clamp. Tighten clamp bolt to 11
(9) Install vehicle speed sensor. Tighten sensor
coupling nut to 17 N*m (150 in. lbs.) torque and in-
stall sensor wires.
(10) Lower vehicle and top off transmission fluid
level.
PARK/NEUTRAL POSITION SWJTCH
The center t ermi nal of t he park/ neut ral position
switch is t he st art er circuit t ermi nal . It provides t he
ground for t he st art er solenoid circuit t hrough t he se-
lector lever in Par k and Neut ral positions only. The
outer t ermi nal s on t he switch are for t he backup
l amp circuit.
SWITCH TEST
To test t he switch, remove t he wiring connector.
Then test continuity between t he center t ermi nal

IN-VEHICLE SERVICE-32RH/3eRH/37RH/42RH/46RH 21 - 135
SPEEDOMETER
ADAPTER LOCK RI NG
OIL SEAL
SPECIAL
TOOL
C-4004
J9321-186
Fig. 11 Replacing Speedometer Adapter Seal
RETAINER
-ADAPTER
- 7^ 6 O'CLOCK POSI TI ON RH75
Fig. 12 Indexing Speedometer Adapter
and t he transmission case. Continuity should exist
only when t he transmission is in Par k or Neut ral .
Shift t he transmission into reverse and t est conti-
nui t y at t he switch outer t ermi nal s. Continuity
should exist only when t he transmission is in Re-
verse. Continuity should not exist between t he outer
t ermi nal s and t he case.
Check gearshift linkage adjustment before replac-
ing a switch t hat tests bad.
SWITCH REPLACEMENT
(1) Raise vehicle and position drain pan under
switch.
(2) Disconnect switch wires.
(3) Remove switch from case.
(4) Move shift lever to Park and Neut ral positions.
Verify t hat switch operating lever fingers are cen-
tered in switch opening in case (Fig. 13).
(5) Install new seal on switch and install switch in
case. Tighten switch to 34 Nnn (25 ft. lbs.) torque.
(6) Test continuity of new switch with 12 volt test
lamp.
(7) Connect switch wires and lower vehicle.
(8) Top off transmission fluid level.
EXTENSION HOUSING YOKE SEAL REPLACEMENT
(1) Raise vehicle.
(2) Mark propeller and axle yokes for al i gnment
reference. Then disconnect and remove shaft.
(3) Remove old seal with Remover Tool C-3985
(Fig. 14).
SWITCH
RH266
Fig. 13 Park/Neutral Position Switch Contacts
(4) St art new seal in housing. Then t ap seal into
place with Installer Tool C- 3995 or C- 397 2 (Fig. 15).
(5) Carefully guide propeller shaft slip yoke into
housing and onto out put shaft splines. Align marks
made at removal and connect propeller shaft to rear
axle pinion yoke.
SPECIAL
TOOL
Fig. 14 Removing Extension Housing Yoke Seal
SPECIAL TOOL
RH78
Fig. 15 Installing Extension Housing Yoke Seal
EXTENSION HOUSING BUSHING AND OUTPUT
SHAFT BEARING SERVlCE-32RH/3eRH/37RH
EXTENSION HOUSING REMOVAL
(1) Shift transmission into 1 (manual low) position.
(2) Raise vehicle.
(3) Mark propeller shaft and axle yokes for align-
ment reference. Then disconnect and remove shaft.
(4) Remove vehicle speed sensor, speedometer
adapter and speedometer pinion gear (Fig. 10).
21 - 136 IN-VEHICLE SERVICE32RH/36RH/37RH/42RH/46RH

(5) Remove bolts at t achi ng extension housing to
rear support.
(6) Raise transmission slightly wi t h jack stand or
floor jack.
(7) Remove crossmember and rear support as as-
sembly.
(8) Remove extension housing at t achi ng bolts.
(9) Remove access plate and gasket from underside
of extension housing. Pl at e must be removed for ac-
cess to rear beari ng locating ring.
(10) Insert parallel j aw snap ri ng pliers into access
plate opening and spread beari ng locating ri ng (Fig.
16).
(11) Hold snap ri ng in a spread position and work
extension housing off rear bearing.
Fig. 16 Releasing Rear Bearing Locating Ring
(12) Carefully pull extension housing rearward to
move park lock rod past sprag and remove housing.
OUTPUT SHAFT REAR BEARING
REPLACEMENT
(1) Remove snap ri ng t hat ret ai ns rear beari ng on
Fig. 17 Rear Bearing Location
(2) Remove beari ng from output shaft. Note t hat
36RH/37RH transmissions have a second snap ri ng
at front of shaft bearing. 32RH transmissions do not
have t hi s second snap ring.
(3) Install new beari ng on shaft. Be sure locating
ri ng groove in outer circumference of bearing is to-
ward front (Fig. 17).
(4) Install rear beari ng ret ai ni ng snap ri ng (Fig.
16). However, do not install t he locating ri ng on t he
bearing. The locating ri ng goes in t he extension
housing. The ri ng is not seated in t he rear beari ng
unt i l t he housing is installed.
EXTENSION HOUSING BUSHING
REPLACEMENT
(1) Remove housing oil seal wi t h Remover Tool
C-3985 (Fig. 18).
Fig. 18 Removing Extension Housing Seal
(2) On 32RH, remove housing bushi ng with bush-
ing Tool C-4470. On 36RH/37RH, remove bushi ng
wi t h Tool C-4469 (Fig. 19).
(3) On 32RH, slide new bushi ng on installing end
of Tool C-4470. On 36RH/37RH, slide bushi ng on
Tool C-4469 (Fig. 19).
(4) Align bushi ng oil hole with oil slot in extension
housing. Then t ap bushi ng into place (Fig. 19).
(5) Install new seal in housing (Fig. 20). On 32RH
use Seal Installer C-3995. On 36RH/37RH, use Seal
Installer C-3972.
Fig. 19 Extension Housing Bushing Replacement
EXTENSION HOUSING INSTALLATION
(1) Position new gasket on housing. Use petroleum
jelly to hold gasket in place.
(2) Install locating ri ng in extension housing, if re-
moved.
(3) Slide housing onto output shaft.
IN-VEHICLE SERV I CE- 32RH / 38RH / 37RH / 4 2RH / 4 6 RH 21 - 137
S P E C I A L T O O L G O V E R N O R S U P P O R T
A N D P A R K I N G G E A R
R H 7 8
Fig. 20 installing Extension Housing Seal
(4) Work par k rod past sprag and move housing
into place on shaft.
(5) Spread r ear bearing locating ri ng wi t h parallel
j aw snap ring pliers.
(6) Hold locating ri ng in spread position. Then
push housing forward until locating ri ng seats in
beari ng and housing seats agai nst t ransmi ssi on case.
Be sure locating ring is fully seat ed in r ear bearing.
(7) Install and tighten housing at t achi ng bolts to
(8) Install gasket and access pl at e on underside of
housing.
(9) Install crossmember and rear mount assembly.
(10) Remove j ack used to support transmission.
(11) Install and t i ght en housing-to-rear mount
(12) Install speedometer pinion and adapter.
(13) Align and install propeller shaft.
(14) Lower vehicle.
(15) Top off transmission fluid level if necessary.
GOVERNOR AND PARK GEAR SERV I CE32RH /
3SRH/37RH
GOVERNOR AND PARK GEAR REMOVAL
(1) Remove extension housing and output shaft
rear bearing. Refer to procedure in t hi s section.
(2) Carefully remove snap ri ng from weight end of
governor valve shaft (Fig. 21).
(3) Slide governor valve and shaft out of governor
body.
(4) Remove large snap ring from weight end of gover-
nor body and remove governor weight assembly.
(5) Remove snap ring from governor weight and
remove i nner weight and spring from outer weight
(Fig. 21).
(6) Remove snap ring ret ai ni ng governor body and
park gear on output shaft (Fig. 22).
(7) Slide governor body and par k gear assembly off
output shaft.
(8) Remove bolts at t achi ng governor body to gear
and separate body from gear.
(9) Remove filter screen from governor body.
GOVERNOR/PARK GEAR CLEANING AND
INSPECTION
Thoroughly clean all t he governor par t s in a suit-
able cleaning solution but do not use any type of
caustic cleaning agent s.
G O V E R N O R B O D Y
L O C K I N G B O L T S ( 4)
Fig. 21 Governor Snap Ring Locations-
37RH
R H 2 69
-32RH/36RH/
The weights and valves should fall freely in t hei r
bores when clean and dry.
Minor surface scratches and burrs can be removed
wi t h crocus cloth. Inspect t he governor weight spring
for distortion. Replace t he spring, if damaged.
Clean t he filter in solvent and dry it wi t h com-
pressed air. Replace t he filter if damaged.
Inspect t he par k gear for chipped or worn gear
t eet h or damaged ri ng grooves. Replace t he gear, if
damaged.
S P R I N G
O U T E R W E I G H T
SNAP
R I N G S
I N N E R W E I G H T
V A L V E T S H A F T
V A L V E
S N A P
R I N G
F I L T E R S C R E E N
J9221-51
Fig. 22 Governor Components32RH/36RH/37RH
GOVERNOR/PARK GEAR ASSEMBLY AND
INSTALLATION
(1) Assemble governor body, filter screen and park
gear.
21 - 138 IN-VEHICLE SERVSCE-32RH / 36 RH / 37RH / 4 2RH / 4 6 RH
(2) Install and t i ght en gear-to-body bolts finger
tight. Make sure oil passage in governor body aligns
with mat chi ng passage in gear.
(3) Install assembled governor body and gear on
output shaft.
(4) Position governor body so valve shaft hole in
body aligns with mat chi ng hole in output shaft. Then
slide body and park gear into place.
(5) Install snap ring securing governor and park
gear to output shaft (Fig. 22).
(6) Tighten bolts attaching governor body to park
gear to 11 Nm (95 in. lbs.) torque.
(7) Assemble governor weights and spring. Secure
i nner weight and spring in outer weight with snap
ri ng (Fig. 21 ) .
(8) Install weight assembly in governor body and
install ret ai ni ng snap ri ng (Fig. 21).
(9) Place governor valve on valve shaft. Insert shaft
in governor body, through governor weights and output
shaft. Be sure valve is properly seated in body.
(10) Secure valve shaft with small snap ring.
(11) Install output shaft beari ng and extension
housing. Refer to procedure in t hi s section.
GOVERNOR AND PARK LOCK SE RV I CE 4 2RH /
4 6 RH
The governor and park lock components are located
wi t hi n t he overdrive uni t and cannot be serviced in
t he vehicle.
The overdrive unit must be removed and disassem-
bled for access to the governor and park lock compo-
nents.
Refer to t he 42RH/46RH overdrive uni t service sec-
tions for repair procedures.
PARK LOCK SERVICE32RH/ 36 RH/ 37RH
PARK LOCK COMPONENT REMOVAL
(1) Remove extension housing as described in t hi s
section.
(2) Slide sprag shaft out of extension housing and
remove sprag and spring (Fig. 23).
(3) Remove snap ri ng and slide reaction plug and
pin assembly out of housing.
(4) If park rod requires service, it will be necessary
to remove valve body. Refer to Valve Body Service
procedures in t hi s section.
COMPONENT INSPECTION
Inspect t he sprag shaft for scores and free move-
ment in t he housing and sprag. Inspect t he sprag and
control rod springs for distortion and loss of tension.
Inspect t he square lug on t he sprag for broken
edges. Check t he lugs on t he park gear for damage.
Inspect t he ball on t he end of t he control rod for
nicks and burrs. Also be sure t he ball rot at es freely.
J9221-249
Fig. 23 Park Lock Components-32RH/36RH/37RH
PARK LOCK COMPONENT INSTALLATION
(1) Install reaction plug and pin assembly in hous-
ing and secure with new snap ri ng (Fig. 23).
(2) Position sprag and spring in housing and insert
sprag shaft. Be sure square lug on sprag is toward
park gear. Also be sure spring is positioned so it
moves sprag away from gear.
(3) Replace park rod if necessary.
(4) Install extension housing as described in t hi s
section.
VALVE BODY SERVICE
The valve body can be removed for service without
havi ng to remove t he entire transmission assembly.
The valve body can be disassembled for cleaning
and inspection of t he individual components. Refer to
t he procedures in t he Transmission Uni t Subassem-
bly Overhaul section.
The only serviceable valve body components are
the:
manual lever
manual lever washer/seal/E-clip and shaft seal
manual lever detent ball
t hrot t l e lever
fluid filter
overdrive solenoid and connector assembly
switch valve, spring and adjusting screw bracket
converter clutch solenoid
The remai ni ng valve body components are serviced
only as part of a complete valve body assembly.
VALVE BODY REMOVAL
(1) Raise vehicle.
(2) Remove oil pan and drai n fluid.
(3) Loosen clamp bolts and remove throttle and
manual valve levers from manual lever shaft.
(4) Remove park/ neut ral position switch.
(5) Remove filter from valve body.
(6) Disconnect converter clutch solenoid wire from
case connector.

(7) Push solenoid connector out of case.
(8) Remove valve body at t achi ng screws.
(9) Lower valve body enough to remove accumula-
tor piston and piston spring (Fig. 24) .
(10) Pull valve body forward to disengage park rod.
(11) Push manual lever shaft and solenoid case
connector out of transmission case. Lower valve body,
rotate it away from case, pull park rod out of sprag
and remove valve body (Figs. 25 and 26).
ACCUMULATOR OUTER
PISTON SPRING
INNER SEAL
SPRING RINGS J932M87
Fig. 24 Accumulator Piston And Springs (42RH/
46RH Shown)
Fig. 25 Valve Body Assembly4-Speed Transmission
VALVE BODY INSTALLATION
(1) Verify t hat park/ neut ral position switch has
NOT been installed. Valve body cannot be installed
with switch in place. Remove switch if necessary.
(2) Install new seals on accumulator piston and in-
stall piston in case.
(3) Place valve body manual lever in low (1 posi-
tion) to ease installing park rod in sprag.
(4) Use screwdriver to push park sprag into en-
gagement wi t h par k gear. This allows knob on rod to
MANUAL CONVERTER
LEVER CLUTCH
- Fig. 26 Valve Body Assembly3-Speed
Transmission
move past sprag when valve body is installed. Rotate
output shaft to verify sprag engagement.
(5) Position accumulator spring between accumula-
tor piston and valve body.
(6) Position valve body on transmission and work
park rod past sprag. Be sure accumulator piston and
spring remai n in position.
(7) Hold valve body in position and install valve
body at t achi ng screws linger t i ght only.
(8) Install park/ neut ral position switch in case.
(9) Tighten valve body at t achi ng screws alter-
nately and evenly to 11 N
#
(10) Install new fluid filter on valve body. Install
and t i ght en filter screws to 4 N-m (35 in. lbs.) torque.
(11) Connect solenoid wire to case connector.
(12) Install manual and throttle levers on t hrot t l e
lever shaft. Tighten lever clamp screws and check for
free operation. Shaft and levers must operate freely
without any bind.
(13) Install oil pan and new gasket.
(
Ti ght en pan
bolts to 17 Nm (150 in. lbs.) torque.
(14) Connect park/ neut ral position switch and con-
verter clutch solenoid wires.
(15) Install speedometer pinion gear, adapter and
speed sensor.
(16) Lower vehicle.
(17) Fill transmission with Mopar ATF Plus, Type
7176, or Dexron II fluid if ATF Plus is not readily
available.
(18) Adjust gearshift and throttle linkage.
21 140 IN-VEHICLE SERVICE-32RH/36RH/37RH/42RH/46RH

VALVE BODY CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
valve body which are: Line pressure and throttle pres-
sure.
The val ve body mus t be r e move d f r om t he
t r ans mi s s i on i n or de r t o per f or m t he adj ust -
ment s . Ref er t o t he val ve body r emoval / i nst al l a-
t i on pr oc e dur e s i n t hi s sect i on.
Because line and t hrot t l e pressures are interdepen-
dent (each affects shift quality and timing), both ad-
j ust ment s must be performed properly and in t he
correct sequence. Adjust line pressure first and throt-
tle pressure last.
LINE PRESSURE ADJUSTMENT
Measure distance from t he valve body to t he i nner
edge of t he adjusting screw with an accurate steel
scale (Fig. 27).
Distance should be 1-5/16 in. (33.4 mm).
If adjustment is required, t ur n t he adjusting screw
in, or out, to obtain required distance setting.
The 1-5/16 in. (33.4 mm) setting is an approximate
setting only. Because of manufacturing tolerances, it
may be necessary to vary from t hi s dimension to ob-
t ai n desired pressure.
One complete t urn of the adjusting screw changes line
pressure approximately 1-2/3 psi (9 kPa). Turning the
adjusting screw counterclockwise increases pressure
while turning the screw clockwise decreases pressure.
RH258
Fig. 27 Line Pressure Adjustment
THROTTLE PRESSURE ADJUSTMENT
Insert Gauge Tool C-3763 between t he t hrot t l e le-
ver cam and kickdown valve (Fig. 28).
Push t he gauge tool inward to compress t he kick-
down valve agai nst t he spring and bottom t he throt-
tle valve.
Mai nt ai n pressure agai nst kickdown valve spring.
Tur n t hrot t l e lever stop screw unt i l t he screw head
touches t hrot t l e lever t ang and t he throttle lever cam
touches gauge tool.
The ki c kdown val ve spring must be fully com-
pr e s s e d and the ki ckdown val ve compl etel y bot-
tomed to obtai n correct adjustment.
HEX
WRENCH
^ KI CKDOWN y L _
THROTTLE
LEVER
SPECIAL
" TOOL
C-3763
J9121-542
Fig. 28 Throttle Pressure Adjustment
TRANSMISSION COOLER SERVICE
FLUSHING COOLERS AND LINES
If a transmission malfunction contaminates t he
fluid, t he cooler and lines must be reverse flushed
thoroughly. This is necessary to prevent sludge and
particles from flowing back into t he transmission af-
t er repair. The flushing procedure applies to stan-
dard and auxiliary coolers.
Pressure equipment is preferred for cooler reverse
flushing. However, reverse flushing can be performed
with hand operated equipment as follows.
Flushing Procedure
(1) Identify and disconnect cooler pressure and re-
t ur n lines at transmission (Fig. 29).
INLET
FITTING
(RETURN
_ LINE)
COOLER ^
PRESSURE
LINE A N D
HOSE
OUTLET
FITTING
(PRESSURE
LINE)
COOLER
RETURN
LINE
AND
HOSE
J9121-364
Fig. 29 Transmission Cooler Line Identification

(2) Position drai n pan under cooler pressure line to
catch mat eri al flushed through cooler and lines.
(3) Reverse flush cooler using hand operated suc-
tion gun filled with mineral spirits. Insert gun nozzle
(or hose) into cooler return line. Then force mi neral
spirits into line and through cooler.
(4) Continue reverse flushing unt i l fluid exiting
cooler pressure line is clear and free from debris. Re-
pl ace cool er if fluid cannot be pumped through.
(5) Clear flushing mat eri al s from cooler and lines
with short pulses of compressed air. Insert air gun
nozzle into cooler r et ur n line and continue short air
pulses unt i l all fluid is cleared from cooler and lines.
(6) Pump one quart of fresh automatic transmission
fluid through cooler and lines before reconnecting lines.
CHECKING COOLER FLUID FLOW
Cooler flow is checked, by measuri ng t he amount of
fluid pumped t hrough t he cooler in a specified t i me
by t he transmission oil pump.
(1) Disconnect cooler ret urn line from transmission
and place it in one quar t test container.
(2) Add extra quart of fluid to transmission.
(3) Use stopwatch to check test time.
(4) Shift into Neut ral .
(5) St ar t and r un engine at curb idle speed and
note cooler flow. A mi ni mum of one quart (0.9 liter)
of fluid should flow into test container in 20 seconds.
(6) If fluid flow is i nt ermi t t ent , flows less t han one
quart in 20 seconds, or fails to flow at all, cooler is
plugged or damaged and should be replaced.
MAIN COOLER REPLACEMENT
The mai n transmission cooler is located in t he ra-
diator lower t ank. The cooler is not a serviceable
component. If t he cooler is damaged in any way, t he
radi at or will have to be replaced.
AUXILIARY COOLER REPLACEMENT
(1) Remove grille. Also remove A/C condenser for
access if necessary.
(2) Remove brackets securing cooler to radi at or
and radiator support (Fig. 30).
(3) Tag cooler hoses for installation reference.
(4) Position drai n pan under cooler lines.
(5) Loosen cooler connecting hose clamps and dis-
connect hoses.
(6) Remove cooler
(7) Connect cooler to hoses.
(8) Position cooler on radiator and install cooler
support brackets and at t achi ng fasteners.
(9) Tighten cooler hose clamps securely.
(10) Install grille and ai r conditioning condenser, if
removed.
(11) Check and adjust transmission fluid level.
ALUMINUM THREAD REPAIR
Damaged or worn t hreads in t he al umi num t rans-
mission case and in t he valve body can be repaired
with Heli-Coil t hread inserts, or equivalent. Stain-
less steel inserts are preferred.
Essentially, t hread repair consists of drilling out
t he worn or damaged t hreads, t appi ng t he hole with
a special t ap and installing a Heli-Coil, or equivalent
t hread insert into t he tapped hole. This procedure re-
t ur ns t he hole t hreads to original size. Heli-Coil, or
equivalent, tools and inserts are readily available
from most automotive part s suppliers.
CONNECTING HOSE RADIATOR SUPPORT
FAN
SHROUD
PRESSURE LINE
AUXILARY
COOLER
CONNECTING
HOSE
PRESSURE
LINE
HFRONT
Fig. 30 Auxiliary Cooler Mounting
RETURN
LINE J9021-74
!1 - 142 AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION

AUTOM ATI C TRAN SM I SSI ON RE MOW AL AN D I N STALLATI ON
INDEX
page
Dverdrlve Unit Installation 150
Overdrive Unit Re mov al - 4 2 RH / 4 6 RH . . . . . . . . 14 9
Pump Oil Seal 14 6
Starter Ring Gear Replacement 14 4
Torque Converter and Drive Plate Service . . . . . 14 4
Transmission and Torque Converter Installation
2-Wheel Drive 14 6
page
Transmi ssi on and Torque Converter Installation
4 -Wheel Drive . . .' 1 4 8
Transmi ssi on and Torque Converter Removal
2-Wheel Drive 1 4 2
Transmi ssi on and Torque Converter Removal
4 -Wheel Drive 1 4 3
TRANSMISSION AND TORQUE CONVERTER
REMOVAL2-WHEEL DRIVE
Th e transmi ssi on and torque converter shoul d
be removed as an assembl y to avoi d component
damage. The converter drive plate, pump bush-
ing, or oil seal can be damaged if the converter
is left attached to the driveplate during removal.
Be sure to remove the transmi ssi on and con-
verter as an assembl y.
(1) Raise vehicle.
(2) Disconnect or remove exhaust components as
needed for service access.
(3) Remove engine-to-transmission st rut s, if
equipped.
(4) Disconnect fluid cooler lines at transmission.
(5) Remove st art er motor and cooler line bracket.
(6) Remove torque converter bolt access cover.
(7) Remove transmission oil pan, drain fluid and
reinstall pan.
(8) Remove transmission fill t ube bracket bolts and
remove t ube and O-ring from transmission case.
(9) Mark torque converter and drive plate for as-
sembly al i gnment (Fig. 1). Note t hat bolt holes in
crankshaft flange, drive plate and torque converter
all have one offset hole.
(10) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
damper pulley bolt.
(11) Mark propeller shaft and axle yokes for as-
sembly alignment. Then disconnect and remove pro-
peller shaft (Fig. 2).
(12) Disconnect wires from park/ neut ral position
switch and transmission solenoids.
(13) Disconnect gearshift rod and torque shaft as-
sembly from brackets on transmission and frame
rail.
(14) Disconnect t hrot t l e valve rod (or cable) from
transmission t hrot t l e lever.
(15) Disconnect vehicle speed sensor wires.
(16) Support engine with Fi xt ure C-3487-A and
adapters, or a similar tool.
(17) Support t ransmi ssi on with transmission jack.
Fig. 1 Marking Converter And Driveplate For
Alignment Reference
(18) Raise transmission slightly with jack to re-
lieve load on crossmember and insulator.
(19) Remove bolts attaching transmission to insu-
lator and crossmember and remove crossmember and
brackets.
(20) Remove bolts at t achi ng converter housing to
engine block.
(21) Carefully work transmission and converter as-
sembly rearward until clear of engine block dowels
and crankshaft.
(22) Secure converter in housing with small
C-clamp attached to edge of housing.
(23) Lower transmission and remove assembly
from under vehicle.
(24) Remove C-clamp and carefully slide converter
out of pump. Store converter on bench during service
operations. Cover converter hub with tape, card-
board, or paper to prevent dirt entry.

AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION 21 - 143
AXLE
YOKE
PROPELLER
SHAFT
YOKE
U-JOINT RETAINER
RETAINER
BOLT
(170 IN-LBS)
TRANSMI SSI ON
OUTPUT
SHAFT J9021-146
Fig. 2 Propeller Shaft Attachment
REMOVAL4 -WHEEL DRIVE
The transmi ssi on and torque converter shoul d
be removed as an assembl y to avoi d component
damage. The converter drive plate, pump bush-
ing, or oil seal can be damaged if the converter
is left attached to the driveplate duri ng removal .
Be sure to remove the transmi ssi on and con-
verter as an assembl y.
(1) Raise vehicle.
(2) Disconnect or remove exhaust components as
needed for service access.
(3) Remove engine-to-transmission st rut s, if
equipped.
(4) Disconnect fluid cooler lines at transmission.
(5) Remove st art er motor and cooler line bracket.
(6) Remove torque converter access cover.
(7) Remove transmission oil pan, drai n fluid and
reinstall pan.
(8) Remove transmission fill tube bracket bolts and
remove t ube and O-ring from transmission case.
(9) Mark torque converter and drive pl at e for as-
sembly alignment. Note t hat bolt holes in crankshaft
flange, drive plate and torque converter all have one
offset hole.
(10) Rotate crankshaft in clockwise direction unt i l
converter bolts are accessible. Then remove bolts one
at a t i me. Rotate crankshaft using breaker bar and
socket installed on damper pulley bolt.
(11) Mark front/rear propeller shaft and axle yokes
for assembly alignment.
(12) Disconnect and remove both propeller shafts
(Fig. 2).
(13) Disconnect wires from park/ neut ral position
switch and transmission solenoids.
(14 ) Disconnect transmission gearshift rods and
torque shaft assembly from brackets on transmission
and frame rail.
(15) Disconnect t hrot t l e valve cable from t ransmi s-
sion t hrot t l e lever.
(16) Remove transfer case skid plate and skid plate
crossmember (Fig. 3).
(17) Disconnect wires from vehicle speed sensor.
(18) Disconnect necessary vacuum harness hoses.
SKI D
PLATE
CROSSMEMBER
TRANSFER
CASE
SKI D
PLATE
J9121-525
Fig. 3 Skid Plate Mounting
(19) Disconnect transfer case shift lever from
range lever.
mission adapter.
(22) Pull transfer case rearward until clear of
transmission. Lower jack and move transfer case
from under vehicle. Then remove transfer case from
jack and leave on bench unt i l ready for installation.
(24) Remove bolts/nuts at t achi ng transmission in-
sulator plate to rear crossmember (Figs. 4 and 5).
(25) Remove bolts/nuts at t achi ng crossmember and
brackets to frame rails and remove crossmember.
(26) Support engine with Fi xt ure C-3487-A and
adapters, or a jack stand and wood blocks.
(27) Remove bolts at t achi ng converter housing to
engine.
(28) Carefully work transmission-converter assem-
bly rearward until clear of crankshaft and engine
block dowels.
2 1 - 1 4 4 AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION
TRANSMISSION
ADAPTER
BOLT AND
; WASHER (2)
INSULATOR
SPACER (2)
UPPER
INSULATOR (2)
INSULATOR
MOUNTING
PLATE
WITH 7" RAIL
(135 " WHEELBASE)
LOWER
INSULATOR (2)
J9121-532
Fig. 4 Transmission-To-Crossmember Attachment (Except 46RH)
(29) Secure converter in place with small C-clamp
attached to edge of converter housing.
(30) Lower transmission and remove assembly
from under vehicle.
(31) Remove C-clamp securing converter in hous-
ing.
(32) Carefully slide converter out of pump and re-
move it from transmission. Place converter on bench
and cover converter hub with tape, cardboard, or pa-
per to prevent dirt entry.
TORQUE CONVERTER AND DRIVE PLATE SERVICE
After t he transmission has been removed, t he drive
plate and torque converter can be replaced or re-
moved for service access.
The torque converter is not a serviceable part . If
t he converter is contaminated by a transmission mal-
function, or damaged in any way, i t must be replaced
as an assembly. Do not attempt to flush a con-
verter contami nated by metal or cl utch faci ng
particles. Fl ushi ng will not remove these con-
tami nants.
A new torque converter and oil pump are used
in 1993, 42RH transmi ssi ons. The new converter
has a different style drive hub. The hub was
changed to accept the new desi gn drive flats on
the oil pump i nner gear. The drive flats repl ace
the square l ugs used previ ousl y. If converter re-
pl acement shoul d become necessary, be sure to
use the new style converter. The new converter
and oil pump are not i nterchangeabl e wi th pre-
vi ous style parts.
STARTER RING GEAR REPLACEMENT
C A U T I O N : The starter ring gear on st andar d torque
converters can be replaced when necessary. How-
ever, the ring gear on torque converters with a
modul ated converter cl utch, cannot be replaced.
The heat from welding will damage the converter
clutch friction material. Converters with a cl utch
must be replaced a s an assembl y if the ring gear i s
damaged.
RING GEAR REMOWAL
(1) Cut t hrough weld mat eri al at rear side of ri ng
gear with a hack saw or grinding wheel. Be careful
to avoid cutting or grinding into front cover.
(2) Scribe heavy line on front cover next to front
face of ri ng gear. Line is needed to properly locate
new gear on converter.
(3) Support torque converter on front cover with
blocks of wood (Fig. 6) Position blocks adjacent to
converter lugs to avoid altering lug position. The
torque converter must not rest on the front
cover hub duri ng this operation.

AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION 21 - 14 5
I T E M S E T - T O - T O R Q U E SPECIFICATION
() 203 Nm (150 ft. lbs.)
(D 41 N*m (30 ft. lbs.)
m Nm (50 ft. lbs.)
WI TH
7" RAIL
TRANSFER
CASE
Fig. 5 Transmission~To-Cross
(4) Remove ri ng gear wi t h drift and hammer. Tap
downward on gear near welded areas to break any
remai ni ng weld mat eri al (Fig. 6).
(5) Tap around ring gear unt i l it comes off con-
verter.
(6) Smooth weld areas on converter wi t h a mill
file.
Fig. 6 Removing Starter Ring Gear
mber Attachment (With 46RH)
RING GEAR INSTALLATION
(1) Heat and expand new ring gear for installation
on converter. Any of t he following methods are ac-
ceptable:
(a) OVEN: Place gear in oven and set tempera-
t ur e at 200-250 F (93 C) Allow ring gear to re-
mai n in oven for 15 to 20 minutes.
(b) BOILING WATER: Place ri ng gear in shal-
low container. Add wat er and heat for approxi-
mately eight mi nut es after wat er has come to a
boil.
(c) STEAM: Place ring gear on a flat surface and
direct st eam flow around gear for approximately 2
minutes.
(2) After ri ng gear is expanded by heating, imme-
diately place gear in position on converter front
cover.
(3) Quickly t ap gear onto cover evenly with plastic
or rawhide mallet. Continue t appi ng gear unt i l face
of gear is even wi t h scribe line (made duri ng re-
moval) on t he front cover.
(4) Before proceeding, make sure gear is even with
scribed line around full circumference of t he front
cover.
(5) The following recommendations are provided as
an aid to successfully welding a new ring gear to t he
converter.
Do NOT weld wi t h oxy-acetylene equipment
21 - 146 AUTOMATIC TRANSMI SSI ON REMOVAL AND INSTALLATION

Use a D.C. welder set at st rai ght polarity, or use
an A.C. welder if t he proper electrode is available
Use 1/8 inch diameter welding rod and a welding
current of 80 to 125 amps.
Direct arc at intersection of gear and front cover at
an angle of 45 from rear face of gear.
( 6 ) Weld new ri ng gear to torque converter front
cover. Take care to place same amount of weld mat e-
rial (or as nearly as possible) in original weld loca-
tions. This is essential in mai nt ai ni ng converter
balance. Position welds al t ernat el y on opposite sides
of converter and ri ng gear to minimize distortion.
(7) Inspect gear t eet h and remove any nicks, raised
metal, weld spatter, or rough surfaces.
PUMP OIL SEAL
Seal Removal
On 32RH/42RH pumps, remove t he seal with Spe-
cial Tool C-3981B (Fig. 7).
On 36RH/37RH/46RH pumps, remove t he seal wi t h
Special Tool C-3861 (Fig. 8).
To use t he remover tool, First st art t he tool into
t he seal by hand. Next, t hread t he tool into t he seal
as far as it will go. Use a wrench on t he tool hex to
t ur n t he tool. Continue t i ght eni ng unt i l all t he tool
t hreads firmly grip t he met al part of t he seal. Then
t i ght en t he tool puller screw to wi t hdraw t he seal
from t he pump body.
Fig. 7 Pump Seal Removal42RH
Fig. 8 Pump Seal Removal46RH
Seal Installation
On 32RH/42RH pumps, use Installer Tool C-4193
to install t he new seal (Fig. 9).
On 36RH/37RH/46RH pumps, use Installer Tool
C-3860-A (Fig. 9).
To use t he tool, place t he seal in t he pump opening
with t he seal lip facing inward. Then t ap t he seal
into place with t he installer tool (Fig. 9). Tool Han-
dle C-4171 may be used with t he installer tool if de-
sired.
J 932 M 80
Fig. 9 Pump Seal Installation
INSTALLATION2-WHEEL DRIVE
(1) Mount transmission on jack. Secure t ransmi s-
sion with safety chains.
(2) Check converter hub and hub drive notches for
sharp edges, burrs, scratches, or nicks. Polish hub
and notches with 400 grit wet/dry paper or crocus
cloth if necessary. Hub surface must be smooth to
avoid damagi ng pump seal at installation.
(3) Lubricate converter drive hub and pump seal
lip with transmission fluid.
(4) Install converter in oil pump.
(5) Verify t hat converter is fully seated. Use
st rai ght edge and steel rul er to check seating (Fig.
10). Surface of converter lugs should be approxi-
mately 13 mm (1/2 in.) to rear of st rai ght edge when
converter is fully seated.
(6) Temporarily secure converter with C-clamp at-
tached to housing or with met al st rap attached
across converter housing.
(7) Mount transmission on jack and secure it with
safety chains.
(8) Check condition of converter driveplate. Re-
place plate if cracked, distorted or damaged. If
dr i vepl at e repl acement was necessary, be sure
transmi ssi on dowel pi ns are seated in engi ne
bl ock and protrude far enough to hel d transmis-
si on in alignment.
(9) Raise transmission and align converter with
crankshaft and drive plate.

AUTOMATIC TRANSMI SSI ON REMOVAL AND INSTALLATION 21 - 147
Fig. 10 Checking Torque Converter Seating
(10) Move t ransmi ssi on forward. Then raise, lower
or tilt transmission to align converter housing with
dowels in engine block.
(11) Rotate converter unt i l alignment mar k scribed
on converter is aligned wi t h mar k on driveplate. Off-
set holes in plate are next to 1/8 in. hole in inner cir-
cle of plate (Fig. 1).
(12) Carefully work transmission forward until
converter hub is seated.
(13) Install bolts at t achi ng converter housing to
engine block.
(14) Install crossmember and brackets.
(15) Lower transmission onto crossmember and in-
sulator. Then install bolts at t achi ng transmission
mount to crossmember.
(16) Remove fixture used to support engine.
(17) Connect wires to vehicle speed sensor.
(18) Install new plastic ret ai ner grommet on any
shift linkage rod or lever t hat was disconnected. Old
grommets should not be reused. Use pry tool to re-
move rod from grommet and cut away old grommet.
Use pliers to snap new grommet into lever and to
snap rod into grommet.
(19) Connect gearshift linkage and transmission
throttle cable to levers on manual valve shaft.
(20) Connect wires to park/ neut ral position switch,
transmission solenoid(s) and oxygen sensor. Be sure
transmission harnesses are properly routed (Figs. 11
and 12).
C A U T I O N : It i s essenti al that correct length bol ts be
used to attach the converter to the driveplate. Bol t s
that are too l ong will damage the clutch surface in
the converter. If new bol ts are required, use the
bol ts speci fi ed in thi s procedure and in the parts
book onl y.
SENSOR
NEUTRAL START AND
BACKUP LAMP SWITCH
J9021-76
Fig. 11 Transmission Wire Routing32RH/36RH
ENGINE
J9021-75
Fig. 12 Transmission Wire Routing42RH/46RH
(21) Verify converter bolt length. Bolt measure-
ment is from bottom (underside) of bolt head to end
of bolt t hreads.
On 9.5 in., 3-lug converter, bolts should be 0.46 in.
(11.7 mm) long.

I T E M T O R Q U E
A 2 7- 5 4 N-m ( 2 0 - 40 ft. lbs.)
B
9- 14 N - m (80-120 in. lbs.)
C 3- 6 N - m ( 30 - 5 0 in. lbs.)
D 47- 88 N - m ( 35 - 65 ft. lbs.)
E 14- 20 N - m ( 12 5 - 175 in. lbs.)
PLATE
FILL
TUBE
BRACKET
TRANSMISSION
DIPSTICK
DAMPER
WEIGHT
STRUT
DUST
COVER
J9321-232
Fig. 13 Transmission And Fill Tube Attachment
3-lug converter, t i ght en
4-lug converter, t i ght en
On 9.5 in., 4-lug converter, bolts should be 0.52 in.
(13.2 mm) long.
On 10.75 in., 4-lug converter, bolts should be 0.44
in. (11.2 mm) long.
(22) Install torque converter at t achi ng bolts.
Tighten bolts as follows:
On models wi t h 9.5 in.,
bolts to 54 Nnn (40 ft. lbs.)
On models with 9.5 in.,
bolts to 74 Nnn (55 ft. lbs.)
On models with 10.75 in., 4-lug converter, t i ght en
bolts to 31 Nnn (270 in. lbs.)
On diesel models, t i ght en converter bolts to 47
Nnn (35 ft. lbs.) torque
(23) Install converter housing dust cover.
(24) Install st art er motor and cooler line bracket.
(25) Connect cooler lines to transmission.
(26) Install transmission fill t ube (Fig. 13). Install
new O-ring seal on t ube before installation.
(27) Install any exhaust components t hat were re-
moved, or moved for service access.
(28) Align and install propeller shaft. Tighten
shaft U-joint clamp bolts to 19 Nnn (170 in. lbs.)
torque.
(29) Lower vehicle.
(30) Fill transmission wi t h Mopar ATF Plus, Type
7176, or Mopar Dexron II if ATF Pl us is not readily
available.
(31) Check and adjust gearshift and t hrot t l e valve
linkage if necessary.
TRANSMI SSI ON AND TORQUE CONVERTER
INSTALLATION4-WHEEL DRIVE
C A U T I O N : The t r ansmi ssi on cooler and lines must
be f l ushed if repair corrected a probl em that gener-
ated sl udge, metal particles, or clutch friction mate-
rial. The torque converter shoul d also be replaced
when contami nated by a mal functi on. The t ransmi s-
si on, fluid and converter will be contami nated agai n
if resi due/ debri s i s not fl ushed from the cooler and
lines beforehand.
(1) Check torque converter hub and hub drive
notches for sharp edges burrs, scratches, or nicks.
Polish hub and notches with 400 grit paper or crocus
cloth if necessary. Hub must be smooth to avoid dam-
aging pump seal during installation.
(2) Lubricate converter hub and pump seal lip with
transmission fluid.
(3) Position converter hub so drive slots will be
aligned with pump gears. Then carefully insert con-
vert er hub into pump and gears.
(4) Verify t hat converter is fully seated. Use
st rai ght edge and steel ruler to check seating (Fig.

AUTOMATIC TRANSMI SSI ON REMOVAL AND INSTALLATION 21 - 149
10). Surface of converter lugs should be approxi-
mately 13 mm (1/2 in.) to rear of straight edge when
converter is fully seated.
(5) Temporarily secure converter in pump and
housing with C-clamp attached to housing edge, or
with metal strap attached across converter housing.
(6) Position transmission on jack. Secure transmis-
sion to jack with safety chains.
(7) Check condition of converter driveplate. Re-
place plate if cracked, distorted or damaged. If
driveplate repl acement was necessary, be sure
transmi ssi on dowel pi ns are seated i n engi ne
block and protrude far enough to hel d transmis-
sion i n alignment.
(8) Coat pilot hub of torque converter with trans-
mission fluid.
(9) Raise transmission and align converter with
drive plate and crankshaft.
(10) Move transmission forward. Then raise, lower
or tilt transmission to align converter housing with
dowels on engine block.
(11) Rotate converter to align marks scribed on
converter and driveplate. Offset holes in plate are
next to 1/8 in. hole in inner circle of plate (Fig. 1).
(12) Carefully work transmission forward and over
engine block dowels until converter hub is seated in
crankshaft.
(13) Install bolts attaching converter housing to
engine.
(14) Install crossmember.
(15) Lower transmission onto crossmember and in-
stall bolts attaching transmission and insulator to
crossmember (Figs. 4 and 5).
(16) Remove fixture used to support engine.
(17) Connect vehicle speed sensor wires.
(18) Install new plastic retainer grommet on any
shift linkage rod or lever that was disconnected. Old
grommets should not be reused. Use pry tool to re-
move rod from grommet and cut away old grommet.
Use pliers to snap new grommet into lever and to
snap rod into grommet.
(19) Connect gearshift and throttle linkage to
transmission.
(20) Connect wires to park/neutral position switch,
transmission solenoids and to oxygen sensor. Be sure
transmission harnesses are properly routed.
C A U T I O N : It i s essenti al that correct length bol ts be
used to attach the converter to the driveplate. Bol t s
that are too long will damage the cl utch surface in
the converter. If new bol ts are required, use the
bol ts speci fi ed in thi s procedure and in the parts
book onl y.
(21) Verify converter bolt length. Bolt measure-
ment is from bottom (underside) of bolt head to end
of bolt threads.
mm (0.46 in.) long.
mm (0.52 in.) long.
mm (0.52 in.) long.
mm (0.44 in.) long.
(22) Install torque converter bolts. Tighten bolts as
follows:
On models with 9.5 in., 3-lug converter, tighten
bolts to 54 Nnn (40 ft. lbs.).
bolts to 74 Nnn (55 ft. lbs.).
bolts to 31 Nnn (270 in. lbs.).
On diesel models with 12.2 in. converter, tighten
(23) Install converter housing access cover.
(24) Install starter motor and cooler line bracket.
(25) Connect cooler lines to transmission.
(26) Install transmission fill tube. Install new
O-ring seal on tube before installation.
(27) Install any exhaust components removed for
service access.
(28) Support transfer case on transmission jack.
(29) Install gasket on transmission adapter. Coat
gasket with Mopar perfect, seal, or silicone sealer be-
forehand.
(30) Install transfer case on transmission. Tighten
transfer case attaching nuts to 47 Nnn (35 ft. lbs.)
torque.
(31) Remove jack supporting transfer case.
(32) Connect transfer case shift lever to range le-
ver.
(33) Align and install propeller shafts. Tighten
clamp bolts to 19 Nnn 170 in. lbs.) torque.
(34) Install transfer case skid plate and crossmem-
ber.
(35) Lower vehicle.
(36) Fill transmission with Mopar ATF Plus, Type
7176, or Mopar Dexron II if ATF Plus is not readily
available.
(37) Check and adjust gearshift, throttle valve and
transfer case shift linkages if necessary.
OVERDRIVE UNIT REMOVAL42RH/46RH
The following removal and installation procedures
apply to the 42RH/46RH overdrive unit only. If the
complete transmission assembly must be removed,
refer to the Transmission And Converter Removal
and Installation procedures.
(1) Shift transmission into Park.
(2) Raise vehicle.

(3) Remove transmission oil pan, remove gasket,
drain oil and reinstall pan.
(4) If overdrive uni t had malfunctioned, or if fluid
is contaminated, remove entire transmission. If diag-
nosis indicated overdrive clutch or governor problems
only, remove overdrive uni t only.
(5) Mark propeller shaft universal joint and axle
pinion yoke for alignment reference at installation
(Fig. 14). On 4WD models, mar k both shafts for ref-
erence.
Fig. 14 Marking Propeller Shaft And Axle Yoke For
Alignment Reference
(6) Disconnect and remove propeller shaft. On
4WD models, remove both shafts.
(7) On 4WD models, disconnect transfer case shift
linkage and distance sensor and remove transfer
case.
(10) Remove vehicle speed sensor and speedometer
adapter.
(11) Remove bolts at t achi ng overdrive uni t to
transmission (Fig. 15).
C A U T I O N : S upport the overdrive unit with a jack
before movi ng it rearward. T hi s i s necessary to pre-
vent damagi ng the intermediate shaft. D o not allow
the shaft to support the entire wei ght of the over-
drive unit.
(12) Work overdrive uni t rearward and off t rans-
mission i nt ermedi at e shaft.
(a) If overdrive uni t does not require service, in-
sert Tool 6227-2 in overdrive uni t overrunning
clutch and pl anet ary gear to mai nt ai n spline align-
ment . If cl utch and gear spl i nes rotate out of
alignment, overdri ve unit will have to be disas-
sembl ed in order to real i gn spl i nes.
(b) If overdrive uni t does requires service, refer
to Overdrive uni t Overhaul section.
Fig. 15 Removing/Installing Overdrive Attaching
Bolts
(13) Remove and ret ai n overdrive piston t hr ust
bearing. Bearing may remai n on piston or in clutch
hub duri ng removal.
(14) Position drain pan on workbench.
(15) Place overdrive uni t over drain pan. Tilt uni t
to drai n residual fluid from case.
(16) Exami ne fluid for clutch mat eri al or met al
fragments. If fluid contains these items, overhaul
will be necessary.
OVERDRIVE UNIT INSTALLATION
(1) Be sure Alignment Tool 6227-2 is fully seated
in overdrive pl anet ary and overrunning clutch
splines before moving unit.
(2) If overdrive piston ret ai ner was not removed
duri ng service and original case gasket is in good
condition, proceed to step (6). However, if original
case gasket is not reusable, t ri m and install replace-
ment gasket as described in steps (3) t hrough (5).
(3) Cut out old case gasket around piston ret ai ner
wi t h razor knife (Fig. 16).
(4) Use old gasket as t empl at e and t ri m new gas-
ket to fit.
(5) Position new gasket over piston ret ai ner and on
transmission case. Use petroleum jelly to hold gasket
in place if necessary. Do not use any type of seal er
to secure gasket. Use petrol eum jelly only.
(6) Install selective spacer on intermediate shaft if
removed. Spacer goes in groove j ust rearward of shaft
rear splines (Fig. 17).
(7) Install overdrive piston in ret ai ner if removed.
Lubricate piston seals with Ru-Glyde, Door-Eze or
petroleum jelly to ease installation. Be sure piston lo-
cat i ng lugs are aligned in piston retainer.
(8) Install t hr ust beari ng in overdrive uni t sliding
hub. Use petroleum jelly to hold beari ng in position.
C A U T I O N : Be sure the shoul der on the i nsi de di am-
eter of the bearing i s faci ng forward.

AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION 21 - 151
Fig. 17 Intermediate Shaft Selective Spacer Location
(9) Raise overdrive uni t on transmission jack and
align it with i nt ermedi at e shaft.
(10) Carefully remove Alignment Tool 6227-2 from
overdrive compounder.
(11) Slide overdrive uni t st rai ght onto i nt ermedi -
at e shaft. Be sure park rod goes into park lock reac-
tion plug at same time.
C A U T I O N : D o not tilt or jounce the overdrive unit
duri ng installation. T hi s coul d cause the overdrive
planetary and overrunni ng clutch spl i nes to rotate
out of al i gnment. If the spl i nes rotate out of al i gn-
ment, it will be necessary to di sassembl e the over-
drive unit to realign the spl i nes with Tool 6227-2.
(12) Align slip-fit governor tubes in piston ret ai ner
and work compounder uni t forward on i nt ermedi at e
shaft and seat uni t agai nst transmission case.
(13) Install bolts at t achi ng overdrive uni t to t rans-
mission. Ti ght en bolts in diagonal pat t ern to 34 Nm
(25 ft-lbs).
(14) Inst al l crossmember.
(15) On 4WD models, install transfer case and con-
nect shift linkage and distance sensor.
(16) Inst al l speedometer adapter and vehicle speed
sensor. Be sure to index adapter.
(17) Connect vehicle speed sensor and overdrive so-
lenoid wires.
(18) Align and install propeller shaft, or shafts on
4WD models.
(19) If valve body was also removed, adjust bands,
install valve body and install transmission oil pan
and gasket.
(20) Lower vehicle and refill transmission wi t h
Mopar ATF Plus, Type 7176. Use Mopar Dexron II if
ATF Plus is not readily available.
21 - 152 TRANSMISSION OVERHAUL32RH

T RA N S M I S S I ON OW E RH A UL 3 2 RH
INDEX
page
Ex tension H ousi ng and Park Lock Component
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 0
Front Clutch Overhaul 1 6 5
Front Ser vo and Band Overhaul 1 75
Governor and Park Gear Overhaul 16 0
Oil Pump and Reaction Shaft Support Overhaul . 1 6 2
Overhaul Service Information 158
Overrunning CI utchLow- Reverse DrumRear
(1) Clean transmission exterior with steam gun or
with solvent. Wear eye protection duri ng cleaning
process.
(2) Remove t hrot t l e and shift levers from valve
body manual shaft and t hrot t l e lever shaft.
(3) Mount t ransmi ssi on in repair st and C-3750-B
or similar type st and (Fig. 1).
Fig. 1 Transmission Mounted On Repair Stand
(4 ) Remove bolts at t achi ng extension housing to
transmission case. Then remove rear beari ng locat-
ing ri ng access cover from housing (Fig. 2)
(5) Spread r ear beari ng locating ri ng wi t h parallel
j aw snap ri ng pliers (Fig. 2). Then work extension
housing off rear beari ng and output shaft. Remove
housing gasket after removing housing.
(6 ) Remove r ear beari ng and snap ri ng from out-
put shaft (Fig. 3).
page
Support Overhaul 1 58
Planetary Gear Tr ai n- Out put Shaft Overhaul . . 171
Rear Clutch Overhaul 1 6 8
Rear Servo and Band Overhaul . . . . . . . . . . . . . 1 75
Transmi ssi on Assembl y and Adjustment . . . . . . 184
Transmi ssi on Cas e Cleaning and Inspection . . . 1 58
Transmi ssi on Di sassembl y 1 52
V al ve Body Service and Adjustment . . . . . . . . . 1 76
Fig. 2 Extension Housing Removal32RH
Fig. 3 Output Shaft Rear Bearing Position32RH
(7) Remove oil pan bolts and remove pan and gas-
ket.
(8) Remove park/ neut ral position switch and seal
(Fig. 4 ) .
(9) Remove hex head valve body at t achi ng bolts
(Fig. 5).
(10) Disconnect solenoid wire from case connector
(Fig. 6).
(11) Lift valve body upward, guide park rod out of
case opening and remove valve body (Fig. 5).
(12) Remove accumulator spring and piston (Fig.
8).

Fig. 4 Park/Neutral Position Switch Removal/
Installation
Fig. 5 Valve Body Attaching Bolt Locations32RH
Fig. 6 Solenoid Wire Connection32RH
(13) Remove front band reaction pin access plug
(Fig. 9). Pl ug is accessible t hrough converter hous-
ing. Use 1/4 inch drive extension to remove plug as
shown.
(14) Loosen front band adjusting screw locknut 4-5
t urns. Then t i ght en band adjusting screw until band
is t i ght around front clutch ret ai ner. This prevents
front/rear clutches from coming out with pump and
possibly damagi ng clutch or pump components.
TRANSMISSION OVERHAUL32RH 2 1 - 1 1 3
Fig. 7 Removing/Installing Valve Body32RH
Fig. 8 Removing/Installing Accumulator Piston And
Spring32RH
Fig. 9 Removing/Installing Front Band Reaction Pin
Access Plug32RH
(15) Remove oil pump bolts.
(16) Thread bolts of Slide Hammer Tools C-3752
into t hreaded holes in pump body flange (Fig. 10).
(17) Bump slide hammer weights outward to re-
move pump and reaction shaft support assembly from
case (Fig. 10).
(18) Loosen front band adjusting screw unt i l band
is completely loose.
VALVE

Fig. 10 Removing Oil Pump/Reaction Shaft Support
Assembly32 RH
(19) Squeeze front band together and remove band
st rut (Fig. 11).
Fig. 11 Removing/Installing Front Band Strut32RH
(20) Remove front band reaction pin with pencil
magnet. Pi n is accessible from converter housing side
of case (Fig. 12).
Fig. 12 Removing Front Band Reaction Pin32RH
(21) Remove front band lever (Fig. 13)
Fig. 13 Removing/Installing Front Band
Lever32RH
(22) Slide front band rearward and onto driving
shell. Band will not be removed unt i l after front/rear
clutch removal.
(23) Remove front and rear clutch uni t s as assem-
bly. Grasp i nput shaft, hold clutch uni t s together and
remove t hem from case (Fig. 14).
J9121-124
Fig. 14 Removing Front/Rear Clutch
Assemblies32RH
(24) Lift front clutch off rear clutch (Fig. 15). Set
clutch uni t s aside for overhaul.
(25) Remove output shaft t hr ust washer from out-
put shaft (or from rear clutch hub).
(26) Remove output shaft t hr ust plate from output
shaft hub (Fig. 16).
TRANSMISSION OVERHAUL32RH 21 - 115
FRONT
CLUTCH
REAR
CLUTCH
J9121-125
Fig. 15 Separating Front/Rear Clutch
Assemblies32 RH
OUTPUT
SHAFT
HUB
OUTPUT
SHAFT
THRUST
PLATE
J9121-126
Fig. 16 Removing/Installing Output Shaft Thrust
Plate-32RH
(27) Slide front band off driving shell (Fig. 17) and
remove band from case.
(28) Remove governor body snap ring (Fig. 18).
(29) Remove E-clip from one end of governor valve
shaft and remove valve and shaft from governor body
(Fig. 19). Reinstall E-clip on shaft to avoid losing it.
(30) Loosen bolts at t achi ng governor body to park
gear.
(31) Mark position of governor body on park gear
with center punch or scriber.
(32) Remove governor body and park gear as as-
sembly (Fig. 20). Work park gear out of rear support
and slide assembly off output shaft.
^ DRIVING
SHELL
J9121-127
Fig. 17 Front Band Removal/Installation32RH
GOVERNOR
BODY
SNAP
RING
PARK
GEAR
Fig. 18 Removing/Installing Governor Body Snap
Ring-32RH
E-CLIP (2 REQ'D)
GOVERNOR
VALVE
V SHAFT
Fig. 19 Removing Governor Valve And Shaft32RH
GOVERNOR/PARK GEAR ASSEMBLY GOVERNOR
Fig. 20 Removing/Installing Governor And Park
Gear32RH
(33) Remove pl anet ary geart rai n as assembly (Fig.
21). Support geart rai n with both hands duri ng re-
moval. Do not allow machined surfaces on output
shaft to become nicked or scratched.
Fig. 21 Planetary Geartrain Removal32RH
(34) Loosen rear band adjusting screw 4-5 t ur ns.
(35) Remove snap ri ng t hat secures low-reverse
drum to rear support hub, however do not remove
drum at this t i me (Fig. 22).
(36) Remove rear band upper and lower reaction
pins with parallel j aw snap ri ng pliers (Fig. 23).
Spread plier j aws in pin bore to grip pin. Then twist
and pull pins to remove t hem as shown.
(37) Remove rear band lever and st rut .
(38) Mark position of rear support for assembly
reference (Fig. 24). Use scriber or center punch to
mar k case and support.
(39) Remove rear support bolts and remove support
from low-reverse drum and case (Fig. 25). Keep r ear
Fig. 23 Removing Rear Band Reaction Pins32RH
support bolts together for assembly reference.
(40) Remove bolts at t achi ng overrunning clutch
cam to case (Fig. 26).
(41) Remove low-reverse drum and overrunning
clutch as assembly. Slide drum and clutch t hrough
rear band and out of case. Set drum and clutch as-
sembly aside for cleaning and inspection.
(42) Remove rear band from case.
(43) Compress front servo rod guide about 1/8 in.
wi t h valve spring compressor tool C-3422-B (Fig. 27).
A C-clamp and tool C-4470 can also be used to com-
press rod guide.

Fig. 24 Marking 32RH Rear Support For Assembly
Reference
Fig. 26 Overrunning Clutch Cam Bolt
Locations32RH
(44) Remove front servo rod guide snap ri ng (Fig.
27). Excer ci s e caut i on wh e n r emovi ng s n a p r i ng.
Ser vo bor e c a n be s c r a t c he d or ni cked if c a r e i s
not excer ci sed.
(45) Remove compressor tools and remove front
servo rod guide, spring and servo piston.
Fig. 27 Compressing Front Servo Rod Guide32RH
(46) Compress rear servo spring ret ai ner about
1/16 in. wi t h C-clamp and Tool C-4470 or SP-5560
(Fig. 28). Valve Spring Compressor C-3422-A can
also be used to compress spring retainer.
(47) Remove rear servo spring ret ai ner snap ring.
Then remove compressor tools and remove rear servo
spring and piston.
Fig. 28 Compressing Rear Servo Spring32RH
21 - 158 TRANSMI SSI ON OVERHAUL32RH

OVERHAUL SERVICE INFORMATION
Inspect all t he transmission bushings during over-
haul . Bushi ng condition is important as worn, scored
bushings contribute to low pressures, clutch slip and
accelerated wear of other components. Do not replace
bushings as a mat t er of course. Replace bushings
only when actually worn or scored.
Use recommended tools to replace bushings. The
tools are sized and designed to remove, install and
seat bushi ngs correctly, The bushing replacement
tools are included in Bushing Tool Set C-3887-B. The
tool set is manufactured by t he Miller Tool Co. and is
available t hrough t he dealer tool program.
Pre-sized service bushings are available for re-
placement purposes. Only t he sun gear bushings are
not serviced. Low cost of t he sun gear assembly
makes it easier to simply replace t he gear and bush-
ings as an assembly.
Heli-Coil inserts are recommended for repai ri ng
damaged, stripped or worn t hreads in al umi num
part s. These inserts are available from most automo-
tive jobbers. Stainless steel inserts are preferred.
The use of crocus cloth is permissible where neces-
sary, providing it is used carefully. When used on
valves, use extreme care to avoid rounding off sharp
edges. Sharp edges are vital as they prevent foreign
mat t er from getting between t he valve and valve
bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings duri ng overhaul. Replace these part s as a
mat t er of course. Also do not reuse snap rings or
E-clips t hat are bent or distorted. Replace these part s
as well.
Lubricate transmission part s with Mopar ATF
Plus, Type 7176, or Dexron II transmission fluid
during overhaul and assembly.
Use Ru-Glyde or Door Eze to lubricate clutch pis-
ton seals. Use petroleum jelly to lubricate O-rings
and t hr ust washers. Petroleum jelly can also be used
to hold part s in place during reassembly.
TRANSMISSION CASE CLEAN1N8 AND
INSPECTION
Clean t he case in a solvent t ank. Fl ush t he case
bores and fluid passages thoroughly with solvent.
Dry t he case and all fluid passages with compressed
air. Be sure all solvent is removed from t he case and
t hat all fluid passages are clear.
Do not us e s hop t owel s or r a gs to dr y t he cas e
(or a ny ot he r t r ans mi s s i on component ) unl es s
t hey a r e ma d e f r om l i nt -free mat er i al s . Li nt wi l l
r eadi l y a d h e r e t o cas e sur f aces a n d t r ans mi s s i on
c ompone nt s a n d wi l l ci r cul at e t hr oughout t he
t r ans mi s s i on aft er as s embl y. A suffi ci ent qua n-
t i t y of l i nt c a n bl ock fluid pa s s a ge s a n d i nt er f er e
wi t h val ve body oper at i on.
Inspect t he case for cracks, porous spots, worn
bores, or damaged t hreads. Damaged t hreads can be
repaired with Helicoil t hread inserts. However, t he
case will have to be replaced if it exhibits any type of
damage or wear.
Lubricate t he front band adjusting screw t hreads
with petroleum jelly and t hread t he screw part-way
into t he case. Be sure t he screw t ur ns freely.
Remount t he case in Repair St and C-3750-B after
cleaning and inspection.
OVERRUNNING CLUTCH - LOW- RE V E RSE
D RUM - RE AR SUPPORT OVERHAUL
DISASSEMBLING OVERRUNNING CLUTCH/
LOW-REVERSE DRUM
If t he clutch assembly came out wi t h t he low-re-
verse drum, t hread two clutch cam bolts into t he
cam. Then lift t he cam out of t he drum with t he bolts
(Fig. 29) . Rotate t he cam back and forth to ease re-
moval if necessary. Remove t he clutch roller and
spring assembly from t he race afterward.
Fig, 29 Removing Overrunning Clutch From Low-
Reverse Drum32RH
Clean t he overrunning clutch assembly, clutch
cam, low-reverse drum and rear support in solvent.
Dry t hem with compressed air after cleaning.
Inspect condition of each clutch part after cleaning.
Replace t he overrunning clutch roller and spring as-
sembly if any rollers or springs are worn or dam-
aged, or if t he roller cage is distorted, or damaged.
Replace t he cam if worn, cracked or damaged.
Replace t he low-reverse drum if t he clutch race,
roller surface or inside diameter is scored, worn or
damaged. Do not r emove t he cl ut ch r a c e from t he
l ow- r ever s e d r u m u n d e r a ny ci r cums t ances . Re-
pl ace t he d r u m a nd r a c e as a n as s embl y if ei t her
c ompone nt is da ma ge d.
Exami ne t he rear support carefully for wear,
cracks, scoring or other damage. Be sure t he support
hub is a snug fit in t he case and drum. Replace t he
support if worn or damaged.

ASSEMBLING OVERRUNNING CLUTCH/LOW*
REVERSE DRUM
(1) Assemble clutch rollers and springs in ret ai ner
if necessary (Fig. 30).
RETAINER
J9121-139
Fig. 30 Overrunning Clutch Rollers, Springs,
Retainer32RH
(2) Install overrunning clutch roller, spring and re-
t ai ner assembly in clutch cam (Fig. 31).
CLUTCH
ROLLER
ASSEMBLY
CLUTCH CAM
J9121-138
Fig. 31 Assembling Overrunning Clutch And
Cam-32RH
(3) Temporarily assemble and check overrunni ng
clutch operation as follows:
(a) Assemble cam and clutch.
(b) Install clutch assembly on low-reverse drum
with twisting motion (Fig. 32).
(c) Install drum-clutch assembly in case and in-
stall clutch cam bolts.
(d) Install rear support and support at t achi ng
bolts.
(e) Check low-reverse drum rotation. Drum
shoul d rotate freely in cl ockwi se direction and
lock when turned in countercl ockwi se direc-
tion (as vi ewed from front of case).
LOW-REVERSE ^ /
DRUM
CLUTCH
RACE (ON
HUB OF DRUM)
OVERRUNNING
CLUTCH
J9121-135
Fig. 32 Temporary Assemby Of Clutch And Drum To
Check Operation32RH
(4) Note component position for assembly refer-
ence. Bolt holes in clutch cam are countersunk on
one side, Be sure t hi s side of cam will face rearward
when installed (Fig. 33).
(5) Remove rear support, overrunning clutch and
low-reverse drum. Set components aside for final as-
sembly. If overrunni ng clutch will be i nstal l ed
LOW-REVERSE DRUM
OVERRUNNING
CLUTCH
CAM
ROLLER
AND
SPRING ASSEMBLY
CLUTCH
RACE
HUB OF
LOW-REVERSE
DRUM
J9121-140
Fig. 33 Assembled Overrunning Clutch
Components32RH
2 1 - 1 6 0 TRANSMISSION OVERHAUL32RH

bef or e final as s embl y, i nst al l c a m onl y a s de-
s cr i bed i n Tr ans mi s s i on As s embl y And Adj ust -
me nt sect i on. Cl ut ch c a m mus t be pr ope r l y
i ndexed i n cas e t o fit a n d ope r a t e pr oper l y.
EXTENSION HOUSING AND PARK LOCK
COMPONENT OVERHAUL
Clean t he housing and park lock components in
solvent and dry t hem with compressed air.
Inspect t he housing bushing, seal and beari ng snap
ri ng (Fig. 34). Replace t he bushi ng if scored, worn or
damaged. Replace t he seal if cut, torn or distorted.
Replace t he snap ri ng if distorted or broken.
BEARING
SNAP EXTENSION
RING HOUSI NG BUSHING
J9121-250
Fig. 34 Extension Housing Components32RH
Exami ne t he park lock components in t he housing.
If replacement is necessary, remove t he shaft with
parallel j aw snap ri ng pliers (Fig. 35) and remove t he
sprag and spring. Then remove t he spring clip and
reaction plug (Fig. 36).
Compress the reacti on pl ug spri ng clip onl y
enough to remove or install it. The clip is easi l y
distorted if overcompressed. Repl ace the clip if
it becomes bent or distorted. Do not strai ghten
and reuse the clip if this occurs.
Be sure a replacement sprag is installed so t he
sprag locking lug will face t he park gear (Fig. 37).
Also be sure t he spring is correctly positioned as
shown (Fig. 37). The sprag may not ret ract if t he
spring is improperly installed.
GOVERNOR AND PARK GEAR OVERHAUL
GOVERNOR/PARK GEAR DISASSEMBLY
(1) Loosen bolts at t achi ng governor to park gear.
(2) Remove governor snap ri ng and locating snap
ri ng from output shaft (Fig. 38).
(3) Remove E-clip securing governor valve shaft
and remove shaft and valve from governor body.
(4) Slide governor and park gear off output shaft.
(5) Remove governor ret ai ni ng bolts and separat e
governor from park gear.
(6) Remove governor filter from park gear. Keep
filter with governor body.
Fig. 35 Park Sprag, Shaft And Spring
Removal32RH
Fig. 36 Park Sprag Reaction Plug And Spring
Location32RH
(7) Remove governor weight snap ri ng and remove
weight assembly from governor body. Remove i nner
snap ri ng and separat e governor weights.
GOVERNOR/PARK GEAR CLEANING AND
INSPECTION
Clean t he governor and park gear components in

J9121-47
Fig. 37 Correct Position Of Sprag And
Spring32RH
Exami ne t he governor components carefully (Fig.
38). Discard any snap rings or E-clips if distorted, or
worn. Be sure t he governor weights operate freely in
t he bores and do not bind. Also verify t hat t he gov-
ernor valve slides freely on t he shaft and in t he bore.
Minor scratches, or burrs on governor components
can be cleaned up wi t h oil-soaked crocus cloth. How-
ever, do not at t empt to salvage components t hat are
severely worn or scored.
There are two governor component changes
on current transmi ssi ons that affect servi ce pro-
cedures. The first change i nvol ves the governor
valve. The val ve is now made of aluminum. The
second change i nvol ves the output shaft whi ch
has been spotfaced for governor val ve end clear-
ance. The new al umi num val ve must only be
used wi th an output shaft that has a spotface. In
addition, the governor body and spotfaced si de
of the val ve shaft hol e i n the output shaft must
be i ndexed.
Check condition of t he park gear seal rings, ri ng
grooves and gear t eet h (Fig. 39). Replace t he gear as
an assembly if t he t eet h or ri ng grooves are worn, or
damaged.
Replace t he park gear front and rear seal rings if
cracked, or worn. The production style front ring is a
plain type and t he rear ri ng is a hook style. If re-
placement rings are both hook-style, be sure t he ri ng
ends are properly hooked together.
ASSEMBLING GOVERNOR AND PARK GEAR
(1) Coat governor body bores and valves with
transmission fluid.
TRANSMISSION OVERHAUL32RH 21 - 16 1
Fig. 39 Park Gear And Seal Rings32RH
(2) Assemble governor weights and springs. Then
install weight assembly in governor body but do not

install valve and shaft at t hi s time. These part s are
not installed unt i l after governor and park gear are
in place on output shaft.
(3) Install new seal rings on park gear if neces-
sary.
(4) Insert filter screen in park gear and install
governor body on park gear. Tighten at t achi ng bolts
finger t i ght only. Bolts will not be final tightened
unt i l after governor and park gear are mounted on
output shaft.
OIL PUMP AND REACTION SHAFT SUPPORT
OVERHAUL
PUMP AND SUPPORT DISASSEMBLY
(1) Remove seal from around pump housing (Fig.
40).
Fig. 40 Removing Pump Housing Seal32RH
(2) Mark pump housing and support assembly for
al i gnment reference.
(3) Loosen bolts t hat at t ach pump body to support
(Fig. 41).
Fig. 41 Loosening Pump Support Bolts
(4) Remove pump-to-support bolts and separat e
support from pump housing (Fig. 42).
(5) Remove i nner and outer gears from reaction
shaft support (Fig. 43).
(6) If pump seal was not removed duri ng t ransmi s-
sion disassembly, remove seal wi t h punch and ham-
mer.
(7) Remove front clutch t hr ust washer from sup-
port hub (Fig. 44).
J9321-213
Fig. 42 Separating Pump Housing From Reaction
Shaft Support-32RH
J9321-214
Fig. 43 Pump Gear Removal32RH
Clean pump and reaction shaft support components
with solvent and dry t hem with compressed air.
Inspect t he pump housing and support components.
Replace t he housing or support if t he seal ri ng
grooves or machined surfaces are worn, scored, pit-
ted, or damaged.
Replace t he pump gears if pitted, worn chipped, or
damaged. Inspect t he t hrust washer for wear or dam-
age. Replace t he washer if necessary. Not e t ha t t he
i nne r ge a r us e d i n 1993 32RH oil p u mp s ha s a
n e w des i gn dr i ve l ug. The ne w des i gn i ncor po-
r a t e s dr i ve fl at s i ns t ead of t he s qua r e l ug us e d
pr evi ousl y. The 1993 t or que conver t er h u b ha s
al so be e n r edes i gned t o accept t he ne w dr i ve. If
p u mp gear r e pl a c e me nt i s neces s ar y, be ver y
s ur e t o or de r a n d i nst al l t he ne w st yl e gear s .
Inspect t he pump and reaction shaft support bush-
ings. Minor bushi ng wear is acceptable. Replace t he
bushings only if scored, or severely worn.
Install t he gears in t he pump housing and measure
end clearance with a feeler gauge and straightedge
(Fig. 45). Clearance should be 0.010 - 0.06 mm
(0.0004 - 0.0025 in.).
Measure clearance between t he outer gear and t he
pump body (Fig. 46). Clearance should be 0.08 - 0.19
mm (0.0035 - 0.0075 in.).
Measure gear tooth clearance with a feeler gauge.
Align one tooth of t he outer gear in i nner gear and
TRANSMISSION OVERHAUL32RH 21 163
OIL SEAL
REACTION SHAFT
SUPPORT
GASKET
BOLT (6)
O-RING
SEAL
PUMP HOUSING
THRUST
WASHER
J9321-207
Fig. 44 Oil Pump And Reaction Shaft Support Components32RH
measure clearance (Fig. 4 7 ) . Clearance should be
STRAIGHT EDGE
FEELER
GAUGE
0.08 - 0.19 mm ( 0.0035 - 0.0075 in.) ,
INNER
GEAR
J 9321- 215
Fig. 45 Measuring Pump Gear End Clearance32RH
FEELER
GAUGE
INNER
GEAR
J 9321- 216
Fig. 46 Measuring Pump Housing-To-Inner Gear
Clearances
OUTER
GEAR If!
Fig. 47 Measuring Pump Gear Tooth Clearance
REPLACING OIL PUMP BUSHING
(1) Remove pump bushing with Tool Handle
C-4171 and Bushing Remover SP-3551 (Fig. 48).
(2) Install new pump bushi ng with Tool Handle
C-4171 and Bushing Installer SP-5117 (Fig. 48).
Bushing should be flush with pump housing bore.
(3) St ake new pump bushi ng in two places with
bl unt punch (Fig. 49). Remove burrs from stake
points with knife blade afterward.

SPECIAL
TOOL
C-4171
PUMP HOUSING
BUSHING
REMOVAL
SPECIAL
TOOL
C-4171
SPECIAL TOOL
SP-3551
BUSHING
SPECIAL
TOOL
SP- 5117
BUSHING
J 9221- 242
Fig. 48 Removing OH Pump Bushing32RH
RH282
Fig. 49 Staking Oil Pump Bushing
REPLACING REACTION SHAFT SUPPORT
BUSHING
(1) Assemble Bushing Remover Tools SP-1191,
3633 and 5324 (Fig. 50). Do not cl amp any part of
reacti on shaft or support i n vise.
(2) Hold Cup Tool SP-3633 firmly against reaction
shaft and thread remover SP-5324 into bushing as
far as possible by hand. Then thread remover tool 3-4
additional turns into bushing with a wrench.
(3) Turn remover tool hex nut down against re-
mover cup to pull bushing from shaft. Clean all chips
from shaft after bushing removal.
(4) Lightly grip old bushing in vise or with pliers
and back remover tool out of bushing.
(5) Assemble Bushing Installer Tools C-4171 and
SP-5325 (Fig. 50).
(6) Slide new bushing onto Installer Tool SP-5325.
(7) Position reaction shaft support upright on a
clean smooth surface.
(8) Align bushing in bore. Then tap bushing into
place until Bushing Installer SP-5325 bottoms.
(9) Clean reaction shaft support thoroughly after
installing bushing.
SPECIAL
TOOL
SP-1191
SPECIAL
TOOL
C-4171
SPECIAL
_ U
T Q Q L
SP- 5325
BUSHING
INSTALLATION
J 9221- 243
Fig. 50 Replacing Reaction Shaft Support
Bushing32RH
ASSEMBLING OIL PUMP AND REACTION
SHAFT SUPPORT
(1) Lubricate gear bore in pump housing with
transmission fluid.
(2) Lubricate pump gears with transmission fluid.
(3) Support pump housing on wood blocks (Fig. 51).
(4) Install outer gear in pump housing (Fig. 51).
Gear can be installed either way (it is not a one-way
fit).
OUTER
GEAR
PUMP
HOUSI NG
WOOD
BLOCKS
J 9321- 219
Fig. 51 Supporting Pump And Installing Outer
Gear-32RH
(5) Install pump inner gear (Fig. 52). Gear can be
installed either way (it is not a one-way fit).
(6) Install new thrust washer on hub of reaction
shaft support. Lubricate washer with transmission
fluid or petroleum jelly.
TRANSMISSION OVERHAUL32RH 21 - 16 5
OUTER
GEAR
I NNER
GEAR
PUMP
HOUSI NG'
REACTION
SHAFT
SUPPORT
J9321-220
Fig. 52 Pump Inner Gear Installation32RH
(7) If reaction shaft seal ri ngs are being replaced,
install new seal rings on support hub (Fig. 53). Lu-
bricate seal rings with t ransmi ssi on fluid or petro-
leum jelly after installation. Squeeze each ri ng until
ring ends are securely hooked together.
C A U T I O N : The reaction shaft support seal ri ngs will
break if overspread, or twisted. If new r i ngs are be-
ing installed, spread them onl y enough for installa-
tion. A l s o be very sure the ring ends are securely
hooked together after installation. Otherwise, the
ri ngs will either prevent pump installation, or break
during installation.
SEAL
RI NGS
SUPPORT S*^
HUB
J9321-218
Fig. 53 Hub Seal Ring Position32RH
(8) Install reaction shaft support on pump housing
(Fig. 54).
(9) Align reaction support on pump housing. Use
al i gnment mar ks made at disassembly. Or, rotate
support until bolt holes in support and pump housing
are all aligned (holes are offset for one-way fit).
(10) Install all bolts t hat at t ach support to pump
housing. Then t i ght en bolts finger tight.
(11) Tighten support-to-pump bolts to required
torque as follows:
(a) Reverse pump assembly and install it in
transmission case. Position pump so bolts are fac-
ing out and are accessible.
|l rJ9321- 221
Fig. 54 Assembling Reaction Shaft Support And
Pump Housing32RH
(b) Secure pump assembly in case with 2 or 3
bolts, or with pilot studs.
(c) Tighten support-to-pump bolts to 20 Nm (15
ft. lbs.).
(d) Remove pump assembly from transmission
case.
(12) Install new oil seal in pump with Special Tool
C-4193 and Tool Handle C-4171 (Fig. 55) . Be sure
seal lip faces inward.
(13) Install new seal ring around pump housing.
Be sure seal is properly seated in groove.
(14) Lubricate lip of pump oil seal with petroleum
jelly. Lubricate pump seal with Ru-Glyde or petro-
leum jelly.
SPECIAL
TOOL
C-4193
PUMP
BODY
PUMP
SEAL
LCC. ,^77/OS
J9321-183
Fig. 55 Pump Oil Seal Installation-32RH
FRONT CLUTCH OVERHAUL
FRONT CLUTCH DISASSEMBLY
(1) Remove waved snap ri ng and remove pressure
plate, clutch plates and clutch discs (Fig. 56).
(2) Compress clutch piston spring with Compressor
Tool C-3575-A (Fig. 57). Be sure legs of tool are
seated squarely on spring ret ai ner before compress-
ing spring.
(3) Remove ret ai ner snap ri ng and remove com-
pressor tool.
(4) Remove spring ret ai ner and clutch spring.
(5) Remove clutch piston from clutch ret ai ner.
(6) Remove seals from clutch piston and clutch re-
t ai ner hub. Discard both seals as they are not reus-
able.
CLUTCH
> PISTON
SPRING
RETAINER
SNAP RING
SNAP RING
(WAVED)
FRONT CLUTCH RETAINER
J9121-144
CLUTCH PLATES
Fig. 56 Front Clutch Components32RH
FRONT
CLUTCH
SPRING
COMPRESSOR
TOOL C-3575-A
The steel plates should slide freely in t he slots. Re-
place t he piston ret ai ner if t he grooves are worn or
damaged. Also check action of t he check ball in t he
piston retainer. The ball must move freely and not
stick.
Replace t he ret ai ner bushi ng if worn, scored, or
t here is any doubt about bushi ng condition.
Inspect t he piston and ret ai ner seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace t he piston and/or
ret ai ner if t he seal surfaces are seriously scored. In-
spect t he ret ai ner check ball (Fig. 58). Be t he check
ball moves freely in its seat.
RETAINER
CHECK BALL
SPRING
RETAINER \ ^
RETAINER
SNAP RING
^/ J 912 M 47
Fig. 57 Compressing Front Clutch Piston
Spring32RH
FRONT CLUTCH INSPECTION
Clean t he front clutch components in solvent and
dry t hem wi t h compressed air only. Do not use rags
or shop towels to dry any of t he clutch part s. Lint
from such mat eri al s will adhere to t he component
surfaces and could restrict or block fluid passages af-
t er assembly.
Replace t he clutch discs if warped, worn, scored,
burned or charred, or if t he facing is flaking off. Re-
place t he steel plates if heavily scored, warped, or
broken. Be sure t he driving lugs on the plates are in
good condition. The lugs must not be bent, cracked or
damaged in any way.
Replace t he clutch spring and spring ret ai ner if ei-
t her is distorted, warped or broken.
Check t he lug grooves in t he clutch piston ret ai ner.
J9121-368
Fig. 58 Front Clutch Retainer Check Ball
Location32RH
REPLACING FRONT CLUTCH RETAINER
BUSHING
(1) Assemble Tool Handl e C-4171 and Bushing Re-
mover SP-3627 (Fig. 59).
(2) Insert remover tool in bushing and drive old
bushing out of ret ai ner (Fig. 59).
(3) Mount Bushi ng Installer SP-3626 on Tool Han-
dle C-4171. Then slide new bushing onto installer
tool.
(4) Align and i nst al l new bushing. Tap bushi ng
into ret ai ner unt i l installer tool bottoms against re-
tainer (Fig. 59).
(5) Remove bushi ng replacement tools and clean
retainer thoroughly.
SPECIAL
TOOL
C-4171
FRONT
CLUTCH
RETAINER
\
SPECIAL
TOOL
SP-3627
SPECIAL
TOOL
C-4171
SPECIAL
TOOL
SP-3626
BUSHING
BUSHING
REMOVAL
BUSHING
INSTALLATION
J9221-246
Fig. 59 Replacing Front Clutch Retainer
Bushing32RH
ASSEMBLING FRONT CLUTCH
(1) Lubricate clutch plates and soak clutch discs in
transmission fluid.
(2) Install new seals on piston and in hub of re-
tainer. Be sure lip of each seal faces interior of clutch
retainer.
(3) Lubricate lip of piston and ret ai ner seals with
liberal quant i t y of Door Eze, or petroleum jelly. Then
lubricate ret ai ner hub, bore and piston with t rans-
mission fluid.
(4) Install clutch piston in ret ai ner (Fig. 60). Use
twisting motion to seat piston in bottom of ret ai ner.
Do not attempt to push the pi ston straight in.
This coul d fold the seal s over causi ng l eakage
and cl utch slip.
(5) Position spring on clutch piston. Then place
spring ret ai ner on top of spring.
(6) Compress ret urn spring and spring ret ai ner
with Compressor Tool C-3575-A. Then install new
snap ri ng to secure spring retainer.
(7) Install clutch plates and discs (Fig. 56). Install
steel plate t hen disc unt i l all plates and discs are in-
stalled.
(8) Install pressure plate and waved snap ri ng
(Fig. 56).
FRONT
CLUTCH
RETAINER
J9121-146
Fig. 60 Installing Front Clutch Piston32RH
(9) Check clutch pack clearance (Fig. 61). Clear-
ance should be 1.70 to 3.40 mm (0.067 to 0.134 in.)
with 4-disc clutch and 1.90 to 3.86 mm (0.075 to
0.152 in.) with 5-disc clutch. If clearance is incorrect,
clutch pack components may have to be changed.
FEELER GAUGE
FEELER GAUGE
R H
2 88
Fig. 61 Measuring Front Clutch Pack Clearance
2 1 - 1 6 8 TRANSMISSION OVERHAUL32RH
REAR
CLUTCH
PI STON
CLUTCH
PI STON
SEALS
OUTPUT
SHAFT
THRUST
WA S HE R
(METAL)
INPUT
SHAFT
S N A P
R I N G
REAR
CLUTCH
RETAINER
INPUT
SHAFT
- R E A R
CLUTCH
. THRUST
" / SHAFT WA S HE R
/ FRONT ( ' I "")
SHAFT SEAL
REAR R I N G r n i T r u
SEAL (TEFLON)
C
^ T C H
R I N G PACK
S N A P
R I N G
(SELECTIVE)
PI STON
S PR I NG
BOTTOM
PRESSURE
PLATE
CLUTCH
DI S C S (4)
TOP
PRESSURE
PLATE
J9121-539
Fig. 62 Rear Clutcl
REAR CLUTCH OVERHAUL
REAR CLUTCH DISASSEMBLY
(1) Remove fiber t hr ust washer from forward side
of clutch ret ai ner.
(2) Remove selective clutch pack snap ri ng (Fig.
62).
(3) Remove top pressure pl at e, clutch discs, steel
plates, bottom pressure pl at e and wave spring (Fig.
62).
(4) Remove clutch piston wi t h rot at i ng motion.
(5) Remove and discard piston seals.
(6) Remove i nput shaft snap ri ng (Fig. 63).
(7) Press i nput shaft out of ret ai ner with shop
press and suitable size press tool (Fig. 64).
(8) Remove i nput shaft front/rear seal rings.
REAR CLUTCH INSPECTION
Clean t he clutch components wi t h solvent and dry
t hem wi t h compressed air. Do not use rags or shop
towels to dry any of t he clutch part s. Lint from such
mat eri al s will adhere to component surfaces and
could restrict or block fluid passages after assembly.
burned/charred, t he lugs are damaged, or if t he fac-
ing is flaking off. Replace t he top and bottom pres-
sure plates if scored, warped, or cracked. Be sure t he
driving lugs on t he pressure and clutch plates are
Components32 RH
Fig. 63 Removing/Installing Input Shaft Snap
Ring-32RH
also in good condition. The lugs must not be bent,
cracked or damaged in any way.
Replace t he piston spring and wave spring if either
par t is distorted, warped or broken.
Check t he lug grooves in t he clutch ret ai ner. The
clutch and pressure plates should slide freely in t he
slots. Replace t he ret ai ner if t he grooves are worn or

J9121-150
Fig. 64 Pressing input Shaft Out Of Rear Clutch
Retainer32RH
damaged. Also check action of t he check balls in t he
ret ai ner and piston. Each check ball must move
freely and not stick.
Replace t he ret ai ner bushing if worn, scored, or
doubt exists about bushi ng condition.
with crocus cloth. However, replace the piston and/or
ret ai ner if t he seal surfaces are seriously scored.
Check condition of t he fiber t hrust washer and
metal output shaft t hr ust washer. Replace ei t her
washer if worn or damaged.
Check condition of t he seal ri ngs on t he input shaft
and clutch ret ai ner hub. Replace t he seal ri ngs only
if worn, distorted, or damaged. The i nput shaft front
seal ri ng is teflon with chamfered ends. The r ear
ri ng is met al wi t h interlocking ends.
Check t he i nput shaft for wear, or damage. Replace
t he shaft if worn, scored or damaged in any way.
ASSEMBLING REAR CLUTCH
(1) Soak clutch discs and steel plates in t ransmi s-
sion fluid.
(2) Install new seal rings on clutch ret ai ner hub
and input shaft (Fig. 65).
(a) Be sure clutch hub seal ri ng is fully seated in
groove and is not twisted.
(b) Note t hat i nput shaft front seal ri ng is teflon
and r ear seal ri ng is met al (Fig. 66). Be sure cham-
fered ends of teflon ri ng are properly joined and
t hat ends of r ear ri ng are securely hooked together.
Lubricate both rings with light coat of petroleum
jelly after installation.
(3) Lubricate splined end of input shaft and clutch
ret ai ner with transmission fluid. Then press input
shaft into ret ai ner (Fig. 67).
(4 ) Install i nput shaft snap ri ng (Fig. 63).
(5) Install new seals on clutch piston. Be sure lip
of each seal faces interior of clutch retainer.
J9121 -538
Fig. 65 Rear Clutch Retainer And input Shaft Seal
Ring Installation32RH
J912M51
Fig. 66 input Shaft Seal Ring Identification32RH
(6) Lubricate lip of piston seals with liberal quan-
tity of Door Eze, or petroleum jelly. Then lubricate
ret ai ner hub and bore with transmission fluid.
(7) Install clutch piston in ret ai ner. Use twisting
motion to seat piston in bottom of ret ai ner. Do not
a t t e mpt t o pus h t he pi st on s t r ai ght i n. Thi s
coul d fold t he seal s over caus i ng l eakage a n d
cl ut ch sl i p.

Fig. 67 Pressing input Shaft into Rear Clutch
Retainer32RH
(8) Install piston spring in ret ai ner and on top of
piston (Fig. 68). Concave side of spring faces down-
ward (toward piston).
(9) Install wave spring in ret ai ner (Fig. 68). Be
sure spring is completely seated in ret ai ner groove.
Fig. 68 Piston And Wave Spring Position32RH
(10) Install bottom pressure plate (Fig. 62). Ridged
side of plate faces downward (toward piston) and flat
side toward clutch pack.
(11) Install first clutch disc in ret ai ner on top of
bottom pressure plate. Then install a clutch plate fol-
lowed by a clutch disc unt i l entire clutch pack is in-
stalled. Total of 4 discs and 3 plates are required
(Fig. 62).
(12) Install top pressure plate (Fig. 62).
(13) Install selective snap ri ng (Fig. 62). Be sure
snap ri ng is fully seated in ret ai ner groove.
(14) Measure clutch pack clearance (Fig. 69).
Clearance should be 0.64 - 1.14 mm (0.025 - 0.045
in.). If clearance is incorrect, steel plates, discs, snap
ring and pressure plates may have to be changed.
Fig. 69 Typical Method Of Checking Rear Clutch
Pack Clearance
(15) Coat rear clutch fiber t hrust washer with pe-
troleum jelly and install washer over input shaft and
into clutch ret ai ner (Fig. 70). Use enough petroleum
jelly to hold washer in place.
(16) Set rear clutch aside for installation duri ng fi-
nal assembly.
Fig. 70 Installing Rear Clutch Thrust Washer32RH
PLANETARY GEAR TRAIN
OVERHAUL
OUTPUT SHAFT
PLANETERY GEARTRAIN DISASSEMBLY (FIG.
71)
(1) Remove snap ring, tabbed t hr ust washer and
t hrust plate from front of output shaft.
(2) Remove front annul us gear and support assem-
bly.
(3) Remove front planetary front t hr ust washer.
(4) Remove front planetary gear.
(5) Remove front planetary rear t hr ust washer.
(6) Remove sun gear and driving shell.
(7) Remove snap ring t hat ret ai ns sun gear in
driving shell and remove sun gear and t hr ust plates.
Note t hr ust plate position for assembly reference.
(8) Remove tabbed t hrust washer from rear plane-
t ary gear.
(9) Remove rear planetary gear from rear annul us
gear and remove annul us gear from output shaft.
(10) Remove snap rings t hat secure annul us gears
to supports and separate each gear from t he support.
PLANETARY GEARTRAIN INSPECTION
Clean t he pl anet ary components in solvent and dry
t hem with compressed air.
Check sun gear and driving shell condition. Re-
place t he gear if damaged or if t he bushings are
scored or worn. The bushi ngs are not serviceable. Re-
place t he driving shell if worn, cracked or damaged.
Replace pl anet ary gear sets if gears, pinion pins, or
carrier are damaged in any way. Replace t he annu-
lus gears and supports if ei t her component is worn or
damaged.
Inspect the geart rai n spacers, t hrust plates, snap
rings, and t hr ust washers. Replace any of these part s
t hat are worn, distorted or damaged. Do not at t empt
to reuse these part s.
Inspect the output shaft carefully. Pay particular
attention to t he machined bushing/bearing surfaces
on the shaft and t he governor valve shaft bore at the
shaft rear.
Replace the output shaft if t he machined surfaces
are scored, pitted, or damaged in any way. Also re-
place t he shaft if the splines are damaged, or exhib-
its cracks at any location (especially at t he governor
valve shaft bore).
ASSEMBLING PLANETARY GEARTRAIN
(1) Lubricate output shaft and pl anet ary compo-
nents with transmission fluid. Use petroleum jelly to
lubricate and hold t hrust washers and plates in posi-
tion.
(2) Assemble rear annul us gear and support if dis-
assembled. Be sure support snap ring is seated and
SELECT
FIT
PLANETARY
S NAP
RI NG
FRONT
ANNULUS
S NAP
RI NG
SUPPORT ANNULUS GEAR
SNAP RI NG SUPPORT
FRONT
PLANETARY
THRUST
WASHERS
S UN
GEAR
S UN
GEAR
SPACER
DRI VI NG SHELL FRONT DRI VI NG
THRUST PLATE SHELL
FRONT
ANNULUS.
THRUST
WASHER
DRI VI NG
SHELL
REAR
THRUST
PLATE
OUTPUT
SHAFT
THRUST
PLATE
OUTPUT
SHAFT
J9221-17
Fig. 71 Planetary Gear Train32RH

t hat shoulder-side of support faces rearward (Fig.
72).
(3) Install r ear t hrust washer on rear pl anet ary
gear (Fig. 72). Use enough petroleum jelly to hold
washer in place. Also be sure washer t abs are prop-
erly engaged in gear slots.
(4) Install rear annul us over and onto rear plane-
t ary gear (Fig. 72).
Fig. 72 Assembling Rear Annulus And Planetary
Gear-32RH
(5) Install assembled rear pl anet ary and annul us
gear on output shaft (Fig. 73). Verify t hat assembly
is fully seated on shaft.
Fig. 73 installing Assembled Rear Annulus And
Planetary Gear On Output Shaft-32RH
(6) Install front t hrust washer on rear pl anet ary
washer on gear.
(7) Inst al l spacer on sun gear (Fig. 75).
(8) Inst al l t hr ust plate on sun gear (Fig. 76). Note
t hat driving shell t hrust plates are interchangeable.
Use ei t her plate on sun gear and at front/rear of
shell.
Fig. 74 installing Rear Planetary Front Thrust
Washer-32RH
Fig. 75 Installing Spacer On Sun Gear32RH
Fig. 76 Installing Driving Shell Front Thrust Plate
On Sun Gear-32RH

(9) Hold sun gear in place and install t hr ust plate
over sun gear at rear of dri vi ng shell (Fig. 77).
DRI VI NG
SHELL
SUN
GEAR
REAR
THRUST
PLATE
J912M62
Fig. 77 Installing Driving Shell Rear Thrust
Piate-32RH
(10) Position wood block on bench and support sun
gear on block (Fig. 78). This makes it easier to align
and install sun gear lock ri ng. Keep wood block
handy as it will also be used for geart rai n end play
check.
SUN
GEAR
DRI VI NG
SHELL
WO O D
BLOCK
J912M63
Fig. 78 Supporting Sun Gear On Wood Block32RH
(11) Align rear t hrust pl at e on driving shell and
install sun gear lock ring. Be sure ri ng is fully
seated in sun gear ring groove (Fig. 79).
(12) Install assembled driving shell and sun gear
(13) Install rear t hrust washer on front pl anet ary
washer on gear and be sure washer tabs are all prop-
erly seated.
(14) Install front pl anet ary gear on output shaft
and in driving shell (Fig. 82).
LOCK
RI NG
GROOV E
SUN
GEAR
LOCK
RI NG
REAR
THRUST
PLATE
DRI VI NG
SHELL
Fig. 79 Installing Sun Gear Lock Ring32RH
SUN GE AR /
DRI VI NG SHELL
ASSEMBLY
OUTPUT
SHAFT
J912M65
Fig. 80 Installing Assembled Sun Gear And Driving
Shell On Output Shaft-32RH
REAR
TABBED
THRUST
WASHER
FRONT
PLANETARY
GEAR
J912M66
Fig. 81 Installing Rear Thrust Washer On Front
Planetary Gear32RH

(15) Install front t hrust washer on front pl anet ary
washer in place on gear and be sure washer t abs are
seated.
(16) Assemble front annul us gear and support. Be
sure support snap ri ng is seated.
(17) Position t hrust plate on front annul us gear
support (Fig. 83). Use enough petroleum jelly to hold
t hrust plate in place.
(18) Install front annul us assembly on front plane-
Fig. 82 Installing Front Planetary And Annulus
Gears32RH
Fig. 83 Positioning Thrust Plate On Annulus
Support32RH
(19) Install front annul us t hrust washer (Fig. 84).
Align flat on washer with flat on pl anet ary hub. Also
be sure washer t ab is facing forward.
(20) Install front annul us snap ri ng (Fig. 85). Use
snap ri ng pliers to avoid distorting ri ng during in-
stallation. Also be sure ri ng is fully seated.
(21) Install pl anet ary selective snap ri ng with snap
ring pliers (Fig. 86). Be sure ri ng is fully seated.
(22) Turn pl anet ary geart ai n assembly over so
Fig. 84 installing Front Annulus Thrust
Washer-32RH
Fig. 85 Installing Front Annulus Snap Ring32RH
SELECTIVE
Fig. 86 Installing Planetary Selective Snap
Ring32 RH
driving shell is facing workbench. Then support
geart rai n on wood block positioned under forward

TRANSMI SSI ON OVERHAUL32RH 21 - 175
end of output shaft. This allow geart rai n components
to move forward for accurate end play check.
(23) Check pl anet ary geart rai n end play with
feeler gauge (Fig. 87). Gauge goes between shoulder
on output shaft and end of rear annul us support.
(24) Geartrain end play should be 0.12 to 1.22 mm
(0.005 to 0.048 in.). If end play is incorrect, snap ri ng
(or t hrust washers) may have to be replaced. Snap
ring is available i n t hree different thicknesses for ad-
j ust ment purposes.
Fig. 87 Checking Planetary Geartrain End
Play-32RH
FRONT SERVO AND BAND OVERHAUL
FRONT SERWO DISASSEMBLY (FIG. 88)
(1) Remove small snap ri ng from servo piston.
(2) Remove piston, rod, springs and guide.
(3) Remove and discard servo piston rings and
O-ring.
FRONT SERWO AND BAND INSPECTION
Clean t he servo components with solvent and dry
Inspect t he servo components. Replace t he springs
if collapsed, distorted or broken. Replace the guide,
rod and piston if cracked, bent, or worn. Discard t he
servo snap ri ng if distorted or warped.
Replace t he front band if distorted, t he lining is
burned or flaking off, or excessively worn.
Check t he servo piston bore for wear. Replace t he
piston and rod as an assembly if either part is worn
or damaged.
Replace any servo component if doubt exists about
its condition. Do not reuse suspect part s.
SERVO
PISTON
SNAP GUIDE
RING
S E A L
J 912 M 72
Fig. 88 Front Servo Components32RH
ASSEMBLING FRONT SERVO PISTON
(1) Lubricate seal rings and O-rings wi t h petro-
leum jelly. Lubricate other servo part s with t rans-
mission fluid.
(2) Install new O-ring on servo piston rod.
(3) Install new seal on piston rod guide and install
new seal rings on piston.
(4) Assemble rod, piston, servo springs and snap
ri ng (Fig. 88).
REAR SERVO AND BAND OVERHAUL
REAR SERVO PISTON DISASSEMBLY
(1) Remove seal from servo piston. Note which way
seal lip faces for assembly reference.
(2) Compress cushion spring in vise only enough to
allow piston plug snap ring removal (Fig. 89). Use
wood block between vise jaws and end of piston plug
to keep plug aligned and in position.
(3) Remove snap ring from end of piston plug (Fig.
89).
(4) Open vise and remove wood block, piston plug,
cushion spring and servo piston.
REAR SERVO INSPECTION
Check rear band condition. Replace t he band if dis-
torted, t he lining is burned or flaking off, or t he lin-
ing is excessively worn.
Check t he band reaction pins. Replace t he O-rings
on both pins. Minor pin scoring can be cleaned up
with crocus cloth. However, replace t he pins if worn,
severely scored, or cracked.
Inspect t he servo components (Fig. 90). Replace t he

SMALL
WO O D
BLOCK
PISTON
PLUG
S NAP
RI NG
SNAP
RI NG
PLIERS
J912M74
Fig. 89 Removing/installing Servo Piston Plug Snap
Ring-32 RH
servo and cushion springs if collapsed, distorted or
broken. Replace t he plug or piston if cracked, bent,
or worn. Discard t he servo snap ri ng and spring re-
t ai ner if distorted or warped.
If doubt exists about t he condition of any servo
component, replace it. Do not reuse suspect part s.
SPRI NG
RETAINER
SERVO
SPRI NG
PISTON
PLUG
CUS HI ON
SPRI NG
SERVO
S NAP
RI NG
PISTON
SEAL
PI STON
PLUG
S N A P
RI NG
SERVO
PISTON J9121-173
Fig. 90 Rear Servo Components32RH
ASSEMBLING REAR SERVO PISTON
(1) Assemble piston plug, cushion spring and pis-
ton (Fig. 90).
(2) Compress cushion spring in vise and install pis-
ton plug snap ri ng (Fig. 90).
(3) Install new seal on piston. Be sure seal lip is
toward servo bore (Fig. 91).
(4) Lubricate piston seal wi t h petroleum jelly. Lu-
bricate other servo part s wi t h t ransmi ssi on fluid.
BE SURE
SEAL LIP
IS TOWARD
SERVO BORE
REAR
SERVO
PISTON
J9121-175
Fig. 91 Installing Rear Servo Piston Seal32RH
VALVE BODY SERVICE AND ADJUSTMENT
VALVE BODY DISASSEMBLY
C A U T I O N : D o not cl amp any part of the valve body
assembl y (Fi g. 92) in a vi se. T hi s practice will di s-
tort the val ve body and transfer plate resulting in
val ve bi nd. Sl i de val ves and pl ugs out carefully. D o
not use force at any time. The val ves and valve
body will be damaged if force i s used. A l so tag or
mark the val ve body spr i ngs for reference a s they
are removed. D o not allow them to become inter-
mi xed.
M A N U A L
LE V E R
CONVERTER
CLUTCH
MODULE
A N D TUBE
MANUAL
VALVE
SOLENOID
WIRE
PARK
ROD
CONVERTER
CLUTCH
SOLENOID
J9321-125
Fig. 92 Valve Body Assembly32RH
(1) Remove screws at t achi ng adjusting screw
bracket to valve body and transfer plate. Hold
bracket firmly agai nst spring force while removing
last screw.
(2) Remove adjusting screw bracket, line pressure
adjusting screw, pressure regulator spring and switch
valve spring (Fig. 93). Do not remove throttle

pressure adjusting screw from bracket and do
not disturb adjusting screw settings duri ng re-
moval.
SPRI NG J912 M76
Fig. 93 Adjusting Screw Bracket And Spring
Removal32RH
(3) Secure detent ball and spring in housing with
Retainer Tool 6583 (Fig. 94).
DETENT BALL AND SPRING HOUSING J9321-121
Fig. 94 Securing Detent Ball And Spring With
Retainer Tool
(4) Remove manual shaft E-clip and washer (Fig.
95).
(5) Pul l manual shaft and park rod assembly up-
ward out of valve body and off throttle lever (Fig.
95).
(6) Remove ret ai ner tool and remove detent ball
(7) Remove t hrot t l e lever (Fig. 95).
(8) Remove park rod E-clip and separat e rod from
manual lever (Fig. 96).
(9) Remove screws at t achi ng converter clutch mod-
ule to valve body and remove module and connecting
t ube (Fig. 97).
(10) Tur n valve body over so transfer plate is fac-
ing upward (Fig. 98). With valve body in this posi-
tion, valve body check balls will remai n in place and
not fall out when transfer plate is removed.
(11) Remove screws at t achi ng transfer plate to
valve body (Fig. 98).
SHUTTLE
VALVE PARK
END PLATE ROD
Fig. 95 Removing Manual And Throttle Levers
MANUAL
Fig. 96 Park Rod Removal32RH
J912M78
Fig. 97 Converter Clutch Module And Connecting
Tube Removal/Installation32RH
(12) Remove transfer plate and separator pl at e
from valve body. Note position of filter and converter
clutch solenoid for reference (Fig. 99).
(13) Position transfer pl at e on bench so separator
plate, filter and clutch solenoid are facing up. This
will avoid havi ng rear clutch and r ear servo check
balls fall out when plates are separated.

VALVE
BODY
TRANSFER
PLATE J9121-181
Fig. 98 Valve Body- To- Transfer Plate Screw
Locations32RH
Fig. 99 Transfer Plate Removal/Installation32RH
(14) Remove screws at t achi ng separator pl at e to
transfer plate.
(15) Remove converter clutch solenoid from separa-
tor pl at e (Fig. 100).
(16) Note position of filter, clutch solenoid and rear
clutch/rear servo check balls for assembly reference
(Fig. 101).
(17) Remove shut t l e valve end plate (Fig. 102).
(18) Remove shut t l e valve E-clip and remove sec-
ondary spring and spring guides from end of valve
(Fig. 102).
(19) Remove governor valve end plate (Fig. 103).
(20) Remove switch valve and pressure regul at or
valve from valve body (Fig. 103).
Fig. 100 Removing Converter Clutch
Solenoid32RH
SEPARATOR
J9121-
Fig. 101 Transfer And Separator Plates32RH
(21) Remove t hrot t l e valve and spring, kickdown
valve and detent and manual valve from valve body
(Fig. 103).
(22) Remove 1-2 and 2-3 shift valve governor plugs
from valve body (Fig. 103).
(23) Remove shut t l e valve t hrot t l e plug, pri mary
spring and shut t l e valve from valve body (Fig. 103).
(24) Remove 1-2 shift control valve and spring
from valve body (Fig. 104).
E-CLIP SHUTTLE
VALVE
Fig. 102 Shuttle Valve E-Clip And Secondary Spring
Location32RH
(25) Remove 2-3 shift valve and spring from valve
body (Fig. 104).
body (Fig. 104).
(27) Remove regulator valve end plate (Fig. 104).
(28) Remove regulator valve line pressure plug,
pressure plug sleeve, throttle pressure plug and
spring (Fig. 104).
VALVE BODY CLEANING AND INSPECTION
The only serviceable valve body components are:
park lock rod and E-clip
switch valve and spring
pressure adjusting screw bracket
throttle valve lever
manual shaft
manual shaft seal, washer, E-clip and detent ball
fluid filter.
converter clutch solenoid
Clean t he valve body components in a part s clean-
ing solution only. Do not use gasoline, kerosene, or
any type of caustic solution. Dry t he part s with com-
pressed air. Make sure all passages are clean and
free from obstructions.
Do not use rags or shop towel s to wi pe off
val ve body components. Lint from these materi-
als will adhere to the val ve body components.
Lint will interfere wi th val ve operati on and may
cl og filters and fluid passages.
Inspect t he t hrot t l e and manual valve levers and
shafts. Do not at t empt to st rai ght en a bent shaft or
correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.
Inspect all of t he valve body mat i ng surfaces for
scratches, nicks, burrs, or distortion. Use a straight-
SHUTTLE
VALVE
E ND PLATE
SWI TCH
VALVE
LINE
PRESSURE
REGULATOR
VALVE
S E CONDARY
S PRI NG & GUI DE S
SHUTTLE
VALVE
PRI MARY
S PRI NG
SHUTTLE
VALVE
THROTTLE
PLUG
GOV E R N OR
PLUG-
E ND PLATE
J9121-50
Fig. 103 Control Valves And Governor Plugs32RH

REGULATOR
VALVE
THROTTLE
PRESSURE
PLUG
REGULATOR
VALVE
SPRING
SLEEVE
LINE
PRESSURE
PLUG
REGULATOR
VALVE
END
PLATE
SHIFT VALVE
END PLATE
2-3 SHIFT
VALVE AND
SPRING
J912M80
Fig. 104 Shift Valves And Pressure Regulator Plugs32RH
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.
Minor distortion of a valve body mating surface
may be corrected by smoothing the surface with cro-
cus cloth. The cloth should be in sheet form and be
positioned on a surface plate, sheet of plate glass, or
equally flat surface. However, if distortion is severe
or any surfaces are heavily scored, the valve body
will have to be replaced.
C A U T I O N : The throttle val ve, shuttle val ve pl ug, 1-2
shift val ve and 1-2 governor pl ug are made of
coated al umi num. These components are identified
in Fi gure 105 with the abbreviation (Al um.). Al umi -
num component s can be identified by the dark
col or of the speci al coati ng applied to the surf ace
(or by testing with a magnet). D O NOT pol i sh or
sand al umi num val ves or pl ugs with any type of
material, or under any ci r cumst ances. T hi s practice
will remove the special coati ng and cause the
val ves and pl ugs to sti ck and bi nd.
Inspect the valves and plugs for scratches, burrs,
nicks, or scores. Also inspect the coating on the alu-
minum valves and plugs (Fig. 105). If the coating is
damaged or worn through, the valve (or valve body)
should be replaced.
Aluminum valves and plugs must not be sanded or
polished under any circumstances. However, minor
burrs or scratches on steel valves and plugs can be
removed with crocus cloth but do not round off the
valve or plug edges. Squareness of these edges is vi-
tally important. These edges prevent foreign matter
from lodging between the valves, plugs and bore.
Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors. Re-
place the valve body if any bores are distorted or
scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken
coils.
Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores. Valve
body bores do not change dimensionally with use. If
the valve body functioned correctly when new, it will
continue to operate properly after cleaning and in-
spection. It should not be necessary to replace a
valve body assembly unless it is damaged in han-
dling.
SHI FT VALVE
E N D PLATE
2-3 SHI FT
VALVE A N D
S PR I NG
SHUTTLE VALVE
S E C ON D A R Y S PR I NG,
GU I D E S , E-CLIP
1-2 SHI FT
C O N T R O L VALVE
A N D S PR I NG
REGULATOR
VALVE
E N D PLATE
REGULATOR
VALVE
PRESSURE
PLUG
SLEEVE
MO D U L E
A N D
C O N N E C T I N G
TUBE
SHUTTLE VALVE
COV E R
REGULATOR
VALVE THROTTLE
PRESSURE PLUG
LI NE
PRESSURE
A D J U S T I N G
S C R E W
A D J U S T I N G
S CRE W
BRACKET
THROTTLE
PRESSURE
A D J U S T I N G
SCREW
S WI T C H
VALVE
A N D
S PR I NG
PRESSURE
REGULATOR
VALVE
A N D
S PR I NG
2-3 SHI FT
VALVE G O V E R N O R
PLUG
SHUTTLE VALVE
PLUG (ALUM.)
G O V E R N O R
VALVE E N D
PLATE
M A N U A L LEVER
DETENT BALL
A N D S PR I NG
J9121-369
Fig. 105 Valve Body Components32RH (Alum. Indicates Aluminum Part)

VAL VE BODY ASSEMBL Y
CAUTI ON : D o not force the val ves or pl ugs into
pl ace dur i ng r eassembl y. If the val ve body bor es,
val ves and pl ugs are free of di storti on or bur r s, the
val ve body c omponent s shoul d all sl i de into pl ace
easi l y. In addi ti on, do not overti ghten the transfer
plate and val ve body s c r ews duri ng r eassembl y.
Overti ghteni ng can distort the val ve body resul ti ng
in val ve st i cki ng, c r os s l eakage and unsati sfactory
operati on. Ti ghten val ve body sc r ews to r ecom-
mended torque onl y.
(1) Lubricate valve body bores, valves and plugs
with transmission fluid.
(2) Insert rear clutch and rear servo check balls in
transfer plate (Fig. 100).
(3) Install filter screen in separator plate (Fig.
100).
(4) Align and install separator plate on transfer
plate. Verify check ball position before installing sep-
arator plate on transfer plate.
(5) Install new O-ring on converter clutch solenoid
and insert solenoid in separator plate (Fig. 106).
Fig. 106 Installing Converter Clutch Solenoid32RH
(6) Position valve body so internal passages and
check ball seats are facing upward. Then install
check balls in valve body (Fig. 107). There are a total
of seven check balls; The one large check ball is ap-
proximately 11/32 inch in diameter. The remaining
check balls are approximately 1/4 inch in diameter.
(7) Align and install assembled transfer and sepa-
rator plates on valve body. Install and tighten valve
body screws alternately in a diagnonal pattern to 4
(8) Assemble converter clutch module and valves.
Then install assembly on valve body (Fig. 108).
(9) Assemble regulator valve line pressure plug,
sleeve, throttle plug and spring (Fig. 104). Insert as-
sembly in valve body and install end plate. Tighten
end plate screws to 4 Nm (35 in. lbs.) torqe.
1/4" CHECK BALLS (6)
11/32" CHECK BALL (1) J912M83
Fig. 107 Correct Position Of Valve Body Check
Baiis-32RH
(10) Install 1-2 and 2-3 shift valves and springs
(Fig. 104).
(11) Install 1-2 shift control valve and spring (Fig.
104)
(12) Install shuttle valve as follows:
(a) Insert shuttle valve in bore.
(b) Insert plastic guides in shuttle valve second-
ary spring.
(c) Install spring on end of valve.
(d) Hold shuttle valve in place. Then compress
secondary spring and install E-clip in groove at end
of valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.
(13) Install shuttle valve cover plate (Fig. 103).
Tighten end plate screws to 4 Nm (35 in. lbs.)
torque.
(14) Install 1-2 and 2-3 valve governor plugs in
valve body (Fig. 103). Then install shuttle valve pri-
mary spring and throttle plug.
(15) Align and install governor plug end plate on
valve body and install end plate screws. Tighten
screws to 4 N*m (35 in. lbs.) torque.
(16) Install manual valve (Fig. 103).
(17) Install throttle valve and spring. Then install
kickdown valve and detent (Fig. 103).
(18) Install pressure regulator valve and switch
valve in valve body.
(19) Install manual lever detent spring in housing.
Place detent ball on end of spring and push ball and
spring into housing. Secure ball and spring with De-
tent Retainer 7684 or C-3765 (Fig. 94).

MODULE
J932 M2 3
Fig. 108 Converter Clutch Module Components32RH
(20) Insert line pressure adjusting screw in adjust-
ing screw bracket (Fig. 93).
(21) Install spring on end of line pressure regula-
tor valve.
(22) Install switch valve spring on t ang at end of
adjusting screw bracket (Fig. 94).
(23) Position adjusting screw bracket on valve
body. Align valve springs and press bracket into
place. Install short, upper bracket screws first and
long bottom screw last. Verify t hat valve springs and
bracket are properly aligned. Then t i ght en all t hr ee
bracket screws to 4 N*m (35 in. lbs.) torque.
(24) Install converter clutch module and connect-
ing tube. Be sure long end of tube goes to module
(Fig. 97). Tighten module screws to 4 Nr n (35 in.
lbs.) torque.
(25) Install throttle lever in valve body. Then in-
stall manual lever over t hrot t l e lever and st art man-
ual lever into valve body.
(26) Align manual lever detent wi t h detent ball
and align lever arm wi t h manual valve. Hold throt-
tle lever upward. Then press down on manual lever
unt i l lever is fully seated.
(27) Install manual lever seal, washer and retain-
ing E-clip.
(28) Lubricate shaft of manual lever with light
coat of petroleum jelly. This will help protect seal lip
when manual shaft seal is installed.
(29) Verify t hat t hrot t l e lever is aligned with end
of kickdown valve stem and t hat manual lever ar m
is engaged in manual valve (Fig. 109).
Fig. 109 Manual And Throttle Lever
Alignment32RH
(30) If line pressure and/or t hrot t l e pressure ad-
j ust ment screw settings were not disturbed, continue
with overhaul or reassembly. However, if adjustment
screw settings were moved or changed, readjust as
described in Valve Body Control Pressure Adjust-
ment procedure.
VALVE BODY CONTROL PRESSURE
ADJUSTMENTS
There are two control pressure adjustments on t he
valve body which are, line pressure and throttle pres-
sure.
21 - 184 TRANSMI SSI ON OVERHAUL32RH -
Fig. 110 Line Pressure Adjustment32RH
Throttle Pressure Adjustment
ver cam and t he kickdown valve stem (Fig. 111).
tle valve.
Tur n t hrot t l e lever stop screw unt i l t he screw head
touches t hrot t l e lever t ang and t he t hrot t l e lever cam
touches gauge tool.
The ki c kdown val ve s pr i ng mus t be fully com-
pr e s s e d a n d t he ki c kdown val ve compl et el y bot -
t ome d t o obt ai n cor r ect adj us t ment .

Fig. 111 Throttle Pressure Adjustment32RH
TRANSMI SSI ON ASSEMBLY AND ADJUSTMENT
Assembly Tips
Do not allow dirt, grease, or foreign mat eri al to en-
t er t he case or transmission components during as-
sembly. Keep t he transmission case and components
clean. Also make sure t he tools and workbench area
used for assembly are equally clean.
Shop towels used for wiping off your hands and ser-
vice tools must be made of l i nt free mat eri al s. Li nt
will adhere to tranmission part s and could interfere
with valve operation, or even restrict fluid passages.
Lubricate t he transmission components with ATF
Plus, or Dexron II duri ng reassembly. Use petro-
leum jelly, Door Eze, or Ru-Glyde on seals and
O-rings to ease installation.
Petroleum jejly can also be used to hold t hr ust
washers and plates in position duri ng assembly oper-
ations. However, do not use chassis grease, beari ng
grease, white grease, or similar lubricants on any
transmission part . These types of lubricants can
eventually block or restrict fluid passages and valve
operation. Use petroleum jelly only.
Do not force part s into place. Most of t he t ransmi s-
sion components are easily installed by hand when
properly aligned. If a part seems extremely difficult
to install, it is either misaligned or incorrectly as-
sembled. Also verify t hat t hr ust washers, t hr ust
plates and seal rings are correctly positioned before
assembly. These part s can interfere with proper as-
sembly if mispositioned or "left out" by accident.
TRANSMISSION ASSEMBLY PROCEDURE
(1) Install rear servo piston, spring and spring re-
t ai ner. Compress r ear servo spring and ret ai ner wi t h
Compressor Tool C-3422-A or a large C-clamp.
(2) Install front servo piston, spring and rod guide.
Compress front servo rod guide with Valve Spring
Compressor C-3422-B and install servo snap ring.
The two pressures are interdependent because each
affects shift quality and timing. Each pressure ad-
j ust ment must be performed properly and in t he cor-
rect sequence. The correct sequence is line pressure
adjustment first and t hrot t l e pressure adjustment
last.
Line Pressure Adjustment
scale (Fig. 110).
Distance should be 33.4 mm (1-5/16 in.).
The 33.4 mm (1-5/16 in,) set t i ng Is a n appr oxi -
ma t e set t i ng. Becaus e of ma nuf a c t ur i ng t ol er-
ances , i t ma y be neces s ar y t o va r y f r om t hi s
di mens i on t o obt ai n des i r ed pr e s s ur e .
One complete t ur n of t he adjusting screw changes
line pressure approximately 1-2/3 psi (9 kPa). Turn-
ing t he adjusting-screw counterclockwise increases
pressure while t ur ni ng t he screw clockwise decreases
pressure.

TRANSMISSION OVERHAUL32RH 2 1 - 1 8 5
(3) Exami ne bolt holes in overrunning clutch cam.
Note t hat one hole is not t hr e a de d (Fig. 112 This
hole must align wi t h bl ank area in clutch cam bolt
circle (Fig. 113).
Fig. 113 Location Of Blank Area in Clutch Cam Seat
(in Case)-32RH
(4) Mark location of non threaded hole in clutch
cam and bl ank area of case with paint stripe or
grease pencil (Fig. 114).
(5) Install overrunni ng clutch roller and spring as-
sembly in clutch cam (Fig. 114).
(6) Align and install overrunning clutch in case
(Fig. 114). Be sure cam is correctly installed. Bolt
hol es i n cam are slightly countersunk on one
side. This side of cam faces rearward (toward
rear support).
(7) Verify t hat non threaded hole in clutch cam is
properly aligned (Fig. 114). Check alignment by
t hreadi ng a clutch cam bolt into each hole. Adjust
cam position if necessary before proceeding.
(8) Install clutch cam bolts. Note t hat cam bolts
are shorter t han rear support bolts. Tighten cam
bolts to 17 Nm (150 in. lbs.) torque.
(9) Lubricate overrunning clutch rollers wi t h
transmission fluid.
(10) Install r ear band reaction pi n (Fig. 105). Be
sure pin is fully seated in case.
Fig. 114 Overrunning Clutch And Rear Band Pin
Installation32RH
(11) Install rear band in case (Fig. 115). Twin lugs
on band seat agai nst reaction pin and single l ug
faces band lever.
(12) Install low-reverse drum as follows (Fig. 115):
(a) Lubricate overrunning clutch race (on hub of
drum) with transmission fluid.
(b) Guide drum through rear band.
(c) Tilt drum slightly and st art clutch race into
overrunning clutch rollers.
(d) Rotate drum in clockwise direction and push
drum inward unt i l it seats in overrunni ng clutch.
Fig. 115 Installing Rear Band And Low-Reverse
Drum32RH
(13) Install rear band lever and pivot pin (Fig.
116). Be sure pin is fully seated in case.
Fig. 116 Installing Rear Band Lever And Pivot
Pin-32RH
(14) Hold low-reverse drum in position and install
rear support. Align support with punch marks made
during disassembly.
(15) Install and t i ght en rear support bolts to 17
N*m (150 in. lbs. or 13 ft. lbs.) torque.
(16) Install snap ri ng t hat ret ai ns low-reverse
drum to hub of rear support (Fig. 117).
Fig. 117 Installing Low-Reverse Drum Snap
Ring32RH
(17) Lubricate out put shaft, rear support bore and
low-reverse drum hub wi t h transmission fluid.
(18) Install assembled output shaft and pl anet ary
geart rai n in case (Fig. 118).
(19) Align drive lugs on rear pl anet ary gear with
slots in low-reverse drum (Fig. 119). Then seat plan-
et ary assembly in drum.
(20) Lubricate governor components and park gear
seal ri ngs wi t h t ransmi ssi on fluid.

Fig. 118 Installing Output Shaft/Planetary
Geartrain32RH
Fig. 119 Aligning/Seating Rear Planetary In Low-
Reverse Drum32RH
(21) Install governor filter in park gear and install
governor body on gear (Fig. 120). Align governor
body on gear using mar ks made at disassembly.
(22) Install new seal rings on hub of park gear
(Fig. 120). Be sure ri ng (or rings) with hooked ends
are properly connected.
(23) Install governor weight assembly in governor
body. Be sure governor weight snap rings are se-
curely seated.
(24) Align and install governor/park gear assembly
on output shaft. Note that output shaft i n current
transmi ssi on is spotfaced for governor val ve end
cl earance (Fig. 120). Shaft must be i ndexed so
that small end of governor val ve will seat in this
spotface. Install governor body and park as fol-
l ows to ensure proper al i gnment and operati on.

(a) Rotate output shaft until spotface (at gover-
nor valve shaft hole) is facing upward (Fig. 120).
(b) Position valve bore in governor body over
spotface on output shaft (Fig. 120). Then align
valve shaft holes in governor body and output
shaft.
(c) Align splines in output shaft and park gear
hub.
(d) Carefully push assembly into place in rear
support (Fig. 121).
(e) Verify t hat governor valve shaft holes in out-
put shaft and governor body are still in alignment.
Reposition governor body and par k gear if align-
ment is not correct.
(f) Tighten bolts at t achi ng governor body to park
gear to 11 N*m (95 in. lbs.) torque.
OUTPUT
SHAFT
GOV E R NOR
BODY
GOV E R NOR
VALVE
BORE
J9221-52
Fig. 120 Governor Valve And Output Shaft Spotface
Alignment32RH
GOVERNOR/ PARK GEAR ASSEMBLY
GOV E R N OR
VALVE
SHAFT
BORE
J9121-130
Fig. 121 Installing Governor Body And Park
Gear-32RH
i n val ve and i n output shaft. If val ve shaft bi nds,
governor/ park gear i s mi sal i gned.
E-CLIP (2 REQ'D)
G O V E R N O R
VALVE
\- SHAFT
Fig. 122 Installing Governor Valve And Shaft32RH
(26) Rotate output shaft unt i l opposite end of gov-
ernor valve shaft is facing upward. Then install re-
mai ni g E-clip on governor valve shaft (Fig. 123). Be
very sure both E-clips are firmly seated on shaft.
GOVERNOR
VALVE
SHAFT
J9121-188
Fig. 123 Securing Governor Valve Shaft32RH
(27) Install snap ri ng t hat ret ai ns governor body
(28) Install output shaft t hr ust plate on shaft hub
(Fig. 125) . Use petroleum jelly to hold t hrust plate in
place.
(29) Check input shaft seal rings (Fig. 126). Verify
t hat diagonal-cut ends of teflon seal ri ng are properly
joined and ends of metal ri ng are correctly hooked to-
gether. Also be sure ri ngs are installed sequence
shown.
(30) Check rear clutch t hr ust washer. Use addi-
tional petroleum jelly to hold washer in place if nec-
essary.
(25) Install first E-clip on governor valve shaft.
Then install governor valve and shaft in governor
body (Fig. 122). Be sure val ve shaft moves freely

Fig. 124 Installing Governor Body Snap Ring32RH
Fig. 125 Installing Output Shaft Thrust PIate-32RH
Fig. 126 input Shaft Seal Ring Location-32RH
(31) Align clutch discs in front clutch and install
front clutch on rear clutch (Fig. 127). Rotate front
clutch ret ai ner back and forth unt i l completely
seated on rear clutch.
Fig. 127 Assembling Front And Rear Clutch
Units-32RH
(32) Coat output shaft t hrust washer with petro-
leum jelly. Then install washer in rear clutch hub
(Fig. 128). Use enough petroleum jelly to hold
washer in place. Be sure grooved side of washer
faces rearward (toward output shaft) as shown.
Al so note that washer only fits one way in
cl utch hub.
Fig. 128 Installing Output Shaft Thrust
Washer-32RH
(33) Align drive t eet h on rear clutch discs with
small screwdriver (Fig. 129). This will make installa-
tion on front pl anet ary easier.
(34) Raise front end of transmission upward as far
as possible and support case with wood blocks. Front/
r ear clutch and oil pump assemblies are easier to in-
stall if transmission is as close to upri ght position as
possible.
(35) Install front and rear clutch uni t s as assembly
(Fig. 130). Align rear clutch with front annul us gear
and install assembly in driving shell. Be sure out-
put shaft thrust washer and thrust plate are not
di spl aced duri ng installation.

Fig. 129 Aligning Rear Clutch Disc Lugs32RH
(36) Carefully work assembled clutches back and
forth to engage and seat r ear clutch discs on front
annul us gear. Verify t hat front clutch drive lugs are
fully engaged in slots of driving shell after installa-
tion.
J9121-124
Fig. 130 Installing Front/Rear Clutch
Assemblies32RH
(37) Slide front band over front clutch ret ai ner
(Fig. 131).
(38) Insert front band reaction pin part way into
case (Fig. 131).
(39) Install front band lever, strut, lever pin and
adjusting screw (Fig. 132).
j ust grips clutch ret ai ner. Verify t hat front/rear
clutches are still seated before continuing.
Fig. 131 Installing Front Band And Reaction
Pin-32RH
BAND BAND
Fig. 132 Front Band Linkage Installation32RH
(41) Coat band lever pin access plug with sealer
and install plug in converter housing (Fig. 133).
Fig. 133 Installing Front Band Reaction Pin Access
Plug-32RH
(42) Check reaction shaft support hub. Verify t hat
seal rings are hooked together and t hat front clutch

t hrust washer is properly positioned (Fig. 134). Use
extra petroleum jelly to hold t hr ust washer in place
if necessary.
SEAL
RI NGS J9121-194
Fig. 134 Reaction Shaft Support Seal Rings And
Front Clutch Thrust Washer Position32RH
(43) Thread two Pilot Stud Tools C-32S8-B into
bolt holes in oil pump flange (Fig. 135).
(44) Align and install oil pump gasket (Fig. 135).
Fig. 135 Installing Pilot Studs And Oil Pump
Gasket-32RH
(45) Lubricate oil pump seals with t ransmi ssi on
fluid, petroleum jelly, or Ru-Glyde.
(46) Install oil pump (Fig. 136). Align and position
pump on pilot studs. Slide pump down studs and
work it into front clutch hub and case by hand. Then
install two or t hree pump bolts to hold pump in
place.
(47) Remove pilot stud tools and install remai ni ng
oil pump bolts. Ti ght en bolts al t ernat el y in diagonal
pat t ern to 20 N-m (15 ft-lbs).
Fig. 136 Installing Oil Pump And Reaction Shaft
Support-32RH
(48) Measure i nput shaft end play (Fig. 137). At-
tach dial indicator to converter housing. Position in-
dicator plunger agai nst i nput shaft and zero
indicator. Move i nput shaft in and out and record
reading. End play should be 0.56 - 2.31 mm (0.022 -
0.091 in.). If end play is incorrect, change output
shaft t hrust washer and/or t hr ust plate.
Fig. 137 Checking Input Shaft End Play-32RH
(49) Make sure neut ral switch has not been in-
stalled in case. Remove switch if necessary as it will
interfere with valve body installation.
(50) Install new seal rings on accumulator piston
(Fig. 138). Lubricate accumulator piston, seals and
accumulator bore with transmission fluid.
(51) Install accumulator piston and spring (Fig.
138) in case.
(52) Place valve body manual lever in low to move
park lock rod rearward.

Fig. 138 installing Accumulator Piston And
Spring32RH
(53) Position valve body on case. Work park rod
past sprag and install valve body-to-case bolts finger
tight.
(54) Install neutral switch in case. Tighten switch
(55) Align valve body on case (Fig. 139). Tighten
valve body-to-case bolts alternately and evenly to 12
Nm (105 in. lbs.) torque. Start at center and work
outward when tightening bolts. Do not overtighten
val ve body bolts. Thi s coul d result in distortion
and cross l eakage after Installation..
VALVE
Fig. 139 Installing Valve Body32RH
TRANSMISSION OVERHAUL32RH 21 - 1S1
(56) Install new filter on valve body. Tighten filter
screws to 4 Nm (35 in. lbs.).
(57) Position new extension housing gasket on
transmission case. Use petroleum jelly to hold gasket
in place.
(58) Install rear bearing and snap ring on output
shaft.
(59) Install extension housing on transmission
case. Tighten housing fasteners to 33 Nm (24 ft.
lbs.). Be sure park lock rod is properly engaged in
sprag before tightening fasteners.
(60) Adjust front/rear bands as follows:
(a) Loosen locknut on each band adjusting screw
4-5 turns.
(b) Tighten both adjusting screws to 8 N*m (72
in. lbs.).
(c) Back off front band adjusting screw 2-1/2
turns and rear band adjusting screw 4 turns.
(d) Hold each adjusting screw in position and
tighten locknuts to 34 N*m (25 ft. lbs.).
(61) Install new pan gasket on transmission and
install oil pan. Tighten pan bolts to 17 Nm (13 ft.
lbs.).
(62) Turn transmission over.
(63) Install new manual lever shaft seal in case.
Use 15/16 deep well socket to install seal.
(64) Install throttle valve and manual valve levers
on shaft.
(65) Lubricate converter hub with transmission
fluid and carefully install converter. Turn converter
back and forth until seated. Be sure converter hub
slots are fully seated in oil pump gear lugs.
(66) Secure converter in oil pump before mounting
transmission on jack and before moving transmission
back under vehicle. Use metal strapping or small
C-clamp to hold converter in place. Attach strapping
or clamp to converter housing.
CAUTI ON : The t r ansmi ssi on cool er and l i nes must
be reverse fl ushed if overhaul corrected a mal func-
tion that generated sl udge, metal particl es, or
cl utch friction material. The torque converter shoul d
al so be repl aced if contami nated by the s ame mal -
functi on. Debr i s and resi due not fl ushed from the
cool er and lines will fl ow back into the t r ansmi ssi on
and converter. The resul t coul d be a repeat failure
and s hop comeback.
21 - 192 TRANSMISSION OVERHAUL38RH/37RH

TRANSMISSION OVERHAUL36RH/37RH
INDEX
page
Ex tension H ousi ng and Park Lock Components . 202
Front Clutch Overhaul 210
Front Ser vo and Band Overhaul 207
Governor and Park Gear Overhaul . 202
Oil Pump and Reaction Shaft Support Overhaul . 208
Overhaul Service Information . . 202
Overrunning Clutch Overhaul 204
Planetary Gear Train and Output Shaft Overhaul . 214
TRANSMISSION DISASSEMBLY
(1) Clean transmission exterior with st eam gun or
solvent. Wear safety goggles while cleaning t rans-
mission.
(2) Mount transmission on Repair St and C-3750-B
(Fig. 1).
Fig. 1 Transmission Mounted On Repair Stand
C- 37 5 0- 0
(3) Remove bolts at t achi ng extension housi ng to
transmission case. Then remove rear beari ng snap
ri ng access cover from housing (Fig. 2)
(4) Spread r ear beari ng locating ri ng with parallel
j aw snap ri ng pliers (Fig. 2). Then work extension
housing off beari ng and output shaft. Remove hous-
ing gasket after removing housing.
(5) Remove rear beari ng and snap ri ngs from out-
put shaft (Fig. 3). Note t hat two snap ri ngs are used
to ret ai n beari ng on 36RH.
(6) Remove t hrot t l e and manual valve levers from
valve body manual shaft.
(7) Remove oil pan bolts and remove pan (Fig. 4)
and gasket (Fig. 5). Oil pan magnet can be removed
page
Rear Clutch Overhaul 212
Rear Servo and Band Overhaul 207
Rear Support and Low- Reverse Drum Service . . 204
Transmi ssi on Assembl y and Adjustment . . . . . . 224
Transmi ssi on Case Cl eaning and Inspection . . . 202
Transmi ssi on Di sassembl y . . . . . . . . . . . . . . . . . 192
Valve Body Service and Adjustment 217
Fig. 2 Extension Housing Removal36RH/37RH
Fig. 4 Removing/Installing Oil Pan-36RH/37RH

TRANSMI SSI ON OVERHAUL36RH/37RH 2 1- 193
or left in pan as needed (Fig. 6). Exercise care when
removing pan to avoid distorting or bendi ng pan
flange.
Fig. 5 Removing/installing Pan Gasket36RH/37RH
Fig. 6 OH Pan Magnet Location36RH/37RH
(8) Remove neut ral switch (Fig. 7) . If switch gas-
ket is in good condition, ret ai n gasket and keep it
wi t h switch.
Fig. 7 Neutral Switch Removal/Installation
(9) Remove t hree fluid filter at t achi ng screws and
remove filter (Fig. 8).
Fig. 8 Fluid Filter Removal/installation36RH/37RH
(Fig. 9).
Fig. 9 Valve Body Attaching Bolt Locations36RH/
37RH
(11) Lift valve body upward, guide park rod out of
case opening and remove valve body (Fig. 10).
Fig. 10 Valve Body Removal/Installation36RH/
37RH
21 - 194 TRANSMISSION OVERHAUL36 RH/37RH

(12) Remove accumulator spring and piston (Fig.
11). Note position of piston and spring for assembly
reference. Remove and discard piston seals if worn or
cut.
Fig. 11 Removing/Installing Accumulator Piston And
Spring-36RH/37RH
(13) Remove front band lever pin access plug (Fig.
12). Square end of 1/4 inch drive extension can be
used to remove plug as shown.
Fig. 12 Removing/Installing Front Band Lever Pin
Access Plug-36RH/37RH
(14) Remove oil pump and reaction shaft support
assembly as follows:
(a) Tighten front band adjusting screw unt i l
band is t i ght around front clutch ret ai ner (Fig. 13).
This will prevent ret ai ner from coming out wi t h
pump and possibly damagi ng clutch or pump com-
ponents.
(b) Remove oil pump bolts.
(c) Thread Slide Hammer Tools C-3752 into
t hreaded holes in flange of oil pump housing (Fig.
14).
Fig. 13 Tightening Front Band To Hold Front Clutch
In PIace-36RH/37RH
Fig. 14 Installing OH Pump Remover Tools36RH/
37RH
(d) Remove oil pump and reaction shaft support
by bumpi ng slide hammers outward al t ernat el y to
pull pump from case (Fig. 15).
Fig. 15 Removing Oil Pump-36RH/37RH
# , , TRANSMISSION OVERHAUL38RH/37RH 21 - 115
(15) Remove oil pump gasket (Fig. 16). Note gas-
ket position in case for assembly reference.
Fig. 16 Removing Oil Pump Gasket36RH/37RH
(17) Remove front band st rut and anchor (Fig. 17).
(18) Squeeze front band together slightly and slide
band over front clutch ret ai ner and out of case (Fig.
18).
LEVER STRUT
J9121-18
Fig. 17 Front Band Linkage-36RH/37RH
Fig. 18 Removing Front Band36RH/37RH
(19) Remove front and rear clutch assemblies as a
uni t (Fig. 19). Set assemblies aside for disassembly
and inspection after removal.
Fig. 19 Removing Front And Rear Clutch
Assemblies36RH/37RH
(20) Remove front band reaction pin and lever.
St art pin t hrough lever and out of case bore. Use
pencil magnet to complete pin removal (Fig. 20).
(21) Remove t ri angul ar shaped t hr ust washer from
output shaft hub if washer remai ned on hub during
clutch removal (Fig. 21 ) . Or remove washer from in-
put shaft hub in rear clutch if washer remained in
hub during removal.
2 1 - 1 1 8 TRANSMISSION OVERHAUL36 RH/37RH

Fig. 20 Removing Front Band Lever And Pin36RH/
37RH
Fig. 21 Removing Output Shaft Thrust Washer-36RH/37RH
(22) Remove t hr ust plate from output shaft hub
(Fig. 22).
Fig. 22 Removing Output Shaft Thrust Plate-36RH/
37RH
(23) If the output shaft or planetary geartrain
components must be di sassembl ed for service,
conti nue on to step (24). However, if the shaft
and geartrain components do not need servic-
ing, the shaft and geartrain can be removed as a
unit (Fig. 23). In this case, simply remove the
governor val ve shaft, governor a n d park gear
a nd remove the compl ete assembl y.
Fig. 23 Removing Output Shaft And Planetary
Geartrain-36RH/37RH
(24) Remove pl anet ary gear ret ai ni ng snap ri ng
from output shaft (Fig. 24). Retain snap ri ng if in
good condition (it is reusable).
Fig. 24 Removing Planetary Snap Ring36RH/37RH
(25) Remove front pl anet ary gear and front annu-
lus gear from output shaft as assembly (Fig. 25).
(26) Remove front pl anet ary gear and t hr ust
washer from front annul us gear (Fig. 26). Note
t hr ust washer position for assembly reference.

TRANSMISSION OV E RH AUL- 36 RH / 37 RH 21 - 197
Fig. 25 Removing Front Planetary And Annulus
Gears36RH/37RH
FRONT
Fig. 2 6 Disassembling Front Planetary And Annulus
Gears36RH/37RH
(27) Remove tabbed t hr ust washer from dri vi ng
shell (Fig. 27). Note washer position for assembly ref-
erence.
Fig. 27 Removing Driving Shell Thrust
Washer-36RH/37RH
(28) Remove sun gear and driving shell (Fig. 28).
FRONT
Fig. 28 Removing Sun Gear And Driving
Shell-36RH/37RH
21 - 118 TRANSMISSION OV E RH I UL- 36 RH / 37 RH
(29) Remove tabbed t hrust washer from rear plan- (31) Remove rear pl anet ary t hr ust plate from rear
et ary gear (Fig. 29). Note washer position on gear for annul us gear (Fig. 31).
assembly reference.
Fig. 29 Removing Rear Planetary Thrust
Washer-36RH/37RH
(30) Remove rear pl anet ary gear from annul us
gear (Fig. 30).
J 91 21 - 30
Fig. 30 Removing Rear Planetary Gear36RH/37RH
Fig. 31 Removing Rear Planetary
Plate-36RH/37RH
(32) Remove rear annul us gear from
(Fig. 32).
J9121-31N
Thrust
output shaft
J91 21 - 32
Fig. 32 Removing Rear Annulus Gear-36RH/37RH

TRANSMISSION OV E RH AUL- 36 RH / 37 RH 21 - 199
(33) Remove output shaft, park gear and governor
assembly from rear of case (Fig. 33).
(36) Slide low-reverse drum off rear support hub
and out of rear band (Fig. 1).
REAR
BA N D
A N D LINK
LOCATING
S NAP RI NG
Fig. 33 Removing Output Shaft, Park Gear And
Governor Assembly36RH/37RH
(34) Loosen rear band adjusting screw.
(35) Remove snap ri ng securing low-reverse drum
to rear support (Fig. 34).
J9221-7
Fig. 35 Removing Low-Reverse Drum36RH/37RH
(37) Note t hat overrunning clutch race will remai n
on splines of low-reverse drum after removal (Fig.
36). The race is a permanent press fit on the hub
spl i nes. Do not attempt to remove the race.
REAR
BAND
LOW-REVERSE
DRUM
REAR
SUPPORT
OV E RRUNNI NG
CLUTCH
RACE
LOW-REVERSE
DRUM
DRUM
RETAI NI NG
SNAP
RI NG
J91 21 - 34
Fig. 34 Removing Low-Reverse Drum Snap
Ring36RH/37RH
J9221-8
Fig. 36 Overrunning Clutch Race Position36RH/
37RH
, CLUTCH
s \ / C A M
REAR
BAND ADJUSTING
LEVER
Fig. 37 Removing Overrunning Clutch36RH/37RH
(38) Remove overrunni ng clutch assembly (Fig.
37). Assembly can be removed without displacing
rollers and springs if care is exercised. Note position
of rollers and springs for assembly reference.
(39) St art rear band reaction pin out of case with
punch or drift (Fig. 38).
(40) Remove band adjusting lever, reaction lever
and reaction pin (Fig. 39).
(41) Remove st rut from rear band. Keep st rut wi t h
levers and pin for cleaning, inspection and assembly
reference.
RtAR
BAND
REACTION
PIN
Fig. 39 Removing Rear Band Levers And Reaction
Pin-36RH/37RH
SELECT
FIT
PLANETARY
SNAP
RING
FRONT
ANNULUS
SNAP
RING
SUPPORT
SNAP RING
ANNULUS GEAR
SUPPORT
FRONT
ANNULUS
GEAR
FRONT
ANNULUS
THRUST
WASHER
DRIVING
SHELL
REAR
THRUST
PLATE
FRONT
PLANETARY
THRUST
WASHERS
SUN
GEAR
SUN
GEAR
SPACER
DRIVING SHELL FRONT DRIVING
THRUST PLATE SHELL
SUN GEAR
LOCK RING
REAR PLANETARY
THRUST WASHERS
REAR
PLANETARY
GEAR
OUTPUT
SHAFT
THRUST
PLATE
OUTPUT
SHAFT
J9221-17
Fig. 38 Starting Rear Band Reaction Pin Out Of Case36RH/37RH

TRANSMISSION OVERHAUL38RH/37RH 21 - 201
(42) Remove r ear band and link (Fig. 40).
Fig. 40 Removing Rear Band And Link36RH/37RH
(43) Compress front servo rod guide with C-clamp
and Tool C-4470, or Valve Spring Compressor
C-3422-B (Fig. 41). Compress guide only enough to
permi t snap ri ng removal (about 3 mm or 1/8 in.).
(44) Remove servo piston snap ring (Fig. 41). Un-
seat one end of ring. Then carefully work removal
tool around back of ri ng unt i l free of ring groove. Ex-
erci se cauti on when removi ng snap ring. Servo
bore c a n be scratched or ni cked if care is not
exerci sed.
(45) Remove tools and remove servo piston and
spring.
Fig. 41 Removing Front Servo Retaining Snap
Ring36RH/37RH
(46) Compress rear servo piston with C-clamp and
Tool C-4470, or Valve Spring Compressor C-3422-B
(Fig. 42). Compress servo spring ret ai ner only
enough to permit snap ring removal.
(47) Remove servo piston snap ri ng (Fig. 42). St art
one end of ri ng out of bore. Then carefully work re-
moval tool around back of snap ri ng until free of ri ng
groove. Exerci se cauti on when removi ng snap
ring. Servo bore can be scratched or ni cked if
care is not exerci sed.
(48) Remove tools and remove rear servo retainer,
spring and piston assembly.
Fig. 42 Removing Rear Servo Retaining Snap
Ring36RH/37RH
(49) Inspect rear support. If support has arrow and
word "pan" on it, note position for assembly refer-
ence. However, if support does not have arrow or
word, mar k position of support with center punch
(Fig. 43).
(50) Remove rear support bolts and remove support
from case (Fig. 44). Use a twisting motion to remove
support if necessary.
Fig. 43 Marking Rear Support For Assembly
Reference-36RH/37RH
21 - 202 TRANSMI SSI ON OVERHAUL36RH/37RH
Fig. 44 Removing Rear Support36RH/37RH
haul . Bushing condition is i mport ant as worn, scored
accelerated wear of other components. Replace worn,
or scored bushings, or if doubt exists about bushi ng
condition.
seat bushings correctly. The bushi ng replacement
tools are included in Bushi ng Tool Set C-3887-B.
Heli-Coil inserts are recommended for repairing
part s. These i nsert s are available from most automo-
tive jobbers. Stainless steel i nsert s are preferred.
mat t er from getting between t he valve and valve
bore.
mat t er of course. Also do not reuse snap ri ngs or
E-clips t hat are bent or distorted. Replace these par t s
as well.
Plus, Type 7176 transmission fluid duri ng assembly.
This is t he preferred fluid for use in 36RH/37RH
transmissions. Use Mopar Dexron II only when ATF
Pl us is not readily available.
Use Ru-Glyde, Door-Eze, or petroleum jelly to pre-
lubricate seals, O-rings, and t hr ust washers. Petro-
leum jelly can also be used to hold part s in place
duri ng reassembly.
TRANSMISSION CASE CLEAN1NI AND
INSPECTION
Do not use shop towel s or rags to dry the ease
(or any other transmi ssi on component) unl ess
they are made from lint-free materials. Lint will
readily adhere to case surfaces and transmi ssi on
components and will circulate throughout the
transmi ssi on after assembl y. A sufficient quan-
tity of lint can bl ock fluid passages and interfere
wi th val ve body operation.
servo bores, or damaged t hreads. Damaged t hreads
can be repaired with Helicoil t hread inserts. How-
ever, t he case will have to be replaced if it exhibits
damage or wear.
Lubricate t he front band adjusting screw wi t h pe-
troleum jelly and t hread it part way into t he case. Be
sure t he screw t ur ns freely and does not bind.
Remount t he transmission case in Repair Stand
C-3750-B after cleaning and inspection.
EXTENSION HOUSING AND PARK LOCK
COMPONENTS
Clean t he housing and park lock components in
solvent and dry t hem with compressed air.
Exami ne t he park lock components in t he housing.
If replacement is necessary, remove t he shaft with
parallel j aw snap ri ng pliers (Fig. 45) and remove t he
sprag and spring. Then remove t he spring clip and
reaction plug (Fig. 46). Compress the reacti on
pl ug spri ng clip onl y enough to remove and in-
stall it. Do not distort the clip duri ng removal or
installation.
Be sure a replacement sprag is installed so t he
sprag locking lug will face t he park gear (Fig. 47).
Also be sure t he spring is correctly positioned as
shown (Fig. 47). The sprag may not ret ract if t he
spring is improperly installed.
GOVERNOR AND PARK GEAR OVERHAUL
GOWERNOR/PARK GEAR DISASSEMBLY
(1) Loosen bolts at t achi ng governor to park gear.
(2) Remove governor snap ring from output shaft
(Fig. 48).
(3) Remove E-clip securing governor valve shaft
and remove shaft and valve from governor body.
(4) Slide governor and park gear off output shaft.
(5) Remove governor ret ai ni ng bolts and separate
governor from park gear.
(6) Remove governor filter from park gear. Keep
filter wi t h governor body.

TRANSMISSION OVERHAUL36 RH/37RH 21 - 203
Fig. 45 Park Sprag, Shaft And Spring
Removal-36RH/37RH
Fig. 46 Park Sprag Reaction Plug And Spring
Location-36RH/37RH
(7) Remove governor weight snap ri ng and remove
weight assembly from governor body. Remove inner
snap ri ng and separate governor weights.
Fig. 48 Governor Snap Rings36RH/37RH
Examine t he governor components carefully (Fig.
49). Discard any snap rings or E-clips if distorted, or
worn. Be sure t he valve and weights operate freely
in the bores and do not bind. Also be sure t he valve
slides freely on t he shaft. Minor scratches or burrs
can be reduced with crocus cloth soaked in t ransmi s-
sion fluid. However, do not at t empt to salvage com-
ponents t hat are severely worn or scored.
There are three governor component changes
on current 36RH/37RH transmi ssi ons that affect
servi ce procedures. The first change i nvol ves
the governor val ve whi ch is now made of alumi-
num. The second change concerns the 37RH
governor wei ght assembl y whi ch is made of al-
Clean t he governor and park gear components in

l oyed b r a s s . The t hi r d c ha nge i nvol ves t he
36RH/37RH o u t p u t shaft wh i c h h a s be e n spot -
f aced f or gove r nor val ve e n d cl ear ance. The n e w
a l u mi n u m v al v e mu s t o n l y b e u s e d wi t h a n out -
put s h a f t t h a t h a s a spot f ace. T h e al l oyed gover -
nor wei ght mu s t onl y b e u s e d I n 37RH di esel
t r ans mi s s i ons . I n addi t i on, t h e gove r nor body
a nd spot f aced si de of t he out put shaf t mus t be
i ndexed dur i ng assembl y.
Check condition of t he park gear seal rings, ri ng
grooves and gear t eet h (Fig. 50). Replace t he gear as
an assembly if t he t eet h or ri ng grooves are worn, or
damaged.
Replace t he park gear front and rear seal rings if
cracked, or worn. The production style front ri ng is a
plain type and t he rear ring is a hook style. If re-
placement rings are both hook-style, be sure t he ri ng
ends are properly hooked together as shown (Fig. 50).
S P R J N G
O U T E R W E I G H T
P A R K
G E A R
R E A R F R O N T
S E A L S E A L
R I N G R I N G
S N A P *
R I N G S
I N N E R W E I G H T
V A L V E T S H A F T
V A L V E
S N A P
R I N G
F I L T E R S C R E E N
G O V E R N O R
V A L V E
S P O T F A C E
J9221-51
Fig. 49 Governor Components36RH/37RH
ASSEMBLING GOVERNOR AND PARK GEAR
The al l oyed brass governor wei ght assembl y is
desi gned for excl usi ve use in 37RH di esel trans-
mi ssi ons. Do not i nterchange this wei ght assem-
bly.
(1) Coat governor body bores governor components
with t ransmi ssi on fluid.
(2) Assemble and install governor weights and
spring in governor body but do not install shaft and
valve at t hi s time. These part s will not be installed
unt i l after governor and park gear are installed on
out put shaft.
(3) Install new seal rings on park gear if neces-
sary.
J9121-48
Fig. 50 Park Gear And Seal Rings36RH/37RH
(4) Insert filter screen in park gear and install
governor body on park gear.
(5) Install governor body-to-park gear bol ts
finger tight only. Bol ts are fully ti ghtened only
after installation on output shaft. This is neces-
sary to ensure proper al i gnment of park gear
and governor body.
REAR SUPPORT AND LOW-REVERSE DRUM
SERVICE
Clean t he drum and support in part s cleaning sol-
vent and dry t hem with compressed air.
Inspect t he drum and support for evidence of wear,
scoring, or cracks. Assemble t he support, drum and
overrunning clutch race and check fit of t he compo-
nent s.
Exami ne t he overrunni ng clutch race. The race is a
permanent press fit on t he hub splines of t he low-re-
verse drum. The drum and race are replaced as an
assembly if either part is worn or damaged. Also
check fit of t he race on t he drum. Replace t he assem-
bly if t he race is loose on t he hub splines.
OVERRUNNING CLUTCH OVERHAUL
Inspect condition of t he overrunning clutch compo-
nent s.

TRANSMI SSI ON OVERHAUL36RH/37RH 21 - 201
Replace t he clutch cam if worn or damaged in any
way. Also check fit of t he cam in t he transmission
case. If t he cam is loose, t he case may worn, or
cracked.
The clutch race is a permanent press fit on t he low-
reverse drum hub splines. The drum and race are to
be replaced as an assembly if either par t is worn or
damaged. Replace t he race and drum if the drum is
damaged or the race is spalled, scored, cracked, or
loose.
Examine t he overrunni ng clutch rollers, springs
and ret ai ner. Replace t he assembly if t he rollers are
worn, chipped, or cracked. Replace t he assembly if
the springs are distorted, or damaged, or if t he cage
type ret ai ner is bent or broken.
If t he clutch cam must be replaced, install t he new
cam as follows:
REPLACING OVERRUNNING CLUTCH CAM
AND SPRING RETAINER
(1) Remove clutch cam setscrew (Fig. 51).
Fig. 51 Removing/installing Clutch Cam
Setscrew-36RH/37RH
(2) Tap old cam out of case with pin punch. Insert
punch t hrough bolt holes at rear of case (Fig. 52). Al-
t ernat e position of punch to avoid cocking cam dur-
ing removal.
(3) Clean clutch cam bore and case. Be sure to re-
move all chips/shavings generated during cam re-
moval.
(4) Install rear support in case. Align support with
reference mar ks made at disassembly.
(5) Align and st art new clutch cam in case. Be
sure serrations on cam and i n case are aligned. Then
t ap cam into case j ust enough to hold it in place.
(6 ) Verify that cam is correctly posi ti oned be-
fore proceedi ng any further. Narrow ends of
cam ramps shoul d be to left when cam is vi ewed
from front end of case.
Fig. 52 Removing Overrunning Clutch Cam36RH/
37RH
(7) Insert Adapter Tool SP-5124 into r ear support
(Fig. 53).
Fig. 53 Positioning Adapter Tool In Rear
Support-36RH/37RH
(8) Assemble Puller Bolt SP-3701 and Press Pl at e
SP-3583-A (Fig. 54).
(9) Install assembled puller plate and bolt (Fig.
55). Insert bolt t hrough cam, case and adapter tool.
Be sure plate is seated squarely on cam.
(10) Hold puller plate and bolt in place and install
puller nut on puller bolt (Fig. 56).
(11) Tighten puller nut to draw clutch cam into
case (Fig. 56). Be s ur e c a m I s d r a w n I n t o cas e
evenl y a n d does n o t become cocked.
(12) Install clutch cam setscrew (Fig. 50).
(13) Remove clutch cam installer tools and rear
support.
(14) St ake case in 12 places around new clutch
cam to help secure cam in case. Use bl unt punch or
chisel to stake case.

PULLER
BOLT
SP-3701
ADAPTER
J91 21 - 58
Fig. 54 Assembling Clutch Cam Puller Bolt And
Press Piate-36RH/37RH
BE SURE
PLATE IS
SEATED SQUARELY
O N C AM
J9121-59
Fig. 55 Positioning Puller Plate On Clutch
Cam-36RH/37RH
(15) Clean case and cam thoroughly. Be sure any
chips/shavings generated during cam installation are
removed from case.
INSTALLING OVERRUNNING CLUTCH
(1) Lubricate rear support hub, clutch race, clutch
cam, and overrunni ng clutch rollers with t ransmi s-
sion fluid or petroleum jelly.
(2) If any overrunni ng clutch rollers and springs
came out of ret ai ner, reinstall t hem as follows: In-
stall and seat spring in ret ai ner first. Then insert
roller between spring and ret ai ner stop as shown
(Fig. 57). Verify t hat each roller and spring are fully
TIGHTEN
PULLER
NUT TO
D R A W CAM
I NTO CASE
J91 21 - 6 0
Fig. 56 Installing Overrunning Clutch Cam36RH/
37RH
J 9 2 2 M 0
Fig. 57 Overrunning Clutch Roller, Spring And
Retainer Assembly36RH/37RH
(3) Install and seat clutch assembly in cam (Fig.
58). The retainer is a one-way fit i n the cam. The
flanged side of the retainer shoul d be faci ng out-
ward. The retainer and rollers will slip easily
into the cam when properly posi ti oned.
(4) Align and install rear support. Tighten rear
support bolts to 11 N
#
Fig. 58 Overrunning Clutch Seated in Cam36RH/
37RH
Checking Clutch Operation
(1) Temporarily install low-reverse drum to check
overrunning clutch operation.
(2) Tilt drum slightly and carefully engage clutch
race in clutch rollers.
(3) Raise drum to level position. Then rot at e drum
in clockwise direction unt i l fully seated.
(4) Check clutch operation by t urni ng low-reverse
drum back and forth. Drum should rotate freely in
clockwise direction but lock in counterclockwise di-
rection.
(5) Remove low-reverse drum after checking clutch
operation.
SERVO AND BAND INSPECTION
Clean t he servo piston components with solvent
and dry t hem with compressed air. Wipe t he band
clean with lint free shop towels.
Replace t he front band if distorted, lining is
burned, flaking off, or worn to t he point where t he
grooves in t he lining mat eri al are no longer visible.
if collapsed, distorted or broken. Replace t he guide,
Check t he servo piston bore for wear. If t he bore is
severely scored, or damaged, it will be necessary to
replace t he case.
FRONT SERVO PISTON OVERHAUL (FIG. 59)
(1) Remove seal ri ng from rod guide.
(2) Remove small snap ring from servo piston rod.
Then remove piston rod, spring and washer from pis-
ton.
(3) Remove and discard servo component O-ring
and seal rings.
(4 ) Lubricate new O-ring and seal rings with pe-
troleum jelly and install t hem on piston, guide and
rod.
(5) Install rod in piston. Install spring and washer
on rod. Compress spring and install snap ring.
(6) Set servo components aside for installation dur-
ing transmission reassembly.
RH307
Fig. 59 Front Servo Components36RH/37RH
SERVO AND BAND INSPECTION
Inspect t he servo components. Replace t he spring if
collapsed, distorted or broken. Replace t he plug and
piston if cracked, bent, or worn. Discard t he servo
snap ri ng if distorted or warped.
ing is worn (grooves no longer visible at any point on
t he lining material).
REAR SERVO PISTON OVERHAUL (FIG. 60)
(1) Remove small snap ring and remove plug and
spring from servo piston.
(2) Remove and discard servo piston seal ring.
(3) Lubricate piston and guide seals with petro-
leum jelly. Lubricate other servo part s with t rans-
mission fluid.
(4) Install new seal ri ng on servo piston.
(5) Assemble piston, plug, spring and snap ring.
(6) Lubricate piston seal lip with petroleum jelly.
(7) Set servo components aside for assembly instal-
lation.

S NAP
RI NG
PISTON
SEAL
PI STON
PLUG
SPRI NG
RETAINER
SN AP
RI NG
PISTON
CUS HI ON
SPRI NG
PISTON
SPRI NG
J9121-64
Fig. 60 Rear Servo Components36RH/37RH
OVERHAUL
DISASSEMBLING PUMP AND SUPPORT (FIG.
61)
(1) Mark position of support with scriber.
(2) Remove support bolts and separate support and
pump body (Fig. 61).
(3) Remove O-ring seal from pump body.
(4) Remove seal rings and t hrust washer from re-
action shaft support.
(5) Clean pump and support components with sol-
vent and dry t hem with compressed air.
INSPECTING PUMP AND SUPPORT
Inspect t he pump and support components. Replace
t he pump or support if t he seal ri ng grooves or ma-
chined surfaces are worn, scored, pitted, or damaged.
damaged. Inspect t he fiber t hrust washer. Replace
t he washer if worn or damaged.
Inspect t he pump and reaction shaft bushings. Re-
place t he bushings only if heavily worn, scored or
damaged. It is not necessary to replace t he bushings
unless they are actually damaged or worn.
Install t he gears in t he pump body and measure
(Fig. 62). Clearance should be 0.025 to 0.064 mm
(0.001 to 0.0025 in.).
Fig. 61 Oil Pump And Reaction Shaft Components36RH/37RH

TRANSMISSION OVERHAUL36 RH/ 37RH 21 - 209
Measure side clearances wi t h feeler gauge (Fig.
63). Clearance between gear t eet h and between outer
gear and pump body should be 0.89 to 1.90 mm
(0.0035 to 0.0075 in.).
STRAIGHTEDGE PUMP
Fig. 62 Checking Pump Gear End Clearance
(1) Position pump housing on clean, smooth sur-
face wi t h gear cavity facing down.
(2) Remove bushi ng with Tool Handle C-4171 and
Bushi ng Remover SP-3550 (Fig. 64).
(3) Assemble Tool Handle C-4171 and Bushi ng In-
staller SP-5118 (Fig. 6 4 ) .
(4) Place bushing on installer tool and st art bush-
ing into shaft (Fig. 64).
(5) Tap bushi ng into place until Installer Tool SP-
3550 bottoms in pump cavity (Fig. 64). Keep tool and
bushi ng square with bore. Do not allow bushi ng to
become cocked duri ng installation.
(6) St ake pump bushi ng in two places wi t h bl unt
punch. Remove burrs from stake points with knife
blade (Fig. 65).
BUSHING
(1) Assemble Cup Tool SP-3633, Nut SP-1191 and
Bushi ng Remover SP-5301 (Fig. 66).
(2) Hold cup tool firmly against reaction shaft.
Thread remover tool into bushing as far as possible
by hand.
(3) Using wrench, t hread remover tool an addi-
tional 3-4 t ur ns into bushing to firmly engage tool.
(4) Tighten tool hex nut against cup tool to pull
bushi ng from shaft. Clean all chips from shaft and
support after bushing removal.
(5) Place reaction shaft support upright on a clean,
smooth surface.
(6) Assemble Bushi ng Installer Tools C-4171 and
SP-5302 (Fig. 66). Then slide new bushi ng onto in-
staller tool.
J8921-388
Fig. 63 Checking Pump Gear Side Clearances
(7) St art bushi ng in shaft. Tap bushi ng into shaft
unt i l installer tool bottoms agai nst support flange
(Fig. 66).
bushi ng replacement (to remove any chips).
SHAFT SUPPORT
(1) Lubricate pump gears wi t h transmission fluid
and install t hem in pump body.
(2) Install new t hr ust washer and seal rings on re-
action shaft support. Lubricate seal rings wi t h t rans-
mission fluid or petroleum jelly.
(3) Align and install reaction shaft support on
pump body.
21 - 210 TRANSMISSION OV E RH AUL- 36 RH / 37RH

SPECIAL
TOOL
C-4171
BUSHING
m REMOVAL
PUMP HOUSING
SPECIAL
TOOL
C-4171
SPECIAL TOOL
SP-3550
BUSHING
SPECIAL
TOOL
SP-5118
J9221-244
Fig. 64 Oil Pump Bushing Replacement36RH/
37RH
mm
Fig. 65 Staking And Deburring Oil Pump Bushing
(4) Install bolts at t achi ng reaction shaft support to
pump. Tighten bolts to 20 Nm (175 in. lbs.) torque.
(5) Install new pump seal wi t h Seal Installer
C-3860-A and Tool Handle C-4171.
(6) Install new O-ring on pump body. Lubricate oil
seal and O-ring with transmission fluid or petroleum
jelly.
(7) Set pump and support aside for assembly in-
stallation.
(1) Remove waved snap ri ng and remove pressure
plate, clutch plates and driving discs (Fig. 67).
SPECIAL
TOOL
SP-119
SPECIAL
TOOL
C-4171
SPECIAL
TOOL
SP-5302
BUSHING
BUSHING
X REACTION
SHAFT
BUSHING
REMOVAL BUSHING
INSTALLATION
J9221-245
Fig. 66 Reaction Shaft Bushing
Replacement36RH/37RH
(2) Compress clutch piston ret ai ner and springs
with Compressor Tool C-3863-A (Fig. 68).
(3) Remove piston snap ri ng and spring ret ai ner
(Fig. 6 7) .
(4) Remove piston springs. Note number and po-
sition of pi ston spri ngs for assembl y reference.
(5) Remove compressor tool and remove clutch pis-
ton.
(6) Remove and discard clutch piston seals. Also
discard spring ret ai ner snap ring.
FRONT CLUTCH CLEANING AND INSPECTION
Clean and inspect t he front clutch components. Re-
place t he clutch discs if warped, worn, scored, burned
or charred, t he lugs are damaged, or if t he facing is
flaking off. Replace t he steel plates if heavily scored,
warped, or broken. Be sure t he driving lugs on t he
discs and plate are also in good condition. The lugs
must not be bent, cracked or damaged in any way.
Replace t he piston springs and spring ret ai ner if ei-
t her are distorted, warped or broken.
place t he piston ret ai ner if t he grooves are worn or
piston ret ai ner. The ball must move freely and not
stick.
t here is any doubt about bushi ng condition.
wi t h crocus cloth. However, replace t he piston and/or
4 _ , TRANSMISSION OVERH AUL3IRH / 37RH 21 - 211
PISTON SEAL
REACTI ON PLATE J9121-65
SPECIAL
TOOL
C-3863-A
Fig. 67 Front Clutch Components36RH/37RH
(5) Install new bushing until installer head bot-
toms agai nst ret ai ner (Fig. 69).
(6) Remove installer tools and clean ret ai ner thor-
oughly.
RH290
Fig. 68 Removing Front Clutch Spring Retainer
Snap Ring-36RH/37RH
REPLACING FRONT CLUTCH RETAINER
BUSHING
(1) Assemble Tool Handle C-4171 and Bushing Re-
mover SP-3629 (Fig. 69).
(2) Insert remover tool in bushing and drive bush-
ing st rai ght out of piston retainer.
(3) Mount Bushing Installer SP-5511 on tool han-
dle (Fig. 69).
(4) Slide new bushing onto installer head and st art
bushing in ret ai ner.
SPECIAL
TOOL-
C-4171
FRONT CLUTCH
RETAINER
I t BUSHING
REMOVAL
SPECIAL
TOOL
SP-3629
SPECIAL
TOOL
C-4171
SPECIAL
TOOL
SP-5511
J9221-247
Fig. 69 Front Clutch Retainer Bushing
Replacement36RH/37RH
(1) Soak clutch discs in transmission fluid.
(2) Lubricate new inner and outer piston seals
with Ru-Glyde, or Door Ease.
(3) Install new seals on clutch piston. Be sure seal
lips face interior of retainer.

motion to seat piston in ret ai ner. Do not f or ce pi s-
t on s t r ai ght i n. Thi s coul d fold seal s over caus -
i ng l eakage a nd cl ut ch sl i p.
(5) Install clutch piston springs. If clutch has nine
springs, position springs as shown (Fig. 70).
9 SPRI NG
CLUTCH
11 SPRI NG
CLUTCH
13 SPRI NG
CLUTCH
J9221-260
Fig. 70 Front Clutch Spring Position36RH/37RH
(6) Install ret ai ner on piston springs.
(7) Compress spring ret ai ner and piston springs
with Compressor Tool C-3863-A.
(8) Install new spring ret ai ner snap ri ng and re-
move compressor tool.
(9) Lubricate clutch plates and pressure plate with
transmission fluid.
(10) Install clutch plates and discs. Install steel
plate followed by a disc unt i l 4 plates and discs are
installed.
(11) Install pressure plate and waved snap ring.
(12) Check clutch pack clearance (Fig. 71). Clear-
ance between waved spring and pressure pl at e
should be 2.08 to 3.83 mm (0.082 to 0.151 in.). If
clearance is incorrect, clutch plates, discs, snap ri ng
and/or pressure pl at e will have to be changed.
FEELER GAUGE RH288
(Typical)
(2) Remove outer pressure plate and steel plates
and discs.
(3) Remove inner pressure plate, wave spring,
spacer ri ng and piston spring.
(4) Remove clutch piston and piston ret ai ner from
clutch ret ai ner. Bump clutch ret ai ner on a wood
block to dislodge piston and retainer.
(5) Remove input shaft t hrust washer.
(6) Remove i nput shaft snap ri ng and press shaft
out of clutch ret ai ner.
(7) Remove and discard clutch piston seals.
(8) Do not remove shaft seal rings unless they are
obviously damaged (broken, cracked).
REAR CLUTCH CLEANING AND INSPECTION
Clean t he clutch components with solvent and dry
ing is flaking off.
Replace t he steel plates and t he pressure plate if
heavily scored, warped, or broken. Be sure t he driv-
ing lugs on t he discs and plates are also in good con-
dition. The lugs must not be bent, cracked or
damaged in any way.
Check t he lug grooves in t he clutch ret ai ner. The
steel plates should slide freely in t he slots. Replace
t he ret ai ner if t he grooves are worn or damaged.
REAR CLUTCH DISASSEMBLY (FIG. 72)
(1) Remove clutch pack select fit snap ring.
# . . , , TRANSMISSION OV E RH AUL- 3I RH / 37 RH 21 - 213
Fig. 72 Rear Clutch C
Also check action of t he ret ai ner check ball. The ball
must move freely and not stick.
ret ai ner if t he seal surfaces are seriously damaged.
Check t hr ust washer condition. Washer thickness
should be 1.55 to 1.60 mm (0.061 to 0.063 in.). Re-
place t he washer if worn or damaged.
Check condition of t he two seal rings on t he i nput
shaft and t he single seal ring on the piston ret ai ner.
Replace t he seal rings if worn or damaged.
Check t he input shaft for wear, or damage. Replace
ASSEMBLING REAR CLUTCH (FIG. 72)
(1) Soak clutch discs in transmission fluid.
(2) Install new seal ri ngs on i nput shaft and piston
ret ai ner (Fig. 73).
(3) Press input shaft into retainer. Secure shaft
wi t h snap ring. Use new snap ri ng if old one is dis-
torted, or damaged.
(4) Install new seals on clutch piston. Lubricate
piston seals with Ru-Glyde, or Door Ease. Be sure
seal lips face i nput shaft.
(5) Install clutch piston in retainer. Use twisting
motion to seat piston in ret ai ner. Do not push pis-
ton straight in. This coul d distort seal s causi ng
l eakage and cl utch slip.
(6) Install t hrust washer on ret ai ner (Fig. 72). Use
petroleum jelly to hold t hr ust washer in place.
(7) Install assembled piston ret ai ner in clutch re-
t ai ner (Fig. 72).
-36RH/37RH
Fig. 73 Input Shaft And Retainer Seal Ring
Locations-36RH/37RH
(8) Install piston spring, spacer ri ng and wave
spring in clutch retainer. Be sure wave spring is
fully seated. Tap spring into place if necessary.
(9) Lubricate clutch plates with transmission fluid.
(10) Install inner pressure plate.
(11) Install first clutch disc followed by a steel
plate until all discs and plates are installed.
(12) Install outer pressure plate and snap ring.
(13) Check clutch pack clearance with feeler gauge
(Fig. 74). Clearance should be 0.63 to 1.14 mm (0.025
to 0.045 in.). A low limit clearance is preferred.
(14) If clutch pack clearance is incorrect, clutch
pack snap ring, pressure plate, steel plates and discs
will have to be replaced.
21 - 214 TRANSMISSION OVERHAUL3SRH/37RH
SELECTIVE
S NAP RI NG
FEELER
GAUGE
RH295
Fig. 74 Measuring Rear Clutch Pack Clearance
(Typical)
PLANETARY GEAR TRAIN AND OUTPUT SHAFT
OVERHAUL
GEARTRAIN AND SHAFT INSPECTION
Clean t he output shaft and geart rai n components
(Fig. 75). Use part s cleaning solvent and dry wi t h
compressed air.
Remove one of t he snap rings t hat ret ai n t he sun
gear in t he driving shell. Then remove t he sun gear
and t hr ust plate.
place t he sun gear as an assembly if t he gear t eet h
are chipped or worn. Also replace t he gear as an as-
S NAP RI NG
(SELECTIVE)
THRUST
WASHER
FRONT
ANNULUS GEAR
sembly if t he bushings are scored or worn. The sun
gear bushings are not serviceable. Replace t he t hrust
plate if worn, or severely scored. Replace t he driving
shell if distorted, cracked, or damaged in any way.
Inspect t he pl anet ary gear sets and annul us gears.
The pinion gears, pinion shafts, pinion washers and
shaft ret ai ni ng pins are all serviceable and can be re-
placed if worn or damaged. However, if a pinion car-
rier is damaged, t he ent i re pl anet ary gear set must
be replaced as an assembly.
Replace t he annul us gears if t he teeth are chipped,
broken, or worn, or t he gear is cracked. Replace t he
pl anet ary t hr ust plates and t he tabbed t hrust wash-
ers if cracked, scored or worn.
Inspect t he machined surfaces of the output shaft.
Be sure t he oil passages are open and clear. Replace
t he shaft if scored, pitted, or damaged.
PLANETARY GEARTRAIN ASSEMBLY AND
ADJUSTMENT
(1) Lubricate sun gear and pl anet ary gears with
transmission fluid duri ng assembly. Use petroleum
jelly to hold part s in place and to lubricate output
shaft bushi ng surfaces, t hr ust washers and t hrust
plates.
(2) Install front snap ri ng on sun gear and install
gear in driving shell. Then install t hrust plate over
sun gear and agai nst rear side of driving shell. In-
stall rear snap ri ng to secure sun gear and t hr ust
plate in driving shell.
(3) Install rear annul us gear on output shaft (Fig.
76).
(4) Install t hrust plate in annul us gear (Fig. 77).
Be sure plate is seated on shaft splines and agai nst
gear.
DRI VI NG SHELL
THRUST
PLATE
REAR
PLANETARY GEAR
ASSEMBLY
REAR ANNULUS
GEAR
FRONT
PLANETARY GEAR
ASSEMBLY
THRUST
PLATE
OUTPUT SHAFT
LOW-REVERSE
DRUM
J9121-67
Fig. 75 Planetary Geartrain Components36RH/37RH

OUTPUT
SHAFT
J9121-68
Fig. 76 Installing Rear Annulus Gear On Output
Shaft-36RH/37RH
THRUST
PLATE
J9121-69
Fig. 77 Installing Rear Annulus Thrust Plate36RH/
37RH
(5) Install rear planetary gear in r ear annul us
gear (Fig. 78). Be sure planetary carrier is seated
agai nst annul us gear.
REAR
ANNULUS
GEAR
REAR
PLANETARY
GEAR
J9121-70
Fig. 78 installing Rear Planetary Gear36RH/37RH
(6) Install tabbed t hr ust washer on front face of
rear pl anet ary gear (Fig. 79). Seat washer tabs in
matching slots in face of gear carrier. Use extra pe-
troleum jelly to hold washer in place if desired.
REAR
PLANETARY
GEAR
WASHER
J9121-71
Fig. 79 Installing Rear Planetary Thrust
Washer-36RH/37RH
(7) Lubricate sun gear bushings wi t h petroleum
jelly or transmission fluid.
(8) Install sun gear and driving shell on output
shaft (Fig. 80). Seat shell agai nst rear planetary
gear. Verify t hat t hrust washer on pl anet ary gear
was not displaced during installation.
OUTPUT
SHAFT
DRIVING
SHELL
REAR
PLANETARY
GEAR
SUN
GEAR
OUTPUT
SHAFT
J9121-72
Fig. 80 Installing Sun Gear And Driving
Shell-36RH/37RH
(9) Install tabbed t hrust washer in driving shell
(Fig. 81). be sure washer t abs are seated in t ab slots
of driving shell. Use ext ra petroleum jelly to hold
washer in place if desired.
(10) Install tabbed t hrust washer on front plane-
t ary gear (Fig. 82). Seat washer t abs in matching
slots in face of gear carrier. Use ext ra petroleum jelly
to hold washer in place if desired.
2 1 - 2 1 6 TRANSMISSION OVERHAUL36 RH/37RH
Fig. 81 Installing Driving Shell Thrust
Washer-36RH/37RH
Fig. 82 Installing Thrust Washer On Front Planetary
Gear36RH/37RH
(11) Install front annul us gear over and onto front
pl anet ary gear (Fig. 83). Be sure gears are fully
meshed and seated.
(12) Install front pl anet ary and annul us gear as-
sembly (Fig. 84). Hold gears together and slide t hem
onto shaft. Be sure pl anet ary pinions are seated on
sun gear and t hat pl anet ary carrier is seated on out-
put shaft.

Fig. 83 Assembling Front Planetary And Annulus
Gears36RH/37RH
Fig. 84 Installing Front Planetary And Annulus Gear
Assembly-36RH/37RH
(13) Place geart rai n in upri ght position. Rotate
gears to be sure all components are seated and prop-
erly assembled. Snap ri ng groove at forward end of
output shaft will be completely visible when compo-
nent s are correctly assembled.
(14) Install pl anet ary snap ri ng in groove at end of
(15) Turn pl anet ary geart rai n over. Position wood
block under front end of output shaft and support
TAB DRI VI NG

Fig. 85 Installing Planetary Snap Ring36RH/37RH
geart rai n on shaft. Be sure all geart rai n part s have
moved forward agai nst pl anet ary snap ring. This is
important for accurate end play check.
(16) Check planetary geart rai n end play wi t h
feeler gauge (Fig. 86). Insert gauge between rear an-
nul us gear and shoulder on out put shaft as shown.
End play should be 0.15 to 1.22 mm (0.006 to 0.048
in.).
(17) If end play is incorrect, install thinner/thicker
planetary snap ring as needed.
Play-36RH/37RH
VALWE BODY DISASSEMBLY
C A U T I O N : D o not cl amp any part of the val ve body
in a vi se. T hi s practice will distort the valve body
and transfer plate resul ti ng in valve bi nd. S l i de
val ves and pl ugs out carefully. D o not use force at
any time. The val ves and valve body will be dam-
aged if force i s used. A l s o tag or mark the val ve
body spr i ngs for reference a s they are removed. D o
not allow them to become intermixed.
(1) Remove screws at t achi ng adjusting screw
bracket to valve body and transfer plate. Hold
bracket firmly agai nst spring force while removing
last screw.
not disturb adjusting screw settings during re-
moval.
Removal-36RH/37RH
(3) Secure det ent ball and spring in housing with
Detent Ret ai ner Tool 6583 (Fig. 88).
DETENT BALL AND SPRING HOUSING J932M21
Fig. 88 Securing Detent Ball And Spring
(4) Remove manual shaft E-clip, washer and seal
(Fig. 89).
(5) Pull manual shaft and park rod assembly up-
ward out of valve body and off throttle lever.
(6) Remove ret ai ner tool and ret ai n detent ball and
spring (Fig. 89).
(7) Remove t hrot t l e lever (Fig. 89) ,

THROTTLE
LEVER
PARK
ROD
LEVER WASHER
AND
E-CLIP
J9121-80
Fig. 89 Removing Manual And Throttle
Levers-36RH/37RH
MANUAL
LEVER
PARK
ROD
J9121-81
Fig. 90 Park Rod Removal-36RH/37RH
(9) Remove shut t l e valve cover (Fig. 91).
(10) Remove governor valve end plate (Fig. 91).
(11) Remove stiffener plate (Fig. 91).
(12) Remove switch valve, pressure regulator
valve, t hrot t l e valve, t hrot t l e valve detent and man-
ual valve (Fig. 92).
(13) Remove 1-2 and 2-3 valve governor plugs (Fig.
92).
(14) Remove E-clip t hat ret ai ns shut t l e valve and
spring in valve body. Then remove secondary spring
and guides, shut t l e valve, pri mary spring and shut t l e
REGULATOR
VALVE END
PLATE
STIFFENER
PLATE
Q / <o> SHUTTLE
SHUTTLE = VALVE
VALVE SECONDARY
END PLATE SPRI NG
DOWNSHI FT
HOUS I NG
SHIFT
VALVE
END
PLATE
J9121-51
Fig. 91 Stiffener Plate And Shift Valve End
Piates-36RH/37RH
valve t hrot t l e plug (Fig. 92).
(15) Remove shift valve end plate and 3-2 down-
shift housing (Fig. 91). Keep housing screws with
housing for installation reference.
(16) Remove t hrot t l e plug from downshift housing.
Then remove spring ret ai ner and remove limit valve
and spring from downshift housing (Fig. 92).
(17) Remove 1-2 shift control valve and spring, 2-3
shift valve and spring and 1-2 shift valve and spring
(Fig. 92).
(18) Remove regulator valve end plate (Fig. 91).
(19) Remove regulator valve line pressure plug,
pressure plug sleeve, t hrot t l e pressure plug and
spring (Fig. 92).
(20) Turn valve body over so transfer plate is fac-
ing upward. With valve body in t hi s position, valve
body check balls will remai n in place and not fall out
when transfer plate is removed.
(21) Remove screws at t achi ng transfer plate to
valve body and remove transfer plate from valve
body. Note position of valve body check balls for as-
sembly reference.
(22) Position transfer plate on bench so separator
plate and filter are facing up. This will avoid havi ng
rear clutch check ball fall out when plates are sepa-
rated.
(23) Remove screws at t achi ng separator plate to
transfer plate and remove separator plate and filter.
Note position of filter and rear clutch check ball for
assembly reference.
SHI FT VALVE
E N D PLATE
THROTTLE
PLUG
1-2 SHI FT
C O N T R O L VALVE
A N D S PR I N G
SHUTTLE VALVE
S E C O N D A R Y S PR I N G,
2- 3 SHI FT
G U , D E S
-
E
"
C L , P
VALVE A N D
S PR I N G
REGULATOR
VALVE
E N D PLATE
SHUTTLE VALVE
COV E R
REGULATOR
VALVE
PRESSURE
PLUG
REGULATOR
VALVE THROTTLE
PRESSURE
PLUG
2-3 SHI FT
VALVE G O V E R N O R
PLUG
SHUTTLE VALVE
PLUG (ALUM.)
LI NE
PRESSURE
A D J U S T I N G
S CRE W
G O V E R N O R
VALVE E N D
PLATE
M A N U A L LEVER
DETENT BALL
A N D S PR I NG
A D J U S T I N G
SCREW
BRACKET J912 1- 5 2
Fig. 92 Valve Body Components36RH/37RH (ALUM, indicates aluminum part)
21 - 220 TRANSMISSION OVERHAUL36RH/37RH

the:
park lock rod and E-clip
throttle valve lever
manual shaft
manual shaft seal/washer/E-clip/detent ball
fluid filter.
only as part of a complete valve body assembly (Fig.
92).
Clean t he valve body components in a part s clean-
ing solution only. Do not use gasoline, kerosene, or
any type of caustic solution.
Dry the part s with compressed air. Make sure all
passages are clean and free from obstructions.
Do not use rags or shop towel s to dry or wi pe
off val ve body components unl ess they are made
from lint free material. Lint will adhere to the
val ve body components causi ng val ve bind. Lint
can al so cl og filters and small fluid passages.
shafts. Do not attempt to straighten a bent shaft
or correct a l oose lever. Repl ace these compo-
nents if worn, bent , l oose or damaged in any
way.
pressure.
Minor distortion of a valve body mat i ng surface
may be corrected by smoothing t he surface wi t h cro-
cus cloth. Position t he crocus cloth sheet on a surface
plate, sheet of plate glass, or equally flat surface. If
distortion is severe or any surfaces are heavily
scored, t he valve body will have to be replaced.
C A U T I O N : The throttle val ve, shuttle val ve pl ug, 1-2
shift val ve and 1-2 governor pl ug are made of
coated al umi num. Al umi num component s can be
identified by the dark col or of the speci al coati ng
applied to the surface (or by testing with a magnet).
D O N O T pol i sh or sand al umi num val ves or pl ugs
with any type of material, or under any ci rcum-
st ances. T hi s practice will remove the speci al coat-
ing and cause the val ves and pl ugs to sti ck and
bi nd.
Inspect t he valves and plugs for scratches, burrs,
nicks, or scores. Also inspect t he coating on t he alu-
mi num valves and plugs. If t he coating is damaged
or worn t hrough, t he valve (or valve body) should be
replaced.
Al umi num valves and plugs must not be sanded or
polished under any circumstances. However, minor
burrs or scratches on steel valves and plugs can be
removed with crocus cloth but do not round off t he
valve or plug edges. Squareness of these edges is vi-
tally important; they prevent foreign mat t er from
lodging between t he valves and plugs and t he bore.
Inspect all t he valve and plug bores in t he valve
body. Use a penlight to view t he bore interiors. Re-
place t he valve body if any bores are distorted or
scored. Inspect all of t he valve body springs. The
coils.
freedom of operation. When clean and dry, t he valves
and plugs should drop freely into t he bores.
Valve body bores do not change dimensionally with
use. If t he valve body functioned correctly when new,
it will continue to operate properly after cleaning
and inspection. It should not be necessary to replace
a valve body assembly unless it is damaged in han-
dling.
VALVE BODY ASSEMBLY
C A U T I O N : D o not force the val ves or pl ugs into
pl ace duri ng reassembl y. If the valve body bores
and the val ves and pl ugs are free of distortion or
burrs, the val ves and pl ugs shoul d sl i de into place
easi l y. I n addition, do not overtighten the transfer
plate and valve body scr ews duri ng reassembl y.
Overtightening can distort the valve body resulting
in val ve st i cki ng, c r os s l eakage and unsati sfactory
operati on. Ti ghten the scr ews alternately and
evenly to 4 Nnn (35 i n. lbs.) torque onl y.
(1) Lubricate valve body bores, valves and plugs
wi t h ATF Plus, or Dexron II transmission fluid.
(2) Insert rear clutch check ball in transfer plate
and install filter in separator plate (Fig. 93).
SEPARATOR TRANSFER
PLATE PLATE
FILTER BALL J9121-82
Fig. 93 Installing Filter and Rear Clutch Check
Bali36RH/37RH

(3) Align and install separator plate on transfer
plate (Fig. 94).
(4) Verify rear clutch check ball position before se-
curing separat or plate (Fig. 95). Ball should be visi-
ble in fifth orifice at lower ri ght side of separator
plate as shown.
(5) Inst al l stiffener plate on separator plate. Then
secure separat or and stiffener plates to transfer pl at e
with short at t achi ng screws. Tighten screws to 4 Nnn
1/4" DIAMETER
CHECK BALLS
TRANSFER
PLATE
SEPARATOR
PLATE
J9121-83
Fig. 94 Installing Separator Plate36RH/37RH
f ^ - ^ . ) REAR CLUTCH-
J9121-53-
Fig. 95 Verifying Rear Clutch Check Ball
Position-36RH/37RH
(6) Position valve body so i nt ernal passages and
check ball seats are facing upward. Then install
check balls in valve body (Fig. 96). There are a total
of 7 check balls. Single large check ball has a diam-
eter of approximately 11/32 inch. Remaining 6 check
balls have a diameter of approximately 1/4 inch.
(7) Align and install transfer/separator plate as-
sembly on valve body (Fig. 97). Install screws attach-
ing transfer pl at e to valve body. Tighten screws
alternately and in a diagonal pat t ern to 4 Nnn (35
in. lbs.) torque.
sleeve, t hrot t l e plug and spring (Fig. 98). Insert as-
sembly in valve body and install end plate. Tighten
end plate screws to 4 Nnn (35 in. lbs.) torque.
(9) Install 1-2 and 2-3 shift valves and springs
(Fig. 98).
11/32" DIAMETER
CHECK BALL
J9121-84
Fig. 96 Correct Position Of Valve Body Check
Balis-36RH/37RH
TRANSFER PLATE/
SEPARATOR PLATE ASSEMBLY
VALVE
BODY J9121-85
Fig. 97 Installing Transfer Plate On Valve
Body-36RH/37RH
(10) Install 1-2 shift control valve and spring (Fig.
98)
(11) Assemble 3-2 downshift housing (Fig. 92). In-
stall throttle plug, limit valve and spring and secure
in housing with retainer.
(12) Position shift valve end plate on 3-2 downshift
housing. Then align housing and end plate on valve
body. Carefully compress shift valve springs and in-
stall screws t hat secure housing and end plate to
valve body (Fig. 91). Tighten screws to 4 Nnn (35 in.
lbs.) torque.
(13) Install shuttle valve as follows.
(a) Insert shut t l e valve in bore.
(b) Insert plastic guides in shuttle valve second-
ary spring.
(c) Install secondary spring on end of valve.
(d) Hold shut t l e valve in place.
(e) Compress secondary spring and install E-clip
in groove at end of shut t l e valve. Verify t hat
spring and E-clip are properly seated before pro-
ceeding.
(14) Install shut t l e valve cover (Fig. 99) and cover
screws to 4 Nnn (35 in. lbs.) torque.
(15) Install 1-2 and 2-3 valve governor plugs. Then
install shuttle valve pri mary spring and t hrot t l e plug
(Fig. 99).
21 - 222 TRANSMISSION OV E RH AUL- 86 RH / 37RH
REGULATOR
VALVE
SPRI NG
THROTTLE
PRESSURE
PLUG
2-3
SHIFT
VALVE
A N D
SPRI NG
SLEEVE
SWI TCH
VALVE
LINE
PRESSURE
REGULATOR
VALVE
1-2
SHIFT
VALVE
A N D
SPRI NG
1-2
SHIFT
CONTROL
VALVE
A N D
SPRI NG
Fig. 98 Shift Valve And Spring installation-36RH/37RH
LINE
PRESSURE
PLUG
J9121-86
SHUTTLE
VALVE
E N D PLATE
S E CONDARY
S PR I NG & GUI DE S
SHUTTLE
VALVE
PRIMARY
S PR I NG
SHUTTLE
VALVE
THROTTLE
PLUG
GOV E R N OR
PLUG-
E ND PLATE J9121-50
Fig. 99 Control Valve Locations36RH/37RH

TRANSMISSION OVERHAUL36RH/37RH 21 - 223
(16) Align and install governor plug end plate
(Fig. 99) on valve body and install end pl at e screws.
Tighten screws to 4 Nm (35 in. lbs.) torque.
(17) Install manual valve (Fig. 99).
(18) Install throttle valve and spring. Then install
kickdown valve and detent (Fig. 99).
(19) Install pressure regulator valve and switch
valve (Fig. 99).
(20) Install manual lever detent spring in housing.
Place det ent ball on end of spring and push ball and
spring into housing. Secure ball and spri ng with Re-
t ai ner Tool 6583 (Fig. 88).
(21) Insert line pressure adjusting screw in adjust-
ing screw bracket (Fig. 92).
(22) Place valve spring on end of line pressure reg-
ulator valve.
adjusting screw bracket (Fig. 87).
(24) Install adjusting screw bracket on valve body.
Align springs, press bracket toward valve body and
install long bottom bracket at t achi ng screw first. Do
not t i ght en screw fully at t hi s time.
(25) Carefully align bracket on valve body and
transfer plate and install remai ni ng (two) bracket
screws. Verify t hat valve springs and bracket are
properly aligned. Then t i ght en all t hree bracket
(26) Install throttle lever in valve body. Then in-
ual lever into valve body.
(27) Align manual lever detent with detent ball
and align lever arm with manual valve. Hold throt-
tle lever upward. Then press down on manual lever
unt i l lever is fully seated.
(28) Install manual lever seal, washer and retain-
ing E-clip.
(29) Lubricate shaft of manual lever wi t h light
coat of petroleum jelly. This will help protect seal lip
when manual shaft seal is installed.
(30) Verify t hat throttle lever is aligned with end
ment procedure.
ADJUSTMENTS
valve body which are, line pressure and t hrot t l e pres-
sure.
Line and t hrot t l e pressures are interdependent be-
cause each affects shift quality and timing. As a re-
Alignment-36RH/37RH
suit, both adjustments must be performed properly
and in the correct sequence. Adjust line pressure first
and throttle pressure last.
Measure distance from t he valve body to t he inner
edge of the adjusting screw with an accurate steel
scale (Fig. 101).
The 33.4 mm (1-5/16 in.) setting is an approxi-
mate setting. Manufacturi ng tol erances may
make it necessary to vary from this di mensi on to
obtain desi red pressure.
ing t he adjusting screw counterclockwise increases
pressure while t urni ng t he screw clockwise decreases
pressure.
Fig. 101 Line Pressure Adjustment36RH/37RH

tle valve.
Turn t hrot t l e lever stop screw unt i l t he screw head
touches gauge tool.
The ki c kdown val ve s pr i ng mus t be fully com-
pr e s s e d a n d t he ki c kdown val ve compl et el y bot -
t omed t o obt ai n cor r ect adj us t ment .
HEX
WRENCH
THROTTLE
LEVER
SPECIAL
TOOL
C-3763
J9121-542
Fig. 102 Throttle Pressure Adjustment36RH/37RH
ASSEMBLY TIPS
t er t he case or transmission components duri ng as-
sembly.
Keep t he t ransmi ssi on case and components clean.
Also make sure t he tools and workbench area used
for reassembly operations are equally clean.
Shop towels used for wiping off tools and your
hands must be made from l i nt free mat eri al s. Li nt
will adhere to transmission part s and could interfere
with valve operation or even restrict fluid passages.
Lubricate transmission clutch and gear components
with Mopar ATF Pl us, type 7176 transmission fluid
duri ng reassembly. This is t he preferred fluid for use
in 36RH/37RH transmissions. Use Mopar Dexron II
only when ATF Pl us is not readily available.
Use Ru-Glyde, or Door-Eze, or petroleum jelly on
seals and O-rings to ease installation. Pet rol eum
jelly can also be used to hold t hrust washers and
plates in position duri ng assembly operations. How-
ever, do not use chassis grease, beari ng grease,
white grease, or similar lubricants on any part .
These types of lubricants can eventually block or re-
strict fluid passages and valve operation.
Do not force part s into place. Most of t he t ransmi s-
sion components/sub-assemblies are easily installed
by hand. If a par t seems difficult to install, it is ei-
t her misaligned or incorrectly assembled. Verify t hat
t hr ust washers, t hr ust plates and seal rings are cor-
rectly positioned. These part s will prevent proper as-
sembly is mispositioned (or "left out" by accident.
The pl anet ary geart rai n, front/rear clutch assem-
blies and oil pump are all much easier to install
when t he transmission case is upri ght or as close to
t hi s position as possible. Ei t her t i l t t he case upward
with wood blocks, or cut a hole in t he bench large
enough for t he output shaft and rear support. Then
lower t he shaft and support into t he hole and support
t he rear of t he case directly on t he bench.
Assembly Procedure
(1) Lubricate rear servo piston seal with petroleum
jelly, Ru-Glyde, or Door Eze. Lubricate servo bore in
case with transmission fluid.
(2) Install rear servo piston in case. Position piston
at slight angle to bore and insert piston with twist-
ing motion (Fig. 103).
REAR
SERVO
PISTON
J9121-87>
Fig. 103 Installing Rear Servo Piston36RH/37RH
(3) Install rear servo spring and ret ai ner in case
bore (Fig. 104). Be sure spring is seated on piston.
SPRING
RETAINER
v - ' J9121-88
Fig. 104 Installing Rear Servo Piston Spring And
Retainer-36RH/37RH

(4) Compress rear servo piston with C-clamp or
Valve Spring Compressor C-3422-B and install servo
piston snap ring (Fig. 105).
Fig. 105 Installing Rear Servo Snap Ring36RH/
37RH
(5) Install overrunning clutch cam, springs, rollers,
race and rear support if not yet installed. Refer to in-
stallation procedure in Subassembly Overhaul sec-
tion.
(6) Position rear band and link in case (Fig. 106).
Be s ur e not ched si de of l i nk f aces a wa y f r om
ba nd.
Fig. 106 Installing Rear Band And Link36RH/37RH
(7) Install low-reverse drum (Fig. 107). Slide drum
t hrough rear band, onto rear support hub and into
engagement with overrunning clutch race.
Fig. 107 Installing Low-Reverse Drum36RH/37RH
(8) Install snap ri ng t hat secures low-reverse drum
to rear support hub (Fig. 108).
Ring36RH/37RH
(9) Install new O-rings on band reaction pin. Lu-
bricate pin and O-rings. Then insert pin into case
and part way into band link (Fig. 109).
(10) Install rear band adjusting lever, st rut and re-
action lever (Fig. 110). Be sure levers and st rut are
aligned and engaged before seating band reaction pin
in case.

REACTION
PIN
O-RINGS
J9121-91
Fig. 109 Installing Rear Band Reaction Pin36RH/
37RH
ADJUSTING
SCREW
ADJUSTING
LEVER
REACTION
LEVER
STRUT
J9121-92
Fig. 110 Rear Band Levers And Strut36RH/37RH
(11) Lubricate front servo piston components and
servo bore in case with t ransmi ssi on fluid.
(12) Install front servo piston in bore. Carefully
"run" small, suitable tool around piston ri ng to press
it back into groove and ease installation (Fig. 111).
Rotate piston into bore at same time. Rock piston
slightly to ease piston ri ng past snap ri ng groove and
into bore.
(13) Bottom front servo piston in bore and i nst al l
servo spring.
(14) Install front servo piston rod guide as follows:
(a) Place Tool SP-5560 (or similar size tool) on
guide to serve as press tool for C-clamp.
(b) Position C-clamp on press tool and case (Fig.
112).
USE SUITABLE TOOL
TO HELP SEAT
PISTON RING
FRONT
SERVO
PISTON
-J9121-98
Fig. 111 Installing Front Servo Piston36RH/37RH
(c) Slowly compress rod guide while simulta-
neously easing seal ring into bore with suitable
tool (tighten clamp screw with one hand and "run"
tool around guide ri ng with other hand).
(15) Install rod guide snap ri ng (Fig. 112).
C-CLAMP
ROD SMALL
GUIDE SCREWDRIVER
ROD
GUIDE
SNAP
RING
J9121-99"
Fig. 112 Installing Front Servo Rod Guide And Snap
Ring36RH/37RH
(16) Position front band lever in case and over
servo rod guide. Then install front band reaction pin
in case and slide it through lever.
(17) Coat t hreads of front band reaction pin access
plug wi t h sealer and install it in case. Tighten plug
gear components (Fig. 113). Suppor t shaf t car e-

fully dur i ng I nst al l at i on. Do not al l ow shaf t
bear i ng/ bus hi ng sur f aces t o become ni cked or
s cr at ched.
ASSEMBLY
J Y , i M
^
Fig. 113 installing Output Shaft And Planetary
Geartrain-36RH/37RH
(19) Align and install governor/park gear assembly
on output shaft. Not e t ha t out put shaft In c ur r e nt
t r ans mi s s i on i s spot f aced for gover nor val ve e nd
cl ear ance (Fig. 114). Shaft mus t be i ndexed so
t ha t smal l e nd of gover nor val ve wi l l s eat i n t hi s
spot f ace. I nst al l gover nor body a n d p a r k as fol-
l ows t o e ns ur e p r o p e r al i gnment a n d oper at i on.
(a) Rotate output shaft unt i l spotface (at gover-
nor valve shaft hole) is facing upward (Fig. 114).
(b) Position valve bore in governor body over
spotface on output shaft. Then align valve shaft
holes in governor body and output shaft.
(c) Align splines in output shaft and park gear
hub.
J9221-52
Fig. 115 Installing Governor And Park Gear
Assembly-36RH/37RH
(d) Carefully push assembly into place i n rear
support (Fig. 115).
(e) Verify t hat governor valve shaft holes i n out-
put shaft and governor body are still in alignment.
Reposition governor body and park gear if align-
ment is not correct.
(f) Tighten bolts at t achi ng governor body to park
gear to 11 N-m (95 in. lbs.) torque.
(20) Assemble and install governor valve and shaft
(Fig. 116). Be s ur e val ve shaft oper at es freel y be-
fore pr oceedi ng.
Fig. 114 Governor Valve And Output Shaft Spotface
Alignment-36RH/37RH
Fig. 116 Installing Governor Valve And
Shaft-36RH/37RH

(21) Install E-clips t hat ret ai n governor valve shaft
(Fig. 117). One clip is required at each end of shaft.
Fig. 117 Installing Governor Valve Shaft
E-CIips-36RH/37RH
(22) Lubricate output shaft t hr ust plate with petro-
leum jelly and install plate on output shaft hub (Fig.
118).
Fig. 118 Installing Output Shaft Thrust Plate-36RH/
37RH
(23) Check i nput shaft front seal rings, fiber t hr ust
washer and rear seal ri ng (Fig. 119). Be ends of r ear
seal ri ng are hooked together and diagonal cut ends
of front seal ri ngs are firmly seated agai nst each
other as shown. Lubricate seal rings with petroleum
jelly after checking t hem.
(24) Assemble front and rear clutches (Fig. 120).
Align lugs on front clutch discs. Mount front clutch
Fig. 119 Input Shaft Seal Ring And Thrust Washer
instaliation-36RH/37RH
on rear clutch. Turn front clutch ret ai ner back and
forth unt i l front clutch discs are fully seated on rear
clutch splined hub.
Fig. 120 Assembling Front And Rear
Clutches~36RH/37RH
(25) Measure thickness of output shaft t hr ust
washer with micrometer. Record thickness for refer-
ence when checking i nput shaft end play.
(26) Install output shaft t hrust washer in hub rear
clutch ret ai ner (Fig. 121). Use petroleum jelly to hold
washer in place. Posi t i on wa s he r so gr ooves a r e
faci ng out wa r d. Al so not e t ha t wa s he r onl y fits
one wa y i n cl ut ch r et ai ner h u b .
Fig. 121 Installing Output Shaft Thrust
Washer-36RH/37RH
(27) Slide front band onto driving shell but do not
install band st rut or anchor at this time.
(28) Place transmission case in upright position, or
place blocks under front end of transmission repai r
stand to tilt case rearward. This makes it easier to
install front/rear clutch assembly.
(29) Align discs in rear clutch. Then install and
engage assembly in front planetary and driving shell
(Fig. 122). Turn clutch ret ai ners back and forth unt i l
both clutches are seated.
(30) Slide front band over front clutch ret ai ner and
install front band st rut and anchor (Fig. 123).
is t i ght on clutch retainer. Verify t hat front/rear
clutch assembly is still properly seated before tight-
ening band.
(32) Install oil pump Pilot Studs C-3288-B in case
(Fig. 124).
(33) Install new oil pump gasket on pilot studs and
seat it in case. Be sure gasket is properly aligned
with fluid passages in case (Fig. 124).
J9121-18
Fig. 123 Front Band Linkage Installation36RH/
37RH
21 - 230 TRANSMISSION OWE RH AUL- 3I RH / 37RH

J 9121- 103
Fig. 124 Installing Oil Pump Gasket And Pilot
Studs-36RH/37RH
(34) Check seal rings on reaction shaft support. Be
sure rings are hooked together correctly. Also be sure
fiber t hr ust washer is in position (Fig. 125). Use pe-
troleum jelly to hold washer in place if necessary.
J 9121- 104
Fig. 125 Reaction Shaft Seal Ring And Thrust
Washer Installation-36RH/37RH
(35) Lubricate oil pump seals wi t h petroleum jelly
or transmission fluid.
(36) Mount oil pump on pilot studs and slide pump
into case opening (Fig. 126). Work pump into case
by hand. Do not use a mallet or similar tool s to
seat pump.
(37) Remove pilot studs and install oil pump bolts.
Tighten pump bolts al t ernat el y and evenly to fully
seat pump in case. Then final-tighten pump bolts to
SEAT
OIL PUMP IN
CASE
BY HAND
REMOVE
PILOT STUDS
WHEN PUMP
IS SEATED
J 9121- 105
Fig. 126 Oil Pump Installation-36RH/37RH
(38) Verify correct assembly. Rotate i nput and out-
put shafts and check for bind. If bind exists, compo-
nent s are either misassembled, or not seated.
Disassemble and correct as necessary before proceed-
ing.
(39) Check input shaft end play as follows:
(a) Attach dial indicator to converter housing
(Fig. 127). Position indicator plunger against i nput
shaft and zero indicator.
(b) Move i nput shaft in and out and record read-
ing.
(c) End play should be 0.86 - 2.13 mm (0.034 -
0.084 in.).
(d) If end play is incorrect, change output shaft
t hr ust washer, t hrust plate, or front clutch t hr ust
f
RH278
Fig. 127 Measuring Input Shaft End Play36RH/
37RH
#
s
; _ TRANSMISSION OWERHAUL38RH/37RH 21 - 231
washer as needed. Thrust washer is select and
comes in t hree thicknesses.
(40) Install accumulator piston and spring (Fig.
128).
Fig. 128 Installing Accumulator Piston And
Spring-36RH/37RH
not been installed in case. Valve body cannot be in-
stalled if switch is in position.
(42) Place valve body manual lever in low to move
park lock rod rearward.
(43) Position valve body on case and install valve
body bolts finger tight.
(44) Install park/ neut ral position switch in case.
Tighten switch to 34 Nnn (25 ft. lbs.) torque.
(45) Align valve body on case (Fig. 129). Tighten
valve body bolts alternately and evenly to 12 Nnn
(105 in. lbs.) torque. St art at center and work out-
ward when tightening bolts. Do not overtighten
val ve body bolts. This coul d result i n distortion
and cross l eakage after installation..
Fig. 129 Installing Valve Body-36RH/37RH
(46) Install new filter on valve body (Fig. 130).
Tighten filter screws to 4 Nnn (35 in. lbs.).
Fig. 130 Installing Valve Body Filter-36RH/37RH
(47) Install seal on park/ neut ral position switch
(Fig. 131). Then install and tighten switch to 34 Nnn
(25 ft. lbs.).
Fig. 131 Park/Neutral Position Switch Seal
Position-36RH/37RH
(48) Adjust front and rear band as follows:
4-5 t urns.
(b) Tighten both band adjusting screws to 8 Nnn
(72 in. lbs.).
t urns.
(d) Back off rear band adjusting screw 2 t urns.
(e) Hold each adjusting screw in position and
t i ght en locknuts to 34 Nnn (25 ft. lbs.). Do not al-
low adjusting screws to t ur n when t i ght eni ng lock-
nut s.
(49) Install magnet in oil pan. Magnet fits over
small protrusion at corner of pan.
(50) Position new oil pan gasket on case and in-
stall oil pan. Tighten pan bolts to 17 Nnn (13 ft. lbs.).
(51) Install rear beari ng and bearing snap rings on
output shaft. Be sure ri ng groove in bearing outer
surface is toward front of transmission.
(52) Position new extension housing gasket on rear
of transmission case. Use petroleum jelly to hold gas-
ket in place if necessary.

(53) Spread rear beari ng locating ri ng and st art
extension housing on output shaft and rear bearing.
(54) Align park rod in sprag and work housing
into place. Install and t i ght en housing bolts to 4 3
Ni n (32 ft. lbs,).
(55) Install rear beari ng locating ri ng access cover
and gasket.
(56) Remove repai r st and and t ur n transmission
over.
(57) Install new valve body manual shaft seal in
case (Fig. 132). Lubricate seal lip and manual shaft
with petroleum jelly. St art seal over shaft and into
case. Seat seal with 15/16 inch, deep well socket.
(58) Install t hrot t l e and shift levers on manual and
t hrot t l e levers.
(59) Cap or cover transmission openings (cooler
line fittings, filler t ube bore, etc.) to prevent dirt en-
try.
(60) Install torque converter. Use C-clamp or met al
strap to hold converter in place for installation.
(61) Mount transmission on jack preparatory to in-
stallation in vehicle.
C A U T I O N ; The t r ansmi ssi on cooler and lines must
Fig. 132 Installing Manual Lever Shaft Seal
be reverse fl ushed if overhaul corrected a mal func-
tion that generated sl udge, metal particles, or
clutch friction material. The torque converter shoul d
al so be replaced if contaminated by the same mal-
functi on. Debri s and residue not f l ushed from the
cool er and lines will flow back into the t r ansmi ssi on
and converter. The result coul d be a repeat failure
and s hop comeback.

TRANSMISSION OVERHAUL-4 2RH 21 - 233
TRANSMISSION 0ERHAUL42RH
INDEX
page
Front Clutch Overhaul 24 5
Front Servo and Band Overhaul 254
Oil Pump and Reaction Shaft Support Overhaul . 24 1
Overhaul Service Information 239
Overrunning Cl utchLow- Reverse DrumOverdrive
Piston Retainer Inspection and Overhaul . . . . 24 0
Planetary Gear Train and Intermediate Shaft
Overhaul 250
page
Rear Clutch Overhaul . . . . . . . . . . . . . . . . . . . . 24 7
Rear Servo and Band Overhaul 255
Transmi ssi on Assembl y and Adjustment . 26 9
Transmi ssi on Case Cl eaning and Inspection . . . 24 0
Transmi ssi on Di sassembl y . 233
Valve Body Cl eaning and Inspection 26 2
Valve Body Service and Adjustment 256
(1) Remove torque converter if not previously re-
moved.
with solvent. Wear eye protection during cleaning
operations.
(3) Remove shift and t hrot t l e levers from valve
body manual lever shaft.
(4 ) Remove bolts at t achi ng overdrive uni t to t rans-
mission (Fig. 1).
Fig. 1 Overdrive Unit Attaching Bolt Removal
(5) Loosen overdrive unit. Use pry tool to st art
overdrive uni t off i nt ermedi at e shaft and t ransmi s-
sion case. Position pry tool between flange on over-
drive case and transmission r ear servo boss (Fig. 2) .
(6 ) Work overdrive uni t rearward and off t ransmi s-
sion intermediate shaft (Fig. 3) . Keep overdrive uni t
level during removal.
sert Alignment Tool 6 227 - 2 in overrunning clutch
and pl anet ary gear splines to mai nt ai n alignment
(Fig. 4 ) . I f c l ut c h a n d gear spl i nes rotate out of
al i gnment , over dr i ve uni t wi l l ha ve to be di s as -
sembl ed i n or der to r eal i gn spl i nes.
J9121-209
Fig. 3 Overdrive Unit Removal42RH
21 - 234 TRANSMISSION 0VERHAUL-4 2RH
J9321-133
Fig. 4 Overdrive Spline Alignment Tool Installation
(7) Remove overdrive piston from ret ai ner (Fig. 5).
(8) Mount transmission uni t on Repair Stand
Fig. 5 Overdrive Piston Removal42RH
C-3750-B or similar device.
(9) Remove pump oil seal with Special Tool C-3981
(Fig. 6). Be sure to t i ght en tool t hreads completely
into seal before using puller bolt to wi t hdraw seal.
Fig. 6 Oil Pump Seal Removal42RH
I (10) Remove park/ neut ral position switch (Fig. 7).

Installation
(11) Remove oil pan bolts and remove oil pan and
gasket. Note location of oil pan magnet for assembly
reference (Fig. 8).
J9121-115
Fig. 8 Oil Pan Magnet Position42RH
(12) Remove filter from valve body (Fig. 9). Keep
filter at t achi ng screws with filter for assembly refer-
ence. Filter screws are longer t han valve body
screws.
Fig. 9 Fluid Filter Removal/Installation42RH

(13) Remove hex head valve body attaching bolts
(Fig. 10).
J9321-135
Fig. 10 Valve Body Bolt Locations42RH
(14) Lift valve body upward. Work solenoid connec-
tor out of case and remove valve body (Fig. 11). Set
valve body aside for disassembly, cleaning and in-
spection.
VALVE BOOST
BODY VALVE
ASSEMBLY TUBE
PARK CASE
ROD CONNECTOR J9321-136
Fig. 11 Valve Body Removal42RH
(15) Remove accumulator piston and inner and
outer springs (Fig. 12).
(16) Remove front band reaction pin access plug
(Fig. 13). Pl ug is accessible t hrough converter hous-
ing. Use 1/4 inch drive extension to remove plug as
shown.
TRANSMISSION 0VERHAUL-4 2RH 21 - 235
ACCUMULATOR OUTER
Fig. 12 Accumulator Piston And Springs42RH
Fig. 13 Removing/Installing Front Band Reaction
Pin Access Plug42RH
(17) Loosen front band adjusting screw locknut 4-5
t urns. Then tighten band adjusting screw unt i l band
is t i ght around front clutch retainer. This prevents
front/rear clutches from coming out with pump and
possibly damaging clutch or pump components.
(18) Remove oil pump bolts.
(19) Thread bolts of Slide Hammer Tools C-3752
into t hreaded holes in pump body flange (Fig. 14).
(20) Bump slide hammer weights outward to re-
move pump and reaction shaft support assembly from
case (Fig. 14).
Fig. 14 Removing Oil Pump And Reaction Shaft
Support Assembly42RH

(22) Squeeze front band together and remove band
st rut (Fig. 15).
Fig. 15 Removing/Installing Front Band Strut42RH
(23) Remove front band reaction pin with pencil
magnet. Pin is accessible from converter housing side
of case (Fig. 16).
Fig. 16 Removing Front Band Reaction Pin42RH
(24) Remove front band lever (Fig. 17)
Fig. 17 Removing/Installing Front Band
Lever42RH
(25) Slide front band rearward and onto driving
shell. Band will not be removed unt i l after front/rear
clutch removal.
(26) Remove front and rear clutch uni t s as assem-
bly. Grasp i nput shaft, hold clutch uni t s together and
remove t hem from case (Fig. 18).
J9121-124
Fig. 18 Removing 42RH Front/Rear Clutch
Assemblies
(27) Lift front clutch off rear clutch (Fig. 19). Set
clutch units aside for overhaul.
Fig. 19 Separating Front/Rear Clutch Assemblies
(28) Remove intermediate shaft t hrust washer
from front end of shaft or from rear clutch hub (Fig.
20).
(29) Remove output shaft t hrust plate from inter-
mediate shaft hub (Fig. 21).
INTERMEDIATE
SHAFT THRUST
WASHER
^ DR I V I NG
SHELL
REAR
CLUTCH
RETAINER
HUB
J9121-127
Fig. 22 Front Band Removal/Installation42RH
moval. Do not allow machined surfaces on intermedi-
ate shaft or overdrive piston ret ai ner to become
nicked or scratched.
INPUT
SHAFT
J9121-214
Fig. 20 Removing Intermediate Shaft Thrust
Washer-42RH
INTERMEDIATE
SHAFT HUB
INTERMEDIATE
SHAFT
THRUST PLATE
J9121-215
Fig. 21 Removing Intermediate Shaft Thrust
Plate-42RH
(30) Slide front band off driving shell (Fig. 22) and
remove band from case.
(31) Remove pl anet ary geart rai n as assembly (Fig.
23). Support geart rai n with both hands during re-
J9121-217
Fig. 23 Removing Planetary Geartrain And
Intermediate Shaft Assembly42RH
(32) Loosen rear band adjusting screw 4-5 t urns.
(33) Remove low-reverse drum snap ri ng (Fig. 24).
(34) Remove bolts at t achi ng overdrive piston re-
t ai ner to rear of case (Fig. 25). Then remove piston
ret ai ner and gasket.
(35) Remove rear band pivot and reaction pins
(Fig. 26). Use parallel jaw snap ri ng pliers to remove
pins. Insert and spread plier j aws in pin bore to grip
pin. Then twist and pull pins to remove t hem.
Fig. 24 Removing Low-Reverse Drum Snap
Ring-42RH
RETAI NER
BOLTS
J 9 1 2 1 - 2 1 9
Fig. 25 Overdrive Piston Retainer Bolt
Location42RH
(36 ) Remove rear b a n d lever.
(37) Remove low-reverse drum and rear band as
assembly. Turn drum clockwise and pull outward to
remove it from overrunni ng clutch (Fig. 27) .
(38) Remove bolts at t achi ng overrunni ng clutch
cam to case (Fig. 28).
(39) Remove overrunni ng clutch cam and roller
clutch assembly as a uni t (Fig. 29). Tur n cam back
and forth and tilt it inward to remove it from case.
Fig. 26 Rear Band Pivot And Reaction Pin
Location42RH
Fig. 27 Low-Reverse Drum And Rear Band
Removal42RH
Fig. 28 Overrunning Clutch Cam Bolt
Locations42RH
(40) Compress front servo rod guide about 1/8 inch
with Valve Spring Compressor C- 34 22- B (Fig. 30) . A
C-clamp and Special Tool C-4470 can also be used to
compress rod guide.
(41) Remove front servo rod guide snap ring. Ex-

CLUTCH
ASSEMBLY J9121- 222
Fig. 29 Overrunning Clutch Assembly
Removal42RH
cer ci se caut i on whe n r emovi ng s n a p r i ng. Ser vo
bor e c a n be s cr at ched or ni c ke d if car e i s not
excer ci sed.
(42) Remove compressor tools and remove front
servo rod guide, spring and servo piston.
Fig. 30 Compressing Front Servo Rod Guide42RH
(43) Compress rear servo spring ret ai ner about
1/16 inch wi t h Valve Spring Compressor C-3422-B
(Fig. 31). A C-clamp and Tool C-4470 or SP-5560 can
also be used to compress spring ret ai ner.
(44) Remove rear servo spring ret ai ner snap ring.
Then remove compressor tools and remove rear servo
spring and piston.
(45) Inspect transmission and overdrive compo-
nent s. If maj or component s s uc h a s t he over -
dr i ve uni t , front cl ut ch, or oil p u mp r e qui r e
ser vi ce, r ef er t o a ppr opr i a t e ove r ha ul pr oce-
dur e .
Fig. 31 Compressing Rear Servo Spring42RH
Inspect t he transmission bushings duri ng overhaul.
Bushing condition is i mport ant as worn, scored bush-
ings contribute to low pressures, clutch slip and ac-
celerated wear of other components. However, do not
replcae bushings as a mat t er of course. Replace bush-
ings only when they are actually worn, or scored.
tools are sized and designed to remove, install, and
Heli-Coil inserts can be used to repai r damaged,
stripped or worn t hreads in al umi num part s. These
inserts are available from most automotive jobbers.
Stainless steel inserts are recommended.
shafts, or valves, use extreme care to avoid rounding
off sharp edges. Sharp edges are vital as they pre-
vent foreign mat t er from getting between t he valve
and valve bore.
as well.
Plus, Type 7176, or Dexron II transmission fluid
during overhaul and assembly. Use petroleum jelly,
21 - 240 TRANSMI SSI ON OVERHAUL-42RH _ . *
J9121-225
Fig. 33 Installing Overrunning Clutch Rollers In
Retainer42RH
(2) Install roller and spring assembly in clutch
cam (Fig. 34).
(3) Lubricate overrunning clutch rollers, springs
cam and race with transmission fluid. Verify compo-
nent installation before proceeding. Bolt holes in
clutch cam are countersunk on one side. Be sure t hi s
side of cam will face rearward as shown (Fig. 34).
(4) Inspect bolt holes in overrunning clutch cam.
Note t hat one hole is not threaded. Identify location
of non t hreaded hole with pai nt mar k for assembly
reference (Fig. 35).
(5) Set assembly aside for final installation after
overhaul is complete.
Fig. 32 Removing Overrunning Clutch From Low-
Reverse Drum42RH
CLEANING A N D INSPECTION
Clean t he clutch rollers, springs and ret ai ner,
clutch cam, low-reverse drum and overdrive piston
ret ai ner in solvent. Dry t hem with light burst s of
compressed air, or allow t hem to air dry after clean-
ing.
Inspect condition of each clutch part after cleaning.
Replace t he rollers and t he ret ai ner and spring as-
sembly if t he rollers, springs or spring ret ai ner are
worn or damaged. Replace t he clutch cam if worn,
cracked or damaged.
Inspect t he overrunning clutch race and low-re-
verse drum. Replace t he drum and race as an assem-
bly if either part is worn, scored or damaged.
Exami ne t he overdrive piston ret ai ner carefully for
wear, cracks, scoring or other damage. Be sure t he
ret ai ner hub is a snug fit in t he case and low-reverse
drum. Replace t he ret ai ner if worn or damaged.
OVERRUNNING CLUTCH ASSEMBLY
(1) Install clutch rollers in spring ret ai ner (Fig.
33). Be sure springs are seated squarely agai nst roll-
ers.
Ru-Glyde, Door-Eze or similar products to prelubri-
cate seals, O-rings, and t hr ust washers. Petroleum
jelly can also be used to hold part s in place during
reassembly.
TRANSMI SSI ON CASE CLEANING AND
INSPECTION
Do not us e s hop t owel s or r a gs t o dr y t he cas e
(or a ny ot he r t r ans mi s s i on component ) unl es s
t hey a r e ma d e from l i nt -free mat er i al s . Li nt will
st i ck t o cas e s ur f aces a n d t r ans mi s s i on compo-
ne nt s a n d ci r cul at e t hr oughout t he t r ans mi s s i on
aft er as s embl y. A suffi ci ent qua nt i t y of l i nt c a n
bl ock fluid pa s s a ge s a n d i nt er f er e wi t h val ve
body oper at i on.
bores, or damaged t hreads. Damaged t hreads can be
repaired with Helicoil t hread inserts. However, t he
case will have to be replaced if it exhibits any type of
damage or wear.
Lubricate t he front band adjusting screw t hreads
with petroleum jelly and t hread t he screw part-way
into t he case. Be sure t he screw t ur ns freely.
OVERRUNNING CLUTCH-LOW-REVERSE
DRUM- OV E RDRI V E PISTON RETAINER
INSPECTION AND OVERHAUL
If t he overrunni ng clutch and cam came out with
t he low-reverse drum, remove t he cam and clutch
from t he drum as follows: Thread two clutch cam
bolts into t he cam. Then lift t he clutch and cam out
of t he drum with t he bolts (Fig. 32). Rotate t he cam
back and forth to ease removal if necessary.

LOW-REVERSE D R U M OVERRUNNING
J9121-140
Fig. 34 Checking Overrunning Clutch
Installation-42RH
Fig. 35 Marking Location Of Non-Threaded Hole in
Clutch Cam-42RH
OVERHAUL
(1) Remove seal from around pump housing (Fig.
36).
(2) Mark pump housing and support assembly for
(3) Loosen bolts t hat at t ach pump body to support
(Fig. 37).
(4) Remove pump-to-support bolts and separate
support from pump housing (Fig. 38).
(5) Remove i nner and outer gears from reaction
shaft support (Fig. 39).
(6) If pump seal was not removed duri ng t ransmi s-
Fig. 36 Removing Pump Housing Seal
Fig. 37 Loosening Pump Support Bolts
J 9321- 213
Fig. 38 Separating Pump Housing From Reaction
Shaft Support-42RH
J 9321- 214
sion disassembly, remove seal wi t h punc h a nd ham-
mer.
21 - 242 TRANSMISSION OVERHAUL-4 2RH

OIL SEAL
REACTION SHAFT
SUPPORT
GASKET
BOLT (6)
O- RI NG
SEAL
PUMP HOUS I NG
THRUST
WASHER
J9321-207
STRAIGHT EDGE
FEELER
GAUGE
Fig. 40 Oil Pump And Reaction Shaft Support Components42RH
(7) Remove front clutch t hrust washer from sup-
port hub (Fig. 40).
OIL PUMP AMD REACTION SHAFT SUPPORT
Clean pump and reaction shaft support components
with solvent and dry t hem with compressed air.
Inspect t he pump housing and support components.
Replace t he housing or support if t he seal ri ng
grooves or machined surfaces are worn, scored, pit-
ted, or damaged.
damaged. Inspect t he t hr ust washer for wear or dam-
age. Replace t he washer if necessary. Note that the
i nner gear used in 1993 42RH oil pumps has a
new desi gn drive lug. The new desi gn i ncorpo-
rates drive flats i nstead of the square l ug used
previously. The 1993 torque converter hub has
also been redesi gned to accept the new drive. If
pump gear repl acement is necessary, be very
sure to order and install the new style gears.
Inspect t he pump and reaction shaft support bush-
ings. Minor bushi ng wear is acceptable. Replace t he
bushings only if scored, or severely worn.
Install t he gears in t he pump housing and measure
(Fig. 41). Clearance should be 0.010 - 0.06 mm
(0.0004 - 0.0025 in.).
ii!
l
|i"j9321-215
Fig. 41 Measuring Pump Gear End Clearance42RH
Measure clearance between t he outer gear and t he
pump body (Fig. 42). Clearance should be 0.08 - 0.19
mm (0.0035 - 0.0075 in.).
Measure gear tooth clearance with a feeler gauge.
Align one tooth of t he outer gear in inner gear and
measure clearance (Fig. 43). Clearance should be
0.08 - 0.19 mm (0.0035 - 0.0075 in.).

FEELER
GAUGE
I NNER
GEAR
J9321-216
Fig. 42 Measuring Pump Housing-To-Inner Gear
Clearances42RH
I NNER
GEAR
OUTER 77
GEAR
J9321-217
Fig. 43 Measuring Pump Gear Tooth
Clearance42RH
(1) Remove pump bushing with Tool Handle
C-4171 and Bushi ng Remover SP-3551 (Fig. 44).
(2) Install new pump bushing with Tool Handle
C-4171 and Bushi ng Installer SP-5117 (Fig. 44).
Bushing should be flush with pump housing bore.
SPECIAL
T OOL
C - 4171
PUMP HO U S I N G
BUSHI NG
REMOVAL
SPECIAL
TOOL
C - 4171
SPECIAL TOOL
SP- 35 5 1
BUSHI NG
SPECIAL
TOOL
S P- 5 117
BUSHI NG
J 92 2 1- 2 42
Fig. 44 Removing Oil Pump Bushing42RH
(3) St ake new pump bushi ng in two places with
bl unt punch (Fig. 45). Remove burrs from st ake
points with knife blade afterward.
RH282
Fig. 45 Staking Oil Pump BushingAll
BUSHING
(1) Assemble Bushing Remover Tools SP-1191,
3633 and 5324 (Fig. 46). Do not cl amp any part of
reacti on shaft or support in vise.
(2) Hold Cup Tool SP-3633 firmly agai nst reaction
shaft and thread remover SP-5324 into bushi ng as
far as possible by hand. Then t hread remover tool 3-4
additional t ur ns into bushing with a wrench.
SPECIAL
TOOL
SP- 1191
SPECIAL
TOOL
C - 4171
J 92 2 1- 2 43
Fig. 46 Replacing Reaction Shaft Support
Bushing42RH
(3) Turn remover tool hex nut down agai nst re-
mover cup to pull bushing from shaft. Clean all chips
from shaft after bushing removal.
(4) Lightly grip old bushing in vise or with pliers
and back remover tool out of bushing.
(5) Assemble Bushing Installer Tools C-4171 and
SP-5325 (Fig. 46).
(6) Slide new bushing onto Installer Tool SP-5325.
(7) Position reaction shaft support upri ght on a
clean smooth surface.

(8) Align bushing in bore. Then tap bushing into
place until Bushing Installer SP-5325 bottoms.
installing bushing.
SHAFT SUPPORT
(1) Lubricate gear bore in pump housing with
transmission fluid.
(2) Lubricate pump gears with transmission fluid.
(3) Support pump housing on wood blocks (Fig. 47).
(4) Install outer gear in pump housing (Fig. 47).
Gear can be installed either way (it is not a one-way
fit).
OUTER
GE AR
J9321-219
Fig. 47 Supporting Pump And Installing Outer
Gear-42RH
(5) Install pump inner gear (Fig. 48). Gear can be
installed either way (it is not a one-way fit).
OUT E R
GE AR
INNER
GE AR
J9321-220
Fig. 48 Pump Inner Gear Installation42RH
(6) Install new thrust washer on hub of reaction
shaft support. Lubricate washer with transmission
fluid or petroleum jelly.
(7) If reaction shaft seal rings are being replaced,
install new seal rings on support hub (Fig. 4 9) . Lu-
bricate seal rings with transmission fluid or petro-
leum jelly after installation. Squeeze each ring until
ring ends are securely hooked together.
CAUTI ON : Th reaction shaft suppor t seal rings will
break if overspread, or twisted. If new rings are be-
ing installed, spread them only enough for installa-
tion. Al so be very sure the ring ends are securely
rings will either prevent pump installation, or break
during installation.
S U PPO R T S -
HUB
Fig. 49 Hub Seal Ring Position42RH
(8) Install reaction shaft support on pump housing
(Fig. 50).
(9) Align reaction support on pump housing. Use
alignment marks made at disassembly. Or, rotate
support until bolt holes in support and pump housing
are all aligned (holes are offset for one-way fit).
Fig. 50 Assembling Reaction Shaft Support And
Pump Housing42RH
(10) Install all bolts that attach support to pump
housing. Then tighten bolts finger tight.
(11) Tighten support-to-pump bolts to required
torque as follows:
(a) Reverse pump assembly and install it in
transmission case. Position pump so bolts are fac-
ing out and are accessible.
(b) Secure pump assembly in case with 2 or 3
bolts, or with pilot studs.
(c) Tighten support-to-pump bolts to 20 N
#
m (15
ft. lbs.).
(d) Remove pump assembly from transmission
case.

(12) Install new oil seal in pump with Special Tool
C-4193 and Tool Handle C-4171 (Fig. 51). Be sure
seal lip faces inward.
(13) Install new seal ring around pump housing.
Be sure seal is properly seated in groove.
(14) Lubricate lip of pump oil seal with petroleum
jelly. Lubricate pump seal with Ru-Glyde or petro-
leum jelly.
SPECIAL
TOOL
C-4193
PUMP
BODY
FRONT
CLUTCH
SPRING
COMPRESSOR
TOOL C-3575-A
PUMP
SEAL
J932M83
SPRING
RETAINER \ ^
RETAINER
SNAP RING
/J9121-147
Fig. 51 Pump Oil Seal Installation42RH
(1) Remove waved snap ring and remove pressure
plate, clutch plates and clutch discs (Fig. 52).
(2) Compress clutch piston spring with Compressor
Tool C-3575-A (Fig. 53). Be sure legs of tool are
seated squarely on spring ret ai ner before compress-
ing spring.
pressor tool.
Fig. 53 Compressing Front Clutch Piston
Spring42RH
(4) Remove spring ret ai ner and clutch spring. Note
position of ret ai ner on spring for assembly reference.
(5) Remove clutch piston from clutch ret ai ner. Re-
move piston by rot at i ng it up and out of ret ai ner.
(6) Remove seals from clutch piston and clutch re-
t ai ner hub. Discard both seals as they are not reus-
able.
RETAINER HUB
SEAL
CLUTCH
PISTON
SNAP RING
(WAVED)
PISTON
SPRING
SPRING
RETAINER
SNAP RING
PRESSURE
PLATE
FRONT CLUTCH RETAINER
CLUTCH PLATES
Fig. 52 Front Clutch Components42RH
J9321 - 222
21 - 241 TRANSMISSION OWERHAUL-42RH
RETAINER
CHECK BALL
J9121-36 8
Fig. 54 Front dutch Piston Retainer Check Ball
Location42RH
FRONT CLUTCH ASSEMBLY
(1) Soak clutch discs in transmission fluid while
assembling other clutch part s.
(2) Check piston spring fit. Trial fit each end of
spri ng in pi ston (Fig. 56). One end of spring has
slightly larger i nsi de diameter. This end will be
slip fit over hub of pi ston and ensure full spri ng
seating. Mark spri ng wi th chal k or paint after
determi ni ng whi ch end is best fit in spring seat.

FRONT
CLUTCH J C < T 7
R E T A I N E R ^
BUSHI NGS V ^ = = = = * F = = ^ ^ /
(NON-SERVICEABLE) ^Mp^^^yr^^
J9321-223
Fig. 55 Retainer Bushing Locations42RH
TRIAL FIT
SPRI NG FOR
CORRECT FIT
J9321-225
Fig. 56 Checking Spring Fit In Clutch Piston42RH
(3) Install new seals on piston and in hub of re-
t ai ner. Be sure lip of each seal faces interior of clutch
ret ai ner.
(4) Lubricate lips of piston and ret ai ner seals wi t h
liberal quant i t y of Door Eze, or petroleum jelly. Then
lubricate ret ai ner hub, bore and piston wi t h t rans-
mission fluid.
(5) Install clutch piston in ret ai ner (Fig. 57). Use
twisting motion to seat piston in bottom of ret ai ner.
Do not attempt to push the pi ston straight in.
This coul d fold the seal s over causi ng l eakage
and cl utch slip.
(6) Position spring in clutch piston.
(7) Position spring ret ai ner on top of piston spring
(Fig. 58). Make sure retainer is properl y in-
stalled. Small rai sed tabs shoul d be facing up-
ward. Semicircular l ugs on undersi de of retainer
are for posi ti oni ng retainer in spring.
(8) Compress piston spring and ret ai ner with Com-
pressor Tool C-3575-A (Fig. 53). Then install new
snap ri ng to secure spring ret ai ner and spring.
(9) Install clutch plates and discs (Fig. 52). Install
steel plate t hen disc until all plates and discs are in-
stalled.
(10) Install pressure plate and waved snap ri ng
(Fig. 52).
Clean t he front clutch components in solvent and
dry t hem with compressed air only. Do not use rags
or shop towels to dry any of t he clutch part s. Lint
from such mat eri al s will adhere to t he component
surfaces and could restrict or block fluid passages af-
ter assembly.
burned or charred, or if t he facing is flaking off. Re-
place t he steel plates if heavily scored, warped, or
broken. Be sure t he driving lugs on t he plates are in
damaged in any way.
Replace t he clutch spring and spring ret ai ner if ei-
t her is distorted, warped or broken.
Check t he lug grooves in t he clutch retainer. The
t he ret ai ner if t he grooves are worn or damaged.
Check action of t he check ball in t he ret ai ner (Fig.
54). The ball must move freely and not stick.
Inspect the cl utch retainer bushi ngs carefully
(Fig. 55). The retainer bushi ngs are not service-
able. It will be necessary to repl ace the retainer
if either bushi ng i s scored, or worn.
FRONT
CLUTCH
RETAINER
FEELER GAUGE
J9121-146
Fig. 57 Front Clutch Piston Installation42RH
SMALL TABS
O N RETAINER
- FACE
UPWARD
J9321-224
Fig. 58 Correct Spring Retainer Installed
Position42RH
(11) Check clutch plate clearance (Fig. 59). Clear-
ance should be 1.70 to 3.40 mm (0.067 to 0.134 in.).
If clearance is incorrect, clutch discs, plates pressure
plates and snap ring may have to be changed.
REAR CLUTCH DISASSEMBLY
(1) Remove fiber t hr ust washer from forward side
of clutch retainer.
(2) Remove selective clutch pack snap ri ng (Fig.
60).
(3) Remove top pressure plate, clutch discs, steel
plates, bottom pressure plate and wave spring (Fig.
60).
(4) Remove clutch piston. Grasp piston and rotate
piston up and out of retainer.
(5) Remove and discard piston seals.
(6) Remove i nput shaft snap ri ng (Fig. 61).
(7) Press i nput shaft out of ret ai ner with shop
press and suitable size press tool (Fig. 62).
(8) Remove i nput shaft front/rear seal rings.
Clean t he clutch components with solvent and dry
t hem with compressed air. Do not use rags or shop
towels to dry any of t he clutch part s. Li nt from such
FEELER GAUGE
RH288
mat eri al s will adhere to component surfaces and
could restrict or block fluid passages after assembly.
ing is flaking off. Replace t he top and bottom pres-
sure plates if scored, warped, or cracked. Be sure t he
driving lugs on t he pressure and clutch plates are
also in good condition. The lugs must not be bent,
cracked or damaged in any way.
Check t he l ug grooves in t he clutch retainer. The
clutch and pressure plates should slide freely in t he
slots. Replace t he ret ai ner if t he grooves are worn or
piston. The check ball must move freely and not
stick.
Replace t he ret ai ner bushi ng if worn, scored, or
doubt exists about bushi ng condition.
ret ai ner if the seal surfaces are seriously scored.
Check condition of t he fiber t hrust washer and
met al output shaft t hr ust washer. Replace either
washer if worn or damaged.
Check condition of t he seal rings on t he input shaft
and clutch ret ai ner hub. Replace t he seal rings only
if obviously damaged. The i nput shaft front seal ri ng
is teflon wi t h chamfered ends. The rear ring is met al
with interlocking ends.
REAR
CLUTCH
PISTON
CLUTCH
PISTON
SEALS
OUTPUT
SHAFT
THRUST
WASHER
(METAL)
INPUT
SHAFT
SNAP
RING
REAR
CLUTCH
RETAINER
INPUT
SHAFT
-REAR
CLUTCH
. THRUST
^ / SHAFT W A | H E R
/ F RON T (FIBER)
SHAFT SE AL
REAR RING -
M
u
SEAL (TEFLON)
C
^ H
RING PACK
(METAL) SNAP
RING
(SELECTIVE)
PISTON
SPRING
BOTTOM
PRESSURE
PLATE
CLUTCH
DISCS (4)
TOP
PRESSURE
PLATE
J9121-539
Fig. 60 Rear Clutch Components42RH
Fig. 61 Removing/Installing Input Shaft Snap
Ring-42RH
Check t he i nput shaft for wear, or damage. Replace
REAR CLUTCH ASSEMBLY
(1) Soak clutch discs i n t ransmi ssi on fluid.
(2) Install new seal ri ngs on clutch ret ai ner hub
and i nput shaft (Figs. 63 and 64).
J 912 M 5 0
Fig. 62 Removing Input Shaft From Rear Clutch
Retainer42RH
(a) Be sure clutch hub ret ai ner seal ri ng is fully
seated in groove (Fig. 63). Ring must not be
twisted, or distorted.
(b) Note t hat i nput shaft front seal ri ng is teflon
and rear seal ri ng is met al (Fig. 64). Be sure cham-
fered ends of teflon ri ng are properly joined and
t hat ends of rear ri ng are securely hooked together.
(c) Lubricate ret ai ner and shaft seal rings wi t h
light coat of petroleum jelly after installation.

TRANSMISSION OVERHAUL-4 2RH 21 - 24 S
J9121-538
Fig. 63 Installing Rear Clutch Retainer And Input
Shaft Seal Rings42RH
J912M51
Fig. 64 input Shaft Seal Ring Identification42RH
(3) Lubricate splined end of input shaft and clutch
ret ai ner with transmission fluid. Then press i nput
shaft into ret ai ner (Fig. 65).
(4) Install input shaft ret ai ni ng ri ng (Fig. 61).
(5) Install new seals on clutch piston. Be sure lip
of each seal faces interior of cl utch retainer.
(6) Lubricate lip of piston seals with liberal quan-
tity of Door Eze, or petroleum jelly. Then lubricate
ret ai ner hub and bore with transmission fluid.
Fig. 65 Pressing Input Shaft Into Rear Clutch
Retainer42RH
(7) Install clutch piston in retainer. Use twisting
motion to seat piston in bottom of ret ai ner. Do not
attempt to push the pi ston straight in. This
coul d fold the seal s over causi ng l eakage and
cl utch slip.
(8) Install piston spring in ret ai ner and on top of
piston (Fig. 56). Concave side of spring faces up as
shown.
(9) Install wave spring in ret ai ner (Fig. 66). Be
sure spring is completely seated in ret ai ner groove.
Fig. 66 Piston And Wave Spring Position42RH
(10) Install bottom pressure plate (Fig. 60). Ridged
side of plate faces downward (toward piston) and flat
side toward clutch pack.
Fig. 67 Checking Rear Clutch Pack Clearance
(15) Coat rear clutch fiber t hr ust washer wi t h pe-
troleum jelly and install washer over i nput shaft and
into clutch ret ai ner (Fig. 68). Use enough petroleum
jelly to hold washer in place.
(16) Set rear clutch aside for installation duri ng fi-
nal assembly.
PLANETARY GEAR TRAIN AND INTERMEDIATE
SHAFT OVERHAUL
GEARTRAIN DISASSEMBLY (FIG* 69)
(1) Remove snap ring, tabbed t hr ust washer and
t hr ust plate from front of output shaft.
(2) Remove front annul us gear and support assem-
bly.
(3) Remove front pl anet ary front t hr ust washer.
(4) Remove front pl anet ary gear.
(5) Remove front pl anet ary rear t hr ust washer.
(6) Remove sun gear and driving shell.

Fig. 68 Installing Rear Clutch Thrust Washer42RH
(7) Remove snap ring t hat ret ai ns sun gear in
driving shell and remove sun gear and t hrust plates.
Note t hrust plate position for assembly reference.
t ary gear.
(9) Remove rear pl anet ary gear from rear annul us
gear and remove annul us gear from i nt ermedi at e
shaft.
(10) Remove snap rings securing annul us gears to
supports. Then separate each gear from support.
PLANETARY GEARTRAIN INSPECTION
Clean t he pl anet ary components in solvent and dry
place t he gear if damaged or if t he bushings are
scored or worn. The bushings are not serviceable. Re-
place t he driving shell if worn, cracked or damaged.
Replace pl anet ary gear sets if gears, pinion pins, or
carrier are damaged in any way. Replace t he annu-
lus gears and supports if either component is worn or
damaged.
Inspect t he geart rai n spacers, t hrust plates, snap
rings, and t hrust washers. Replace any part t hat is
worn or damaged. Do not at t empt to reuse these
part s.
Inspect t he i nt ermedi at e shaft carefully. Pay par-
ticular attention to t he machined bushing/bearing
surfaces on t he shaft.
Replace t he i nt ermedi at e shaft if any machined
surfaces are scored, pitted, or damaged in any way.
Also replace t he shaft if t he splines are damaged, or
exhibits cracks at any location. Be sure t he select
spacer groove on t he shaft is in good condition. Trial
fit t he spacer if necessary.
(11) Install first clutch disc in ret ai ner on top of
bottom pressure plate. Then install a clutch pl at e fol-
lowed by a clutch disc unt i l ent i re clutch pack is in-
stalled. 4 clutch discs and 3 met al plates are
required.
(12) Install top pressure plate (Fig. 60).
(13) Install selective snap ri ng (Fig. 60). Be sure
snap ri ng is fully seated in ret ai ner groove.
(14) Measure clutch pack clearance (Fig. 67).
Clearance should be 0.64 to 1.14 mm (0.025 to 0.045
in.). If clearance is incorrect, steel plates, discs, snap
ring and pressure plates may have to be changed
(Fig. 53).
# , , . , _ TRANSMISSION 0VERHAUL-4 2RH 21 - 251
SELECT FRONT
FIT ANNULUS
PLANETARY S NAP
S NAP RI NG
RI NG
SUPPORT
SNAP
RI NG
FRONT
ANNULUS
GEAR
FRONT
PLANETARY
THRUST
WASHERS
S U N
GEAR
S UN
GEAR
SPACER
DRI VI NG SHELL
FRONT THRUST
PLATE
FRONT
ANNULUS
THRUST
WASHER
DRI VI NG
SHELL
REAR
THRUST
PLATE
OVERDRIVE
PISTON
RETAINER
INTERMEDIATE
SHAFT THRUST
PLATE
DRI VI NG
, SHELL
CLUTCH
C AM BOLTS
INTERMEDIATE
SHAFT
Fig. 69 Transmission Planetary Gear Train42RH
J9221-18
PLANETARY GEARTRAIN ASSEMBLY
(1) Lubricate intermediate shaft and pl anet ary
components with transmission fluid. Use petroleum
jelly to lubricate and hold t hr ust washers and plates
in position.
(2) Assemble rear annul us gear and support if dis-
assembled. Be sure support snap ri ng is seated and
t hat shoulder side of support faces rearward.
(3) Install rear t hrust washer on rear pl anet ary
washer in place. Also be sure washer tabs are prop-
erly engaged in gear slots.
(4) Install rear annul us over and onto rear plane-
(5) Install assembled rear pl anet ary and annul us
gear on i nt ermedi at e shaft (Fig. 71). Verify t hat as-
sembly is fully seated on shaft.
(6) Install front t hrust washer on rear pl anet ary
washer on gear.
(7) Install spacer on sun gear (Fig. 73).
(8) Install t hr ust plate over sun gear and on top of
spacer (Fig. 74). Note t hat t hr ust plates are inter-
changeable. Use either plate on sun gear and rear of
driving shell.
REAR
ANNULUS
GEAR
TABBED
THRUST
WASHER
REAR
PLANETARY
J9121- 156
Fig. 70 Assembling Rear Annulus And Planetary
Gear-42RH
(9) Insert sun gear into driving shell (Fig. 75).
(10) Hold sun gear in position and install rear
t hr ust plate. Pl at e goes over sun gear at rear of driv-
ing shell (Fig. 75).
21 - 252
TRANSMISSION OVERHAUL-42RH
REAR ANNULUS
A N D PLANETARY GEAR
ASSEMBLY
INTERMEDIATE
SHAFT
J9121-275
Fig. 71 installing Assembled Rear Annulus And
Planetary Gear On Intermediate Shaft42RH
FRONT
TABBED
THRUST
WASHER
REAR
PLANETARY
GEAR
J9121-158
Fig. 72 Installing Rear Planetary Front Thrust
Washer-42RH
SUN
GEAR
SUN GEAR
SPACER
J 912 M 5 9
Fig. 73 Installing Sun Gear Spacer42RH
(11) Position wood block on bench and support sun
gear on block (Fig. 76). This makes it easier to align
THRUST
PLATE
Fig. 74 Installing Spacer And Thrust Plate On Sun
Gear-42RH
SUN
DRI VI NG GEAR
SHELL
REAR
THRUST
PLATE J9121-162
Fig. 75 Installing Sun Gear And Rear Thrust Plate In
Driving Shell-42RH
and install sun gear lock ring. Keep wood block
handy as it will also be used for geart rai n end play
check.
SUN
GEAR
DRI VI NG
SHELL
WO O D
BLOCK
J912M63
Fig. 76 Supporting Sun Gear On Wood Block-42RH

(12) Align rear t hrust plate on driving shell and
install sun gear lock ring. Be sure ri ng is fully
seated in sun gear ri ng groove (Fig. 77).
Fig. 77 Installing Sun Gear Lock Ring42RH
(13) Install assembled driving shell and sun gear
on i nt ermedi at e shaft (Fig. 78).
Fig. 78 Installing Assembled Sun Gear And Driving
Shell On Intermediate Shaft42RH
(14) Install rear t hrust washer on front pl anet ary
washer on gear and be sure washer t abs are all prop-
erly seated.
(15) Assemble front annul us gear and support if
necessary.
(16) Position t hrust plate on front annul us gear
support (Fig. 80). Use liberal quant i t y of petroleum
jelly to hold plate in place.
(17) Install front pl anet ary gear on i nt ermedi at e
shaft and in driving shell (Fig. 81).
(18) Install front t hrust washer on front pl anet ary
washer in place on gear and be sure washer t abs are
seated.
Fig. 79 Installing Rear Thrust Washer On Front
Planetary Gear42RH
Fig. 80 Installing Thrust Plate On Front Annulus
Support42RH
Fig. 81 Installing Front Planetary And Annulus
Gears42RH

(19) Assemble front annul us gear and support. Be
sure support snap ri ng is seated.
(20) Install front annul us t hr ust washer (Fig. 82).
Align flat on washer with flat on pl anet ary hub. Also
be sure washer t ab is facing forward.
Fig. 82 Installing Front Annulus Thrust
Washer-42RH
(21) Install front annul us snap ri ng (Fig. 83). Use
snap ri ng pliers to avoid distorting ring duri ng in-
stallation. Also be sure ri ng is fully seated.
Fig. 83 Installing Front Annulus Snap Ring42RH
(22) Install pl anet ary selective snap ri ng with snap
ri ng pliers (Fig. 84). Be sure ri ng is fully seated.
(23) Turn pl anet ary geart ai n assembly over so
driving shell is facing workbench. Then support
geart rai n on wood block positioned under forward
end of output shaft. This is necessary so geart rai n
components will move forward for accurate end play
check.
(24) Check pl anet ary geart rai n end play wi t h
feeler gauge (Fig. 85). Gauge goes between shoulder
on i nt ermedi at e shaft and end of rear annul us sup-
port.
SELECTIVE
Fig. 84 Installing Planetary Selective Snap
Ring-42RH
(25) Geart rai n end play should be 0.12 to 1.22 mm
(0.005 to 0.048 in.). If end play is incorrect, snap ri ng
(or t hr ust washers) may have to be replaced. Snap
ri ng is available in t hree different thicknesses for ad-
j ust ment purposes.
Play-42RH
FRONT SERVO DISASSEMBLY (FIG. 86)
(1) Remove small snap ri ng from servo piston.
(2) Remove piston, rod, springs and guide.
(3) Remove and discard servo piston rings and
O-ring.
FRONT BAND AND SERVO INSPECTION
Clean t he servo components wi t h solvent and dry
servo snap ring if distorted or warped.
Replace t he front band if distorted, t he lining is
burned or flaking off, or excessively worn.
Check t he servo piston bore for wear. Replace t he
piston and rod as an assembly if ei t her part is worn
or damaged.
PISTON PISTON
ROD
R
OD
SNAP
RING
SERVO
PISTON
ROD
GUIDE
PISTON
SEALS
PISTON
ROD
SEAL
PISTON
SPRING
SERVO
R O D
SNAP GUIDE
RING
S E A L
J912M72
ASSEMBLING FRONT SERVO PISTON
(1) Lubricate seal rings and O-rings wi t h petro-
leum jelly. Lubricate other servo par t s wi t h t rans-
mission fluid.
(2) Install new O-ring on servo piston rod.
(3) Install new seal on piston rod guide and install
new seal rings on piston.
(4) Assemble rod, piston, servo springs and snap
ri ng (Fig. 86 ) .
REAR SER0 AND BAND OVERHAUL
REAR SERVO PISTON DISASSEMBLY
(1) Remove seal from servo piston. Note which way
seal lip faces for assembly reference.
(2) Compress cushion spring in vise only enough to
allow piston plug snap ri ng removal (Fig. 87). Use
wood block between vise jaws and end of piston plug
to keep plug aligned and in position.
(3) Remove snap ring from end of piston plug (Fig.
87).
(4) Open vise and remove wood block, piston plug,
cushion spring and servo piston.
SMALL
WOOD
BLOCK
PISTON
PLUG
SNAP
RI NG
SNAP
RI NG
PLIERS
J9121-174
Fig. 87 Removing/lnstailing Servo Piston Piug Snap
Ring42RH
REAR SERVO INSPECTION
Clean t he servo components (Fig. 88) with solvent
and dry t hem with compressed air.
ing is excessively worn. Check t he band pivot and
reaction pins. Minor pin scoring can be cleaned up
with crocus cloth. However, replace t he pins if worn,
severely scored, or cracked. Replace t he pin O-rings.
Inspect t he servo components. Replace t he servo
and cushion springs if collapsed, distorted or broken.
SPRI NG
RETAINER
SERVO
SPRI NG
PISTON
PLUG
CUSHI ON
SPRI NG
SERVO
S NAP
RI NG
PISTON
PLUG
S NAP
RI NG
SERVO
PISTON J9121-173
Replace t he plug or piston if cracked, bent, or worn.
Discard t he servo snap ri ng and spring ret ai ner if
distorted or warped.
ASSEMBLING REAR SERWO PISTON
(1) Assemble piston plug, cushion spring and pis-
ton (Fig. 88).
(2) Compress cushion spring in vise and install pis-
ton plug snap ri ng (Fig. 87).
(3) Install new seal on piston. Be sure seal lip is
toward servo bore (Fig. 89).
(4) Lubricate piston seal with petroleum jelly. Lu-
bricate other servo part s with transmission fluid.
BE SURE
SEAL LIP
IS TOWARD
SERVO BORE
REAR
SERVO
PISTON
J9121-175
Fig. 89 installing Rear Servo Piston Seal
WALWE BODY MAIN COMPONENT
DISASSEMBLY
C A U T I O N : D o not cl amp any val ve body compo-
nent in a vi se. T hi s practice c an damage the c om-
ponent resul ti ng in unsati sfactory operation after
assembl y and installation. R emove val ves, pl ugs
and spr i ngs with a pencil magnet . D o not use pliers
to remove any of the val ves, pl ugs or spr i ngs and
do not force any of the component s out or into
pl ace. The val ves and val ve body hous i ngs will be
damaged if force i s used. Tag or mark the val ve
body spr i ngs for reference as they are removed. D o
not allow them to become intermixed.
(1) Remove boost valve cover (Fig. 90).
(2) Remove boost valve ret ai ner, valve spring and
boost valve (Fig. 91).
(3) Secure det ent ball and spring wi t h Ret ai ner
Tool 6583 (Fig. 92) .
(4) Remove E-clip t hat secures t hrot t l e lever in
(5) Lift and rot at e manual lever far enough to
clear det ent housing.
I K ) O o O O O O
UPPER
HOUSI NG J9321-126
Fig. 90 Boost Valve Cover Location42RH
BOOST
VALVE
INSTALLED
LOCATION
SPRING BOOST
AND VALVE BOOST
VALVE SPRING VALVE
RETAINER
COVER
SCREWS
J9321-127
Fig. 91 Boost Valve Components
SPECIAL
TOOL 6583
DETENT BALL AND SPRING HOUSI NG J9321 -121

THROTTLE
LEVER
AAANUAL
LEVER
E-CLIP
J9321-138
Fig. 93 Removing Throttle Lever E-Clip
(6) Remove ret ai ni ng tool and remove detent ball
and spring (Fig. 9 4 ) .
AAANUAL
LEVER
DETENT
HO U S I N G
DETENT
BALL.
AND
SPRING J9321-139
Fig. 94 Detent Bali And Spring Removal
(7) Remove washer at top of manual lever shaft.
Then lift manual lever and park rod assembly up-
ward and out of valve body (Fig. 95).
AAANUAL
LEVER
AND
PARK
ROD
ASSEMBLY
MANUAL
LEVER
WASHER
J932 M40
Fig. 95 Manual Lever Removal42RH
(8) Remove t hrot t l e lever from valve body housi ng
(Fig. 96).
THROTTLE
LEVER
J932 M41
Fig. 96 Throttle Lever Removal42RH
MANUAL
LEVER
PARK
ROD
J9121-81
(10) Remove screws attaching pressure adjusting
screw bracket to valve body and transfer plate. Hold
bracket firmly agai nst spring tension while removing
last screw.
valve spring (Fig. 98). Do not r e move t hr ot t l e
pr e s s ur e adj ust i ng s cr ew from br a c ke t a n d do
not di s t ur b adj us t i ng s cr ew set t i ngs dur i ng r e-
moval .
(12) Remove solenoid connector from 3-4 accumula-
tor housing (Fig. 99). Not e t hat connect or i s at -
t a c he d t o hous i ng wi t h s houl der - t ype s cr ew.
Keep t hi s s cr ew wi t h a c c umul a t or hous i ng t o
avoi d l osi ng it.
(13) Note routing of solenoid wires for assembly
(14) Remove screws at t achi ng solenoid assembly to
valve body lower housing and remove solenoid and
connector assembly (Fig. 101).

PRESSURE
REGULATOR
VALVE SPRI NG
ADJUSTI NG
SCREW
BRACKET
SWITCH
VALVE
SPRI NG
LINE PRESSURE
ADJUSTI NG SCREW
J9121-512
Removal42RH
SOLENOID
CONNECTOR
3-4
ACCUMULATOR
HOUSI NG
a
=
J 9 3 2 M 43
Fig. 99 Solenoid Connector Position42RH
SOLENOID
WIRES
(NOTE
WIRE
ROUTING)
s
\ ^ t % U ^
r
^^^^
Fig. 100 Solenoid Wire Routing42RH
SOLENOID
ATTACHING
SCREWS
LOWER
HOUSI NG
SOLENOID
ASSEMBLY J932 M44
Fig. 101 Solenoid Assembly Removal42RH
(15) Remove 3-4 accumulator housing at t achi ng
screws and remove housing from valve body (Fig.
102).
3-4
ACCUMULATOR-
HOUSI NG HOUSI NG
ATTACHING
SCREWS
Fig. 102 Removing 3-4 Accumulator Housing42RH
(16) Remove following part s from valve body lower
housing: 3-4 shift valve and spring; pressure regula-
tor valve spring; clutch valve; clutch valve spring;
and clutch valve plug (Fig. 103).
(17) Remove boost valve connecting t ube (Fig.
104). Disengage t ube from upper housing port first.
Then rock opposite end of t ube back and forth to
work it out of lower housing.
C A U T I O N : D o not use t ool s to l oosen or pry the
connect i ng tube out of the val ve body housi ngs.
L oosen and remove the tube by hand onl y.
(18) Turn valve body over so valve lower housing
is facing upward (Fig. 105). In t hi s position, check
balls in upper housing will remai n in place and not
fall out when lower housing and transfer plate are
removed.
LOWER
HO U S I N G
CLUTCH
VALVE A N D
SPRI NG
3- 4
SHIFT
VALVE
A N D
SPRI NG
PRESSURE
CLUTCH REGULATOR
VALVE VALVE
PLUG SPRI NG J 932 1- 146
Fig. 103 Clutch Valve And 3-4 Shift Vaive
Locations42 RH
BOOST
.VALVE
TUBE
LOWER
HO U S I N G
UPPER
HO U S I N G
DI S E NGAGE
THI S E ND OF
TUBE FIRST J 932 1- 147
Fig. 104 Boost Valve Tube Removal42RH
(19) Remove screws at t achi ng valve body lower
housing to upper housing and transfer plate (Fig.
105). Note posi ti on of boost val ve tube brace for
assembl y reference.
(20) Remove lower housing and overdrive separa-
tor plate from transfer plate (Fig. 106).
(21) Remove transfer plate from upper housing
(Fig. 107).
(22) Turn transfer plate over so upper housing sep-
arat or plate is facing upward (Fig. 108).
(23) Remove brace plate from lower housing sepa-
rator plate and transfer pl at e (Fig. 108).
(24) Remove upper housing separator plate from
transfer plate (Fig. 109). Note position of filter in
separator pl at e for assembly reference.
LOWER
HO U S I N G
VALVE
BODY
SCREWS ( 13)
S ^
c
TUBE
BRACE J 932 1- 148
Fig. 105 Valve Body Screw And Tube Brace
Location42RH
OVERDRIVE
SEPARATOR
PLATE
TRANSFER
PLATE A N D
UPPER
HO U S I N G
LOWER
HO U S I N G
J 932 1- 149
Fig. 106 Lower Housing Removal42RH
UPPER
HO U S I N G
TRANSFER
PLATE
J 9 3 2 M 5 2
Fig. 107 Removing Transfer Plate From Upper
Housing42RH
(25) Remove rear clutch check ball from transfer
plate. Note check ball l ocati on for assembl y ref-
erence before removi ng it (Fig. 110).

BRACE
J9321-15 0
SEPARATOR TRANSFER
PLATE PLATE
Fig. 108 Brace Plate Removal42RH
TRANSFER
PLATE
UPPER
HOUSI NG
'SEPARATOR
PLATE
FILTER
SCREEN
BRACE J 932 M 5 1
Fig. 109 Upper Housing Separator Plate
Removal42RH
TRANSFER
PLATE
REAR
CLUTCH
CHECK
BALL
Fig. 110 Rear Clutch Check Ball Location42RH
VALVE BODY UPPER HOUSING
DISASSEMBLY
(1) Note location of check balls in valve body upper
housing (Fig. 111). Then remove one large and six
smaller diameter check balls with magnet (total of 7
check balls are used).
SMALL
DIAMETER
CHECK
BALLS (6)
LARGE DIAMETER
CHECK
BALL (1)
J9321-15 4
Fig. 111 Valve Body Check Ball Locations42RH
(2) Remove E-clip t hat secure shut t l e valve second-
ary spring on valve stem (Fig. 112).
E-CLIP SECONDARY SHUTTLE
VALVE
J9121-179
Location42RH
(3) Remove governor plug and shut t l e valve covers
(Fig. 113).
(4) Remove t hrot t l e plug, pri mary spring, shut t l e
valve, secondary spring, and spring guides (Fig. 113).
(5) Remove boost valve retainer, spring and valve
if not previously removed.

TRANSMISSION OV ERH AUL4 2RH 21 - 26 1
-15 6
Fig. 113 Shuttle And Boost Valve Components42RH
(6) Turn upper housing over and remove switch (8) Remove t hrot t l e plug and 1-2 and 2-3 governor
valve, regulator valve and spring, and manual valve plugs (Fig. 114). Also remove shut t l e valve pri mary
(Fig. 114). spring if not removed in prior step.
(7) Remove kickdown detent, kickdown valve, and
t hrot t l e valve and spring (Fig. 114).
Fig. 114 Control Valve Locations42RH Upper Housing
UPPER
HOUSI NG
1-2
SHIFT
CONTROL
VALVE
AND SPRING
2-3
SHIFT
VALVE
A N D SPRING
THROTTLE
PRESSURE
SPRING
AND
PLUG
COVER
PLUG
SLEEVE
LINE
PRESSURE
PLUG
PRESSURE
PLUG
COVER
J9321-243
Fig. 115 Shift Waives And Pressure Plugs42RH Upper Housing
(9) Turn upper housing around and remove limit
valve and shift valve covers (Fig. 115).
(10) Remove limit valve housing. Then remove re-
tainer, spring, limit valve, and 2-3 t hrot t l e plug from
limit valve housing (Fig. 115).
(Fig. 115).
(12) Remove 1-2 shift valve and spring (Fig. 115).
body (Fig. 115).
(14) Remove pressure plug cover (Fig. 115).
(15) Remove line pressure plug, sleeve, t hrot t l e
pressure plug and spring (Fig. 115).
VALWE BODY LOWER HOUSING
DISASSEMBLY (FIG. 116)
(1) Remove t i mi ng valve cover.
(2) Remove 3-4 t i mi ng valve and spring.
(3) Remove 3-4 shut t l e valve E-clip and remove
shut t l e valve spring and plug.
(4) Remove 3-4 shift valve and spring.
(5) Remove converter clutch valve, spring and
plug.
(6) Remove converter clutch t i mi ng valve, ret ai ner
and valve spring.
3- 4 ACCUMULATOR HOUSING DISASSEMBLY
(FIG. 117)
(1) Remove end plate from housing.
(2) Remove piston spring.
(3) Remove piston. Remove and discard piston
seals.
VALWE 1 0DY CLEANING AND INSPECTION
(Fig. 118):"
solenoid and connector assembly
solenoid gasket and connector screw
pressure adjusting screw and bracket
t hrot t l e valve lever
manual lever and shaft seal
t hrot t l e lever shaft seal, washer, and E-clip
fluid filter and screws
detent ball
valve body screws
The park rod and park rod E-clip are also service-
able. Refer to t he park lock components and over-
drive case information in t he part s catalogue. The
remai ni ng valve body components are serviced only
as par t of a complete valve body assembly.
Clean t he valve body components with a st andard
par t s cleaning solution only. Do not use gasoline,
kerosene, or any type of caustic solution.
4
TRANSMISSION QVERHAUL-4 2RH 21 - 26 3
Fig. 116 Shift Valves And
3-4 ACCUMULATOR
^ HOUSING
PLATE J9121-277
Fig. 117 3-4 Accumulator Housing
Components42 RH
Dry t he part s wi t h compressed air. Make sure all
passages are clean and free from obstructions. Do
not use rags or shop towel s to dry or wi pe off
wings42RH Lower Housing
val ve body components. Lint from these materi-
als will adhere to the val ve body components.
Lint will interfere wi th val ve operati on and may
clog filters and fluid passages.
Inspect t he throttle and manual valve levers and
pressure.
Minor distortion of a valve body' mat i ng surface
may be corrected by smoothing t he surface with a
sheet of crocus cloth. Position t he crocus cloth on a
surface plate, sheet of plate glass or equally flat sur-
face. If distortion is severe or any surfaces are
heavily scored, t he valve body will have to be re-
placed.
21 - 264 TRANSMISSION QVERHAUL-4 2RH
ADJUSTING
- SCREW
AND SW I TCH
CONNECTOR
SEAL
J9321-226
Fig. ! *8 Serviceable Valve Body
Components42RH
CAUTI ON ; Many of the waives and pl ugs, s uc h as
the throttle val ve, shuttl e val ve pl ug, 1-2 shift val ve
and 1-2 gover nor pl ug, are made of coat ed al umi -
num (Fi g. 1 1 9) . Al umi num component s are identi-
fied by the dark col or of the speci al coati ng applied
to the surface (or by testing with a magnet). D O
N O T pol i sh or sand al umi num val ves or pl ugs un-
der any ci rcumst ances. T hi s practice coul d damage
the speci al coati ng.
nicks, or scores. Minor surface scratches can be re-
moved with crocus cloth but do not round off the
edges of the val ve or pl ug l ands. Mai nt ai ni ng
sharpness of these edges is vitally important. The
edges prevent foreign mat t er from lodging between
t he valves and plugs and t he bore.
Inspect all the valve and plug bores in the valve
coils.
Check t he two separator plates for distortion or.
damage of any kind. Inspect t he upper housing,
lower housing, 3 - 4 accumulator housing, and transfer
plate carefully. Be sure all fluid passages are clean
and clear. Check condition of t he upper housing and
transfer plate check balls as well. The check balls
and ball seats must not be worn or damaged.
Valve body bores do not change dimensionally with
use. If the valve body functioned correctly when new,
dling.
SHIFT VALVE
END PLATE
2-3 SHIFT
VALVE AND
SPRING
SHUTTLE VALVE
SECONDARY SPRING,
GUIDES, E-CLIP
1-2 SHIFT
CONTROL VALVE
AND SPRING
REGULATOR
VALVE
END PLATE
SHUTTLE VALVE
COVER
SLEEVE
REGULATOR
VALVE THROTTLE
PRESSURE PLUG
RETAINER
VALVE
SPRING
2-3 SHIFT
VALVE GOVERNOR
PLUG
LINE
PRESSURE
ADJUSTING-
SCREW
ADJUSTING
SCREW
BRACKET
PRESSURE
SWITCH REGULATOR*
VALVE VALVE
AND AND
SPRING SPRING
SHUTTLE VALVE
PLUG (ALUM.)
GOVERNOR
VALVE END
PLATE
MANUAL LEVER
DETENT BALL
AND SPRING
J9221-21
Fig. 119 Upper Housing Components-42RH Valve Body (Alum. Indicates Aluminum Part)

VALVE BODY REASSEMBLY
CAUTI ON: Do not force valves or pl ugs into place
during reassembly. If the valve body bores, valves
and pl ugs are free of distortion or burrs, the valve
body components shoul d all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the housi ngs resulting in
valve sticking, cr oss leakage and unsatisfactory op-
eration. Tighten valve body screws t o recom-
mended torque only.
Lower Housing Assembly (Fig. 116)
(1) Lubricate valves, springs, and t he housing
valve and plug bores wi t h transmission fluid.
(2) Install 3-4 t i mi ng valve spring and valve in
lower housing.
(3) Install 3-4 shut t l e valve in lower housing.
Press valve i nward and install E-clip on end of valve
to secure it in housing.
(4) Install 3-4 shut t l e valve spring and t hrot t l e
plug in housing.
(5) Install t i mi ng valve end plate. Tighten end
plate screws to 4 Nm (35 in. lbs.) torque.
(6) Install 3-4 shift valve and spring.
(7) Install converter clutch valve, spring and plug.
(8) Install converter clutch t i mi ng valve and
spring.
3-4 Accumulator Assembly (Fig. 117)
(1) Lubricate accumulator piston, seals and hous-
ing piston bore wi t h transmission fluid.
(2) Install new seal rings on accumulator piston.
(3) Install piston and spring in housing.
(4) Install end pl at e on housing.
Transfer Plate Assembly
(1) Install rear clutch check ball in transfer pl at e
(Fig. 110).
(2) Install filter screen in upper housing separator
plate (Fig. 109).
(3) Align and position upper housing separator
plate on transfer pl at e (Fig. 109).
(4) Install brace plate (Fig. 108). Tighten brace at-
taching screws to 4 Nm (35 in. lbs.) torque.
(5) Install remai ng separator plate at t achi ng
screws. Ti ght en screws to 4 Nr n (35 in. lbs.) torque.
Assembling Upper And Lower Housings
(1) Position upper housing so i nt ernal passages
and check ball seats are facing upward. Then install
check balls in housing (Fig. 111). Seven check balls
are used. The single large check ball is approxi-
mat el y 8.7 mm (11/32 in.) diameter. The remai ni ng 6
check balls are approximately 6.3 mm (1/4 in.) in di-
ameter.
(2) Position transfer plate assembly on upper hous-
ing (Fig. 120).
(3) Position lower housing separator plate on
TRANSFER UPPER
PLATE HOUSING J932M59
Fig. 120 Lower Housing Separator Plate Installation
(4) Install lower housing on assembled transfer
pl at e and upper housing (Fig. 121).
(5) Install and st art valve body screws by hand.
Then t i ght en screws evenly to 4 N * m (35 in. lbs.)
torque. St art at center and work out to sides when
t i ght eni ng screws.
Fig. 121 Assembling Valve Body Upper And Lower
Housings42 RH
Upper Housing Valve And Plug Installation (Figs. 114 , 115,
118)
(1) Lubricate valves, plugs, springs with Mopar
ATF Pl us transmission fluid.
sleeve, throttle plug and spring. Insert assembly in
upper housing and install cover plate. Tighten cover
pl at e screws to 4 N *m (35 in. lbs.) torqe.
(3) Install 1-2 and 2-3 shift valves and springs.
(4) Install 1-2 shift control valve and spring.
(5) Install shift valve cover plate.

(6) Install shuttle valve as follows:
(a) Insert plastic guides in shut t l e valve second-
ary spring and install spring on end of valve.
(b) Hold shuttle valve in place.
(c) Compress secondary spring and install E-clip
in groove at end of shut t l e valve.
(d) Verify t hat spring and E-clip are properly
(7) Install shut t l e valve cover plate. Tighten cover
plate screws to 4 N*m (35 in. lbs.) torque.
valve body.
(9) Install shut t l e valve pri mary spring and throt-
tle plug.
(10) Align and install governor plug cover. Tighten
cover screws to 4 N
#
rn (35 in. lbs.) torque.
(11) Install manual valve.
(12) Install t hrot t l e valve and spring.
(13) Install kickdown valve and detent.
(14) Install regulator valve.
(15) Install switch valve.
Boost Valve Tube Installation
(1) Position valve body assembly so lower housing
is facing upward (Fig. 122).
(2) Lubricate t ube ends and housing ports with
transmission fluid or petroleum jelly.
(3) Position t ube behind tube brace (Fig. 122).
(4) St art t ube in lower housing port first. Then
swing t ube downward and work opposite end of tube
into upper housing port (Fig. 122).
Seat both ends of tube once in position.
TUBE BRACE UPPER
LOWER
HOUS I NG
PORT J932M62
Fig. 122 Boost Vaive Tube Installation-42RH
3-4 Accumulator Installation
(1) Position converter clutch valve and 3-4 shift
valve springs in housing (Fig. 123).
(2) Loosely at t ach accumulator housing with right-
side screw (Fig. 123). Install only one screw at this
t i me as accumulator must be free to pivot upward for
ease of installation.
(3) Position plug on end of converter clutch valve
spring. Then compress and hold springs and plug in
place with fingers of one hand.
(4) Swing accumulator housing upward over valve
springs and plug.
(5) Hold accumulator housing firmly in place and
install remai ni ng two at t achi ng screws. Be sure
springs and clutch valve plug are properly seated
(Fig. 124).
RIGHT-SIDE SCREW
3-4 ACCUMULATOR
Fig. 123 Installing Converter Clutch And 3-4 Shift
Valve Springs42RH
CLUTCH ACCUMULATOR
VALVE PLUG BOSS J932M61
Fig. 124 Seating 3-4 Accumulator On Lower
Housing42RH
(6) Attach solenoid case connector to 3-4 accumula-
tor with shoulder-type screw. Connector has small lo-
cating t ang t hat fits in dimple at top of accumulator
housing (Fig. 125). Seat t ang in dimple before tight-
ening connector screw.
(7) Install solenoid assembly and gasket. Tighten
solenoid at t achi ng screws to 8 N*m (72 in. lbs.)
torque.
SOLENOID
CASE CONNECTOR
Fig. 125 Solenoid Connector Installation42RH
(8) Verify t hat solenoid wires are properly routed
(Fig. 126). Sol enoi d wi r es mus t be cl ear of r e a r
b a n d l ever , ma n u a l l ever a n d p a r k r o d .
Fig, 126 Solenoid Wire Routing42RH
Valve Body Final Assembly And Adjustment
(1) Insert manual lever detent spring in upper
housing.
(2) Position line pressure adjusting screw in ad-
j ust i ng screw bracket.
(3) Install spring on end of line pressure regulator
valve.
adjusting screw bracket.
(5) Position adjusting screw bracket on valve body.
Align valve springs and press bracket into place. In-
stall short, upper bracket screws first and long bot-
tom screw last. Verify t hat valve springs and bracket
_ . . _ +
Alignment-42RH
ADJUSTMENTS
valve body which are, line pressure and throttle pres-
sure.
Line and t hrot t l e pressure work together as each
affects shift quality and timing. Both adjustments
are properly aligned. Then tighten all t hree bracket
(6) Install t hrot t l e lever in upper housing. Then in-
stall manual lever over throttle lever and st art man-
ual lever into housing.
(7) Position detent ball on end of spring. Then hold
detent ball and spring in detent housing with Re-
(8) Align manual lever with detent ball and man-
ual valve. Hold t hrot t l e lever upward. Then press
down on manual lever unt i l fully seated. Remove de-
t ent ball ret ai ner tool after lever is seated.
(9) Then Install manual lever seal, washer and
E-clip.
(10) Lubricate solenoid case connector O-rings and
shaft of manual lever with light coat of petroleum
jelly.
(11) Verify t hat throttle lever is aligned with end
(12) Install boost valve, valve spring, ret ai ner and
cover plate. Tighten cover plate screws to 4 N*m (35
in. lbs.) torque.
(13) Obtain new fluid filter for valve body but do
not install filter at t hi s time.
screw settings we r e moved or changed, readjust as
ment procedure.

must be performed properly and in t he correct se-
quence. Line pressure is adjusted first and t hrot t l e
pressure is adjusted last.
scale (Fig. 128).
Distance should be 33.4 mm (1-5/16 inch).
The 33.4 mm (1-5/16 inch) setting i s an approx-
imate setting. Because of manufacturi ng toler-
ances, it may be necessary to vary from this
di mensi on to obtain desi red pressure.
ing t he adjusting screw counterclockwise increases
pressure while t urni ng t he screw clockwise decreases
pressure.
Insert Gauge C-3763 between the t hrot t l e lever
cam and t he kickdown valve stem (Fig. 129).
down valve against t he spring and bottom t he throt-
t l e valve.
Turn t hrot t l e lever stop screw until t he screw head
touches gauge tool.
The ki ckdown val ve spring must be fully com-
pressed and the ki ckdown val ve compl etel y bot-
tomed to obtai n correct adjustment.
Assembly Tips
t er t he case or transmission components during as-
sembly. Keep t he transmission case and components
Fig. 129 Throttie Pressure Adjustment
clean. Also make sure t he tools and workbench area
used for assembly operations are equally clean.
Shop towels used for wiping off tools and hands
must be made from lint free mat eri al . Lint will stick
to transmission part s and could interfere with valve
operation, or even restrict fluid passages.
Lubricate t he transmission components with Mopar
transmission fluid duri ng reassembly. Use petroleum
jelly, Door Eze, or Ru-Glyde on seals and O-rings to
ease installation.
Petroleum jelly can also be used to hold t hrust
washers, t hrust plates and gaskets in position during
assembly. However, do not use chassis grease, bear-
i ng grease, white grease, or similar lubricants on any
transmission part . These types of lubricants can
eventually block or restrict fluid passages and inter-
fere with valve operation. Use petroleum jelly only.
Do not force part s into place. The transmission
components and sub-assemblies are easily installed
by hand when properly aligned.
If a part seems extremely difficult to install, it is
either misaligned or incorrectly assembled. Also ver-
ify t hat t hrust washers, t hr ust plates and seal rings
are correctly positioned before assembly. These parts
can interfere with proper assembly if mispositioned
(or "left out" by accident).
The pl anet ary geart rai n, front/rear clutch assem-
when t he transmission case is upright or as close to
t hi s position as possible. Ei t her tilt t he case upward
with wood blocks, or cut a hole in t he bench large
enough for t he output shaft. Then lower t he shaft
through t he hole and support t he transmission case
directly on t he bench.
(1) Install rear servo piston, spring and retainer
(Fig. 130). Install spring on top of servo piston and
install ret ai ner on top of spring.
(2) Install front servo piston assembly, servo
spring and rod guide (Fig. 131).

SERVO
PISTON
PISTON
SPR NG
SNAP
RING
PISTON
SEAL RETAINER J9121-343
PISTON
SEAL
RI NGS
SERVO PISTON SNAP RING
(4) Examine bolt holes in overrunning clutch cam.
Note t hat one hole is not t hr e a de d (Fig. 133). This
hole must align with bl ank area in clutch cam bolt
circle (Fig. 134). Mark hole location on clutch cam
and blank area in case with grease pencil, pai nt
stripe, or scribe mark for assembly reference.
NON-THREADED
HOLE
OVERRUNNING
CLUTCH CAM
J9121-226
ROD
ROD SPRI NG GUI DE J9121-344
(3) Compress front/rear servo springs with Valve
Spring Compressor C-3422-B and install each servo
snap ri ng (Fig. 132).
S PR I NG
C OMPR E S S OR
TOOL
C-3422-B
ROD
QUI DE
S N A P
R I N G J9121-136
Fig. 132 Compressing Front/Rear Servo Springs
Fig. 133 Location Of Non-Threaded Hole In Clutch
Cam-42RH
S> OVERRUNNING
CLUTCH CAM
SEAT IN CASE
40N-THREADED
HOLE I N CLUTCH
C AM A L I GN S
HERE (BLANK AREA)
OF SEAT i
J9121-541
Fig. 134 Location Of Blank Area In Clutch Cam Bolt
Circle-42RH
(5) Mark location of non-threaded hole in clutch
cam and bl ank area in bolt circle with grease pencil.
(6) Align and install overrunning clutch and cam
in case (Fig. 135). Be sure cam is correctly in-
stalled. Bolt hol es in cam are slightly counter-
sunk on one side. Be sure this side of cam faces
rearward (toward pi ston retainer).
(7) Verify t hat non-threaded hole in clutch cam is
properly aligned. Check alignment by t hreadi ng a
bolt into each bolt hole. Adjust clutch cam position if
necessary.
(8) Install and t i ght en overrunning clutch cam
bolts to 17 Nm (13 ft. lbs.) torque. Note t hat clutch
cam bolts are shorter t han piston ret ai ner bolts.

Fig. 135 Overrunning Clutch Installation42RH
(9) Lubricate clutch cam rollers with transmission
fluid.
(10) Install rear band reaction pin (Fig. 136). Be
sure pin is fully seated in case.
Fig. 136 Installing Rear Band Reaction Pin42RH
(11) Install rear band in case (Fig. 137). Be sure
twin lugs on band are seated agai nst reaction pin.
(12) Install low-reverse drum and check overrun-
ning clutch operation as follows:
(a) Lubricate overrunning clutch race (on drum
hub) with transmission fluid.
(b) Guide drum t hrough rear band.
(c) Tilt drum slightly and st art race (on drum
hub) into overrunning clutch rollers.
(d) Press drum rearward and t ur n it in clockwise
direction until drum seats in overrunning clutch
(Fig. 138).
(e) Turn drum back and forth. Drum shoul d ro-
tate freely in cl ockwi se direction and lock i n
countercl ockwi se direction (as vi ewed from
front of case).
(13) Install new gasket at rear of transmission
case. Use petroleum jelly to hold gasket in place. Be
Fig. 137 Rear Band Installation42RH
Fig. 138 Installing Low-Reverse Drum42RH
sure to align governor feed holes in gasket with feed
passages in case (Fig. 139). Also install gasket before
overdrive piston ret ai ner. Center hole in gasket is
smaller t han ret ai ner and cannot be installed over
retainer.
(14) Install overdrive piston ret ai ner. Be sure gov-
ernor t ube bores in ret ai ner are aligned with gover-
nor feed passages in gasket and case (Fig. 140).
Install and t i ght en ret ai ner bolts to 17 N
#
m (13 ft.
lbs.) torque.
(15) Install snap ri ng t hat secures low-reverse
drum to hub of piston ret ai ner (Fig. 141).
(16) Install rear band lever and pivot pin (Fig.
142). Align lever with pin bores in case and push
pivot pin into place.
Fig. 139 Installing/Aligning Case Gasket42RH
Fig. 140 installing Overdrive Piston Retainer42RH
(17) Install pl anet ary geart rai n assembly (Fig.
143)
(18) Install t hr ust plate on i nt ermedi at e shaft hub
(Fig. 144). Use petroleum jelly to hold t hr ust pl at e in
place.
(19) Check seal ri ng on rear clutch ret ai ner hub
(Fig. 49) and seal rings on input shaft (Fig. 145).
Verify t hat diagonal-cut ends of teflon seal rings are
properly joined and ends of met al ring are correctly
Fig. 141 Installing Low-Reverse Drum Retaining
Snap Ring
Fig. 142 Rear Band Lever And Pivot Pin Installation
hooked together. Also verify t hat shaft seal rings are
installed in sequence shown.
(20) Check rear clutch fiber t hr ust washer (Fig.
146). Use additional petroleum jelly to hold washer
in place if necessary.
(21) Align clutch discs in front clutch and install
front clutch on rear clutch (Fig. 147). Rotate front
clutch ret ai ner back and forth unt i l completely
seated on rear clutch.
(22) Coat intermediate shaft t hr ust washer with
petroleum jelly. Then install washer in rear clutch
hub (Fig. 148). Use enough petroleum jelly to hold
washer in place. Be sure grooved side of washer
faces rearward (toward output shaft) as s hown.
Al so note t ha t wa s he r onl y fits one wa y in
cl ut ch hub.

TRANSMISSION OVERHAUL-4 2RH 2"! - 273
J9121-217
Fig. 143 installing Planetary Geartrain42RH
INTERMEDIATE
SHAFT HUB
INTERMEDIATE
SHAFT
THRUST PLATE
J9121-215
Fig. 144 installing intermediate Shaft Thrust Plate
(23) Align drive t eet h on rear clutch discs wi t h
small screwdriver (Fig. 149). This makes installation
on front pl anet ary easier.
(24) Raise front end of transmission upward as far
as possible and support case with wood blocks. Front/
rear clutch and oil pump assemblies are easier to in-
stall if transmission is as close to upright position as
possible.
(25) Install front and rear clutch units as assembly
(Fig. 150). Align rear clutch wi t h front annul us gear
and install assembly in driving shell. Re sure out-
put shaft thrust washer and thrust plate are not
di spl aced during installation.
I NPUT
SHAFT TEFLON
SEAL
/ RI NG
METAL
SEAL
RI NG
Fig. 145 Input Shaft Seal Ring Location-42RH
REAR
CLU1CH
ÊTA'Mnk
Fig, 146 Installing Rear Clutch Thrust
Washer-42RH
REAR
CLUTCH
ASSEMBLY
i i Jfi N
" FRONT
CLI PCr
BACK & FO-TH
{ UNTIL
i SEATED
J9121-190
Fig. 147 Assembling Front And Rear Clutch
Units-42RH
(26) Carefully work assembled clutches back and
forth to engage and seat rear clutch discs on front
21 - 274 TRANSMISSION 0WERHAUL-4 2RH
INTERMEDIATE
SHAFT THRUST
WASHER
INPUT
SHAFT
FRONT
CLUTCH
REAR
'CLUTCH
REAR
CLUTCH
RETAINER
HUB
INPUT
SHAFT
J9121-214
J9121-124
Fig. 148 Installing Intermediate Shaft Thrust
Washer-42RH
Assemblies42RH
REAR
CLUTCH
DI SCS
USE
SMALL
SCREWDRIVER
TO
ALI GN
CLUTCH DISC
TEETH
^J9121-192
:FRONT
BAND
FRONT
BAND
REACTION
PIN
FRONT
CLUTCH
RETAINER
J912M93
Fig. 149 Aligning Rear Clutch Disc Lugs42RH
annul us gear. Also be sure front clutch drive lugs are
fully engaged in slots of driving shell after installa-
tion.
(27) Slide front band over front clutch ret ai ner
(Fig. 151).
(28) Insert front band reaction pin part way into
case (Fig. 151).
(29) Install front band lever, st rut and adjusting
screw (Fig. 152).
(30) Push front band reaction pin completely into
place. Then t i ght en band adjusting screw unt i l band
j ust grips clutch ret ai ner. Verify t hat front/rear
clutches are still seated before continuing.
(31) Coat band reaction pin access plug with sealer
and install plug in converter housing.
Fig. 151 Installing Front Band And Reaction
Pin-42RH
(32) Check seal rings on reaction shaft support
hub. Verify t hat seal rings are hooked together and
t hat front clutch t hrust washer is properly positioned
(Fig. 153). Use extra petroleum jelly to hold t hr ust
washer in place if necessary.
(33) Thread two Pilot Stud Tools C-3288-B into
bolt holes in oil pump flange (Fig. 154).
(34) Align and install oil pump gasket (Fig. 154).
(35) Lubricate oil pump body seal with Ru-Glyde,
or petroleum jelly. Lubricate pump shaft seal lip
wi t h petroleum jelly.
(36) Install oil pump (Fig. 155). Align and position
pump on pilot studs. Slide pump down studs and

BAND BAND
Fig. 152 Front Band Linkage Installation42RH
SEAL
RINGS J9121-194
Fig. 153 Reaction Shaft Support Seal Rings And
Front Clutch Thrust Washer Position42RH
work it into front clutch hub and case by hand. Then
install 2 or 3 pump bolts to hold pump in place.
(37) Remove pilot stud tools arid install remai ni ng
oil pump bolts. Tighten bolts al t ernat el y in diagonal
pat t ern to 20 N*m (15 ft. lbs.).
(38) Measure input shaft end play (Fig. 156). At-
tach dial indicator to converter housing. Position in-
dicator plunger against input shaft and zero
indicator. Move input shaft in and out and record
reading. End play should be 0.56 - 2.31 mm (0.022 -
0.091 in.).
(39) Install new seals on overdrive piston. Then lu-
bricate seals with Ru-Glyde, Door-Eze or petroleum
jelly.
(40) Install overdrive piston in ret ai ner. Align lo-
cating l ugs on piston in locating bores in re-
tainer (Fig. 157). Use t hi n plastic strip or feeler
gauge to help guide piston outer seal into ret ai ner.
(41) Install spacer on intermediate shaft, if not
previously installed.
Fig. 154 Installing Pilot Studs And Oil Pump
Gasket-42RH
Fig. 155 Installing Oil Pump Assembly In
Case42RH
(42) Install overdrive piston t hrust plate (Fig. 158).
Use liberal quant i t y of petroleum jelly to hold t hrust
plate in position on piston.
(43) Install overdrive piston t hrust bearing in di-
rect clutch hub (Fig. 159). Use liberal quant i t y of pe-
troleum jelly to hold t hrust beari ng in place. Note
that one side of beari ng has dark coated sur-
face. This surface faces overdri ve piston. Al so
be sure rai sed shoul der on inside diameter of
beari ng faces forward as well.
(44) Apply small amount of petroleum jelly to pilot
hub of intermediate shaft.
(45) Verify alignment of splines in overdrive uni t
pl anet ary gear and overrunning clutch. Be sure
OVERDRIVE
RETAINER
LUG
BORES
Fig. 156 Measuring input Shaft End Play
PISTON
LOCATING
LUGS
J9121-353
Fig. 157 Overdrive Piston Alignment42RH
Alignment Tool 6227-2 is still fully seated (Fig. 160).
If pl anetary gear and overrunni ng cl utch spl i nes
become mi sal i gned, overdri ve unit cannot be
fully i nstal l ed on i nt er medi at e shaft. Overdrive
unit will have to be di sassembl ed in order to re-
align spl i nes.
(46) Carefully withdraw al i gnment tool from over-
drive unit.
OVERDRIVE
PISTON
THRUST
PLATE
J9121-354
Fig. 158 Installing Overdrive Piston Thrust
Plate-42RH
BE SURE
THIS SHOULDER
OVERDRIVE
PISTON
THRUST
IARINC
Fig. 159 Installing Overdrive Piston Thrust
Bearing42RH
SPECIAL
TOOL 6227-2
J9221-36
Fig. 160 Checking Alignment Of Overdrive Planetary
Gear And Overrunning Clutch Splines42RH

(47) Lubricate intermediate shaft splines and bushing
surfaces with transmission fluid or petroleum jelly.
(48) Install overdrive unit. Be sure governor t ubes
are aligned with feed holes in piston ret ai ner boss.
Note t hat i nt ermedi at e shaft is snug fit in overdrive
pl anet ary gear and overrunni ng clutch. If overdrive
uni t will not seat fully, rotate overdrive output shaft
slightly to align splines and t ry again.
(49) Apply 1-2 drops of Mopar t hread adhesive (or
Loctite 242) to overdrive uni t attaching bolts. Then
install and t i ght en bolts to 34 N (25 ft. lbs.) torque.
(50) Install accumulator i nner spring, piston and
outer spring (Fig. 161).
ACCUMULATOR OUTER
Fig. 161 Installing Accumulator Piston And
Springs42RH
not been installed in case. Valve body can not be in-
(52) Install valve body as follows:
(a) St art park rod into park pawl. If rod will not
slide past park pawl, pawl is engaged in park gear.
Rotate overdrive output shaft with socket to free
pawl and allow rod to engage.
(b) Align and seat valve body on case. Be sure
manual lever shaft and overdrive connector are
fully seated in case.
(c) Install and st art all valve body at t achi ng
bolts by hand. Then t i ght en bolts evenly, in a di-
agonal pat t ern to 12 Nm (105 in. lbs.) torque. Do
not overtighten val ve body bolts. Thi s coul d
result in distortion and cross l eakage after in-
stallation..
screws to 4 N*m (35 in. lbs.).
(54) Adjust front and rear bands as follows:
(a) Loosen band adjusting screw locknuts.
(b) Tighten each band adjusting screw to 5 Nnn
(72 in. lbs.) with torque wrench.
(c) Back off front band adjusting screw 2-1/2 turns.
(d) Back off rear band screw 4 t ur ns.
(e) Tighten each adjusting screw locknut. Hold
adjusting screws with wrench to prevent t ur ni ng
when t i ght eni ng locknut.
(Fig. 162). Then install and tighten switch to 34 Nm
(25 ft. lbs.).
Fig. 162 Park/Neutral Position Switch Seal Position
(56) Install magnet in oil pan. Magnet goes on
stall oil pan. Tighten pan bolts to 17 N*m (13 ft. lbs.).
with petroleum jelly. St art seal over shaft and into
case. Seat seal with 15/16 inch, deep well socket.
(59) Install t hrot t l e valve and shift selector levers
on valve body manual lever shaft.
(60) Cap or cover transmission openings (cooler line
fittings, filler tube bore, etc.) to prevent dirt entry.
(61) Install torque converter. Use C-clamp or metal
strap to hold converter in place for installation.
vehicle.
(63) Apply dielectric grease to t ermi nal pins of so-
lenoid case connector and neut ral switch.
C A U T I O N : The t r ansmi ssi on cooler and lines must
be reverse f l ushed if overhaul corrected a mal func-
also be replaced if contami nated by the same mal-
function. Debris and residue not fl ushed from the
cooler and lines will flow back into the t r ansmi ssi on
and shop comeback.
21 - 278 TRANSMISSION 0VERH AUL-4 IRH

TRANSMI SSI ON OWERHAUL- 46RH
INDEX
page
Accumulator Overhaul 28 8
Front Clutch Overhaul 293
Front Servo and Band Overhaul . . . . . . . . . . . . 28 9
Oil Pump and Reaction Shaft Support Overhaul . 28 9
Overdrive Piston and Retainer Service 28 6
Overhaul Service Information 28 5
Overrunning Clutch Overhaul 28 6
Planetary Geartrain Overhaul . . . . . . . . . . . . . . . 297
(1) Remove torque converter, if not previously re-
moved.
solvent. Wear safety goggles while cleaning t rans-
mission.
(3) Remove shift and t hrot t l e levers from shaft of
valve body manual lever.
(4) Remove bolts at t achi ng overdrive uni t to t rans-
mission case (Fig. 1).
Fig. 1 Removing Overdrive Unit Attaching Bolts
(5) Loosen overdrive unit. Use pry tool to st art
overdrive uni t off i nt ermedi at e shaft and t ransmi s-
sion case. Position pry tool between flange on over-
drive case and transmission rear servo boss (Fig. 2).
(6) Work overdrive uni t rearward and off t ransmi s-
sion i nt ermedi at e shaft (Fig. 3).
sert Al i gnment Tool 6227-2 in overdrive uni t over-
r unni ng clutch and pl anet ary gear to mai nt ai n
spline al i gnment (Fig. 4). If cl utch and gear
spl i nes rotate out of alignment, overdri ve unit
will have to be di sassembl ed i n order to re-
align spl i nes.
(b) If overdrive uni t does requires service, refer
to Overdrive uni t Overhaul section.
page
Rear Clutch Overhaul 295
Rear Servo and Band Overhaul . 28 9
Transmi ssi on Assembl y . . . . . . . . . . . . . . . . . . . 31 5
Transmi ssi on Case Cleaning and Inspection . . . 28 5
Transmi ssi on Di sassembl y 27 8
Val ve Body Cleaning and Inspection 308
Val ve Body Service and Adjustment . 302
Fig. 2 Loosening Overdrive Unit From Transmission
J9121-209
Fig. 3 Removing Overdrive Unit From
Transmission46RH
(7) Remove t hrust plate from overdrive piston (Fig.
5).
(8) Remove overdrive piston from ret ai ner (Fig. 6 ) .
(9) Remove overdrive pistop t hrust beari ng (Fig.
7).
(10) Mount transmission uni t on Repair St and
C-3750-B, or support transmission with wood blocks.
TRANSMISSION OVERHAUL-4 6 RH 21 - 279
SPECIAL
J9321-133
Fig. 4 Overdrive Spline Alignment Tool Installation
>sPISTON THRUST PLATE
(SELECT FIT)
W
OVERDRIVE
PISTON J9121-503
Fig. 5 Removing Overdrive Piston Thrust Plate46RH
PISTON
OVERDRIVE
PISTON
THRUST
BEARING
\ \
J9121-279
Fig. 7 Removing/Installing Overdrive Piston Thrust
Bearing
(11) Remove pump oil seal with Special Tool C-3861
(Fig. 8). Be sure to tighten tool threads completely into
seal before using puller bolt to withdraw seal.
J9321-182\>
s
Fig. 8 Removing Pump Oil Seal46RH
(12) Remove oil pan bolts and remove pan (Fig. 9)
and gasket (Fig. 10). Oil pan magnet can be removed
or left i n pan as needed (Fig. 11). Exercise care when
removing pan to avoid distorting or bending pan
flange.
PISTON
RETAINER
Fig. 6 Removing Overdrive Piston46RH
J9121-5
Fig. 9 Removing/Installing Oil Pan46RH
21 - 280 TRANSMISSION 0VERHAUL-4 6 RH
Fig. 11 Oil Pan Magnet Location46RH
(13) Remove park/ neut ral position switch (Fig. 12).
If switch gasket is in good condition, ret ai n gasket
and keep it with switch.
J9321-128 " ' SWITCH
Installation
(14) Remove fluid filter at t achi ng screws and re-
move filter (Fig. 13). Keep filter screws separat e.
They are longer t han valve body screws.
(Fig. 14). A total of 10 hex head bolts are used to se-
cure valve body to case.
(16) Lift valve body upward. Push solenoid connec-
tor and manual lever shaft out of case. Then raise
valve body, guide park rod out of case and remove
valve body (Fig. 15). Do not use boost val ve tube
to lift val ve body. Set valve body aside for disas-
sembly, cleaning and inspection.
J9321-135
Fig. 14 Valve Body Bolt Locations46RH
VALVE BOOST
BODY VALVE
ASSEMBLY TUBE
PARK CASE
ROD CONNECTOR J9321-136
Fig. 15 Valve Body Removal46RH

(17) Remove accumulator outer spring, piston and
i nner spring (Fig. 16). Note position of piston and
springs for assembly reference. Remove and discard
piston seals if worn or cut.
ACCUMULATOR OUTER
Fig. 16 Accumulator Component Removal--46RH
(18) Remove front band lever pin access plug (Fig.
17). Use square end of 1/4 in. drive extension to re-
move plug as shown.
Fig. 17 Removing/Installing Front Band Lever Pin
Access Plug46RH
(19) Remove oil pump and reaction shaft support
assembly as follows:
(a) Tighten front band adjusting screw unt i l
band is t i ght around front clutch ret ai ner (Fig. 18).
This will prevent ret ai ner from coming out wi t h
pump and possibly damaging clutch or pump com-
ponents.
(b) Remove oil pump bolts.
(c) Thread Slide Hammer Tools C-3752 into
threaded holes in flange of oil pump housing (Fig.
19).
(d) Remove oil pump and reaction shaft support
by bumping slide hammers outward alternately to
pull pump from case (Fig. 20) .
Fig. 18 Tightening Front Band To Hold Front Clutch
In Piace-46RH
Fig. 19 Installing Oil Pump Remover Tools46RH
Fig. 20 Oil Pump Removal46RH
21 - 282 TRANSMISSION OVERHAUL-4 6 RH

(20) Remove oil pump gasket (Fig. 21). Note gas-
ket position in case for assembly reference.
Fig. 21 Removing Oil Pump Gasket46RH
(22) Remove front band st rut and anchor (Fig. 22).
LEVER STRUT
J9121-18
Fig. 22 Front Band Linkage46RH
(23) Squeeze front band together slightly and slide
band over front clutch ret ai ner and out of case (Fig.
23).
(24) Remove front and rear clutch assemblies as a
uni t (Fig. 24). Set assemblies aside for disassembly
and inspection after removal.
(25) Remove front band reaction pin and lever.
St art pin t hrough lever and out of case bore with
drift or punch. Then use pencil magnet to wi t hdraw
pin completely (Fig. 25).
Fig. 24 Removing/Installing Front And Rear Clutch
Assemblies46RH
Fig. 25 Removing Front Band Lever And Pin46RH

Fig. 26 Removing intermediate Shaft Thrust
Washer-46RH
Fig. 27 Removing intermediate Shaft Thrust
Plate-46RH
(26) Remove intermediate shaft t hr ust washer. Tri-
angul ar shaped washer will either be on shaft pilot
hub or in rear clutch ret ai ner (Fig. 26).
(27) Remove t hrust plate from i nt ermedi at e shaft
hub (Fig. 27).
(28) Remove intermediate shaft-planetary
geart rai n assembly (Fig. 28). Set assembly aside for
disassembly and inspection later in procedure.
(29) Loosen rear band adjusting screw 3-4 t urns.
(30) Remove snap ring t hat ret ai ns low-reverse
drum on overdrive piston ret ai ner hub (Fig. 29).
(31) Slide low-reverse drum off piston ret ai ner hub
and out of rear band (Fig. 30).
(32) Note t hat overrunning clutch race will remai n
on splines of low-reverse drum after removal (Fig.
31). The race is a permanent press fit on the hub
spl i nes. Do not at t empt to remove the race.
(33) Remove overrunning clutch assembly (Fig.
32). Assembly can be removed without displacing
TRANSMISSION 0WERHAUL-4 6 RH 21 - 283
ASSEMBLY J9121-508
Fig. 28 Removing Intermediate Shaft And Planetary
Geartrain Assembly46RH
Fig. 29 Removing/Installing Low-Reverse Drum
Snap Ring46RH
Fig. 30 Removing/Installing Low-Reverse
Drum46RH
21 - 284 TRANSMISSION 0ERHAUL-4 6 RH
OV E RRUNNI NG
CLUTCH
RACE
LOW-REVERSE
DRUM
REAR
BAND A D J U S T I N G
LEVER
J9221-8
Fig. 31 Overrunning Clutch Race Position46RH
rollers and springs if care is exercised. Note position
of rollers and springs for assembly reference.
^C L U T C H
C A M
Fig. 32 Removing/Installing Overrunning
Clutch-46RH
(34) Remove rear band adjusting lever, reaction le-
ver and reaction pin (Fig. 33).
(35) Remove st rut from rear band. Keep st rut with
levers and pin for cleaning, inspection and assembly
reference.
(36) Remove rear band and link (Fig. 34).
(37) Compress front servo rod guide with C-clamp
and Tool C-4470, or Valve Spring Compressor
C-3422-B (Fig. 35). Compress guide only enough to
permi t snap ri ng removal (about 1/8 in.).
(38) Remove servo piston snap ri ng (Fig. 35). Un-
seat one end of ring. Then carefully work removal
tool around back of ri ng unt i l free of ri ng groove. Ex-
REAR
BAND
REACTI ON _ ^ , , ,
P I N
~ y / ( /\~y/ J9121-37
Fig. 33 Removing Rear Band Levers And Reaction
Pin-46RH
BAND
LINK
- J 912 1- 38
Fig. 34 Removing Rear Band And Link46RH
^ ) FRCNT
SERVO
ROD
GUI DE
TOOL
/C4470
J9121-39
Fig. 35 Removing Front Servo Retaining Snap Ring-46RH

er ci se caut i on whe n r e movi ng s n a p r i ng. Ser vo
bor e can be s c r a t c he d or ni cked if c a r e is not
exer ci sed.
(39) Remove tools and remove servo piston and
spring.
(4 0) Compress rear servo piston wi t h C-clamp and
Tool C-4470, or Valve Spri ng Compressor C-3422-B
(Fig. 36). Compress servo spring ret ai ner only
enough to permit snap ri ng removal.
(41) Remove servo piston snap ring (Fig. 36). St art
one end of ring out of bore. Then carefully work re-
moval tool around back of snap ring unt i l free of ri ng
groove. Exer ci se caut i on wh e n r emovi ng s na p
r i ng. Ser vo bor e can be s c r a t c he d or ni cked if
car e is not exer ci sed.
(42) Remove tools and remove rear servo retainer,
spring and piston assembly.
Fig. 36 Removing Rear Servo Retaining Snap
Ring46RH
(43) Remove overdrive piston ret ai ner bolts and re-
move ret ai ner from case (Fig. 37).
(44) Remove gasket from rear of case after remov-
ing piston retainer.
haul . Bushing condition is i mport ant as worn, scored
accelerated wear of other components. Replace worn,
or scored bushings, or if doubt exists about bushing
condition.
Fig. 37 Removing Overdrive Piston Retainer46RH
Heli-Coil inserts are recommended for repairing
part s. These inserts are available from most automo-
tive jobbers. Stainless steel inserts are preferred.
mat t er from get t i ng between t he valve and valve
bore.
as well.
Plus, Type 7176 transmission fluid during assembly.
Use Ru-Glyde, petroleum jelly, or Door-Eze to prelu-
bricate seals, O-rings, and t hrust washers. Petroleum
jelly can also be used to hold part s in place duri ng
reassembly.
TRANSMISSION CASE CLEANING AND
INSPECTION
Clean t he case in a solvent t ank. Flush t he case
Do not use shop towel s or rags to dry the case
(or any other transmi ssi on component) unl ess
they are made from lint-free materials. Lint will
readily adhere to case surfaces and transmi ssi on
components and will circulate throughout the
21 - 286 TRANSMI SSI ON OVERHAUL-46RH

t r ans mi s s i on aft er as s embl y. A suffi ci ent quan-
t i t y of l i nt c a n bl ock fl ui d pa s s a ge s a n d I nt er f er e
wi t h val ve body oper at i on.
servo bores, or damaged t hreads. Damaged t hreads
can be repaired with Helicoil t hread inserts. How-
ever, t he case will have to be replaced if it exhibits
damage or wear.
Lubricate t he front band adjusting screw and lock-
nut with petroleum jelly and t hread it part way into
the case. Be sure t he screw t ur ns freely and does not
bind. Install t he locknut on t he screw after checking
screw t hread operation.
OVERDRIVE PISTON AND RETAINER SERVICE
Remove and discard t he piston seals.
Clean t he piston and ret ai ner in part s cleaning sol-
vent. Do not use any type of caustic mat eri al s for
cleaning. Such mat eri al s may etch t he surfaces caus-
ing damage.
Inspect t he piston and ret ai ner carefully. Replace
either part if cracked, porous or damaged in any
way. Check condition of t he locating lugs on t he pis-
ton. Be sure t he lugs are in good condition and are
not worn, chipped or broken.
Inspect t he check ball in t he piston (Fig. 38). Be
sure t he ball is secure and is not partially dislodged,
or loose. Replace t he piston if doubt exists about pis-
ton or check ball condition.
Check t he governor feed t ube boss in t he ret ai ner.
Be sure t he boss is in good condition and is not dam-
aged in any way.
Fig. 38 Overdrive Piston46RH
OWERRUNNlNG CLUTCH OVERHAUL
Inspect condition of t he clutch cam, cage-type re-
t ai ner, rollers, springs and clutch race.
Replace t he clutch cam if worn or damaged. Also
check fit of t he cam in t he transmission case. If t he
cam is loose, t he case may be worn, or cracked.
The clutch race is permanent l y pressed onto t he
low-reverse drum hub. If either t he drum or race are
worn or damaged, replace t he drum and race as an
assembly. Check fit of t he race on t he low-reverse
drum hub splines. Replace t he drum and race as an
assembly if t he race is loose on t he hub splines.
Exami ne the overrunning clutch assembly care-
fully. Replace assembly if t he rollers, springs, or
cage-type ret ai ner are worn, or damaged.
If t he clutch cam requires replacement, install a
new cam as described in t he following procedure.
OVERRUNNING CLUTCH CAM REPLACEMENT
(1) Remove clutch cam setscrew (Fig. 39).
Fig. 39 Removing/Installing Clutch Cam
Setscrew46RH
(2) Tap old cam and spring ret ai ner out of case
wi t h pin punch. Insert punch t hrough bolt holes at
r ear of case (Fig. 40). Al t ernat e position of punch to
avoid cocking cam duri ng removal.
(3) Clean clutch cam bore and case. Be sure to re-
move all chips/shavings generated duri ng cam re-
moval.
(4) Install rear support in case. Align support with
reference marks made at disassembly.
(5) Align and st art new clutch cam and spring re-
t ai ner in case. Be sure serrations on cam and in case
are aligned (Fig. 41). Then t ap cam into case j ust
enough to hold it in place.
(6) Veri fy t ha t c a m i s cor r ect l y pos i t i oned be-
fore pr oc e e di ng a ny f ur t her . Na r r ow e nds of
c a m r a mp s s houl d be t o left whe n c a m i s vi ewed
f r om f r ont e nd of cas e (Fig. 41).

Fig. 40 Removing Overrunning Clutch Cam46RH
Fig. 41 Positioning Replacement Clutch Cam And
Spring Retainer46RH
(7) Insert Adapter Tool SP-5124 into piston re-
t ai ner (Fig. 42).
(8) Assemble Pul l er Bolt SP-3701 and Press Pl at e
SP-3583-A (Fig. 43).
(9) Install assembled puller plate and bolt (Fig.
44). Insert bolt t hrough cam, case and adapter tool.
Be sure plate is seated squarely on cam.
(10) Hold puller plate and bolt in place and install
puller nut SP 3701 on puller bolt (Fig. 45).
(11) Tighten puller nut to draw clutch cam into
case (Fig. 45). Be sure cam i s drawn into case
evenl y and does not become cocked.
(12) Install clutch cam setscrew (Fig. 39).
(13) Remove clutch cam installer tools and piston
retainer.
(14) Stake case i n 12 pl aces around clutch cam
to hel p secure cam in case. Use blunt punch or
chi sel to stake case.
TRANSMISSION 0WERHAUL-4 8RH 21 - 287
Fig. 43 Assembling Clutch Cam Puller Bolt And
Press Plate
(15) Clean case and cam thoroughly. Be sure any
chips/shavings generated during cam installation are
removed from case.
INSTALLING OVERRUNNING CLUTCH
ASSEMBLY
(1) Lubricate overdrive piston ret ai ner hub, clutch
race, clutch cam, and overrunning clutch rollers wi t h
transmission fluid.
(2) If any overrunning clutch rollers or springs
came out of retainer, reinstall t hem as follows: In-
Fig. 44 Positioning Puller Plate On Clutch Cam
Fig. 45 Installing Overrunning Clutch Cam46RH
stall and seat spring in ret ai ner first. Then insert
roller between spring and ret ai ner stop as shown
(Fig. 46). Verify t hat each roller and spring are fully
(3) Install and seat clutch assembly in cam (Fig.
47). The retainer is a one- way fit i n the cam. The
flanged si de of the retainer shoul d be f aci ng out-
ward. The retainer and rollers will slip easi l y
into the cam when properl y posi ti oned.
(4) Install low-reverse drum. Tilt drum slightly
and carefully engage clutch race (on drum hub) in
overrunni ng clutch rollers. Raise drum to level posi-
tion. Then rot at e t he drum in clockwise direction un-
til fully seated.

Fig. 47 Overrunning Clutch Seated In Cam
(5) Check overrunni ng clutch operation. Low-re-
verse drum should rot at e freely in clockwise direc-
tion and lock in counterclockwise direction.
(6) Align and reinstall overdrive piston ret ai ner.
Ti ght en ret ai ner bolts to 11 N*m (95 in. lbs.) torque.
ACCUMULATOR OVERHAUL
Inspect t he accumulator piston and seal rings (Fig.
48). Replace t he seal ri ngs if worn or cut. Replace t he
piston if chipped or cracked.
Check condition of t he accumulator i nner and outer
springs (Fig. 48). Replace t he springs if t he coils are
cracked, distorted or collapsed.
TRANSMISSION 0VERHAUL-4 6 RH 21 - 289
ACCUMULATOR
PISTON
INNER
SPRING
OUTER
SPRING
SEAL
RINGS
J9121-230
Fig. 48 Accumulator Components46RH
Clean t he servo piston components with solvent
and dry t hem with compressed air. Wipe t he band
clean wi t h lint free shop towels.
Replace t he front band if distorted, lining is
burned, flaking off, or worn to t he point where t he
grooves in t he lining mat eri al are no longer visible.
Check the servo piston bore for wear. If t he bore is
severely scored, or damaged, it will be necessary to
replace t he case.
Replace any servo component if in doubt about its
condition. Do not reuse suspect part s.
FRONT SERVO PISTON OVERHAUL (FIG. 49)
(1) Remove seal ring from rod guide.
(2) Remove small snap ring from servo piston rod.
Then remove piston rod, spring and washer from pis-
ton.
(3) Remove and discard servo component O-ring
and seal rings.
(4) Lubricate new O-ring and seal ri ngs wi t h pe-
troleum jelly and install t hem on piston, guide and
rod.
(5) Install rod in piston. Install spring and washer
on rod. Compress spring and install snap ring.
(6) Set servo components aside for installation dur-
ing transmission reassembly.
t hem with compressed air. Inspect t he servo compo-
nent s. Replace t he spring if collapsed, distorted or
broken. Replace t he plug and piston if cracked, bent,
or worn. Discard t he servo snap ring if distorted or
warped.
ing is worn (grooves no longer visible at any point on
PISTON RINGS (2)
SERVO PISTON
O" RI NG
PISTON ROD:
SPRI NG
< WASHER
. S N A P RI NG
PISTON ROD GUI DE
PISTON ROD
(A-727 ONLY)'
SERVO SPRI NG-
SEAL R I N G .
S NAP R I NG-
RH307
t he lining material). If doubt exists about t he condi-
tion of any servo component, replace it. Do not reuse
suspect part s.
REAR SERVO PISTON OVERHAUL (FIG. 50)
(1) Remove small snap ri ng and remove plug and
spring from servo piston.
(2) Remove and discard servo piston seal ring.
(3) Lubricate piston and guide seals with petro-
leum jelly. Lubricate other servo part s wi t h Mopar
(4) Install new seal ri ng on servo piston.
(5) Assemble piston, plug, spring and snap ring.
(6) Lubricate piston seal lip wi t h petroleum jelly.
(7) Set servo components aside for assembly instal-
lation.
S NAP
RI NG
PISTON
SEAL
PISTON
PLUG
SPRI NG
RETAINER
SNAP
RING
PISTON
CUSHI ON
SPRI NG
PISTON
SPRI NG
J9121-64
OVERHAUL
(1) Mark position of support in oil pump body for
assembly alignment reference. Use scriber or pai nt to
make alignment marks.
(2) Place pump body on two wood blocks.
(3) Remove reaction shaft support bolts and sepa-
rat e support from pump body (Fig. 51).
(4) Remove pump i nner and outer gears (Fig. 52).
(5) Remove O-ring seal from pump body (Fig. 53).
Discard seal after removal.
21 - 290 TRANSMI SSI ON OVERHAUL-46RH
REACTION
SHAFT
SUPPORT
GEAR
BORE
J932M76
Fig. 51 Reaction Shaft Support Removal46RH
(6) Remove oil pump seal with Remover Tool
C-3981. Discard seal after removal.
INSPECTING PUMP AND SUPPORT
Clean pump and support components with solvent
and dry t hem with compressed air.
Check condition of t he seal rings and t hr ust
washer on t he reaction shaft support. The seal ri ngs
do not need to be replaced unless cracked, severely
worn, or no longer hooked together.
PUMP BODY
I NNER
GEAR
OUTER
GEAR J 932 M 77
Inspect t he pump and support components. Replace
t he pump or support if t he seal ri ng grooves or ma-
chined surfaces are worn, scored, pitted, or damaged.
damaged.
Fig. 53 Oil Pump And Reaction Shaft Components46RH
+
Fig. 55 Checking Pump Gear End Clearance
OIL PUMP BUSHING REPLACEMENT (FIG. 57}
(1) Position pump housing on clean, smooth sur-
face with gear cavity facing down.
(2) Remove bushing with Tool Handle C-4171 and
Bushing Remover SP-3550.
J8921-388
Fig. 56 Checking Pump Gear Side Clearances
(3) Assemble Tool Handl e C-4171 and Bushing In-
staller SP-5118.
(4) Place bushing on installer tool and st art bush-
ing into shaft.
(5) Tap bushi ng into place unt i l Installer Tool SP-
5118 bottoms in pump cavity. Keep tool and bushing
square with bore. Do not allow bushi ng to become
cocked during installation.
(6) St ake pump bushi ng in two places with bl unt
punch. Remove burrs from stake points with knife
blade (Fig. 58).
Check t he pump vent (Fig. 54). The vent must be
secure. Replace t he pump body if t he vent is cracked,
broken, or loose.
Inspect t he pump bushing (Fig. 54). Then check t he
reaction shaft support bushing. Replace either bush-
ing only if heavily worn, scored or damaged. It is not
necessary to replace t he bushings unl ess they are ac-
t ual l y damaged.
Install t he gears in t he pump body and measure
(Fig. 55). Clearance should be 0.89 to 1.90 mm
(0.0035 to 0.0075 in.).
Measure side clearances wi t h feeler gauge (Fig.
56). Clearance between gear t eet h and between outer
gear and pump body should be 0.89 to 1.90 mm
(0.0035 to 0.0075 in.).
PUMP

SPECIAL
TOOL
C-4171
BUSHING
REMOVAL
PUMP HOUSI NG
SPECIAL
TOOL
C-4171
SPECIAL TOOL
SP-3550
BUSHING
SPECIAL
TOOL
SP-5118
J9221-244
Fig. 57 Replacing Oil Pump Bushing
mm
Fig. 58 Staking-Debum'ng Oil Pump Bushing
BUSHING (FIG. 59)
(1) Assemble Cup Tool SP-3633, Nut SP-1191 and
Bushi ng Remover SP-5301.
(2) Hold cup tool firmly agai nst reaction shaft.
Thread remover tool into bushi ng as far as possible
by hand.
(3) Using wrench, t hread remover tool an addi-
tional 3-4 t ur ns into bushi ng to firmly engage tool.
(4) Tighten tool hex nut agai nst cup tool to pull
bushi ng from shaft. Clean all chips from shaft and
support after bushi ng removal.
(5) Place reaction shaft support upri ght on a clean,
smooth surface.
(6) Assemble Bushi ng Installer Tools C-4171 and
SP-5302. Then slide new bushi ng onto installer tool.
(7) St art bushing in shaft. Tap bushi ng into shaft
unt i l installer tool bottoms agai nst support flange.
bushi ng replacement (to remove any chips).
SPECIAL
TOOL
SP-1191
SPECIAL
TOOL
C-4171
SPECIAL
TOOL
SP-5302
BUSHING
BUSHING
X REACTION
SHAFT
BUSHING
REMOVAL BUSHING
INSTALLATION
J9221-245
Fig. 59 Reaction Shaft Bushing Replacement46RH
SHAFT SUPPORT
(1) Lubricate pump gears with transmission fluid
and install t hem in pump body.
(2) Install t hr ust washer on reaction shaft support
hub. Lubricate washer with petroleum jelly or t rans-
mission fluid before installation.
(3) If reaction shaft seal rings are being replaced,
install new seal rings on support hub. Lubricate seal
ri ngs with transmission fluid or petroleum jelly after
installation. Squeeze each ri ng until ri ng ends are
securely hooked together.
C A U T I O N : The reaction shaft support seal r i ngs will
break if overspread, or twisted. If new ri ngs are be-
i ng installed, spread them onl y enough for installa-
tion. A l s o be very sure the ring ends are securel y
r i ngs will either prevent pump installation, or break
duri ng installation.
(4) Align and install reaction shaft support on
pump body.
(5) Install bolts at t achi ng reaction shaft support to
pump. Tighten bolts to 20 Nm (175 in. lbs.) torque.
(6) Install new pump seal with Seal Installer
C-3860-A (Fig. 60). Use hammer or mallet to t ap seal
into place.
(7) Install new O-ring on pump body. Lubricate oil
seal and O-ring with petroleum jelly.
(4) Remove clutch piston springs. Not e n u mb e r
a n d pos i t i on of pi s t on s pr i ngs for as s embl y ref-
er ence.
(5) Remove clutch piston from ret ai ner wi t h a
twisting motion.
(6) Remove and discard clutch piston inner and
outer seals.
Clean and inspect the front clutch components. Re-
place t he clutch discs if warped, worn, scored, burned
or charred, t he lugs are damaged, or if t he facing is
flaking off. Replace the steel plates and reaction
plate if heavily scored, warped, or broken. Be sure
t he driving lugs on t he discs and plate are also in
damaged in any way.
Replace t he piston springs and spring ret ai ner if ei-
t her are distorted, warped or broken.
place t he piston ret ai ner if the grooves are worn or
piston ret ai ner. The ball must move freely and not
stick.
t here is any doubt about bushing condition.
Check t he clutch piston check ball. The ball should
be securely in place. Replace t he piston if t he ball is
missing, or seized in place.
INNER CLUTCH CLUTCH PISTON CLUTCH CLUTCH
Fig. 61 46RH Front Clutch Components (3-Disc Clutch Shown)
SPECIAL
TOOL
C-3860-A
PUMP
SEAL
PUMP
BODY
J932M79
Fig. 60 Oil Pump Seal Installation46RH
(8) Set pump assembly aside for installation dur-
ing transmission assembly.
(1) Remove waved snap ri ng and remove reaction
plate, clutch plates and clutch discs (Fig. 61). Not e
n u mb e r of pl at es a n d di scs i n cl ut ch pa c k for as-
sembl y r ef er ence. Some model s us e 3 di scs,
whi l e s ome ma y ha ve 4 di scs.
(2) Compress clutch piston ret ai ner and piston
springs with Compressor Tool C-3863-A (Fig. 62).
pressor tool.
SPECIAL
TOOL
C-3863-A
RH290
Fig. 62 Removing Front Clutch Spring Retainer
Snap Ring
FRONT CLUTCH RETAINER BUSHING
REPLACEMENT (FIG. 63)
(1) Assemble Tool Handl e C-4171 and Bushi ng Re-
mover SP-3629.
(2) Insert remover tool in bushi ng and drive bush-
ing st rai ght out of clutch ret ai ner.
(3) Mount Bushing Installer SP-5511 on tool han-
dle.
(4) Slide new bushi ng onto installer tool and st art
bushing into ret ai ner.
(5) Tap new bushi ng into place unt i l installer tool
bottoms agai nst clutch ret ai ner.
(6) Remove installer tools and clean ret ai ner thor-
oughly.
(1) Soak clutch discs in t ransmi ssi on fluid. Lubri-
cate remai ni ng clutch components wi t h transmission
fluid. Retainer bushi ng can be lubricated wi t h petro-
leum jelly if desired.
(2) Install new i nner and outer seals on clutch pis-
ton. Be sure seal lips face interior of ret ai ner.
(3) Lubricate new i nner and outer piston seals
with Ru-Glyde, or Door Eze.
motion to seat piston in ret ai ner. Do not force pis-
ton straight in. This coul d fold seal s over caus-
ing l eakage and cl utch slip.
(5) Install and position clutch piston springs as
shown in Fi gure 64.
(6) Install spring ret ai ner on top of piston springs.
(7) Compress spring ret ai ner and piston springs
with Compressor Tool C-3863-A.
SPECIAL
TOOL-
C-4171
FRONT CLUTCH
RETAINER
v s v
v
n
HI
BUSHING
HI
REMOVAL
SPECIAL
TOOL
SP-3629
SPECIAL
TOOL
C-4171
SPECIAL
TOOL
SP-5511
J9221-247
Fig. 63 Front Clutch Retainer Bushing
Replacement46RH
9 SPRING
CLUTCH
11 SPRING
CLUTCH
13 SPRING
CLUTCH
J9221-260
Fig. 64 Front Clutch Spring Location
(8) Install spring ret ai ner snap ri ng and remove
compressor tool.
(9) Install clutch plates and discs. Install steel
pl at e followed by clutch disc until all plates and discs

are installed. I ns t al l s ame n u mb e r of di scs and
pl at es as r e move d dur i ng di sassembl y. Some
model s r e qui r e 3 pl at es a n d di scs. Ot her s r e-
qui r e 4 pl at es a n d di scs.
(10) Install reaction plate and waved snap ring.
as follows (Fig. 65):
On 3 disc clutch, clearance between waved spring
and pressure pl at e should 1.78 - 3.28 mm (0.070 -
0.129 in.).
On 4 disc clutch, clearance between waved spring
and pressure pl at e should be 2.08 to 3.83 mm (0.082
to 0.151 in.).
If cl ear ance Is I ncor r ect , cl ut ch pl at es, cl ut ch
di scs, s na p r i ng a n d pr e s s ur e pl at e will ha ve to
be changed. Cl ut ch pa c k wa ve d s na p r i ng is not
sel ect fit.
FEELER GAUGE
R H
2 88
REAR CLUTCH DISASSEMBLY (FIG. 66)
(1) Remove clutch pack select fit snap ring.
(2) Remove reaction plate and remove clutch plates
and discs.
(3) Remove pressure plate, wave spring, spacer
ri ng and piston spring from clutch retainer.
(4) Remove clutch piston from piston ret ai ner with
a twisting motion.
(5) Remove i nput shaft t hrust washer, if washer
remained in piston ret ai ner hub during removal.
(6) Remove seals from clutch piston. Discard seals
after removal.
Clean t he clutch components wi t h solvent and dry
Check condition of the i nput shaft seal ri ngs. It is
not necessary to remove or replace rings unless they
are broken, cracked, or no longer securely hooked to-
gether.
Inspect t he input shaft splines and machined sur-
faces. Very minor nicks or scratches can be smoothed
off wi t h crocus cloth, replace the shaft if t he splines
are damaged, or any of t he machined surfaces are se-
verely scored.
i ng is flaking off.
Replace t he steel plates and t he pressure plate if
heavily scored, warped, or broken. Be sure t he driv-
ing lugs on t he discs and plates are also in good con-
dition. The lugs must not be bent, cracked or
damaged in any way.
Check the lug grooves in t he clutch ret ai ner. The
t he ret ai ner if the grooves are worn or damaged.
Also check action of the ret ai ner check ball. The ball
must move freely and not stick.
wi t h crocus cloth. However, replace the piston and/or
ret ai ner if t he seal surfaces are seriously damaged.
Check t hrust washer condition. Washer thickness
should be 1.55 to 1.60 mm (0.061 to 0.063 in.). Re-
place t he washer if worn or damaged.
Check condition of the two seal rings on t he input
shaft and t he single seal ri ng on t he piston ret ai ner
hub. Replace the seal rings only if severely worn,
cracked, or if they can no longer be hooked together.
INPUT SHAFT REPLACEMENT
If t he input shaft must be replaced, first remove
t he ret ai ni ng ring t hat secures t he shaft in t he pis-
ton ret ai ner hub. Then press the old shaft out of t he
ret ai ner with a shop press.
Lubricate t he splines of t he new shaft with petro-
l eum jelly or ATF Plus. Then align t he shaft in t he
piston ret ai ner and carefully press it into place. Do
not allow t he shaft to become cocked duri ng installa-
tion. The ret ai ner can be cracked if mi sal i gnment oc-
curs.
Install the shaft ret ai ni ng ring after pressing t he
. shaft into place. Be sure t he ring is fully seated be-
fore proceeding with clutch assembly.
Fig. 66 Rear Clutch
REAR CLUTCH ASSEMBLY
(1) Soak clutch discs in transmission fluid. Lubri-
cate remai ni ng clutch components wi t h t ransmi ssi on
fluid. Clutch ret ai ner bushing can be lubricated wi t h
petroleum jelly if desired.
(2) Install new seals on clutch piston. Lubricate
piston seals wi t h Ru-Glyde or petroleum jelly to ease
installation. Be sure seal lips face i nput shaft.
(3) Install clutch piston in piston ret ai ner. Use
twisting motion to seat piston in ret ai ner. Do not
push pi ston straight i n. This coul d di s t or t seal s
causi ng l eakage and cl utch slip.
(4) Assemble piston ret ai ner and clutch ret ai ner.
(5) Support clutch ret ai ner with wood blocks, or in-
sert i nput shaft t hrough predrilled, appropriate di-
amet er hole in workbench. Clutch pack components
are easier to install if both ret ai ners are properly
supported.
(6) Install piston spring in clutch ret ai ner. Con-
cave side of spring faces upward and away from
clutch piston. Convex side faces downward toward
piston.
(7) Install spacer ri ng on top of piston spring.
(8) Inst al l wave spring on top of spacer ring. Then
seat wave spring in ret ai ner groove. If wave s pr i ng
will not seat properly, spacer ring has probabl y
shifted over and into wave spring groove i n re-
tainer. Use small screwdri ver to real i gn spacer
ring if necessary.
(9) Install i nner pressure plate in clutch ret ai ner.
(10) Install first clutch disc followed by steel pl at e
unt i l all discs and plates are installed.
(11) Install reaction plate on top of last clutch disc.
Components46RH
(12) Install selective snap ri ng to secure clutch
pack in ret ai ner.
(13) Install new seal rings on i nput shaft if neces-
sary (Fig. 67). Be very sure ri ng ends are all securely
hooked together before proceeding.
Fig. 67 Input Shaft Seal Ring Locations
(Fig. 68). Clearance should be 0.63 to 1.14 mm (0.025
to 0.045 in.).
(15) If clutch pack clearance is incorrect, clutch
pack snap ring, reaction plate, or clutch pack may
have to be replaced.
(16) Install t hr ust washer on piston ret ai ner hub
(Fig. 66). Use petroleum jelly to hold t hrust washer
in place.

J9321-167
Fig. 68 Measuring Rear Clutch Pack Clearance
PLANETARY GEARTRAIN OVERHAUL
PLANETARY GEARTRAIN DISASSEMBLY
(1) Remove pl anet ary snap ri ng from i nt ermedi at e
shaft (Fig. 69). Retain snap ring if in good condition.
It is reusable.
Fig. 69 Removing Planetary Snap Ring46RH
(2) Remove front pl anet ary gear and front annul us
gear as assembly (Fig. 70).
(3) Remove front pl anet ary gear and t hr ust washer
from front annul us gear (Fig. 71). Note t hr ust
washer position for assembly reference.
(4) Remove tabbed t hrust washer from driving
shell (Fig. 72). Note washer position for assembly ref-
erence.
(5) Remove sun gear and driving shell as assembly
(Fig. 73).
t ary gear (Fig. 74). Note washer position on gear for
assembly reference.
(7) Remove rear pl anet ary gear and rear annul us
gear from i nt ermedi at e shaft (Fig. 75).
(8) Remove t hr ust plate from rear annul us gear
(Fig. 76).
TRANSMI SSI ON 0VERHAUL-46RH 21 - 297
Fig. 71 Disassembling Front Planetary And Annulus
Gears46RH
Intermediate Shaft And Geartrain Inspection
Clean t he i nt ermedi at e shaft and pl anet ary compo-
nent s (Fig. 77) in part s cleaning solvent and dry
Inspect t he pl anet ary gear sets and annul us gears.
The pinion gears, pinion shafts, pinion washers and
shaft ret ai ni ng pins are all serviceable and can be re-
placed if worn or damaged. However, if a pinion car-
ri er is damaged, t he entire pl anet ary gear set must
be replaced as an assembly.
Replace t he annul us gears if t he t eet h are chipped,
broken, or worn, or the gear is cracked. Replace the
pl anet ary t hrust plates and t he tabbed t hr ust wash-
ers if cracked, scored or worn.
21 - 298 TRANSMISSION 0IRH AUL-4 8RH

Fig. 72 Driving Shell Thrust Washer Removal46RH
INTERMEDIATE
SHAFT
Fig. 73 Sun Gear And Driving Shell Assembly
Removal46RH
SUN REAR
SHELL J932M72
Fig. 74 Rear Planetary Thrust Washer
Removal46RH
Inspect t he machined surfaces of t he i nt ermedi at e
shaft. Be sure t he oil passages are open and clear.
Replace t he shaft if scored, pitted, or damaged.
INTERMEDIATE REAR REAR
SHAFT ANNULUS PLANETARY
J932M73
Fig. 75 Rear Planetary And Annulus Gear
Removal46RH
REAR
J9321-174
Fig. 76 Rear Annulus Thrust Plate Removal46RH
Inspect t he sun gear and driving shell (Fig. 77) . If
either component is worn or damaged, remove t he
sun gear rear ret ai ni ng ri ng and separate t he sun
gear and t hrust plate from t he driving shell. Then
replace t he necessary component.
Replace t he sun gear as an assembly if t he gear
t eet h are chipped or worn. Also replace t he gear as
an assembly if t he bushings are scored or worn. The
sun gear bushings are not serviceable. Replace t he
t hr ust plate if worn, or severely scored. Replace t he
driving shell if distorted, cracked, or damaged in any
way.
PLANETARY GEARTRAIN ASSEMBLY AND
ADJUSTMENT
(1) Lubricate sun gear and pl anet ary gears with
transmission fluid during assembly. Use petroleum
jelly to lubricate output shaft bushi ng surfaces,
t hr ust washers and t hr ust plates.
(2) Install front snap ri ng on sun gear and install
gear in driving shell. Then install t hr ust plate over
sun gear and agai nst rear side of driving shell (Fig.

TRANSMISSION QVERHAUL-4 6 RH 21 - 299
Fig. 77 Planetary Geartrain Components46 RH
78). Install rear snap ri ng to secure sun gear and
t hr ust plate in driving shell.
J932M75
Fig. 78 Sun Gear Installation46RH
(3) Install rear annul us gear on i nt ermedi at e shaft
(Fig. 79).
(4) Install t hrust plate in annul us gear (Fig. 80).
Be sure plate is seated on shaft splines and against
gear.
(5) Install rear pl anet ary gear in rear annul us
gear (Fig. 81). Be sure pl anet ary carrier is seated
agai nst annul us gear.
(6) Install tabbed t hr ust washer on front face of
rear pl anet ary gear (Fig. 82). Seat washer tabs in
mat chi ng slots in face of gear carrier. Use extra pe-
t rol eum jelly to hold washer in place if desired.
(7) Lubricate sun gear bushings with petroleum
jelly or transmission fluid.
Fig. 79 Installing Rear Annulus Gear On
Intermediate Shaft46RH
(8) Install sun gear and driving shell on output
shaft (Fig. 83). Seat shell agai nst rear planetary
gear. Verify t hat t hr ust washer on planetary gear
was not displaced duri ng installation.
(9) Install tabbed t hr ust washer in driving shell
(Fig. 84). be sure washer t abs are seated in t ab slots
of driving shell. Use ext ra petroleum jelly to hold
washer in place if desired.
(10) Install tabbed t hr ust washer on front plane-
t ary gear (Fig. 85). Seat washer t abs in matching
slots in face of gear carrier. Use ext ra petroleum jelly
to hold washer in place if desired.
(11) Install front annul us gear over and onto front
pl anet ary gear (Fig. 86). Be sure gears are fully
meshed and seated.
21 300 TRANSMISSION OVERHAUL-4 8RH

OUTPUT
SHAFT
DRIVING
SHELL
THRUST
PLATE
J9121-69
Fig. 80 installing Rear Annulus Thrust Plate46RH
REAR
ANNULUS
GEAR
REAR
PLANETARY
GEAR
SUN
GEAR
OUTPUT
SHAFT
J9121-72
Fig. 83 installing Sun Gear And Driving Shell46RH
TAB
SLOTS (3)
DRIVING
SHELL
REAR
PLANETARY
GEAR
J9121-70
Fig. 81 Installing Rear Planetary Gear46RH
REAR
PLANETARY
GEAR
TABBED
THRUST _
WASHER ^
1 2 1
-
7 1
Fig. 82 Installing Rear Planetary Thrust
Washer-46RH
(12) Install front pl anet ary and annul us gear as-
sembly (Fig. 87). Hold gears together and slide t hem
TABBED
THRUST
WASHER
J9121-73
Fig. 84 Installing Driving Shell Thrust
Washer-46RH
onto shaft. Be sure pl anet ary pinions are seated on
sun gear and t hat pl anet ary carrier is seated on out-
put shaft.
(13) Place geart rai n in upright position. Rotate
gears to be sure all components are seated and prop-
erly assembled. Snap ri ng groove at forward end of
output shaft will be completely exposed when compo-
nent s are assembled correctly.
(14) Install pl anet ary snap ring in groove at end of
(15) Turn pl anet ary geart rai n over. Position wood
block under front end of output shaft and support
geart rai n on shaft. Be sure all geart rai n part s have
moved forward agai nst pl anet ary snap ring. This is
i mport ant for accurate end play check.

TRANSMISSION 0WERHAUL-4 SRH 21 - 301
Fig. 85 Installing Thrust Washer On Front Planetary
Gear-46RH
Fig. 86 Assembling Front Planetary And Annulus
Gears46RH
(16) Check pl anet ary geart rai n end play with
feeler gauge (Fig. 89). Insert gauge between rear an-
nul us gear and shoulder on output shaft as shown.
End play should be 0.15 to 1.22 mm (0.006 to 0.048
in.).
(17) If end play is incorrect, install thinner/thicker
pl anet ary snap ri ng as needed.
Fig. 87 Installing Front Planetary And Annulus Gear
Assembly46RH
Fig. 88 Installing Planetary Snap Ring46RH
21 - 302 TRANSMISSION OVERHAUL-46RH
Fig. 89 Checking Planetary Geartrain End Play
VALVE BODY MAIN COMPONENT
DISASSEMBLY
CAUTI ON : D o not cl amp any valve body component
in a vi se. Thi s pr act i ce can damage the component
resul ti ng in unsati sfactory operati on after assembl y
and instal l ation. Remove val ves, pl ugs and spr i ngs
with a pencil magnet D o not use pl i er s to r emove
any of the val ves, pl ugs or spr i ngs and do not force
any of the c omponent s out or into place. The val ves
and val ve body hous i ngs will be damaged if force i s
used. Tag or mark the valve body spr i ngs for refer-
ence as they are r emoved. D o not al l ow them to be-
c ome intermix ed.
(1) Remove boost valve cover (Fig. 90).
(2) Remove boost valve ret ai ner, valve spring and
boost valve (Fig. 91).
HOUSING J932 M2 6

Fig. 91 Boost Valve Components46RH
DETENT BALL AND SPRING HOUSING J9321-121
(4) Remove E-clip t hat secures t hrot t l e lever in
J932 M38
Fig. 93 Removing Throttle Lever E-Clip-46RH
(5) Lift and rotate manual lever far enough to
clear detent housing.
Fig. 90 Boost Valve Cover Location46RH
(3) Secure detent ball and spring with Ret ai ner
Tool 6583 (Fig. 92).
(6) Remove ret ai ni ng tool and remove detent ball
MANUAL
LEVER
DETENT
HOUSI NG
DETENT
BALL.
AND
SPRING J9321-139
Fig. 94 Detent Ball And Spring Removal
(7) Remove washer at top of manual lever shaft.
Then lift manual lever and park rod assembly up-
ward and out of valve body (Fig. 95).
MANUAL
LEVER
AND
PARK
ROD
ASSEMBLY
MANUAL
LEVER
WASHER
J 932 1- 140
Fig. 95 Manual Lever Removal46RH
(8) Remove t hrot t l e lever from valve body housing
(Fig. 96).
THROTTLE
LEVER
J 9 3 2 M 41
Fig. 96 Throttle Lever Removal46RH
MANUAL
LEVER
PARK
ROD
J9121-81
(10) Remove screws at t achi ng pressure adjusting
screw bracket to valve body and transfer plate. Hold
bracket firmly against spring tension while removing
last screw.
not disturb adjusting screw settings during re-
moval .
PRESSURE
REGULATOR
VALVE SPRING
SWITCH
VALVE
SPRING
LINE PRESSURE
ADJUSTING SCREW
ADJUSTING
SCREW
BRACKET
mm
J9121-512
Removal46RH
(12) Remove solenoid connector from 3-4 accumula-
tor housing (Fig. 99). Note that connector is at-
tached to housi ng wi th shoulder-type screw.
Keep this screw wi th accumul ator housi ng to
avoi d l osi ng it.
(13) Note routing of solenoid wires for assembly

SOLENOID
CONNECTOR
3-4
ACCUMULATOR
HOUSI NG
a
- J932 1- 143
Fig. 99 Solenoid Connector Position46RH
SOLENOID
WIRES
(NOTE
WIRE
ROUTING)
J 9 3 2 M 4 2
(14) Remove screws attaching solenoid assembly to
valve body lower housing and remove solenoid and
connector assembly (Fig. 101).
SOLENOID
ATTACHING
SCREWS
LOWER
HOUSI NG
SOLENOID
ASSEMBLY J9321-144
Fig. 101 Solenoid Assembly Removal46RH
(15) Remove 3-4 accumulator housing attaching
screws and remove housing from valve body (Fig.
102).
3-4
ACCUMULATOR
HOUSI NG HOUSI NG
ATTACHING
SCREWS
Fig. 102 Removing 3-4 Accumulator Housing
(16) Remove following parts from valve body lower
housing: 3-4 shift valve and spring; pressure regula-
tor valve spring; clutch valve; clutch valve spring;
and clutch valve plug (Fig. 103).
LOWER
HOUSI NG
CLUTCH
VALVE A N D
SPRING
3-4
SHIFT
VALVE
AND
SPRING
CLUTCH
VALVE
PLUG
PRESSURE
REGULATOR
VALVE
SPRING J9321-146
Fig. 103 Clutch Valve And 3-4 Shift Valve
Locations46RH
(17) Remove boost valve connecting tube (Fig.
104). Disengage tube from upper housing port first.
Then rock opposite end of tube back and forth to
work it out of lower housing.
C A U T I O N : D o not use t ool s to l oosen or pry the
connect i ng tube out of the val ve body housi ngs.
L oosen and remove the tube by hand onl y.
BOOST
.VALVE
TUBE
LOWER
HOUSING
UPPER
HOUSING
DISENGAGE
THIS END OF
TUBE FIRST J 9 3 2 1 - 1 4 7
Fig. 104 Boost Valve Tube Removal46RH
(18) Turn valve body over so valve lower housing
is facing upward (Fig. 105). In this position, check
balls in upper housing will remai n in place and not
fall out when lower housing and transfer pl at e are
removed.
(19) Remove screws attaching valve body lower
housing to upper housing and transfer pl at e (Fig.
105). Note posi ti on of boost val ve tube brace for
assembl y reference.
LOWER
HOUSING
VALVE
BODY
SCREWS (13)
~\L^ VALVE
TUBE
BRACE J 9 3 2 M4 8
Fig. 105 Valve Body Screw And Tube Brace
Location46RH
(20) Remove lower housing and overdrive separa-
tor plate from transfer plate (Fig. 106).
(21) Remove transfer plate from upper housi ng
(Fig. 107).
(22) Tur n transfer plate over so upper housing sep-
arat or plate is facing upward (Fig. 108).
(23) Remove brace plate from lower housi ng sepa-
rat or plate and transfer plate (Fig. 108).
(24) Remove upper housing separator pl at e from
transfer plate (Fig. 109). Note position of filter in
separator plate for assembly reference.
(25) Remove rear clutch check ball from transfer
plate. Note check ball location for assembl y ref-
OVERDRIVE
SEPARATOR
PLATE
TRANSFER
PLATE AND
UPPER
HOUSING
LOWER
HOUSING
J 9 3 2 M4 9
Fig. 106 Lower Housing Removal46RH
UPPER
HOUSING
TRANSFER
PLATE
J932M52
Fig. 107 Removing Transfer Plate From Upper
Housing46RH
BRACE
J 9 3 2 M5 0
SEPARATOR TRANSFER
PLATE PLATE
Fig. 108 Brace Plate Removal46RH
erence before removi ng it (Fig. 110).

TRANSFER U PPE R
J9321-151
Fig. 109 Upper Housing Separator Plate
RemovalRH
Fig. 110 Rear Clutch Check Ball Location46RH
VALWE BODY UPPER HOUSING
DISASSEMBLY
(1) Note location of check balls in valve body upper
housing (Fig. 111). Then remove one large and six
smaller diameter check balls with magnet (total of 7
check balls are used).
(2) Remove E-clip t hat secure shut t l e valve second-
ary spring on valve stem (Fig. 112).
(3) Remove governor plug and shut t l e valve covers
(Fig. 113).
(4) Remove t hrot t l e plug, pri mary spring, shut t l e
valve, secondary spring, and spring guides (Fig. 113).
(5) Remove boost valve ret ai ner, spring and valve
if not previously removed.
(6) Turn upper housing over and remove switch
valve, regulator valve and spring, and manual valve
(Fig. 114).
(7) Remove kickdown detent, kickdown valve, and
t hrot t l e valve and spring (Fig. 114).
(8) Remove t hrot t l e plug and 1-2 and 2-3 governor
plugs (Fig. 114). Also remove shut t l e valve pri mary
spring if not removed in prior step.
SMALL
DIAMETER
CHECK
BALLS (6)
LARGE DIAMETER
CHECK
BALL (1) J932 M5 4
Location
(9) Turn upper housing around and remove limit
valve and shift valve covers (Fig. 115).
(10) Remove limit valve housing. Then remove re-
t ai ner, spring, limit valve, and 2-3 t hrot t l e plug from
limit valve housing (Fig. 115).
(Fig. 115).
(12) Remove 1-2 shift valve and spring (Fig. 115).
body (Fig. 115).
(14) Remove pressure plug cover (Fig. 115).
(15) Remove line pressure plug, sleeve, t hrot t l e
pressure plug and spring (Fig. 115).
-156
Fig. 113 Shuttle And Boost Valve Components46RH
Fig. 114 Control Valve Locations46RH Upper Housing
UPPER
HOUSI NG
PLUG RETAINER A N D VALVE
COVER SPRING COVER J9321-157
Fig. 115 Shift Valves And Pres
VALVE BODY LOWER HOUSING
DISASSEMBLY (FIG. 116)
(1) Remove t i mi ng valve cover.
(2) Remove 3-4 t i mi ng valve and spring.
(3) Remove 3-4 shut t l e valve E-clip and remove
shut t l e valve spring and plug.
(4) Remove 3-4 shift valve and spring. (5) Remove
converter clutch valve, spring and plug.
(6) Remove converter clutch t i mi ng valve, ret ai ner
and valve spring.
3-4 ACCUMULATOR HOUSING DISASSEMBLY
(FIG. 117)
(1) Remove end plate from housing.
(2) Remove piston spring.
(3) Remove piston. Remove and discard piston
seals.
The only serviceable valve body components are:
solenoid and connector assembly
solenoid gasket
park rod and E-clip
t hrot t l e valve lever
manual lever
manual shaft seal, washer, and E-clip
e Plugs46RH Upper Housing
fluid filter
detent ball and spring
Clean t he valve body components with a st andard
part s cleaning solution only. Do not use gasoline,
kerosene, or any type of caustic solution.
Dry t he part s with compressed air. Make sure all
passages are clean and free from obstructions. Do
not us e r a gs or s hop t owel s t o dr y or wi pe off
val ve body component s . Li nt from t hes e mat er i -
al s wi l l st i ck t o t he val ve body component s . Li nt
wi l l i nt er f er e wi t h val ve oper at i on a n d ma y cl og
fi l t ers a n d fl ui d pas s ages .
pressure.
Minor distortion of a valve body mat i ng surface
may be corrected by smoothing t he surface with a
sheet of crocus cloth. Position t he crocus cloth on a
surface plate, sheet of plate glass or equally flat sur-
TRANSMISSION 0VERH AUL-4 IRH 21 - 309
LOWER HOUSING 3-4 SHUTTLE 3-4 ACCUMULATOR PISTON 3-4 ACCUMULATOR HOUSING
3-4
SHUTTLE VALVE
THROTTLE PLUG
TIMING
VALVE
COVER
3-4 SHIFT
VALVE AND
SPRING
SPRING
RETAINER
CONVERTER CLUTCH
TIMING VALVE
AND SPRING
CONVERTER
CLUTCH
SOLENOID SOLENOID
GASKET
OVERDRIVE
SEPARATOR PLATE
J932M58
3^4 ACCUMULATOR
HOUSING
ACCUMULATOR
PISTON
Fig. 116 Shift Valves And Springs46RH Lower Housing
C A U T I O N : Many of the val ves and pl ugs, s uc h a s
the throttle val ve, shuttle valve pl ug, 1-2 shift val ve
and 1-2 governor pl ug, are made of coated al umi -
num (Fi g. 118). Al umi num component s are identi-
fied by the dark col or of the speci al coati ng appl i ed
to the surface (or by testing with a magnet). D o not
pol i sh or sand al umi num val ves or pl ugs with any
type of material. T hi s practice coul d damage the
speci al coati ng and cause the val ves and pl ugs to
stick and bi nd.
PISTON
SEAL
RING
PISTON
SPRING
END
PLATE
J9121-277
Fig. 117 3-4 Accumulator Housing
Components46RH
nicks, or scores. Minor surface scratches on steel
valves or plugs can be removed with crocus cloth but
do not round off the edges of the val ve or pl ug
l ands. Mai nt ai ni ng sharpness of these edges is vi-
tally i mport ant . The edges prevent foreign mat t er
from lodging between t he valves and plugs and t he
bore.
Inspect all t he valve and plug bores in t he valve
coils.
Check t he two separator plates for distortion or
damage of any kind. Inspect t he upper housing,
lower housing, 3-4 accumulator housing, and transfer
face. If distortion is severe or any surfaces are
heavily scored, t he valve body will have to be re-
placed.
21 - 310 TRANSMISSION 0VERHAUL-4 6 RH

plate carefully. Be sure all fluid passages are clean
and clear. Check condition of t he upper housing and
transfer plate check balls as well. The check balls
and ball seats must not be worn or damaged.
Valve body bores do not change dimensionally wi t h
use. If t he valve body functioned correctly when new,
dling.
VALWE BODY BEASSEMBLY
CAUTION; D o not force val ves or pl ugs into pl ace
duri ng reassembl y. If the val ve body bor es, val ves
and pl ugs are free of distortion or burrs, the val ve
body component s shoul d all sl i de into pl ace easi l y.
I n addi ti on, do not overtighten the transfer plate
and val ve body scr ews duri ng reassembl y. Over-
tightening can distort the hous i ngs resulting in
val ve st i cki ng, c r os s l eakage and unsati sfactory op-
eration. Ti ghten val ve body scr ews to recom-
mended torque onl y.
Lower Housing Assembly (Fig. 116)
(1) Lubricate valves, springs, and t he housing
valve and plug bores wi t h Mopar ATF Pl us, or
Dexron II transmission fluid.
(2) Install 3-4 t i mi ng valve spring and valve i n
lower housing.
(3) Install 3-4 shut t l e valve in lower housing.
Press valve inward and install E-clip on end of valve
to secure i t in housing.
(4) Install 3-4 shut t l e valve spring and t hrot t l e
plug in housing.
(5) Install t i mi ng valve end plate. Tighten end
(6) Install 3-4 shift valve and spring.
(7) Install converter clutch valve, spring and plug.
(8) Install converter clutch t i mi ng valve and
spring.
3-4 Accumulator Assembly (Fig. 117)
(1) Lubricate accumulator piston, seals and hous-
ing piston bore with ATF Plus, or Dexron II.
(2) Install new seal rings on accumulator piston.
(3) Install piston and spring in housing.
(4) Install end plate on housing.
Transfer Plate Assembly
(1) Install r ear clutch check ball in transfer pl at e
(Fig. 110).
(2) Install filter screen in upper housing separator
plate (Fig. 109).
(3) Align and position upper housing separator
plate on transfer plate (Fig. 109).
(4) Install brace plate (Fig. 108). Tighten brace at-
t achi ng screws to 4 Nnn (35 in. lbs.) torque.
(5) Install remai ni ng separator pl at e at t achi ng
screws. Tighten screws to 4 N*m (35 in. lbs.) torque.
SHIFT VALVE
END PLATE
2-3 SHIFT
VALVE AND
SPRING
SHUTTLE VALVE
SECONDARY SPRING,
GUIDES, E-CLIP
1-2 SHIFT
CONTROL VALVE
AND SPRING
REGULATOR
VALVE
END PLATE
SHUTTLE VALVE
COVER
SLEEVE
REGULATOR
VALVE THROTTLE
PRESSURE PLUG
RETAINER
VALVE
SPRING
2-3 SHIFT
VALVE GOVERNOR
PLUG
LINE
PRESSURE
ADJUSTING*
SCREW
ADJUSTING
SCREW
BRACKET
SHUTTLE VALVE
PLUG (ALUM.)
GOVERNOR
VALVE END
PLATE
AAANUAL LEVER
DETENT BALL
AND SPRING
J9221-21
E
w
00
o
z
m
30
Fig. 118 Upper Housing Components46RH Valve Body (Alum. Indicates Aluminum Part)

Assembling Upper And Lower Housings
(1) Position upper housing so i nt ernal passages
and check ball seats are facing upward. Then install
check balls in housing (Fig. 111). Seven check balls
are used. The single large check ball is approxi-
mately 8.7 mm (11/32 in.) diameter. The remai ni ng 6
check balls are approximately 6.3 mm (1/4 in.) in di-
ameter.
(2) Position transfer plate assembly on upper hous-
ing (Fig. 119).
(3) Position lower housing separator plate on
T RA N S F E R UPPER
PLATE HOUSING J 9 3 2 M 5 9
Fig. 119 Lower Housing Separator Plate
Installation46RH
(4) Inst al l lower housing on assembled transfer
plate and upper housing (Fig. 120).
(5) Install and st art valve body screws by hand.
Then t i ght en screws evenly to 4 N*m (35 in. lbs.)
torque. St ar t at center and work out to sides when
t i ght eni ng screws.
Fig. 120 Assembling Valve Body Upper And Lower
Housings46RH
Upper Housing Valve And Plug Installation (Figs. 114 , 111,
118)
(1) Lubricate valves, plugs, springs with Mopar
(2) Assemble regulator val ve line pressure plug,
sleeve, t hrot t l e plug and spring. Insert assembly in
upper housing and install cover plate. Tighten cover
pl at e screws to 4 Nm (35 in. lbs.) torque.
(3) Install 1-2 and 2-3 shift valves and springs.
(4) Install 1-2 shift control valve and spring.
(5) Install shift valve cover plate.
(6) Install shut t l e valve as follows:
(a) Insert plastic guides in shut t l e valve second-
ary spring and install spring on end of valve.
(b) Hold shuttle valve in place.
(c) Compress secondary spring and install E-clip
in groove at end of shut t l e valve.
(d) Verify t hat spring and E-clip are properly
(7) Install shut t l e valve cover plate. Tighten cover
valve body.
(9) Install shuttle valve pri mary spring and throt-
tle plug.
(10) Align and install governor plug cover. Tighten
cover screws to 4 N
#
(11) Install manual valve.
(12) Install throttle valve and spring.
(13) Install kickdown valve, and detent.
(14) Install regulator valve.
(15) Install switch valve.
Boost Valve Tube Installation
(1) Position valve body assembly so lower housing
is facing upward (Fig. 121).
(2) Lubricate tube ends and housing ports wi t h
transmission fluid or petroleum jelly.
(3) Position tube behind t ube brace (Fig. 121).
(4) St art tube in lower housing port first. Then
swing t ube downward and work opposite end of t ube
into upper housing port (Fig. 121).
(5) Seat each end of t ube in housings.
3-4 Accumulator Installation
(1) Position converter clutch valve and 3-4 shift
valve springs in housing (Fig. 122).
(2) Loosely at t ach accumulator housing with right-
side screw (Fig. 122). Install only one screw at t hi s
t i me as accumulator must be free to pivot upward for
ease of installation.
(3) Position plug on end of converter clutch valve
spring. Then compress and hold springs and plug i n
place wi t h fingers of one hand.
(4) Swing accumulator housing upward over valve
springs and plug.
(5) Hold accumulator housing firmly in place and
install remai ni ng two at t achi ng screws. Be sure

TUBE BRACE UPPER
LOWER
H O U S I N G
PORT J932M62
Fig. 121 Boost Valve Tube Installation46RH
springs and clutch valve plug are properly seated
(Fig. 123).
RIGHT-SIDE SCREW
3-4 ACCUMULATOR
Fig. 122 Installing Converter Clutch And 3-4 Shift
Valve Springs46RH
CLUTCH ACCUMULATOR
VALVE PLUG BOSS J9321-161
Fig. 123 Seating 3-4 Accumulator On Lower
Housing46RH
(6) Attach solenoid case connector to 3-4 accumula-
tor with shoulder-type screw. Connector has small lo-
cating t ang t hat fits in dimple at top of accumulator
housing (Fig. 124). Seat t ang in dimple before tight-
eni ng connector screw.
(7) Install solenoid assembly and gasket. Tighten
solenoid at t achi ng screws to 8 N*m (72 in. lbs.)
torque.
SOLENOID
CASE CONNECTOR
Fig. 124 Solenoid Connector Installation46RH
(8) Verify t hat solenoid wires are properly routed
(Fig. 125). Sol enoi d wi res must be clear of rear
band lever, manual l ever and park rod.
Valve Body Final Assembly And Adjustment
(1) Insert manual lever det ent spring in upper
housing.

Fig. 126 Manual And Throttle Lever Alignment
The 33.4 mm (1-5/16 in.) setting is an approxi-
mate setting. Manufacturing tol erances may
make it necessary to vary from this di mensi on to
obtain desi red pressure.
line pressure approximately 1-2/3 psi (9 kPa).
Turni ng t he adjusting screw counterclockwise in-
creases pressure while t urni ng t he screw clockwise
decreases pressure.
down valve against t he spring and bottom t he throt-
tle valve.
Turn t hrot t l e lever stop screw unt i l t he screw head
touches throttle lever t ang and t he t hrot t l e lever cam
touches gauge tool.
(2) Position line pressure adjusting screw in ad-
j ust i ng screw bracket.
(3) Install spring on end of line pressure regulator
valve.
adjusting screw bracket.
(5) Position adjusting screw bracket on valve body.
Align valve springs and press bracket into place. In-
stall short, upper bracket screws first and long bot-
tom screw last. Verify t hat valve springs and bracket
are properly aligned. Then t i ght en all t hree bracket
(6) Install t hrot t l e lever in upper housing. Then in-
ual lever into housing.
(7) Position detent ball on end of spring. Then hold
detent ball and spring in det ent housing with Re-
(8) Align manual lever with det ent ball and man-
ual valve. Hold t hrot t l e lever upward. Then press
down on manual lever unt i l fully seated. Remove de-
t ent ball ret ai ner fool after lever is seated.
(9) Then Install manual lever seal, washer and
E-clip.
(10) Lubricate solenoid case connector O-rings and
shaft of manual lever with light coat of petroleum
jelly.
(11) Verify t hat t hrot t l e lever is aligned with end
(12) Install boost valve, valve spring, ret ai ner and
cover plate. Tighten cover plate screws to 4 Nm (35
in. lbs.) torque.
(13) Obtain new fluid filter for valve body but do
not install filter at t hi s time.
ment procedure.
ADJUSTMENTS
valve body which are, line pressure and t hrot t l e pres-
sure.
Line and t hrot t l e pressures are interdependent be-
cause each affects shift quality and timing. As a re-
sult, both adjustments must be performed properly
and in t he correct sequence. Adjust line pressure first
and t hrot t l e pressure last.
edge of t he adjusting screw wi t h an accurate steel
scale (Fig. 127).

The ki ckdown val ve s pr i ng mus t be fully com-
pr es s ed a n d t he ki c kdown val ve compl et el y bot -
t omed t o obt ai n cor r ect adj us t ment .
Fig. 128 Throttle Pressure Adjustment
TRANSMISSION ASSEMBLY
Assembly Tips
Do not allow dirt, grease, or foreign material to en-
ter the case or transmission components during as-
sembly. Keep the transmission case and components
clean. Also make sure the tools and workbench area
used for reassembly operations are equally clean.
Shop towels used for wiping off tools and your
hands must be made from lint free materials. Lint
will stick to transmission parts and could interfere
with valve operation or even restrict fluid passages.
Lubricate transmission clutch and gear components
with Mopar ATF Plus or Dexron II during reassem-
bly. Soak clutch discs in transmission fluid before in-
stallation.
Use Ru-Glyde, Door-Eze, or petroleum jelly on
seals and O-rings to ease installation. Petroleum
jelly can also be used to hold thrust washers and
plates in position during assembly operations. How-
ever, do not use chassis grease, bearing grease,
white grease, or similar lubricants on any part.
These types of lubricants can eventually block or re-
strict fluid passages and valve operation. Use petro-
leum jelly only.
Do not force parts into place. The transmission
components and sub-assemblies are easily installed
by hand when properly aligned. If a part seems diffi-
cult to install, it is either misaligned or incorrectly
assembled. Verify that thrust washers, thrust plates
and seal rings are correctly positioned. These parts
will prevent proper assembly is mispositioned (or
"left out"by accident).
The planetary geartrain, front/rear clutch assem-
when the transmission case is upright or as close to
this position as possible. Either tilt the case upward
with wood blocks, or cut a hole in the bench large
enough for the output shaft and rear support. Then
lower the shaft and support into the hole and support
the rear of the case directly on the bench.
(1) Lubricate rear servo piston seal with petroleum
jelly, or Door Eze. Lubricate servo bore in case with
transmission fluid.
(2) Install rear servo piston in case. Position piston
at slight angle to bore and insert piston with twist-
ing motion (Fig. 129).
Fig. 129 Installing Rear Servo Piston46RH
(3) Install rear servo spring and retainer in case
bore (Fig. 130). Be sure spring is seated on piston.
Fig. 130 Installing Rear Servo Piston Spring And
Retainer46RH
(4) Compress rear servo piston with C-clamp or
Valve Spring Compressor C-3422-B and install servo
piston snap ring (Fig. 131).
(5) Install new gasket at rear of transmission case.
Use petroleum jelly to hold gasket in place. Be sure
to align governor feed hol es in gasket wi th feed
passages i n case (Fig. 132). Install gasket before
21 - 31S TRANSMISSION 0VERHAUL-4 6 RH
Fig. 131 Installing Rear Servo Snap Ring46RH
over dr i ve pi s t on r et ai ner . Cent er hol e i n gas ket
i s s mal l er t h a n r e t a i ne r a n d c a nnot be i nst al l ed
over r et ai ner .
Fig. 132 Installing Case Gasket46RH
(6) Install overdrive piston ret ai ner. Be sure gover-
nor t ube bores in ret ai ner are aligned with governor
feed passages in gasket and case (Fig. 133). Install
and t i ght en ret ai ner bolts to 17 Nm (13 ft. lbs.)
torque.
(7) Install overrunni ng clutch components if not
yet installed. Refer to Overrunni ng Clutch Overhaul
in t hi s section if necessary.
(8) Position rear band and link in case (Fig. 134).
Be s ur e not c he d si de of l i nk f aces a wa y f r om
ba nd.

Fig. 133 Installing Overdrive Piston Retainer46RH
Fig. 134 Installing Rear Band And Link46RH
(9) Install low-reverse drum (Fig. 135). Slide drum
t hrough rear band, onto rear support hub and into
engagement with overrunning clutch race.
(10) Install snap ri ng t hat secures low-reverse
drum to rear support hub (Fig. 136).
(11) Insert band reaction pin part way case and
band link (Fig. 137).

Ring-46RH
(12) Install rear band adjusting lever, st rut and re-
action lever (Fig. 138). Be sure levers and st rut are
aligned and engaged before seating band reaction pin
in case.
(13) Lubricate front servo piston components and
servo bore in case wi t h transmission fluid.
(14) Install front servo piston in bore. Carefully
"run" small, suitable tool around piston ri ng to press
it back into groove and ease installation (Fig. 139).
Rotate piston into bore at same time. Rock piston
slightly to ease piston ri ng past snap ring groove and
into bore.
(15) Bottom front servo piston in bore and install
servo spring.
(16) Install front servo piston rod guide as follows:
TRANSMISSION 0VERHAUL-4 SRH 21 - 317
Fig, 137 Installing Rear Band Reaction Pin46RH
ADJUSTI NG ADJUSTI NG
J9121-92
Fig. 138 Rear Band Levers And Strut46RH
(a) Place Tool SP-5560 (or similar size tool) on
guide and position C-clamp on tool and case (Fig.
140).
(b) Slowly compress rod guide while simulta-
neously easing seal ring into bore with suitable
tool.
(17) Install rod guide snap ri ng (Fig. 140).
(18) Position front band lever in case and over
servo rod guide. Then install front band lever pin in
case and slide it t hrough lever.
(19) Coat t hreads of front band lever pin access
plug wi t h sealer and install it in case. Tighten plug
21 - 318 TRANSMISSION 0WERHAUL-4 6 RH
Fig. 140 Installing Front Servo Rod Guide And Snap
Ring-46RH
gear components (Fig. 141). Suppor t shaft car e-
fully dur i ng i nst al l at i on. Do not al l ow shaf t
bear i ng/ bus hi ng s ur f aces t o be c ome ni cked or
s cr at ched.
(21) Lubricate i nt ermedi at e shaft t hrust plate wi t h
petroleum jelly and install plate on shaft pilot hub
(Fig. 142).
(22) Check i nput shaft front seal rings, fiber t hr ust
washer and rear seal ring (Fig. 143). Be ends of rear
seal ri ng are hooked together and diagonal cut ends
of front seal ri ngs are firmly seated agai nst each
other as shown. Lubricate seal ri ngs wi t h petroleum
jelly after checking t hem.
(23) Assemble front and rear clutches (Fig. 144).
Align lugs on front clutch discs. Mount front clutch

ASSEMBLY J9121-508
Fig. 141 Installing Intermediate Shaft And Planetary
Geartrain46RH
Fig. 142 Installing Intermediate Shaft Thrust
Plate-46RH
on rear clutch. Turn front clutch ret ai ner back and
forth unt i l front clutch discs are fully seated on rear
clutch splined hub.
(24) Install intermediate shaft t hr ust washer in
hub of rear clutch ret ai ner (Fig. 145). Use petroleum
jelly to hold washer in place. Position washer so
grooves are facing outward. Was her onl y fits one
wa y i n cl ut ch r et ai ner hub.
(25) Place transmission case in upri ght position, or
place blocks under front end of transmission repai r
st and to tilt case rearward. This makes it easier to
i nst al l front/rear clutch assembly.
(26) Align discs in rear clutch. Then install and
engage assembly in front pl anet ary and driving shell
(Fig. 146). Turn clutch ret ai ners back and forth unt i l
both clutches are seated.
(27) Slide front band over front clutch ret ai ner and
install front band st rut and anchor (Fig. 147).

Fig. 143 input Shaft Seat Ring And Thrust Washer
Installation46RH
Fig. 144 Assembling Front And Rear
Clutches-46RH
is t i ght on clutch retainer. Verify t hat front/rear
clutch assembly is still properly seated bef or e tight-
eni ng band.
(29) Install oil pump Pilot Studs C-3288- B in case
(Fig. 148).
Fig. 145 Installing intermediate Shaft Thrust
Washer-46RH
Assemblies46RH
(30) Install new oil pump gasket on pilot studs and
seat it in case. Be sure gasket is properly aligned
with fluid passages in case (Fig. 148).
(31) Check seal rings on reaction shaft support. Be
sure rings are hooked together correctly. Also be sure
fiber t hrust washer is in position (Fig. 149). Use pe-
troleum jelly to hold washer in place if necessary.
21 - 320 TRANSMISSION 0ERHAUL-4 6 RH
LEVER STRUT
J9121-18
Fig. 147 Front Band And Linkage Installation46RH
Fig. 148 Installing Oil Pump Gasket And Pilot
Studs-46RH
(32) Lubricate oil pump seals with petroleum jelly
or transmission fluid.
(33) Mount oil pump on pilot studs and slide pump
into case opening (Fig. 150). Work pump i nto case
by hand. Do not use a mallet or similar tool s to
seat pump.
(34) Remove pilot studs and install oil pump bolts.
Tighten pump bolts al t ernat el y and evenly to fully
seat pump in case. Then final-tighten pump bolts to
(35) Verify correct assembly. Rotate input and out-
put shafts and check for bind. If bind exists, compo-
nent s are either misassembled, or not seated.
Disassemble and correct as necessary before proceed-
ing.

Fig. 149 Reaction Shaft Seal Ring And Thrust
Washer installation46RH
Fig. 150 Oil Pump installation46RH
(a) Attach dial indicator to converter housing
(Fig. 151). Position indicator plunger agai nst i nput
shaft and zero indicator.
(b) Move input shaft in and out and record read-
ing.
(c) End play should be 0.86 - 2.13 mm (0.034 -
0.084 in.).
(36) Check i nput shaft end play as follows:

TRANSMISSION 0V ERH AUL- 4 IRH 21 - 321
(d) If end play is incorrect, change out put shaft
t hr ust washer, t hrust plate, or front clutch t hr ust
washer.
Fig. 151 Checking input Shaft End Play
(37) Install new seals on overdrive piston. Then lu-
bricate seals with transmission fluid, Ru-Glyde,
Door-Eze or petroleum jelly.
(38) Install overdrive piston in ret ai ner. Al i gn lo-
cati ng l ugs on pi ston in locating bores i n re-
tainer (Fig. 152). Use t hi n plastic strip or feeler
gauge to help guide piston outer seal into ret ai ner.
Fig. 152 Overdrive Piston Alignment
(39) Install spacer on i nt ermedi at e shaft, if not
previously installed.
(40) Install overdrive piston t hr ust pl at e (Fig. 153).
Use liberal quant i t y of petroleum jelly to hold t hrust
plate in position on piston.
(41) Install overdrive piston t hrust beari ng in di-
rect clutch hub (Fig. 154). Use liberal quant i t y of pe-
troleum jelly to hold t hr ust beari ng i n place. Note
that one side of beari ng has dark coated sur-
face. This surface faces overdri ve pi ston. Al so
be sure rai sed shoul der on i nsi de diameter of
beari ng faces forward as wel l .
Fig. 153 Installing Overdrive Piston Thrust Plate
Fig. 154 Installing Overdrive Piston Thrust Bearing
(42) Apply small amount of petroleum jelly to pilot
hub of i nt ermedi at e shaft.
(43) Verify alignment of splines in overdrive uni t
pl anet ary gear and overrunni ng clutch. Be sure
Alignment Tool 6227-2 is fully seated (Fig. 155). If
pl anetary gear and overrunni ng cl utch splines
become mi sal i gned, overdri ve uni t cannot be
fully installed on intermediate shaft. Overdrive
unit will have to be di sassembl ed i n order to re-
align splines.

J932M33
Fig. 155 Checking Alignment Of Overdrive Planetary
Gear And Overrunning Clutch Splines46RH
(44) Carefully withdraw al i gnment tool from over-
drive unit.
(45) Lubricate i nt ermedi at e shaft splines and
bushi ng surfaces with transmission fluid or petro-
leum jelly.
(46) Install overdrive unit. Be sure governor tubes
are aligned with feed holes in piston ret ai ner boss.
Int ermedi at e shaft is snug fit in overdrive pl anet ary
gear and overrunni ng clutch. If overdrive uni t will
not seat fully, rotate overdrive output shaft slightly
to align splines and t ry again.
(47) Apply 1-2 drops of Mopar t hread adhesive (or
Loctite 242) to overdrive uni t at t achi ng bolts. Then
install and t i ght en bolts to 34 N (25 ft. lbs.) torque.
(48) Install accumulator i nner spring, piston and
outer spring (Fig. 156).
ACCUMULATOR OUTER
Fig. 156 Installing Accumulator Piston And Springs
not been installed in case. Valve body can not be in-
(50) Install valve body as follows:
(a) St art park rod into par k pawl. If rod will not
slide past park pawl, pawl is engaged in park gear.
Rotate overdrive output shaft wi t h socket to free
pawl and allow rod to engage.
(b) Align and seat valve body on case. Be sure
manual lever shaft and overdrive connector are
fully seated in case.
(c) Install and st art all valve body at t achi ng
bolts by hand. Then t i ght en bolts evenly, in a di-
agonal pat t ern to 12 Nnn (105 in. lbs.) torque. Do
not over t i ght en val ve body bol t s. Thi s coul d
r es ul t i n di st or t i on a n d cr os s l eakage aft er in-
st al l at i on. .
screws to 4 Nnn (35 in. lbs.).
(Fig. 157). Then install and t i ght en switch to 34 Nnn
(25 ft. lbs.).
Fig. 157 Park/Neutral Position Switch Seal Position
(53) Adjust front and rear bands as follows:
4-5 t urns.
(b) Tighten both adjusting screws to 8 Nnn (72
in. lbs.).
t urns.
(d) Back off rear band adjusting screw 2 t urns.
(e) Hold each adjusting screw in position and
t i ght en locknuts to 34 Nnn (25 ft. lbs.) torque.
(54) Install magnet in oil pan. Magnet goes on
stall oil pan. Tighten pan bolts to 17 Nnn (13 ft. lbs.).
wi t h petroleum jelly. St art seal over shaft and into
case. Seat seal wi t h 15/16 inch, deep well socket.
(57) Install t hrot t l e valve and shift selector levers
on valve body manual lever shaft.
(58) Cap or cover transmission openings (cooler
line fittings, filler t ube bore, etc.) to prevent dirt en-
try.
(59) Install torque converter. Use C-clamp or met al
st rap to hold converter in place for installation.
vehicle.
(61) Apply dielectric grease to t ermi nal pins of so-
lenoid case connector and neut ral switch.

C A U T I O N : The t r ansmi ssi on cool er and lines must
be reverse f l ushed if overhaul corrected a mal func-
al so be replaced if contami nated by the same mal-
function. Debri s and resi due not fl ushed from the
cooler and lines will flow back into the t r ansmi ssi on
and shop comeback.
Fig. 158 Installing Manual Lever Shaft Seal
21 - 324 OVERDRIVE UNIT OVERHAUL42RH/46RH

O V E R D R I V E U N I T O V E R H A U L 42 R H / 46R H
INDEX
page
Overdrive Geartrain Assembl y 333
Overdrive Geartrain Di sassembl y 326
Overdrive Unit Assembl y and Adjustment 338
OVERDRIVE UNIT DI SASSEMBLY
(1) Remove overdrive piston t hr ust plate (Fig. 1).
Ret ai n t hr ust plate. It is a select fit part and can be
reused.
Fig. 2 Intermediate Shaft Spacer Location
(3) Remove overdrive piston from ret ai ner (Fig. 3).
(4) Remove overdrive piston t hr ust beari ng from
direct clutch hub (Fig. 4).
(5) Remove overdrive clutch pack ret ai ni ng ri ng
(Fig. 5).
page
Overdrive Unit Cleaning and Inspection . . . . . . . 330
Overdrive Unit Di sassembl y 324
Fig. 3 Removing Overdrive Piston
Fig. 4 Removing Overdrive Piston Thrust Bearing
(6) Remove overdrive clutch pack (Fig. 6). Note t hat
thickest plate is positioned at rear of clutch pack.
(7) Remove overdrive clutch wave spring (Fig. 7).
(8) Remove overdrive clutch reaction snap ri ng
(Fig. 8). Note t hat snap ri ng is located in same
groove as wave spring.
(9) Remove access cover and gasket from case (Fig.
9). Cover provides access to output shaft front bear-
ing locating ring.
(10) Expand output shaft beari ng snap ri ng with
snap ri ng pliers and push output shaft forward to re-
lease shaft front beari ng from locating ri ng (Fig. 10).

OVERDRIVE UNIT OVERHAUL42RH/46RH 21 - 325
Fig. 5 Removing/Installing Overdrive Clutch Pack
Retaining Ring
Fig. 6 Overdrive Clutch Pack Removal
Fig. 7 Removing/installing Overdrive Clutch Wave
Spring
Fig. 8 Removing Overdrive Clutch Reaction Snap
Ring
Fig. 9 Removing/Installing Locating Ring Access
Cover
Fig. 10 Releasing Shaft Front Bearing From
Locating Ring

(11) Remove geart rai n assembly from housing
(Fig. 11). Set geart rai n aside.
Fig. 11 Removing Overdrive Unit Geartrain
(12) Remove output shaft front beari ng locating
ri ng and governor support snap ri ng (Fig. 12).
Fig. 12 Front Bearing Locating Ring And Governor
Support Snap Ring Location
(13) Remove governor support and t ube assembly
from case (Fig. 13).
(14) Remove park pawl ret ai ni ng bolt and reaction
plug snap ri ng (Fig. 14). Compress snap ri ng only
enough to remove it. Snap ri ng can be distorted if
overcompressed.
(15) Remove park pawl shaft, park pawl, pawl
spring and reaction pl ug (Fig. 14).
(16) Remove out put shaft rear beari ng snap ri ng
(Fig. 15). Remove snap ri ng with long j aw i nt ernal
type snap ri ng pliers. Or, rotate snap ri ng unt i l one
end is adjacent to notch in case. Then unseat ri ng
wi t h long flat blade screwdriver.
(17) Remove rear beari ng by t appi ng overdrive
case on wood block to dislodge bearing.
Fig. 13 Removing Governor Support And Tube
Assembly
Fig. 14 Park Lock Component Removal
OVERDRIVE GEARTRAIN DI SASSEMBLY
(1) Remove E-clip from one end of governor valve
shaft and remove shaft and valve (Fig. 16).
(2) Remove governor snap ri ng (fig. 17).
(3) Remove governor body and drive as assembly
(Fig. 18).
(4) Remove governor drive key (Fig. 19).
(5) Remove output shaft front beari ng snap ri ng
(Fig. 20).
(6) Remove front beari ng from output shaft (Fig.
21).
OVERDRIVE UNIT OVERHAUL4 2RH/4 8RH 21 - 327
OUTPUT S H A F T /
REAR BE AR I NG
S N A P-
R I N G
8921-239
Fig. 15 Output Shaft Rear Bearing And Snap Ring
Location
E-CLIP
J9121-302
GOVERNOR
BODY
GOVERNOR
VALVE
SHAFT
GOVERNOR
VALVE E-CLIP-
Fig. 16 Governor Valve And Shaft
GOV E RNOR
ASSEMBLY
GOVERNOR
SNAP RI NG
j m r r /
j9121
-
303
Fig. 17 Removing/Installing Governor Snap Ring
GOVERNOR
BODY A N D
DRIVE ASSEMBLY
J9221-39
Fig. 18 Removing/Installing Governor Body And
Drive Assembly
OUTPUT
SHAFT
GOVERNOR
DRIVE KEY
J9221-43
Fig. 19 Removing Governor Drive Key
FRONT
BEARI NG
S NAP RI NG
Fig. 20 Removing/Installing Front Bearing Snap
Ring

Fig. 21 Removing/Installing Output Shaft Front
Bearing
WARNING: THE NEXT STEP IN GEARTRAIN
DISASSEMBLY INVOLVES COMPRESSING THE DI-
RECT CLUTCH SPRING. IT IS EXTREMELY IMPOR-
TANT THAT PROPER EQUIPMENT BE USED TO
COMPRESS THE SPRING AS SPRING FORCE IS
APPROXIMATELY 800 POUNDS. USE SPRING COM-
PRESSOR TOOL C-6227-1 AND A HYDRAULIC-
TYPE SHOP PRESS WITH A MINIMUM RAM
TRAVEL O F 5-6 INCHES. THE PRESS MUST ALSO
HAVE A BED THAT CAN BE ADJUSTED UP OR
DOWN AS REQUIRED. RELEASE CLUTCH SPRING
TENSION SLOWLY AND COMPLETELY TO AVOID
PERSONAL INJURY.
(7) Mount geart rai n assembly in shop press
(8) Position Compressor Tool 6227-1 on clutch hub
(Fig. 22). Support output shaft flange wi t h steel press
plates as shown and center assembly under press
ram.
(9) Use Bushi ng Tool MB990891 (or similar size
tool) at top of Tool 6227-1 to help distribute load and
provide needed ext ra press length.
(10) Apply press pressure slowly. Compress hub
and spring far enough to expose clutch hub ret ai ni ng
ring and relieve spring pressure on clutch pack snap
ri ng (Fig. 22).
(11) Remove direct clutch pack snap ri ng first (Fig.
22).
(12) Remove direct clutch hub ret ai ni ng ri ng (Fig.
23).
(13) Release press load on clutch spring sl owl y
and compl etel y. Remove press tools and geart rai n.
(14) Remove direct clutch pack from hub (Fig. 24).
(15) Remove direct clutch hub and spring (Fig. 25).
(16) Remove sun gear and spring plate, pl anet ary
t hr ust beari ng and pl anet ary gear (Fig. 26).
(17) Remove overrunning clutch assembly wi t h ex-
pandi ng type snap ri ng pliers (Fig. 27). Insert pliers
Fig. 22 Removing Direct Clutch Pack Snap Ring
Fig. 23 Removing Direct Clutch Hub Retaining Ring
into clutch hub. Expand pliers to grip hub splines
and remove clutch with counterclockwise, twisting
motion.
(18) Remove t hr ust bearing from overrunning
clutch hub (Fig. 28).
(19) Remove overrunning clutch from hub (Fig.
28).

OVERDRIVE UNIT OVERHAUL4 2RH/4 6 RH 21 - 321
Fig. 24 Direct Clutch Pack Removal Fig. 27 Removing Overrunning Clutch Assembly
J9121-312
Fig. 26 Removing Sun Gear/Thrust
Bearing/Planetary Gear
21 - 330 OVERDRIVE UNIT OVERHAUL4 2RH/4 6 RH

DIRECT
CLUTCH
DRUM
PUNCH
8921-249
OUTER
RETAINING RING
J9121-293
Fig. 29 Marking Direct Clutch Drum And Annulus
Gear For Assembly Alignment
INNER
RETAINING
RING
DIRECT
CLUTCH
DRUM
Fig. 31 Removing Clutch Drum Outer Retaining
Ring
OUTPUT SHAFT-
ANNULUS
GEAR
J9121-292
Fig. 30 Removing Clutch Drum Inner Retaining Ring
(20) Mark position of annul us gear and direct
clutch drum for assembly alignment reference (Fig.
29). Use small center punch or scriber to make align-
ment mar ks.
(21) Remove direct clutch drum rear ret ai ni ng ri ng
(Fig. 30).
(22) Remove direct clutch drum outer ret ai ni ng
ri ng (Fig. 31).
(23) Mark annul us gear and output shaft for as-
sembly al i gnment reference (Fig. 32).
(24) Remove annulus gear from output shaft (Fig.
33). Use rawhide or plastic mallet to tap gear off shaft.
(25) Remove output shaft front beari ng if not pre-
viously removed.
OVERDRIVE UNIT CLEANING AND INSPECTION
Clean t he geart rai n (Fig. 34) and case components
(Fig. 35) wi t h solvent. Dry all part s except t he bear-
ings wi t h compressed air. Allow bearings to air dry.
Do not use shop towels for wiping part s dry unless
t he towels are made from a lint-free mat eri al . A suf-
PUNCH J9221-46
Fig. 32 Marking Annulus Gear And Output Shaft For
Assembly Alignment
OUTPUT
SHAFT
ANNULUS
GEAR
J9021-288
Fig. 33 Removing Annulus Gear
ficient quant i t y of lint (from shop towels, cloths,
rags, etc.) could plug t he transmission filter and fluid
passages.
OVERDRIVE
CLUTCH
PISTON
RETAINER
SPRI N G
PLATE
THRUST SUN PLANETARY GEAR
BE ARI NG GEAR
OV E R R UNNI NG CLUTCH
OUTER
RETAI NI NG RI NG
f
DIRECT CLUTCH
DRUM
INNER
RETAI NI NG RI NG
OVERDRIVE
CLUTCH PISTON
PISTON
THRUST
PLATE
(SELECTIVE)
CLUTCH HUB
SNAP RI NG
PISTON
THRUST
BEARI NG
CLUTCH PACK
RETAI NI NG
RI NG
OVERDRIVE
CLUTCH PACK
REACTI ON
PLATE
REACTION
S NAP RI NG
J9J21-289
SEAL
Fig. 34 Overdrive Geartrain Components (42RH Shown)
ACCESS PLATE
A N D GASKET
CASE GASKET
PLATE
SPACER
INSULATOR
DAMPER
WEI GHT
SHAFT
RETAI NI NG BOLT
PARK PAWL
SPRI NG
REACTI ON
PLUG A N D S NAP RI NG PARK LOCK ROD
J9121-290
Fig. 35 Overdrive Case And Park Lock Components

GOVERNOR GOVERNOR REAR BEARING OUTPUT SHAFT
Fig. 36 Output Shaft And
Discard t he old case gasket and seals. Do not at-
t empt to salvage these part s. They are not reusable.
Replace any of t he overdrive uni t snap rings if dis-
torted or damaged.
Minor nicks or scratches on components can be
smoothed wi t h crocus cloth. However, do not at t empt
to reduce severe scoring on any components wi t h
abrasive mat eri al s. Replace severely scored compo-
nent s; do not t ry to salvage t hem.
Check condition of t he park lock components and
t he overdrive case (Fig. 36).
Replace t he case if cracked, scored, or damaged.
Replace t he park lock pawl, plug, or spring if worn or
damaged. Re sure t he bullet at t he end of t he park
lock rod is in good condition. Replace t he rod if t he
bullet is worn or t he rod itself is bent or distorted.
Do not at t empt to st rai ght en t he rod.
Check t he bushings in t he overdrive case. Replace
t he bushings if severely scored or worn. Also replace
t he case seal if loose, distorted, or damaged.
Exami ne t he overdrive and direct clutch discs and
plates (Fig. 34). Replace t he discs if t he facing is
worn, severely scored, or burned and flaking off. Re-
place t he clutch plates if worn, heavily scored, or
cracked. Check t he lugs on t he clutch plates for
wear. The plates should slide freely in t he drum. Re-
place t he plates or drum if binding occurs.
Governor Components
Check condition of t he annul us gear, direct clutch
hub, clutch drum and clutch spring (Fig. 34). Replace
t he gear, hub and drum if worn or damaged. Replace
t he spring if collapsed, distorted, or cracked.
Be sure t he splines and lugs on t he gear, drum and
hub are in good condition. The clutch plates and
discs should slide freely in these components.
Inspect t he t hrust bearings and spring plate (Fig.
34). Replace t he plate if worn or scored. Replace t he
beari ngs if rough, noisy, brinneled, or worn.
Inspect t he planetery gear assembly and t he sun
gear and bushings (Fig. 34). If either t he sun gear or
t he bushings are damaged, replace t he gear and
bushings as an assembly. The gear and bushings are
not serviced separately.
The pl anet ary carrier and pinions must be in good
condition. Also be sure t he pinion pins are secure
and in good condition. Replace t he carrier if worn or
damaged.
Inspect t he overrunning clutch and race. The race
surface should be smooth and free of scores. Replace
t he overrunning clutch assembly or t he race if either
assembly is worn or damaged in any way.
Inspect t he output shaft and governor components
(Fig. 36). Replace t he shaft pilot bushing and i nner
bushi ng if damaged. Replace either shaft beari ng if
rough or noisy. Replace t he bearing snap ri ngs if dis-
torted or cracked.

OVERDRIVE UNIT OVERHAUL42RH/46RH 21 - 333
Check t he machined surfaces on t he output shaft.
These surfaces should clean and smooth. Very minor
nicks or scratches can be smoothed with crocus cloth.
Replace t he shaft if worn, scored or damaged in any
way.
Check condition of t he governor components. Re-
place t he governor drive seal rings if damaged. Be
sure t he drive ri ng grooves are in good condition.
Check operation of t he governor valve, weights and
shaft. The valves and weights should slide freely in
t he governor body (Fig. 36).
There are two governor component changes in
current overdrive unit units. The first i nvol ves
the governor val ve whi ch is now made of alumi-
num. The second i nvol ves the output shaft
whi ch has a spotface for governor val ve end
clearance. The new al umi num val ve is not inter-
changeabl e. It must onl y be used wi th an output
shaft that has the spotface for val ve end clear-
ance.
Inspect the governor support and t he two oil pres-
sure tubes (Fig. 36). The tubes are an integral
part of the support. Do not attempt to remove
them.
The oil tubes must not be pinched, kinked, col-
lapsed, or distorted. Blow t hem out with compressed
air to be sure they are clear. The tubes are designed
to be a slip fit in t he piston ret ai ner boss. Do not
modify t he tube ends in an effort to make t hem fit
tighter.
Replace t he governor support and t he oil tubes as
an assembly if either component is damaged.
Check condition of t he governor valve and weight
snap rings. Replace any snap ri ng t hat appears bent
or distorted. Replace any snap ri ng if its condition is
doubtful.
Inspect t he output shaft bushings (Fig. 37). The
small bushing is t he intermediate shaft pilot bush-
ing. The large bushi ng is t he overrunning clutch hub
bushing. Replace either bushing if scored, pitted,
cracked, or worn.
The bushings can be removed with "blind hole
puller tools" such as Snap-On set CG40CB for small
bushings and set CG46 for large bushings. New
bushings can be installed with tools from an all pur-
pose installer kit such as t he Snap-On A257 bushi ng
driver set.
OVERDRIVE GEARTRAIN ASSEMBLY
(1) Lubricate geart rai n components with Mopar
ATF Plus or Dexron II transmission fluid.
(2) Soak direct and overdrive clutch discs in t rans-
mission fluid before installation.
(3) Install new pilot bushing and clutch hub bush-
ing in output shaft if necessary (Fig. 37). Lubricate
new (or old) bushings with petroleum jelly.
(4) Install front beari ng and beari ng snap ri ng on
output shaft (Fig. 38)
Fig. 37 Output Shaft Bushing Location
(5) Align and install annul us gear on output shaft
(Fig. 38).
(6) Install annul us snap ri ng (Fig. 38).
Fig. 38 Installing Annulus Gear And Snap Ring
(7) Align and install clutch drum on annul us gear
(Fig. 39). Be sure drum is engaged in annul us gear
lugs.
(8) Install clutch drum outer ret ai ni ng ri ng (Fig.
31).
(9) Slide clutch drum forward and install i nner re-
t ai ni ng ring (Fig. 39).
(10) Install overrunning clutch on hub (Fig. 40).
Note that cl utch only fits one way. Shoul der on
cl utch shoul d seat in small recess at edge of
hub.
(11) Install t hr ust bearing on overrunning clutch
hub (Fig. 41). Use generous amount of petroleum
jelly to hold beari ng in place for installation. Bear-
ing fits one way only. Be sure beari ng is seated
squarely agai nst hub. Reinstall beari ng if it does
not seat squarely.

I NNER
RETAI NI NG
RI NG
ANNUL US
GEAR
J9121-294
Fig. 39 installing Clutch Drum Inner Retaining Ring
CLUTCH
HUB
OV E RRUNNI NG
CLUTCH
J9121-322
Fig. 40 Assembling Overrunning Clutch And Hub
BE SURE
THRUST BEARI NG
IS SEATED SQUARELY
AGAI NST CLUTCH HUB
CLUTCH
HUB
J9121-323
Fig. 41 Installing Overrunning Clutch Thrust
Bearing
(12) Install overrunning clutch (Fig. 42). Insert
snap r i n g pliers in hub splines. Expand pliers to grip
hub. Then install assembly with counterclockwise,
twisting motion.
CLUTCH
DRUM
OV E RRUNNI NG
CLUTCH
ASSEMBLY
EXPAN DING-TYPE
S NAP RI NG
PLIERS
OV E R R UNNI NG
CLUTCH ASSEMBLY
SEATED I N
OUTPUT SHAFT
CLUTCH
DRUM
ANNULUS
GEAR
J9121-314
Fig. 42 Installing Overrunning Clutch
(13) Install planetary gear in annul us gear (Fig.
43). Be sure planetary pinions are fully seated in
annul us gear before proceeding.
PLANETARY
GEAR
ANNULUS
GEAR
J9121-324
Fig. 43 Installing Planetary Gear

(14) Install direct clutch spring pl at e on sun gear.
Shoulder side of plate should face out ward and to-
ward front. Then secure plate to sun gear with snap
ring (Fig. 44).
SUN
Fig. 44 Sun Gear And Spring Plate Assembly
(15) Coat planetary t hrust beari ng and beari ng
contact surface of spring plate with generous amount
of petroleum jelly. This will help hold bearing in
place during installation.
(16) Install pl anet ary t hrust beari ng on sun gear
(Fig. 45). Slide bearing onto gear and seat it against
spring plate as shown. Beari ng fits one way only.
If it does not seat squarel y agai nst spring plate,
remove and reposition bearing.
J9121-326
Fig. 45 Installing Planetary Thrust Bearing
(17) Install assembled sun gear, spring plate and
t hrust bearing (Fig. 46). Be sure sun gear and t hrust
bearing are fully seated before proceeding.
(18) Align splines in hubs of pl anet ary gear and
overrunning clutch with Alignment tool 6227-2 (Fig.
47). Insert tool t hrough sun gear and into splines of
both hubs. Be sure alignment tool is fully seated be-
fore proceeding.
Fig. 46 Sun Gear Installation
(19) Install direct clutch spring. Be sure spring is
properly seated on spring plate (Fig. 47).
Fig. 47 Installing Direct Clutch Spring
(20) Assemble direct clutch pack for installation on
hub (Fig. 4 8) .
(21) Install direct clutch reaction plate on clutch
hub. Note that one side of reacti on plate is coun-
terbored. Be sure this side faces rearward.
Splines at rear of hub are rai sed slightly. Coun-
terbore in plate fits over raised splines. Pl ate
shoul d be flush wi th this end of hub (Fig. 49).
(22) Install remai nder of direct clutch components
as follows:
(a) Install first clutch disc on reaction plate fol-
lowed by a steel plate.
(b) Install remai ni ng discs and plates alternately
until required number of discs and plates are in-
stalled.
CLUTCH DISCS (6)
A
42RH
PRESSURE
PLATE
REACTION
PLATE
CLUTCH PLATES (5) CLUTCH
DISCS ( 8 )
46RH
PRESSURE
PLATE
REACTION
PLATE
COUNTERBORE
R E A C T I O N CLUTCH
PLATE PLATES (7)
Fig. 48 Direct Clutch Pack Components
(c) Check direct clutch pack. 42RH requires 6
discs and 5 steel plates. 46RH requires 8 discs and
7 steel plates (Fig. 48).
(d) Last clutch pack item installed is clutch pres-
sure plate. Be sure plate is installed with shoulder
side of plate facing upward (Fig. 50).
(23) Install clutch hub and clutch pack on direct
clutch spring (Fig. 51).
(24) Mount geart rai n assembly in shop press (Fig.
52)
WARNING: THE NEXT STEP IN GEARTRAIN AS-
SEMBLY INVOLVES COMPRESSING THE DIRECT
CLUTCH HUB AND SPRING. IT IS EXTREMELY IM-
PORTANT THAT PROPER EQUIPMENT BE USED
TO COMPRESS THE SPRING AS SPRING FORCE I S
APPROXIMATELY 8 00 POUNDS. USE SPRING COM-
PRESSOR TOOL C - 6 227 - 1 AND A HYDRAULIC-
TYPE SHOP PRESS WITH A MINIMUM RAM
TRAVEL OF 5-6 INCHES. THE PRESS MUST ALSO
HAVE A BED THAT CAN BE ADJUSTED UP OR
DOWN AS REQUIRED. RELEASE CLUTCH SPRING
TENSION SLOWLY AND COMPLETELY TO AVOID
PERSONAL INJURY.
J922M41
(25) Position Compressor Tool 6227-2 on clutch
hub (Fig. 52).
(26) Position Tool MB990891 or similar size tool on
top of compressor tool (Fig. 52). Similar size tool
DIRECT
CLUTCH
REACTION
PLATE
(FLUSH WITH
END OF HUB)
CLUTCH
HUB
J9121-329
Fig. 49 Correct Position Of Direct Clutch Reaction Plate
OVERDRIVE UNIT OVERHAUL4 2RH/ 4 IRH 21 - 337
DI RECT
CLUTCH
PRESSURE
PLATE
BE SURE SHOULDER
SI DE OF
PLATE FACES
UPWARD
CLUTCH
PACK
J9121-330
Fig. 50 Correct Position Of Direct Clutch Pressure
Plate
DI RECT
CLUTCH
PACK
CLUTCH
HUB
J9121-331
should have mi ni mum outside diameter of 3-1/2 inch,
mi ni mum wall thickness of 1/4 inch and be approxi-
mately 4 inches long.
(27) Slide direct clutch pack upwards on hub (Fig.
52) . Slide pack upward and set it partially on edge of
hub and compressor tool as shown in Figure 52.
SPECI AL TOOL
MB990891
SPECI AL
TOOL
6227-2
CLUTCH
HUB
SPECI AL
TOOL
6227-1
DI RECT
CLUTCH
PACK
CLUTCH
DRUM
J9221-2
Fig. 52 Mounting Geartrain Assembly In Shop Press
(28) Slowly compress clutch hub and spring (Fig.
53). Compress spring and hub only enough to expose
ri ng grooves for clutch pack snap ri ng and clutch hub
ret ai ni ng ring.
(29) Realign clutch pack on hub and seat clutch
discs and plates in clutch drum (Fig. 53).
SPECI AL
TOOL
6227-2
DI RECT
CLUTCH
PLATES/ DI SCS
Fig. 51 Installing Assembled Direct Clutch Pack And CLUTCH
Hub DRUM
J9221-3
Fig. 53 Seating Clutch Pack In Drum

(30) Install direct clutch pack snap ring (Fig. 54).
Be ver y s ur e s na p r i ng Is fully s eat ed In cl ut ch
d r u m r i ng gr oove.
(31) Install clutch hub ret ai ni ng ring (Fig. 55). Be
ver y s ur e r et ai ni ng r i ng Is fully s eat ed i n s un
gear r i ng gr oove.
(32) Slowly release press ram, remove compressor
tools and remove geart rai n assembly.
Fig. 54 Installing Direct Clutch Pack Snap Ring
J9221 - 5
Fig. 55 Installing Clutch Hub Retaining Ring
OVERDRIVE UNIT ASSEMBLY AND ADJUSTMENT
(1) Install front beari ng and snap ring on output
shaft (Fig. 56). Be s ur e l ocat i ng r i ng gr oove i n
be a r i ng i s t owa r d r e a r of shaft .
(2) Install governor drive key in output shaft (Fig.
56).
(3) Install new seal rings on governor drive. Be
sure ri ng ends are securely interlocked before pro-
ceeding (Fig. 57).
(4) Assemble governor drive and body. Be sure fil-
t er is properly seated and positioned in governor
body before t i ght eni ng at t achi ng bolts.
(5) Assemble governor i nner and outer weights
and spring. Then install weight assembly in governor
Fig. 56 Front Bearing And Drive Key Installation
GOVERNOR
BODY
GOVERNOR
DRIVE
Fig. 57 Governor Drive Seal Rings
Fig. 58 Installing Governor Weight Assembly
body (Fig. 58). Be sure all ret ai ni ng snap rings are
securely seated.

(6) Install governor assembly on output shaft (Fig.
59). Be sure drive key is fully engaged drive slot and
is not displaced duri ng installation.
Fig. 59 Installing Governor Assembly
(7) Align shaft holes in governor body and output
shaft and i nst al l governor valve and shaft (Fig. 16).
Be very sure that E-clip retainer at each end of
governor val ve shaft is securel y engaged.
(8) Install governor snap ri ng (Fig. 17).
(9) Install output shaft rear bearing in case and in-
stall beari ng snap ring. Be sure snap ri ng is fully
seated.
(10) Position park pawl and spring in case and in-
stall park pawl shaft (Fig. 14). Verify t hat spring end
is hooked to pawl and st rai ght end of spring
(11) Install pawl shaft ret ai ni ng bolt. Tighten bolt
(12) Install park lock reaction plug. Note that
pl ug has l ocati ng pin at rear (Fig. 6 0 ) . Be sure
pi n is s eat ed i n hol e in case before installing
snap ring.
REACTION
Fig. 60 Reaction Plug Locating Pin And Snap Ring
(13) Install reaction plug snap ring (Fig. 61). Com-
press snap ring only enough for installation; do
not distort it.
PLIERS 8921-240
Fig. 61 Reaction Plug And Snap Ring Installation
(14) Install alignment clip on governor t ubes (Fig.
62). Slide clip up against shoulder on each tube.
GOVERNOR
Fig. 62 Positioning Governor Tube Alignment Clip
(15) Install governor support and pressure tubes in
case (Fig. 63).
Fig. 63 Installing Governor Support And Pressure
Tubes
(16) Install governor support snap ri ng (Fig. 64).
S N A P / ^ S ^ ^ S ^ / ^S C R E WD R I V E R
R I N G
7
8921-264
Fig. 64 Installing Governor Support Snap Ring
(17) Install output shaft front beari ng locating ri ng
in case (Fig. 65).
OUTPUT SHAFT
FRONT BEARI NG
LOCATI NG RI NG
J9121-339
Fig. 65 Front Bearing Locating Ring Installation
(18) Support geart rai n on Tool 6227-1 (Fig. 66). Be
sure tool is securely seated in clutch hub.
(19) Install overdrive unit case over geartrain (Fig.
66).
(20) Expand front beari ng locating ri ng with snap
ri ng pliers. Then slide case downward unt i l locating
ri ng locks in beari ng groove and release snap ring.
(21) Install locating ri ng access plate and gasket in
overdrive uni t case (Fig. 9).
(22) Install overdrive clutch components as follows:
(a) Install reaction ri ng first. Reaction ri ng is
flat with notched ends (Fig. 67).
(b) Install wave spring on top of reaction ring.
Reacti on ring and wave ring both fit in same
ring groove. Use screwdriver to seat each ri ng se-
curely in groove.
(c) Install reaction pl at e (Fig. 68).
(d) Install first clutch disc followed by first
clutch plate.
SPECIAL
TOOL
6227-2
CASE
GEARTRAI N
SPECIAL
TOOL
6227-1
J9221-6
Fig. 66 Installing Overdrive Case On Geartrain
(e) Install remai ni ng clutch discs and plates in
same order.
(f) Verify clutch pack before proceeding:
gas engine version of 42RH/46RH, requires 4
clutch discs, 3 steel plates, 1 reaction plate and 1
pressure plate.
diesel engine version of 46RH, requires 5 clutch
discs, 4 steel plates, 1 reaction plate and 1 pressure
plate.
(g) Install clutch pack pressure plate (Fig. 68).
(h) Install clutch pack wire-type ret ai ni ng ri ng
(Fig. 67).
WAVE
SPRI NG
REACTI ON
RI NG
RETAI NI NG RI NG
(WIRE-TYPE) J9121-470
Fig. 67 Overdrive Clutch Ring Identification
(23) Place overdrive uni t in vertical position.
Mount uni t in vise or in workbench with appropriate
size mount i ng hole cut into it. Be sure uni t is facing
upward for access to direct clutch hub.

NP205 TRANSFER CASE 21 - 341
REACTI ON
PLATE
CLUTCH DI SCS (4)
J9321-227
Fig. 68 Overdrive Clutch Pack (Gas Engine Version
Shown)
(24) Determine correct thickness i ntermedi ate
shaft spacer as follows:
(a) Insert Special Tool 6312 through sun gear, plan-
etary gear and into pilot bushing in output shaft. Be
sure tool bottoms against planetary shoulder.
(b) Position Gauge Tool 6311 across face of over-
drive case (Fig. 69). Then position Dial Caliper
C-4962 over gauge tool.
(c) Extend sliding scale of dial caliper downward
through gauge tool slot until scale contacts end of
Alignment Tool 6312. Lock scale in place. Remove
dial caliper tool and note distance measured (Fig. 69).
(d) Select proper thickness end play spacer from
spacer chart based on distance measured (Fig. 70).
(e) Remove Alignment Tool 6312.
SPECIAL
TOOL 6311
SPECIAL
TOOL 6312
J9221-47
Fig. 69 Shaft End Play Measurement
(25) Determine correct thickness overdri ve pi ston
thrust plate as follows:
(a) Position Gauge Tool 6311 across face of over-
drive case. Then position Dial Caliper C-4962 over
gauge tool (Fig. 71).
(b) Measure distance to clutch hub t hr ust bear-
ing seat at four points 90 apart. Then average
measurement s by adding t hem and dividing by 4.
E nd Pl a y
M e a s u r e me n t
( I nches)
S pacer T hi ckness
(I nches)
.7336 - .7505 .158 - .159
.7506 - .7675 .175 - .176
.7676 - .7855 .193 - .194
.785 6- .8011 .211 - .212
J91 21 - 34 1
Fig. 70 Intermediate Shaft End Play Spacer Selection
(c) Select and install required thrust plate from in-
formation provided in thrust plate chart (Fig. 72).
(26) Leave Alignment Tool 6227-2 in place. Tool
will keep pl anet ary and clutch hub splines in align-
ment until overdrive uni t is ready for installation on
transmission.
(27) Set overdrive uni t aside for final assembly of
transmission.
Fig. 71 Overdrive Piston Thrust Plate Measurement
E nd Pl oy
M e a s ur e me nt
(I nches)
S pacer T hi ckness
(I nches)
1.7500 - 1.7649 .108 - .110
1.7650- 1.7799 .123 - .125
1.7800 - 1.7949 .138 - .140
1.7950 - 1.8099 .153 - .155
1.8100 - 1.8249 .168 - .170
1.8250 - 1.8399 .183 - .185
1.8400 - 1.8549 .198 - .200
1.8550 - 1.8699 .213 - .215
1.8700 - 1.8849 .228 - .230
1.8850 - 1.8999 .243 - .245
J9121-342
Fig. 72 Overdrive Piston Thrust Plate Selection
21 - 34 2 NP205 TRANSFER CASE

NP205 TRANSFER CASE
INDEX
page
Recommended Lubricants 34 2
Service Di agnosi s 34 2
Shift Linkage Adjustment 34 4
Speedometer Service 34 5
GENERAL INFORMATION
The NP205 transfer case is a heavy duty, part -t i me
uni t with constant mesh, helical gears. The gears are
mounted in a one-piece, cast iron gear case.
The NP205 provides four operating ranges which
are: 4-wheel drive high, neut ral , 2-wheel drive hi gh
and 4-wheel drive low (Fig. 1).
The transfer case gears rotate on shafts supported
by ball and roller bearings. Sliding clutch sleeves
and shift forks are used to engage or disengage t he
drive gears.
The NP205 geart rai n provides high and low ranges
in 4-wheel drive mode. The high range has a 1:1 ra-
tio for normal operation and a low range with a re-
duction ratio of 1.96:1 for ext ra pulling power in off
road situations.
In two-wheel drive range, t he transfer case front
output shaft drive gear is disengaged. Torque is not
t ransmi t t ed to t he front propeller shaft.
Fig. 1 NP205 Transfer case
RECOMMENDED LUBRICANTS
Recommended lubricants for t he NP205 transfer
case include multi-purpose gear lubricants and single
weight engine oils.
Engi ne oil should be API classification SF/CC or
SF/CD. Use SAE 30 at ambi ent t emperat ures below
0 C ( + 32 F) and SAE 50 at ambient t emperat ures
above t hi s point.
page
Transfer Case Assembl y 34 8
Transfer Case Di sassembl y . . . . . . . . . . 34 5
Transfer Case Identification 34 2
Transfer Case Installation 34 5
Transfer Case Removal 34 5
SAE multi-purpose gear lubricants wi t h an API
grade rat i ng of GL 5 are recommended for severe
duty operation. SAE grades 80, 75W-90, 90, 80W-90,
140 and 80W-140 are all acceptable.
Use SAE 80 or 75W-90 when ambi ent tempera-
t ures are below -23 C (-10 F). Use SAE 90, or
80W-90 when ambient t emperat ure is above t he
stated range.
SAE 140, or 80W-140 can be used when severe ser-
vice is anticipated, or when ambient t emperat ures
are expected to exceed +32 C (90 F).
Transfer Case Shift Linkage Lubrication
The transfer case shift linkage pivot and contact
surfaces should be lubricated with engine oil at rec-
ommended intervals. Lubrication frequency for t he
linkage is described in Lubrication And Maintenance
Group O.
TRANSFER CASE IDENTIFICATION
The NP205 identification t ag is attached to t he
PTO cover on t he driver side of t he transfer case.
The t ag contains transfer case manufacturing and as-
sembly part numbers. Refer to t hi s information when
ordering service replacement part s.
SERVICE DIAGNOSIS
The most frequent causes of transfer case malfunc-
tions are:
improper operation
insufficient lubricant
non-recommended lubricant
misadjusted shift linkage
improper assembly after repair.
The general problems and causes of transfer case
malfunctions are outlined below.
LOW LUBRICANT LEVEL
A low lubricant level is usually t he result of loose
components, leakage, or improper checking and/or
filling techniques.
Lubricant leaks can occur at t he shaft seals, case
vent, or gasket joints. Most leaks will be evident by
t he presence of lubricant around t he leakage point.
However, be sure t he leakage is actually from a
transfer case component.

Leakage from other sources (engine, transmission,
etc.) can be blown back onto t he t ransfer case by ai r
flow under t he vehicle. A blocked transfer case vent
can also cause leakage at t he shaft seals due to in-
t ernal pressure build up.
Overfilling t he transfer case can force fluid out t he
vent and be mi st aken for a leak. Correct fluid level
checking methods should prevent overfill problems.
Checking Fluid Level
The correct method of checking transfer case fluid
level requires t hat t he vehicle be level.
If fluid level is checked with t he vehicle parked on
t he shop floor, be sure t he floor area used is level. If
a hoist is used, a drive-on, or swivel ar m type is pre-
ferred.
Allow t he transfer case fluid to settle for a mi nut e
or so before checking. Correct fluid level is to t he
bottom edge of t he fill plug hole.
HARD SHIFTING
Hard shifting is generally caused by:
misadjusted or binding linkage
loose linkage or driveline components
torque loads caused by 4WD operation on hard
paved surfaces
improper shifting techniques
lack of lubricant which caused i nt ernal wear and
damage.
Loose linkage or driveline components are a resul t
of improperly tightened, stripped, or missing fasten-
ers. Remember t hat loose crossmember and mount i ng
part s can also generate a hard shift condition.
Torque loads in t he transfer case can cause hard
shifting or even prevent shifting. Such loads are gen-
erally a product of extensive operation on hard,
paved surfaces in 4WD range, unequal size tires, or
by mismatched front/rear axle gear ratios.
Linkage adjustment should be performed as de-
scribed in t he service section. Improper shift and op-
erat i ng techniques can be corrected by instructing
t he driver. Int ernal component damage will require
overhaul to correct.
Fai l ure to lubricate t he shift l i nkage at recom-
mended intervals will cause t he l i nkage to bind. If
bind is severe enough to cause hard shifting, t he
linkage will have to be removed in order to correct
t he condition. The linkage can be soaked in auto-
matic transmission fluid if necessary. The fluid will
break up accumulated rust and corrosion.
NOISE
Some transfer case operating noise is normal. The
rot at i ng gear t rai n can produce sounds t hat may be-
come audible at hi gher speeds and loads. However,
unusual noise is an indicator t hat i nt ernal compo-
nent s may be worn or damaged.
Low lubricant levels are a frequent cause of noisy
operation. Insufficient lubricant will lead to over-
heating, subsequent damage to beari ng and gear sur-
faces and hard shifting.
Transfer case beari ng noise is higher in pitch t han
gear noise. If t he uni t is noisy in 4WD range only,
t he front shaft beari ngs are probably at fault. If t he
uni t is noisy in all ranges, an overhaul will be nec-
essary to locate t he faulty bearing.
Gear noise is lower in pitch and usually most no-
ticeable when engaged and under load. Gear noise in
4WD drive range only is an indicator t hat the front
shaft gears are damaged. Noise in all ranges could be
t he idler or drive gears. An overhaul will be neces-
sary to determine which is at fault.
Frequently, suspected transfer case noise may actu-
ally originate from anot her driveline component. The
proximity of other driveline components can some-
times make it difficult to pinpoint t he noise source.
TRANSFER CASE OPERATIONAL CHECK
The transfer case should not be removed unt i l di-
agnosis indicates t he uni t has actually malfunc-
tioned. If a transfer case problem is suspected, check
and verify operation before at t empt i ng repair. A
transfer case operational check may reveal t hat a
problem is actually rel at ed to another driveline com-
ponent.
(1) Raise vehicle on a hoist t hat will allow all four
wheels to rot at e.
(2) Check lubricant level. If lubricant level is low,
check for leaks at t he beari ng and seal retainers,
yokes, drain/fill plugs, PTO cover and vent.
(3) If vehicle is equipped with locking hubs, en-
gage hubs.
(4) St art engine, shift transmission into gear and
operate transfer case in all ranges. Observe propeller
shaft action, shift efforts and operational sound lev-
els as follows:
(a) Only t he rear propeller shaft should rot at e in
two-wheel drive. Both propeller shafts should both
rotate in four-wheel drive high and low ranges.
(b) If t he front propeller shaft did not rotate in
either four-wheel drive range, t he transfer case
shift components may be worn or damaged. Or, if
t he front shaft did rot at e but t he front wheels did
not, check t he front axle shift mechanism and t he
locking hubs (if equipped).
(c) If both propeller shafts rot at e in four-wheel
drive but t he wheels on one axle did not rotate, t he
problem is in t he axle.
(d) If nei t her propeller shaft rotates in any
range, t he problem is in t he transmission or t rans-
fer case. To determine which component is at fault,
proceed to next step.
(5) Determine if fault is with transfer case or
transmission as follows:
21 - 344 NP205 TRANSFER CASE

(a) Raise vehicle and disconnect both propeller
shafts at the transfer case.
(b) Position supports under the transmission.
(c) Remove the bolts/nuts attaching the transfer
case adapter to the crossmember and transmission.
(d) Support the transfer case with a transmission
jack and slide the transfer case and adapter clear
of the transmission output shaft.
(e) Have helper start engine and shift transmis-
sion into gear. If transmission output shaft rotates,
problem is with transfer case. If transmission shaft
does not rotate, problem is with transmission or re-
lated component.
SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into neutral.
(2) Remove screws attaching shift lever boot and
seal to floor pan (Fig. 2) .
(3) Slide shift lever boot and seal upward for vi-
sual access to shift gate. Verify that lever is in Neu-
tral position.
(4) Loosen bolts"attaching shift lever bracket to
adapter (Fig. 3).
Fig. 2 Shift Lever Boot And Seal
Fig. 3 NP205 Shift Linkage

NP20I TRANSFER CASE 21 - 34 i
(5) Verify t hat transfer case range lever is in Neu-
tral.
(6) Move shift lever bracket forward and retighten
bracket bolts (Fig. 3). Shift rod should not bind in
shift lever and range lever. Rod should be slip-fit
both levers.
(7) Shift transfer case into 4H range. Shift rod
should now be tension-fit in each lever. Shift lever
should be in 4H det ent in gat e and range lever
should be fully into 4H position.
(8) Shift transfer case into 2H and 4L ranges to
verify correct adjustment.
SPEEDOMETER SERVICE
The speedometer driven gear, adapter and vehicle
speed sensor can be serviced wi t h the transfer case in
the vehicle.
SPEEDOMETER COMPONENT REMOVAL/
INSTALLATION (FIG. 4)
(1) Shift transfer case into Neut ral .
(2) Raise vehicle.
(3) Disconnect wires at vehicle speed sensor.
(4) Loosen and disconnect coupling nut t hat at-
taches speed sensor to adapter. Then loosen and dis-
connect coupling nut at t achi ng adapter to driven
gear.
(5) Remove vehicle speed sensor and speedometer
adapter.
(6) Loosen and remove speedometer driven gear.
(7) Lubricate driven gear with engine or gear oil
and install gear in transfer case. Tighten gear to 11
(8) Install adapter and speed sensor. Tighten cou-
pling nut s to 17 Nm (150 in. lbs.) torque.
(9) Connect wires to speed sensor.
(10) Lower vehicle.
TRANSFER CASE REMOVAL
(1) Raise vehicle.
(2) Remove drain plug and drai n transfer case lu-
bricant.
(3) Disconnect vehicle speed sensor wires.
(4) Mark front/rear propeller shafts and yokes for
installation reference.
(5) Disconnect and remove propeller shafts. Or dis-
connect shafts at transfer case yokes. Then move
shafts aside for working clearance and secure t hem
to frame rails with wire.
(6) Disconnect transfer case shift lever from range
lever on transfer case.
Secure transfer case to jack wi t h safety chains.
mission adapter.
(9) Slide transfer case rearward until it is clear of
transmission output shaft.
DISTANCE
SENSOR
ADAPTER
DRIVEN
GEAR J9021-151
Fig. 4 Speedometer Components.
(10) Lower jack and move transfer case from under
vehicle.
(11) Remove old gasket mat eri al from transmission
adapter.
TRANSFER CASE INSTALLATION
(1) Apply Mopar perfect seal, silicone sealer, or
Permat ex No. 2 sealer to both sides of transfer case-
to-transmission gasket. Then position gasket on
transmission.
(2) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
wi t h transmission output shaft. Align splines by ro-
t at i ng transfer case rear output shaft yoke if neces-
sary. Do not install any transfer case a t t a c hi ng
nuts until the transfer case is compl etel y seated
agai nst the transmission.
(3) Install and t i ght en transfer case at t achi ng nut s
to 47 N*m (35 ft. lbs.).
(4) Install r ear crossmember.
(5) Remove jack stand from under transmission.
(6) Align and connect propeller shafts.
(7) Connect vehicle speed sensor wires.
(8) Connect transfer case shift lever to range lever.
Tighten lever locknut to 10 Nm (90 in. lbs.).
(9) Fill transfer case with recommended lubricant.
(10) Install transfer case fill plug.
(11) Install skid plate and skid plate crossmember.
(12) Lower vehicle.
TRANSFER CASE DISASSEMBLY (FIG. S)
REAR RETAINER AND OUTPUT SHAFT
REMOVAL/DISASSEMBL Y
(1) Loosen rear yoke nut unt i l only 2-3 t hreads are
holding nut on shaft.
(2) Remove bolts at t achi ng rear bearing ret ai ner to
case.
(3) Pull yoke rearward to st art rear output shaft
out of clutch.
(4) Remove rear yoke nut, washer, seal washer and
yoke.
LEGEND FOR NP205 TRANSFER CASE
Y OK E NUT
W ASH E R
SE AL W ASH E R
REAR Y OK E
OI L SE AL
REAR SE AL RETAI NER
GASK E T
SN AP RI N G
RE AR OUTPUT SH AF T BE ARI N G
SPE E DOME TE R GE AR
BE ARI N G RE TAI NE R - RE AR
V E NT TUBE CON N E CTOR
GASK E T
REAR OUTPUT SH AF T SUPPORT
BE ARI N G
LOW GE AR RE TAI NI NG RI N G
TH RUST W ASH E R ( 3/ 1 6 " THICK)
THRUST W ASH E R (1/ 16 " THICK)
LOW GE AR ROLLER BE ARI N GS
[64)
BE ARI N G SPACER
LOW GE AR - RE AR SH AF T
TH RUST W ASH E R (1/ 16 " THICK)
RE AR OUTPUT SH AF T
THRUST W ASH E R PI N
SLI D I N G CLUTCH
PILOT BE ARI N G ROLLERS (15)
PILOT BE ARI N G TH RUST
W ASH E R
LOCK RI N G
INPUT GE AR
IDLER SH AF T COV E R
GASK E T
IDLER SH AF T
IDLER GE AR BE ARI N GS
BE ARI N G RACE S
BE ARI N G SPACE R
IDLER GE AR
IDLER GE AR BE ARI N G SH I MS
W ASH E R
IDLER SH AF T LOCK NUT
THRUST W ASH E R PI N
F RONT OUTPUT SH AF T
SLI DI NG CLUTCH
H I GH GE AR
THRUST W ASH E R
F RONT OUTPUT SH AF T F RONT
BE ARI N G
BE ARI N G SN AP RI N G
F RONT OUTPUT SH AF T REAR
BE ARI N G
BE ARI N G RE TAI NE R - F RONT
GASK E T
RE TAI NI NG RI N G
THRUST W ASH E R ( 3/ 1 6 " THICK)
LOW GE AR - F RONT SH AF T
LOW GE AR ROLLER BE ARI N GS
(S3.
i RI NG SPACER
F LANGE
OI L SE AL
F RONT SE AL RETAI NER
GASK E T
D RAI N PLUG

^

CASE M AGN E T AN D CLIP
FILL PLUG
PTO COV E R AN D GASK E T
GE AR CASE
SHIFT RAIL DETENT BALLS
AN D SPRI N GS
4 W D I NDI CATOR LIGHT
SWI TCH AN D GASK E T
SHIFT F ORK AN D RAI L - RE AR
W H E E L
I NTE RLOCK PI NS (2)
FORK-TO-RAIL LOCK PI N
SHIFT RAIL OI L SE ALS
SHIFT RAIL LI NK
RE TAI NI NG CLIP (21
LINK-TO-RAIL RE TAI NI NG PI N
3
HIFT FORK AN D RAIL -
F RONT W H E E L
I NTE RLOCK H OLE PLUGS (4)
F RONT OUTPUT SHAFT
BE ARI N G
BE ARI N G SN AP RI N G
INPUT SH AF T SN AP RI N G
ADAPTE R OI L SE AL (2)
GASK E T
TRANSF E R CASE ADAPTE R
ADAPTE R SLEEV E
SLEEV E RE TAI NI NG RI N G
GASK E T
TRAN SM I SSI ON ADAPTE R
J9021-14 9
(5) Remove rear ret ai ner, rear output shaft and
gears as assembly.
(6) Remove rear seal ret ai ner from bearing re-
tainer.
(7) Remove snap ring.
(8) Remove rear beari ng ret ai ner.
(9) Remove rear bearing, speedometer gear, shaft
support bearings, t hr ust washer pin and low gear
from rear output shaft (Fig. 5) .
(10) Remove lock ring, t hrust washer and pilot
bearing rollers from rear output shaft (Fig. 5).
FRONT OUTPUT SHAFT RETAINER REMOVAL
(1) Remove front yoke nut , washer and flange (Fig.
5).
(2) Remove front seal ret ai ner and gasket.
(3) Remove PTO cover and gasket.
(4 ) Remove det ent plug and 4 WD indicator light
switch from case (Fig. 5).
(5) Remove shift rail detent springs and balls (Fig.
5) . Use pencil magnet to remove these components.
(6) Remove bolts at t achi ng front bearing ret ai ner
to case.
(7) Tap front output shaft with plastic mallet to
loosen it. Then remove shaft, ret ai ner and gears (Fig.
6).
(8) Remove shaft snap ri ng (Fig. 7).
(9) Remove t hrust washer, gear, bearings and
spacer.
HAMMER
FRONT
OUTPUT
SHAFT
REAR
BEARI NG
RETAINER
RH320
Fig. 6 Removing/Installing Front Output Shaft
SHIFT RAIL, IDLER GEAR, INPUT GEAR AND
FRONT SHAFT REMOVAL
(1) Remove adapter and gasket.
(2) Remove idler shaft nut and washer.
(3) Remove idler shaft cover plate and gasket.
21 - 348 NP20S TRANSFER CASE
Fig. 7 Removing/installing Front Shaft Snap Ring
(4) Remove cup plugs at top of case for access to shift
fork lock pins. Use small punch to remove plugs.
(5) Place shift rails in Neut ral position.
(6) Remove lock, pins from shift forks wi t h long
handl e easy-out tool (Fig. 8).
Fig. 8 Removing/Installing Shift Fork Lock Pins
(7) Remove pins at t achi ng shift rai l link and re-
move link.
(8) Remove shift forks and sliding clutches.
(9) Remove snap ring, t hr ust washer and beari ng
from front shaft.
(10) Remove front shaft and high gear.
(11) Remove i nput gear, bearing, seals and washer.
(12) Loosen and remove idler shaft with plastic
mallet (Fig. 9).
(13) Tilt case, roll idler gear toward front shaft open-
ing in case and remove gear through this opening.
(14) Remove and ret ai n idler shaft shims. Tie
shims together to avoid losing them.
(15) Remove beari ng cups and beari ngs from idler
gear.
4
Fig. 9 Idler Shaft Removal
(16) Remove interlock pins from inside case. Re-
move pins t hrough PTO cover opening.
(17) If front output shaft rear beari ng must be re-
placed, replace t he beari ng and ret ai ner as an assem-
bly only.
TRANSFER CASE ASSEMBLY
Lubricate t he transfer case gears and shafts with
gear oil duri ng assembly. Use petroleum jelly to pre-
lubricate and hold bearings in place duri ng installa-
tion.
Use new gaskets and seals throughout. Do not re-
use these components. Replace snap rings if distorted
or damaged and use new yoke locknuts to secure t he
yoke and flange.
(1) Install beari ng cups in idler gear with shop
press (Fig. 10).
(2) Assemble idler gear, gear bearing cones, bear-
ing spacer and shims on Shaft Tool DD1272 (Fig. 10).
(3) Check gear end play (Fig. 10). End play should
be 0.000 to 0.05 mm (0.000 to 0.002 in.). Add or re-
move shims as needed to adjust end play.
(4) Press shift rail seals into case. Seals are wiper-
type and should be installed with seal lip facing out-
ward.
(5) Install assembled idler gear assembly and shaft
tool in case. Insert assembly t hrough front shaft
bore, large end first. Tilt case at 45 angle to ease
beari ng installation at boss (Fig. 11).
(6) Install idler shaft. Insert shaft from large bore
side and t ap shaft into gear and bearings with dead-
blow hammer. Remove shaft al i gnment tool as idler
shaft pushes it out of gear and case.
(7) Install idler shaft washer and ne w locknut.
Check end play and free rotation. Tighten locknut to
203 N-m (150 ft. lbs.).
(8) Install front beari ng and snap ri ng on i nput
gear.
(9) Assemble front output shaft. Install gears, slid-
ing clutch, bearings, t hr ust washer pin, t hrust wash-
ers, snap ri ng and ret ai ner on front output shaft.
1

NP24 1 TRANSFER CASE 21 - 349
Fig. 11 Installing Idler Gear
(10) Install interlock pins through large case bore
or PTO opening,
(11) Install input gear in case. Then install sliding
clutch on i nput gear and position shift fork in clutch.
(12) Install rear wheel shift rail into case (from
back), wi t h slotted end first and detent notches fac-
ing up (Fig. 8). Then push rail t hrough shift fork and
into opposite end of case.
(13) Install front output shaft in case.
(14) Install front wheel shift fork in sliding clutch
on front shaft. Then install front wheel shift rai l into
case and t hrough shift fork.
(15) Secure shift forks to shift rails with new lock
pins. Install pins t hrough small bores at top of case.
(16) Install front output shaft beari ng ret ai ners.
Be sure oil drain slot in bearing retainer is
al i gned wi th drain hol e i n case bef or e tightening
bolts. Use new gaskets and apply sealer to bolt
t hreads before installation. Use ext ra gasket on re-
t ai ners if necessary.
(17) Install flange on front shaft. Install seal washer
on shaft and install flange locknut finger tight.
(18) Install washer, seals gasket and adapter on
i nput shaft (Fig. 5).
(19) Install shift l i nk and link ret ai ni ng pins, clips.
(20) Assemble rear output shaft. Install gears,
bearings and spacers (Fig. 5).
(21) Install new snap ring. Tap ri ng to seat it and
check end play. End play should be 0.05 to 0.68 mm
(0.002 to 0.027 in.).
(22) Install pilot beari ng rollers in rear output
shaft. Use as much petroleum jelly as needed to hold
beari ng rollers in place.
(23) Install pilot beari ng t hr ust washer and new
snap ring.
(24) Install retainer on rear output shaft install
speedometer gear and spacer, install bearing (Fig. 12).
Fig. 12 Assembling Rear Retainer And Output Shaft
(25) Install ret ai ner and shaft assembly. Be sure
oil dr a i n slot in r et ai ner i s al i gned wi th dr a i n
hol e in case. Use one or two ret ai ner gaskets de-
pending on clearance. Tighten ret ai ner bolts to 54
Nm (40 ft. lbs.).
(26) Install seals in front and rear seal ret ai ners.
Position gaskets on case and install ret ai ners over
shafts and against case. Tighten bolts to 54 Nnn (40
ft. lbs.).
(27) Install yoke and flange. Tighten yoke and
flange nut s to 176 N (130 ft. lbs.).
(28) Install detent balls, springs, plugs, cup plugs
and 4WD indicator light switch.
(29) Install drain plug.
(30) Fill transfer case to bottom edge of fill plug
hole wi t h recommended lubricant.
(31) Install fill plug.

N P2 4 1 TRAN SF E R CASE
I NDE l
page
Checki ng Fluid Level 351
Component Cleaning and Inspection 359
Fluid Drain/Refill 351
Recommended Lubricant . . . . . . . . . . . . . . . . . . 350
Service Di agnosi s . . . . . . . . . . . . . . . . . . . . . . . 350
Shift Linkage Adjustment 354
Speedometer Adapter/ Distance Sensor Service . 352
page
Speedometer Gear, Shaft Seal , Bearing and Retainer
Service 352
Transfer Case Assembl y . . . . . . . . . . . . . . . . . . 36 1
Transfer Case Bearing Replacement . . . . . . . . . 36 0
Transfer Case Di sassembl y . . . . . . . . . . . . . . . . 356
Transfer Case Identification . . . . . . . . . . . . . . . . 350
Transfer Case Installation . . . . . . . . . . . . . . . . . 356
Transfer Case Removal 356
GENERAL INFORMATION
The NP241 is a part-time transfer case with a low-
range gear system. It has t hree operating ranges
plus a Neut ral position. The low range system pro-
vides a gear reduction ratio for increased low speed
torque capability. NP241 operating ranges are:
2-high, 4-high and 4-low.
The NP241 has an al umi num, two-piece gear case.
Drive sprockets and an interconnecting drive chain
are used to t ransmi t engine torque to t he propeller
shafts.
Four-wheel high and low ranges are undifferenti-
ated. The transfer case is not designed for continuous
operation in 4WD range on hard or paved surfaces.
Four wheel drive ranges are recommended for off
road operation, or on snow covered or similar low
traction surfaces.
A front axle disconnect system is used to achieve
two-wheel drive mode. The axle disconnect vacuum
motor is actuated by a vacuum switch on t he transfer
case. The switch is operated by t he transfer case
range rod.
Two-wheel drive range is used for on road, high-
way operation. The four-wheel drive ranges are for
off road operation or when t he vehicle is driven on
paved road surfaces covered by snow, ice or similar
low traction elements.
TRANSFER CASE IDENTIFICATION
An identification t ag (Fig, 1) is attached to t he rear
case of each NP241 transfer case. The t ag provides
t he transfer case model number, assembly number,
serial number, and low range ratio.
The transfer case serial number also represents t he
dat e of build. For example, a serial number of
9-10-92 would represent September 10, 1992.
Transfer case operating ranges are selected wi t h a
floor-mounted shift lever. The shift lever is connected
to t he transfer case range lever by an adjustable
linkage rod (Fig. 2). A st rai ght line shift pat t ern is
used. Range positions are marked on t he gearshift le-
ver knob.
Fig. 1 NP 241 Transfer Case
A synchronizer assembly in t he transfer case al-
lows t he uni t to be shifted between 2H and 4H
ranges while t he vehicle is in motion. The vehicle
should be stopped before shifting into 4L range.
RECOMMENDED LUBRICANT
Recommended lubricant for t he NP241 is Mopar
ATF Plus, type 7176, or Dexron II automatic t rans-
mission fluid. Use either fluid for topping off t he
level, or refilling after service, or normal fluid
changes.
Do not use anti-friction additives or similar prod-
ucts in t he NP241 transfer case. Use t he recom-
mended lubricant only.
NP241 transfer case lubricant should be changed
at t he intervals specified in t he Maintenance Sched-
ule or after service repairs.
SERVICE DIAGNOSIS
Before at t empt i ng to repair a suspected transfer
case malfunction, check all other driveline compo-
nent s beforehand.
The actual cause of a problem may be related to
such items as: front hubs, axles, propeller shafts,
wheels and tires, transmission, or clutch instead. If
all other driveline components are in good condition

SERVICE DIAGNOSIS
TRAN SF E R C ASE
D I F F I CULT TO S H I R
OR W I L L N OT SH I F T
I N TO D E SI RE D
RA N GE
TRAN SF E R C A S E
N OI S Y I N AL L
D RI V E M OD E S
N OI S Y I N - O R
J U M PS OUT OF
F OUR- W H E E L - D RI V E
L OW RA N GE
L UBRI C AN T
L E A K I N G F ROM
OUTPUT SH AF T
SE AL S OR F ROM
V E N T
A B N ORM A L
TIRE W E A R
(a) Vehicle speed too great t o permit
shifting.
(b) If vehicle was operated for extended
period in 4H mode on dry paved
surface, driveline torque load may
cause difficulty.
(c) Transfer case external shift linkage
binding.
(d) Insufficient or incorrect lubricant.
(e) Internal components binding, worn or
damaged.
(a) Insufficient or incorrect lubricant.
(a) Transfer case not completely engaged
in 4L position.
(b) Shift linkage loose or binding.
(c) Range fork cracked, inserts worn, or
fork is binding on shift rail.
(d) Annulus gear or lockplate work or
damaged.
(a) Transfer case overfilled.
(b) Vent closed or restricted.
(c) Output shaft seals damaged or
installed correctly.
(a) Extended operation on dry hard
surface (paved) roads in 4H range.
(a) Stop vehicle and shift into desired
range. 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
D E XR ON II Automatic Transmission
Fluid.
(e) Disassemble unit and replace worn or
damaged components as necessary.
(a) Drain and refill to edge of fill hole with
MOPAR ATF PLUS (Type 7176) or
DE XR ON II Automatic Transmission
Fluid. Check for leaks and repair if
necessary. If unit is still noisy after
drain and refill, disassembly and
inspection may be required to locate
source of noise.
(a) Stop vehicle, shift transfer case to
Neutral, then shift back into 4L position.
(b) Tighten, lubricate, or repair linkage as
necessary.
(c) Disassemble unit and repair as
necessary
(d) Disassemble unit and repair as
necessary
(a) Drain to correct level.
(b) Clear or replace vent if necessary.
(c) Replace seals. Be sure seal lip faces
interior of case when installed. Also be
sure yoke seal surfaces are not scored
or nicked. Remove scores and nicks with
fine sandpaper or replace yoke(s) if
necessary.
(a) Operate in 2H on hard surface (paved)
roads.
and operating properly, refer to t he Service Diagno-
sis chart for further information.
CHECKING FLUID LEVEL
Correct fluid level for t he NP241 transfer case is to
t he bottom edge of t he fill plug hole.
A correct method of checki ng fluid level is im-
portant. An accurate check requi res that the
transfer case be level.
If fluid level is checked with t he vehicle parked on
t he shop floor, be sure t he floor area used is level. If
J9021-152
fluid level is checked with t he vehicle raised, use ei-
t her a swivel ar m or drive-on type hoist to be sure
t he vehicle is level.
FLUID DRAIN/REFILL
(1) Raise vehicle.
(2) Position drain pan under transfer case.
( 3 ) Remove drain and fill plugs and drai n lubri-
cant completely.
(4) Install drai n plug. Tighten plug to 54 Nm (40
ft. lbs.).
(5) Remove drain pan.

Fig. 2 Loosening Rear Retainer
Fig. 3 Removing/Installing Rear Retainer
(7) Install speedometer driven gear.
(8) Install drain plug. Tighten plug to 54 N-m (40
ft. lbs.).
(9) Fill transfer case to edge of fill plug opening
wi t h recommended transmission fluid.
(10) Install fill plug. Tighten plug to 54 N-m (40 ft.
lbs.).
(11) Connect propeller shaft. Tighten at t achi ng
bolts to 19 N-m (170 in. lbs.).
(12) Lower vehicle.
SPEEDOMETER ADAPTER/DISTANCE SENSOR
SERVICE
ADAPTER/SENSOR REMOVAL
(1) Raise vehicle.
(2) Remove skid plate and crossmember for access,
if necessary.
(3) Remove vehicle speed sensor from pinion gear
adapt er (Fig. 4). On models with automatic t ransmi s-
sion, remove sensor adapter as well.
(6) Fill transfer case to bottom edge of fill plug
opening with Mopar ATF Plus, or Dexron II auto-
matic transmission fluid.
(7) Install fill plug. Tighten plug to 54 Nm (40 ft.
lbs.).
(8) Lower vehicle.
SPEEDOMETER GEAR, SHAFT SEAL, BEARING
AND RETAINER SERVICE
The front and rear yokes, out put shaft seals, re-
t ai ners and bearings, and speedometer drive gear can
all be serviced wi t h t he transfer case in t he vehicle.
The following combined procedure outlines removal
and installation of these components:
RETAINER AND SPEEDOMETER COMPONENT
REMOVAL
(1) Raise vehicle.
(2) Remove fill and drai n plugs and drai n oil from
transfer case.
(3) Mark propeller shaft and transfer case yoke for
(4) Disconnect propeller shaft. Secure shaft to un-
derside of vehicle.
(5) Remove transfer case yoke ret ai ni ng nut and
seal washer. Use Special Tool C-3281 to hold yoke
while removing nut .
(6) Remove transfer case yoke.
(7) Remove ret ai ner seal (if seal or bushi ng is to be
replaced) using suitable tool.
(8) Install a new seal, if old seal was removed.
(9) Remove speedometer gear from r ear ret ai ner.
(10) Mark rear ret ai ner for assembly al i gnment
reference.
(11) Remove ret ai ner at t achi ng bolts and remove
ret ai ner. Pry ret ai ner wi t h screwdrivers to remove it
(Fig. 2).
(12) Remove rear ret ai ner (Fig. 3). Remove speed-
ometer drive gear, if necessary.
(13) Completely clean off old sealant.
(14) If t he ret ai ner or beari ng are to be replaced,
remove beari ng ret ai ner snap ri ng from rear ret ai ner
and remove bearing.
RETAINER AND SPEEDOMETER COMPONENT
INSTALLATION
(1) Install r ear output beari ng in rear ret ai ner and
install snap ring.
(2) Apply a 5 mm (3/16 in.) wide bead of Mopar
Gasket Maker, Loctite 518, or Loctite 573 seal ant to
mat i ng surface of rear ret ai ner.
(3) Align ret ai ner case reference mar ks and install
rear ret ai ner on case.
(4) Inst al l and t i ght en rear ret ai ner at t achi ng
bolts to 24 Nm (18 ft. lbs.).
(5) Install output shaft seal (if required).
(6) Install yoke, a new yoke seal washer and yoke
nut . Tighten nut to 149 N-m (110 ft. lbs.) torque.

LOCK OIL
RING SEAL
ADAPTER
(OVERDRIVE ONLY)
SPEEDOMETER
PINION GEAR
ADAPTER O-RING
SPEEDOMETER ADAPTER
RETAINER
DISTANCE SENSOR
J9021-99
Fig. 4 Speedometer Components
(4) Check vehicle speed sensor mounting area in
pinion adapter. If transmission fluid is found in this
area, adapter oil seal is leaking and will have to be
replaced.
(5) Remove bolt and ret ai ner securing pinion gear
adapter to extension housing.
(6) Carefully work adapter and gear out of hous-
ing.
(7) Remove and discard adapt er O-ring (Fig. 4).
SPEEDOMETER ADAPTER OIL SEAL
REPLACEMENT
Remove adapt er oil seal if necessary. St art new
seal in adapter by hand. Then press seal into adapter
with Installer Tool C-4004 unt i l tool bottoms (Fig. 5).
ADAPTER LOCK RING
TOOL
(3) Count number of t eet h on pinion gear before
i nst al l i ng gear in adapter.
(4) Note range numbers on adapt er face (Fig. 6 ) .
These numbers correspond to number of t eet h on pin-
ion.
(5) Inst al l adapt er in housing.
(6) Rotate adapt er unt i l required range numbers
are at six o-clock position (Fig. 6 ) . Be sure adapt er
range numbers correspond to number of t eet h on pin-
ion.
(7) Seat adapt er i n housing.
(8) Install adapt er retainer. Tighten ret ai ner bolt
(9) Inst al l vehicle speed sensor. Tighten sensor
coupling nut to 17 N-m (150 in. lbs.) torque and in-
stall sensor wires.
(10) Check and correct transfer case lubricant level
if necessary.
(11) Install skid plate and crossmember if re-
moved.
(12) Lower vehicle.
ADAPTER
O'CLOCK POSITION
Fig. 6 Indexing Speedometer Adapter
RH75
OIL SEAL
RH263
Fig. 5 Replacing Speedometer Adapter Seal
ADAPTER/SENSOR INSTALLATION
C A U T I O N : Before installing the pi ni on arid adapter
assembl y make sur e the adapter fl ange and its
mounti ng area in transfer case are perfectly cl ean.
Dirt or sand will cause mi sal i gnment resulting in
speedometer pi ni on gear damage.
(1) Thoroughly clean adapter flange and adapter
mount i ng surface i n extension housing. These sur-
faces must be clean for proper adapt er alignment and
speedometer operation.
(2) Lubricate adapt er oil seal and O-ring with
transmission fluid.

SHIFT LINKAGE ADJUSTMENT
(1) Remove screws at t achi ng shift lever boot and
seal to floorpan (Fig. 7). Then move boot and seal
aside for visual access to shift gate.
(2) Move shift lever into 4H position. Be sure lever
is agai nst 4H position in gate.
(3) Raise vehicle.
(4) Loosen lock bolt in shift rod adjusting swivel
(Fig. 8).
(5) Check shift rod fit in swivel. Be sure rod does
not bind in swivel.
(6) Verify t hat transfer case range lever is in 4H
position (vertical). Move lever if necessary.
(7) Ti ght en shift rod lock bolt to (90 in. lbs.)
torque.
(8) Lower vehicle.
(9) Check shift linkage operation.
Fig. 7 Shift Lever Boot And Seal

TRANSFER CASE REMOVAL
(1) Raise vehicle.
(2) Position drai n oil container under transfer case.
(3) Remove transfer case drai n plug and drai n lu-
bricant into container.
(4) Disconnect wires at vehicle speed sensor.
(5) Disconnect vacuum hoses at vacuum switch.
(6) Disconnect transfer case shift lever from range
lever.
(7) Remove skid plate and skid plate crossmember.
(8) Support transmission with jack stand.
(10) Mark front and rear propeller shaft yokes for
assembly reference.
(11) Remove front and rear propeller shafts.
(12) Support transfer case with suitable jack. Se-
cure transfer case to jack with safety chains.
mission.
(14) Move transfer case assembly rearward unt i l
free of t ransmi ssi on output shaft.
(15) Lower jack and move transfer case from under
vehicle.
(16) Remove all gasket mat eri al from rear of
transmission adapt er housing.
TRANSFER CASE INSTALLATION
(1) Apply Mopar Perfect Seal, silicone sealer, or
Permat ex No. 2 to both sides of transfer case-to-
transmission gasket. Then position gasket on t rans-
mission.
(2) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with t ransmi ssi on output shaft. Align splines by ro-
t at i ng transfer case rear output shaft yoke if neces-
sary. Do not install any transfer case attachi ng
nuts until the transfer case is compl etel y seated
agai nst t he t r ans mi s s i on.
(3) Install and t i ght en transfer case at t achi ng nut s
to 47 N*m (35 ft. lbs.).
(5) Remove jack st and from under transmission.
(6) Align and connect propeller shafts.
(7) Connect speed sensor wires and vacuum switch
hoses.
(8) Connect transfer case shift lever to range lever.
Tighten lever locknut to 10 N*m (90 in. lbs.).
(9) Fill transfer case with recommended t ransmi s-
sion fluid.
(10) Install transfer case fill plug.
(11) Install skid plate and skid plate crossmember.
(12) Lower vehicle.
TRANSFER CASE DI SASSEMBLY
(2) Remove rear ret ai ner (Figs. 2-3). Remove and
discard ret ai ner seal.
(3) Remove upper snap ri ng t hat ret ai ns speedom-
eter gear on shaft. Then remove speedometer gear
(Fig. 1).
Fig. 1 Snap Ring And Speedometer Gear Removal/
Installation
(4) Remove shaft lower snap ri ng (Fig. 2)
(5) Remove oil pump. Remove and discard oil
pump seal.
(6) Loosen rear case by prying corners loose to
break sealant bead (Fig. 3).
Fig. 2 Removing/Installing Shaft Lower Snap Ring
(7) Remove rear case from front case (Fig. 4)
(8) Remove oil pickup screen, t ube and magnet
from rear case.
DRIVE CHAIN, SPROCKET, SHIFT FORK AND
MAINSHAFT SHAFT REMOVAL
(1) Remove mode spring from shift rai l (Fig. 5).
(2) Remove driven sprocket snap ri ng (Fig. 6).
(3) Remove sprocket and drive chain (Fig. 7). Tilt
mainshaft for clearance if necessary.
RETAINER AND REAR CASE REMOVAL
(1) Remove indicator switch from front case.

Fig. 3 Loosening Rear Case
Fig. 5 Removing/Installing Mode Spring
(4 ) Remove mainshaft, mode fork and shift rail as
assembly.
(5) Remove front output shaft (Fig. 8) .
NP24 1 TRANSFER CASE 21 - 3i 7
Fig. 8 Removing/Installing Front Output Shaft
21 - 358 NP24 1 TRANSFER CASE

RANGE FORK
SH IR HUB
RANGE FORK
ANNULUS
LOW RANGE GEAR
-RR21F42
Fig. 9 Removing/Installing Range Fork And Hub
INPUT SHAFT
^ BE ARI N G RETAINER
, RR21F49
Fig. 10 Removing/Installing input Gear Bearing Retainer
SNAP RING /
PLIERS
L
INPUT GEAR
SNAP RING RR21F53
Fig. 11 Removing/instaliing Input Gear Snap Ring
(6) Remove range fork and hub (Fig. 9).
INPUT GEAR LOW, RANGE GEAR, RETAINER
AND SECTOR REMOVAL
(1) Remove input gear bearing ret ai ner (Fig. 10).
(2) Remove i nput gear snap ring (Fig. 11).
Fig. 12 Removing/Installing Low Range Gear And
Input Shaft
FRONT
SNAP
RING
LOW
RANGE
GEAR
RR21F44
Fig. 13 Removing/Installing Low Range Gear Snap
Ring
(3) Remove low range gear and i nput gear as as-
sembly (Fig. 12).
(4) Remove low range gear snap ri ng (Fig. 13).
(5) Remove i nput gear and t hr ust washer from low
range gear.
(6) Remove shift detent plug and O-ring seal. Then
remove t he detent spring and plunger (Fig. 14). Re-
place O-ring seal on plug if seal is worn or cut.
(7) Remove shift sector and sector seals (Fig. 15).
MAINSHAFT DISASSEMBLY
(1) Remove Synchronizer snap ri ng (Fig. 16).
(2) Remove synchronizer sleeve and hub as assem-
bly (Fig. 17). It is not necessary to disassemble t he
synchronizer components unless wear or damage is
evident.
(3) Remove stop ri ng (Fig. 17).
(4) Remove drive sprocket from mainshaft (Fig. 18)

J U L L
V AC UUM
SWI TCH
MAINSHAFT
ASSEMBLY
SYNCHRONIZER
ASSEMBLY
DETENT
SPRING
O-RING
SEAL J9121-536
Fig. 14 Detent Plug-Spring-Plunger Location
SHI FT
SECTOR
J90 2 1- 8
Fig. 15 Removing/Installing Shift Sector
COMPONENT CLEANING AND INSPECTION
Wash all part s thoroughly in clean solvent. Be sure
all old
lubricant, sealant, metal particles, dirt and foreign
mat eri al are removed from t he surfaces of every part .
Apply compressed air to each oil feed port and
channel in both case halves to remove any foreign
mat eri al or cleaning solvent residue.
Inspect t he spline t eet h on synchronizer sleeve,
hub, and stop ring. If there is evidence of chipping or
excessive wear, install new part s at reassembly. Be
sure t he clutch sleeve slides easily on t he clutch hub.
Synchronizer springs should be in place wi t h t he
t ang inside t he cavity of one strut. The rings should
not exhibit any evidence of interference with t he pol-
ished gear cone or inside diameters of t he clutch hub.
SNAP
RING
SNAP
RING
PLIERS
RR21F45
Fig. 16 Removing/Installing Synchronizer Snap Ring
SYNCHRONIZER
SLEEVE AND
HUB
MAINSHAFT
DRIVE SPROCKET
STOP
RING
RR21F46
Fig. 17 Removing/Installing Synchronizer Sleeve,
Hub And Stop Ring
DRIVE
SPROCKET
MAINSHAFT
RR21F47
Fig. 18 Removing/Installing Mainshaft Drive
Sprocket
Inspect t he stop ri ng for cracks and wear. Replace
t he ri ng if cracked or excessively worn on t he
threaded bore. Check new ri ngs for proper fit on the
21 - 360 NP24 1 TRANSFER CASE

cone with a mi ni mum of wobble. Also check t he syn-
chronizer st rut s for wear or damage.
Inspect all gear t eet h for excessive wear or damage
and check all gear splines for burrs, nicks, wear, or
damage. Remove minor nicks or scratches with an oil
stone. Replace any par t exhibiting excessive wear or
damage.
Inspect all snap ri ngs and t hr ust washers for exces-
sive wear, distortion or damage. Replace worn or
damaged part s.
Inspect t he two case halves for cracks, porosity,
damaged mat i ng surfaces, stripped bolt t hreads, or
distortion. Replace either case half if necessary.
Inspect condition of all needle, roller, ball, and
t hrust bearings in t he front and rear case halves and
t he i nput gear. Also check condition of t he beari ng
bores in both cases and in t he i nput gear, rear output
shaft, side gear, and rear ret ai ner. Replace any com-
ponent exhibiting excessive wear or damage.
If t he case or i nput gear beari ngs require replace-
ment, refer to t he Transfer Case Beari ng Replace-
ment procedures.
TRANSFER CASE BEARING REPLACEMENT
C A U T I O N : M ost of the transfer case beari ng bores
contai n oil feed hol es. Be sure replacement bear-
i ngs do not bl ock these feed hol es.
DRIVE SPROCKET BEARING REPLACEMENT
(1) Remove both drive sprocket bearings simulta-
neously using a shop press, Tool Handl e C-4171 and
Remover/Installer Tool C-4697-1 (Fig. 19).
(2) Clean sprocket beari ng bore after removing old
bearings.
(3) Before proceeding, note t hat sprocket beari ngs
are positioned differently (Fig. 20). Front beari ng is
installed flush with end of bore. However, r ear bear-
ing is recessed slightly. Be sure to install beari ngs as
shown in Fi gure 20.
Fig. 19 Removing Drive Sprocket Bearings
(4) Install new sprocket bearings one at a time
st art i ng with front bearing.
(a) Press front beari ng flush with end of bore as
shown (Fig. 20).
(b) Press rear beari ng into sprocket until bearing
is 4.6 mm (11/64 in.) below edge of bore.
RR21F32
Fig. 20 Drive Sprocket Bearing Installation
MAINSHAFT PILOT BEARING REPLACEMENT
The mainshaft pilot bearing is located in t he i nput
shaft. The beari ng is removed from t he shaft bore
with Remover Tool MD-998346 and two appropriate
size backup wrenches (Fig. 21).
The new beari ng is installed with Tool Handle
C-4171 and Installer 506 5 (Fig. 22) .
A shop press is recommended to press t he beari ng
into place. The beari ng is seated when t he installer
tool contacts t he i nput shaft.
REPLACING MAINSHAFT REAR (OUTPUT)
BEARING
The mainshaft rear (output) bearing is located in
t he rear ret ai ner. The seal must be removed before
t he beari ng can be replaced.
(1) Remove seal with Remover Tool C-4613 (Fig.
23).

NP24 1 TRANSFER CASE 21 - 36 1
Fig. 21 Removing Mainshaft Pilot Bearing
Fig. 22 Installing Mainshaft Pilot Bearing
(2) Remove beari ng wi t h Tool Handle C-4171 and
Remover C-4610 (Fig. 24).
(3) Clean beari ng bore thoroughly.
(4) Install new beari ng with Handl e C-4171 and
Installer C-4609 (Fig. 25).
(5) Install new seal in rear retainer.
FRONT OUTPUT SHAFT FRONT BEARING
REPLACEMENT
(1) Remove beari ng from front case bore wi t h Tool
Handle C-4171, Remover C-4610 and a shop press
(Fig. 26).
(3) Install new beari ng with Tool C-4210, Handl e
C-4171 and a shop press (Fig. 27).
FRONT OUTPUT SHAFT REAR BEARING
REPLACEMENT
(1) Remove beari ng from r ear case bore wi t h Re-
mover Tools L-4518-1 and L-4454-1 (Fig. 28).
Fig. 23 Removing Rear Retainer Seal
Fig. 24 Removing Mainshaft Rear (Output) Bearing
(3) Install new beari ng wi t h Handle C-4171 and
Inst al l er C-4608 (Fig. 29).
TRANSFER CASE ASSEMBLY
(1) Lubricate transfer case components with auto-
matic transmission fluid during assembly.
(2) If transfer case bearings were replaced, verify
t hat new bearings do not block any oil feed holes.
(3) Assemble i nput gear, t hr ust washer and low
range gear. Be sure low range snap ri ng is fully
seated.
(4) Install input and low range gear assembly in
front case. Secure i nput gear wi t h snap ri ng (Fig.
11).
(5) Install shift sector and new sector shaft seals.
Install range lever on sector shaft and t i ght en lever
locknut to 30 N*m (22 ft. lbs.) torque.
(6) Install range fork and hub (Fig. 9).
21 - 3S2 NP24 1 TRANSFER CASE

Fig. 26 Removing Front Output Shaft Front Bearing
Fig. 27 installing Front Output Shaft Front Bearing
(7) Install front output shaft in case (Fig. 8).
Fig. 28 Removing Front Output Shaft Rear Bearing
Fig. 29 Installing Front Output Shaft Rear Bearing
(8) Assemble mainshaft, stop ring, synchronizer
and mainshaft drive sprocket.
(9) Insert mode fork in synchronizer sleeve. Then
install mainshaft and fork as assembly. Be sure shift
rail is aligned in range fork and is seated in case
bore.
(10) Install drive chain and front shaft sprocket
(Fig. 7).
(11) Install snap ri ng t hat secures driven sprocket
to front output shaft (Fig. 6).
(12) Install detent plunger, spring and plug (Fig.
14). Replace O-ring on plug if necessary. Do not re-
use old O-ring if damaged. Tighten plug to 21 Nm
(13) Install mode spring on shift rai l (Fig. 5).
(14) Install oil pump, pickup t ube and screen i n
rear case.
(15) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker, silicone adhesive/sealer, or Loctite 515 to
front case sealing surface.
NP24 1 TRANSFER CASE 21 - 36 3
(16) Align and install rear case on front case. In-
stall and t i ght en rear case-to-front case bolts to 27-34
Nnn (20-25 ft. lbs.).
(17) Inst al l lower snap ri ng on mainshaft (Fig. 2).
(18) Install speedometer gear and upper snap ri ng
(Fig. 1).
(19) Install new seals in retainers if necessary.
(20) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker, silicone adhesive/sealer, Loctite 518, or
Loctite 573 to sealing surface of rear ret ai ner. Then
install ret ai ner and t i ght en ret ai ner bolts to 31 Nnn
(23 ft. lbs.).
(21) Install yokes, seal washers and ret ai ni ng nut s.
Tighten yoke nut s to 176-271 Nnn (130-200 ft. lbs.)
torque.
(22) Install vacuum switch. Ti ght en switch to 27
Nnn (20 ft. lbs.).
(23) Fill transfer case with Mopar ATF Pl us, type
7176 transmission fluid.
21 - 364 TRANSMISSION/TRANSFER CASE SPECIFICATIONS
AUTOMATIC TRANSMISSION GENERAL SPECIFICATIONS
TRA N S M I S S I ON M O D E L 3 2 RH I 4 2 RH ' 3 6 RH / 3 7 RH I 4 6 RH
Oil Pump Clearances (all) 0.089-0.190 mm
(0.0035-0.0075 in)
0.089-0.190 mm
(0.0035-0.0075 in)
Planetary End Play 0.127-1.22 mm
(0.005-0.048 in)
0.15-1.22 mm
(0.006-0.048 in)
Input Shaft End Play 0.56-2.31 mm
(0.022-0.091 in)
0.86-2.13 mm
(0.034-0.084 in)
Clutch Pack Clearance:
Front Clutch - 3 Disc
Rear Clutch - 3 Disc
Rear Clutch - 4 Disc
1.88-3.17 mm
(0.074-0.125 in)
1.70-3.40 mm
(0.067-0.134 in)
1.90-3.86 mm
(0.075-0.152 in)
0.81-1.40 mm
(0.032-0.055 in)
0.81-1.40 mm
(0.032-0.055 in)
1.78-3.28 mm
(0.070-0.129 in)
2.08-3.83 mm
(0.082-0.151 in)
0.64-1.14 mm
(0.025-0.045 in)
Clutch Disc Usage:
Front Clutch
Rear Clutch
Overdrive Clutch (Gas)
Overdrive Clutch (Diesel)
Direct Clutch
32 R H 42 R H 36R H / 37 R H 46R H Clutch Disc Usage:
Front Clutch
Rear Clutch
Overdrive Clutch (Gas)
Overdrive Clutch (Diesel)
Direct Clutch
4
4
4
4
4
6
3/4
4
3/4
4
4
5
8
Front Clutch Spring Usage 1 1 9 9/11
Band Adjustments:
(backed off from 72 in. lbs.)
Front Band
Rear Band
2Vi
4
2Yi
4
214
2
Th
2
Recommended Fluid (all) MOPAR ATF Plus, Type 7176 Automatic Transmission Fluid
J9321-210
32RH/36RH/37RH SPACER/THRUST PLATE/SNAP RING SPECIFICATIONS
T R A N S M I S S I O N M O D E L
C O M P O N E N T 32RH 36R H/ 37R H
Front Clutch Thrust Washer
(on reaction shaft support hub)
.061 in. .061 in
.084 in
.102 in
Rear Clutch Thrust Washer
(on clutch retainer)
.061 in .061 in
Output Shaft Thrust Plate
(on Output shaft pilot hub)
.060-.063 in .060-.063 in
Output Shaft Thrust Washer
(in rear clutch hub)
.052-.054 in
.068-.070 in
.083-085 in
.068-.070 in
Rear Clutch Pack Snap Ring
.068 in
.060 in
.076 in
.098 in
.060 - .062 in
.074 - .076 in
.088 - .090 in
.106 - .108 in
Planetary Geartrain Snap Ring
(At front end of output shaft)
.040 - .044 in
.062 - .066 in
.082 - .086 in
.048 - .052 in
.055 - .059 in
.062 - .066 in
J922M42
T R A N S M I S S I O N / T R A N S F E R C A S E S P E C I F I C A T I O N S

TRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 365
411H m m
Front Clutch Thrust Washer
(on reaction shaft support hub)
.016 in. .061 in.
.084 in.
.102 in.
Rear Clutch Thrust Washer
(on clutch retainer)
.061 in. .061 in.
Intermediate Shaft Thrust Plate
(on shaft pilot hub)
.060-.063 in. .060-.063 in.
Output Shaft Thrust Washer
(in rear clutch hub)
.068-.070 in. .052-.054 in.
.068-.070 in.
.083-.085 in.
Rear Clutch Pack Snap Ring .060 in.
.076 in.
.098 in.
.060 in.
.074 in.
Planetary Geartrain Snap Ring
(at front end of intermediate shaft)
.062 in.
.074 in.
.055-059 in.
.062-.066 in.
Overdrive Piston Thrust Plate
Thrust plate and spacer are select fit
components. Refer to size charts and
selection procedures in "Overdrive Unit
Assembly and Adjustment."
Intermediate Shaft Spacer
Thrust plate and spacer are select fit
components. Refer to size charts and
selection procedures in "Overdrive Unit
Assembly and Adjustment."
J9221-143
AUTOMATIC TRANSMISSION PRESSURE TEST SPECIFICATIONS (32RH/36RH/37RH)
Overdrive Clutch Fourth Gear Only
Pressure should be within 21 kPa
(3 psi) of line pressure
Line Pressure
(at accumulator)
Closed Throttle
1000 rpm and above
372-414 kPa (54-60 psi)
648 kPa (94 psi)
Front Servo Third Gear Only N o more than 21 kPa (3 psi) lower than line pressure.
Rear Servo
1 Range
R Range
N o more than 21 kPa (3 psi) lower than line pressure. 1103 kPa (160 psi) at idle,
builds to 1862 kPa (270 psi) at 1600 rpm.
Governor
D Range
Closed Throttle
Pressure should respond smoothly to changes in mph and return to 0-7 kPa (0-114
psi) when stopped with transmission in D, 1, 2. Pmmmf mb&wm 7 kPm (1 Va psi)
at standstill will p r mn f transmission from drnwrnhlfflmg*
J9121-524
42RH/46RH SPACER/THRUST PLATE/SNAP RING SPECIFICATIONS
21 366 TRANSMISSION/TRANSFER CASE SPECIFICATIONS
Overdrive Clutch Fourth Gear Only
Pressure should be 469-496 kPa (68-72 psi) with closed throttle and increase to
620-896 kPa (90-130 psi) at 1/2 to 3/4 throttle.
Line Pressure
(at accumulator)
Closed Throttle
1000 rpm and above
372-414 kPa (54-60 psi)
648 kPa (94 psi)
Front Servo Third Gear Only No more than 21 kPa (3 psi) lower than line pressure.
Rear Servo
1 Range
R Range
No more then 21 kPa (3 psi) lower than line pressure. 1103 kPa (160 psi) at idle,
builds to 1862 kPa (270 psi) at 1600 rpm.
Governor
D Range
Closed Throttle
Pressure should respond smoothly to changes in mph and return to 0-7 kPa (0-1 Vi
psi) when stopped with transmission in D, 1, 2. Pressure a b o v e 7 k Pa (IV2
psi ) a t s t a nds t i l l wi l l pr event t r a n s mi s s i o n f r o m d o w n s h i f t i n g .
J9321-192
AUTOMATIC TRANSMISSION TORQUE SPECIFICATIONS
DESCRI PTI ON TORQUE DESCRI PTI ON TORQUE
Cooler Line Fittings 18 N-m (13 ft. lbs.)
Converter Bolts:
9.5 in., 3-lug converter 54 N-m (40 ft. lbs.
10.75 in., 4-lug converter 31 N-m (270 in. lbs.
Crossmember Bolts/Nuts 68 N-m (50 ft. lbs.
Driveplate Bolts 75 N-m (55 ft. lbs.
Extension Housing Bolts 43 N-m (32 ft. lbs.
Front Band Reaction Pin Access Plug 17 N-m (13 ft. lbs.
Front Band Adjusting Screw Locknut 34 N-m (25 ft. lbs.
Governor Body-to-Park Gear Bolts 11 N-m (8 ft. lbs.
Lockup Module Screws 4 N-m (35 in. lbs.
Neutral Switch 34 N-m (25 ft. lbs.
Oil Filter Screws 4 N-m (35 in. lbs.
Oil Pan Bolt 17 N-m (13 ft. lbs.
Oil Pump Bolt 20 N-m (15 ft. lbs.
Overrunning Clutch Cam Set
Screw (36RH/46RH) 5 N-m (40 in. lbs.
Overrunning Clutch Cam Bolts 17 N-m (150 in. lbs.
Overdrive Compounder-to-
Transmission Case Bolts 34 N-m (25 ft. lbs.
Overdrive Piston Retainer
Bolts (42RH/46RH) 17 N-m (150 in. lbs.
Pressure Test Port Plugs 14 N-m (10 ft. lbs.
Propeller Shaft Clamp Bolts 19 N-m (170 in. lbs.
Reaction Shaft Support Bolts 20 N-m (15 ft. lbs.
Rear Band Adjusting Screw Locknut 41 N-m (30 ft. lbs.
Rear Mount Bolts/Nuts 68 N-m (50 ft. lbs.
Rear Support Bolts (32RH/36RH) 17 N-m (150 in. lbs.
Solenoid Wiring Connector Screw 17 N-m (13 ft. lbs.
Solenoid-to-Transfer Plate Screw 4 N-m (35 in. lbs.
Speedometer Adapter Bolt 11 N-m (8 ft. lbs.
Valve Body Housing Screws 4 N-m (35 in. lbs.
Valve Body-to-Case Bolts 12 N-m (100 in. lbs.
J9221-157
AUTOMATIC TRANSMISSION PRESSURE TEST SPECIFICATIONS (42RH/46RH)
TRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 367
DESCRIPTION TORQUE
Backup Light Switch 22-34 N-m (193-300 in. lbs.)
Countershaft Bearing
Plate Bolts 19-26 N-m (170-230 in. lbs.)
Fifth Gear Nut 339-475 N-m (250-350 ft. lbs.)
Drain and Fill Plugs 34-47 N-m (25-35 ft. lbs.)
Front Bearing Retainer Bolts 27-34 N-m (235-305 in. lbs.)
Mainshaft Bearing Plate Bolts 19-26 N-m (170-230 in. lbs.)
PTO Cover Bolts 27-54 N-rn (20-40 ft. lbs.)
Extension/Adapter Housing Bolts 41-68 N-m (30-50 ft. lbs.)
Reverse Inhibitor Screws 8-14 N-m (75-115 in. lbs.)
Shift Cover Bolts 27-31 N-m (216-276 in. lbs.)
J9221-12
DESCRI PTI ON T O R Q U E
Bearing Preload
Case Bolts
Distance Sensor
Coupling Nut
Detent Bolt
Drain/Fill Plugs
Front/Rear Yoke Nuts
Indicator Switch
Range Lever Locknut..
Rear Retainer Bolts . . .
Speedometer Driven
Gear Nut
Transfer Case
Mounting Nuts. . . . .
7-41 Nm (5-30 in. lbs.)
31 mm (23 ft. lbs.)
17 Nm (150 in. lbs.)
31 Nm (23 ft. lbs.)
54 Nm (40 ft. lbs.)
176 Nm (130 ft. lbs.)
24 Nm (18 ft. lbs.)
10 N * m (90 in. lbs.)
54 Nm (40 ft. lbs.)
11 Nm (100 in. lbs.)
54 Nm (40 ft. lbs.)
J9221-250
G360 SET-TO TORQUE SPECIFICATIONS
NP241 TORQUE SPECIFICATIONS
Clutch Housing Bolts 47 N-m (35 ft. lbs.)
Drain/Fill Plugs 47 Nm (35 ft. lbs.)
Front/Rear Bearing
Retainer Bolts . 22-30 N-m (16 -22 ft. lbs.)
Rear Crossmember
Bolts/Nuts . 68 N-m (50 ft. lbs.)
Shift Cover Bolts 22-30 N-m (16-22 ft. lbs.)
Skid Plate And Crossmember
Bolts/Nuts 41 N-m (30 ft. lbs.)
Transfer Case Attaching
Nuts 47 Nm (35 ft. lbs.)
Transmission-To-Clutch
Housing Bolts 68 N-m (35 ft. lbs.)
U-Joint Clamp Bolts 19 Nm (14 ft. lbs.)
Yoke Nut 380 N-m (280 ft. lbs.)
J9321-333
DESCRI PTI ON TORQUE
Oil Pump Screws 1.4-1.8 Nm (12-15 in. lbs.)
Yoke Nut (front/rear) 176-271 Nm (130-200 ft. lbs.)
Vacuum Switch 20-34 Nm (15-25 ft. lbs.)
Range Lever Nut 27-34 Nm (20-25 ft. lbs.)
Front Case-To-Rear Case Bolts . . 27-34 Nm (20-25 ft. lbs.)
Rear Retainer Bolts 47-61 Nm (35-45 ft. lbs.)
Extension Housing Bolts 35-46 Nm (26-34 ft. lbs.)
Drain/Fill Plugs 41-54 N* m (30-40 ft. lbs.)
Detent Plug 16-24 N@m (12-18 ft. lbs.)
Front Bearing Retainer Bolts 16-24 Nm (12-18 ft. lbs.)
Vacuum Switch 20-34 N* m (15-25 ft. lbs.)
Rear Case Stud Nut 27-34 N* m (20-25 ft. lbs.)
Strut Mounting Bracket Stud Nut 27-34 Nm (20-25 ft. lbs.)
J9221-248
NV4500 TORQUE SPECIFICATIONS NP205 TORQUE SPECIFICATIONS

WHEELS AND TIRES 22 - 1
C O N T E N T S
page page
TIRES 1 VEHICLE VIBRATION 11
TORQUE SPECIFICATIONS 13 WHEELS 6
T I R E S
INDEX
page
Cleaning of Tires 2
Pressure Gauges . 2
Repairing Leaks 3
Replacement Tires 2
GENERAL INFORMATION
Tires are designed for each specific vehicle. They
provide t he best overall performance for normal op-
eration. The ride and handl i ng characteristics match
the vehicle's requi rement s. Wi t h proper care they
will give excellent reliability, traction, skid resis-
tance, and t read life. These t i res have specific load
carrying capacities. When correctly inflated, they
will operate properly.
Tires used in cool climates, and wi t h light loads
will have a longer life t han t i res used in hot climates
with heavy loads. Abrasive road surfaces will accel-
erate tire wear.
Driving habits have more effect on t i re life t han
any other factor. Careful drivers will obtain much
greater mileage t han careless drivers.
Driving habits t hat shorten t he life of any tire;
Rapid acceleration and deceleration
Severe application of brakes
High-speed driving
Taki ng t ur ns at excessive speeds
Striking curbs and other obstacles
It is very i mport ant to follow t he tire rotation in-
terval
IDENTIFICATION
Tire type, size, aspect ratio and speed rat i ng are
encoded in t he letters and numbers imprinted on the
side wall of t he t i re. Refer to t he chart to decipher
t he tire identification code (Fig. 1).
Performance t i res will have a speed rat i ng letter
after the aspect ratio number. The speed rat i ng is
page
Rotation . 3
Tire Inflation Pressures 2
Tire Noi se or Vibration 4
Tire Wear Patterns 4
Tread Wear Indicators 3
not always printed on the tire side wall. The l et t er S
indicates t hat t he t i re is speed rat ed up to 112 mph.
Q up to 100 mph
T up to 118 mph
U up to 124 mph
H up to 130 mph
V up to 149 mph
Z more t han 149 mph (consult the tire manufac-
t ur er for t he specific speed rating)
An All Season type t i re will have either M + S, M
& S or MS (indicating mud and snow traction) im-
pri nt ed on t he side wall.
RADIAL-PLY TIRES
Radial-ply t i res improve handling, t read life, ride
qual i t y and decrease rolling resistance.
Radial-ply t i res must always be used in sets of
four. Under no circumstances should they be used on
t he front only. They may be mixed with t emporary
spare tires when necessary, but reduced speeds are
recommended.
Radial-ply tires have t he same load-carrying capac-
ity as other types of tires of t he same size. They use
t he same recommended inflation pressures.
SPARE TIRE (TEMPORARY)
The compact spare t i re is designed for emergency
use only. The original tire should be repaired and re-
installed at t he first opportunity. Refer to Owner' s
Manual for complete details.
W H E E L S A N D T I R E S
22 - 2 WHEELS AND TIRES

METRIC TIRE SIZES
P 205 / 75 I 15
J932 2 - 6
Fig. 1 Tire Size identification
TIRE CHAINS
Tire snow chains may be used on certain models.
Refer to Owner' s Manual for more information.
CLEANING OF TIRES
Steam cleaning may be used for cleaning.
DO NOT use gasoline or wire brush for cleaning.
DO NOT use mi neral oil or an oil-based solvent.
PRESSURE GAUGES
High-quality, dial-type, air-pressure gauges are
recommended. After checking with t he gauge, re-
place valve caps and t i ght en finger tight.
TIRE INFLATION PRESSURES
Under inflation (Fig. 2) causes rapid shoulder wear
and t i re flexing.
Over inflation (Fig. 3) causes rapid center wear
and loss of t he tire' s ability to cushion shocks.
Improper inflation can cause;
Uneven wear pat t erns
Reduced t read life
Reduced fuel economy
Unsatisfactory ride
Cause t he vehicle to drift
Refer to t he Owner' s Manual for information re-
garding proper t i re inflation pressure.
This pressure has been carefully selected to provide
for safe vehicle operation. Tire pressure should be
Fig. 2 Under infiation Wear
Fig. 3 Over Infiation Wear
checked cold once per month. Tire pressure de-
creases when t he outside t emperat ure drops.
Inflation pressures specified on t he placards are al-
ways cold i n f l a t i o n pressure. Cold inflation pres-
sure is obtained after t he vehicle has not been
operated for at least 3 hours. Tire inflation pressures
may increase from 2 to 6 pounds per square inch
(psi) during operation. Do not reduce t hi s normal
pressure build-up.
Vehicles loaded to t he maxi mum capacity should
not be driven at continuous speeds above 75 mph
(120 km/h).
W ARN I N G: OV E R OR UN D E R I N F LATE D TI RE S C AN
AF F E CT V E H I CL E H AN D LI N G AN D C AN F AI L SUD -
D E N L Y , RE SUL TI N G I N L OS S OF V E H I CL E C ON -
T ROL
REPLACEMENT TIRES
OEM tires provide a proper balance of many fea-
t ures such as;
Ride

Noise
Handling
Durability
Tread life
Traction
Rolling resistance
Speed capability
We recommend that tires equivalent to the original
equipment tires be used when replacement is needed.
Refer to the pl acard on the vehi cl e or the
Owner' s Manual for the correct repl acement
tire.
Failure to use original equipment replacement
tires may adversely affect the handling of the vehi-
cle.
The use of oversize tires is not recommended.
They may cause interference with vehicle suspension
and steering travel. This can cause tire damage or
failure.
W ARN I N G: F AI L URE T O E QU I P TH E V E H I CL E W I TH
TI RE S H AV I N G AD E Q UATE L OAD CAPABI LI TY C AN
RE SUL T I N SUD D E N TI RE F AI L URE .
ROTATION
Tires on the front and rear axles operate at differ-
ent loads and perform different steering, driving, and
braking functions. For these reasons;
They wear at unequal rates
Tend to develop irregular wear patterns
These effects can be reduced by timely rotation of
tires. The benefits of rotation are especially worth-
while. Rotation will:
Increase tread life
Help to maintain mud, snow, and wet traction lev-
els
Contribute to a smooth, quiet ride
The suggested method of tire rotation is the same
side front to rear pattern (Fig. 4). Other rotation
methods can be used, but they will not provide all
the tire longevity benefits.
Dual wheel vehicles require a different tire rota-
tion than that of the conventional four wheel type.
Refer to Figure 5 for the proper tire rotation with
dual wheels.
FRONT
m
kz ~i
J9222-8
LEFT 'I RI GHT
FRONT I I FRONT
LEFT I I RI GHT
REAR p REAR
1 | | |
L
HN838
Fig. 5 Dual Wheel Tire Rotation Pattern
TREAD WEAR INDICATORS
Tread wear indicators are molded into the bottom
of the tread grooves. When t read is 1.6 mm (1/16 in.),
the tread wear indicators will appear as a 13 mm
(1/2 in.) band.
Tire replacement is necessary when indicators ap-
pear in two or more grooves, or if localized balding
occurs (Fig. 6).
TREAD
ACCEPTABLE
TREAD
UNACCEPTABLE
WEAR
INDICATOR
v
J8922- 5
Fig. 4 Tire Rotation Pattern
Fig. 6 Tread Wear Indicators
REPAIRING LEAKS
For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the

puncture is in the tread area (Fig. 7). If outside the
tread area t he tire should be replaced.
J8922-6
Fig. 7 Tire Repair Area
Deflate t i re completely before dismounting t i re
from t he wheel. Use lubrication such as a mild soap
solution when dismounting or mount i ng tire. Use
tools free of burrs or sharp edges.
Before mounting tire on wheel, make sure all rust
scale is removed from t he rim. Repaint or seal if nec-
essary.
TIRE NOISE OR VIBRATION
The radial-ply tire on your vehicle is more sensi-
tive to improper mounting, or imbalance.
To determine if tires are t he cause of vibration,
drive t he vehicle over a smooth road at different
speeds. Note t he effect of acceleration and decelera-
tion on noise level. Differential and exhaust noise
will change in intensity as speed varies. Tire noise
will usually remai n constant.
TIRE WEAR PATTERNS
Under inflation results in faster wear on shoulders
of t i re. Over inflation causes faster wear at center of
tread.
Excessive camber causes t he tire to r un at an angle
to t he road. One side of tread is worn more t han t he
other.
Excessive toe-in or toe-out causes wear on t he
t read edges of t he tire, from dragging of tire. There
is a feathered effect across t he tread (Fig. 8).
CRACKED TREADS
WEAR ON
ONE SIDE
FEATHERED EDGE BALD SPOTS
IP
fa
SCALLOPED WEAR
EXCESSIVE CAMBER INCORRECT TOE
EXCESSIVE SPEED*
UNBALANCED
WHEEL
LACK OF
ROTATION
OF TIRES
OR
WORN OR OUT-
OF-ALIGNMENT
SUSPENSION.
OR TIRE DEFECT*
ADJUST PRESSURE TO
SPECIFICATIONS WHEN
TIRES ARE COOL
ROTATE TIRES
ADJUST CAMBER
TO
SPECIFICATIONS
ADJUST TOE-IN
TO
SPECIFICATIONS
DYNAMI C OR
STATIC
BALANCE WHEELS
ROTATE TIRES AND
INSPECT SUSPENSION
SEE GROUP 2
HAVE TIRE INSPECTED FOR FURTHER USE.
RN797
Fig. 8 Abnormal Tire Tread Wear Patterns
LEAD CORRECTION CHART
A D J U S T TI RE PR E S S U R E
T O R E D U C E D L O A D O N
PR E S S U R E PL A C A R D
R O A D TEST
O K
I
C A R L E A D S
S A M E D I R E C T I O N
CAR LEADS
CROSS SWITCH FRONT
TIRE & WHEEL ASSEMBLIES
I
R O A D TEST
I
PR O BA BL E C A U S E - V E HI C L E
C H E C K F R O N T A L I G N M E N T
T O E - C A S T E R - C A M BE R
I
ALIGNMENT NOT OK
ADJUST ALIGNMENT TO
PREFERRED SETTINGS.
O K
1
C A R L E A D S
O PPO S I T E D I R E C T I O N
PR O BA BL E C A U S E - T I R E S
S WI T C H T I R E S F R O N T T O R E A R
LEFT F R O N T T O LEFT R E A R
LEFT R E A R T O LEFT F R O N T
R I G HT F R O N T T O R I G HT R E A R
R I G HT R E A R T O R I G HT F R O N T
R O A D TEST

O K
CAR STILL LEADS
CROSS SWITCH FRONT TIRES
R O A D TEST
A
CAR STILL LEADS
SWITCH RIGHT FRONT
1
R O A D TEST
CAR STI L L LEADS
LEAD CAUSED BY
LEFT F RONT
TIRE - REPLACE
OK
9122-77
22 - e WHEELS AND TIRES

WHEELS
GENERAL INFORMATION
Original equipment wheels are designed for all
loads up to t he specified Maxi mum Vehicle Capacity.
All models use steel or cast al umi num drop center
wheels. The safety rim wheel (Fig. 1) has raised sec-
tions between t he ri m flanges and t he ri m well.
S J9022-3
Fig. 1 Wheel Safety Rim
Initial inflation of t he t i re forces t he bead over
these raised sections. In case of t i re failure, t he
raised sections hold t he tire in position on t he wheel
unt i l t he vehicle can be brought to a safe stop.
Cast al umi num wheels require special balance
weights and al i gnment equipment.
DUAL REAR WHEELS
Ram Truck Models D-35 0 and W- 35 0 equipped
with dual rear wheels have eight-stud hole rear
wheels. Four equally-spaced stud holes flanged out-
ward and four flanged inward. The wheels must be
installed so t he flanged stud holes mat e correctly
(Fig. 2) .
LOCATING PIN HOLE IN BOTH INNER & OUTER WHEEL MUST EN-
GAGE LOCATING PIN IN HUB WHEN WHEELS ARE INSTALLED.
PR1100
Fig. 2 Dual Rear Wheels
A locating pin in t he hub provides assistance for
correctly aligning t he i nner and outer wheels.
WHEEL INSTALLATION
The wheel studs and nut s are designed for specific
applications. They must be replaced with equivalent
part s. Do not use replacement part s of lesser quality
or a subst i t ut e design. All al umi num and some steel
wheels have wheel stud nut s which feature an en-
larged nose. This enlarged nose is necessary to en-
sure proper retention of t he al umi num wheels.
Before installing t he wheel, be sure to remove any
build up of corrosion on t he wheel mounting surfaces.
Ensure wheels are installed wi t h good metal-to-metal
contact. Improper installation could cause loosening
of wheel nut s. This could affect t he safety and han-
dling of your vehicle.
To install t he wheel, first position it properly on
t he mount i ng surface. All wheel nut s should t hen be
tightened j ust snug. Gradually t i ght en t hem in se-
quence to 129 N-m (95 ft. lbs.) torque (Fig. 3, 4).
Never use oil or grease on studs or nuts.
A. 5 STUD WHEEL
B. 8 STUD WHEEL
J9122-7
Fig. 3 Lug Nut Tightening Pattern
118 LBS. FORCE THESE NUMBERS SHOW THE
SEQUENCE IN WHICH STUD NUTS
ARE TO BE TIGHTENED.
FT. LBS.
TORQUE
PU884
Fig. 4 Dual Rear Wheel Tightening Pattern
DUAL REAR WHEELS
Dual rear wheels: a special heavy duty lug nut
wrench is required (Fig. 4). It is recommended to re-

move and install dual r ear wheels only when t he
proper wrench is available.
INSTALLATION
The tires on both wheels must be completely raised
off t he ground when t i ght eni ng t he l ug nut s (Fig. 5).
This will ensure correct wheel centering and maxi-
mum wheel clamping.
HUB ^ I NWAR D
Fig. 5 Flange Centering And Alignment
A 1 1/8-inch diameter flanged-type wheel lug nut
with right-hand t hreads is used for ret ai ni ng dual
rear wheels on t he hubs. A special, heavy duty wheel
lug nut wrench is necessary to correctly t i ght en t he
nut s with t he required torque (Fig. 4 ) .
The dual rear wheel l ug nut s should be tightened
according to the following procedure:
Tighten t he wheel lug nut s in t he numbered se-
quential pat t ern unt i l t hey are snug t i ght (Fig. 4 ) .
Tighten t he wheel lug nut s in t he numbered se-
quent i al pat t ern to 4 4 0 N
#
m ( 325 ft-lb) torque.
Tighten t he lug nut s in t he numbered sequential
pat t ern a second t i me to t he specified torque. This
will ensure t hat t he wheels are thoroughly mated.
Retighten t he lug nut s to t he specified torque after
100 miles (160 kilometers). Also ret i ght en after 500
miles (800 kilometers) of vehicle operation.
The wheel l ug nuts shoul d be ti ghtened wi th
the specified torque at every chassi s lubrication
interval thereafter.
WHEEL REPLACEMENT
Wheels must be replaced if t hey have:
Excessive runout
Bent or dented
Leak air t hrough welds
Have damaged bolt holes
Wheel repairs employing hammeri ng, heating, or
welding are not allowed.
Original equipment wheels are available t hrough
your dealer. Replacement wheels from any other
source should be equivalent in:
Load carrying capacity
Diameter
Width
Offset
Mounting configuration
Fai l ure to use equivalent replacement wheels may
affect t he safety and handl i ng of your vehicle. Re-
placement wi t h us e d wheels is not recommended.
Their service history may have included severe t reat -
ment.
Ref er t o t h e Speci f i cat i ons Cha r t for i nf or ma-
t i on r e g a r d i n g a bove r e qui r e me nt s .
WHEEL ORNAMENTATION
W ARN I N G; H AN D L E AL L W H E E L ORN AM E N TATI ON
W I TH E X TRE M E C A RE D URI N G RE M OV AL A N D I N-
STAL L ATI ON . S H A RP E D GE S ON TH E C OV E RS OR
C A PS C AN C A US E PE RSON AL I N J URY .
TIRE AND WHEEL BALANCE
It is recommended t hat a two plane dynamic bal-
ancer be used when a wheel and t i re assembly re-
quire balancing. Static should be used only when a
two pl ane balancer is not available.
For static imbalance, find location of heavy spot
causing imbalance. Counter balance wheel directly
opposite the heavy spot. Determine weight required
to counterbalance t he area of imbalance. Place half
of this weight on t he i nne r ri m flange and t he other
half on t he out e r ri m flange (Fig. 6, Fig. 7). Off-ve-
hicle balancing is necessary.
Wheel balancing can be accomplished wi t h ei t her
on or off vehicle equipment. When using on-vehicle
balancing equipment, follow these precautions:
Limited-slip rear axle differential, remove t he op-
posite wheel/tire
Before balancing t he wheels/tires on a vehicle
equipped with a transfer case, disconnect t he drive
shafts
MATCH MOUNTING
Wheels and t i res are match mounted at t he factory.
This means t hat t he hi gh spot of t he t i re is matched
to t he low spot on t he wheel rim. This technique is
used to reduce run-out in t he wheel/tire assembly.
The high spot on t he t i re is marked with a pai nt
mar k or a bri ght colored adhesive label on t he out-
board sidewall. The low spot on t he ri m is at t he
valve stem location on t he wheel rim.
Before dismounting a tire from its wheel, a refer-
ence mar k should be placed on t he tire at t he valve
stem location. This reference will ensure t hat it is re-
mounted in t he original position on t he wheel.
(1) Measure t he total indicator runout on t he cen-
t er of t he tire t read rib. Record t he indicator reading.

A D P BALANCE
WEIGHTS HERE
TIRE OR WHEEL TRAMP,
OR WHEEL HOP
Fig. 6 Static Unbalance & Balance
CORRECTIVE
WEIGHT
LOCATI ON
A D D BALANCE
WEIGHTS HERE
J8922-8
HEAVY SPOT
WHEEL SHI MMY
A N D VIBRATION
CORRECTIVE WEIGHT
LOCATI ON
J 8 9 2 2 - 9
Fig. 7 Dynamic Unbalance & Balance
Mark t he t i re to indicate t he hi gh spot. Place a mar k
on t he t i re at t he valve stem location (Fig. 8).
(2) Break down t he t i re and remount it 180 de-
grees on t he ri m (Fig. 9).
(3) Measure t he total indicator runout again. Mark
t he t i re to indicate t he high spot.
(4) If runout is still excessive, t he following proce-
dures must be done.
If t he hi gh spot is wi t hi n 101.6 mm (4.0 in.) of t he
first spot and is still excessive, replace t he t i re.
If t he hi gh spot is wi t hi n 101.6 mm (4.0 in.) of t he
first spot on t he wheel, t he wheel may be out of spec-
ifications. Refer to Wheel and Tire Runout.
If t he high spot is NOT wi t hi n 101.6 mm (4.0 in.)
of either high spot, draw an arrow on t he t read from
second high spot to first. Break down t he t i re and re-
mount it 90 degrees on t he ri m in t hat direction (Fig.
10). This procedure will normally reduce t he runout
to an acceptable amount.
TIRE AND WHEEL RUNOUT
Radial runout is t he difference between t he high
and low points on t he t i re or wheel (Fig. 11).
Lat eral runout is t he wobbl e of t he t i re or wheel.
Radial runout of more t han 1.5 mm (.060 inch)
measured at t he center line of t he t read may cause
t he vehicle to shake.

Fig. 8 First Measurement On Tire
VALVE STEM
REFERENCE
AAARK J9322-4
Fig. 9 Remount Tire 180 Degrees
Lateral runout of more t han 2.0 mm (.080 inch)
measured near t he shoulder of t he tire may cause t he
vehicle to shake.
Sometimes radi al runout can be reduced. Relocate
t he wheel and t i re assembly on t he mount i ng studs
(See Method 1). If t hi s does not reduce runout to an
acceptable level, t he tire can be rotated on t he wheel.
(See Method 2).
2 N D H I GH SPOT
ON TIRE
SPOT ON
TIRE
J9322-5
Fig. 10 Remount Tire 90 Degrees In Direction of
Arrow
J9022-4
Fig. 11 Checking Tire Runout
METHOD 1 (RELOCATE WHEEL ON HUB)
Check accuracy of t he wheel mount i ng surface; ad-
j ust wheel bearings.
Drive vehicle a short distance to el i mi nat e t i re flat
spotting from a parked position.
Make sure all wheel nut s are properly torqued.
Relocate wheel on t he mounting, two st uds over
from t he original position.
Re-tighten wheel nut s unt i l all are properly
torqued, to eliminate brake distortion.
Check radial runout . If still excessive, mar k t i re
sidewall, wheel, and stud at point of maxi mum
runout and proceed to Method 2.

J8922-11
Fig. 12 Checking Wheel Runout
METHOD 2 (RELOCATE TIRE ON WHEEL)
Rotating t i re on wheel is particularly effective
when t here is runout in both tire and wheel.
Remove t i re from wheel and re-mount wheel on
hub in former position.
Check wheel radi al runout (Fig. 12).
STEEL WHEELS: Radial runout 0.040 in., Lat eral
runout 0.045 in.
ALUMINUM WHEELS: Radial runout 0.030 in.,
Lat eral runout 0.035 in.
If point of greatest runout is near original chalk
mark, remount t i re 180 degrees. Recheck runout.

WHEELS AND TIRES 2 2 - 1 1
VEHICLE VIBRATION
Vehicle vibration can be caused by:
Tire/wheel unbalance or excessive runout
Defective t i res wi t h extreme t read wear
Nylon overlay flat spots (performance t i res only)
Incorrect wheel beari ng adjustment (if applicable)
Loose or worn suspension/steering components
Cert ai n t i re tread pat t erns
Incorrect drive shaft angles or excessive drive
shaft/yoke runout
Defective or worn U-joints
Excessive brake rotor or drum runout
Loose engine or transmission supports/mounts
And by engine operated accessories
Refer to the appropriate Groups i n this man-
ual for additional information.
VIBRATION TYPES
There are two types of vehicle vibration:
Mechanical
Audible.
Mechanical vehicle vibration can be felt t hrough
the seats, floor pan and/or steering wheel.
Audible vehicle vibration is heard above normal
background noise. The sound can be a droning or
drummi ng noise.
Vibrations are sensitive to change i n engine
torque, vehicle speed or engine speed.
ENGINE TORQUE SENSITIVE VIBRATION
This vibration can be increased or decreased by:
Accelerating
Decelerating
Coasting
Mai nt ai ni ng a constant vehicle speed
VEHICLE SPEED SENSITIVE VIBRATION
This vibration condition always occurs at t he same
vehicle speed regardless of t he engine torque or en-
gine speed.
ENGINE SPEED {RPM} SENSITIVE VIBRATION
This vibration occurs at varying engine speeds. It
can be isolated by increasing or decreasing the en-
gine speed wi t h t he transmission in NEUTRAL posi-
tion.
VIBRATION DIAGNOSIS
A vibration diagnosis should always begin with a
10 mile (16 km) t ri p (to war m t he vehicle and tires).
Then a road t est to identify t he vibration. Corrective
action should not be at t empt ed unt i l t he vibration
type has been identified via a road test.
Duri ng t he road test, drive t he vehicle on a smooth
surface. If vibration exists, note and record t he fol-
lowing information:
Identify t he vehicle speed range when t he vibra-
tion occurs
Identify t he type of vibration
Identify t he vibration sensitivity
Determine if the vibration is affected by changes
in vehicle speed, engine speed and engine torque.
When t he vibration has been identified, refer to t he
Vibration Diagnosis chart for causes. Consider cor-
recting only those causes coded in t he chart t hat are
related to t he vibration condition.
Refer to t he following cause codes and descriptions
for explanations when referring to t he chart.
TRRTire and Wheel Radi al Runout: Vehicle
speed sensitive, mechanical vibration. The runout
will not cause vibration below 20 mph (32 km/h).
WHWheel Hop: Vehicle speed sensitive, me-
chanical vibration. The wheel hop generat es rapid
up-down movement in t he steering wheel. The vibra-
tion is most noticeable in t he 20 - 40 mph (32 - 64
km/h) range. The wheel hop will not cause vibration
below 20 mph (32 km/h). Wheel hop is caused by a
tire/wheel t hat has a radi al runout of more t han
0.045 of-an-inch (1.14 mm). If wheel runout is accept-
able and combined runout cannot be reduced by re-
positioning t he tire on wheel, replace tire.
TBTire/Wheel Bal ance: Vehicle speed sensitive,
mechanical vibration. Static tire/wheel unbalance
will not cause vibration below 30 mph (46 km/h). Dy-
namic tire/wheel unbalance will not cause vibration
below 40 mph (64 km/h).
TLRTire/Wheel Lateral runout: Vehicle speed
sensitive, mechanical vibration. The runout will not
cause vibration below 50 - 55 mph (80 - 88 km/h).
Excessive l at eral runout will also cause front-end
shimmy.
TWTire Wear: Vehicle speed sensitive, audible
vibration. Abnormal t i re wear causes small vibration
in t he 30 - 55 mph (88 km/h) range. This will pro-
duce a whine noise at high speed. The whine will
change to a growl noise when t he speed is reduced.
WTire Waddle: Vehicle speed sensitive, mechan-
ical vibration. Irregul ar t i re uniformity can cause
side-to-side motion during speeds up to 15 mph (24
km/h). If t he motion is excessive, identify t he defec-
tive tire and replace it.
U A JUniversal Joi nt (Drive Shaft) Angl es:
Torque/vehicle speed sensitive, mechanical/audible
vibration. Incorrect drive shaft angles cause mechan-
ical vibration below 20 mph (32 km/h) and in t he 70
mph (112 km/h) range. The incorrect angles can also
produce an audible vibration in t he 20 - 50 mph (32 -
80 km/h) range. Caster adjustment could be required
to correct t he angles.
UJUniversal Joi nts: Engi ne torque/vehicle
speed sensitive, mechanical/audible vibration. If t he
2 2 - 1 2 WHEELS AND TIRES
VIBRATION DIAGNOSIS
Vibration
Sensitivity
Correction Codes For Mechanical Vibrations Within Specific M PH (km/ h) Ranges
10
( 16km)
2 0
(32 km)
30
(48 km)
40
(64 km)
5 0
(80 km)
60
(96 km)
70
(112 km)
80
(128 km)
90
(144 km)
Vehicle
S peed
Sensitive
W
-WH-
-TRR and S S C -
- UJ and A N -
- WB -
- T B-
- D S Y
TLR-
Torque
Sensitive
I
- U J A -
UJ and A N
U J A -
Engine
Speed
Sensitive
E S
E A -
D E M -
Vibration
Sensitivity
Correction Codes For Audible Vibrations Within Specific M PH (km/h) Ranges
10
(16 km)
20
(32 km)
30
(48 km)
40
(64 km)
50
(80 km)
60
(96 km)
70
(112 km)
80
(128 km)
90
(144 km)
Vehicle
Speed
Sensitive
U J A -
JU and WH
D S Y "
- T W-
WB-
Torque
Sensitive
- A N *
- UJ and TED,
Engine
Speed
Sensitive
E A and E S -
- A D B -
- D E M -
J8922- 12
U-joint is worn it will cause vibration with almost
any vehicle speed/engine torque condition.
DSYDrive Shaft and Yokes: Vehicle speed sen-
sitive, mechanical/audible vibration. The condition
will not cause vibration below 35 mph (56 km/h). Ex-
cessive runout , unbalance or dent s and bends in t he
shaft will cause t he vibration. Identify t he actual
cause and repair/replace as necessary.
WBWheel Beari ngs: Vehicle speed sensitive,
mechanical/audible vibration. Loose wheel bearings
cause shimmy-like vibration at 35 mph (56 km/h)
and above. Worn bearings will also produce a growl
noise at low vehicle speed and a whine noise at hi gh
vehicle speed. The wheel beari ngs must be adjusted
or replaced, as applicable.
ANAxl e Noise: Engi ne torque/vehicle speed sen-
sitive, mechanical/audible vibration. The axle will
not cause mechanical vibration unless t he axle shaft
is bent. Worn or damaged axle pinion shaft or differ-
ential gears and beari ngs will cause noise. Replace
t he defective component(s) as necessary.
SSCSuspensi on and Steeri ng Components:
Vehicle speed sensitive, mechanical vibration. Worn
suspension/steering components can cause mechani-
cal vibration at speeds above 20 mph (32 km/h).
Identify and repai r or replace t he defective compo-
nent (s).
EAEngi ne Dri ven Accessori es: Engine speed
sensitive, mechanical/audible vibration. Vibration
can be caused by loose or broken A/C compressor, PS
pump, wat er pump, generator or brackets, etc. Usu-
ally more noticeable when t he transmission is shifted
into t he NEUTRAL position and t he engine speed
(rpm) increased. Inspect t he engine driven accesso-
ries in t he engine compartment. Repair/replace as
necessary.
ADBAccessory Drive Belts: Engine speed sen-
sitive, audible vibration. Worn drive belts can cause
a vibration t hat produces either a droning, fluttering
or rumbl i ng noise. Inspect t he drive belt(s) and tight-
en/replace as necessary.
DEMDamaged Engi ne or Transmi ssi on Sup-
port Mounts: Engi ne speed sensitive, mechanical/
audible vibration. If a support mount is worn, noise
or vibration will occur. Inspect t he support mount s
and repair/replace as necessary.
ESExhaust System: Engine speed sensitive, me-
chanical/audible vibration. If loose exhaust compo-
nent s contact t he vehicle body they will cause noise
and vibration. Inspect t he exhaust system for loose,
broken and mis-aligned components and repair/re-
place as necessary.

LUG NUT TORQUE
1/ 2x20 with 60 Cone
15 Inch Wheel
16 Inch Single Wheel
16 Inch Single Wheel
5/ 8x18 with Flanged Nut..
16 Inch Dual Wheel
T O R QU E
109 to 150 N-m
(80 to 110 ft. lbs.)
115 to 155 N-m
(85 to 115 ft. lbs.)
240 to 305 N-m
(175 to 225 ft. lbs.)
410 to 475 N-m
(300 to 350 ft. lbs.)
J9322-9
T O R Q U E S P E C I F I C A T I O N S

BODY COMPONENTS 23 - 1
CONTENTS
page page
CAB/BODY INTERIOR COMPONENTS 35 FIXED GLASS . 29
DOORS 21 PAINT CODE CHART 54
EXTERIOR COMPONENTS 1 REFINISHING PROCEDURES 54
EXTERIOR COMPONENTS
INDEX
page
Battery Tray 7
Blower Motor H ousi ng Insulation Panel Diesel
Engine Only 7
Body Moul di ngs, Nameplates and Decal s . . . . . . . 9
Cab . 14
Cab/ Body and Car go Box Stripes 11
Cargo Box 19
Cowl Grille 7
Front Fenders 8
Fuel Filler Door and Nozzl e/ Tubes 12
Grille and Grille Ex tension Panel 1
Grille Ex tension Panel Support Bracket (With
Diesel Engi ne Only) 3
page
Grille Openi ng Panel ( GOP) and Radiator
Support Panel 3
Hatchgate and Components 16
H ood 5
H ood Inside Rel ease Cabl e 5
H ood Latch 4
Label s/ Decal s/ Pl ates 1
Outside Mirrors 1 3
Roof V entRamcharger . 20
Spl ash Shiel dsF ront Fender 9
Sport Bar 18
Tailgate 14
LABELS/DECALS/PLATES
GENERAL INFORMATION
The labels, decals and plates t hat are attached to
Ram Van and Wagon vehicles contain safety or oth-
erwise essential information (Figs. 1, 2, 3 and 4).
INSTALLATION
Follow t he instructions included with each replace-
ment label, decal or plate to affix it to a panel or
component.
GRILLE AND GRILLE EXTENSION PANEL
GRILLE REMOVAL
(1) Remove screws t hat at t ach t he headl amp bezels
(Fig. 5) to t he grille.
(2) Separate t he bezels from t he headlamps (Fig.
5).
(3) Raise and support t he hood.
(4) Remove t he grille screws from t he radiator sup-
port panel and t he extension panel (Fig. 6).
(5) Remove t he grille from t he front of t he vehicle.
EMISSION CONTROL DRIVE BELT
INFORMATION AND VACUUM ROUTING LABEL
HOSE ROUTING LABEL (DIESEL
Fig. 1 Underhood Labels, Decals & Plates
B O D Y C O M P O N E N T S
23 - 2 BODY COMPONENTS

EXPORT
LABEL
VEHICLE ORI GI N
LABEL
NATI ONAL
SAFETY
MARK
(CANADA)
B-PILLAR
GLASS
EXHAUST
G A S
WA R N I N G
DECAL
UNLEADED/DIESEL
FUEL LABEL
(U.S.)
EXHAUST E MI S S I ON
STANDARDS-CALIF.
(MODELS 30 A N D 60)
EXHAUST
EMI SSI ON
STADARDS-CALIF.
(RAMCHARGER)
UNLEADED/DIESEL
FUEL LABEL
(CANADA)
J9123-408
Fig. 2 Exterior Labels & Decals
ARM
BRACKET
NOI SE
CERTIFICATION
LABEL
UOVER 10,000 LBS)
5
S N O W
PLOW
TRANSMI SSI ON
CAUTI ON HEADLINER
LABEL
TRANSFER CASE
SHIFT LABEL
(4WD)
S UN
VI SOR
REAR
VI EW
MI RROR SCREW *
BRACKET
J9123-410
Fig. 3 Sunvisor Rear Labels
GRILLE INSTALLATION
(1) Position t he grille at t he radi at or support panel
and extension panel. Install t he screws (Fig. 6).
(2) Ti ght en t he extension panel screws to 2 Nm
(17 in. lbs.) torque. Tighten t he radi at or support
panel screws to 3 Nnn (21 in. lbs.) torque.
(3) Install t he headl amp bezels and t he screws
(Fig. 5). Ti ght en t he screws to 2 Nnn (17 in. lbs.)
torque.
(4) Remove t he support and lower t he hood.
GRILLE EMTENSION PANEL REMOVAL
(2) Remove t he grille. If necessary, refer to t he re-
moval procedure.
(3) Remove t he screws from t he fender panel s and
t he support bracket (Fig. 7).
EXTERNAL
NOISE
CERTIFICATION
LABEL
(OVER 10,000 LBS.)
VEHICLE
HANDLING
LABEL
(RAMCHARGER)
J9123-599
Fig. 4 Sunvisor Front Labels
SCREW
A N C HOR
HE ADI AMP
BEZEL
GRILLE
J9123-6 00
Fig. 5 Headlamp Bezel & Grille
GRILLE
RADIATOR
SUPPORT
PANEL
NUT
PUSH-IN
NUT
SCREW NUT SCREW
SUPPORT
BRACKET
J9123-328
Fig. 6 Grille, Radiator Support Panel & Extension
Panel
(4) Remove t he extension panel.

GRILLE EXTENSION PANEL INSTALLATION
(1) Position t he grille extension panel at t he fender
panels and t he support bracket.
(2) Install t he panel screws. Tighten t he screws to
(3) Install t he grille. If necessary, refer to t he in-
stallation procedure.
(4) Remove t he support and close t he hood.
U-NUT RADIATOR GRILLE
Fig. 7 Grille Extension Panel
GRILLE EXTENSION PANEL SUPPORT BRACKET
(WITH DIESEL ENGINE ONLY)
REMOWAL
(1) Remove t he grille.
(3) Remove support bracket-to-grille opening panel
screw.
(4) Remove t he support bracket-to-radiator support
panel screw (Fig. 8).
(5) Remove t he support bracket from t he vehicle.
INSTALLATION
(1) Position t he support bracket at t he grille open-
ing panel (GOP) and radi at or support panel.
(2) Install t he support bracket-to-radiator support
panel screw. Tighten t he screw to 11 N*m (95 in. lbs.)
torque.
(3) Install t he support bracket-to-grille opening
panel (GOP) screw. Tighten t he screw to 23 N-m (200
in. lbs.) torque.
(4) Install t he grille extension panel.
(5) Install t he grille.
SCREW U-NUT RADIATOR
Fig. 8 Grille Extension Panel Support
BracketDiesel Engine only
GRILLE OPENING PANEL (GOP) AND RADIATOR
SUPPORT PANEL
REMOVAL
(1) Raise and support t he hood. Remove t he bat-
tery.
(4) If equipped, remove t he extension panel sup-
port bracket.
(5) Remove t he headlamps from t he headl amp re-
ceptacles in t he GOP.
(6) Drain t he engine coolant from t he radi at or in a
clean container for reuse. Remove t he radi at or from
t he GOP. If necessary, refer to Group 7Cooling
System for t he procedure.
(7) Remove t he bat t ery and t ray from t he GOP.
(8) Remove t he horns from t he GOP.
(9) Remove t he screws, hood latch and t he rein-
forcement plate from t he radi at or support panel.
(10) Detach t he latch release cable from t he clip on
t he radi at or support panel.
(11) Remove t he screws t hat at t ach t he splash
shields to t he GOP (Fig. 9).
(12) Remove t he cab/body front holddowns from
t he front crossmember (Fig. 10).
(13) Remove t he screws t hat at t ach t he fenders to
t he GOP.
(14) Remove t he screws t hat at t ach t he fenders to
(15) Remove t he screws t hat at t ach t he splash
shield to t he ri ght fender i nner support panel.
(16) Repeat step (15) for t he left fender panel.
(17) Move both fender panels outward at t he front.
Remove t he GOP and t he radi at or support panel
from t he vehicle.

INSTALLATION
(1) If necessary, install U-nut s at t he GOP lower
flange.
(2) Move both fender panels outward at t he front.
Position t he GOP on t he frame rails (Fig. 10).
(3) Move both fender panels inward at t he front.
Install t he screws to at t ach t he fender splash shields
to t he fender i nner support panels. Tighten t he
screws to 11 N
#
(4) Install t he cab/body front holddown bolts at t he
GOP to t he front crossmember. Tighten t he nut s to
(5) Install t he screws at t he fenders to t he GOP
and radi at or support panel. Tighten t he screws to 11
Nm (95 in. lbs.) torque. Tighten t he radiator support
panel screws to 23 Nnn (200 in. lbs.) torque.
(6) Align t he holes and install t he splash shield
screws. Tighten t he screws to 11 Nm (95 in. lbs.)
torque.
(7) Install t he horns on t he GOP.
(8) At t ach t he bat t ery t ray to t he GOP. If neces-
sary, refer to t he installation procedure. Tighten t he
screws to 11 Nnn (95 in. lbs.) torque.
(9) Install t he radi at or on t he GOP. Refill t he en-
gine wi t h coolant. If necessary, refer to Group
7Cooling System for t he procedures.
(10) Attach t he hood release cable to t he clip on
(11) Adjust t he hood latch cable.
(12) Position t he shield and t he hood latch on t he
radi at or support panel. Install t he screws. Tighten
t he screws to 23 Nnn (200 in. lbs.) torque.
(13) Test t he hood latch and t he release cable for
proper operation.
(14) Install t he headl amps in t he headl amp recep-
tacles.
(15) Install t he extension panel support bracket (if
equipped). Install t he grille extension panel and t he
grille.
(16) Install t he bat t ery and t he holddown bracket.
Tighten t he holddown rod nut s to 2 Nnn (20 in. lbs.)
torque.
(18) If necessary, adjust t he headl amp beams.
HOOD LATCH
REMOVAL
(1) Open and support t he hood.
(2) Remove t he hood latch and screws from t he ra-
diator support panel (Fig. 11).
(3) Disconnect release cable from t he hood latch.
INSTALLATION
If a repl acement hood l atch i s bei ng installed,
lubricate it thoroughl y.
SCREW
U-NUT
BUMPER INNER FENDER
SUPPORT PANEL
PANEL
SPLASH
SHIELD
SCREW
U-NUT
REINFORCEMENT
PANEL
(4WD ONLY)
GRILLE
PANEL
J9123-567
Fig. 9 Grille Opening Panel (GOP) & Radiator
Support Panel
BOLT
(RAMCHARGER)
WASHER
GRILLE OPENING AND
RADIATOR SUPPORT
PANEL
INSULATOR
BOLT
WITH INSULATOR
(MODELS 30 AND 60)
FRAME
RAIL
WASHER
NUT
SPACER
WASHER (4 FOR ADI)
INSULATOR ^
BOLT RETAINER
. FRAME
" " CROSSMEMBER
J9113-19
Fig. 10 Cab/Body Front Holddowns
(1) Position t he hood latch on t he radi at or support
panel. Install t he screws. Tighten t he screws to 23
Nnn (200 in. lbs.) torque.
(2) Connect latch release cable to t he hood latch.
(3) Adjust t he hood latch cable.
(4) Test t he hood latch and release cable for proper
operation.

(5) If necessary, align t he hood, the latch, and t he
striker. Refer to Fore/Aft And Latch/Striker Adjust-
ment.
BOLT
CABLE
SHIELD
RADIATOR
GRILL SUPPORT
RB1346
Fig. 11 Hood Latch & Release Cable
HOOD INSIDE RELEASE CABLE
REMOWAL
(1) Open and support t he hood.
(2) Disconnect release cable from t he hood latch.
(3) Detach t he release cable from t he clip in t he
engine compartment (Fig. 12).
(4 ) Separat e t he release cable grommet from the
dash panel hole.
(5) From inside t he vehicle, remove t he screws. Re-
move t he release cable handle bracket from t he bot-
tom of t he i nst rument panel.
(6) Route t he hood release cable t hrough t he dash
panel hole. Remove it via t he inside of t he vehicle.
INSTALLATION
(1) Route t he hood release cable t hrough t he hole
in t he dash panel.
(2) Position t he release cable handle at t he bottom
of t he i nst rument panel. Install t he screws. Tighten
t he screws to 11 N
e
(3) Install t he cable grommet in t he dash panel
hole (Fig. 12).
(4 ) Attach t he cable to t he rear clip in t he engine
compartment.
(5) Route t he cable under t he radiator support
panel flange. Attach it to t he clip and t hen connect it
to t he hood latch.
(6) Adjust t he latch cable.
(7) Test t he hood latch release cable for proper op-
eration.
RELEASE
CABLE
HANDLE
BRACKET
HO O D
LATCH
RADIATOR
BAFFLE
PANEL J9123-376
Fig. 12 Release Cable Removal/Installation
LOCATOR
CLIP
HO O D
LATCH
RELEASE
CABLE
BRACKET
I NSTRUMENT
PANEL
LOWER
REI NFORCEMENT
BRACKET
RWAL BRAKE
TEST CONNE CTOR J9123-360
Fig. 13 Release Cable Handle Bracket & RWAL
Brake Test Connector
HOOD
POSITION ADJUSTMENT
The hood hinge bolt holes are oversize and elon-
gated for ease of adjustment (Fig. 15). Loosen t he
hinge bolts at t he fender for up/down adjustment.
Loosen t he hinge bolts at t he hood for front/back ad-
j ust ment .
REMOVAL
(1) Raise and support t he hood at t he full-open po-
sition.
(2) If equipped, disconnect t he underhood lamp
wire connector (Fig. 16).
(3) With t he aid of an assistant, remove t he hinge
arm-to-hood bolts. Remove t he hood from vehicle.

INSTRUMENT PANEL
COWL
PANEL
REGULATOR
BRACKET J9123-437
Fig. 14 Release Cable Handle Bracket & Diesel
Engine Speed Control Regulator Bracket
(4) If a replacement hood is being installed, t rans-
fer t he underhood lamp and t he insulator panel (Fig.
17).
(5) Test t he hood hinges for correct operation.
(6) Lubricate the hood hinges with engine oil.
INSTALLATION
(1) With t he aid of an assistant, position t he hood
on t he vehicle. Align t he hood bolt holes with t he
hinge ar m holes. Install and finger-tighten t he bolts.
(2) Align t he hood, t he latch, and t he striker.
HINGE REPLACEMENT
REMOVAL
If both hi nges are bei ng repl aced, remove the
hood and both hi nges as a unit. If onl y one
hi nge is bei ng repl aced, use the fol l owi ng proce-
dure.
(1) Raise and support t he hood at t he full-open po-
sition.
(2) Mark t he position of t he hinge bolts. Loosen
t he bolts (Fig. 15).
(3) Support t he hood at t he side being removed.
Remove t he bolts and hinge from t he hood and
fender panel.
INSTALLATION
(1) Position t he replacement hinge agai nst t he
fender panel. Install and finger-tighten t he bolts.
(2) Align t he hood bolt holes with t he marks.
(3) Tighten t he hinge bolts to 23 N-m (200 in. lbs.)
torque.
LATCH STRIKER
LATCH SAFETY SUPPORT HOOD
STRIKER LATCH PANEL HINGE J9123-375
Fig. 16 Underhood Lamp
INSTALLATION
(1) Position t he st ri ker on t he hood.
(2) Install and t i ght en t he screws.
HOOD SUPPORT ROD
REMOVAL
(2) Drill out t he support rod rivet from t he radia-
tor support panel.
(3) Remove t he support rod from t he radiator sup-
port panel.
INSTALLATION
(1) Position t he support rod on t he radi at or support
panel.
(2) Install t he rivet to at t ach t he rod to t he panel.
REMOVAL
(2) Remove t he screws and t he latch st ri ker from
t he hood.

Fig. 17 Hood Insulator Panel
BLOWER MOTOR HOUSING INSULATION
PANE L- DI E SE L ENGINE ONLY
REMOVAL
(1) Remove the insulation panel screws from t he
dash panel (Fig. 18).
(2) Remove the insulation panel from t he blower
motor housing and t he dash panel.
INSTALLATION
(1) Position t he insulation panel over t he blower
motor housing.
(2) Install the insulation panel screws. Tighten t he
screws to 1 N
#
COWL GRILLE
REMOVAL
(1) Remove t he windshield wiper arms. If neces-
sary, refer to the procedure in Group 8Electrical.
(3) Remove the cowl grille screws (Fig. 19).
Ramcharger vehi cl es have extra screws lo-
cated at the rear of the cowl grille under the
seal.
(4) Disengage t he rear of t he grille from t he wind-
shield weatherstrip seal.
(5) Detach windshield washer hoses from t he noz-
zles and t he clips.
(6) Separat e t he grille from t he cowl. Remove it
from t he cowl upper panel.
DASH TAB
ENGINE) SCREW J9123-385
Fig. 18 Blower Motor Housing Insulation Panel
INSTALLATION
(1) Position t he grille on t he cowl upper panel and
under t he windshield weat herst ri p seal. Align t he
screw holes.
(2) Attach windshield washer hoses to the nozzles
and t he clips.
(3) Install t he grille screws. Tighten t he front
screws to 1 Nm (12 in. lbs.) torque.
(4) Remove t he support and close the hood.
(5) Install t he windshield wiper arms.
SCREW WEATHERSTRIP
Fig. 19 Cowl Grille Removal/Installation
BATTERY TRAY
REMOVAL
(1) Remove t he nut s, holddown strap and support
bracket from t he holddown rods.

(2) Disconnect t he cables. Remove t he bat t ery from
t he tray.
(3) Remove t he bolts t hat at t ach t he bat t ery t ray
to t he fender inner panel and t he radiator baffle
panel.
(4) Remove t he screws t hat at t ach t he r ear brace
to t he t r ay and to t he inner fender panel.
(5) Remove t he bat t ery t ray from t he vehicle.
(6) If necessary, remove t he holddown rods from
t he bat t ery t ray.
INSTALLATION
(1) If removed, install t he holddown rods on t he
bat t ery t ray.
(2) Position t he bat t ery t ray agai nst t he radi at or
baffle panel and t he fender i nner panel.
(3) At t ach t he bat t ery t ray to t he radi at or baffle
panel and t he fender i nner panel. Tighten t he bolts
(4) Position t he rear brace at t he t ray and at t he
fender i nner panel. Install t he brace screws in t he
t ray and t he fender i nner panel. Tighten t he screws
to 11 N*m (95 in. lbs.) torque.
(5) Install t he bat t ery in t he t ray.
(6) Position t he holddown st rap and t he support
bracket over t he holddown rods.
(7) Install t he nut s on t he holddown rods. Ti ght en
t he nut s to 2 Nm (20 in. lbs.) torque.
(8) Connect t he cables to t he bat t ery.
HOLDDOWN
STRAP
REAR
BRACE
NUT SUPPORT
' BRACKET
BATTERY
SCREW
U- NUT
SUPPORT
BRACKET
NUT-
J9123-355
WASHER^
BOLT-^ F W D
U- NUT
LEFT
FRONT
FENDER
NUT
BOLT
RADI ATOR
BAFFLE
PANEL
Fig. 20 Battery Tray Removal/Installation
FRONT FENDERS
(3) Remove t he grille extension panel.
(4) Remove t he bat t ery and t ray for left fender re-
moval only.
(5) Remove t he screws t hat at t ach t he fender and
i nner panel (Fig. 21) to t he radi at or support panel.
SCREW
U- NUT
BUMPER I NNER FENDER
SUPPORT PANEL
PANEL
SPLASH
SHI ELD
SCREW
U- NUT
REI NFORCEMENT
PANEL
(4WD ONLY)
GRI LLE
PANEL
J9123-567
Fig. 21 Front Fender-To-Grille/Radiator Support
Panels Hardware
(6) Remove t he screw and nut t hat at t ach t he top
of t he fender (Fig. 22) to t he cowl.
- SCREW
NUT SPACER CAB
STUD \ HOLDDOWN
BRACKET
COWL
SI DE
PANEL
FENDER
PANEL
SPACER
GRI LLE
PANEL
V
SPACER SCREW
SCREW
J9123-566
Fig. 22 Front Fender-To-Cowl/Dash Panel Hardware
(7) Remove t he screws t hat at t ach t he bottom of
t he fender and inner panel to t he dash panel.
REMOWAL

(8) Remove t he fender and t he i nner panel from
t he cab/body.
(9) Remove t he screws t hat at t ach t he fender inner
panel to t he fender panel. Remove t he i nner panel
from the fender outer panel (Fig. 23).
INSTALLATION
(1) Position t he fender i nner panel liner on t he
outer panel. Install the screws. Tighten t hem to 23
(2) Position t he fender wi t h i nner panel on t he cab/
body.
(3) Install t he screws t hat at t ach t he fender to t he
radiator support panel. Ti ght en t he screws to 23 N-m
(4) Install t he screws t hat at t aches t he fender and
inner panel to t he dash panel. Tighten t he screws to
23 N-m (200 in. lbs.) torque.
(5) Install t he screw and nut t hat attaches t he top
of t he fender to t he cowl. Ti ght en t he screw and nut
(6) If removed, install t he bat t ery and tray.
Tighten t he bat t ery t ray bolts to 11 N-m (95 in. lbs.)
torque. Tighten t he support bracket-to-fender inner
panel bolt to 23 N-m (200 in. lbs.) torque.
(7) Install t he grille extension panel and t he grille.
FENDER
PANEL
GRILLE
EXTENSI ON
PANEL
J9123-565
Fig. 23 Front Fender Outer Panel
SPLASH SH IELDSFRONT FENDER
REMOVAL
(1) Remove t he plastic clip t hat at t ach t he splash
shield to t he frame rail.
(2) Remove t he pushnut s and t he screws t hat at-
t ach t he splash shield to t he frame rail.
(3) Remove t he push ret ai ners t hat at t ach t he
splash shield to t he fender i nner panel.
(4) Remove t he splash shield from t he frame rail
and t he fender i nner panel.
INSTALLATION
(1) Position t he splash shield on t he frame rai l and
t he fender inner panel.
(2) Install t he ret ai ners to attach t he shield to the
fender i nner panel and to t he frame rail.
(3) Install the frame rail-to-shield screws and
pushnut s.
RIGHT
FRONT
FENDER
CLIP RETAINER CLIP RETAINER
FRAME
LEFT
FRONT
FENDER
SPLASH
SHIELD
FRAME
RAIL
RIGHT SIDE
SCREW
LEFT
FRONT
FENDER
SPLASH
SHIELD
J9123-327
Fig. 24 Splash ShieldsFront Fender
BODY MOULDINGS, NAMEPLATES AND DECALS
BODY SIDE (VINYL) MOULDING
REPLACEMENT
Vinyl mouldings are attached to outer panels by
tape.
Wheel lip mouldings are attached by screws and
tape.
Ensure t hat t he method of moulding at t achment is
known before at t empt i ng removal (Fig. 25).
REMOV ALMOULDI NGS ATTACHED WITH ADHESIVE TAPE
(1) Soften t he body side moulding tape adhesive
(Fig. 25 with a heat gun.
(2) Lift one edge of t he moulding with a put t y
knife and peel t he moulding and t ape from t he panel.
Apply heat to any location where t he moulding tape
remai ns adhered to a panel.
(3) Remove t he residual tape adhesive from the
panel with 3M All Purpose Cleaner or an equivalent.
INSTALLATION MOULDINGS ATTACHED WITH ADHESIVE
TAPE
(1) Clean t he panel surface with a commercial wax
and silicone removal solution. Wipe t he surface with
a clean cloth and allow it to dry.
(2) To ensure proper vertical alignment, use mask-
ing t ape as an alignment reference.
(3) Remove t he backing from t he double-sided
tape. Align t he moulding with t he alignment refer-
ence tape. Position it on t he panel.
(4) Verify t hat t he moulding is properly aligned.
Remove t he al i gnment reference t ape.
2 3 - 1 0 BODY COMPONENTS
(5) Press t he moulding onto t he panel with a roller
(or use hand pressure) to ensure complete adhesion.
QUARTER PANEL
MOLDING
FRONT
FENDER
REAR
MOLDING
FRONT
FENDER
FRONT
MOLDING
REAR CARGO DOOR
FRONT
^ W H E E W OU S E ~SST MSSNG
W
^| S
$ E
SIDE OPENING SIDE
PANEL MOLDING PANEL
REAR MOLDING
MOLDING
QUARTER
PANEL
MOLDING
OPENING
MOLDING
ADHESIVE-BACKED
MOLDING
NUT
QUARTER
PANEL
MOLDING
EXTENDED CAB STANDARD CAB
10.5 MMlyx
CHARACTER \
UNE
J9123-603
Fig. 25 Ram Truck Body Side Mouldings
REMOVALWHEEL LIP MOULDINGS
(1) Remove t he screws from t he moulding (Fig. 25).
(2) Soften t he wheel lip moulding tape adhesive
with a heat gun.
(3) Peel t he moulding and tape from t he wheel-
house. Apply additional heat to any location where
t he moulding adhesive remai ns.
INSTALLATIONWHEEL LIP MOULDINGS
(1) Remove t he backing from t he double sided
tape.
(2) Align t he moulding with t he screws holes in
t he fender panel. Install t he screws into t he fender
panel. Tighten t he screws to 3 N*m (24 in. lbs.)
torque.
(3) Press t he moulding onto t he wheelhouse wi t h a
roller (or use hand pressure).
NAMEPLATES
REMOVAL
(1) Soften t he nameplate/badge t ape adhesive
(Figs. 26 and 27) wi t h a heat gun.
(2) Lift one edge of t he namepl at e with a put t y
knife (or a similar thin-blade tool). Peel t he mould-
ing and t ape from t he panel. Apply additional heat to
any location where t he t ape remai ns.
(3) Remove t he residual tape adhesive from t he
panel wi t h 3M All Purpose Cleaner or an equivalent.
INSTALLATION
(1) Clean t he painted panel surface with a com-
mercial wax and silicone removal solution. Wipe t he
surface with a clean cloth and allow it to dry.
(2) Use maski ng tape to indicate t he upper posi-
tion for t he namepl at e on t he panel (Figs. 26 and 27).
(3) Remove t he backing from t he namepl at e. Align
t he namepl at e with t he alignment reference tape. Po-
sition t he namepl at e on t he panel.
(4) Verify t hat t he namepl at e is properly aligned.
Remove t he al i gnment reference tape.
(5) Press t he namepl at e onto t he panel with a
roller (or use hand pressure).
DOOR
OPENI NG
B-PILLAR
NAMEPLATE
J9123-356
Fig. 26 Ram Truck Nameplates
SI DE
WI NDOW
B-PILLAR
NAMEPLATE DOOR OPENI NG
FRONT
FENDER
NAMEPLATE
J9123-357
Fig. 27 Ramcharger Nameplates
TAILGATE AND CARGO BOM DECALS
The raised letters on t he tailgate are covered with
a durable, weat her-resi st ant decal. The cargo box
side panel decal also is a durable, weather-resistant
decal.
REMOVAL
(1) Soften t he decal adhesive with a heat gun.
(2) Lift one edge of t he decal with a put t y knife.
Slowly peel t he decal from t he panel.

(3) Apply additional heat to any location where t he
decal remai ns adhered to t he panel.
(4) Remove t he extra adhesive from t he panel with
a cloth sat urat ed with an adhesive remover.
INSTALLATION
(1) Clean the panel surface with a commercial wax
and silicone removal solution. Wipe t he surface with
a clean cloth.
(2) Remove t he backing from t he decal. Position it
on t he panel.
(3) Verify t hat t he decal is properly aligned.
(4) Press t he decal onto t he panel with a roller to
ensure complete adhesion.
Fig. 28 Tailgate & Cargo Box Decals
TMILGA TE/HA TCHGA TE APPLIQUE
REMOVAL
(1) Open t he tailgate/hatchgate.
(2) If applicable, remove t he hat chgat e t ri m panel.
(3) Remove t he applique screws (Figs. 29 and 30).
(4) Pry t he applique from t he tailgate/hatchgate to
separate t he corner studs from t he ret ai ners.
(5) Remove t he applique from t he tailgate/hatch-
gate.
INSTALLATION
(1) Position t he applique on t he tailgate/hatchgate
with t he corner studs mat ed with t he ret ai ners.
(2) Install t he applique screws in t he tailgate/
hat chgat e (Figs. 29 and 30). Tighten the screws to 2
(3) If applicable, install t he hat chgat e t ri m panel.
(4) Close t he tailgate/hatchgate.
ROOF MOULDING
REMOVAL
(1) Remove t he moulding end caps.
(2) Pry t he moulding from t he drip rail. Remove
t he moulding from t he roof edge.
RETAINER APPLIQUE J9123-538
Fig. 29 Tailgate Applique
Fig. 30 Hatchgate Applique
INSTALLATION
(1) Position t he roof moulding with ret ai ners at
t he roof drip rail.
(2) Force t he moulding onto t he drip rail until it is
seated against the roof edge.
(3) Install the moulding end caps.
CAB/BODY AND CARGO BOX STRIPES
GENERAL INFORMATION
The cab/body and cargo box stripes are durable,
weather-resistant tape stripes with pressure-sensitive
backing (Figs. 32 and 33). The tape stripe is pro-
tected by a carrier until installed on a body panel.
The carrier also is an installation alignment aid.

Fig. 31 Roof Moulding
REMOVAL
(1) Remove exterior t ri m as necessary to clear cap-
tured edges of t he t ape stripe being removed
(2) Remove tape stripe using a suitable heat gun
or lamp.
This will soften t he adhesive backing.
(3) Clean adhesive residue from body finish using
a suitable adhesive remover.
INSTALLATION
INSTALLATION EQUIPMENT
Bucket filled with a mild dish soap solution.
Lint free applicator cloth or sponge.
Body put t y applicator squeegee.
Heat gun or sun lamp.
Razor knife.
The painted surface of t he body panel to be covered
by a t ape stripe must be smooth and completely
cured before t he stripe can be applied. If t he painted
surface is not smooth, wet sand wi t h 600 grit wet/dry
sand paper unt i l surface is smooth.
Ripples and feather edges will read t hrough t he
stripe if surface is not properly prepared.
(1) With backing still in place, position stripe
across panel to receive t he stripe. Apply maski ng at
top of stripe to hold it in position.
(2) Mark outside edge of panel on stripe with
grease pencil.
(3) Tri m stripe to wi t hi n 17 mm (0.750 in.) of out-
line marks.
(4) Spread stripe across a smooth flat work surface,
stripe side down.
(5) Peel paper backing away from stripe exposing
adhesive backing of stripe.
(6) Apply soap solution liberally to adhesive back-
ing of stripe.
(7) Apply soap solution to body panel surface.
(8) Place stripe into position on body panel.
Smooth out wrinkles by pulling lightly on edges of
tape stripe unt i l it lays flat on panel surface.
(9) Push air pockets from under tape stripe to t he
perimeter of t he panel from t he center of t he tape
stripe out.
(10) Remove air bubbles from under tape stripe us-
ing a body put t y squeegee (Fig 34).
C A U T I O N : Do nut cut Into painted surface of body
when trimming tape stripe to si ze.
(11) Trim tape stripe to size using a razor knife.
Leave at least 13 mm (0.5 in.) for edges of doors and
openings.
CAUTI ON; D o not overheat tape stripe when per-
forming step 12.
(12) Apply heat to tape stripe to evaporate residual
moisture from edges of tape stripe. This will also al-
low t ape stripe to be stretched into concave surfaces.
(13) Edge t ur n tape stripe around doors or fenders
(Fig 35).
(14) Install exterior t ri m if necessary. Small air or
wat er bubbles under tape stripe can be pierced wi t h
a pin and smoothed out.
TAILGATE CARGO BOX CAB AND FENDER
TAPE SIDE TAPE DOOR TAPE TAPE
STRIPE STRIPE STRIPE STRIPE
J9123-532
Fig. 32 Cab & Cargo Box Upper Stripes
FUEL FILLER DOOR AND NOZZLE/TUBES
DOOR
REMOVAL
(1) Open t he fuel filler door.
(2) Remove t he screws from t he cargo box side
outer panel.
(3) Remove t he door from t he panel.
INSTALLATION
(1) Position t he fuel filler door on t he cargo box
side outer panel.
(2) Install t he door screws in t he cargo box side
outer panel. Tighten t he screws to 4 Nnn (35 in. lbs.)
torque.

A M .
TAPE
STRIPE
WHEELHOUSE
LIP
CARGO BOX
LOW E R
RE AR, SI DE PAN E L
BUMPER
SE C ON D ARY
COLOR
D OOR
PAN E L
FRONT /
FENDER
SCRE W
J9123-555
FUEL
FILLER
DOOR
SIDE OUTER
PANEL
J91 23- 34 2
Fig. 33 Cab & Cargo Box Stripes With Two-Tom
Paint
TAPE STRIPE
FLANGE J 91 23- 593
Fig. 35 Tape Stripe installation On Door Flange
(3) Close t he fuel filler door.
Fig. 36 Fuel Filler Door
NOZZLE/TUBES
REMOVAL
(1) Remove t he fuel filler door (Fig. 36).
(2) Remove t he cap from t he nozzle (Fig. 37).
(3) Loosen t he clamps and separate the hose from
t he tube.
(4) Remove t he screws t hat at t ach t he housing and
nozzle to t he cargo box panel.
T h e f uel c a p t e t h e r i s a l s o a t t a c h e d t o t he
c a r g o box pa ne l wi t h o n e of t h e s c r e ws ,
(5) Remove t he housing and nozzle/tube from t he
cargo box panel.
INSTALLATION
(1) Position t he fuel filler housing and nozzle/tube,
and t he fuel cap t et her at t he opening in t he cargo
box panel.
(2) Install t he housing, nozzle and t et her screws in
t he panel. Tighten t he screws to 2 Nm (20 in. lbs.)
torque.
(3) Attach t he hose to t he tube with t he clamp.
Tighten t he fuel hose clamp screw to 2 N*m (20 in.
lbs.) torque. Tighten t he vent hose clamp screw to 1
N
#
(4) Install t he cap on the nozzle (Fig. 37),
(5) Install t he fuel filler door.
OUTSIDE MI RRORS
STANDARD (NON-REMOTE) MANUAL MIRROR
REMOVAL
(1) Remove t he screws from t he mirror base.
(2) Remove t he mirror and base from t he door out-
side panel.
(3) If necessary, separate t he mirror from t he base.
HO U S I N G U-NUT C A R G O BOX
FWD HOS E CLAMP J9123-551
Fig. 37 Fuel Filler Housing & Nozzle/Tubes
I NSTALLATI ON
(1) If necessary, clean t he door panel-mirror base
contact surface.
(2) If separated, at t ach t he mirror to t he base.
Tighten t he stud-nut to 11 N-m (95 in. lbs.) torque.
(3) Position the mirror base on the door outside panel
with its screw holes aligned with the panel holes.
(4) Install t he mirror base screws. Tighten t he
screws to 4 N-m (35 in. lbs.) torque.
LOCKWASHER OUTSIDE REINFORCEMENT
PLATE
61/2 x 9 I N. MIRROR
MANUAL MIRROR MANUAL OR POWER
J9123-332
Fig. 38 Standard&6X9 Wide-View Mirrors
6X9 WIDE-VIEW MIRROR
RE M OV AL
(1) Remove t he mirror cover screw. Separat e t he
mirror cover from t he base.
(2) Remove t he mirror base nut s from t he rein-
forcement pl at e studs.
(3) Remove t he mirror and t he base from t he door
outside panel.
(2) Position the mirror base on the door outside panel
with the studs inserted in the mirror base holes.
(3) Install t he mirror base nut s. Tighten t he nut s
(4) Position t he cover over t he mirror base.
(5) Install t he cover screw. Tighten t he screw to 2
LOW PROFILE OUTSIDE MIRROR
RE MOV AL
(1) Remove t he bolts t hat at t ach t he support
braces to t he door outer panel.
(2) Remove t he mirror and braces from t he door
outer panel.
I NSTALLATI ON
(1) Position t he mirror and braces on t he door
outer panel with t he brace holes aligned with t he nut
inserts.
(2) Install t he mirror brace bolts in t he nut inserts.
WASHER
Fig. 39 Low Profile Mirror
CAB
SERVICE INFORMATION
The cab is attached to t he vehicle frame st ruct ure
with bolts (Figs. 40 and 41). If necessary, t he cab can
be removed for repair or service access. Refer to t he
procedure within Group 13Frame.
TAILGATE
REMOVAL
(1) Open t he t ai l gat e.
(2) Separat e t he t ai l gat e check ar ms from t he pins.
Separat e t he check arms from t he t ai l gat e (Fig. 42).
Single wheel vehicles: On t he ri ght side, remove
t he t ai l gat e hinge-half from t he slot in cargo box
I NSTALLATI ON
(1) If necessary, clean t he door panel-mirror base
contact surface.

BOLT
Fig. 40 Cab/Body Front-End Holddowns
hinge-half. On the left side, remove t he t ai l gat e
hinge-half from the cargo box hinge-half by moving
t he t ai l gat e to t he right.
Dual wheel vehicles: On t he ri ght side, remove t he
rivet. Remove t he tailgate hinge-half from t he slot in
cargo box hinge-half. On t he left side, pull t he tail-
gate clearance/ID lamp wire harness outward from
t he cargo box and disconnect the connectors (Fig. 43).
(3) Remove t he tailgate from t he cargo box.
INSTALLATION
(1) Position t he t ai l gat e at t he cargo box.
CAB FRONT DOWN HOLD CAB REAR DOWN HOLD
J9113-18
Fig. 41 Cab HolddownsTypical
Single rear wheel: On t he left side, insert t he tail-
gate hinge-half into t he cargo box hinge-half. Move
the t ai l gat e to t he left. On t he right side, insert t he
tailgate hinge-half into t he slot in cargo box hinge-
half.
Dual r ear wheel: On t he left side, connect t he tail-
gate clearance/ID lamp wire harness connectors. In-
sert t he wire harness in t he cargo box. Insert t he
tailgate hinge-half into t he cargo box hinge-half.
Move t he tailgate to t he left. On t he right side, in-
stall t he rivet in t he t ai l gat e hinge-halves.
(2) Install t he check ar ms onto t he pins.
Note that the t ai l gat e e nd of the check arms
are identified as to whi ch side faces the tailgate.
Fig. 42 Tailgate Removal/Installation
(3) Test t he handle and latches for correct opera-
tion. If necessary, adjust t he st ri kers to eliminate
tailgate looseness and noise.
(4) Close t he tailgate.
CONNECTOR
TO LT TAIL. STOP,
TURN & B/ UP
L AM PS
HOUS I NG
CLEARANCE
AND ID
LAMPS
J9123-570
Fig. 43 Tailgate Clearance/ID Lamps & Wire Harness
STRIKER ADJUSTMENT
(1) Remove t he striker from t he cargo box i nner
panel.
(2) As necessary, add or remove spacers.
(3) Install t he st ri ker in the cargo box i nner panel.
Tighten t he st ri ker to 23 N-m (200 in. lbs.) torque.
TAILGATE DISASSEMBLY
(1) Remove t he screws t hat at t ach the lock and
latch release handl e to t he tailgate inside panel.
(2) Lower t he lock and handle. Remove from t he
t ai l gat e opening.
(3) Disconnect t he clips t hat at t ach t he lock latch
rods to t he lock arms.
(4) Remove t he bolts, t he latch and the rod from
each end of t he tailgate.
(5) Separate t he clip and rod from each latch.
TAILGATE ASSEMBLY
(1) Lubricate t he latches, t he handl e and lock, and
t he rod ends before assembly.
(2) Install t he rod and clip on each latch.
(3) At each end of t he tailgate, insert t he rod into
t he opening. Position t he latch on t he end of t he tail-
gate. Install t he bolts. Tighten t hem to 23 N-m (200
in. lbs) torque.
(4) Connect t he lock latch rods to t he lock arms.
Retain t hem with t he clips.
(5) Insert t he handl e and lock in t he tailgate open-
ing.
(6) Install t he lock and handl e screws in t he tail-
gate inner panel. Tighten t he screws to 11 N-m (95
in. lbs.) torque.
(7) Test t he handle and latches for correct opera-
tion. Adjust t he strikers to eliminate tailgate loose-
ness and noise.
HATCHGATE AND COMPONENTS
SUPPORT ROD
REMOVAL
WA R N I N G : D O N OT D I S C O N N E C T A S U PPO R T
R O D WI T H T HE H A T C H G A T E C L O S E D . T HE S U P-
PO R T R O D PI S T O N S A R E O PE R A T E D BY HI G H
P R E S S U R E G A S . T HI S C O U L D C A U S E D A M A G E
A N D / O R PE R S O N A L I N J U R Y I F T HE Y A R E R E -
M O V E D WHI L E T HE PI S T O N S A R E C O M P R E S S E D .
Fig. 44 Tailgate Disassembly/Assembly

(1) Open and support t he hat chgat e.
(2) Remove t he support rod upper bolt from t he
rear pillar (Fig. 4 5) .
(3) Remove the support rod lower screw from t he
hatchgate (Fig. 46).
(4) Remove t he support rod from t he hatchgate.
I NSTALLATI ON
(1) Position t he upper end of t he support rod at t he
roof panel. Install t he nut and bolt. Tighten t hem to
23 N' m (200 in. lbs.) torque.
(2) Position t he lower end of t he support rod at t he
hatchgate. Install t he nut and screw. Tighten t hem
(3) Test t he support rod and hat chgat e for correct
operation.
ROOF PANEL REAR
Fig. 45 Hatchgate
HATCHGATE HINGE
RE MOV AL
(2) Remove the hi nge roof panel screws.
(3) Remove the hi nge hat chgat e screws.
(4) Remove t he hi nge from t he hat chgat e and roof
panel.
I NSTALLATI ON
(1) Position t he hi nge on t he hat chgat e.
(2) Install t he hi nge hat chgat e screws. Tighten t he
(3) Position t he hi nge on t he roof panel.
(4) Install t he hinge roof panel screws. Tighten the
(5) Test t he hat chgat e and hinge operation. If nec-
essary, add spacer(s) for hinge adjustment.
AUXILIARY RETAINER
SCREW NUT HATCHGATE J9123-387
Fig. 46 Hatchgate Support Rod & Hinge Removal/
Installation
HATCHGATE
RE M OV AL
(1) Open and support the hat chgat e.
(2) Remove t he hinge roof panel screws.
W ARN I N G: D O N OT D I SCON N E CT TH E SUPPORT
ROD S WI T H TH E H ATCH GATE C L OSE D . TH E SUP-
PORT ROD PI STON S ARE OPE RATE D BY H I GH
PRE S S U RE GAS. TH I S COUL D C AUSE D AM AGE
AN D / OR PE RSON AL I N J URY IF TH E Y A RE RE -
M OV E D W H I L E TH E PI STON S ARE C OM PRE S S E D .
(3) Remove support rod upper bolts from t he rear
pillar.
(4) Remove hat chgat e and support rods from t he
vehicle.
I NSTALLATI ON
(1) Position and support t he hat chgat e in t he vehi-
cle opening.
(2) Align t he support rod bolt holes. Inst al l t he
nut s and bolts. Tighten t he bolts to 23 N*m (200 in.
lbs.) torque.
(3) Install t he hinge roof panel screws. Ti ght en
(4) Test t he hat chgat e and hinge operation. If nec-
essary, add spacer(s) for hinge adjustment.
LATCH STRIKER REMOVAL/INSTALLATION
(1) Raise t he hat chgat e.

(2) Remove t he latch st ri ker from t he inner quar-
ter panel (Fig. 45)
(3) Install the latch st ri ker in t he i nner quart er
panel. Tighten striker to 23 Nm (200 in. lbs.) torque.
(4) Close t he hat chgat e.
HATCHGATE OPENING WEATHERSTRIP SEAL
REMOVAL
(1) Separate the weatherstrip seal at the lower cen-
terline of the rear cross sill. Remove the connector.
(2) Pull t he seal away from t he flange around t he
perimeter
of t he hat chgat e opening.
(3) Clean t he flange as necessary.
INSTALLATION
(1) Position t he left end of t he seal at t he lower
centerline rear cross sill. Install it in a clockwise di-
rection.
(2) Seat t he installed part of t he seal with a roller.
Move t he roller from t he left-bottom end of t he seal
to t he top-left half of t he seal.
(3) Move around t he edge of t he flange and seat
the seal.
(4) Center and but t the seal ends together at t h
centerline.
(5) Seat t he remai ni ng part of t he seal with a
roller. Move the roller from the top-left half of t he
seal to t he right-bottom end of t he seal.
(6) Install t he connector in t he butted seal ends.
TRIM PANEL
REMOVAL
(1) Use a t ri m panel removal tool to detach t he
panel from t he hat chgat e (Fig. 47).
(2) Remove the t ri m panel from t he hat chgat e.
INSTALLATION
(1) Position t he t ri m panel on t he hat chgat e.
(2) Align t he t ri m panel ret ai ners with t he holes
in t he hat chgat e i nner panel. Force t he t ri m panel
inward to seat the ret ai ners in t he holes.
LATCH, LOCK TUBES AND LOCK CYLINDER
REMOVAL
(2) Use a t ri m panel removal tool to detach t he re-
t ai ners from t he inner panel. Remove t he t ri m panel
from t he hat chgat e.
(3) Remove the screws and the latch cover (Fig. 48).
(4) Remove t he screws at each side of t he hatch-
gate. Disengage both lock t ubes from t he latch.
(5) Remove both lock tubes from t he hat chgat e.
(6) Disconnect t he hat chgat e ajar switch and
ground wire from t he latch (Fig. 49).
(7) Remove t he screws and t he latch from t he
hat chgat e i nner panel.
(8) Remove t he ret ai ner and t he lock cylinder from
t he hat chgat e.
INSTALLATION
(1) Position t he lock cylinder in t he hat chgat e
opening. Install t he retainer.
(2) Position t he latch in t he inner panel opening.
Mate it with t he lock cylinder. Install t he screws in
t he i nner panel. Tighten t he screws to 4 N
#
m (35 in.
lbs.) torque.
(3) Connect t he hat chgat e ajar switch and ground
wire to t he latch (Fig. 49).
(4) Insert both lock tubes in t he hat chgat e. Engage
t hem with t he latch.
(5) Install the lock tube screws at each side of the
hatchgate. Tighten the screws to 4 N*m (35 in. lbs.)
torque.
(6) Position t he latch cover on t he hat chgat e inner
panel. Install t he screws. Tighten t he screws to 1
(7) Position t he t ri m panel on t he hat chgat e i nner
panel. Align t he ret ai ners with t he i nner panel holes.
Force t he t ri m panel inward to engage t he ret ai ners
wi t h t he holes.
(8) Remove t he support and close t he hat chgat e.
(9) Test t he latch, lock tubes and lock for correct
operation.
TRIM PANEL RB514
Fig. 47 Hatchgate Trim Panel Removal/Installation
SPORT BAR
REMOWAL
(1) Remove t he bolts t hat at t ach t he sport bar base
flanges to t he cargo box floor panel and wheelhouses.
(2) Lift t he sport bar upward. Remove it from t he
vehicle.
(3) Remove and retain the four base flange gaskets.
(4) If necessary, disassemble t he sport bar tubes
and st rut s.

SCREW REINFORCEMENT
Fig. 49 Hatchgate Ajar Switch & Ground Wire
INSTALLATION
(1) If disassembled, assemble t he sport bar tubes
and st rut s.
(2) Position t he base plate gaskets on t he cargo
box floor panel and at each wheelhouse.
(3) Position the sport bar base flanges on the gaskets.
(4) Apply seal ant to t he underside of each base
flange bolt head. Install and tighten t he bolts to 41
CAR00 BOX
SERVICE INFORMATION
The cargo box is attached to the vehicle rear frame
structure with bolts (Fig. 51). If necessary, the box can
be removed for repair, service access, or replacement.
Refer to the procedure within Group 13Frame.
Fig. 50 Sport Bar
CARGO CARGO BOX
SIDE PANEL BRACES-DUAL REAR WHEELS
REMOVAL
(1) Remove t he brace side panel screw and U-nut.
(2) Remove t he floor cross sill screw.
(3) Remove t he brace from t he cargo box.
INSTALLATION
(1) Position the brace at the cargo box floor cross sill.
(2) Install t he floor cross sill screw finger-tight.
(3) Position t he brace and U-nut at t he cargo box
side panel.
(4) Install t he brace side panel screw. Tighten t he
screw to 11 N
#
(5) Tighten t he floor cross sill screw to 11 Nm (95
in. lbs.) torque.

Fig. 52 Cargo Box Side Panel Braces
ROOF VENTRAMCHARGER
WENT COWER
RE M OV AL
(1) Open t he vent cover.
(2) Remove t he upper rivet head from t he cover/
handle with a drill and bit.
(3) Remove the screws and t he vent cover hinge.
(4) Remove the vent cover from the seal and frame.
I NSTALLATI ON
(1) Position the vent cover on the seal and the frame.
(2) Install t he hinge on t he cover with t he screws.
Tighten t he screws to 11 N-m (95 in. lbs.) torque.
(3) Install t he handle on t he cover with a rivet
from t he replacement handl e package.
WENT COWER SEAL
RE MOV AL
(1) Open t he vent cover.
(2) Remove t he screws and t he vent cover hinge.
(3) Remove the vent cover from the seal and frame.
(4) Remove t he seal from t he frame.
I NSTALLATI ON
(1) Clean t he seal contact area on t he frame.
(2) Apply a weat herst ri p cement to t he seal. Install
it on t he frame.
(3) Position the vent cover on the seal and the frame.
(4) Install t he hinge on t he cover with t he screws.
Tighten t he screws to 11 N-m (95 in. lbs.) torque.
(5) Wat er test t he roof vent.
FRAME
RE MOV AL
(1) Remove t he screws and t he i nner t ri m ri ng
from t he headliner and roof panel.
Fig. 53 Roof Vent
(2) Separate t he seal between t he frame and t he
roof panel.
(3) Remove t he vent cover and frame from t he roof
panel as a unit.
I NSTALLATI ON
(1) Clean frame and roof panel seal contact surfaces.
(2) Position t he seal on t he frame.
(3) Position frame and seal on t he roof panel.
(4) Position the inner trim ring on the headliner. In-
stall and tighten the screws to 11 N-m (95 in. lbs.)
torque.
(5) Wat er test t he roof vent frame and seal area.
HANDLE
RE M OV AL
(1) Open t he vent cover
(2) Remove the handle rivet head with a drill and bit.
(3) Remove t he handle frame rivet head with a
drill and a bit.
(4) Remove t he handle from t he frame.
I NSTALLATI ON
(1) Position t he handl e on t he cover.
(2) Install t he handl e cover rivet (the rivet is sup-
plied wi t h t he replacement handle).
(3) Install t he handl e frame rivet (the rivet is sup-
plied with t he replacement handle).

DOORS
INDEX
page
Complete Door . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Door Adjustment . 21
Door Inside Handle . 26
Door Latch 27
Door Latch Striker 25
Door Outside Handle 26
Door Trim Panel/ Waterdam 21
SERVICE INFORMATION
The front door service procedures include:
Complete door removal/installation
f Component removal/installation
Component replacement
Adjustments
Care shoul d be taken to prevent undercoati ng
material from contacti ng the door internal com-
ponents. A major cause of door component fail-
ure is contami nati on by rust pr event i on
material.
BLIND RIVET REMOVAL
The rivets used to at t ach t he various door compo-
nent s should be removed according to t he following
information:
Remove t he center of t he rivet with a drift punch
Drill out t he rivet with a 6 mm (1/4-in) diameter
drill bit.
When installed, t he components should be attached
to t he door with 1/4-20 x 1/2 bolts and nut s. Tighten
t he nut s to 10 Nm (90 in. lbs.) torque.
HINGE REPLACEMENT
REMOVAL
(1) Use a wax pencil to mark t he outline of t he
hinge-halves on t he door and t he cowl for installation
(2) Support t he door with a padded floor jack.
(3) Remove t he hinge screws. Remove t he hinge
from t he door and the cowl.
INSTALLATION
(1) Clean t he hinge.
(2) Color coat t he hinge to match t he body color.
(3) Lubricate t he hinge with engine oil.
(4) Position t he hinge on t he door. Install t he
hinge screws finger-tight.
(5) Align t he hinge with t he installation reference
outlines.
(6 ) Tighten t he hinge screws to 41 Nm (30 ft. lbs.)
torque.
page
Hinge Replacement , 21
K ey Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 25
Power Door Lock Motor 26
Vent Window and Channel 23
Window Gl ass and Door Weatherstrip Seal s . . . . 27
Window Gl ass/ Channel s/ Regul ators . . . . . . . . . . . 23
(7) Remove t he floor jack from t he door.
(8) If necessary, adjust t he door. Refer to t he ad-
j ust ment procedure(s).
DOOR ADJUSTMENT
The door position is adjusted at t he hinge locations
at either t he cowl or t he door, as applicable. Slightly
enlarged bolt holes are located in t he cowl for fore/aft
and up/down adjustments. Slightly enlarged bolt
holes are located in t he door for in/out adjustments.
It is important to adjust a door properly. If not
the door weatherstri p seal coul d be damaged. A
simple test of weat herst ri p seal contact can be done
wi t h a strip of newspaper. Place t he paper adjacent
to the door pillar. Close t he door. Pull the paper out-
ward. A slight drag should be detected. If t he paper
is difficult to remove, t he door should be re-adjusted.
Prior to door adjustment, t he door latch must be re-
moved. This will allow t he door to close freely and be
properly aligned without interference.
(2) Loosen t he hinge bolts. Move t he door to t he
correct position.
(3) Tighten t he hinge bolts to 41 Nm (30 ft. lbs.)
torque.
DOOR TRIM PANEL/WATERDAM
REMOVAL
(1) If equipped, remove the:
Power switch housing
Window regulator handl e (Figs. 1 and 2)
Inside latch release handl e
Inside release handle bezel
Trim panel lower screws
(2) Use a t ri m removal tool and carefully pry t he
t ri m panel away from t he door i nner panel. Remove
t he t ri m panel from t he door.
(3 Separate t he wat erdam from t he door i nner
panel (Fig. 3). Remove t he wat erdam from t he door
i nner panel.

INSTALLATION
(1) Apply an appropriate adhesive/sealant to t he
wat erdam.
(2) Position t he wat erdam on t he door inner panel.
Press it inward to at t ach it to t he i nner panel.
(3) Position t he t ri m panel on t he door i nner panel.
Press inward around t he edge of t he panel to at t ach
t he ret ai ners to t he inner panel holes.
(4) Install t he t ri m panel lower screws. Tighten
t he screws to 4 Nm (35 in. lbs.) torque. Install t he
cover plugs.
(5) Install t he:
Inside release handle bezel
Inside latch release handl e
Window glass regulator handle
Power switch housing
When the wi ndow is cl osed the wi ndow regu-
lator handl e shoul d be installed in the horizontal
position wi th knob forward.
GLASS
U-NUT
WI N D O W
REGULATOR'
HANDLE
TRIM
PANEL
DOOR
J9123-404
Fig. 1 Window Glass Regulator Handle
COMPLETE DOOR
REMOVAL
(1) For doors equipped with a power window,
power door lock, and radio speaker, remove t he door
t ri m panel and wat erdam. If necessary, refer to t he
removal procedure.
(2) Disconnect t he component wire harness from
t he mai n wire harness. Remove t he mai n wire har-
ness ret ai ner from t he door panel. Remove t he mai n
wire harness from t he door.
(4) Remove t he door hinge bolts from t he cowl. Re-
move t he floor jack and t he door from t he vehicle.
(5) If equipped, ret ai n t he door hi nge shims for
proper installation.
INSTALLATION
(1) If a replacement front door is being installed,
coat t he door interior with anti-corrosion wax. Also,
seal t he door hem flange with sealant.
SPACER
I NNER
LATCH
RELEASE
HANDLE
TRIM
PANEL RETAINER SCREW PLUG
WI N D O W
REGULATOR
HANDLE J9123-382
Fig. 2 Door Trim Panel Removal/Installation
AIR
EXHAUST
LOUVER
(UPPER)
DOOR
OUTER
PANEL
BEZEL
WATER
DAM
f
AIR
EXHAUST
LOUVER _
RIVET (LOWER) ^
DOOR
I NNER
PANEL J9123-399
Fig. 3 Door Waterdam
(2) Before installing a replacement door, as appli-
cable, transfer:
Window glass and regulator
Electric motors
Key lock cylinder
Latch release handles
Tri m panel
Remai ni ng components to t he replacement door.
If necessary, refer to t he applicable removal/instal-
lation procedures.
(3) Lubricate t he hinges with engine oil.

(4) Position t he door in t he door opening.
(6) Align t he door hinge holes wi t h t he bolt holes
in the cowl. Install (but do not tighten) t he hinge
screws.
(7) Adjust t he door as necessary. If necessary, refer
to the adjustment procedure. Ti ght en t he hinge
screws to 35 Nm (26 ft. lbs.) torque.
(8) Adjust t he latch striker and t he latch as neces-
sary.
(10) If applicable, insert t he mai n wire harness in
the door. Install t he ret ai ner in t he door panel. Con-
nect t he necessary component connectors to t he mai n
wire harness connectors.
(11) If removed, install t he wat erdam and t he t ri m
panel.
VENT WINDOW AND CHANNEL
REMOVAL
(1) Remove t he door t ri m panel and t he wat erdam.
(2) Lower t he window glass to t he full open posi-
tion. Remove the inner beltline weat herst ri p seal.
(3) Raise window glass 20 - 25 cm (8 - 10 in).
(4) Remove window glass front channel lower
bracket screw and J-nut (Fig. 4).
(5) Remove vent window frame front screw located
under door weat herst ri p.
(6) Tilt vent window rearward. Lift it out of t he
door opening.
INSTALLATION
(1) Use a replacement plastic nut spacer and J-nut
when installing t he vent window.
(2) Tilt t he vent window rearward. Position it in
t he door opening.
(3) Install t he window frame plastic nut spacer and
upper screw finger-tight.
(4) Install t he window glass front channel lower
bracket screw and J- nut finger-tight.
(5) Mate the glass rear channel with t he vent win-
dow glass channel.
(6) Install t he beltline weat herst ri p seal.
(7) Raise or lower t he vent window to provide a 1.6
mm (0.06 in) fore-aft glass freeplay. Then, raise t he
window to the closed position. Tighten the upper
screw to 2 Nm (18 in. lbs.) torque.
(8) Lower t he window glass completely. Position
t he front channel tightly against t he glass. Tighten
t he front channel lower bracket screw to 11 N
#
m (95
in. lbs.) torque.
(9) Test t he vent window operation. Adjust as nec-
essary.
(10) Install the door wat erdam and t he t ri m panel.
Fig. 4 Vent Window & Glass Channels
VENT WINDOW GLASS
REMOVAL
(1) Remove t he vent window (Fig. 4). If necessary,
refer to t he removal procedure.
(2) Remove t he screw from t he glass lower pivot.
(3) Remove t he glass upper pivot rivet. Remove t he
glass from t he vent window frame.
INSTALLATION
(1) Lubricate t he glass lower pivot with a white lu-
bricant spray, or an equivalent.
(2) Install the glass lower pivot in t he glass frame.
(3) Install the glass upper pivot rivet.
(4) Install t he vent window.
WINDOW GLASS/CHANNELS/REGULATORS
GLASS RUN CHANNEL
The window glass r un channel is press-fitted into
the door top channel guide and t he door rear/side
channel guide.
REMOVAL
(1) Remove t he door t ri m panel and t he waterdam.
(2) Lower t he window glass. Pry t he r un channel
from the door top and side channel guide.
(3) Raise the window glass.
(4) Use t he door i nner panel opening for access.
Pry t he r un channel from lower part of t he door side
channel guide.
(5) Remove r un channel from window opening.
INSTALLATION
(1) Lower window glass. Position r un channel in
the window opening.
(2) Force the r un channel into door top channel
guide and the upper part of t he door side channel
guide.
(3) Raise window glass.

(4) Use t he door i nner panel opening for access.
Position r un channel into t he lower part of door side
channel guide while lowering t he window glass.
(5) Test t he window glass operation and correct as
necessary.
(6) Install t he door wat erdam and t he t ri m panel.
WINDOW GLASS
REMOVAL
Remove door t ri m panel and the wat erdam.
(2) Remove t he beltline weat herst ri p seals (Fig. 5) .
(3) Lower t he glass to t he full open position. Re-
move t he vent window.
(4) Slide t he glass forward unt i l t he channel sepa-
rat es from t he window regulator ar m roller.
(5) Remove t he glass and channel from t he door.
INSTALLATION
(1) Lubricate t he glass channel.
( 2) Position t he glass and channel in t he door.
(3) Slide t he glafes rearward and engage t he chan-
nel with t he regulator ar m roller.
(4) Install t he vent window. If necessary, refer to
t he installation procedure. Raise t he glass to t he full
closed position.
(5) Install t he beltline weat herst ri p seals.
(6 ) Install t he door wat erdam and t he t ri m panel.
WEATHERSTRIP
GLASS
DOOR
INNER
PANEL
DOOR
OUTER
PANEL
REGULATOR
(MANUAL)
J9123-398
Fig. 5 Window Glass, Regulator, Weatherstrip Seals
& Channel
MANUAL WINDOW GLASS REGULATOR
REMOVAL
(2) Lower t he glass to t he full open position. Re-
move t he vent window.
rat es from t he window regulator arm roller.
(4) Lower t he glass and channel to t he bottom of
t he door.
(5) Remove t he center of t he regulator rivets wi t h
a drift punch (Fig. 6). Drill t hem out with a 6 mm
(1/4-in) diameter drill bit.
(6) Remove t he regulator from t he door.
INSTALLATION
(1) Position t he regulator in t he door (Fig. 6). Re-
t ai n it on t he i nner door panel with 1/4-20 x 1/2 bolts
and nut s. Tighten t he nut s to 10 N*m (90 in. lbs.)
torque.
(2) Raise t he glass. Slide it rearward and engage
t he channel with t he regulator arm roller.
(4) Test t he window glass and regulator operation.
DOOR OUTER
PANEL
GUIDE DOOR
INNER
PANEL
REAR FRONT
RIVET RIVET
HOLES HOLES
RIVET
MANUAL
REGULATOR
J9123-395
Fig. 6 Manual Window Glass Regulator
POWER WINDOW GLASS REGULATOR
REMOVAL
(1) Remove t he t ri m panel and t he wat erdam.
(2) Open t he window glass.
(3) Remove t he vent window.
rat es from t he window regulator ar m roller.
(5) Lower t he glass and channel to t he bottom of
t he door.
(6) Remove t he center of t he regulator rivets (Fig.
7) with a drift punch. Drill t hem out with a 6 mm
(1/4-in) diameter drill bit.
(7) Disconnect t he regulator motor wire harness
connector.
(8) Remove t he power regulator from t he door.
INSTALLATION
(1) Position t he power regulator in t he door. Re-
t ai n it on t he i nner door panel wi t h 1/4-20 x 1/2 bolts
and nut s. Tighten t he nut s to 10 Nnn (90 in. lbs.)
torque.
(2) Connect t he regulator motor wire harness con-
nector.

BODY COMPONENTS 23 - 2 i
(3) Raise t he glass. Slide it rearward and engage
the channel with t he regul at or ar m roller.
(5) Test t he window glass and regulator operation.
Fig. 7 Power Window Glass Regulator
KEY LOCK CYLINDER
REMOVAL
(1) Raise t he window glass to t he closed position.
(3) Disconnect t he lock cylinder latch rod at the
door latch.
(4) Remove t he key lock cylinder ret ai ner clip. Re-
move t he lock cylinder from t he door (Fig. 8).
INSTALLATION
(1) Install t he lock cylinder in t he door hole. Re-
t ai n t he lock cylinder with t he ret ai ner clip.
(2) Connect t he lock cylinder latch rod to t he door
latch.
(3) Test (and adjust, if necessary) t he door lock cyl-
inder latch rod operation.
(4) Install t he door t ri m panel and t he wat erdam.
DETERMINING KEY/LOCK CODE
When t he door key or t he key code is not available,
t he following procedure can be used to determine t he
key code.
(1) Remove t he lock cylinder from t he door.
(2) Remove t he tumbler cover from t he lock cylin-
der housing and discard it (Fig. 9).
(3) Individually remove each spring, driver and
t umbl er set from t he lock cylinder housing.
DOOR KEY
Fig. 8 Key Lock Cylinder Removal/Installation
(4) Use t he code plate to determine t he code num-
ber for each set and record t he results.
(5) Continue, as instructed above, to determine t he
complete key/lock code with t he remai ni ng sets of
spring, driver and tumbler.
(6 ) Assemble t he original tumbler, driver and
spring sets (if not damaged) in t he lock cylinder
housing.
(7) Install a replacement t umbl er cover on t he lock
cylinder housing.
(8) Install t he key lock cylinder in t he door. If nec-
essary, refer to t he installation procedure.
Fig. 9 Key Lock Cylinder Components
DOOR LATCH STRIKER
REPLACEMENT
(1) Remove t he st ri ker and spacer from t he B-pil-
lar (Fig. 10).

(2) Install t he spacer and replacement st ri ker on
t he B-pillar.
(3) Adjust t he door latch st ri ker to engage com-
pletely when t he door is closed. When closed, t he
door should be flush with t he adjacent body panels.
IOCK
KNOB
OUTSIDE
HANDLE
GROMMET
B-PILLAR
DOOR
LATCH
OUTSIDE
HANDLE-TO-
LATCH ROD
SCREW
INSIDE
HANDLE
LOCK MOTOR-TO- ACTUATOR
LATCH ROD
LOCK
MOTOR
J9123-601
Fig. 10 Striker, Lock Motor, Door Handle, Latch &
Rods
POWER DOOR LOCK MOTOR
REMOVAL
(1) Raise t he window glass to t he completely closed
position.
(3) Disconnect wire harness connector from t he
lock motor.
(4) Disconnect t he lock motor latch rod from t he
motor (Fig. 10).
(5) Remove t he screws and t he motor from t he
door.
INSTALLATION
(1) Position t he motor in door i nner panel.
(2) Connect t he lock motor latch rod to t he motor.
(3) Install t he lock motor screws. Tighten t he
screws to 11 N
#
(4) Connect t he lock motor connector to t he door
harness connector.
(5) Test and verify t hat t he lock motor and latch
lock operate correctly.
If necessary, refer to t he installation procedure.
DOOR INSIDE HANDLE
REMOVAL
(3) Remove t he handl e latch rod from t he inside
handl e actuator (Fig. 10).
(4) Remove t he screws from t he reinforcement
plate. Remove inside handl e (and seal) from t he door
i nner panel.
INSTALLATION
(1) Position t he seal and inside handl e on t he door
i nner panel.
(2) Connect t he handle latch rod to t he handle ac-
tuator.
(3) Position t he reinforcement plate at t he inside of
t he door i nner panel. Attach t he inside handl e to t he
door panel. Tighten t he screws to 15 N
#
m (130 in.
lbs.) torque.
(4) If necessary, adjust to eliminate excess handl e
travel.
DOOR
INNER
PANEL
REINFORCEMENT
PLATE
INSIDE
LATCH
RELEASE
HANDLE
SCREW
DOOR
OUTER
PANEL
INSIDE
LATCH
RELEASE
HANDLE
DOOR
INNER
PANEL
J9123-394
Fig. 11 Door Inside Handle Removal/Installation
DOOR OUTSIDE HANDLE
REMOVAL
(3) Remove t he door handl e nut s from t he inside of
t he door.
(4) Disconnect handle latch rod from latch.
(5) Remove handl e from door outer panel.

INSTALLATION
(1) Apply silicone spray lubricant to t he handl e in-
t ernal moving part s.
(2) Install t he handl e on t he door outer panel.
(3) Tighten t he handl e nut s to 7 N*m (6 5 in. lbs.)
torque.
(4) Connect t he handl e latch rod to t he latch.
(5) Test and verify t he handle operates correctly.
OUTSIDE HANDLE LATCH ROD RELEASE
ADJUSTMENT
(1) Locate t he 4-mm (5/32-in) diameter Allen-head
adjustment screw inside t he door panel face slot near
t he latch (Fig. 12).
(2) Loosen t he door latch adjustment screw.
(3) Push upward on t he latch lever to remove all
t he slack from t he handl e latch rod.
(4) Tighten adjustment screw.
(5) Test and verify proper operation.
I NNER
RELEASE
HANDLE-TO
LATCH
ROD
LOCK
K N OB
TO-LATCH
ROD
POWER LOCK
MOTOR-TO-
LATCH ROD
DOOR
LATCH
LOCK
/CYLINDER-TO
LATCH ROD
S CRE W DOOR
OUTER
PANEL
DOOR
LATCH
DOOR
I NNER
OUTER
P A N E L
RELEASE
HANDLE-TO
LATCH ROD
ADJUSTMENT
S CRE W SLOT
LEFT D OOR LATCH
OUTER RELEASE HANDLE-TO-
LATCH ROD ADJUSTMENT
SCREW AC C E S S SLOT
J9123-384
Fig. 12 Door Latch & Rods
DOOR LATCH
REMOVAL
(3) Disconnect the:
Outside handl e latch rod
Key lock cylinder latch rod
Inside handl e latch rod
Lock knob latch rod
Lock motor latch rod
(4) Remove t he door latch screws from t he door in-
ner panel face.
(5) Remove t he door latch from t he door.
INSTALLATION
(1) Install t he latch striker, if removed.
(2) Insert t he door latch. Position it at t he door in-
ner panel face and connect t he rods to it.
(3) Install t he latch screws i n t he door panel face
(Fig. 12). Tighten t he screws to 9 Nnn (7 ft-lbs)
torque.
(4) Test and verify t hat t he latch operates cor-
rectly.
(5) Install t he door wat erdam and t he t r i m panel.
WINDOW GLASS AND DOOR WEATHERSTRIP
SEALS
WINDOW GLASS BELTLINE WEATHERSTRIP
SEALS
REMOVAL
The window glass beltline weat herst ri p seals can
be removed according to t he following procedure.
(1) Open t he window glass.
(2) Pry t he i nner and outer beltline weat herst ri p
seals from t he door panels wi t h a small put t y knife.
(3) Remove t he beltline seals from t he door (Fig.
13).
INSTALLATION
Position t he beltline weat herst ri p seals on t he door
panels. Force t hem downward unt i l t he ret ai ners are
seated in t he panel slots.
WEATHERSTRIP
GLASS
DOOR
I NNER
PANEL
DOOR
OUTER
PANEL
REGULATOR
(MANUAL)
J9123-398
Fig. 13 Beltline Weatherstrip Seals
DOOR WEATHERSTRIP SEAL
REMOVAL
(1) St art at t he lower ends and pull outward on t he
seal. Separate it from t he door opening panel flanges
(Fig. 14).
(2) Continue around t he edge of t he seal and pull
outward on t he seal to separat e it from t he flanges.
(3) Remove t he seal from t he door opening.
INSTALLATION
(1) Position t he weat herst ri p seal in t he door open-
ing.

(2) St art at t he upper, rear corner of t he door open-
ing. Move forward and downward around t he edge of
t he door opening. Force t he seal inward agai nst t he
panel. Seat t he flange in t he seal slot.
Seal posi t i oni ng at t he c or ne r s i s cr i t i cal . The
seal mus t be s eat ed at e a c h cor ner . Avoi d puck-
er i ng a n d s t r et chi ng t he seal at t he cor ner s .
(3) When correctly installed, t he seal ends will
meet at t he door lower centerline.
(4) Inspect t he fit of t he door in t he door opening.
If not correct, adjust t he door fit so t he seal is not
damaged when t he door is closed. Refer to t he door
adjustment procedure.
BUTYL DOOR
Fig. 14 Cab/Body-To-Door Weatherstrip Seat

IODY COMPONENTS 23 - 29
FIX ED GLASS
1NDE1
page
Cab Rear Wi ndow 30
Hatchgate Wi ndow Gl assRamcharger . . . . . . . . 32
Mirror Support Bracket 29
Quarter Vent W i ndow- Cl ub Cab 30
page
Quarter Window Gl ass . 32
Rearview Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Windshield Gl ass 29
SERVICE INFORMATION
Do not use a put t y knife, a razor blade, or steel
wool to remove foreign mat eri al from glass. Glass
surfaces are best cleaned with t he use of a commer-
cial glass cleaner.
REARVIEW MIRROR
REMOVAL
(1) Loosen t he mirror base setscrew.
(2) Slide t he mirror base upward and off t he sup-
port bracket.
INSTALLATION
(1) Position t he mirror base at t he support bracket.
Slide it downward onto t he support bracket.
CAUTION: D o not over-tighten the mirror base set-
scr ew. W i ndshi el d gl as s chi ppi ng and/ or br eakage
coul d resul t.
(2) Tighten t he setscrew securely.
MIRROR SUPPORT BRACKET
REPLACEMENT
(1) To replace t he mirror support bracket follow
t he directions provided in t he repai r kit.
Fig. 1 Rearview Mirror Bracket.
WINDSHIELD GLASS
REMOVAL
(1) Remove t he wiper arms. Place a cover over t he
upper cowl area. If necessary, refer to Group 8Elec-
trical for t he wiper arm removal procedure.
(2) Remove t he interior rearview mirror.
(3) Remove t he locking strip ret ai ner from t he
windshield glass weat herst ri p seal (Fig. 2).
(4) Position an assistant outside t he vehicle to re-
ceive t he windshield glass.
(5) St art i ng at either inside, upper corner, gently
push t he glass outward. Separat e it from t he weath-
erstrip seal. Continue unt i l t he glass is completely
separated from t he seal (Fig. 3).
(6) The assi st ant now can remove t he glass from
outside t he vehicle.
(7) Remove t he weat herst ri p seal from t he wind-
shield opening.
(8) Remove t he residual sealant from t he wind-
shield opening flange.
(9) Clean t he windshield opening flange and
groove with an appropriate cleaning solution.
INSTALLATION
(1) Apply a 3-mm (1/8-in) diameter bead of syn-
thetic rubber-based seal ant to t he windshield open-
ing flange and groove.
(2) Install t he weat herst ri p seal on t he flange. Ver-
ify t hat it is completely seated around t he edge of t he
windshield opening.
(3) With t he aid of an assistant, insert one corner
of t he windshield glass into t he weat herst ri p seal
groove.
(4) Use a t ri m stick to force t he seal lip over t he
glass around t he edge of t he seal.
If necessary, use mineral spirits as a lubricant
to aid l ocki ng strip installation.
(5) St art at t he lower, center area of t he weather-
strip seal. Install t he locking strip in t he weather-
strip seal with Tool L-4567, or an equivalent (Fig. 4).
(6) Install t he locking strip end cap over t he ends
of t he locking strip.
(7) Test t he windshield for wat er leaks.
(8) Install t he wiper arms. If necessary, refer to
Group 8Electrical for t he installation procedure.

(9) If necessary, install t he rearview mirror sup-
port bracket on t he windshield glass.
(10) Install t he rearview mirror. If necessary, refer
to t he installation procedure.
Fig. 2 Windshield Glass
Fig. 3 Windshield Glass Removal
QUARTER WENT WINDOW-CLUB CAB
REMOVAL
(1) Remove t he vent window latch screws from t he
cab quart er panel.
(2) Remove t he hinge screws from t he cab side, in-
ner panel.
(3) Remove t he vent window from t he cab.
(4) If necessary, remove t he latch and hi nge from
t he glass.
INSTALLATION
(1) If removed, install t he latch and hinge on t he
glass.
Fig. 4 Weatherstrip Seal Locking Strip Retainer
Installation
(2) Position t he vent window in t he cab. Install t he
screws. Tighten t he nut s to 3 N
#
m (24 in. lbs.)
torque.
(3) Attach the latch to t he quart er panel. Tighten
t he screws to 3 Nm (24 in. lbs.) torque.
(4) Test t he vent window for wat er leaks.
WEATHERSTRIP SEAL
REMOVAL
(1) Remove t he vent window. If necessary, refer to
t he removal procedure.
(2) Pull t he seal away from t he flange.
(3) Clean t he flange as necessary.
INSTALLATION
(1) Position t he seal at t he window opening.
(2) Mate t he seal with t he front flange.
(3) Move upward and mat e t he seal with t he top
flange.
(4) Mate t he seal with t he rear flange.
(5) Mate t he seal with t he bottom flange.
CAB REAR WINDOW
SERVICE INFORMATION
The rear window glass is attached to t he window
frame with uret hane adhesive (Figs. 6 and 7). The
ur et hane adhesive seals t he window frame and t he
glass. The window weat herst ri p seal attaches t he
window frame to t he window opening flange.
REMOVAL-STANDARD GLASS
(1) As applicable, remove t he window reveal moul-
ding/retainer.

WEATHERSTRIP
SEAL
VENT
GLASS
AND FRAME
SCREW
RIVET-NUT
RETAINER
J9123-340
Fig. 5 Vent Window Removal/installation
(2) Separate the seal lip from t he glass at one cor-
ner with a t ri m stick. Carefully push t he glass out of
t he seal (Fig. 8).
(3) Force the glass out of t he weat herst ri p seal. Re-
move it from the seal and the window opening.
(4) Remove the weat herst ri p seal from t he window
opening.
INSTALLATION
(1) Clean the seal channels and the window
flanges in t he cab.
(2) Install the seal on t he window glass or frame.
(3) Apply a 6-mm (1/4-in) di amet er bead of seal ant
to t he window flange.
(4) Install the glass according to t he following in-
structions:
Moisten a length of 6-mm (1/4-in) diameter cord
with a soap and wat er solution
Verify t hat the cord is long enough to go around
t he edge of the seal.
Insert t he cord into t he window flange in t he seal
(Fig. 9)
Position t he window and seal in t he opening with
t he free ends of t he cord inside t he vehicle
Pull on the cord ends. Pull t he seal channel lip
over t he window flange.
(5) Test t he window for water leaks.
(6) As applicable, install t he window reveal moul-
ding or retainer.
(7) Clean the vehicle, as necessary.
SLIDING WENT GLASS
REMOVAL
(1) Remove the complete rear window from t he cab
opening. If necessary, refer to t he removal procedure.
(2) Place the frame and glass on a clean, padded
area.
(3) Loosen t he screws located on t he bottom of t he
frame.
CAB
BACK
PANEL
WEATHERSTRIP
SEAL
SLI DI NG
GLASS
A N D FRAME
RETAINER
Fig. 6 Cab Rear Windows
CAB
PANEL WEATHERSTRIP SEAL
WI TH
MOULDI NG
WEATHERSTRIP
SEAL
RETAINER
FIXED
WI N D O W
GLASS
WEATHERSTRIP SEAL
' WI TH MOULDI NG
CAB
BACK
PANEL
RETAINER
CAP
RETAINER
<tOF WI N D O W
LOWER
WEATHERSTRIP
SEAL
UPPER
FIXED
GLASS
J9123-339
CAB
BACK
PANEL
FIXED
WI N D O W
GLASS
SLI DI NG
GLASS
A N D FRAME
J9123-338
Fig. 7 Rear Window
Glass/FrameRemoval/Installation
PU866
Fig. 8 Rear Window Removal Typical
(4) Carefully spread t he frame apart.
(5) Remove t he sliding vent glass from t he frame
track.

Fig. 9 Window installation CordTypical
INSTALLATION
(1) Position t he sliding vent glass in t he frame
track.
(2) Tighten all t he screws at t he bottom of t he
frame,
(3) Test for correct travel. Check t he latch opera-
tion for t he sliding vent glass.
(4) Install rear window in t he cab opening. If nec-
essary, refer to t he installation procedure.
(5) Verify t hat t he drai n holes are not restricted.
HATCHGATE WINDOW GLASS- RAMCH ARGE R
REMOVAL
(1) Use a t ri m stick to separat e t he glass seal lip
from t he hat chgat e flanges. Push t he window glass
and seal outward from t he top.
(2) Remove t he seal and glass from t he hat chgat e.
(3) Remove t he ret ai ner strip from t he weather-
strip seal.
(4) Remove t he seal from t he window glass.
(5) Clean t he seal channels and window opening
flanges.
INSTALLATION
(1) Install t he seal on t he window glass.
(2) Apply mi neral spirits to t he ret ai ner strip
channel in t he weat herst ri p seal.
(3) Install t he ret ai ner strip in t he seal channel.
(4) Install t he hat chgat e window glass according to
t he following instructions:
Moisten a l engt h of 6-mm (1/4-in) diameter cord
with a soap and wat er solution;
Verify t hat t he cord is long enough to go all t he
way around t he edge of t he weat herst ri p seal
Insert t he cord into t he window flange in t he seal
Position t he glass in t he window opening wi t h t he
free ends of t he cord inside t he vehicle
Pull on t he cords to pull t he seal channel lip over
t he window flange
(5) After installation, release any curls from t he
seal outer lip.
(6) Test t he hat chgat e window for wat er leaks.
(7) Clean t he glass.
HATCHGATE RETAINER WEATHERSTRIP
Fig. 10 Hatchgate Window Glass & Seal
QUARTER WINDOW GLASS
REMOVAL
(1) Remove t he quart er window glass interior t ri m
panel (Fig. 11).
Fig. 11 Quarter Window Interior Trim Panel
(2) Remove t he quart er window exterior mouldings
(Fig. 12).
(3) Use an electric knife (Tool 4386 or an equiva-
lent) to cut t he butyl tape.
(4) Remove t he glass from t he opening by applying
even pressure to t he inside of t he glass.

Fig. 12 Quarter Window Exterior Mouldings
INSTALLATION
(1) Remove t he residual butyl tape from t he win-
dow opening. If t he original glass will be installed,
remove all t he residual butyl tape from t he glass.
(2) Apply pri mer to t he glass and allow 10 mi nut es
for it to dry. Avoid contact with t he primed surface.
(3) Inspect t he quart er window spacers for correct
installation (Fig. 13).
(4) Apply butyl t ape to t he entire edge of t he win-
dow flange (Fig. 14).
SECTION A-A SECTION B-B
Fig. 14 Butyl Tape Installation
(5) Remove excess tape and but t t he tape-ends
firmly together.
(6) Install t he quart er window glass on t he butyl
t ape (Fig. 15)
(7) Force t he glass against t he butyl t ape to obtain
a good seal (Fig. 15).
(8) Test t he quart er window glass for wat er leaks.
(9) If leakage occurs, additional sealing will be re-
quired. Use an appropriate windshield sealer (Fig.
16).
(10) Install t he exterior mouldings.
(11) Install t he interior t ri m panel.
(12) Clean t he glass.

CAB/BODY INTERIOR COMPONENTS
INDEX
page
Carpets and Floor Mats 51
Floor Consol e and Rear Storage Tray . . . . . . . . . 50
Front Seat s 38
Headliners 4 8
Instrument Panel 35
page
Interior Trim Panel s . 4 2
Rear Seat s 4 1
Shoulder Belts/ Lap Belt/ Buckles 4 5
Spare Tire Carrier 4 5
INSTRUMENT PANEL
INSTRUMENT CLUSTER BEZEL
REMOVAL
(1) Remove t he bezel screws.
(2) Remove t he bezel from t he i nst rument panel.
INSTALLATION
(1) Position t he bezel on t he i nst rument panel.
(2) Install t he bezel screws. Tighten t he screws to
INSTRUMENT
PANEL
EDGE
TRIM
4WD
INDICATOR
COVER
4WD)
INSTRUMENT
CLUSTER
BEZEL SCREW
Fig. 11nstrument Cluster Bezel Removal/Installation
INSTRUMENT CLUSTER AND/OR IP
COMPONENT
REMOVAL
(1) Remove the i nst rument cluster bezel screws
(Fig. 1). Remove t he bezel from t he i nst rument
panel.
(2) As applicable, remove t he i nst rument cluster or
other IP component screws (Fig. 2).
(3) Disconnect t he wire harness connector(s) from
t he IP cluster or component. Refer to Group 8Elec-
trical for additional information.
(4) If applicable, disconnect the shift position indi-
cator from t he steering column (Fig. 3).
(5) Remove t he IP cluster or component from t he
i nst rument panel.
INSTALLATION
(1) Position t he IP cluster or component at t he in-
st rument panel. Connect t he wire harness connec-
tors).
(2) Install t he cluster or component in t he instru-
ment panel (Fig. 2).
(3) If applicable, connect t he shift position indica-
tor to t he steering column (Fig. 3).
(4) Install t he IP cluster or component screws.
Tighten t he screws to 2 N
#
(5) Position t he bezel on t he i nst rument panel.
(6) Install t he bezel screws. Tighten t he screws to
INSTRUMENT
PANEL
LAMP
ACC
SWITCH
BEZEL
HEADLAMP
SWITCH
HEADLAMP
SWITCH
A N D POWER
MIRROR
CONTROL
BEZEL
SCREW
INSTRUMENT
J 9 1 2 3 3 5 1
CLUSTER J9123-351
Fig. 2 Instrument Cluster Removal/Installation
A/T SHIFT POSITION (PRNDL) INDICATOR
REMOVAL
(1) Disconnect t he shift position (PRNDL) indicator
cable from t he steering column.
(2) Remove t he indicator screws from t he rear of
t he i nst rument cluster.
(3) Remove t he indicator from t he i nst rument clus-
ter.
S C R E W
I NSTRUMENT
CLUSTER
(REAR)
SHIFT
I NDI CATOR
STEERI NG
C OL U MN J9123-539
Fig. 3 A/T Shift Position Indicator
INSTALLATION
(1) Position t he shift position (PRNDL) indicator
on t he i nst rument cluster.
(2) Install t he indicator screws in t he rear of t he
i nst rument cluster. Tighten t he screws to 2 Nm (17
in. lbs.) torque.
(3) Connect t he indicator wire to t he steering col-
umn.
ASH RECEIVER TRAY AND HOUSING
REMOVAL
cigarette lighter. Remove t he ash receiver t r ay from
t he housing.
(2) Remove t he housing screws from t he instru-
ment panel.
lamp. Remove t he housing from t he i nst rument
panel.
INSTALLATION
(1) Position t he ash receiver t ray housing at t he
i nst rument panel. Connect t he wire harness connec-
tor to t he lamp.
(2) Install t he housing screws in t he i nst rument
panel. Tighten t he screws to 2 Nm (17 in. lbs.)
torque.
(3) Position t he ash receiver t ray in t he housing.
Connect t he wire harness connector to t he cigarette
lighter.
GLOVE BOX
REMOVAL
(1) Remove t he glove box door hinge screws from
t he i nst rument panel (Fig. 5).
(2) Remove t he glove box from t he i nst rument
panel.
INSTRUMENT
PANEL
SCREW
LAMP
HOOD
PANEL
ASH
TRAY
' HOUS I NG -
LIGHTER
ELEMENT
SCREW
LIGHTER
CLAMP
AS H
TRAY
HOUS I NG
LIGHTER
SHELL
AS H
RECEIVER
TRAY
J9123-346
Fig. 4 Ash Receiver Tray & Housing
INSTALLATION
(1) Position t he glove box at t he i nst rument panel.
(2) Install t he door hinge screws. Tighten t he
INSTRUMENT
PANEL
STRIKER SCREW BUMPER
GLOVE
BOX
DOOR
LAMP
SWITCH
LAMP
LENSE SCREW HI NGE
NAME
PLATE
J9123-345
Fig. 5 Glove Box
LOCK CYLINDER AND LATCH REMOVAL
(1) Remove t he glove box latch screws from t he
door panel.
(2) Separate t he latch from t he lock cylinder.
(3) Remove t he lock cylinder and t he latch from
t he door panel.
LOCK CYLINDER AND LATCH INSTALLATION
(1) Insert t he lock cylinder in t he door panel hole.
Engage it with t he latch.
(2) Install t he latch screws in t he door panel.
Ti ght en t he screws to 2 Nm (17 in. lbs.) torque.
DOOR LATCH STRI K E R AD J USTME N T
(1) Insert a small pry bar in the latch st ri ker slot.
(2) Pry on t he striker as necessary to obt ai n cor-
rect adjustment.
INSTRUMENT PANEL (UP)
RE MOV AL
(1) Remove t he I/P screws from t he dash panel
(Fig. 6).
(2) Remove t he steering column cover i nsert s from
t he I/P (Fig. 7).
(3) Remove t he I/P reinforcement bracket screws
from t he brace.
(4) Remove t he hood and parki ng brake release
handle bracket s from t he I/P (Fig. 8).
(5) If equipped, remove t he hand t hrot t l e bracket
from t he I/P (Fig. 9).
(6) Remove t he I/P screws from t he each cowl
panel.
(7) Pul l t he I/P outward from t he dash panel for
clearance and disconnect t he:
Wire harness connectors
Window defogger tubes
Speedometer cable
Heat/vent tube
PRNDL cable
Temperat ure control cable
Refer to t he applicable service information groups
for additional information.
(8) Remove t he I/P from t he dash panel.
(9) If necessary, remove t he reinforcement brackets
from t he inside of t he panel (Fig. 10).
I NSTALLATI ON
(1) If applicable, install t he reinforcement brackets
at t he inside of the I/P (Fig. 10). Tighten t he bracket
screws to 23 N
#
m (200 in. lbs.) torque. Tighten t he
reinforcement bracket I/P screws to 3 N*m (24 in.
lbs.) torque.
(2) Position t he I/P at t he dash panel.
(3) Connect the:
Wire harness connectors
Window defog tubes
Speedometer cable
Heat/vent tube
PRNDL cable
Temperat ure control cable
to t he I/P. Refer to t he applicable service informa-
tion groups for additional information.
(4) Install t he I/P screws. Tighten t he IP cowl
screws to 23 N-m (200 in. lbs.) torque. Tighten t he IP
dash panel screws and reinforcement bracket screws
(5) Install t he steering column cover i nsert s on t he
17P (Fig. 7). Tighten t he screws to 2 N*m (17 in. lbs.)
torque.
(6) Install t he hood and parki ng brake release han-
dle brackets on t he I/P (Fig. 8). Tighten t he screws to
(7) If equipped, install t he hand t hrot t l e bracket on
t he I/P (Fig. 9). Tighten t he locknut to 2 N*m (17 in.
lbs.) torque. Ti ght en t he screw to 3 N*m (24 in. lbs.)
torque.
SCREW PLENUM SCREW BRACE PLENUM
Fig. 6 Instrument Panel
INSTRUMENT LOWER UPPER
i r t
PANEL COVER COVER J9123-350
Fig. 7 Steering Column Cover Inserts Removal/
Installation
DASH PANEL INSULATION MAT
RE MOV AL
(1) Remove t he i nst rument panel from t he dash
panel. If necessary, refer to t he removal procedure.
(2) Remove t he defroster duct from t he dash panel.
(3) Remove t he heater/A/C uni t from t he dash
panel. If necessary, refer to t he removal procedure in
Group 24.
23 - 38 BODY COMPONENTS ^ _ _ _ _ _
PAWU
NUT
WASHER
SEALS
DASH
PANEL
SEAL
SUPPORT
BRACKET
NUT
I NSTRUMENT
PANEL
RELEASE
HANDLE
SCREW
RETAI NER'
PARKI NG
BRAKE
SCREW LEVER J9123- 568
Fig. 8 Parking Brake Release Handle
LOCK
NUT
HAND
THROTTLE
BRACKET
SCREW
I NSTRUMENT
PANEL
HAND ^ TfJl
L E
>TTLE
RETAI NER
CLI P
( WI TH HYD. CLUTCH)
DASH
PANEL
ACCELERATOR
PEDAL
J9123- 556
Fig. 9 Hand Throttle
(4) As applicable, remove t he ret ai ners, screws and
insulation mat from t he dash panel (Figs. 11 and 12).
INSTALLATION
(1) Position t he insulation mat on t he dash panel.
As applicable, install t he screws. Tighten t he screws
(2) Install t he heater/A/C uni t s on t he dash panel.
If necessary, refer to t he installation procedure in
Group 24.
(3) Position t he defroster duct on t he dash panel.
Install t he screws. Tighten t he screws to 2 N*m (20
in. lbs.) torque.
(4) Install t he i nst rument panel on t he dash panel.
GLOVE
BOX
OPENI NG
SCREW
I NSTRUMENT
PANEL
I NSTRUMENT
- CLUSTER
OPENI NG
l/P-T
PLENUM PANEL
REI NFORCEMENT;
BRACKET
7
LOWER
RI GHT
SCREW
REI NFORCEMENT REI NFORCEMENT
BRACKET BRACKET J9123- 348
Fig. 10 Inside Of Instrument Panel
PROTECTI VE
CAP
DASH
PANEL
NOI SE I NSULATOR
RI GHT
COWL
NOI SE I NSULATOR
LEFT COWL
NOI SE I NSULATOR
LEFTDIP
NOI SE
I NSULATOR
CENTERDIP
NOI SE
I NSULATOR
DASH
PANEL
J9123-411
Fig. 11 Insulation MatGasoline Engine
FRONT SEATS
BENCH SEAT
REMOVAL
(1) Detach t he shoulder belt and lap belt/buckle
from t he seat.
(2) For convenience, raise and support t he vehicle.
Remove t he seat platform nut s from t he studs. Re-
move t he support. Lower t he vehicle.
(3) Remove t he seat from t he cab.
(4) Remove t he platforms and seat t racks from t he
seat, if necessary.
INSTALLATION
(1) Install t he seat t racks and platforms on t he
seat, if removed.

Fig. 12 Insulation MatDiesel Engine
(2) Position t he seat in t he cab.
Install t he seat platform nut s on t he studs. Tighten
t he nut s to 26 Nnn (230 in. lbs.) torque. Remove t he
support. Lower t he vehicle.
(4) Position t he shoulder belt buckles and lap belt/
buckle between t he seatback and seat cushion.
Fig. 13 Bench Seat
BUCKET SEATS-RAMCHARGER AND CLUB
CAB
REMOVALLEFT SEAT
(1) Remove t he bolts t hat at t ach t he seat platform
to the reinforcement panel and t he floor panel.
(2) Remove t he left bucket seat from t he vehicle.
(3) The bucket seat can be removed without the
platform. Remove t he seat platform stud nut s, spac-
ers and ret ai ners.
platform stud spacers, ret ai ners, and nut s. Tighten
t he nut s to 26 Nnn (230 in. lbs.) torque.
(2) Position t he seat in t he vehicle.
(3) Install t he platform bolts. Tighten t he nut s to
8923-56
Fig. 14 Left-Side Bucket Seat
REMOVALRIGHT SEAT
The ri ght side bucket seat is equipped wi t h a tilt-
able platform. This is to provide entry to t he rear
seating area (Fig. 15). When tilted, a gas operated
rod supports t he seat. The tilt-latch release levers
are located on t he side and on t he rear of t he seat.
(1) Remove t he bolts t hat at t ach the seat platform
tilt hinge to t he reinforcement panel and t he floor
panel.
(2) Disconnect t he gas operated support rod from
t he seat platform (Fig. 15).
(3) Release t he latch. Remove t he seat from t he ve-
hicle.
(4) The bucket seat can be removed without t he
platform. Remove the seat platform stud nut s, spac-
ers and ret ai ners.
I NSTALLATI ON-RI GHT SEAT
(1) If removed without t he platform, position t he
bucket seat on t he seat platform. Install the seat
platform stud spacers, ret ai ners, and nut s. Tighten
t he nut s to 26 Nnn (230 in. lbs.) torque.
(2) Position t he seat in t he vehicle.
INSTALLATIONLEFT SEAT
(1) If removed without t he platform, position t he
bucket seat on t he seat platform. Install t he seat

(3) Install t he tilt-hinge bolts. Tighten t he bolts to
(4) Connect t he gas operated support rod to t he
seat platform.
(5) The seat latch should be aligned with t he latch
striker.
If necessary, the l atch striker can be adjusted.
TI LT- LATCH RE LE ASE LE V E RSRI GH T SE AT
The tilt-latch release levers have a handle, escutch-
eon, spring pin and snap ring. For removal and in-
stallation, refer to Figures 15 and 16.
BUCKET
SEAT
REINFORCEMENT SEAT
PANEL
L A T C H
PLUG
(W/O BENCH SEAT)
ARMREST
TILT
I RELEASE
SEAT ' LEVER
PLATFORM
TILT
HINGE
STUD
SPACER
RETAINER
GAS
SUPPORT
ROD
SCREW
TILT
STOP
BRACKET
FLOOR
PANEL
SUPPORT
ROD
REINFORCEMENT
PANEL
SEAT
LATCH
STRIKER
FLOOR
PANEL
GAS PROP
RR23A52
J91 23- 337
Fig. 15 Right-Side Bucket Seat
TILT LATCH RE M OV AL - RI GH T SE AT
(1) Remove t he screws t hat at t ach t he latch to t he
seat platform.
(2) Remove t he clip from t he inside end of t he link.
(3) Remove t he latch from t he seat platform.
TILT LATCH I N STALLATI ON - RI GH T SE AT
(1) Position t he latch on t he seat platform. Install
t he screws. Tighten t hem to 23 N*m (200 in. lbs.)
torque.
(2) At t ach t he clip to t he inside end of t he link.
(3) Adjust t he latch to eliminate all vertical
freeplay at rear of t he seat platform.
TI LT- LATCH STRI K E R RE M OV AL - RI GH T SE AT
(1) Remove t he st ri ker bolts from t he reinforce-
ment panel and t he floor panel.
(2) Remove t he st ri ker from t he panels.
TI LT- LATCH STRI K E R I N STALLATI ON - RI GH T SE AT
The l at ch st ri ker can be adjusted via t he slotted
holes i n t he st ri ker base.
(1) Position t he striker on t he reinforcement panel.
(2) Inst al l t he st ri ker bolts in t he reinforcement
panel and t he floor panel.
Fig. 16 Tilt-Latch Release Levers
SE AT TRACK S RE M OV AL - L E F T SE AT
(1) Remove t he seat platform stud nut s, spacers
and ret ai ners. Remove t he seat from t he platform.
(2) Remove t he seat t rack platform screws from
t he seat cushion frame.
(3) Remove t he t racks from t he seat cushion frame
(Fig. 17).
SE AT TRACK S I N STALLATI ON - LE F T SE AT
(1) Position t he t racks on t he seat cushion frame.
(2) Install t he seat t rack screws in t he seat cushion
frame.
(3) Adjust t he seat track adjustment release wire
as necessary.
(4) Position t he seat on t he platform. Install t he
seat platform stud spacers, ret ai ners, and nut s.
Tighten the nut s to 26 N*m (230 in. lbs.) torque.
ARM RE ST RE M OV AL
(1) Position t he armrest at an angle t hat will allow
access to t he armrest pivot support bracket screw
(Fig. 18).
(2) Remove t he armrest pivot support bracket
screw.
(3) Remove t he armrest from t he bracket.
(4) Remove t he armrest pivot support bracket from
t he seatback.

BODY COMPONENTS 23 - 4 1
RELEASE
SCREW TRACK
J 9 1 2 3
"
3 3 5
Fig. 17 Left Seat Tracks
ARM RE ST I NSTALLATI ON
(1) Position t he armrest pivot support bracket on
t he seatback.
(2) Install t he screws in the seatback. Tighten t he
(3) Position t he armrest on t he pivot support
bracket.
(4) Install t he armrest screw in t he pivot support
bracket. Tighten t he screw to 11 N*m (100 in. lbs.)
torque.
SEAT BACK SEAT
Fig. 18 Armrest Removal/Installation
REAR SEATS
JUMP SEAT-CLUB CAB
RE M OV AL
(1) Remove t he cab side t ri m panel.
(2) Remove t he nut s from t he studs. Pull outward.
Remove t he backrest from t he cab side panel support
brackets.
(3) Raise and support t he vehicle. Remove t he
j ump seat hinge stud nut s from t he under side of t he
cab.
(4) Remove the support. Lower t he vehicle. Re-
move t he j ump seat cushion from t he cab.
I NSTALLATI ON
(1) Position t he backrest at t he cab side panel. In-
stall t he nut s. Tighten t hem to 4 N*m (35 in. lbs.)
torque.
(2) Install the cab side t ri m panel.
(3) Position t he seat cushion in t he cab.
(4) Raise and support t he vehicle. Install t he nut s
on t he hinge studs. Tighten t he nut s to 23 N
#
m (200
in. lbs.) torque.
(5) Remove t he support. Lower t he vehicle.
SIDE BACK REST
Fig. 19 Jump Seat Removal/installation
FOLDING HEAR SEAT-RAMCHARGER
The instructions for operating t he folding rear seat
mechanism is included in t he owners manual . This
manual is included with t he vehicle.
RE MOV AL
(2) Remove t he nut s and washers from the seat
front hinge studs (Fig. 20).
(4) Release t he seat cushion rear latches from t he
strikers (Fig. 20).
(5) Remove the folding seat from t he vehicle.
23 - 4 2 BODY COMPONENTS

(6 ) If necessary, remove t he seat cushion hinges.
Remove t he torsion bar and armrest s. Remove t he
armrest supports and seatback hinges from t he seat
(Figs. 22 and 23) .
INSTALLATION
(1) If applicable, install t he seat cushion hinges.
Install t he torsion bar and armrest s. Install t he arm-
rest supports and seatback hinges on t he seat.
(2) Position t he folding seat in t he vehicle. Engage
t he seat cushion rear latches with t he strikers.
(4) Install t he washers and nut s on t he seat front
hinge studs. Tighten t he nut s to 11 Nm (95 in. lbs.)
torque.
Fig. 20 Folding Rear Seat
INTERIOR TRIM PANELS
SERVICE INFORMATION
Ram Truck, Chassis Cab and Ramcharger interior
t ri m panels are comprised of t he:
Windshield header t ri m panel
Door header t ri m panel s
A-pillar t r i m panels
Cowl side t r i m panels
Rear corner t r i m panels
Quart er window t ri m panels
Rear window upper t ri m panel
RD156
Fig. 21 Folded Seatback
V l t w I I N
DIRECTION OF ARROW D
DIRECTION OF ARROW C
SEAT CUSHI ON
Fig. 22 Folding Seat Cushion Hinges & Torsion Bar
Rear window lower t ri m panel
Rear header (hatchgate) t ri m panel
Lower side t r i m panels
Seat belt retractor covers
All t he interior t ri m panels are attached with
screws and/or clip ret ai ners.
C A U T I O N : R emove overl appi ng panel s before re-
movi ng i nboard trim panel s. A l s o verify that all
scr ews and retainer cl i ps are removed before re-
movi ng a trim panel. Trim panel s are somewhat
flexible but can be damaged if handled improperly.
Install t he screws finger-tight, align t he panels at
each end and t hen tighten t he screws. Use care to
avoi d overti ghteni ng the screws or, otherwi se,
the trim panel s will be damaged.

BODY COMPONENTS 23 - 4 3
HINGE
AND LATCH
ARM REST
SEAT BACK
NUT SUPPORT RY670
Fig. 23 Folding Seatback Armrests, Supports & Hinges
COWL SIDE TRIM PANEL
REMOVAL
(1) Remove t he screws from t he cowl side t ri m
panel (or air vent) and t he cowl panel (Fig. 24 ) .
(2) Remove t he t ri m panel (or ai r vent) from t he
cowl panel.
INSTALLATION
(1) Position t he cowl side t ri m panel at t he cowl
panel.
(2) Install t he screws in the cowl panel. Tighten
t he screws to 4 Nm (35 in. lbs.) torque. Avoi d over-
t i ght eni ng t he s cr ews .
AIR VENT
( W/ O TRIM PANEL)
AIR
VENT
AND
COWL
SIDE
TRIM PANEL
SCREW
COWL
SI DE
TRIM
PANEL
COWL
SIDE
PANEL
COWL
SIDE
RIGHT SIDE PANEL
SCREW SCREW J 9123- 354
Fig. 24 Cowl Side Trim Panels & Air Vent
WINDSHIELD HEADER, A-PILLAR AND FRONT
DOOR HEADER TRIM PANELS
REMOVAL
Remove the nearest screw in an adjacent over-
l appi ng trim panel to avoi d possi bl e damage to
both trim panel s (Fig. 25).
ROOF
I NNER PANEL
REAR
TRIM
PANEL
WEATHERSTRIP
SEAL
A-PILLAR
A-PILLAR
TRIM <
PANEL
DOOR
HEADER
TRIM
PANEL
DOOR HEADER
AND REAR
TRIM PANEL
J UNCTI ON
ROOF
I NNER
PANEL
WI NDSHI ELD
GLASS
DOOR
HEADER
TRIM
PANEL
DOOR
HEADER
TRIM
PANEL
WI NDSHI ELD
HEADER
TRIM
PANEL
WI NDSHI ELD
GLASS
DOOR HEADER
AND A-PILLAR
TRIM PANEL
J UNCTI ON
DOOR HEADER
AND WI NDSHI ELD
HEADER TRIM
PANEL J UNCTI ON
J 9123- 380
Fig. 25 Overlapping Trim Panels
(1) Remove t he t r i m panel screws from the body
inner panels (Fig. 26).
(2) Remove the t r i m panels from the body i nner
panels (Fig. 26).
INSTALLATION
(1) Position t he t r i m panels at t he body inner pan-
els.
(2) Install t he t ri m panel screws in t he body i nner
panels. Tighten t he screws to 1 Nm (12 in. lbs.)
torque.
UPPER REAR
TRIM PANEL
ROOF
I NNER
PANEL
A-PILLAR WI NDSHI ELD
HEADER
TRIM
PANEL
FWD
SCREW
DOOR
HEADER
TRIM PANEL
A-PILLAR
TRIM PANEL
WI NDSHI ELD
GLASS
SCREW
J 9123- 379
Fig. 26 Door Header, A-PUIar & Windshield Header
Trim Panels

CAB REAR CORNER/QUARTER WINDOW AND
REAR WINDOW UPPER/LOWER TRIM PANELS
REMOVAL
(1) Remove t he t ri m panel screws from t he body
inner panels (Figs. 27 and 28).
(2) Remove t he screw and coat hanger hook from
the rear window upper t ri m panel (Fig. 29).
(3) Remove t he t ri m panels from t he body interior
panels. .
INSTALLATION
(1) Position t he t ri m panels at t he body inner pan-
els.
(2) Install t he t ri m panel screws in t he body i nner
panels. Tighten t he screws to 1 Nm (12 in. lbs.)
torque.
(3) Position t he coat hanger hook at t he rear win-
dow upper t ri m panel (Fig. 29). Install and t i ght en
t he screw to 1 N
e
REAR
WI N D O W
UPPER TRIM
PANEL
SCREW
REAR
CORNE R
TRIM
PANEL
RE A R WI N D O W
LOWER TRIM
PANEL S CRE W J9123-390
Fig. 27 Standard Cab Rear Corner & Rear Window
Upper/Lower Trim Panels
ROOF RAIL
TRIM PANEL'
k
REAR WI N D O W
UPPER*
k
TRIM PANEL
REAR WI N D O W
LOWER TRIM PANEL
QUARTER
WI N D O W
TRIM
PANEL
COAT
HOOK
REAR WI N D O W
LOWER TRIM
PANEL
J9023-58
Fig. 28 Club Cab Quarter Window & Rear Window
Upper/Lower Trim Panels
S CRE W
COAT
HANGE R
HOOK
REAR
UPPER
TRIM
PANEL
J9123-381
Fig. 29 Coat Hanger Hook
QUARTER WINDOW UPPER AND HATCHGATE
HEADER TRIM PANELS
REMOVAL
(1) For convenience, fold forward t he rear passen-
ger seat. If necessary, refer to t he removal procedure.
(2) Remove t he spare tire.
(3) Remove t he t ri m panel screws from t he quart er
i nner panel and t he hat chgat e header panel (Figs. 30
and 31).
(4) Remove t he t ri m panels from t he quart er i nner
panel and t he header panel.
INSTALLATION
(1) Position t he t ri m panels at t he quart er i nner
panel and t he hat chgat e header panel.
(2) Install t he t ri m panel screws in the quart er in-
ner panel and header panel. Tighten t he screws to 1
(3) Install t he spare t i re.
COAT
HANGE R
HOOK
SCREW
LOWER
SI DE TRIM
PANEL
CLIP
RETAINER
RETRACTOR
COVER
QUARTER SCREW
WI N D O W
S CRE W
REAR
HEADER
TRIM
PANEL
([BODY
FOAM
SPACER
REAR
PILLAR
LOWER
TRIM PANEL
RETAINER
S CRE W FLOOR
RAIL PANEL
WHEELHOUSE RETAINER J9123-391
Fig. 30 Quarter Panel Upper/Lower & Hatchgate
Header Trim PanelsRamcharger

LOWER
SIDE TRIM
PANEL
Q UARTE R
WI NDOW
TRI M
PANEL
ROOF
I NNE R
PANEL
\
C
SCREW
QUARTER
PANEL
SCREW
QUARTER WI NDOW QUARTER WI NDOW
TRIM PANEL TRIM PANEL
LOWER SECTI ON UPPER SECTION
SCREW
ASH
RECEIVER
BEZEL
ASH RECEIVER
LOWER SIDE
TRIM PANEL
CLIP
RETAINER
LOWER
SIDE TRIM
PANEL
ROOF
I NNER
PANEL
RETAINER
RAIL
LOWER SIDE
TRIM PANEL
AT FLOOR PANEL
S C R E W
REAR
HEADER
TRIM
PANEL
ABOVE HATCHGATE
J 9123- 392
Fig. 31 Quarter Panel & Hatchgate Header Trim
PanelsRemoval/Installation
QUARTER PANEL LOWER TRIM PANELS
RE MOV AL
(1) For convenience, fold forward the rear passen-
ger seat.
(2) Remove the spare tire.
(3) Remove the rear pillar panel screws from the
hatchgate pillar inner panel (Fig. 30).
(4) Pry the trim panel end retainers from the quar-
ter inner panel slots.
(5) Disengage the lower trim panel clip retainers
from the wheelhouse.
(6) Remove the lower trim panel from the vehicle.
I NSTALLATI ON
(1) Position the lower trim panel in the vehicle at
the quarter.
(2) Engage the trim panel clip retainers with the
wheelhouse rail retainers.
(3) Engage the trim panel end retainers with the
quarter inner panel slots.
(4) Position the rear pillar panel at the hatchgate
pillar panel. Install the screws and tighten to 1 Nm
(5) Install the spare tire.
SPARE TIRE CARRIER
RETAINER ROD AND STAND-OFF
(2) Remove the quarter window trim panel and the
quarter panel lower trim panels. If necessary, refer
to the removal procedures.
(3) Remove the rod retainer from the quarter panel
support bracket.
(4) Remove the tire stand-off cap, nut, bolt and
spacer from the quarter window lower panel.
I NSTALLATI ON
(1) Install the tire stand-off bolt, spacer, nut and
cap. Tighten the nut to 41 Nm (30 ft. lbs.) torque.
(2) Install the rod retainer in the quarter panel
support bracket hole.
(3) Install the quarter window trim panel and the
quarter panel lower trim panels. If necessary, refer
to the installation procedures.
(4 ) Install the spare tire.
QUARTER
WI NDOW
TRIM PANEL
SPACER
BOLT
SIDE
INNER
' PANEL
SIDE
INNER
PANEL
STAND-OFF
CAP
TIRE STAND-OFF
NUT AND INSERT
J9123- 409
Fig. 32 Spare Tire/Wheel
SHOULDER BELTS/LAP BELT/BUCKLES
WA R N I N G : WH E N I N S T A L L I N G S H O U L D E R BE L T ,
L A P BE L T AN D BUC K L E AN C H OR BO L T S , V E RI F Y
T HA T T HE Y A R E T I G HT E N E D T O 40 N-M (350 I N .
LBS. ) TORQUE.
INSPECTION
Inspect the condition of all the belts and buckles
(Figs. 33, 34 and 35). Replace any belt or buckle that
is damaged in any way. Also, replace the shoulder
belt if the retractor is inoperative.
FRONT SHOULDER BELTS/LAP
BELT/BUCKLES
RE MOV AL
(1) If necessary, move the front seat(s) all the way
forward for access.
(2) Disconnect the shoulder belt warning wire har-
ness connectors.
RE M OV AL
(1) Remove the spare tire (Fig. 32).

(3) Bucket seatsdetach t he covers from t he an-
chor bolts for t he left and ri ght shoulder belt buckles.
(4) Remove t he anchor bolts from t he anchor plates
on t he floor panel.
(5) Remove t he buckles and t he lap belt from t he
floor panel.
Ram Trucks and Chassis CabsRemove t he cover
concealing t he shoulder belt upper anchor bolt.
RamchargersRemove t he quart er window t ri m
panel. If necessary, refer to t he removal procedure.
(6) Remove t he upper anchor bolt from t he cab in-
ner side panel/B-pillar.
Ram Trucks and Chassis CabsRemove t he shoul-
der belt retractor and lower anchor bolt from t he
B-pillar.
RamchargersRemove t he screw and belt retrac-
tor cover from t he side i nner panel. Remove t he an-
chor bolts. Remove t he retractor and lower belt from
t he side i nner panel.
(7) Remove t he shoulder belts and retractors from
t he vehicle.
INSTALLATION
(1) Position t he shoulder belt retractor and t he
lower end of t he shoulder belt at t he side i nner
panel. Align t he anchor bolt holes. Install t he anchor
bolts. Tighten t he anchor bolts to 40 N*m (350 in.
lbs.) torque.
RamchargersInstall t he belt retractor cover and
t he screw in t he side inner panel. Tighten t he screw
(2) Position t he shoulder belt upper anchor plate
on t he t r i m panel. Install t he upper anchor bolts in
t he side panels. Tighten t he anchor bolts to 40 N
#
m
Ram Trucks and Chassis CabsInstall t he cover
to conceal t he shoulder belt upper anchor bolt.
RamchargersInstall t he quart er window t ri m
panel. If necessary, refer to t he installation proce-
dure.
(3) Position t he belt buckles on t he floor panel.
(4) Install t he shoulder belt buckles. Install t he lap
belt and buckle anchor bolts in t he floor panel.
Tighten t he anchor bolts to 40 Nm (350 in. lbs.)
torque.
Bucket seatsPosition t he covers over t he left and
ri ght shoulder belt buckle anchor bolts.
(5) Connect t he shoulder belt warni ng wire har-
ness connectors.
(6) If moved all t he way forward for access, cor-
rectly position t he front seat.
REAR SHOULDER BELTS/LAP
BELT/BUCKLES-RAMCHARGER
REMOVAL
(1) If necessary, move t he front seat(s) all t he way
forward for access.
Fig. 33 Ramcharger Bucket Seat Shoulder Belt
Buckles
SHOULDER ANCHOR LAP
BELT
BUCKLE . J9123-608
Fig. 34 Bench Seat Shoulder Belt Buckle & Lap
Belt/Buckle Anchors
(2) Remove t he anchor bolts from t he folding rear
seat frame (Fig. 36).
(3) Remove t he buckles and t he lap belt from t he
folding seat frame.
(4) Remove t he covers concealing t he shoulder belt
upper anchor bolt.
(5) Remove t he shoulder belt upper anchor bolts
from t he roof inner liner.
(6) Remove t he shoulder belt lower anchor bolts
from t he floor panel.
(7) Remove t he shoulder belt covers from t he t r i m
panel.
(8) Remove t he quart er panel lower t ri m panels. If
necessary, refer to t he removal procedure.

BODY COMPONENTS 23 47
SPACER
SHOULDER
BELT
COVER
TRIM
"PANEL
INNER
PANEL
SPACER
PILLER
SHOULDER
BELT
ANCHOR
BOLT
SHOULDER
BELT
RETRACTOR
ANCHOR
BOLT
SHOULDER
BELT
RETRACTOR
COVER
ANCHOR
BOLT
ANTI-
RATTLE
WASHER
SCREW
ANC HOR ]
B O L T
RAMCHARGER
ANTI-
RATTLE
WASHER
MODELS 30 & 60
J9123-329
Fig. 35 Shoulder Belt, Anchor Bolts & Retractor
(9) Remove the belt retractor support bracket an-
chor bolts from the quarter panels.
(10) Remove the shoulder belts and the retractors
from the vehicle.
INSTALLATION
(1) Position the shoulder belt retractor support
brackets at the quarters above the wheelhouse. In-
stall the support bracket anchor bolts in the quarter
panels. Tighten the anchor bolts to 40 Nnn (350 in.
lbs.) torque.
(2) Position the other end of the shoulder belt at
the floor panel. Install the lower anchor bolt in the
floor panel. Tighten the anchor bolts to 40 Nnn (350
in. lbs.) torque.
(3) Position the shoulder belt upper anchor plate at
the roof inner liner. Install the upper anchor bolts in
the roof inner liner. Tighten the anchor bolts to 40
Nnn (350 in. lbs.) torque.
(4) Position the covers over the upper anchor bolts.
(5) Install the quarter panel lower trim panel. If
necessary, refer to the installation procedure.
(6) Install the shoulder belt cover on the trim
panel. Tighten the screws to 1 Nnn (12 in. lbs.)
torque.
(7) Position the buckles and the lap belt on the
folding seat frame.
(8) Install the anchor bolts in the seat frame.
Tighten the bolts to 40 N-m (350 in. lbs.) torque.
(9) If applicable, adjust the front seat position.
REAR
FOLDI NG
SEAT
FLOOR
PANEL
ANC HOR
BOLT
SEAT
RELEASE
J9123-610
Fig. 36 Rear Folding Seat Shoulder Belt Buckle &
Lap Belt/Buckle Anchors
ANC HOR
B O L T
SHOULDER
BELT
ROOF OUTER
LINER
COVER
S C R E W"
S H O U L D E R ^
BELT
RETRACTOR
ANCHOR
BOLT
SIDE
I NNER
PANEL
J9123 -330
Fig. 37 Rear Seat Shoulder BeltRamcharger
JUMP SEAT LAP BELT/BUCKLE
REMOVAL
(1) If necessary, move t he front seat(s) all t he way
forward for access.
(2) Remove the lap belt buckle anchor bolt (Fig.
38).
(3) Remove t he lap belt and retractor anchor bolt.
(4) Remove t he buckle and t he lap belt/retractor
from t he floor panel.
INSTALLATION
(1) Position t he lap belt/retractor and buckle on
the floor panel.
(2) Install t he anchor bolts in t he anchor plates.
Tighten t he anchor bolts to 40 N*m (350 in. lbs.)
torque.
Fig. 38 Jump Seat Lap Belt/Buckle Anchors
HEADLINERS
SERVICE INFORMATION
The base headliner is constructed of molded hard-
board (Fig. 39). A cloth-covered, molded headliner is
used for most applications (Fig, 40).
Ramchargers are equipped with a cloth-covered,
molded two-piece headliner. The separation between
the front and rear headliners is concealed by a
push-on t ri m moulding (Fig. 41).
To remove a headliner, all of t he overlapping t ri m
must be removed along with (as applicable):
Sunvisors
Dome/cargo lamps
Dome/reading lamp
Coat hooks
Any other interfering attached component
REMOVAL
be bent duri ng removal/installation. Permanent
damage possi bl y will result.
(1) Remove t he sunvisors and clips. If necessary,
refer to t he removal procedure.
(2) As applicable, remove t he dome/cargo lamp
and/or t he dome/reading lamp.
(3) Ram Trucks and Chassis Cabs, remove the:
Windshield header t ri m moulding
Door header t ri m moulding
Rear corner t ri m panel or quart er window t ri m
panel (club cab)
Rear window upper t ri m moulding.
If necessary, refer to t he t ri m removal procedure.
(4) Ramchargers, remove the:
Windshield header t ri m moulding
Door header t ri m moulding
Side t ri m moulding
Center t ri m moulding
Hat chgat e header t ri m moulding
If necessary, refer to t he t ri m removal procedure.
(5) Remove all other interfering components.
(6) As applicable, remove t he headliner ret ai ners
and screws (Fig. 41).
(7) Remove the headliner from t he vehicle (Figs.
40 and 41).
INSTALLATION
(1) Position t he headliner in the vehicle adjacent
to t he roof panel.
(2) As applicable, install the headliner ret ai ners
and screws. Tighten t he screws to 1 N*m (12 in. lbs.)
torque.
(3) Install t he trim, lamps and all other compo-
nent s t hat were removed. If necessary, refer to t he
applicable installation procedures.
Fig. 39 Molded Hardboard Cab Headliner
C A U T I O N : Headl i ners are constructed of mol ded
material. They have limited flexibility. They must not
^ ^ BODY COMPONENTS 23 - 49
HEADLINER
ROOF
INNER
PANEL
ROOF
INNER
PANEL
SCREW
ROOF
RAIL
HEADER
TRIM PANEL HEADLINER
J9123-353
Fig. 40 Cloth-Covered Molded Cab Headliner
ROOF
INNER
PANEL
RETAINER RAIL
CENTERING
HOLE
REAR
HEADLINER
RETAINER
PERIMETER
RETAINER INSTALLATION
TRIM
'MOULDING
J9123-358
Fig. 41 Ramcharger Headliner
INNER
BACK
PANEL
ROOF
INNER
PANEL
REAR
WINDOW
UPPER TRIM
SUNVISOR
SUNVISOR
AND WINDSHIELD
HEADER TRIM
DOME LAMP LENSE
DOME AND WINDOW TRIM
LAMP
L E N S E
J9l 23-352
Fig. 42 Ram Truck/Chassis Cab Sunvisor & Dome
Lamp
ROOF
INNER
v
PANEL \
SIDE
TRIM
MOULDING
HEADLINER RETAINER
RAIL
FRONT
HEADLINER
SCREW
SIDE OF VEHICLE
ROOF INNER
PANEL
WINDSHIELD
WEATHERSTRIP
SEAL
ROOF
INNER
PANEL
REAR
HEADLINER
SCREW
RETAINER SNAP-ON
TRIM MOULDING ENDCAP
CENTER OF VEHICLE
FRONT
HEADLINER
REAR
HEADLINER
ROOF INNER
PANEL
WINDSHIELD
HEADER
TRIM
MOULDING
FRONT OF VEHICLE
S C R E W
SCREW
SUN VISOR SCREW
REAR TRIM
ARM MOULDING
REAR OF VEHICLE
J9123-359
Fig. 43 Ramcharger Sunvisor & Headliner Trim
Moulding
ROOF
INNER
PANEL
BRACKET
BULB
HOLDER
DOME
LAMP
BRACKET
HEADLINER
LENSE
DOME LAMP
WITH HEADLINER
SCREW
DOME LAMP
CLUB CAB
BULB
HOLDER
J9123-401
Fig. 44 Ram Truck/Chassis Cab Dome Lamps
DOME/READING LAMP
REMOVAL
(1) Squeeze t he dome lamp lense to remove it from
t he bracket.
(2) If applicable, remove t he lense bracket screws.
(3) Remove t he lense bracket from t he headliner
and roof inner panel.
(4) Disconnect t he bulb holder wire harness con-
nectors (Fig. 44).
(5) Remove t he lense, bulb holder and bracket
from the roof inner panel.
I NSTALLATI ON
(1) Position t he dome/reading lense, bulb holder
and lense bracket to t he roof inner panel.
23 - 50 BODY COMPONENTS < ^ ^
DOME LAMP DOME/READING LAMP
J9123-400
Fig. 45 Ramcharger Dome Lamp & Dome/Reading
Lamp
(2) Connect t he bulb holder wire harness connec-
tors.
(3) Insert t he lense bracket in t he headliner hole.
Install t he screws in t he roof i nner panel. Tighten
t he screws to 4 N
#
(4) Install t he lamp lense on t he bracket.
DOME LAMP-CLUB CAB
REMOVAL
(1) Remove t he screws and t he dome lamp lense
from t he lamp housing (Fig. 44).
(2) Disconnect t he bulb holder wire harness con-
nectors.
(3) Remove t he screws and t he bulb holder bracket
from t he lamp housing.
(4) Remove the bulb holder and bracket from the
lamp housing.
INSTALLATION
(1) Position t he bulb holder and bracket at t he
lamp housing.
(2) Install t he bulb holder bracket screws in t he
lamp housing. Tighten t he screws to 4 Nm (35 in.
lbs.) torque.
(3) Connect t he bulb holder wire harness connec-
tors.
(4) Position t he lense on t he lamp housing. Install
t he screws. Tighten the screws to 4 N
#
m (35 in. lbs.)
torque.
SUNVISORS
REMOVAL
(1) Remove t he screws t hat at t ach t he sunvisor
arm support bracket to t he roof i nner panel (Figs. 42
and 43).
(2) Detach t he sunvisor from t he clip.
(3) Remove t he sunvisor from t he roof inner panel.
(4) Remove t he screw and t he clip from t he roof in-
ner panel.
INSTALLATION
(1) Install t he sunvisor clip with t he screw.
Tighten t he screw to 4 N*m (35 in. lbs.) torque,
(2) Position t he sunvisor in the clip. Align t he ar m
support bracket holes with the headliner holes.
(3) Install t he screws t hat at t ach t he sunvisor arm
support bracket to t he roof i nner panel. Tighten t he
screws to 4 N *m (35 in. lbs.) torque.
FLOOR CONSOLE AND REAR STORAGE TRAY
CONSOLE
REMOVAL
(1) Open t he console lid (Fig. 46).
(2) Remove t he console front and rear screws from
t he floor panel.
(3) Remove t he console from t he floor.
INSTALLATION
(1) Position t he console on t he floor.
(2) Install t he screws in t he floor panel. Tighten
(3) Close t he console lid.
STORAGE TRAY-STANDARD CAB
REMOVAL
(1) Remove t he contents from t he storage t ray.
(2) Remove the screws from t he floor panel and t he
t ray (Fig. 47).
(3) Remove t he storage t ray from t he floor panel.
INSTALLATION
(1) Position t he storage t ray on t he floor panel.
(2) Install t he screws in t he t ray and floor panel.
Tighten t he screws to 4 Nm (35 in. lbs.) torque.
Fig. 46 Floor Console

Fig. 47 Standard Cab Storage Tray
CARPETS AND FLOOR H ATS
To remove a carpet/mat, all of t he adjacent t ri m
panels must be removed. Also interfering components
should be removed as well as:
Seat(s)
Scuff plates
Transmission and transfer case floor shift levers,
bezels and boots.
Floor console
REMOWAL
(1) Remove t he protective floor mat s (if equipped).
(2) Remove all t he interfering components.
(3) Remove t he t ri m panels, ret ai ners, sill-well
covers and scuff plates.
(4) Remove t he carpet/mat from t he floor panel
and t he vehicle.
INSTALLATION
(1) Position t he carpet/mat on t he floor panel.
(2) Install seat(s) and all other necessary compo-
nent s. If necessary, refer to t he applicable installa-
tion procedure(s).
(3) Install t he t ri m panels, ret ai ners, sill-well cov-
ers and scuff plates.
(4) Place t he floor mat s (if equipped) on t he carpet/
mat .
Fig. 48 Carpet Or MatStandard Cab
CAB
Fig. 49 Rear Floor Noise Insulator & Sill-Well
CoverStandard Cab
CLUB RETAINER
Fig. 50 Carpet, Scuff Plate, Sill-Well Cover & Rear
Retainer Club Cab
CAB
SI DE
TRI M
CARPET
CAB
REAR
TRI M
CARPET
J9123-378
Fig. 51 Side & Rear Panel Trim Carpet-Club Cab
REAR
FLOOR
MAT
RETAI NER
DASH
PANEL
FRONT
FLOOR
MAT
NOI SE
I NSULATOR
FLOOR
MAT 1/2 I NCH
FLOOR FLOOR
MAT PANEL
SI LL- WELL
COVER
SCUFF
PLATE
DOOR
SI LL
J9123-418
Fig. 52 Floor Mat, Scuff Plate, Si 11-Wei I Cover &
Rear RetainerClub Cab
WHEELHOUSE REAR SCREW
CARPET FLOOR
CARPET
REAR
RETAI NER
SCREW
REAR SEAT
ESCUTCHEON
,1.5 IN-
ADHESI VE
NOI SE ^
N D
I NSULATORnj
FRONT ~*
RETAI NERS
FRONT ;
FLOOR
!
CARPET .
NOI SE:
I NSULATOR
DASH \ CARPET SCUFF
PANEL XARPET PLATE
PANEL
SCUFF
PLATE
REAR *
FLOOR
CARPETS DOOR
SI LL
PANEL
J9123-413
Fig. 54 Carpet, Scuff Plate, Rear Seat Striker
Escutcheon & Retainers-Ramcharger
REAR
FLOOR
NOI SE
I NSULATOR
PAD
CARPET
ADHESI VE
; WHEELHOUSE
NOI SE
I NSULATOR
PAD
I NSULATI ON
FI LLER
J9123-412
Fig. 55 Rear Floor Noise Insulator Pad, Insulation
Filler & CarpetRamcharger
CLUB
CAB
REAR
FLOOR
NOI SE
I NSULATOR
PAD
K52' \ ^
J9123
-
416
Fig. 53 Rear Floor Noise Insulator-Club Cab
HOLE FOR
4- SPEED
TRANSMI SSI ON
TRANSMI SSI ON
SCREW
CARPET
OR FLOOR*
MAT "
TRANSFER
CASE
SHI FT LEVER
COVER
CARPET
OR MAT
TRANSMI SSI ON
SHI FT LEVER
BOOT SEAL
COVER
SCREW SEAL
CARPET
OR MAT
>QR\
t
HOLE FOR TRANSFER CASE
HOLE FOR A833 OVERDRI VE
SCREW
PLATE
SCREW
SCREW '
FLOOR
1
I NSULATI ON^,
PANEL PAD
SHI FT
LEVER
COVER
WASHER
SCREW CARPET
FLOOR OR MAT
PANEL
BOOT
SEAL
I NSULATI ON
PAD
4- SPEED TRANSMI SSI ON
ANb TRANSFER CASE
A833
OVERDRI VE TRANSMI SSI ON
J9123- 406
Fig. 56 Transmission & Transfer Case Shift
Mechanisms

R E F I N I S H I N G P R O C E D U R E S
SERVICE INFORMATION
Exterior vehicle body colors are identified on t he
Body Code plate. The plate is attached to t he top,
ri ght side of t he cowl below the cowl grille. The color
code location is described in t he manual introduction.
OEM pai nt colors are generally available from all
of t he major pai nt suppliers. They are supplied in t he
form of either mixing formulas or factory packaged
(pre-mixed) paint.
The exterior colors and corresponding Ram Truck,
Chassis Cab and Ramcharger pai nt codes are listed
in t he following chart.
BASE COAT/CLEAR COAT FINISH
On most vehicles a two part pai nt application (base
coat/clear coat) is used. Color pai nt t hat is applied to
primer is called base coat. The clear coat protects
base coat from ultraviolet light. It also provides a du-
rable hi gh gloss finish.
WET SANDING, BUFFING AND POLISHING
Minor acid etching, orange peel or smudging in
clear coat can be reduced with light wet sanding,
hand buffing and polishing. If t he finish has been
wet sanded in t he past, it cannot be repeated. Wet
sanding operation should be performed by a t rai ned
automotive painter.
C A U T I O N : D o not remove clear coat f i ni sh, if
equi pped. Ba s e coat paint must retain clear coat to
shi ne.
ble. For best results, use MoparScratch Filler/
Primer, Touch-up Pai nt s and Clear Top Coat. Refer
to Introduction group of t hi s manual for Body Code
Pl at e information.
TOUCH-UP PROCEDURE
\l) Scrape loose pai nt and corrosion from inside
scratch or chip.
(2) Clean affected area with MoparTar/Road Oil
Remover and allow to dry.
(3) Fill t he inside of t he scratch or chip with a coat
of filler/primer. Do not overlap pri mer onto good sur-
face finish. The applicator should be wet enough to
puddle/fill t he defect without runni ng. Do not stroke
brush applicator on body surface. Allow t he filler/
primer to dry hard.
(4) Cover t he filler/primer with color touch-up
paint. Do not overlap color touch-up onto t he original
color coat. But t t he new color to t he original color if
possible. Do not stroke applicator brush on body sur-
face. Allow touch-up pai nt to dry hard.
(5) On vehicles without clear coat, t he touch-up
color can be lightly (600 grit) wet sanded and pol-
ished with rubbing compound.
(6) On vehicles with clear coat, apply clear top coat
to touch-up pai nt with t he same technique as de-
scribed in step 4. Allow clear top coat to dry hard. If
desired, step 5 can be performed on clear top coat.
PAINTED SURFACE TOUCH-UP
When a painted met al surface has been scratched
or chipped, it should be touched-up as soon as possi-
P A I N T C O D E C H A R T
GENERAL INFORMATION
The following pai nt code chart lists t he pai nt color
name on t he left side and t he pai nt code on t he ri ght
side. The pai nt colors listed are available at your lo-
cal pai nt supplier. Clear Coat ( CO colors are desig-
nat ed after t he color title.
EXTERIOR COLORS
Colorado Re d - CC HE4
Dk. Copper Pe a r l - CC LVB
Lt. Champagne Me t . - CC KV4
Dk. Forest Gr e e n- CC GG7
Dk. Spectrum Blue Me t . - CC JB6
Banzai Blue Me t . - CC KC3
Black - C C DX8
Dk. Silver Me t . - CC KS7
Silver St ar Me t . - CC KAC
Bright Whi t e - CC GW7
Bright Turquoise Me t . - CC KQ2
Medium Turquoise Me t . - CC MQF
Light Tur quoi se- CC MQG
Parade Blue Me t . - CC. . . MC6
Dark Arctic Gr a y - CC MS9
Light Arctic Gr a y - CC MSC
INTERIOR COLORS
Charcoal S8
Crimson Red M6
Spice/Dk. Spice TT

HEATING AND AIR CONDITIONING 24 - 1
CON TE N TS
page
CLIMATE CONTROL SYSTEM . . . . . . . . . . . . . 21 REFRIGERANT SYSTEM SERWICE
COMPRESSOR SERWICE (SD-709) . . . . . . . . . 21 PROCEDURES . . . . . . . . . . . . .
DIAGNOSTIC PROCEDURES 3 TORQUE SPECIFICATIONS
page
. 17
. 31
GE N E RAL I N F ORM ATI ON
HEATER SYSTEM
All models use a Blend-Air type heater. Outside ai r
enters t he heat er t hrough t he cowl opening and
passes t hrough a pl enum chamber to t he heat er core.
Air i nt ake openings must be kept free of snow, ice
and other obstructions for t he heat er system to pick
up sufficient outside air. A t emperat ure control door
in t he heat er housing directs incoming air through
t he heat er core and/or t he heat er core bypass. The
amount of blend (heated and non-heated air) is deter-
mined by t he setting of t he t emperat ure lever on t he
i nst rument panel. Direction of t he blended air is con-
trolled by t he HEAT-DEFROST lever on t he instru-
ment panel.
The blower switch and resistor block controls t he
speed of t he blower motor. This in t ur n controls t he
velocity of t he air flow from t he heat er outlets.
The resistor block consists of 2 helical wound wire
resistors connected to t ermi nal s which are mechani-
cally attached to a glass-filled phenolic board. This
assembly is bolted to t he plenum.
The blower switch controls t he blower motor speed
by selectively connecting t he resistors in series to t he
blower motor.
A self-adjusting clip, on each of 2 control cables has
been incorporated to simplify cable adjustment. This
clip snaps onto t he control cable core wire and will
slide along t he wire under a specific load to provide
an automatic cable adjustment.
AIR CONDITIONING SYSTEM
Air i nt ake openings must be kept free of snow, ice
and other obstructions for t he air conditioning sys-
t em to pick up sufficient outside air.
COMPONENTS
COMPRESSOR- The seven piston SD-709 com-
pressor is used on all vehicles. This compressor com-
presses t he low pressure refrigerant vapor into a
hi gh pressure, high t emperat ure vapor.
CLUTCH PULLEY AND COI L- Thes e are
mounted on t he compressor, providing a convenient
way to drive it and disengage it in accordance to t he
cooling needs.
CONDENSER- The condenser is located in front
of t he radiator. Its function is to cool t he hot, high
pressure refrigerant gas causing it to condense into
hi gh pressure liquid refrigerant.
FILTER-DRIERThe filter-drier is used to remove
any traces of moisture from t he refrigerant system.
Thi s component incorporates t he sight glass and t he
hi gh pressure relief valve.
SIGHT GLASS- The sight glass is provided as a
diagnostic tool to observe refrigerant flow and indi-
cate refrigerant level. It is located at t he top of t he
filter drier.
HIGH -PRESSURE RELIEF VALVE- Thi s is a
safety device designed to open automatically if t he
system pressure reaches a predetermined level. This
will prevent system component damage.
EXPANSION (H) VALVE- The expansion (H)
valve is used to meter refrigerant into t he evaporator
in accordance with cooling requirements.
EVAPORATOR COI L- The evaporator coil is lo-
cated in t he A/C unit. Its function is to cool and de-
humidify t he air before it ent ers the vehicle.
FREEZE CONTROL- The mai n function of freeze
control is to prevent water on t he evaporator coil face
from freezing which restricts t he airflow. An elec-
tronic t emperat ure cycling switch is located on t he
refrigerant plumbing (suction line) near t he H-Valve.
The switch t ur ns t he compressor ON-OFF depending
on t he t emperat ure in the suction line. The switch is
a sealed, specially calibrated unit. If found defective,
t he switch must be replaced.
REFRIGERANT LI NES- Thes e lines are needed
to carry t he refrigerant between t he various system
components.
CONDENSATE DRAIN TUBE- Condensat i on
which accumulates on t he bottom of t he evaporator
H E A T I N G A N D A I R C O N D I T I O N I N G
24 - 2 HEATING AND AIR CONDITIONING

housing is expelled t hrough t he molded rubber drai n
t ube into t he engine compartment. The t ube must be
kept open to prevent condensation from collecting in
t he bottom of t he housing.
The squeezed rubber flap at t he drain t ube tip is
designed to keep engine compartment ai r from enter-
ing into t he system yet allow condensation to drain.
If t he tip is not properly formed or has been dam-
aged, t he system will not drai n properly. Therefore,
if t he t ube is damaged, it should be replaced.
SERVICE VALVESThe service valves at t he
compressor suction line and discharge t ube are used
to test and service t he refrigerant system. A special
adapter (Tool C-4803) is required for performance
testing.
OPERATION
The compressor increases t he pressure and temper-
at ure of t he refrigerant. The heated refrigerant vapor
is t hen pumped into t he condenser where it cools by
giving off heat to ai r passing over t he condenser fins.
As t he refrigerant cools in t he condenser, it con-
denses into a liquid. Still under high pressure, t he
liquid refrigerant passes into t he receiver. The re-
ceiver acts as a reservoir to furnish refrigerant to t he
expansion (H) valve at all times. From t he receiver,
t he high pressure liquid refrigerant passes to t he ex-
pansion (H) valve. The expansion (H) valve met ers
refrigerant into t he evaporator where a low pressure
is mai nt ai ned by t he suction side of t he compressor.
As it ent ers t he evaporator, t he refrigerant immedi-
ately begins to boil by absorbing heat from t he air
passing over t he evaporator core. Havi ng given up its
heat to boil t he refrigerant, t he ai r is cooled and
passes into t he passenger compartment of t he vehi-
cle. From t he evaporator t he vaporized refrigerant is
drawn back to t he compressor to repeat t he cycle.
RADIATOR CAP
Air conditioned vehicles must be equipped with a
radi at or cap havi ng a holding pressure of 98-122
kPag (14-18 psig). Replace t he radiator cap t hat does
not t est wi t hi n t hi s specification.
CONDENSER
Inspect t he condenser for obstruction or foreign
mat t er. Clean if present.
Any obstruction to t he free flow of air across t he
condenser will decrease heat dissipation from t he
condenser. This will in t ur n decrease t he efficiency of
t he condenser and decrease t he evaporator' s effi-
ciency. These conditions result in increasing t he dis-
charge pressure and horsepower load on t he engine.
The use of a bug screen is not recommended, it also
will decrease t he free flow of air.
Inspect t he condenser for bent or damaged fins.
The bent fins on t he condenser deflect air flow and
decrease t he condenser area.
BUG SCREENS
Bug screens should NOT be installed on vehicles
equipped wi t h air conditioning. A bug screen in-
stalled in front of t he condenser will reduce air flow
and air conditioner performance. Under severe heat
conditions a bug screen may cause t he engine to
over-heat.
RESISTOR BLOCK
The blower motor switch and resistor block, con-
trols t he speed of t he blower motor. The resistor
block consists of 3 helical-wound wire resistors, con-
nected to t ermi nal s which are mechanically attached
to a phenolic board. This assembly is bolted to t he
plenum.
The blower switch controls t he blower motor speed
by selectively connecting in series one, two, t hree or
none of t he resistors to t he blower motor.

D I A G N O S T I C P R O C E D U R E S
INDEX
page page
. . 7 General Information 3
. . 3 Heating System Output 3
Air Conditioning System
Blower Motor
GENERAL INFORMATION
The reason for owner dissatisfaction must be thor-
oughly understood before any attempt is made to re-
pair or replace any parts. It must be determined if
the condition is the heater system, the refrigerant
system, air conditioning air flow or related to the
compressor. After confirming the condition, a func-
tional test is suggested using the diagnostic charts.
After the condition has been properly diagnosed and
corrected, check out the complete system to assure
that it is performing satisfactorily.
The following charts have been developed for quick
reference. If the step by step method used is not com-
pletely understood, refer to the correct section of the
Service Manual for detailed explanations.
HEATING SYSTEM OUTPUT
WA R N I N G : I F V E H I C L E H A S B E E N R U N R E C E N T L Y ,
WA I T 15 M I N U T E S B E F O R E R E M O V I N G C A P, T HE N
PL A C E A R A G O V E R T HE C A P A N D T U R N IT T O
T HE F I R S T S T O P. A L L O W P R E S S U R E TO E S C A P E
T H R O U G H T HE O V E R F L O W T U BE AND WH E N T HE
S Y S T E M S T A BI L I Z E S , R E M O V E T HE C A P C O M -
PL E T E L Y .
Check the radiator coolant level, drive belt tension,
engine vacuum line connections, radiator air flow
and radiator fan operation. Start engine and bring to
normal operating temperature (refer to Group 7,
Cooling System).
Engine coolant is provided to the heater system by
2 heater hoses. With engine idling at normal operat-
ing temperature, set the heater control to maximum
heat, defrost and high blower setting. Using a test
thermometer, check the air temperature coming from
the defroster outlets (refer to Temperature Reference
Chart).
Should the temperature not meet the minimum
values shown, refer to Heater Diagnosis (Mechanical)
for possible causes and corrections.
(1) Remove radiator pressure cap.
(2) Drain 1 pint of coolant from the radiator.
(3) Warm the engine to operating temperature by
idling for 20 minutes, with the pressure cap off. Idle
longer if working outdoors in cold temperatures.
(4) With the engine idling, place a thermometer
into the coolant in the radiator filler neck.
TEMPERATURE REFERENCE CHART
AMBIENT MINIMUM HEATER SYSTEM
TEMPERATURE AIR OUTLET TEMPERATURE
C F C F
15.5 60 62.2 144
21.1 70 63.8 147
26.6 80 65.5 150
32.2 90 67.2 153
J9124-11
(5) Engine coolant temperature should stabilize at
no lower than 86C (187F) or 4C (8F) below the
thermostat opening temperature. This should happen
during the vehicle operating cycle.
(6) Instrument panel control in HEAT mode.
(7) Set to high blower speed.
(8) Temperature lever to maximum heat position.
BLOWER MOTOR
The heater control blower speed selector switch and
resistor block supplies the blower motor with voltage.
A varied voltage is supplied for low and middle
speeds while battery voltage is supplied for high
speed (Fig. 1).
Fig. 1 Blower Motor Resistor Block (Typical)
Refer to Heater Blower Motor/Control System Di-
agnosis (Electrical) Chart and Blower Motor Noise/
Vibration Chart.

(1) Possible location or cause of blower motor vi-
bration are as follows:
(a) Blower motor assembly loose in heat er A/C
housing.
(b) Blower wheel loose on motor shaft.
(c) Blower wheel out of balance or bent.
(d) Blower motor defective.
(2) Possible location or cause of blower motor noise
are as follows: (To verify blower noise disconnect
blower motor wire lead connector and operate heat er
or A/C system. If noise goes away, proceed with pro-
cedure.)
(a) Refer to vibration section of t hi s procedure.
(b) Foreign mat eri al in Heater-A/C housing
around blower wheel.
(c) Blower wheel rubbing Heater-A/C housing.
(d) Blower motor defective.
HEATER DIAGNOSIS (MECHANICAL)
INSUFFICIENT HEAT
OBSTRUCTED HEATER OUTLETS
TEMPERATURE DOOR MISDIRECTED
OR BINDING, KINKED OR UNATTACHED
CONTROL CABLE (SEE CONTROL CABLE
SECTION).
MODE DOOR IMPROPERLY ADJUSTED OR
BINDING. UNATTACHED CONTROL CABLE.

OBSTRUCTED HEATER HOSE

KINKED HEATER HOSE, SEE ROUTING.

AIR IN HEATER CORE
LOW COOLANT FLOW, INSUFFICIENT
COOLANT IN SYSTEM. DEFECTIVE
THERMOSTAT. WATER PUMP BELT LOOSE.
GREATER THAN 50% MIXTURE
OF ANTIFREEZE. ENGINE TEMPERATURE
LOW SEE GROUP 7. ENGINE COOLING
DIAGNOSIS.

OBSTRUCTED INTAKE IN MANIFOLD
PASSAGE.
1_
HEATER CORE PLUGGED.
WATER VALVE PARTIALLY OR
FULLY CLOSED.
TOO M U C H HEAT
IMPROPERLY ADJUSTED TEMPERATURE
CONTROL CABLE.
DISCONNECTED OR BROKEN, KINKED
TEMPERATURE CABLE.
BLEND-AIR (TEMP) DOOR
BINDING OR MISDIRECTED
ENGINE THERMOSTAT DEFECTIVE.
J9124-115

HEATER BLOWER MOTOR / CONTROL SYSTEM DIAGNOSIS (ELECTRICAL)
BLOWER MOTOR
INOPERATIVE
]
[
I N S P E C T F U S E I - -*JT
FUSE L O O K S GOOD
CHECK FOR
STALLED MOTOR
MOTOR
STALLED
REPLACE
MOTOR
REPLACE
FUSE
MOTOR
O.K.
CHECK FOR
SHORT
CORRECT
SHORT
REPLACE
FUSE
MOTOR
O.K.
CHECK FOR
SHORT
CORRECT
SHORT
REPLACE
FUSE
h
VOLTAGE AT BOTH
ENDS OF FUSE
CHECK FOR BATTERY VOLTAGE
AT BOTH ENDS OF FUSE
VOLTAGE AT BATTERY
SIDE OF FUSE ONLY
ATTACH JUMPER WIRE BETWEEN MOTOR GR OUND WIRE A N D BODY OR ENGI NE
MOTOR
RUNS
LOCATE A N D CORRECT
OPEN CONNECTI ON
CHECK BLOWER REPLACE
MOTOR GR OUND FUSE
MOTOR DOES
NOT RUN
CHECK MOTOR CONTI NUI TY
IF MOTOR DOES
NOT RUN
REPLACE MOTOR
MOTOR RUNS
ATTACH JUMPER WIRE FROM THE MOTOR FEED WIRE TO THE
POSITIVE POST OF THE BATTERY. MA K E SURE THAT
MOTOR GR OUND WIRE IS PROPERLY GROUNDED FOR THIS
TEST. REASSEMBLE MOTOR WIRE CONNECTOR.
MAKE SURE FEED
WIRE TERMINALS ARE
NOT BACKED OUT OF
INSULATOR OR OFF
CENTER
CHECK RESISTOR
CONTI NUI TY A N D
RESISTOR CONNECTI ONS
VOLTAGE AT
BATTERY LEAD
CONNECTOR
REMOVE WI RI NG CONNECTORS FROM RESISTOR TERMINALS.
MAKE SURE THAT TERMI NALS ARE NOT BACKED OUT OF INSULATOR.
CHECK FOR BATTERY VOLTAGE I N EACH FAN SWITCH POSI TI ON.
REPLACE
SLOWER
SWI TCH*
VOLTAGE I N
ALL SWITCH
POSI TI ONS
CHECK BLOWER SWITCH N O VOLTAGE I N ONE OR REPLACE
A N D CONNECTI ONS MORE SWITCH POSI TI ONS RESISTOR
REMOVE WI RI NG CONNECTOR FROM SWITCH TERMINALS. MAKE
SURE THE TERMINALS ARE PROPERLY LOCKED I N SOCKETS OF
INSULATOR. CHECK FOR BATTERY VOLTAGE AT BATTERY CONNECTOR I N
THE I NSULATOR.
BLOWER MOTOR
DOES NOT OPERATE
AT ALL SPEEDS
tfEl
J
RESISTOR
BLOCK O.K.
CHECK WI RI NG
CONNECTI ONS AT
RESISTOR BLOCK
A N D BLOWER
SWITCH
IF DEFECTIVE,
REPLACE
BLOWER SWITCH
INSPECT
BLOWER SWITCH
INSPECT
RESISTOR
BLOCK
RESISTOR BLOCK DEFECTIVE
REPLACE RESISTOR BLOCK
*IF BLOWER SWITCH HAS FAILED DUE TO BURNI NG OR CHARRI NG,
CHECK CURRENT DRAW OF THE BLOWER MOTOR. J 9124- 10 1
BLOWER MOTOR NOISE / WIBRATION
BLOWER MOTOR NOISE
OR VIBRATION
NOISE
VI BRATI ON
ENGINE ON
CHECK BLOWER
MOTOR I N ALL
SPEED MO D E S
CHECK MOTOR
M O U N T I N G
NOI S E PRESEh n
A/ C BUT
NOT HTR.
A/ C
A N D HTR.
POSSI BLE
RADI ATOR
FAN OR
C OMPR E S S OR
NOI S E
LEAVE E NGI NE O N
SHUT BLOWER
MOTOR OFF
NOI S E STILL PRESENT
LO( DSE
TI GHTEN
RE-CHECK
MOU N T I N G
OK
OK
NOI S E G O N E
PROBLEM NOT
I N BLOWER
SYSTEM
VI BRATI ON
STILL PRESENT
CHECK BLOWER
SCROLL A R E A
FORE I GN MATERI AL I N
FAN OR SCROLL
YES
REMOVE
FORE I GN
MATERI AL
FAN
RUBBI NG
HO U S I N G
N O
REPLACE
MOTOR
RE-CHECK
VI BRATI ON
G O N E
YES
A
TO C
DJUST
Z ORRECT
RE-CHECK
REMOVE BLOWER
WHEEL A N D
OPERATE BLOWER
MOTOR AT
LOW SPEED
REPLACE BLOWER
WHEEL
RE-CHECK
NOI S E STILL
PRESENT
NOI SE
G O N E
VI BRATI ON
STILL
PRESENT
REPLACE
MOTOR
RE-CHECK
REPLACE
MOTOR
RE-CHECK
J 9124- 10 2

AIR CONDITIONING SYSTEM
SIGHT GLASS REFRIGERANT LEWEL TEST
The sight glass, which is an integral part of t he fil-
ter-drier, is a refrigerant level indicator (Fig. 2). To
check t he refrigerant level, clean the sight glass and
st art t he engine. Place t he air conditioning controls
on A/C, the fan switch on high and t he t emperat ure
lever on cool. The room t emperat ure should be at
least 21C (70F). After operating for a few mi nut es
in this manner, check t he sight glass.
SIGHT GLASS
FILTER
DRIER
ASSEMBLY
9024-3
Fig. 2 Sight Glass
(1) If t he sight glass is clear, t he A/C clutch is en-
gaged, t he compressor discharge line is warm and
t he compressor inlet line is cool; t he system has a
full charge.
(2) If the sight glass is clear, t he A/C clutch is en-
gaged and t here is not significant t emperat ure differ-
ence between compressor inlet and discharge lines;
t he system is empty or nearl y empty. Connect a
gauge to t he compressor discharge port. If t he gauge
reads less t han 172 kPag (25 psi), t he suction t ube
cycling switch has failed.
(3) If the sight glass is clear and the A/C clutch is
disengaged; the clutch is defective or, the clutch circuit
is open, or the system is out of refrigerant. Perform suc-
tion tube cycling switch test to determine condition.
(4) If the sight glass shows foam or bubbles, t he
system could be low on charge. Occasional foam or
bubbles is normal when t he room t emperat ure is
above 43C (110F) or below 21C (70F).
Adjust t he engine speed to 1,300 RPM. Block t he
airflow t hrough t he condenser to increase t he com-
pressor discharge pressure to 1 552-1 724 kPag (225-
250 psig). If sight glass still shows bubbles or foam,
system charge level is low.
The refrigerant system will not be low on charge un-
less there is a leak. Find and repair the leak. If the leak
can be repaired without discharging the system, the low
refrigerant charge level can be corrected as follows.
Maintaining the discharge pressure of 1 550-1 720 kPag
(225-250 psig), add refrigerant gas through compressor
suction line until foam is cleared from sight glass. Then
add 13 oz. (368 g) or 1 can of refrigerant.
HIGH PRESSURE RELIEF WALWE
The high pressure relief valve vents only a small
amount of refrigerant necessary to reduce system pres-
sure and then reseats itself. The majority of the refrig-
erant is conserved in the system. The valve is calibrated
to vent at a pressure of 3 100-3 790 kPag (450-550
psig). However, the fact t hat the valve vented refriger-
ant, does not mean the valve is defective.
ELECTRONIC TEMPERATURE CYCLING
SWITCH TEST
The electronic temperature cycling switch (Fig. 3) is
located on the refrigerant plumbing, suction line near
the H-valve. It electrically inputs to the engine control-
ler on gasoline vehicles and in series with the clutch
coil on diesel vehicles. The switch turns the compressor
on and off depending on the temperature in the suction
line. The switch is a sealed, specially calibrated unit
and if found defective, must be replaced.
ELECTRONIC
TEMPERATURE
CYCLI NG SWI TCH
J9324-97
Fig. 3 Electronic Temperature Cycling Switch
(1) Remove t he wires (boot connector) from t he
electronic t emperat ure cycling switch.
(2) Check continuity of t he switch. Switch contacts
are closed at t emperat ures above 45F (7C). If no
continuity, replace switch.
(3) If contacts are closed, verify switch operation as
follows:
(a) Connect wires to cycling switch.
(b) Set temperature control lever to full cool position.
(c) Set A/C blower motor on low speed and push
A/C button.
(d) Operate engine at 1,300 RPM for approxi-
mately 5 mi nut es to stabilize t he A/C system and
verify t hat refrigerant system is full.

(e) If compressor clutch cycles 3 to 10 times per
minute with temperature between 20C-32C (68F-
90F), the cycling switch is normal. If the compressor
clutch fails to engage, check for continuity in the elec-
trical circuit. Above 32C (90F) the compressor clutch
may be continuously engaged (non-cycling) due to the
high heat load. This condition is normal.
(4) Refer to t he Evaporator Heat er Assembly for
t he Removal/Installation procedures.
TESTING THE SYSTEM FOR LEAKS
If the air conditioning system is not cooling properly,
check t hat the refrigerant system is fully charged with
R-12. Follow the procedures in the Sight Glass Refrig-
erant Level Test section of this group.
If t he refrigerant system is empty or low in refrig-
erant charge, a leak at any of t he line fittings or
component seals is likely (Fig. 4) . To detect a leak in
t he refrigerant system, perform one of t he following
procedures as indicated by t he symptoms.
ELECTRONIC
TEMPERATURE
CYCLI NG
SWITCH
EXPANSI ON
" H " VALVE
J9324-96
Fig. 4 Testing for Leaks
EMPTY REFRIGERANT SYSTEM LEAK TEST
(1) Evacuat e t he refrigerant system to t he lowest
degree of vacuum possible.
(2) Prepare a 14 oz. refrigerant (R-12) charge to be
injected into t he system.
(3) Connect and dispense 14 ozs. of refrigerant (R-
12) into t he evacuated refrigerant system,
(4) Proceed to Step 2 of Low Refrigerant Level
Leak Test.
LOW REFRIGERANT LEVEL LEAK TEST
(1) Review t he Safety Precautions section of t hi s
group to det ermi ne if t here is still R-12 in t he refrig-
erant system.
(2) Position t he vehicle in a breeze free work area
to make it less difficult to detect a small leak.
(3) With t he engine not runni ng, use an Electronic
Leak Detector, or equivalent, to search for leaks in
t he most accessible areas first.
(a) Fittings, lines, or components t hat appear
oily usually will implicate a refrigerant leak.
(b) To inspect t he evaporator core for leaks, it is
possible to insert t he leak detector probe into t he
opening on t he ri ght side of t he i nst rument panel.
COMPRESSOR OIL LEVEL
It is important to have t he correct amount of oil in
t he A/C system to ensure proper lubrication of t he
compressor. Too little oil will result in damage to t he
compressor. Too much oil will reduce t he cooling ca-
pacity of t he system and consequently result in
hi gher discharge air t emperat ures.
To provide t he desired balance for adequate lubri-
cation and cooling capacity, each compressor is
charged with 135 ml (4.6 oz.) of oil at t he factory.
The oil used in t he compressors is a 500 SUS vis-
cosity, wax-free refrigerant oil. Only refrigerant oil
of t he same type should be used to service t he sys-
tem. Do not use any other oil. The oil container
should be kept tightly capped unt i l it is ready for
use, and t hen tightly capped after use to prevent en-
t rance of dirt and moisture. Refrigerant oil will
quickly absorb any moisture it comes in contact with.
After the compressor has been installed and operated
in the A/C system, the oil will be distributed through-
out the system. Some of the oil will be trapped by com-
ponents in the system. An equivalent amount of oil
must be added to the system to compensate for the
trapped oil when replacing the following:
Evaporator Coil: 59.2 ml (2 oz.)
Condenser: 30 ml (1 oz.)
Filter-Drier: 30 ml (1 oz.)
It will not be necessary to check oil level in t he
compressor or to add oil unless t here has been an oil
loss. Oil loss at a leak point will be evident by t he
presence of a wet, shiny surface around t he leak.
Replacement compressors are also charged with
135 ml (4.6 oz.). When replacing compressor; remove,
drai n oil, measure amount and discard old oil. For
t he replacement compressor use t he same amount of
refrigerant oil as recovered from t he failed compres-
sor. This adjustment is not needed if t he system has
been flushed, removing retained oil.
The Compressor Oil Level Adjustment Chart
should be followed to determine t he need to perform
an oil level adjustment.
Check oil level (basic fill) as follows:
(1) Slowly discharge complete system.
(2) With system discharged, disconnect suction and
discharge lines and remove compressor. Drain and dis-
card oil through suction port and discharge port on top.

COMPRESSOR OIL LEVEL ADJUSTMENT
WHEN REPLACI NG I
A/ C SYSTEM I
C OMPON E N T S 1
CHECK FOR EVIDENCE
OF OIL LEAKAGE
1 SYSTEM C OI
I
c
I COMPRE S S
OTAMINATEI^
m
1
O t FAILED 1
1 f
DISCHARGE SYSTEM
I COMPLE
1 c
I REFRIG
TE LOSS I
f 1
ERANT 1
i
f
CHARGE SYSTEM
PARTIALLY WITH R-12
1 PARTI A
1 c
REFRIG
L LOSS 1
)
I
ERANT 1
f
CHECK FOR LEAKS
NONE
NOTED
OIL LEAK
NOTED
r
DISCHARGE
SYSTEM
DISCHARGE
SYSTEM
r ] r
REPLACE
COMPONENT
CORRECT
LEAK
OIL ADDED
IF REPLACING:
EVAPORATOR-
60 ML (2 FL. OZ .)
CONDENSER-
30 ML (1 FL. OZ .)
FILTER-DRIER-
30 ML (1 FL. OZ .)
REPLACE
COMPONENT
COMPRESSOR
DRAI N
OIL
REMOVE FILTER-DRIER
AND COMPRESSOR
CHECK FOR LEAKS
REMOVE, VISUALLY
INSPECT FOR
CONTAMI NATI ON,
A N D CLEAN:
H-VALVE
1
1
DISCHARGE SYSTEM
A N D CORRECT LEAKS
1
f
REPLACE FILTER-
DRIER
INSTALL NEW
FILTER-DRIER
COMPRESSOR
DRAI N
OIL
INSTALL
REPLACEMENT
COMPRESSOR
OIL REQUIRED
I N COMPRESSORS:
136 ml
(4.6 oz)
CORRECT LEAKS
CHECK FOR EVIDENCE
OF OIL LEAKAGE
OIL LEAK
NOTED
NONE
NOTED
DISCHARGE
SYSTEM
ADD R-12
A S REQUIRED
* R E A D C A R E F U L L Y
" C O M PR E S S O R O I L L E V E L "
S E C T I O N BE F OR E PR O C E E D I N G
WI T H C HE C K .
EVACUATE A N D RECHARGE SYSTEM
J9324-98
CHECK SYSTEM COOLI NG PERFORMANCE
(SEE OVERALL PERFORMANCE TEST)

(3) Add 50 ml (1.7 oz.) of clean refrigerant oil
t hrough t he suction port.
(4) Install compressor.
(5) Install t he suction and discharge lines to t he
compressor. Use new gaskets to prevent leakage.
Tighten t he line nut s to 23 N*m (200 in. lbs.) torque.
(6 ) Evacuate and charge system.
OVER-ALL PERFORMANCE TEST
Humidity has an i mport ant beari ng on t he temper-
at ure of t he air delivered to t he vehicle' s interior.
This is t rue of all air conditioning systems It is im-
port ant to underst and t he effect humi di t y has on t he
performance of t he system. When humidity is high,
t he evaporator has to perform a double duty. It must
lower t he air t emperat ure and t he t emperat ure of t he
moisture carried in t he air. Condensing t he moisture
in t he air transfers a great deal of heat energy into
t he evaporator fins and tubing. This reduces t he
amount of heat t he evaporator can absorb from t he
air.
Evaporator capacity used to reduce t he amount of
moisture in t he ai r is not wasted. Wringing some of
t he moisture out of t he air ent eri ng t he vehicle adds
to t he comfort of t he passengers. However, an owner
may expect too much from t hei r air conditioning sys-
t em on humi d days. A performance test is t he best
way to determine whet her or not t he system is per-
forming up to st andard. This test also provides valu-
able clues to t he possible cause of trouble.
To perform t he test t he air t emperat ure in t he test
room must be 21C (70F) mi ni mum.
(1) Connect a tachometer and manifold gauge set
(Fig. 5) .
(2) Set A/C controls to MAX A/C, t emperat ure le-
ver on full cool and blower on HIGH.
(3) St art engine and adjust rpm to 1,000 RPM with
A/C clutch engaged.
(4) Engi ne should be warmed up with doors, win-
dows and hood closed.
(5) Insert a t hermomet er in t he left center A/C
outlet and operate t he engine for 5 mi nut es. The A/C
clutch may cycle depending on ambi ent conditions.
(6 ) After 5 mi nut es note t he discharge air temper-
at ure. (If t he clutch cycles t ake t he reading before
t he clutch disengages).
(7) Open t he hood and disconnect t he gray vacuum
line going to t he heat er wat er control valve. Observe
t he valve ar m for movement as t he line is discon-
nected. If it does not move refer to t he heat er valve
controls sections of t hi s group. Pl ug t he vacuum line
to prevent leakage.
(8) Operate t he A/C for 2 more mi nut es and t ake
t he discharge air t emperat ure readi ng again. If t he
t emperat ure increased by more t han 2C (5F), check
LEFT SUCTION RIGHT
J 9124- 10 9
Fig. 5 Manifold Gauge Tester Connections
t he blend air door cable for correct operation. If tem-
perat ure does not increase more t han 2C (5F), com-
pare discharge air t emperat ure, suction and
discharge pressures with Performance Temperat ure
Chart. Connect t he gray vacuum line.
(9) If the discharge air t emperat ure fails to meet
t he specifications in t he Performance Temperat ure
Chart , refer to t he diagnostic analysis chart s for fur-
t her t est information.
HEATING AND AIR CONDITIONING 24 -
TEMPERATURE IN TEST AREA 21-29 C (70-85 F)
VERIFY R-12 CHARGE-CONNECT MANIFOLD GAUGES
SEE MAINTENANCE AND ADJUSTMENTS SECTION
IF R-12 CHARGE IS LOW, CORRECT LEAK, EVACUATE,
AND CHARGE SYSTEM
BYPASS CYCLING CLUTCH SWITCH
USING JUMPER WIRE REFER TO
GROUP 8W, WIRING DIAGRAMS
START ENGINE ADJUST IDLE TO
1000 rpm IN PARK OR NEUTRAL
WITH PARK BRAKE SET
LOCATE AND REMOVE BOTH
VACUUM LINES AT RECIRC
DOOR ACTUATOR INSTALL
LT-GN LINE WHERE DK-GN
LINE HAD BEEN
CLOSE PASSENGER COMPARTMENT
SET CONTROL TO A/C, PANEL, HIGH
BLOWER, FULL HEAT
E NGI NE
RPM
BLOWER
MOTOR
SPEED
I EVAPORATOR
I SUCTI ON GAUGE
I PSI G (kPag) 1
COMPRESSOR
DI SCHARGE GAUGE
PSI G (kPag) 2
m
POSSIBLE I
CAUSE I
20-35 PSIG 140-240 PSIG
1000 HI
(140 TO 240 kPag) (966 TO 1656 kPag) i NORMAL
Cr
a
FREEZE
H-VALVE
15 INCHES
OF VACUUM
THAW
H-VALVE
38 PSIG (262 kPag)
OR MORE THEN
DROPS TO 25 TO 35
PSIG (172
TO 240 kPag)
RETURN RECIRC DOOR VACUUM LINES TO NORMAL
a
1000 HI
20 30 PSIG
(140 TO 207 kPag)
H240 PSIG OR HIGHER
(1656 kPag)
20-30 PSIG
(140-207 kPag)
140 PSIG (966 kPag)
OR LESS
H-VALVE
STUCK OPEN IF
CONDITIONS
CANNOT BE MET
H-VALVE
STUCK CLOSED IF
CONDITIONS
CANNOT BE MET
RESTRICTED
CONDENSER-
RESTRICTED
DISCHARGE LINE
-RADIATOR
OVERHEATING-
AIR IN SYSTEM-
OVERCHARGED
SYSTEM-COOLING
FAN INOP.
RECONNECT LOW PRESSURE/CYCLING SWITCH
AND RECONNECT THE VACUUM
LINES TO THE RECIRC/ACUATOR
DEFECTIVE
COMPRESSOR HEAD
GASKET OR
DISCHARGE REEDS
J 9124- 10 4
AIR CONDITIONING REFRIGERANT SYSTEM DIAGNOSIS
2 4- 12 HEATING AND AIR CONDITIONING
PERFORMANCE TEMPERATURE CHART
Garage Ambient Temperature
21 C
(70F)
26.5C
(80F)
32C
(90F)
3/.5'J
(100T)
43C
(110F)
Discharge Air Temperature
3-10C
(38-50F)
6-12C
(42-54'F)
8-14C
(46-58F)
10-17C
(50-62F)
12-19C
(54-66F)
Compressor Discharge Pressure
1344
a
1620
a
1861
k P a g
2103
a
1 3 7 9
k P c g
2344
a
Compressor Discharge Pressure
120
195
P S
'
9
160 .
235
P S
'
9
200 .
270
P S
'
9
240 .
305
P S
'
9
280 .
340
P S
'
9
Evaporator Suction Pressure
1 2 4
kPag
207
a
1 3 8
kPag
241
J
269
k P a g
III
k P
9
296
179 ,
D
324
k P a g
Evaporator Suction Pressure
18 .
30
P S
'
9
20 .
35
p S
'
g
22
39
p S , g
25 .
43
p S
'
g
26 .
47
p S
'
9
J9124-97
pressure must drop to below -50 kPag (15 inch of vacu-
um). If the condition is not met the H-valve is stuck
open and should be replaced. Remove Liquid C0
2
and
watch evaporator suction pressure; it should increase to
a minimum of 262 kPag (38 psig) and then stabilize to a
pressure of 172-240 kPag (25-35 psig). Any H-valve
which does not produce this response is stuck open and
should be replaced.
(4) Connect A/C wat er valve vacuum hose (gray)
and set t emperat ure control in cool position.
(5) Set engine speed at 1,000 RPM and blower on
HI. The evaporator suction pressure should be in t he
range of 138-207 kPag (20-30 psig). If compressor dis-
charge is hi gher t han 1 656 kPag (240 psig), check
for restricted discharge line, radi at or overheating, air
in system or faulty viscous fan drive. If discharge
pressure is less t han 966 kPag (140 psig), check com-
pressor head gasket s and discharge reeds.
(6) Connect t he electrical wires to t he electronic
t emperat ure cycling clutch switch.
VACUUM CONTROL SYSTEM ADJUSTMENTS
AND TESTS
To keep t he vacuum harness in place, common vi-
nyl tape (sometimes called plastic tape of electri-
cian' s tape) cannot be used. It will cause t he t ube to
deteriorate directly under t he tape, when high under-
hood t emperat ures are involved. A compatible nylon
type of tape such as MS CH69 (#281) or an equiva-
lent must be used.
The test of t he push but t on switch operation deter-
mi nes whet her or not t he vacuum and electrical cir-
cuits are properly connected and t he controls are
functioning properly. However, it is possible t hat t hi s
system operating perfectly at engine idle during high
manifold vacuum, may not function properly at high
engine speeds. Before st art i ng this test, stop engine
and make certain t he vacuum source hose at engine
i nt ake manifold is t i ght on its connector.
EXPANSION (H) VALVE TEST
Test must be made at ambi ent t emperat ure of
21C-29C (70F-85F).
After performing all previously mentioned tests,
conduct t he H-valve test as follows:
(1) Operate t he engine at 1,000 RPM wi t h t he win-
dows closed. Set air conditioning controls for MAX
A/C, hi gh blower, t emperat ure control lever in full
reheat position and cycling clutch switch electrically
bypassed. Disconnect and plug t he wat er valve vac-
uum hose in t he engine compartment.
(2) Operate t he system for at least 5 mi nut es in or-
der to obtain part i al stabilization and sufficient re-
heat to load t he system. Pressure at t he discharge
service port should reach 966-1 656 kPag (140-240
psig) (Fig. 6). If head pressure of 966-1 656 kPag
(140-240 psig) cannot be obtained, check system
charge level.
Fig. 6 Expansion (H) Valve Test
WA R N I N G : E XT R E M E C A R E M U S T B E U S E D WH E N
H AN D L I N G LI Q UI D C 0
2
A S SK I N I N J URY C A N OC -
CUR IF PROTE CTI V E GL OV E S A RE N OT W ORN .
(3) Put Liquid C0
2
on control head (completely cover
head) for a minimum of 30 seconds. Evaporator suction

St art Vacuum Pump Tool C- 4 2 8 9 and connect t he
Vacuum Test Set Tool C- 37 07 . With t he prod
blocked, adjust bleed valve to obtain a vacuum read-
ing of exactly - 27 kPag (8 inches of mercury) - (Fig.
7) .
VACUUM PUMP
Fig. 7 Adjust Vacuum Test Bleed Valve
It is essential t hat t he bleed valve be adjusted so
t he vacuum gauge pointer will r et ur n to exactly -27
kPag (8 inches) with t he prod blocked. Otherwise a
false reading will be obtained when t he control cir-
cuit is tested.
Alternately release and block t he hose prod several
times. Make sure t he bleed valve is adjusted so t he
vacuum gauge pointer ret urns to exactly -27 kPag (8
inches of vacuum) when t he prod blocked (Fig. 7) .
Disconnect engine vacuum source hose at engine
i nt ake manifold and insert vacuum t est er hose prod
into source hose leading to push but t on switch. Place
vacuum gauge on t he cowl so it can be observed from
t he driver' s position as push buttons are operated.
St art t he t est by depressing t he control HEAT
mode button. Vacuum tester gauge needle will drop
unt i l t he actuator has operated. It should t hen r et ur n
to - 25 to -27 kPag (7-1/ 4 to 8 inches) depending on
vacuum leakage. Continue to depress; OFF, MAX.
A/C, A/C, V E N T, D E F ROS T and H E A T mode but-
tons. Allowing time for actuators to operate after
each button is pushed and for t he vacuum to stabi-
lize. Note t he vacuum drop below -27 kPag (8 inches)
after each operation. The maxi mum allowable vac-
uum drop below -27 kPag (8 inches) after each oper-
ation is - 3 kPag (3/ 4 inch). (Bypass t he vacuum
storage t ank if so equipped).
If t he vacuum drop is more t han - 3 kPag (3/4 inch),
first recheck t he t est er for readi ng exactly -27 kPag
(8 inches). If correct, inspect t he fit of t he 7 port hose
connector plug on t he push button switch. This plug
must be positioned all the way onto t he 7 ports on
t he push button switch.
CAUTI ON : D o not use l ubricant on the swi tch port s
or in the hol es in the pl ug, a s lubricant will damage
the vacuum val ve in the swi t ch. If it i s difficult t o
properly posi ti on connect or pl ug on the swi tch
ports, put a drop or t wo of cl ean water in the con-
nector pl ug hol es. T hi s will allow the plug to sl i de
completely on the swi t ch ports.
If vacuum drop is now within limits, proceed wi t h
t he over-all performance test. If vacuum drop is still
in excess of - 3 kPag ( 3/ 4 inch), remove 7 port connec-
tor from switch and seal port No. 6 with a finger to
check source hose. Then remove prod from source
line and insert it al t ernat el y into each connector port
except No. 6 (Fig. 8) .
Fig. 8 Vacuum Tube Assembly Test
Note amount of vacuum drop below -27 kPag (8
inches) after each act uat or has operated. If vacuum
test gauge comes back to -27 kPag (8 inches) at each
of t he 7 ports, t he hoses and actuators are not leak-
ing. The control switch is faulty and must be re-
placed. If excessive vacuum drop shows up at one or
more ports in connector block, isolate faulty hose or
actuator.
Inspect hose connections to t he actuator involved.
Then t est whether actuator or hose is at fault; use
t he t est hose on t he actuator involved (Fig. 9) .
A leak in a hose may be detected with vacuum t est
set by runni ng t he fingers along t he hose and watch-
ing vacuum gauge readi ng. The t ube can be repaired
by cutting out t he "leak" and i nsert i ng the t ube ends
into a 3 mm (1/8 inch) inside diameter rubber tube.
Wet t he tube with wat er to aid assembly.
A vacuum drop in excess of 3 kPag (3/4 inch) below
-27 kPag (8 inches) will not interfere with engine op-
eration. A rough idle may occur. It can, however, in-

Fig. 9 Vacuum Actuator Test
terfere with t he proper operation of t he ai r
conditioning and heat i ng controls at high speeds and
duri ng acceleration.
COMPRESSOR NOISE
Noises t hat develop duri ng air conditioning opera-
tion can often be misleading.
FOR EXAMPLE: What sounds like a failed front
beari ng or connecting rod, may be caused by loose
bolts, nut s, mount i ng brackets or a loose clutch as-
sembly.
Improper belt tension is also often t he source of an
objectionable noise and can easily be mi st aken for in-
t ernal compressor troubles.
Drive belts are speed sensitive. That is, at different
engine speeds, and depending upon belt tension, belts
can develop unusual noises t hat are often mi st aken
for mechanical problems wi t hi n t he compressor.
The adjustment procedures follows:
(1) Select a quiet area for testing. Switch compres-
sor on and off several t i mes to clearly identify com-
pressor noise.
(2) Tighten all compressor mount i ng bolts, clutch
mount i ng bolt, clutch coil mount i ng screws and com-
pressor drive belts. Check t hat plumbing is not rub-
bing other part s.
(3) Make sure t hat matched drive belts are in
equal tension. Replace any part s t hat are defective or
missing.
(4) Test t he vehicle. If noise persists, continue
trouble shooting system for source of noise.
Refer to A/C Compressor and Clutch Diagnosis
Chart s.
CLUTCH COIL TEST
(1) Verify bat t ery st at e of charge (test indicator
should be green.)
(2) Connect an ammet er (0-10 ampere scale) in se-
ries with t he clutch coil t ermi nal . Use a voltmeter
(0-20 volt scale) with clip leads measuri ng voltage
across t he bat t ery and A/C clutch.
(3) With A/C control in A/C mode and blower at
low speed, st art t he engine and r un at normal idle.
(4) The A/C clutch should engage in 11 seconds af-
t er t he start. The clutch voltage should be within 2
volts of t he bat t ery voltage. If t he A/C clutch does
not engage, check t he fuse.
(5) The A/C coil is acceptable, if t he current draw
is 2.0 to 3.7 amperes at 11.5 to 12.5 volts. The t est
room t emperat ure should be 18C to 24C (65F to
75F). Where voltage is more t han 12.5 volts, add
electrical loads as needed by increasing blower speed
and/or switching other electrical accessories on. If
coil current reads zero, t he coil is open and should be
replaced. If t he ammet er readi ng is 4 amperes or
more, t he coil is shorted and should be replaced. If
t he coil voltage is not within 2 volts of t he bat t ery
voltage, check t he circuit ext ernal to t he clutch coil
for excessive voltage drop and repai r accordingly.
Refer to A/C Compressor and Clutch Diagnosis
Chart s.
HEATING AND AIR CONDITIONING 24 -
A/C COMPRESSOR AND CLUTCH DIAGNOSIS
A/ C COMPRESSOR NOI SY
?
COMPRESSOR OFF COMPRESSOR ON
I
CLUTCH PULLEY
RUBBING
EVALUATE INSIDE
VEHICLE MODE-
MAX A / C
BLOWER-LOW
OUTLETS-OPEN
WINDOWS-
CLOSED
EVALUATE INSIDE
VEHICLE MODE-
MAX A / C
BLOWER-LOW
OUTLETS-OPEN
WINDOWS-
CLOSED
CLUTCH BEARING
NOISY
MOUNTING
BOLTS LOOSE
TIGHTEN

REMOVE BELTS
RECHECK RUBBING
AND BEARING
NOISE
LOOSE
BELTS
ADJUST
*
CHECK AIR GAP
RESET IF NOT
0.406 - 0.787 m m
(0.016-0.031 In)
BELT
INTERFERENCE
I
BENT PULLEY
REPLACE PULLEY
AND
ARMATURE
KNOCKING OR
GRINDING NOISE
FROM
COMPRESSOR
_ *
DEFECTIVE COIL
IF SO
REPLACE
REPLACE
COMPRESSOR
\
FRONT ALIGNMENT
PIN LOOSE OR
OUT OF
SPECIFICATION
REPLACE
COMPRESSOR
FRONT
COVER
COMPRESSOR WONT TURN
PROPERLY CLUTCH ENGAGES
BUT SLIPS OR SMOKES
CLUTCH SLIPPING
LOW VOLTAGE
AT CLUTCH
CHECK WIRING,
SWITCHES, CLUTCH
AMPERAGE AND
GROUND
I
AMPERAGE
GREATER THAN
5 AMPS
CLUTCH COIL
PARTIALLY
SHORTED
REPLACE
COIL
OIL/GREASE ON
FRICTION SURFACES
CHECK SHAFT
SEAL FELT
COIL SNAP
RING NOT
PROPERLY
INSTALLED
IF BEARING
DEFECTIVE
REPLACE
PULLEY AND
ARMATURE
NOTE: APPLY PARKING BRAKE AND RUN
ENGINE IN NEUTRAL ONLY.
* CLUTCH OR BELT SUPPING CAN BE
CAUSED BY OVERCHARGED
SYSTEM OR CONDENSER FAN NOT
RUNNING.
OIL SATURATED
FELT REPLACE
COMPRESSOR
SHAFT SEAL
ADJUST BELT
TENSION
REPLACE IF
NECESSARY
CLUTCH
PULLEY RUBS
ON COIL
COIL
MISMOUNTED
SEIZ ED
COMPRESSOR
T
REPLACE
COMPRESSOR
AND CLUTCH
ASSEMBLY
GREASE PURGED
FROM BEARING
REPLACE CLUTCH
PULLEY AND
ARMATURE
GREASE PURGED
FROM BEARING
REPLACE CLUTCH
PULLEY AND
ARMATURE
J 93 24- 99
A/C COMPRESSOR AND CLUTCH DIAGNOSIS (CONT.)
COMPRESSOR CLUTCH WON'T
ENGAGE
\
f
f
NO VOLTAGE VOLTAGE AT
AT CLUTCH CLUTCH NORMAL
f t
OPEN FUSE
FAULTY
GROUND
f 1
PUSHBUTTON
SWITCH
OPEN COIL
f
FAULTY
WIRING
REPLACE COIL
f r
POOR VOLTAGE AT
GROUND CLUTCH LOW
f
CHECK WIRING
AND SWITCHES
f
CHECK VOLTAGE
DROPS FROM
CLUTCH TOWARD
BATTERY
CYCLI NG
SWITCH
IF CONTACT OPEN
CHECK
REFRIGERANT
CHARGE
IF CHARGE
OK REPLACE
SWITCH
COMPRESSOR LEAKS
OI L OR REFRIGERANT
DEFECTIVE
CRANKSHAFT
SEAL
CARTRIDGE
DEFECTIVE
CRANKSHAFT
SEAL
PLATE
DEFECTIVE
SEAL ( "O' RING),
FRONT COVER,
REAR COVER
DEFECTIVE
COMPRESSOR
THRU BOLT
READ
COMPRESSOR
SERVICE SECTION
FOR REPAIR
DEFECTIVE
COMPRESSOR
BODY
REPLACE
COMPRESSOR
NOTE: APPLY PARKING BRAKE
AND RUN ENGINE IN NEUTRAL
ONLY.

HEATING AND AIR CONDITIONING 2 4 - 1 7
REFRIGERANT SYSTEM SERWICE PROCEDURES
INDEX
page
Charging the Syst em 19
Correcting Low Refrigerant Level . . . . . . . . . . . . . 20
Discharging the Syst em . 19
Evacuating the Syst em 19
REFRIGERANT
SAFETY PRECAUTIONS
W ARN I N G: E X TRE M E C A RE M UST BE TAK E N TO
PRE V E N T AN Y LI Q UI D RE F RI GE RAN T F ROM C OM -
I NG I N CON TACT W I TH TH E SK I N AN D E S PE -
CI ALLY TH E E Y E S. AL W AY S W E AR SAF E TY
GOGGL E S W H E N SE RV I CI N G AN Y PART OF TH E
RE F RI GE RAN T SY STE M . IF E Y E CON TACT I S
M AD E , APPL Y A F E W D ROPS OF M I N E RAL OI L TO
TH E E Y E S AN D F L USH W I TH W ATE R F OR SE V -
E RAL M I N UTE S. S E E K M E D I CAL ATTE N TI ON I M M E -
D I ATE LY .
The refrigerant used in t he air conditioner system
is Refrigerant-12 (R-12). R-12 is nonexplosive, non-
flammable, non-corrosive, has practically no odor and
is heavier t han air. Although it is classified as a safe
refrigerant, certain precautions must be observed to
protect t he part s involved and t he person who is
working on t he unit. Liquid R-12, at normal atmo-
sphere pressures and t emperat ures, evaporates so
quickly t hat it has t he tendency to freeze anyt hi ng it
contacts.
W ARN I N G: TO AV OI D A D AN GE ROUS E X PL OSI ON ,
N E V E R W E L D OR STE AM C L E AN N E AR AI R C ON -
DI TI ONI NG L I N E S OR C OM PON E N TS. D O N OT
H E AT R- 1 2 ABOV E 52C (125F) BE C A US E TH E
C AN M AY E X PL OD E .
The R-12 in t he system is always under pressure.
Because t he system is tightly sealed, heat applied to
any part could cause t hi s pressure to build up exces-
sively.
W ARN I N G: L ARGE AM OUN TS OF RE F RI GE RAN T
RE L E ASE D I N A C L OSE D W ORK A RE A W I LL D I S-
PL AC E TH E OX Y GE N AN D C AUSE SUF F OCATI ON .
AL W AY S M AI N TAI N GOOD V E N TI LATI ON SUR-
ROUN D I N G TH E W ORK ARE A.
R-12 gas, under normal conditions, is non-poison-
ous. The discharge of R-12 gas near an open flame
page
Pressure Gauge and Manifold Assembl y 18
Refrigerant . 17
Refrigerant Leak Repair Procedure 20
Service Precautions . 17
can produce a very poisonous gas called phosgene.
Phosgene is generated when a flame-type l eak detec-
tor is used.
C A U T I O N : When chargi ng an A / C syst em al ways
keep the tank in an upright posi t i on. If the tank i s
on its si de or upsi de down, liquid refrigerant will
enter the syst em and may damage the compr essor .
In most instances, moderate heat is required to
bri ng t he pressure of t he refrigerant above system
pressure when charging or adding refrigerant. A
bucket or large pan of hot water, not over 52C
(125F), is all t he heat required for t hi s purpose. Do
not heat t he refrigerant container wi t h a blow torch
or any other means t hat would raise t he t emperat ure
and pressure above t hi s t emperat ure.
C A U T I O N : D o not allow liquid refrigerant to t ouch
bright metal.
Refrigerant will t arni sh bright met al and chrome
surfaces. Avoid splashing t he refrigerant on any sur-
face. Refrigerant in combination wi t h moisture is
very corrosive and can cause extensive damage to all
met al surfaces.
RECYCLING
(R-12) refrigerant is a chloroflorocarbon (CFC) t hat
can contribute to the depletion of t he ozone layer in
t he upper atmosphere. Harmful radi at i on from t he
sun is filtered out by t he ozone. To assist in protect-
ing t he ozone layer, Chrysler Corporation recom-
mends t hat an (R-12) refrigerant recycling device
t hat meets SAE st andard J1991 be used. Contact an
automotive service equipment supplier for refriger-
ant recycling equipment t hat is available in your
area. Refer to t he operating instructions provided
with t he recycling equipment for proper operation.
SERVICE PRECAUTIONS
Kinks in t he refrigerant t ubi ng or sharp bends in
t he refrigerant hose lines will greatly reduce t he ca-
pacity of t he entire system. High pressures are pro-
duced in t he system when it is operating. Ext reme
care must be exercised to make sure t hat all connec-
tions are pressure tight. Dirt and moisture can ent er

t he system when it is opened for repai r or replace-
ment of lines or components, The following precau-
tions must be observed.
The system must be completely discharged before
opening any fitting or connection in t he refrigeration
system. Open fittings with caution even after t he
system has been discharged. If any pressure is no-
ticed as a fitting is loosened, allow trapped pressure
to bleed off very slowly.
Keep t he radi us of all bends at least 10 t i mes t he
diameter of t he hose. Sharper bends will reduce t he
flow of refrigerant. The flexible hose lines should be
routed so they are at least 80 mm (3 inches) from t he
exhaust manifold. It is a good practice to inspect all
flexible hose lines at least once a year to make sure
they are in good condition and properly routed.
Unified plumbing connections with aluminum-N-
gaskets cannot be serviced wi t h O-rings. These gas-
kets are not reusable and do not require lubrication
before installing.
The use of correct wrenches when maki ng connec-
tions is very important. Improper wrenches or im-
proper use of wrenches can damage t he fittings.
The i nt ernal part s of t he refrigeration system will
remai n in a st at e of chemical stability as long as
pure-moisture-free R-12 and refrigerant oil is used.
Abnormal amount s of dirt, moisture or air can upset
t he chemical stability and cause operational troubles
or even serious damage if present in more t han
mi nut e quantities.
When it is necessary to open t he refrigeration sys-
tem, have everything needed ready so t he system
will not be left open any longer t han necessary. Cap
or plug all lines and fittings as soon as t hey are
opened to prevent t he ent rance of di rt and moisture.
All tools, including t he refrigerant dispensing man-
ifold, t he manifold gauge set and test hoses should be
kept clean and dry.
PRESSURE GAUGE AND MANIFOLD ASSE MBLY
Pressure Gauge and Manifold Assembly Tool
C-3740-A is t he most i mport ant tool used to service
t he air conditioning system (Fig. 1).
COMPONENTS
EAP0RAT0R SUCTi Ol GAUi E
The left side of t he manifold set is calibrated to
register 0 to -100 kPag (0 to 30 inches of vacuum).
The gauge will also register 0 to 1 000 kPag (0 to
150 psig). This gauge is connected to t he suction ser-
vice port of t he compressor. A special service port
adapter, supplied with t he gauge set, provides t he
means of connecting t he gauge set manifold hose to
t he service port. When t he adapt er is installed at t he
port and tightened, t he stem of t he valve in t he ser-
vice port is depressed, opening t he service port valve.
COMPOUND GAUGE HIGH SIDE
Fig. 1 Pressure Gauge and Manifold Assembly Tool
C-3740-A
DISCHARGE PRE SSURE GAUGE
The center of t he manifold set is calibrated to reg-
ister 0-2 100 kPag (0-300 psig). For all tests t hi s
gauge is connected to t he discharge service port of
t he system. The needle valve, located below t he dis-
charge pressure gauge, is used to damp out gauge
needle oscillations so t hat accurate readings can be
obtained.
CENTER MANIFOLD OUTLET
This outlet provides t he necessary connection for a
long service hose. This hose is used:
To discharge t he system.
For a vacuum pump to pull a vacuum before
charging t he system.
For connecting t he supply of refrigerant when
charging t he system.
MANIFOLD GAUGE WALWES
This valve should be closed when connecting t he
gauge set manifold to t he service ports of t he com-
pressor. The suction gauge valve at t he left is opened
to provide a passage between t he suction gauge and
t he center manifold outlet. The discharge gauge
valve at t he ri ght is opened to provide a passage be-
tween t he discharge pressure gauge and t he center
manifold outlet.
SERVICE VALVES
The discharge (high pressure) and inlet (suction)
service valves are used for diagnosis, charging, dis-
charging and evacuating t he system.
CONNECT PRESSURE GAUGE AND MANIFOLD
ASSEMBLY
Remove t he protective caps from t he service valve
gauge ports and valve stems.
Close both of t he hand valves on t he gauge mani -
fold set.

Connect t he compound gauge hose to t he compres-
sor suction service valve gauge port (low-side).
Connect t he high pressure gauge hose to t he dis-
charge service valve gauge port (high-side).
Purge air from t he high side test hose by opening
t he hi gh side hand valve on t he manifold for 3 to 5
seconds. The center connection on t he manifold must
be open.
Purge air from t he low side test hose by opening
t he low side hand valve on t he manifold for 3 to 5
seconds. The center connection on t he manifold must
be open.
The air conditioning system may be operated with
t he gauge manifold assembly connected in t hi s man-
ner. The gauges will indicate respective operative
pressures.
DISCHARGING THE SYSTEM
Since t he air conditioning refrigerant system is
pressurized, it will be necessary to completely dis-
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 t he gauge set
valves are closed before at t achi ng t he hoses to t he re-
frigerant system.
(2) Install a long hose to t he manifold gauge set
connector. Run this hose to t he oil collector can near
t he shop exhaust system.
A good oil collector can may be made from a large
empty coffee can wi t h a plastic top. Slit t he plastic
top in t he form of a Y to make an ent rance for t he
refrigerant hose and exit for t he gas.
(3) Open t he compressor discharge and suction line
pressure valves and discharge t he refrigerant into
t he oil collector can. Watch to make sure t he hose
does not blow out of t he collector can.
(4) When t he system has been completely dis-
charged, measure t he amount of oil collected in t he
can. The amount of oil measured should be added to
t he refrigerant system before it is charged. Discard
t he used oil. Add new oil.
EVACUATING THE SYSTEM
Whenever t he system has been opened to t he atmo-
sphere, it is absolutely essential t hat t he system be
evacuated to remove all t he air and moisture. Air in
t he refrigerant system causes hi gh compressor dis-
charge pressures, a loss in system performance, and
oxidation of t he compressor oil into gum and varnish.
Moisture in t he refrigerant system can cause t he ex-
pansion valve to malfunction. Under certain condi-
tions i t can react with t he refrigerant to form
destructive acids. It is necessary to adhere to t he fol-
lowing procedure to keep air and moisture out of t he
system.
(1) Connect t he manifold gauge set to t he compres-
sor and long t est hose from manifold gauge set center
connection to Vacuum Pump Tool C-4289.
(2) Open both manifold gauge set valves.
(3) St art t he vacuum pump and operate until t he
evaporator suction gauge registers at least -88 kPag
(26 inches of vacuum). If at least -88 kPag (26 inches
of vacuum) cannot be obtained, either t he system has
a leak or t he vacuum pump is defective. Check t he
vacuum pump. If the pump proves to be functioning
properly, t he system has a leak. Charge t he system
with 1 pound of refrigerant. Locate and repair all
leaks. Discharge t he refrigerant and evacuate t he
system.
(4) Continue to operate t he pump for at least 5
mi nut es.
(5) Close manifold valves. Turn off t he vacuum
pump and observe evaporator suction gauge for 2
mi nut es. The vacuum level should remai n constant.
If t he vacuum level falls off, t he system has a leak.
Charge t he system wi t h 450 g (1 pound) of refriger-
ant . Locate and repair all leaks. Discharge the sys-
t em and repeat evacuation procedure.
CHARGING THE SYSTEM
The refrigerant system must have been evacuated
using t he previous procedure before charging. Charge
using only R-12 refrigerant. R-12 is available in bulk
t anks or 437 g (14 oz.) cans.
The special refrigerant dispensing manifold per-
mits charging 3 cans of refrigerant at a time. When
using disposable cans of t hi s type, carefully follow
t he can manufacturers instructions.
W ARN I N G: N E V E R USE TH E SE C A N S TO C H ARGE
I NTO TH E H I GH PRE S S URE SI D E OF TH E SY STE M
( C OM PRE SSOR D I SC H ARGE PORT) OR I NTO A
SY STE M TH AT I S AT H I GH TE M PE RATURE . TH E
H I GH SY STE M PRE S S U RE S C OUL D BE TRAN S-
F E RRE D I NTO TH E CH ARGI N G C AN CAUSI N G IT
TO E X PL OD E .
Keep t he refrigerant manifold valves capped when
not in use. Keep a supply of ext ra refrigerant-can-to
refrigerant-manifold gasket s on hand so t he gaskets
can be replaced periodically. This will insure a good
seal without excessive t i ght eni ng of t he can or t he
manifold nut s.
(1) Attach center hose from manifold gauge set to
refrigerant dispensing manifold. Turn refrigerant
manifold valves completely counterclockwise so they
are fully open. Remove protective caps from refriger-
ant manifold.
(2) Screw refrigerant cans into manifold. Be sure
manifold-to-can gasket is in place and in good condi-
tion. Tighten can and manifold nut s to 9.5 Nm (7 ft.
lbs.) torque.

(3) Turn 3 refrigerant manifold valves completely
clockwise to puncture t he cans and close t he mani -
fold valves.
(4) Purge t he ai r from t he charging line by loosen-
ing t he charging hose at t he manifold gauge set and
t ur n one of t he refrigerant valves counterclockwise.
When t he refrigerant gas st art s escaping from t he
loose connection, t i ght en t he hose.
(5) Fully open all 3 refrigerant manifold valves
and place t he cans of refrigerant into a pan contain-
ing 52C (125F) water. The wat er will warm t he
charging can and aid in t he transfer of t he charge
into t he system.
(6) St art t he engine and move t he controls to A/C
low blower position.
The electronic t emperat ure cycling switch will pre-
vent t he clutch from engaging unt i l refrigerant is
added to t he system. If t he clutch does engage, re-
place t he switch before proceeding any further.
(7) Charge t hrough t he suction side of t he system
by slowly opening the suction manifold valve. Adjust
t he valve as necessary so charging pressure does not
exceed 345 kPag (50 psig). Mai nt ai n t he t emperat ure
of t he wat er in t he pan by adding war m wat er as
necessary.
(8) Adjust t he engine speed to a fast idle of approx-
imately 1,300 RPM.
(9) When all 3 cans of refrigerant are completely
empty, close t he manifold gauge set valves and re-
frigerant manifold valves.
The maxi mum refrigerant charge is 44 oz.
REFRIGERANT LEAK REPAIR PROCEDURE
LOST CHARGE
If t he system has lost all charge due to a leak:
(1) Evacuat e t he system.
(2) Charge t he system wi t h approximately 1 pound
of refrigerant.
(3) Locate all leaks.
(4) Repair all leaks.
(5) Replace filter-drier bottle.
CAUTI ON : Replacement filter-drier units must be
sealed while in storage. The drier used in these
units absorbs and traps moisture quickly upon ex -
posure to the atmosphere. When installing a drier,
have all tools and supplies ready for quick reas-
sembly to avoid keeping the system open any
longer than necessary.
(6) Check system oil level.
(7) Evacuat e and charge t he system.
LOW CHARGE
If t he system has not lost all of its refrigerant
charge; locate and repair all leaks. If it is necessary
to increase t he system pressure to find t he leak (be-
cause of an especially low charge), add 230 g (1/2 lb)
of refrigerant. If t here has been a significant oil loss,
check t he system oil level. If leak repair was possible
without discharging system and an oil level check
was not necessary, use procedure for correcting low
refrigerant level.
CORRECTING LOW REFRIGERANT LEVEL
Since t he refrigeration system is completely sealed,
t he refrigerant level will not be low unless t here is a
leak in t he system.
Before adding refrigerant where the cause of a low
level is not known, the system should be tested for
leaks. Assuming t hat leaks have been corrected without
discharging the system, proceed with partial charge.
Install and connect manifold gauge set.
(1) Close both manifold gauge set valves. Open
manifold gauge set needle valve.
(2) Connect t he suction gauge test hose to t he suc-
tion service port of t he compressor. Connect t he dis-
charge gauge t est hose to t he discharge service port.
(3) Connect an end of long test hose to t he center
manifold outlet, and other end to refrigerant dispens-
ing manifold.
(4) Close t he 2 dispensing manifold valves and
open remai ni ng dispensing manifold valve. Remove
protective cap from opened valve.
WA R N I N G : N E V E R U S E T H E S E C A N S T O C H A R G E
I NT O T HE HI G H P R E S S U R E S I D E O F T HE S Y S T E M
( C O M P R E S S O R D I S C H A R G E PO R T ) O R I NT O A
S Y S T E M T HA T I S A T HI G H T E M PE R A T U R E . T HE
HI G H S Y S T E M P R E S S U R E S C O U L D BE T R A N S -
F E R R E D I NT O T HE C H A R G I N G C A N C A U S I N G IT
TO E X PL OD E .
(5) Screw a can of R-12 to t he opened manifold
valve. Be sure gasket is in place and in good condi-
tion. Tighten refrigerant can and manifold locking
nut to ensure a good seal. Do not overtighten.
Tighten to 9.5 N*m (7 ft. lbs.) torque, if gasket is in
good condition.
(6) Turn manifold valve (above t he refrigerant can)
completely clockwise to punct ure t he can. This closes
t he valve and seals t he refrigerant in t he can.
C A U T I O N : D o not heat refrigerant 12 above 52C
(125F).
(7) Place refrigerant can in a large pan of wat er
heat ed to 52C (125F). Place pan of wat er containing
t he refrigerant can on an accurate scale so t he
amount of refrigerant added can be weighed. Open
t he refrigerant manifold valve.
(8) Purge all air from test hoses. Air in t he system
will be trapped in t he condenser causing abnormally
hi gh discharge pressures and interfering wi t h con-
densing of t he refrigerant.

(a) Loosen both test hoses at t he manifold gauge
set. Tighten t he hoses as soon as t he air is purged.
(b) Loosen charging hose connection at manifold
gauge set. This will purge ai r from t he charging
hose. Tighten connection as soon as air is purged.
(9) With vehicle windows open and hood up, oper-
ate engine at 1,300 RPM.
(10) Place ai r conditioner control on A/C and place
t he fan switch on high.
(11) If necessary, block t he condenser to mai nt ai n
a discharge pressure of 1 550-1 725 kPag (225-250
psig). System must be charged t hrough t he evapora-
tor suction service ports as follows:
(a) Slowly open t he suction service gauge valve.
Meter flow of refrigerant by adjusting t he suction
service gauge valve so t he pressure registered at
the suction service gauge does not exceed 345 kPag
COMPRESSOR J
(50 psig). Keep refrigerant container upright.
(b) Add refrigerant gas until there is no foam visi-
ble at the sight glass. As soon as all foam clears, note
the weight registered on the refrigerant scale.
(c) Watch t he refrigerant weighing scale and add
437 g (14 oz.) of refrigerant (equivalent to 1 can).
(d) Close t he suction gauge valve.
CAUTION: TOO much refrigerant in the syst em can
cause abnormally hi gh di scharge pr essur es. Care
must be used s o the ex act recommended amount of
refrigerant is added after foam clears in the si ght
gl ass.
(e) Close dispensing manifold valve. Remove t est
hoses and adapt ers from t he service ports of com-
pressor and install protective caps at service ports.
R V I C E ( S D - 70 9 )
INDEX
page
Compressor 21
Compressor Shaft Seal . . . . . . . . . . . . . . . . . . . . 25
The A/C system uses a 7 piston design Sanden SD-
709 compressor. Designated t he SD-709, t he compres-
sor is mounted on t he front ri ght side of t he engine
and is driven by a serpentine belt.
System lubrication is provided by 135cc 15cc (4.6
cu. in. 0. 5 cu. in.) of 500 viscosity refrigerant oil.
The clutch used on t he compressor consists of 3 ba-
sic components:
(1) The pulley.
(2) The front plate.
(3) The field coil.
The pulley and field coil are attached to t he front
head of t he compressor with snap rings. The hub is
keyed to the compressor shaft and is retained on t he
shaft with a self-locking nut. Special service tools are
required to remove and install t he clutch pl at e on
t he compressor shaft.
COMPRESSOR
REMOVAL
(2) Disconnect t he clutch lead wire.
(3) Remove t he discharge and inlet (suction) ser-
vice valves from t he compressor. Pl ug or tape all t he
openings.
(4) Refer to Group 7, Cooling System and remove
t he drive belt(s).
(5) Remove t he bolts and lift t he compressor from
t he mounting bracket (Fig. 1).
page
Cylinder H ead / V al ve Plate 27
Magnetic Clutch 22
Fig. 1 Compressor Mounting
INSTALLATION
If a replacement compressor is being installed,
check t he oil level. Add or subtract oil as necessary.
Install t he magnetic clutch on t he compressor.
(1) Install the compressor on the mounting bracket.
Tighten the bolts to 27 N*m (20 ft. lbs.) torque.
(2) Refer to Group 7, Cooling System and install
t he drive belt(s).
(3) Check t he belt tension.
@ New drive bel t - 800- 900 N (180-200 lbs-f).
Used bel t - 623- 712 N (140-160 lbs-f).

(4 ) Remove t he t ape or plastic plugs from all t he
suction and discharge openings and install t he ser-
vice valves on t he compressor.
(5) Connect t he clutch lead wire.
(7) Evacuate, charge and test t he system for leaks.
MAGNETIC CLUTCH
The magnetic clutch consists of a stationary electro-
magnetic coil and a rotating pulley and plate assembly.
The electromagnetic coil is retained on t he com-
pressor with a snap ri ng and is dimpled to mai nt ai n
its position.
The pulley and plate assembly are mounted on t he
compressor shaft.
When t he compressor is not in operation, t he pul-
ley free wheels on t he clutch hub bearing. When t he
coil is energized t he plate is magnetically engaged
with t he pulley and t ur ns t he compressor shaft.
J8924-18
Fig. 3 Clutch Front Plate
REMOVAL
(1) Insert t he 2 pins of t he front plate spanner into
any 2 threaded holes of t he clutch front plate (Fig.
2). Hold clutch plate stationary. Remove hex nut .
(2) Remove clutch front plate using puller. Align
puller center bolt to compressor shaft (Fig. 3). Thumb
t i ght en t he puller bolts into t he t hreaded holes.
(3) Tur n center bolt clockwise unt i l front plate is
loosened.
(4) Remove shaft key by lightly tapping it loose
with a slot screw driver and hammer (Fig. 4).
(5) Remove t he external front housing snap ri ng
(Fig. 5) .
J8924-19
Fig. 4 Shaft Key
J8924-20
Fig. 5 External Snap Ring
PULLER
SHAFT
PROTECTOR
J A WS
(10) Loosen coil lead wire from clip on top of com-
pressor front housing (Fig. 8).
(11) Remove snap ring and field coil (Fig. 9).
J8924-21
Fig. 6 Shaft Protector
(6 ) Insert t he lip of t he j aws of t he rotor puller into
t he snap ring groove exposed in t he previous step
(Fig. 6 ).
(7) Place rotor puller shaft protector over t he ex-
posed shaft.
(8) Install t he puller plate and bolt (Fig. 7). 2 bolts
go through t he plate and into t he jaws. Finger
tighten bolts.
(9) Turn puller center bolt clockwise using 3/4 inch
socket until rotor pulley is free.
J8924-23
Fig. 8 Loosen Coil Lead Wire
FIELD
COIL
SNAP
RING
J8924-22
J8924-24
Fig. 9 Snap Ring and Field Coil
INSTALLATION
(1) Install t he field coil with t he snap ring.
(2) Place coil lead wire under clip on top of com-
pressor front housing and tighten t he ret ai ni ng
screw.
Fig. 7 Puller Plate
(3) Support t he compressor on t he 4 mount i ng ears
at t he compressor rear. If a vise is being used, clamp
only on t he mount i ng ears. Never clamp on t he com-
pressor body.
(4) Align rotor assembly squarely on t he front
housing hub.
(5) Using Rotor Installer Set, place t he ri ng part of
t he set into t he beari ng cavity (Fig. 10). Make cer-
t ai n t he outer edge rests firmly on t he rotor bearing
i nner race.
(6) Place t he tool set driver into t he ri ng as shown
(Fig. 11).
J 8 9 2 4 - 2 5
Fig. 10 Rotor installer Set
J 8 9 2 4 - 2 6
Fig. 11 Rotor Installation
(7) With a plastic hammer, gently t ap t he end of
t he driver while guiding t he rotor to prevent binding.
Tap unt i l t he rotor bottoms against t he compressor
front housing hub. Listen for a distinct change of
sound duri ng t he tapping process.
(8) Install external front housing snap ri ng with
spread type snap ri ng pliers.
(a) Check t hat original clutch shims are in place
on compressor shaft.
(b) Replace compressor shaft key.
(c) Align front plate keyway to compressor shaft
key.
(9) Install front plate assembly.
(10) Usi ng shaft protector, gently t ap front plate to
shaft unt i l it has bottomed to t he clutch shims (Fig.
12). Listen for a distinct change of sound during t he
tapping process.
J8924-27
Fig. 12 Front Plate to Shaft Installation
(11) Replace shaft hex nut . Tighten t he hex nut to
37 N*m (27 ft, lbs.) torque.
(12) Check ai r gap with feeler gauge. The specifi-
cation is 0.406-0.787 mm (0.016-0.031 inch). If air
gap is not consistent around t he circumference,
lightly pry up at t he mi ni mum variations (Fig. 13).
Lightly t ap down at points of maxi mum variation.
The air gap is determined by t he spacer shims.
When installing t he original or a new clutch assem-
bly, t ry t he original shims first. When installing a
new clutch onto a compressor t hat previously did not
have a clutch, use 0.040, 0.020, and 0.005 shims from
t he clutch accessory sack.
(13) If t he air gap does not meet t he specification
given, add or subtract shims as required.

J8924-28
Fig. 13 Check Air Gap
COMPRESSOR SHAFT SEAL
REMOWAL
(1) Insert t he 2 pins of t he front plate spanner into
any 2 t hreaded holes of t he clutch front plate (Fig.
2). Hold clutch plate stationary. Remove hex nut .
(2) Remove clutch front plate using puller. Align
puller center bolt to compressor shaft. Thumb t i ght en
t he 3 puller bolts into t he threaded holes.
(3) Turn center bolt clockwise until front plate is
loosened.
Shaft seal replacement should be done on t he
bench. Never use any old parts of the shaft seal
assembl y. Rebuild t he complete assembly.
(4) Insert the snap ri ng tool points into t he 2 holes
of t he felt ri ng metal ret ai ner and remove felt ri ng
(Fig. 14).
(5) Remove t he clutch shim. Use O-ring hook and
a small screwdriver to prevent shim from binding on
shaft (Fig. 15).
(6) Remove shaft seal seat ret ai ni ng snap ri ng
with pinch type snap ri ng pliers (Fig. 16).
J8924-31
Fig. 16 Snap Ring
Fig. 14 Felt Ring

(7) Remove t he shaft seal seat, using seal seat tool
(Fig. 17).
J8924-32
Fig. 17 Shaft Seal Seat
(8) Insert t he Seal Remover and Installer Tool
agai nst t he seal assembly. Press down agai nst t he
seal spring and twist t he tool unt i l it engages t he
slots of t he seal cage (Fig. 18). Lift out seal assembly.
J8924-33
Fig. 18 Seal Assembly
INSTALLATION
(1) Clean seal cavity thoroughly with a lint-free or
synthetic cloth and clean refrigerant oil. Then blow
out with dry pressurized vapor.
(2) Make sure all foreign substances are thor-
oughly removed.
(3) Insert Seal Sleeve Protector over compressor
shaft (Fig. 19).
J8924-34
Fig. 19 Insert Seal Sleeve Protector
(4) Do not touch t he new seal lapping surfaces. Dip
t he mat i ng surfaces in clean refrigerant oil before
proceeding.
(5) Engage slots of Seal Remover and Installer to
new seal cage and insert seal assembly firmly into
place in t he compressor seal cavity (Fig. 20). Twist
tool in opposite direction to disengage tool from seal
cage. Remove tool.
Fig. 20 Seal Assembly

(6) Coat seal ret ai ner with clean refrigerant oil.
Use seal seat tool to install (Fig. 21). Press lightly
against seal.
J8924-36
Fig. 21 Seal Retainer
(7) Install snap ring. Beveled edge lies outward
from compressor. Fl at side lies toward compressor. It
may be necessary to lightly t ap t he snap ri ng to se-
curely position it in its groove.
(8) Replace clutch spacer shims.
(9) Tap new felt ri ng into place (Fig. 22).
J8924-37
Fig. 22 New Felt Ring
(10) Align front plate keyway to compressor shaft
key.
(11) Using shaft protector, t ap front plate to shaft
unt i l it has bottomed to t he clutch shims (Fig. 12).
Listen for a distinct change of sound duri ng the t ap-
ping process.
(12) Replace shaft hex nut . Tighten t he hex nut to
(13) Check air gap wi t h feeler gauge. The specifi-
cation is 0.406-0.787 mm (0.016-0.031 inch). If air
gap is not consistent around t he circumference,
lightly pry up at t he mi ni mum variations. Lightly
t ap down at points of maxi mum variation.
The air gap is determined by t he spacer shims.
When installing t he original or a new clutch assem-
bly, try t he original shims first. When installing a
new clutch onto a compressor t hat previously did not
have a clutch, use 0.040, 0.020, and 0.005 shims from
t he clutch accessory sack.
(14) If t he air gap does not meet t he specification
given, add or subtract shims as required.
CYLINDER HEAD / VALVE PLATE
REMOVAL
(1) Remove cylinder head bolts.
(2) Using a small hammer and a gasket scraper
separate t he cylinder head from t he valve plate (Fig.
23).
J8924-39
Fig. 23 Compressor Cylinder Head
J8924-40
Fig. 24 Waive Plate
(5) Visually inspect t he rear valves and discharge
ret ai ner for damage. Discard any component if any
portion is damaged.
If valve plate and/or cylinder head are to be reused,
carefully remove gasket mat eri al s using t he gasket
scraper. Do not damage cylinder block or valve pl at e
surfaces.
. . . _ #
E8924-207
Fig. 25 Cylinder Head Bolt Torque Sequence
INSTALLATION
When installing t he cylinder head valve plate, use
t he new gaskets in t he part s kit.
(1) Coat new valve plate gasket with clean refrig-
erant oil.
(2) Install valve plate gasket by aligning valve
plate gasket to locating pin holes and oil orifice in
cylinder block. (For easy reference, t he gaskets have
a notch at t he bottom outside edge).
(3) Install valve plate by aligning valve plate lo-
cating pins to t he pin holes in t he block and position
valve plate.
(4) Install cylinder head and t i ght en bolts in order
to 32 N*m (24 ft. lbs.) torque (Fig. 25).
(3) Visually inspect all part s for damage.
(4) Separat e t he valve plate from t he cylinder
block (Fig. 24).
CLIMATE CONTROL SYSTEM
INDEX
page
Air Conditioner Distribution and Spot Cooler
Duc t s- Cent er . . 38
Duct s- Left Bi-Level 38
D uc t s- Ri ght Bi-Level 38
Air Outlet Assembl i es Right Si de . . . . . . . . . . . . . 38
Control Test . . . . . . 30
Defroster Duct 34
Electrical Controls and Circuits 30
Electronic Temperature Cycling Switch 37
Evaporator Control Unit . . 34
GENERAL INFORMATION
This air conditioner is designed specifically for con-
ventional cab trucks with t he heater-evaporator
package designed to fit under t he i nst rument panel.
The system is manual l y controlled by t he operator.
Controls have been kept simple for ease of service
and operation.
In t he blend air reheat air conditioning unit, all
t he air entering t he system passes t hrough t he evap-
orator. A selected portion passes t hrough t he heat er
core depending on t he position of t he blend ai r door.
The system controls are located in t he center of t he
i nst rument panel within easy reach of t he driver.
The combination electrical and vacuum switch con-
trols t he compressor clutch, mode of operation and
blower. Modes are Off, Max. A/C, A/C, Vent, Heat
and Defrost. A 4-speed blower motor switch controls
t he amount of air flow. The evaporator-heater pack-
age includes:
The blower motor.
Int ake duct with outside air recirculating door.
Evaporator coil
Heat er core.
Defroster discharge doors.
Blower motor speed resistors.
Vacuum harness.
Vacuum actuators.
A/C air outlets to t he distribution ducts.
Defrost, Heat, A/C and Vent modes automatically
supply 100% outside air.
The air distribution ducts supply air from t he uni t
to 4 panel mounted, fully directional, outlets. The
faceplate has 2 outlets and 2 are snapped into t he
panel on t he ri ght side.
Satisfactory performance of t he air conditioning
and heat i ng system is dependent upon correct opera-
tion and adjustment of all operating controls. The in-
spections, tests and adjustments should be used to
locate t he cause of a malfunction. The tests in this
page
Evaporator Heater Assembl y 36
Ex pansi on (H) V al ve 37
Faceplate 32
General Information . 29
Heater Assembl y . 33
Heater Control 32
Louver Assembl i es 39
Operation of All Controls 29
Resistor Block 33
Temperature and Mode Control Cabl es . 32
V acuum Actuators 36
V acuum Controls and Circuits 30
manual have been arranged in a logical sequence
t hat has proved to be t he surest and shortest route to
accurate diagnosis. It is recommended t hat they be
followed and performed in t he order they are pre-
sented.
OPERATION OF ALL CONTROLS
Operation must be tested as described in t he fol-
lowing sequence:
(1) Inspect, test, and adjust compressor drive belt.
(2) St art engine and adjust engine speed to 1,300
RPM. Use a reliable tachometer.
(3) Move t emperat ure control lever to Cool position
and mode lever to A/C position.
(4) The inlet ai r door should be open to outside air.
Open vehicle windows.
(5) Test t he blower operation at all 4 speed posi-
tions. If t he blower does not operate correctly refer to
Electrical Controls and Circuit. Leave t he blower
switch in t he HIGH position.
(6 ) The compressor should be runni ng and t he air
conditioning system in operation.
In addition to t he six position push button selector,
t he A/C Heat er control consists of:
TEMPERATURE LEVER- Cont r ol s t he t empera-.
t ure of t he discharge air in all modes except MAX
A/C and Off when t he vacuum operated wat er valve
is closed. Moving t he lever to t he left provides cooler
air and moving it to t he ri ght provides warmer air.
BLOWER SWI TCH- The system blower can be op-
erated at 4 speeds.
LOW at t he bottom.
MEDIUM 1 at t he lower center.
MEDIUM 2 at t he upper center.
HIGH at t he top switch position.
The blower will be on and operating at t he speed
selected, in all push button positions except Off.
AIR DIRECTIONAL VANES- Ai r is delivered
t hrough 4 panel outlets. The 4 outlets are adjustable

up, down or to either side and can be shut off by
pushing t he vanes up. Floor air is delivered t hrough
t he lower outlets.
VACUUM CONTROLS AND CIRCUITS
For an explanation of t he vacuum and electrical
logic t hat controls t he operation of t he uni t (Fig. 1
and Control Chart).
MODESThe vacuum and electrical logic is deter-
mined by t he push button switch. The vacuum por-
tion of t he switch controls t he wat er valve and
positions all doors in t he uni t except t he blend air
door. The electrical portion of t he switch controls t he
compressor and blower operation. The following is a
breakdown of t he vacuum and electrical logic for
each mode. Refer to Control Chart in this section.
OFF
Vacuum application is as indicated in Fig. 1. The
inlet air door is closed to outside, open to recirculat-
ing air. The mode door is in t he A/C position. The
Heat/Defrost door is in t he Heat position. The heat er
core coolant flow is shut-off.
No air flows t hrough t he uni t and t he compressor
is idle because t he blower and compressor clutch cir-
cuits are open.
MAX A/C
All of t he doors are in t he same position as they
are in Off. The Max. A/C mode merely closes t he
electrical circuits to t he blower motor and t he com-
pressor clutch. This mode is recommended for initial
cool down, extreme outside humidity or high ambient
t emperat ure.
A/C
This mode is recommended for use after t he vehicle
has been cooled to t he desired t emperat ure. The vac-
uum application at t he outside-recirculating air door
actuator is transferred to t he rod side. This moves
t he door away from t he outside-air inlet and closes
t he recirculating inlet. The wat er valve is open. All
other vacuum applications and door positions are t he
same for t he Max. A/C position. The blower motor
and compressor are on.
VENT
The vacuum circuit remai ns t he same as in t he
A/C position but t he compressor clutch electrical cir-
cuit is opened, prevent i ng t he compressor from oper-
ating. The blower motor is used to force outside ai r
into t he passenger compartment t hrough t he A/C
outlets in t he i nst rument panel.
HEAT
In t he Heat mode t he outside air door is open same
as A/C mode.
Vacuum is applied to t he top side of t he air condi-
tioning door actuator. This will close off t he passage
to t he air conditioning distribution duct and open t he
passage to t he heater/defroster duct. Since t he heat -
er-defroster door is in t he heat position, t he full flow
of heated air goes through t he heat er outlets. A
small amount of heated air will bleed t hrough t he
defroster outlets. The wat er valve is open, t he blower
switch is activated and the compressor is off.
DEFROST
When t he defrost mode is selected all conditions
are t he same as for heat er operation, except t hat no
vacuum is applied to t he defrost door actuator. The
defrost door is spring loaded to t he defrost position.
The door opens t he defroster outlets and partially
closes off t he heat er outlets. The heat er outlets are
left open far enough to direct about 30 percent of t he
air to t he floor. The other 70% is defrost air directed
to t he windshield area. The compressor clutch will be
engaged.
ELECTRICAL CONTROLS AND CIRCUITS
The electrical feed for t he air conditioning circuit is
from 2 fuses in t he fuse block. A 20 ampere fuse pro-
tects t he compressor clutch circuit, and a 30 ampere
fuse protects t he blower motor control circuit.
CONTROL TEST
Test operation of controls in t he following manner.
(1) Inspect compressor drive belt. Adjust, if neces-
sary.
(2) St art engine.
(3) Move t emperat ure lever to extreme left (cool)
position.
(4) Push A/C button.
(5) Refer to Control Chart. Check position of doors,
operation of compressor clutch, blower motor and wa-
t er valve. The wat er valve is open when t here is no
vacuum to valve.
(6) Check blower switch by moving it to all 4 posi-
tions and noting air flow change. In case of malfunc-
tion refer to Electrical Control Circuit.
(7) Check operation of blend air door by moving
t emperat ure lever from full warm toward cool posi-
tion. Discharge air t emperat ure should change wi t h
lever movement if t he engine coolant is warm.
(8) Repeat steps 5 and 6 in each push-button posi-
tion.
If actuation of t he doors is slow or incomplete,
check for mechanical misalignment, binding or vac-
uum leaks. The air conditioning door has a seven
second vacuum delay in mode switching from Off,
Max A/C, A/C, or Vent to Heat or Defrost. Check
t emperat ure control cable for correct adjustment.

SOLID LINE INDICATES
ENGI NE VACUUM VIOLET
CHECK VALVE f
ENGINE VACUUM VIOLET
Y E L L OW I
ACTUATOR
ÔUTSIDE
AIR
OFF, MAX A/C A/ C, VENT
RED
/ I
CHECK VALVE I
DEFROSTER-*-*-
H 5 W N
RESTRICTOR
DARK
GREEN
AIR/COND.
t
ACTUATOR
I
HEATING
WATER VALVE
ACTUATOR ^ |
ON -*-ÔFF
YELLOW
HEAT
ACTUATOR
LIGHT GREEN
RECIRCULATING
GRAY
ACTUATOR
OUTSIDE
AIR
ACTUATOR
HEAT
* PUSH BUTTON CONTROL
VACUUM SWITCH
** RESTRICTOR IS PART OF
VACUUM CONNECTOR
AND NOT VISIBLE
ACTUATOR
OUTSIDE
RN1001
Fig. 1 Vacuum Circuits (Air Conditioning and Heating)
CONTROL CHART
Control Position Off Max. A / C A/C Vont Hoot Defrost
Inlet Air Door (Open To) Inside Inside Outside Outside Outside Outside
Mode Door (Open To) A / C A / C A / C A / C Heat Heat
Heat Defrost (Open To) Heat Heat Heat Heat Heat Defrost
Compressor Clutch Off On On Off Off On
Blower Motor Off On On On On On
Water Valve Off Off On On On On
FACEPLATE
REMOVAL
(2) Remove screws which at t ach faceplate to base
panel. Make sure t he screw below t he Heater-A/C
control is removed (Fig. 2).
MOUNTING
SCREWS
LOCATIONS
RB458
Fig. 2 Mounting Screw Location
(3) Pull column shift lever in position 1.
(4) Remove faceplate by pulling t he top edge rear-
ward to clear t he brow, disengage at t achi ng clips
around t he bottom of t he faceplate, and complete re-
moval of faceplate.
(5) Disconnect wires to 4 WD indicator, if
equipped.
INSTALLATION
(1) Engage at t achi ng clips around bottom of face-
plate.
(2) Connect 4 WD drive indicator wiring, if
equipped.
(3) Roll faceplate into position and install mount-
ing screws (Fig. 2).
HEATER CONTROL
REMOVAL
(1) Remove faceplate.
(2) Remove at t achi ng screws (Fig. 3).
(3) Pull control outward.
TAB FLAG FLAG
RETAINER
J9124-118
MOUNTING
SCREW(2)
HEATER
CONTROL
UNIT
RB459
Fig. 3 Heater Control
(4) Disconnect 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 uni t in i nst rument panel and secure
with mounting screws.
(4) Move t he levers to t he extreme ri ght to adjust
t he clips.
(5) Install faceplate.
TEMPERATURE AND MODE CONTROL CABLES
REMOVAL
(2) Open glove box past stops.
(3) Remove control uni t from i nst rument panel.
(4) Remove cables from control lever pins and re-
move flags from ret ai ners (Figs. 4 and 5).
DEPRESS TAB
FOR
REMOVAL
FLAG
RED-TEMPERATURE
DOOR
YELLOW-MODE
DOOR
CONTROL CABLE
ASSEMBLY
PR413C
Fig. 4 Flag Tab Depressed for Removal

Fig. 5 Heater Control
(5) Detach cables from uni t by removing self adjust
clips from crank arms and removing flags from re-
tainers (Fig. 6).
TAB
HOUSING CRANK RB461
Fig. 6 Cables from Unit
(6) Remove cable assemblies t hrough glove box
opening.
(7) Place a 7 mm (1/4 inch) I.D. tube over clip and
pry self-adjust clip off core wire if required (Fig. 7).
Fig. 7 Self-Adjusting Clip
INSTALLATION
(1) Position self-adjust clip on cable core wire 50
mm (2 inches) from t he small loop at heat er assem-
bly flag end. With a 7 mm (1/4 inch) I.D. tube, snap
self-adjust clip on core wire.
(2) Install cable assemblies t hrough glove box
opening.
(3) Attach self-adjust clips to crank arms and re-
place flags in receivers on heat er assembly.
(4) Install flanges in ret ai ners and at t ach cables to
control levers on control unit.
(5) Install control uni t into i nst rument panel.
(7) Move levers to extreme ri ght to adjust clips.
RESISTOR BLOCK
REMOVAL
(1) Remove connector from resistor block.
(2) Remove mounting screws.
(3) Remove resistor block from plenum.
INSTALLATION
(1) Place resistor block on pl enum.
(2) Install mounting screws.
(3) Connect wiring connector.
HEATER ASSEMBLY
REMOVAL
(2) Remove wat er hoses on engine side and plug
hoses and inlets on package (Fig. 8).
WIRE RB464
Fig. 8 Water Hose Connections
(3) Remove right cowl side t ri m panel, if equipped.
(4) Remove glove box by removing mounting
screws at base and swinging out from t he bottom to
avoid catch and stops.
(5) Remove structural brace t hrough glove box
opening.
(6) Remove ri ght half of i nst rument panel lower
reinforcement (8 screws). Be sure to disconnect t he
ground strap.
(7) Disconnect control cables.
(8) Disconnect blower motor wires on engine side.
(9) Remove screw t hat ret ai ns package to cowl side
sheet metal.

(10) Remove uni t ret ai ni ng nut s on engine side (6
nuts).
(11) Remove uni t .
(12) Remove screws and mode door crank to sepa-
rat e cover from housing.
(13) Carefully slide heat er core out.
(14) Peel dash panel seal below cover. Remove re-
t ai ni ng screws and remove cover from blower motor
assembly.
(15) Separat e fan from motor, motor from housing
and inspect all part s.
INSTALLATION
(1) Assemble heat er assembly using necessary new
part s.
(2) Position heat er assembly to dash and install re-
t ai ni ng nut s on engine side.
(3) Install cowl side ret ai ni ng screws.
(4) Connect blower motor.
(5) Connect control cables.
(6) Install right, lower i nst rument panel reinforce-
ment.
(7) Install st ruct ural brace t hrough glove box open-
ing.
(8) Inst al l glove box.
(9) Install ri ght cowl side t ri m panel, if equipped.
(10) Unpl ug inlets and wat er hoses and connect
hoses to inlets on package (Fig. 8).
DEFROSTER DUCT
REMOVAL
(3) If equipped, remove ri ght upper air duct by re-
moving mount i ng screw and pulling duct out t hrough
glove box openings (Fig. 9).
(4) Remove i nst rument panel center brace.
(5) Remove ri ght kick pad.
(6) Remove ri ght i nst rument panel pivot bolt.
(7) Remove i nst rument panel cluster.
(8) Disconnect shift lever cable, if equipped.
(9) Lower steering column.
(10) Remove steering column studs.
(11) Remove radio, if equipped.
(12) Remove mount i ng screws and remove scoop
connecting heat er uni t to center distribution duct, if
equipped.
(13) Remove mount i ng screws and remove center
distribution duct by pulling bottom of i nst r ument
panel out and dropping duct out (Fig. 9).
(14) Remove heat er control.
(15) Remove mount i ng screws and t he cover t hat
ret ai ns i nst rument panel wiring. Let wiring hang
free.
(16) Remove mounting screw and slide left air duct
out t hrough i nst rument cluster opening, if equipped
(Fig. 9).
(17) Remove screws at t achi ng defroster duct to
dash panel (Fig. 9).
(18) Reach in through i nst rument panel opening
and disengage snaps to separat e defroster duct into 2
pieces.
(19) Remove defroster duct halves t hrough instru-
ment cluster opening.
INSTALLATION
(1) Install defroster duct halves t hrough instru-
ment cluster opening.
(2) Reach in through i nst rument panel opening
and engage snaps to connect defroster duct halves.
(3) Install screws at t achi ng defroster duct to dash
panel (Fig. 9).
(4) Slide left air duct out t hrough i nst rument clus-
t er opening, if equipped (Fig. 9). Install mount i ng
screw.
(5) Position t he cover t hat ret ai ns i nst rument
panel wiring. Install mount i ng screws.
(6) Install t he heat er control.
(7) Position t he center distribution duct in bottom
of i nst rument panel out, if equipped (Fig. 9). Install
mounting screws.
(8) Position t he scoop connecting heat er uni t to
center distribution duct, if equipped. Install mount-
ing screws.
(9) Install t he radio, if equipped.
(10) Install steering column studs.
(11) Position t he steering column in place.
(12) Connect shift lever cable, if equipped.
(13) Install i nst rument panel cluster.
(14) Install ri ght i nst rument panel pivot bolt.
(15) Install ri ght kick pad.
(16) Install i nst rument panel center brace.
(17) Position t he ri ght upper air duct in t hrough
glove box openings, if equipped (Fig. 9). Install
mount i ng screw.
EVAPORATOR CONTROL UNIT
REMOVAL
(2) Remove at t achi ng screws.
(3) Pull control uni t out, away from i nst rument
panel.
(4) Disconnect blower control switch wiring con-
nector.
(5) Disconnect 3 wiring connectors to evaporator
control unit.
(6) Disconnect illumination light.
(7) Disconnect vacuum harness.
(8) Disconnect t emperat ure control cable.
^ ^ ^ ^ ^ ^ HEATING AND AIR CONDITIONING 24 - 35
CENTER DISTRIBUTION
DUCT
RIGHT SPOT
COOLER DUCT
LEFT SPOT COOLER
DUCT
MOU N T I N G
SCREW
AIR
OUTLET ASSEMBLIES
HEAT/DEFROST
DOOR ACTUATOR
DEFROSTER
DUCT
MOUNT I NG
SCREW
TEMPERATURE CONTROL
CABLE (RED FLAG)
MO U N T I N G .
HARNESS
TAB
V AC UUM
HARNESS
MOUNT I NG
NUT
BLOWER
MOTOR
RECEIVER
TEMPERATURE
CONTROL LEVER
HEATER-A/C
CONTROL ASSEMBLY
MOUNTI NG
NUT
BLOWER
MOTOR
FEED WIRES
V ACUUM
LINES
i DRAI N
TUBE
RB4#B
Fig. 9 Heater and Evaporator Assembly

(9) Remove control.
INSTALLATION
(1) Connect t emperat ure control cable.
(2) Install illumination light.
(3) Install 3 wiring connectors to push button
switch and vacuum harness.
(4) Connect blower motor control switch wiring
connector.
(5) Place control uni t in place in i nst rument panel
and secure with at t achi ng screws.
VACUUM ACTUATORS
The mode and ai r circulator actuators are serviced
t hrough t he glove box opening after opening t he
glove box past its stops.
The heater/defroster actuator is serviced under t he
i nst rument panel on t he left end of t he A/C unit.
EVAPORATOR HEATER ASSEMBLY
REMOVAL
(2) Discharge refrigerant from t he A/C system.
(3) Disconnect refrigerant and heat er lines from
uni t on engine side.
(4) Pl ug heat er hoses and uni t and remove conden-
sate t ube (Fig. 9).
(5) Move transfer case and/or gear shift levers
away from i nst rument panel.
(6) Remove ri ght cowl side t ri m panel, if so
equipped.
(7) Remove glove box by removing mount i ng
screws at base and swinging out from t he bottom to
avoid catch and stops.
(8) Remove st ruct ural brace t hrough glove box
opening. Remove screws, loosen nut s.
(9) Remove ash receiver.
(10) Remove ri ght half of lower reinforcement by
removing screws at t achi ng it to t he i nst rument panel
and t he sctew at t achi ng it to t he cowl side t ri m
panel.
(11) Detach radio ground st rap.
(12) Remove center distribution duct.
(13) Remove floor air distribution duct.
(14) Disconnect t emperat ure control cable from
uni t t hrough glove box and t ape out of way.
(15) Disconnect vacuum lines from extension on
control uni t and detach vacuum lines from defroster
duct (Fig. 10).
(16) Remove wiring connector from resistor block.
(17) Remove blower motor connector on engine
side.
(20) Remove screw t hat ret ai ns t he evaporator
heat er assembly to cowl side sheet metal.
(21) Remove t he evaporator heat er assembly. Plas-
tic i nst rument panel may have to be flexed outward.
Fig. 10 Evaporator Heater Assembly
DISASSEMBLE
(1) Remove nut t hat attaches 3 door arms to doors
on t he top cover of t he unit. Remove t he 3 arms (Fig.
11).
ATTACHI NG
NUTS RB463
Fig. 11 Door Arms
(2) Remove screws to separate cover from housing.
(3) Slide out evaporator core.
(4) Remove mounting screw and slide out heat er
core.
(5) Disconnect blower motor feed wire on engine
side.
(6) Remove ret ai ni ng screws to separat e blower
motor from housing.
(7) Separat e fan from motor (Fig. 12).
(8) Inspect all part s.
ASSEMBLE
(1) Position t he fan onto t he motor.
(2) Position t he blower motor to t he housing.
Tighten t he ret ai ni ng screws.
(3) Connect blower motor feed wire on engine side.
(4) Slide t he heat er core in and install t he mount-
ing screws.
(5) Install evaporator core.
(6) Position t he cover onto t he housing. Install and
t i ght en t he screws.
(18) Disconnect vacuum lines on engine side, make
sure grommet is free from dash panel.
(19) Remove ret ai ni ng nut s on engine side.

Fig. 12 Blower Wheel
(7) Install t he 3 arms. Install nut t hat at t aches 3
door arms to doors on t he top cover of t he uni t (Fig.
11).
INSTALLATION
(1) Install t he evaporator heat er assembly. Plastic
i nst rument panel may have to be flexed outward.
(2) Install and tighten t he screw t hat ret ai ns t he
evaporator heat er assembly to cowl side sheet metal.
(3) Install t he ret ai ni ng nut s on engine side.
(4) Connect vacuum lines on engine side.
(5) Install blower motor connector on engine side.
(6) Remove wiring connector from resistor block.
(7) Connect vacuum lines from extension on con-
trol uni t and at t ach vacuum lines to defroster duct
(Fig. 10).
(8) Connect t emperat ure control cable to uni t
t hrough glove box.
(9) Install floor air distribution duct.
(10) Install center distribution duct.
(11) Attach radio ground strap.
(12) Remove ri ght half of lower reinforcement by
removing screws at t achi ng it to t he i nst rument panel
and t he screw at t achi ng it to t he cowl side t ri m
panel.
(13) Install ash receiver.
(14) Install st ruct ural brace t hrough glove box
opening. Install screws and loosen nut s.
(15) Install glove box by installing mount i ng
screws.
(16) Install ri ght cowl side t r i m panel, if so
equipped.
(17) Position transfer case and/or gear shift levers.
(18) Remove plugs from heat er hoses and unit. In-
stall condensate tube (Fig. 9).
(19) Connect refrigerant and heat er lines to uni t
on engine side.
} (20) Connect t he negative cable to t he battery.
(21) Fill t he cooling system (refer to Group 7, Cool-
ing System).
(22) Evacuate and charge t he system.
(23) Check operation of all controls and perfor-
mance of t he A/C system.
'H" VALVE
Fig. 13 Expansion (H) Valve Assembly
ELECTRONIC TEMPERATURE CYCLING SWITCH
REMOVAL
(1) Remove t he electrical wires to t he switch.
(2) Rotate switch counterclockwise to remove from
pressure switch port.
(3) Remove and discard old O-ring.
INSTALLATION
(1) Install new O-ring. Refrigerant oil must be ap-
plied to t he new O-ring.
(2) Rotate switch clockwise to install on suction
line pressure switch port. Tighten switch to 5.65 N
#
m
C A U T I O N : Power t ool s shoul d not be used for in-
stallation of the swi t ch. The possi bi l i ty of stri ppi ng
the swi tch t hreads occur s above 5.88 N*m (52 i n.
l bs.) torque.
(3) Connect wires.
(4) Verify operation.
EXPANSION (H) VALVE
REMOVAL
The system must be completely discharged before
opening any refrigerant lines.
(1) Remove t he bolt in center of plumbing sealing
plate (Fig. 13).
(2) Carefully pull refrigerant line assembly to-
wards front of vehicle. Take care NOT to scratch
valve sealing surfaces with tube pilots.
(3) Remove t he Torx Head screws (Fig. 13). Hold
valve, once cap screws are removed valve is com-
pletely disconnected.
(4) Carefully remove valve.
INSTALLATION
(1) Remove and replace t he al umi num N-gaskets
(1 on evaporator pl at e and 1 on plumbing plate).
(2) Remove sealing cap from H-valve control head
side sealing surface and hold it agai nst evaporator
sealing plate. DO NOT scratch sealing surface. In-
stall t he Torx Drive screws and t i ght en to 11 N-m
(3) Remove sealing cap from plumbing side sealing
surface and hold plumbing up to valve. Install t he
bolt and t i ght en to 23 N*m (200 in. lbs.) torque.
(4) Connect wires to electronic t emperat ure cycling
switch.
(5) After expansion valve is installed and system
charged and leak checked, repeat performance check.
AIR CONDITIONER DISTRIBUTION AND SPOT
COOLER DUCTS- CE NTE R
REMOVAL
(3) Remove ri ght upper air duct by removing
mounting screw and pulling duct out t hrough glove
box opening (Fig. 9).
(4) Remove i nst rument panel center brace.
(5) Remove ri ght kick pad.
(6) Remove ri ght i nst rument panel pivot bolt.
(8) Disconnect shift indicator cable.
(9) Lower steering column.
(10) Remove steering column studs.
(11) Remove radio.
(12) Remove mount i ng screws and remove scoop
connecting heat er uni t to center distribution duct.
(13) Remove mount i ng screws and remove center
distribution duct by pulling bottom of i nst rument
panel out and dropping duct out (Fig. 9).
INSTALLATION
(1) Position t he center distribution duct t hrough
t he bottom of i nst rument panel (Fig. 9). Install
mounting screws.
(2) Position t he scoop connecting heat er uni t to
center distribution duct. Install mount i ng screws.
(3) Install radio.
(4) Install steering column studs.
(5) Place steering column into position.
(6) Connect shift indicator cable.
(8) Install ri ght i nst rument panel pivot bolt.
(9) Install ri ght kick pad.
(10) Install i nst rument panel center brace.
(11) Position t he duct in t hrough glove box open-
ing (Fig. 9). Install mount i ng screw.
COOLER DUCTS- RI GH T BI-LEVEL
REMOVAL
(3) Remove ri ght upper air duct by removing
mount i ng screw and pulling duct out t hrough glove
box opening (Fig. 9).
INSTALLATION
(1) Position t he ri ght upper air duct t hrough glove
box opening (Fig. 9). Install mounting screw.
COOLER DUCTS- LE F T BI-LEVEL
REMOVAL
(3) Disconnect shift indicator cable.
(4) Remove heat er control.
(5) Remove mounting screws and cover t hat re-
t ai ns i nst rument panel wiring and let wiring hang
free.
(6) Remove mount i ng screw and slide left air duct
out t hrough i nst rument cluster opening (Fig. 9).
INSTALLATION
(1) Slide left air duct in through i nst rument clus-
t er opening (Fig. 9). Install mount i ng screw.
(2) Position t he cover t hat ret ai ns i nst rument
panel wiring. Install mount i ng screws.
(3) Install heat er control.
(4) Connect shift indicator cable.
AIR OUTLET ASSEMBLI ES RIGHT SIDE
Both ri ght side outlets are held in place with
spring loaded ret ai ni ng clips.
REMOVAL
(1) With outlet facing out and louver vanes open,
grasp adjusting vane with fingers.
(2) Pull smoothly and firmly to unseat clips and
complete removal toward rear of vehicle.
INSTALLATION
(1) Position outlet assembly in panel opening, f
maki ng sure lettering stamped TOP is up (ribs on
housing match notches on i nst rument panel).
(2) Press housing assembly until both ret ai ni ng
clips lock into place.

LOUER ASSEMBLIES
REMOVAL
(2) Set faceplate wi t h t r i m surface down, insert a
small screwdriver t i p into t he outlet housing pivot
hole.
(3) While forcing down louver assembly pivot pin,
pull louver assembly out of r ear of faceplate (Fig. 9).
INSTALLATION
(1) Position louver assembly, bottom pivot first,
into t he faceplate outlet housing. The bottom pivot
pin is a smaller diameter t han t he top pivot pin.
(2) While deflecting t he upper louver assembly
pivot pin, carefully swing t he assembly into housing,
so t he felt pads are not damaged. Ensure top and bot-
t om pivot pins are properly engaged.
D E SCRI PTI ON f ORQ UE D E S C R I PT I O N
Compressor (SD-709)
Cylinder Head Bolts 32 N-m (24 ft. lbs.)
Magnetic Clutch Hex Nut... 37 N-m (27 ft. lbs.)
Mounting Bolts 27 N-m (20 ft. lbs.)
Oil Filter Plug 10 N-m (7 ft. lbs.)
Service Valve-to-Compressor Fitting* ........ 47 N-m (35 ft. lbs.)
T O R QU E
H-Valve Control Head Torx
Drive Bolts 11 N-m (100 in. lbs.)
H-Valve Plumbing Sealing Plate Bolt 23 N-m (200 in. lbs.)
Refrigerant Cans-to-Manifold Gauge
Set Nuts 9.5 N-m (7 ft. lbs.)
Wet Torque - Lubricate the service valve coupling threads and O- ri ngs with
compressor oil.
J9324-100

EMISSION CONTROL SYSTE MS 25 - 1
CONTENTS
page page
AIR INJECTION SY STE M - o 9L HDC-GAS EVAPORATIVE EMISSION CONTROLS 6
ENGINE 15 EXHAUST EMISSION CONTROLS 10
COMPONENT REMOVAL/INSTALLATION 17 GENERAL INFORMATION 1
GENERAL INFORMATION
by t he part i cul ar vehicle nameplate. A chart showing
a breakdown of alphabetical designations is included
in t he Introduction section at t he beginning of this
manual .
The 5.9L (V-8) gas powered engine will be referred
to in t hi s group as either the: LDC (Light Duty Cy-
cle) or HDC (Heavy Duty Cycle) engine. The HDC
engine can be easily identified by t he use of an en-
gine mounted air injection pump. The 3.9L/5.2L/5.9L
LDC engine will not use an air injection pump.
Mai nt enance requi rement s for LDC and HDC emis-
sion systems differ because of different load and op-
erat i ng conditions.
This section will cover emission control systems for
the 3.9L (V-6), 5.2L (V-8), 5.9L LDC (V-8), 5.9L HDC
(V-8) and 5.9L (in-line six cylinder) diesel engines.
SERVICE REMINDER INDICATOR (SRI) LIGHT
The i nst rument panel mounted SRI light was for-
merly referred to as t he emission mai nt enance re-
minder (EMR) light. It is used with 5.9L HDC-gas
powered engines only. It is not used with diesel en-
gines.
The SRI system is incorporated into t he powertrain
control module (PCM) (the PCM was formerly re-
ferred to as t he engine controller or SBEC). The
PCM records t he vehicles mileage and stores it into
memory every 8 miles. At t hat time, t he PCM checks
for t he 60,000 and 82,500 mileage t ri p points. When
t he current mileage matches one of t he above men-
tioned t ri p points, t he SRI light is activated.
The following part s are to be replaced at either t he
indicated mileage or when t he SRI light remai ns on
when t he key is in t he ON position. After performing
t he required mai nt enance, t he SRI light must be re-
set to t ur n t he light off.
96,000 km (60,000 miles):
Replace EGR Valve
Clean EGR passage
Replace PCV Valve
132,000 km (82,500 miles):
Replace Oxygen Sensor
Refer to Group 0, Lubrication and Maintenance for
all required mai nt enance schedules.
Fai l ure to perform t he required mai nt enance and
only reset t he SRI light may be a violation of federal
law. Only after performing t he required mai nt e-
nance, should t he SRI light be reset.
RESETTING SRI LIGHT
(1) Connect t he DRB II scan tool to t he dat a l i nk
connector (Fig. 1) in t he engine compartment.
TORQUE CONVERTER
CLUTCH RELAY
A / C CLUTCH RELAY . STARTER RELAY
AUTO SHUTDOWN RELAY
FUEL PUMP RELAY
DATA LINK
CONNECTOR
POWERTRAIN
CONTROL
MODULE J9314-164
Fig. 1 Data Link Connector
(2) Refer to DRB II scan tool operation in t he ap-
propriate Powertrain Diagnostic Procedures manual .
(3) Reset SRI light.
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL
All vehicles equipped with a gasoline powered en-
gine have a VECI label.
The 3.9L/5.2L/5.9L LDC-gas powered engine will
have a label t hat combines both emission control in-
formation and vacuum hose routing.
EMISSION CONTROL SYSTEMS
25 - 2 EMISSION CONTROL SYSTE MS

This label is located in t he engine compartment
(Fig. 2) and contains t he following:
Engine family and displacement
Evaporative family
Emission control system schematic
Certification application
Engine t i mi ng specifications (if adjustable)
Idle speeds (if adjustable)
Spark plug and gap
The 5. 9L HDC-gas powered engine will have two
labels. One of t he labels is located in t he engine com-
part ment (Fig. 2) and will contain vacuum hose rout-
ing only. The other is attached to t he engine air
filter housing and will contain t he following:
Engi ne family and displacement
Evaporative family
Certification application
Engi ne t i mi ng specifications (if adjustable)
Idle speeds (if adjustable)
Spark plug and gap
There are uni que labels for vehicles built for sale
in t he st at e of California, t he country of Canada and
for both Light Duty Cycle (LDC) and Heavy Duty
Cycle (HDC) engines. Canadi an labels are wri t t en in
both t he English and French languages. These labels
Fig. 2 VECI Label Location
are permanent l y attached and cannot be removed
without defacing information and destroying it.
The fol l owi ng VECI l abel illustrations are used
as exampl es only. If t here are any differences be-
tween these illustrations and t he VECI label, those
shown on vehicle label should be used.
FEDERAL VEHICLE EMISSION CONTROL INFORMATION LABEL-TYPICAL
I MPORTANT VEH ICLE I NF ORMATI ON
T H I S V E H I C L E C O N F O R M S T O U . S . E PA R E G U L A T I O N S A P P L I C A B L E
T O 1993 M O D E L Y E A R N E W L I G H T - D U T Y T R U C K S WI T H A C U R B
WE I G H T G R E A T E R T H A N 3. 45 0 P O U N D S A T A L L A L T I T U D E S .
C/5
> ]
* BASIC IGNITION TIMING AND IDLE FUEL/AIR MIXTURE HAVE BEEN
PRESET AT THE FACTORY. SEE THE SERVICE MANUAL FOR PROPER
PROCEDURES AND OTHER ADDITIONAL INFORMATION.
o ADJUSTMENTS MADE BY OTHER THAN APPROVED SERVICE
MANUAL PROCEDURES MAY VIOLATE FEDERAL AND STATE LAWS.
CAUTION: APPLY PARKING BRAKE WHEN SERVICING VEHICLE.
5 . 2 LI TER
PC R 5 . 9T 5 F E Y4
P T A P G
S PA R K P L U G S
. 0 35 i n. G A P
R C 12 Y C
N O A D J U S T M E N T S N E E D E D
TEE CONNECTOR
W/ORIFICE
ROLLOVER VALVE
W/ORIFICE
PCV VALVE-
TO CLIMATE CONTROL,
VEHICLE SPEED CONTROL,
4X4 AXLE
(WHEN EQUIPPED)
INTAKE MANIFOLD "
ORIFICE
EVAP PURGE
SOLENOID
FILTER
M THROTTLE M
M BODY M
M fO~0| M
TO
AIR
J CLEANER
-CRANKCASE
BREATHER
J9325-22
EMISSION CONTROL SYSTEMS 25 - :
CALIFORNIA VEHICLE EMISSION CONTROL INFORMATION LABEL-TYPICAL
or,
o _
UJ u_
U ^
> CO
CQ
o
I MPORTANT VEH ICLE INFORAAATION
THIS VEHICLE CONFORMS TO U.S. EPA A N D STATE OF CALIFORNIA
REGULATIONS APPLICABLE TO 1993 MODEL YEAR NEW LIGHT-DUTY
TRUCKS A N D MEDIUM-DUTY VEHICLES PROVIDED THAT THIS
VEHICLE IS ONLY INTRODUCED I NTO COMMERCE FOR SALE I N THE
STATE OF CALI FORNI A.
* BASIC IGNITION TIMING AND IDLE FUEL/AIR MIXTURE HAVE BEEN
PRESET AT THE FACTORY. SEE THE SERVICE MANUAL FOR PROPER
PROCEDURES AND OTHER ADDITIONAL INFORMATION.
o ADJUSTMENTS MADE BY OTHER THAN APPROVED SERVICE
MANUAL PROCEDURES MAY VIOLATE FEDERAL AND STATE LAWS.
5.2 LITER
PCR360T5FHB2
PTAPG
SPARK PLUGS
.035 in. GAP
RC12YC
N O ADJUSTMENTS NEEDED
R H C / C O / N O x STDS. .50/9.0/1.0
TEE CONNECTOR
W/ORIFICE
TO
ATMOSPHERE
ROLLOVER VALVE
W/ORIFICE
/
PCV VALVE-
TO CLIMATE CONTROL,
4X4 AXLE
(WHEN EQUIPPED)
INTAKE MANIFOLD"
ORIFICE
M
r - M
EVAP PURGE
SOLENOID
FILTER
THROTTLE
BODY
FUEL TANK PRESSURE RELIEF/
ROLLOVER VALVE W/ORIFICE
FUEL
PRESSURE
REGULATOR
1
r O
O^
-
CRANKCASE
TO
AIR
CLEANER
APPLICABLE TO 35
GALLON FUEL TANK ONLY
J9325-23
CANADA VEHICLE EMISSION CONTROL INFORMATION LABEL-ATYPICAL
V E HI C L E E M I S S I O N C O N T R O L I N F OR A A A T I ON
THIS VEHICLE WAS BUILT FOR SALE IN CANADA AND WAS DESIGNED TO MEET THE EMISSION
REQUIREMENTS OF THE CANADA MOTOR VEHICLE ACT. IT WAS NOT DESIGNED TO COMPLY WITH THE
REQUIREMENTS OF OTHER COUNTRIES.
' BASIC IGNITION TIMING AND FUEL INJECTION MIXTURE HAVE BEEN
PRESET AT THE FACTORY. ADJUSTMENTS SHOULD NOT BE MADE
DURING ROUTINE SERVICE.
5 .2 LI TRES
S PA R K PL U G S
0.9 mm GAP
RC12YC
R E N S E I G N E M E N T S RELATI FS A U S Y S T E M E A N T I PO L L U T I O N
LE PRESENT VEHICULE A ETE FABRIQUE' POUR ETRE VENDU AU CANADA ET IL A ETE CONCU DE
MANIERE A SE CON FORMER AUX NORMES ANTIPOLLUTION DE LA LOI SUR LA SECURITE DES
VEHICULES AUTOMOBILES DU CANADA. IL N'EST PAS DESTINE' A SE CON FORMER AUX NORMES
D'AUTRES PAYS.
* LE CALAGE DE L'ALLUMAGE INITIAL ET LE MELANGE D'INJECTION
D'ESSENCE ONT ETC: PREREGLE'S A L'USINE. N'EFFECTUEZ AUCUN
REGLAGE LORS DE TRAVAUX D'ENTRETIEN REGULIERS.
AVERTISSEMENT: SERREZ LE FREIN DE STATIONNEMENT POUR FAIRE
L'ENTRETIEN OU LA RE'PARATION DU VEHICULE.
5 .2 LI TRES
, BO U G I E S
ECARTEMENT 0.9 mm
RC12YC
CLAPET DE DECHARGE
AVEC AJUTAGE
EVAP PURGE SOLENOID
E'LECTROVALVE DE _ FUEL TANK
PURGE DUFILTRE RESERVOIR D'ESSENCE -
A CHARBON ACTIF
/
TO CLIMATE CONTROL,
VEHICLE SPEED CONTROL.
4X4 AXLE (WHEN EQUIPPED)
VERS LA COWMANDE DE
TEMPERATURE. LE REGULATEUR
DE VITESSE, LESSIEU
4X4 (LORSQU'AINSI EQUIPE')
INTAKE MANIFOLD ORIFICE
AJUTAGE DE LA TUBULURE
D'ADMISSION
FUEL TANK PRESSURE RELIEF/ I
CLAPET DE DECHARGE DU RESERVOIR
D'ESSENCE AVEC AJUTAGE
REGULATEUR DE PRESSION DE CARBURANT
CHECK VALVE W/ORIFICE
SOUPAPE A DOUBLE EFFET -
AVEC AJUTAGE
AAAP SENSOR "
CAPTEUR DE PRESSION
ABSOLUE DE LA TUBULURE
THROTTLE BODY
CORPS DE PAPILLON
APPLICABLE TO 35
GALLON FUEL TANK ONLY
UNIQUEMENT APPLICABLE AU
RESERVOIR D'ESSENCE DE 132 L
2 i - 4 EMISSION CONTROL SYSTE MS

VACUUM HOSE ROUTING SCHEMATICS
The following va c uum hos e routing s chemat i cs
a r e us e d as exampl es onl y. If t here are any differ-
ences between these schematics and t he Vehicle
Emission Control Information (VECI) label schemat-
ics, those shown on t he VECI label should be used.
ENGINE VACUUM SCHEMATIC-3.9U5.2L/5.9L LDC ENGINES
TO ATMOSPHERE
i
TRANSDUCER
FUEL TANK
PRESSURE RELIEF
ROLLOVER VALVE
W/ORIFICE
EVAP
CANI STER
TO CLIMATE CONTROL,
CRUISE CONTROL,
4WD AXLE
(WHEN EQUIPPED)
INTAKE MANIFOLD ORIFICE
E NGI NE
VALVE
COVER
FUEL PRESSURE
REGULATOR
M
P
= MANI FOL D V AC UUM
= PORTED V ACUUM
"8^ EGR VALVE
EVAP PURGE
SOLENOI D
M A P
SENSOR
CHECK VALVE
W/ ORI FI CE
CRANKCAS E
BREATHER
TO
AI R
CLEANER
E NGI NE
VALVE
COVER
TO BRAKE
BOOSTER
FRONT OF VEHICLE J9325 -13
EMISSION CONTROL SYSTE MS 25 I
ENGINE VACUUM SCHEMATIC-5,9L HOC ENGINE
M = MANIFOLD VACUUM
P = PORTED VACUUM
EVAP
CANISTER
ROLLOVER VALVE
W/ORIFICE
CRANKCASE
BREATHER
DOWNSTREAM
AIR
t t
TO CLIAAATE CONTROL,
4X4 AXLE
(WHEN EQUIPPED)
TO BRAKE
BOOSTER
AIR PUMP
INTAKE MANIFOLD
ORIFICE
CHECK VALVE
W/ORIFICE J9325-34

EWAPORATIWE EMISSION CONTROLS
INDEX
page
Crankcase Breather/FilterGas Powered
E ngi nes . . . 9
E V AP (Evaporation) Control Syst em . 6
E V AP Canister . . 6
page
E vap Canister Purge Sol enoid 6
Fuel Tank Filler Tube Cap . 7
Positive Crankcase Ventilation ( PCV ) System . . . . 7
Pressure Relief/Rollover Valve 6
EVAP (EVAPORATION) CONTROL SYSTEM
GENERAL INFORMATION
The function of t he EVAP control system is to pre-
vent t he emissions of gasoline vapors from t he fuel
t ank into t he atmosphere. When fuel evaporates in
the fuel t ank, t he vapors pass t hrough vent hoses or
tubes to a carbon filled EVAP canister. They are
temporarily held in t he canister unt i l they can be
drawn into t he i nt ake manifold when t he engine is
runni ng.
The vapors are drawn into t he engine at idle as
well as off idle. This system is called a Bi-level Purge
System where t here is a dual source of vacuum to re-
move fuel vapor from t he EVAP canister.
The EVAP canister is a feature on all models for
t he storage of fuel vapors from t he fuel t ank.
The hoses used in this system are specially
manufactured. If repl acement becomes neces-
sary, it is important to use onl y fuel resi stant
hose.
PRESSURE RELIEF/ROLLOVER VALVE
These vehicles are equipped wi t h a combination
pressure relief and rollover valve. This dual function
valve will relieve fuel t ank pressure and also prevent
fuel flow t hrough t he fuel t ank vent hoses in t he
event of an accidental vehicle rollover.
The valve incorporates a pressure relief mechanism
t hat releases fuel t ank pressure when t he pressure
increases above t he calibrated sealing value. Refer to
t he Fuel Tank section of Group 14, Fuel Systems for
removal and installation procedures.
EVAP CANISTER
A sealed, mai nt enance free, EVAP canister is used
on all vehicles. The canister is mounted in t he en-
gine compartment on t he ri ght side wheel well (Fig.
1). The EVAP canister is filled wi t h granul es of an
activated carbon mi xt ure. Fuel vapors ent eri ng t he
EVAP canister are absorbed by t he charcoal gran-
ules.
Fuel t ank pressure vents into t he EVAP canister.
Fuel vapors are temporarily held in t he canister un-
til t hey can be drawn into t he i nt ake manifold. The
EVAP canister purge solenoid allows t he EVAP can-
ister to be purged at predetermined times and at cer-
t ai n engine operating conditions.
Refer to t he Component Removal/Installation sec-
tion of t hi s group for replacement procedures.
EVAPORATIVE
Fig. 1 EVAP Canister Location
EVAP CANISTER PURGE SOLENOID
Vacuum for t he EVAP canister is controlled by t he
EVAP canister purge solenoid (Fig. 2). The solenoid
is operated by t he powertrain control module (PCM).
The PCM regulates t he solenoid by switching t he
ground circuit on and off based on engine operating
conditions. When energized, t he solenoid prevents
vacuum from reaching t he EVAP canister. When not
energized, t he solenoid allows vacuum to flow
t hrough to t he EVAP canister.
During warm-up and for a specified time period af-
t er hot st art s, t he PCM grounds t he EVAP canister
purge solenoid causing it to energize. This will pre-
vent vacuum from reaching t he EVAP canister
valve. When t he engine reaches an operating temper-
at ure of approximately 27C (80F) and a t i me delay
interval of about 100 seconds has occurred, t he PCM
removes t he ground to solenoid. The de-energized so-
lenoid allows vacuum to flow to t he EVAP canister
and purge fuel vapors t hrough t he i nt ake manifold.
The EVAP canister purge solenoid will also be en-
ergized duri ng certain idle conditions in order to up-
dat e t he fuel delivery calibration.
tion of this group for replacement procedures.

Fig. 2 EVAP Canister Purge SolenoidTypical
The fuel tank is sealed with a pressure-vacuum re-
lief fuel tank filler tube cap (Fig. 3) . The relief valves
in the cap are a safety feature. They operate only to
prevent excessive pressure or vacuum in tank caused
by a malfunction in system or damage to vent lines.
PLASTIC
GASKET
RN348
Fig. 3 Fuel Tank Filler Tube CapTypical
The cap has a threaded configuration. This allows
the seal to be broken and pressure to be relieved
without separation of cap from filler tube. Approxi-
mately two and a half turns are required to remove
the cap.
If replacement of filler tube cap is necessary, it
must be replaced with an identical cap to be sure of
correct system operation.
C A U T I O N : Remove the fuel tank filler tube cap to
relieve any fuel tank pressure. The cap must be re-
moved prior to disconnecting any fuel system com-
ponent or before draining the fuel tank,
- EMISSION CONTROL SYSTEMS 25 - 7
Fig. 4 PCV Valve/HoseTypical
A closed engine crankcase breather/filter, with a
hose connecting it to t he air filter housing, provides
t he source of air for system.
The PCV system operates by engine i nt ake mani -
fold vacuum (Fig. 5). Filtered ai r is routed into t he
crankcase t hrough t he air filter hose and crankcase
breather/filter. This forces crankcase vapors t hrough
t he PCV valve. It is t hen drawn into a passage in t he
i nt ake manifold. Here it becomes part of t he cali-
brat ed air/fuel mixture to be consumed in t he com-
bustion chamber. The PCV system constantly
ventilates t he crankcase to help prevent sludge for-
mat i on and vapors from ent eri ng the atmosphere.
POSITIVE CRANKCASE VENTILATION (PCV)
VALVE
The PCV valve contains a spring loaded plunger.
This plunger met ers the amount of crankcase vapors
routed into t he combustion chamber based on i nt ake
manifold vacuum.
When t he engine is not operating or duri ng an en-
gine popback, t he spring forces the plunger back
agai nst t he seat. This will prevent vapors from flow-
ing t hrough t he valve (Fig. 6).
Duri ng periods of high manifold vacuum, such as
idle or cruising speeds, vacuum is sufficient to com-
pletely compress spring. It will t hen pull t he plunger
to t he top of t he valve (Fig. 7). In this position t here
is mi ni mal vapor flow t hrough t he valve.
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM
DESCRIPTION/OPERA TION
All gas engines are equipped with a closed crank-
case ventilation system and PCV valve (Fig. 4).
This system consists of a crankcase PCV valve
mounted on t he cylinder head (valve) cover with a
hose extending from t he valve to t he i nt ake mani-
fold.
25 - 8 EMISSION CONTROL SYSTEMS

Fig. 5 Typical Closed Crankcase Ventilation System
J 9 0 2 5 - 2 0
Fig. 6 Engine Off or Engine PopBackNo Vapor
Flow
J8925-14
Fig. 7 High Intake Manifold VacuumMinimal Vapor
Flow
Duri ng periods of moderate manifold vacuum, t he
plunger is only pulled part way back from inlet. This
results in maxi mum vapor flow t hrough t he valve
(Fig. 8) .
J8925-15
Fig. 8 Moderate Intake Manifold VacuumMaximum
Vapor Flow
TESTING
(1) With engine idling, remove t he PCV valve from
cylinder head (valve) cover. If t he valve is not
plugged, a hissing noise will be heard as air passes
t hrough t he valve. Also, a strong vacuum should be
felt at t he valve inlet (Fig. 9).
Fig. 9 Check Vacuum at PCV ValveTypical
(2) Install t he PCV valve. Remove t he crankcase
breather/filter. Hold a piece of stiff paper, such as a
part s tag, loosely over t he opening of crankcase
breather/filter at t he cylinder head (valve) cover (Fig.
10).
(3) The paper should be drawn agai nst t he opening
in t he cylinder head (valve) cover with noticeable
force. This will be after allowing approximately one
mi nut e for crankcase pressure to reduce.
CRANKCASE BREATHER REMOVED J9325-17
Fig. 10 Check Vacuum at Crankcase Breather
OpeningTypical

(4) Tur n engine off and remove PCV valve from
cylinder head (valve) cover. The valve should rat t l e
when shaken (Fig. 11).
Fig. 11 Shake PCV Valve-Typical
Replace t he PCV valve and retest t he system if it
does not operate as described in the preceding t est s.
Do not a t t e mpt to cl ean t he ol d PCV val ve.
(5) If t he paper is not held against t he opening in
cylinder head (valve) cover after new valve is in-
stalled, t he PCV valve hose may be restricted and
must be replaced. The passage in t he i nt ake manifold
must also be checked and cleaned.
To clean t he i nt ake manifold fitting, t ur n a 1/4
inch drill (by hand) through t he fitting to dislodge
any solid particles. Blow out t he fitting with shop
air. If necessary, use a smaller drill to avoid remov-
ing any met al from t he fitting.
CRANKCASE BRE ATH E R/ F I LTE R- GAS POWERED
ENGINES
The crankcase breather/filter (Fig. 12) is located on
t he cylinder head (valve) cover. It must be kept clean
and lubricated. At the recommended interval, remove
t he filter and wash it thoroughly in kerosene or sim-
ilar solvent. Lubricate or wet t he filter by inverting
it and filling wi t h SAE 30 engine oil. Fi l t er must
t hen be thoroughly drained. More frequent service
may be necessary for vehicles operated extensively
on short run, stop and go or extended engine idle ser-
vice.
The filter must be replaced at correct intervals. Re-
fer to Lubrication and Maintenance, Group 0 in this
service manual .
8925-28
Fig. 12 Crankcase Breather/FilterGas Powered
Engines
2 5 - 10 EMI SSI ON CONTROL SYSTEMS
E X H A U S T E M I S S I O N C O N T R O L S
INDEX
page
Air Inlet5.9L Diesel Engine 13
Ex haust Gas Recirculation ( E GR) Syst ems 10
HEATED INLET AIR SYSTEM
The air filter housing mounted-heated inlet air sys-
t em is no longer used on any Dodge Truck gas pow-
ered engine.
EXHAUST GAS RECIRCULATION (EGR) SYSTE MS
GENERAL INFORMATION
The EGR system reduces oxides of nitrogen (NOx)
in t he engine exhaust and helps prevent spark
knock. This is accomplished by allowing a predeter-
mined amount of hot exhaust gas to recirculate and
dilute t he incoming fuel/air mixture. This dilution
reduces peak flame t emperat ure during combustion.
The system consists of an i nt ake manifold mounted
EGR valve (Fig. 1) and connecting hoses. The vac-
uum to t he EGR is controlled by t he electric EGR
transducer (EET) (Figs. 1 and 2). The EET is a dual
electric/vacuum function switch. It is controlled by
engine vacuum and t he powertrain control module
(PCM).
Fig. 1 EGR SystemGas Powered Engines
EGR OPERATION
The electric exhaust gas recirculation transducer
(EET) is a back pressure transducer and an electric
vacuum solenoid combined into a single uni t (Figs. 1
and 2). The vacuum solenoid portion of t he EET re-
ceives its electrical signal from t he powertrain con-
trol module (PCM). Using t hi s signal, t he solenoid
regul at es t he vacuum flowing through to t he t rans-
ducer portion of t he EET. The back pressure t rans-
page
Heated Inlet Air Syst em . 10
Ox ygen ( 0
2
) Sensor 13
ELECTRICAL VACUUM
CONNECTION SUPPLY
9125-34
Fig. 2 Electric EGR Transducer (EET)Gas
Powered Engines
ducer measures t he amount of exhaust gas back
pressure on t he exhaust side of t he EGR valve. It
t hen varies t he st rengt h of t he vacuum signal ap-
plied to t he EGR valve. The transducer uses this
back pressure signal to provide the correct amount of
exhaust gas recirculation under all conditions.
The vacuum supply for t he EGR valve is controlled
by t he EET. The electrical solenoid portion of t he
EET is controlled by t he powertrain control module
(PCM). The PCM monitors engine coolant tempera-
t ur e and other operating conditions to determine
when EGR operation is desired. Refer to Open Loop/
Closed Loop Modes of Operation in Group 14, Fuel
Systems for a description of EGR solenoid operation
based on engine operating conditions.
If the electrical connector to the EET is dis-
connect ed or the electrical signal is lost, the
EGR val ve will operate at all times. This results
in poor engine performance and reduced driveability
duri ng certain operating conditions.
Vacuum flows between t he solenoid portion of t he
EET and t he transducer portion of t he EET. This
happens only when t he solenoid is not electrically en-
ergized. The transducer is connected to t he EGR
valve by a vacuum hose and a back pressure hose.
The t ransducer is controlled by exhaust back pres-
sure and is ported to t he exhaust manifold t hrough a
hose connecting it to t he bottom of t he EGR valve.
Vacuum will be supplied to t he EGR valve and
EGR operation will begin when:

The electrical solenoid portion of t he EET is not
energized.
The engine back pressure ent eri ng t he EGR valve
inlet is strong enough to close t he t ransducer bleed
valve.
If back pressure is not strong enough to close t he
transducer bleed valve, t he t ransducer will bleed off
t he vacuum preventing EGR operation.
When t he electrical solenoid portion of t he EET is
de-energized by t he powertrain control module
(PCM), vacuum flows to t he t ransducer. The t rans-
ducer is connected to t he engine exhaust system by a
small hose t hat connects to t he base of t he EGR
valve.
The vacuum section of t he t ransducer is controlled
by exhaust system back pressure. When back pres-
sure is high enough it will close a bleed valve in t he
t ransducer allowing vacuum to act uat e t he EGR
valve. If back pressure does not close t he bleed valve,
vacuum will be bled off.
For more information, refer to Group 14, Fuel Sys-
t ems.
tion of t hi s group for EGR valve replacement proce-
dures.
EGR SYSTEM ON-BOARD DIAGNOSTICS
(CALIFORNIA VEHICLES ONLY)
The powertrain control module (PCM) performs an
On-Board Diagnostic (OBD) check of t he EGR system
on all California vehicles. The diagnostic system uses
t he electric EGR transducer (EET) for t he system
tests.
The OBD check activates only during selected en-
gine/driving conditions. When t he conditions are met,
t he PCM energizes t he EET solenoid to disable t he
EGR. The PCM checks for a change in t he oxygen
sensor signal. If t he air-fuel mi xt ure goes lean, t he
PCM will at t empt to enrichen t he mi xt ure. The PCM
registers a diagnostic trouble code (DTC) if t he EGR
system has failed or degraded. After registering a
DTC, t he PCM t ur ns t he mal f unct i on i ndi cat or
l a mp (MIL) on. (The malfunction indicator lamp was
formerly referred to as t he check engine lamp). The
malfunction indicator lamp indicates t he need for im-
medi at e service.
If a malfunction is indicated by t he malfunction in-
dicator lamp and a DTC for t he EGR system was set,
check for proper operation of EGR system. Use t he
following: System Test, EGR Gas Flow Test and EGR
Diagnosis Chart.
If t he EGR system tests properly, check t he system
using t he DRB II scan tool. For use of t he DRB II,
refer to t he appropriate Powertrain Diagnostics Pro-
cedure service manual .
EGR SYSTEM SERVICE
A malfunctioning EGR system can cause engine
spark knock, sags or hesitation, rough idle, engine
stalling and poor driveability. To be sure of proper
operation of t he EGR system, inspect all passages for
blockage. Check moving part s for binding. Inspect
t he complete system for leaks. Replace system com-
ponents or hoses t hat are leaking.
Inspect all hose connections between throttle body,
i nt ake manifold, EGR valve and EGR purge solenoid.
Replace any vacuum harness components t hat are
leaking or damaged.
Refer to EGR Control System Test and EGR Gas
Flow Test to check EGR System operation.
EGR GAS FLOW TEST
(1) Disconnect hose from EGR valve and connect a
hand vacuum pump to EGR valve nipple. Apply a
mi ni mum of 12 inches vacuum t he valve.
(2) The engine should now idle roughly or stall. If
this occurs, the valve is performing correctly. Proceed
to Electric EGR Transducer Test.
(3) If t he engine idle speed did not change, remove
t he EGR valve and inspect t he valve and t he exhaust
passage in t he manifold for blockage. Repair as nec-
essary. If blockage is not present, replace t he EGR
valve.
ELECTRIC EGR TRANSDUCER (EET)
TESTING ELECTRIC SOLENOID PORTION OF TRANSDUCER
(1) Bring t he engine to normal operating tempera-
t ure. Operate at idle speed. Test t he EET as follows:
(2) Check vacuum at EET vacuum source. Discon-
nect the hose and at t ach a vacuum gauge to it.
(3) Vacuum should be a mi ni mum of 15 inches:
If vacuum is low, check t he line for kinks, twists
or a loose connection at vacuum connector or i nt ake
manifold.
If vacuum is correct, remove gauge. Connect t he
vacuum line and proceed to next step.
(4) Check EET operation using t he appropriate
Powertrain Diagnostic Procedures service manual .
Refer to t hi s manual for use of t he DRB II scan tool
and repair EET as necessary.
TESTING VACUUM PORTION OF TRANSDUCER
(1) Disconnect t he EET vacuum lines, back pres-
sure line and electrical connector. Remove t rans-
ducer.
(2) Plug t he EET EGR valve port.
(3) Apply 1-2 pounds ai r pressure to exhaust back
pressure port. Air pressure can be supplied with a
hand operated air pump or compressed air (regulated
to correct psi).
(4) Apply a mi ni mum of 12 inches of vacuum to
vacuum supply port.
Replace t he EET if it will not hold vacuum.
EGR DIAGNOSIS CHART
NOTE: ALL TESTS MU S T BE M A D E WI T H FULLY WA R M E N G I N E R U N N I N G
C ON T I N U OU S L Y FOR AT LEAST T WO MI N U T E S
WA R N I N G : BE S URE TO APPLY PA R K I N G BRAKE A N D / O R BL O C K WHE E LS BEFORE PE R F O R MI N G
IDLE CHECK O R ADJUSTMENT, O R A N Y E N G I N E R U N N I N G TESTS O R ADJUSTMENTS.
EGR VALVE STEM
DOE S NOT M O V E O N
SYSTEM TEST.
(a) Cracked, leaking, disconnected or
plugged hoses.
EGR VALVE STEM
DOE S N OT M O V E O N
SYSTEM TEST.
OPERATES N O R M A L L Y
O N EXTERNAL
V A C U U M S O U R C E .
E N G I N E WI LL N OT
I DLE. DI ES OUT O N
RETURN TO IDLE O R
IDLE I S V E RY R O U G H
O R S L O W.
(a) Defective control systemPlugged passages.
(b) Defective control systemsolenoid or solenoid
control circuit,
(a) High EGR valve leakage in closed
position.
(b) EGR tube to intake manifold leak.
(c) Solenoid or control signal to solenoid failure.
(a)
(b)
(a)
(b)
(a)
Verify correct hose connections and leak
check and confirm that alt hoses are open.
If defective hoses are found, replace hose
harness.
Disconnect hose harness from EGR vacuum
transducer and connect auxiliary vacuum
supply. Raise engine rpm to 2000 rpm and
hold. Apply 10" Hg vacuum while checking
valve movement. If no valve movement oc-
curs, replace valve/transducer assy. If valve
opens (approx. 3mm or 1/8" travel), hold
supply vacuum to check for diaphragm
leakage. Valve should remain open 30
seconds or longer. If leakage occurs, replace
valve/transducer assy. If valve is satisfac-
tory, check control system.
Remove throttle body and inspect port (slot
type) in throttle bore and associated
passage in throttle body. Use suitable sol-
vent to remove deposits and check for flow
with light air pressure. Normal operation
should be restored to EGR system.
Refer to Group 14. General Diagnosis "On
Board Diagnostics" to check solenoid.
If removal of vacuum hose from EGR valve
does not correct rough idle,
(a 1) Turn engine off. Remove the air cleaner ex-
posing the inlet to the throttle body.
(a2) Disconnect the backpressure hose from the
EGR valve.
(a3) Using a nozzle with a rubber grommet con-
nection, direct compressed air (50 to 60 psi)
down through the steel backpressure tube on
the EGR valve while opening and closing the
throttle blade.
(a4) If the sound from the compressed air changes
distinctly in step a3, the poppet is leaking
and air is entering the intake manifold.
Replace the EGR valve.
Remove tube and visually inspect tube seal
on gasket. Tube end should be uniformally
indented on gasket with no signs of leak. If
signs of exhaust gas leakage are present,
replace gaskets and tighten flange nuts to
23 N-m (200 in. lbs.). If an intake plenum
leak persists, replace EGR tube and gaskets,
following installation instructions.
Verify correct hose connections and leak
check and confirm that all hoses are open.
If defective hoses are found, replace nose
harness.
(cl) Refer to Group 14, General Diagnosis "On
Board Diagnostics" to check solenoid.
(b)
(c)
NOTE: D O N OT ATTEMPT TO CLEAN BACK- PRESSURE EGR V ALV E , REPLACE
ENTI RE VALVE/ TRANSDUCER A S S E MBL Y IF NE C E S S AR Y.
9 2 2 5 - 2 6
EMISSION CONTROL SYSTEMS 25 - 13
For electrical t est s of t he EET and its circuitry, re-
fer to t he appropriate Powert rai n Diagnostic Proce-
dures service manual for use of t he DRB II scan tool.
tion of t hi s group for EET replacement procedures.
OXYGEN (0
2
) SENSOR
For description, operation, diagnosis and removal/
installation procedures of t he 0
2
sensor, refer to
Group 14, Fuel Systems.
AIR INLET5.9L DIESEL ENGINE
The diesel engine ai r inlet system consists of the:
Air filter housing
Filter element
Air filter housing-to-turbocharger inlet t ube
Air crossover t ube
Air i nt ake heat ers
Ambient air ent ers t he air filter housing t hrough
an opening at t he bottom of t he housing (Fig. 3). Air
in t he housing is filtered by t he air filter element
(Fig. 4) before it is drawn into t he turbocharger.
The turbocharger increases t he amount of ai r flow
to t he engine. The turbocharger allows t he engine to
use a hi gher air-to-fuel ratio. This results in im-
proved emissions.
Air flows from t he turbocharger into t he inter-
cooler (Fig. 5). Air leaves t he intercooler, passes
t hrough t he air i nt ake heat ers and enters t he i nt ake
manifold.
TURBOCHARGER TURBOCHARGER
TO INTERCOOLER
INTERCOOLER J9114-238
Fig. 5 IntercoolerDiesel
AIR INTAKE HEATER-DIESEL ENGINE
The air i nt ake heat er warms t he i nt ake air before
it ent ers t he manifold. If i nt ake manifold air temper-
at ure is below 16C (60F) t he powertrain control
module (PCM) will energize t he heat ers t hrough t he
air i nt ake heat er relays for start-up and initial
warm-up. Refer to Group 14, Fuel Systems for addi-
tional information.
The heat er is located on top of t he i nt ake manifold,
below the ai r crossover tube (Fig. 6).
l ays more than once per 15 mi nutes. If the rel ays
are cycl ed and the key i s then turned off, wait 15
mi nutes before turning the key to the ON posi t i on.
The 15 minute period i s to prevent damagi ng the
engi ne.
AIR INTAKE HEATER RELAYS-DIESEL
ENGINE
The powertrain control module (PCM) operates t he
air i nt ake heat ers t hrough t he air i nt ake heat er re-
lays (Fig. 7). The relays are energized before crank-
ing if t he charge air t emperat ure sensor i nput to t he
PCM indicates air t emperat ure is 16C (60F) or be-
HEATER
RELAYS
J9114-240
Fig. 6 Air intake HeatersDiesel Engine
low. When t he ignition key is t urned to t he ON po-
sition, t he solenoids will make a clicking noise. This
indicates they are energized. Refer to Group 14, Fuel
System for ai r i nt ake heat er relay operation.
WHEEL
WELL J9114-67
Fig. 7 Air Intake Heater RelaysDiesel Engine

A I R I N J E C T I O N S Y S T E M 5 . 9 L H D C - G A S E N G I N E
INDEX
page
Air Injection Pump 15
Check ValveAir Injection Tube 16
General Information
page
. . 15
GENERAL INFORMATION
The air injection system (Fig. 1) is used on the 5.9L
(V-8) heavy dut y cycle (HDC) gas powered engines
only. The air injection system consists of:
A belt-driven ai r injection pump
An air relief valve
Rubber hoses and check valves
The check valves (Fig. 1) protect t he hoses and in-
jection tubes from hot exhaust gases.
The air injection system adds a controlled amount
of air to t he exhaust gases aiding oxidation of hydro-
carbons and carbon monoxide in t he exhaust stream.
The system does not interfere with t he ability of t he
EGR system to control nitrous oxide (NOx) emis-
sions.
Outside air is drawn into t he front of t he air injec-
tion pump (Fig. 2) where it is compressed and ex-
pelled into t he relief valve (also refer to Air Injection
Pump in this group for additional information). Pres-
sure relief holes in t he air relief valve (Fig. 2) will
prevent excess downstream pressure.
Air is injected at both of t he catalytic convertors
(referred to as downstream). All injected ai r is routed
by t he air relief valve (Figs. 1 or 2).
Downstream air flow assists t he oxidation process
in t he catalyst, but does not interfere wi t h EGR op-
eration.
AIR INJECTION PUMP
The air pump is mounted on t he front of t he engine
and driven by a belt connected to t he crankshaft pul-
ley (Fig. 1 or 2). Int ake air passes t hrough a fan at
t he front of t he pump. Foreign mat eri al s are sepa-
rat ed from t he air by centrifugal force. Air is t hen
delivered to t he air relief valve.
The air injection system is not compl etel y
noi sel ess. Under normal conditions, noise rises in
pitch as engine speed increases. To det ermi ne if ex-
HOSE
TEE
CATALYTIC
CONVERTORS (2)
AI R
PUMP
RELIEF
VALVE
GASKET
J9325-35
Fig. 1 Air injection System Components5.9L Heavy Duty Cycle Engine
25 - 16 EMI SSI ON CONTROL SYSTEMS

DOWNSTREAM d c i i c c
H O S E RELI EF
HO L E S J9325-37
Fig. 2 Air Injection Pump Operation
cessive noise is fault of air injection system, discon-
nect drive belt and operate engine.
C A U T I O N : Do not lubricate air injection pump. Wipe
all oil off of pump housing. Oil in the pump will
cause rapid deterioration and failure.
C A U T I O N : Completely cover the air pump before
cleaning the engine or underhood compartment.
Refer to the Component Removal/Installation section
of this group for air pump replacement procedures.
CHECK VALVEAIR INJECTION TUBE
A check valve (Fig. 1) is located on each of t he air
injection downstream tubes.
The check valve has a one-way diaphragm which pre-
vents hot exhaust gases from backing up into the hose
and pump. The check valve will protect the system if
the air injection pump belt fails, an air hose ruptures or
exhaust system pressure becomes abnormally high.
TESTING CHECK VALVE
The check valves are not repairable. To determine
condition of valve, remove t he rubber air t ube from
t he inlet side of each check valve. St art t he engine. If
exhaust gas is escaping t hrough t he inlet side of
valve, it must be replaced.
Refer to the Component Removal/Installation section
of this group for check valve replacement procedures.
AIR PUMP DIAGNOSIS
EXCESSIVE BELT N O I S E (a) Loose belt or defective auto, belt tensioner. (a) Refer to Group 7, Cooling.
(b) Seized pump. (b) Replace pump.
EXCESSIVE PUMP NOI SE.
CHIRPING
(a) Insufficient break-in. (a) Recheck for noise after 160 0 km.
(1,0 0 0 miles) of operation.
EXCESSIVE PUMP NOISE CHIRPING,
RUMBUNG, OR KNOCKI NG
(a) Leak in hose. (a) Locate source of leak using soap
solution and correct.
(b) Loose hose.
(b) Reassemble and replace or tighten
hose clamp.
(c) Hose touching other engine parts. (c) Adjust hose position.
(d) Relief valve inoperative. (d) Replace relief valve.
(e) Check valve inoperative. (e) Replace check valve.
(f) Pump mounting fasteners loose. (f) Tighten mounting screws as specified.
(g) Pump failure. (g) Replace pump.
N O AIR SUPPLY (ACCELERATE ENGINE TO
15 0 0 RPM AND OBSERVE AIR FLOW FROM
HO S E S . IF THE FLOW INCREASES A S THE
RPM'S INCREASE, THE PUMP IS FUNCTION-
I NG NORMALLY. IF NOT, CHECK POSSIBLE
CAUSE.
(a) Loose drive belt.
(b) Leaks in supply hose.
(c) Leak at fitting(s).
(a) Refer to Group 7, Cooling.
(b) Locate leak and repair or replace as
required.
(c) Tighten or replace clamps.
(d) Check valve inoperative. (d) Replace check valve.
J9325-38

COM PON E N T R E M O V A L / I N S T A L L A T I O N
I NDE I
page
Air Filter/Filter H ousi ngDi esel E ngi nes 17
Air Filter/Filter H ousi ngGas E ngi nes 17
Air Injection Pump 17
Air Injection Pump Relief Val ve 18
Check Val veAir Injection Tube 18
Coolant Temperature Sensor . 18
E GR TubeGas Powered E ngi nes 19
E GR V al ve 19
AIR FILTER/FILTER HOUS I NG- GAS ENGINES
REMOVAL/INSTALLATION
Remove crankcase breather/filter hose at side of air
filter housing. Remove wingnut (Fig. 1) and remove
housing from engine. Check condition of gasket at
t hrot t l e body and replace as necessary.
To replace air filter element only: Remove wi ngnut
and ai r filter housing cover (Fig. 1). Clean inside of
housing before replacing filter. Housing removal is
not necessary for filter replacement.
^ WI NG NUT
COVER :
GASKET |
I MOUNTING
STUD
Fig. 1 Air Filter HousingGas Powered
EnginesTypical
page
Electric E GR Transducer ( E E T) 20
E V AP Canister 20
E V AP Canister Purge Solenoid 20
Fuel Tank Filler Tube Cap . 21
Ox ygen ( 0
2
) Sensor 21
Pressure Relief/Rollover Valve 21
If housing-to-throttle body mount i ng stud is being
installed, tighten to 10 Nm (90 in. lbs.) torque. In-
stall housing to engine and t i ght en wi ngnut to 1.5
AIR FILTER/FILTER HOUSI NG- DI ESEL ENGINES
REMO VAL/INSTALLA TION
Remove t he hose clamp at ai r filter housing (Fig.
2). Remove mounting nut s and remove air filter
housing from vehicle.
To replace air filter element only: Remove hose clamp
and hose at air filter housing inlet tube. Remove three
wingnuts and air filter housing cover (Figs. 2 and 3).
Clean inside of housing before replacing filter. Housing
removal is not necessary for filter replacement.
When installing a new air filter element, push el-
ement into cover. Be sure it is pushed into tabs in
back of filter housing. Install wing nut s.
If housing had been removed, install mount i ng
nut s and tighten to 10 Nm (95 in. lbs.) torque.
AIR INJECTION PUMP
REMOVAL
(1) Remove t he relief valve hose clamp (Fig. 4) and
remove hose at relief valve.
(2) Remove relief valve from air pump (two bolts)
(Fig. 4).
(3) Loosen (but do not remove at this time) t he
t hree air pump pulley mount i ng bolts (number
2figure 4).
(4) Relax t he automatic belt tensioner and remove
t he engine accessory drive belt. Refer to Group 7,
Cooling System. See Belt Removal/Installation.
(5) Remove t he t hree air pump pulley bolts and re-
move pulley from pump.
(6) Remove t he two air pump mounting bolts
(number 1figure 4) and remove pump from mount-
ing bracket.
Fig. 2 Air Filter HousingDiesel
INSTALLATION
(1) Install air injection pump and two bolts to
mount i ng bracket. Tighten bolts to 40 N*m (30 ft.
lbs.) torque.
(2) Install pulley and t hree mounting bolts.
Tighten bolts to 11 N*m (105 in. lbs.) torque.
(3) Install drive belt. Refer to Group 7, Cooling
System. See Belt Removal/Installation.
(4) Clean t he gasket mount i ng area on t he air
pump and valve.
(5) Install a new gasket (Fig. 4) (relief valve-to-
pump) and install relief valve to pump. Tighten bolts
(6) Install relief valve hose and hose clamp to re-
lief valve.

RELIEF
VALVE J9325-39
Fig. 4 Air Injection Pump and Components
AIR INJECTION PUMP RELIEF VALVE
REMOVAL
(1) Remove t he relief valve hose clamp (Fig. 4) and
remove hose at relief valve.
(2) Remove relief valve from air pump (two bolts)
(Fig. 4). Discard old gasket.
INSTALLATION
(1) Clean t he gasket mounting area on t he pump
and valve.
(2) Install a new gasket (Fig. 4) (relief valve-to-
pump) and install relief valve to pump. Tighten bolts
(3) Install relief valve hose and hose clamp to re-
lief valve.
CHECK VALVEAIR INJECTION TUBE
REMOVAL
(1) Remove t he hose clamp at inlet side of valve.
(2) Remove hose from valve.
(3) Remove valve from catalyst tube (unscrew). To
prevent damage to catalyst tube, a backup
wrench must be used on tube.
INSTALLATION
(1) Install valve to catalyst tube. Tighten to 33
(2) Install hose and hose clamp to valve.
COOLANT TEMPERATURE SENSOR
installation procedures, refer to Group 14, Fuel Sys-
tems.

EGR VALVE
REMOVAL
The EGR valve and t he electric EGR transducer
(EET) are serviced as one unit.
(1) Disconnect vacuum hose t o EGR valve/trans-
ducer assembly. Note position of hoses on EGR valve
and transducer for easier installation.
(2) Remove EGR mount i ng bolts (Fig. 5).
Fig. 5 EGR Valve Mounting Bolts
(3) Remove EGR valve and gasket. Discard old
gasket. Clean i nt ake manifold mat i ng surface and
check for cracks.
INSTALLATION
(1) Place new EGR gasket on i nt ake manifold.
(2) Install EGR valve. Tighten mount i ng bolts to
(3) Connect vacuum hose to valve/transducer as-
sembly.
EGR TUBE - GAS POWERED ENGINES
REMOVAL
(1) Remove air filter housing.
(2) Remove t he spark plug cable loom and plug ca-
bles from valve cover mounting st ud at rear of ri ght
valve cover. Position spark plug cables to top of valve
cover.
(3) Disconnect two vacuum hoses at exhaust gas
recirculation (EGR) valve.
(4) Remove 2 EGR valve mount i ng bolts (Fig. 5)
and remove EGR valve. Discard old gasket.
(5) Disconnect electrical connector at engine oil
pressure sending unit.
(6) To prevent damage to oil pressure sending uni t ,
a special tool, such as number C-4597 must be used
(Fig. 6). Remove sending uni t from engine.
(7) Loosen EGR t ube mounting nut at i nt ake man-
ifold (Fig. 7).
Fig. 6 Oil Pressure Sending UnitRemoval/Installation
Fig. 7 EGR TubeTypical
(8) Remove EGR t ube mount i ng bolts at exhaust
manifold (Fig. 7) and remove EGR tube.
INSTALLATION
(1) Clean the EGR t ube and exhaust manifold (at
EGR t ube mount i ng point) of any old gasket mat e-
rial.
(2) Install a new gasket to exhaust manifold end of
EGR tube.
(3) Install EGR t ube to both manifolds. Tighten
mount i ng nut at i nt ake manifold. Tighten two
mounting bolts at exhaust manifold to 23 Nm (204
in. lbs.) torque.
(4) Coat t he t hreads of t he oil pressure sending
unit wi t h t hread sealant. Do not allow any of t he
thread sealant to get into t he sending uni t opening
or t he opening at t he engine. Install sending uni t to

engine and t i ght en to 14 N*m (130 in. lbs.) torque.
Install electrical connector to sending unit.
(5) Clean t he i nt ake manifold and EGR valve of
any old gasket mat eri al .
(6) Install a new EGR valve gasket to i nt ake man-
ifold.
(7) Install EGR valve to i nt ake manifold. Tighten
two mounting bolts to 23 N*m (200 in. lbs.) torque.
(8) Install vacuum lines to EGR valve.
(9) Install spark plug cable loom and plug cables to
valve cover mount i ng stud.
(10) Install air filter housing.
ELECTRIC EGR TRANSDUCER (EET)
The EGR valve and t he EET are serviced as one
unit. Also refer to EGR valve removal/installation.
REMOVAL
(2) Disconnect wiring connector at EET (Fig. 8).
(3) Disconnect hoses at EET. Note position of hoses
for easier installation.
(4) Remove EET from engine.
INSTALLATION
(1) Position EET to engine and connect hoses.
(2) Connect wiring connector.
ELECTRICAL
CONNECTOR
TRANSDUCER
J9325-15
Fig. 8 Electric EGR Transducer (EET)Typical
EVAP CANISTER
The EVAP canister is mounted in t he engine com-
part ment on t he ri ght side wheel well (Fig. 9).
REMOVAL
(1) Remove fuel tubes/lines at EVAP canister.
Note location of tubes/lines before removal for easier
installation.
(2) Remove mount i ng bolt at canister mount i ng
st rap (Fig. 9).
(3) Remove canister and two-piece st rap from
mount i ng bracket.
CANI STER
M O U N T I N G
STRAPS
CANI STER
M O U N T I N G
BRACKET
RIGHT FRONT
I NNER FENDER
MO U N T I N G
BOLT
EVAP
CANI STER J9325-36
Fig. 9 EVAP Canister Removal/Installation
INSTALLATION
(1) Position canister to mount i ng bracket.
(2) Install canister and both mount i ng straps to
mount i ng bracket.
(3) Install canister bolt and tighten to 10 N*m (95
in. lbs.) torque.
(4) Install fuel tubes/lines to canister.
EVAP CANISTER PURGE SOLENOID
REMOVAL
(2) Disconnect wiring connector at solenoid (Fig.
10).
BRACKET MO U N T I N G
NUT
ELECTRICAL
CONNECTOR
CANISTER PURGE
SOLENOI D/BRACKET
VACUUM
CONNECTOR
J9214-50
Fig. 10 EVAP Canister Purge Solenoid Typical
(3) Disconnect vacuum harness at solenoid (Fig.
10).

(4) Remove solenoid and its support bracket from
i nt ake manifold (one bolt5.2L/5.9L engine, one
nut3.9L engine).
(5) Remove EVAP canister purge solenoid from en-
gine.
INSTALLATION
(1) Install EVAP canister purge solenoid and its
mounting bracket to i nt ake manifold.
(2) Connect vacuum harness and wiring connector.
If replacement of t he fuel filler t ube cap (Fig. 11) is
necessary, it must be replaced with an identical cap
to be sure of correct system operation.
C A U T I O N : R emove the fuel tank filler tube cap to
relieve fuel tank pressure. The cap must be re-
moved prior to di sconnect i ng any fuel syst em com-
ponent or before draining the fuel tank.
PLASTIC
GASKET
RN348
Fig. 11 Fuel Tank Filler Tube CapTypical
OXYGEN (0
2
) SENSOR
installation procedures of t he 0
2
sensor, refer to
PRESSURE RELIEF/ROLLOWER WALWE
t he Fuel Tank section of Group 14, Fuel Systems.
COMPONENT AND SYSTEM INDEX
Name Group- page
AUDI O SY STE M S 8F - 1
SE RV I CE PROCE D URE S 8F-7
TE ST PROCE D URE S 8F - 2
BATTE RY / STARTE R/ GE NE RATOR SE RV I CE 8 B- 1
BATTE RY SE RV I CE PROCE D URE S 8B-1
GE NE RATOR SE RV I CE 8 B- 6
SPE CI F I CATI ONS 8 B- 9
STARTE R SE RV I CE PROCE D URE S 8 B- 4
BODY COMPON E N TS 23- 1
CAB/ BODY I NTE RI OR COM PON E N TS 23- 35
D OORS 23- 21
E X TE RI OR COM PON E N TS 23- 1
FIX ED GLASS 23- 29
PAINT CODE CH ART 23- 54
RE F I NI SH I NG PROCE D URE S 23- 54
BRAK E S 5-1
BE NDI X D I SC BRAK E 5- 37
BRAK E AD J USTM E N TS- BRAK E BLE E DI NG 5-7
BRAK E D I AGN OSI S 5- 3
CH RY SLE R D I SC BRAK E 5-27
D RUM BRAK E SE LE V E N I NCH 5- 4 6
D RUM BRAK E S- TW E L V E I NCH 5-50
GE NE RAL I NF ORMATI ON 5-1
MASTE R CY LI N D E RCOMBI N ATI ON V AL V E - BRAK E
LI NE S 5-10
PARK I NG BRAK E S 5- 56
POW E R BRAK E BOOSTE R- BRAK E PE DAL 5-20
POW E R BRAK E V ACUUM PUM P- D I E S E L E N GI N E . . 5- 22
RE AR W H E E L ANTI LOCK ( RW AL) BRAK E S 5- 59
SPE CI F I CATI ONS 5- 6 5
CH I ME / BUZ Z E R W ARN I N G SY STE M S 8 U- 1
CLUTCH 6 -1
CLUTCH D I AGN OSI S 6 -2
CLUTCH SE RV I CE 6 - 1 1
COOLI NG SY STE M 7-1
D I AGN OSI S 7-4
E NGI NE ACCE SSORY DRI V E BE LTS 7-4 0
E NGI NE BLOCK H E ATE RS 7- 4 8
SE RV I CE PROCE D URE S 7- 1 5
SPE CI F I CATI ONS 7- 4 9
E LE CTRI CAL 8 A- 1
BATTE RY TE ST PROCE D URE S 8 A- 2
E NGI NE STARTE R MOTOR TE ST PROC E D U RE S . . . . 8 A- 9
GE NE RAL I NF ORMATI ON 8 A- 1
GE NE RATOR TE ST PROCE D URE S ON V E H I CLE . . . 8 A- 1 3
GROUP I NDE X 8 A- 1
SPE CI F I CATI ONS 8 A- 1 8
BATTE RY / STARTI NG/ CH ARGI NG SY STE M S
DI AGNOSTI CS 8 A- 1
E M I SSI ON CONTROL SY STE M S. 25- 1
AI R I NJE CTI ON SY STE M 5 . 9 L H D C- GAS E NGI NE . 25- 1 5
COMPONE NT RE MOV AL/ I NSTALLATI ON 25- 1 7
E V APORATI V E E M I SSI ON CON TROLS 25- 6
E X H AUST E M I SSI ON CON TROLS 25- 1 0
GE NE RAL I NF ORMATI ON 25- 1
E NGI NE S 9-1
3.9L E NGI NE SE RV I CE PROCE D URE S 9- 1 7
5.2L E NGI NE SE RV I CE PROCE D URE S 9- 4 7
5.9L ( DI E SE L) E NGI NE SE RV I CE PROCE D URE S . . . 9- 1 07
Name Group- page
5. 9L E NGI NE SE RV I CE PROCE D URE S 9- 7 7
E NGI NE D I AGN OSI S 9- 5
STAN D ARD SE RV I CE PROCE D URE S 9- 1
E X H AUST SY STE M AND I NTAK E MANI F OLD 1 1 - 1
E X H AUST SY STE M D I AGN OSI S 1 1 - 3
GE N E RAL I NF ORMATI ON 1 1 - 1
SE RV I CE PROCE D URE S ( DI E SE L E NGI NE S) 1 1 - 1 7
SE RV I CE PROCE D URE S ( GASOLI NE E NGI NE S) 1 1 - 4
SPE CI F I CATI ONS 1 1 - 27
F RAM E AND BUM PE RS 1 3- 1
ATTACH E D COMPON E N TS 1 3- 30
BUM PE RS 1 3- 1
F RAM E 1 3- 20
SN OW PLOW 1 3- 3
F RONT SUSPE N SI ON AN D AX LE 2- 1
F RONT SUSPE N SI ON 2 W D V E H I CLE S 2- 7
F RONT SUSPE N SI ON 4 W D V E H I CLE S 2- 1 4
F RONT W H E E L ALI GN ME N T 2- 3
GE NE RAL I NF ORMATI ON 2- 1
M OD E L 4 4 F RONT AX LE 2- 1 7
M OD E L 6 0 F RONT AX LE 2- 4 9
TORQ UE SPE CI F I CATI ONS 2- 7 5
F UEL SY STE M 1 4 - 1
ACCE LE RATOR PE DAL AND TH ROTTLE CABLE . . . 1 4 - 25
D I E SE L F UEL I N J E CTI ON COMPON E N T
D E SCRI PTI ON / SY STE M OPE RATI ON 1 4 - 7 6
D I E SE L F UEL I N J E CTI ON - GE N E RAL D I AGN OSI S. . 1 4 - 8 8
D I E SE L F UEL I N J E CTI ON - SE RV I CE
PROCE D URE S 1 4 - 1 06
F UE L DE LI V E RY SY STE M - E X C E PT D I E SE L 1 4 - 3
F UE L D E L I V E RY - D I E SE L E NGI NE 1 4 - 1 5
F UEL TAN K S 1 4 - 20
GE N E RAL I NF ORMATI ON 1 4 - 1
MULTI - PORT F UEL I NJE CTI ON ( M PI ) - COM PON E N T
D E SCRI PTI ON / SY STE M OPE RATI ON - E X CE PT
D I E SE L 1 4 - 29
MULTI - PORT F UE L I NJE CTI ON ( M Pl j - COM PON E N T
RE M OV AL/ I N STALLATI ON - E X CE PT DI E SE L . . . . 1 4 - 6 4
MULTI - PORT F UEL I NJE CTI ON ( MPI ) GE N E RAL
D I AGN OSI S- E X CE PT DI E SE L 1 4 - 4 3
SE RV I CE AD J USTM E N TS- D I E SE L 1 4 - 1 22
SPE CI F I CATI ONS 1 4 - 1 23
H E ATI NG AN D AI R CONDI TI ONI NG 24 - 1
CLI MATE CONTROL SY STE M 24 - 29
COM PRE SSOR SE RV I CE ( SD- 7 09) 24 - 21
DI AGNOSTI C PROCE D URE S 24 - 3
GE NE RAL I NF ORMATI ON 24 - 1
RE F RI GE RANT SY STE M SE RV I CE PROCE D URE S . . 24 - 1 7
TORQ UE SPE CI F I CATI ONS 24 - 39
H ORN S 8 G- 1
SE RV I CE PROCE D URE S 8 G- 3
TE ST PROCE D URE S 8 G- 1
I GNI TI ON SY STE M S 8 D - 1
COMPON E N T I DE NTI F I CATI ON/ SY STE M OPE RATI ON . 8 D - 1
COMPON E N T RE MOV AL/ I NSTALLATI ON 8 D- 1 8
D I AGN OSTI CS/ SE RV I CE PROCE D URE S 8 D- 7
I GNI TI ON SW I TCH 8 D- 2 5
SPE CI F I CATI ONS 8 D- 2 8
I N STRUME N T PANE L AND GAUGE S 8 E - 1
CLUSTE R AN D GAUGE SE RV I CE PROCE D URE S . . . 8 E - 1 2
CLUSTE R AN D GAUGE TE ST PROCE D URE S 8 E - 5
GE NE RAL I NF ORMATI ON 8 E - 1
M E SSAGE C E N TE R- D I E SE L E NGI NE 8 E - 4
M E SSAGE C E N TE R- GAS E NGI NE 8 E - 3
SW I TCH AND PANE L COMPON E N T SE RV I CE 8 E - 1 6
I NTRODUCTI ON lntro.-1
D E SI GN ATI ON S, LABE LS/ PLATE S/ D E CALS, COD E S
AN D D I M E N SI ON S/ W E I GH TS Intro.-1
M E ASURE M E N T AN D TORQ UE
SPE CI F I CATI ONS lntro.-11
L AM PS 8 L- 1
BULB APPLI CATI ON 8 L- 1 1
E X TE RI OR L AM PS 8 L- 1
E X TE RI OR L AM PS SE RV I CE PROCE D URE S 8 L- 3
I NTE RI OR L AM PS 8 L- 1 0
LUBRI CATI ON AN D MAI NTE NANCE 0-1
CH ASSI S AN D BODY 0- 28
DRI V E TRAI N 0- 22
E NGI NE MAI NTE NANCE 0- 1 4
GE NE RAL I NF ORMATI ON 0-1
POW E R DOOR LOCK S 8 P- 1
SE RV I CE PROCE D URE S 8 P- 2
TE ST PROCE D URE S 8 P- 1
POW E R M I RRORS 8T- 1
SE RV I CE PROCE D URE S 8 T- 2
TE ST PROCE D URE S 8T- 1
POW E R W I N D OW S 8 S- 1
SE RV I CE PROCE D URE S 8 S- 3
TE ST PROCE D URE S 8 S- 1
PROPE LLE R SH AF TS 1 6 - 1
GE NE RAL I NF ORMATI ON 1 6 - 1
PROPE LLE R SH AF T RE PLACE ME N T 1 6 - 8
SE RV I CE D I AGN OSI S/ PROCE D URE S 1 6 - 3
TORQ UE SPE CI F I CATI ONS 1 6 - 1 5
UN I V E RSAL JOI NT RE PLACE ME N T 1 6 - 1 0
RE AR SUSPE N SI ON AN D AX LE 3-1
8 3/ 8 and 9 1/4 AX LE 3- 1 1
GE N E RAL I NF ORMATI ON 3-1
MOD E L 6 0 and 70 AX LE S 3- 29
POW E R- LOK DI F F E RE NTI AL 3- 55
RE AR SUSPE N SI ON 2 W D and 4 W D V E H I CLE S . . . . 3- 3
SE RV I CE D I AGN OSI S 3-6
SPE CI F I CATI ONS 3- 27
SURE - GRI P DI F F E RE NTI AL SE RV I CE 3- 28
TORQ UE SPE CI F I CATI ONS 3- 59
TRAC- LOK DI F F E RE NTI AL 3- 51
RE AR W I N D OW DE F OGGE R 8 N- 1
RE PAI R PROCE D URE S ( GRI D LI N E S, TE RM I N ALS,
AN D PI GTAI LS) 8 N- 3
SE RV I CE PROCE D URE S 8 N- 4
TE ST PROCE D URE S 8 N- 1
STE E RI NG 1 9- 1
GE N E RAL I NF ORMATI ON 1 9- 1
POW E R STE E RI N G PUM P 1 9- 1 1
POW E R STE E RI NG SY STE M D I AGN OSI S 1 9- 2
RE CI RCULATI NG BALL POW E R STE E RI NG GE AR . . 1 9- 20
STE E RI N G COLUMN 1 9- 35
STE E RI N G LI NK AGE 1 9- 1 7
TORQ UE SPE CI F I CATI ONS 1 9- 4 0
TRAN SM I SSI ON AN D TRAN SF E R CASE 21 - 1
AUTOMATI C TRAN SM I SSI ON D I AGN OSI S AN D
TE STI NG 21 - 8 5
AUTOMATI C TRAN SM I SSI ON RE MOV AL AND
I NSTALLATI ON 21 - 1 4 2
AUTOMATI C TRAN SM I SSI ON 3 2 RH / 3 6 RH / 3 7 RH /
4 2 RH / 4 6 RH 21 - 7 3
G36 0 MAN UAL TRAN SM I SSI ON 21 - 4 6
G36 0 TRAN SM I SSI ON OV E RH AUL 21 - 53
GE NE RAL I N F ORM ATI ON - 3 2 RH / 3 6 RH / 3 7 RH 21 - 7 3
GE N E RAL I N F ORMATI ON 4 2 RH / 4 6 RH . . . 21 - 7 8
I N- V E H I CLE SE RV I CE 3 2 RH / 3 6 RH / 3 7 RH /
4 2 RH / 4 6 RH 21 - 1 30
NP2 05 TRAN SF E R CASE 21 - 34 2
NP24 1 TRAN SF E R CASE 21 - 350
NV 4 500 MAN UAL TRAN SM I SSI ON 21 - 1
NV 4 500 TRAN SM I SSI ON OV E RH AUL 21 - 6
OV E RD RI V E UNIT OV E RH AUL4 2 RH / 4 6 RH 21 - 324
TRAN SM I SSI ON OV E RH AUL3 2 RH 21 - 1 52
TRAN SM I SSI ON OV E RH AUL3 6 RH / 3 7 RH 21 - 1 92
TRAN SM I SSI ON OV E RH AUL4 2 RH 21 - 233
TRAN SM I SSI ON OV E RH AUL4 6 RH 21 - 27 8
TRAN SM I SSI ON / TRAN SF E R CASE
SPE CI F I CATI ONS 21 - 36 4
TURN SI GN ALS AN D H AZ ARD W ARN I N G F LASH E R . . . 8J- 1
GE N E RAL I NF ORMATI ON 8J- 1
MULTI F UNCTI ON SW I TCH SE RV I CE PROCE D URE S. . 8 J- 3
MULTI F UNCTI ON SW I TCH TE STI NG PROCE D URE S. . 8 J- 2
V E H I CLE SPE E D CONTROL SY STE M 8 H - 1
SE RV I CE PROCE D URE S 8 H - 1 1
TE ST PROCE D URE S 8 H - 7
W H E E LS AN D TI RE S 22- 1
TI RE S 22- 1
TORQ UE SPE CI F I CATI ONS 22- 1 3
V E H I CLE V I BRATI ON 22- 1 1
W H E E LS 22- 6
W I N D SH I E LD W I PE R AN D W ASH E R SY STE M S 8 K - 1
I NTE RMI TTE NT W I N D SH I E LD W I PE R F UNCTI ON AN D
SW I TCH TE STI NG PROCE D URE S 8 K - 6
TW O SPE E D W I N D SH I E LD W I PE R MOTOR AN D
SW I TCH TE STI NG PROCE D URE S 8 K - 1
W I N D SH I E LD W ASH E RS 8 K - 1 0
W I N D SH I E LD W I PE R SY STE M SE RV I CE
PROCE D URE S 8 K - 7
W I RI N G D I AGRAM S 8 W - 1
COMPON E N T I DE NTI F I CATI ON 8 W - 9
GE NE RAL I NF ORMATI ON 8 W - 1
SPLI CE LOCATI ONS 8 W - 2 9
W I RI N G D I AGRAM S AD - BOD Y 8 W - 37

93 Dodge Truck Service Manual

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

93 Dodge Truck Service Manual

Caricato da

Copyright:

Formati disponibili

1 9 9 3

C - SEAT ANGLE (INTAKE & EXHAUST) 447/ - 44

Potrebbero piacerti anche