2004 Dodge Ram Service Manual

GROUP TAB LOCATOR
Introduction
0
Lubrication & Maintenance
2
Suspension
3
Differential & Driveline
5
Brakes
6
Clutch
7
Cooling
8A
Audio/Video
8B
Chime/Buzzer
8E
Electronic Control Modules
8F
Engine Systems
8G
Heated Systems
8H
Horn
8I
Ignition Control
8J
Instrument Cluster
8L
Lamps
8M
Message Systems
8N
Power Systems
8O
Restraints
8P
Speed Control
8Q
Vehicle Theft Security
8R
Wipers/Washers
8T
Navigation/Telecommunication
8W
Wiring
9
Engine
11
Exhaust System
13
Frame & Bumpers
14
Fuel System
19
Steering
21
Transmission and Transfer Case
22
Tires/Wheels
23
Body
24
Heating & Air Conditioning
25
Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)
INTRODUCTION
TABLE OF CONTENTS
page page
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
VEHICLE EMISSION CONTROL INFORMATION
(VECI)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BODY CODE PLATE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INTERNATIONAL VEHICLE CONTROL &
DISPLAY SYMBOLS
DESCRIPTION - INTERNATIONAL SYMBOLS . . . 5
FASTENER IDENTIFICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FASTENER USAGE
DESCRIPTION - FASTENER USAGE . . . . . . . . . 8
THREADED HOLE REPAIR
DESCRIPTION - THREADED HOLE REPAIR . . . . 8
METRIC SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TORQUE REFERENCES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
VEHICLE CERTIFICATION LABEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
VIN CODING/LOCATIONS
The Vehi cl e I denti fi cati on Number (VI N) pl ate i s
l ocated on the l ower wi ndshi el d fence near the l eft
a-pi l l ar (Fi g. 1). The VI N contai ns 17 characters that
provi de data concerni ng the vehi cl e. Refer to the VI N
decodi ng chart to determi ne the i denti fi cati on of a
vehi cl e.
The VI N i s al so i mpri nted on the:
Body Code Pl ate.
Equi pment I denti fi cati on Pl ate.
Vehi cl e Safety Certi fi cati on Label .
Frame rai l .
To protect the consumer from theft and possi bl e
fraud the manufacturer i s requi red to i ncl ude a
Check Di gi t at the ni nth posi ti on of the VI N. The
check di gi t i s used by the manufacturer and govern-
ment agenci es to veri fy the authenti ci ty of the vehi -
cl e and offi ci al documentati on. The formul a to use
the check di gi t i s not rel eased to the general publ i c.
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = Manufactured By DaimlerChrysler Corporation
3 = Manufactured By DaimlerChrysler De Mexico
2 Make D = Dodge
3 Vehicle Type 2 = Incomplete with Side Airbag
3 = Truck with Side Airbag
6 = Incomplete Less Side Airbag
7 = Truck Less Side Airbag
Fig. 1 VIN LOCATION
1 - DASH PANEL
2 - VIN CODE PLATE
DR INTRODUCTION 1
POSITION INTERPRETATION CODE = DESCRIPTION
4 Gross Vehicle Weight Rating G = 5,001-6000 lbs.
H = 6,001-7,000 lbs.
J = 7,001-8,000 lbs.
K = 8,001-9,000 lbs.
L = 9,001-10,000 lbs.
M = 10,001-14,000 lbs.
W = Buses/Incomplete Vehicles with Hydraulic Brakes
5 Vehicle Line A = Ram Pickup 4X2
U = Ram Pickup 4X4
N = Ram Pickup 4X2 DX Family
6 Series 1 = 1500
2 = 2500
3 = 3500 Less Dual Rear Wheels
4 = 3500 With Dual Rear Wheels
5 = 4000 DX Family
7 Body Style 6 = Conventional Cab/Cab Chassis
8 = Quad Cab Full Rear Doors
8 Engine K = 3.7L 6 cyl. MPI Gasoline
N = 4.7L 8 cyl. MPI Gasoline
D = 5.7L 8 cyl. SMPI Gasoline
6 = 5.9L 6 cyl. Turbo Diesel 24v
C = 5.9L 6 cyl. Turbo Diesel High Output
9 Check Digit 0 through 9 or X
10 Model Year 4 = 2004
11 Plant Location S = Dodge City
G = Saltillo
J = St. Louis (North)
12 thru 17 Vehicle Build Sequence
VEHICLE EMISSION CONTROL
INFORMATION (VECI)
DESCRIPTION
Al l model s have a Vehi cl e Emi ssi on Control I nfor-
mati on (VECI ) Label . Dai ml erChrysl er permanentl y
attaches the l abel i n the engi ne compartment (Fi g.
2). The l abel cannot be removed wi thout defaci ng
l abel i nformati on and destroyi ng l abel .
The l abel contai ns the vehi cl es emi ssi on speci fi ca-
ti ons and vacuum hose routi ngs. Al l hoses must be
connected and routed accordi ng to the l abel .
The l abel al so contai ns an engi ne vacuum sche-
mati c. There are uni que l abel s for vehi cl es bui l t for
sal e i n the state of Cal i forni a and the country of
Canada. Canadi an l abel s are wri tten i n both the
Engl i sh and French l anguages.
The VECI l abel contai ns the fol l owi ng:
Engi ne fami l y and di spl acement
Evaporati ve fami l y
Emi ssi on control system schemati c
Certi fi cati on appl i cati on
Engi ne ti mi ng speci fi cati ons (i f adjustabl e)
I dl e speeds (i f adjustabl e)
Spark pl ug and gap
Fig. 2 VEHICLE EMISSIONS CERTIFICATION
INFORMATION LABEL
1 - VECI LABEL LOCATION
2 - RADIATOR SUPPORT
2 INTRODUCTION DR
VEHICLE IDENTIFICATION NUMBER (Continued)
BODY CODE PLATE
DESCRIPTION
The Body Code Pl ate (Fi g. 4) i s l ocated on the ri ght
front hydroform fender rai l just behi nd the headl i ght
assembl y (Fi g. 3). There are seven l i nes of i nforma-
ti on on the body code pl ate. Li nes 5, 6, and 7 are not
used to defi ne servi ce i nformati on. I nformati on reads
from l eft to ri ght, starti ng wi th l i ne 4 i n the center of
the pl ate to l i ne 1 at the bottom of the pl ate.
The l ast code i mpri nted on a vehi cl e code pl ate wi l l
be fol l owed by the i mpri nted word END. When two
vehi cl e code pl ates are requi red, the l ast avai l abl e
spaces on the fi rst pl ate wi l l be i mpri nted wi th the
l etters CTD (for conti nued).
When a second vehi cl e code pl ate i s necessary, the
fi rst four spaces on each row wi l l not be used because
of the pl ate overl ap.
BODY CODE PLATE LINE 4
DIGITS 1 THROUGH 12
Vehi cl e Order Number
DIGITS 13, 14, AND 15
Transmi ssi on Codes
DG4 = 4speed Automati c (45RFE)
DG8 = 4speed Automati c (48RE)
DDC = 5speed Manual (NV3500)
DDP = 5speed Manual (NV4500)
DEC = 6speed Manual (NV5600)
DEE = 6speed Manual Tremec (T-56)
Car Li ne Shel l
DR1 = 1500 4 X 2
DR6 = 1500 4 X 4
DR2 = 2500 4 X 2
DR7 = 2500 4 X 4
DR3 = 3500 4 X 2
DR8 = 3500 4 X 4
DIGIT 19
Pri ce Cl ass
L = Low
H = Hi ghl i ne
DIGITS 20 AND 21
Body Type
41 = Ram Truck Quad Cab, Short Box
42 = Ram Truck Quad Cab, Long Box
61 = Ram Truck Standard Cab, Short Box
62 = Ram Truck Standard Cab, Long Box
Fig. 3 BODY CODE PLATE LOCATION
1 - FENDER
2 - RADIATOR CROSSMEMBER
3 - HYDROFORM FENDER RAIL
4 - RIVOT (2)
5 - BODY CODE PLATE
Fig. 4 BODY CODE PLATE
1 - PRIMARY PAINT
2 - SECONDARY PAINT
3 - TRANSMISSION CODE
4 - VEHICLE MODEL NUMBER
5 - ENGINE CODE
6 - INTERIOR TRIM CODE
7 - VEHICLE IDENTIFICATION NUMBER
8 - TAILGATE CODE
9 - CARGO BOX CODE
10 - TAILGATE TRIM CODE
11 - BODY-IN-WHITE SEQUENCE
12 - MARKET CODE
13 - SPECIES CODE
14 - PAINT PROCEDURE
15 - VEHICLE ORDER NUMBER
DR INTRODUCTION 3
DIGITS 1, 2, AND 3
Pai nt Procedure
APA = Monotone
AP9 = Speci al
APD = Two-tone (Lower break)
DIGIT 4
Open Space
DIGITS 5 THROUGH 8
Pri mary Pai nt
(Refer to 23 - BODY/PAI NT - SPECI FI CATI ONS)
for col or codes.
DIGIT 9
Open Space
DIGITS 10 THROUGH 13
Secondary Pai nt
DIGIT 14
Open Space
DIGITS 15 THROUGH 18
I nteri or Tri m Code
DIGIT 19
Open Space
Engi ne Code
EKG = 3.7 L 6 cyl . MPI Gasol i ne
EVA = 4.7 L 8 cyl . MPI Gasol i ne
EZA = 5.7 L 8 cyl . SMPI Gasol i ne
ETC = 5.9 L 6 cyl . Cummi ns Turbo Di esel
ETH = 5.9 L 6 cyl . Cummi ns Turbo Di esel Hi gh
Output
DIGIT 1 Open Space
DIGITS 2 AND 3 Species Code. (Used for Manufacturing)
DIGIT 4
Open Space
DIGIT 5
Market Code
B = I nternati onal
C = Canada
M = Mexi co
U = Uni ted States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehi cl e I denti fi cati on Number (VI N)
(Refer to VEHI CLE DATA/VEHI CLE I NFORMA-
TI ON/VEHI CLE I DENTI FI CATI ON NUMBER -
DESCRI PTI ON) for proper breakdown of VI N code.
DIGITS 1 THROUGH 6 Body-in-white assembly sequence.
DIGIT 7
Open Space
DIGIT 8 Tailgate trim code.
DIGIT 9
Open Space
DIGITS 10 THROUGH 12 Cargo box code
DIGIT 13
Open Space
DIGITS 14 THROUGH 16 Tailgate code
4 INTRODUCTION DR
BODY CODE PLATE (Continued)
INTERNATIONAL VEHICLE
CONTROL & DISPLAY
SYMBOLS
DESCRIPTION - INTERNATIONAL SYMBOLS
The graphi c symbol s i l l ustrated i n the fol l owi ng
I nternati onal Control and Di spl ay Symbol s Chart are
used to i denti fy vari ous i nstrument control s. The
symbol s correspond to the control s and di spl ays that
are l ocated on the i nstrument panel .
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bol t strength grades range from grade 2
to grade 8. The hi gher the grade number, the greater
the bol t strength. I denti fi cati on i s determi ned by the
l i ne marks on the top of each bol t head. The actual
bol t strength grade corresponds to the number of l i ne
marks pl us 2. The most commonl y used metri c bol t
strength cl asses are 9.8 and 10.9. The metri c
strength cl ass i denti fi cati on number i s i mpri nted on
the head of the bol t. The hi gher the cl ass number,
the greater the bol t strength. Some metri c nuts are
i mpri nted wi th a si ngl e-di gi t strength cl ass on the
nut face. Refer to the Fastener I denti fi cati on and
Fastener Strength Charts (Fi g. 5) and (Fi g. 6).
INTERNATIONAL SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
DR INTRODUCTION 5
Fig. 5 FASTENER IDENTIFICATION
6 INTRODUCTION DR
FASTENER IDENTIFICATION (Continued)
Fig. 6 FASTENER STRENGTH
DR INTRODUCTION 7
FASTENER IDENTIFICATION (Continued)
FASTENER USAGE
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fasteners and torque speci fi cati ons references i n
thi s Servi ce Manual are i denti fi ed i n metri c and SAE
format.
Duri ng any mai ntenance or repai r procedures, i t i s
i mportant to sal vage al l fasteners (nuts, bol ts, etc.)
for reassembl y. I f the fastener i s not sal vageabl e, a
fastener of equi val ent speci fi cati on must be used.
THREADED HOLE REPAIR
DESCRIPTION - THREADED HOLE REPAIR
Most stri pped threaded hol es can be repai red usi ng
a Hel i coi l . Fol l ow the vehi cl e or Hel i coi l recommen-
dati ons for appl i cati on and repai r procedures.
METRIC SYSTEM
DESCRIPTION
The metri c system i s based on quanti ti es of one,
ten, one hundred, one thousand and one mi l l i on.
The fol l owi ng chart wi l l assi st i n converti ng metri c
uni ts to equi val ent Engl i sh and SAE uni ts, or vi se
versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY BY TO GET MULTIPLY BY TO GET
in-lbs x 0.11298 = Newton Meters (Nm) Nm x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters (Nm) Nm x 0.7376 = ft-lbs
Inches Hg (60
F)
x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/Hr.
(Km/h)
x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.
(Km/h)
COMMON METRIC EQUIVALENTS
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
Refer to the Metri c Conversi on Chart to convert
torque val ues l i sted i n metri c Newton- meters (Nm).
Al so, use the chart to convert between mi l l i meters
(mm) and i nches (i n.) (Fi g. 7).
8 INTRODUCTION DR
Fig. 7 METRIC CONVERSION CHART
DR INTRODUCTION 9
METRIC SYSTEM (Continued)
TORQUE REFERENCES
DESCRIPTION
I ndi vi dual Torque Charts appear wi thi n many or
the Groups. Refer to the Standard Torque Speci fi ca-
ti ons Chart for torque references not l i sted i n the
i ndi vi dual torque charts (Fi g. 8).
Fig. 8 TORQUE SPECIFICATIONS
10 INTRODUCTION DR
VEHICLE CERTIFICATION
LABEL
DESCRIPTION
A vehi cl e certi fi cati on l abel (Fi g. 9) i s attached to
every Dai ml erChrysl er Corporati on vehi cl e. The l abel
certi fi es that the vehi cl e conforms to al l appl i cabl e
Federal Motor Vehi cl e Standards. The l abel al so l i sts:
Month and year of vehi cl e manufacture.
Gross Vehi cl e Wei ght Rati ng (GVWR). The gross
front and rear axl e wei ght rati ngs (GAWRs) are
based on a mi ni mum ri m si ze and maxi mum col d ti re
i nfl ati on pressure.
Vehi cl e I denti fi cati on Number (VI N).
Type of vehi cl e.
Type of rear wheel s.
Bar code.
Month, Day and Hour (MDH) of fi nal assembl y.
Pai nt and Tri m codes.
Country of ori gi n.
The l abel i s l ocated on the dri ver-si de door
shut-face.
Fig. 9 VEHICLE CERTIFICATION LABEL - TYPICAL
DR INTRODUCTION 11
LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - ENGINE OIL AND
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - POWER STEERING FLUID . . 3
DESCRIPTION - ENGINE COOLANT . . . . . . . . 3
DESCRIPTION - TRANSFER CASE . . . . . . . . . 4
DESCRIPTION - AXLE . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION - MANUAL TRANSMISSION . . . 4
DESCRIPTION - AUTOMATIC
TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . 4
OPERATION - AUTOMATIC TRANSMISSION
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . 5
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE SCHEDULES 24VALVE
CUMMINS TURBO DIESEL . . . . . . . . . . . . . . 12
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . 19
HOISTING
STANDARD PROCEDURE - HOISTING . . . . . . . 20
TOWING
STANDARD PROCEDURE - TOWING . . . . . . . . 21
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
DESCRIPTION
WARNING: Do not use alcohol or gasoline as a fuel
blending agent. They can be unstable under certain
conditions and hazardous or explosive when mixed
with diesel fuel.
Use good qual i ty di esel fuel from a reputabl e sup-
pl i er i n your Dodge truck. For most year-round ser-
vi ce, number 2 di esel fuel meeti ng ASTM
speci fi cati on D-975 wi l l provi de good performance. I f
the vehi cl e i s exposed to extreme col d (bel ow 0F/-
18C), or i s requi red to operate at col der-than-normal
condi ti ons for prol onged peri ods, use cl i mati zed No. 2
di esel fuel or di l ute the No. 2 di esel fuel wi th 50%
No. 1 di esel fuel . Thi s wi l l provi de better protecti on
from fuel gel l i ng or wax-pl uggi ng of the fuel fi l ters.
Di esel fuel i s sel dom compl etel y free of water. To
prevent fuel system troubl e, i ncl udi ng fuel l i ne freez-
i ng i n wi nter, drai n the accumul ated water from the
fuel /water separator usi ng the fuel /water separator
drai n provi ded. I f you buy good-qual i ty fuel and fol -
l ow the col d-weather advi ce above, fuel condi ti oners
shoul d not be requi red i n your vehi cl e. I f avai l abl e i n
your area, a hi gh cetane premi um di esel fuel may
offer i mproved col d starti ng and warm-up perfor-
mance.
DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
When servi ce i s requi red, Dai ml erChrysl er Corpo-
rati on recommends that onl y Mopar brand parts,
l ubri cants and chemi cal s be used. Mopar provi des
the best engi neered products for servi ci ng
Dai ml erChrysl er Corporati on vehi cl es.
Onl y l ubri cants beari ng desi gnati ons defi ned by
the fol l owi ng organi zati on shoul d be used.
Soci ety of Automoti ve Engi neers (SAE)
Ameri can Petrol eum I nsti tute (API )
DR LUBRICATION & MAINTENANCE 0 - 1
Nati onal Lubri cati ng Grease I nsti tute (NLGI )
API SERVICE GRADE CERTIFIED
Use an engi ne oi l that i s API Certi fi ed. MOPAR
provi des engi ne oi l s, that meet or exceed thi s
requi rement.
SAE VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . Use onl y engi ne oi l s wi th mul ti -
pl e vi scosi ti es such as 5W-30 or 10W-30. These are
speci fi ed wi th a dual SAE vi scosi ty grade whi ch i ndi -
cates the col d-to-hot temperature vi scosi ty range.
Sel ect an engi ne oi l that i s best sui ted to your par-
ti cul ar temperature range and vari ati on (Fi g. 1).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. The desi gnati on of ENERGY CON-
SERVI NG i s l ocated on the l abel of an engi ne oi l con-
tai ner.
CONTAINER IDENTIFICATION
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the front
l abel of engi ne oi l pl asti c bottl es and the top of
engi ne oi l cans (Fi g. 2).
Thi s symbol means that the oi l has been certi fi ed
by the Ameri can Petrol eum I nsti tute (API ). Di aml er-
Chrysl er onl y recommend API Certi fi ed engi ne oi l s.
Use Mopar engi ne oi l or equi val ent.
GEAR LUBRICANTS
SAE rati ngs al so appl y to mul ti grade gear l ubri -
cants. I n addi ti on, API cl assi fi cati on defi nes the
l ubri cants usage. Such as API GL-5 and SAE 75W-
90.
LUBRICANTS AND GREASES
Lubri cati ng grease i s rated for qual i ty and usage
by the NLGI . Al l approved products have the NLGI
symbol (Fi g. 3) on the l abel . At the bottom of the
NLGI symbol i s the usage and qual i ty i denti fi cati on
l etters. Wheel beari ng l ubri cant i s i denti fi ed by the
l etter G. Chassi s l ubri cant i s i denti fi ed by the l etter
L. The l etter fol l owi ng the usage l etter i ndi cates
the qual i ty of the l ubri cant. The fol l owi ng symbol s
i ndi cate the hi ghest qual i ty.
SPECIALIZED LUBRICANTS AND OILS
Some mai ntenance or repai r procedures may
requi re the use of speci al i zed l ubri cants or oi l s. Con-
sul t the appropri ate secti ons i n thi s manual for the
correct appl i cati on of these l ubri cants.
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
Use onl y Di esel Engi ne Oi l meeti ng standard MIL-
2104C or API Cl assi fi cati on CD or higher or CCML
D4, D5.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation. (Fig. 4)
To assure of properl y formul ated engi ne oi l s, i t i s
recommended that SAE Grade 10W-40 engi ne oi l s
that meet Chrysl er materi al standard MS-6395, be
used i n accordance to ACEA B3, B4 speci fi cati on.
European Grade 10W-40 oi l s are al so acceptabl e.
Fig. 1 TEMPERATURE/ENGINE OIL VISCOSITY
Fig. 2 API SYMBOL
Fig. 3 NLGI SYMBOL
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION & MAINTENANCE DR
FLUID TYPES (Continued)
Oi l s of the SAE 5W-40 grade number are preferred
when mi ni mum temperatures consi stentl y fal l bel ow
-15C. (Fi g. 5)
DESCRIPTION - POWER STEERING FLUID
Mopar ATF +4, Automati c Transmi ssi on Fl ui d i s
requi red i n the power steeri ng system. Substi tute
fl ui ds can i nduce power steeri ng system fai l ure.
Mopar ATF +4, Automati c Transmi ssi on Fl ui d
when new i s red i n col or. The ATF i s dyed red so i t
can be i denti fi ed from other fl ui ds used i n the vehi cl e
such as engi ne oi l or anti freeze. The red col or i s not
permanent and i s not an i ndi cator of fl ui d condi ti on.
As the vehi cl e i s dri ven, the ATF wi l l begi n to l ook
darker i n col or and may eventual l y become brown.
This is normal. ATF+4 al so has a uni que odor that
may change wi th age. Consequentl y, odor and col or
cannot be used to i ndi cate the fl ui d condi ti on or the
need for a fl ui d change.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cool i ng system i s desi gned around the cool ant.
The cool ant must accept heat from engi ne metal , i n
the cyl i nder head area near the exhaust val ves and
engi ne bl ock. Then cool ant carri es the heat to the
radi ator where the tube/fi n radi ator can transfer the
heat to the ai r.
The use of al umi num cyl i nder bl ocks, cyl i nder
heads, and water pumps requi res speci al corrosi on
protecti on. Mopar Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (MS-9769), or the equi va-
l ent ethyl ene gl ycol base cool ant wi th organi c corro-
si on i nhi bi tors (cal l ed HOAT, for Hybri d Organi c
Addi ti ve Technol ogy) i s recommended. Thi s cool ant
offers the best engi ne cool i ng wi thout corrosi on when
mi xed wi th 50% Ethyl ene Gl ycol and 50% di sti l l ed
water to obtai n a freeze poi nt of -37C (-35F). I f i t
l oses col or or becomes contami nated, drai n, fl ush,
and repl ace wi th fresh properl y mi xed cool ant sol u-
ti on.
CAUTION: Mopar Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon cl i mate and vehi cl e operati ng
condi ti ons. The cool ant performance of vari ous mi x-
tures fol l ows:
Pure Water-Water can absorb more heat than a
mi xture of water and ethyl ene-gl ycol . Thi s i s for pur-
pose of heat transfer onl y. Water al so freezes at a
hi gher temperature and al l ows corrosi on.
100 percent Ethylene-Glycol-The corrosi on
i nhi bi ti ng addi ti ves i n ethyl ene-gl ycol need the pres-
ence of water to di ssol ve. Wi thout water, addi ti ves
form deposi ts i n system. These act as i nsul ati on
causi ng temperature to ri se to as hi gh as 149C
(300F). Thi s temperature i s hot enough to mel t pl as-
Fig. 4 API RATING WRAP FIGURE
Fig. 5 DIESEL OIL VISCOSITY CHART
ti c and soften sol der. The i ncreased temperature can
resul t i n engi ne detonati on. I n addi ti on, 100 percent
ethyl ene-gl ycol freezes at -22C (-8F).
50/50 Ethylene-Glycol and Water-I s the recom-
mended mi xture, i t provi des protecti on agai nst freez-
i ng to -37C (-34F). The anti freeze concentrati on
must always be a mi ni mum of 44 percent, year-
round i n al l cl i mates. I f percentage i s l ower, engi ne
parts may be eroded by cavi tati on. Maxi mum protec-
ti on agai nst freezi ng i s provi ded wi th a 68 percent
anti freeze concentrati on, whi ch prevents freezi ng
down to -67.7C (-90F). A hi gher percentage wi l l
freeze at a warmer temperature. Al so, a hi gher per-
centage of anti freeze can cause the engi ne to over-
heat because speci fi c heat of anti freeze i s l ower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION AND ADDITIVES
NOTE: Refer to the vehicles coolant bottle to iden-
tify HOAT or Non-HOAT coolant. Non-HOAT coolant
is green in color.
heads and water pumps requi res speci al corrosi on
protecti on. Onl y Mopar Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (gl ycol base cool ant wi th
corrosi on i nhi bi tors cal l ed HOAT, for Hybri d Organi c
mi xed wi th 50% di sti l l ed water to obtai n to obtai n a
freeze poi nt of -37C (-35F). I f i t l oses col or or
becomes contami nated, drai n, fl ush, and repl ace wi th
fresh properl y mi xed cool ant sol uti on.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
DESCRIPTION - TRANSFER CASE
Recommended l ubri cant for the NV241 GENI I ,
NV271, NV243, NV244 GENI I , and NV273 transfer
cases i s Mopar ATF +4, Automati c Transmi ssi on
Fl ui d.
DESCRIPTION - AXLE
NOTE: DaimlerChrysler recommends using Mopar
lubricants or lubricants of equal quality.
FRONT AXLE
C205F - Mopar Gear Lubri cant 75W-90
9 1/4 AA - Mopar Syntheti c Gear Lubri cant
75W-90
REAR AXLE
9 1/4 - Mopar Syntheti c Gear Lubri cant 75W-
140
75W-90
75W-90
NOTE: Trac-Lok differentials require Limited Slip
Additive in the lubricant. Trac-Rite differentials
DO NOT require Limited Slip Additive.
DESCRIPTION - MANUAL TRANSMISSION
NOTE: DaimlerChrysler recommends using Mopar
lubricants or lubricants of equal quality.
NV3500 - Mopar Manual Transmi ssi on Lubri -
cant
NV4500 - Mopar Syntheti c 75W85 Manual
Transmi ssi on Lubri cant
NV5600 - Mopar Manual Transmi ssi on Lubri -
cant
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.
Mopar ATF +4, Automati c Transmi ssi on Fl ui d i s
the recommended fl ui d for Dai ml erChrysl er auto-
mati c transmi ssi ons.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
Mopar ATF +4, Automati c Transmi ssi on Fl ui d
when new i s red i n col or. The ATF i s dyed red so i t
can be i denti fi ed from other fl ui ds used i n the vehi cl e
such as engi ne oi l or anti freeze. The red col or i s not
permanent and i s not an i ndi cator of fl ui d condi ti on.
As the vehi cl e i s dri ven, the ATF wi l l begi n to l ook
darker i n col or and may eventual l y become brown.
This is normal. ATF+4 al so has a uni que odor that
may change wi th age. Consequentl y, odor and col or
cannot be used to i ndi cate the fl ui d condi ti on or the
need for a fl ui d change.
FLUID ADDITIVES
Dai ml erChrysl er strongl y recommends agai nst the
addi ti on of any fl ui ds to the transmi ssi on, other than
those automati c transmi ssi on fl ui ds l i sted above.
Excepti ons to thi s pol i cy are the use of speci al dyes
to ai d i n detecti ng fl ui d l eaks.
Vari ous speci al addi ti ves and suppl ements exi st
that cl ai m to i mprove shi ft feel and/or qual i ty. These
addi ti ves and others al so cl ai m to i mprove converter
cl utch operati on and i nhi bi t overheati ng, oxi dati on,
varni sh, and sl udge. These cl ai ms have not been sup-
ported to the sati sfacti on of Dai ml erChrysl er and
these addi ti ves must not be used. The use of trans-
mi ssi on seal ers shoul d al so be avoi ded, si nce they
may adversel y affect the i ntegri ty of transmi ssi on
seal s.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automati c transmi ssi on fl ui d i s sel ected based
upon several qual i ti es. The fl ui d must provi de a hi gh
l evel of protecti on for the i nternal components by
provi di ng a l ubri cati ng fi l m between adjacent metal
components. The fl ui d must al so be thermal l y stabl e
so that i t can mai ntai n a consi stent vi scosi ty through
a l arge temperature range. I f the vi scosi ty stays con-
stant through the temperature range of operati on,
transmi ssi on operati on and shi ft feel wi l l remai n con-
si stent. Transmi ssi on fl ui d must al so be a good con-
ductor of heat. The fl ui d must absorb heat from the
i nternal transmi ssi on components and transfer that
heat to the transmi ssi on case.
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES
DESCRIPTION SPECIFICATION
FUEL TANK
Short Box (Lt. Duty) 98 L (26 gal.)*
Long Box (Lt. Duty) 132 L (35 gal.)*
ENGINE OIL WITH FILTER
3.7L 4.7 L (5.0 qts.)
4.7L 5.6 L (6.0 qts.)
5.7L 6.6 L (7.0 qts.)
5.9L DIESEL 11.4 L (12.0 qts.)
COOLING SYSTEM
3.7L 15.4 L (16.2 qts.)**
4.7L 15.4 L (16.2 qts.)**
5.7L 15.4L (16.2 qts.)**
5.9L Diesel Engine 28L (29.5 qts.)**
POWER STEERING
Power steering fluid capacities are dependent on
engine/chassis options as well as steering gear/cooler
options. Depending on type and size of internal
cooler, length and inside diameter of cooler lines, or
use of an auxiliary cooler, these capacities may vary.
Refer to 19, Steering for proper fill and bleed
procedures.
AUTOMATIC TRANSMISSION
Service Fill - 48RE 3.8 L (4.0 qts.)
O-haul - 48RE 14-16L (29-33 pts.)
Service Fill - 45RFE/
545RFE
4X2 - 5.2 L (11.0 pts.)
4X4 - 6.2 L (13.0 pts.)
O-haul - 45RFE/545RFE 14-16 L (29-33 pts.)
Dry fill capacity Depending on type and size of
internal cooler, length and inside diameter of cooler
lines, or use of an auxiliary cooler, these figures may
vary. (Refer to 21 - TRANSMISSION/AUTOMATIC/
FLUID - STANDARD PROCEDURE)
MANUAL TRANSMISSION
NV3500 4X2 2.27 L (4.8 pts.)
NV3500 4X4 1.99 L (4.2 pts.)
NV4500 3.79 L (8.0 pts.)
NV5600 4.50 L (9.5 pts.)
TRANSFER CASE
NV241 GENII 1.6 L (3.4 pts.)
NV243 1.6 L (3.4 pts.)
NV244 GENII 1.6 L (3.4 pts.)
NV271 1.89 L (4.0 pts.)
NV273 1.89 L (4.0 pts.)
FRONT AXLE .03 L (1 oz)
C205F 1.66 L (3.5 pts.)
9 1/4 AA 2.25 L (4.75 pts.)
REAR AXLE .03 L (1 oz)
9 1/4 2.32 L (4.9 pts.)***
10 1/2 AA 2.25 L (4.75 pts.)
11 1/2 AA 3.62 L (7.65 pts)
*** With Trac-Lok add 118 ml (4 oz.) of Limited Slip
Additive.
** Includes 0.9L (1.0 qts.) for coolant reservoir.
*Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION
Mai ntenance Schedul e I nformati on not i ncl uded i n
thi s secti on, i s l ocated i n the appropri ate Owners
Manual .
There are two mai ntenance schedul es that show
the required servi ce for your vehi cl e.
Fi rst i s Schedul e B. I t i s for vehi cl es that are
operated under the condi ti ons that are l i sted bel ow
and at the begi nni ng of the schedul e.
Day or ni ght temperatures are bel ow 0 C (32
F).
Stop and go dri vi ng.
Extensi ve engi ne i dl i ng.
Dri vi ng i n dusty condi ti ons.
Short tri ps of l ess than 16 km (10 mi l es).
More than 50% of your dri vi ng i s at sustai ned
hi gh speeds duri ng hot weather, above 32 C (90 F).
Trai l er towi ng.
Taxi , pol i ce, or del i very servi ce (commerci al ser-
vi ce).
Off-road or desert operati on.
If equipped for and operating with E-85
(ethanol) fuel.
NOTE: If ANY of these apply to the vehicle then
change the engine oil every 3,000 miles (5 000 km)
or 3 months, whichever comes first and follow
schedule B of the Maintenance Schedules sec-
tion of this manual.
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule B.
Second i s Schedul e A. I t i s for vehi cl es that are
not operated under any of the condi ti ons l i sted under
Schedul e B.
Use the schedul e that best descri bes the dri vi ng
condi ti ons. Where ti me and mi l eage are l i sted, fol l ow
the i nterval that occurs fi rst.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
At Each Stop for Fuel
Check the engi ne oi l l evel about 5 mi nutes after
a ful l y warmed engi ne i s shut off. Checki ng the oi l
l evel whi l e the vehi cl e i s on l evel ground wi l l
i mprove the accuracy of the oi l l evel readi ng. Add oi l
onl y when the l evel i s at or bel ow the ADD or MI N
mark.
Check the wi ndshi el d washer sol vent and add i f
requi red.
Once a Month
Check ti re pressure and l ook for unusual wear
or damage.
I nspect the battery and cl ean and ti ghten the
termi nal s as requi red.
Check the fl ui d l evel s of cool ant reservoi r, brake
master cyl i nder, power steeri ng and transmi ssi on
and add as needed.
Check al l l i ghts and al l other el ectri cal i tems for
correct operati on.
At Each Oil Change
Change the engi ne oi l fi l ter.
I nspect the exhaust system.
I nspect the brake hoses.
I nspect the CV joi nts (i f equi pped) and front sus-
pensi on components.
Check the automati c transmi ssi on fl ui d l evel .
Check the manual transmi ssi on fl ui d l evel .
Check the cool ant l evel , hoses, and cl amps.
Rotate the ti res at each oi l change i nterval
shown on Schedul e A 10 000 km (6,000 mi l es) or
every other i nterval shown on Schedul e B 10 000
km (6,000 mi l es).
Tire Rotation
Rotate the ti res at 6,000 mi l es (10 000 km).
Schedule B
Fol l ow schedul e B i f you usual l y operate your
vehi cl e under one or more of the fol l owi ng condi ti ons.
F).
FLUID CAPACITIES (Continued)
Trai l er towi ng.
Snowpl owi ng.
Heavy Loadi ng.
vi ce).
If equipped for and operating with E-85
(ethanol) fuel.
NOTE: If ANY of these apply to the vehicle then
change the engine oil every 3,000 miles (5 000 km)
or 3 months, whichever comes first and follow
schedule B of the Maintenance Schedules sec-
tion of this manual.
If none of these apply to the vehicle, then change
the engine oil at every interval shown on schedule
A of the Maintenance Schedules section of this
manual.
Miles 3,000 6,000 9,000 12,000 15,000
(Kilometers) (5 000) (10 000) (14 000) (19 000) (24 000)
Change engine oil and engine oil filter. X X X X X
Lubricate outer tie rod ends 2500/3500
(4X4) models only.
X X
Change rear axle fluid. X
Change front axle fluid (4X4). X
Inspect brake linings. X
Inspect engine air cleaner filter, replace
if necessary.
X
Miles 18,000 21,000 24,000 27,000 30,000
(Kilometers) (29 000) (34 000) (38 000) (43 000) (48 000)
(4X4) models only.
X X X
Check transfer case fluid level (4X4). X
if necessary.
X
Replace spark plugs. X
Inspect PCV valve, replace as necessary. X*
Drain and refill automatic tranmission fluid
and change main sump filter (45RFE/
545RFE only).
X
MAINTENANCE SCHEDULES (Continued)
Miles 33,000 36,000 39,000 42,000 45,000
(Kilometers) (53 000) (58 000) (62 000) (67 000) (72 000)
(4X4) models only.
X
X
if necessary.
X
Miles 48,000 51,000 54,000 57,000 60,000
(Kilometers) (77 000) (82 000) (86 000) (91 000) (96 000)
(4X4) models only.
X X
X
Drain and refill transfer case fluid (4X4). X
Inspect brake linings. X X
if necessary.
X
Replace ignition cables. X
and change main sump filter (45RFE/
545RFE only).
X
Miles 63,000 66,000 69,000 72,000 75,000
(Kilometers) (101 000) (106 000) (110 000) (115 000) (120 000)
(4X4) models only.
X
X
Inspect engine air cleaner filter. X
Inspect auto tension drive belt and replace
if required. (3.7L/4.7L/5.7L).
X
Miles 78,000 81,000 84,000 87,000 90,000
(Kilometers) (125 000) (130 000) (134 000) (139 000) (144 000)
(4X4) models only.
X X
X
if necessary.
X
Inspect auto tension drive belt and replace
if required (3.7L/4.7L/5.7L).
X
and change main sump and spin-on cooler
return filter (if equipped) [45RFE/545RFE
only].
X
Miles 93,000 96,000 99,000 100,000 102,000
(Kilometers) (149 000) (154 000) (158 000) (160 000) (163 000)
Change engine oil and engine oil filter. X X X X
(4X4) models only.
X
X
Flush and replace engine coolant. X
Flush and replace Power Steering Fluid. X
Miles 105,000 108,000 111,000 114,000 117,000 120,000
(Kilometers) (168 000) (173 000) (178 000) (182 000) (187 000) (192 000)
Change engine oil and engine
oil filter.
X X X X X X
Lubricate outer tie rod ends
2500/3500 (4X4) models only.
X
X X
Drain and refill transfer case
fluid (4X4).
X
Change rear axle fluid. X X
Change front axle fluid (4X4). X X
Inspect engine air cleaner
filter, replace if necessary.
X X
Inspect PCV valve, replace
as necessary.
X*
Inspect auto tension drive belt
and replace if required
(3.7L/4.7L/5.7L).
X X
Drain and refill automatic
tranmission fluid and change
main sump filter (45RFE/
545RFE only).
X
* Thi s mai ntenance i s recommended by the manu-
facture to the owner but i s not requi red to mai ntai n
the emi ssi ons warranty.
Thi s mai ntenance i s not requi red i f previ ousl y
repl aced.
I nspecti on and servi ce shoul d al so be performed
anyti me a mal functi on i s observed or suspected.
Retai n al l recei pts.
Schedule A
Miles 6,000 12,000 18,000 24,000 30,000
(Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000)
[Months] [6] [12] [18] [24] [30]
(4X4) models only.
X X X X X
Replace engine air cleaner filter. X
Miles 36,000 42,000 48,000 54,000 60,000 66,000
(Kilometers) (58 000) (67 000) (77 000) (84 000) (96 000) (106 000)
[Months] [36] [42] [48] [54] [60] [66]
oil filter.
X X X X X
X
Check transfer case fluid level
(4X4).
X
2500/3500 (4X4) models only.
X X X X X X
Flush and replace engine
coolant at 60 months,
regardless of mileage.
X
Replace engine air cleaner
filter.
X
as necessary.
X*
Miles 72,000 78,000 84,000 90,000 96,000 100,000
(Kilometers) (115000) (125 000) (134 000) (144 000) (154 000) 160 000
[Months] [72] [78] [84] [90] [96]
oil filter.
X X X X X
2500/3500 (4X4) models only.
X X X X X
Check transfer case fluid level
(4X4).
X
Flush and replace Power
Steering Fluid.
X
Replace engine air cleaner
filter.
X
as necessary.
X*
Inspect auto tension drive belt
and replace if required
(3.7L/4.7L/5.7L).
X
tranmission fluid and change
main sump filter and spin-on
cooler return filter (if
equipped) [45RFE/545RFE
only].
X
Miles 102,000 108,000 114,000 120,000
(Kilometers) (163 000) (173 000) (182 000) (192 000)
[Months] [102] [108] [114] [120]
Flush and replace engine coolant, if not done at 60 mos. X
Lubricate outer tie rod ends 2500/3500 (4X4) models
only.
X X X X
Inspect auto tension drive belt and replace if required
(3.7L/4.7L/5.7L).
X
X
Replace engine air cleaner filter. X
Inspect PCV Valve, replace as necessary X*
* Thi s mai ntenance i s recommended by the manu-
facture to the owner but i s not requi red to mai ntai n
the emi ssi ons warranty.
Thi s mai ntenance i s not requi red i f previ ousl y
repl aced.
WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
MAINTENANCE SCHEDULES 24VALVE
CUMMINS TURBO DIESEL
There are two mai ntenance schedul es that show
the required servi ce for your vehi cl e.
Fi rst i s Schedul e B. I t i s for vehi cl es that are
operated under the condi ti ons that are l i sted bel ow
and at the begi nni ng of the schedul e.
F).
Trai l er towi ng.
vi ce).
NOTE: Most vehicles are operated under the condi-
tions listed for Schedule B.
Second i s Schedul e A. I t i s for vehi cl es that are
not operated under any of the condi ti ons l i sted under
Schedul e B.
Use the schedul e that best descri bes your dri vi ng
condi ti ons. Where ti me and mi l eage are l i sted, fol l ow
the i nterval that occurs fi rst.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
At Each Stop for Fuel
Check the engi ne oi l l evel about 15 mi nutes
after a ful l y warmed engi ne i s shut off. Checki ng the
oi l l evel whi l e the vehi cl e i s on l evel ground wi l l
i mprove the accuracy of the oi l l evel readi ng. Add oi l
onl y when the l evel i s at or bel ow the ADD or MI N
mark.
Check the wi ndshi el d washer sol vent and add i f
requi red.
Drai n water from the fuel fi l ter.
Once a Month
Check ti re pressure and l ook for unusual wear
or damage.
I nspect the batteri es and cl ean and ti ghten the
termi nal s as requi red.
Check the fl ui d l evel s of cool ant reservoi r, brake
master cyl i nder, power steeri ng and transmi ssi on
and transfer case (i f equi pped), add as needed.
Check Filter Minder. Replace air cleaner
filter element if necessary.
Check al l l i ghts and al l other el ectri cal i tems for
correct operati on.
At Each Oil Change
Change the engi ne oi l fi l ter.
I nspect the exhaust system.
I nspect the brake hoses.
I nspect the CV joi nts (i f equi pped) and front sus-
pensi on components.
Check the automati c transmi ssi on fl ui d l evel .
Check the manual transmi ssi on fl ui d l evel .
Check the cool ant l evel , hoses, and cl amps.
Tire Rotation
Rotate the ti res every 7,500 mi l es (12 000 km).
Engine Oil Change Chart Notes
Ti er 1 EPA (250 hp or 305 hp) Engi nes Onl y
(see engi ne data l abel for your engi ne type)
Cal i forni a LEV (235 hp) Engi nes Onl y (see
engi ne data l abel for your engi ne type)
Schedule B
Fol l ow schedul e B i f you usual l y operate your
vehi cl e under one or more of the fol l owi ng condi ti ons.
F).
Trai l er towi ng.
vi ce).
Miles 3,750 7,500 11,250 15,000 18,750
(Kilometers) (6 000) (12 000) (18 000) (24 000) (30 000)
(4X4) models only.
X
X
Inspect water pump weep hole for
blockage.
X
Replace fuel filter element. Clean the water
in fuel sensor.
X
Inspect and adjust parking brake if
necessary.
X
Miles 22,500 26,250 30,000 33,750 37,500
(Kilometers) (36 000) (42 000) (48 000) (54 000) (60 000)
(4X4) models only.
X X
X
Inspect drive belt, replace as required. X
Inspect fan hub. X
Inspect damper. X
blockage.
X
in fuel sensor.
X
Drain and refill automatic transmission fluid.
Replace filter and adjust bands.
X
Miles 41,250 45,000 48,750 52,500 56,250
(Kilometers) (66 000) (72 000) (78 000) (84 000) (90 000)
(4X4) models only.
X
X
blockage.
X
in fuel sensor.
X
necessary.
X
Miles 60,000 63,750 67,500 71,250 75,000
(Kilometers) (96 000) (102 000) (108 000) (114 000) (120 000)
(4X4) models only.
X X
X
Inspect fan hub. X
Inspect damper. X
blockage.
X
X
in fuel sensor.
X
X
Inspect front wheel bearings. X
necessary.
X
X
X
Miles 78,750 82,500 86,250 90,000 93,750
(Kilometers) (126 000) (132 000) (138 000) (144 000) (150 000)
(4X4) models only.
X
X
Inspect fan hub. X
Inspect damper. X
blockage.
X
in fuel sensor.
X
necessary.
X
X
Miles 97,500 100,000 101,250 105,000 108,750 112,500
(Kilometers) (156 000) (160 000) (162 000) (168 000) (174 000) (180 000)
oil filter.
X X X X X
2500/3500 (4X4) models only.
X
X X
coolant.
X
Inspect drive belt, replace as
required.
X
Inspect water pump weep
hole for blockage.
X
Replace fuel filter element.
Clean the water in fuel sensor.
X
Inspect and adjust parking
brake if necessary.
X
Miles 116,250 120,000 123,750 127,500 131,250 135,000
(Kilometers) (186 000) (192 000) (198 000) (204 000) (210 000) (216 000)
oil filter.
X X X X X X
2500/3500 (4X4) models only.
X
X X
Clean engine air filter canister. X
Adjust valve lash clearance. X
Inspect drive belts, replace as
required.
X
fluid (4X4).
X
Inspect fan hub. X
Inspect damper. X
hole for blockage.
X
X
Clean the water in fuel sensor.
X
X
brake if necessary.
X
X
transmission fluid. Replace
filter and adjust bands.
X
Schedule A
Miles 7,500 15,000 22,500 30,000 37,500
(Kilometers) (12 000) (24 000) (36 000) (48 000) (60 000)
[Months] [6] [12] [18] [24] [30]
(4X4) models only.
X X X X X
Inspect water pump weep hole for blockage X X
in fuel sensor.
X
X
Inspect drive belts, replace as necessary. X
necessary.
X
Inspect fan hub. X
Inspect damper. X
Miles 45,000 52,500 60,000 67,500 75,000
(Kilometers) (72 000) (84 000) (96 000) (108 000) (120 000)
[Months] [36] [42] [48] [54] [60]
(4X4) models only.
X X X X X
Check transfer case fluid level. X
Flush and replace engine coolant at 60
months, regardless of mileage.
X
Inspect drive belts, replace as necessary. X X
Inspect water pump weep hole for blockage X X X
in fuel sensor.
X
X
necessary.
X
X
Inspect fan hub. X
Inspect damper. X
in fuel sensor
X
Miles 82,500 90,000 97,500 100,000 105,000
(Kilometers) (132 000) (144 000) (156 000) (160 000) (168 000)
[Months] [66] [72] [78] [84]
(4X4) models only.
X X X X X
Flush and replace engine coolant, if not
done at 60 mos.
X
Inspect fan hub. X
Inspect damper. X
blockage.
X
X
in fuel sensor.
X
X
necessary.
X
X
Miles 112,500 120,000 127,500 135,000 142,500 150,000
(Kilometers) (181 000) (193 000) (205 000) (217 000) (229 000) (241 000)
[Months] [90] [96] [102] [108] [114] [150]
oil filter.
X X X X X X
2500/3500 (4X4) models only.
X X X X X X
coolant, if it has been 160
000 km (100, 000 miles) or 60
months since last change.
X
Inspect drive belt, replace as
required.
X
X
fluid (4X4).
X
Check tranfer case fluid level
(4X4).
X
Inspect fan hub. X X
Inspect damper. X X
hole for blockage.
X
X X
Clean the water in fuel
sensor.
X X
X
Miles 112,500 120,000 127,500 135,000 142,500 150,000
(Kilometers) (181 000) (193 000) (205 000) (217 000) (229 000) (241 000)
[Months] [90] [96] [102] [108] [114] [150]
Inspect front wheel bearings. X X
brake if necessary.
X
X
Adjust valve lash clearance. X
WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
J UMP STARTING
STANDARD PROCEDURE - JUMP STARTING
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN THE BATTERY SYSTEM SEC-
TION OF THE SERVICE MANUAL. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN-
DARD PROCEDURE)
DO NOT JUMP START A FROZEN BATTERY,
PERSONAL INJURY CAN RESULT.
IF EQUIPPED, DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR.
DO NOT JUMP START A VEHICLE WHEN THE
BATTERY FLUID IS BELOW THE TOP OF LEAD
PLATES.
DO NOT ALLOW JUMPER CABLE CLAMPS TO
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE.
DO NOT USE OPEN FLAME NEAR BATTERY.
REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT.
WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING USED.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN PERSONAL INJURY.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Rai se hood on di sabl ed vehi cl e and vi sual l y
i nspect engi ne compartment for:
Battery cabl e cl amp condi ti on, cl ean i f necessary.
Frozen battery.
Yel l ow or bri ght col or test i ndi cator, i f equi pped.
Low battery fl ui d l evel .
Generator dri ve bel t condi ti on and tensi on.
Fuel fumes or l eakage, correct i f necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When usi ng another vehi cl e as a booster
source, park the booster vehi cl e wi thi n cabl e reach.
Turn off al l accessori es, set the parki ng brake, pl ace
the automati c transmi ssi on i n PARK or the manual
transmi ssi on i n NEUTRAL and turn the i gni ti on
OFF.
(3) On di sabl ed vehi cl e, pl ace gear sel ector i n park
or neutral and set park brake. Turn off al l accesso-
ri es.
(4) Connect jumper cabl es to booster battery. RED
cl amp to posi ti ve termi nal (+). BLACK cl amp to neg-
ati ve termi nal (-). DO NOT al l ow cl amps at opposi te
end of cabl es to touch, el ectri cal arc wi l l resul t.
Revi ew al l warni ngs i n thi s procedure.
(5) On di sabl ed vehi cl e, connect RED jumper cabl e
cl amp to posi ti ve (+) termi nal . Connect BLACK
jumper cabl e cl amp to engi ne ground as cl ose to the
ground cabl e attachi ng poi nt as possi bl e.
(6) Start the engi ne i n the vehi cl e whi ch has the
booster battery, l et the engi ne i dl e a few mi nutes,
then start the engi ne i n the vehi cl e wi th the di s-
charged battery.
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(7) Al l ow battery i n di sabl ed vehi cl e to charge to
at l east 12.4 vol ts (75% charge) before attempti ng to
start engi ne. I f engi ne does not start wi thi n 15 sec-
onds, stop cranki ng engi ne and al l ow starter to cool
(15 mi n.), before cranki ng agai n.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
Di sconnect BLACK cabl e cl amp from engi ne
ground on di sabl ed vehi cl e.
When usi ng a Booster vehi cl e, di sconnect
BLACK cabl e cl amp from battery negati ve termi nal .
Di sconnect RED cabl e cl amp from battery posi ti ve
termi nal .
Di sconnect RED cabl e cl amp from battery posi -
ti ve termi nal on di sabl ed vehi cl e.
HOISTING
STANDARD PROCEDURE - HOISTING
Refer to the Owners Manual for emergency vehi cl e
l i fti ng procedures.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT (Fig. 6) OR SECURE VEHICLE TO HOIST-
ING DEVICE WHEN THESE CONDITIONS EXIST.
FLOOR JACK
When properl y posi ti oned, a fl oor jack can be used
to l i ft a vehi cl e (Fi g. 7). Support the vehi cl e i n the
rai sed posi ti on wi th jack stands at the front and rear
ends of the frame rai l s (Fi g. 6).
CAUTION: Do not lift vehicle with a floor jack posi-
tioned under:
An axle tube.
A body side sill.
A steering linkage component.
A drive shaft.
The engine or transmission oil pan.
The fuel tank.
A front suspension arm.
NOTE: Use the correct frame rail lifting locations
only (Fig. 8) and (Fig. 9).
HOIST
A vehi cl e can be l i fted wi th:
A si ngl e-post, frame-contact hoi st.
A twi n-post, chassi s hoi st.
A ramp-type, dri ve-on hoi st.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly
(Fig. 7). The forward lifting pads should be posi-
tioned against the forward flange of the transmis-
sion crossmember brackets at the bottom of the
frame rail (Fig. 8). The real lifting pads should be
wedged between the forward flange of the leaf
spring bracket and the frame rail (Fig. 9). Safety
stands should be placed under the frame rails at
the front and rear ends (Fig. 6).
Fig. 6 Safety Stands
1 - SAFETY STANDS
J UMP STARTING (Continued)
TOWING
STANDARD PROCEDURE - TOWING
A vehi cl e equi pped wi th SAE approved sl i ng-type
towi ng equi pment can be used to tow al l vehi cl es.
When towi ng a 4WD vehi cl e usi ng a wheel -l i ft towi ng
devi ce, use tow dol l i es under the opposi te end of the
vehi cl e. A vehi cl e wi th fl at-bed devi ce can al so be
used to transport a di sabl ed vehi cl e (Fi g. 10).
Fig. 7 Vehicle Lifting Locations
Fig. 8 FRONT LIFT PAD LOCATION
1 - BODY MOUNT BRACKET
2 - FRONT LIFT PAD
3 - TRANSMISSION CROSSMEMBER BRACKET
4 - FRAME RAIL
Fig. 9 REAR LIFT PAD LOCATION
1 - FRAME RAIL
2 - REAR LIFT PAD
3 - LEAF SPRING MOUNTING BRACKET
4 - BOX MOUNTING BRACKET
Fig. 10 Tow Vehicles With Approved Equipment
1 - SLING TYPE
2 - WHEEL LIFT
3 - FLAT BED
TOWING (Continued)
A wooden crossbeam may be requi red for proper
connecti on when usi ng the sl i ng-type, front-end tow-
i ng method.
SAFETY PRECAUTIONS
CAUTION: The following safety precautions must be
observed when towing a vehicle:
Secure l oose and protrudi ng parts.
Al ways use a safety chai n system that i s i nde-
pendent of the l i fti ng and towi ng equi pment.
Do not al l ow towi ng equi pment to contact the
di sabl ed vehi cl es fuel tank.
Do not al l ow anyone under the di sabl ed vehi cl e
whi l e i t i s l i fted by the towi ng devi ce.
Do not al l ow passengers to ri de i n a vehi cl e
bei ng towed.
Al ways observe state and l ocal l aws regardi ng
towi ng regul ati ons.
Do not tow a vehi cl e i n a manner that coul d
jeopardi ze the safety of the operator, pedestri ans or
other motori sts.
Do not attach tow chai ns, T-hooks, J-hooks, or a
tow sl i ng to a bumper, steeri ng l i nkage, dri ve shafts
or a non-rei nforced frame hol e.
Do not tow a heavi l y l oaded vehi cl e. Damage to
the cab, cargo box or frame may resul t. Use a fl atbed
devi ce to transport a l oaded vehi cl e.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums or rotors.
A towed vehi cl e shoul d be rai sed unti l l i fted wheel s
are a mi ni mum 100 mm (4 i n) from the ground. Be
sure there i s adequate ground cl earance at the oppo-
si te end of the vehi cl e, especi al l y when towi ng over
rough terrai n or steep ri ses i n the road. I f necessary,
remove the wheel s from the l i fted end of the vehi cl e
and l ower the vehi cl e cl oser to the ground, to
i ncrease the ground cl earance at the opposi te end of
the vehi cl e. I nstal l l ug nuts on wheel attachi ng studs
to retai n brake drums or rotors.
RAMP ANGLE
I f a vehi cl e wi th fl at-bed towi ng equi pment i s used,
the approach ramp angl e shoul d not exceed 15
degrees.
TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehi cl e i s l ocked and keys are not avai l -
abl e, use a fl at bed haul er. A Wheel -l i ft or Sl i ng-type
devi ce can be used on 4WD vehi cl es provi ded all the
wheels are lifted off the ground using tow dol-
lies.
FOUR-WHEEL-DRIVE VEHICLE TOWING
Chrysl er Corporati on recommends that a vehi cl e be
transported on a fl at-bed devi ce. A Wheel -l i ft or
Sl i ng-type devi ce can be used provi ded all the
wheels are lifted off the ground using tow dol-
lies.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
TOWING (Continued)
SUSPENSION
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1
FRONT - INDEPENDENT FRONT SUSPENSION . . 8
FRONT - LINK/COIL . . . . . . . . . . . . . . . . . . . . . . 29
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - PRE-ALIGNMENT
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - HEIGHT
MEASUREMENT - 4WD (LD) . . . . . . . . . . . . . . 3
ADJUSTMENT - 4WD (LD) . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE - CAMBER AND
CASTER ADJUSTMENT. . . . . . . . . . . . . . . . . . 4
STANDARD PROCEDURE - TOE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4
STANDARD PROCEDURE - CAMBER,
CASTER AND TOE ADJUSTMENT . . . . . . . . . . 4
STANDARD PROCEDURE - ALIGNMENT
LINK/COIL SUSPENSION. . . . . . . . . . . . . . . . . 5
SPECIFICATIONS
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . 7
WHEEL ALIGNMENT
DESCRIPTION
NOTE: Suspension components with rubber/ure-
thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. If springs are not at their
normal ride position, vehicle ride comfort could be
affected and premature bushing wear may occur.
Wheel al i gnment i nvol ves the correct posi ti oni ng of
the wheel s i n rel ati on to the vehi cl e. The posi ti oni ng
i s accompl i shed through suspensi on and steeri ng
l i nkage adjustments. An al i gnment i s consi dered
essenti al for effi ci ent steeri ng, good di recti onal stabi l -
i ty and to mi ni mi ze ti re wear. The most i mportant
measurements of an al i gnment are caster, camber
and toe (Fi g. 1).
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
Fig. 1 Wheel Alignment Measurements
1 - FRONT OF VEHICLE
2 - STEERING AXIS INCLINATION
3 - PIVOT POINT
4 - TOE-IN
DR SUSPENSION 2 - 1
OPERATION
CASTER i s the forward or rearward ti l t of the
steeri ng knuckl e from verti cal . Ti l ti ng the top of the
knuckl e forward provi des l ess posi ti ve caster. Ti l ti ng
the top of the knuckl e rearward provi des more posi -
ti ve caster. Posi ti ve caster promotes di recti onal sta-
bi l i ty. Thi s angl e enabl es the front wheel s to return
to a strai ght ahead posi ti on after turns (Fi g. 1)
CAMBER i s the i nward or outward ti l t of the
wheel rel ati ve to the center of the vehi cl e. Ti l ti ng the
top of the wheel i nward provi des negati ve camber.
Ti l ti ng the top of the wheel outward provi des posi ti ve
camber. I ncorrect camber wi l l cause wear on the
i nsi de or outsi de edge of the ti re (Fi g. 1)
TOE i s the di fference between the l eadi ng i nsi de
edges and trai l i ng i nsi de edges of the front ti res.
Wheel toe posi ti on out of speci fi cati on causes unsta-
bl e steeri ng, uneven ti re wear and steeri ng wheel off-
center. The wheel toe posi ti on i s the final front
wheel al i gnment adjustment (Fi g. 1)
THRUST ANGLE i s the angl e of the rear axl e
rel ati ve to the centerl i ne of the vehi cl e. I ncorrect
thrust angl e can cause off-center steeri ng and exces-
si ve ti re wear. Thi s angl e i s not adjustabl e, damaged
component(s) must be repl aced to correct the thrust
angl e (Fi g. 1)
DIAGNOSIS AND TESTING - PRE-ALIGNMENT
INSPECTION
Before starti ng wheel al i gnment, the fol l owi ng
i nspecti on and necessary correcti ons must be com-
pl eted. Refer to Suspensi on and Steeri ng System
Di agnosi s Chart bel ow for addi ti onal i nformati on.
(1) I nspect ti res for si ze, ai r pressure and tread
wear.
(2) I nspect front wheel beari ngs for wear.
(3) I nspect front wheel s for excessi ve radi al or l at-
eral runout and bal ance.
(4) I nspect bal l studs, l i nkage pi vot poi nts and
steeri ng gear for l ooseness, roughness or bi ndi ng.
(5) I nspect suspensi on components for wear and
noi se.
(6) On 4x4 vehi cl es check suspensi on hei ght (LD
onl y).
(7) Road test the vehi cl e.
SUSPENSION AND STEERING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
2. Loose or worn steering or
suspension components.
2. Tighten or replace components as
necessary.
necessary.
EXCESSIVE PLAY IN
STEERING
1. Loose or worn wheel bearing. 1. Replace wheel bearing.
necessary.
3. Loose or worn steering gear. 3. Replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
VEHICLE INSTABILITY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
necessary.
3. Tire pressure. 3. Adjust tire pressure.
2 - 2 WHEEL ALIGNMENT DR
WHEEL ALIGNMENT (Continued)
EXCESSIVE STEERING
EFFORT
1. Loose or worn steering gear. 1. Replace steering gear.
2. Column coupler binding. 2. Replace coupler.
VEHICLE PULLS TO ONE
SIDE
2. Tire. 2. Criss-Cross Front Tires.
necessary.
5. Radial tire lead. 5. Rotate or replace tire as necessary.
6. Brake pull. 6. Repair brake as necessary.
7. Weak or broken spring. 7. Replace spring.
8. Ride height (LD) 4WD only. 8. Measure and adjust ride height. (LD
only)
STANDARD PROCEDURE
MEASUREMENT - 4WD (LD)
The vehi cl e suspensi on hei ght MUST be measured
and adjusted before performi ng wheel al i gnment pro-
cedure. Al so when front suspensi on components have
been repl aced. Thi s measure must be performed wi th
the vehi cl e supporti ng i ts own wei ght and taken on
both si des of the vehi cl e.
(1) I nspect ti res and set to correct pressure.
(2) Jounce the front of the vehi cl e.
(3) Measure and record the hei ght from the ground
at the centerl i ne of the rear l ower control arm bol t
front ti p (Fi g. 2).
(4) Measure and record the hei ght from the ground
at the front spi ndl e centerl i ne (Stati c Load Radi us)
(Fi g. 2).
(5) Subtract the fi rst measurement from the sec-
ond measurement. The di fference between the two
measurement shoul d be 58 mm (2.3 i nches) 3 mm
(0.12 i nches).
(6) I f val ue i s greater than 61 mm (2.4 i nches),
ti ghten the torsi on bar bol t unti l the speci fi cati on i s
achi eved (Refer to 2 - SUSPENSI ON/WHEEL
ALI GNMENT - STANDARD PROCEDURE).
(7) I f val ue i s l ess than 55 mm (2.1 i nches), l oosen
the torsi on bar bol t unti l the speci fi cati on i s achi eve-
d,(Refer to 2 - SUSPENSI ON/WHEEL ALI GNMENT
- STANDARD PROCEDURE).
(8) Repeat the previ ous steps unti l the ri de hei ght
i s wi thi n speci fi cati ons.
ADJUSTMENT - 4WD (LD)
The vehi cl e suspensi on hei ght MUST be measured
and adjusted before performi ng wheel al i gnment pro-
cedure (Refer to 2 - SUSPENSI ON/WHEEL ALI GN-
MENT - STANDARD PROCEDURE). Al so when
front suspensi on components have been repl aced.
Thi s measurement must be performed wi th the vehi -
cl e supporti ng i ts own wei ght and taken on both
si des of the vehi cl e.
Fig. 2 HEIGHT MESUREMENT
1 - HEIGHT FROM THE GROUND AT THE FRONT SPINDLE
CENTERLINE (STATIC LOAD RADIUS)
2 - CENTERLINE OF THE REAR LOWER CONTROL ARM BOLT
FRONT TIP
3 - GROUND LINE
DR WHEEL ALIGNMENT 2 - 3
To adjust the vehi cl e hei ght turn the torsi on bar
adjustment bol t CLOCKWI SE to rai se the vehi cl e
and COUNTER CLOCKWI SE to l ower the vehi cl e.
CAUTION: ALWAYS raise the vehicle to the correct
suspension height, NEVER lower the vehicle to
obtain the correct suspension height. If the vehicle
suspension height is too high, lower the vehicle
below the height specification. Then raise the vehi-
cle to the correct suspension height specification.
This will insure the vehicle maintains the proper
suspension height.
NOTE: If a height adjustment has been made, per-
form height measurement again on both sides of
the vehicle.
STANDARD PROCEDURE - CAMBER AND
CASTER ADJUSTMENT
NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASURE-
MENT MUST BE PERFORMED BEFORE AN ALIGN-
MENT.
NOTE: When the upper control arm pivot bolts are
loosened the upper control arm will normally go
inwards toward the frame automatically with the
weight of the vehicle.
Camber and caster angl e adjustments i nvol ve
changi ng the posi ti on of the upper control arm i ncon-
juncti on wi th the sl otted hol es i n the frame brackets,
I nstal l speci al tool 8876 between the top of the upper
control arm bracket and the upper control arm (on
1500 seri es 4X2 & 4X4). I nstal l speci al tool 8876
between the bottom of the upper control arm bracket
pressi ng the tool agai nst the frame and the upper
control arm (on 2500/3500 seri es 4X2) i n order to
move the upper control arm outwards for proper
adjustment wi th the vehi cl e at normal ri de hei ght
(Fi g. 3).
STANDARD PROCEDURE - TOE ADJUSTMENT
4X4 SUSPENSI ON HEI GHT MESUREMENT
MUST BE PERFORMED BEFORE AN ALI GN-
MENT.
The wheel toe posi ti on adjustment i s the fi nal
adjustment.
(1) Start the engi ne and turn wheel s both ways
before strai ghteni ng the wheel s. Secure the steeri ng
wheel wi th the front wheel s i n the strai ght-ahead
posi ti on.
(2) Loosen the ti e rod jam nuts.
NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification. This
will ensure the steering wheel will be centered
when the wheels are positioned straight-ahead.
(3) Adjust the wheel toe posi ti on by turni ng the
i nner ti e rod as necessary (Fi g. 4).
(4) Ti ghten the ti e rod jam nut to 75 Nm (55 ft.
l bs.).
(5) Veri fy the speci fi cati ons
(6) Turn off engi ne.
STANDARD PROCEDURE - CAMBER, CASTER
AND TOE ADJUSTMENT
NOTE: 4X4 (LD) SUSPENSION HEIGHT MEASURE-
MENT MUST BE PERFORMED BEFORE AN ALIGN-
MENT.
Camber and caster angl e adjustments i nvol ve
changi ng the posi ti on of the upper control arm wi th
the sl ots i n the frame brackets usi ng speci al tool
8876 to move the upper control arm outwards for
proper adjustment. (Fi g. 3)
NOTE: When the upper control arm pivot bolts are
loosened the upper control arm will normally go
inwards toward the frame automatically with the
weight of the vehicle.
CASTER
Movi ng the front or rear posi ti on of the upper con-
trol arm i n or out, wi l l change the caster angl e and
camber angl e si gni fi cantl y. To mai ntai n the camber
Fig. 3 CASTER & CAMBER ADJUSTMENT
1 - FRONT PIVOT BOLT
2 - REAR PIVOT BOLT
3 - SLOTTED HOLES FOR ADJUSTMENT OF CASTER &
CAMBER
4 - UPPER CONTROL ARM
angl e whi l e adjusti ng caster, move one pi vot bol t of
the upper control arm i n or out. Then move the other
pi vot bol t of the upper control arm i n the opposi te
di recti on. I nstal l speci al tool 8876 between the top of
the upper control arm bracket and the upper control
arm (on 1500 seri es 4X2 & 4X4). I nstal l speci al tool
8876 between the bottom of the upper control arm
bracket pressi ng the tool agai nst the frame and the
upper control arm (on 2500/3500 seri es 4X2) i n order
to move the upper control arm outwards for proper
adjustment wi th the vehi cl e at normal ri de hei ght
(Fi g. 3).
To i ncrease posi ti ve caster angl e, move the rear
posi ti on of the upper control arm i nward (toward the
engi ne). Move the front of the upper control arm out-
ward (away from the engi ne) sl i ghtl y unti l the ori gi -
nal camber angl e i s obtai ned usi ng speci al tool 8876
to move the upper control arm for proper adjustment.
(Fi g. 3)
CAMBER
Move both pi vot bol ts of the upper control arm
together i n or out. Thi s wi l l change the camber angl e
si gni fi cantl y and l i ttl e effect on the caster angl e
usi ng speci al tool 8876 to move the upper control
arm for proper adjustment. (Fi g. 3)
After adjustment i s made ti ghten the upper control
arm nuts to proper torque speci fi cati on.
TOE ADJUSTMENT
The wheel toe posi ti on adjustment i s the fi nal
adjustment.
before strai ghteni ng the wheel s. Secure the steeri ng
wheel wi th the front wheel s i n the strai ght-ahead
posi ti on.
(2) Loosen the ti e rod jam nuts.
NOTE: Each front wheel should be adjusted for
one-half of the total toe position specification. This
will ensure the steering wheel will be centered
when the wheels are positioned straight-ahead.
(3) Adjust the wheel toe posi ti on by turni ng the
i nner ti e rod as necessary (Fi g. 4).
(4) Ti ghten the ti e rod jam nut to 75 Nm (55 ft.
l bs.).
(5) Veri fy the speci fi cati ons
(6) Turn off engi ne.
STANDARD PROCEDURE - ALIGNMENT
LINK/COIL SUSPENSION
Before each al i gnment readi ng the vehi cl e shoul d
be jounced (rear fi rst, then front). Grasp each
bumper at the center and jounce the vehi cl e up and
down several ti mes. Al ways rel ease the bumper i n
the down posi ti on. Set the front end alignment to
specifications while the vehicle is in its NOR-
MALLY LOADED CONDITION.
CAMBER: The wheel camber angl e i s preset and
i s not adjustabl e.
CASTER: Check the caster of the front axl e for
correct angl e. Be sure the axl e i s not bent or twi sted.
Road test the vehi cl e and make l eft and ri ght turn.
Observe the steeri ng wheel return-to-center posi ti on.
Low caster wi l l cause poor steeri ng wheel returnabi l -
i ty.
Caster can be adjusted by rotati ng the cams on the
l ower suspensi on arm (Fi g. 5).
TOE POSITION: The wheel toe posi ti on adjust-
ment shoul d be the fi nal adjustment.
Fig. 4 TIE ROD END
1 - JAM NUT
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER
Fig. 5 ALIGNMENT ADJUSTMENT CAM
1 - BRACKET REINFORCEMENT
2 - ADJUSTING BOLT
3 - ADJUSTMENT CAM
before strai ghteni ng the wheel s. Center and Secure
the steeri ng wheel and turn off engi ne.
(2) Loosen the adjustment sl eeve cl amp bol ts.
(3) Adjust the ri ght wheel toe posi ti on wi th the
drag l i nk. Turn the sl eeve unti l the ri ght wheel i s at
the correct TOE-I N posi ti on. Posi ti on cl amp bol ts to
thei r ori gi nal posi ti on and ti ghten to speci fi cati ons.
Make sure the toe setting does not change dur-
ing clamp tightening.
(4) Adjust l eft wheel toe posi ti on wi th ti e rod at
l eft knuckl e. Turn the sl eeve unti l the l eft wheel i s at
the correct TOE-I N posi ti on. Posi ti on cl amp bol ts to
thei r ori gi nal posi ti on and ti ghten to speci fi cati ons.
Make sure the toe setting does not change dur-
ing clamp tightening.
(5) Veri fy the ri ght toe setti ng and a strai ght steer-
i ng wheel .
(6) Road test the vehi cl e.
SPECIFICATIONS
ALIGNMENT
NOTE: All alignment specifications are in degrees.
SPECIFICATIONS
DESCRIP-
TION
SPECIFICATION
VEHICLE
1500
WHEEL
BASE
CASTER
(4.0
Min,
+.75
Max)
CAMBER
( .50)
TOTAL
TOE-IN
( .10)
4X2 120.5 in 4.0 .0 .10
4X2 140.5 in 4.2 .0 .10
4X2 160.5 in 4.4 .0 .10
VEHICLE
1500
WHEEL
BASE
CASTER
(4.0
Min,
+.75
Min)
CAMBER
(.50)
TOTAL
TOE-IN
(.10)
4X4 120.5 in 4.2 .0 .10
4X4 140.5 in 4.4 .0 .10
4X4 160.5 in 4.6 .0 .10
MAX
RT/LT
DIF-
FERENCE
4X2
1500
.40 .50 0.06
DESCRIP-
TION
SPECIFICATION
MAX
RT/LT
DIF-
FERENCE
4X4
1500
.40 .60 0.06
VEHICLE
4X2
2500 &
3500
WHEEL
BASE
CASTER
(3.55
Min,
+.75
Max)
CAMBER
(.50)
TOTAL
TOE-IN
(0.20
.10)
4X2
2500&3500
140 4.0 0.0 .10
.05
4X2
2500&3500
160 4.3 0.0 .10
.05
MAX
RT/LT
DIF-
FERENCE
4X2
2500&3500
0.4 0.6 0.1
VEHICLE
4X4
2500&3500
WHEEL
BASE
CASTER
(4.0
Min,
+.75
Max)
CAMBER
(.25
.5)
TOTAL
TOE-IN
(0.20
.10)
4X4
2500&3500
140 4.5 .25 .10
.05
4X4
2500&3500
160 4.7 .25 .10
.05
MAX
RT/LT
DIF-
FERENCE
4X4
2500&3500
.5 .5 0.1
DESCRIP-
TION
REAR SPECIFICATION
CAMBER
(-.10 0.35)
TOTAL TOE-IN
(0.30 0.35)
THRUST ANGLE 0 0.4
4X2
4X4
1500
THRUST ANGLE -0.2 0.2
4X2
4X4
2500&3500
SPECIAL TOOLS
WHEEL ALIGNMENT
8876 - CAMBER/CASTER ADJUSTMENT TOOL
FRONT - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page page
FRONT - INDEPENDENT FRONT SUSPENSION
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 9
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . 12
BUSHINGS
REMOVAL
REMOVAL - LOWER CONTROL ARM
BUSHINGS - 4WD (LD) . . . . . . . . . . . . . . . . . 13
REMOVAL - TORSION BAR
CROSSMEMBER BUSHING. . . . . . . . . . . . . . 13
BUSHINGS - 2WD (LD) . . . . . . . . . . . . . . . . . 13
INSTALLATION
INSTALLATION - LOWER CONTROL ARM
BUSHINGS - 4WD (LD) . . . . . . . . . . . . . . . . . 14
INSTALLATION - TORSION BAR CROSS
MEMBER BUSHING. . . . . . . . . . . . . . . . . . . . 15
BUSHINGS - 2WD (LD) . . . . . . . . . . . . . . . . . 15
HUB / BEARING
REMOVAL
REMOVAL - 4X4 . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL - 4X2 . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION
INSTALLATION - 4X4 . . . . . . . . . . . . . . . . . . . 17
INSTALLATION - 4X2 . . . . . . . . . . . . . . . . . . . 18
KNUCKLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
LOWER BALL JOINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
LOWER CONTROL ARM
REMOVAL
REMOVAL - 4X4 (LD) . . . . . . . . . . . . . . . . . . . 21
REMOVAL - 4X2 . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION
INSTALLATION - 4X4 (LD) . . . . . . . . . . . . . . . 21
INSTALLATION - 4X2 . . . . . . . . . . . . . . . . . . . 22
SPRING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
SHOCK
DIAGNOSIS AND TESTING - SHOCK . . . . . . . . 24
REMOVAL
REMOVAL - 4X2 . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL - 4X4 . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION
INSTALLATION - 4X2 . . . . . . . . . . . . . . . . . . . 24
INSTALLATION - 4X4 . . . . . . . . . . . . . . . . . . . 24
STABILIZER BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
STABILIZER LINK
REMOVAL
REMOVAL - 4X4 . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL - 4X2 . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION
INSTALLATION - 4X4 . . . . . . . . . . . . . . . . . . . 26
INSTALLATION - 4X2 . . . . . . . . . . . . . . . . . . . 26
TORSION BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
UPPER BALL JOINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
UPPER CONTROL ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
2 - 8 FRONT - INDEPENDENT FRONT SUSPENSION DR
FRONT - INDEPENDENT
FRONT SUSPENSION
DESCRIPTION
DESCRIPTION
The front suspensi on i s desi gned to al l ow each
wheel to adapt to di fferent road surfaces i ndepen-
dentl y. The wheel s are mounted to hub/beari ngs
uni ts bol ted to the steeri ng knuckl e. The doubl e-row
hub beari ngs are seal ed and l ubri cated for l i fe. The
steeri ng knuckl es turn (pi vot) on bal l joi nts.
The front suspensi on i s compri sed of (Fi g. 1) (Fi g.
2):
Shock absorbers
Torsi on bar - 4X4 (LD onl y)
Coi l Spri ng - 4X2
Control arms
Steeri ng knuckl es
Stabi l i zer bar
Stabi l i zer l i nk
Ti e Rod Ends
Hub/Beari ng
Rack & Pi ni on
Bal l Joi nts
NOTE: Components attached with a nut must be
torqued to specification.
NOTE: Suspension components with rubber/ure-
thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. If springs are not at their
normal ride position, vehicle ride comfort could be
affected and premature bushing wear may occur.
Fig. 1 FRONT SUSPENSION - 4X2
1 - STABILIZER BAR
3 - STEERING KNUCKLE
4 - ROTOR
5 - CALIPER ADAPTER
6 - OUTER TIE ROD END
7 - STABILIZER LINK
8 - LOWER CONTROL ARM
9 - RACK & PINION
10 - COIL SPRING
11 - SHOCK ABSORBER
DR FRONT - INDEPENDENT FRONT SUSPENSION 2 - 9
DESCRIPTION
The upper control arm bol ts on frame brackets.
The frame brackets have sl otted hol es whi ch al l ow
the arms to be adjusted for caster and camber.
The l ower control arms bol t to the l ower frame
brackets and pi vots through bushi ngs.
The control arms have l ube for l i fe bal l studs. The
control arm travel (jounce) i s l i mi ted through the use
of rubber/urethane bumpers. Rebound travel i s l i m-
i ted by the shock absorber.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION Nm Ft. Lbs. In. Lbs.
Shock Absorber
Upper Nut
4X4
54 40
Shock Absorber
Lower Bolt
4X4
135 100
Shock Absorber
Upper Nut
4X2
54 40
Shock Absorber
Lower Bolt
4X2
28 21
Fig. 2 FRONT SUSPENSION - 4X4 (LD ONLY)
1 - STABILIZER BAR
4 - ROTOR
6 - SHOCK ABSORBER
7 - STABILIZER LINK
9 - INNER TIE ROD
10 - RACK & PINION
FRONT - INDEPENDENT FRONT SUSPENSION (Continued)
Lower Suspension Arm
Frame Nuts
204 150
Frame Nuts
285 210
Ball Joint Nut
1500 series only
52
Then an additional 90
38

Ball Joint Nut
(HD 4X2 only
135 100
Upper Suspension Arm
Frame Nuts
(LD)
132 97
Frame Nuts
(HD 4X2 only)
170 125
Ball Joint Nut
1500 series only
54
40
Stabilizer Bar
Frame Bolt
61 45
Stabilizer Link
Lower Control Arm Nut
102 75
Stabilizer Link
Stabilizer Bar Nut
38 27
Hub/Bearing
Bolts
(LD)
163 120
Hub/Bearing
Bolts
(HD 4X2)
176 130
Tie Rod End
Nut
61
45

SPECIAL TOOLS
FRONT SUSPENSION
PULLER - 8677
4WD BUSHING REMOVAL/INSTALL KIT - 8682
TORSION BAR LOADER/UNLOADER - 8686
TORSION BAR BUSHING REMOVAL/INSTALL - 8835
RECEIVER/ DRIVER BALLJOINT - 8698
BALL JOINT PRESS - C-4212F
2WD - LOWER CONTROL ARM BUSHING
REMOVAL/INSTALL - 8836
BUSHINGS
REMOVAL
BUSHINGS - 4WD (LD)
(1) Remove the l ower control arm (Refer to 2 -
SUSPENSI ON/FRONT/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the control arm i n a vi se.
NOTE: Extreme pressure lubrication must be used
on the threaded portions of the tool. This will
increase the longevity of the tool and insure proper
operation during the removal and installation pro-
cess.
FRAME MOUNTED BUSHING
(1) I nstal l the bushi ng tool 8682-3 (recei ver) and
8682-4 (dri ver) wi th the threaded rod and the two
beari ngs as shown for the repl acement of the frame
bushi ng (Fi g. 3)
CONTROL ARM BUSHING
(1) I nstal l bushi ng remover tool s 8682-2 (adapter),
8682-3 (recei ver) and 8682-4 (dri ver) wi th the
threaded rod and the two beari ngs as shown (Fi g. 4)
REMOVAL - TORSION BAR CROSSMEMBER
BUSHING
(1) Remove the torsi on bar cross member (Refer to
13 - FRAME & BUMPERS/FRAME/REAR CROSS-
MEMBER - REMOVAL).
(2) Secure the cross member i n a vi se.
cess.
(3) I nstal l speci al tool s 8838 threaded rod, 8835-1,
8835-4 and 8835-3 as shown i n the graphi c bel ow
(Fi g. 5).
(4) Press out the bushi ng.
BUSHINGS - 2WD (LD)
NOTE: HD 4X2 bushings are not servicable.
(1) Remove the l ower control arm (Refer to 2 -
SUSPENSI ON/FRONT/LOWER CONTROL ARM -
REMOVAL).
(2) Secure the control arm i n a vi se.
cess.
Fig. 3 FRAME BUSHING REMOVAL
1 - THREADED ROD
2 - BEARINGS
3 - 8682-3 (RECEIVER)
4 - FRAME
5 - 8682-4 (DRIVER)
6 - NUT
7 - BUSHING
Fig. 4 CONTROL ARM BUSHING REMOVAL
1 - 8682-4 (DRIVER)
2 - BUSHING
4 - 8682-2 (ADAPTER)
5 - 8682-3 (RECEIVER)
6 - BEARING
7 - THREADED ROD
LARGE BUSHING
(1) I nstal l bushi ng remover tool s 8836-2 (recei ver),
8836-4 (spacer) and 8836-5 (dri ver) wi th the threaded
rod 8839 and the beari ng as shown (Fi g. 6) for
repl acement of the l arge bushi ng.
SMALL BUSHING
(1) I nstal l the bushi ng tool 8836-6 (dri ver), 8836-3
(spacer) and 8836-2 (recei ver) wi th the threaded rod
8839 and the beari ng as shown for the repl acement
of the smal l bushi ng (Fi g. 7)
INSTALLATION
BUSHINGS - 4WD (LD)
NOTE: Be careful to properly orient the bushing
voids in the correct position to within 10. The
correct position places the long narrow void out-
board of the bushing and the short wide void
inboard of the bushing (Fig. 8).
Fig. 5 TORSION BAR CROSS MEMBER BUSHING -
REMOVAL
1 - 8838
2 - 8835-1
3 - 8835-4
4 - 8835-3
Fig. 6 LARGE LOWER CONTROL ARM BUSHING -
REMOVAL
1 - 8836-4 (SPACER)
2 - 8836-5 (DRIVER)
3 - 8839 (THREADED ROD)
4 - 8836-2 (RECEIVER)
Fig. 7 SMALL LOWER CONTROL ARM BUSHING -
REMOVAL
2 - 8836-6 (DRIVER)
3 - 8836-3 (SPACER)
4 - 8836-2 (RECEIVER)
Fig. 8 REAR LOWER CONTROL ARM BUSHING
1 - SHORT - WIDE VOID
2 - INWARD TOWARD VEHICLE
3 - LONG - THIN VOID
BUSHINGS (Continued)
FRAME MOUNTED BUSHING
cess.
(1) I nstal l the new bushi ng i nto the frame usi ng
speci al tool s 8682-3 (recei ver), 8682-1 (dri ver) wi th
the two beari ngs and the threaded rod (Fi g. 9)mak-
i ng sure to properl y ori ent the bushi ng as shown
(Fi g. 8).
CONTROL ARM BUSHING
(1) I nstal l the new l ower control arm bushi ngs i nto
the l ower control arm usi ng tool s 8682-1 (dri ver),
8682-5 (recei ver) and the two beari ngs wi th the
threaded rod (Fi g. 10) maki ng sure to properl y ori ent
the bushi ng i n the control (Fi g. 8).
(1) Remove the control arm from the vi se.
(2) I nstal l the l ower control arm (Refer to 2 - SUS-
PENSI ON/FRONT/LOWER CONTROL ARM -
I NSTALLATI ON).
(3) Reset the vehi cl e ri de hei ght (Refer to 2 - SUS-
PENSI ON/WHEEL ALI GNMENT - STANDARD
PROCEDURE).
(4) Perform a wheel al i gnment (Refer to 2 - SUS-
PROCEDURE).
INSTALLATION - TORSION BAR CROSS
MEMBER BUSHING
cess.
(1) I nstal l the new bushi ng i nto the cross member
usi ng speci al tool s 8835-2, 8835-4 and 8835-3 wi th
the beari ng and the threaded rod 8838 (Fi g. 11) mak-
i ng sure to properl y ori ent the bushi ng.
(2) Remove the cross member from the vi se.
(3) I nstal l the torsi on bar cross member (Refer to
13 - FRAME & BUMPERS/FRAME/REAR CROSS-
MEMBER - I NSTALLATI ON).
PROCEDURE).
PROCEDURE).
BUSHINGS - 2WD (LD)
NOTE: HD 4X2 bushings are not servicable.
Fig. 9 FRAME BUSHING INSTALL
1 - THREADED ROD
2 - BEARINGS
3 - 8682-3 (RECEIVER)
4 - BUSHING
5 - 8682-1 (DRIVER)
Fig. 10 CONTROL ARM BUSHING INSTALL
1 - THREADED ROD
2 - BEARINGS
3 - 8682-1 (DRIVER)
4 - BUSHING
5 - CONTROL ARM
6 - 8682-5 (RECEIVER)
7 - NUT
LARGE BUSHING
cess.
(1) I nstal l the new bushi ng i nto the l ower control
arm usi ng speci al tool s 8836-2 (recei ver), 8836-1
(dri ver), 8836-4 (spacer) wi th the beari ng and the
threaded rod (8839) (Fi g. 12).
SMALL BUSHING
(1) I nstal l the smal l bushi ngs i nto the l ower con-
trol arm usi ng tool s 8836-7 (dri ver), 8836-2 (recei ver),
88363 (spacer) and the beari ng wi th the threaded
rod (8839) (Fi g. 13).
(1) Remove the control arm from the vi se.
(2) I nstal l the l ower control arm (Refer to 2 - SUS-
PENSI ON/FRONT/LOWER CONTROL ARM -
I NSTALLATI ON).
PROCEDURE).
PROCEDURE).
HUB / BEARING
REMOVAL
REMOVAL - 4X4
(1) Rai se and support the vehi cl e.
(2) Remove the wheel and ti re assembl y.
(3) Remove the brake cal i per and rotor (Refer to 5
- BRAKES/HYDRAULI C/MECHANI CAL/ROTORS -
REMOVAL).
(4) Remove the ABS wheel speed sensor i f
equi pped, (Refer to 5 - BRAKES/ELECTRI CAL/
FRONT WHEEL SPEED SENSOR - REMOVAL).
(5) Remove the hal fshaft nut.
Fig. 11 TORSION BAR CROSS MEMBER BUSHING -
INSTALLATION
1 - 8835-2
2 - 8835-4
3 - 8835-3
4 - 8838
Fig. 12 LARGE LOWER CONTROL ARM BUSHING -
INSTALL
1 - 8836-1 (DRIVER)
3 - 8836-2 (RECEIVER)
4 - 8836-4 (SPACER)
Fig. 13 SMALL LOWER CONTROL ARM BUSHING -
INSTALL
1 - 8836-2 (RECEIVER)
3 - 8836-3 (SPACER)
4 - 8836-7 (DRIVER)
NOTE: Do not strike the knuckle with a hammer to
remove the tie rod end or the ball joint. Damage to
the steering knuckle will occur.
(6) Remove the ti e rod end nut and separate the
ti e rod from the knuckl e usi ng speci al tool 8677.
(7) Remove the upper bal l joi nt nut and separate
the upper bal l joi nt from the knuckl e usi ng speci al
tool 8677.
(8) Pul l down on the steeri ng knuckl e to separate
the hal fshaft from the hub/beari ng.
(9) Remove the three hub/beari ng mounti ng bol ts
from the steeri ng knuckl e (Fi g. 14).
(10) Sl i de the hub/beari ng out of the steeri ng
knuckl e (Fi g. 14).
(11) Remove the brake dust shi el d.
REMOVAL - 4X2
REMOVAL).
(4) Remove the ABS wheel speed sensor i f
equi pped, (Refer to 5 - BRAKES/ELECTRI CAL/
FRONT WHEEL SPEED SENSOR - REMOVAL)
(Fi g. 15)
(5) Remove the three hub/beari ng mounti ng bol ts
from the steeri ng knuckl e (Fi g. 15).
(6) Sl i de the hub/beari ng out of the steeri ng
(7) Remove the brake dust shi el d (Fi g. 15).
INSTALLATION
INSTALLATION - 4X4
(1) I nstal l the brake dust shi el d (Fi g. 16).
(2) I nstal l the hub/beari ng i nto the steeri ng
knuckl e and ti ghten the bol ts to 163 Nm (120 ft.
l bs.) (Fi g. 16).
(3) I nstal l the brake rotor and cal i per (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/ROTORS -
I NSTALLATI ON).
Fig. 14 HALFSHAFT / HUB/BEARING
1 - HUB/BEARING MOUNTING NUTS
2 - HALF SHAFT
Fig. 15 HUB/BEARING 4X2
1 - HUB/BEARING
2 - DUST SHIELD
4 - WHEEL SPEED SENSOR WIRE
5 - HUB/BEARING MOUNTING NUT
Fig. 16 HUB/BEARING 4X4
1 - HUB/BEARING
2 - DUST SHIELD
4- WHEEL SPEED SENSOR WIRE
5 - HUB/BEARING MOUNTING NUT
HUB / BEARING (Continued)
(4) I nstal l the ABS wheel speed sensor i f equi pped
(Refer to 5 - BRAKES/ELECTRI CAL/FRONT
WHEEL SPEED SENSOR - I NSTALLATI ON).
(5) I nstal l the upper bal l joi nt nut to the steeri ng
knuckl e and ti ghten to 54 Nm (40 ft. l bs.) (on 1500
seri es onl y an addi ti onal 90 turn).
(6) I nstal l the ti e rod end nut to the steeri ng
knuckl e and ti ghten to 61 Nm (45 ft. l bs.) then an
addi ti onal 90.
(7) I nstal l the hal fshaft nut and ti ghten to 251
Nm (185 ft. l bs.).
(8) I nstal l the wheel and ti re assembl y (Refer to 22
- TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Remove the support and l ower vehi cl e.
INSTALLATION - 4X2
(1) I nstal l the brake dust shi el d (Fi g. 15).
(2) I nstal l the hub/beari ng i nto the steeri ng
knuckl e and ti ghten the bol ts to 163 Nm (120 ft.
l bs.) (Fi g. 15).
(3) I nstal l the brake rotor and cal i per (Refer to 5 -
I NSTALLATI ON).
WHEEL SPEED SENSOR - I NSTALLATI ON) (Fi g.
15).
DURE).
KNUCKLE
DESCRIPTION
The knuckl e i s a si ngl e casti ng wi th l egs machi ned
for the upper and l ower bal l joi nts. The knuckl e al so
has machi ned mounti ng l ocati ons for the front brake
cal i pers and hub beari ng.
OPERATION
The steeri ng knuckl e pi vot between the upper and
l ower bal l joi nt. Steeri ng l i nkage attached to the
knuckl e al l ows the vehi cl e to be steered.
REMOVAL
(3) Remove the brake cal i per, rotor (Refer to 5 -
REMOVAL), shi el d and ABS wheel speed sensor i f
equi pped (Refer to 5 - BRAKES/ELECTRI CAL/
FRONT WHEEL SPEED SENSOR - REMOVAL).
(4) Remove the front hal fshaft nut (i f equi pped).
(5) Remove the ti e rod end nut. Separate the ti e
rod from the knuckl e wi th Remover 8677.
CAUTION: When installing Remover 8677 to sepa-
rate the ball joint, be careful not to damage the ball
joint seal.
(6) Remove the upper bal l joi nt nut. Separate the
bal l joi nt from the knuckl e wi th Remover 8677 (Fi g.
17)
(7) Remove the l ower bal l joi nt nut. Separate the
bal l joi nt from the knuckl e wi th Remover 8677 (Fi g.
18) and remove the knuckl e.
Fig. 17 STEERING KNUCKLE
2 - SHOCK
3 - HALFSHAFT
4 - DISC BRAKE CALIPER
5 - HUB/BEARING
Fig. 18 LOWER BALL JOINT SEPARATION
2 - SPECIAL TOOL 8677
(8) Remove the hub/beari ng from the steeri ng
knuckl e (Refer to 2 - SUSPENSI ON/FRONT/HUB /
BEARI NG - REMOVAL).
INSTALLATION
CAUTION: The ball joint stud tapers must be
CLEAN and DRY before installing the knuckle.
Clean the stud tapers with mineral spirits to remove
dirt and grease.
NOTE: When installing hub/bearing with ABS
brakes, position the speed sensor opening towards
the front of the vehicle.
(1) I nstal l the hub/beari ng to the steeri ng knuckl e
and ti ghten the bol ts to 163 Nm (120 ft. l bs.)(LD) or
176 Nm (130 ft. l bs.)(HD 4X2) (Fi g. 19).
(2) I nstal l the knuckl e onto the upper and l ower
bal l joi nts (Fi g. 19).
(3) I nstal l the upper and l ower bal l joi nt nuts.
Ti ghten the upper bal l joi nt nut to 54 Nm (40 ft.
l bs.) (on 1500 seri es onl y an addi ti onal 90 turn i s
requi red) and the l ower bal l joi nt nut to 52 Nm (38
ft. l bs.)(on 1500 seri es onl y an addi ti onal 90 turn i s
requi red)(LD) or 135 Nm (100 ft. l bs.)(HD 4X2).
(4) Remove the hydraul i c jack from the l ower sus-
pensi on arm.
(5) I nstal l the ti e rod end and ti ghten the nut to
61 Nm (45 ft. l bs.).
(6) I nstal l the front hal fshaft i nto the hub/beari ng
(i f equi pped).
(7) I nstal l the the hal fshaft nut and ti ghten to 251
Nm (185 ft. l bs.) (i f equi pped).
WHEEL SPEED SENSOR - I NSTALLATI ON) and
brake shi el d, rotor and cal i per (Refer to 5 - BRAKES/
HYDRAULI C/MECHANI CAL/ROTORS - I NSTALLA-
TI ON).
DURE).
(10) Remove the support and l ower the vehi cl e.
PROCEDURE).
LOWER BALL J OINT
JOINT
NOTE: If the ball joint is equipped with a lubrication
fitting, grease the joint then road test the vehicle
before performing test.
(1) Rai se the front of the vehi cl e. Pl ace safety fl oor
stands under both l ower control arms as far outboard
as possi bl e. Lower the vehi cl e to al l ow the stands to
support some or al l of the vehi cl e wei ght.
(2) Mount a di al i ndi cator sol i dl y to the topsi de of
the l ower control arm and then zero the di al i ndi ca-
tor.
(3) Posi ti on the i ndi cator pl unger agai nst the bot-
tom surface of the steeri ng knuckl e.
NOTE: The dial indicator plunger must be perpen-
dicular to the machined surface of the steering
knuckle.
(4) Posi ti on a pry bar under the ti re assembl y. Pry
upwards on the ti re assembl y.
(5) I f the travel exceeds 0.5 mm (0.020 i n.), repl ace
the l ower bal l joi nt (Refer to 2 - SUSPENSI ON/
FRONT/LOWER BALL JOI NT - REMOVAL).
REMOVAL
(1) Remove the ti re and wheel assembl y.
REMOVAL).
(3) Di sconnect the ti e rod from the steeri ng
knuckl e (Refer to 19 - STEERI NG/LI NKAGE/TI E
ROD END - REMOVAL).
(4) Remove the steeri ng knuckl e (Fi g. 20)(Refer to
2 - SUSPENSI ON/FRONT/KNUCKLE - REMOVAL).
(5) Move the hal fshaft to the si de and support the
hal fshaft out of the way (I f Equi pped).
3 - LOWER BALL JOINT NUT
KNUCKLE (Continued)
(6) Remove the snap ri ng, from the l ower control
arm (HD 4X2 onl y)
cess.
(7) Press the bal l joi nt from the l ower control arm
usi ng speci al tool s C-4212F (PRESS), 8698-2
(RECEI VER) and 8698-3 (DRI VER) (Fi g. 21).
INSTALLATION
cess.
(1) I nstal l the bal l joi nt i nto the control arm and
press i n usi ng speci al tool s C-4212F (press), 8698-1
(dri ver) and 8698-3 (recei ver) (Fi g. 22).
(2) I nstal l the bal l joi nt boot.
(3) Stake the bal l joi nt fl ange i n four evenl y
spaced pl aces around the bal l joi nt fl ange, usi ng a
chi sel and hammer (LD onl y).
(4) Repl ace the snap ri ng (HD 4X2 onl y)
(5) Remove the support for the hal fshaft and
i nstal l i nto posi ti on (I f Equi pped).
(6) I nstal l the steeri ng knuckl e (Refer to 2 - SUS-
PENSI ON/FRONT/KNUCKLE - I NSTALLATI ON).
(7) I nstal l the ti e rod end i nto the steeri ng knuckl e
(Refer to 19 - STEERI NG/LI NKAGE/TI E ROD END -
I NSTALLATI ON).
(8) I nstal l and ti ghten the hal fshaft nut to 251
Nm (185 ft. l bs.). (I f Equi pped).
(9) I nstal l the brake cal i per and rotor (Refer to 5 -
I NSTALLATI ON).
(10) I nstal l the ti re and wheel assembl y (Refer to
22 - TI RES/WHEELS/WHEELS - STANDARD PRO-
CEDURE).
(11) Check the vehi cl e ri de hei ght (Refer to 2 -
SUSPENSI ON/WHEEL ALI GNMENT - STANDARD
PROCEDURE).
Fig. 20 LOWER BALL JOINT SEPARATION
Fig. 21 REMOVAL LOWER BALL JOINT
1 - PRESS - C-4212-F
2 - DRIVER - 8698-3
3 - BALL JOINT
4 - RECEIVER - 8698-2
Fig. 22 INSTALL LOWER BALL JOINT
1 - PRESS - C-4212-F
2 - DRIVER - 8698-1
3 - BALL JOINT
5 - RECEIVER - 8698-3
LOWER BALL J OINT (Continued)
PROCEDURE).
LOWER CONTROL ARM
REMOVAL
REMOVAL - 4X4 (LD)
(3) Remove the upper bal l joi nt nut. Separate bal l
joi nt from the steeri ng knuckl e wi th Remover 8677.
(4) Remove the front hal fshaft, (Refer to 3 - DI F-
FERENTI AL & DRI VELI NE/HALF SHAFT -
REMOVAL).
(5) Remove the torsi on bar, (Refer to 2 - SUSPEN-
SI ON/FRONT/TRACK BAR - REMOVAL).
(6) Remove the shock absorber l ower bol t.
(7) Remove the stabi l i zer bar l i nk (Refer to 2 -
SUSPENSI ON/FRONT/STABI LI ZER LI NK -
REMOVAL).
(8) Remove the l ower bal l joi nt nut. Separate bal l
joi nt from the steeri ng knuckl e wi th Remover 8677.
(9) Remove the control arm pi vot bol ts and suspen-
si on arm from frame rai l brackets (Fi g. 23).
REMOVAL - 4X2
(3) Support the l ower control arm at the outboard
si de of the l ower control arm to support vehi cl e
wei ght.
(4) Remove the shock (Refer to 2 - SUSPENSI ON/
FRONT/SHOCK - REMOVAL).
(5) I nstal l Spri ng Compressor DD-1278 up through
the l ower suspensi on arm, coi l spri ng and shock hol e
i n the frame. The bel l -shaped adapter goes agai nst
the l ower suspensi on arm. I nstal l the nut on top of
the tool at the shock hol e.
(6) Ti ghten the spri ng compressor nut agai nst bel l -
shaped adapter fi nger ti ght then l oosen 1/2 turn.
NOTE: This will hold the spring in place until the
lower suspension arm is separated from the steer-
ing knuckle.
(7) Remove the stabi l i zer l i nk (Refer to 2 - SUS-
PENSI ON/FRONT/STABI LI ZER LI NK - REMOVAL).
(8) Remove the l ower bal l joi nt nut at the steeri ng
knuckl e.
(9) I nstal l Bal l Joi nt Remover tool 8677 on the
l ower bal l joi nt and separate the bal l joi nt from the
knuckl e.
NOTE: Do not allow the upper control arm and
steering knuckle to rebound downwards they must
be supported.
(10) Support the upper control arm and steeri ng
knuckl e out of the way.
(11) Remove the l ower control arm support.
(12) Ti ghten the spri ng compressor tool to al l ow
cl earance for the l ower bal l joi nt to be removed out of
the knuckl e.
(13) Loosen the tensi on on the spri ng compressor
tool sl owl y al l owi ng the l ower suspensi on arm to
pi vot downward.
(14) Remove the spri ng compressor tool .
(15) Remove coi l spri ng and i sol ator pad from the
vehi cl e (Fi g. 26).
(16) Remove the front and rear pi vot bol ts (Fi g.
24).
(17) Remove the l ower control arm.
INSTALLATION
INSTALLATION - 4X4 (LD)
(1) Posi ti on the l ower control arm at the frame rai l
brackets. I nstal l the pi vot bol ts and nuts. Ti ghten the
nuts fi nger-ti ght.
CAUTION: The ball joint stud taper must be CLEAN
and DRY before installing the knuckle. Clean the
stud taper with mineral spirits to remove dirt and
grease.
(2) I nsert the l ower bal l joi nt i nto the steeri ng
knuckl e. I nstal l and ti ghten the retai ni ng nut to 52
Fig. 23 LOWER CONTROL ARM
3 - FRONT BOLT
4 - NUTS
5 - REAR BOLT
Nm (38 ft. l bs.)(on 1500 seri es onl y an addi ti onal 90
turn i s requi red).
(3) I nstal l the torsi on bar, (Refer to 2 - SUSPEN-
SI ON/FRONT/TRACK BAR - I NSTALLATI ON).
(4) I nstal l shock absorber l ower bol t and ti ghten to
135 Nm (100 ft. l bs.).
(5) I nstal l the front hal fshaft, (Refer to 3 - DI F-
FERENTI AL & DRI VELI NE/HALF SHAFT -
I NSTALLATI ON).
(6) I nsert the upper bal l joi nt i nto the steeri ng
knuckl e. I nstal l and ti ghten the retai ni ng nut to 54
Nm (40 ft. l bs.)(on 1500 seri es onl y an addi ti onal 90
turn i s requi red).
(7) I nstal l the stabi l i zer bar l i nk (Refer to 2 - SUS-
PENSI ON/FRONT/STABI LI ZER LI NK - I NSTALLA-
TI ON).
(8) Ti ghten the l ower control arm front pi vot nut
to 204 Nm (150 ft. l bs.). Ti ghten rear pi vot bol t to
204 Nm (150 ft. l bs.).
(9) I nstal l the wheel and ti re assembl y,(Refer to 22
DURE).
(11) Adjust the front suspensi on hei ght and per-
form a wheel al i gnment (Refer to 2 - SUSPENSI ON/
WHEEL ALI GNMENT - STANDARD PROCEDURE).
INSTALLATION - 4X2
(1) I nstal l the l ower control arm i nto pl ace on the
vehi cl e.
(2) I nstal l the front and rear control arm pi vot
bol ts fi nger ti ght.
(3) I nstal l the coi l spri ng i nto the frame pocket(Re-
fer to 2 - SUSPENSI ON/FRONT/SPRI NG - I NSTAL-
LATI ON).
(4) I nstal l the Spri ng Compressor DD-1278 up
through the l ower suspensi on arm, coi l spri ng and
shock hol e i n the frame.
(5) Ti ghten the tool nut to compress the coi l
spri ng.
(6) Remove the support from the upper control
arm and steeri ng knuckl e.
(7) Posi ti on the l ower bal l joi nt i nto the steeri ng
knuckl e.
(8) I nstal l the retai ni ng nut on the l ower bal l joi nt
and ti ghten to 52 Nm (38 ft. l bs.)(on 1500 seri es onl y
an addi ti onal 90 turn i s requi red) or 135 Nm (100
ft. l bs.)(HD 4X2 onl y).
wei ght.
(11) I nstal l the shock absorber. (Refer to 2 - SUS-
PENSI ON/FRONT/SHOCK - I NSTALLATI ON).
(12) I nstal l the stabi l i zer l i nk (Refer to 2 - SUS-
TI ON).
(14) I nstal l the wheel and ti re assembl y and l ower
the vehi cl e. (Refer to 22 - TI RES/WHEELS/WHEELS
(15) Lower the vehi cl e to the fl oor wi th vehi cl e
wei ght and Ti ghten the front and rear control arm
pi vot bol ts to 204 Nm (150 ft. l bs.)(LD) or 285 Nm
(210 ft. l bs.)(HD 4X2 onl y).
PROCEDURE).
SPRING
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove the front wheel and ti re assembl y.
wei ght.
(4) Remove the shock absorber (Refer to 2 - SUS-
PENSI ON/FRONT/SHOCK - REMOVAL).
i n the frame. The bel l -shaped adapter goes agai nst
the l ower suspensi on arm. I nstal l the nut on top of
the tool at the shock hol e (Fi g. 25).
(6) Ti ghten the spri ng compressor nut agai nst bel l -
shaped adapter fi nger ti ght then l oosen 1/2 turn.
NOTE: This will hold the spring in place until the
lower suspension arm is separated from the steer-
ing knuckle.
Fig. 24 LOWER CONTROL ARM - 4X2
2 - REAR PIVOT BOLT
LOWER CONTROL ARM (Continued)
(7) Remove the stabi l i zer l i nk (Refer to 2 - SUS-
PENSI ON/FRONT/STABI LI ZER LI NK - REMOVAL).
(8) Remove the l ower bal l joi nt nut at the steeri ng
knuckl e.
(9) I nstal l Bal l Joi nt Remover tool 8677 on the
l ower bal l joi nt and separate the bal l joi nt from the
knuckl e.
(10)
NOTE: Do not allow the upper control arm and
steering knuckle to rebound downwards they must
be supported.Support the upper control arm and
steering knuckle out of the way.
(12) Ti ghten the spri ng compressor tool to al l ow
cl earance for the l ower bal l joi nt to be removed out of
the knuckl e.
NOTE: It may necessary to loosen the control arm
pivot bolt to allow downward swing.
(13) Loosen the tensi on on the spri ng compressor
tool sl owl y al l owi ng the l ower suspensi on arm to
pi vot downward.
(15) Remove coi l spri ng and i sol ator pad from the
INSTALLATION
(1) Tape the i sol ator pad to the top of the coi l
spri ng. Posi ti on the spri ng i n the l ower suspensi on
arm wel l . Be sure that the coi l spri ng i s seated i n the
wel l .
i n the frame.
(3) Ti ghten the tool nut to compress the coi l
spri ng.
(4) Remove the support from the upper control
arm and steeri ng knuckl e.
(5) Posi ti on the l ower bal l joi nt i nto the steeri ng
knuckl e.
(6) I nstal l the retai ni ng nut on the l ower bal l joi nt
and ti ghten to 52 Nm (38 ft. l bs.)(on 1500 seri es onl y
an addi ti onal 90 turn i s requi red) or 135 Nm (100
ft. l bs.)(HD 4X2 onl y).
wei ght.
(9) I nstal l the shock absorber. (Refer to 2 - SUS-
PENSI ON/FRONT/SHOCK - I NSTALLATI ON).
(10) I nstal l the stabi l i zer l i nk (Refer to 2 - SUS-
TI ON).
(12) I nstal l the wheel and ti re assembl y and l ower
the vehi cl e. (Refer to 22 - TI RES/WHEELS/WHEELS
(13) Lower the vehi cl e to the fl oor wi th vehi cl e
wei ght and Ti ghten the front and rear control arm
pi vot bol ts i f l oosened to 204 Nm (150 ft. l bs.)(LD) or
285 Nm (210 ft. l bs.)(HD 4X2 onl y).
PROCEDURE).
Fig. 25 SPRING COMPRESSOR TOOL
1 - SPECIAL TOOL DD-1278
2 - BELL-SHAPED ADAPTER
Fig. 26 COIL SPRING
1 - COIL SPRING
5 - SHOCK
SPRING (Continued)
SHOCK
DIAGNOSIS AND TESTING - SHOCK
A knocki ng or rattl i ng noi se from a shock absorber
may be caused by movement between mounti ng
bushi ngs and metal brackets or attachi ng compo-
nents. These noi ses can usual l y be stopped by ti ght-
eni ng the attachi ng nuts. I f the noi se persi sts,
i nspect for damaged and worn bushi ngs, and attach-
i ng components. Repai r as necessary i f any of these
condi ti ons exi st.
A squeaki ng noi se from the shock absorber may be
caused by the hydraul i c val vi ng and may be i ntermi t-
tent. Thi s condi ti on i s not repai rabl e and the shock
absorber must be repl aced.
The shock absorbers are not refi l l abl e or adjust-
abl e. I f a mal functi on occurs, the shock absorber
must be repl aced. To test a shock absorber, hol d i t i n
an upri ght posi ti on and force the pi ston i n and out of
the cyl i nder four or fi ve ti mes. The acti on throughout
each stroke shoul d be smooth and even.
The shock absorber bushi ngs do not requi re any
type of l ubri cati on. Do not attempt to stop bushi ng
noi se by l ubri cati ng them. Grease and mi neral oi l -
base l ubri cants wi l l deteri orate the bushi ng.
REMOVAL
REMOVAL - 4X2
(2) Support the l ower control arm outboard end.
(3) Remove the upper shock absorber nut, retai ner
and grommet.
(4) Remove the l ower nuts and remove the shock
absorber.
REMOVAL - 4X4
(3) Support the l ower control arm outboard end.
(4) Remove the upper shock nut and wi th the i nsu-
l ator and retai ner (Fi g. 27).
(5) Remove the l ower shock bol t (Fi g. 27).
(6) Remove the shock
INSTALLATION
INSTALLATION - 4X2
NOTE: Upper shock nut must be replaced or use
Mopar Lock N Seal or Loctite 242 on existing nut.
(1) I nstal l the l ower retai ner and grommet on the
shock absorber stud. I nsert the shock absorber
through the frame bracket hol e.
(2) I nstal l the l ower nuts and ti ghten the nuts to
28 Nm (21 ft. l bs.).
(3) I nstal l the upper grommet, retai ner and new
nut or use Mopar Lock N Seal or Locti te 242 on
exi sti ng nut, on the shock absorber stud. Ti ghten nut
to 54 Nm (40 ft. l bs.).
(4) Remove the support from the l ower control arm
outboard end.
(5) Lower the vehi cl e.
INSTALLATION - 4X4
(1) I nstal l the upper part of the shock i nto the
frame bracket wi th the i nsul ators and retai ners (Fi g.
27).
(2) I nstal l the nut and Ti ghten to 54 Nm (40 ft.
l bs.).
(3) I nstal l the l ower part of the shock i nto the
l ower control arm and Ti ghten the bol t to 135 Nm
(100 ft. l bs.) (Fi g. 27).
(4) Remove the support from the l ower control arm
outboard end.
(5) I nstal l the ti re and wheel assembl y (Refer to 22
DURE).
STABILIZER BAR
DESCRIPTION
The bar extends across the front undersi de of the
chassi s and connects to the frame crossmember. The
Fig. 27 SHOCK 4X4
1 - INSULATOR & RETAINER
2 - NUT
3 - SHOCK ABSORBER
4 - BOLT
ends of the bar mount to the l ower suspensi on arm.
Al l mounti ng poi nts of the stabi l i zer bar are i sol ated
by bushi ngs (Fi g. 28).
OPERATION
The stabi l i zer bar i s used to mi ni mi ze vehi cl e front
sway duri ng turns. The bar hel ps to mai ntai n a fl at
atti tude to the road surface.
REMOVAL
NOTE: To service the stabilizer bar the vehicle
should be on a drive on hoist. The vehicle suspen-
sion must be at curb height for stabilizer bar instal-
lation.
(1) Remove the stabi l i zer bar l i nk upper nuts and
remove the retai ners and grommets (Fi g. 29).
(2) Remove the stabi l i zer bar retai ner, bol ts and
retai ners from the frame crossmember (Fi g. 29) and
remove the bar.
(3) I f necessary, remove the bushi ngs from the sta-
bi l i zer bar Do not cut the old bushings off the
stabilizer bar use a mixture of soapy water in
order to aid in sliding the bushing off.
INSTALLATION
NOTE: To service the stabilizer bar the vehicle must
be on a drive on hoist. The vehicle suspension
must be at curb height for stabilizer bar installation.
(1) I f removed, I nstal l the bushi ngs on the stabi -
l i zer bar usi ng a mi xture of soapy water or equi va-
l ent i n order to sl i de the bushi ng over the bar wi th
ease Do not cut the new bushing for installa-
tion.
(2) Posi ti on the stabi l i zer bar on the frame cross-
member brackets and i nstal l the bracket and bol ts
fi nger-ti ght (Fi g. 29).
NOTE: Check the alignment of the bar to ensure
there is no interference with the either frame rail or
chassis component. Spacing should be equal on
both sides.
(3) I nstal l the stabi l i zer bar to the stabi l i zer l i nk
and i nstal l the grommets and retai ners.
(4) I nstal l the nuts to the stabi l i zer l i nk and
ti ghten to 38 Nm (27 ft. l bs.).
(5) Ti ghten the brackets to the frame to 61 Nm
(45 ft. l bs.).
STABILIZER LINK
REMOVAL
REMOVAL - 4X4
(2) Remove the l ower nut (Fi g. 29).
(3) Remove the upper nut, retai ners and grommets
(Fi g. 29).
(4) Remove the stabi l i zer l i nk from the vehi cl e
(Fi g. 29).
REMOVAL - 4X2
(2) Remove the l ower nut (Fi g. 29).
(3) Remove the upper nut, retai ner and grommets
(Fi g. 29).
(4) Remove the stabi l i zer l i nk from the vehi cl e
(Fi g. 29).
Fig. 28 STABILIZER BAR
Fig. 29 STABILIZER LINK
1 - STABILIZER LINK
2 - SWAY BAR BRACKET
STABILIZER BAR (Continued)
INSTALLATION
INSTALLATION - 4X4
(1) I nstal l the stabi l i zer l i nk to the vehi cl e.
(2) I nstal l the l ower nut and Ti ghten to 102 Nm
(75 ft. l bs.).
(3) I nstal l the retai ners, grommets and upper nut
and Ti ghten to 38 Nm (27 ft. l bs.).
INSTALLATION - 4X2
(1) I nstal l the stabi l i zer l i nk to the vehi cl e (Fi g.
29).
(2) I nstal l the l ower nut and Ti ghten to 102 Nm
(75 ft. l bs.).
(3) I nstal l the retai ners, grommets and upper nut
and Ti ghten to 38 Nm (27 ft. l bs.).
TORSION BAR
DESCRIPTION
The front of the bar connects to the back si de of
the l ower suspensi on arm. The rear end of the bar i s
mounted i n a anchor that rests i n the frame cross-
member.
OPERATION
The torsi on bars are used to control ri de hei ght
and ri de qual i ty. The vehi cl e hei ght i s adjusted
through an anchor adjustment bol t that i ncreases or
decreases the wi nd up of the torsi on bar. I ncreasi ng
or decreasi ng the bar angl e changes the wi nd up of
the suspensi on arms.
REMOVAL
CAUTION: The left and right side torsion bars are
NOT interchangeable. The bars are identified and
stamped R or L, for right or left. The bars do not
have a front or rear end and can be installed with
either end facing forward.
(1) Rai se and support the vehi cl e wi th the front
suspensi on hangi ng.
(2) Remove the transfer case ski d pl ate (Refer to
13 - FRAME & BUMPERS/FRAME/TRANSFER
CASE SKI D PLATE - REMOVAL).
NOTE: Count and record the number of turns for
installation reference.
(3) Mark the adjustment bol t setti ng.
(4) I nstal l Speci al Tool - 8686 to the anchor arm
and the cross member (Fi g. 30).
(5) I ncrease the tensi on on the anchor arm tool
unti l the l oad i s removed from the adjustment bol t
and the adjuster nut (Fi g. 30).
(6) Turn the adjustment bol t countercl ockwi se to
remove the bol t and the adjuster nut..
(7) Remove the Speci al Tool - 8686, al l owi ng the
torsi on bar to unl oad (Fi g. 30).
(8) Remove torsi on bar and anchor. Remove anchor
from torsi on bar (Fi g. 31).
(9) Remove al l forei gn materi al from torsi on bar
mounti ng i n anchor and suspensi on arm.
(10) I nspect adjustment bol t, beari ng and swi vel
for damage.
Fig. 30 LOADING/UNLOADING TORSION BAR
2 - CROSSMEMBER
Fig. 31 TORSION BAR
1 - ANCHOR
2 - SWIVEL
3 - TORSION BAR
STABILIZER LINK (Continued)
INSTALLATION
CAUTION: The left and right side torsion bars are
NOT interchangeable. The bars are identified and
stamped R or L, for right or left. The bars do not
have a front or rear end and can be installed with
either end facing forward.
(1) I nsert torsi on bar ends i nto anchor and suspen-
si on arm.
(2) Posi ti on the anchor i n the frame crossmember.
(3) I nstal l Speci al Tool - 8686 to the anchor and
the crossmember (Fi g. 30).
(4) I ncrease the tensi on on the anchor i n order to
l oad the torsi on bar.
(5) I nstal l the adjustment bol t and the adjuster
nut.
(6) Turn adjustment bol t cl ockwi se the recorded
amount of turns.
(7) Remove tool - 8686 from the torsi on bar cross-
member (Fi g. 30).
(8) I nstal l the transfer case ski d pl ate (Refer to 13
- FRAME & BUMPERS/FRAME/TRANSFER CASE
SKI D PLATE - I NSTALLATI ON).
(9) Lower vehi cl e and adjust the front suspensi on
hei ght (Refer to 2 - SUSPENSI ON/WHEEL ALI GN-
MENT - STANDARD PROCEDURE).
PROCEDURE).
UPPER BALL J OINT
JOINT
NOTE: If the ball joint is equipped with a lubrication
fitting, grease the joint then road test the vehicle
before performing test.
(2) Remove the front ti res.
(3) Mount a di al i ndi cator sol i dl y to the frame and
then zero the di al i ndi cator.
(4) Posi ti on di al i ndi cator pl unger on the topsi de of
the upper bal l joi nt (Fi g. 32).
dicular to the machined surface of the ball joint
(Fig. 32).
NOTE: Use care not to pry or tear the ball joint
boot, when checking the free play.
(5) Posi ti on a pry bar between the steeri ng
knuckl e and the upper control arm. Pry upwards on
the upper control arm (Fi g. 32).
the upper control arm si nce the upper bal l joi nt i s
i ntegral to the arm (Refer to 2 - SUSPENSI ON/
FRONT/UPPER CONTROL ARM - REMOVAL).
(7) I f the upper bal l joi nt i s wi thi n specs rei nstal l
the front ti res (Refer to 22 - TI RES/WHEELS/
WHEELS - STANDARD PROCEDURE).
Fig. 32 UPPER BALL JOINT PLAY
1 - DIAL INDICATOR
3 - PRY BAR
4 - KNUCKLE
5 - BALL JOINT BOOT
TORSION BAR (Continued)
UPPER CONTROL ARM
REMOVAL
(2) Remove wheel and ti re assembl y.
(3) Remove the nut from upper bal l joi nt.
(4) Separate upper bal l joi nt from the steeri ng
knuckl e wi th Remover 8677 (Fi g. 33)
CAUTION: When installing Remover 8677 to sepa-
rate the ball joint, be careful not to damage the ball
joint seal.
(5) Remove the control arm pi vot bol ts and remove
control arm (Fi g. 34).
INSTALLATION
(1) Posi ti on the control arm i nto the frame brack-
ets. I nstal l bol ts and ti ghten to 132 Nm (97 ft.
l bs.)(LD) or 170 Nm (125 ft. l bs.)(HD 4X2 onl y).
(2) I nsert the bal l joi nt i n steeri ng knuckl e and
ti ghten the upper bal l joi nt nut to 54 Nm (40 ft.
l bs.)(on 1500 seri es onl y an addi ti onal 90 turn i s
requi red).
(3) I nstal l the wheel and ti re assembl y,(Refer to 22
DURE).
(5) Perform a wheel al i gnment, (Refer to 2 - SUS-
PROCEDURE).
Fig. 33 UPPER BALL JOINT SEPARATION
2 - REMOVER
Fig. 34 UPPER CONTROL ARM
1 - REAR PIVOT BOLT
FRONT - LINK/COIL
TABLE OF CONTENTS
page page
FRONT - LINK/COIL
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 29
SPECIAL TOOLS
9 1/4 AA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
HUB / BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
LOWER BALL JOINT
JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
UPPER BALL JOINT
JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
KNUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
UPPER SUSPENSION ARM
REMOVAL
REMOVAL - LEFT . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL - RIGHT . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION
INSTALLATION - LEFT . . . . . . . . . . . . . . . . . . 37
INSTALLATION - RIGHT . . . . . . . . . . . . . . . . 37
LOWER SUSPENSION ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
SHOCK
DIAGNOSIS AND TESTING - SHOCK . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
SPRING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
STABILIZER BAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
FRONT - LINK/COIL
SPECIFICATIONS
TORQUE CHART
Shock Absorber
Upper Nut
54 40
Shock Absorber
Lower Bolt
136 100
Frame Nuts
217 160
Axle Nut
217 160
Frame Nuts
149 110
Axle Nut
149 110
DR FRONT - LINK/COIL 2 - 29
Stabilizer Bar
Frame Bolt
61 45
Stabilizer Link
Lower Control Arm Nut
102 75
Stabilizer Link
Axle Bracket
71 52
Stabilizer Link
Stabilizer Bar Nut
38 27
Hub/Bearing
Bolts
202 149
Axle Nut 179 Beginning Torque,
Then Rotate 5 to 10
Times With a Final Torque
of 356
132 Beginning Torque,
Then Rotate 5 to 10
Times With a Final Torque
of 263
Tie Rod End

Nut
75 55
NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at nor-
mal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners
are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and pre-
mature bushing wear may occur.
SPECIAL TOOLS
9 1/4 AA
Puller C-3894A
Remover, Wheel Stud C-4150A
BALL JOINT PRESS - C-4212F
REMOVER / INSTALLER BALLJOINT - 8445
2 - 30 FRONT - LINK/COIL DR
FRONT - LINK/COIL (Continued)
HUB / BEARING
REMOVAL
(3) Remove the hub extensi on mounti ng nuts and
remove the extensi on from the rotor i f equi pped (Fi g.
1).
(4) Remove the brake cal i per, (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/DI SC
BRAKE CALI PERS - REMOVAL).
(5) Remove the cotter pi n and the hub nut from
the axl e shaft (Fi g. 2).
(6) Di sconnect the ABS wheel speed sensor wi re
from under the hood. Remove the sensor wi re from
the frame and steeri ng knuckl e i f equi pped.
(7) Back off the hub/beari ng mounti ng bol ts 1/4
i nch each (Fi g. 3). Then tap the bol ts wi th a hammer
to l oosen the hub/beari ng from the steeri ng knuckl e.
(8) Remove the hub/beari ng mounti ng bol ts and
remove the hub/beari ng.
(9) Remove the rotor assembl y (Fi g. 4), brake
shi el d and spacer from the steeri ng knuckl e.
RECEIVER CUP - 6761
BALLJOINT RECIEVER/INSTALLER KIT- 8975
Fig. 1 Hub Extension
1 - HUB EXTENSION
2 - HUB
Fig. 2 Hub Nut Cotter Pin
1 - HUB NUT
2 - COTTER PIN
Fig. 3 Hub/Bearing Mounting Bolts
1 - SOCKET AND EXTENSION
2 - ROTOR AND HUB
FRONT - LINK/COIL (Continued)
(10) Press out the wheel studs/hub extensi on studs
and separate the rotor from the hub (Fi g. 5).
(11) Remove the wheel speed sensor (Fi g. 6) from
the hub beari ng i f equi pped.
INSTALLATION
(1) I nstal l the wheel speed sensor i n the hub bear-
i ng i f equi pped.
(2) Posi ti on the rotor on the hub/beari ng.
(3) Press the wheel studs/hub extensi on studs
through the back si de of the rotor and through the
hub beari ng fl ange (Fi g. 7).
(4) Appl y a l i beral quanti ty of anti -sei ze compound
to the spl i nes of the front dri ve shaft.
(5) I nsert the two rearmost, top and bottom rotor
hub bol ts i n the steeri ng knuckl e. I nsert the bol ts
through the back si de of the knuckl e so they extend
out the front face as shown.
Fig. 4 Rotor Hub/Bearing Assembly
1 - ROTOR AND HUB
2 - UNIT BEARING ASSEMBLY
3 - SEAL
Fig. 5 ROTOR AND HUB/BEARING
1 - HUB BEARING
2 - ROTOR
Fig. 6 Wheel Speed Sensor
1 - HUB BEARING
2 - WHEEL SPEED SENSOR
Fig. 7 Rotor, Hub/Bearing And Stud
1 - HUB BEARING
2 - ROTOR
3 - STUD
(6) Posi ti on the hub spacer (Fi g. 8) and brake
shi el d (Fi g. 9) on bol ts just i nstal l ed i n knuckl e.
NOTE: If the vehicle is equipped with a wheel speed
sensor the brake shield must be positioned on the
hub bearing (Fig. 10).
(7) Al i gn the rotor hub wi th the dri ve shaft and
start the shaft i nto the rotor hub spl i nes.
NOTE: Position wheel speed sensor wire at the top
of the knuckle if equipped.
(8) Al i gn the bol t hol es i n the hub beari ng fl ange
wi th the bol ts i nstal l ed i n the knuckl e. Then thread
the bol ts i nto the beari ng fl ange far enough to hol d
the assembl y i n pl ace.
(9) I nstal l the remai ni ng bol ts. Ti ghten the hub/
beari ng bol ts to 202 Nm (149 ft. l bs.
(10) I nstal l the washer and axl e nut and ti ghten a
begi nni ng torque of 179 Nm (132 ft. l bs.).
(11) Rotate the axl e 5 to 10 ti mes to seat the hub
beari ng.
(12) Ti ghten to a fi nal torque of 356 Nm (263 ft.
l bs.).
(13) Al i gn the axl e nut to the next forward cotter
pi n hol e and i nstal l a new cotter pi n i n the axl e nut.
(14) I nstal l the brake cal i per, (Refer to 5 -
BRAKE CALI PERS - I NSTALLATI ON).
(15) I nstal l the sensor wi re to the steeri ng knuckl e
and frame and i f equi pped. Connect the wheel speed
sensor wi re under the hood.
(16) I nstal l the wheel and ti re assembl i es, (Refer
to 22 - TI RES/WHEELS/WHEELS - STANDARD
PROCEDURE).
(18) Appl y the brakes several ti mes to seat the
brake shoes and cal i per pi ston. Do not move the vehi -
cl e unti l a fi rm brake pedal i s obtai ned.
Fig. 8 Hub Spacer
1 - ROTOR HUB BOLTS
2 - HUB SPACER (POSITION FLAT TO REAR)
3 - APPLY ANTI-SEIZE COMPOUND TO SPLINES
Fig. 9 Brake Shield
1 - BRAKE SHIELD
2 - HUB BEARING BOLTS
Fig. 10 Brake Shield With Wheel Speed Sensor
2 - HUB BEARING
3 - SHIELD
LOWER BALL J OINT
JOINT
To properl y di agnose the l ower bal l joi nt two read-
i ngs from the di al i ndi cator are necessary, The two
readi ngs must be added together to fi nd a total bal l
joi nt movement as i denti fi ed i n the steps bel ow.
(2) Attach a di al i ndi cator wi th the i ndi cator rest-
i ng on the fl at part of the steeri ng knuckl e by the
l ower bal l stud (Fi g. 11).
(3) Set the di al i ndi cator to zero.
NOTE: Use care not to damage the upper ball joint
grease seal.
(4) Pry between the knuckl e and the axl e tube
yoke next to the upper bal l joi nt, Record the readi ng
on the di al i ndi cator This will be the first reading
(Fi g. 12).
(5) Set the di al i ndi cator back to zero.
(6) Set up a jackstand and use a l ong prybar to l i ft
the knuckl e assembl y (Fi g. 13), pry upwards on the
fl at part of the steeri ng knuckl e next to the bal l joi nt
stud and nut (Fi g. 14) usi ng the jackstand as l ever-
age. Record the readi ng on the di al i ndi cator This
will be the second reading.
(7) Add the two readi ng together for a total l ower
bal l joi nt movement, I f thi s readi ng i s above 2.29 mm
(0.090 i n) then repl acement of the l ower bal l joi nt i s
necessary (Refer to 2 - SUSPENSI ON/FRONT/
LOWER BALL JOI NT - REMOVAL).
Fig. 11 DIAL INDICATOR POSITION
2 - DIAL INDICATOR
Fig. 12 FIRST READING
1 - PRY BAR
2 - UPPER BALL JOINT
3 - GEASE SEAL
Fig. 13 SECOND READING
1 - PRY BAR
2 - DIAL INDICATOR
3 - JACK STAND
REMOVAL
(1) Remove l ower snap ri ng from the l ower bal l
joi nt (Fi g. 15).
(2) Posi ti on speci al tool 89752 (RECEI VER) and
89754 (DRI VER) wi th tool C4212F as shown to
remove l ower bal l stud (Fi g. 16).
INSTALLATION
(1) Posi ti on speci al tool 89751 (DRI VER) and
89753 (RECEI VER) wi th C4212F as shown to
i nstal l l ower bal l stud (Fi g. 17).
Fig. 14 PRYING LOCATION
1 - PRY BAR
3 - AXLE YOKE
4 - GRESE SEAL
Fig. 15 LOWER SNAP RING
Fig. 16 LOWER BALL JOINT REMOVAL
1 - SPECIAL TOOL
C4212-F
2 - SPECIAL TOOL
8975-2
3 - KNUCKLE
4 - SPECIAL TOOL
8975-4
Fig. 17 LOWER BALL JOINT INSTALLATION
1 - SPECIAL TOOL
C4212-F
2 - SPECIAL TOOL
8975-1
3 - BALL JOINT
4 - KNUCKLE
5 - SPECIAL TOOL
8975-3
UPPER BALL J OINT
JOINT
To properl y di agnose the upper bal l joi nt two read-
i ngs from the di al i ndi cator are necessary, The two
readi ngs must be added together to fi nd a total bal l
joi nt movement as i denti fi ed i n the steps bel ow.
(2) Attach a di al i ndi cator wi th the i ndi cator rest-
i ng on ei ther the front or back si des of the steeri ng
knuckl e as cl ose to the upper bal l joi nt as possi bl e
(Fi g. 18).
(3) Set the di al i ndi cator to zero.
(4) Grab the ti re by pushi ng i n on the top of the
ti re and pul l i ng out on the bottom of the ti re. Record
the readi ng on the di al i ndi cator This will be the
first reading (Fi g. 18).
(5) Set the di al i ndi cator back to zero.
(6) Grab the ti re by pul l i ng i n on the top of the
ti re and pushi ng out on the bottom of the ti re.
Record the readi ng on the di al i ndi cator This will be
the second reading (Fi g. 18).
(7) Add the two readi ng together for a total upper
bal l joi nt movement, I f thi s readi ng i s above 1.52 mm
(0.060 i n) then repl acement of the upper bal l joi nt i s
necessary (Refer to 2 - SUSPENSI ON/FRONT/UP-
PER BALL JOI NT - REMOVAL).
REMOVAL
(1) Posi ti on speci al tool 6761 (RECEI VER) and
84453 (DRI VER) wi th C-4212F as shown to
remove upper bal l stud (Fi g. 19).
INSTALLATION
(1) Posi ti on speci al tool 84452 (DRI VER) and
89755 (RECEI VER) wi th C-42121F as shown to
i nstal l upper bal l stud (Fi g. 20).
Fig. 18 UPPER BALL JOINT MOVEMENT
2 - AXLE YOKE
3 - DIAL INDICATOR
4 - STEERING KNUCKLE FLAT
Fig. 19 UPPER BALL JOINT REMOVAL
1 - SPECIAL TOOL
C4212-F
2 - SPECIAL TOOL
6761
3 - KNUCKLE
4 - SPECIAL TOOL
8445-3
Fig. 20 UPPER BALL JOINT INSTALLATION
1 - SPECIAL TOOL
C4212-F
2 - SPECIAL TOOL
8445-2
3 - BALL JOINT
4 - KNUCKLE
5 - SPECIAL TOOL
8975-5
KNUCKLE
REMOVAL
(1) Remove the hub beari ng (Refer to 2 - SUSPEN-
SI ON/FRONT/HUB / BEARI NG - REMOVAL).
(2) Remove ti e-rod or drag l i nk end from the steer-
i ng knuckl e arm.
(3) Remove the ABS sensor wi re and bracket from
knuckl e. Refer to Brakes, for proper procedures.
(4) Remove the cotter pi n from the upper bal l stud
nut. Remove the upper and l ower bal l stud nuts.
(5) Stri ke the steeri ng knuckl e wi th a brass ham-
mer to l oosen.
(6) Remove knuckl e from axl e tube yokes.
INSTALLATION
(1) Posi ti on the steeri ng knuckl e on the bal l studs.
(2) I nstal l and ti ghten l ower bal l stud nut to 47
Nm (35 ft. l bs.) torque. Do not i nstal l cotter pi n at
thi s ti me.
(3) I nstal l and ti ghten upper bal l stud nut to 94
Nm (70 ft. l bs.) torque. Advance nut to next sl ot to
l i ne up hol e and i nstal l new cotter pi n.
(4) Retorque l ower bal l stud nut to 190217 Nm
(140160 ft. l bs.) torque. Advance nut to next sl ot to
l i ne up hol e and i nstal l new cotter pi n.
(5) I nstal l the hub beari ng (Refer to 2 - SUSPEN-
SI ON/FRONT/HUB / BEARI NG - I NSTALLATI ON).
(6) I nstal l ti e-rod or drag l i nk end onto the steer-
i ng knuckl e arm.
(7) I nstal l the ABS sensor wi re and bracket to the
knuckl e. Refer to Brakes, for proper procedure.
UPPER SUSPENSION ARM
REMOVAL
REMOVAL - LEFT
(2) Remove the upper suspensi on arm nut and bol t
at the axl e bracket (Fi g. 21).
(3) Remove the nut and bol t at the frame rai l and
remove the upper suspensi on arm.
REMOVAL - RIGHT
(2) Di sconnect the exhaust system at the mani -
fol ds.
(3) Di sconnect the rubber exhaust mounts at the
muffl er.
(4) Support the transmi ssi on.
(5) Remove the transmi ssi on cross member.
(6) Lower the exhaust system down i n order to
gai n access to the removal of the upper bol t.
(7) Remove the nut and bol t at the frame rai l and
remove the upper suspensi on arm.
(8) Remove the upper suspensi on arm nut and bol t
at the axl e bracket.
(9) Remove the suspensi on arm from the vehi cl e.
INSTALLATION
INSTALLATION - LEFT
(1) Posi ti on the upper suspensi on arm at the axl e
and frame rai l .
(2) I nstal l the bol ts and fi nger ti ghten the nuts.
(3) Remove the supports and l ower the vehi cl e.
(4) Ti ghten nut at the axl e bracket to 163 Nm
(120 ft. l bs.). Ti ghten nut at frame bracket to 163
Nm (120 ft. l bs.).
INSTALLATION - RIGHT
(1) Posi ti on the upper suspensi on arm at the axl e
and frame rai l .
(2) I nstal l the bol ts, then fi nger ti ghten the nuts.
(3) Reconnect the rubber exhaust mounts at the
muffl er.
(4) Reconnect the exhaust at the mani fol ds.
(5) I nstal l the transmi ssi on crossmember.
(7) Ti ghten nut at the axl e bracket to 163 Nm
(120 ft. l bs.). Ti ghten nut at frame bracket to 163
Nm (120 ft. l bs.).
Fig. 21 Link/Coil Suspension
1 - STABILIZER BAR
2 - SHOCK ABSORBER
3 - COIL SPRING
4 - UPPER SUSPENSION ARM
5 - LOWER SUSPENSION ARM
6 - TRACK BAR
LOWER SUSPENSION ARM
REMOVAL
(2) Pai nt or scri be al i gnment marks on the cam
adjusters and suspensi on arm for i nstal l ati on refer-
ence (Fi g. 22).
(3) Remove the l ower suspensi on arm nut, cam
and cam bol t from the axl e.
(4) Remove the nut and bol t from the frame rai l
bracket and remove the l ower suspensi on arm (Fi g.
22).
INSTALLATION
(1) Posi ti on the l ower suspensi on arm at the axl e
bracket and frame rai l bracket.
(2) I nstal l the rear bol t and fi nger ti ghten the nut.
(3) I nstal l the cam bol t, cam and nut i n the axl e
and al i gn the reference marks.
(4) Remove support and l ower the vehi cl e.
(5) Ti ghten cam nut at the axl e bracket to 217
Nm (160 ft. l bs.). Ti ghten rear nut at the frame
bracket to 217 Nm (160 ft. l bs.).
SHOCK
DIAGNOSIS AND TESTING - SHOCK
The shock absorber bushi ngs do not requi re any
type of l ubri cati on. Do not attempt to stop bushi ng
noi se by l ubri cati ng them. Grease and mi neral oi l -
base l ubri cants wi l l deteri orate the bushi ng.
REMOVAL
(1) Remove the nut, retai ner and grommet from
the upper stud i n the engi ne compartment.
(2) Remove three nuts from the upper shock
bracket (Fi g. 23).
(3) Remove the l ower bol t from the axl e bracket
(Fi g. 24). Remove the shock absorber from engi ne
compartment.
INSTALLATION
(1) Posi ti on the l ower retai ner and grommet on the
upper stud. I nsert the shock absorber through the
spri ng from engi ne compartment.
(2) I nstal l the l ower bol t and ti ghten to 135 Nm
(100 ft. l bs.).
(3) I nstal l the upper shock bracket and three nuts.
Ti ghten nuts to 75 Nm (55 ft. l bs.).
(4) I nstal l upper grommet and retai ner. I nstal l
upper shock nut and ti ghten to 54 Nm (40 ft. l bs).
Fig. 22 Adjustment Cam
1 - ADJUSTMENT CAM
2 - AXLE BRACKET
3 - BRACKET REINFORCEMENT
SPRING
REMOVAL
(1) Rai se and support the vehi cl e. Posi ti on a
hydraul i c jack under the axl e to support i t.
(2) Pai nt or scri be al i gnment marks on l ower sus-
pensi on arm cam adjusters and axl e bracket for
i nstal l ati on reference.
(3) Remove the upper suspensi on arm and l oosen
l ower suspensi on arm bol ts.
(4) Mark and di sconnect the front propel l er shaft
from the axl e 4x4 model s.
(5) Di sconnect the track bar from the frame rai l
bracket.
(6) Di sconnect the drag l i nk from pi tman arm.
(7) Di sconnect the stabi l i zer bar l i nk and shock
absorber from the axl e.
(8) Lower the axl e unti l the spri ng i s free from the
upper mount. Remove the coi l spri ng.
INSTALLATION
(1) Posi ti on the coi l spri ng on the axl e pad.
(2) Rai se the axl e i nto posi ti on unti l the spri ng
seats i n the upper mount.
(3) Connect the stabi l i zer bar l i nks and shock
absorbers to the axl e bracket. Connect the track bar
to the frame rai l bracket.
(4) I nstal l the upper suspensi on arm.
(5) I nstal l the front propel l er shaft to the axl e 4x4
model .
(6) I nstal l drag l i nk to pi tman arm and ti ghten
nut to speci fi cati ons. I nstal l new cotter pi n.
(8) Ti ghten the fol l owi ng suspensi on components
to speci fi cati ons:
Li nk to stabi l i zer bar nut.
Lower shock bol t.
Track bar bol t at axl e shaft tube bracket.
Upper suspensi on arm nut at axl e bracket.
Upper suspensi on nut at frame bracket.
Al i gn l ower suspensi on arm reference marks and
ti ghten cam nut.
Lower suspensi on nut at frame bracket.
STABILIZER BAR
REMOVAL
(2) Hol d the stabi l i zer l i nk shafts wi th a wrench
and remove the l i nk nuts at the stabi l i zer bar.
(3) Remove the retai ners and grommets from the
stabi l i zer bar l i nks.
(4) Remove the stabi l i zer bar l i nk nuts from the
axl e brackets.
Fig. 23 Shock Absorber and Bracket
1 - GROMMET
2 - RETAINER
3 - BRACKET
4 - RETAINER
5 - SHOCK
6 - GROMMET
Fig. 24 Shock Absorber Axle Mount
1 - SHOCK
2 - SPRING
3 - FLAG NUT
4 - SHOCK BOLT
SHOCK (Continued)
(5) Remove the l i nks from the axl e brackets wi th
Pul l er C-3894-A (Fi g. 25).
(6) Remove the stabi l i zer bar cl amps from the
frame rai l s and remove the stabi l i zer bar.
INSTALLATION
(1) Posi ti on the stabi l i zer bar on the frame rai l
and i nstal l the cl amps and bol ts. Ensure the bar i s
centered wi th equal spaci ng on both si des.
(2) Ti ghten the cl amp bol ts to 61 Nm (45 ft. l bs.).
(3) I nstal l l i nks to the axl e bracket and ti ghten
nut to 71 Nm (52 ft. l bs.).
(4) I nstal l l i nks, retai ners, grommets and nuts to
the stabi l i zer bar. Hol d the l i nk shaft wi th a wrench
and ti ghten the nuts to 37 Nm (27 ft. l bs.).
Fig. 25 Stabilizer Link
1 - PULLER
2 - LINK
STABILIZER BAR (Continued)
REAR
TABLE OF CONTENTS
page page
REAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
DIAGNOSIS AND TESTING - SPRING AND
SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 42
BUSHINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
JOUNCE BUMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
AUXILIARY SPRING BUMPERS (3500)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
SHOCK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
SPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
SPRING TIP INSERTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
REAR
DESCRIPTION
The rear suspensi on i s compri sed of:
Shock Absorbers
Jounce Bumpers
Leaf Spri ngs
Auxi l i ary Leaf Spri ng (3500 seri es)
Auxi l i ary Spri ng Bumpers (3500 seri es)
Dri ve Axl e
CAUTION: A vehicle should always be loaded so
the vehicle weight center-line is located immedi-
ately forward of the rear axle. Correct vehicle load-
ing provides proper front tire-to-road contact. This
results in maximum vehicle handling stability and
safety. Incorrect vehicle weight distribution can
cause excessive tire tread wear, spring fatigue or
failure, and erratic steering.
CAUTION: Suspension components with rubber/ure-
thane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
DIAGNOSIS AND TESTING - SPRING AND
SHOCK
The spri ng eye and shock absorber bushi ngs do not
requi re any type of l ubri cati on. Do not attempt to
stop spri ng bushi ng noi se by l ubri cati ng them.
Grease and mi neral oi l -base l ubri cants wi l l deteri o-
rate the bushi ng rubber.
I f the vehi cl e i s used for severe, off-road operati on,
the spri ngs shoul d be exami ned peri odi cal l y. Check
for broken and shi fted l eafs, l oose and mi ssi ng cl i ps,
and broken center bol ts. Refer to Spri ng and Shock
Absorber Di agnosi s chart for addi ti onal i nformati on.
DR REAR 2 - 41
SPRING AND SHOCK ABSORBER
SPRING SAGS 1. Broken leaf. 1. Replace spring.
2. Spring fatigue. 2. Replace spring.
SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification.
2. Worn bushings. 2. Replace bushings.
3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.
SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.
2. Worn bushings. 2. Replace shock.
3. Leaking shock. 3. Replace shock.
SPECIFICATIONS
TORQUE CHART
Shock Absorber
Lower Nut
135 100
Shock Absorber
Upper Nut
135 100
Spring Clamp U-Bolts
Nuts
149 110
Spring
Front & Rear Bolt & Nut
LD
163 120
Spring
Front & Rear Bolt & Nut
HD
230 170
Spring
Spring Rear Shackle Nuts
163 120
Spring
Spring Rear Shackle Nuts
230 170
Jounce Bumper
Bolts
LD
40 30
Jounce Bumper
Bolts
HD
61 45
Auxialiary Spring Bumpers 34 25
2 - 42 REAR DR
REAR (Continued)
BUSHINGS
REMOVAL
(1) Remove the spri ng from the vehi cl e.
(2) Make smal l rel i ef cuts i n the fl ared up end of
the bushi ng metal bei ng careful not to cut the spri ng.
Use a punch to bend the fl ared bushi ng metal down
for push out.
(3) Posi ti on the spri ng eye i n a press.
(4) Press the bushi ng out wi th an appropri ate si ze
dri ver.
INSTALLATION
(1) Press new bushi ng i nto the spri ng eye wi th an
appropri ate si ze dri ver. The bushi ng shoul d be cen-
tered i n the spri ng eye.
(2) Stake the outermetal of the bushi ng i n a mi ni -
mum of si x poi nts to retai n the bushi ng.
(3) I nstal l the spri ng on the vehi cl e.
J OUNCE BUMPER
REMOVAL
(1) Remove the two bol ts securi ng the jounce
bumper to the bracket (Fi g. 1).
(2) Remove the jounce bumper.
INSTALLATION
(1) I nstal l the jounce bumper.
(2) I nstal l the two bol ts securi ng the jounce
bumper to the bracket. Ti ghten the bol ts to 40 Nm
(30 ft. l bs.)(LD) or Ti ghten the bol ts to 61 Nm (45 ft.
l bs.)(HD).
AUXILIARY SPRING BUMPERS
(3500)
REMOVAL
(1) Remove the nut securi ng the auxi l i ary spri ng
bumper to the bracket (Fi g. 2).
(2) Remove the auxi l i ary spri ng bumper.
INSTALLATION
(1) I nstal l the auxi l i ary spri ng bumper.
(2) I nstal l the nut securi ng the auxi l i ary spri ng
bumper to the bracket (Fi g. 2). Ti ghten the nut to 25
Nm (34 ft. l bs.).
SHOCK
REMOVAL
(1) Rai se vehi cl e and support the axl e.
NOTE: The rear upper shock attachment uses a flag
nut. Do not use an air tool to remove the bolt, the
flag may rotate into the bottom of the bed and
cause damage. Use a wrench to hold the nut when
loosening.
(2) Remove the upper shock bol t and nut (Fi g. 3).
(3) Remove the l ower shock bol t and nut.
(4) Remove the rear shock absorber from the vehi -
cl e.
INSTALLATION
(1) Posi ti on the shock absorber i n the brackets.
(2) I nstal l the bol ts through the brackets and the
shock. I nstal l the fl ag nut on the top bol t and nut on
l ower bol t.
Fig. 1 JOUNCE BUMPER
1 - MOUNTING BOLTS
2 - JOUNCE BUMPER
Fig. 2 AUXILIARY SPRING BUMPER (3500)
1 - NUTS
2 - AUXILIARY SPRING BUMPERS
DR REAR 2 - 43
(3) Ti ghten the upper and l ower bol t/nuts Ti ghten
to 135 N.m (100 ft. l bs.)
SPRING
DESCRIPTION
The rear suspensi on system uses a mul ti -l eaf
spri ngs and a sol i d dri ve axl e. The forward end of the
spri ngs are mounted to the body rai l hangers
through rubber bushi ngs. The rearward end of the
spri ngs are attached to the body by the use of shack-
l es. The spri ng and shackl es use rubber bushi ngs.
OPERATION
The spri ngs control ri de qual i ty and mai ntai n vehi -
cl e ri de hei ght. The shackl es al l ow the spri ngs to
change thei r l ength as the vehi cl e moves over vari ous
road condi ti ons.
REMOVAL
(2) Support the axl e wi th a sui tabl e hol di ng fi x-
ture.
(3) Remove the nuts, spri ng cl amp bol ts and the
pl ate that attach the spri ng to the axl e (Fi g. 4).
(4) Remove the nuts and bol ts from the spri ng
front and rear shackl e (Fi g. 4).
(5) Remove the spri ng from the vehi cl e.
INSTALLATION
(1) Posi ti on spri ng on axl e shaft tube so spri ng
center bol t i s i nserted i nto the l ocati ng hol e i n the
axl e tube.
(2) Al i gn the front of the spri ng wi th the bol t hol e
i n the front bracket. I nstal l the eye pi vot bol t and
nut.
(3) Al i gn the rear of the spri ng i nto the shackl e
and i nstal l the bol t and nut.
(4) Ti ghten the spri ng front and rear eye pi vot bol t
snug do not torque.
(5) I nstal l the spri ng cl amp bol ts, pl ate and the
retai ni ng nuts.
(6) Remove the hol di ng fi xture for the rear axl e.
(7) Remove the supports and l ower the vehi cl e so
that the wei ght i s bei ng supported by the ti res.
(8) Ti ghten the spri ng cl amp retai ni ng nuts to 149
Nm (110 ft. l bs.).
(9) Ti ghten the spri ng front and rear pi vot bol t
nuts to 163 Nm (120 ft. l bs.)(LD) or 230 Nm (170 ft.
l bs.)(HD).
SPRING TIP INSERTS
REMOVAL
(2) Remove both rear ti reand wheel assembl i es
(3) Posi ti on a l arge C-Cl amp adjacent to the spri ng
cl i nch cl i p and cl amp the l eaves of the spri ng
together
Fig. 3 SHOCK ABSORBER
1 - NUT
2 - AXLE
3 - SHOCK ABSORBER
Fig. 4 REAR SPRING
1 - LEAF SPRING
2 - PLATE
3 - NUTS
4 - FRONT NUT & BOLT
5 - SPRING CLAMP BOLTS
6 - SHACKLES
2 - 44 REAR DR
SHOCK (Continued)
CAUTION: When working on the front leaf spring
clinch clamps finish the front before starting on the
rear to prevent personal injury.
(4) Use an appropri ate pry bar to bend open the
spri ng cl i nch cl i p (Fi g. 5). I f necessary, remove the
exi sti ng spri ng cl i nch cl i p i sol ators.
(5) Use the pry bar to spread apart the l eaf (Fi g.
6). The cl earance between the l eaves shoul d be
enough to remove the ol d l i ner (i f necessary) and
i nstal l the repl acement l i ner.
(6) I f necessary, remove the ol d spri ng ti p l i ner
(Fi g. 7).
INSTALLATION
(1) Wi th the prybar sti l l i nserted between the
l eaves, i nstal l a new spri ng ti p l i ner onto the l eaf.
(2) Fi rml y seat the spri ng ti p l i ner onto the l eaf. A
C-Cl amp can be used to compress the adjacent l eaves
together (Fi g. 8) whi ch wi l l seat the l i ner retai ni ng
pi n i nto the hol e.
NOTE: THE SPRING TIP LINER IS PROPERLY
INSTALLED WHEN THE RETAINING PIN IS POINT-
ING TOWARD THE PAVEMENT AND THE WEAR PAD
IS CONTACTING THE LEAF SPRING.
(3) Appl y a smal l amount of l ubri cant oi l onto the
ti p l i ner wear pad.
(4) I nstal l al l the spri ng ti p l i ners.
Fig. 5 C-CLAMP AND PRY BAR
1 - REAR LEAF SPRING CLINCH CLAMP
2 - PRY BAR
3 - C-CLAMP
Fig. 6 SPRING SEPARATION
1 - REAR LEAF SPRING
2 - PRY BAR
Fig. 7 SPRING TIP LINER REMOVAL
1 - SPRING TIP LINER
2 - RUBBER MALLET
Fig. 8 CLINCH CLIP
1 - C-CLAMP
2 - SPRING CLINCH CLAMP
DR REAR 2 - 45
SPRING TIP INSERTS (Continued)
(5) Pl ace one spri ng cl i nch cl i p i sol ator onto the
outboard si de of the spri ng cl i nch cl i p (Fi g. 9) and
one i sol ator on the i nboard si de of the spri ng cl i nch
cl i p.
(6) Usi ng l arge adjustabl e pl i ers, cl ose the spri ng
cl i nch cl i p unti l the i sol ator contacts the l eaf spri ng
(Fi g. 10).
CAUTION: DO NOT USE A HAMMER TO CLOSE THE
SPRING CLINCH CLIP. DAMAGE TO THE ISOLATOR
MAY RESULT.
(7) Use an appropri ate pry bar to bend open the
spri ng cl i nch cl i p. I f necessary, remove the exi sti ng
spri ng cl i nch cl i p i sol ators.
(8) Repeat procedure for the other si de of the vehi -
cl e.
(9) I i nstal l the ti re wheel assembl i es.
Fig. 9 CLINCH CLIP ISOLATOR
1 - SPRING CLINCH CLIP ISOLATOR
2 - C-CLAMP
Fig. 10 CLINCH CLIP REASSEMBLY
1 - SPRING CLINCH CLIP
2 - ADJUSTABLE PLIERS
3 - C-CLAMP
2 - 46 REAR DR
SPRING TIP INSERTS (Continued)
DIFFERENTIAL & DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 1
HALF SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FRONT AXLE - C205F . . . . . . . . . . . . . . . . . . . . 27
FRONT AXLE - 9 1/4 AA . . . . . . . . . . . . . . . . . . . 54
REAR AXLE - 9 1/4 . . . . . . . . . . . . . . . . . . . . . . . 80
REAR AXLE - 10 1/2 AA . . . . . . . . . . . . . . . . . . 112
REAR AXLE - 11 1/2 AA . . . . . . . . . . . . . . . . . . 140
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 6
PROPELLER SHAFT- LD FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PROPELLER SHAFT - HD FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR PROPELLER SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CENTER BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 9
SINGLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY
DISASSEMBLY - WITH SNAP RINGS . . . . . . 10
DISASSEMBLY - WITH INJECTED RINGS . . . 11
ASSEMBLY
ASSEMBLY - WITH SNAP RINGS . . . . . . . . . 12
ASSEMBLY - WITH INJECTED RINGS . . . . . . 13
DOUBLE CARDAN UNIVERSAL JOINTS
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 16
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PROPELLER SHAFT
DIAGNOSIS AND TESTING
PROPELLER SHAFT VIBRATION
Out-of-round ti res or wheel s that are out of bal -
ance, wi l l cause a l ow frequency vi brati on.
Dri vel i ne vi brati on can al so caused by l oose or
damaged engi ne mounts.
Propel l er shaft vi brati on i ncreases wi th vehi cl e
speed. A vi brati on that occurs at a speci fi c speed
range, i s not usual l y caused by an out of bal ance pro-
pel l er shaft. Defecti ve uni versal joi nts or an i ncorrect
propel l er shaft angl e are usual l y the cause of such a
vi brati on.
DR DIFFERENTIAL & DRIVELINE 3 - 1
DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1) Undercoating or other foreign
material on shaft.
1) Clean exterior of shaft and wash
with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws
and tighten to proper torque.
3) Loose or bent U-joint yoke or
excessive runout.
3) Install new yoke.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in
seat.
5) Loosen spring u-bolts and seat
center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out
of balance.
7) Installl new propeller shaft.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced
condition.
9) Re-index propeller shaft, test,
and evaluate.
10) Excessive drive pinion gear
shaft runout.
10) Re-index propeller shaft and
evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws
and tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as
necessary.
PROPELLER SHAFT BALANCE
I f propel l er shaft i s suspected of bei ng out of bal -
ance, use the fol l owi ng procedure.
NOTE: Indexing propeller shaft 180 relative to the
yoke may eliminate some vibrations.
(2) Cl ean al l forei gn materi al from the propel l er
shaft and uni versal joi nts.
(3) I nspect propel l er shaft for mi ssi ng bal ance
wei ghts, broken wel ds and bent areas. If propeller
shaft is bent, it must be replaced.
(4) I nspect uni versal joi nts for wear and properl y
i nstal l ed.
(5) Check propel l er shaft bol t torques.
(6) Remove wheel s and i nstal l l ug nuts to retai n
brake rotors.
(7) Mark and number the shaft si x i nches from the
pi ni on yoke end at four posi ti ons 90 apart.
(8) Run and accel erate vehi cl e unti l vi brati on
occurs. Note the i ntensi ty and speed the vi brati on
occurred. Stop the engi ne.
(9) I nstal l a screw cl amp at posi ti on 1 (Fi g. 1).
Fig. 1 CLAMP SCREW AT POSITION 1
1 - CLAMP
2 - SCREWDRIVER
3 - 2 PROPELLER SHAFT DR
PROPELLER SHAFT (Continued)
(10) Start engi ne and check vi brati on. I f there i s
l i ttl e or no change move the cl amp to the next posi -
ti ons. Repeat the vi brati on test.
NOTE: If there is no difference in vibration at this
positions, the vibration may not be the propeller
shaft.
(11) I f vi brati on decreased, i nstal l a second cl amp
(Fi g. 2) and repeat the test.
(12) I f addi ti onal cl amp causes an addi ti onal vi bra-
ti on, separate the cl amps 1/2 i nch above and bel ow
the mark. Repeat the vi brati on test (Fi g. 3).
(13) I ncrease di stance between the cl amp screws
and repeat test, unti l the l east amount of vi brati on i s
noti ced. Bend the sl ack end of the cl amps so screws
wi l l not l oosen.
(14) I f vi brati on remai ns unacceptabl e, repeat the
procedure to the front end of the propel l er shaft.
(15) I nstal l wheel s and l ower vehi cl e.
PROPELLER SHAFT RUNOUT
(1) Cl ean propel l er shaft surface, where di al i ndi -
cator wi l l contact the shaft.
(2) I nstal l di al i ndi cator perpendi cul ar to the shaft
surface.
(3) Measure runout at the center and ends of the
shaft away from wel d areas, so wel d process does not
affect measurements.
(4) Refer to Runout Speci fi cati ons chart.
(5) I f runout i s out of speci fi cati on, i ndex the shaft
180 and take shaft runout measurements agai n.
(6) I f runout i s now wi thi n speci fi cati ons, mark
shaft and yokes for proper ori entati on.
(7) I f runout i s not wi thi n speci fi cati ons, veri fy
runout of the transmi ssi on/transfer case and axl e are
wi thi n speci fi cati ons. Correct as necessary and mea-
sure propel l er shaft runout agai n.
(8) Repl ace propel l er shaft i f the runout sti l l
exceeds the l i mi ts.
RUNOUT SPECIFICATIONS
Front of Shaft 0.030 in. (0.76 mm)
Center of Shaft 0.015 in. (0.38 mm)
Rear of Shaft 0.030 in. (0.76 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. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
STANDARD PROCEDURE
PROPELLER SHAFT ANGLE
Thi s procedure appl i es to front and rear propel l er
shafts.
NOTE: To obtain output angle (A) on the front pro-
peller shaft equipped with a C/V joint, place incli-
nometer on machined surface of the C/V joint.
(1) Pl ace vehi cl e i n Neutral .
(2) Rai se vehi cl e and support the axl es as l evel as
possi bl e.
(3) Remove uni versal joi nt snap ri ngs i f equi pped,
so I ncl i nometer 7663 base si ts fl at.
(4) Rotate shaft unti l transmi ssi on/transfer case
output yoke beari ng i s faci ng downward.
NOTE: Always take measurements from front to
rear and on the same side of the vehicle.
(5) Pl ace i ncl i nometer on yoke beari ng cap or pi n-
i on fl ange ri ng (A) paral l el to the shaft (Fi g. 4). Cen-
ter bubbl e i n si ght gl ass and record measurement.
Fig. 2 TWO CLAMP SCREWS
Fig. 3 CLAMP SCREWS SEPARATED
1 -
1
2 INCH
DR PROPELLER SHAFT 3 - 3
This measurement will give you the transmis-
sion yoke Output Angle (A).
(6) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on yoke beari ng paral l el to the shaft
(Fi g. 5). Center bubbl e i n si ght gl ass and record mea-
surement. Thi s measurement can al so be taken at
the rear end of the shaft.
This measurement will give you the Propeller
Shaft Angle (C).
(7) Rotate propel l er shaft 90 degrees and pl ace
i ncl i nometer on compani on fl ange yoke beari ng par-
al l el to the shaft (Fi g. 6). Center bubbl e i n si ght gl ass
and record measurement.
This measurement will give you the pinion
Companion Flange Input Angle (B).
(8) Subtract smal l er fi gure from l arger (C mi nus
A) to obtai n Transmi ssi on/Transfer Case Output
Operating Angle.
(9) Subtract smal l er fi gure from l arger (C mi nus
B) to obtai n axl e Input Operating Angle.
Refer to rul es and exampl e i n (Fi g. 7) for addi -
ti onal i nformati on.
RULES
Good cancel l ati on of U-joi nt operati ng angl es
shoul d be wi thi n 1 degree.
Operati ng angl es shoul d be l ess than 3 degrees.
Operati ng angl es l ess than 10 degrees for doubl e
cardan U-joi nt.
At l east 1/2 of one degree conti nuous operati ng
propel l er shaft angl e.
TWO-PIECE PROPELLER SHAFT
Two-pi ece propel l er shaft angl es measurement (Fi g.
8) i s the same as a one-pi ece propel l er shaft.
Fig. 4 OUTPUT ANGLE (A)
Fig. 5 PROPELLER SHAFT ANGLE (C)
Fig. 6 INPUT ANGLE (B)
Fig. 7 UNIVERSAL JOINT ANGLE EXAMPLE
1 - 4.9ANGLE (C)
2 - 3.2ANGLE (B)
3 - INPUT YOKE
4 - 3.0ANGLE (A)
5 - OUTPUT YOKE
Fig. 8 UNIVERSAL JOINT ANGLE
1 - YOKES MUST BE IN SAME PLANE
SPECIFICATIONS
Center Bearing Bolts 54 40 -
Transfer Case Flange
Bolts
88 65 -
LD - Front Pinion Flange
Bolts
115 85 -
HD - Front Pinion Flange
Bolts
28 21 -
Rear Pinion Flange Bolts 115 85 -
Rear Pinion Yoke Bolts 29 22 -
SPECIAL TOOLS
PROPELLER SHAFT- LD
FRONT
REMOVAL
(1) Wi th vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove exhaust crossover pi pe.
(3) Mark a l i ne across the axl e compani on fl ange,
propel l er shaft fl ange yoke and transfer case (Fi g. 9)
for i nstal l ati on reference.
INCLINOMETER 7663
Bearing Splitter 1130
INSTALLER 6052
Fig. 9 COMPANION FLANGE
1 - COMPANION FLANGE
2 - PROPELLER SHAFT
3 - FLANGE YOKE
4 - REFERENCE MARK
(4) Remove axl e/transfer case compani on fl ange
bol ts. Remove dust boot cl amp (Fi g. 10) from the C/V
joni t end of the shaft i f equi pped.
(5) Remove propel l er shaft.
INSTALLATION
(1) I nstal l propel l er shaft wi th al l reference marks
al i gned.
(2) I nstal l wi th dust boot cl amp at transfer case
end.
(3) I nstal l new axl e compani on fl ange bol ts and
NOTE: Companion flange bolts incorporate a Loc-
tite patch, new bolts should be used. If bolts are
not available, clean bolts and apply Loctite 242 to
the threads.
(4) I nstal l ski d pl ate, i f equi pped.
PROPELLER SHAFT - HD
FRONT
REMOVAL
hoi st.
(2) Remove exhaust crossover pi pe.
(3) Mark a l i ne across axl e/transfer case compan-
i on fl ange and propel l er shaft fl ange yokes for i nstal -
l ati on reference.
(4) Remove axl e/transfer case compani on fl ange
bol ts (Fi g. 11).
INSTALLATION
(1) I nstal l propel l er shaft wi th al l reference marks
al i gned.
(2) I nstal l transfer case compani on fl ange bol ts
and ti ghten to 88 Nm (65 ft. l bs.).
(3) I nstal l new axl e compani on fl ange bol ts and
the threads.
Fig. 10 DUST BOOT
1 - C/V JOINT
2 - TRANSFER CASE
3 - BOOT CLAMP
4 - PROPELLER SHAFT
Fig. 11 PROPELLER SHAFT - HD
1 - PROPELLER SHAFT
2 - TRANSFER CASE FLANGE
3 - AXLE FLANGE
PROPELLER SHAFT- LD FRONT (Continued)
REAR PROPELLER SHAFT
REMOVAL
hoi st.
(2) Mark pi ni on fl ange or yoke and propel l er shaft
fl ange or yoke (Fi g. 12) for i nstal l ati on reference.
(3) Mark the outl i ne of the center beari ng (Fi g. 13)
on the crossmember for i nstal l ati on reference, i f
equi pped.
(4) Remove center beari ng mounti ng nuts, i f
equi pped.
(5) Remove pi ni on fl ange or yoke cl amp bol ts.
(6) Sl i de propel l er shaft off transmi ssi on or trans-
fer case and remove shaft.
INSTALLATION
(1) Sl i de sl i p yoke onto the transmi ssi on/transfer
case output shaft.
(2) Al i gn and i nstal l center beari ng on crossmem-
ber, i f equi pped and ti ghten nuts to 54 Nm (40 ft.
l bs.).
(3) Al i gn reference marks on propel l er shaft and
pi ni on fl ange or pi non yoke.
(4) I nstal l new bol ts and ti ghten to:
(Fi g. 14) Compani on fl ange bol ts 15 Nm (85 ft.
l bs.)
(Fi g. 15) Yoke cl amp bol ts 29 Nm (22 ft. l bs.)
the threads.
1 - PROPELLER SHAFT
3 - REFERENCE MARK
4 - SHAFT FLANGE YOKE
Fig. 13 CENTER BEARING
1 - CENTER BEARING
2 - DUST BOOT
3 - MOUNTING NUTS
Fig. 14 REAR PROPELLER SHAFT
2 - PROPELLER SHAFT
CENTER BEARING
REMOVAL
(1) Remove rear propel l er shaft.
(2) Mark the two shafts (Fi g. 16) for i nstal l ati on
reference.
(3) Remove sl i p joi nt boot cl amp and separate the
two shafts.
(4) Use hammer and punch to tap sl i nger away
from shaft to provi de room for beari ng spl i tter.
(5) Posi ti on Beari ng Spl i tter Tool 1130 between
sl i nger and shaft.
CAUTION: Do not damage shaft spline during
removal of center bearing.
(6) Set shaft i n press and press beari ng off the
shaft.
INSTALLATION
NOTE: Two types of center bearings are used and
are not interchangeable. Install the same type as
the vehicle was built with.
(1) I nstal l new sl i nger on shaft and dri ve i nto posi -
ti on wi th appropri ate i nstal l er tool .
(2) I nstal l new center beari ng on shaft wi th Bear-
i ng I nstal l er Tool 6052. Dri ve on shaft wi th hammer
unti l beari ng i s seated.
(3) Cl ean shaft spl i nes and appl y a coat of mul ti -
purpose grease.
(4) Al i gn master spl i nes and sl i de front and rear
hal f-shafts together. Reposi ti on sl i p yoke boot and
i nstal l new cl amp.
(5) I nstal l propel l er shaft i n vehi cl e.
ADJUSTMENTS
CENTER BEARING
Launch shudder i s a vi brati on that occurs at fi rst
accel erati on from a stop. Shudder vi brati on usual l y
peaks at the engi nes hi ghest torque output. Shudder
i s a symptom associ ated wi th vehi cl es usi ng a two-
pi ece propel l er shaft. To decrease shudder, l ower the
center beari ng i n 1/8 i nch i ncrements. Use shi m
stock or fabri cated pl ates. Pl ate stock must be used
to mai ntai n compressi on of the rubber i nsul ator
around the beari ng. Do not use washers. Repl ace the
ori gi nal bol ts wi th the appropri ate i ncreased l ength
bol ts.
Fig. 15 REAR PROPELLER SHAFT - SRT
1 - SLIP YOKE
2 - PROPELLER SHAFT
3 - PINION YOKE
4 - CLAMP
5 - BOLTS
6 - OUTPUT SHAFT
Fig. 16 REFERENCE MARKS
1 - REFERENCE MARK
2 - CENTER BEARING
3 - BOOT CLAMP
4 - DUST BOOT
REAR PROPELLER SHAFT (Continued)
SINGLE CARDAN UNIVERSAL
J OINTS
DISASSEMBLY
DISASSEMBLY - WITH SNAP RINGS
(1) Tap outsi de of beari ng cap wi th a dri ft to
l oosen snap ri ng.
(2) Remove snap ri ngs (1) from both si des of yoke
(Fi g. 17).
(3) Posi ti on yoke wi th the grease fi tti ng i f
equi pped, poi nti ng up.
(4) Posi ti on a socket wi th a i nsi de di ameter l arge
enough to recei ve the beari ng cap, beneath the yoke
on a press.
(5) Pl ace another socket wi th an outsi de di ameter
smal l er than beari ng cap on the upper beari ng cap
and press (1) the l ower cap through the yoke (Fi g.
18).
NOTE: If the bearing cap will not pull out of the
yoke by hand after pressing, tap the yoke ear near
the bearing cap to dislodge the cap.
(6) Pul l beari ng cap of the yoke.
(7) Turn yoke over i n the press and strai ghten the
cross (1). Press the cross unti l the remai ni ng beari ng
cap (2) can be removed (Fi g. 19).
CAUTION: If cross or bearing cap are not straight
during removal, the bearing cap will score the walls
of the yoke bore and damage can occur.
Fig. 17 SNAP RING
1 - SNAP RING
Fig. 18 PRESS OUT BEARING
1 - PRESS
2 - SOCKET
Fig. 19 PRESS OUT REMAINING BEARING
1 - CROSS
2 - BEARING CAP
DISASSEMBLY - WITH INJECTED RINGS
(1) Pl ace shaft yoke i n vi se.
(2) Posi ti on U-joi nt press (1) wi th recei ver (2) on
propel l er shaft yoke (Fi g. 20).
(3) Pressed U-joi nt beari ng caps (1) out of shaft
yoke (2) (Fi g. 21).
(4) Remove l ower beari ng cap from shaft yoke.
(5) Turn shaft over and posi ti on press (1) wi th
recei ver (2) on shaft yoke (Fi g. 22).
(6) Press remai ni ng U-joi nt beari ng cap out of
shaft yoke.
(7) Remove fl ange (1) wi th U-joi nt out of shaft
yoke (2) (Fi g. 23).
fl ange (Fi g. 24).
(9) Press U-joi nt beari ng caps (1) out of fl ange (2)
(Fi g. 25).
(10) Remove beari ng cap on the outsi de of the
fl ange.
Fig. 20 PRESS ON YOKE
1 - PRESS
2 - RECEIVER
Fig. 21 BEARING OUT OF YOKE
1 - BEARING CAPS
2 - YOKE
Fig. 22 PRESS REMAINING BEARING
1 - PRESS
2 - RECEIVER
Fig. 23 FLANGE WITH U-JOINT
1 - FLANGE
2 - YOKE
SINGLE CARDAN UNIVERSAL J OINTS (Continued)
fl ange (Fi g. 26).
(12) Press remai ni ng U-joi nt beari ng cap out of
fl ange.
(13) Remove U-joi nt from fl ange.
ASSEMBLY
ASSEMBLY - WITH SNAP RINGS
(1) Appl y (EP) N.L.G.I . Grade 1 or 2 grease to
i nsi de of yoke bores.
Fig. 24 PRESS ON FLANGE
1 - RECEIVER
2 - PRESS
Fig. 25 BEARING OUT OF FLANGE
1 - BEARINGS
2 - FLANGE
Fig. 26 REMAINING BEARING
1 - RECEIVER
2 - PRESS
Fig. 27 CROSS IN YOKE
1 - CROSS
2 - YOKE
(2) Posi ti on cross (1) i n yoke wi th l ube fi tti ng
poi nti ng up, i f equi pped (Fi g. 27).
(3) Pl ace a beari ng cap (1) over the cross end (2)
and al i gn cap wi th yoke bore (Fi g. 28).
(4) Press beari ng cap i nto the yoke bore enough to
cl ear snap ri ng groove.
(5) Repeat Step 3 and Step 4 to i nstal l the oppo-
si te beari ng cap.
NOTE: If joint is stiff or binding, strike the yoke with
a soft hammer to seat the needle bearings.
(6) Add grease to l ube fi tti ng, i f equi pped.
(7) I nstal l propel l er shaft.
ASSEMBLY - WITH INJECTED RINGS
NOTE: Replacement joint has internal snap rings.
(1) Pl ace joi nt i n fl ange wi th one beari ng cap.
(2) Posi ti on press (3) wi th recei ver (1) on fl ange
and beari ng cap (2) (Fi g. 29).
Fig. 28 BEARING AND CROSS
1 - BEARING CAP
2 - CROSS
Fig. 29 PRESS ON FLANGE
1 - RECEIVER
2 - BEARING
3 - PRESS
Fig. 30 SNAP RING GROOVE
1 - YOKE
2 - GROOVE
(3) Press beari ng cap unti l snap ri ng groove (1) i s
through the fl ange (2) (Fi g. 30).
(4) I nstal l snap ri ng (2) on beari ng (1) (Fi g. 31).
(5) Posi ti on press (3) wi th recei ver (2) on remai n-
i ng beari ng cap (1) and fl ange (Fi g. 32).
(6) Press beari ng cap unti l snap ri ng groove i s
through the fl ange.
(7) I nstal l snap ri ng (1) on beari ng cap (2) (Fi g.
33).
Fig. 31 SNAP RING
1 - BEARING
2 - SNAP RING
1 - BEARING
2 - RECEIVER
3 - PRESS
Fig. 33 SNAP RING
1 - SNAP RING
2 - BEARING
Fig. 34 FLANGE WITH U-JOINT
1 - FLANGE
2 - YOKE
(8) I nstal l fl ange (1) wi th U-joi nt i n yoke (2) (Fi g.
34).
(9) Posi ti on press (2) wi th recei ver (1) and l ower
beari ng cap (3) on yoke (Fi g. 35).
(10) Press beari ng cap unti l snap ri ng groove i s
through the yoke.
36).
(12) Posi ti on press (2) wi th recei ver (3) on remai n-
i ng beari ng cap (1) and yoke (Fi g. 37).
(13) Press remai ni ng beari ng cap unti l snap ri ng
groove i s through the yoke.
38).
Fig. 35 PRESS ON YOKE
1 - RECEIVER
2 - PRESS
3 - BEARING
Fig. 36 SNAP RING
1 - BEARING
2 - SNAP RING
1 - BEARING
2 - PRESS
3 - RECEIVER
Fig. 38 SNAP RING
1 - BEARING
2 - SNAP RING
DOUBLE CARDAN UNIVERSAL
J OINTS
DISASSEMBLY
(2) Mark propel l er shaft, l i nk yoke and fl ange yoke
for assembl y reference.
(3) Tap outsi de of the beari ng cap assembl y wi th
dri ft to l oosen snap ri ngs.
(4) Remove al l beari ng cap snap ri ngs (Fi g. 39).
(5) Remove grease fi tti ngs i f equi pped.
(6) Posi ti on a socket on the press wi th an i nsi de
di ameter l arge enough to recei ve the beari ng cap
under the l i nk yoke.
(7) Pl ace another socket wi th an outsi de di ameter
smal l er than the beari ng cap on the upper beari ng
cap.
(8) Press one beari ng cap from outboard si de of the
l i nk yoke, enough to grasp the cap wi th vi se jaws
(Fi g. 40).
(9) Grasp protrudi ng beari ng cap wi th vi se jaws
and tap l i nk yoke wi th a mal l et to remove beari ng
cap (Fi g. 41).
Fig. 39 SNAP RINGS
Fig. 40 PRESS OUT BEARING
Fig. 41 REMOVE BEARING FROM YOKE
(10) Fl i p assembl y and repeat Step 6, Step 7, Step
8 and Step 9 to remove the opposi te beari ng cap.
(11) Remove cross centeri ng ki t assembl y and
spri ng (Fi g. 42).
(12) Press remai ni ng beari ng caps out the other
end of the l i nk yoke.
ASSEMBLY
CAUTION: All alignment marks on the link yoke and
propeller shaft yoke must be aligned during assem-
bled.
(1) Appl y (EP) N.L.G.I . Grade 1 or 2 grease to
i nsi de of yoke bores.
(2) Fi t cross i nto the propel l er shaft yoke (Fi g. 43).
(3) Pl ace beari ng cap over the trunni on and al i gn
cap wi th the yoke bore (Fi g. 44). Keep needl e bear-
i ngs upri ght i n the beari ng cap.
(4) Press beari ng cap i nto yoke bore enough to
cl ear snap ri ng groove and i nstal l snap-ri ng (Fi g. 45).
Fig. 42 REMOVE CENTERING KIT
Fig. 43 INSTALL CROSS IN YOKE
Fig. 44 INSTALL BEARING CAP
Fig. 45 PRESS IN BEARING CAP
DOUBLE CARDAN UNIVERSAL J OINTS (Continued)
(5) Fl i p propel l er shaft yoke and i nstal l other bear-
i ng cap onto the opposi te trunni on and i nstal l a snap
ri ng (Fi g. 46).
(6) Fi t l i nk yoke onto remai ni ng trunni ons and
press both beari ng caps i nto pl ace and i nstal l snap
ri ngs (Fi g. 47).
(7) I nstal l centeri ng ki t assembl y i nsi de the l i nk
yoke (Fi g. 48).
NOTE: Verify spring is properly positioned.
(8) Pl ace two beari ng caps on opposi te trunni ons of
the remai ni ng cross. Fi t open trunni ons i nto the l i nk
yoke bores and beari ng caps i nto the centeri ng ki t
(Fi g. 49).
Fig. 47 INSTALL LINK YOKE
Fig. 48 INSTALL CENTERING KIT
Fig. 49 INSTALL REMAINING CROSS
(9) Press remai ni ng two beari ng caps i nto pl ace
and i nstal l snap ri ngs (Fi g. 50).
(10) Tap snap ri ngs to seat them i nto the grooves
(Fi g. 51).
(11) Fl exi ng the joi nt beyond center, the joi nt
shoul d snap over-center i n both di recti ons i f correctl y
assembl ed (Fi g. 52).
Fig. 51 SEAT SNAP RINGS IN GROOVE
Fig. 52 CHECK ASSEMBLY
HALF SHAFT
TABLE OF CONTENTS
page page
HALF SHAFT
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 21
CV JOINT-OUTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
CV JOINT-INNER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
HALF SHAFT
CAUTION
CAUTION:: Never grasp half shaft assembly by the
boots. This may cause the boot to pucker or crease
and reduce the service life of the boot.
Avoid over angulating or stroking the C/V joints
when handling the half shaft.
Half shafts exposed to battery acid, transmission
fluid, brake fluid, differential fluid or gasoline may
cause the boots to deteriorate. Failure to heed cau-
tion may result in damage.
Check i nboard and outboard C/V joi nt for l eaki ng
grease. Thi s i s a si gn of boot or boot cl amp damage.
NOISE/VIBRATION IN TURNS
A cl i cki ng noi se or vi brati on i n turns coul d be
caused by a damaged outer C/V or i nner tri pod joi nt
seal boot or seal boot cl amps. Thi s wi l l resul t i n the
l oss/contami nati on of the joi nt grease, resul ti ng i n
i nadequate l ubri cati on of the joi nt. Noi se coul d al so
be caused by another component of the vehi cl e com-
i ng i n contact wi th the hal f shafts.
CLUNKING NOISE DURING ACCELERATION
Thi s noi se may be a damaged or worn C/V joi nt. A
torn boot or l oose/mi ssi ng cl amp on the i nner/outer
joi nt whi ch has al l owed the grease to be l ost wi l l
damage the C/V joi nt.
SHUDDER/VIBRATION DURING ACCELERATION
Thi s coul d be a worn/damaged i nner tri pod joi nt or
a sti cki ng tri pod joi nt. I mproper wheel al i gnment
may al so cause a shudder or vi brati on.
VIBRATION AT HIGHWAY SPEEDS
Thi s probl em coul d be a resul t of out of bal ance
front ti res or ti re/wheel runout. Forei gn materi al
(mud, etc.) packed on the backsi de of the wheel (s)
wi l l al so cause a vi brati on.
REMOVAL
hoi st.
(2) Remove hal f shaft hub nut.
(3) Remove brake cal i per and rotor.
(4) Posi ti on hydraul i c jack under l ower suspensi on
arm and rai se jack to unl oad rebound bumper.
(5) Remove l ower shock absorber bol t.
(6) Remove upper bal l joi nt nut and seperate bal l
wi th Remover 8677 (Fi g. 1).
(7) Di sengage i nner C/V joi nt from axl e shaft wi th
two pry bars between the C/V housi ng and axl e hous-
i ng.
Fig. 1 UPPER BALL JOINT SEPARATION
2 - REMOVER
3 - 20 HALF SHAFT DR
(8) Ti l t knuckl e out and push hal f shaft out of the
knuckl e (Fi g. 2).
(9) Remove hal f shaft from vehi cl e.
INSTALLATION
(1) Cl ean hub beari ng bore, hub beari ng mati ng
surface and hal f shaft spl i nes.
(2) Appl y a l i ght coati ng of grease to the front axl e
shaft output spl i nes.
(3) I nstal l hal f shaft i nto the knuckl e (Fi g. 3).
(4) I nstal l hal f shaft on axl e shaft. Push fi rml y to
engage axl e shaft snap ri ng i nto the i nner C/V hous-
i ng.
(5) I nstal l upper bal l joi nt i nto the knuckl e.
(6) I nstal l upper bal l joi nt nut and ti ghten to spec-
i fi cati on.
(7) I nstal l l ower shock absorber bol t and ti ghten to
speci fi cati on.
(8) I nstal l brake rotor and cal i per.
(9) I nstal l hal f shaft hub nut and ti ghten to 251
Nm (185 ft. l bs.).
SPECIFICATIONS
Half Shaft Nut 251 185 -
SPECIAL TOOLS
2 - SHOCK
3 - HALFSHAFT
5 - HUB/BEARING
Fig. 3 HALF SHAFT AND HUB/BEARING
1 - HUB/BEARING MOUNTING NUTS
2 - HALF SHAFT
CLAMP INSTALLER C-4975A
DR HALF SHAFT 3 - 21
HALF SHAFT (Continued)
CV J OINT-OUTER
REMOVAL
(1) Cl amp shaft i n a vi se (wi th soft jaws) and sup-
port C/V joi nt.
CAUTION: Do not damage C/V housing or half
shaft.
(2) Remove cl amps (2) (4) wi th a cut-off wheel or
gri nder (Fi g. 4).
(3) Sl i de the boot down the shaft.
(4) Remove l ubri cant to expose the C/V joi nt snap
ri ng.
(5) Spread snap ri ng (1) and sl i de the joi nt off the
shaft (Fi g. 5).
(6) Sl i de boot off the shaft and di scard ol d boot.
(7) Mark al i gnment marks (1) on the i nner race/
hub (2), beari ng cage (3) and housi ng wi th dabs of
pai nt (Fi g. 6).
(8) Cl amp C/V joi nt i n a verti cal posi ti on i n a soft
jawed vi se.
(9) Press down one si de of the beari ng cage (3) to
gai n access to the bal l at the opposi te si de.
NOTE: If joint is tight, use a hammer and brass drift
to loosen the bearing hub. Do not contact the bear-
ing cage with the drift.
Fig. 4 BOOT CLAMP LOCATIONS
1 - C/V HOUSING
2 - CLAMP
3 - HALF SHAFT
4 - CLAMP
5 - C/V BOOT
Fig. 5 OUTER C/V JOINT
1 - SNAP RING
2 - SNAP RING GROVE
3 - SNAP RING PLIERS
Fig. 6 BEARING ACCESS
1 - ALIGNMENT MARKS
2 - BEARING HUB
3 - BEARING CAGE
4 - HOUSING
Fig. 7 BEARING
1 - HOUSING
2 - INNER RACE/HUB
3 - BEARING CAGE
4 - BALL
(10) Remove bal l (4) from the beari ng cage (3) (Fi g.
7).
(11) Repeat step above unti l al l si x bal l s are
removed from the beari ng cage.
(12) Li ft cage and i nner race (2) upward and out
from the housi ng (1) (Fi g. 8).
(13) Turn i nner race 90 i n the cage and rotate the
i nner race/hub out of the cage (Fi g. 9).
INSTALLATION
NOTE: If C/V joint is worn, replace entire C/V joint
and boot.
(1) Cl ean al l C/V joi nt components and shaft.
(2) Appl y a l i ght coat of grease suppl i ed wi th the
joi nt/boot to the C/V joi nt components before assem-
bl i ng them.
(3) Al i gn the i nner race, cage and housi ng accord-
i ng to the al i gnment reference marks.
(4) I nsert the i nner race i nto the cage (Fi g. 10) and
rotate race i nto the cage.
(5) Rotate the i nner race/hub i n the cage (Fi g. 11).
(6) I nsert cage i nto the housi ng (Fi g. 12). Rotate
the cage 90 i nto the housi ng so the l arge beari ng
hub counterbore i s faci ng outwards.
Fig. 8 CAGE AND INNER RACE/HUB
1 - HOUSING
2 - INNER RACE
3 - CAGE WINDOW
Fig. 9 INNER RACE/HUB
Fig. 10 INNER RACE/HUB
1 - INNER RACE/HUB
2 - BEARING CAGE
Fig. 11 CAGE AND INNER RACE/HUB
1 - CAGE WINDOWS
2 - SNAP RING
CV J OINT-OUTER (Continued)
(7) Appl y the grease suppl i ed wi th the joi nt/boot to
the bal l races. Spread the grease equal l y between al l
the races.
(8) Ti l t i nner race/hub and cage and i nstal l the
bal l s (Fi g. 13).
(9) Pl ace new cl amps onto new boot and sl i de boot
onto the shaft to i ts ori gi nal posi ti on.
(10) Appl y the rest of grease to the C/V joi nt and
boot.
(11) I nstal l the joi nt onto the shaft. Push the joi nt
onto the shaft unti l the snap ri ng seats i n the groove
(Fi g. 14).
NOTE: Pull on the joint to verify the span ring has
engaged.
(12) Posi ti on the boot on the joi nt i n i ts ori gi nal
posi ti on.
NOTE: Verify boot is not twisted and remove any
excess air.
(13) Secure both boot cl amps (Fi g. 15) wi th Cl amp
I nstal l er C-4975A. Pl ace tool on cl amp bri dge and
ti ghten tool unti l jaws of the tool are cl osed.
Fig. 12 BEARING CAGE AND HOUSING
1 - OUTER RACE
2 - BEARING CAGE WINDOW
3 - CV JOINT HOUSING
Fig. 13 BALL BEARING
1 - C/V HOUSING
2 - INNER RACE/HUB
3 - BEARING CAGE
4 - BEARING
Fig. 14 OUTER C/V JOINT
1 - SNAP RING
2 - SHAFT TAPER
3 - SNAP RING GROVE
4 - BEARING HUB
Fig. 15 BOOT CLAMP LOCATIONS
1 - C/V HOUSING
2 - CLAMP
3 - HALF SHAFT
4 - CLAMP
5 - C/V BOOT
CV J OINT-OUTER (Continued)
CV J OINT-INNER
REMOVAL
(1) Cl amp shaft i n vi se (wi th soft jaws) and sup-
port C/V joi nt.
(2) Remove cl amps (2) (4) wi th a cut-off wheel or
gri nder (Fi g. 16).
CAUTION: Do not damage C/V housing or half shaft
with cut-off wheel or grinder.
(3) Remove housi ng (1) from the hal f shaft (Fi g.
17) and sl i de boot (2) down shaft.
(4) Remove housi ng bushi ng from the housi ng.
(5) Remove tri pod (2) snap ri ng (1) (Fi g. 18).
(6) Remove tri pod and boot from the hal f shaft.
(7) Cl ean and i nspect C/V components for exces-
si ve wear and damage. Repl ace the tri pod as a uni t
onl y i f necessary.
INSTALLATION
(1) Cl ean al l C/V joi nt components and shaft.
(2) Sl i de new boot down the hal f shaft.
(3) I nstal l tri pod and tri pod snap ri ng on the hal f
shaft (Fi g. 19).
(4) Pack grease suppl i ed wi th the joi nt/boot i nto
the housi ng and boot.
(5) Coat tri pod wi th suppl i ed grease.
(6) I nstal l new bushi ng (Fi g. 20) onto the housi ng.
(7) I nsert the tri pod and shaft i n the housi ng.
Fig. 16 BOOT CLAMP LOCATION
1 - C/V HOUSING
2 - CLAMP
3 - BOOT
4 - CLAMP
Fig. 17 C/V HOUSING
1 - BOOT
2 - HOUSING
Fig. 18 TRIPOD SNAP RING
1 - SNAP RING
2 - TRIPOD
3 - PLIERS
Fig. 19 C/V TRIPOD
1 - BOOT
2 - TRIPOD
(8) Posi ti on the boot on the joi nt and shaft i n i ts
ori gi nal posi ti on (Fi g. 21).
NOTE: Verify boot is not twisted and remove any
excess air.
(9) Measure the di stance from the end of the hous-
i ng to the end of the boot on the shaft. Thi s measure-
ment shoul d be 260 mm (10.25 i n.).
NOTE: If measurement is not correct, allow more or
less air into the boot.
(10) Secure both boot cl amps wi th Cl amp I nstal l er
C-4975A. Pl ace tool on cl amp bri dge and ti ghten tool
unti l the jaws of the tool are cl osed.
Fig. 20 HOUSING BUSHING
1 - BUSHING
2 - HOUSING
Fig. 21 INNER C/V BOOT
1 - CLAMP
2 - BOOT
3 - CLAMP
4 - SHAFT
5 - HOUSING
CV J OINT-INNER (Continued)
FRONT AXLE - C205F
TABLE OF CONTENTS
page page
FRONT AXLE - C205F
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 32
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 39
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 40
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 47
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
DIFFERENTIAL CASE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
PINION GEAR/RING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51
FRONT AXLE - C205F
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, worn/damaged
gears or the carri er housi ng not havi ng the proper
offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peak-noi se range. I f the noi se stops or changes
greatl y check for:
I nsuffi ci ent l ubri cant.
I ncorrect ri ng gear backl ash.
Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. The si de gears are l oaded dur-
i ng turns. They usual l y do not cause noi se duri ng
strai ght-ahead dri vi ng when the gears are unl oaded.
A worn pi ni on mate shaft can al so cause a snappi ng
or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pinion bearings have a constant-pi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Differential bearings usual l y produce a l ow pi tch
noi se. Di fferenti al beari ng noi se i s si mi l ar to pi ni on
beari ng noi se. The pi tch of di fferenti al beari ng noi se
i s al so constant and vari es onl y wi th vehi cl e speed.
Axle shaft bearings produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 m.p.h.
LOW SPEED KNOCK
Low speed knock i s general l y caused by:
Worn U-joi nts/CV joi nt.
Worn si de-gear thrust washers.
Worn pi ni on shaft bore.
DR FRONT AXLE - C205F 3 - 27
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by:
Damaged dri ve shaft.
Mi ssi ng dri ve shaft bal ance wei ght(s).
Worn or out of bal ance wheel s.
Loose wheel l ug nuts.
Worn U-joi nt(s).
Loose/broken spri ngs.
Damaged axl e shaft beari ng(s).
Loose pi ni on gear nut.
Excessi ve pi ni on yoke run out.
Bent axl e shaft(s).
Check for l oose or damaged front end components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rear end
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged) can be caused by:
Hi gh engi ne i dl e speed.
Transmi ssi on shi ft operati on.
Loose engi ne/transmi ssi on/transfer case mounts.
Worn U-joi nts/CV joi nt.
Loose spri ng mounts.
Loose pi ni on gear nut and yoke.
Excessi ve ri ng gear backl ash.
Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear and l i s-
ten for the noi se. A mechani cs stethoscope i s hel pful
i n i sol ati ng the source of a noi se.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.
5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as
necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after
correcting tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid
or correct erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect
and repair clutch as necessary.
3 - 28 FRONT AXLE - C205F DR
FRONT AXLE - C205F (Continued)
Differential Cracked 1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears
Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears
Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears
Avoid erratic use of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill
and quantity.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct
level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal
cover.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct
fluid type and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other
gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine
remaining parts for damage.
4. Improper adjustments. 4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion
contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched
ring gear and pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing
pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out.
Replace components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components
and replace as necessary. Ensure
that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
REMOVAL
hoi st.
(2) Remove axl e hal f shafts.
(3) Remove exhaust crossover.
(4) Mark front propel l er shaft and remove shaft.
(5) Remove suspensi on crossmember mounti ng
bol ts (Fi g. 1) and remove crossmember.
(6) Support axl e wi th hydraul i c jack.
(7) Remove axl e housi ng pi ni on mounti ng bol ts
(Fi g. 2).
(8) Remove axl e shaft tube mounti ng bol ts (Fi g. 3).
(9) Remove di fferenti al housi ng mounti ng bol ts
(Fi g. 4).
(10) Lower axl e from the vehi cl e.
INSTALLATION
(1) Rai se axl e i nto posi ti on.
(2) I nstal l axl e mounti ng bol ts and ti ghten nuts to
95 Nm (70 ft. l bs.).
(3) I nstal l suspensi on crossmember and bol ts.
Ti ghten crossmember nuts to 102 Nm (75 ft. l bs.).
(4) I nstal l front propel l er shaft wi th reference
marks al i gned (Fi g. 5) and ti ghten bol ts to 115 Nm
(85 ft. l bs.).
(5) I nstal l exhaust crossover.
(6) I nstal l axl e hal f shafts.
Fig. 1 SUSPENSION CROSSMEMBER
1 - PINION FLANGE
2 - AXLE TUBE MOUNTING BRACKET
3 - CROSSMEMBER BOLTS
Fig. 2 HOUSING PINION MOUNTING BOLTS
1 - MOUNTING BOLTS
2 - PINION FLANGE
Fig. 3 AXLE TUBE MOUNT
1 - MOUNTING
2 - BOLTS
ADJUSTMENTS
Ri ng gear and pi ni on are suppl i ed as a matched
sets. I denti fyi ng numbers for the ri ng gear and pi n-
i on are pai nted onto the pi ni on gear shaft and the
si de of the ri ng gear. A pl us (+) number, mi nus ()
number or zero (0) al ong wi th the gear set sequence
number (01 to 99) i s on each gear. Thi s fi rst number
i s the amount (i n thousandths of an i nch) the depth
vari es from the standard depth setti ng of a pi ni on
marked wi th a (0). The next two numbers are the
sequence number of the gear set. The standard depth
provi des the best teeth contact pattern.
Compensati on for pi ni on depth vari ance i s
achi eved wi th sel ect shi ms l ocated between the rear
pi ni on beari ng cone and pi ni on gear head (Fi g. 6).
I f i nstal l i ng a new gear, note the depth vari ance
number of the ori gi nal and repl acement pi ni on. Add
or subtract thi s number from the ori gi nal depth
shi m/oi l sl i nger to compensate for the di fference i n
the depth vari ances. The numbers represent thou-
sands of an i nch devi ati on from the standard. I f the
number i s negati ve, add that val ue to the requi red
thi ckness of the depth shi ms. I f the number i s posi -
ti ve, subtract that val ue from the thi ckness of the
depth shi m.
Pinion Gear Depth Variance Chart: Note where
Ol d and New Pi ni on Marki ng col umns i ntersect.
I ntersecti ng fi gure represents pl us or mi nus the
amount needed.
Fig. 4 DIFFERENTIAL MOUNT
1 - DIFFERENTIAL MOUNT
2 - DIFFERENTIAL HOUSING
3 - MOUNTING BOLTS
2 - PROPELLER SHAFT
3 - FLANGE YOKE
4 - REFERENCE MARK
Fig. 6 ADJUSTMENT SHIM
1 - PINION GEAR DEPTH SHIM
2 - DIFFERENTIAL BEARING PRELOAD SHIM
3 - RING GEAR
5 - COLLAPSIBLE SPACER
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
New 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 0.001 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 DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken wi th pi ni on cups and pi n-
i on beari ngs i nstal l ed i n housi ng. Take measure-
ments wi th a Pi ni on Gauge Set, Pi ni on Bl ock 8177,
Arbor Di scs 8541 and Di al I ndi cator C-3339 (Fi g. 7).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 8177 and rear pi ni on beari ng onto Screw 6741
(Fi g. 7).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto the housi ng through the
pi ni on beari ng cups (Fi g. 8).
(3) I nstal l front pi ni on beari ng and Cone-Nut 6740
onto the screw. Ti ghten cone-nut unti l Torque To
Rotate the screw i s 2.0 Nm (18 i n. l bs.) (Fi g. 7).
(4) Pl ace Arbor Di scs 8541 on Arbor D-115-3 i n
posi ti on i n the housi ng si de beari ng cradl es (Fi g. 9).
I nstal l di fferenti al beari ng caps on arbor di scs and
ti ghten cap bol ts to speci fi cati on.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
Fig. 7 PINION GEAR DEPTH GAUGE
1 - DIAL INDICATOR
2 - ARBOR
3 - PINION HEIGHT BLOCK
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
Fig. 8 PINION HEIGHT BLOCK
1 - PINION BLOCK
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n the housi ng so di al probe and scooter bl ock are
fl ush agai nst the surface of the pi ni on hei ght bl ock.
Hol d scooter bl ock i n pl ace and zero the di al i ndi ca-
tor. Ti ghten di al i ndi cator face l ock screw.
(7) Sl i de the di al i ndi cator probe across the gap
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 10). Sl i de the di al probe to the crest of the arbor
bar and record the hi ghest readi ng.
(8) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
marked on the shaft of the pi ni on gear usi ng the
opposi te si gn on the vari ance number. For exampl e, i f
the depth vari ance i s 2, add +0.002 i n. to the di al
i ndi cator readi ng.
(9) Remove the pi ni on depth gauge components
from the housi ng
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms i nserted between the
beari ng cup and the housi ng. The proper shi m thi ck-
ness can be determi ned usi ng sl i p-fi t Dummy Bear-
i ngs 8398 i n pl ace of the di fferenti al si de beari ngs
and a Di al I ndi cator C-3339. Before measuri ng di ffer-
enti al beari ng prel oad and gear backl ash, measure
pi ni on gear depth and prepare pi ni on for i nstal l ati on.
Pi ni on gear depth i s essenti al to establ i shi ng gear
backl ash and tooth contact patterns. After measuri ng
shi m thi ckness to take up di fferenti al si de pl ay,
i nstal l pi ni on and measure gear backl ash shi m thi ck-
ness. Overal l shi m thi ckness i s the di al i ndi cator
readi ng and prel oad speci fi cati on added together. The
gear backl ash measurement determi nes the shi m
thi ckness used on the ri ng gear si de of the di fferen-
ti al case. Subtract gear backl ash shi m thi ckness from
overal l shi m thi ckness to determi ne shi m thi ckness
for pi ni on gear si de of the di fferenti al (Fi g. 11).
Fig. 9 PINION GAUGE TOOLS
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
Fig. 10 PINION GEAR DEPTH MEASUREMENT
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
Fig. 11 ADJUSTMENT SHIM
1 - PINION GEAR DEPTH SHIM
3 - RING GEAR
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove si de beari ngs from di fferenti al case.
(2) I nstal l ri ng gear i f necessary, on di fferenti al
case and ti ghten bol ts to speci fi cati on.
(3) I nstal l Dummy Beari ngs 8398 on di fferenti al
case.
(4) I nstal l di fferenti al case i n the housi ng.
(5) I nsert Dummy Shi ms 8107 3.0 mm (0.118 i n.)
starti ng poi nt shi ms between both dummy beari ngs
and the housi ng (Fi g. 12).
(6) I nstal l the marked beari ng caps i n thei r correct
posi ti ons. I nstal l and snug the bol ts.
(7) Usi ng a dead-bl ow hammer to seat the di ffer-
enti al dummy beari ngs to each si de of the di fferenti al
housi ng (Fi g. 13) and (Fi g. 14).
(8) I nstal l Pi l ot Stud C-3288-B i n cover bol t hol e
bel ow ri ng gear.
Fig. 12 DUMMY SHIM
1 - DUMMY SHIM
3 - DIFFERENTIAL CASE
4 - DUMMY BEARINGS
Fig. 13 SEAT PINION GEAR SIDE
1 - DEAD-BLOW HAMMER
2 - HOUSING
3 - PINION GEAR SIDE
Fig. 14 SEAT RING GEAR SIDE
1 - HOUSING
2 - DEAD-BLOW HAMMER
3 - RING GEAR SIDE
(9) Attach Di al I ndi cator C-3339 to post and posi -
ti on di al i ndi cator pl unger on a fl at surface on a ri ng
gear bol t head (Fi g. 15).
(10) Push and hol d di fferenti al to the pi ni on gear
si de of the housi ng (Fi g. 16) and zero di al i ndi cator.
(11) Push and hol d di fferenti al case to the ri ng
gear si de and record di al i ndi cator readi ng (Fi g. 17).
(12) Add the di al i ndi cator readi ng to the starti ng
poi nt shi m thi cknesses to determi ne the total shi m
thi ckness necessary to achi eve zero di fferenti al end
pl ay.
(13) Add 0.2 mm (0.008 i n) to the zero end pl ay
total . Thi s new total represents the shi ms needed to
prel oad the new di fferenti al case beari ngs.
(14) Rotate di al i ndi cator out of the way on pi l ot
stud.
(15) Remove di fferenti al case, dummy beari ngs
and dummy shi ms from the housi ng.
(16) I nstal l the pi ni on gear i n the housi ng. I nstal l
the compani on fl ange and establ i sh the correct pi ni on
rotati ng torque.
(17) I nstal l di fferenti al case and Dummy Beari ngs
i n the housi ng wi th a si ngl e dummy shi m on the ri ng
gear si de of the axl e and ti ghten retai ni ng cap bol ts.
(18) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads (Fi g. 15).
(19) Push and hol d di fferenti al case toward pi ni on.
(20) Zero di al i ndi cator face to poi nter.
(21) Push and hol d di fferenti al case to ri ng gear
si de of the housi ng.
(22) Record di al i ndi cator readi ng.
Fig. 15 DIFFERENTIAL SIDE PLAY
1 - DIFFERENTIAL
2 - PILOT STUD
3 - DIAL INDICATOR
Fig. 16 ZERO DIAL INDICATOR
1 - PINION GEAR SIDE
2 - PILOT STUD
3 - DIAL INDICATOR
Fig. 17 RECORD DIAL INDICATOR
1 - DIAL INDICATOR
2 - HOUSING
3 - RING GEAR SIDE
(23) Subtract 0.05 mm (0.002 i n.) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Add the resul ti ng measure-
ment to the thi ckness of the si ngl e dummy shi m.
Thi s i s the thi ckness of shi m requi red to achi eve
proper backl ash.
(24) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
housi ng.
(25) Rotate di al i ndi cator out of the way on pi l ot
stud.
(26) Remove di fferenti al case, dummy beari ngs
and dummy shi m from the housi ng.
(27) I nstal l new si de beari ng cones and cups on
di fferenti al case.
(28) I nstal l Spreader W-129-B and Adapter Pl ates
8142-A on the housi ng and spread open enough to
recei ve di fferenti al case.
CAUTION: Never spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(29) Pl ace the si de beari ng shi ms i n the di fferen-
ti al housi ng agai nst the housi ng shoul der.
(30) I nstal l the di fferenti al case i n the housi ng.
(31) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(32) Posi ti on the di al i ndi cator pl unger agai nst a
ri ng gear tooth (Fi g. 18).
(33) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(34) Zero di al i ndi cator face to poi nter.
(35) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm (0.005 i n.) and
0.20 mm (0.008 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the di fferenti al housi ng to the
other (Fi g. 19).
(36) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform the
Gear Contact Pattern procedure.
GEAR CONTACT PATTERN
Gear tooth contact pattern i s used to veri fy the cor-
rect runni ng posi ti on of the ri ng and pi ni on gears.
Thi s wi l l produce l ow noi se and l ong gear l i fe. Gears
whi ch are not posi ti oned properl y may be noi sy and
have shorten gear l i fe.
(1) Wi pe cl ean each tooth of the ri ng gear.
(2) Appl y gear marki ng compound to al l of the ri ng
gear teeth.
(3) Veri fy beari ng cap bol ts are torque speci fi ca-
ti on.
(4) Appl y the brakes l i ghtl y to create at 14 Nm
(10 ft. l bs.) pi ni on rotati ng torque.
(5) Rotate the pi ni on/pi ni on yoke 4 ful l revol uti ons
i n each di recti ons.
(6) Read gear tooth contact pattern:
Gear contact pattern correct (Fi g. 20). Backl ash
and pi ni on depth i s correct.
Fig. 18 RING GEAR BACKLASH
1 - RING GEAR
2 - DIAL INDICATOR
Fig. 19 BACKLASH SHIM ADJUSTMENT
Ri ng gear too far away from pi ni on gear (Fi g.
21). Decrease backl ash by movi ng the ri ng cl oser to
the pi ni on gear.
Ri ng gear too cl ose to pi ni on gear (Fi g. 22).
I ncrease backl ash, by movi ng the ri ng away from the
pi ni on gear.
23). Decrease backl ash, by movi ng the ri ng cl oser to
the pi ni on gear.
pi ni on gear.
Pi ni on gear set too l ow (Fi g. 25). I ncrease pi ni on
gear hei ght, by i ncreasi ng the pi ni on depth shi m
thi ckness.
Fig. 20 CORRECT CONTACT PATTERN
Fig. 21 INCORRECT BACKLASH
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
1 - DRIVE SIDE TOE
2 - COAST SIDE HEEL
1 - DRIVE SIDE HEEL
2 - COAST SIDE HEEL
1 - DRIVE SIDE TOE
2 - COAST SIDE TOE
Fig. 25 LOW PINION HEIGHT
Pi ni on gear set too hi gh (Fi g. 26). Decrease pi n-
i on depth, by decreasi ng the pi ni on depth shi m thi ck-
ness.
SPECIFICATIONS
AXLE SPECIFICATIONS
Axle Ratio 3.55, 3.92
Differential Case Flange Runout 0.076 mm (0.003 in.)
Differential Side Gear Clearance 0-0.15 mm (0-0.006 in.)
Ring Gear Diameter 205 mm (8.0 in.)
Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Ring Gear Runout 0.12 mm (0.005 in.)
Pinion Bearing Preload - New Bearings 2.0-2.8 Nm (18-25 in. lbs.)
Pinion Bearing Preload - Original Bearings 1-2 Nm (10-20 in. lbs.)
Mounting Nuts 95 70 -
Differential Fill Hole Plug 34 25 -
Differential Cover Bolts 22 15 -
Bearing Cap Bolts 61 45 -
Ring Gear Bolts 108 80 -
Pinion Nut 271-475 200-350 -
Fig. 26 HIGH PINION HEIGHT
SPECIAL TOOLS
PULLER C-293-PA
PLUG C-293-3
ADAPTER C-293-42
ADAPTER C-293-48
PILOTS C-3288-B
DIAL INDICATOR C-3339
INSTALLER C-3716-A
INSTALLER C-3718
HANDLE C-4171
PULLER C-452
REMOVER C-4660-A
SPREADER W-129-B
INSTALLER 5063
INSTALLER 6448
HOLDER 6719A
PINION DEPTH SET 6775
DUMMY SHIM 8107
ADAPTER PLATES 8142A
PINION BLOCK 8177
REMOVER 8240A
DUMMY BEARING 8398
REMOVER 8401
INSTALLER 8692
INSTALLER 8693
INSTALLER 8694
INSTALLER 8695
REMOVER 8831
AXLE SHAFTS
REMOVAL
(2) Remove ski d pl ate, i f equi pped.
(3) Cl ean axl e seal area.
(4) Remove snap ri ng from the axl e shaft.
(5) Remove axl e wi th Remove 8420A Col l ar 8420-3
and Sl i de Hammer C-3752 (Fi g. 27).
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant.
(2) I nstal l axl e shaft and engage shaft i nto si de
gear. Push fi rml y on axl e shaft to engage snap-ri ng.
(3) Check the di fferenti al fl ui d l evel and add fl ui d
i f necessary.
(4) I nstal l hal f shaft.
(5) I nstal l ski d pl ate, i f necessary.
AXLE SHAFT SEALS
REMOVAL
(3) Cl ean axl e seal area.
(4) Remove axl e shaft O-ri ng.
(5) Remove axl e shaft.
(6) Remove axl e shaft seal wi th a smal l pry bar.
INSTALLATION
(1) Cl ean axl e shaft bore cl ean.
(2) I nstal l a new axl e shaft seal wi th I nstal l er
8694 and Handl e C-4171 (Fi g. 28).
(3) Lubri cate seal l i p wi th gear l ubri cant.
(4) I nsert axl e shaft through seal , beari ng, and
engage i t i nto si de gear spl i nes. Push fi rml y on the
axl e shaft to engage the snap-ri ng.
(5) I nstal l axl e shaft O-ri ng.
AXLE BEARINGS
REMOVAL
(1) Remove hal f shaft, axl e shaft and seal .
Fig. 27 AXLE SHAFT PULLER
1 - SNAP RING GROVE
2 - SLID HAMMER THREADS
3 - REMOVER BLOCKS
4 - REMOVER COLLAR
Fig. 28 SEAL INSTALLER
1 - INSTALLER
2 - HANDLE
Fig. 29 BEARING REMOVER
1 - AXLE BEARING
2 - NUT
3 - REMOVER
(2) I nstal l axl e shaft beari ng Remover C-4660-A (3)
i n the beari ng (1) (Fi g. 29). Then ti ghten the nut (2)
to spread the remover i n the beari ng.
(3) I nstal l beari ng remove cup (1) beari ng (2) and
nut (3) (Fi g. 30). Ti ghten nut (3) to draw the beari ng
out.
(4) I nspect axl e shaft tube bore for roughness and
burrs.
INSTALLATION
(1) Wi pe the axl e shaft tube bore cl ean.
(2) I nstal l axl e shaft beari ng wi th I nstal l er 5063
and Handl e C-4171 (Fi g. 31).
(3) I nstal l a new axl e shaft seal wi th I nstal l er
8694 and Handl e C-4171.
(4) Lubri cate seal l i p wi th gear l ubri cant.
(5) I nsert axl e shaft through seal , beari ng and
engage i t i nto si de gear spl i nes. Push fi rml y on the
axl e shaft to engage the snap-ri ng.
(6) I nstal l axl e shaft O-ri ng.
PINION SEAL
REMOVAL
(1) Remove both hal f shafts.
(2) Remove front propel l er shaft.
(3) Rotate pi ni on gear three or four ti mes and ver-
i fy pi ni on rotates smoothl y.
(4) Record pi ni on rotati ng torque wi th an i nch
pound torque wrench, for i nstal l ati on reference (Fi g.
32).
(5) Posi ti on Hol der 6719 agai nst the compani on
fl ange and i nstal l a four bol ts and washers i nto the
threaded hol es and ti ghten the bol ts.
(6) Remove pi ni on nut.
(7) Remove compani on fl ange wi th Remover C-452
(Fi g. 33).
(8) Remove pi ni on seal wi th a pry tool or a sl i de
hammer mounted screw.
Fig. 30 BEARING REMOVER CUP
1 - REMOVER CUP
2 - BEARING
3 - NUT
Fig. 31 BEARING INSTALLER
1 - INSTALLER
2 - HANDLE
Fig. 32 PINION ROTATING TORQUE
2 - INCH POUND TORQUE WRENCH
AXLE BEARINGS (Continued)
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal .
(2) I nstal l seal wi th I nstal l er 8695 and Handl e
C-4171 (Fi g. 34).
(3) I nstal l compani on fl ange onto the pi ni on wi th
I nstal l er C-3718 and Hol der 6719A.
(4) Posi ti on hol der agai nst the compani on fl ange
and i nstal l four bol ts and washers i nto the threaded
hol es. Ti ghten the bol t and washer so that the hol der
i s hel d to the fl ange.
(5) I nstal l a new pi ni on nut onto the pi ni on shaft
and ti ghten the pi ni on nut unti l there i s zero beari ng
end-pl ay (Fi g. 35).
CAUTION: Do not exceed 271 Nm (200 ft. lbs.) the
minimum tightening torque when installing the
companion flange at this point. Failure to heed cau-
tion may result in damage.
CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. Failure to heed caution may
result in damage.
(6) Record pi ni on rotati ng torque usi ng an i nch
pound torque wrench. The rotati ng torque shoul d be
equal to the readi ng recorded duri ng removal pl us an
addi ti onal 0.56 Nm (5 i n. l bs.) (Fi g. 36).
(7) I f rotati ng torque i s l ow, ti ghten the pi ni on nut
i n 6.8 Nm (5 ft. l bs.) i ncrements unti l the proper
rotati ng torque i s achi eved.
CAUTION: If maximum tightening torque 475 Nm
(350 ft. lbs.) is reached prior to reaching the
required rotating torque, the collapsible spacer may
have been damaged. Failure to heed caution may
result in damage.
Fig. 33 COMPANION FLANGE REMOVER
2 - PULLER TOOL
Fig. 34 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 35 COMPANION FLANGE HOLDER
2 - COMPANION FLANGE HOLDER
3 - TORQUE WRENCH
PINION SEAL (Continued)
DIFFERENTIAL
REMOVAL
(1) Remove di fferenti al housi ng cover and drai n
fl ui d.
(2) Remove axl e shafts.
(3) Loosen beari ng cap bol ts.
NOTE: Differential bearing cap reference numbers
are stamped on caps and machined flat on the
housing. If reference numbers cannot be found,
make new marks for later reference.
(4) I nstal l Adapter Pl ates 8142-A onto the housi ng.
(5) I nstal l Spreader W-129-B onto the adapter
pl ates (Fi g. 37) and ti ghten the turnbuckl e fi nger-
ti ght.
(6) I nstal l a Pi l ot Stud L-4438 at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load the i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero the i ndi cator.
(7) Spread the housi ng to remove the di fferenti al
case from the housi ng (Fi g. 38). Measure the di stance
wi th the di al i ndi cator.
CAUTION: Never spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(8) Remove di al i ndi cator.
(9) Whi l e hol di ng the di fferenti al case i n posi ti on,
remove beari ng cap bol ts and caps.
(10) Remove di fferenti al from the housi ng (Fi g.
39). Ensure di fferenti al beari ng cups and shi ms
remai n i n posi ti on on the di fferenti al beari ngs.
(11) Tag di fferenti al beari ng cups and shi ms to
i ndi cate thei r l ocati on.
Fig. 36 PINION ROTATION TORQUE
2 - INCH POUND TORQUE WRENCH
Fig. 37 ADAPTER PLATES AND SPREADER
1 - ADAPTER PLATE
2 - SPREADER
Fig. 38 DIAL INDICATOR LOCATION
1 - DIAL INDICATOR
2 - SPREADER
(12) Remove spreader from housi ng.
DISASSEMBLY
(1) Remove ri ng gear.
(2) Remove rol l -pi n hol di ng mate shaft i n housi ng.
(3) Remove pi ni on gear mate shaft.
(4) Rotate di fferenti al si de gears (2) and remove
pi ni on gears (3) and thrust washers (1) (Fi g. 40).
(5) Remove di fferenti al si de gears and thrust
washers.
ASSEMBLY
NOTE: If the same gears and thrust washers are
being used, install them into their original locations.
(1) Lubri cate di fferenti al components wi th hypoi d
gear l ubri cant.
(2) I nstal l si de gears and thrust washers i nto the
di fferentai l case.
(3) Rotate pi ni on mate gears and thrust washers
i nto the di fferentai l case.
(4) I nstal l pi ni on gear mate shaft.
(5) Al i gn hol e i n pi ni on gear mate shaft wi th hol e
i n the di fferenti al case.
(6) I nstal l rol l -pi n (3) i n the di fferenti al case wi th
a punch (1) and hammer (Fi g. 41). Peen edge of rol l -
pi n hol e i n di fferenti al case i n two pl aces 180 apart.
(7) I nstal l ri ng gear.
Fig. 39 DIFFERENTIAL
1 - HOUSING
2 - DIFFERENTIAL
3 - BEARING CUPS
Fig. 40 PINION MATE GEAR
1 - THRUST WASHER
2 - SIDE GEAR
3 - PINION MATE GEAR
Fig. 41 PINION MATE SHAFT ROLL-PIN
1 - PUNCH
2 - PINION MATE SHAFT
3 - MATE SHAFT LOCKPIN
DIFFERENTIAL (Continued)
INSTALLATION
NOTE: If replacement differential bearings or differ-
ential case are replaced, Refer to adjustments for
Differential Bearing Preload and Gear Backlash pro-
cedures.
(1) I nstal l Spreader W-129-B wi th the Adapter
Pl ates 8142-A and i nstal l the safety hol ddown
cl amps. Ti ghten the tool turnbuckl e fi nger-ti ght.
(2) I nstal l a Pi l ot Stud L-4438 at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to pi l ot stud. Load i ndi cator pl unger agai nst the
opposi te si de of the housi ng and zero the i ndi cator.
(3) Spread housi ng and measure the di stance wi th
the di al i ndi cator.
CAUTION: Never spread housing over 0.50 mm
(0.020 in). Failure to heed caution may result in
damage.
(4) Remove di al i ndi cator.
(5) I nstal l di fferenti al case i n the housi ng. Ensure
di fferenti al beari ng cups remai n i n posi ti on on the
beari ngs and the di fferenti al prel oad shi ms are
seated i n the housi ng. Tap di fferenti al case to ensure
beari ngs cups are seated i n the housi ng.
(6) I nstal l beari ng caps to thei r ori gi nal l ocati ons
and l oosel y i nstal l cap bol ts.
(7) Remove housi ng spreader.
(8) Ti ghten the beari ng cap bol ts to 61 Nm (45 ft.
l bs.).
(9) I nstal l axl e shafts.
(10) Appl y a bead of orange Mopar Axl e RTV seal -
ant or equi val ent to the housi ng cover.
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied. Failure to heed caution may result in dam-
age.
(11) I nstal l cover and ti ghten bol ts i n a cri ss-cross
pattern to 22 Nm (15 ft. l bs.).
(12) Fi l l di fferenti al wi th l ubri cant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al from housi ng.
(2) Remove beari ngs (3) from di fferenti al case (4)
wi th Pul l er C-293-PA (1) Adapters C-293-48 (2) and
Pl ug C-293-3 (5) (Fi g. 42).
INSTALLATION
(1) I nstal l di fferenti al case beari ngs wi th I nstal l er
C-3716-A and Handl e C-4171 (Fi g. 43).
(2) I nstal l di fferenti al i nto the housi ng.
Fig. 42 DIFFERENTIAL CASE BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
REMOVAL
NOTE: The ring gear and pinion are serviced in a
matched set. Never replace one without replacing
the other.
(2) Pl ace di fferenti al case i n a vi se wi th soft jaw
(Fi g. 44).
(3) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
(4) Dri ve ri ng gear from di fferenti al case wi th a
soft hammer (Fi g. 44).
(5) Mark compani on yoke and compani on fl ange
(6) Remove compani on fl ange bol ts and ti e the pro-
pel l er shaft to the vehi cl e underbody.
(7) Rotate compani on fl ange three or four ti mes
and veri fy fl ange rotates smoothl y.
(8) Record pi ni on rotati ng torque an i nch pound
torque wrench for i nstal l ati on reference (Fi g. 45).
(9) I nstal l bol ts i nto two of the threaded hol es i n
the compani on fl ange 180 apart.
fl ange and i nstal l a bol t and washer i nto one of the
remai ni ng threaded hol es. Ti ghten the bol ts so that
the Hol der 6719 i s hel d to the fl ange.
(11) Remove the pi ni on nut.
(12) Remove the compani on fl ange wi th Remover
C-452 (Fi g. 46).
(13) Remove pi ni on from di fferenti al housi ng.
(14) Remove pi ni on seal wi th a pry tool or a sl i de
(15) Remove oi l sl i nger, i f equi pped and front pi n-
i on beari ng.
(16) Remove front pi ni on beari ng cup wi th
Remover 8831 and Handl e C-4171 (Fi g. 47).
Fig. 43 DIFFERENTIAL CASE BEARINGS
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 44 RING GEAR
2 - RING GEAR
3 - HAMMER
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
DIFFERENTIAL CASE BEARINGS (Continued)
(17) Remove rear pi ni on beari ng cup from housi ng
(Fi g. 48) wi th Remover 8401 and Handl e C-4171.
(18) Remove col l apsi bl e prel oad spacer (Fi g. 49).
(19) Remove rear pi ni on beari ng wi th Pul l er/Press
C-293-PA and Adapters C-293-42 (Fi g. 50).
(20) Remove depth shi ms from the pi ni on shaft
and record thi ckness of shi ms.
Fig. 46 COMPANION FLANGE REMOVER
2 - PULLER TOOL
Fig. 47 FRONT PINION BEARING CUP
1 - HOUSING
2 - REMOVER
3 - HANDLE
Fig. 48 REAR PINION BEARING CUP
1 - HOUSING
2 - REMOVER
3 - HANDLE
Fig. 49 COLLAPSIBLE SPACER
2 - REAR PINION BEARING
3 - PINION DEPTH SHIM
PINION GEAR/RING GEAR (Continued)
INSTALLATION
matched set. Never replace one gear without replac-
ing the other matching gear. If ring and pinion
gears or bearings are replaced, Refer to Adjust-
ments for Pinion Gear Depth Setting.
(1) Appl y Mopar Door Ease or equi val ent l ubri cant
to outsi de surface of the beari ng cups.
(2) I nstal l rear pi ni on beari ng cup wi th I nstal l er
8692 and Dri ver Handl e C-4171 (Fi g. 51).
(3) I nstal l front pi ni on beari ng cup wi th I nstal l er
(4) Lubri cate front pi ni on beari ng and i nstal l bear-
i ng i n the housi ng.
(6) I nstal l pi ni on seal wi th I nstal l er 8695 and
Handl e C-4171 (Fi g. 52).
Fig. 50 REAR PINION BEARING
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - DRIVE PINION GEAR SHAFT
1 - HOUSING
2 - INSTALLER
3 - HANDLE
Fig. 52 PINION SEAL
1 - HANDLE
2 - INSTALLER
(7) Pl ace pi ni on depth shi m (Fi g. 53) on the pi ni on
shaft.
(8) I nstal l rear pi ni on beari ng wi th I nstal l er 6448
and a press (Fi g. 54).
(9) I nstal l new col l apsi bl e spacer onto the pi ni on
shaft (Fi g. 55).
(10) Lubri cate rear pi ni on beari ng and i nstal l the
pi ni on gear i n the housi ng.
(11) I nstal l compani on fl ange wi th I nstal l er
C-3718 and Hol der 6719.
(12) I nstal l new pi ni on nut and ti ghten to 271
Nm (200 ft. l bs.) (Fi g. 56).
(13) Usi ng Hol der 6719 and a torque wrench set at
475 Nm (350 ft. l bs.). Ti ghten pi ni on nut unti l bear-
i ng end pl ay i s taken up.
(14) Sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l bs.)
i ncrements unti l desi red rotati ng torque i s achi eved.
Measure rotati ng torque frequentl y to avoi d over-
crushi ng the col l apsi bl e spacer (Fi g. 57). The pi ni on
rotati ng torque shoul d be:
Ori gi nal Beari ngs: 1 to 2.5 Nm (10 to 20 i n.
l bs.)
New Beari ngs: 2.0 to 2.8 Nm (18 to 25 i n. l bs.)
ified preload torque. Failure to heed caution may
result in damage.
Fig. 53 PINION DEPTH SHIM
2 - PINION GEAR
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
(15) I nvert di fferenti al case and start two ri ng
gear bol ts to provi de ri ng gear bol t hol e al i gnment.
(16) I nvert di fferenti al case i n the vi se.
(17) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 108 Nm (80 ft. l bs.) (Fi g. 58).
CAUTION: Never reuse the ring gear bolts. Failure
to heed caution may result in damage.
(18) I nstal l di fferenti al i n housi ng and veri fy gear
mesh, backl ash and contact pattern.
Fig. 56 PINION NUT
3 - TORQUE WRENCH
1 - PINION COMPANION FLANGE
2 - TORQUE WRENCH
Fig. 58 RING GEAR BOLTS
1 - TORQUE WRENCH
2 - BOLTS
3 - RING GEAR
FRONT AXLE - 9 1/4 AA
TABLE OF CONTENTS
page page
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 59
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 63
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 64
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 68
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 72
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 75
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77
GEAR NOISE
cant, i ncorrect backl ash, tooth contact, worn/damaged
gears or the carri er housi ng not havi ng the proper
offset and squareness.
greatl y check for:
Gear damage.
A worn pi ni on mate shaft can al so cause a snappi ng
or a knocki ng noi se.
BEARING NOISE
source.
LOW SPEED KNOCK
Worn U-joi nt(s).
3 - 54 FRONT AXLE - 9 1/4 AA DR
VIBRATION
Vi brati on at the front/rear of the vehi cl e i s usual l y
caused by:
Worn or out of bal ance wheel s.
Worn U-joi nt(s).
Check for l oose or damaged front end components
can contri bute to what appears to be a vi brati on. Do
not overl ook engi ne accessori es, brackets and dri ve
bel ts.
DRIVELINE SNAP
i nto gear (or the cl utch engaged) can be caused by:
Worn U-joi nts.
DIAGNOSTIC CHART
3. End-play in pinion bearings. 3. Refer to pinion pre-load
information and correct as
necessary.
4. Excessive gear backlash
between the ring gear and pinion.
4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.
5. Improper adjustment of pinion
gear bearings.
5. Adjust the pinion bearings
pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact
surfaces.
necessary.
DR FRONT AXLE - 9 1/4 AA 3 - 55
FRONT AXLE - 9 1/4 AA (Continued)
properly.
and quantity.
and quantity.
wheel/tire.
level.
cover.
damage.
adjustment.
contact pattern.
pinion.
pre-load.
bolts.
REMOVAL
hoi st.
(2) Remove brake cal i pers and rotors.
(3) Di sconnect ABS wheel speed sensors.
(4) Di sconnect axl e vent hose.
(5) Remove front propel l er shaft.
(6) Remove stabi l i zer bar l i nks at the axl e brack-
ets (Fi g. 1).
(7) Di sconnect shock absorbers from axl e brackets
(Fi g. 2).
(8) Remove track bar from the axl e bracket (Fi g.
3).
(9) Remove ti e rod and drag l i nk (Fi g. 4) from the
steeri ng knuckl es.
(10) Posi ti on l i ft under the axl e assembl y and
secure axl e to l i ft.
(11) Mark suspensi on al i gnment cams for i nstal l a-
ti on reference.
Fig. 1 STABILIZER LINK
1 - PULLER C-3894-A
2 - LINK
(12) Remove upper and l ower suspensi on arms
from the axl e bracket (Fi g. 5).
(13) Lower the axl e. The coi l spri ngs wi l l drop
wi th the axl e.
(14) Remove coi l spri ngs from the axl e bracket.
INSTALLATION
CAUTION: Suspension components with rubber
bushings should be tightened with the weight of the
vehicle on the suspension. Failure to heed caution
may result in damage.
(1) Support the axl e on a sui tabl e l i fti ng devi ce.
(2) Secure axl e to l i fti ng devi ce.
(3) Posi ti on the axl e under the vehi cl e.
(4) I nstal l spri ngs, retai ner cl i p and bol ts.
(5) Rai se axl e and al i gn i t wi th the spri ng pads.
(6) Posi ti on upper and l ower suspensi on arms i n
the axl e brackets. I nstal l bol ts, nuts and al i gn the
suspensi on al i gnment cams to the reference marks.
Do not ti ghten at thi s ti me.
1 - SHOCK
2 - SPRING
3 - FLAG NUT
4 - SHOCK BOLT
Fig. 3 TRACK BAR
1 - TRACK BAR
2 - BOLT
3 - NUT
Fig. 4 DRAG LINK
1 - PITMAN ARM
2 - DRAGLINK
3 - PULLER C-3894-A
Fig. 5 LINK/COIL SUSPENSION
1 - STABILIZER BAR
2 - SHOCK ABSORBER
3 - COIL SPRING
6 - TRACK BAR
(7) Connect track bar to the axl e bracket and
i nstal l the bol t. Do not ti ghten at thi s ti me.
(8) I nstal l shock absorber and ti ghten bol ts to 121
Nm (89 ft. l bs.).
(9) I nstal l stabi l i zer bar l i nk to the axl e bracket.
Ti ghten the nut to 68 Nm (50 ft. l bs.).
(10) I nstal l drag l i nk and ti e rod to the steeri ng
knuckl es and ti ghten the nuts to 108 Nm (80 ft.
l bs.).
(11) I nstal l ABS wheel speed sensors.
(12) I nstal l rotors and brake cal i pers.
(13) Connect the axl e vent hose.
(14) I nstal l front propel l er shaft.
(15) Wi th vehi cl e on the ground, ti ghten upper
suspensi on arm nuts at axl e to 149 Nm (110 ft. l bs.).
Ti ghten upper suspensi on arm nuts at frame to 149
Nm (110 ft. l bs.).
(16) Wi th vehi cl e on the ground, ti ghten l ower sus-
pensi on arm nuts at axl e to 190 Nm (140 ft. l bs.).
Ti ghten the l ower suspensi on arm nuts at frame to
190 Nm (140 ft. l bs.).
(17) Ti ghten track bar bol t at the axl e bracket to
176 Nm (130 ft. l bs.).
(18) Check front wheel al i gnment.
ADJUSTMENTS
Ri ng and pi ni on gears are suppl i ed as matched
sets. Compensati on for pi ni on depth vari ance i s
achi eved wi th a sel ect shi m. l ocated between the rear
pi ni on beari ng and pi ni on gear head.
Measurements are taken wi th pi ni on beari ng cups
and pi ni on beari ngs i nstal l ed i n the housi ng. Take
measurements wi th Pi ni on Gauge Set and Di al I ndi -
cator C-3339 (Fi g. 6).
(Fi g. 6).
rear beari ng and screw i nto the housi ng through pi n-
i on beari ng cups (Fi g. 7).
Rotate the screw i s 1.7-2.26 Nm (15-20 i n. l bs.).
(4) Pl ace Arbor Di sc 8289 on Arbor D-115-3 i n posi -
ti on i n the housi ng si de beari ng cradl es (Fi g. 8).
(5) I nstal l di fferenti al beari ng caps on arbor di scs
and snug the beari ng cap bol ts. Then cross ti ghten
cap bol ts to 85 Nm (63 ft. l bs.).
NOTE: Arbor should rotate freely in the arbor disc.
(7) Posi ti on Scooter Bl ock/Di al I ndi cator fl ush on
the pi ni on hei ght bl ock. Hol d scooter bl ock and zero
Fig. 6 PINION GEAR DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
1. PINION HEIGHT BLOCK
2. PINION BLOCK
(8) Sl owl y sl i de the scooter bl ock across the pi ni on
hei ght bl ock over to the arbor (Fi g. 9). Move scooter
bl ock ti l l di al i ndi cator crests the arbor, then record
the hi ghest readi ng.
i ng.
(10) I nstal l the sel ect shi m between the rear pi n-
i on beari ng and the pi ni on gear head.
DIFFERENTIAL CASE BEARING PRELOAD AND
GEAR BACKLASH
Backl ash i s adjusted by movi ng the adjusters i n
and out or both. By movi ng the adjusters the case/
ri ng gear wi l l move cl oser or further away from the
pi ni on. I n most cases thi s adjustment can be used to
achi eve the correct gear tooth pattern and set the
case beari ng prel oad.
(1) Remove adjuster l ock bol ts and adjuster l ocks
(Fi g. 10).
(2) Loosen the di fferenti al beari ng caps.
(3) Sl i de di fferenti al case toward the pi ni on gear
unti l the gears make contact/zero backl ash. I f zero
backl ash cannot be obtai ned, turn the pi ni on si de
adjuster unti l zero backl ash i s obtai ned.
(4) Hol di ng the di fferenti al case toward the pi ni on
gear, turn beari ng adjusters wi th Spanner Wrench
8883 unti l they make contact wi th the di fferenti al
beari ngs/cups.
(5) Back off the ri ng gear si de adjuster 4 hol es, to
obtai n i ni ti al ri ng gear backl ash.
(6) I nstal l ri ng gear si de adjuster l ock and bol t. Do
not ti ghten adjuster l ock bol t at thi s ti me.
(7) Ti ghten pi ni on gear si de adjuster fi rml y
agai nst the di fferenti al case beari ng cup.
(8) Rotate the pi ni on several ti mes to seat the di f-
ferenti al beari ngs.
Fig. 8 GAUGE TOOLS IN HOUSING
1. PINION HEIGHT BLOCK
2. PINION BLOCK
3. ARBOR
4. ARBOR DISCS
Fig. 9 PINION DEPTH MEASUREMENT
1. DIAL INDICATOR
2. ARBOR
3. SCOOTER BLOCK
Fig. 10 ADJUSTER LOCK BOLT
2 - ADJUSTER LOCK
3 - ADJUSTER LOCK BOLT
4 - BEARING CAP BOLT
(9) Loosen pi ni on gear si de adjuster unti l i t i s no
l onger i n contact wi th the beari ng cup, then ti ghten
i t unti l i t makes contact.
(10) Ti ghten pi ni on gear si de adjuster an addi -
ti onal :
New Bearings: 6 Adjuster Hol es
Original Bearings: 4 Adjuster Hol es
(11) I nstal l pi ni on gear si de adjuster l ock and bol t.
Do not ti ghten adjuster l ock bol t at thi s ti me.
(12) Ti ghten beari ng cap bol ts to 85 Nm (63 ft.
l bs.).
(13) Ti ghten adjuster l ock bol ts to 25 Nm (18 ft.
l bs.).
(14) Measure ri ng gear backl ash wi th a Di al I ndi -
cator C-3339 and Di al I ndi cator Stud L-4438 at ei ght
poi nts around the dri ve si de of the ri ng gear (Fi g.
11). The backl ash shoul d be 0.08-0.25 mm
(0.003-0.010 i n) wi th a preferred backl ash of
0.13-0.18 mm (0.005-0.007 i n).
NOTE: Backlash measurement should not vary
more than 0.05 mm (0.002 in) between measuring
points. If measurement does vary inspect the gears
for burrs, the differential case flange and ring gear
mounting.
GEAR TOOTH CONTACT PATTERN
have shortened gear l i fe.
gear teeth.
(3) Veri fy beari ng cap bol ts are torque to speci fi ca-
ti on.
(4) Appl y the brakes l i ghtl y to create a 14 Nm (10
ft. l bs.) pi ni on rotati ng torque.
Gear contact pattern i s correct (Fi g. 12). Back-
l ash and pi ni on depth i s correct.
the pi ni on gear usi ng the adjusters.
pi ni on gear usi ng the adjusters.
1 - DIAL INDICATOR
2 - RING GEAR
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
thi ckness.
ness.
1 - DRIVE SIDE TOE
2 - COAST SIDE HEEL
1 - DRIVE SIDE HEEL
2 - COAST SIDE HEEL
1 - DRIVE SIDE TOE
2 - COAST SIDE TOE
SPECIFICATIONS
AXLE SPECIFICATIONS
Pinion Bearing Preload - New Bearing 1.7-2.8 Nm (15-25 in. lbs.)
Pinion Bearing Preload - Original Bearing 1.1-2.2 Nm (10-20 in. lbs.)
Pinion Bearing Preload + Differential Case Bearing
Preload - New Bearing
3.4-5.6 Nm (30-50 in. lbs.)
Preload - Original Bearing
2.8-5.1 Nm (25-45 in. lbs.)
Fill Hole Plug 32 24 -
Axle Nut 356 263 -
Pinion Shaft Lock Bolt 52 38 -
Adjuster Lock Bolt 25 18 -
SPECIAL TOOLS
PULLER C-293-PA
INSTALLER C-3095-A
DIAL INDICATOR SET C-3339
HANDLE C-4171
CUP INSTALLER D-146
DIAL INDICATOR STUD L-4438
SPLITTER 1130
REMOVER/EXTRACTOR 6310
PINION DEPTH SET 6730
ARBOR DISCS 8289
RECEIVER 8498
PINION BLOCK 8878
ADAPTERS 8879
BEARING INSTALLER 8881
SEAL INSTALLER 8882
ADJUSTER WRENCH 8883
SEAL INSTALLER 8885
CUP INSTALLER 8886
PLUG 8888
PINION DRIVER 8976
FLANGE WRENCH 8979
AXLE SHAFTS
REMOVAL
(1) Wi th the vehi cl e i n neutral , posi ti on vehi cl e on
hoi st.
(2) Remove brake cal i per, rotor and ABS wheel
speed sensor i f equi pped.
(3) Remove axl e shaft cotter pi n, hub nut and
washer (Fi g. 19).
(4) Remove four hub beari ng bol ts (Fi g. 20) from
the back of the steeri ng knuckl e.
PINION INSTALLER 8982
FLANGE PULLER 8992
BRIDGE 938
Fig. 19 AXLE NUT
1 - AXLE NUT
2 - AXLE
3 - COTTER PIN
Fig. 20 HUB BEARING BOLTS
1 - STUB SHAFT
2 - BEARING BOLTS
3 - AXLE SHAFT
(5) Remove hub beari ng from the steeri ng knuckl e.
(6) Remove axl e shaft (Fi g. 21) from steeri ng
knuckl e and axl e housi ng.
DISASSEMBLY
Si ngl e cardan U-joi nt components are not servi ce-
abl e. I f defecti ve they must be repl aced as a uni t.
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. To avoid distorting the yoke,
do not over tighten the vise jaws.
(1) Remove the beari ng cap retai ni ng snap ri ngs
(Fi g. 22).
NOTE: Saturate the bearing caps with penetrating
oil prior to removal.
(2) Locate a socket wi th an i nsi de di ameter that i s
l arger than the beari ng cap. Pl ace the socket
(recei ver) agai nst the yoke and around the peri meter
of the beari ng cap to be removed.
(3) Locate a socket wi th an outsi de di ameter that
i s smal l er than the beari ng cap. Pl ace the socket
(dri ver) agai nst the opposi te beari ng cap.
(4) Posi ti on the yoke wi th the sockets i n a vi se
(Fi g. 23).
(5) Ti ghten the vi se jaws to force the beari ng cap
i nto the l arger socket (recei ver).
(6) Rel ease the vi se jaws. Remove the sockets and
beari ng cap that was parti al l y forced out of the yoke.
(7) Repeat the above procedure for the remai ni ng
beari ng cap and remove spi der from the propel l er
shaft yoke.
1 - KNUCKLE
2 - AXLE SHAFT
Fig. 22 AXLE SHAFT OUTER U-JOINT
1 - SHAFT YOKE
2 - BEARING CAP
3 - SNAP RINGS
4 - BEARING CAP
5 - SPINDLE YOKE
6 - BEARING
7 - BEARING CAP
8 - SNAP RINGS
9 - BEARING CAP
Fig. 23 YOKE BEARING CAP
1 - LARGE-DIAMETER SOCKET WRENCH
2 - VISE
3 - SMALL-DIAMETER SOCKET WRENCH
AXLE SHAFTS (Continued)
ASSEMBLY
(1) Pack the beari ng caps 1/3 ful l of wheel beari ng
l ubri cant. Appl y extreme pressure (EP), l i thi um-base
l ubri cant to ai d i n i nstal l ati on.
(2) Posi ti on the spi der i n the yoke. I nsert the seal s
and beari ngs. Tap the beari ng caps i nto the yoke
bores far enough to hol d the spi der i n posi ti on.
(3) Pl ace the socket (dri ver) agai nst one beari ng
cap. Posi ti on the yoke wi th the socket i n a vi se.
(4) Ti ghten the vi se to force the beari ng caps i nto
the yoke. Force the caps enough to i nstal l the retai n-
i ng cl i ps.
(5) I nstal l the beari ng cap retai ni ng cl i ps.
(6) I nstal l axl e shaft.
INSTALLATION
(1) Cl ean axl e shaft and appl y a thi n fi l m of
Mopar Wheel Beari ng Grease to the shaft spl i nes
and hub bore.
(2) I nstal l axl e shaft through the steeri ng knuckl e
and i nto the di fferenti al si de gears (Fi g. 24).
(3) I nstal l hub beari ng i n the knuckl e.
(4) I nstal l hub beari ng bol ts and ti ghten to 202
Nm (149 ft. l bs.).
(5) I nstal l ABS wheel speed sensor, brake rotor
and cal i per.
(6) I nstal l axl e washer and nut. Ti ghten axl e nut
to 179 Nm (132 ft. l bs.).
(7) Rotate axl e several 5 to 10 ti mes to seat the
wheel beari ng.
(8) Ti ghten axl e nut to fi nal torque of 356 Nm
(263 ft. l bs.).
(9) Al i gn nut to next cotter pi n hol e and i nstal l
new cotter pi n.
AXLE SHAFT SEALS
REMOVAL
(1) Remove hub beari ngs and axl e shafts.
(2) Remove di fferenti al from di fferenti al housi ng.
(3) Remove di fferenti al beari ng adjusters (Fi g. 25).
(4) Remove axl e seal s (Fi g. 26) l ocated behi nd
adjusters wi th Recei ver 8498 and Extractor 6310.
(5) I nstal l Recei ver 8498 i nto the adjuster bore.
Fig. 24 AXLE SHAFT
1 - AXLE YOKE
2 - AXLE SHAFT
3 - KNUCKLE
Fig. 25 ADJUSTERS
1 - DIFFERENTIAL CASE BEARING ADJUSTERS
Fig. 26 AXLE SHAFT SEAL
1 - ADJUSTER THREADS
2 - SEAL
(6) I nstal l Extractor Rod 6310 wi th Extractor Foot
6310-9 through the recei ver and the axl e seal (Fi g.
27).
(7) I nstal l Extractor Pl ate 6310-2 and Nut 6310-7
on the extractor rod.
(8) Ti ghten nut on the extractor rod (Fi g. 28) and
pul l the seal out and i nto the recei ver.
INSTALLATION
(1) I nstal l axl e seal on I nstal l er Cups 8885-2 and
posi ti on cups wi th seal s i nto the housi ng.
NOTE: Seal are installed with the axle guide facing
outward.
(2) I nstal l Turnbuckl e 8885-1 (Fi g. 29) i nto the
i nstal l er cups and expand the turnbuckl e unti l the
seal bottom out i n the housi ng.
(3) I nstal l di fferenti al i nto the axl e housi ng.
(4) I nstal l axl e shaft and hub beari ngs
PINION SEAL
REMOVAL
(1) Mark the propel l er shaft and pi ni on fl ange for
(4) Rotate pi ni on gear three or four ti mes.
(5) Measure and record the torque necessary to
rotate (Fi g. 30) the pi ni on gear wi th an i nch pound
torque wrench.
Fig. 27 SEAL RECEIVER
1 - RECEIVER
2 - EXTRACTOR FOOT
Fig. 28 SEAL EXTRACTOR
1 - EXTRACTOR ROD
2 - EXTRACTOR NUT
Fig. 29 AXLE SEAL INSTALLER
1 - INSTALLER CUP
2 - INSTALLER TURNBUCKLE
3 - INSTALLER CUP
AXLE SHAFT SEALS (Continued)
(6) Hol d pi ni on fl ange wi th Fl ange Wrench 8979
(Fi g. 31) and remove pi ni on fl ange nut and washer.
(7) Remove pi ni on fl ange wi th Pi ni on Fl ange
Pul l er 8992 (Fi g. 32).
(8) Remove pi ni on shaft seal wi th a pry tool or
sl i de hammer mounted screw.
INSTALLATION
(1) I nstal l new pi ni on seal wi th I nstal l er 8882 and
Handl e C-4171 (Fi g. 33).
(2) Appl y a l i ght coat of tefl on thread seal ant to
the pi ni on fl ange spl i nes.
(3) Li ghtl y tap the pi ni on fl ange onto the pi ni on
unti l a few threads are showi ng.
(4) I nstal l fl ange washer and new pi ni on nut.
(5) Hol d fl ange wi th Fl ange Wrench 8979 and
ti ghten pi ni on nut unti l pi ni on end pl ay i s taken up.
(6) Rotate pi ni on several ti mes to seat beari ngs.
(7) Measure pi ni on rotati ng torque wi th an i nch
pound torque wrench and compare i t to recorded
measurement. Ti ghten pi ni on nut i n smal l i ncre-
ments, unti l pi ni on rotati ng torque i s 0.40-0.57 Nm
(3-5 i n. l bs.) greater than recorded measurement.
(8) Rotate pi ni on several ti mes then veri fy pi ni on
rotati ng torque agai n.
(9) I nstal l axl e shafts and hub beari ngs.
(10) I nstal l propel l er shaft wi th reference marks
al i gned.
1 - PINION FLANGE
2 - TORQUE WRENCH
Fig. 31 FLANGE WRENCH
1 - PINION FLANGE
2 - WRENCH
Fig. 32 PINION FLANGE PULLER
1 - PINION FLANGE
2 - PULLER
1 - HANDLE
2 - INSTALLER
DIFFERENTIAL
REMOVAL
l ubri cant from the housi ng.
(Fi g. 34).
(4) Mark beari ng caps l eft and ri ght for i nstal l a-
ti on reference.
(5) Remove beari ng cap bol ts and remove beari ng
caps.
(6) Loosen di fferenti al beari ng adjusters (Fi g. 35)
wi th Spanner Wrench 8883.
(7) Remove di fferenti al case from the housi ng.
(8) Remove beari ng cups and tag them l eft and
ri ght for i nstal l ati on reference.
DISASSEMBLY
(1) Remove pi ni on shaft l ock bol t.
(2) Remove pi ni on shaft (Fi g. 36).
Fig. 34 ADJUSTERS AND LOCKS
2 - ADJUSTER LOCK
3 - ADJUSTER
4 - BEARING CAP
Fig. 35 ADJUSTERS
1 - BEARING CUP
2 - ADJUSTER
3 - BEARING CUP
4 - ADJUSTER
Fig. 36 PINION SHAFT
1 - PINION SHAFT
2 - PUNCH
3 - PINION GEAR
4 - SIDE GEAR
(3) Rotate di fferenti al pi ni on gears to di fferenti al
wi ndow and remove pi ni on gears and thrust washers
(Fi g. 37).
washers (Fi g. 38).
ASSEMBLY
being used, install them into their orignial locations.
(1) Lubri cate al l di fferenti al components wi th axl e
l ubri cant.
(2) I nstal l di fferenti al si de gears and thrust wash-
ers (Fi g. 39).
(3) Rotate the one pi ni on gear wi th thrust washer
i nto the di fferenti al case (Fi g. 40). Then rotate the
other pi ni on gear wi th thrust washer i nto the di ffer-
enti al case.
Fig. 37 PINION GEAR
1 - DIFFERENTIAL WINDOW
2 - PINION GEAR
3 - THRUST GEAR
Fig. 38 SIDE GEARS
1 - SIDE GEAR
2 - SIDE GEAR
3 - PINION GEARS
Fig. 39 SIDE GEARS
2 - SIDE GEAR
Fig. 40 PINION GEAR
2 - SIDE GEARS
3 - PINION GEAR
(4) Al i gn hol e i n the pi ni on gears wi th hol e i n the
di fferenti al case.
(5) I nstal l pi ni on shaft.
(6) I nstal l new pi ni on shaft l ock bol t and ti ghten
to 52 Nm (38 ft. l bs.).
INSTALLATION
(1) Cl ean the housi ng cavi ty wi th a fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth.
CAUTION: Do not use water, steam, kerosene or
gasoline for cleaning.
(2) Lubri cate di fferenti al case beari ng.
(3) I nstal l di fferenti al case wi th beari ngs cups i nto
the housi ng.
(4) I nstal l beari ng caps and bol ts (Fi g. 41). Ti ghten
the beari ng cap bol ts fi nger-ti ght.
NOTE: Do not torque bearing cap and bolts at this
time.
beari ngs/cups.
l onger i n contact wi th the beari ng cup.
(12) Ti ghten pi ni on gear si de adjuster unti l i t just
makes contact wi th the beari ng cup.
ti onal :
l bs.).
l bs.) (Fi g. 42).
(17) Measure ri ng gear backl ash and check gear
tooth contact pattern. Refer to Adjustments for pro-
cedure.
(18) I nstal l axl e shafts and hub beari ngs.
(19) I nstal l di fferenti al housi ng gasket and cover.
Ti ghten cover bol ts to 40 Nm (30 ft. l bs.).
Fig. 41 CASE BEARING CAP
2 - BEARING CAP
3 - ADJUSTER
2 - ADJUSTER LOCK
(20) Fi l l di fferenti al wi th l ubri cant, refer to Lubri -
cati on & Mai ntenance for capaci ty and l ubri cant
type.
(21) I nstal l fi l l pl ug and ti ghten to 32 Nm (24 ft.
l bs.).
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove the di fferenti al case from the housi ng.
(2) I nstal l Pl ug 8888 i nto the end of the case.
(3) Remove di fferental case beari ngs wi th Beari ng
Spl i tter 1130 and Bri dge 938 (Fi g. 43).
INSTALLATION
(1) Set di fferenti al case on Pl ug 8888.
(2) I nstal l di ffereni al case beari ngs wi th I nstal l er
8881 and Handl e C-4171 (Fi g. 44).
(3) I nstal l di fferentai l case i nto housi ng.
REMOVAL
NOTE: The ring and pinion gears are service in a
matched set. Never replace the ring gear/pinion
gear without replacing the other matching gear.
(1) Mark pi ni on fl ange and propel l er shaft for
i nstal l ati on al i gnment.
(2) Di sconnect propel l er shaft from pi ni on fl ange
and remove propel l er shaft.
(5) Pl ace di fferenti al case i n a vi se wi th soft metal
jaw protectors
case.
Fig. 43 DIFFERENTIAL CASE BEARING
1 - BRIDGE
2 - SPLITTER
3 - BEARING
4 - PLUG
1 - HANDLE
3 - BEARING
4 - INSTALLER
(9) Remove pi ni on fl ange from pi ni on wi th Pi ni on
Fl ange Pul l er 8992 (Fi g. 47).
(10) Remove pi ni on gear from housi ng wi th Pi ni on
Dri ver 8976 and a hammer (Fi g. 48).
NOTE: Thread drive on shaft until it bottoms out.
Fig. 45 RING GEAR
2 - RING GEAR
3 - HAMMER
1 - PINION FLANGE
2 - WRENCH
1 - PINION FLANGE
2 - PULLER
Fig. 48 PINION DRIVER
1 - PINION SHAFT
2 - PINION DRIVER
(11) Remove pi ni on seal wi th a sl i de hammer or
pry bar.
(12) Remove and di scard front pi ni on beari ng
CAUTION: Do not reuse front pinion bearing/cup.
(13) Remove col l apsi bl e spacer from the pi ni on
shaft.
(14) Remove rear pi ni on beari ng wi th Pul l er
C-293-PA and Adapters 8879 (Fi g. 49).
(15) Remove pi ni on depth shi m from the pi ni on
gear shaft and record thi ckness of the shi ms.
(16) Remove front pi ni on beari ng cup from the
housi ng wi th a punch and hammer and di scard.
(17) Remove rear pi ni on beari ng cup from the
housi ng wi th a punch and hammer, i f beari ng i s
repl aced.
INSTALLATION
(1) I nstal l front pi ni on beari ng cup (Fi g. 50) wi th
I nstal l er D-146 and Handl e C-4171.
(2) I nstal l rear pi ni on beari ng cup (Fi g. 51) wi th
I nstal l er 8886 and Handl e C-4171, i f beari ng i s
repl aced.
1 - PULLER
2 - VISE
3 - PINION SHAFT
4 - ADAPTER BLOCKS
1 - INSTALLER
2 - HANDLE
1 - INSTALLER
2 - HANDLE
(3) I nstal l pi ni on depth shi m (Fi g. 52) on the pi n-
i on gear shaft.
(4) I nstal l rear pi ni on beari ng (Fi g. 53) wi th
I nstal l er C-3095-A and a press.
(5) I nstal l new col l apsi bl e spacer (Fi g. 54).
(6) Lubri cate pi ni on and beari ngs.
(7) I nstal l pi ni on i nto the housi ng and pl ace front
pi ni on beari ng onto the pi ni on shaft. Draw the pi ni on
shaft i nto the front beari ng wi th I nstal l er 8982 (Fi g.
55).
2 - PINION GEAR
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
Fig. 54 COLAPSIBLE SPACER
1 - COLAPSIBLE SPACER
2 - PINION GEAR
Fig. 55 PINION GEAR INSTALLER
1 - INSTALLER
(8) I nstal l new pi ni on seal (Fi g. 56) wi th I nstal l er
(9) Appl y a l i ght coat of tefl on seal ant to the pi n-
i on fl ange spl i nes.
(10) Hol d pi ni on and l i ghtl y tap the pi ni on fl ange
onto the pi ni on shaft, unti l a few threads are show-
i ng.
(11) I nstal l pi ni on fl ange washer and new pi ni on
nut.
and ti ghten pi ni on nut unti l end pl ay i s taken up.
pound torque wrench (Fi g. 57). Ti ghten pi ni on nut i n
smal l i ncrements unti l pi ni on rotati ng torque i s:
New Pinion Bearings: 1.7-2.8 Nm (15-25 i n.
l bs.)
Original Pinion Bearings: 1.1-2.2 Nm (10-20
i n. l bs.)
(16) Posi ti on the ri ng gear on di fferenti al case and
start two new ri ng gear bol ts.
(17) I nstal l the rest of the new ri ng gear bol ts and
ti ghten them al ternatel y to seat the ri ng gear.
(18) Torque ri ng gear bol ts to 140 Nm (103 ft.
l bs.).
(19) I nstal l di fferenti al i n housi ng.
(20) Measure fi nal rotati ng torque wi th an i nch
pound torque wrench. The fi nal pi ni on rotati ng
torque pl us di fferenti al case beari ng prel oad i s:
New Bearings: 3.4-5.6 Nm (30-50 i n. l bs.)
Original Bearings: 2.8-5.1 Nm (25-45 i n. l bs.)
(22) Veri fy ri ng gear backl ash and gear contact
pattern.
(23) I nstal l the propel l er shaft wi th the reference
marks al i gned.
(24) I nstal l di fferenti al cover wi th gasket and
(25) Fi l l di fferenti al wi th fl ui d and ti ghten fi l l pl ug
to 32 Nm (24 ft. l bs.).
1 - HANDLE
2 - INSTALLER
1 - PINION FLANGE
2 - TORQUE WRENCH
REAR AXLE - 9 1/4
TABLE OF CONTENTS
page page
REAR AXLE - 9 1/4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 83
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 90
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 90
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 94
AXLE SHAFT SEALS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 94
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 95
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 96
DIFFERENTIAL COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 97
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 98
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 99
DIFFERENTIAL-TRAC-LOK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 100
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 100
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 100
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 101
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 106
PINION GEAR/RING GEAR/TONE RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 108
REAR AXLE - 9 1/4
GEAR NOISE
cant, i ncorrect backl ash, i ncorrect pi ni on depth, tooth
contact, worn/damaged gears, or the carri er housi ng
not havi ng the proper offset and squareness.
greatl y check for:
Gear damage.
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ght-ahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on shaft can al so cause a snap-
pi ng or a knocki ng noi se.
BEARING NOISE
source.
i s usual l y not noti ceabl e at speeds above 30 mph.
3 - 80 REAR AXLE - 9 1/4 DR
LOW SPEED KNOCK
Worn U-joi nt.
Worn si de gear thrust washers.
VIBRATION
caused by a:
Worn or out-of-bal ance wheel s.
Worn U-joi nt(s).
Check for l oose or damaged front-end components
can contri bute to what appears to be a rearend vi bra-
ti on. Do not overl ook engi ne accessori es, brackets
and dri ve bel ts.
NOTE: All driveline components should be exam-
ined before starting any repair.
DRIVELINE SNAP
i nto gear (or the cl utch engaged), can be caused by:
Worn U-joi nts.
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
DIAGNOSTIC CHART
DR REAR AXLE - 9 1/4 3 - 81
REAR AXLE - 9 1/4 (Continued)
properly.
and quantity.
and quantity.
wheel/tire.
level.
cover.
3 - 82 REAR AXLE - 9 1/4 DR
damage.
adjustment.
contact pattern. Adjust backlash or
pinion depth.
pinion.
pre-load.
bolts.
REMOVAL
(2) Posi ti on a l i ft under axl e and secure axl e to
l i ft.
(3) Remove wheel s and ti res assembl i es.
(4) Remove al l brake components.
(5) Remove axl e vent hose.
(6) Mark propel l er shaft and compani on fl ange for
i nstal l ati on al i gnment reference.
(8) Remove shock absorbers from axl e (Fi g. 1).
(9) Remove U-bol ts from axl e (Fi g. 2).
(10) Remove axl e from the vehi cl e.
INSTALLATION
(1) Rai se axl e wi th l i ft and al i gn to the l eaf spri ng
centeri ng bol ts.
(2) I nstal l axl e U-bol ts and ti ghten to 149 Nm
(110 ft. l bs.).
(3) I nstal l shock absorbers to axl e and ti ghten to
speci fi cati on.
(4) I nstal l al l brake comonents.
(5) I nstal l axl e vent hose.
(6) Al i gn propel l er shaft and pi ni on compani on
fl ange reference marks and ti ghten compani on fl ange
bol ts to 115 Nm (85 ft. l bs.).
(7) I nstal l the wheel s and ti res.
(8) Fi l l di fferenti al to speci fi cati ons.
(9) Remove l i ft from axl e and l ower the vehi cl e.
ADJUSTMENTS
Ri ng gear and pi ni on are suppl i ed as matched sets.
I denti fyi ng numbers for the ri ng gear and pi ni on are
pai nted onto the pi ni on gear shaft (Fi g. 3) and the
si de of the ri ng gear. A pl us (+) number, mi nus ()
DR REAR AXLE - 9 1/4 3 - 83
number or zero (0) al ong wi th the gear set sequence
number (01 to 99) i s on each gear. Thi s fi rst number
i s the amount (i n thousandths of an i nch) the depth
vari es from the standard depth setti ng of a pi ni on
marked wi th a (0). The next two numbers are the
sequence number of the gear set. The standard depth
provi des the best teeth contact pattern.
Compensati on for pi ni on depth vari ance i s
achi eved wi th sel ect shi ms. The shi ms are pl aced
behi nd the rear pi ni on beari ng. (Fi g. 4).
I f i nstal l i ng a new gear, note the depth vari ance
number of the ori gi nal and repl acement pi ni on. Add
or subtract thi s number from the ori gi nal depth
shi m/oi l sl i nger to compensate for the di fference i n
the depth vari ances. The numbers represent thou-
sands of an i nch devi ati on from the standard. I f the
number i s negati ve, add that val ue to the requi red
thi ckness of the depth shi ms. I f the number i s posi -
ti ve, subtract that val ue from the thi ckness of the
depth shi m.
Pinion Gear Depth Variance Chart: Note where
Ol d and New Pi ni on Marki ng col umns i ntersect.
I ntersecti ng fi gure represents pl us or mi nus the
amount needed.
1 - NUT
2 - AXLE
3 - SHOCK ABSORBER
Fig. 2 REAR SPRING
1 - LEAF SPRING
2 - PLATE
3 - NUTS
6 - SHACKLES
Fig. 3 PINION ID NUMBER
1 - VARIANCE NUMBER
2 - SEQUENCE NUMBER
Fig. 4 ADJUSTMENT SHIM LOCATIONS
3 - PINION BEARING
5 - PINION GEAR
6 - BEARING CUP
3 - 84 REAR AXLE - 9 1/4 DR
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement 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 0.001 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 DEPTH MEASUREMENT
cator C-3339 (Fi g. 5).
(Fi g. 5).
rear beari ng, and screw i nto the housi ng through
pi ni on beari ng cups (Fi g. 6).
Rotate the screw i s 1.7 Nm (15 i n. l bs.) (Fi g. 5).
Fig. 5 PINION DEPTH GAUGE TOOLS
1 - DIAL INDICATOR
2 - ARBOR
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
1 - PINION BLOCK
DR REAR AXLE - 9 1/4 3 - 85
I nstal l di fferenti al beari ng caps on arbor di scs and
ti ghten cap bol ts to 41 Nm (30 ft. l bs.).
NOTE: Arbor Discs 8541 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n axl e housi ng so di al probe and scooter bl ock are
fl ush agai nst the rearward surface of the pi ni on
hei ght bl ock (Fi g. 5). Hol d scooter bl ock i n pl ace and
zero the di al i ndi cator. Ti ghten di al i ndi cator face
l ock screw.
(7) Sl i de the di al i ndi cator probe across the gap
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 8). Conti nue movi ng the di al probe to the crest
of the arbor bar and record the hi ghest readi ng.
i ng pl us the dri ve pi ni on gear depth vari ance number
marked on the shaft of the pi ni on. For exampl e, i f
the depth vari ance i s 2, add +0.002 i n. to the di al
i ndi cator readi ng.
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
The fol l owi ng must be consi dered when adjusti ng
beari ng prel oad and gear backl ash:
The maxi mum ri ng gear backl ash vari ati on i s
0.076 mm (0.003 i n.).
Mark the gears so the same teeth are meshed
duri ng al l backl ash measurements.
Mai ntai n the torque whi l e adjusti ng the beari ng
prel oad and ri ng gear backl ash.
Excessi ve adjuster torque wi l l i ntroduce a hi gh
beari ng l oad and cause premature beari ng fai l ure.
I nsuffi ci ent adjuster torque can resul t i n excessi ve
di fferenti al case free-pl ay and ri ng gear noi se.
I nsuffi ci ent adjuster torque wi l l not support the
ri ng gear correctl y and can cause excessi ve di fferen-
ti al case free-pl ay and ri ng gear noi se.
NOTE: The differential bearing cups will not always
immediately follow the threaded adjusters as they
are moved during adjustment. To ensure accurate
bearing cup responses to the adjustments:
Maintain the gear teeth engaged (meshed) as
marked.
The bearings must be seated by rapidly rotat-
ing the pinion gear a half turn back and forth.
Do this five to ten times each time the threaded
adjusters are adjusted.
Fig. 7 PINION DEPTH TOOLS
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
3 - 86 REAR AXLE - 9 1/4 DR
(1) Through the axl e tube use Wrench C-4164 to
adjust each threaded adjuster i nward unti l the di ffer-
enti al beari ng free-pl ay i s el i mi nated. Al l ow some
ri ng gear backl ash approxi matel y 0.25 mm (0.01 i n.)
between the ri ng and pi ni on gear. Seat the beari ng
cups wi th the procedure descri bed above.
(2) I nstal l di al i ndi cator and posi ti on the pl unger
agai nst the dri ve si de of a ri ng gear tooth (Fi g. 9).
Measure the backl ash at 4 posi ti ons, 90 degrees
apart around the ri ng gear. Locate and mark the
area of mi ni mum backl ash.
(3) Rotate the ri ng gear to the posi ti on of the l east
backl ash. Mark the gear so that al l future backl ash
measurements wi l l be taken wi th the same gear
teeth meshed.
(4) Loosen the ri ght-si de, ti ghten the l eft-si de
threaded adjuster. Obtai n backl ash of 0.076 to 0.102
mm (0.003-0.004 i n.) wi th each adjuster ti ghtened to
14 Nm (10 ft. l bs.). Seat the beari ng cups wi th the
procedure descri bed above.
(5) Ti ghten the di fferenti al beari ng cap bol ts 136
Nm (100 ft. l bs.).
(6) Ti ghten the ri ght-si de threaded adjuster to 102
Nm (75 ft. l bs.). Seat the beari ng cups wi th the pro-
cedure descri bed above. Conti nue to ti ghten the
ri ght-si de adjuster and seat beari ng cups unti l the
torque remai ns constant at 102 Nm (75 ft. l bs.)
(7) Measure the ri ng gear backl ash. The range of
backl ash i s 0.15 to 0.203 mm (0.006 to 0.008 i n.).
(8) Conti nue i ncreasi ng the torque at the ri ght-
si de threaded adjuster unti l the speci fi ed backl ash i s
obtai ned.
NOTE: The left-side threaded adjuster torque
should have approximately 102 Nm (75 ft. lbs.). If
the torque is considerably less, the complete
adjustment procedure must be repeated.
(9) Ti ghten the l eft-si de threaded adjuster unti l
102 Nm (75 ft. l bs.) torque i s i ndi cated. Seat the
beari ng rol l ers wi th the procedure descri bed above.
Do thi s unti l the torque remai ns constant.
(10) I nstal l the threaded adjuster l ocks and
ti ghten the l ock screws to 10 Nm (90 i n. l bs.).
GEAR CONTACT PATTERN
gear teeth.
ti on.
(4) Appl y parki ng brakes l i ghtl y to create at 14
Nm (10 ft. l bs.) pi ni on rotati ng torque.
Gear contact pattern i s correct (Fi g. 10). Back-
l ash and pi ni on depth i s correct.
1 - DIAL INDICATOR
2 - RING GEAR
3 - EXCITER RING
DR REAR AXLE - 9 1/4 3 - 87
thi ckness.
ness.
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
1 - DRIVE SIDE TOE
2 - COAST SIDE HEEL
1 - DRIVE SIDE HEEL
2 - COAST SIDE HEEL
1 - DRIVE SIDE TOE
2 - COAST SIDE TOE
3 - 88 REAR AXLE - 9 1/4 DR
SIDE GEAR CLEARANCE
When measuri ng si de gear cl earance, check each
gear i ndependentl y. I f i t necessary to repl ace a si de
gear, repl ace both gears as a matched set.
(1) I nstal l the axl e shafts and C-l ocks and pi ni on
mate shaft.
(2) Measure each si de gear cl earance. I nsert a
matched pai r of feel er gauge bl ades between the gear
and di fferenti al housi ng on opposi te si des of the hub
(Fi g. 17).
(3) I f si de gear cl earances i s no more than 0.005
i nch. Determi ne i f the axl e shaft i s contacti ng the
pi ni on mate shaft. Do not remove the feeler
gauges, inspect the axle shaft with the feeler
gauge inserted behind the side gear. I f the end of
the axl e shaft i s not contacti ng the pi ni on mate
shaft, the si de gear cl earance i s acceptabl e.
(4) I f cl earance i s more than 0.005 i nch (axl e shaft
not contacti ng mate shaft), record the si de gear cl ear-
ance. Remove the thrust washer and measure i ts
thi ckness wi th a mi crometer. Add the washer thi ck-
ness to the recorded si de gear cl earance. The sum of
gear cl earance and washer thi ckness wi l l determi ne
requi red thi ckness of repl acement thrust washer
(Fi g. 18).
I n some cases, the end of the axl e shaft wi l l move
and contact the mate shaft when the feel er gauge i s
i nserted. The C-l ock i s preventi ng the si de gear from
sl i di ng on the axl e shaft.
(5) I f there i s no si de gear cl earance, remove the
C-l ock from the axl e shaft. Use a mi crometer to mea-
sure the thrust washer thi ckness. Record the thi ck-
ness and re-i nstal l the thrust washer. Assembl e the
di fferenti al case wi thout the C-l ock i nstal l ed and re-
measure the si de gear cl earance.
(6) Compare both cl earance measurements. I f the
di fference i s l ess than 0.012 i nch (0.305 mm), add
cl earance recorded when the C-l ock was i nstal l ed to
thrust washer thi ckness measured. The sum wi l l
determi ne the requi red thi ckness of the repl acement
thrust washer.
(7) I f cl earance i s 0.012 i nch (0.305 mm) or
greater, both si de gears must be repl aced (matched
set) and the cl earance measurements repeated.
(8) I f cl earance (above) conti nues to be 0.012 i nch
(0.305 mm) or greater, the case must be repl aced.
Fig. 17 SIDE GEAR CLEARANCE
1 - FEELER GAUGE
2 - SIDE GEAR
Fig. 18 SIDE GEAR CALCULATIONS
DR REAR AXLE - 9 1/4 3 - 89
SPECIFICATIONS
AXLE SPECIFICATIONS
Axle Ratio 3.21, 3.55, 3.92
Differential Case Flange Runout 0.076 mm (0.003 in.)
Differential Case Clearance 0.12 mm (0.005 in.)
Ring Gear Runout 0.12 mm (0.005 in.)
Pinion Bearing Preload - New Bearings 1.7-4 Nm (15-35 in. lbs.)
Pinion Nut Minimum 285 210 -
Adjuster Lock Screw 10 7.5 90
Backing Plate Bolts 65 48 -
Pinion Mate Shaft Lock
Screw
11 8 -
Axle U-Bolt Nuts 149 110 -
SPECIAL TOOLS
PULLER C-293-PA
PLUG C-293-3
ADAPTERS C-293-37
ADAPTERS C-293-47
3 - 90 REAR AXLE - 9 1/4 DR
INSTALLER C-3095-A
INSTALLER C-3718
INSTALLER C-4076-B
WRENCH C-4164
HANDLE C-4171
INSTALLER C-4198
INSTALLER C-4213
REMOVER C-4307
DR REAR AXLE - 9 1/4 3 - 91
INSTALLER C-4308
INSTALLER C-4345
TRAC-LOK TOOLS C-4487
PULLER C-452
HANDLE C-4735
INSTALLER D-130
REMOVER 6310
HOLDER 6719A
PINION GAUGE SET 6730/6774/6775
TRAC-LOK TORQUE FIXTURE 6790
3 - 92 REAR AXLE - 9 1/4 DR
AXLE SHAFTS
REMOVAL
(1) Pl ace transmi ssi on i n neutral .
(4) Remove brake cal i per, adapter and rotor (Fi g.
19).
l ubri cant.
(6) Rotate di fferenti al case so pi ni on mate shaft
l ock screw i s accessi bl e. Remove l ock screw and pi n-
i on mate shaft from di fferenti al case (Fi g. 20).
FIXTURE 8136
TRAC-LOK TOOLS 8139
ARBOR DISCS 8541
PINION BLOCK 8542
Fig. 19 REAR ROTOR
1 - ROTOR
2 - CALIPER ADAPTER
3 - CALIPER
Fig. 20 PINION MATE SHAFT LOCK SCREW
1 - LOCK SCREW
2 - PINION MATE SHAFT
DR REAR AXLE - 9 1/4 3 - 93
(7) Push axl e shaft i nward and remove axl e shaft
C-l ock from the axl e shaft (Fi g. 21).
(8) Remove axl e shaft (Fi g. 22) careful l y to prevent
damage to the shaft beari ng and seal i n the axl e
tube.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant.
(2) I nsal l axl e shaft and engage i nto si de gear
spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal.
(3) I nsert C-l ock i n end of axl e shaft then push
axl e shaft outward to seat C-l ock i n si de gear.
(4) I nsert pi ni on shaft i nto di fferenti al case and
through thrust washers and di fferenti al pi ni ons.
(5) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te on the
threads. Ti ghten l ock screw to 11 Nm (8 ft. l bs.).
(6) I nstal l di fferenti al cover and fi l l wi th gear
l ubri cant to the bottom of the fi l l pl ug hol e.
(7) I nstal l brake rotor, cal i per adapter and cal i per.
(8) I nstal l wheel and ti re.
(9) Remove support and l ower vehi cl e.
AXLE SHAFT SEALS
REMOVAL
(2) Remove axl e shaft seal (Fi g. 23) from the axl e
tube wi th a smal l pry bar.
INSTALLATION
(1) Wi pe the axl e tube bore cl ean. Remove any ol d
seal er or burrs from the tube.
(2) Coat the l i p of the new seal wi th axl e l ubri cant
and i nstal l a seal wi th I nstal l er C-4076-B and Han-
dl e C-4735-1.
NOTE: When tool contacts the axle tube, the seal is
installed to the correct depth.
Fig. 21 AXLE SHAFT C-LOCK
1 - C-LOCK
2 - AXLE SHAFT
3 - SIDE GEAR
Fig. 22 AXLE SHAFT
1 - AXLE SHAFT
2 - SUPPORT PLATE
3 - CALIPER
4 - PARK BRAKE SHOE ASSEMBLY
Fig. 23 AXLE SHAFT SEAL
1 - AXLE SEAL
2 - AXLE BEARING
3 - 94 REAR AXLE - 9 1/4 DR
(3) I nstal l the axl e shaft.
AXLE BEARINGS
REMOVAL
(2) Remove axl e shaft seal from axl e tube wi th a
smal l pry bar.
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(3) Remove axl e shaft beari ng wi th Beari ng
Remover 6310 and Foot 6310-9 (Fi g. 24).
INSTALLATION
(1) Wi pe the axl e tube bore cl ean. Remove any ol d
seal er or burrs from the tube.
(2) I nstal l axl e shaft beari ng wi th I nstal l er C-4198
and Handl e C-4171. Dri ve beari ng i n unti l tool con-
tacts the axl e tube.
NOTE: Bearing is installed with the bearing part
number against the installer.
(3) Coat the l i p of the new axl e seal wi th axl e
l ubri cant and i nstal l wi th I nstal l er C-4076-B and
Handl e C-4735-1.
NOTE: When tool contacts the axle tube, the seal is
installed to the correct depth.
(4) I nstal l the axl e shaft.
PINION SEAL
REMOVAL
(1) Mark uni versal joi nt, compani on fl ange and
pi ni on shaft for i nstal l ati on reference.
(2) Remove propel l er shaft from the compani on
fl ange.
(3) Remove the brake rotors to prevent any drag.
(4) Rotate compani on fl ange three or four ti mes
and record pi ni on rotati ng torque wi th an i nch pound
torque wrench.
(5) I nstal l two bol ts i nto the compani on fl ange
threaded hol es, 180 apart. Posi ti on Hol der 6719A
agai nst the compani on fl ange and i nstal l and ti ghten
two bol ts and washers i nto the remai ni ng hol es.
(6) Hol d the compani on fl ange wi th Hol der 6719A
and remove pi ni on nut and washer.
(7) Remove compani on fl ange wi th Remover C-452
(Fi g. 25).
Fig. 24 AXLE SHAFT BEARING REMOVER
1 - AXLE SHAFT TUBE
2 - NUT
3 - GUIDE PLATE
4 - GUIDE
5 - THREADED ROD
6 - ADAPTER
7 - FOOT
Fig. 25 COMPANION FLANGE PULLER
2 - PULLER
DR REAR AXLE - 9 1/4 3 - 95
AXLE SHAFT SEALS (Continued)
(8) Remove pi ni on seal wi th pry tool or sl i de-ham-
mer mounted screw.
INSTALLATION
(2) I nstal l new pi ni on seal wi th I nstal l er C-3860-A
and Handl e C-4171 (Fi g. 26)
(3) I nstal l compani on fl ange on the end of the
shaft wi th the reference marks al i gned.
(4) I nstal l two bol ts i nto the threaded hol es i n the
compani on fl ange, 180 apart.
remai ni ng threaded hol es. Ti ghten the bol ts so hol der
i s hel d to the fl ange.
(6) I nstal l compani on fl ange on pi ni on shaft wi th
I nstal l er C-3718 and Hol der 6719.
(7) I nstal l pi ni on washer and a new pi ni on nut.
The convex si de of the washer must face outward.
CAUTION: Never exceed the minimum tightening
torque 285 Nm (210 ft. lbs.) when installing the
companion flange retaining nut at this point. Dam-
age to collapsible spacer or bearings may result.
(8) Hol d compani on fl ange wi th Hol der 6719 and
ti ghten the pi ni on nut wi th a torque set to 285 Nm
(210 ft. l bs.) (Fi g. 27). Rotate pi ni on several revol u-
ti ons to ensure the beari ng rol l ers are seated.
(9) Rotate pi ni on wi th an i nch pound torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal pl us an addi ti onal 0.56
Nm (5 i n. l bs.) (Fi g. 28).
ified preload torque. If rotating torque is exceeded,
a new collapsible spacer must be installed.
1 - HANDLE
2 - INSTALLER
3 - HOUSING
Fig. 27 TIGHTENING PINION NUT
3 - TORQUE WRENCH
2 - TORQUE WRENCH
3 - 96 REAR AXLE - 9 1/4 DR
(10) I f rotati ng torque i s l ow, use Hol der 6719 to
hol d the compani on fl ange and ti ghten pi ni on nut i n
6.8 Nm (5 ft. l bs.) i ncrements unti l proper rotati ng
torque i s achi eved.
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
NOTE: The seal replacement is unacceptable if the
final pinion nut torque is less than 285 Nm (210 ft.
lbs.).
(11) I nstal l propel l er shaft wi th the i nstal l ati on
reference marks al i gned.
(12) Ti ghten the compani on fl ange bol ts to 108
Nm (80 ft. l bs.).
(13) I nstal l brake rotors.
(14) Check the di fferenti al l ubri cant l evel .
DIFFERENTIAL COVER
REMOVAL
hoi st.
(2) Remove drai n pl ug.
(3) Remove cover bol ts.
(4) Remove cover and drai n l ubri cant.
INSTALLATION
(1) Appl y a 6.35mm (1/4 i n.) bead of Mopar Si l i -
cone Rubber Seal ant or equi val ent to the housi ng
cover (Fi g. 29).
CAUTION: If housing cover is not installed within 3
to 5 minutes, the cover must be cleaned and new
RTV applied. Failure to heed caution may result in
damage.
(2) I nstal l cover and i denti fi cati on tag. Ti ghten
cover bol ts i n a cri ss-cross pattern to 41 Nm (30 ft.
l bs.).
(4) I nstal l fi l l pl ug.
DIFFERENTIAL
REMOVAL
(1) Remove fi l l er pl ug from the di fferenti al cover.
(2) Remove di fferenti al cover and drai n the l ubri -
cant.
(3) Cl ean housi ng cavi ty wi th fl ushi ng oi l , l i ght
engi ne oi l or a l i nt free cl oth.
NOTE: Do not use steam, kerosene or gasoline to
clean the housing.
(5) Remove RWAL/ABS sensor from housi ng.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(6) Mark di fferenti al housi ng and beari ng caps for
i nstal l ati on reference (Fi g. 30).
(7) Remove beari ng threaded adjuster l ock from
each beari ng cap.
(8) Loosen di fferenti al beari ng cap bol ts.
Fig. 29 COVER SEALANT
1 - SEALANT
2 - DIFFERENTIAL COVER
Fig. 30 REFERENCE MARKS
1 - REFERENCE MARKS
2 - REFERENCE MARK
3 - BEARING CAPS
DR REAR AXLE - 9 1/4 3 - 97
(9) Loosen di fferenti al beari ng adjusters through
the axl e tubes wi th Wrench C-4164 (Fi g. 31).
(10) Hol d di fferenti al case whi l e removi ng beari ng
caps and adjusters.
(11) Remove di fferenti al case.
NOTE: Tag the differential bearing cups and
threaded adjusters to indicate their location.
DISASSEMBLY
(1) Rotate one pi ni on gear (2) wi th thrust washer
(3) (Fi g. 32) to the di fferenti al wi ndow (1) and
remove gear and thrust washer.
(2) Rotate remai ni ng pi ni on gear (3) wi th thrust
washer (2) (Fi g. 33) to the di fferenti al wi ndow (1)
and remove gear and washer.
(3) Remove di fferenti al si de gears (1) (2) and
thrust washers (Fi g. 34).
Fig. 31 THREADED ADJUSTER TOOL
1 - AXLE TUBE
2 - BACKING PLATE
3 - THREAD ADJUSTER WRENCH
Fig. 32 FRIST PINION GEAR
1 - DIFFERNTIAL CASE WINDOW
2 - PINION GEAR
3 - THRUST WASHER
Fig. 33 SECOND PINION GEAR
2 - THRUST WASHER
3 - PINION GEAR
Fig. 34 SIDE GEARS
1 - SIDE GEAR
2 - SIDE GEAR
3 - PINION GEARS
3 - 98 REAR AXLE - 9 1/4 DR
ASSEMBLY
NOTE: If same gears and thrust washers are being
used, install them into their original locations.
l ubri cant.
(2) I nstal l di fferenti al si de gears (2) and thrust
washers (Fi g. 35).
(3) I nstal l fi rst pi ni on gear (3) wi th thrust washer
i nto di fferenti al wi ndow (1) and si de gears (2). Rotate
pi ni on gear i nto the case (Fi g. 36).
(4) I nstal l remai ni ng pi ni on gear and thrust
washer. Rotate gears to al i gn hol e i n the pi ni on gears
wi th hol e i n the di fferenti al case.
(5) Sl i de pi ni on shaft (4) i nto the case and through
the pi ni on gears (3) to al i gn the gears (Fi g. 37).
INSTALLATION
(1) Appl y a coati ng of hypoi d gear l ubri cant to the
di fferenti al beari ngs, beari ng cups, and threaded
adjusters. A dab of grease can be used to keep the
adjusters i n posi ti on.
(2) I nstal l di fferenti al assembl y i nto the housi ng.
(3) I nstal l di fferenti al beari ng caps i n thei r ori gi -
nal l ocati ons (Fi g. 38).
(4) I nstal l beari ng cap bol ts and ti ghten the upper
bol ts to 14 Nm (10 ft. l bs.). Ti ghten the l ower bol ts
fi nger-ti ght unti l the bol t head i s seated.
(5) Perform the di fferenti al beari ng prel oad and
adjustment procedure.
NOTE: Be sure that all bearing cap bolts are tight-
ened to their final torque of 136 Nm (100 ft.lbs.)
before proceeding.
(7) Appl y a bead of orange Mopar Axl e RTV Seal -
ant or equi val ent to the housi ng cover (Fi g. 39).
Fig. 35 SIDE GEAR
2 - SIDE GEAR
Fig. 36 PINION GEAR
2 - SIDE GEARS
3 - PINION GEAR
1 - PINION SHAFT SNAP-RING
2 - SIDE GEAR
3 - PINION GEAR
4 - PINION SHAFT
DR REAR AXLE - 9 1/4 3 - 99
CAUTION: If cover is not installed within 3 to 5 min-
utes, the cover must be cleaned and new RTV
applied or adhesion quality will be compromised.
(8) I nstal l the cover and any i denti fi cati on tag and
ti ghten cover bol ts to 41 Nm (30 ft. l bs.).
(9) Fi l l di fferenti al wi th l ubri cant to bottom of the
fi l l pl ug hol e. Refer to the Lubri cant Speci fi cati ons
for the correct quanti ty and type.
NOTE: Trac-lok differential equipped vehicles
should be road tested by making 10 to 12 slow fig-
ure-eight turns. This maneuver will pump the lubri-
cant through the clutch discs to eliminate a
possible chatter noise complaint.
DIFFERENTIAL-TRAC-LOK
DESCRIPTION
The opti onal Trac-Lok di fferenti al case has a one-
pi ece desi gn and the si mi l ar i nternal components as
a standard di fferenti al , pl us two cl utch di sc pack-
s.The di fferenti al pi ni on mate shaft i s retai ned wi th
a threaded pi n. Di fferenti al beari ng prel oad and ri ng
gear backl ash are set and mai ntai ned by threaded
adjusters at the outsi de of the di fferenti al housi ng.
Pi ni on beari ng prel oad i s set and mai ntai ned by the
use of a col l apsi bl e spacer. The removabl e di fferenti al
cover provi des a means for i nspecti on and servi ce.
OPERATION
Thi s di fferenti al cl utches are engaged by two con-
current forces. The fi rst bei ng the prel oad force
exerted through Bel l evi l l e spri ng washers wi thi n the
cl utch packs. The second i s the separati ng forces gen-
erated by the si de gears as torque i s appl i ed through
the ri ng gear (Fi g. 40).
Thi s desi gn provi des the di fferenti al acti on needed
for turni ng corners and for dri vi ng strai ght ahead
duri ng peri ods of unequal tracti on. When one wheel
l ooses tracti on, the cl utch packs transfer addi ti onal
torque to the wheel havi ng the most tracti on. Thi s
di fferenti al resi st wheel spi n on bumpy roads and
provi de more pul l i ng power when one wheel l ooses
tracti on. Pul l i ng power i s provi ded conti nuousl y unti l
both wheel s l oose tracti on. I f both wheel s sl i p due to
unequal tracti on, Trac-l ok operati on i s normal . I n
extreme cases of di fferences of tracti on, the wheel
wi th the l east tracti on may spi n.
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng the uni t for repai r,
drai n, fl ush and refi l l the axl e wi th the speci fi ed
l ubri cant. Add a contai ner of Mopar Li mi ted Sl i p
Addi ti ve after repai r servi ce or duri ng a l ubri cant
change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
Fig. 38 BEARING CAPS
1 - REFERENCE MARKS
2 - REFERENCE MARKS
3 - ADJUSTER LOCK
4 - BEARING CAP
Fig. 39 COVER SEALANT
1 - SEALANT
3 - 100 REAR AXLE - 9 1/4 DR
DIFFERENTIAL TEST
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 or
equi val ent tool to studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 41).
(6) I f rotati ng torque i s l ess than 41 Nm (30 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
DISASSEMBLY
(1) Cl amp Hol di ng Fi xture 8136 i n vi se and set
di fferenti al case on fi xture (Fi g. 42).
(2) Remove pi ni on gear mate shaft screw.
(3) Remove pi ni on gear mate shaft.
Fig. 40 TRAC-LOK LIMITED SLIP DIFFERENTIAL
1 - CASE
2 - RING GEAR
3 - DRIVE PINION
4 - PINION GEAR
5 - MATE SHAFT
6 - CLUTCH PACK
7 - SIDE GEAR
8 - CLUTCH PACK
Fig. 41 ROTATING TORQUE TEST
1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE
2 - TORQUE WRENCH
Fig. 42 DIFFERENTIAL CASE FIXTURE
1 - HOLDING FIXTURE
2 - VISE
3 - DIFFERENTIAL
DR REAR AXLE - 9 1/4 3 - 101
DIFFERENTIAL-TRAC-LOK (Continued)
(4) Lubri cate and i nstal l di sc, that i s not threaded
from Trac-Lok Tool Ki t 8139 i nto the l ower si de gear
(Fi g. 43).
(5) I nstal l threaded di sc from Trac-Lok Tool Ki t
8139 i nto top si de gear. Thread forci ng screw from
Trac-Lok Tool Ki t C-4487 through top di sc unti l i t
comes i n contact wi th l ower di sc.
(6) Posi ti on a smal l screw dri ver i n sl ot of top di sc
(Fi g. 44) to prevent di sc from turni ng.
(7) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
maxi mum to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 45).
(8) Wi th a feel er gauge remove thrust washers
from behi nd the pi ni on gears (Fi g. 46).
(9) I nsert turni ng bar from tool ki t i nto pi ni on
mate shaft hol e i n the case (Fi g. 47).
Fig. 43 ADAPTER DISC
1 - LOWER SIDE GEAR
3 - DISC
Fig. 44 THREAD ADAPTER DISC
1 - SOCKET
2 - SLOT IN DISC
3 - SCREWDRIVER
4 - DISC
5 - FORCING SCREW
6 - THREADED DISC
Fig. 45 COMPRESS BELLEVILLE SPRING
1 - TORQUE WRENCH
2 - FORCING SCREW
3 - 102 REAR AXLE - 9 1/4 DR
(10) Loosen forci ng screw i n smal l i ncrements
unti l the cl utch pack tensi on i s rel i eved and di fferen-
ti al case can be turned usi ng turni ng bar.
(11) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(12) Remove pi ni on gears from di fferenti al case.
(13) Remove forci ng screw and di scs.
(14) Remove top si de gear, cl utch pack retai ner
and cl utch pack (Fi g. 48).
NOTE: Keep plates in correct order during removal.
(15) Remove di fferenti al case from fi xture. Remove
l ower si de gear, cl utch pack retai ner and cl utch pack.
NOTE: Keep plates in correct order during removal.
ASSEMBLY
Cl ean al l components i n cl eani ng sol vent and dry
components wi th compressed ai r. I nspect cl utch pack
pl ates for wear, scori ng or damage. Repl ace both
cl utch packs i f any one component i n ei ther pack i s
damaged. I nspect si de gears and pi ni ons. Repl ace
any gear that i s worn, cracked, chi pped or damaged.
I nspect di fferenti al case and pi ni on shaft. Repl ace i f
worn or damaged.
(1) Lubri cate each component wi th gear l ubri cant
before assembl y.
Fig. 46 PINION GEAR THRUST WASHER
1 - THRUST WASHER
2 - FEELER GAUGE
Fig. 47 PINION GEAR
1 - PINION GEARS
2 - TURNING BAR
Fig. 48 SIDE GEAR & CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR AND CLUTCH DISC PACK
DR REAR AXLE - 9 1/4 3 - 103
(2) Assembl e cl utch di scs i nto packs and secure
di sc packs wi th retai ni ng cl i ps (Fi g. 49).
NOTE: New Plates and discs with fiber coating (no
grooves or lines) must be presoaked in Friction
Modifier before assembly. Soak plates and discs for
a minimum of 20 minutes.
(3) Posi ti on di fferenti al case on the Hol di ng Fi x-
ture 8136.
(4) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(5) I nstal l cl utch pack and si de gear i n the di ffer-
enti al case (Fi g. 50).
CAUTION: Verify clutch pack retaining clips are in
position and seated in case pockets.
(6) I nstal l l ubri cated di sc from Trac-Lok Tool Ki t
8139 i n l ower si de gear.
(7) I nstal l upper si de gear and cl utch di sc pack
(Fi g. 51).
CAUTION: Verify clutch pack retaining clips are in
position and seated in case pockets.
(8) Hol d assembl y i n posi ti on and i nstal l threaded
di sc from tool ki t i nto top si de gear.
(9) I nstal l forci ng screw from Trac-Lok Tool Ki t
C-4487 and ti ghten screw to sl i ghtl y compress cl utch
di sc.
Fig. 49 CLUTCH DISC PACK
1 - CLUTCH PACK
2 - RETAINER
3 - SIDE GEAR
4 - RETAINER
Fig. 50 CLUTCH PACK AND SIDE GEAR
2 - LOWER SIDE GEAR AND CLUTCH PACK
3 - 104 REAR AXLE - 9 1/4 DR
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol e i s al i gned.
(11) Rotate case wi th turni ng bar unti l pi ni on
mate shaft hol es i n pi ni on gears al i gn wi th hol es i n
case.
NOTE: It may be necessary to slightly tighten the
forcing screw in order to install the pinion gears.
(12) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(14) Remove Forci ng Screw, Di scs and Threaded
Adapter.
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l pi ni on mate shaft screw.
(17) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
DIFFERENTIAL CASE
BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
(2) Remove di fferenti al beari ngs from the case
wi th Pul l er/Press C-293-PA and Adapters C-293-47
and Pl ug C-293-3 (Fi g. 52).
Fig. 51 CLUTCH PACK AND UPPER SIDE GEAR
1 - SIDE GEAR AND CLUTCH PACK
3 - LOWER DISC
Fig. 52 DIFFERENTIAL BEARING PULLER
1 - PULLER
2 - ADAPTERS
3 - BEARING
4 - DIFFERENTIAL
5 - PLUG
DR REAR AXLE - 9 1/4 3 - 105
INSTALLATION
(1) I nstal l di fferenti al si de beari ngs (3) wi th
I nstal l er C-4213 (4) and Handl e C-4171 (1) (Fi g. 53).
(2) I nstal l di fferenti al case i nto housi ng.
PINION GEAR/RING GEAR/
TONE RING
REMOVAL
matched set. Never replace one gear without replac-
ing the other matching gear.
(1) Mark compani on fl ange and propel l er shaft for
(2) Di sconnect propel l er shaft from the compani on
fl ange and ti e propel l er shaft to underbody.
(4) Remove di fferenti al from the di fferenti al hous-
i ng.
jaw protectors..
(6) Remove ri ng gear bol ts from the di fferenti al
case.
(7) Dri ve ri ng gear off the di fferenti al case wi th a
rawhi de hammer (Fi g. 54).
remai ni ng threaded hol es. Ti ghten the bol ts so the
Hol der 6719 i s hel d to the fl ange.
(10) Use Hol der 6719 to hol d compani on fl ange
and remove the compani on fl ange nut and washer.
(11) Remove compani on fl ange wi th Remover
C-452 (Fi g. 55).
1 - HANDLE
2 - DIFFERENTIAL
3 - BEARING
4 - INSTALLER
Fig. 54 RING GEAR
1 - CASE
2 - RING GEAR
3 - RAWHIDE HAMMER
2 - REMOVER
3 - 106 REAR AXLE - 9 1/4 DR
(12) Remove pi ni on gear from the housi ng (Fi g. 56).
(13) Remove pi ni on seal wi th a pry tool or sl i de-
(14) Remove front pi ni on beari ng and oi l sl i nger i f
equi pped.
(15) Remove front pi ni on beari ng cup wi th
Remover C-4345 and Handl e C-4171 (Fi g. 57).
(16) Remove rear pi ni on beari ng cup from housi ng
(Fi g. 58) wi th Remover C-4307 and Handl e C-4171.
shaft (Fi g. 59).
Fig. 56 PINION GEAR
1 - RAWHIDE HAMMER
1 - REMOVER
2 - HANDLE
1 - DRIVER
2 - HANDLE
DR REAR AXLE - 9 1/4 3 - 107
PINION GEAR/RING GEAR/TONE RING (Continued)
(18) Remove rear pi ni on beari ng (Fi g. 60) from the
pi ni on shaft wi th Pul l er C-293-PA and Adapters
C-293-37.
(19) Remove pi ni on depth shi m (Fi g. 61) from the
pi ni on shaft and record shi m thi ckness.
INSTALLATION
matched set. Do not replace one gear without
replacing the other matching gear. If ring and pinion
gears or bearings are replaced, Refer to Adjust-
ments for Pinion Gear Depth Setting.
(1) Appl y Mopar Door Ease or equi val ent sti ck
l ubri cant to outsi de surface of the pi ni on beari ng
cups.
(2) I nstal l rear pi ni on beari ng cup (Fi g. 62) wi th
I nstal l er C-4308 and Dri ver Handl e C-4171 and ver-
i fy cup i s seated.
1 - PULLER
2 - VISE
3 - ADAPTERS
4 - PINION SHAFT
2 - PINION GEAR
1 - INSTALLER
2 - HANDLE
3 - 108 REAR AXLE - 9 1/4 DR
(3) I nstal l front pi ni on beari ng cup (Fi g. 63) wi th
I nstal l er D-129 and Handl e C-4171 and veri fy cup i s
seated.
(4) Lubri cate and i nstal l front pi ni on beari ng i nto
the housi ng.
l i p of pi ni on seal . I nstal l seal wi th I nstal l er C-4076-B
and Handl e C-4735-1 (Fi g. 64).
i on gear shaft.
(7) I nstal l rear beari ng on the pi ni on (Fi g. 66) wi th
I nstal l er C-3095-A and a press.
1 - INSTALLER
2 - HANDLE
1 - HANDLE
2 - INSTALLER
3 - HOUSING
2 - PINION GEAR
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
DR REAR AXLE - 9 1/4 3 - 109
(8) I nstal l a new col l apsi bl e spacer on the pi ni on
shaft (Fi g. 67).
(9) Lubri cate rear pi ni on beari ng and i nstal l pi n-
i on gear i nto the housi ng.
(10) I nstal l compani on fl ange wi th I nstal l er
C-3718 and Hol der 6719.
remai ni ng threaded hol es. Ti ghten the bol ts so the
Hol der 6719 i s hel d to the fl ange.
(13) I nstal l compani on fl ange washer and a new
nut on the pi ni on and ti ghten the nut unti l there i s
zero beari ng end-pl ay.
(14) Wi th a torque wrench ti ghten the nut to 285
Nm (210 ft. l bs.) (Fi g. 68).
ion rotating torque and never exceed specified pre-
load torque. If preload torque or rotating torque is
exceeded a new collapsible spacer must be
installed.
(15) Sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l bs.)
i ncrements unti l the desi red rotati ng torque i s
achi eved. Measure pi ni on rotati ng torque frequentl y
to avoi d over crushi ng the col l apsi bl e spacer.
(16) Check pi ni on rotati ng torque wi th an i nch
pound torque wrench (Fi g. 69). The pi ni on rotati ng
torque shoul d be:
Ori gi nal Beari ngs: 1 to 3 Nm (10 to 20 i n. l bs.).
New Beari ngs: 1.7 to 5 Nm (15 to 35 i n. l bs.).
Fig. 68 PINION NUT
2 - HOLDER
3 - TORQUE WRENCH
2 - TORQUE WRENCH
3 - 110 REAR AXLE - 9 1/4 DR
(17) Posi ti on exci ter ri ng on di fferenti al case. Wi th
a brass dri ft, sl owl y and evenl y tap the exci ter ri ng
i nto posi ti on.
(18) Posi ti on ri ng gear on the di fferenti al case and
start two ri ng gear bol ts. Thi s wi l l provi de case-to-
ri ng gear bol t hol e al i gnment.
(19) I nvert the di fferenti al case i n the vi se.
(20) I nstal l new ri ng gear bol ts and al ternatel y
CAUTION: Never reuse the ring gear bolts. The
bolts can fracture causing extensive damage.
mesh, backl ash and contact pattern.
l ubri cant.
al i gned.
Fig. 70 RING GEAR BOLTS
1 - TORQUE WRENCH
2 - RING GEAR BOLTS
3 - RING GEAR
DR REAR AXLE - 9 1/4 3 - 111
REAR AXLE - 10 1/2 AA
TABLE OF CONTENTS
page page
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 116
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 116
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 120
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 120
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 125
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 128
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 130
DIFFERENTIAL TRAC-RITE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 131
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 131
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 131
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 132
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 134
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 137
GEAR NOISE
greatl y check for:
Gear damage.
A worn pi ni on shaft can al so cause a snappi ng or a
knocki ng noi se.
BEARING NOISE
source.
LOW SPEED KNOCK
Worn U-joi nt(s).
3 - 112 REAR AXLE - 10 1/2 AA DR
VIBRATION
caused by:
Worn U-joi nt(s).
DRIVELINE SNAP
Worn U-joi nts.
DIAGNOSTIC CHART
3. Erratic clutch operation. 3. Replace broken shaft and avoid or
correct erratic clutch operation.
DR REAR AXLE - 10 1/2 AA 3 - 113
REAR AXLE - 10 1/2 AA (Continued)
and bearings for further damage. Set
differential bearing pre-load properly.
ring gear backlash properly.
and quantity.
and quantity.
wheel/tire.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal cover.
2. Improper grade of lubricant. 2. Fill differential with the correct fluid
type and quantity.
damage.
3 - 114 REAR AXLE - 10 1/2 AA DR
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid
type and quantity.
adjustment.
2. Check ring gear and pinion contact
pattern. Adjust backlash or pinion
depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring
gear and pinion.
pinion.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
components as necessary.
bolts.
8. Inspect differential components and
replace as necessary. Ensure that the
bearing caps are torqued tot he
proper specification.
REMOVAL
(2) Posi ti on a l i ft under axl e and secure l i ft to the
axl e.
1 - NUT
2 - AXLE
3 - SHOCK ABSORBER
Fig. 2 REAR SPRING
1 - LEAF SPRING
2 - PLATE
3 - NUTS
6 - SHACKLES
DR REAR AXLE - 10 1/2 AA 3 - 115
INSTALLATION
centeri ng bol ts.
(110 ft. l bs.).
speci fi cati on.
(4) I nstal l al l brake components.
ADJUSTMENTS
achi eved wi th a sel ect shi m. The shi m i s l ocated
between the rear pi ni on beari ng and the pi ni on gear
head.
cator C-3339 (Fi g. 3).
(Fi g. 3).
(3) I nstal l front pi ni on beari ng and Cone-nut 6740
Rotate the screw i s 1.7-2.26 Nm (15-20 i n. l bs.) (Fi g.
3).
NOTE: Arbor should rotate freely in the arbor discs.
hei ght bl ock over to the arbor (Fi g. 6). Move the
scooter bl ock ti l l di al i ndi cator crests the arbor, then
record the hi ghest readi ng.
i ng.
1 - DIAL INDICATOR
2 - ARBOR
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
1 - PINION BLOCK
3 - 116 REAR AXLE - 10 1/2 AA DR
GEAR BACKLASH
(Fi g. 7).
8883 (Fi g. 8) unti l they make contact wi th the di ffer-
enti al beari ngs/cups.
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
2 - ADJUSTER LOCK
Fig. 8 ADJUSTER SPANNER WRENCH
1 - WRENCH
2 - DIFFERENTIAL
DR REAR AXLE - 10 1/2 AA 3 - 117
(8) Rotate the pi ni on several ti mes to seat the def-
erenti al beari ngs.
ti onal :
l bs.).
l bs.).
poi nts around the dri ve si de of the ri ng gear (Fi g. 9).
The backl ash shoul d be 0.08-0.25 mm (0.003-0.010
i n) wi th a preferred backl ash of 0.13-0.18 mm (0.005-
0.007 i n).
mounting.
gear teeth.
ti on.
11). Decrease the backl ash, by movi ng the ri ng cl oser
to the pi ni on gear usi ng the adjusters.
I ncrease the backl ash, by movi ng the ri ng away from
1 - DIAL INDICATOR
2 - RING GEAR
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
3 - 118 REAR AXLE - 10 1/2 AA DR
13). Decrease the backl ash, by movi ng the ri ng cl oser
to the pi ni on gear usi ng the adjusters.
I ncrease the backl ash, by movi ng the ri ng away from
Pi ni on gear i s set too l ow (Fi g. 15). I ncrease the
pi ni on gear hei ght, by i ncreasi ng the pi ni on depth
shi m thi ckness.
Pi ni on gear i s set too hi gh (Fi g. 16). Decrease
the pi ni on depth, by decreasi ng the pi ni on depth
shi m thi ckness.
1 - DRIVE SIDE TOE
2 - COAST SIDE HEEL
1 - DRIVE SIDE HEEL
2 - COAST SIDE HEEL
1 - DRIVE SIDE TOE
2 - COAST SIDE TOE
DR REAR AXLE - 10 1/2 AA 3 - 119
SPECIFICATIONS
AXLE SPECIFICATIONS
Pinion Bearing Preload + Diff Case Bearing Preload -
New Bearings
3.4-5.6 Nm (30-50 in. lbs.)
Pinion Bearing Preload + Diff Case Bearing Preload -
Original Bearings
2.8-5.1 Nm (25-45 in. lbs.)
Axle Flange Bolts 129 95 -
SPECIAL TOOLS
PULLER C-293-PA
HANDLE C-4171
3 - 120 REAR AXLE - 10 1/2 AA DR
BEARING INSTALLER MD-998805
SPLITTER 1130
PINION DEPTH GAUGE 6730
ARBOR DISCS 6732
ADAPTERS 8879
DR REAR AXLE - 10 1/2 AA 3 - 121
PLUG 8888
SEAL INSTALLER 8896
GAUGE BLOCK 8899
SOCKET 8954
CUP INSTALLER 8959
3 - 122 REAR AXLE - 10 1/2 AA DR
CUP INSTALLER 8960
CUP INSTALLER 8961
CUP INSTALLER 8962
SEAL INSTALLER 8963
PINION DRIVER 8977
FLANGE WRENCH 8979
DR REAR AXLE - 10 1/2 AA 3 - 123
AXLE SHAFTS
REMOVAL
(1) Remove axl e shaft fl ange bol ts (Fi g. 17).
(2) Sl i de axl e shaft out of the axl e tube.
(3) Remove axl e shaft gasket.
INSTALLATION
NOTE: Axle flange bolts must be replaced or use
Mopar Lock N Seal or Loctite 242 on cleaned
existing bolts.
(1) Cl ean axl e fl ange and hub.
(2) I nstal l new axl e shaft gasket.
(3) Sl i de axl e shaft i nto the axl e tube.
(4) I nstal l axl e shaft fl ange bol ts and ti ghten to
129 Nm ( 95 ft. l bs.).
FLANGE PULLER 8992
BRIDGE 938
Fig. 17 AXLE FLANGE BOLTS
1 - AXLE FLANGE
2 - FLANGE BOLT
3 - 124 REAR AXLE - 10 1/2 AA DR
AXLE BEARINGS
REMOVAL
(1) Remove axl e shaft fl ange bol ts and remove axl e
shaft.
(2) Remove reti aner ri ng (Fi g. 18) from the axl e
shaft tube.
(3) Remove hub beari ng nut l ocki ng key (Fi g. 19).
(4) Remove hub beari ng nut wi th Socket 8954.
(5) Remove hub and beari ngs from the axl e.
(6) Pry out hub beari ng seal from the back of the
hub.
NOTE: The inner part of the seal may stay on the
axle tube (Fig. 20). This part must also be removed.
(7) Remove rear beari ng.
(8) Remove hub beari ng cups wi th a hammer and
dri ft.
INSTALLATION
(1) I nstal l outer hub beari ng cup wi th I nstal l er
(2) I nstal l i nner hub beari ng cup wi th I nstal l er
(3) Pack beari ngs wi th the appropri ate grease.
(4) I nstal l rear beari ng and i nstal l new grease
seal wi th I nstal l er 8963 and Handl e C-4171.
(5) Sl i de hub on the axl e tube and i nstal l front
beari ng i nto the hub.
(6) I nstal l hub beari ng nut wi th Socket 8954 and
ti ghten to 30 Nm (22 ft. l bs.) whi l e rotati ng the hub
(Fi g. 21).
(7) Back off nut about 30 and al i gn next hub nut
key sl ot wi th axl e tube key sl ot and i nstal l l ocki ng
key.
NOTE: End play should be 0.025-0.25 mm
(0.001-0.010 in.).
Fig. 18 RETAINER RING
1 - RETAINER RING
2 - LOCKING KEY
3 - BEARING NUT
Fig. 19 LOCKING KEY
1 - BEARING NUT
2 - LOCKING KEY
3 - AXLE TUBE
Fig. 20 INNER PART OF SEAL
1 - PRY BAR
2 - AXLE TUBE
3 - REMAINING SEAL
DR REAR AXLE - 10 1/2 AA 3 - 125
(8) I nstal l retai ner ri ng wi th ri ng end i n the key sl ot.
(9) I nstal l new axl e shaft gasket and i nstal l axl e
shaft.
PINION SEAL
REMOVAL
(2) Mark propel l er shaft and pi ni on fl ange for
i nstal l ati on reference and remove shaft.
(4) Measure and record the amount of torque nec-
essary to rotate the pi ni on gear wi th an i nch pound
torque wrench (Fi g. 22).
Pul l er 8992 (Fi g. 24).
INSTALLATION
(1) I nstal l new pi ni on seal wi th I nstal l er 8896 and
Handl e C-4171 (Fi g. 25).
Fig. 21 HUB NUT SOCKET
1 - SOCKET
2 - TORQUE WRENCH
1 - PINION FLANGE
2 - TORQUE WRENCH
1 - PINION FLANGE
2 - FLANGE WRENCH
1 - PINION FLANGE
2 - PULLER
3 - 126 REAR AXLE - 10 1/2 AA DR
(5) Hol d fl ange wi th Fl ange Wrench 8979 (Fi g. 26)
and ti ghten pi ni on nut unti l pi ni on end pl ay i s taken
up.
measurement.
(8) Ti ghten pi ni on nut i n smal l i ncrements, unti l
pi ni on rotati ng torque i s 0.40-0.57 Nm (3-5 i n. l bs.)
greater than recorded measurement.
al i gned.
(12) Check and fi l l di fferenti al i f necessary.
DIFFERENTIAL
REMOVAL
(1) Remove l ubri cant fi l l hol e pl ug from the di ffer-
enti al housi ng cover.
the l ubri cant from housi ng.
(Fi g. 27).
ti on reference.
caps.
1 - HANDLE
2 - INSTALLER
1 - FLANGE WRENCH
2 - PINION FLANGE
Fig. 27 ADJUSTER LOCKS
1 - LOCK BOLT
2 - ADJUSTER LOCK
3 - ADJUSTER
4 - BEARING CAP
DR REAR AXLE - 10 1/2 AA 3 - 127
DISASSEMBLY
(1) Remove pi ni on shaft wi th a hammer and punch
from the si de wi th the hol e i n the pi ni on shaft (Fi g.
29).
(2) Rotate one pi ni on gear wi th thrust washer
(Fi g. 30) to the di fferenti al wi ndow and remove the
gear.
(3) Rotate the other pi ni on gear wi th thrust
washer (Fi g. 31) to the di fferenti al wi ndow and
remove the gear.
washers (Fi g. 32).
Fig. 28 BEARING ADJUSTERS
1 - BEARING CUP
2 - ADJUSTER
3 - BEARING CUP
4 - ADJUSTER
1 - PINION GEAR
2 - PINION SHAFT
3 - RING GEAR
4 - EXCITER RING
Fig. 30 FRIST PINION GEAR
1 - DIFFERNTIAL CASE WINDOW
2 - PINION GEAR
3 - THRUST WASHER
2 - THRUST WASHER
3 - PINION GEAR
3 - 128 REAR AXLE - 10 1/2 AA DR
ASSEMBLY
l ubri cant.
ers (Fi g. 33).
(3) I nstal l fi rst pi ni on gear i nto the di fferenti al
wi ndow and si de gears. Rotate the pi ni on gear to the
back of the case (Fi g. 34).
(4) I nstal l the other pi ni on gear and thrust
washer. Rotate the gears to al i gn hol e i n the pi ni on
gears wi th hol e i n the di fferenti al case.
(5) Sl i de pi ni on shaft i nto the case and through
the pi ni on gears. Tap the shaft to seat the pi ni on
shaft snap-ri ng i nto the case (Fi g. 35).
Fig. 32 SIDE GEARS
1 - SIDE GEAR
2 - SIDE GEAR
3 - PINION GEARS
Fig. 33 SIDE GEAR
2 - SIDE GEAR
Fig. 34 PINION GEAR
2 - SIDE GEARS
3 - PINION GEAR
Fig. 35 PINION SHAFT INSTALLATION
1 - PINION SHAFT SNAP-RING
2 - SIDE GEAR
3 - PINION GEAR
4 - PINION SHAFT
DR REAR AXLE - 10 1/2 AA 3 - 129
INSTALLATION
the housi ng.
NOTE: A light coat of grease on the cups will hold
them in place during installation.
time.
beari ngs/cups.
ti onal :
New Bearings 6 Adjuster Hol es
Original Bearings 4 Adjuster Hol es
l bs.).
l bs.) (Fi g. 37).
cedure.
(20) Fi l l axl e wi th l ubri cant, refer to Lubri cati on &
Mai ntenance for capaci ty and l ubri cant type.
l bs.).
2 - BEARING CAP
3 - ADJUSTER
2 - ADJUSTER LOCK
3 - 130 REAR AXLE - 10 1/2 AA DR
DESCRIPTION
The Trac-Ri te di fferenti al i s a hel i cal gear di ffer-
enti al . The di fferenti al has two si de gears, si x pi ni on
gears and si x pi ni on brake shoes.
NOTE: The differential is seviced as an assembly
only if damaged, but can be disassembled for
cleaning. The assembly should be cleaned every
time a bearing is changed due to damage.
OPERATION
When one wheel begi ns to spi n the pi ni on gears on
that si de are forced toward the pi ni on brake shoes.
The pi ni on brake shoes then cause fri cti onal drag on
the opposi te pi ni on gears and the si de gear. These
fri cti on forces transfer the power to the opposi te
wheel . Once the fri cti onal forces are overcome, di ffer-
enti ati on wi l l occur. The torque wi l l be conti nual l y
bi ased by the fri cti onal forces to the hi gh tracti on
wheel .
DISASSEMBLY
(1) Remove di fferenti al ri ng gear bol ts.
(2) Remove di fferenti al case cover l ocati ng screws
(Fi g. 38).
(3) Remove di fferenti al case cover.
(4) Remove si de gear and thrust washer (Fi g. 39).
NOTE: Mark all component locations.
(5) Remove three pi ni on brake shoes (Fi g. 40).
Fig. 38 LOCATION SCREWS
2 - LOCATION SCREWS
Fig. 39 SIDE GEAR AND THRUST WASHER
1 - SIDE GEAR
2 - THRUST WASHER
Fig. 40 PINION BRAKE SHOES
1 - BRAKE SHOES
2 - PINION GEARS
DR REAR AXLE - 10 1/2 AA 3 - 131
(6) Remove si x pi ni on gears (Fi g. 41).
(7) Remove remai ni ng si de gear thrust washer and
spacer.
(8) Remove remai ni ng three pi ni on brake shoes.
CLEANING
Cl ean the di fferenti al case and gears wi th l i ght oi l
or a l i nt free cl oth.
NOTE: Never use water, steam, kerosene or gaso-
line for cleaning.
INSPECTION
NOTE: Minor corrosion, nicks or scratches can be
smoothed with 400 grit emery cloth and polished
out with crocus cloth.
(1) I nspect pi ni on gears teeth for chi ps and cracks
(Fi g. 42).
(2) I nspect pi ni on gears shafts and brake shoes for
scratches, fl at-spots or worn (Fi g. 42).
(3) I nspect si de gears teeth for chi ps and cracks
(Fi g. 43).
(4) I nspect pi ni on and si de gear bores for scratches
(Fi g. 44).
NOTE: If any damage is found the differential must
be replaced as an assembly. Individual components
can not be replaced separately.
Fig. 41 PINION GEARS
1 - PINION GEARS
2 - SIDE GEAR
Fig. 42 PINION GEAR AND BRAKE SHOE
1 - BRAKE SHOES
2 - PINION GEAR
3 - PINION SHAFT
Fig. 43 SIDE GEARS
1 - THRUST WASHERS
2 - SPACER
3 - SIDE GEARS
3 - 132 REAR AXLE - 10 1/2 AA DR
DIFFERENTIAL TRAC-RITE (Continued)
ASSEMBLY
NOTE: Install all component in their original loca-
tions.
(1) Lubri cate al l gears and di fferenti al bores wi th
di fferenti al l ubri cant.
(2) I nstal l one set of pi ni on brake shoes i nto the
case bores.
NOTE: Brake shoes can be installed upside down,
but if install wrong pinion gear will not fit.
(3) I nstal l si de gear thrust washer, si de gear and
spacer (Fi g. 45).
(4) I nstal l one set of pi ni on gears i nto the bores
next to the brake shoes, wi th the pi ni on shaft faci ng
up.
(5) I nstal l other si de gear and thrust washer.
(6) I nstal l other set of pi ni on gears i nto the brake
shoes i n the case.
(7) I nstal l other set of brake shoes onto the pi ni on
gears shafts (Fi g. 46).
(8) I nstal l di fferenti al cover and l ocati on screws.
(9) I nstal l new ri ng gear bol ts and ti ghten to 237
Nm (175 ft. l bs.).
Fig. 44 PINION/SIDE GEAR BORE
1 - PINION BORES
2 - SIDE GEAR BORE
Fig. 45 SIDE GEAR AND SPACER
1 - SPACER
2 - SIDE SPACER
1 - BRAKE SHOES
2 - PINION GEARS
DR REAR AXLE - 10 1/2 AA 3 - 133
DIFFERENTIAL CASE
BEARINGS
REMOVAL
INSTALLATION
8956 and Handl e C-4171 (Fi g. 48).
TONE RING
REMOVAL
(3) Remove di fferenti al from axl e housi ng.
1 - BRIDGE
2 - SPLITTER
3 - BEARING
4 - PLUG
1 - HANDLE
3 - BEARING
4 - INSTALLER
3 - 134 REAR AXLE - 10 1/2 AA DR
(4) Pl ace di fferenti al on Pl ug 8888 and dri ve
exci ter ri ng off the di fferenti al case wi th a hammer
and punch (Fi g. 49).
NOTE: Do not remove the exciter ring if it is not
being replaced.
jaw protectors
case.
(Fi g. 51) and remove pi ni on fl nage nut and washer.
Fig. 49 EXCITER RING
2 - RING GEAR
3 - PUNCH
4 - EXCITER RING
Fig. 50 RING GEAR
2 - RING GEAR
3 - HAMMER
1 - PINION FLANGE
2 - FLANGE WRENCH
DR REAR AXLE - 10 1/2 AA 3 - 135
(9) Remove pi ni on fl ange from the pi ni on wi th Pi n-
i on Fl ange Pul l er 8992 (Fi g. 52).
(10) Remove pi ni on gear from housi ng, wi th Pi ni on
Dri ver 8977 (Fi g. 53) and a hammer.
NOTE: Thread the driver on the pinion shaft till it
bottoms out.
pry bar.
(12) Remove and di scard front pi ni on beari ng.
shaft.
(14) Remove rear pi ni on beari ng wi th Pul l er
C-293-PA and Adapter Bl ocks 8879 (Fi g. 54).
housi ng wi th a punch and hammer and di scard cup.
goi ng to be repl aced.
1 - PINION FLANGE
2 - PULLER
1 - PINION SHAFT
2 - PINION DRIVER
1 - PULLER
2 - VISE
3 - PINION SHAFT
4 - ADAPTER BLOCKS
3 - 136 REAR AXLE - 10 1/2 AA DR
INSTALLATION
(1) I nstal l new front pi ni on beari ng cup (Fi g. 55)
wi th I nstal l er 8960 and Handl e C-4171.
(2) I nstal l new rear pi ni on beari ng cup (Fi g. 56)
i on gear shaft.
I nstal l er MD-998805 and a press.
1 - INSTALLER
2 - HANDLE
1 - INSTALLER
2 - HANDLE
2 - PINION GEAR
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
DR REAR AXLE - 10 1/2 AA 3 - 137
60).
(10) Hol d the pi ni on and l i ghtl y tap the pi ni on
fl ange onto the pi ni on, unti l a few threads are show-
i ng.
nut.
(Fi g. 62) and ti ghten pi ni on nut unti l pi ni on end pl ay
i s taken up.
2 - PINION GEAR
1 - INSTALLER
1 - HANDLE
2 - INSTALLER
1 - FLANGE WRENCH
2 - PINION FLANGE
3 - 138 REAR AXLE - 10 1/2 AA DR
l bs.)
i n. l bs.)
l bs.).
(19) I f exci ter ri ng was removed, posi ti on di fferen-
ti al assembl y on di fferenti al Pl ug 8888 (Fi g. 64) and
pl ace exci ter ri ng on the di fferenti al case.
(20) I nstal l the exci ter ri ng on the di fferenti al case
evenl y wi th a hammer and brass punch (Fi g. 65).
Dri ve the ri ng down unti l i t i s seated agai nst the
ri ng gear.
CAUTION: Do not damage exciter ring teeth during
installation.
(21) I nstal l di fferenti al i nto the housi ng.
(22) Veri fy ri ng gear backl ash and gear contact
pattern.
marks al i gned.
ti ghten bol ts to 40 Nm (30 ft. l bs.).
to 32 Nm (24 ft. l bs.).
1 - PINION FLANGE
2 - TORQUE WRENCH
1 - EXCITER RING
2 - RING GEAR
3 - DIFFERENTIAL PLUG
Fig. 65 EXCITER RING INSTALLATION
1 - EXCITER RING
2 - PUNSH
3 - RING GEAR
DR REAR AXLE - 10 1/2 AA 3 - 139
TABLE OF CONTENTS
page page
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 144
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 144
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 148
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 148
AXLE SHAFTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 152
AXLE BEARINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 153
PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 154
DIFFERENTIAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 155
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 157
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 158
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 158
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 158
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 160
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 161
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 164
GEAR NOISE
greatl y check for:
Gear damage.
A worn pi ni on shaft can al so cause a snappi ng or a
knocki ng noi se.
BEARING NOISE
source.
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Worn U-joi nt(s).
Worn si de gear thrust washers.
3 - 140 REAR AXLE - 11 1/2 AA DR
VIBRATION
caused by:
Worn U-joi nt(s).
DRIVELINE SNAP
Worn U-joi nts.
DIAGNOSTIC CHART
3. Erratic clutch operation. 3. Replace broken shaft and avoid or
correct erratic clutch operation.
DR REAR AXLE - 11 1/2 AA 3 - 141
differential bearing pre-load properly.
ring gear backlash properly.
and quantity.
and quantity.
wheel/tire.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal cover.
2. Improper grade of lubricant. 2. Fill differential with the correct fluid
type and quantity.
damage.
3 - 142 REAR AXLE - 11 1/2 AA DR
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid
type and quantity.
adjustment.
2. Check ring gear and pinion contact
pattern. Adjust backlash or pinion
depth.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring
gear and pinion.
pinion.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
bolts.
8. Inspect differential components and
replace as necessary. Ensure that the
bearing caps are torqued tot he
proper specification.
REMOVAL
(2) Posi ti on a l i fti ng devi ce under axl e and secure
l i ft to the axl e.
1 - NUT
2 - AXLE
3 - SHOCK ABSORBER
Fig. 2 REAR SPRING
1 - LEAF SPRING
2 - PLATE
3 - NUTS
6 - SHACKLES
DR REAR AXLE - 11 1/2 AA 3 - 143
INSTALLATION
centeri ng bol ts.
(110 ft. l bs.).
speci fi cati on.
(4) I nstal l al l brake components.
ADJUSTMENTS
achi eved wi th a sel ect shi m, l ocated between the rear
pi ni on beari ng and pi ni on gear head.
cator C-3339 (Fi g. 3).
(Fi g. 3).
(3) I nstal l front pi ni on beari ng and Cone-nut 6740
Rotate the screw i s 1.7-2.26 Nm (15-20 i n. l bs.) (Fi g.
3).
(4) Pl ace Arbor Di scs 8289 on Arbor D-115-3 i n
posi ti on i n the housi ng si de beari ng cradl es (Fi g. 5).
NOTE: Arbor should rotate freely in the arbor discs.
hei ght bl ock over to the arbor (Fi g. 6). Move the
scooter bl ock ti l l di al i ndi cator crests the arbor, then
record the hi ghest readi ng.
i ng.
1 - DIAL INDICATOR
2 - ARBOR
4 - CONE
5 - SCREW
6 - PINION BLOCK
7 - SCOOTER BLOCK
8 - ARBOR DISC
1 - PINION BLOCK
3 - 144 REAR AXLE - 11 1/2 AA DR
GEAR BACKLASH
(Fi g. 7).
8883 (Fi g. 8) unti l they make contact wi th the di ffer-
enti al beari ngs/cups.
1 - ARBOR DISC
2 - PINION BLOCK
3 - ARBOR
1 - ARBOR
2 - SCOOTER BLOCK
3 - DIAL INDICATOR
2 - ADJUSTER LOCK
Fig. 8 ADJUSTER SPANNER WRENCH
1 - WRENCH
2 - DIFFERENTIAL
DR REAR AXLE - 11 1/2 AA 3 - 145
(8) Rotate the pi ni on several ti mes to seat the def-
erenti al beari ngs.
ti onal :
l bs.).
l bs.).
poi nts around the dri ve si de of the ri ng gear (Fi g. 9).
The backl ash shoul d be 0.08-0.25 mm (0.003-0.010
i n) wi th a preferred backl ash of 0.13-0.18 mm (0.005-
0.007 i n).
mounting.
gear teeth.
ti on.
1 - DIAL INDICATOR
2 - RING GEAR
1 - COAST SIDE TOE
2 - DRIVE SIDE HEEL
3 - 146 REAR AXLE - 11 1/2 AA DR
Pi ni on gear i s set too l ow (Fi g. 15). I ncrease pi n-
i on gear hei ght, by i ncreasi ng the pi ni on depth shi m
thi ckness.
Pi ni on gear i s set too hi gh (Fi g. 16). Decrease
pi ni on depth, by decreasi ng the pi ni on depth shi m
thi ckness.
1 - DRIVE SIDE TOE
2 - COAST SIDE HEEL
1 - DRIVE SIDE HEEL
2 - COAST SIDE HEEL
1 - DRIVE SIDE TOE
2 - COAST SIDE TOE
DR REAR AXLE - 11 1/2 AA 3 - 147
SPECIFICATIONS
AXLE SPECIFICATIONS
Preload - New Bearing
3.4-5.6 Nm (30-50 in. lbs.)
Preload - Original Bearing
2.8-5.1 Nm (25-45 in. lbs.)
Axle Flange Bolts 129 95 -
SPECIAL TOOLS
HANDLE C-4171
BEARING INSTALLER D-389
3 - 148 REAR AXLE - 11 1/2 AA DR
SPLITTER 1130
PINION DEPTH GAUGE 6730
CUP INSTALLER 8153
ARBOR DISCS 8289
SEAL INSTALLER 8896
DR REAR AXLE - 11 1/2 AA 3 - 149
PINION BLOCK 8897
SOCKET 8954
CUP INSTALLER 8960
CUP INSTALLER 8961
SEAL INSTALLER 8963
PLUG 8964
3 - 150 REAR AXLE - 11 1/2 AA DR
CUP INSTALLER 8968
PINION DRIVER 8977
FLANGE WRENCH 8979
FLANGE PULLER 8992
DR REAR AXLE - 11 1/2 AA 3 - 151
AXLE SHAFTS
REMOVAL
(1) Remove axl e shaft fl ange bol ts (Fi g. 17).
(2) Sl i de axl e shaft out of the axl e tube.
(3) Remove axl e shaft gasket.
INSTALLATION
NOTE: Axle flange bolts must be replaced or use
Mopar Lock N Seal or Loctite 242 on cleaned
existing bolts.
(1) Cl ean axl e fl ange and hub.
(2) I nstal l new axl e shaft gasket.
(3) Sl i de axl e shaft i nto the axl e tube.
(4) I nstal l axl e shaft fl ange bol ts and ti ghten to
129 Nm ( 95 ft. l bs.).
AXLE BEARINGS
REMOVAL
(1) Remove axl e shaft fl ange bol ts and remove
shaft.
(2) Remove reti aner ri ng (Fi g. 18) from the axl e
shaft tube.
(3) Remove hub beari ng nut l ocki ng key (Fi g. 19).
BRIDGE 938
Fig. 17 AXLE FLANGE BOLTS
1 - AXLE FLANGE
2 - FLANGE BOLT
Fig. 18 RETAINER RING
1 - RETAINER RING
2 - LOCKING KEY
3 - BEARING NUT
Fig. 19 LOCKING KEY
1 - BEARING NUT
2 - LOCKING KEY
3 - AXLE TUBE
3 - 152 REAR AXLE - 11 1/2 AA DR
(4) Remove hub beari ng nut wi th Socket 8954.
(5) Remove hub and beari ngs from the axl e.
(6) Pry out hub beari ng seal from the back of the
hub.
NOTE: The inner part of the seal may stay on the
axle tube (Fig. 20). This part must also be removed.
(7) Remove rear beari ng.
(8) Remove hub beari ng cups wi th a hammer and
dri ft.
INSTALLATION
(1) I nstal l outer hub beari ng cup wi th I nstal l er
(2) I nstal l i nner hub beari ng cup wi th I nstal l er
(3) Pack beari ngs wi th the appropri ate wheel bear-
i ng grease.
(4) I nstal l rear beari ng and i nstal l new grease
seal wi th I nstal l er 8963 and Handl e C-4171.
(5) Sl i de hub on the axl e tube and i nstal l front
beari ng i nto the hub.
(6) I nstal l hub beari ng nut wi th Socket 8954 and
ti ghten to 30 Nm (22 ft. l bs.) whi l e rotati ng the hub
(Fi g. 21).
(7) Back off nut about 30 and al i gn next hub nut
key sl ot wi th axl e tube key sl ot and i nstal l l ocki ng
key.
NOTE: End play should be 0.025-0.25 mm
(0.01-0.001 in.)
(8) I nstal l retai ner ri ng wi th ri ng end i n the key
sl ot.
(9) I nstal l new axl e shaft gasket and i nstal l the
axl e shaft.
PINION SEAL
REMOVAL
(2) Mark the propel l er shaft and pi ni on fl ange for
(5) Measure and record the amount of torque nec-
essary to rotate the pi ni on gear wi th an i nch pound
torque wrench (Fi g. 22).
(Fi g. 23) and remove pi ni on fl ange nut.
Fig. 20 INNER PART OF SEAL
1 - PRY BAR
2 - AXLE TUBE
3 - REMAINING SEAL
Fig. 21 HUB NUT SOCKET
1 - SOCKET
2 - TORQUE WRENCH
1 - PINION FLANGE
2 - TORQUE WRENCH
DR REAR AXLE - 11 1/2 AA 3 - 153
Pul l er 8992 (Fi g. 24).
INSTALLATION
(1) I nstal l new pi ni on seal wi th I nstal l er 8896
(Fi g. 25).
i s taken up.
measurement. Ti ghten pi ni on nut i n smal l i ncre-
ments, unti l pi ni on rotati ng torque i s 0.40-0.57 Nm
(3-5 i n. l bs.) greater than recorded measurement.
al i gned.
(11) Check di fferenti al fl ui d l evel .
1 - PINION FLANGE
2 - FLANGE WRENCH
1 - PINION FLANGE
2 - PULLER
1 - HANDLE
2 - INSTALLER
1 - FLANGE WRENCH
2 - PINION FLANGE
3 - 154 REAR AXLE - 11 1/2 AA DR
DIFFERENTIAL
REMOVAL
(1) Remove fi l l hol e pl ug from the di fferenti al
housi ng cover.
the l ubri cant.
(Fi g. 27).
ti on reference.
caps.
DISASSEMBLY
(1) Remove ri ng gear.
(2) Remove pi ni on shaft wi th a hammer and punch
from the si de wi th the hol e i n the pi ni on shaft (Fi g.
29).
Fig. 27 ADJUSTER LOCKS
1 - LOCK BOLT
2 - ADJUSTER LOCK
3 - ADJUSTER
4 - BEARING CAP
Fig. 28 ADJUSTERS
1 - BEARING CUP
2 - ADJUSTER
3 - BEARING CUP
4 - ADJUSTER
1 - PINION GEAR
2 - PINION SHAFT
3 - EXCITER RING
DR REAR AXLE - 11 1/2 AA 3 - 155
(3) Rotate one pi ni on gear wi th thrust washer
(Fi g. 30) to the di fferenti al wi ndow and remove the
gear.
(4) Rotate the other pi ni on gear wi th thrust
washer (Fi g. 31) to the di fferenti al wi ndow and
remove the gear.
washers (Fi g. 32).
ASSEMBLY
l ubri cant.
ers (Fi g. 33).
Fig. 30 FIRST PINION GEAR
2 - PINION GEAR
3 - THRUST WASHER
2 - THRUST WASHER
3 - PINION GEAR
Fig. 32 SIDE GEARS
1 - SIDE GEAR
2 - SIDE GEAR
3 - PINION GEARS
Fig. 33 SIDE GEAR
2 - SIDE GEAR
3 - 156 REAR AXLE - 11 1/2 AA DR
(3) I nstal l fi rst pi ni on gear i nto the di fferenti al
wi ndow and si de gears. Rotate the pi ni on gear to the
back of the case (Fi g. 34).
(4) I nstal l the other pi ni on gear and thrust
washer. Rotate the gears to al i gn hol e i n the pi ni on
gears wi th hol e i n the di fferenti al case.
(5) Sl i de pi ni on shaft i nto the case and through
the pi ni on gears. Tap the shaft to seat the pi ni on
shaft snap-ri ng i nto the case (Fi g. 35).
(6) I nstal l ri ng gear.
INSTALLATION
the housi ng.
NOTE: A light coat of grease on the cups will hold
them in place during installation.
time.
Fig. 34 PINION GEAR
2 - SIDE GEARS
3 - PINION GEAR
Fig. 35 PINION SHAFT INSTALLATION
1 - SNAP RING
2 - SIDE GEAR
3 - PINION GEAR
4 - PINION SHAFT
2 - BEARING CAP
3 - ADJUSTER
DR REAR AXLE - 11 1/2 AA 3 - 157
beari ngs/cups.
ti onal :
New Bearings 6 Adjuster Hol es
Original Bearings 4 Adjuster Hol es
l bs.).
l bs.) (Fi g. 37).
cedure.
(18) I nstal l axl e shaft gasket and i nstal l axl e
shafts.
(20) Fi l l axl e wi th l ubri cant, refer to Lubri cati on &
Mai ntenance for capaci ty and l ubri cant type.
l bs.).
DESCRIPTION
The Trac-Ri te di fferenti al i s a hel i cal gear di ffer-
enti al . The di fferenti al has two si de gears, si x pi ni on
gears and si x pi ni on brake shoes.
NOTE: The differential is seviced as an assembly
only if damaged, but can be disassembled for
cleaning. The assembly should be cleaned every
time a bearing is changed due to damage.
OPERATION
When one wheel begi ns to spi n the pi ni on gears on
that si de are forced toward the pi ni on brake shoes.
The pi ni on brake shoes then cause fri cti onal drag on
the opposi te pi ni on gears and the si de gear. These
fri cti on forces transfer the power to the opposi te
wheel . Once the fri cti onal forces are overcome, di ffer-
enti ati on wi l l occur. The torque wi l l be conti nual l y
bi ased by the fri cti onal forces to the hi gh tracti on
wheel .
DISASSEMBLY
(1) Remove di fferenti al ri ng gear bol ts.
(2) Remove di fferenti al case cover l ocati ng screws
(Fi g. 38).
(3) Remove di fferenti al case cover.
(4) Remove si de gear and thrust washer (Fi g. 39).
NOTE: Mark all component locations.
2 - ADJUSTER LOCK
3 - 158 REAR AXLE - 11 1/2 AA DR
(5) Remove three pi ni on brake shoes (Fi g. 40).
(6) Remove si x pi ni on gears (Fi g. 41).
(7) Remove remai ni ng si de gear thrust washer and
spacer.
(8) Remove remai ni ng three pi ni on brake shoes.
Fig. 38 LOCATION SCREWS
2 - LOCATION SCREWS
Fig. 39 SIDE GEAR AND THRUST WASHER
1 - SIDE GEAR
2 - THRUST WASHER
1 - BRAKE SHOES
2 - PINION GEARS
Fig. 41 PINION GEARS
1 - PINION GEARS
2 - SIDE GEAR
DR REAR AXLE - 11 1/2 AA 3 - 159
CLEANING
Cl ean the di fferenti al case and gears wi th l i ght oi l
or a l i nt free cl oth.
NOTE: Never use water, steam, kerosene or gaso-
line for cleaning.
INSPECTION
NOTE: Minor corrosion, nicks or scratches can be
smoothed with 400 grit emery cloth and polished
out with crocus cloth.
(1) I nspect pi ni on gears teeth for chi ps and cracks
(Fi g. 42).
(2) I nspect pi ni on gears shafts and brake shoes for
scratches, fl at-spots or worn (Fi g. 42).
(3) I nspect si de gears teeth for chi ps and cracks
(Fi g. 43).
(4) I nspect pi ni on and si de gear bores for scratches
(Fi g. 44).
NOTE: If any damage is found the differential must
be replaced as an assembly. Individual components
can not be replaced separately.
Fig. 42 PINION GEAR AND BRAKE SHOE
1 - BRAKE SHOES
2 - PINION GEAR
3 - PINION SHAFT
Fig. 43 SIDE GEARS
1 - THRUST WASHERS
2 - SPACER
3 - SIDE GEARS
Fig. 44 PINION/SIDE GEAR BORE
1 - PINION BORES
2 - SIDE GEAR BORE
3 - 160 REAR AXLE - 11 1/2 AA DR
ASSEMBLY
NOTE: Install all component in their original loca-
tions.
(1) Lubri cate al l gears and di fferenti al bores wi th
di fferenti al l ubri cant.
(2) I nstal l one set of pi ni on brake shoes i nto the
case bores.
NOTE: Brake shoes can be installed upside down,
but if install wrong pinion gear will not fit.
(3) I nstal l si de gear thrust washer, si de gear and
spacer (Fi g. 45).
(4) I nstal l one set of pi ni on gears i nto the bores
next to the brake shoes, wi th the pi ni on shaft faci ng
up.
(5) I nstal l other si de gear and thrust washer.
(6) I nstal l other set of pi ni on gears i nto the brake
shoes i n the case.
(7) I nstal l other set of brake shoes onto the pi ni on
gears shafts (Fi g. 46).
(8) I nstal l di fferenti al cover and l ocati on screws.
(9) I nstal l new ri ng gear bol ts and ti ghten to 237
Nm (175 ft. l bs.).
DIFFERENTIAL CASE
BEARINGS
REMOVAL
INSTALLATION
8965 and Handl e C-4171 (Fi g. 48).
Fig. 45 SIDE GEAR AND SPACER
1 - SPACER
2 - SIDE SPACER
1 - BRAKE SHOES
2 - PINION GEARS
DR REAR AXLE - 11 1/2 AA 3 - 161
TONE RING
REMOVAL
(3) Remove di fferenti al from the housi ng.
(4) Pl ace di fferenti al on Pl ug 8964. Dri ve exci ter
ri ng off the di fferenti al case wi th a hammer and
punch (Fi g. 49).
NOTE: Do not remove the exciter ring if it is not
being replaced.
jaw protectors
case.
(Fi g. 51) and remove pi ni on fl ange nut.
(9) Remove pi ni on fl ange from pi ni on wi th Pi ni on
Fl ange Pul l er 8992 (Fi g. 52).
1 - BRIDGE
2 - SPLITTER
3 - BEARING
4 - PLUG
1 - HANDLE
3 - BEARING
4 - INSTALLER
2 - RING GEAR
3 - PUNCH
4 - EXCITER RING
3 - 162 REAR AXLE - 11 1/2 AA DR
(10) Remove pi ni on gear from housi ng wi th Pi ni on
Dri ver 8977 and a hammer (Fi g. 53).
NOTE: Thread the driver on the pinion shaft till it
bottoms out.
pry bar.
(12) Remove front pi ni on beari ng and di scard bear-
i ng.
shaft.
Fig. 50 RING GEAR
2 - RING GEAR
3 - HAMMER
1 - PINION FLANGE
2 - FLANGE WRENCH
1 - PINION FLANGE
2 - PULLER
1 - PINION SHAFT
2 - PINION DRIVER
DR REAR AXLE - 11 1/2 AA 3 - 163
(14) Remove rear pi ni on beari ng wi th Beari ng
Spl i tter 1130 and a press (Fi g. 54).
housi ng wi th a punch and hammer, and di scard cup.
goi ng to be repl aced.
INSTALLATION
(1) I nstal l new front pi ni on beari ng cup (Fi g. 55)
(2) I nstal l new rear pi ni on beari ng cup (Fi g. 56)
i on gear shaft.
Fig. 54 BEARING SPLITTER
1 - PINION BEARING
2 - SPLITTER
1 - INSTALLER
2 - HANDLE
1 - INSTALLER
2 - HANDLE
2 - PINION GEAR
3 - 164 REAR AXLE - 11 1/2 AA DR
I nstal l er D-389 and a press.
60).
(10) Hol d pi ni on and l i ghtl y tap the pi ni on fl ange
onto the pi ni on, unti l a few threads are showi ng.
nut.
i s taken up.
l bs.)
i n. l bs.)
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
2 - PINION GEAR
1 - INSTALLER
1 - HANDLE
2 - INSTALLER
DR REAR AXLE - 11 1/2 AA 3 - 165
l bs.).
(19) I f exci ter ri ng was removed, posi ti on di fferen-
ti al assembl y on di fferenti al Pl ug 8965 (Fi g. 64) and
pl ace exci ter ri ng on the di fferenti al case.
(20) I nstal l the exci ter ri ng on the di fferenti al case
evenl y wi th a hammer and brass punch (Fi g. 65).
Dri ve the ri ng down unti l i t i s seated agai nst the
ri ng gear.
CAUTION: Do not damage exciter ring teeth during
installation.
1 - FLANGE WRENCH
2 - PINION FLANGE
1 - PINION FLANGE
2 - TORQUE WRENCH
1 - EXCITER RING
2 - RING GEAR
3 - DIFFERENTIAL PLUG
Fig. 65 EXCITER RING INSTALLATION
1 - EXCITER RING
2 - PUNSH
3 - RING GEAR
3 - 166 REAR AXLE - 11 1/2 AA DR
backl ash and gear contact pattern.
marks al i gned.
ti ghten bol ts to 40 Nm (30 ft. l bs.).
to 32 Nm (24 ft. l bs.).
DR REAR AXLE - 11 1/2 AA 3 - 167
BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL
BLEEDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STANDARD PROCEDURE - PRESSURE
BLEEDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 5
ADJUSTABLE PEDAL SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ADJUSTABLE PEDAL MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HYDRAULIC/MECHANICAL
SPECIFICATIONS
SPECIFICATIONS - TORQUE CHART . . . . . . . 8
BASE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKE LINES
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE
INVERTED FLARING . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - ISO FLARING . . 11
REMOVAL
REMOVAL - REAR BRAKE HOSE . . . . . . . . . 11
REMOVAL - REAR TUBE / HOSE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL - FRONT HOSE . . . . . . . . . . . . . . 12
INSTALLATION
INSTALLATION - REAR BRAKE HOSE . . . . . . 12
INSTALLATION - REAR TUBE / HOSE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION - FRONT BRAKE HOSE . . . . 13
BRAKE PADS/SHOES
REMOVAL
REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 13
REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION
INSTALLATION - FRONT . . . . . . . . . . . . . . . . 16
INSTALLATION - REAR . . . . . . . . . . . . . . . . . 16
DISC BRAKE CALIPERS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL
REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 17
REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . 17
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION
DISC BRAKE CALIPER ADAPTER
REMOVAL
REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 21
REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION
DISC BRAKE CALIPER ADAPTER MOUNT
REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION . . . . . . . . . . . . . . . . . . . . . 23
STANDARD PROCEDURE - BRAKE FLUID
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SPECIFICATIONS
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . 23
DR BRAKES 5 - 1
FLUID RESERVOIR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
BRAKE JUNCTION BLOCK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
MASTER CYLINDER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER . . . . . . . . . . . 25
STANDARD PROCEDURE - MASTER
CYLINDER BLEEDING . . . . . . . . . . . . . . . . . . 26
REMOVAL
REMOVAL - ALL EXCEPT HYDROBOOST . . . 26
REMOVAL - HYDROBOOST . . . . . . . . . . . . . 26
INSTALLATION
INSTALLATION - ALL EXCEPT
HYDROBOOST . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION - HYDROBOOST . . . . . . . . . . 27
PEDAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
POWER BRAKE BOOSTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
HYDRO-BOOST BRAKE BOOSTER
DIAGNOSIS AND TESTING - HYDRAULIC
BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
STANDARD PROCEDURE - BLEEDING . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
ROTORS
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . 32
REMOVAL
REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 33
REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL - REAR DUAL WHEELS . . . . . . . . 34
INSTALLATION
INSTALLATION - REAR DUAL WHEELS . . . . 35
SUPPORT PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
PARKING BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CABLES
REMOVAL
REMOVAL - FRONT PARKING BRAKE
CABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL - REAR PARK BRAKE CABLE . . . 37
REMOVAL - RIGHT REAR CABLE . . . . . . . . . 37
REMOVAL - LEFT REAR CABLE . . . . . . . . . . 38
INSTALLATION
INSTALLATION - FRONT PARKING BRAKE
CABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION - REAR PARK BRAKE
CABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION - RIGHT REAR CABLE . . . . . 38
INSTALLATION - LEFT REAR CABLE . . . . . . 39
SHOES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CLEANING - REAR DRUM IN HAT BRAKE . . . . 39
INSPECTION - REAR DRUM IN HAT BRAKE . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES . . 41
ADJUSTMENT - WITH ADJUSTING TOOL . . . 42
PEDAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
CABLE TENSIONER
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 43
RELEASE HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
BRAKES - BASE
DIAGNOSIS AND TESTING - BASE BRAKE
SYSTEM
Base brake components consi st of the brake pads,
cal i pers, brake drum i n hat rotor i n the rear, rotors,
brake l i nes, master cyl i nder, booster, and parki ng
brake components.
Brake di agnosi s i nvol ves determi ni ng i f the prob-
l em i s rel ated to a mechani cal , hydraul i c, or vacuum
operated component.
The fi rst di agnosi s step i s the prel i mi nary check.
PRELIMINARY BRAKE CHECK
(1) Check condi ti on of ti res and wheel s. Damaged
wheel s and worn, damaged, or underi nfl ated ti res
can cause pul l , shudder, vi brati on, and a condi ti on
si mi l ar to grab.
(2) I f compl ai nt was based on noi se when braki ng,
check suspensi on components. Jounce front and rear
of vehi cl e and l i sten for noi se that mi ght be caused
by l oose, worn or damaged suspensi on or steeri ng
components.
(3) I nspect brake fl ui d l evel and condi ti on. Note
that the brake reservoi r fl ui d l evel wi l l decrease i n
proporti on to normal l i ni ng wear. Also note that
brake fluid tends to darken over time. This is
5 - 2 BRAKES - BASE DR
normal and should not be mistaken for contam-
ination.
(a) I f fl ui d l evel i s abnormal l y l ow, l ook for evi -
dence of l eaks at cal i pers, wheel cyl i nders, brake
l i nes, and master cyl i nder.
(b) I f fl ui d appears contami nated, drai n out a
sampl e to exami ne. System wi l l have to be fl ushed
i f fl ui d i s separated i nto l ayers, or contai ns a sub-
stance other than brake fl ui d. The system seal s
and cups wi l l al so have to be repl aced after fl ush-
i ng. Use cl ean brake fl ui d to fl ush the system.
(4) Check parki ng brake operati on. Veri fy free
movement and ful l rel ease of cabl es and pedal . Al so
note i f vehi cl e was bei ng operated wi th parki ng
brake parti al l y appl i ed.
(5) Check brake pedal operati on. Veri fy that pedal
does not bi nd and has adequate free pl ay. I f pedal
l acks free pl ay, check pedal and power booster for
bei ng l oose or for bi nd condi ti on. Do not road test
unti l condi ti on i s corrected.
(6) Check booster vacuum check val ve and hose.
(7) I f components checked appear OK, road test
the vehi cl e.
ROAD TESTING
(1) I f compl ai nt i nvol ved l ow brake pedal , pump
pedal and note i f i t comes back up to normal hei ght.
(2) Check brake pedal response wi th transmi ssi on
i n Neutral and engi ne runni ng. Pedal shoul d remai n
fi rm under constant foot pressure.
(3) Duri ng road test, make normal and fi rm brake
stops i n 25-40 mph range. Note faul ty brake opera-
ti on such as l ow pedal , hard pedal , fade, pedal pul sa-
ti on, pul l , grab, drag, noi se, etc.
(4) Attempt to stop the vehi cl e wi th the parki ng
brake onl y and note grab, drag, noi se, etc.
PEDAL FALLS AWAY
A brake pedal that fal l s away under steady foot
pressure i s general l y the resul t of a system l eak or
fl ui d contami nati on. The l eak poi nt coul d be at a
brake l i ne, fi tti ng, hose, or cal i per/wheel cyl i nder. I f
l eakage i s severe, fl ui d wi l l be evi dent at or around
the l eaki ng component.
I nternal l eakage (seal by-pass) i n the master cyl i n-
der caused by worn or damaged pi ston cups, may
al so be the probl em cause.
An i nternal l eak i n the ABS or RWAL system may
al so be the probl em wi th no physi cal evi dence.
LOW PEDAL
I f a l ow pedal i s experi enced, pump the pedal sev-
eral ti mes. I f the pedal comes back up worn l i ni ngs,
rotors, drums, or rear brakes out of adjustment are
the most l i kel y causes. The proper course of acti on i s
to i nspect and repl ace al l worn component and make
the proper adjustments.
SPONGY PEDAL
A spongy pedal i s most often caused by ai r i n the
system. However, thi n brake drums or substandard
brake l i nes and hoses can al so cause a spongy pedal .
The proper course of acti on i s to bl eed the system,
and repl ace thi n drums and substandard qual i ty
brake hoses i f suspected.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or hi gh pedal effort may be due to
l i ni ng that i s water soaked, contami nated, gl azed, or
badl y worn. The power booster or check val ve or a
vacuum hose coul d al so be faul ty.
PEDAL PULSATION
Pedal pul sati on i s caused by components that are
l oose, or beyond tol erance l i mi ts.
The pri mary cause of pul sati on are di sc brake
rotors wi th excessi ve l ateral runout or thi ckness vari -
ati on, or out of round brake drums. Other causes are
l oose wheel beari ngs or cal i pers and worn, damaged
ti res.
NOTE: Some pedal pulsation may be felt during
ABS activation.
BRAKE DRAG
Brake drag occurs when the l i ni ng i s i n constant
contact wi th the rotor or drum. Drag can occur at one
wheel , al l wheel s, fronts onl y, or rears onl y.
Drag i s a product of i ncompl ete brake shoe rel ease.
Drag can be mi nor or severe enough to overheat the
l i ni ngs, rotors and drums.
Mi nor drag wi l l usual l y cause sl i ght surface char-
ri ng of the l i ni ng. I t can al so generate hard spots i n
rotors and drums from the overheat-cool down pro-
cess. I n most cases, the rotors, drums, wheel s and
ti res are qui te warm to the touch after the vehi cl e i s
stopped.
Severe drag can char the brake l i ni ng al l the way
through. I t can al so di stort and score rotors and
drums to the poi nt of repl acement. The wheel s, ti res
and brake components wi l l be extremel y hot. I n
severe cases, the l i ni ng may generate smoke as i t
chars from overheati ng.
Common causes of brake drag are:
Sei zed or i mproperl y adjusted parki ng brake
cabl es.
Loose/worn wheel beari ng.
Sei zed cal i per or wheel cyl i nder pi ston.
Cal i per bi ndi ng on corroded bushi ngs or rusted
sl i de surfaces.
Loose cal i per mounti ng.
DR BRAKES - BASE 5 - 3
BRAKES - BASE (Continued)
Drum brake shoes bi ndi ng on worn/damaged
support pl ates.
Mi s-assembl ed components.
Long booster output rod.
I f brake drag occurs at al l wheel s, the probl em
may be rel ated to a bl ocked master cyl i nder return
port, or faul ty power booster (bi nds-does not rel ease).
BRAKE FADE
Brake fade i s usual l y a product of overheati ng
caused by brake drag. However, brake overheati ng
and resul ti ng fade can al so be caused by ri di ng the
brake pedal , maki ng repeated hi gh decel erati on stops
i n a short ti me span, or constant braki ng on steep
mountai n roads. Refer to the Brake Drag i nformati on
i n thi s secti on for causes.
BRAKE PULL
Front brake pul l condi ti on coul d resul t from:
Contami nated l i ni ng i n one cal i per
Sei zed cal i per pi ston
Bi ndi ng cal i per
Loose cal i per
Rusty cal i per sl i de surfaces
I mproper brake pads
Damaged rotor
A worn, damaged wheel beari ng or suspensi on
component are further causes of pul l . A damaged
front ti re (brui sed, pl y separati on) can al so cause
pul l .
A common and frequentl y mi sdi agnosed pul l condi -
ti on i s where di recti on of pul l changes after a few
stops. The cause i s a combi nati on of brake drag fol -
l owed by fade at one of the brake uni ts.
As the draggi ng brake overheats, effi ci ency i s so
reduced that fade occurs. Si nce the opposi te brake
uni t i s sti l l functi oni ng normal l y, i ts braki ng effect i s
magni fi ed. Thi s causes pul l to swi tch di recti on i n
favor of the normal l y functi oni ng brake uni t.
An addi ti onal poi nt when di agnosi ng a change i n
pul l condi ti on concerns brake cool down. Remember
that pul l wi l l return to the ori gi nal di recti on, i f the
draggi ng brake uni t i s al l owed to cool down (and i s
not seri ousl y damaged).
REAR BRAKE GRAB OR PULL
Rear grab or pul l i s usual l y caused by i mproperl y
adjusted or sei zed parki ng brake cabl es, contami -
nated l i ni ng, bent or bi ndi ng shoes and support
pl ates, or i mproperl y assembl ed components. Thi s i s
parti cul arl y true when onl y one rear wheel i s
i nvol ved. However, when both rear wheel s are
affected, the master cyl i nder or proporti oni ng val ve
coul d be at faul t.
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
WATER PUDDLES
Thi s condi ti on i s general l y caused by water soaked
l i ni ng. I f the l i ni ng i s onl y wet, i t can be dri ed by
dri vi ng wi th the brakes very l i ghtl y appl i ed for a
mi l e or two. However, i f the l i ni ng i s both soaked and
di rt contami nated, cl eani ng and/or repl acement wi l l
be necessary.
BRAKE LINING CONTAMINATION
Brake l i ni ng contami nati on i s mostl y a product of
l eaki ng cal i pers or worn seal s, dri vi ng through deep
water puddl es, or l i ni ng that has become covered
wi th grease and gri t duri ng repai r. Contami nated l i n-
i ng shoul d be repl aced to avoi d further brake prob-
l ems.
WHEEL AND TIRE PROBLEMS
Some condi ti ons attri buted to brake components
may actual l y be caused by a wheel or ti re probl em.
A damaged wheel can cause shudder, vi brati on and
pul l . A worn or damaged ti re can al so cause pul l .
Severel y worn ti res wi th very l i ttl e tread l eft can
produce a grab-l i ke condi ti on as the ti re l oses and
recovers tracti on. Fl at-spotted ti res can cause vi bra-
ti on and generate shudder duri ng brake operati on. A
ti re wi th i nternal damage such as a severe brui se,
cut, or pl y separati on can cause pul l and vi brati on.
BRAKE NOISES
Some brake noi se i s common wi th rear drum
brakes and on some di sc brakes duri ng the fi rst few
stops after a vehi cl e has been parked overni ght or
stored. Thi s i s pri mari l y due to the formati on of trace
corrosi on (l i ght rust) on metal surfaces. Thi s l i ght
corrosi on i s typi cal l y cl eared from the metal surfaces
after a few brake appl i cati ons causi ng the noi se to
subsi de.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to l i ni ngs that
are wet or contami nated wi th brake fl ui d, grease, or
oi l . Gl azed l i ni ngs and rotors wi th hard spots can
al so contri bute to squeak. Di rt and forei gn materi al
embedded i n the brake l i ni ng wi l l al so cause squeak/
squeal .
A very l oud squeak or squeal i s frequentl y a si gn of
severel y worn brake l i ni ng. I f the l i ni ng has worn
through to the brake pads i n spots, metal -to-metal
contact occurs. I f the condi ti on i s al l owed to conti nue,
rotors can become so scored that repl acement i s nec-
essary.
BRAKE CHATTER
Brake chatter i s usual l y caused by l oose or worn
components, or gl azed/burnt l i ni ng. Rotors wi th hard
spots can al so contri bute to chatter. Addi ti onal causes
of chatter are out-of-tol erance rotors, brake l i ni ng not
securel y attached to the shoes, l oose wheel beari ngs
and contami nated brake l i ni ng.
THUMP/CLUNK NOISE
Thumpi ng or cl unk noi ses duri ng braki ng are fre-
quentl y not caused by brake components. I n many
cases, such noi ses are caused by l oose or damaged
steeri ng, suspensi on, or engi ne components. However,
cal i pers that bi nd on the sl i de surfaces can generate
a thump or cl unk noi se.
STANDARD PROCEDURE
STANDARD PROCEDURE - MANUAL BLEEDING
Use Mopar brake fl ui d, or an equi val ent qual i ty
fl ui d meeti ng SAE J1703-F and DOT 3 standards
onl y. Use fresh, cl ean fl ui d from a seal ed contai ner at
al l ti mes.
(1) Remove reservoi r fi l l er caps and fi l l reservoi r.
(2) I f cal i pers were overhaul ed, open al l cal i per
bl eed screws. Then cl ose each bl eed screw as fl ui d
starts to dri p from i t. Top off master cyl i nder reser-
voi r once more before proceedi ng.
(3) Attach one end of bl eed hose to bl eed screw
and i nsert opposi te end i n gl ass contai ner parti al l y
fi l l ed wi th brake fl ui d (Fi g. 1). Be sure end of bl eed
hose i s i mmersed i n fl ui d.
NOTE: Bleed procedure should be in this order (1)
Right rear (2) Left rear (3) Right front (4) Left front.
(4) Open up bl eeder, then have a hel per press
down the brake pedal . Once the pedal i s down cl ose
the bl eeder. Repeat bl eedi ng unti l fl ui d stream i s
cl ear and free of bubbl es. Then move to the next
wheel .
(5) Before movi ng the vehi cl e veri fy the pedal i s
fi rm and not mushy.
(6) Top off the brake fl ui d and i nstal l the reservoi r
cap.
STANDARD PROCEDURE - PRESSURE
BLEEDING
Use Mopar brake fl ui d, or an equi val ent qual i ty
fl ui d meeti ng SAE J1703-F and DOT 3 standards
onl y. Use fresh, cl ean fl ui d from a seal ed contai ner at
al l ti mes.
Fol l ow the manufacturers i nstructi ons careful l y
when usi ng pressure equi pment. Do not exceed the
tank manufacturers pressure recommendati ons. Gen-
eral l y, a tank pressure of 15-20 psi i s suffi ci ent for
bl eedi ng.
Fi l l the bl eeder tank wi th recommended fl ui d and
purge ai r from the tank l i nes before bl eedi ng.
Do not pressure bl eed wi thout a proper master cyl -
i nder adapter. The wrong adapter can l ead to l eak-
age, or drawi ng ai r back i nto the system.
SPECIAL TOOLS
BASE BRAKES
Fig. 1 Bleed Hose Setup
1 - BLEED HOSE
2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID
INSTALLER, BRAKE CALIPER DUST BOOT C-4340
INSTALLER, BRAKE CALIPER DUST BOOT
C-3716-A
ADJ USTABLE PEDAL SWITCH
REMOVAL
(1) Remove the l ower dri vers si de bezel (Refer to
23 - BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL DR SI DE BEZEL - REMOVAL).
(2) Di sconnect the el ectri cal connector from the
adjustabl e pedal swi tch.
(3) Remove the swi tch from the l ower dri vers si de
bezel by squeezi ng the retai ni ng cl i ps together and
pushi ng the swi tch outwards (Fi g. 2).
INSTALLATION
(1) I nstal l the swi tch to the l ower dri vers si de
bezel by pushi ng the swi tch i nwards seati ng the
retai ni ng cl i ps to the l ower dri vers si de bezel .
(2) Reconnect the el ectri cal connector to the
adjustabl e pedal swi tch.
(3) I nstal l the l ower dri vers si de bezel (Fi g. 2)
(Refer to 23 - BODY/I NSTRUMENT PANEL/I N-
STRUMENT PANEL DR SI DE BEZEL - I NSTALLA-
TI ON).
ADJ USTABLE PEDAL MOTOR
DESCRIPTION
The Adjustabl e Pedal s System (APS) i s desi gned to
enabl e the fore and aft reposi ti oni ng of the brake and
accel erator pedal s. Thi s resul ts i n i mproved ergonom-
i cs i n rel ati on to the steeri ng wheel for tal l er and
shorter dri vers. Bei ng abl e to adjust the pedal posi -
ti ons al so al l ows the dri ver to set steeri ng wheel ti l t
and seat posi ti on to the most comfortabl e posi ti on.
The posi ti on of the brake and accel erator pedal s can
be adjusted wi thout compromi si ng safety or comfort
i n actuati ng the pedal s.
Change of pedal posi ti on i s accompl i shed by means
of a motor dri ven screw. Operati ng the adjustabl e
pedal swi tch acti vates the pedal dri ve motor (Fi g. 3).
The pedal dri ve motor turns a screw that changes
the posi ti on of the brake and accel erator pedal s. The
pedal can be moved rearward (cl oser to the dri ver) or
forward (away from dri ver). The brake pedal i s
moved on i ts dri ve screw to a posi ti on where the
dri ver feel s most comfortabl e.
The accel erator pedal i s moved at the same ti me
and the same di stance as the brake pedal .
Nei ther the pedal dri ve motor (Fi g. 3) nor dri ve
mechani sm are subject to the mechani cal stress of
brake or accel erator appl i cati on.
SYSTEM FEATURES:
Range of Adjustment: The pedal s may be
adjusted up to 3 i n. (75 mm)
Pedal Adjustment Speed: 0.5 i n./sec (12.5
mm/sec)
HANDLE C-4171
CAP, MASTER CYLINDER PRESSURE BLEED 6921
GAUGE, BRAKE SAFE-SET C-3919
Fig. 2 LOWER DRIVERS SIDE BEZEL
1 - SCREWS (2)
2 - ADJUSTABLE PEDAL SWITCH (if equipped)
3 - PEDAL SWITCH ELECTRICAL CONNECTOR
4 - BEZEL
Pedal Adjustment I nhi bi tors: Pedal adjust-
ment i s i nhi bi ted when the vehi cl e i s i n reverse or
when crui se control i s acti vated.
REMOVAL
(1) Di sconnect the negati ve battery cabl e.
(2) Remove the kneebl ocker (Refer to 23 - BODY/
I NSTRUMENT PANEL/STEERI NG COLUMN
OPENI NG COVER - REMOVAL).
(3) Remove the brake l i ght swi tch and di scard
(Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG -
EXTERI OR/BRAKE LAMP SWI TCH - REMOVAL).
(4) Di sconnect the adjustabl e pedal cabl es from the
brake and accel erator pedal s Also clutch pedal if
equipped with a manual transmission.
(5) Di sconnect the el ectri cal connector.
(6) Uncl i p the cabl e fasteners to the support.
(7) Remove the one mounti ng bol t for the adjust-
abl e pedal motor (Fi g. 4).
(8) Remove the adjustabl e pedal motor wi th the
cabl es.
NOTE: Adjustable pedal cables are not serviceable.
If they need service the adjustable pedal motor with
the cables must be installed.
INSTALLATION
NOTE: Adjustable pedal cables are not serviceable.
If they need service the adjustable pedal motor with
the cables must be installed.
(1) I nstal l the adjustabl e pedal motor wi th the
cabl es.
(2) I nstal l the one mounti ng bol t for the adjustabl e
pedal motor (Fi g. 4).
(3) Cl i p the cabl e fasteners to the support.
(4) Reconnect the el ectri cal connector.
(5) Reconnect the adjustabl e pedal cabl es to the
brake and accel erator pedal s Also clutch pedal if
equipped with a manual transmission.
(6) I nstal l the new brake l i ght swi tch (Refer to 8 -
ELECTRI CAL/LAMPS/LI GHTI NG - EXTERI OR/
BRAKE LAMP SWI TCH - REMOVAL).
(7) I nstal l the kneebl ocker (Refer to 23 - BODY/I N-
STRUMENT PANEL/STEERI NG COLUMN OPEN-
I NG COVER - I NSTALLATI ON).
(8) Reconnect the negati ve battery cabl e.
(9) Check for proper operati on of the pedal s.
Fig. 3 ADJUSTABLE PEDAL MOTOR
1 - ADJUSTABLE PEDAL MOTOR
2 - CABLES
3 - ELECTRICAL CONNECTOR
Fig. 4 ADJUSTABLE PEDAL MOTOR
2 - MOUNTING BOLT
ADJ USTABLE PEDAL MOTOR (Continued)
SPECIFICATIONS
SPECIFICATIONS - TORQUE CHART
Brake Booster
Mounting Nuts
28 21 250
Master Cylinder
Mounting Nuts
18 160
Caliper
Mounting Pins
Front
32 24
Caliper
Mounting Pins
Rear
15 11
Caliper
Adapter Mounting Bolts
Front
LD
176 130
Caliper
Front
HD
339 250
Caliper
Rear
LD
135 100
Caliper
Rear
HD
197 145
Junction Block
Bolts To Frame
10 7.5
Brake Pedal Assembly
Bracket
Nuts
28 21
Support Plate
Mounting Bolts/Nuts
64 47
Brake Line Fittings
Master Cylinder
19 14 170
Brake Line Fittings
Junction Block
19 14 170
Caliper
Brake Line Banjo Bolt
Front
27 20 245
Caliper
Brake Line Banjo Bolt
Rear
27 20 245
Brake Hose
Front Bolts To Frame
10 7.5
Brake Hose
Front Fitting
19 14 250
Brake Hose
Rear Fitting
19 14 250
Parking Brake Pedal
Assembly
19 14 250
Rotor to Hub Bolt
Rear
128 95
Hub/Bearing
Bolts
LD
163 120
Hub/Bearing
Bolts
HD
176 130
HYDRAULIC/MECHANICAL (Continued)
BASE BRAKE
SPECIFICATIONS
Front Disc Brake Caliper
Type
Dual Piston Sliding
Rear Disc Brake Caliper
Type
LD
Single Piston Sliding
Type
HD
Dual Piston Sliding
LD
54 mm (2.12 in.)
HD
56 mm (2.20 in.)
Front Disc Brake Rotor
LD
33628 mm (13.21.1
in.)
Front Disc Brake Rotor
HD
35335.5 mm
(13.891.397 in.)
Front/Rear Disc Brake
Rotor
Max. Runout
LD
0.127 mm (0.005 in.)
Rotor
Max. Runout
HD
SRW
0.131 mm (0.005 in.)
Rear Disc Brake Rotor
Max. Runout
HD
DRW
0.328 mm (0.012 in.)
Rotor
Max. Thickness Variation
LD
0.015 mm (0.0059 in.)
Rotor
Max. Thickness Variation
HD
0.013 mm (0.0005 in.)
Loose Rotor
Minimum Front Rotor
Thickness
LD
26.4 mm (1.039 in.)
Minimum Front Rotor
Thickness
HD
34 mm (1.33 in.)
Mininium Rear Rotor
Thickness
LD&HD
28.39 mm (1.117 in)
LD
1x54 mm (2.12 in)
HD
SRW
2x45 mm (1.77 in)
HD
DRW
2x51 mm (2.00 in)
LD
350x22 mm (13.77 X .86
in)
HD
353x30 mm (13.89 X
1.18 in)
Brake Booster
Type
Gasoline Engines
LD
Vacuum Dual Diaphragm
Brake Booster
Type
Gasoline Engines
HD
SRW
Vacuum Dual Diaphragm
Brake Booster
Type
Diesel Engines
HD
DRW
Hydroboost
BRAKE LINES
STANDARD PROCEDURE
STANDARD PROCEDURE - DOUBLE INVERTED
FLARING
A preformed metal brake tube i s recommended and
preferred for al l repai rs. However, doubl e-wal l steel
tube can be used for emergency repai r when factory
repl acement parts are not readi l y avai l abl e.
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Ream cut edges of tubi ng to ensure proper
fl are.
(3) I nstal l repl acement tube nut on the tube.
(4) I nsert tube i n fl ari ng tool .
(5) Pl ace gauge form over the end of the tube.
(6) Push tubi ng through fl ari ng tool jaws unti l
tube contacts recessed notch i n gauge that matches
tube di ameter.
(7) Ti ghten the tool bar on the tube
(8) I nsert pl ug on gauge i n the tube. Then swi ng
compressi on di sc over gauge and center tapered fl ar-
i ng screw i n recess of compressi on di sc (Fi g. 5).
HYDRAULIC/MECHANICAL (Continued)
(9) Ti ghten tool handl e unti l pl ug gauge i s
squarel y seated on jaws of fl ari ng tool . Thi s wi l l start
the i nverted fl are.
(10) Remove the pl ug gauge and compl ete the
i nverted fl are.
STANDARD PROCEDURE - ISO FLARING
A preformed metal brake tube i s recommended and
preferred for al l repai rs. However, doubl e-wal l steel
tube can be used for emergency repai r when factory
repl acement parts are not readi l y avai l abl e.
To make a I SO fl are use an I SO fl ari ng tool ki t.
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Remove any burrs from the i nsi de of the tube.
(3) I nstal l tube nut on the tube.
(4) Posi ti on the tube i n the fl ari ng tool fl ush wi th
the top of the tool bar (Fi g. 6). Then ti ghten the tool
bar on the tube.
(5) I nstal l the correct si ze adaptor on the fl ari ng
tool yoke screw.
(6) Lubri cate the adaptor.
(7) Al i gn the adaptor and yoke screw over the tube
(Fi g. 6).
(8) Turn the yoke screw i n unti l the adaptor i s
squarel y seated on the tool bar.
REMOVAL
REMOVAL - REAR BRAKE HOSE
(1) I nstal l prop rod on the brake pedal to keep
pressure on the brake system.
(3) Remove the brake l i ne from the hose at the
frame (Fi g. 7).
(4) Remove the brake hose cl i p at the top of the
hose l ocated at the frame (Fi g. 7).
(5) Remove the vent tube (Fi g. 8).
(6) Remove the two brake l i nes at the bottom of
the hose l ocated at the axl e (Fi g. 8).
Fig. 5 Inverted Flare Tools
Fig. 6 ISO Flaring
1 - ADAPTER
2 - LUBRICATE HERE
3 - PILOT
4 - FLUSH WITH BAR
5 - TUBING
6 - BAR ASSEMBLY
Fig. 7 BRAKE LINE CLIP
1 - BRAKE HOSE
2 - CLIP
3 - BRAKE LINE
BRAKE LINES (Continued)
(7) Remove the mounti ng bol t for the brake hose
at the axl e (Fi g. 8).
(8) Remove the hose.
REMOVAL - REAR TUBE / HOSE ASSEMBLY
(3) Remove the brake l i ne l ocated at the axl e.
(4) Remove the mounti ng bol t for the brake hose
at the axl e (Fi g. 9).
(5) Remove the banjo bol t at the cal i per (Fi g. 9).
REMOVAL - FRONT HOSE
(1) I nstal l a prop rod on the brake pedal to keep
(4) Remove the brake hose from the brake l i ne
l ocated at the frame (Fi g. 10).
(5) Remove the brake hose banjo bol t at the cal i per
(Fi g. 10).
(6) Remove the mounti ng bol t securi ng the brake
hose to the frame and remove the wheel speed sensor
wi re from the brake hose (Fi g. 10).
INSTALLATION
INSTALLATION - REAR BRAKE HOSE
(1) I nstal l the hose.
(2) I nstal l the mounti ng bol t for the brake hose at
the axl e (Fi g. 8).
(3) I nstal l the two brake l i nes at the bottom of the
hose l ocated at the axl e (Fi g. 8).
(4) I nstal l the vent tube (Fi g. 8).
(5) I nstal l the brake hose cl i p at the top of the
hose l ocated at the frame (Fi g. 7).
(6) I nstal l the brake l i ne to the hose at the frame
(Fi g. 7).
(7) Lower the vehi cl e and remove the support.
(8) Remove the prop rod.
(9) Bl eed the brake system (Refer to 5 - BRAKES -
STANDARD PROCEDURE).
Fig. 8 REAR HOSE
1 - BRAKE HOSE
2 - VENT HOSE
3 - BRAKE LINES
Fig. 9 BRAKE LINE WITH RUBBER HOSE
1 - BANJO BOLT
2 - MOUNTING BOLT
3 - REAR TUBE / HOSE ASSEMBLY
Fig. 10 BRAKE HOSE MOUNTED PASSENGER SIDE
1 - MOUNTING BOLT
2 - BRAKE HOSE
3 - BANJO BOLT
INSTALLATION - REAR TUBE / HOSE
ASSEMBLY
(2) I nstal l the banjo bol t at the cal i per (Fi g. 9) and
ti ghten fi tti ng bol t to 27 Nm (245 i n. l bs.).
the axl e (Fi g. 9).
(4) I nstal l the brake l i ne l ocated at the axl e.
(5) Lower the vehi cl e and remove the support.
INSTALLATION - FRONT BRAKE HOSE
the frame (Fi g. 11).
(3) I nstal l the brake hose banjo bol t at the cal i per
(Fi g. 10).
(4) Rei nstal l the wheel speed sensor wi re to the
brake hose (Fi g. 10).
(6) Remove the prop rod from the brake pedal .
BRAKE PADS/SHOES
REMOVAL
REMOVAL - FRONT
(2) Remove the wheel and ti re assembl i es.
(3) Compress the cal i per.
(4) Remove the cal i per, (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/DI SC BRAKE CALI PERS
- REMOVAL).
(5) Remove the cal i per by ti l ti ng the top up and off
the cal i per adapter (Fi g. 12).
NOTE: Do not allow brake hose to support caliper
assembly.
(6) Support and hang the cal i per. (Fi g. 13)
(7) Remove the i nboard brake shoe from the cal i -
per adapter (Fi g. 14).
Fig. 11 BRAKE HOSE MOUNT DRIVERS SIDE
1 - MOUNTING BOLT
3 - BRAKE HOSE
Fig. 12 Caliper
1 - CALIPER
2 - CALIPER ADAPTER
Fig. 13 DISC BRAKE CALIPER - FRONT
3 - CALIPER MOUNTING ADAPTER
4 - DISC BRAKE ROTOR
(8) Remove the outboard brake shoe from the cal i -
per adapter (Fi g. 15).
(9) Remove the anti -rattl e spri ngs from the cal i per
adapter (Fi g. 16) and (Fi g. 17).
NOTE: Anti-rattle springs are not interchangeable.
REMOVAL - REAR
(2) Remove the rear wheel and ti re assembl i es.
(3) Compress the cal i per.
(4) Remove cal i per sl i de bol ts
assembly.
(5) Remove the cal i per, (Refer to 5 - BRAKES/HY-
- REMOVAL) and then ti l t the top up and off the cal -
i per adapter (Fi g. 18) or (Fi g. 19).
(6) Remove i nboard brake shoe from the cal i per
adapter (Fi g. 20).
Fig. 14 Inboard Brake Shoe
1 - INBOARD SHOE
2 - CALIPER ADAPTER
Fig. 15 Outboard Brake Shoe
1 - OUTBOARD SHOE
2 - CALIPER ADAPTER
Fig. 16 Top Anti-Rattle Spring
1 - CALIPER ADAPTER
2 - ANTI-RATTLE SPRING
Fig. 17 Bottom Anti-Rattle Spring
2 - CALIPER ADAPTER
BRAKE PADS/SHOES (Continued)
(7) Remove outboard brake shoe from cal i per
adapter (Fi g. 21).
(8) Remove the anti -rattl e spri ngs from the cal i per
adapter (Fi g. 22) and (Fi g. 23).
Fig. 18 DISC BRAKE CALIPER - REAR
1 - CALIPER ADAPTER
2 - CALIPER ADAPTER MOUNTING BOLTS
3 - CALIPER SLIDE BOLTS
4 - BRAKE HOSE
5 - CABLE
6 - CALIPER
7 - ROTOR
8 - ANTI-RATTLE CLIPS
Fig. 19 ROTOR / PADS/ CALIPER DUAL REAR
WHEELS
1 - Rotor
2 - Brake Shoes
3 - Disc Brake Caliper
Fig. 20 Inboard Brake Shoe
1 - INBOARD SHOE
2 - CALIPER ADAPTER
Fig. 21 Outboard Brake Shoe
1 - OUTBOARD SHOE
2 - CALIPER ADAPTER
INSTALLATION
INSTALLATION - FRONT
(1) Bottom pi stons i n cal i per bore wi th C-cl amp.
Pl ace an ol d brake shoe between a C-cl amp and cal -
i per pi ston.
(2) Cl ean cal i per mounti ng adapter and anti -rattl e
spri ngs.
(3) Lubri cate anti -rattl e spri ngs wi th Mopar brake
grease.
(4) I nstal l new anti -rattl e spri ngs.
(5) I nstal l i nboard brake shoe i n adapter.
(6) I nstal l outboard brake shoe i n adapter.
(7) Ti l t the top of the cal i per over rotor and under
adapter. Then push the bottom of the cal i per down
onto the adapter.
(8) I nstal l cal i per, (Refer to 5 - BRAKES/HY-
- I NSTALLATI ON).
(9) I nstal l wheel and ti re assembl i es and l ower
vehi cl e, (Refer to 22 - TI RES/WHEELS/WHEELS -
(10) Appl y brakes several ti mes to seat cal i per pi s-
tons and brake shoes and obtai n fi rm pedal .
(11) Top off master cyl i nder fl ui d l evel .
INSTALLATION - REAR
(1) Cl ean cal i per mounti ng adapter and anti -rattl e
spri ngs.
(2) Lubri cate anti -rattl e spri ngs wi th Mopar brake
grease.
(3) I nstal l new anti -rattl e spri ngs.
(4) I nstal l i nboard brake shoe i n adapter.
(5) I nstal l outboard brake shoe i n adapter.
(6) Ti l t the bottom of the cal i per over rotor and
under adapter. Then push the top of the cal i per down
onto the adapter.
(7) I nstal l cal i per, (Refer to 5 - BRAKES/HY-
- I NSTALLATI ON) (Refer to 5 - BRAKES/HYDRAU-
LI C/MECHANI CAL/DI SC BRAKE CALI PERS -
I NSTALLATI ON).
(8) I nstal l wheel and ti re assembl i es and l ower
vehi cl e, (Refer to 22 - TI RES/WHEELS/WHEELS -
(9) Appl y brakes several ti mes to seat cal i per pi s-
tons and brake shoes and obtai n fi rm pedal .
(10) Top off master cyl i nder fl ui d l evel .
DISC BRAKE CALIPERS
DESCRIPTION
The cal i pers are a si ngl e pi ston type i n the rear
and dual pi ston type i n the front. The cal i pers are
free to sl i de l ateral l y, thi s al l ows conti nuous compen-
sati on for l i ni ng wear.
OPERATION
When the brakes are appl i ed fl ui d pressure i s
exerted agai nst the cal i per pi ston. The fl ui d pressure
i s exerted equal l y and i n al l di recti ons. Thi s means
pressure exerted agai nst the cal i per pi ston and
wi thi n the cal i per bore wi l l be equal (Fi g. 24).
Fl ui d pressure appl i ed to the pi ston i s transmi tted
di rectl y to the i nboard brake pad. Thi s forces the pad
l i ni ng agai nst the i nner surface of the di sc brake
Fig. 22 Top Anti-Rattle Spring
1 - CALIPER ADAPTER
Fig. 23 Bottom Anti-Rattle Spring
2 - CALIPER ADAPTER
rotor. At the same ti me, fl ui d pressure wi thi n the pi s-
ton bore forces the cal i per to sl i de i nward on the
mounti ng bol ts. Thi s acti on bri ngs the outboard
brake pad l i ni ng i nto contact wi th the outer surface
of the di sc brake rotor.
I n summary, fl ui d pressure acti ng si mul taneousl y
on both pi ston and cal i per, produces a strong cl amp-
i ng acti on. When suffi ci ent force i s appl i ed, fri cti on
wi l l attempt to stop the rotors from turni ng and
bri ng the vehi cl e to a stop.
Appl i cati on and rel ease of the brake pedal gener-
ates onl y a very sl i ght movement of the cal i per and
pi ston. Upon rel ease of the pedal , the cal i per and pi s-
ton return to a rest posi ti on. The brake pads do not
retract an appreci abl e di stance from the rotor. I n
fact, cl earance i s usual l y at, or cl ose to zero. The rea-
sons for thi s are to keep road debri s from getti ng
between the rotor and l i ni ng and i n wi pi ng the rotor
surface cl ear each revol uti on.
The cal i per pi ston seal control s the amount of pi s-
ton extensi on needed to compensate for normal l i ni ng
wear.
Duri ng brake appl i cati on, the seal i s defl ected out-
ward by fl ui d pressure and pi ston movement (Fi g.
25). When the brakes (and fl ui d pressure) are
rel eased, the seal rel axes and retracts the pi ston.
The amount of pi ston retracti on i s determi ned by
the amount of seal defl ecti on. General l y the amount
i s just enough to mai ntai n contact between the pi s-
ton and i nboard brake pad.
REMOVAL
REMOVAL - FRONT
CAUTION: Never allow the disc brake caliper to
hang from the brake hose. Damage to the brake
hose will result. Provide a suitable support to hang
the caliper securely.
(4) Compress the di sc brake cal i per.
(5) Remove the banjo bol t and di scard the copper
washer.
(6) Remove the cal i per sl i de bol ts.
(7) Remove the di sc brake cal i per (Fi g. 26) or (Fi g.
27).
REMOVAL - REAR
(4) Drai n smal l amount of fl ui d from master cyl i n-
der brake reservoi r wi th sucti on gun.
(5) Remove the brake hose banjo bol t and di scard
the copper washers i f repl aci ng cal i per (Fi g. 28).
Fig. 24 Brake Caliper Operation
1 - CALIPER
2 - PISTON
3 - PISTON BORE
4 - SEAL
5 - INBOARD SHOE
6 - OUTBOARD SHOE
Fig. 25 Lining Wear Compensation By Piston Seal
1 - PISTON
2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
4 - CALIPER HOUSING
5 - DUST BOOT
6 - PISTON SEAL BRAKE PRESSURE ON
DISC BRAKE CALIPERS (Continued)
(6) Remove the cal i per sl i de bol ts (Fi g. 28).
(7) Remove the cal i per from vehi cl e.
DISASSEMBLY
(1) Drai n the brake fl ui d from cal i per.
(2) C-cl amp a bl ock of wood over one pi ston (Fi g.
29).
(3) Take another pi ece of wood and pad i t wi th
one-i nch thi ckness of shop towel s. Pl ace thi s pi ece i n
the outboard shoe si de of the cal i per i n front of the
other pi ston. Thi s wi l l cushi on and protect cal i per
pi ston duri ng removal (Fi g. 30).
(4) To remove the cal i per pi ston di rect short
bursts of low pressure air wi th a bl ow gun
through the cal i per brake hose port. Use onl y enough
ai r pressure to ease the pi ston out.
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston.
Fig. 26 DISC BRAKE CALIPER - FRONT
3 - CALIPER MOUNTING ADAPTER
Fig. 27 8 LUG ROTOR & CALIPER ASSEMBLY
1 - ROTOR
2 - CALIPER ADAPTER
4 - BRAKE HOSE WITH BANJO BOLT
6 - OUTBOARD BRAKE PAD
Fig. 28 DISC BRAKE CALIPER - REAR
1 - CALIPER ADAPTER
2 - CALIPER ADAPTER MOUNTING BOLTS
3 - CALIPER SLIDE BOLTS
4 - BRAKE HOSE
5 - CABLE
6 - CALIPER
7 - ROTOR
Fig. 29 C-Clamp One Piston
1 - BLOCK OF WOOD
2 - C-CLAMP
3 - CALIPER
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS COULD
RESULT IN PERSONAL INJURY.
(5) Remove the C-cl amp and bl ock of wood from
the cal i per and cl amp i t over the dust boot of the
fi rst pi ston removed. Thi s wi l l seal the empty pi ston
bore.
(6) Move the padded pi ece of wood i n front of the
other pi ston.
(7) Remove the second pi ston usi ng the same pro-
cedure wi th short bursts of low pressure air.
(8) Remove pi ston dust boots wi th a sui tabl e pry
tool (Fi g. 31).
(9) Remove pi ston seal s from cal i per (Fi g. 32).
CAUTION: Do not scratch piston bore while remov-
ing the seals.
(10) Push cal i per mounti ng bol t bushi ngs out of
the boot seal s and remove the boot seal s from the
cal i per (Fi g. 33).
(11) Remove cal i per bl eed screw.
INSPECTION
The pi ston i s made from a phenol i c resi n (pl asti c
materi al ) and shoul d be smooth and cl ean.
The pi ston must be repl aced i f cracked or scored.
Do not attempt to restore a scored pi ston surface by
sandi ng or pol i shi ng.
Fig. 30 Protect Caliper Piston
1 - CALIPER
2 - PADDED BLOCK OF WOOD
3 - C-CLAMP
Fig. 31 Piston Dust Boot Removal
1 - CALIPER
2 - DUST BOOT
Fig. 32 Piston Seal
1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL
Fig. 33 Bushings And Boot Seals
1 - CALIPER
2 - BUSHING
3 - BOOT SEAL
CAUTION: If the caliper piston is replaced, install
the same type of piston in the caliper. Never inter-
change phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
piston tolerances are different.
The bore can be lightly pol i shed wi th a brake
hone to remove very mi nor surface i mperfecti ons
(Fi g. 34). The cal i per shoul d be repl aced i f the bore i s
severel y corroded, rusted, scored, or i f pol i shi ng
woul d i ncrease bore di ameter more than 0.025 mm
(0.001 i nch).
ASSEMBLY
CAUTION: Dirt, oil, and solvents can damage cali-
per seals. Insure assembly area is clean and dry.
(1) Lubri cate cal i per pi stons, pi ston seal s and pi s-
ton bores wi th cl ean, fresh brake fl ui d.
(2) I nstal l new pi ston seal s i nto cal i per bores (Fi g.
35).
NOTE: Verify seal is fully seated and not twisted.
(3) Li ghtl y l ubri cate l i p of new boot wi th si l i cone
grease. I nstal l boot on pi ston and work boot l i p i nto
the groove at the top of pi ston.
(4) Stretch boot rearward to strai ghten boot fol ds,
then move boot forward unti l fol ds snap i nto pl ace.
(5) I nstal l pi ston i nto cal i per bore and press pi ston
down to the bottom of the cal i per bore by hand or
wi th hammer handl e (Fi g. 36).
(6) Seat dust boot i n cal i per (Fi g. 37) wi th Handl e
C-4171 and I nstal l er:
HD 56 mm cal i per: I nstal l er C-4340
LD 54 mm cal i per: I nstal l er C-3716-A
(7) I nstal l the second pi ston and dust boot.
(8) Lubri cate cal i per mounti ng bol t bushi ngs, boot
seal s and bores wi th Mopar brake grease or Dow
Corni ng 807 grease onl y.
CAUTION: Use of alternative grease may cause
damage to the boots seals.
(9) I nstal l the boot seal s i nto the cal i per seal bores
and center the seal s i n the bores.
(10) I nstal l mounti ng bol t bushi ngs i nto the boot
seal s and i nsure seal l i p i s engaged i nto the bushi ng
grooves at ei ther end of the bushi ng.
(11) I nstal l cal i per bl eed screw.
Fig. 34 Polishing Piston Bore
1 - HONE
2 - CALIPER
3 - PISTON BORE
Fig. 35 Piston Seal
1 - CALIPER
2 - PISTON BORE
3 - PISTON SEAL
Fig. 36 Caliper Piston Installation
1 - CALIPER
2 - DUST BOOT
3 - PISTON
INSTALLATION
NOTE: Install a new copper washers on the banjo
bolt when installing
(1) I nstal l the di sc brake cal i per (Fi g. 26) or (Fi g.
27).
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(2) I nstal l the banjo bol t wi th new copper washers
to the cal i per. Ti ghten to 27 Nm (20 ft. l bs.)
(3) I nstal l the cal i per sl i de pi n bol ts. ti ghten to 32
Nm (24 ft. l bs.)
(5) Bl eed the base brake system, (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL - STAN-
DARD PROCEDURE).
(6) I nstal l the ti re and wheel assembl y, (Refer to
CEDURE).
INSTALLATION - REAR
(1) I nstal l cal i per to the cal i per adapter.
(2) Coat the cal i per mounti ng sl i de pi n bol ts wi th
si l i cone grease. Then i nstal l and ti ghten the bol ts to
15 Nm (11 ft. l bs.).
(3) I nstal l the brake hose banjo bol t i f removed.
(4) I nstal l the brake hose to the cal i per wi th new
seal washers and ti ghten fi tti ng bol t to 27 Nm (245
i n. l bs.).
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(5) Remove the prop rod from the vehi cl e.
(6) Bl eed the base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
5 - BRAKES - STANDARD PROCEDURE).
(7) I nstal l the wheel and ti re assembl i es (Refer to
CEDURE).
(9) Veri fy a fi rm pedal before movi ng the vehi cl e.
DISC BRAKE CALIPER
ADAPTER
REMOVAL
REMOVAL - FRONT
(3) Remove the di sc brake cal i per (Refer to 5 -
(4) Remove the bol ts securi ng the cal i per adapter
to the steeri ng knuckl e (Fi g. 38)
(5) Remove the cal i per adapter.
REMOVAL - REAR
(3) Drai n a smal l amount of fl ui d from master cyl -
i nder brake reservoi r wi th a clean sucti on gun.
Fig. 37 Seating Dust Boot
1 - HANDLE
2 - CALIPER
3 - DUST BOOT INSTALLER
Fig. 38 CALIPER ADAPTER
1 - CALIPER ASSEMBLY
2 - MOUNTING BOLT
(4) Bottom the cal i per pi stons i nto the cal i per by
pryi ng the cal i per over.
(5) Remove the cal i per sl i de bol ts.
(6) Remove the di sc brake cal i per from the mount.
(7) Remove the i nboard and outboard brake pads
(Fi g. 39).
(8) Remove the anti -rattl e cl i ps (Fi g. 39).
(9) Remove the cal i per adapter mounti ng bol ts
(Fi g. 39).
(10) Remove the cal i per adapter.
INSTALLATION
(1) I nstal l the cal i per adapter to the steeri ng
(2) I nstal l the cal i per adapter mounti ng bol ts and
ti ghten to 176 Nm (130 ft.l bs.) (Fi g. 38).
(3) I nstal l the di sc brake cal i per (Refer to 5 -
DURE).
INSTALLATION - REAR
(1) I nstal l the cal i per adapter mounti ng bol ts.
Ti ghten the mounti ng bol ts to 135 Nm (100 ft.l bs)
(Fi g. 39).
(2) I nstal l the anti -rattl e cl i ps (Fi g. 39).
(3) I nstal l the i nboard and outboard pads (Fi g. 39).
(4) I nstal l the cal i per mounti ng bol ts.
(5) I nstal l the ti re and wheel assembl y
DISC BRAKE CALIPER
ADAPTER MOUNT
REMOVAL - REAR
(3) Remove the cal i per adapter (Refer to 5 -
BRAKE CALI PER ADAPTER - REMOVAL).
(4) Remove the rotor (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/ROTORS - REMOVAL).
(5) Remove the axl e shaft (Refer to 3 - DI FFER-
ENTI AL & DRI VELI NE/REAR AXLE - 9 1/4/AXLE
SHAFTS - REMOVAL).
(6) Remove the park brake shoes (Refer to 5 -
BRAKES/PARKI NG BRAKE/SHOES - REMOVAL).
(7) Remove the parki ng brake cabl e from the
brake l ever.
(8) Remove the bol ts attachi ng the support pl ate to
the axl e and remove the support pl ate (Fi g. 65).
(9) Remove the cal i per adapter mount from the
axl e housi ng (Fi g. 40).
INSTALLATION
(1) I nstal l the cal i per adapter mount on the axl e
housi ng (Fi g. 40).
(2) I nstal l support pl ate on axl e fl ange (Fi g. 66).
Ti ghten attachi ng bol ts to 115 Nm (85 ft. l bs.).
Fig. 39 CALIPER MOUNT
1 - DISC BRAKE PADS
3 - CALIPER ADAPTER
4 - MOUNTING BOLTS
Fig. 40 CALIPER ADAPTER MOUNT - REAR
1 - CALIPER ADAPTER MOUNT
2 - AXLE TUBE
3 - MOUNTING STUDS
DISC BRAKE CALIPER ADAPTER (Continued)
(3) I nstal l parki ng brake cabl e i n the brake l ever.
(4) I nstal l the park brake shoes (Refer to 5 -
BRAKES/PARKI NG BRAKE/SHOES - I NSTALLA-
TI ON). (Fi g. 66).
(5) I nstal l axl e shaft, (Refer to 3 - DI FFEREN-
TI AL & DRI VELI NE/REAR AXLE - 9 1/4/AXLE
SHAFTS - I NSTALLATI ON).
(6) Adjust brake shoes to drum wi th brake gauge
(Refer to 5 - BRAKES/PARKI NG BRAKE/SHOES -
ADJUSTMENTS).
(7) I nstal l the rotor (Refer to 5 - BRAKES/HY-
DRAULI C/MECHANI CAL/ROTORS - I NSTALLA-
TI ON).
(8) I nstal l the cal i per adapter (Refer to 5 -
BRAKE CALI PER ADAPTER - I NSTALLATI ON).
(9) I nstal l the cal i per (Refer to 5 - BRAKES/HY-
- I NSTALLATI ON).
(10) I nstal l wheel and ti re assembl y.
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or
deteri orated rubber parts.
Swol l en rubber parts i ndi cate the presence of
petrol eum i n the brake fl ui d.
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f fl ui d sepa-
rates i nto l ayers, there i s mi neral oi l or other fl ui d
contami nati on of the brake fl ui d.
I f brake fl ui d i s contami nated, drai n and thor-
oughl y fl ush system. Repl ace master cyl i nder, propor-
ti oni ng val ve, cal i per seal s, wheel cyl i nder seal s,
Anti l ock Brakes hydraul i c uni t and al l hydraul i c
fl ui d hoses.
STANDARD PROCEDURE - BRAKE FLUID
LEVEL
Al ways cl ean the master cyl i nder reservoi r and
caps before checki ng fl ui d l evel . I f not cl eaned, di rt
coul d enter the fl ui d.
The fl ui d fi l l l evel i s i ndi cated on the si de of the
master cyl i nder reservoi r (Fi g. 41).
The correct fl ui d l evel i s to the MAX i ndi cator on
the si de of the reservoi r. I f necessary, add fl ui d to the
proper l evel .
SPECIFICATIONS
BRAKE FLUID
The brake fl ui d used i n thi s vehi cl e must conform
to DOT 3 speci fi cati ons and SAE J1703 standards.
No other type of brake fl ui d i s recommended or
approved for usage i n the vehi cl e brake system. Use
onl y Mopar brake fl ui d or an equi val ent from a
ti ghtl y seal ed contai ner.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container of brake fluid will absorb moisture
from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum-based
fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle
brake hydraulic system causing a failure of the
vehicle brake system. Petroleum based fluids would
be items such as engine oil, transmission fluid,
power steering fluid, etc.
FLUID RESERVOIR
REMOVAL
(1) I nstal l the prop rod on the brake pedal to keep
(2) Remove the reservoi r cap and si phon fl ui d i nto
a drai n contai ner (Fi g. 42).
(3) Remove the el ectri cal connector from the fl ui d
l evel swi tch i n the reservoi r (Fi g. 42).
(4) Remove the reservoi r mounti ng bol t (Fi g. 42).
Fig. 41 FLUID LEVEL TYPICAL
1 - FLUID RESERVOIR
2 - MAX LEVEL MARK
DISC BRAKE CALIPER ADAPTER MOUNT (Continued)
(5) Remove the reservoi r from the master cyl i nder
by pul l i ng upwards.
(6) Remove ol d grommets from cyl i nder body (Fi g.
42).
INSTALLATION
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubri cate the new grommets wi th cl ean brake
fl ui d and I nstal l new grommets i n cyl i nder body. Use
fi nger pressure to i nstal l and seat grommets.
(2) Start the reservoi r i n grommets. Then rock the
reservoi r back and forth whi l e pressi ng downward to
seat i t i nto the grommets.
(3) I nstal l the mounti ng bol t for the reservoi r to
the master cyl i nder.
(4) Reconnect the el ectri cal connector to the fl ui d
reservoi r l evel swi tch.
(5) Remove the prop rod from the vehi cl e.
(6) Fi l l and bl eed base brake system,(Refer to 5 -
BRAKES - STANDARD PROCEDURE).
BRAKE J UNCTION BLOCK
REMOVAL
(1) Remove the brake l i nes from the juncti on bl ock
(Fi g. 43).
(2) Remove the juncti on bl ock mounti ng bol t and
remove the juncti on bl ock from the bracket (Fi g. 43).
INSTALLATION
(1) Posi ti on the juncti on bl ock on the bracket and
i nstal l the mounti ng bol t. Ti ghten the mounti ng bol t
to 23 Nm (210 i n. l bs.) (Fi g. 43).
(2) I nstal l the brake l i nes i nto the juncti on bl ock
and ti ghten to 19-23 Nm (170-200 i n. l bs.) (Fi g. 43).
(3) Bl eed the base brake system, (Refer to 5 -
DARD PROCEDURE).
MASTER CYLINDER
DESCRIPTION
A two-pi ece master cyl i nder i s used on al l model s.
The cyl i nder body contai ni ng the pri mary and sec-
ondary pi stons i s made of al umi num. The removabl e
fl ui d reservoi r i s made of nyl on rei nforced wi th gl ass
fi ber. The reservoi r stores reserve brake fl ui d for the
hydraul i c brake ci rcui ts and has a swi tch for i ndi cat-
i ng l ow fl ui d l evel s. The reservoi r i s the onl y servi ce-
abl e component.
The fl ui d compartments of the nyl on reservoi r are
i nterconnected to permi t fl ui d l evel equal i zati on.
However, the equal i zati on feature does not affect ci r-
cui t separati on i n the event of a front or rear brake
mal functi on. The reservoi r compartments wi l l retai n
enough fl ui d to operate the functi oni ng hydraul i c ci r-
cui t.
Care must be exerci sed when removi ng/i nstal l i ng
the master cyl i nder connecti ng l i nes. The threads i n
the cyl i nder fl ui d ports can be damaged i f care i s not
exerci sed. Start al l brake l i ne fi tti ngs by hand to
avoi d cross threadi ng.
Fig. 42 FLUID RESERVOIR
1 - MASTER CYLINDER CAP
2 - FLUID RESERVOIR
3 - FLUID LEVEL SWITCH
4 - MASTER CYLINDER
5 - MOUNTING BOLT
6 - GROMMETS
Fig. 43 JUNCTION BLOCK
1 - BRAKE LINES
2 - JUNCTION BLOCK
FLUID RESERVOIR (Continued)
The cyl i nder reservoi r can be repl aced when neces-
sary. However, the al umi num body secti on of the
master cyl i nder i s not a repai rabl e component.
NOTE: If diagnosis indicates that an internal mal-
function has occurred, the aluminum body section
must be replaced as an assembly.
OPERATION
The master cyl i nder bore contai ns a pri mary and
secondary pi ston. The pri mary pi ston suppl i es
hydraul i c pressure to the front brakes. The secondary
pi ston suppl i es hydraul i c pressure to the rear brakes.
DIAGNOSIS AND TESTING - MASTER
CYLINDER/POWER BOOSTER
(1) Start engi ne and check booster vacuum hose
connecti ons. A hi ssi ng noi se i ndi cates vacuum l eak.
Correct any vacuum l eak before proceedi ng.
(2) Stop engi ne and shi ft transmi ssi on i nto Neu-
tral .
(3) Pump brake pedal unti l al l vacuum reserve i n
booster i s depl eted.
(4) Press and hol d brake pedal under l i ght foot
pressure. The pedal shoul d hol d fi rm, i f the pedal
fal l s away master cyl i nder i s faul ty (i nternal l eak-
age).
(5) Start engi ne and note pedal acti on. I t shoul d
fal l away sl i ghtl y under l i ght foot pressure then hol d
fi rm. I f no pedal acti on i s di scerni bl e, power booster,
vacuum suppl y, or vacuum check val ve i s faul ty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) I f the POWER BOOSTER VACUUM TEST
passes, rebui l d booster vacuum reserve as fol l ows:
Rel ease brake pedal . I ncrease engi ne speed to 1500
rpm, cl ose the throttl e and i mmedi atel y turn off i gni -
ti on to stop engi ne.
(7) Wai t a mi ni mum of 90 seconds and try brake
acti on agai n. Booster shoul d provi de two or more vac-
uum assi sted pedal appl i cati ons. I f vacuum assi st i s
not provi ded, booster i s faul ty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check val ve
wi th short l ength of hose and T-fi tti ng (Fi g. 44).
(2) Start and run engi ne at curb i dl e speed for one
mi nute.
(3) Observe the vacuum suppl y. I f vacuum suppl y
i s not adequate, repai r vacuum suppl y.
(4) Cl amp hose shut between vacuum source and
check val ve.
(5) Stop engi ne and observe vacuum gauge.
(6) I f vacuum drops more than one i nch HG (33
mi l l i bars) wi thi n 15 seconds, booster di aphragm or
check val ve i s faul ty.
POWER BOOSTER CHECK VALVE TEST
(1) Di sconnect vacuum hose from check val ve.
(2) Remove check val ve and val ve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Appl y 15-20 i nches vacuum at l arge end of
check val ve (Fi g. 45).
(5) Vacuum shoul d hol d steady. I f gauge on pump
i ndi cates vacuum l oss, check val ve i s faul ty and
shoul d be repl aced.
Fig. 44 Typical Booster Vacuum Test Connections
1 - TEE FITTING
2 - SHORT CONNECTING HOSE
3 - CHECK VALVE
4 - CHECK VALVE HOSE
5 - CLAMP TOOL
6 - INTAKE MANIFOLD
7 - VACUUM GAUGE
Fig. 45 Vacuum Check Valve And Seal
1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL
MASTER CYLINDER (Continued)
STANDARD PROCEDURE - MASTER CYLINDER
BLEEDING
A new master cyl i nder shoul d be bl ed before i nstal -
l ati on on the vehi cl e. Requi red bl eedi ng tool s i ncl ude
bl eed tubes and a wood dowel to stroke the pi stons.
Bl eed tubes can be fabri cated from brake l i ne.
(1) Mount master cyl i nder i n vi se.
(2) Attach bl eed tubes to cyl i nder outl et ports.
Then posi ti on each tube end i nto reservoi r (Fi g. 46).
(3) Fi l l reservoi r wi th fresh brake fl ui d.
(4) Press cyl i nder pi stons i nward wi th wood dowel .
Then rel ease pi stons and al l ow them to return under
spri ng pressure. Conti nue bl eedi ng operati ons unti l
ai r bubbl es are no l onger vi si bl e i n fl ui d.
REMOVAL
REMOVAL - ALL EXCEPT HYDROBOOST
(1) Depress the brake pedal fi ve ti mes to depl ete
any vacuum that may remai n i n the booster uni t.
(2) Si phon and drai n the fl ui d from the reservoi r.
(3) Di sconnect the el ectri cal connector for the l ow
fl ui d l evel .
(4) Pl ace a towel or rag under the master cyl i nder
outl et port area to protect the vehi cl e from brake
fl ui d damage.
(5) Remove the brake l i nes from the master cyl i n-
der (Fi g. 47).
(6) Remove the mounti ng nuts from the master
cyl i nder (Fi g. 47).
(7) Remove the master cyl i nder.
NOTE: Gently ease the master cylinder & reservoir
assembly away from the booster, During removal
the master cylinder should be kept as perpendicular
to the front of the booster as possible to avoid
excess interference with the booster output rod
(Fig. 49) and in order not to dislodge the output rod
from its seat inside the booster.
REMOVAL - HYDROBOOST
(1) Remove the brake l i nes from the master cyl i n-
der (Fi g. 48).
(2) Di sconnect the el ectri cal connector for the l ow
fl ui d l evel .
(3) Remove the mounti ng nuts from the master
cyl i nder (Fi g. 48).
NOTE: Using care remove the master cylinder
directly forward in order not to dislodge the output
rod from its seat inside the booster.
Fig. 46 Master Cylinder BleedingTypical
1 - BLEEDING TUBES
2 - RESERVOIR
Fig. 47 MASTER CYLINDER
1 - MASTER CYLINDER RESERVOIR
2 - POWER BRAKE BOOSTER
3 - BRAKE LINES
4 - MASTER CYLINDER
INSTALLATION
INSTALLATION - ALL EXCEPT HYDROBOOST
NOTE: If master cylinder is replaced bleed cylinder
before installation.
NOTE: Make sure the output rod of the brake
booster is in position and retained by a output rod
retaining ring, by looking into the boosters master
cylinder mounting hole. This position will enable
the output rod to enter inside of the master cylinder
plunger sleeve during installation. Proper position
is obtained when the output rod is centered perpen-
dicular to the master cylinder mounting hole (Fig.
49).
NOTE: Prior to installing the master cylinder assem-
bly check that there is a vacuum seal present at the
shoulder of the master cylinder flange and its neck.
A square seal must be present to ensure vacuum
integrity with the booster.
(1) Gentl y i nstal l the master cyl i nder on the
booster mounti ng studs.
NOTE: Take precautions to locate the master cylin-
der plunger over the booster output rod, before
installing the master cylinder. If correctly fitted the
master cylinder should slide easily onto the booster
output rod before the mounting studs are engaged
in the flange holes of the master cylinder.
(2) I nstal l new mounti ng nuts and ti ghten to 25
Nm (221 i n. l bs.)
(3) I nstal l the brake l i nes and ti ghten to 19 Nm
(170 i n. l bs.)
(4) Reconnect the el ectri cal connector for the l ow
fl ui d l evel swi tch.
(5) Fi l l and bl eed the base brake system. (Refer to
INSTALLATION - HYDROBOOST
NOTE: If master cylinder is replaced bleed cylinder
before installation.
(1) I nstal l the master cyl i nder on the booster
mounti ng studs (Fi g. 48).
(2) I nstal l new mounti ng nuts and ti ghten to 25
Nm (221 i n. l bs.)
(3) I nstal l the brake l i nes and ti ghten to 19 Nm
(170 i n. l bs.)
(4) Reconnect the el ctri cal connector for the l ow
fl ui d l evel swi tch.
(5) Fi l l and bl eed the base brake system. (Refer to
Fig. 48 HYDROBOOST MASTER CYLINDER
1 - HYDROBOOST UNIT
3 - MASTER CYLINDER
4 - MOUNTING NUTS
Fig. 49 OUTPUT ROD ORIENTATION
2 - CHECK VALVE
3 - VACUUM BOOST UNIT
4 - BOOSTER MOUNTING STUDS
5 - INPUT ROD
6 - OUTPUT ROD
7 - MASTER CYLINDER MOUNTING STUDS
8 - MASTER CYLINDER PLUNGER SLEEVE
9- MASTER CYLINDER
PEDAL
DESCRIPTION
NOTE: The brake pedal is serviced as a complete
assembly including accelerator pedal and the
bracket.
A suspended-type brake pedal i s used. The pedal i s
attached to the pedal support bracket wi th a pi vot
shaft pi n and bushi ngs. I f the bushi ngs become dry a
spray l ubri cant can be used to el i mi nate noi ses. The
booster push rod i s attached to the pedal wi th a cl i p.
The pedal , bushi ngs, pi vot pi n and support bracket
are not servi ceabl e components (Fi g. 50).
OPERATION
The brake pedal i s attached to the booster push
rod. When the pedal i s depressed, the pri mary
booster push rod i s depressed whi ch moves the
booster secondary rod. The booster secondary rod
depress the master cyl i nder pi ston.
REMOVAL
NOTE: The brake pedal is serviced as a complete
assembly including accelerator pedal and the
bracket.
(2) Remove the steeri ng col umn openi ng cover(Re-
fer to 23 - BODY/I NSTRUMENT PANEL/STEERI NG
COLUMN OPENI NG COVER - REMOVAL).
(3) Remove the brake l amp swi tch and di scard(Re-
fer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG - EXTE-
RI OR/BRAKE LAMP SWI TCH - REMOVAL).
(4) On vehicles equipped with adjustable ped-
als. Di sconnect the adjuster cabl e to the pedal (Fi g.
51).
(5) Remove the steeri ng col umn (Refer to 19 -
STEERI NG/COLUMN - REMOVAL).
(6) Remove the brake booster (Fi g. 52)(Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/POWER
BRAKE BOOSTER - REMOVAL).
(7) Di sconnect the el ectri cal connectors.
(8) Remove the modul e mounti ng bol ts.
(9) Di sconnect the accel erator pedal cabl e.
(10) Remove the pedal assembl y mounti ng nuts/
fasteners (Fi g. 52).
INSTALLATION
(1) I nstal l the pedal assembl y to the vehi cl e (Fi g.
52).
(2) I nstal l the mounti ng bol ts (Fi g. 52) and ti ghten
to 28 Nm (21 ft. l bs.).
(3) Reconnect the accel erator cabl e to the pedal .
(4) I nstal l the modul e mounti ng bol ts and ti ghten
to 38 Nm (28 ft. l bs.).
(5) Reconnect the el ectri cal connectors.
(6) I nstal l the brake booster (Refer to 5 - BRAKES/
HYDRAULI C/MECHANI CAL/POWER BRAKE
BOOSTER - I NSTALLATI ON).
(7) I nstal l the steeri ng col umn (Refer to 19 -
STEERI NG/COLUMN - I NSTALLATI ON).
(8) I nstal l a new brake l amp swi tch. (Refer to 8 -
Fig. 50 BRAKE PEDAL
1 - CLIP
2 - BUSHINGS
3 - PIVOT SHAFT PIN
4 - PEDAL ASSEMBLY
ADJUSTABLE PEDAL SHOWN
NON ADJUSTABLE PEDAL IS SIMILIAR
5 - PAD
Fig. 51 PEDAL/CABLE
1 - CABLE
2 - BRAKE PEDAL ASSEMBLY
(9) On vehicles equipped with adjustable
brake pedal. Reconnect the el ectri cal connector to
the motor and the adjuster cabl e at the pedal .
(10) I nstal l the steeri ng col umn openi ng cover
(Refer to 23 - BODY/I NSTRUMENT PANEL/STEER-
I NG COLUMN OPENI NG COVER - I NSTALLA-
TI ON).
POWER BRAKE BOOSTER
DESCRIPTION
Al l model s use a tandem di aphragm, power brake
booster.
NOTE: The power brake booster is not a repairable
component. The booster must be replaced as an
assembly if diagnosis indicates a malfunction has
occurred.
OPERATION
The booster uni t consi sts of a si ngl e housi ng
di vi ded i nto two by a tandem di aphragm. The outer
edge of the di aphragm i s secured to the housi ng. The
booster push rod, whi ch connects the booster to the
brake pedal and master cyl i nder, i s attached to the
center of the di aphragm. A check val ve i s used i n the
booster outl et connected to the engi ne i ntake mani -
fol d. Power assi st i s generated by uti l i zi ng a combi -
nati on of vacuum and atmospheri c pressure to boost
brake assi st.
REMOVAL
(1) Remove master cyl i nder. (Refer to 5 - BRAKES/
HYDRAULI C/MECHANI CAL/MASTER CYLI NDER -
REMOVAL).
(2) Di sconnect vacuum l i ne at booster.
(3) Remove cl i p securi ng booster push rod to brake
pedal (Refer to 5 - BRAKES/HYDRAULI C/MECHAN-
I CAL/PEDAL - REMOVAL). (Fi g. 53).
(4) Remove the nuts from the booster mounti ng
studs (Fi g. 53).
(5) Remove the booster and gasket from front cowl
panel .
INSTALLATION
(1) Gui de the booster studs i nto the cowl panel
hol es and seat the booster on the panel (Fi g. 53).
(2) I nstal l and ti ghten new booster attachi ng nuts
to 28 Nm (250 i n. l bs.).
(3) I nstal l the booster push rod on brake pedal and
i nstal l cl i p (Fi g. 53).
(4) I nstal l the booster check val ve i f removed and
connect the vacuum hose to the check val ve.
(5) I nstal l the master cyl i nder. (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/MASTER
CYLI NDER - I NSTALLATI ON).
(6) Fi l l and bl eed the brake system. (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
Fig. 52 PEDAL ASSEMBLY (ADJUSTABLE PEDALS
SHOWN)
2 - PEDAL ASSEMBLY BRACKET
3 - MOUNTING NUT
4 - BRAKE & ACCELERATOR PEDAL
5 - BRAKE BOOSTER MOUNTING STUDS
Fig. 53 POWER BRAKE BOOSTER
1 - MOUNTING NUT
2 - POWER BRAKE BOOSTER
PEDAL (Continued)
HYDRO-BOOST BRAKE
BOOSTER
BOOSTER
The hydraul i c booster uses hydraul i c pressure from
the power steeri ng pump. Before di agnosi ng a
booster probl em, fi rst veri fy the power steeri ng pump
i s operati ng properl y. Perform the fol l owi ng checks.
Check the power steeri ng fl ui d l evel .
Check the brake fl ui d l evel .
Check al l power steeri ng hoses and l i nes for
l eaks and restri cti ons.
Check power steeri ng pump pressure.
NOISES
The hydraul i c booster uni t wi l l produce certai n
characteri sti c booster noi ses. The noi ses may occur
when the brake pedal i s used i n a manner not asso-
ci ated wi th normal braki ng or dri vi ng habi ts.
HISSING
A hi ssi ng noi se may be noti ced when above normal
brake pedal pressure i s appl i ed, 40 l bs. or above. The
noi se wi l l be more noti ceabl e i f the vehi cl e i s not
movi ng. The noi se wi l l i ncrease wi th the brake pedal
pressure and an i ncrease of system operati ng temper-
ature.
CLUNK-CHATTER-CLICKING
A cl unk-chatter-cl i cki ng may be noti ced when the
brake pedal i s rel eased qui ckl y, after above normal
brake pedal pressure i s appl i ed 50-100 l bs..
BOOSTER FUNCTION TEST
Wi th the engi ne off depress the brake pedal several
ti mes to di scharge the accumul ator. Then depress the
brake pedal usi ng 40 l bs. of force and start the
engi ne. The brake pedal shoul d fal l and then push
back agai nst your foot. Thi s i ndi cates the booster i s
operati ng properl y.
ACCUMULATOR LEAKDOWN
(1) Start the engi ne, appl y the brakes and turn the
steeri ng wheel from l ock to l ock. Thi s wi l l ensure the
accumul ator i s charged. Turn off the engi ne and l et
the vehi cl e si t for one hour. After one hour there
shoul d be at l east two power assi sted brake appl i ca-
ti on wi th the engi ne off. I f the system does not retai n
a charge the booster must be repl aced.
(2) Wi th the engi ne off depress the brake pedal
several ti mes to di scharge the accumul ator. Grasp
the accumul ator and see i f i t wobbl es or turns. I f i t
does the accumul ator has l ost a gas charge and the
booster must be repl aced.
SEAL LEAKAGE
I f the booster l eaks from any of the seal s the
booster assembl y must be repl aced (Fi g. 54).
INPUT ROD SEAL: Fl ui d l eakage from rear
end of the booster.
PISTON SEAL: Fl ui d l eakage from vent at
front of booster.
HOUSING SEAL: Fl ui d l eakage between hous-
i ng and housi ng cover.
SPOOL VALVE SEAL: Fl ui d l eakage near
spool pl ug.
RETURN PORT FITTING SEAL: Fl ui d l eak-
age from port fi tti ng.
Fig. 54 Hydraulic Booster Seals
1 - PUMP
2 - GEAR
3 - INPUT SEAL
4 - HOUSING SEAL
5 - ACCUMULATOR SEAL
6 - PISTON SEAL
7 - SPOOL PLUG SEAL
8 - RETURN
HYDRAULIC BOOSTER DIAGNOSIS CHART
Slow Brake Pedal Return 1. Excessive seal friction in booster. 1. Replace booster.
2. Faulty spool valve action. 2. Replace booster.
3. Restriction in booster return hose. 3. Replace hose.
4. Damaged input rod. 4. Replace booster.
Excessive Brake Pedal
Effort.
1. Internal or external seal leakage. 1. Replace booster.
2. Faulty steering pump. 2. Replace pump.
Brakes Self Apply 1. Dump valve faulty. 1. Replace booster.
2. Contamination in hydraulic
system.
2. Flush hydraulic system and replace
booster.
3. Restriction in booster return hose. 3. Replace hose.
Booster Chatter, Pedal
Vibration
1. Slipping pump belt. 1. Replace power steering belt.
2. Low pump fluid level. 2. Fill pump and check for leaks.
Grabbing Brakes 1. Low pump flow. 1. Test and repair/replace pump.
2. Faulty spool valve action. 2. Replace booster.
STANDARD PROCEDURE - BLEEDING
The hydraul i c booster i s general l y sel f-bl eedi ng,
thi s procedure wi l l normal l y bl eed the ai r from the
booster. Normal dri vi ng and operati on of the uni t wi l l
remove any remai ni ng trapped ai r.
(1) Fi l l power steeri ng pump reservoi r.
(2) Di sconnect fuel shutdown rel ay and crank the
engi ne for several seconds, Refer to Fuel System for
rel ay l ocati on and WARNI NG.
(3) Check fl ui d l evel and add i f necessary.
(4) Connect fuel shutdown rel ay and start the
engi ne.
(5) Turn the steeri ng wheel sl owl y from l ock to
l ock twi ce.
(6) Stop the engi ne and di scharge the accumul ator
by depressi ng the brake pedal 5 ti mes.
(7) Start the engi ne and turn the steeri ng wheel
sl owl y from l ock to l ock twi ce.
(8) Turn off the engi ne and check fl ui d l evel and
add i f necessary.
NOTE: If fluid foaming occurs, wait for foam to dis-
sipate and repeat steps 7 and 8.
REMOVAL
NOTE: If the booster is being replaced because the
power steering fluid is contaminated, flush the
power steering system before replacing the booster.
(1) Wi th engi ne off depress the brake pedal 5
ti mes to di scharge the accumul ator.
(2) Remove brake l i nes from master cyl i nder.
(3) Remove mounti ng nuts from the master cyl i n-
der.
(4) Remove the bracket from the hydraul i c booster
l i nes and master cyl i nder mounti ng studs.
(6) Remove the return hose and the two pressure
l i nes from the hydraul i c booster (Fi g. 55).
(7) Remove the booster push rod cl i p, washer and
rod remove from the brake pedal .
(8) Remove the mounti ng nuts from the hydraul i c
booster and remove the booster.
HYDRO-BOOST BRAKE BOOSTER (Continued)
INSTALLATION
(1) I nstal l the hydraul i c booster and ti ghten the
mounti ng nuts to 28 Nm (21 ft. l bs.).
(2) I nstal l the booster push rod, washer and cl i p
onto the brake pedal .
(3) I nstal l the master cyl i nder on the mounti ng
studs. and ti ghten the mounti ng nuts to 23 Nm (17
ft. l bs.).
(4) I nstal l the brake l i nes to the master cyl i nder
and ti ghten to 19-200 Nm (170-200 i n. l bs.).
(5) I nstal l the hydraul i c booster l i ne bracket onto
the master cyl i nder mounti ng studs.
(6) I nstal l the master cyl i nder mounti ng nuts and
(7) I nstal l the hydraul i c booster pressure l i nes to
the bracket and booster.
(8) Ti ghten the pressure l i nes to 41 Nm (30 ft.
l bs.).
NOTE: Inspect o-rings on the pressure line fittings
to insure they are in good condition before installa-
tion. Replace o-rings if necessary.
(9) I nstal l the return hose to the booster.
(10) Bl eed base brake system, (Refer to 5 -
DARD PROCEDURE).
(11) Fi l l the power steeri ng pump wi th fl ui d,
(Refer to 19 - STEERI NG/PUMP - STANDARD PRO-
CEDURE).
CAUTION: MOPAR (MS-9602) ATF+4 is to be used in
the power steering system. No other power steering
or automatic transmission fluid is to be used in the
system. Damage may result to the power steering
pump and system if any other fluid is used, and do
not overfill.
(12) Bl eed the hydraul i c booster (Refer to 5 -
BRAKES/HYDRAULI C/MECHANI CAL/POWER
BRAKE BOOSTER - STANDARD PROCEDURE).
ROTORS
DISC BRAKE ROTOR
The rotor braki ng surfaces shoul d not be refi ni shed
unl ess necessary.
Li ght surface rust and scal e can be removed wi th a
l athe equi pped wi th dual sandi ng di scs. The rotor
surfaces can be restored by machi ni ng wi th a di sc
brake l athe i f surface scori ng and wear are l i ght.
Repl ace the rotor for the fol l owi ng condi ti ons:
Severel y Scored
Tapered
Hard Spots
Cracked
Bel ow Mi ni mum Thi ckness
ROTOR MINIMUM THICKNESS
Measure rotor thi ckness at the center of the brake
shoe contact surface. Repl ace the rotor i f bel ow mi n-
i mum thi ckness, or i f machi ni ng woul d reduce thi ck-
ness bel ow the al l owabl e mi ni mum.
Rotor mi ni mum thi ckness i s usual l y speci fi ed on
the rotor hub. The speci fi cati on i s ei ther stamped or
cast i nto the hub surface.
ROTOR RUNOUT
Check rotor l ateral runout wi th di al i ndi cator
C-3339 (Fi g. 56). Excessi ve l ateral runout wi l l cause
brake pedal pul sati on and rapi d, uneven wear of the
brake shoes. Posi ti on the di al i ndi cator pl unger
approxi matel y 25.4 mm (1 i n.) i nward from the rotor
edge.
NOTE: Be sure wheel bearing has zero end play
before checking rotor runout.
Maxi mum al l owabl e rotor runout i s 0.127 mm
(0.005 i n.).
ROTOR THICKNESS VARIATION
Vari ati ons i n rotor thi ckness wi l l cause pedal pul -
sati on, noi se and shudder.
Measure rotor thi ckness at 6 to 12 poi nts around
the rotor face (Fi g. 57).
Fig. 55 HYDRO-BOOST UNIT
1 - INLET HOSE
2 - HYDRO-BOOST UNIT
3 - MASTER CYLINDER UNIT
4 - RETURN HOSE
5 - OUTLET HOSE
HYDRO-BOOST BRAKE BOOSTER (Continued)
Posi ti on the mi crometer approxi matel y 25.4 mm (1
i n.) from the rotor outer ci rcumference for each mea-
surement.
Thi ckness shoul d not vary by more than 0.015 mm
(0.0059 i n.) from poi nt-to-poi nt on the rotor. Machi ne
or repl ace the rotor i f necessary.
REMOVAL
REMOVAL - FRONT
(3) Remove the cal i per from the steeri ng knuckl e,
(Refer to 5 - BRAKES/HYDRAULI C/MECHANI CAL/
DI SC BRAKE CALI PERS - REMOVAL) and remove
cal i per adapter assembl y (Fi g. 58).
adapter assembly.
(4) Remove the rotor from the hub/beari ng wheel
studs (Fi g. 59) or (Fi g. 60).
Fig. 56 Checking Rotor Runout And Thickness
Variation
1 - DIAL INDICATOR
Fig. 57 Measuring Rotor Thickness
1 - MICROMETER
2 - ROTOR
Fig. 58 Caliper Adapter Assembly
1 - KNUCKLE
2 - CALIPER
3 - ROTOR
Fig. 59 FRONT ROTOR
1 - ROTOR
2 - HUB/BEARING
ROTORS (Continued)
REMOVAL - REAR
(1) Rai se and support the vehi cl e
(3) Remove the di sc brake cal i per, (Refer to 5 -
(4) Remove the cal i per adapter bol ts (Fi g.
61).(Refer to 5 - BRAKES/HYDRAULI C/MECHANI -
CAL/DI SC BRAKE CALI PER ADAPTER -
REMOVAL)
(5) Remove the retai ni ng cl i ps and rotor assembl y
(Fi g. 61).
REMOVAL - REAR DUAL WHEELS
(3) Remove the di sc brake cal i per, (Refer to 5 -
(4) Remove the cal i per adapter bol ts.
(5) Remove the rear axl e shaft from the housi ng
on dual rear wheel s, (Refer to 3 - DI FFERENTI AL &
DRI VELI NE/REAR AXLE - 286RBI /AXLE SHAFTS -
REMOVAL).
(6) Remove the hub and rotor assembl y (C3500
onl y) (Fi g. 62).
INSTALLATION
(1) On model s wi th al l -wheel anti l ock system
(ABS), check condi ti on of tone wheel on hub/beari ng.
I f teeth on wheel are damaged, hub/beari ng assembl y
wi l l have to be repl aced (tone wheel i s not servi ced
separatel y).
(2) I nstal l the rotor onto the hub/beari ng wheel
studs.
(3) I nstal l the cal i per adapter assembl y,(Refer to 5
- BRAKES/HYDRAULI C/MECHANI CAL/DI SC
BRAKE CALI PERS - I NSTALLATI ON) and ti ghten
adapter bol ts to:
(4) I nstal l the wheel and ti re assembl y, (Refer to
CEDURE) and l ower the vehi cl e.
(5) Appl y the brakes several ti mes to seat brake
pads. Be sure to obtai n fi rm pedal before movi ng
vehi cl e.
INSTALLATION - REAR
(1) I nstal l the rotor to the axl eshaft (Fi g. 61).
Fig. 60 8 LUG ROTOR ASSEMBLY
1 - SPRING
2 - SHOCK
3 - UPPER AND LOWER SUSPENSION ARMS
5 - DISC BRAKE CALIPER ADAPTER
6 - ROTOR
Fig. 61 REAR ROTOR
1 - ROTOR
2 - CALIPER ADAPTER
3 - CALIPER
Fig. 62 ROTOR / HUB REMOVAL
ROTORS (Continued)
(2) I nstal l the cal i per adapter (Fi g. 61) (Refer to 5
- BRAKES/HYDRAULI C/MECHANI CAL/DI SC
(3) I nstal l the cal i per adapter bol ts (Fi g. 61) and
ti ghten the mounti ng bol ts to 135 Nm (100 ft.l bs).
(4) I nstal l the di sc brake cal i per, (Refer to 5 -
DURE).
INSTALLATION - REAR DUAL WHEELS
(1) I nstal l the hub to the rotor. Ti ghten the bol ts to
128 Nm (95 ft. l bs.) (Fi g. 63).
(2) I nstal l the hub and rotor assembl y.
(3) I nstal l the rear axl e shaft to the housi ng wi th
dual wheel s, (Refer to 3 - DI FFERENTI AL & DRI V-
ELI NE/REAR AXLE - 286RBI /AXLE SHAFTS -
I NSTALLATI ON).
(4) I nstal l the cal i per adapter bol ts.
(5) I nstal l the di sc brake cal i per, (Refer to 5 -
BRAKE CALI PERS - I NSTALLATI ON). (Fi g. 64).
(6) I nstal l the ti re and wheel assembl y, (Refer to
CEDURE).
SUPPORT PLATE
REMOVAL
(3) Remove the cal i per adapter (Refer to 5 -
BRAKE CALI PER ADAPTER - REMOVAL).
(4) Remove the rotor (Refer to 5 - BRAKES/HY-
(5) Remove the axl e shaft (Refer to 3 - DI FFER-
ENTI AL & DRI VELI NE/REAR AXLE - 9 1/4/AXLE
SHAFTS - REMOVAL).
(6) Remove the park brake shoes (Refer to 5 -
BRAKES/PARKI NG BRAKE/SHOES - REMOVAL).
(7) Remove the parki ng brake cabl e from the
brake l ever.
(8) Remove the bol ts attachi ng the support pl ate to
the axl e and remove the support pl ate (Fi g. 65).
Fig. 63 ROTOR TO HUB
1 - Hub Bolts
2 - Socket
Fig. 64 ROTOR INSTALLED
Fig. 65 SUPPORT PLATE
1 - SUPPORT PLATE
2 - MOUNTING STUDS
ROTORS (Continued)
INSTALLATION
(1) I nstal l support pl ate on axl e fl ange (Fi g. 66).
Ti ghten attachi ng bol ts to 115 Nm (85 ft. l bs.).
(2) I nstal l parki ng brake cabl e i n the brake l ever.
(3) I nstal l the park brake shoes (Refer to 5 -
BRAKES/PARKI NG BRAKE/SHOES - I NSTALLA-
TI ON). (Fi g. 66).
(4) I nstal l axl e shaft, (Refer to 3 - DI FFEREN-
TI AL & DRI VELI NE/REAR AXLE - 9 1/4/AXLE
SHAFTS - I NSTALLATI ON).
(5) Adjust brake shoes to drum wi th brake gauge
(Refer to 5 - BRAKES/PARKI NG BRAKE/SHOES -
ADJUSTMENTS).
(6) I nstal l the rotor (Refer to 5 - BRAKES/HY-
TI ON).
(7) I nstal l the cal i per adapter (Refer to 5 -
(8) I nstal l the cal i per (Refer to 5 - BRAKES/HY-
- I NSTALLATI ON).
DURE).
PARKING BRAKE
DESCRIPTION
The parki ng brakes are operated by a system of
cabl es and l evers attached to a pri mary and second-
ary shoe posi ti oned wi thi n the drum secti on of the
rotor.
The drum-i n-hat desi gn uti l i zes an i ndependent set
of shoes to park the vehi cl e (Fi g. 67).
OPERATION
To appl y the parki ng brake the pedal i s depressed.
Thi s creates tensi on i n the cabl e whi ch pul l s forward
on the park brake l ever. The l ever pushes the park
brake shoes outward and i nto contact wi th the drum
secti on of the rotor. The contact of shoe to rotor parks
the vehi cl e.
A torsi on l ocki ng mechani sm i s used to hol d the
pedal i n an appl i ed posi ti on. Parki ng brake rel ease i s
accompl i shed by the hand rel ease.
A parki ng brake swi tch i s mounted on the parki ng
brake l ever and i s actuated by movement of the
l ever. The swi tch, whi ch i s i n ci rcui t wi th the red
warni ng l i ght i n the dash, wi l l i l l umi nate the warn-
i ng l i ght whenever the parki ng brake i s appl i ed.
Parki ng brake adjustment i s control l ed by a cabl e
tensi oner mechani sm. The cabl e tensi oner, once
adjusted at the factory, shoul d not need further
adjustment under normal ci rcumstances. Adjustment
may be requi red i f a new tensi oner, or cabl es are
i nstal l ed, or di sconnected.
CABLES
REMOVAL
REMOVAL - FRONT PARKING BRAKE CABLE
(2) Lockout the parki ng brake cabl e (Fi g. 69).
(3) Loosen adjusti ng nut to create sl ack i n front
cabl e.
(4) Remove the front cabl e from the cabl e connec-
tor.
Fig. 66 SUPPORT PLATE WITH BRAKES MOUNTED
1 - SUPPORT PLATE
2 - MOUNTING NUTS
Fig. 67 SUPPORT PLATE WITH BRAKES MOUNTED
1 - SUPPORT PLATE
2 - MOUNTING NUTS
SUPPORT PLATE (Continued)
(5) Compress cabl e end fi tti ng at underbody
bracket and remove the cabl e from the bracket.
(6) Lower vehi cl e.
(7) Push bal l end of cabl e out of pedal cl evi s wi th
smal l screwdri ver.
(8) Compress cabl e end fi tti ng at the pedal bracket
and remove the cabl e (Fi g. 68).
(9) Remove the l eft cowl tri m and si l l pl ate.
(10) Pul l up the carpet and remove the cabl e from
the body cl i p.
(11) Pul l up on the cabl e and remove the cabl e
wi th the body grommet.
REMOVAL - REAR PARK BRAKE CABLE
(3) Loosen cabl e adjuster nut.
(4) Remove the rear park brake cabl e from the
i ntermedi ate park brake cabl e.
(5) Compress tabs on cabl e end fi tti ng on the rear
park brake cabl e to the frame mount bracket. Then
pul l the cabl e through the bracket.
(6) Di sengage the park brake cabl e from behi nd
the rotor assembl y. (Fi g. 70).
(7) Compress cabl e tabs on each cabl e end fi tti ng
at the brake cabl e support pl ate.
(8) Remove the cabl es from the brake cabl e sup-
port pl ates.
REMOVAL - RIGHT REAR CABLE
(3) Loosen the brake cabl e at the equal i zer and
adjuster nut.
(4) Remove the ri ght cabl e from the front cabl e.
(5) Remove the ri ght cabl e from the equal i zer.
(6) Remove the cabl e from the frame bracket.
(7) Remove the cabl e from the axl e bracket.
(8) Remove the cabl e bracket from the shock
bracket.
(9) Remove the brake cabl e from the brake l ever.
(Fi g. 71)
Fig. 68 Parking Brake Pedal
1 - PARK BRAKE PEDAL
2 - FRONT CABLE
Fig. 69 LOCK OUT PARKING CABLE
1 - LOCKING PLIERS
2 - PARKING BRAKE CABLE
Fig. 70 DISENGAGEMENT OF CABLE
1 - LEVER
2 - CABLE END
CABLES (Continued)
REMOVAL - LEFT REAR CABLE
(3) Loosen the brake cabl e at the equal i zer and
adjuster nut.
(4) Remove the l eft brake cabl e from the equal i zer.
(5) Remove the brake cabl e from the frame
bracket.
(6) Remove the brake cabl e from the brake l ever.
(Fi g. 72)
INSTALLATION
INSTALLATION - FRONT PARKING BRAKE
CABLE
(1) From i nsi de the vehi cl e, i nsert the cabl e end
fi tti ng i nto the hol e i n the pedal assembl y.
(2) Seat the cabl e retai ner i n the pedal assembl y.
(3) Engage the cabl e bal l end i n cl evi s on the pedal
assembl y.
(4) Route the cabl e through the fl oorpan and
i nstal l the body grommet.
(5) Pl ace the carpet down and i nstal l the l eft cowl
tri m and si l l pl ate.
(7) Route the cabl e through the underbody bracket
and seat the cabl e end fi tti ng i n the bracket.
(8) Connect the cabl e to the cabl e connector.
(9) Perform the park brake adjustment procedure,
(Refer to 5 - BRAKES/PARKI NG BRAKE/CABLE
TENSI ONER - ADJUSTMENTS).
INSTALLATION - REAR PARK BRAKE CABLE
(1) Push each cabl e end through the brake cabl e
support pl ate hol e unti l the cabl e end fi tti ng tabs
l ock i nto pl ace.
NOTE: Pull on the cable to ensure it is locked into
place.
(2) Push the cabl e through the frame bracket.
(3) Lock the l eft cabl e end fi tti ng tabs i nto the
frame bracket hol e.
(4) I nstal l the rear cabl es i nto the tensi oner rod
behi nd the rear of the brake assembl y.
(5) I nstal l the cabl e to the i ntermedi ate cabl e con-
nector.
(6) Rel ease and remove the l ock out devi ce.
(7) Perform the park brake adjustment procedure,
(Refer to 5 - BRAKES/PARKI NG BRAKE/CABLE
TENSI ONER - ADJUSTMENTS).
INSTALLATION - RIGHT REAR CABLE
(1) I nstal l the brake cabl e to the brake l ever. (Fi g.
73)
(2) I nstal l the cabl e bracket to the shock bracket.
(3) I nstal l the cabl e to the axl e bracket.
(4) I nstal l the cabl e to the frame bracket.
(5) I nstal l the ri ght cabl e to the equal i zer.
(6) I nstal l the ri ght cabl e to the front cabl e.
(7) Adjust the brake cabl e at the equal i zer and
usi ng the adjuster nut.
Fig. 71 CABLE MOUNT
1 - SUPPORT PLAT
2 - CABLE MOUNT
3 - PARK BRAKE LEVER
4 - CABLE
Fig. 72 REAR DISC BRAKE
3 - DUST SHIELD
4 - REAR PARKING BRAKE CABLE
5 - DISC BRAKE CALIPER MOUNTING BOLTS
CABLES (Continued)
INSTALLATION - LEFT REAR CABLE
(1) I nstal l the brake cabl e to the brake l ever (Fi g.
72).
(2) I nstal l the brake cabl e to the frame bracket.
(3) I nstal l the l eft brake cabl e to the equal i zer.
(4) Adjust the brake cabl e at the equal i zer and
adjuster nut.
SHOES
REMOVAL
(3) Remove the di sc brake cal i per,(Refer to 5 -
(4) Remove the di sc brake rotor, (Refer to 5 -
REMOVAL).
(6) Di sengage the park brake cabl e from behi nd
the rotor assembl y to al l ow easi er di sassembl y of the
park brake shoes (Fi g. 75).
(7) Remove the axl eshaft (Fi g. 76) (Refer to 3 -
DI FFERENTI AL & DRI VELI NE/REAR AXLE - 9 1/4/
AXLE SHAFTS - REMOVAL).
(8) Di sassembl e the rear park brake shoes (Fi g.
67).
CLEANING - REAR DRUM IN HAT BRAKE
Cl ean the i ndi vi dual brake components, i ncl udi ng
the support pl ate exteri or, wi th a water dampened
cl oth or wi th brake cl eaner. Do not use any other
cl eani ng agents. Remove l i ght rust and scal e from
the brake shoe contact pads on the support pl ate
wi th fi ne sandpaper.
INSPECTION - REAR DRUM IN HAT BRAKE
As a general rul e, ri veted brake shoes shoul d be
repl aced when worn to wi thi n 0.78 mm (1/32 i n.) of
the ri vet heads. Bonded l i ni ng shoul d be repl aced
when worn to a thi ckness of 1.6 mm (1/16 i n.).
Exami ne the l i ni ng contact pattern to determi ne i f
the shoes are bent or the drum i s tapered. The l i ni ng
shoul d exhi bi t contact across i ts enti re wi dth. Shoes
exhi bi ti ng contact onl y on one si de shoul d be
repl aced and the drum checked for runout or taper
(Fi g. 77).
Fig. 73 PARKING BRAKE CABLE
1 - SUPPORT PLAT
2 - CABLE
3 - LEVER
Fig. 74 LOCK OUT PARKING CABLE
1 - LOCKING PLIERS
2 - PARKING BRAKE CABLE
Fig. 75 DISENGAGEMENT OF CABLE
1 - LEVER
2 - CABLE END
CABLES (Continued)
I nspect the adjuster screw assembl y. Repl ace the
assembl y i f the star wheel or threads are damaged,
or the components are severel y rusted or corroded
(Fi g. 77).
Di scard the brake spri ngs and retai ner components
i f worn, di storted or col l apsed. Al so repl ace the
spri ngs i f a brake drag condi ti on had occurred. Over-
heati ng wi l l di stort and weaken the spri ngs.
I nspect the brake shoe contact pads on the support
pl ate, repl ace the support pl ate i f any of the pads are
worn or rusted through. Al so repl ace the pl ate i f i t i s
bent or di storted (Fi g. 77).
INSTALLATION
NOTE: On a new vehicle or after parking brake lin-
ing replacement, it is recommended that the park-
ing brake system be conditioned prior to use. This
is done by making one stop from 25 mph on dry
pavement or concrete using light to moderate force
on the parking brake foot pedal.
(1) Reassembl e the rear park brake shoes (Fi g. 67)
or (Fi g. 78).
(2) I nstal l the axl eshaft (Fi g. 76) (Refer to 3 - DI F-
FERENTI AL & DRI VELI NE/REAR AXLE - 9 1/4/
AXLE SHAFTS - I NSTALLATI ON) or (Refer to 3 -
DI FFERENTI AL & DRI VELI NE/REAR AXLE - 11
1/2 AA/10 1/2 AA/AXLE SHAFTS - I NSTALLATI ON).
(3) I nstal l the park brake cabl e to the l ever behi nd
the support pl ate.
(4) Unl ock the park brake cabl e.
(5) I nstal l the di sc brake rotor (Refer to 5 -
I NSTALLATI ON).
(6) I nstal l the di sc brake cal i per (Refer to 5 -
(7) Adjust the rear brake shoes (Refer to 5 -
BRAKES/PARKI NG BRAKE/SHOES - ADJUST-
MENTS).
Fig. 76 AXLE SHAFT
1 - AXLE SHAFT
2 - SUPPORT PLATE
3 - CALIPER
4 - PARK BRAKE SHOE ASSEMBLY
Fig. 77 PARK BRAKE SHOES
1 - SUPPORT PLATE
2 - SHOES
3 - RETURN SPRINGS
4 - RETAINER CLIPS
5 - ADJUSTER
Fig. 78 SHOE ASSEMBLY
1 - Park Brake Shoes
2 - Hold Downs
3 - Return Springs
SHOES (Continued)
DURE).
ADJ USTMENTS
ADJUSTMENT - PARKING BRAKE SHOES
CAUTION: Before adjusting the park brake shoes be
sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the
fully released position, the park brake shoes can
not be accurately adjusted.
(1) Rai se vehi cl e.
(2) Remove ti re and wheel .
(3) Remove di sc brake cal i per from cal i per adapter
DI SC BRAKE CALI PERS - REMOVAL).
(4) Remove rotor from the axl eshaft (Refer to 5 -
REMOVAL).
NOTE: When measuring the brake drum diameter,
the diameter should be measured in the center of
the area in which the park brake shoes contact the
surface of the brake drum.
(5) Usi ng Brake Shoe Gauge, Speci al Tool C-3919,
or equi val ent, accurately measure the i nsi de di am-
eter of the park brake drum porti on of the rotor (Fi g.
79).
(6) Usi ng a rul er that reads i n 64th of an i nch,
accuratel y read the measurement of the i nsi de di am-
eter of the park brake drum from the speci al tool
(Fi g. 80).
(7) Reduce the i nsi de di ameter measurement of
the brake drum that was taken usi ng Speci al Tool
C-3919 by 1/64 of an i nch. Reset Gauge, Brake Shoe,
Speci al Tool C-3919 or the equi val ent used, so that
the outsi de measurement jaws are set to the reduced
measurement (Fi g. 81).
(8) Pl ace Gauge, Brake Shoe, Speci al Tool C-3919,
or equi val ent over the park brake shoes. The speci al
tool must be l ocated di agonal l y across at the top of
one shoe and bottom of opposi te shoe (wi dest poi nt)
of the park brake shoes.
(9) Usi ng the star wheel adjuster, adjust the park
brake shoes unti l the l i ni ng on the park brake shoes
just touches the jaws on the speci al tool .
(10) Repeat step 8 above and measure shoes i n
both di recti ons.
(11) I nstal l brake rotor on the axl eshaft (Refer to 5
I NSTALLATI ON).
Fig. 79 Measuring Park Brake Drum Diameter
Fig. 80 Reading Park Brake Drum Diameter
1 - SPECIAL TOOL C-3919
2 - RULER
Fig. 81 Setting Gauge To Park Brake Shoe
Measurement
1 - RULER
SHOES (Continued)
(12) Rotate rotor to veri fy that the park brake
shoes are not draggi ng on the brake drum. I f park
brake shoes are draggi ng, remove rotor and back off
star wheel adjuster one notch and recheck for brake
shoe drag agai nst drum. Conti nue wi th the previ ous
step unti l brake shoes are not draggi ng on brake
drum.
(13) I nstal l di sc brake cal i per on cal i per adapter
DI SC BRAKE CALI PERS - I NSTALLATI ON).
(14) I nstal l wheel and ti re.
(15) Ti ghten the wheel mounti ng nuts i n the
proper sequence unti l al l nuts are torqued to hal f the
speci fi ed torque. Then repeat the ti ghteni ng sequence
to the ful l speci fi ed torque of 180 Nm (135 ft. l bs.)
1500 & 2500 Seri es or 195 Nm (145 ft. l bs.) 3500
Seri es.
(17) Appl y and rel ease the park brake pedal one
ti me. Thi s wi l l seat and correctl y adjust the park
brake cabl es.
CAUTION: Before moving vehicle, pump brake
pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
NOTE: On a new vehicle or after parking brake lin-
ing replacement, it is recommended that the park-
ing brake system be conditioned prior to use. This
is done by making one stop from 25 mph on dry
pavement or concrete using light to moderate force
on the parking brake foot pedal.
(18) Road test the vehi cl e to ensure proper func-
ti on of the vehi cl es brake system.
ADJUSTMENT - WITH ADJUSTING TOOL
Adjustment can be made wi th a standard brake
gauge or wi th adjusti ng tool . Adjustment i s per-
formed wi th the compl ete brake assembl y i nstal l ed
on the backi ng pl ate.
(1) Be sure parki ng brake l ever i s ful l y rel eased.
(2) Rai se vehi cl e so rear wheel s can be rotated
freel y.
(3) Remove pl ug from each access hol e i n brake
support pl ates.
(4) Loosen parki ng brake cabl e adjustment nut
unti l there i s sl ack i n front cabl e.
(5) I nsert adjusti ng tool through support pl ate
access hol e and engage tool i n teeth of adjusti ng
screw star wheel (Fi g. 82).
(6) Rotate adjuster screw star wheel (move tool
handl e upward) unti l sl i ght drag can be fel t when
wheel i s rotated.
(7) Back off adjuster screw star wheel unti l brake
drag i s el i mi nated.
(8) Repeat adjustment at opposi te wheel . Be sure
adjustment i s equal at both wheel s.
(9) I nstal l support pl ate access hol e pl ugs.
(10) Adjust parki ng brake cabl e and l ower vehi cl e.
(11) Depress park brake pedal and make sure park
brakes hol d the vehi cl e stai onary.
(12) Rel ease park brake pedal .
PEDAL
REMOVAL
(1) Rel ease the parki ng brake.
(2) Rai se the vehi cl e.
(3) Loosen the cabl e tensi oner nut at the equal i zer
to create sl ack i n the front cabl e.
(5) Remove the knee bol ster, (Refer to 23 - BODY/
OPENI NG COVER - REMOVAL).
(6) Di sconnect the brake l amp wi re from the
swi tch on the pedal assembl y.
(7) Rol l the carpet back, l oosen the front cabl e
grommet from the fl oorpan and the cabl e retai ner.
(8) Di sengage the rel ease rod (Fi g. 83) from the
arm on the pedal assembl y.
(9) Remove the bol ts/nuts from the pedal assembl y
and remove the assembl y.
INSTALLATION
(1) Posi ti on the repl acement pedal assembl y on the
dash and cowl .
Fig. 82 Brake Adjustment
1 - STAR WHEEL
2 - LEVER
3 - BRAKE SHOE WEB
4 - SCREWDRIVER
5 - ADJUSTING TOOL
6 - ADJUSTER SPRING
SHOES (Continued)
(2) I nstal l the bol ts/nuts and ti ghten to 28 Nm (21
ft. l bs.) (Fi g. 84).
(3) I nstal l the park brake rel ease rod.
(4) Connect the front cabl e to the arm on the pedal
assembl y.
(5) I nstal l the front cabl e grommet i nto the fl oor-
pan and the cabl e retai ner, rol l the carpet back.
(6) Connect the wi res to the brake l amp swi tch.
(7) I nstal l the knee bol ster, (Refer to 23 - BODY/
OPENI NG COVER - I NSTALLATI ON).
(9) Adjust the parki ng brake cabl e tensi oner (Refer
to 5 - BRAKES/PARKI NG BRAKE/CABLE TEN-
SI ONER - ADJUSTMENTS).
CABLE TENSIONER
ADJ USTMENTS
ADJUSTMENT
NOTE: Tensioner adjustment is only necessary
when the tensioner, or a cable has been replaced or
disconnected for service. When adjustment is nec-
essary, perform adjustment only as described in the
following procedure. This is necessary to avoid
faulty park brake operation.
(2) Back off the cabl e tensi oner adjusti ng nut to
create sl ack i n the cabl es.
(3) Remove the rear wheel /ti re assembl i es. Then
remove the brake rotors (Refer to 5 - BRAKES/HY-
(4) Veri fy the brakes are i n good condi ti on and
operati ng properl y.
(5) Veri fy the park brake cabl es operate freel y and
are not bi ndi ng, or sei zed.
(6) Check the rear brake shoe adjustment wi th
standard brake gauge (Refer to 5 - BRAKES/PARK-
I NG BRAKE/SHOES - ADJUSTMENTS).
(7) I nstal l the rotors (Refer to 5 - BRAKES/HY-
TI ON) and veri fy that the rotors rotate freel y
wi thout drag.
(8) I nstal l the wheel /ti re assembl i es, (Refer to 22 -
TI RES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(9) Lower the vehi cl e enough for access to the park
brake foot pedal . Then ful l y appl y the park brakes.
NOTE: Leave park brakes applied until adjustment
is complete.
(10) Rai se the vehi cl e agai n.
(11) Mark the tensi oner rod 6.35 mm (1/4 i n.) from
edge of the tensi oner (Fi g. 85).
(12) Ti ghten the adjusti ng nut on the tensi oner rod
unti l the mark i s no l onger vi si bl e.
CAUTION: Do not loosen, or tighten the tensioner
adjusting nut for any reason after completing
adjustment.
(13) Lower the vehi cl e unti l the rear wheel s are
15-20 cm (6-8 i n.) off the shop fl oor.
(14) Rel ease the park brake foot pedal and veri fy
that rear wheel s rotate freel y wi thout drag. Then
l ower the vehi cl e.
Fig. 83 PARKING BRAKE PEDAL
1 - RELEASE ROD
2 - PEDAL ASSEMBLY
Fig. 84 PARKING BRAKE ASSEMBLY
1 - PEDAL ASSEMBLY
2 - MOUNTING NUT
PEDAL (Continued)
RELEASE HANDLE
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Reach under the dri ver si de outboard end of
the i nstrument panel to access and unsnap the pl as-
ti c retai ner cl i p that secures the park brake rel ease
l i nkage rod to the park brake mechani sm on the l eft
cowl si de i nner panel .
(3) Di sengage the park brake rel ease l i nkage rod
end from the park brake mechani sm.
(4) Li ft the park brake rel ease handl e to access
and unsnap the pl asti c retai ner cl i p that secures the
park brake rel ease l i nkage rod to the l ever on the
back of the park brake rel ease handl e.
(5) Lower the park brake rel ease handl e and reach
under the dri ver si de outboard end of the i nstrument
panel to di sengage the park brake rel ease l i nkage
rod end from the l ever on the back of the park brake
rel ease handl e.
(6) Li ft the park brake rel ease handl e to access the
handl e mounti ng bracket.
(7) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry each of the park brake
rel ease handl e mounti ng bracket l atch tabs away
from the retai ni ng notches i n the i nstrument panel
receptacl e (Fi g. 86).
(8) Wi th both of the park brake rel ease handl e
mounti ng bracket l atches rel eased, sl i de the handl e
and bracket assembl y down and out of the i nstru-
ment panel receptacl e.
INSTALLATION
(1) Posi ti on the park brake rel ease handl e to the
i nstrument panel .
(2) Sl i de the handl e and bracket assembl y up i nto
the i nstrument panel receptacl e unti l both of the
park brake rel ease handl e mounti ng bracket l atches
are engaged wi th the notches i n the i nstrument
panel receptacl e.
(3) Lower the park brake rel ease handl e and reach
under the dri ver si de outboard end of the i nstrument
panel to engage the park brake rel ease l i nkage rod
end wi th the l ever on the back of the park brake
rel ease handl e.
(4) Li ft the park brake rel ease handl e to access
and snap the pl asti c retai ner cl i p that secures the
park brake rel ease l i nkage rod to the l ever on the
back of the park brake rel ease handl e over the l i nk-
age rod.
(5) Reach under the dri ver si de outboard end of
the i nstrument panel to access and engage the park
brake rel ease l i nkage rod end to the park brake
mechani sm.
(6) Snap the pl asti c retai ner cl i p that secures the
park brake rel ease l i nkage rod to the park brake
mechani sm on the l eft cowl si de i nner panel over the
l i nkage rod.
(7) Reconnect the battery negati ve cabl e.
Fig. 85 Adjustment Mark
1 - TENSIONER CABLE BRACKET
2 - TENSIONER
3 - CABLE CONNECTOR
4 - 6.35mm
(1/4 IN.)
5 - ADJUSTER NUT
Fig. 86 Park Brake Release Handle Remove/Install
1 - CLIP
2 - ROD
3 - MOUNTING BRACKET
4 - TRIM STICK
5 - LATCH TABS
6 - PARK BRAKE RELEASE HANDLE
CABLE TENSIONER (Continued)
BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 45
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
STANDARD PROCEDURE - ABS BRAKE
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 46
FRONT WHEEL SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
REAR WHEEL SPEED SENSOR
DIAGNOSIS AND TESTING - REAR WHEEL
ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
TONE WHEEL
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . 49
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING . . . . . . . . . . . . . . . 49
OPERATION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING . . . . . . . . . . . . . . . 49
HCU (HYDRAULIC CONTROL UNIT)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
RWAL VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51
BRAKES - ABS
DESCRIPTION
The anti l ock brake system (ABS) i s an el ectroni -
cal l y operated, three channel brake control system.
The vehi cl e has El ectroni c Vari abl e Brake Propor-
ti oni ng (EVBP) desi gned i nto the system whi ch el i m-
i nates the combi nati on/proporti oni ng val ve.
The system i s desi gned to prevent wheel l ockup
and mai ntai n steeri ng control duri ng braki ng. Pre-
venti ng l ockup i s accompl i shed by modul ati ng fl ui d
pressure to the wheel brake uni ts.
The hydraul i c system i s a three channel desi gn.
The front wheel brakes are control l ed i ndi vi dual l y
and the rear wheel brakes i n tandem. The ABS el ec-
tri cal system i s separate from other el ectri cal ci rcui ts
i n the vehi cl e. A speci al l y programmed control l er
anti l ock brake uni t operates the system components.
ABS system major components i ncl ude:
Control l er Anti l ock Brakes (CAB)
Hydraul i c Control Uni t (HCU)
Wheel Speed Sensors (WSS)
ABS Warni ng Li ght
OPERATION
Battery vol tage i s suppl i ed to the CAB. The CAB
performs a system i ni ti al i zati on procedure at start
up. A check of the ABS motor i s performed at 15
mi l es per hour. I ni ti al i zati on consi sts of a stati c and
dynami c sel f check of system el ectri cal components.
The stati c and dynami c checks occurs at i gni ti on
start up. Duri ng the dynami c check, the CAB bri efl y
cycl es sol enoi ds to veri fy operati on. An audi bl e noi se
may be heard duri ng thi s sel f check. Thi s noi se
shoul d be consi dered normal . The ABS motor and
pump are then checked at a speed of 15 mi l e per
hour.
I f an ABS component exhi bi ts a faul t duri ng i ni -
ti al i zati on, the CAB i l l umi nates the amber warni ng
l i ght and regi sters a faul t code i n the mi croprocessor
memory.
The CAB moni tors wheel speed sensor i nputs con-
ti nuousl y whi l e the vehi cl e i s i n moti on. However,
the CAB wi l l not acti vate any ABS components as
l ong as sensor i nputs i ndi cate normal braki ng.
Duri ng normal braki ng, the master cyl i nder, power
booster and wheel brake uni ts al l functi on as they
woul d i n a vehi cl e wi thout ABS. The HCU compo-
nents are not acti vated.
The purpose of the anti l ock system i s to prevent
wheel l ockup. Preventi ng l ockup hel ps mai ntai n vehi -
cl e braki ng acti on and steeri ng control .
The anti l ock CAB acti vates the system whenever
sensor si gnal s i ndi cate peri ods of wheel sl i p.
The anti l ock system prevents l ockup duri ng a
wheel sl i p condi ti on by modul ati ng fl ui d appl y pres-
sure to the wheel brake uni ts.
DR BRAKES - ABS 5 - 45
Brake fl ui d appl y pressure i s modul ated accordi ng
to wheel speed, degree of sl i p and rate of decel era-
ti on. Sensors at each front wheel convert wheel speed
i nto el ectri cal si gnal s. These si gnal s are transmi tted
to the CAB for processi ng and determi nati on of
wheel sl i p and decel erati on rate.
The ABS system has three fl ui d pressure control
channel s. The front brakes are control l ed separatel y
and the rear brakes i n tandem. A speed sensor i nput
si gnal i ndi cati ng a wheel sl i p condi ti on acti vates the
CAB anti l ock program.
There are Two sol enoi d val ves (I sol ati on and Dump
val ve) whi ch are used i n each anti l ock control chan-
nel . The val ves are al l l ocated wi thi n the HCU val ve
body and work i n pai rs to ei ther i ncrease, hol d, or
decrease appl y pressure as needed i n the i ndi vi dual
control channel s.
Duri ng an ABS stop the I SO val ve i s energi zed
whi ch acts to prevent further pressure bui l d-up to
the cal i pers. Then the Dump val ve dumps off pres-
sure unti l the wheel unl ocks. Thi s wi l l conti nue unti l
the wheel s qui t sl i ppi ng al together.
STANDARD PROCEDURE - ABS BRAKE
BLEEDING
ABS system bl eedi ng requi res conventi onal bl eed-
i ng methods pl us use of the DRB scan tool . The pro-
cedure i nvol ves performi ng a base brake bl eedi ng,
fol l owed by use of the scan tool to cycl e and bl eed the
HCU pump and sol enoi ds. A second base brake bl eed-
i ng procedure i s then requi red to remove any ai r
remai ni ng i n the system.
(1) Perform base brake bl eedi ng,(Refer to 5 -
BRAKES - STANDARD PROCEDURE) OR (Refer to
(2) Connect scan tool to the Data Li nk Connector.
(3) Sel ect ANTI LOCK BRAKES, fol l owed by MI S-
CELLANEOUS, then ABS BRAKES. Fol l ow the
i nstructi ons di spl ayed. When scan tool di spl ays TEST
COMPLETE, di sconnect scan tool and proceed.
(4) Perform base brake bl eedi ng a second ti me,(Re-
fer to 5 - BRAKES - STANDARD PROCEDURE) OR
(Refer to 5 - BRAKES - STANDARD PROCEDURE).
(5) Top off master cyl i nder fl ui d l evel and veri fy
proper brake operati on before movi ng vehi cl e.
SPECIFICATIONS
TORQUE CHART
ABS Assembly
Mounting Bolts
15 11
ABS Assembly
CAB Screws
3.5 31
ABS Assembly
Brake Line Fittings
19 170
Wheel Speed Sensors
Front Sensor Bolt
21 190
Wheel Speed Sensors
Bracket To Knuckle
6.7 60
Wheel Speed Sensors
Rear Sensor Stud
22.5 200
Controller
Mounting Screws
6 53
RWAL Module
Mounting Bolts
15 11
RWAL Valve
Brake Line Fittings
19 170
Rear Wheel Speed
Sensor
Mounting Bolt
24 200
5 - 46 BRAKES - ABS DR
BRAKES - ABS (Continued)
FRONT WHEEL SPEED
SENSOR
DESCRIPTION
The ABS brake system uses 3 wheel speed sensors.
A sensor i s mounted to each front hub/beari ngs. The
thi rd sensor i s mounted on top of the rear axl e di f-
ferenti al housi ng.
OPERATION
The Wheel Speed Sensor consi sts of a magnet sur-
rounded by wi ndi ngs from a si ngl e strand of wi re.
The sensor sends a smal l AC si gnal to the CAB. Thi s
si gnal i s generated by magneti c i nducti on. The mag-
neti c i nducti on i s created when a toothed sensor ri ng
(exci ter ri ng or tone wheel ) passes the stati onary
magneti c WSS.
When the ri ng gear i s rotated, the exci ter ri ng
passes the ti p of the WSS. As the exci ter ri ng tooth
approaches the ti p of the WSS, the magneti c l i nes of
force expand, causi ng the magneti c fi el d to cut across
the sensors wi ndi ngs. Thi s, i n turn causes current to
fl ow through the WSS ci rcui t (Fi g. 1) i n one di rec-
ti on. When the exci ter ri ng tooth moves away from
the sensor ti p, the magneti c l i nes of force col l apse
cutti ng the wi ndi ng i n the opposi te di recti on. Thi s
causes the current to fl ow i n the opposi te di recti on.
Every ti me a tooth of the exci ter ri ng passes the ti p
of the WSS, an AC si gnal i s generated. Each AC si g-
nal (posi ti ve to negati ve si gnal or si newave) i s i nter-
preted by the CAB. I t then compares the frequency of
the si newave to a ti me val ue to cal cul ate vehi cl e
speed. The CAB conti nues to moni tor the frequency
to determi ne a decel erati on rate that woul d i ndi cate
a possi bl e wheel -l ocki ng tendency.
The si gnal strength of any magneti c i nducti on sen-
sor i s di rectl y affected by:
Magneti c fi el d strength; the stronger the mag-
neti c fi el d, the stronger the si gnal
Number of wi ndi ngs i n the sensor; more wi nd-
i ngs provi de a stronger si gnal
Exci ter ri ng speed; the faster the exci ter ri ng/
tone wheel rotates, the stronger the si gnal wi l l be
Di stance between the exci ter ri ng teeth and
WSS; the cl oser the WSS i s to the exci ter ri ng/tone
wheel , the stronger the si gnal wi l l be
The rear WSS i s not adjustabl e. A cl earance speci -
fi cati on has been establ i shed for manufacturi ng tol er-
ances. I f the cl earance i s not wi thi n these
speci fi cati ons, then ei ther the WSS or other compo-
nents may be damaged. The cl earance between the
WSS and the exci ter ri ng i s 0.005 0.050 i n.
The assembl y pl ant performs a Rol l s Test on
every vehi cl e that l eaves the assembl y pl ant. One of
the test performed i s a test of the WSS. To properl y
test the sensor, the assembl y pl ant connects test
equi pment to the Data Li nk Connector (DLC). Thi s
connector i s l ocated to the ri ght of the steeri ng col -
umn and attached to the l ower porti on of the i nstru-
ment panel (Fi g. 2). The rol l s test termi nal i s spl i ced
to the WSS ci rcui t. The vehi cl e i s then dri ven on a
set of rol l ers and the WSS output i s moni tored for
proper operati on.
Fig. 1 Operation of the Wheel Speed Sensor
1 - MAGNETIC CORE
2 - CAB
3 - AIR GAP
4 - EXCITER RING
5 - COIL
Fig. 2 Data Link Connector - Typical
1 - 16WAY DATA LINK CONNECTOR
REMOVAL
(1) Remove the front rotor (Refer to 5 - BRAKES/
HYDRAULI C/MECHANI CAL/ROTORS -
REMOVAL).
(2) Remove the wheel speed sensor mounti ng bol t
from the hub. (Fi g. 3)
(3) Remove the wheel speed sensor from the hub.
(4) Remove the wi ri ng from the cl i ps and di scon-
nect the el ectri cal connector.
INSTALLATION
(1) I nstal l the wi ri ng to the cl i ps and Reconnect
the el ectri cal connector.
(2) I nstal l the wheel speed sensor to the hub.
(3) I nstal l the wheel speed sensor mounti ng bol t to
the hub. Ti ghten the bol t to 21 Nm (190 i n. l bs.).
(4) I nstal l the front rotor and brake cal i per assem-
bl y (Refer to 5 - BRAKES/HYDRAULI C/MECHANI -
CAL/ROTORS - I NSTALLATI ON).
REAR WHEEL SPEED SENSOR
ANTILOCK
Di agnosi s of base brake condi ti ons whi ch are
mechani cal i n nature shoul d be performed fi rst. Thi s
i ncl udes brake noi se, l ack of power assi st, parki ng
brake, or vehi cl e vi brati on duri ng normal braki ng.
The RWAL brake system performs several sel f-
tests every ti me the i gni ti on swi tch i s turned on and
the vehi cl e i s dri ven. The CAB moni tors the system
i nputs and outputs ci rcui ts to veri fy the system i s
operati ng properl y. I f the CAB senses a mal functi on
i n the system i t wi l l set a DTC i nto memory and tri g-
ger the warni ng l amp.
NOTE: The MDS or DRB III scan tool is used to
diagnose the RWAL system. For test procedures
refer to the Chassis Diagnostic Manual.
REMOVAL
(1) Rai se the vehi cl e on a hoi st.
(2) Remove the brake l i ne mounti ng nut and
remove the brake l i ne from the sensor stud.
(3) Remove the mounti ng stud from the sensor and
shi el d (Fi g. 4).
(4) Remove the sensor and shi el d from the di ffer-
enti al housi ng.
(5) Di sconnect the sensor wi re harness and remove
the sensor.
INSTALLATION
(1) Connect the harness to the sensor. Be sure
the seal is securely in place between the sensor
and the wiring connector.
(2) I nstal l the O-ri ng on the sensor (i f removed).
(3) I nsert the sensor i n the di fferenti al housi ng.
(4) I nstal l the sensor shi el d.
(5) I nstal l the sensor mounti ng stud and ti ghten to
24 Nm (200 i n. l bs.).
(6) I nstal l the brake l i ne on the sensor stud and
i nstal l the nut.
Fig. 3 WHEEL SPEED SENSOR
1 - WHEEL SPEED SENSOR MOUNTING BOLT
3 - HUB/BEARING
Fig. 4 REAR WHEEL SPEED SENSOR
2 - MOUNTING BOLT
3 - AXLE HOUSING
FRONT WHEEL SPEED SENSOR (Continued)
TONE WHEEL
SPEED SENSOR
Di agnosi s of base brake condi ti ons whi ch are
mechani cal i n nature shoul d be performed fi rst. Thi s
i ncl udes brake noi se, l ack of power assi st, parki ng
brake, or vehi cl e vi brati on duri ng normal braki ng.
The Anti l ock brake system performs several sel f-
tests every ti me the i gni ti on swi tch i s turned on and
the vehi cl e i s dri ven. The CAB moni tors the system
i nputs and outputs ci rcui ts to veri fy the system i s
operati ng properl y. I f the CAB senses a mal functi on
i n the system i t wi l l set a DTC i nto memory and tri g-
ger the warni ng l amp.
NOTE: The MDS or DRB III scan tool is used to
diagnose the Antilock Brake system. For test proce-
dures refer to the Chassis Diagnostic Manual.
DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING
Vehi cl es equi pped wi th ABS use el ectroni c vari abl e
brake proporti oni ng (EVBP) to bal ance front-to-rear
braki ng. The EVBP i s used i n pl ace of a rear propor-
ti oni ng val ve. The EVBP system uses the ABS sys-
tem to control the sl i p of the rear wheel s i n parti al
braki ng range. The braki ng force of the rear wheel s
i s control l ed el ectroni cal l y by usi ng the i nl et and out-
l et val ves l ocated i n the i ntegrated control uni t
(I CU).
OPERATION - ELECTRONIC VARIABLE BRAKE
PROPORTIONING
EVBP i s abl e to decrease, hol d and i ncrease rear
brake pressure wi thout acti vati ng ful l ABS control .
Upon entry i nto EVBP the i nl et val ve for the rear
brake ci rcui t i s swi tched on so that the fl ui d suppl y
from the master cyl i nder i s shut off. I n order to
decrease the rear brake pressure, the outl et val ve for
the rear brake ci rcui t i s pul sed. Thi s al l ows fl ui d to
enter the l ow pressure accumul ator (LPA) i n the
hydraul i c control uni t (HCU) resul ti ng i n a drop i n
fl ui d pressure to the rear brakes. I n order to i ncrease
the rear brake pressure, the outl et val ve i s swi tched
off and the i nl et val ve i s pul sed. Thi s i ncreases the
pressure to the rear brakes.
The EVBP wi l l remai n functi onal duri ng many
ABS faul t modes. I f both the red BRAKE and amber
ABS warni ng i ndi cators are i l l umi nated, the EVBP
may not be functi oni ng.
HCU (HYDRAULIC CONTROL
UNIT)
DESCRIPTION
The HCU consi sts of a val ve body, pump motor, l ow
pressure accumul ators, i nl et val ves, outl et val ves and
noi se attenuators.
OPERATION
Accumul ators i n the val ve body store extra fl ui d
rel eased to the system for ABS mode operati on. The
pump provi des the fl ui d vol ume needed and i s oper-
ated by a DC type motor. The motor i s control l ed by
the CAB.
The val ves modul ate brake pressure duri ng
anti l ock braki ng and are control l ed by the CAB.
The HCU provi des three channel pressure control
to the front and rear brakes. One channel control s
the rear wheel brakes i n tandem. The two remai ni ng
channel s control the front wheel brakes i ndi vi dual l y.
Duri ng anti l ock braki ng, the sol enoi d val ves are
opened and cl osed as needed.
Duri ng normal braki ng, the HCU sol enoi d val ves
and pump are not acti vated. The master cyl i nder and
power booster operate the same as a vehi cl e wi thout
an ABS brake system.
NOTE: The three modes mentioned below do occur
but not necessarily in the order listed everytime.
Duri ng anti l ock braki ng, sol enoi d val ve pressure
modul ati on occurs i n three stages, pressure i ncrease,
pressure hol d, and pressure decrease. The val ves are
al l contai ned i n the val ve body porti on of the HCU.
PRESSURE DECREASE
The outl et val ve i s opened and the i nl et val ve i s
cl osed duri ng the pressure decrease cycl e.
A pressure decrease cycl e i s i ni ti ated when speed
sensor si gnal s i ndi cate hi gh wheel sl i p at one or
more wheel s. At thi s poi nt, the CAB cl oses the i nl et
then opens the outl et val ve, whi ch al so opens the
return ci rcui t to the accumul ators. Fl ui d pressure i s
al l owed to bl eed off (decrease) as needed to prevent
wheel l ock.
Once the peri od of hi gh wheel sl i p has ended, the
CAB cl oses the outl et val ve and begi ns a pressure
i ncrease or hol d cycl e as needed.
PRESSURE HOLD
Both sol enoi d val ves are cl osed i n the pressure
hol d cycl e but onl y the i nl et val ve i s energi zed. Fl ui d
appl y pressure i n the control channel i s mai ntai ned
at a constant rate. The CAB mai ntai ns the hol d cycl e
unti l sensor i nputs i ndi cate a pressure change i s nec-
essary.
PRESSURE INCREASE
The i nl et val ve i s open and the outl et val ve i s
cl osed duri ng the pressure i ncrease cycl e. The pres-
sure i ncrease cycl e i s used to reappl y thew brakes.
Thi s cycl e control s re-appl i cati on of fl ui d appl y pres-
sure.
REMOVAL
(2) Di sconnect the battery cabl es from the battery.
(3) Remove the battery.
(4) Di sconnect the two el ectri cal harness connec-
tors (Fi g. 5).
(5) Remove the fi ve brake l i nes from the HCU
(Fi g. 5).
(6) Remove HCU/CAB mounti ng bol ts and remove
the HCU/CAB (Fi g. 5).
INSTALLATION
NOTE: If the CAB is being replaced with a new CAB
is must be reprogrammed with the use of a DRB III.
(1) I nstal l HCU/CAB on the mounts and Ti ghten
the bol ts to 15Nm (11 ft. l bs.) (Fi g. 5).
(2) I nstal l the fi ve brake l i nes to the HCU and
ti ghten to 19 Nm (170 i n. l bs.) (Fi g. 5).
(3) I nstal l the two el ectri cal harness connectors to
the HCU/CAB and push down on the rel ease to
secure the connectors.
(4) I nstal l the battery.
(5) I nstal l the battery cabl es to the battery.
(6) Remove the prop rod on the brake pedal .
(7) Bl eed ABS brake system (Refer to 5 - BRAKES
RWAL VALVE
DESCRIPTION
Rear Wheel Anti l ock (RWAL) brake system i s stan-
dard equi pment on 1500 seri es vehi cl es. The RWAL
brake system i s desi gned to prevent rear wheel
l ock-up on vi rtual l y al l types of road surfaces. RWAL
braki ng i s desi rabl e because a vehi cl e whi ch i s
stopped wi thout l ocki ng the rear wheel s wi l l retai n
di recti onal stabi l i ty. Thi s al l ows the dri ver to retai n
greater control of the vehi cl e duri ng braki ng.
The val ve i s l ocated on the dri vers si de i nner
fender under the hood. The val ve modul ates hydrau-
l i c pressure to the rear brakes.
The RWAL components i ncl ude:
RWAL Val ve
Control l er Anti l ock brake (CAB)
Rear Wheel Speed Sensor (WSS)
OPERATION
When the brakes are appl i ed, hydraul i c fl ui d i s
routed from the master cyl i nders secondary ci rcui t to
the RWAL val ve. From there hydraul i c fl ui d i s routed
to the rear brakes. The Control l er Anti l ock Brake
(CAB) contai ns an El ectroni c Vari abl e Brake Propor-
ti oni ng (EVBP) control al gori thm, whi ch proporti ons
the appl i ed braki ng force to the rear wheel s duri ng
braki ng. The EVBP functi on of the RWAL system
takes the pl ace of a conventi onal hydraul i c propor-
ti oni ng val ve. The CAB moni tors the rear wheel
speed through the rear wheel speed sensor and cal -
cul ates an esti mated vehi cl e decel erati on. When an
establ i shed decel erati on threshol d i s exceeded, an
i sol ati on val ve i s cl osed to hol d the appl i ed brake
pressure to the rear brakes constant. Upon further
i ncreases i n the esti mated vehi cl e decel erati on, the
i sol ati on val ve i s sel ecti vel y opened to i ncrease rear
brake pressure i n proporti on to the front brake pres-
sure. I f i mpendi ng rear wheel l ock-up i s sensed, the
CAB si gnal s the RWAL val ve to modul ate hydraul i c
brake pressure to the rear wheel s to prevent l ock-up.
NORMAL BRAKI NG Si nce the RWAL val ve al so
performs the EVBP or proporti oni ng functi on, vehi cl e
decel erati on under normal braki ng may be suffi ci ent
to tri gger the EVBP functi on of the RWAL system
wi thout ful l RWAL acti vi ty as woul d normal l y occur
duri ng an i mpendi ng rear wheel l ock-up. As previ -
ousl y menti oned, the i sol ati on val ve i s sel ecti vel y
cl osed and opened to i ncrease rear brake pressure i n
proporti on to the front brake pressure under EVBP
control . Sl i ght brake pedal pul sati ons may be noti ced
as the i sol ati on val ve i s opened.
Fig. 5 HYDRAULIC CONTROL UNIT
1 - HYDRAULIC CONTROL UNIT
2 - MOUNTING BOLTS
HCU (HYDRAULIC CONTROL UNIT) (Continued)
REMOVAL
(2) Di sconnect the battery cabl es from the battery.
(3) Remove the battery.
(4) Di sconnect the el ectri cal harness connector
(Fi g. 6).
(5) Remove the brake l i nes from the rwal val ve
(Fi g. 6).
(6) Remove rwal val ve mounti ng nuts and remove
the rwal val ve (Fi g. 6).
INSTALLATION
(1) I nstal l rwal val ve and Ti ghten the nuts to 15
Nm (11 ft. l bs.) (Fi g. 6).
(2) I nstal l the brake l i nes to the rwal val ve and
ti ghten to 19 Nm (170 i n. l bs.) (Fi g. 6).
(3) I nstal l the el ectri cal harness connector to the
rwal val ve and secure the connector.
(4) I nstal l the battery.
(5) I nstal l the battery cabl es to the battery.
(6) Remove the prop rod on the brake pedal .
(7) Bl eed ABS brake system (Refer to 5 - BRAKES
Fig. 6 RWAL VALVE
1 - RWAL VALVE
2 - MOUNTING NUTS
RWAL VALVE (Continued)
CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 5
CLUTCH DISC
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLUTCH HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CLUTCH RELEASE BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
FLYWHEEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 11
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
PILOT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
LINKAGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
CLUTCH PEDAL POSITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CLUTCH
WARNING
WARNING: Exercise care when servicing clutch
components. Factory installed clutch discs do not
contain asbestos fibers. Dust and dirt on clutch
parts may contain asbestos fibers from aftermarket
components. Breathing excessive concentrations of
these fibers can cause serious bodily harm. Wear a
respirator during service and never clean clutch
components with compressed air or with a dry
brush. Either clean the components with water
dampened rags or use a vacuum cleaner specifi-
cally designed to remove asbestos fibers and dust.
Do not create dust by sanding a clutch discs.
Replace the disc if the friction material is damaged.
Dispose of all dust and dirt containing asbestos
fibers in sealed bags or containers. This will mini-
mize exposure to yourself and to others. Follow all
recommended safety practices prescribed by the
occupational safety and health administration
(OSHA) and the environmental safety agency (EPA),
for the handling and disposal of products contain-
ing asbestos. Failure to follow these instructions
may result in personal injury or death
Road test and i nspect components to determi ne a
cl utch probl em. Road test the vehi cl e at normal
speeds. Shi ft the transmi ssi on through al l gear
ranges and observe cl utch acti on. I f cl utch chatters,
grabs, sl i ps or does not rel ease properl y, remove and
i nspect cl utch components. I f probl em i s noi se or
hard shi fti ng, further di agnosi s may be needed to the
transmi ssi on and dri vel i ne component.
CLUTCH CONTAMINATION
Contami nati on i s a frequent cause of cl utch mal -
functi ons. Oi l , water or cl utch fl ui d on the cl utch di sc
and pressure pl ate surfaces wi l l cause chatter, sl i p
and grab. Oi l contami nati on i ndi cates a l eak at
ei ther the rear mai n seal or transmi ssi on i nput shaft.
Cl utch fl ui d l eaks are usual l y from damaged sl ave
cyl i nder push rod seal s. Heat bui l dup caused by sl i p-
page between the pressure pl ate, di sc and fl ywheel
can bake the oi l resi due onto the components. The
gl aze-l i ke resi due ranges i n col or from amber to
bl ack.
Road spl ash contami nati on i s di rt/water enteri ng
the cl utch housi ng due to l oose bol ts, housi ng cracks.
Dri vi ng through deep water puddl es can force water/
road spl ash i nto the housi ng through such openi ngs.
IMPROPER RELEASE OR CLUTCH ENGAGEMENT
Cl utch rel ease or engagement probl ems can be
caused by worn or damage cl utch components.
Rel ease probl ems can cause hard shi fti ng and
noi se. Look for l eaks at cl utch cyl i nders, connecti ng
l i ne and l oose sl ave cyl i nder bol ts. Al so worn/l oose
rel ease fork, pi vot stud, cl utch di sc, pressure pl ate or
rel ease beari ng.
DR CLUTCH 6 - 1
Engagement probl ems can cause sl i p, chatter/shud-
der and noi sy operati on. The causes may be cl utch
di sc contami nati on, wear, di storti on or fl ywheel dam-
age.
CLUTCH MISALIGNMENT
Cl utch components must be i n proper al i gnment
wi th the crankshaft and transmi ssi on i nput shaft.
Mi sal i gnment caused by excessi ve runout or warpage
of any cl utch component wi l l cause grab, chatter and
i mproper cl utch rel ease.
CLUTCH COVER AND DISC RUNOUT
Check the cl utch di sc before i nstal l ati on. Axi al
(face) runout of a new di sc shoul d not exceed 0.50
mm (0.020 i n.). Measure runout about 6 mm (1/4 i n.)
from the outer edge of the di sc faci ng. Obtai n
another di sc i f runout i s excessi ve.
Check condi ti on of the cl utch before i nstal l ati on. A
warped cover or di aphragm spri ng wi l l cause grab
and i ncompl ete rel ease or engagement. Be careful
when handl i ng the cover and di sc. I mpact can di stort
the cover, di aphragm spri ng, rel ease fi ngers and the
hub of the cl utch di sc.
Use an al i gnment tool when posi ti oni ng the di sc on
the fl ywheel . The tool prevents acci dental mi sal i gn-
ment whi ch coul d resul t i n cover di storti on and di sc
damage.
A frequent cause of cl utch cover di storti on (and
consequent mi sal i gnment) i s i mproper bol t ti ghten-
i ng.
FLYWHEEL RUNOUT
Check fl ywheel runout whenever mi sal i gnment i s
suspected. Fl ywheel runout shoul d not exceed 0.08
mm (0.003 i n.). Measure runout at the outer edge of
the fl ywheel face wi th a di al i ndi cator.
Common causes of runout are:
heat warpage
i mproper machi ni ng
i ncorrect bol t ti ghteni ng
i mproper seati ng on crankshaft fl ange shoul der
forei gn materi al on crankshaft fl ange
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. Mi nor fl y-
wheel scori ng can be cl eaned up by hand wi th 180
gri t emery or wi th turni ng equi pment. Remove onl y
enough materi al to reduce scori ng (approxi matel y
0.001 - 0.003 i n.). Heavy stock removal i s not rec-
ommended. Repl ace the fl ywheel i f scori ng i s severe
and deeper than 0.076 mm (0.003 i n.). Excessi ve
stock removal can resul t i n fl ywheel cracki ng or
warpage after i nstal l ati on; i t can al so weaken the fl y-
wheel and i nterfere wi th proper cl utch rel ease.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar Lock And Seal or equi val ent.
Ti ghten fl ywheel bol ts to speci fi ed torque onl y. Over-
ti ghteni ng can di stort the fl ywheel hub causi ng
runout.
DIAGNOSIS CHART
The di agnosi s charts Di agnosi s Chart descri be
common cl utch probl ems, causes and correcti on.
DIAGNOSIS CHART
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.
2. Replace cover and disc.
3. Insufficient clutch cover
diaphragm spring tension.
3. Replace cover and disc.
6 - 2 CLUTCH DR
CLUTCH (Continued)
Clutch disc facing contaminated with
oil, grease, or clutch fluid.
1. Leak at rear main engine seal or
transmission input shaft seal.
1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.
2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.
3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.
1. Release bearing sticking or
binding and does not return to the
normal running position.
1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.
1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.
1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.
1. Rough handling. Impact bent
cover, spring, or disc.
1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.
2. Tighten clutch cover using proper
procedure.
Facing on flywheel side of disc torn,
gouged, or worn.
1. Flywheel surface scored or
nicked.
1. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Clutch disc sticking or binding on
transmission input shaft.
2. Inspect components and
correct/replace as necessary.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.
1. Frequent operation under high
loads or hard acceleration
conditions.
1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.
2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
Clutch disc binds on input shaft
splines.
1. Clutch disc hub splines damaged
during installation.
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.
1. Clutch not used for an extended
period of time (e.g. long term
vehicle storage).
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
DR CLUTCH 6 - 3
CLUTCH (Continued)
Pilot bearing seized, loose, or rollers
are worn.
1. Bearing cocked during
installation.
1. Install a new bearing.
2. Bearing defective. 2. Install a new bearing.
3. Bearing not lubricated. 3. Install a new bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
Clutch will not disengage properly. 1. Low hydraulic linkage fluid level. 1. Add hydraulic linkage fluid.
2. Clutch cover loose. 2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring
bent or warped.
4. Replace clutch cover.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot
loose or damaged.
6. Replace fork or pivot as
necessary.
7. Clutch master or slave cylinder
failure.
7. Replace hydraulic linkage
assembly.
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not
lubricated.
2. Lubricate master cylinder
bushing.
3. Pedal bushings worn out or
cracked.
3. Replace and lubricate bushings.
4. Rough surface on front bearing
retainer.
4. Replace front bearing retainer.
Clutch master or slave cylinder
plunger dragging andr binding
1. Master or slave cylinder
components worn or corroded.
1. Replace clutch hydraulic linkage
assembly.
Release bearing is noisy. 1. Release bearing defective or
damaged.
1. Replace release bearing.
Contact surface of release bearing
damaged.
1. Clutch cover incorrect or release
fingers bent or distorted.
1. Replace clutch cover and release
bearing.
2. Release bearing defective or
damaged.
2. Replace the release bearing.
3. Release bearing misaligned. 3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.
6 - 4 CLUTCH DR
CLUTCH (Continued)
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.
1. Clutch pressure plate position
incorrect.
1. Replace clutch disc and cover.
2. Clutch cover, spring, or release
fingers bent or distorted.
2. Replace clutch disc and cover.
3. Clutch disc damaged or
distorted.
2. Replace clutch disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andr
clutch housing. Correct as
necessary.
SPECIFICATIONS
Slave Cylinder Nuts 23 17 -
Clutch Master Cylinder
Nuts
28 21 -
Pressure Plate Bolts - V6
& V8
50 37 -
Pressure Plate Bolts - V10 30 22.5 -
Pressure Plate Bolts -
Diesel
30 22.5 -
Release Bearing Pivot 23 17 -
Flywheel Bolts 95 70 -
CLUTCH DISC
REMOVAL
(1) Support engi ne wi th wood bl ock and adjustabl e
jack stand, to prevent strai n on engi ne mounts.
(2) Remove transmi ssi on and transfer case, i f
equi pped.
(3) I f pressure pl ate wi l l be reused, mark the posi -
ti on on fl ywheel wi th pai nt or scri ber (Fi g. 1). Al so
note l ocati on marks on the pressure next to the bol t
hol es. The mark wi l l be a L or a ci rcl e wi th an X i n
i t.
(4) I nsert cl utch al i gnment tool through cl utch di sc
and i nto pi l ot bushi ng, to hol d di sc i n pl ace whi l e
removi ng bol ts.
(5) Loosen pressure pl ate bol ts evenl y, a few
threads at a ti me and i n a di agonal pattern to pre-
vent warpi ng the pl ate.
(6) Remove bol ts compl etel y and remove pressure
pl ate, di sc and al i gnment tool .
INSTALLATION
(1) Check runout and free operati on of new cl utch
di sc.
(2) Lubri cate crankshaft pi l ot beari ng wi th a NLGI
- 2 rated grease.
(3) I nstal l cl utch al i gnment tool i n cl utch di sc hub
wi th the rai sed si de of hub i s faci ng away from the
fl ywheel .
NOTE: Flywheel side is imprinted on the disc face.
(4) I nstal l al i gnment tool i n pi l ot beari ng and posi -
ti on di sc on the fl ywheel .
(5) Posi ti on pressure pl ate over di sc and onto the
fl ywheel (Fi g. 2).
(6) Al i gn and hol d pressure pl ate i n posi ti on and
i nstal l bol ts fi nger ti ght.
(7) Ti ghten bol ts evenl y and a few threads at a
ti me i n a di agonal pattern.
CAUTION: Bolts must be tightened evenly and to
specified torque to avoid warping pressure plate
cover.
DR CLUTCH 6 - 5
CLUTCH (Continued)
(8) Ti ghten pressure pl ate bol ts to:
V6 & V8 Engi nes - 50 Nm (37 ft. l bs.)
V10 & Di esel Engi nes - 30 Nm (22.5 ft. l bs.)
(9) Remove rel ease l ever and rel ease beari ng from
cl utch housi ng. Appl y Mopar hi gh temperature bear-
i ng grease to bore of rel ease beari ng, rel ease l ever
contact surfaces and rel ease l ever pi vot stud (Fi g. 3).
(10) Appl y l i ght coat of Mopar hi gh temperature
beari ng grease to spl i nes of transmi ssi on i nput shaft
and to rel ease beari ng sl i de surface of the transmi s-
si on front beari ng retai ner (Fi g. 4).
CAUTION: Do not over lubricate shaft splines. This
can result in grease contamination of the disc.
Fig. 1 PRESSURE PLATE POSITION-TYPICAL
1 - FLYWHEEL
2 - ALIGNMENT MARKS
3 - PRESSURE PLATE
Fig. 2 CLUTCH DISC AND PRESSURE PLATE
1 - FLYWHEEL
2 - PRESSURE PLATE AND DISC
3 - ALIGNMENT TOOL
Fig. 3 LUBRICATION POINTS
1 - CLUTCH HOUSING
2 - FORK PIVOT BALL
3 - RELEASE FORK
4 - RELEASE BEARING BORE
5 - LUBE POINTS
Fig. 4 INPUT SHAFT LUBRICATION POINTS
1 - INPUT SHAFT
2 - BEARING RETAINER
3 - SPLINE AND RELEASE BEARING SURFACE
6 - 6 CLUTCH DR
CLUTCH DISC (Continued)
(11) Wi pe pi l ot beari ng surface cl ean.
(12) I nstal l rel ease l ever and beari ng i n cl utch
housi ng. Veri fy spri ng cl i ps that retai n fork on pi vot
bal l and rel ease beari ng on fork are i nstal l ed prop-
erl y (Fi g. 5).
NOTE: If release lever is installed correctly, the
lever part number will be toward the bottom of the
transmission and right side up. There is also a
stamped I in the lever which goes to the pivot ball
side of the transmission.
(13) I nstal l transmi ssi on and transfer case i f
equi pped.
(14) Check fl ui d l evel i n cl utch master cyl i nder.
CLUTCH HOUSING
The cl utch housi ng mai ntai ns al i gnment between
the crankshaft and transmi ssi on i nput shaft. Mi s-
al i gnment can cause cl utch noi se, hard shi fti ng,
i ncompl ete rel ease and chatter. Al so premature pi l ot
beari ng, cover rel ease fi ngers and cl utch di sc wear.
I n severe cases, i t can cause premature wear of the
transmi ssi on i nput shaft and front beari ng.
NOTE: Only the NV4500 clutch housing can be
checked using the following bore and face runout
procedures. The NV5600 clutch housing is a inte-
gral part of the transmission and can only be
checked off the vehicle.
CLUTCH HOUSING BORE RUNOUT
CAUTION: On diesel engines if housing bore runout
exceeds 0.015 inch, the clutch housing/transmis-
sion adapter plate must be replaced. On gas
engines if housing bore runout exceeds 0.053 in.
the clutch housing must be replaced.
NOTE: Offset dowels are available for gas engines
to correct housing bore runout. They are not avail-
able for diesel engines.
(1) Remove the cl utch housi ng.
(2) Remove the cl utch cover and di sc.
(3) Repl ace one of the fl ywheel bol ts wi th an
appropri ate si ze threaded rod that i s 10 i n. (25.4 cm)
l ong (Fi g. 6). The rod wi l l be used to mount the di al
i ndi cator.
(4) Remove rel ease fork from the cl utch housi ng.
(5) I nstal l cl utch housi ng. Ti ghten the housi ng
bol ts nearest the al i gnment dowel s fi rst.
(6) Mount di al i ndi cator on the threaded rod and
posi ti on i ndi cator pl unger on the cl utch housi ng bore
(Fi g. 7).
(7) Rotate crankshaft unti l i ndi cator pl unger i s at
the topof the housi ng bore. Zero the i ndi cator at thi s
poi nt.
(8) Rotate crankshaft and record i ndi cator read-
i ngs at ei ght poi nts (45 apart) around the bore (Fi g.
8). Take measurement at l east twi ce for accuracy.
(9) Subtract each readi ng from the one 180 oppo-
si te to determi ne runout and di recti on. Bore runout
exampl e (Fi g. 8):
0.000 (0.007) = 0.007 i n.
+0.002 (0.010) = 0.012 i n.
+0.004 (0.005) = 0.009 i n.
0.001 (+0.001) = 0.002 i n.
Fig. 5 FORK, BEARING AND SPRING CLIPS
1 - FORK
2 - SPRING CLIP
3 - BEARING
4 - SPRING CLIP
Fig. 6 DIAL INDICATOR MOUNTING STUD
1 - 7/16 - 20 THREAD
2 - NUT
3 - STUD OR THREADED ROD
4 - 10 INCHES LONG
DR CLUTCH 6 - 7
CLUTCH DISC (Continued)
I n thi s exampl e the l argest or total i ndi cator read-
i ng (TI R) di fference i s 0.012 i nch. Thi s means the
housi ng bore i s offset from the crankshaft centerl i ne
by 0.006 i n. whi ch i s 1/2 of 0.012 i nch. The dowel s
needed to correct thi s have an offset of 0.007 i n. (Fi g.
9).
Remove housi ng and i nstal l dowel s wi th the sl otted
si de faci ng out so they can be turned wi th a screw-
dri ver. Then i nstal l the housi ng and mount the di al
i ndi cator and check bore runout agai n. Rotate the
dowel s unti l the TI R i s l ess than 0.010 i nch.
Clutch Housing Face Runout
(1) Posi ti on di al i ndi cator towards the housi ng face
(Fi g. 10) wi th i ndi cator pl unger on the ri m of the
housi ng bore.
(2) Rotate crankshaft unti l i ndi cator pl unger i s at
the 10 Ocl ock posi ti on and zero the di al i ndi cator.
(3) Measure and record face runout readi ngs at
four poi nts 90 apart (Fi g. 11). Take measurement at
l east twi ce for accuracy.
(4) Subtract l owest readi ng from hi ghest to deter-
mi ne total runout. I f l ow readi ng was minus 0.004
i n. and hi ghest readi ng was plus 0.009 i n. the total
runout i s 0.013 i nch.
NOTE: Maximum acceptable face runout is 0.010
inch.
Fig. 7 CLUTCH HOUSING BORE RUNOUT
1 - MOUNTING STUD OR ROD
2 - DIAL INDICATOR
3 - INDICATOR PLUNGER
4 - CLUTCH HOUSING BORE
Fig. 8 MEASUREMENT POINTS AND READINGS
1 - CLUTCH HOUSING BORE CIRCLE
Fig. 9 ALIGNMENT DOWEL SELECTION
1 - SLOT DIRECTION OF OFFSET
2 - OFFSET DOWEL
TIR VALUE OFFSET DOWEL REQUIRED
0.011 - 0.021 inch 0.007 inch
0.022 - 0.035 inch 0.014 inch
0.036 - 0.052 inch 0.021 inch
Fig. 10 DIAL INDICATOR LOCATION
1 - INDICATOR PLUNGER
2 - DIAL INDICATOR
3 - CLUTCH HOUSING FACE
4 - INDICATOR MOUNTING STUD OR ROD
6 - 8 CLUTCH DR
CLUTCH HOUSING (Continued)
To correct thi s exampl e (Fi g. 11) the shi ms needed
between the cl utch housi ng and transmi ssi on are:
0.009 i n. at the 0.000 corner
After i nstal l i ng the cl utch assembl y and housi ng,
ti ghten the housi ng bol ts nearest the al i gnment dow-
el s fi rst.
NOTE: Shims can be made from shim stock or sim-
ilar materials of the required thickness (Fig. 12).
REMOVAL
(1) Remove transmi ssi on and transfer case (Fi g.
13).
(2) Remove starter from cl utch housi ng.
(3) Remove structural dust cover bol ts from cl utch
housi ng.
CAUTION: Do not remove structural dust cover
from enigne block. If cover is removed clutch hous-
ing and cover must be aligned with the engine.
(4) Remove cl utch housi ng bol ts and remove hous-
i ng from the engi ne.
INSTALLATION
(1) Cl ean housi ng mounti ng surface of engi ne
bl ock wi th wax and grease remover.
(2) Veri fy that cl utch housi ng al i gnment dowel s
are i n good condi ti on and properl y seated.
(3) Transfer sl ave cyl i nder, rel ease fork and boot,
fork pi vot stud and wi re/hose brackets to new hous-
i ng.
(4) I nstal l structural dust cover i f removed (Refer
to 9 - ENGI NE/ENGI NE BLOCK/STRUCTURAL
COVER - I NSTALLATI ON).
(5) Al i gn and i nstal l cl utch housi ng on engi ne (Fi g.
14). Ti ghten housi ng bol ts across the top of the hous-
i ng fi rst and to the fol l owi ng torque val ues:
A bol ts 1/4i n. di ameter - 4.5 Nm (40 i n.l b.)
A bol ts 3/8i n. di ameter - 40 Nm (30 ft.l b.)
A bol ts 7/16i n. di ameter - 68 Nm (50 ft.l b.)
B bol ts for 5.7L 5.9L TD/8.0L engi nes - 47.5
Nm (40 ft.l b.)
C bol ts for 5.7L engi ne - 68 Nm (50 ft.l b.)
C bol ts for 5.9L TD engi ne - 47.5 Nm (35
ft.l b.)
C bol ts for 8.0L engi ne - 74.5 Nm (55 ft.l b.)
(6) I nstal l starter to cl utch housi ng.
(7) I nstal l transmi ssi on and transfer case, i f
equi pped.
CLUTCH RELEASE BEARING
REMOVAL
(1) Remove transmi ssi on and transfer case, i f
equi pped.
(2) Remove spri ng cl i p.
Fig. 11 MEASUREMENT POINTS AND READINGS
1 - CLUTCH HOUSING FACE CIRCLE (AT RIM OF BORE)
Fig. 12 ALIGNMENT SHIMS
1 - CUT/DRILL BOLT HOLE TO SIZE
2 - SHIM STOCK
3 - MAKE SHIM 1-INCH DIAMETER
Fig. 13 TRANSMISSION/CLUTCH HOUSING-NV4500
1 - CLUTCH HOUSING
2 - TRANSMISSION
DR CLUTCH 6 - 9
CLUTCH HOUSING (Continued)
(3) Di sconnect rel ease beari ng from rel ease fork
and remove beari ng (Fi g. 15).
INSTALLATION
(1) I nspect beari ng sl i de surface on transmi ssi on
front beari ng retai ner. Repl ace retai ner i f sl i de sur-
face i s scored, worn, or cracked.
(2) I nspect rel ease l ever and pi vot stud. Be sure
stud i s secure and i n good condi ti on. Be sure fork i s
not di storted or worn. Repl ace fork spri ng cl i ps i f
bent or damaged.
(3) Lubri cate i nput shaft spl i nes, beari ng retai ner
sl i de surface, l ever pi vot bal l stud, and rel ease l ever
pi vot surface wi th Mopar hi gh temperature beari ng
grease.
(4) I nstal l rel ease fork and rel ease beari ng (Fi g.
16). Be sure fork and beari ng are properl y secured by
spri ng cl i ps. Al so be sure that the rel ease fork i s
i nstal l ed properl y. The rear si de of the rel ease l ever
has one end wi th a rai sed area. Thi s rai sed area goes
toward the sl ave cyl i nder si de of the transmi ssi on.
(5) I nstal l cl utch housi ng, i f removed.
(6) I nstal l transmi ssi on and transfer case.
(7) Check cl utch master cyl i nder fl ui d l evel .
FLYWHEEL
Check fl ywheel runout whenever mi sal i gnment i s
suspected. Fl ywheel runout shoul d not exceed 0.08
mm (0.003 i n.). Measure runout at the outer edge of
the fl ywheel face wi th a di al i ndi cator. Mount the
i ndi cator on a stud i nstal l ed i n pl ace of one of the fl y-
wheel bol ts.
Fig. 14 CLUTCH HOUSING - NV4500
1 - ENGINE BLOCK
2 - CLUTCH DISC/PRESSURE PLATE
3 - CLUTCH HOUSING
4 - DUST COVER
Fig. 15 CLUTCH RELEASE COMPONENTS
1 - CONED WASHER
2 - CLUTCH HOUSING
3 - RELEASE FORK
4 - RELEASE BEARING AND SLEEVE
5 - PIVOT 23 Nm (200 IN. LBS.)
6 - SPRING CLIP
Fig. 16 Clutch Release Fork And
1 - PIVOT BALL
2 - FORK
3 - SLAVE CYLINDER OPENING
4 - BEARING
6 - 10 CLUTCH DR
CLUTCH RELEASE BEARING (Continued)
Common causes of runout are:
heat warpage
i mproper machi ni ng
i ncorrect bol t ti ghteni ng
i mproper seati ng on crankshaft fl ange shoul der
forei gn materi al on crankshaft fl ange
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. Mi nor fl y-
wheel scori ng can be cl eaned up by hand wi th 180
gri t emery or wi th surface gri ndi ng equi pment.
Remove onl y enough materi al to reduce scori ng
(approxi matel y 0.001 - 0.003 i n.). Heavy stock
removal i s not recommended. Repl ace the fl ywheel
i f scori ng i s severe and deeper than 0.076 mm (0.003
i n.). Excessi ve stock removal can resul t i n fl ywheel
cracki ng or warpage after i nstal l ati on; i t can al so
weaken the fl ywheel and i nterfere wi th proper cl utch
rel ease.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar Lock And Seal or equi val ent.
Ti ghten fl ywheel bol ts to speci fi ed torque onl y. Over-
ti ghteni ng can di stort the fl ywheel hub causi ng
runout.
REMOVAL
(1) Remove transmi ssi on.
(2) Remove pressure pl ate and cl utch.
(3) Remove fl ywheel bol ts and remove fl ywheel .
DISASSEMBLY
NOTE: If the teeth are worn or damaged, the fly-
wheel should be replaced as an assembly. This is
the recommended repair. In cases where a new fly-
wheel is not readily available, (V10/Diesel Engine
only) a replacement ring gear can be installed. The
following procedure must be observed to avoid
damaging the flywheel and replacement gear.
WARNING: WEAR PROTECTIVE GOGGLES OR
SAFETY GLASSES WHILE CUTTING RING GEAR.
(1) Mark posi ti on of the ol d gear for al i gnment ref-
erence on the fl ywheel . Use a scri ber for thi s pur-
pose.
(2) Remove the ol d gear by cutti ng most of the way
through i t (at one poi nt) wi th an abrasi ve cut-off
wheel . Then compl ete removal wi th a col d chi sel or
punch.
ASSEMBLY
NOTE: The ring gear is a shrink fit on the flywheel.
This means the gear must be expanded by heating
in order to install it. The method of heating and
expanding the gear is extremely important. Every
surface of the gear must be heated at the same
time to produce uniform expansion. An oven or
similar enclosed heating device must be used. Tem-
perature required for uniform expansion is approxi-
mately 375 F.
CAUTION: Do not use an oxy/acetylene torch to
remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the fly-
wheel. In addition, using the torch to heat a replace-
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.
WARNING: WEAR PROTECTIVE GOGGLES OR
SAFETY GLASSES AND HEAT RESISTENT GLOVES
WHEN HANDLING A HEATED RING GEAR.
(1) The heated gear must be i nstal l ed evenl y to
avoi d mi sal i gnment or di storti on.
(2) Posi ti on and i nstal l the heated ri ng gear on the
fl ywheel wi th a shop press and a sui tabl e press pl ates.
(3) Pl ace fl ywheel on work bench and l et i t cool i n
normal shop ai r. Al l ow the ri ng gear to cool down
compl etel y before i nstal l ati on i t on the engi ne.
CAUTION: Do not use water or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air will distort or crack the
new gear.
INSTALLATION
(1) I nstal l fl ywheel on the crank shaft.
(2) I nstal l fl ywheel bol ts and ti ghten to 95 Nm
(70 ft. l bs.).
(3) I nstal l cl utch.
(4) I nstal l transmi ssi on.
PILOT BEARING
REMOVAL
(1) Remove transmi ssi on.
(2) Remove cl utch di sc.
(3) Use a sui tabl e bl i nd hol e pul l er to remove pi l ot
beari ng.
DR CLUTCH 6 - 11
FLYWHEEL (Continued)
INSTALLATION
(1) Cl ean beari ng bore wi th sol vent and wi pe dry
wi th shop towel .
(2) I nstal l new beari ng wi th cl utch al i gnment tool
(Fi g. 17). Dri ve beari ng i nto pl ace wi th the l etter si de
of the beari ng faci ng the transmi ssi on. Beari ng
shoul d be fl ush wi th edge of beari ng bore.
CAUTION: Do not allow bearing to become cocked
and do not recess bearing.
(3) I nstal l cl utch di sc, pressure pl ate and trans-
mi ssi on.
LINKAGE
REMOVAL
CAUTION: The hydraulic linkage has a quick dis-
connect at the slave cylinder. This fitting should
never be disconnected or tampered with. Once the
hydraulic line is connected to the slave cylinder, it
should never be disconnected.
(2) Remove nuts attachi ng sl ave cyl i nder to studs
on cl utch housi ng (Fi g. 18).
(3) Remove sl ave cyl i nder from cl utch housi ng.
(4) Remove pl asti c cl i p securi ng the hydraul i c l i ne
to the dash panel from the l ower dash panel fl ange.
(5) Remove pl asti c cl i p securi ng hydraul i c l i ne to
the dash panel from the upper dash panel stud.
(7) Di sconnect cl utch pedal i nterl ock swi tch wi res
(Fi g. 19).
(8) Remove cl utch master cyl i nder rod pi n.
(9) Veri fy that cap on cl utch master cyl i nder reser-
voi r i s ti ght. Thi s wi l l avoi d spi l l age duri ng removal .
(10) Remove cl utch master cyl i nder nuts hol di ng
the to the dash panel .
(11) Remove cl utch cyl i nders, reservoi r and con-
necti ng l i nes from vehi cl e.
INSTALLATION
(1) Posi ti on cyl i nders and connecti ng l i ne i n vehi -
cl e engi ne compartment. Posi ti on cl utch hydraul i c
l i ne agai nst the dash panel and behi nd al l engi ne
hoses and wi ri ng.
Fig. 17 PILOT BEARING
1 - PILOT BEARING
2 - ALIGNMENT TOOL
3 - LETTER SIDE MUST FACE TRANSMISSION
Fig. 18 SLAVE CYLINDER
1 - MOUNTING NUTS
2 - SLAVE CYLINDER
Fig. 19 CLUTCH MASTER CYLINDER
1 - MASTER CYLINDER
2 - INTERLOCK CONNECTOR
3 - ROD PIN
6 - 12 CLUTCH DR
PILOT BEARING (Continued)
(2) Appl y a l i ght coati ng of grease to the i nsi de
di ameter of the master cyl i nder push rod eye.
(3) I nstal l cl utch master cyl i nder on dash panel
and ti ghten cl utch master cyl i nder nuts to 28 Nm
(21 ft. l bs.).
(4) I nstal l cl utch master cyl i nder push rod pi n.
(5) Connect cl utch pedal posi ti on i nterl ock swi tch
wi res.
(6) I nstal l pl asti c cl i p securi ng hydraul i c l i ne to
the dash panel i nto the l ower dash panel fl ange.
(7) I nstal l pl asti c cl i p securi ng hydraul i c l i ne to
the dash panel onto the upper dash panel stud.
(9) I nstal l sl ave cyl i nder and veri fy cyl i nder rod i s
properl y seated i n rel ease l ever.
(10) I nstal l and ti ghten sl ave cyl i nder nuts to 23
Nm (17 ft. l bs.).
(11) I f new cl utch l i nkage i s bei ng i nstal l ed, con-
nect the cl utch hydraul i c l i ne to the cl utch sl ave cyl -
i nder.
CAUTION: Once the clutch hydraulic line is con-
nected to the slave cylinder, it should never be dis-
connected.
(13) Operate l i nkage several ti mes to veri fy proper
operati on.
CLUTCH PEDAL POSITION
SWITCH
DESCRIPTION
A cl utch pedal posi ti on swi tch (CPPS) i s mounted
on the cl utch master cyl i nder push rod (Fi g. 20). The
wi ri ng harness connector i s i nsi de of the vehi cl e
under the l eft si de of the i nstrument panel .
NOTE: Switch is serviced with clutch master cylin-
der.
OPERATION
The cl utch pedal posi ti on swi tch i s used to prevent
starter motor engagement unl ess the cl utch pedal i s
depressed. An i nput from thi s swi tch i s al so used to
ei ther shut down/prevent operati on of the speed con-
trol system when pedal i s depressed. The posi ti on
swi tch i s an i ntegral part of the cl utch master cyl i n-
der push rod.
(1) Di sconnect swi tch 2-wi re connector attached to
pedal support bracket, under i nstrument panel to l eft
of cl utch pedal (Fi g. 21).
(2) Check swi tch conti nui ty wi th an ohmmeter
whi l e operati ng cl utch pedal .
Pedal Depressed - Conti nui ty
Pedal Rel eased - No Conti nui ty
(3) I f conti nui ty i s not present or al ways present,
repl ace cl utch master cyl i nder. Swi tch i s not servi ced
separatel y.
Fig. 20 LOCATION, CLUTCH PEDAL
POSITION SWITCH
1 - CLUTCH MASTER CYLINDER
2 - CLUTCH PEDAL POSITION SWITCH
Fig. 21 CLUTCH SWITCH TEST POINT
1 - PEDAL SUPPORT BRACKET
DR CLUTCH 6 - 13
LINKAGE (Continued)
COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM FLOW
3.7L/4.7L/5.7L ENGINE . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - COOLING SYSTEM FLOW -
5.9L DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DESCRIPTION - HOSE CLAMPS . . . . . . . . . . . 3
OPERATION
OPERATION - COOLING SYSTEM . . . . . . . . . 5
OPERATION - HOSE CLAMPS . . . . . . . . . . . . 5
DIAGNOSIS AND TESTINGON-BOARD
DIAGNOSTICS (OBD) . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - COOLING
SYSTEM - TESTING FOR LEAKS . . . . . . . . . . 5
DIAGNOSIS AND TESTING - COOLING
SYSTEM DIESEL ENGINE . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT
LEVEL CHECK. . . . . . . . . . . . . . . . . . . . . . . . 17
STANDARD PROCEDURE - COOLING
SYSTEM CLEANING/REVERSE FLUSHING . . 17
STANDARD PROCEDURE - DRAINING
COOLING SYSTEM - ALL GAS ENGINES . . . 17
STANDARD PROCEDURE - REFILLING
COOLING SYSTEM - ALL GAS ENGINES . . . 18
STANDARD PROCEDURE - DRAINING
COOLING SYSTEM 5.9L DIESEL ENGINE . . . 18
COOLING SYSTEM 5.9L DIESEL ENGINE . . . 19
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT. . . . . . . . . . . . . . . . . 19
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS - . . . . . . . . . . . . . . . . . . . . 20
SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . 21
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 67
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM FLOW
3. 7L/4. 7L/5. 7L ENGINE
The cool i ng system regul ates engi ne operati ng tem-
perature. I t al l ows the engi ne to reach normal oper-
ati ng temperature as qui ckl y as possi bl e. I t al so
mai ntai ns normal operati ng temperature and pre-
vents overheati ng.
The cool i ng system provi des a means of heati ng
the passenger compartment and cool i ng the auto-
mati c transmi ssi on fl ui d (i f equi pped). The cool i ng
system i s pressuri zed and uses a centri fugal water
pump to ci rcul ate cool ant through the system. The
cool ant recovery/reserve system uti l i zes an ambi ent
overfl ow bottl e (Fi g. 2).
An opti onal factory i nstal l ed maxi mum duty cool -
i ng package i s avai l abl e on most model s. Thi s pack-
age wi l l provi de addi ti onal cool i ng capaci ty for
vehi cl es used under extreme condi ti ons such as
trai l er towi ng i n hi gh ambi ent temperatures (Fi g. 1).
DR COOLING 7 - 1
Fig. 1 Engine Cooling System Flow - 3.7L/4.7L
1 - LH CYL. HEAD
2 - BLEED
3 - THERMOSTAT LOCATION
4 - RH CYL. HEAD
5 - RH BANK CYL. BLOCK
6 - LH BANK CYL. BLOCK
7 - COOLANT TEMP. SENSOR
8 - FROM HEATER CORE
9 - TO HEATER CORE
7 - 2 COOLING DR
COOLING (Continued)
DESCRIPTION - COOLING SYSTEM FLOW -
5. 9L DIESEL
The di esel engi ne cool i ng system consi sts of :
Cross-fl ow radi ator
Bel t dri ven water pump
Cool i ng fan (attached to the el ectroni c vi scous
fan dri ve)
Bel t dri ven El ectroni c vi scous fan dri ve
Two pi ece fan shroud
Radi ator pressure cap
Verti cal l y mounted thermostat
Cool ant reserve/recovery system
Transmi ssi on oi l cool er
Cool ant
Cool ant fl ow ci rcui ts for the 5.9L di esel engi ne are
shown i n (Fi g. 3).
DESCRIPTION - HOSE CLAMPS
The cool i ng system uti l i zes spri ng type hose
cl amps. I f a spri ng type cl amp repl acement i s neces-
sary, repl ace wi th the ori gi nal Mopar equi pment
spri ng type cl amp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter and ensure the
clamp has the same size width (Fig. 4).
Fig. 2 5.7L Engine Coolant System Flow
1 - LH CYLINDER HEAD
2 - TO RADIATOR
3 - FROM RADIATOR
4 - TO RH CYLINDER HEAD
DR COOLING 7 - 3
COOLING (Continued)
Fig. 3 Cooling System Circulation - 5.9L Diesel Engine
7 - 4 COOLING DR
COOLING (Continued)
OPERATION
OPERATION - COOLING SYSTEM
The cool i ng system regul ates engi ne operati ng tem-
perature. I t al l ows the engi ne to reach normal oper-
ati ng temperature as qui ckl y as possi bl e. I t al so
mai ntai ns normal operati ng temperature and pre-
vents overheati ng.
The cool i ng system al so provi des a means of heat-
i ng the passenger compartment and cool i ng the auto-
mati c transmi ssi on fl ui d (i f equi pped). The cool i ng
system i s pressuri zed and uses a centri fugal water
pump to ci rcul ate cool ant throughout the system.
Al l engi nes uti l i ze an ambi ent overfl ow bottl e for
cool ant recovery/reserve.
An opti onal factory i nstal l ed maxi mum duty cool -
i ng package i s avai l abl e on most model s. Thi s pack-
age wi l l provi de addi ti onal cool i ng capaci ty for
vehi cl es used under extreme condi ti ons such as
trai l er towi ng i n hi gh ambi ent temperatures.
OPERATION - HOSE CLAMPS
The spri ng type hose cl amp appl i es constant ten-
si on on a hose connecti on. To remove a spri ng type
hose cl amp, onl y use constant tensi on cl amp pl i ers
desi gned to compress the hose cl amp.
DIAGNOSIS AND TESTING ON-BOARD
DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The Engi ne Control Modul e (ECM) has been pro-
grammed to moni tor certai n cool i ng system compo-
nents:
I f the engi ne has remai ned cool for too l ong a
peri od, such as wi th a stuck open thermostat, a Di ag-
nosti c Troubl e Code (DTC) can be set.
I f an open or shorted condi ti on has devel oped i n
the el ectroni cal l y control l ed vi scous fan cl utch ci rcui t,
a Di agnosti c Troubl e Code (DTC) can be set.
I f fan speed i s not detected a DTC wi l l be set.
Cool ant temperature sensor ci rcui t probl ems can
set a DTC.
I f the probl em i s sensed i n a moni tored ci rcui t
often enough to i ndi cated an actual probl em, a DTC
i s stored. The DTC wi l l be stored i n the ECM mem-
ory for eventual di spl ay to the servi ce techni ci an.
(Refer to 25 - EMI SSI ONS CONTROL - DESCRI P-
TI ON).
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTCs and to obtai n cool i ng system data,
(Refer to 25 - EMI SSI ONS CONTROL - DESCRI P-
TI ON).
ERASING TROUBLE CODES
After the probl em has been repai red, use the
DRBI I I scan tool to erase a DTC. Refer to the
appropri ate Powertrai n Di agnosti c Procedures ser-
vi ce i nformati on for operati on of the DRBI I I scan
tool .
DIAGNOSIS AND TESTING - COOLING SYSTEM
- TESTING FOR LEAKS
ULTRAVIOLET LIGHT METHOD
A l eak detecti on addi ti ve i s avai l abl e through the
parts department that can be added to cool i ng sys-
tem. The addi ti ve i s hi ghl y vi si bl e under ul travi ol et
l i ght (bl ack l i ght). Pour one ounce of addi ti ve i nto
cool i ng system. Pl ace heater control uni t i n HEAT
posi ti on. Start and operate the engi ne unti l the radi -
ator upper hose i s warm to the touch. Ai m the com-
merci al l y avai l abl e bl ack l i ght tool at the components
to be checked. I f l eaks are present, the bl ack l i ght
wi l l cause the addi ti ve to gl ow a bri ght green col or.
The bl ack l i ght can be used i n conjuncti on wi th a
pressure tester to determi ne i f any external l eaks
exi st (Fi g. 5).
Fig. 4 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
DR COOLING 7 - 5
COOLING (Continued)
PRESSURE TESTER METHOD
The engi ne shoul d be at normal operati ng temper-
ature. Recheck the system col d i f the cause of cool ant
l oss i s not l ocated duri ng the warm engi ne exami na-
ti on.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Careful l y remove the radi ator pressure cap from
the fi l l er neck and check the cool ant l evel . Push
down on the cap to di sengage i t from the stop tabs.
Wi pe the i nsi de of the fi l l er neck and exami ne the
l ower i nsi de seal i ng seat for ni cks, cracks, pai nt, di rt
and sol der resi due. I nspect the radi ator-to- reserve/
overfl ow tank hose for i nternal obstructi ons. I nsert a
wi re through the hose to be sure i t i s not obstructed.
I nspect the cams on the outsi de of the fi l l er neck.
I f the cams are damaged, seati ng of the pressure cap
val ve and tester seal wi l l be affected.
Attach pressure tester (7700 or an equi val ent) to
radi ator fi l l er neck.
Operate the tester pump to appl y 103.4 kPa (15
psi ) pressure to the system. I f the hoses enl arge
excessi vel y or bul ges whi l e testi ng, repl ace as neces-
sary. Observe the gauge poi nter and determi ne the
condi ti on of the cool i ng system accordi ng to fol l owi ng
cri teri a:
Holds Steady: I f the poi nter remai ns steady for
two mi nutes, seri ous cool ant l eaks are not present i n
system. However, there coul d be an i nternal l eak
that does not appear wi th normal system test pres-
sure. I f i t i s certai n that cool ant i s bei ng l ost and
l eaks cannot be detected, i nspect for i nteri or l eakage
or perform I nternal Leakage Test. Refer to I NTER-
NAL LEAKAGE I NSPECTI ON.
Drops Slowly: I ndi cates a smal l l eak or seepage
i s occurri ng. Exami ne al l of the connecti ons for seep-
age or sl i ght l eakage wi th a fl ashl i ght. I nspect the
radi ator, hoses, gasket edges and heater. Seal the
smal l l eak hol es wi th a Seal er Lubri cant (or equi va-
l ent). Repai r the l eak hol es and i nspect the system
agai n wi th pressure appl i ed.
Drops Quickly: I ndi cates that seri ous l eakage i s
occurri ng. Exami ne the system for external l eakage.
I f l eaks are not vi si bl e, i nspect for i nternal l eakage.
Large radi ator l eak hol es shoul d be repai red by a
reputabl e radi ator repai r shop.
INTERNAL LEAKAGE INSPECTION
Remove the engi ne oi l pan drai n pl ug and drai n a
smal l amount of engi ne oi l . I f cool ant i s present i n
the pan, i t wi l l drai n fi rst because i t i s heavi er than
oi l . An al ternati ve method i s to operate engi ne for a
short peri od to churn the oi l . After thi s i s done,
remove the engi ne di psti ck and i nspect for water
gl obul es. Al so i nspect the transmi ssi on di psti ck for
water gl obul es and transmi ssi on fl ui d cool er for l eak-
age.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 145 kPa (21 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate the engi ne wi thout the pressure cap on
the radi ator unti l the thermostat opens. Attach a
Pressure Tester to the fi l l er neck. I f pressure bui l ds
up qui ckl y i t i ndi cates a combusti on l eak exi sts. Thi s
i s usual l y the resul t of a cyl i nder head gasket l eak or
crack i n engi ne. Repai r as necessary.
I f there i s not an i mmedi ate pressure i ncrease,
pump the Pressure Tester. Do thi s unti l i ndi cated
pressure i s wi thi n system range of 110 kPa (16 psi ).
Fl uctuati on of the gauge poi nter i ndi cates compres-
si on or combusti on l eakage i nto cool i ng system.
Because the vehi cl e i s equi pped wi th a catal yti c
converter, do not short out cyl i nders to i sol ate com-
pressi on l eak.
I f the needl e on di al of the pressure tester does not
fl uctuate, race engi ne a few ti mes to check for an
abnormal amount of cool ant or steam. Thi s woul d be
emi tti ng from exhaust pi pe. Cool ant or steam from
Fig. 5 Leak Detection Using Black Light - Typical
1 - TYPICAL BLACK LIGHT TOOL
7 - 6 COOLING DR
COOLING (Continued)
exhaust pi pe may i ndi cate a faul ty cyl i nder head gas-
ket, cracked engi ne cyl i nder bl ock or cyl i nder head.
A conveni ent check for exhaust gas l eakage i nto
cool i ng system i s provi ded by a commerci al l y avai l -
abl e Bl ock Leak Check tool . Fol l ow manufacturers
i nstructi ons when usi ng thi s product.
COMBUSTION LEAKAGE TEST - WITHOUT
PRESSURE TESTER
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drai n suffi ci ent cool ant to al l ow thermostat
removal . (Refer to 7 - COOLI NG/ENGI NE/ENGI NE
COOLANT THERMOSTAT - REMOVAL). Remove
accessory dri ve bel t (Refer to 7 - COOLI NG/ACCES-
SORY DRI VE/DRI VE BELTS - REMOVAL).
Add cool ant to radi ator to bri ng l evel to wi thi n 6.3
mm (1/4 i n) of the top of the thermostat housi ng.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engi ne and accel erate rapi dl y three ti mes, to
approxi matel y 3000 rpm whi l e observi ng cool ant. I f
i nternal engi ne combusti on gases are l eaki ng i nto
cool i ng system, bubbl es wi l l appear i n cool ant. I f bub-
bl es do not appear, i nternal combusti on gas l eakage
i s not present.
DIAGNOSIS AND TESTING - COOLING SYSTEM DIESEL ENGINE
COOLING SYSTEM DIAGNOSIS - DIESEL ENGINE
TEMPERATURE GAUGE READS
LOW
1. Vehicle is equipped with a heavy
duty cooling system.
1. None. System operating normally.
NOTE: Information on dash cluster
is displayed based on broadcast
datd from ECM. DTC will be set for
engine sensore circuit concern.
2. Thermostat stuck open 2. Inspect and test thermostat.
3. Coolant level low. 3. Fill cooling system. (Refer to 7 -
COOLING - STANDARD
PROCEDURE)
4. Temperature gauge not
functioning correctly.
4. Check cluster (Refer to 8 -
ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
5. Engine sensor stuck in range 5. Monitor sensor with DRB III to
verify sensor reading changes with
increasing temperature.
6. Engine sensor failed out of
range.
A DTC will be set.
7. Electronically Controlled Vicsous
Fan Drive not operating properly.
7. Check Electronically Controlled
Viscous Fan Drive (Refer to 7 -
COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
DR COOLING 7 - 7
COOLING (Continued)
HIGH. COOLANT MAY OR MAY
NOT BE LEAKING FROM SYSTEM
1. Vehicle overloaded, high ambient
(outside) temperatures with A/C
turned on, stop and go driving or
prolonged operation at idle speeds.
1. Temporary condition, repair not
required. Notify customer of vehicle
operation instructions located in
Owners Manual.
NOTE: Information on dash cluster
information from ECM. DTC will be
set for engine sensor circuit
concern.
2. Temperature gauge not
functioning correctly.
2. Check cluster (Refer to 8 -
TESTING)
3. Air trapped in cooling system 3. Drain cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE) and refill (Refer to 7
- COOLING - STANDARD
PROCEDURE)
4. Radiator cap faulty. 4. Replace radiator cap.
5. Plugged A/C or radiator cooling
fins.
5. Clean all debris away from A/C
and radiator cooling fins.
6. Coolant mixture incorrect. 6. Drain cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE) refill with correct
mixture (Refer to 7 - COOLING -
7. Thermostat stuck shut. 7. Inspect and test thermostat.
Replace thermostat if necessary.
8. Bug screen or winter front being
used.
8. Remove bug screen or winter
front.
9. Electronically controlled viscous
fan drive not operating properly.
9. Check viscous fan (Refer to 7 -
AND TESTING)
10. Cylinder head gasket leaking. 10. Check for leaking head gaskets
(Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
11. Heater core leaking. 11. Replace heater core.
12. Cooling system hoses leaking. 12. Tighten clamps or Replace
hoses.
13. Brakes dragging. 13. Check brakes. (Refer to 5 -
BRAKES/HYDRAULIC/
MECHANICAL - DIAGNOSIS AND
TESTING)
14. Accessory drive belt. 14. Inspect. Replace as necessary.
15. Water Pump. 15. Inspect and replace as
necessary.
16. Engine sensor stuck in range. 16. Monitor sensor with DRBIII to
verify sensor reading changes
increase in temperature.
17. Temperature sensor failed out
of range.
17. A DTC will be set.
7 - 8 COOLING DR
COOLING (Continued)
TEMPERATURE GAUGE READING
INCONSISTENT (ERRATIC,
CYCLES OR FLUCTUATES)
1. Heavy duty cooling system,
extreme cold ambient (outside)
temperature or heater blower motor
in high position.
1. None. System operating normally.
NOTE: Information on daash cluster
data from ECM. DTC will be set for
engine sensore circuit wiring.
2. Temperature gauge or sensor
defective.
2. Check cluster or engine coolant
temp sensor (Refer to 8 -
TESTING)
3. Temporary heavy usage or load. 3. None. Normal condition.
4. Air trapped in cooling system. 4. Fill cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE).
5. Water pump 5. Replace water pump.
6. Air leak on suction side of water
pump.
6. Check for leak. (Refer to 7 -
COOLING - DIAGNOSIS AND
TESTING)
RADIATOR CAP LEAKING STEAM
AND /OR COOLANT INTO
RESERVOIR BOTTLE.
(TEMPERATURE GAUGE MAY
READ HIGH)
1. Radiator cap defective. 1. Replace radiator cap.
2. Radiator neck surface damaged. 2. Replace radiator.
HOSE OR HOSES COLLAPSE
WHEN ENGINE IS COOLING.
1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
reservoir/overflow system.
1. Replace radiator cap, check vent
hose between radiator and reservoir
bottle for blockage also check
reservoir bottle vent for blockage.
NOISY FAN 1. Fan blade(s) loose, damaged. 1. Replace fan blade assembly.
fan drive.
2. None. Normal condition.
3. Fan blades striking surrounding
objects.
3. Locate contact point and repair
as necessary.
fan drive bearing concern.
4. Check viscous fan drive (Refer to
7 - COOLING/ENGINE/FAN DRIVE
AND TESTING)
fan stuck on.
5. Check viscous fan drive(Refer to
AND TESTING)
6. Obstructed air flow through
radiator.
6. Remove obstruction.
DR COOLING 7 - 9
COOLING (Continued)
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED)
1. Radiator and/or A/C condenser
air flow obstructed.
1. Remove obstruction and/or clean.
fan drive not working.
2. Check viscous fan drive (Refer to
AND TESTING)
3. Air seals around radiator
damaged or missing.
3. Inspect air seals, repair or
replace as necessary.
INADEQUATE HEATER
PERFORMANCE. GAUGE MAY OR
MAY NOT READ LOW.
1. Heavy duty cooling system, and
cooler ambient temperatures.
1. None. Normal condition.
2. Obstruction in heater hoses. 2. Remove hoses, remove
obstruction.
fan stuck on.
Check viscous fan drive. (Refer to 7
- COOLING/ENGINE/FAN DRIVE
AND TESTING)
4. Water pump damaged. 4. Replace water pump.
HEAT ODOR 1. Damaged or missing drive line
heat shields.
1. Repair or replace damaged or
missing heat shields.
fan drive damaged.
2. Check viscous fan drive. (Refer
to 7 - COOLING/ENGINE/FAN
DRIVE VISCOUS CLUTCH -
DIAGNOSIS AND TESTING)
CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establ i sh what dri vi ng condi ti ons caused the com-
pl ai nt. Abnormal l oads on the cool i ng system such as
the fol l owi ng may be the cause:
PROLONGED I DLE
VERY HI GH AMBI ENT TEMPERATURE
SLI GHT TAI L WI ND AT I DLE
SLOW TRAFFI C
TRAFFI C JAMS
HI GH SPEED OR STEEP GRADES
Dri vi ng techni ques that avoi d overheati ng are:
I dl e wi th A/C off when temperature gauge i s at
end of normal range.
I ncreasi ng engi ne speed for more ai r fl ow i s rec-
ommended.
TRAILER TOWING:
Consul t Trai l er Towi ng secti on of owners manual .
Do not exceed l i mi ts.
RECENT SERVICE OR ACCIDENT REPAIR:
Determi ne i f any recent servi ce has been per-
formed on vehi cl e that may effect the cool i ng system.
Thi s may be:
Engi ne adjustments (i ncorrect ti mi ng)
Sl i ppi ng engi ne accessory dri ve bel t(s)
Brakes (possi bl y draggi ng)
Changed parts. I ncorrect water pump or pump
rotati ng i n wrong di recti on due to bel t not correctl y
routed
Recondi ti oned radi ator or cool i ng system refi l l -
i ng (possi bl y under fi l l ed or ai r trapped i n system).
Servi ce to el ectri cal l y control l ed vi scous fan
cl utch
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to COOLING SYSTEM DIAGNOSIS
CHART BELOW.
These charts are to be used as a qui ck-reference
onl y. Refer to COOLI NG SYSTEM DI AGNOSI S
CHART
7 - 10 COOLING DR
COOLING (Continued)
COOLING SYSTEM DIAGNOSIS CHART
LOW
1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open thermostat?
1. (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for
On-Board Diagnostics and DTC
information. Replace thermostat if
necessary.
2. Is the temperature sending unit
connected?
2. Check the temperature sensor
connector. (Refer to 8 -
CLUSTER - SCHEMATIC -
ELECTRICAL) Repair connector if
necessary.
3. Is the temperature gauge
operating OK?
3. Check gauge operation. (Refer to
8 - ELECTRICAL/INSTRUMENT
CLUSTER/ENGINE
TEMPERATURE GAUGE -
DESCRIPTION). Repair as
necessary.
4. Coolant level low in cold ambient
temperatures accompanied with
poor heater performance.
4. Check coolant level in the coolant
reserve/overflow tank or degas
bottle and the radiator. Inspect
system for leaks. Repair leaks as
necessary. Refer to the Coolant
section of the manual text for
WARNINGS and CAUTIONS
associated with removing the
radiator cap.
5. Improper operation of internal
heater doors or heater controls.
5. Inspect heater and repair as
necessary. (Refer to 24 - HEATING
& AIR CONDITIONING -
DIAGNOSIS AND TESTING) for
procedures.
HIGH OR THE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST OR LEAKING FROM THE
COOLING SYSTEM
1. Trailer is being towed, a steep
hill is being climbed, vehicle is
operated in slow moving traffic, or
engine is being idled with very high
ambient (outside) temperatures and
the air conditioning is on. Higher
altitudes could aggravate these
conditions.
1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to
the normal range. If the gauge does
not return to the normal range,
determine the cause for overheating
and repair. Refer to Possible
Causes (2-18).
2. Is the temperature gauge reading
correctly?
2. Check gauge. (Refer to 8 -
CLUSTER - SCHEMATIC -
ELECTRICAL). Repair as
necessary.
DR COOLING 7 - 11
COOLING (Continued)
3. Is the temperature warning
illuminating unnecessarily?
3. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER -
SCHEMATIC - ELECTRICAL).
4. Coolant low in coolant reserve/
overflow tank and radiator?
4. Check for coolant leaks and
repair as necessary. (Refer to 7 -
TESTING).
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following Step 6.
5. Tighten cap
6. Poor seals at the radiator cap. 6. (a) Check condition of cap and
cap seals. Refer to Radiator Cap.
Replace cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator (5.9L) or degas
bottle (3.7L, 4.7L).
7. Coolant level low in radiator but
not in coolant reserve/overflow
tank. This means the radiator is not
drawing coolant from the coolant
reserve/overflow tank as the engine
cools (5.9L).
7. (a) Check condition of radiator
cap and cap seals. Refer to
Radiator Cap in this Group. Replace
cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
(c) Check condition of the hose from
the radiator to the coolant tank. It
should fit tight at both ends without
any kinks or tears. Replace hose if
necessary.
(d) Check coolant reserve/overflow
tank and tanks hoses for blockage.
Repair as necessary.
8. Incorrect coolant concentration 8. Check coolant. (Refer to
LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION).
9. Coolant not flowing through
system
9. Check for coolant flow at radiator
filler neck with some coolant
removed, engine warm and
thermostat open. Coolant should be
observed flowing through radiator. If
flow is not observed, determine area
of obstruction and repair as
necessary.
10. Radiator or A/C condenser fins
are dirty or clogged.
10. Remove insects and debris.
7 - 12 COOLING DR
COOLING (Continued)
11. Radiator core is corroded or
plugged.
11. Have radiator re-cored or
replaced.
12. Fuel or ignition system
problems.
12. Refer to 14 - Fuel System or 8 -
Electrical for diagnosis and testing
procedures.
13. Dragging brakes. 13. Check and correct as
necessary. (Refer to 5 - BRAKES -
correct procedures.
14. Bug screen or cardboard is
being , reducing air flow.
14. Remove bug screen or
cardboard.
15. Thermostat partially or
completely shut.
15. Check thermostat operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT -
REMOVAL) .
16. Viscous fan drive not operating
properly.
16. Check fan drive operation and
replace as necessary. (Refer to 7 -
VISCOUS CLUTCH - REMOVAL).
17. Cylinder head gasket leaking. 17. Check for cylinder head gasket
leaks. (Refer to 7 - COOLING -
18. Heater core leaking. 18. Check heater core for leaks.
(Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING -
Repair as necessary.
DR COOLING 7 - 13
COOLING (Continued)
Temperature gauge reading is
inconsistent (fluctuates, cycles or is
erratic)
1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.
1. A normal condition. No correction
necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.
2. Check operation of gauge and
repair if necessary. (Refer to 8 -
TESTING).
3. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)
is necessary. Gauge should return
to normal range after vehicle is
driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
5. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open
late).
5. Check and correct coolant leaks.
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a
thermostat to open late.
6. (a) Check for cylinder head
gasket leaks. (Refer to 7 -
TESTING).
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from the exhaust system. Repair as
necessary.
7. Water pump impeller loose on
shaft.
7. Check water pump and replace
as necessary. (Refer to 7 -
COOLING/ENGINE/WATER PUMP -
REMOVAL).
8. Loose accessory drive belt.
(water pump slipping)
8. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS
- DIAGNOSIS AND TESTING).
Check and correct as necessary.
9. Air leak on the suction side of
the water pump allows air to build
up in cooling system causing
thermostat to open late.
9. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
TO COOLANT TANK.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK
1. Pressure relief valve in radiator
cap is defective.
1. Check condition of radiator cap
and cap seals. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING). Replace cap as
necessary.
7 - 14 COOLING DR
COOLING (Continued)
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE READING
HIGH OR HOT
1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.
1. Pressure test and repair as
necessary. (Refer to 7 - COOLING -
DETONATION OR PRE-IGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH
1. Engine overheating. 1. Check reason for overheating
and repair as necessary.
2. Freeze point of coolant not
correct. Mixture is too rich or too
lean.
2. Check coolant concentration.
(Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
HOSE OR HOSES COLLAPSE
WHILE ENGINE IS RUNNING
1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
reserve/overflow system.
1. (a) Radiator cap relief valve
stuck. (Refer to 7 - COOLING/
ENGINE/RADIATOR PRESSURE
CAP - DIAGNOSIS AND TESTING).
Replace if necessary
(b) Hose between coolant
reserve/overflow tank and radiator is
kinked. Repair as necessary.
(c) Vent at coolant reserve/overflow
tank is plugged. Clean vent and
repair as necessary.
(d) Reserve/overflow tank is
internally blocked or plugged. Check
for blockage and repair as
necessary.
NOISY VISCOUS FAN/DRIVE 1. Fan blades loose. 1. Replace fan blade assembly.
(Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - REMOVAL)
2. Fan blades striking a surrounding
object.
2. Locate point of fan blade contact
3. Air obstructions at radiator or air
conditioning condenser.
3. Remove obstructions and/or
clean debris or insects from radiator
or A/C condenser.
4. Thermal viscous fan drive has
defective bearing.
4. Replace fan drive. Bearing is not
serviceable. (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
5. A certain amount of fan noise
may be evident on models
equipped with a thermal viscous fan
drive. Some of this noise is normal.
5. (Refer to 7 - COOLING/ENGINE/
FAN DRIVE VISCOUS CLUTCH -
DESCRIPTION) for an explanation
of normal fan noise.
DR COOLING 7 - 15
COOLING (Continued)
INADEQUATE HEATER
PERFORMANCE. THERMOSTAT
FAILED IN OPEN POSITION
1. Has a Diagnostic trouble Code
(DTC) been set?
1. (Refer to 25 - EMISSIONS
CONTROL - DESCRIPTION) for
correct procedures and replace
thermostat if necessary
2. Coolant level low 2. (Refer to 7 - COOLING -
3. Obstructions in heater hose/
fittings
3. Remove heater hoses at both
ends and check for obstructions
4. Heater hose kinked 4. Locate kinked area and repair as
necessary
5. Water pump is not pumping
water to/through the heater core.
When the engine is fully warmed
up, both heater hoses should be
hot to the touch. If only one of the
hoses is hot, the water pump may
not be operating correctly or the
heater core may be plugged.
Accessory drive belt may be
slipping causing poor water pump
operation.
5. (Refer to 7 - COOLING/ENGINE/
WATER PUMP - REMOVAL). If a
slipping belt is detected, (Refer to 7
- COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS
AND TESTING). If heater core
obstruction is detected, (Refer to 24
- HEATING & AIR
CONDITIONING/PLUMBING/
HEATER CORE - REMOVAL).
STEAM IS COMING FROM THE
FRONT OF VEHICLE NEAR THE
GRILL AREA WHEN WEATHER IS
WET, ENGINE IS WARMED UP
AND RUNNING, AND VEHICLE IS
STATIONARY. TEMPERATURE
GAUGE IS IN NORMAL RANGE
1. During wet weather, moisture
(snow, ice or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the
radiator. When the moisture
contacts the hot radiator, steam
may be emitted. This usually occurs
in cold weather with no fan or air
flow to blow it away.
1. Occasional steam emitting from
this area is normal. No repair is
necessary.
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.
1. (Refer to LUBRICATION &
DESCRIPTION) Adjust coolant
mixture as necessary.
COOLANT LEVEL CHANGES IN
COOLANT RESERVE/OVERFLOW
TANK. TEMPERATURE GAUGE IS
IN NORMAL RANGE
1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
If the level in the tank was between
the FULL and ADD marks at normal
operating temperature, the level
should return to within that range
after operation at elevated
temperatures.
1. A normal condition. No repair is
necessary.
7 - 16 COOLING DR
COOLING (Continued)
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT LEVEL
CHECK
NOTE: Do not remove radiator cap for routine cool-
ant level inspections. The coolant level can be
checked at coolant recovery bottle or the coolant
degas bottle.
WARNING: DO NOT REMOVE OR LOOSEN THE
RADIATOR CAP WITH THE COOLING SYSTEM HOT
AND UNDER PRESSURE. SERIOUS BURNS FROM
COOLANT OR HIGH PRESSURE STEAM CAN
OCCUR.
The cool ant reserve/overfl ow system provi des a
qui ck method for determi ni ng the cool ant l evel wi th-
out removi ng the radi ator pressure cap. Wi th the
engi ne at normal operati ng temperature and i dl i ng,
observe the l evel of the cool ant on the external l evel
i ndi cator on the si de of the cool ant reserve /overfl ow
bottl e. The cool ant l evel shoul d be between the MI N
and MAX marks. I f the cool ant i s bel ow the MI N
mark, add a 50/50 mi xture of anti freeze and water to
the bottl e unti l the l evel reaches the MI N mark. Do
Not Overfill the bottle by adding fluid above
the MAX line. Thi s may cause cool ant to spi l l onto
the ground duri ng subsequent vehi cl e operati on.
STANDARD PROCEDURE - COOLING SYSTEM
CLEANING/REVERSE FLUSHING
CLEANING
Drai n the cool i ng system and refi l l wi th water. Run
the engi ne wi th the radi ator cap i nstal l ed unti l the
upper radi ator hose i s hot. Stop the engi ne and drai n
the water from system. I f the water i s di rty, fi l l the
system wi th water, run the engi ne and drai n the sys-
tem. Repeat thi s procedure unti l the water drai ns
cl ean.
REVERSE FLUSHING
Reverse fl ushi ng of the cool i ng system i s the forc-
i ng of water through the cool i ng system. Thi s i s done
usi ng ai r pressure i n the opposi te di recti on of normal
cool ant fl ow. I t i s usual l y onl y necessary wi th very
di rty systems wi th evi dence of parti al pl uggi ng.
REVERSE FLUSHING RADIATOR
Di sconnect the radi ator hoses from the radi ator
i nl et and outl et. Attach a secti on of the radi ator hose
to the radi ator bottom outl et fi tti ng and i nsert the
fl ushi ng gun. Connect a water suppl y hose and ai r
suppl y hose to the fl ushi ng gun.
CAUTION: Internal radiator pressure must not
exceed 138 kPa (20 psi) as damage to radiator may
result.
Al l ow the radi ator to fi l l wi th water. When the
radi ator i s fi l l ed, appl y ai r i n short bl asts. Al l ow the
radi ator to refi l l between bl asts. Conti nue thi s
reverse fl ushi ng unti l cl ean water fl ows out through
the rear of the radi ator cool i ng tube passages.
REVERSE FLUSHING ENGINE
Drai n the cool i ng system. Remove the thermostat
housi ng and thermostat. I nstal l the thermostat hous-
i ng. Di sconnect the radi ator upper hose from the
radi ator and attach the fl ushi ng gun to the hose. Di s-
connect the radi ator l ower hose from the water pump
and attach a l ead-away hose to the water pump i nl et
fi tti ng.
CAUTION: On vehicles equipped with a heater water
control valve, 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.
Connect the water suppl y hose and ai r suppl y hose
to fl ushi ng gun. Al l ow the engi ne to fi l l wi th water.
When the engi ne i s fi l l ed, appl y ai r i n short bl asts,
al l owi ng the system to fi l l between ai r bl asts. Con-
ti nue unti l cl ean water fl ows through the l ead away
hose.
Remove the l ead away hose, fl ushi ng gun, water
suppl y hose and ai r suppl y hose. Remove the thermo-
stat housi ng and i nstal l the thermostat. I nstal l the
thermostat housi ng wi th a repl acement gasket. Refer
to Thermostat Repl acement. Connect the radi ator
hoses. Refi l l the cool i ng system wi th the correct anti -
freeze/water mi xture. Refer to Refi l l i ng the Cool i ng
System.
CHEMICAL CLEANING
I n some i nstances, use a radi ator cl eaner (Mopar
Radi ator Kl een or equi val ent) before fl ushi ng. Thi s
wi l l soften scal e and other deposi ts and ai d fl ushi ng
operati on.
CAUTION: Follow manufacturers instructions when
using these products.
STANDARD PROCEDURE - DRAINING COOLING
SYSTEM - ALL GAS ENGINES
DR COOLING 7 - 17
COOLING (Continued)
DO NOT WASTE reusabl e cool ant. I f sol uti on i s
cl ean, drai n cool ant i nto a cl ean contai ner for reuse.
(1) Attach one end of a hose to the drai ncock. Put
the other end i nto a cl ean contai ner.
(2) DO NOT REMOVE THE RADIATOR CAP
when drai ni ng the cool ant from the reservoi r/over-
fl ow tank. Open radi ator drai ncock and when the
tank i s empty, remove the radi ator cap and conti nue
drai ni ng the cool i ng system.
(3) I f drai ni ng the enti re engi ne, remove the cyl i n-
der bl ock drai n pl ugs. Refer to (Fi g. 6) or (Fi g. 7).
COOLING SYSTEM - ALL GAS ENGINES
DO NOT WASTE reusabl e cool ant. I f sol uti on i s
cl ean, drai n cool ant i nto a cl ean contai ner for reuse.
Cl ean cool i ng system pri or to refi l l i ng. (Refer to 7 -
COOLI NG - STANDARD PROCEDURE).
(1) I nstal l cyl i nder bl ock drai n pl ugs. Coat the
threads wi th Mopar Thread Seal ant wi th Tefl on.
(2) Cl ose radi ator petcock.
(3) Fi l l cool i ng system wi th a 50/50 mi xture of
water and anti freeze.
(4) Fi l l cool ant reserve/overfl ow tank to MAX mark
on bottl e.
(5) Start and operate engi ne unti l thermostat
opens (upper radi ator hose warm to touch).
(6) I f necessary, add a 50/50 water and anti freeze
mi xture to the cool ant reserve/overfl ow tank. Thi s i s
done to mai ntai n cool ant l evel between the MAX and
MI N marks. The l evel i n the reserve/overfl ow tank
may drop bel ow the MI N mark after three or four
warm-up and cool -down cycl es.
STANDARD PROCEDURE - DRAINING COOLING
SYSTEM 5. 9L DIESEL ENGINE
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN PLUG WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
(1) Start the engi ne and pl ace the heater control
temperature sel ector i n the Ful l -On posi ti on.
(2) Turn the i gni ti on off.
(3) Do not remove radi ator cap when drai ni ng cool -
ant from reserve/overfl ow tank. Open radi ator drai n
pl ug and when tank i s empty, remove radi ator cap. I f
the cool ant reserve/overfl ow tank does not drai n,
(Refer to 7 - COOLI NG - DI AGNOSI S AND TEST-
I NG). The cool ant need not be removed from tank
unl ess the system i s bei ng refi l l ed wi th fresh mi x-
ture.
(4) Remove radi ator pressure cap.
Fig. 6 Drain PlugsGas Powered EnginesTypical
1 - BLOCK DRAIN PLUG
Fig. 7 Drain Plug - 3.7L/4.7L Engine
1 - CYLINDER BLOCK DRAIN PLUG
2 - EXHAUST MANIFOLD AND HEAT SHIELD
7 - 18 COOLING DR
COOLING (Continued)
COOLING SYSTEM 5. 9L DIESEL ENGINE
Cl ean cool i ng system pri or to refi l l i ng (Refer to 7 -
(1) Cl ose radi ator drai n pl ug.
CAUTION: Due to the use of the one-way check
valve, the engine must not be operating when refill-
ing the cooling system.
NOTE: The diesel engine is equipped with two one-
way check valves (jiggle pins). The check valves
are used as a servicing feature and will vent air
when the system is being filled. Water pressure (or
flow) will hold the valves closed.
(2) Fi l l the cool i ng system wi th a 50/50 mi xture of
water and anti freeze.
(3) Fi l l cool ant reserve/overfl ow tank to the FULL
mark.
(4) Start and operate engi ne unti l thermostat
opens. Upper radi ator hose shoul d be warm to touch.
(5) I f necessary, add 50/50 water and anti freeze
mi xture to the cool ant reserve/overfl ow tank to mai n-
tai n cool ant l evel . Thi s l evel shoul d be between the
ADD and FULL marks. The l evel i n the reserve/over-
fl ow tank may drop bel ow the ADD mark after three
or four warm-up and cool -down cycl es.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
mi xed wi th 50% di sti l l ed water to obtai n a freeze
poi nt of -37C (-35F). I f i t l oses col or or becomes con-
tami nated, drai n, fl ush, and repl ace wi th fresh prop-
erl y mi xed cool ant sol uti on.
Do not remove the radi ator cap to add cool ant to
the system. When addi ng cool ant to mai ntai n the cor-
rect l evel , do so onl y at the reserve/overfl ow bottl e.
Remove the radi ator cap onl y for testi ng or when
refi l l i ng the system after servi ce. Removi ng the cap
unnecessari l y can cause l oss of cool ant and al l ow ai r
to enter the system, whi ch produces corrosi on.
WARNING: DO NOT REMOVE OR LOOSEN THE
RADIATOR CAP WITH THE COOLING SYSTEM HOT
AND UNDER PRESSURE. SERIOUS BURNS FROM
THE COOLANT OR HIGH PRESSURE STEAM CAN
OCCUR.
SPECIFICATIONS
TORQUE
DESCRIPTION Nm Ft.
Lbs.
In.
Lbs.
Bolt - Automatic Belt
Tensioner to Block
41 30 -
Tensioner Pulley
61 45 -
Tensioner Pulley - Diesel
43 32 -
Bolt - Block Heater 2 - 17
Bolts - Generator/
Compressor Mounting
Bracket
# 1 and 2 54 40 -
# 3 40 30 -
Bolts - Generator/
Compressor Mounting
Bracket - Diesel
24 18 -
Bolts - Fan Shroud to
Radiator Mounting - All
Except 5.9L Diesel
6 - 55
5.9L Diesel 11.8 - 105
Bolts - Radiator to Support 8.5 - 75
Bolts - Fan Blade to
Viscous Fan Drive
24 18 -
Fan Drive - All Except
8.0L/5.9L Diesel
50 37 -
8.0L/5.9L Diesel 115 85 -
Bolt - Idler Pulley 54 40 -
Bolt - Idler Pulley - Diesel 43 32 -
Bolts - Thermostat Housing
- All Except 5.9L
13 - 112
5.9L
23 16 -
- Diesel
10 - 89
Bolts - Power Steering Oil
Cooler
8.4 - 75
Bolts - Transmission
Auxiliary Oil Cooler
6 - 55
DR COOLING 7 - 19
COOLING (Continued)
DESCRIPTION Nm Ft.
Lbs.
In.
Lbs.
Nuts - Transmission Oil
Cooler Tube
31.5 24 -
Bolts - Coolant Bottle 8.5 - 75
Tube Nuts - Transmission
Oil Cooler to Transmission
5.9L/46RE 31.5 24 -
3.7L/4.7L/5.7L/45RFE 20 18 -
Bolts - Water Pump -
Diesel
24 18 -
Bolts - Water Pump - 4.7L 58 43 -
Block Heater - Diesel 55 41 -
Transmission Oil Cooler -
Diesel
M8 24 18 -
M12 77 57 -
SPECIFICATIONS -
SPECIFICATIONS
Metric Standard
3.7/4.7L/5.7L
Engine
15.4L 16.2 qts.- to the
middle of the
cold fill range
5.9L Diesel
Engine
28L 29.5 qts.
SPECIAL TOOLS
COOLING
Pliers Constant Pressure Hose Clamp - 6094
3/8 Quick Connect Release Tool - 6935
SPANNER WRENCH6958
Cooling System Pressure Tester - 7700A
Adapter Pins 8346
7 - 20 COOLING DR
COOLING (Continued)
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
BELT TENSIONER - 3.7L / 4.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
BELT TENSIONER-5.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
BELT TENSIONER - 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
DRIVE BELT - 3.7L / 4.7L
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
DRIVE BELT - 5.9L DIESEL
DIAGNOSIS AND TESTINGACCESSORY
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
BELT TENSIONER - 3.7L / 4.7L
DESCRIPTION
Correct dri ve bel t tensi on i s requi red to ensure
opti mum performance of the bel t dri ven engi ne acces-
sori es. I f speci fi ed tensi on i s not mai ntai ned, bel t
sl i ppage may cause; engi ne overheati ng, l ack of
power steeri ng assi st, l oss of ai r condi ti oni ng capac-
i ty, reduced generator output rate, and greatl y
reduced bel t l i fe.
I t i s not necessary to adjust bel t tensi on on the
3.7L or 4.7L engi ne. These engi nes are equi pped wi th
an automati c bel t tensi oner (Fi g. 1). The tensi oner
mai ntai ns correct bel t tensi on at al l ti mes. Due to
use of thi s bel t tensi oner, do not attempt to use a bel t
tensi on gauge on 3.7L or 4.7L engi nes.
OPERATION
The automati c bel t tensi oner mai ntai ns bel t ten-
si on by usi ng i nternal spri ng pressure, a pi voti ng
arm and pul l ey to press agai nst the dri ve bel t.
REMOVAL
On 3.7L and 4.7L engines, the tensioner is
equipped with an indexing tang on back of ten-
sioner and an indexing stop on tensioner hous-
ing. If a new belt is being installed, tang must
be within approximately 24 mm (.94 inches) of
indexing stop. Belt is considered new if it has
been used 15 minutes or less.
I f the above speci fi cati on cannot be met, check for:
The wrong bel t bei ng i nstal l ed (i ncorrect l ength/
wi dth)
Worn beari ngs on an engi ne accessory (A/C com-
pressor, power steeri ng pump, water pump, i dl er pul -
l ey or generator)
A pul l ey on an engi ne accessory bei ng l oose
Mi sal i gnment of an engi ne accessory
Bel t i ncorrectl y routed.
NOTE: A used belt should be replaced if tensioner
indexing arrow has moved to the minimum tension
indicator. Tensioner travel stops at this point.
Fig. 1 AUTOMATIC BELT TENSIONER
1 - AUTOMATIC TENSIONER ASSEMBLY
DR ACCESSORY DRIVE 7 - 21
(1) Remove accessory dri ve bel t (Refer to 7 -
COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(2) Remove tensi oner assembl y from mounti ng
bracket (Fi g. 2).
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY EXCEPT FOR PULLEY ON TENSIONER.
(3) Remove pul l ey bol t. Remove pul l ey from ten-
si oner.
INSTALLATION
(1) I nstal l pul l ey and pul l ey bol t to tensi oner.
Ti ghten bol t to 61 Nm (45 ft. l bs.) torque.
(2) An i ndexi ng sl ot i s l ocated on back of tensi oner.
Al i gn thi s sl ot to the head of the bol t on the front
cover. I nstal l the mounti ng bol t. Ti ghten bol t to 41
Nm (30 ft. l bs.).
(3) I nstal l accessory dri ve bel t (Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - I NSTAL-
LATI ON).
(4) Check bel t i ndexi ng marks (Fi g. 1).
BELT TENSIONER-5.7L
DESCRIPTION
Correct dri ve bel t tensi on i s requi red to ensure
opti mum performance of the bel t dri ven engi ne acces-
sori es. I f speci fi ed tensi on i s not mai ntai ned, bel t
sl i ppage may cause; engi ne overheati ng, l ack of
power steeri ng assi st, l oss of ai r condi ti oni ng capac-
i ty, reduced generator output rate, and greatl y
reduced bel t l i fe.
I t i s not necessary to adjust bel t tensi on on the
5.7L engi nes. Thi s engi nes i s equi pped wi th an auto-
mati c bel t tensi oner. The tensi oner mai ntai ns correct
bel t tensi on at al l ti mes (Fi g. 3). Due to the use of
thi s bel t tensi oner, do not attempt to use a bel t ten-
si on gauge on 5.7L engi ne.
OPERATION
The automati c bel t tensi oner mai ntai ns bel t ten-
si on by usi ng i nternal spri ng pressure, a pi voti ng
arm and pul l ey to press agai nst the dri ve bel t.
REMOVAL
REMOVAL).
(2) Remove tensi oner and mounti ng bracket.
(3) Remove the tensi oner assembl y from the
mounti ng bracket.
(4)
Fig. 2 AUTOMATIC BELT TENSIONER - 3.7L/4.7L
ENGINE
1 - TIMING CHAIN COVER
2 - BOLT TORQUE TO 41 Nm (30 FT LBS)
3 - AUTOMATIC BELT TENSIONER
Fig. 3 Automatic Belt Tensioner
1 - TENSIONER
2 - BOLT
7 - 22 ACCESSORY DRIVE DR
BELT TENSIONER - 3.7L / 4.7L (Continued)
INSTALLATION
(1) I nstal l tensi oner on to the mounti ng bracket.
Ti ghten bol t to 41 Nm (30 ft. l bs.).
(2) I nstal l tensi oner and bracket assembl y
LATI ON).
BELT TENSIONER - 5.9L
DIESEL
DESCRIPTION
Dri ve bel ts on al l engi nes are equi pped wi th a
spri ng l oaded automati c bel t tensi oner (Fi g. 4). Thi s
tensi oner mai ntai ns constant bel t tensi on at al l ti mes
and requi res no mai ntenance or adjustment.
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
OPERATION
WARNING: THE AUTOMATIC BELT TENSIONER
ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT
TO DISASSEMBLE THE TENSIONER ASSEMBLY.
The automati c bel t tensi oner mai ntai ns correct bel t
tensi on usi ng a coi l ed spri ng wi thi n the tensi oner
housi ng. The spri ng appl i es pressure to the tensi oner
arm pressi ng the arm i nto the bel t, tensi oni ng the
bel t.
REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY.
REMOVAL).
(2) Remove tensi oner mounti ng bol t (Fi g. 5) and
remove tensi oner.
Fig. 4 Accessory Drive Belt - 5.9L Diesel
1 - GENERATOR
2 - WATER PUMP
3 - IDLER
4 - POWER STEERING PUMP
5 - RADIATOR FAN PULLEY
6 - CRANKSHAFT
7 - AUTOMATIC TENSIONER
8 - A/C COMPRESSOR
Fig. 5 AUTOMATIC BELT TENSIONER 5.9L DIESEL
ENGINE
1 - GENERATOR
2 - WATER PUMP
3 - IDLER
6 - CRANKSHAFT
8 - A/C COMPRESSOR
BELT TENSIONER-5.7L (Continued)
INSTALLATION
(1) I nstal l tensi oner assembl y to water i nl et
bracket. A dowel i s l ocated on back of tensi oner. Al i gn
thi s dowel to hol e i n tensi oner mounti ng bracket.
Ti ghten bol t to 43 Nm (32 ft. l bs.) torque.
(2) I nstal l dri ve bel t (Refer to 7 - COOLI NG/AC-
CESSORY DRI VE/DRI VE BELTS - I NSTALLA-
TI ON).
DRIVE BELT - 3.7L / 4.7L
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT
VISUAL DIAGNOSIS
When di agnosi ng serpenti ne accessory dri ve bel ts,
smal l cracks that run across the ri bbed surface of the
bel t from ri b to ri b (Fi g. 6), are consi dered normal .
These are not a reason to repl ace the bel t. However,
cracks runni ng al ong a ri b (not across) are not nor-
mal . Any bel t wi th cracks runni ng al ong a ri b must
be repl aced (Fi g. 6). Al so repl ace the bel t i f i t has
excessi ve wear, frayed cords or severe gl azi ng.
Refer to ACCESSORY DRI VE BELT DI AGNOSI S
CHART for further bel t di agnosi s.
NOISE DIAGNOSIS
Noi ses generated by the accessory dri ve bel t are
most noti ceabl e at i dl e. Before repl aci ng a bel t to
resol ve a noi se condi ti on, i nspect al l of the accessory
dri ve pul l eys for al i gnment, gl azi ng, or excessi ve end
pl ay.
ACCESSORY DRIVE BELT DIAGNOSIS CHART
RIB CHUNKING (One or more ribs
has separated from belt body)
1. Foreign objects imbedded in
pulley grooves.
1. Remove foreign objects from
pulley grooves. Replace belt.
2. Installation damage 2. Replace belt
RIB OR BELT WEAR 1. Pulley 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. Inspect belt.
5. Belt rubber deteriorated 5. Replace belt
Fig. 6 Belt Wear Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
BELT TENSIONER - 5.9L DIESEL (Continued)
BELT SLIPS 1. Belt slipping because of
insufficient tension
1. Inspect/Replace tensioner if
necessary
2. Belt or pulley exposed to
substance that has reduced friction
(belt dressing, oil, ethylene glycol)
2. Replace belt and clean pulleys
3. Driven component bearing failure
(seizure)
3. Replace faulty component or
bearing
4. Belt glazed or hardened from
heat and excessive slippage
4. Replace belt.
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley
groove
1. Replace belt
2. Pulley groove tip has worn away
rubber to tensile member
2. Replace belt
GROOVE JUMPING
(Belt does not maintain correct
position on pulley)
1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Pulley(s) not within design
tolerance
2. Replace pulley(s)
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)
1. Incorrect belt tension 1. Replace Inspect/Replace
tensioner if necessary
2. Tensile member damaged during
belt installation
2. Replace belt
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component
and belt
NOISE
(Objectionable squeal, squeak, or
rumble is heard or felt while drive
belt is in operation)
necessary
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration
5. Locate defective driven
component and repair
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)
1. Tension sheeting contacting
stationary object
1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age
2. Replace belt
3. Tension sheeting splice has
fractured
3. Replace belt
DRIVE BELT - 3.7L / 4.7L (Continued)
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)
necessary
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix
4. Replace belt
REMOVAL
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVER DAM-
AGE MAY OCCUR TO THE TENSIONER.
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c (spri ng l oad) bel t ten-
si oner.
(1) Di sconnect negati ve battery cabl e from battery.
(2) Rotate bel t tensi oner unti l i t contacts i ts stop.
Remove bel t, then sl owl y rotate the tensi oner i nto
the freearm posi ti on. (Fi g. 7).
INSTALLATION
Bel t tensi on i s not adjustabl e. Bel t adjustment i s
mai ntai ned by an automati c ( spri ng l oad ) bel t ten-
si oner.
(1) Check condi ti on of al l pul l eys.
CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 7).
(2) I nstal l new bel t (Fi g. 7). Route the bel t around
al l pul l eys except the i dl er pul l ey. Rotate the ten-
si oner arm unti l i t contacts i ts stop posi ti on. Route
the bel t around the i dl er and sl owl y l et the tensi oner
rotate i nto the bel t. Make sure the bel t i s seated onto
al l pul l eys.
(3) Wi th the dri ve bel t i nstal l ed, i nspect the bel t
wear i ndi cator (Fi g. 8). On 4.7L Engi nes onl y, the gap
between the tang and the housi ng stop (measure-
ment A) must not exceed 24 mm (.94 i nches). I f the
measurement exceeds thi s speci fi cati on repl ace the
serpenti ne accessory dri ve bel t.
Fig. 7 BELT ROUTING 3.7L / 4.7L
1 - GENERATOR PULLEY
2 - ACCESSORY DRIVE BELT
3 - POWER STEERING PUMP PULLEY
4 - CRANKSHAFT PULLEY
5 - IDLER PULLEY
6 - TENSIONER
7 - A/C COMPRESSOR PULLEY
8 - WATER PUMP PULLEY
Fig. 8 Accessory Drive Belt Wear Indicator4.7L
Engine
1 - AUTOMATIC TENSIONER ASSEMBLY
DRIVE BELT - 3.7L / 4.7L (Continued)
DRIVE BELT - 5.9L DIESEL
DIAGNOSIS AND TESTING ACCESSORY
DRIVE BELT
VISUAL DIAGNOSIS
When di agnosi ng serpenti ne accessory dri ve bel ts,
smal l cracks that run across the ri bbed surface of the
bel t from ri b to ri b (Fi g. 9), are consi dered normal .
These are not a reason to repl ace the bel t. However,
cracks runni ng al ong a ri b (not across) are not nor-
mal . Any bel t wi th cracks runni ng al ong a ri b must
be repl aced (Fi g. 9). Al so repl ace the bel t i f i t has
excessi ve wear, frayed cords or severe gl azi ng.
Refer to ACCESSORY DRI VE BELT DI AGNOSI S
CHART for further bel t di agnosi s.
NOISE DIAGNOSIS
Noi ses generated by the accessory dri ve bel t are
most noti ceabl e at i dl e. Before repl aci ng a bel t to
resol ve a noi se condi ti on, i nspect al l of the accessory
dri ve pul l eys for al i gnment, gl azi ng, or excessi ve end
pl ay.
ACCESSORY DRIVE BELT DIAGNOSIS CHART
RIB CHUNKING (One or more ribs
has separated from belt body)
1. Foreign objects imbedded in
pulley grooves.
1. Remove foreign objects from
pulley grooves. Replace belt.
2. Installation damage 2. Replace belt
RIB OR BELT WEAR 1. Pulley 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. Inspect belt.
5. Belt rubber deteriorated 5. Replace belt
BELT SLIPS 1. Belt slipping because of
insufficient tension
1. Inspect/Replace tensioner if
necessary
2. Belt or pulley exposed to
substance that has reduced friction
(belt dressing, oil, ethylene glycol)
2. Replace belt and clean pulleys
3. Driven component bearing failure
(seizure)
3. Replace faulty component or
bearing
4. Belt glazed or hardened from
heat and excessive slippage
4. Replace belt.
Fig. 9 Belt Wear Patterns
1 - NORMAL CRACKS BELT OK
2 - NOT NORMAL CRACKS REPLACE BELT
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley
groove
1. Replace belt
2. Pulley groove tip has worn away
rubber to tensile member
2. Replace belt
GROOVE JUMPING
(Belt does not maintain correct
position on pulley)
necessary
2. Pulley(s) not within design
tolerance
2. Replace pulley(s)
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)
1. Incorrect belt tension 1. Replace Inspect/Replace
tensioner if necessary
2. Tensile member damaged during
belt installation
2. Replace belt
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component
and belt
NOISE (Objectional squeal, squeak,
or rumble is heard or felt while drive
belt is in operation)
necessary
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration
5. Locate defective driven
component and repair
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)
1. Tension sheeting contacting
stationary object
1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age
2. Replace belt
3. Tension sheeting splice has
fractured
3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)
necessary
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix
4. Replace belt
NOTE: The engine speed sensor face is very close
to the accessory drive belt. Inspect engine speed
sensor and wire harness for damage when acces-
sory drive belt has been replaced due to failure or
abnormal conditions.
DRIVE BELT - 5.9L DIESEL (Continued)
REMOVAL
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner. Refer to Automatic Belt
Tensioner in this group.
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label.This label is located in
the engine compartment.
Dri ve bel ts on di esel engi nes are equi pped wi th a
spri ng l oaded automati c bel t tensi oner.
Thi s bel t tensi oner wi l l be used on al l bel t confi g-
urati ons, such as wi th or wi thout ai r condi ti oni ng.
For more i nformati on, (Refer to 7 - COOLI NG/AC-
CESSORY DRI VE/BELT TENSI ONERS - DESCRI P-
TI ON).
(1) A 1/2 i nch square hol e i s provi ded i n the auto-
mati c bel t tensi oner. Attach a 1/2 i nch dri ve-l ong
handl e ratchet to thi s hol e.
(2) Rotate ratchet and tensi oner assembl y cl ock-
wi se (as vi ewed from front) unti l tensi on has been
rel i eved from bel t.
(3) Remove bel t from water pump pul l ey fi rst.
(4) Remove bel t from vehi cl e.
INSTALLATION
CAUTION: When installing the accessory drive belt,
the belt must be routed correctly. If not, engine may
overheat due to water pump rotating in wrong
direction. Refer to (Fig. 10) or (Fig. 11)for correct
engine belt routing. The correct belt with correct
length must be used.
(1) Posi ti on dri ve bel t over al l pul l eys except
water pump pul l ey.
(2) Attach a 1/2 i nch ratchet to tensi oner.
(3) Rotate ratchet and bel t tensi oner cl ockwi se.
Pl ace bel t over water pump pul l ey. Let tensi oner
rotate back i nto pl ace. Remove ratchet. Be sure bel t
i s properl y seated on al l pul l eys.
Fig. 10 Belt Routing 5.9L Diesel Engine With A/C
3 - IDLER PULLEY
8 - A/C COMPRESSOR PUMP PULLEY
Fig. 11 Belt Routing - 5.9L Diesel Engine Without
A/C
3 - IDLER PULLEY
DRIVE BELT - 5.9L DIESEL (Continued)
ENGINE
TABLE OF CONTENTS
page page
COOLANT
DESCRIPTION
DESCRIPTION - ENGINE COOLANT . . . . . . . 31
DESCRIPTION - HOAT COOLANT . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
COOLANT RECOVERY CONTAINER- GAS
ENGINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
RADIATOR FAN - GAS ENGINES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
RADIATOR FAN - 5.9L DIESEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
ENGINE BLOCK HEATER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING - ENGINE BLOCK
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
ENGINE BLOCK HEATER - 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
ENGINE COOLANT TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
ENGINE COOLANT THERMOSTAT- 5.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DIAGNOSIS AND TESTINGTHERMOSTAT . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
ENGINE COOLANT THERMOSTAT - 3.7L/4.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DIAGNOSIS AND TESTINGTHERMOSTAT . . . 44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
ENGINE COOLANT THERMOSTAT - 5.9L
DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
DIAGNOSIS AND TESTING - THERMOSTAT . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
ENGINE COOLANT THERMOSTAT - 8.0L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 48
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DIAGNOSIS AND TESTING - THERMOSTAT . . . 48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
FAN DRIVE VISCOUS CLUTCH-GAS ENGINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
DIAGNOSIS AND TESTING - VISCOUS FAN
DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
DIAGNOSIS AND TESTING -
ELECTRONICALLY CONTROLLED VISCOUS
FAN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . 52
RADIATOR-3.7L/4.7L/5.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 54
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DIAGNOSIS AND TESTING - RADIATOR
COOLANT FLOW . . . . . . . . . . . . . . . . . . . . . . 54
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
RADIATOR - 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 56
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
COOLANT FLOW . . . . . . . . . . . . . . . . . . . . . . 56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
RADIATOR PRESSURE CAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 57
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CAP-TO-FILLER NECK SEAL. . . . . . . . . . . . . 58
7 - 30 ENGINE DR
CAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 59
WATER PUMP - 3.7L/4.7L
DESCRIPTION
DESCRIPTION - WATER PUMP . . . . . . . . . . . 59
DESCRIPTION - WATER PUMP BYPASS . . . . 59
OPERATION
OPERATIONWATER PUMP . . . . . . . . . . . . 60
OPERATION - WATER PUMP BYPASS . . . . . 60
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
WATER PUMP - 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 62
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DIAGNOSIS AND TESTINGWATER PUMP . . . 62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 62
WATER PUMP - 5.7L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63
WATER PUMP - 8.0L
DIAGNOSIS AND TESTING - WATER PUMP . . . 63
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66
COOLANT
DESCRIPTION
DESCRIPTION - ENGINE COOLANT
ETHYLENE-GLYCOL MIXTURES
ene-glycol.
year/100,000 Mi l e Formul a (ethyl ene-gl ycol base cool -
ant wi th corrosi on i nhi bi tors cal l ed HOAT, for Hybri d
mi xed wi th 50% di sti l l ed water to obtai n a freeze
poi nt of -37C (-35F).
mi xture depends upon the cl i mate and vehi cl e oper-
ati ng condi ti ons. The anti freeze concentrati on must
always be a mi ni mum of 44 percent, year-round i n
al l cl i mates. If percentage is lower than 44 per-
cent, engine parts may be eroded by cavitation,
and cooling system components may be
severely damaged by corrosion. Maxi mum protec-
ti on agai nst freezi ng i s provi ded wi th a 68% anti -
freeze concentrati on, whi ch prevents freezi ng down to
-67.7 C (-90 F). A hi gher percentage wi l l freeze at a
warmer temperature. Al so, a hi gher percentage of
anti freeze can cause the engi ne to overheat because
the speci fi c heat of anti freeze i s l ower than that of
water.
Use of 100 percent ethyl ene-gl ycol wi l l cause for-
mati on of addi ti ve deposi ts i n the system, as the cor-
rosi on i nhi bi ti ve addi ti ves i n ethyl ene-gl ycol requi re
the presence of water to di ssol ve. The deposi ts act as
i nsul ati on, causi ng temperatures to ri se to as hi gh as
149 C (300 F). Thi s temperature i s hot enough to
mel t pl asti c and soften sol der. The i ncreased temper-
ature can resul t i n engi ne detonati on. I n addi ti on,
100 percent ethyl ene-gl ycol freezes at 22 C (-8 F ).
PROPYLENE-GLYCOL MIXTURES
I ts overal l effecti ve temperature range i s smal l er
than that of ethyl ene-gl ycol . The freeze poi nt of 50/50
propyl ene-gl ycol and water i s -32 C (-26 F). 5 C
hi gher than ethyl ene-gl ycol s freeze poi nt. The boi l i ng
poi nt (protecti on agai nst summer boi l -over) of propy-
l ene-gl ycol i s 125 C (257 F ) at 96.5 kPa (14 psi ),
compared to 128 C (263 F) for ethyl ene-gl ycol . Use
of propyl ene-gl ycol can resul t i n boi l -over or freeze-up
on a cool i ng system desi gned for ethyl ene-gl ycol . Pro-
pyl ene gl ycol al so has poorer heat transfer character-
i sti cs than ethyl ene gl ycol . Thi s can i ncrease cyl i nder
head temperatures under certai n condi ti ons.
Propyl ene-gl ycol /ethyl ene-gl ycol Mi xtures can
cause the destabi l i zati on of vari ous corrosi on i nhi bi -
tors, causi ng damage to the vari ous cool i ng system
components. Al so, once ethyl ene-gl ycol and propy-
l ene-gl ycol based cool ants are mi xed i n the vehi cl e,
conventi onal methods of determi ni ng freeze poi nt wi l l
not be accurate. Both the refracti ve i ndex and spe-
ci fi c gravi ty di ffer between ethyl ene gl ycol and propy-
l ene gl ycol .
DR ENGINE 7 - 31
DESCRIPTION - HOAT COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE-GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene-Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.
The cool i ng system i s desi gned around the cool ant.
The cool ant must accept heat from engi ne metal , i n
the cyl i nder head area near the exhaust val ves and
engi ne bl ock. Then cool ant carri es the heat to the
radi ator where the tube/fi n radi ator can transfer the
heat to the ai r.
heads, and water pumps requi res speci al corrosi on
protecti on. Mopar Anti freeze/Cool ant, 5
Year/100,000 Mi l e Formul a (MS-9769), or the equi va-
l ent ethyl ene-gl ycol base cool ant wi th organi c corro-
si on i nhi bi tors (cal l ed HOAT, for Hybri d Organi c
mi xed wi th 50% ethyl ene-gl ycol and 50% di sti l l ed
water to obtai n a freeze poi nt of -37C (-35F). I f i t
l oses col or or becomes contami nated, drai n, fl ush,
and repl ace wi th fresh properl y mi xed cool ant sol u-
ti on.
CAUTION: Mopar Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.
COOLANT PERFORMANCE
mi xture depends upon cl i mate and vehi cl e operati ng
condi ti ons. The cool ant performance of vari ous mi x-
tures fol l ows:
Pure Water-Water can absorb more heat than a
mi xture of water and ethyl ene-gl ycol . Thi s i s for pur-
pose of heat transfer onl y. Water al so freezes at a
hi gher temperature and al l ows corrosi on.
100 percent Ethylene-Glycol-The corrosi on
i nhi bi ti ng addi ti ves i n ethyl ene-gl ycol need the pres-
ence of water to di ssol ve. Wi thout water, addi ti ves
form deposi ts i n system. These act as i nsul ati on
causi ng temperature to ri se to as hi gh as 149C
(300F). Thi s temperature i s hot enough to mel t pl as-
ti c and soften sol der. The i ncreased temperature can
resul t i n engi ne detonati on. I n addi ti on, 100 percent
ethyl ene-gl ycol freezes at -22C (-8F).
50/50 Ethylene-Glycol and Water-I s the recom-
mended mi xture, i t provi des protecti on agai nst freez-
i ng to -37C (-34F). The anti freeze concentrati on
must always be a mi ni mum of 44 percent, year-
round i n al l cl i mates. I f percentage i s l ower, engi ne
parts may be eroded by cavi tati on. Maxi mum protec-
ti on agai nst freezi ng i s provi ded wi th a 68 percent
anti freeze concentrati on, whi ch prevents freezi ng
down to -67.7C (-90F). A hi gher percentage wi l l
freeze at a warmer temperature. Al so, a hi gher per-
centage of anti freeze can cause the engi ne to over-
heat because speci fi c heat of anti freeze i s l ower than
that of water.
ene-glycol.
COOLANT SELECTION AND ADDITIVES
mi xed wi th 50% di sti l l ed water to obtai n to obtai n a
freeze poi nt of -37C (-35F). I f i t l oses col or or
becomes contami nated, drai n, fl ush, and repl ace wi th
fresh properl y mi xed cool ant sol uti on.
7 - 32 ENGINE DR
COOLANT (Continued)
OPERATION
Cool ant fl ows through the engi ne bl ock absorbi ng
the heat from the engi ne, then fl ows to the radi ator
where the cool i ng fi ns i n the radi ator transfers the
heat from the cool ant to the atmosphere. Duri ng col d
weather the ethyl ene-gl ycol or propyl ene-gl ycol cool -
ant prevents water present i n the cool i ng system
from freezi ng wi thi n temperatures i ndi cated by mi x-
ture rati o of cool ant to water.
COOLANT RECOVERY
CONTAINER- GAS ENGINES
DESCRIPTION
The cool ant reserve/overfl ow tank i s mounted on
top of the fan shroud, and i s made of hi gh tempera-
ture pl asti c (Fi g. 1).
OPERATION
The cool ant reserve/overfl ow system works i n con-
juncti on wi th the radi ator pressure cap. I t uti l i zes
thermal expansi on and contracti on of cool ant to keep
cool ant free of trapped ai r. I t provi des a vol ume for
expansi on and contracti on of cool ant. I t al so provi des
a conveni ent and safe method for checki ng cool ant
l evel and adjusti ng l evel at atmospheri c pressure.
Thi s i s done wi thout removi ng the radi ator pressure
cap. The system al so provi des some reserve cool ant
to the radi ator to cover mi nor l eaks and evaporati on
or boi l i ng l osses.
As the engi ne cool s, a vacuum i s formed i n the
cool i ng system of both the radi ator and engi ne. Cool -
ant wi l l then be drawn from the cool ant tank and
returned to a proper l evel i n the radi ator.
REMOVAL
(1) Remove recovery hose from radi ator.
(2) Remove the cool ant contai ner to fan shroud
mounti ng bol t.
(3) Ti l t the contai ner backward towards the engi ne
to di sengage the mounti ng pi n l ocki ng features and
l i ft the contai ner away from the fan shroud (Fi g. 1).
INSTALLATION
(1) Al i gn the cool ant contai ner mounti ng pi ns i nto
the sl ots on the fan shroud and push the contai ner
onto the fan shroud.
(2) Secure the contai ner to the fan shroud wi th the
bol t. Ti ghten to 8.5Nm (75 i n-l bs).
NOTE: Ensure that the locking feature on the
mounting pins has engaged.
(3) Connect the recovery hose to the radi ator (Fi g.
1).
RADIATOR FAN - GAS
ENGINES
REMOVAL
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
(2) Remove cool ant reserve/overfl ow contai ner from
fan shroud and l ay asi de. Do Not di sconnect the
hoses or drai n cool ant from the contai ner.
(3) The thermal vi scous fan dri ve/fan bl ade assem-
bl y i s attached (threaded) to the water pump hub
shaft (Fi g. 3). Remove the fan bl ade/vi scous fan dri ve
assembl y from the water pump by turni ng the
mounti ng nut countercl ockwi se as vi ewed from the
front. Threads on the vi scous fan dri ve are RIGHT-
HAND. A 36 MM Fan Wrench shoul d be used to pre-
vent pul l ey from rotati ng (Fi g. 2).
Fig. 1 Coolant Recovery Bottle - Gas Engine
1 - SCREW
2 - COOLANT RECOVERY CONTAINER
3 - RADIATOR/RADIATOR CAP
4 - FAN SHROUD
DR ENGINE 7 - 33
COOLANT (Continued)
(4) Do Not attempt to remove the fan/vi scous fan
dri ve assembl y from the vehi cl e at thi s ti me.
(5) Do Not unbol t the fan bl ade assembl y (Fi g. 3)
from vi scous fan dri ve at thi s ti me.
(6) Remove the fan shroud-to-radi ator mounti ng
bol ts.
(7) Pul l the l ower shroud mounts out of the radi a-
tor tank cl i ps.
(8) Remove the fan shroud and fan bl ade/vi scous
fan dri ve assembl y as a compl ete uni t from vehi cl e.
(9) After removi ng the fan bl ade/vi scous fan dri ve
assembl y, do not pl ace the vi scous fan dri ve i n a
hori zontal posi ti on. I f stored hori zontal l y, si l i cone
fl ui d i n the vi scous fan dri ve coul d drai n i nto i ts
beari ng assembl y and contami nate l ubri cant.
CAUTION: Do not remove water pump pulley-to-wa-
ter pump bolts. This pulley is under spring tension.
(10) Remove four bol ts securi ng fan bl ade assem-
bl y to vi scous fan dri ve (Fi g. 3).
CAUTION: Some engines equipped with serpentine
drive belts have reverse rotating fans and viscous
fan drives. They are marked with the word
REVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
engine overheating.
CLEANING
Cl ean the fan bl ades usi ng a mi l d soap and water.
Do not use an abrasi ve to cl ean the bl ades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
INSTALLATION
(1) I nstal l fan bl ade assembl y to the vi scous fan
dri ve. Ti ghten the bol ts (Fi g. 3) to 24 Nm (18 ft. l bs.)
torque.
(2) Posi ti on the fan shroud and the fan bl ade/vi s-
cous fan dri ve assembl y to the vehi cl e as a compl ete
uni t.
(3) I nstal l the fan shroud.
Fig. 2 Using Special Tool 6958 Spanner Wrench
1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER
PINS 8346
2 - FAN
Fig. 3 Fan Blade/Viscous Fan Drive - Gas Engines -
Typical
1 - WATER PUMP BYPASS HOSE
2 - FAN BLADE ASSEMBLY
3 - VISCOUS FAN DRIVE
4 - WATER PUMP AND PULLEY
5 - Bolts (4)
7 - 34 ENGINE DR
RADIATOR FAN - GAS ENGINES (Continued)
(4) I nstal l the fan bl ade/vi scous fan dri ve assembl y
to the water pump shaft (Fi g. 3). Ti ghten mounti ng
nut to 50 Nm (37 ft. l bs.).
(5) I nstal l the cool ant reserve/overfl ow contai ner
to the fan shroud.
(6) Connect the negati ve battery cabl e.
NOTE:
Viscous Fan Drive Fluid Pump Out Requirement:
After installing a new viscous fan drive, bring the
engine speed up to approximately 2000 rpm and
hold for approximately two minutes. This will
ensure proper fluid distribution within the drive.
RADIATOR FAN - 5.9L DIESEL
REMOVAL
CAUTION: If the electronically controlled viscous
fan drive is replaced because of mechanical dam-
age, the cooling fan blades should also be
inspected. Inspect for fatigue cracks, or chipped
blades that could have resulted from excessive
vibration. Replace fan blade assembly if any of
these conditions are found. Also inspect wiring har-
ness and connectors for damage.
(1) Di sconnect the battery negati ve cabl es.
(2) Remove cool ant recovery contai ner (Refer to 7 -
COOLI NG/ENGI NE/COOLANT RECOVERY CON-
TAI NER - REMOVAL).
(3) Usi ng a fastener removal tool , remove the two
push pi n fasteners from the fan shroud l ower hal f.
(4) Unseat the four fasteni ng tabs and remove the
l ower radi ator shroud.
(5) Di sconnect el ectri cal connector.
(6) Remove the el ectroni cal l y control l ed vi scous fan
dri ve el ectri cal wi re from the upper radi ator shroud.
(7) Usi ng a fastener removal tool , remove the wi r-
i ng harness bracket from the upper radi ator shroud.
CAUTION: Do not remove the fan pulley bolts. This
pulley is under spring tension.
(8) The el ectroni cal l y control l ed vi scous fan dri ve/
fan bl ade assembl y i s attached (threaded) to the fan
pul l ey shaft (Fi g. 4). Remove the fan bl ade/fan dri ve
assembl y from fan pul l ey by turni ng the mounti ng
nut countercl ockwi se (as vi ewed from front). Threads
on the vi scous fan dri ve are RIGHT-HAND. A 36
MM Fan Wrench can be used. Pl ace a bar or screw-
dri ver between the fan pul l ey bol ts to prevent pul l ey
from rotati ng.
(9) Remove the upper radi ator shroud mounti ng
bol ts.
(10) Remove the fan shroud and the fan bl ade/vi s-
cous dri ve as an assembl y from vehi cl e.
CAUTION: The electronically controlled viscous fan
drive is vibration and impact sensitive, especially at
the electrical connectors. Do not drop the unit.
(11) Remove the si x fan bl ade-to-vi scous fan dri ve
mounti ng bol ts.
(12) I nspect the fan for cracked, chi pped or dam-
aged fan bl ades.
CLEANING
Cl ean the fan bl ades usi ng a mi l d soap and water.
Do not use an abrasi ve to cl ean the bl ades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
Fig. 4 Fan Blade/Viscous Fan Drive - 5.9L Diesel
3 - FAN BLADE
4 - BOLT (6)
DR ENGINE 7 - 35
RADIATOR FAN - GAS ENGINES (Continued)
INSTALLATION
(1) I nstal l fan bl ade assembl y to el ectri cal l y con-
trol l ed vi scous fan dri ve. Ti ghten mounti ng bol ts to
24 Nm (18 ft. l bs.) torque.
(2) Posi ti on the fan bl ade/vi scous fan dri ve to the
vehi cl e as an assembl y.
(3) I nstal l the vi scous fan dri ve assembl y onto fan
pul l ey hub shaft (Fi g. 4). Ti ghten mounti ng nut to
(4) I nstal l upper fan shroud. Make sure the upper
shroud l ocks i nto the tabs on the l ower radi ator.
(5) I nstal l two upper shroud mounti ng bol ts.
Ti ghten to 11.8 Nm (105 i n. l bs.) torque.
(6) Posi ti on the el ectroni cal l y control l ed vi scous
fan dri ve wi ri ng i nto the channel i n the upper fan
shroud (Fi g. 5). Make sure the wi ri ng i s not pi nched.
(7) I nstal l the l ower fan shroud i nto posi ti on and
veri fy the two l ocki ng tabs have seated.
(8) I nstal l two push pi n fasteners to l ock l ower fan
shroud to the mai n assembl y.
NOTE: Verify that the fan drive electrical wire does
not interfere with fan blade travel when the fan
blade is spun by hand.
(9) Connect the wi ri ng harness connector and
i nstal l the harness bracket to the upper radi ator
shroud.
(10) I nstal l the cool ant recovery contai ner (Refer to
7 - COOLI NG/ENGI NE/COOLANT RECOVERY
CONTAI NER - I NSTALLATI ON).
(11) Connect the battery negati ve cabl es.
NOTE:
Viscous Fan Drive Fluid Pump Out Requirement:
After installing a new viscous fan drive, bring the
engine speed up to approximately 2000 rpm and
hold for approximately two minutes. This will
ensure proper fluid distribution within the drive.
ENGINE BLOCK HEATER
DESCRIPTION
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
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
An opti onal engi ne bl ock heater i s avai l abl e wi th
al l model s. The heater i s equi pped wi th a power cord.
The cord i s attached to an engi ne compartment com-
ponent wi th ti e-straps. The heater warms the engi ne
provi di ng easi er engi ne starti ng and faster warm-up
i n l ow temperatures. The heater i s mounted i n a core
hol e of the engi ne cyl i nder bl ock i n pl ace of a freeze
pl ug wi th the heati ng el ement i mmersed i n engi ne
cool ant. The 3.7L/4.7L gas powered engi nes have the
bl ock heater l ocated to the rear on the ri ght si de of
the engi ne (Fi g. 6).
OPERATION
The heater warms the engi ne cool ant provi di ng
easi er engi ne starti ng and faster warm-up i n l ow
temperatures. Connecti ng the power cord to a
grounded 110-120 vol t AC el ectri cal outl et wi th a
grounded three wi re extensi on cord provi des the el ec-
tri ci ty needed to heat the el ement.
DIAGNOSIS AND TESTING - ENGINE BLOCK
HEATER
I f the uni t does not operate, possi bl e causes can be
ei ther the power cord or the heater el ement. Test the
power cord for conti nui ty wi th a 110-vol t vol tmeter or
110-vol t test l i ght. Test heater el ement conti nui ty
wi th an ohmmeter or a 12-vol t test l i ght.
CAUTION: To prevent damage, the power cord must
be secured in its retainer clips and away from any
components that may cause abrasion or damage,
such as linkages, exhaust components, etc.
Fig. 5 Electronically Controlled Viscous Fan Drive
Wiring
1 - UPPER SHROUD
2 - WIRING
3 - GROMMET
7 - 36 ENGINE DR
RADIATOR FAN - 5.9L DIESEL (Continued)
REMOVAL
(1) Di sconnect the battery negati ve cabl e.
(2) Drai n the cool ant (Refer to 7 - COOLI NG -
(3) Remove the power cord from the heater by
unpl uggi ng (Fi g. 7).
(4) Loosen (but do not compl etel y remove) the
screw at center of bl ock heater (Fi g. 7).
(5) Remove the bl ock heater by careful l y pryi ng
from si de-to-si de. Note the di recti on of the heati ng
el ement coi l (up or down). The el ement coi l must be
i nstal l ed correctl y to prevent damage.
INSTALLATION
(1) Cl ean and i nspect the bl ock heater hol e.
(2) I nstal l the new O-ri ng seal (s) to heater.
(3) I nsert the bl ock heater i nto cyl i nder bl ock and
posi ti on the el ement properl y.
(4) Wi th the heater ful l y seated, ti ghten center
screw to 2 Nm (17 i n. l bs.).
(5) Fi l l the cool i ng system wi th the recommended
cool ant. (Refer to 7 - COOLI NG - STANDARD PRO-
CEDURE).
(6) Start and warm the engi ne.
(7) Check the bl ock heater for l eaks.
ENGINE BLOCK HEATER - 5.9L
DIESEL
DESCRIPTION
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
RETAINING CLIPS AND ROUTED AWAY FROM
EXHAUST MANIFOLDS AND MOVING PARTS.
An opti onal engi ne bl ock heater i s avai l abl e on al l
model s. The heater i s equi pped wi th a power cord.
The heater i s mounted i n a threaded hol e of the
engi ne cyl i nder bl ock wi th the heati ng el ement
i mmersed i n engi ne cool ant. The cord i s attached to
an engi ne compartment component wi th ti e-straps.
The 5.9L di esel engi ne has the bl ock heater l ocated
on the ri ght si de of the engi ne bel ow the exhaust
mani fol d next to the oi l cool er (Fi g. 8).
Fig. 6 Engine Block Heater - 3.7L/4.7L
1 - ENGINE BLOCK HEATER
Fig. 7 Engine Block Heater
1 - FREEZE PLUG HOLE
2 - BLOCK HEATER
3 - SCREW
4 - POWER CORD (120V AC)
5 - HEATING COIL
6 - OIL FILTER
DR ENGINE 7 - 37
ENGINE BLOCK HEATER (Continued)
OPERATION
The heater warms the engi ne cool ant provi di ng
easi er engi ne starti ng and faster warm-up i n l ow
temperatures. Connecti ng the power cord to a
grounded 110-120 vol t AC el ectri cal outl et wi th a
grounded three wi re extensi on cord provi des the el ec-
tri ci ty needed to heat the el ement.
REMOVAL
(2) Drai n cool ant from radi ator and cyl i nder bl ock
(Refer to 7 - COOLI NG - STANDARD PROCE-
DURE).
(3) Unscrew the power cord retai ni ng cap and di s-
connect cord from heater el ement.
(4) Usi ng a sui tabl e si ze socket, l oosen and remove
the bl ock heater el ement (Fi g. 9).
INSTALLATION
(1) Cl ean and i nspect the threads i n the cyl i nder
bl ock.
(2) Coat heater el ement threads wi th Mopar
Thread Seal er wi th Tefl on.
(3) Screw bl ock heater i nto cyl i nder bl ock and
(4) Connect bl ock heater cord and ti ghten retai n-
i ng cap.
(5) Fi l l cool i ng system wi th recommended cool ant
DURE).
(6) Start and warm the engi ne.
(7) Check bl ock heater for l eaks.
ENGINE COOLANT
TEMPERATURE SENSOR
DESCRIPTION
The Engi ne Cool ant Temperature (ECT) sensor i s
used to sense engi ne cool ant temperature. The sensor
protrudes i nto an engi ne water jacket.
The ECT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as engi ne cool ant
temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
At key-on, the Powertrai n Control Modul e (PCM)
sends out a regul ated 5 vol t si gnal to the ECT sensor.
The PCM then moni tors the si gnal as i t passes
through the ECT sensor to the sensor ground (sensor
return).
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
The PCM uses i nputs from the ECT sensor for the
fol l owi ng cal cul ati ons:
for engi ne cool ant temperature gauge operati on
through CCD or PCI (J1850) communi cati ons
I njector pul se-wi dth
Spark-advance curves
ASD rel ay shut-down ti mes
I dl e Ai r Control (I AC) motor key-on steps
Pul se-wi dth pri me-shot duri ng cranki ng
O2 sensor cl osed l oop ti mes
Purge sol enoi d on/off ti mes
EGR sol enoi d on/off ti mes (i f equi pped)
Leak Detecti on Pump operati on (i f equi pped)
Radi ator fan rel ay on/off ti mes (i f equi pped)
Target i dl e speed
Fig. 8 Engine Block Heater 5.9L Diesel Engine
1 - BLOCK HEATER
Fig. 9 Block Heater - 5.9L Diesel Engine
1 - BLOCK HEATER
7 - 38 ENGINE DR
ENGINE BLOCK HEATER - 5.9L DIESEL (Continued)
REMOVAL
3. 7L V-6
The Engi ne Cool ant Temperature (ECT) sensor on
the 3.7L engi ne i s i nstal l ed i nto a water jacket at
front of i ntake mani fol d near rear of generator (Fi g.
10).
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
(1) Parti al l y drai n the cool i ng system.
sensor.
(3) Remove the sensor from the i ntake mani fol d.
4. 7L V-8
ING THE ENGINE COOLANT TEMPERATURE (ECT)
SENSOR.
the 4.7L V-8 engi ne i s l ocated near the front of the
i ntake mani fol d (Fi g. 11).
(1) Parti al l y drai n the cool i ng system. Refer to 7,
COOLI NG.
ECT sensor.
(3) Remove the sensor from the i ntake mani fol d.
5. 7L V-8
the 5.7L engi ne i s l ocated under the ai r condi ti oni ng
compressor (Fi g. 12). I t i s i nstal l ed i nto a water
jacket at the front of the cyl i nder bl ock (Fi g. 13).
(2) Remove fan bel t. Refer to Accessory Dri ve i n
Cool i ng secti on.
(3) Careful l y unbol t ai r condi ti oni ng compressor
from front of engi ne. Do not di sconnect any A/C hoses
from compressor. Temporari l y support compressor to
gai n access to ECT sensor. Refer to Heati ng and Ai r
Condi ti oni ng secti on for i nformati on.
(4) Di sconnect el ectri cal connector from sensor
(Fi g. 13).
(5) Remove sensor from cyl i nder bl ock.
Fig. 10 MAP SENSOR / ECT SENSOR - 3.7L V-6
1 - MOUNTING SCREWS
2 - MAP SENSOR
3 - ECT SENSOR
4 - FRONT OF INTAKE MANIFOLD
Fig. 11 ECT SENSOR - 4.7L V-8
1 - ECT SENSOR
2 - MOUNTING BOLTS (2)
3 - MAP SENSOR
4 - INTAKE MANIFOLD
DR ENGINE 7 - 39
ENGINE COOLANT TEMPERATURE SENSOR (Continued)
5. 9L Diesel
the 5.9L di esel engi ne i s l ocated near the thermostat
sensor.
(3) Remove the sensor from the cyl i nder head.
8. 0L V-10
the 8.0L V-10 engi ne i s threaded i nto the thermostat
sensor.
(3) Remove the sensor from the cyl i nder head.
Fig. 12 ECT LOCATION - 5.7L V-8
1 - TOP OF AIR CONDITIONING COMPRESSOR
2 - ECT SENSOR LOCATION
Fig. 13 ECT REMOVE / INSTALL 5.7L V-8
3 - ECT SENSOR
Fig. 14 ECT LOCATION - 5.9L DIESEL
1 - THERMOSTAT HOUSING
3 - ECT SENSOR
7 - 40 ENGINE DR
INSTALLATION
3. 7L V-6
(1) Appl y thread seal ant to sensor threads.
(2) I nstal l sensor to engi ne.
(3) Ti ghten sensor to 11 Nm (8 ft. l bs.) torque.
(4) Connect el ectri cal connector to sensor.
(5) Repl ace any l ost engi ne cool ant. (Refer to 7 -
4. 7L V-8
5. 7L V-8
5. 9L Diesel
8. 0L V-10
ENGINE COOLANT
THERMOSTAT- 5.7L
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
The thermostat on the 5.7L gas powered engi ne i s
l ocated behi nd the thermostat housi ng at the front of
the i ntake mani fol d (Fi g. 16).
The thermostat i s a wax pel l et dri ven, reverse pop-
pet choke type.
Cool ant l eakage i nto the pel l et contai ner wi l l cause
the thermostat to fai l i n the open posi ti on. Thermo-
stats very rarel y sti ck. Do not attempt to free a ther-
mostat wi th a pryi ng devi ce.
The same thermostat i s used for wi nter and sum-
mer seasons. An engi ne shoul d not be operated wi th-
out a thermostat, except for servi ci ng or testi ng.
Operati ng wi thout a thermostat causes l onger engi ne
warmup ti me, unrel i abl e warmup performance,
i ncreased exhaust emi ssi ons and crankcase condensa-
ti on that can resul t i n sl udge formati on.
OPERATION
The wax pel l et i s l ocated i n a seal ed contai ner at
the spri ng end of the thermostat. When heated, the
pel l et expands, overcomi ng cl osi ng spri ng tensi on
and water pump pressure to force the val ve to open.
Fig. 15 ECT SENSOR - 8.0L V-10
1 - ENGINE COOLANT TEMP. SENSOR (FOR PCM)
2 - HEATER SUPPLY FITTING
3 - BOLTS (6)
4 - HOUSING WITH INTEGRAL SEAL
5 - THERMOSTAT
6 - RUBBER LIP SEAL
7 - TEMP. GAUGE SENDING UNIT
DR ENGINE 7 - 41
DIAGNOSIS AND TESTING THERMOSTAT
ON-BOARD DIAGNOSTICS
Al l gasoline powered models are equi pped wi th
On-Board Di agnosti cs for certai n cool i ng system com-
ponents. Refer to On-Board Di agnosti cs (OBD) i n the
Di agnosi s secti on of thi s group for addi ti onal i nfor-
mati on. I f the powertrai n control modul e (PCM)
detects l ow engi ne cool ant temperature, i t wi l l record
a Di agnosti c Troubl e Code (DTC) i n the PCM mem-
ory. Do not change a thermostat for l ack of heat as
i ndi cated by the i nstrument panel gauge or by poor
heater performance unl ess a DTC i s present. Refer to
the Di agnosi s secti on of thi s group for other probabl e
causes.
The DTC can al so be accessed through the
DRBI I I scan tool . Refer to the appropri ate Power-
trai n Di agnosti c Procedures i nformati on for di agnos-
ti c i nformati on and operati on of the DRBI I I scan
tool .
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE COOLING SYSTEM HOT
AND PRESSURIZED. SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
Do not waste reusabl e cool ant. I f the sol uti on i s
cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
I f the thermostat i s bei ng repl aced, be sure that
the repl acement i s the speci fi ed thermostat for the
vehi cl e model and engi ne type.
Factory i nstal l ed thermostat housi ngs on 5.9L
engi ne i s i nstal l ed on a gasket wi th an anti -sti ck
coati ng. Thi s wi l l ai d i n gasket removal and cl ean-up.
(2) Drai n the cool i ng system unti l the cool ant l evel
i s bel ow the thermostat (Refer to 7 - COOLI NG -
(3) Ai r Condi ti oned vehi cl es: Remove the support
bracket (generator mounti ng bracket-to-i ntake mani -
fol d) l ocated near the rear of the generator (Fi g. 17).
NOTE: On air conditioning equipped vehicles, the
generator must be partially removed.
(4) Remove the accessory dri ve bel t (Refer to 7 -
REMOVAL) (Fi g. 18).
(5) Remove the generator mounti ng bol ts. Do not
remove any of the wi ri ng at the generator. I f
equi pped wi th 4WD, unpl ug the 4WD i ndi cator l amp
wi ri ng harness (l ocated near rear of generator).
(6) Remove the generator. Posi ti on the generator
to gai n access for the thermostat gasket removal .
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN
SERVICING CONSTANT TENSION CLAMPS.
Fig. 16 Thermostat - 5.7L/5.9L Gas Powered
Engines
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVE
Fig. 17 Generator Support Bracket 5.9L Engine
1 - IDLER PULLEY BUSHING
2 - A/C AND/OR GENERATOR MOUNTING BRACKET
3 - IDLER PULLEY
4 - SCREW AND WASHER
7 - 42 ENGINE DR
ENGINE COOLANT THERMOSTAT- 5.7L (Continued)
tongue of the constant tension clamps (Fig. 19). If
replacement is necessary, use only an original
equipment clamp with a matching number, letter
and width.
(7) Remove the radi ator upper hose cl amp and
upper hose at the thermostat housi ng.
(8) Posi ti on the wi ri ng harness (behi nd thermostat
housi ng) to gai n access to the thermostat housi ng.
(9) Remove the thermostat housi ng mounti ng
bol ts, thermostat housi ng, gasket and thermostat
(Fi g. 20). Di scard ol d gasket.
INSTALLATION
(1) Cl ean the mati ng areas of the i ntake mani fol d
and thermostat housi ng.
(2) I nstal l the thermostat (spri ng si de down) i nto
the recessed machi ned groove on the i ntake mani fol d
(Fi g. 20).
(3) I nstal l the gasket on the i ntake mani fol d and
over the thermostat (Fi g. 20).
(4) Posi ti on the thermostat housi ng to the i ntake
mani fol d. Note: The word FRONT stamped on hous-
i ng (Fi g. 21). For adequate cl earance, thi s must be
pl aced towards the front of the vehi cl e. The housi ng
i s sl i ghtl y angl ed forward after the i nstal l ati on to the
i ntake mani fol d.
(5) I nstal l the housi ng-to-i ntake mani fol d bol ts.
Ti ghten the bol ts to 23 Nm (200 i n. l bs.).
(6) I nstal l the radi ator upper hose to the thermo-
stat housi ng.
drive belt, the belt must be routed correctly. If not,
rotating in wrong direction. Refer to (Fig. 22) for the
correct 5.9L engine belt routing. The correct belt
with correct length must be used.
Fig. 18 Automatic Belt Tensioner 5.9L Engines
1 - IDLER PULLEY
2 - TENSIONER
3 - FAN BLADE
Fig. 19 SPRING CLAMP SIZE LOCATION
1 - SPRING CLAMP SIZE LOCATION
Fig. 20 Thermostat 5.9L Engines
2 - GASKET
3 - INTAKE MANIFOLD
4 - THERMOSTAT
5 - MACHINED GROOVE
DR ENGINE 7 - 43
(7) Ai r Condi ti oned vehi cl es; I nstal l the generator.
Ti ghten the bol ts to 41 Nm (30 ft. l bs.).
(8) I nstal l the support bracket (generator mount-
i ng bracket-to-i ntake mani fol d). (Fi g. 17). Ti ghten the
(9) I nstal l the accessory dri ve bel t (Fi g. 18)(Refer
to 7 - COOLI NG/ACCESSORY DRI VE/DRI VE
BELTS - I NSTALLATI ON).
(10) Fi l l the cool i ng system (Refer to 7 - COOLI NG
(11) Connect battery negati ve cabl e.
(12) Start and warm the engi ne. Check for l eaks.
ENGINE COOLANT
THERMOSTAT - 3.7L/4.7L
DESCRIPTION
CAUTION: Do not operate the engine without a ther-
A pel l et-type thermostat control s the operati ng
temperature of the engi ne by control l i ng the amount
of cool ant fl ow to the radi ator. On al l engi nes the
thermostat i s cl osed bel ow 195F (90C). Above thi s
temperature, cool ant i s al l owed to fl ow to the radi a-
tor. Thi s provi des qui ck engi ne warm up and overal l
temperature control . On the 3.7L4.7L engi ne the
thermostat i s desi gned to bl ock the fl ow of the cool -
ant bypass journal by 50% i nstead of compl etel y
bl ocki ng the fl ow. Thi s desi gn control s cool ant tem-
perature more accuratel y (Fi g. 23).
Operati ng wi thout a thermostat causes other prob-
l ems. These are: l onger engi ne warmup ti me, unrel i -
abl e warmup performance, i ncreased exhaust
emi ssi ons and crankcase condensati on. Thi s conden-
sati on can resul t i n sl udge formati on.
OPERATION
DIAGNOSIS AND TESTING THERMOSTAT
Fig. 21 Thermostat Position5.9L Engines
Fig. 22 Belt Routing 5.9L Engines
1 - IDLER PULLEY
4 - IF W/OUT A/C
7 - 44 ENGINE DR
causes.
The DTC can al so be accessed through the
DRBI I I scan tool . Refer to the appropri ate Power-
trai n Di agnosti c Procedures i nformati on for di agnos-
ti c i nformati on and operati on of the DRBI I I scan
tool .
REMOVAL
DRAINCOCK WITH THE COOLING SYSTEM HOT
AND PRESSURIZED. SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
reuse.
(2) Drai n the cool i ng system (Refer to 7 - COOL-
I NG - STANDARD PROCEDURE).
(4) Remove the spl ash shi el d.
(5) Remove the l ower radi ator hose cl amp and the
l ower radi ator hose at the thermostat housi ng.
(6) Remove the thermostat housi ng mounti ng
bol ts, thermostat housi ng and thermostat (Fi g. 24).
INSTALLATION
(1) Cl ean the mati ng areas of the ti mi ng chai n
cover and the thermostat housi ng.
(2) I nstal l the thermostat (spri ng si de down) i nto
the recessed machi ned groove on the ti mi ng chai n
cover (Fi g. 24).
(3) Posi ti on the thermostat housi ng on the ti mi ng
chai n cover.
(4) I nstal l the housi ng-to-ti mi ng chai n cover bol ts.
Ti ghten the bol ts to 13 Nm (112 i n. l bs.).
CAUTION: The housing must be tightened evenly
and the thermostat must be centered into the
recessed groove in the timimg chain cover. If not, it
may result in a cracked housing, damaged timing
chain cover threads or coolant leaks.
(5) I nstal l the l ower radi ator hose on the thermo-
stat housi ng.
(6) I nstal l the spl ash shi el d.
(8) Fi l l the cool i ng system (Refer to 7 - COOLI NG
(9) Connect negati ve battery cabl e.
Fig. 23 Thermostat Cross Section View 3.7L/4.7L
1 - FROM HEATER AND DEGAS CONTAINER
2 - FROM RADIATOR
3 - TO WATER PUMP
4- THERMOSTAT
DR ENGINE 7 - 45
ENGINE COOLANT THERMOSTAT - 3.7L/4.7L (Continued)
ENGINE COOLANT
THERMOSTAT - 5.9L DIESEL
DESCRIPTION
mostat, except for servicing or testing. An engine
with the thermostat removed will operate in the
radiator bypass mode, causing an overheat condi-
tion.
The thermostat of the 5.9L di esel engi ne i s l ocated
i n the front of the cyl i nder head, underneath the
thermostat housi ng (Fi g. 25).
Operati ng wi thout a thermostat wi l l cause overheat-
i ng.
OPERATION
Fig. 24 Thermostat and Thermostat Housing 3.7L/4.7L
2 - THERMOSTAT LOCATION
3 - THERMOSTAT AND GASKET
Fig. 25 Thermostat5.9L Diesel-Typical
2 - CYLINDER HEAD
3 - THERMOSTAT
7 - 46 ENGINE DR
ENGINE COOLANT THERMOSTAT - 3.7L/4.7L (Continued)
DIAGNOSIS AND TESTING - THERMOSTAT
The cool i ng system used wi th the di esel engi ne
provi des the extra cool ant capaci ty and extra cool i ng
protecti on needed for hi gher GVWR (Gross Vehi cl e
Wei ght Rati ng) and GCWR (Gross Combi ned Wei ght
Rati ng) vehi cl es.
Thi s system capaci ty wi l l not effect warm up or
col d weather operati ng characteri sti cs i f the thermo-
stat i s operati ng properl y. Thi s i s because cool ant
wi l l be hel d i n the engi ne unti l i t reaches the ther-
mostat set temperature.
Di esel engi nes, due to thei r i nherent effi ci ency are
sl ower to warm up than gasol i ne powered engi nes,
and wi l l operate at l ower temperatures when the
vehi cl e i s unl oaded. Because of thi s, l ower tempera-
ture gauge readi ngs for di esel versus gasol i ne
engi nes may, at ti mes be normal .
Typi cal l y, compl ai nts of l ow engi ne cool ant temper-
ature are observed as l ow heater output when com-
bi ned wi th cool or col d outsi de temperatures.
To hel p promote faster engi ne warm-up, the el ec-
tri c engi ne bl ock heater must be used wi th cool or
col d outsi de temperatures. Thi s wi l l hel p keep the
engi ne cool ant warm when the vehi cl e i s parked.
A Col d Weather Cover i s avai l abl e from the parts
department through the Mopar Accessori es product
l i ne. Thi s accessory cover i s desi gned to bl ock ai rfl ow
enteri ng the radi ator and engi ne compartment to
promote faster engi ne warm-up. I t attaches to the
front of the vehi cl e at the gri l l openi ng. The cover is
to be used with cool or cold temperatures only.
If used with high outside temperatures, serious
engine damage could result. Refer to the l i tera-
ture suppl i ed wi th the cover for addi ti onal i nforma-
ti on.
(1) To determi ne i f the thermostat i s defecti ve, i t
must be removed from the vehi cl e (Refer to 7 -
COOLI NG/ENGI NE/ENGI NE COOLANT THERMO-
STAT - REMOVAL).
(2) After the thermostat has been removed, exam-
i ne the thermostat and i nsi de of thermostat housi ng
for contami nants. I f contami nants are found, the
thermostat may al ready be i n a stuck open posi ti on.
Fl ush the cool i ng system before repl aci ng thermostat
DURE).
(3) Pl ace the thermostat i nto a contai ner fi l l ed
wi th water.
(4) Pl ace the contai ner on a hot pl ate or other sui t-
abl e heati ng devi ce.
(5) Pl ace a commerci al l y avai l abl e radi ator ther-
mometer i nto the water.
(6) Appl y heat to the water whi l e observi ng the
thermostat and thermometer.
(7) The thermostat wi l l begi n to open at 85.5 -
89.4C. (186 - 193F ). I f the val ve starts to move
before thi s temperature i s reached, i t i s openi ng too
earl y. Repl ace thermostat. The thermostat shoul d be
ful l y open (val ve wi l l stop movi ng) at 97C (207F). I f
the val ve i s sti l l movi ng when the water temperature
reaches 97C (207F), i t i s openi ng too l ate. Repl ace
thermostat. I f the val ve refuses to move at any ti me,
repl ace thermostat.
REMOVAL
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
reuse.
(2) Drai n cool i ng system unti l cool ant l evel i s
bel ow thermostat (Refer to 7 - COOLI NG - STAN-
DARD PROCEDURE).
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094).
is necessary, use only an original equipment clamp
with a matching number or letter.
(3) Remove radi ator hose cl amp and hose from
thermostat housi ng.
(4) Remove the three (3) water outl et-to-cyl i nder
head bol ts and remove the water outl et connector
(Fi g. 26).
(5) Cl ean the mati ng surfaces of the water outl et
connector and cl ean the thermostat seat groove at
the top of the thermostat housi ng (Fi g. 26).
INSTALLATION
(1) I nspect thermostat seal for cuts or ni cks.
Repl ace i f damaged.
(2) I nstal l the thermostat i nto the groove i n the
top of the cyl i nder head (Fi g. 26).
(3) I nstal l the thermostat housi ng and bol ts.
Ti ghten the bol ts to 10 Nm (89 i n. l bs.) torque.
(4) I nstal l the radi ator upper hose and cl amp.
(5) Fi l l the cool i ng system wi th cool ant (Refer to 7
- COOLI NG - STANDARD PROCEDURE).
DR ENGINE 7 - 47
ENGINE COOLANT THERMOSTAT - 5.9L DIESEL (Continued)
(7) Start the engi ne and check for cool ant l eaks.
Run engi ne to check for proper thermostat operati on.
ENGINE COOLANT
THERMOSTAT - 8.0L
DESCRIPTION
The thermostat on al l gas powered engi nes i s
l ocated beneath the thermostat housi ng at the front
of the i ntake mani fol d (Fi g. 27).
The thermostat i s a moveabl e sl eeve type.
Cool ant l eakage i nto the pel l et contai ner wi l l cause
the thermostat to fai l i n the open posi ti on. Thermo-
stats very rarel y sti ck. Do not attempt to free a ther-
mostat wi th a pryi ng devi ce.
Operati ng wi thout a thermostat causes l onger engi ne
warmup ti me, unrel i abl e warmup performance,
i ncreased exhaust emi ssi ons and crankcase condensa-
ti on that can resul t i n sl udge formati on.
OPERATION
DIAGNOSIS AND TESTING - THERMOSTAT
causes. For other DTC numbers, (Refer to 25 - EMI S-
SI ONS CONTROL - DESCRI PTI ON).
Fig. 26 Thermostat Removal/Installation
2 - CYLINDER HEAD
3 - THERMOSTAT
Fig. 27 Thermostat - 8.0L V-10 Engine
1 - COOLANT TEMP. SENSOR (FOR PCM)
3 - BOLTS (6)
5 - THERMOSTAT
6 - RUBBER LIP SEAL
7 - 48 ENGINE DR
ENGINE COOLANT THERMOSTAT - 5.9L DIESEL (Continued)
The DTC can al so be accessed through the DRB
scan tool . Refer to the appropri ate Powertrai n Di ag-
nosti c Procedures i nformati on for di agnosti c i nforma-
ti on and operati on of the DRB scan tool .
REMOVAL
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
reuse.
A rubber l i p-type seal wi th a metal shoul der i s
pressed i nto the i ntake mani fol d beneath the thermo-
stat (Fi g. 28).
(1) Di sconnect negati ve battery cabl e at battery.
(2) Drai n cool i ng system unti l cool ant l evel i s
bel ow thermostat (Refer to 7 - COOLI NG - STAN-
DARD PROCEDURE).
(3) Remove the two support rod mounti ng bol ts
and remove support rod (i ntake mani fol d-to-genera-
tor mount) (Fi g. 29).
6094).
(4) Remove upper radi ator hose cl amp. Remove
upper radi ator hose at thermostat housi ng.
(5) Di sconnect the wi ri ng connectors at both of the
sensors l ocated on thermostat housi ng.
(6) Remove si x thermostat housi ng mounti ng bol ts,
thermostat housi ng and thermostat.
INSTALLATION
(1) Cl ean mati ng areas of i ntake mani fol d and
thermostat housi ng.
(2) Check the condi ti on (for tears or cracks) of the
rubber thermostat seal l ocated i n the i ntake mani fol d
(Fi g. 28). The thermostat shoul d fi t snugl y i nto the
rubber seal .
(3) I f seal repl acement i s necessary, coat the outer
(metal ) porti on of the seal wi th Mopar Gasket
Maker. I nstal l the seal i nto the mani fol d usi ng Spe-
ci al Seal Tool number C-3995-A wi th handl e tool
number C-4171.
(4) I nstal l thermostat i nto recessed machi ned
groove on i ntake mani fol d (Fi g. 28).
(5) I nstal l thermostat housi ng (Fi g. 30).
(6) I nstal l housi ng-to-i ntake mani fol d bol ts.
Ti ghten bol ts to 25 Nm (220 i n. l bs.) torque.
CAUTION: Housing bolts should be tightened
evenly to prevent damage to housing and to pre-
vent leaks.
(7) Connect the wi ri ng to both sensors.
(8) I nstal l the upper radi ator hose and hose cl amp
to thermostat housi ng.
Fig. 28 Thermostat Seal - 8.0L V-10 Engine
1 - METAL SEAL SHOULDER
2 - RUBBER LIP SEAL
3 - THERMOSTAT OPENING
Fig. 29 Support Rod - 8.0L V-10 Engine
1 - BOLTS
2 - SUPPORT ROD
DR ENGINE 7 - 49
ENGINE COOLANT THERMOSTAT - 8.0L (Continued)
(9) I nstal l support rod.
(10) Fi l l cool i ng system (Refer to 7 - COOLI NG -
(11) Connect negati ve battery cabl e to battery.
(12) Start and warm engi ne. Check for l eaks.
FAN DRIVE VISCOUS CLUTCH-
GAS ENGINES
DESCRIPTION
The thermal vi scous fan dri ve (Fi g. 31) i s a si l i -
cone-fl ui d- fi l l ed coupl i ng used to connect the fan
bl ades to the water pump shaft. The coupl i ng al l ows
the fan to be dri ven i n a normal manner. Thi s i s
done at l ow engi ne speeds whi l e l i mi ti ng the top
speed of the fan to a predetermi ned maxi mum l evel
at hi gher engi ne speeds.
OPERATION
A thermostati c bi metal l i c spri ng coi l i s l ocated on
the front face of the vi scous fan dri ve uni t (a typi cal
vi scous uni t i s shown i n (Fi g. 32). Thi s spri ng coi l
reacts to the temperature of the radi ator di scharge
ai r. I t engages the vi scous fan dri ve for hi gher fan
speed i f the ai r temperature from the radi ator ri ses
above a certai n poi nt. Unti l addi ti onal engi ne cool i ng
i s necessary, the fan wi l l remai n at a reduced rpm
regardl ess of engi ne speed.
Onl y when suffi ci ent heat i s present, wi l l the vi s-
cous fan dri ve engage. Thi s i s when the ai r fl owi ng
through the radi ator core causes a reacti on to the
bi metal l i c coi l . I t then i ncreases fan speed to provi de
the necessary addi ti onal engi ne cool i ng.
Once the engi ne has cool ed, the radi ator di scharge
temperature wi l l drop. The bi metal l i c coi l agai n
reacts and the fan speed i s reduced to the previ ous
di sengaged speed.
DIAGNOSIS AND TESTING - VISCOUS FAN
DRIVE
NOISE
NOTE: It is normal for fan noise to be louder (roar-
ing) when:
The underhood temperature i s above the engage-
ment poi nt for the vi scous dri ve coupl i ng. Thi s may
occur when ambi ent (outsi de ai r temperature) i s very
hi gh.
Fig. 30 Thermostat - 8.0L V-10 Engine
1 - COOLANT TEMP. SENSOR (FOR PCM)
3 - BOLTS (6)
5 - THERMOSTAT
6 - RUBBER LIP SEAL
Fig. 31 Viscous Fan
5 - Bolts (4)
7 - 50 ENGINE DR
ENGINE COOLANT THERMOSTAT - 8.0L (Continued)
Engi ne l oads and temperatures are hi gh such as
when towi ng a trai l er.
Cool si l i cone fl ui d wi thi n the fan dri ve uni t i s
bei ng redi stri buted back to i ts normal di sengaged
(warm) posi ti on. Thi s can occur duri ng the fi rst 15
seconds to one mi nute after engi ne start-up on a col d
engi ne.
LEAKS
Vi scous fan dri ve operati on i s not affected by smal l
oi l stai ns near the dri ve beari ng. I f l eakage appears
excessi ve, repl ace the fan dri ve uni t.
VISCOUS DRIVE
I f the fan assembl y free-wheel s wi thout drag (the
fan bl ades wi l l revol ve more than fi ve turns when
spun by hand), repl ace the fan dri ve. Thi s spi n test
must be performed when the engi ne i s cool .
For the fol l owi ng test, the cool i ng system must be
i n good condi ti on. I t al so wi l l ensure agai nst exces-
si vel y hi gh cool ant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Dri l l a 3.18-mm (1/8-i n) di ameter hol e i n the
top center of the fan shroud.
(2) Obtai n a di al thermometer wi th an 8 i nch stem
(or equi val ent). I t shoul d have a range of -18-to-
105C (0-to-220 F). I nsert thermometer through the
hol e i n the shroud. Be sure that there i s adequate
cl earance from the fan bl ades.
(3) Connect a tachometer and an engi ne i gni ti on
ti mi ng l i ght. The ti mi ng l i ght i s to be used as a
strobe l i ght. Thi s step cannot be used on the di esel
engi ne.
(4) Bl ock the ai r fl ow through the radi ator. Secure
a sheet of pl asti c i n front of the radi ator. Use tape at
the top to secure the pl asti c and be sure that the ai r
fl ow i s bl ocked.
(5) Be sure that the ai r condi ti oner (i f equi pped)
and bl owe fan i s turned off.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(6) Start the engi ne and operate at 2400 rpm.
Wi thi n ten mi nutes the ai r temperature (i ndi cated on
the di al thermometer) shoul d be up to 88 C (190 F).
Fan dri ve engagement shoul d start to occur at/be-
tween:
3.7L Automati c - 93 C - 99C (200 F - 210 F)
3.7L Manual /4.7L Automati c/5.9L - 85 - 91 C
(185 - 195 F)
4.7L Manual - 74 - 79 C (165 - 175 F)
5.7L
5.9L
Engagement i s di sti ngui shabl e by a defi ni te
increase i n fan fl ow noi se (roari ng). The ti mi ng l i ght
al so wi l l i ndi cate an i ncrease i n the speed of the fan.
(7) When vi scous dri ve engagement i s veri fi ed,
remove the pl asti c sheet. Fan dri ve disengagement
shoul d start to occur at or between:
3.7L Automati c - 76C - 81C (168 F - 178 F)
3.7L Manual /4.7L Auto/5.9L - 67C - 73C (153
F - 163 F)
4.7L Manual - 56C - 62C (133 F - 143 F)
5.7L
5.9L
8.0L engi ne - 93 to 101 C (190 - 205 F) Mi n-
i mum 73C (163F). A defi ni te decrease of fan fl ow
noi se (roari ng) shoul d be noti ced. I f not, repl ace the
defecti ve vi scous fan dri ve uni t.
CAUTION: Some engines equipped with serpentine
drive belts have reverse rotating fans and viscous
fan drives. They are marked with the word
REVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
engine overheating.
Fig. 32 Viscous Fan Drive - Typical
2 - THERMOSTATIC SPRING
3 - MOUNTING NUT TO WATER PUMP HUB
DR ENGINE 7 - 51
FAN DRIVE VISCOUS CLUTCH-GAS ENGINES (Continued)
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
FAN DRIVE VISCOUS CLUTCH
- 5.9L DIESEL
DESCRIPTION
The el ectroni cal l y control l ed vi scous fan dri ve (Fi g.
34) and (Fi g. 33)i s attached to the fan dri ve pul l ey
mounted to the engi ne. The coupl i ng al l ows the fan
to be dri ven i n a normal manner. The fan speed i s
control l ed by the el ectroni c control modul e.
OPERATION
The Engi ne Control Modul e (ECM) control s the
l evel of engagement of the el ectroni cal l y control l ed
vi scous fan cl utch by moni tori ng cool ant tempera-
ture, i ntake mani fol d temperature, and ai r condi ti on-
i ng status. Based on cool i ng requi rements, the ECM
sends a si gnal to the vi scous fan cl utch to i ncrease or
decrease the fan speed.
Fan speed i s moni tored by the ECM. Fan speeds
above or bel ow a cal i brated threshol d wi l l set a DTC.
Ci rcui t concerns wi l l al so set fan cl utch DTCs.
DIAGNOSIS AND TESTING - ELECTRONICALLY
CONTROLLED VISCOUS FAN DRIVE
NOISE
NOTE: It is normal for fan noise to be louder (roar-
ing) when:
Fan duty cycl e hi gh. Thi s may occur when ambi -
ent (outsi de ai r temperature) i s very hi gh.
Engi ne l oads and temperatures are hi gh such as
when towi ng a trai l er.
Aggressi ve engi ne braki ng down a steep grade
where transmi ssi on temperatures may be hi gh
Cool si l i cone fl ui d wi thi n the fan dri ve uni t i s
bei ng redi stri buted back to i ts normal di sengaged
(warm) posi ti on. Thi s can occur duri ng the fi rst 15
seconds to one mi nute after engi ne start-up on a col d
engi ne.
Fig. 33 Electronically Controlled Viscous Drive
1 - ELECTRONICALLY CONTROLLED VISCOUS FAN DRIVE
2 - MOUNTING NUT
3 - WIRING SUPPORT BRACKET
Fig. 34 Fan Blade/Viscous Fan Drive - 5.9L Diesel
Engine
3 - FAN BLADE
4 - BOLT (6)
7 - 52 ENGINE DR
FAN DRIVE VISCOUS CLUTCH-GAS ENGINES (Continued)
LEAKS
Vi scous fan dri ve operati on i s not affected by smal l
oi l stai ns near the dri ve beari ng. I f l eakage appears
excessi ve, repl ace the fan dri ve uni t.
ELECTRONICALLY CONTROLLED VISCOUS DRIVE
I f the fan assembl y free-wheel s wi thout drag (the
fan bl ades wi l l revol ve more than fi ve turns when
spun by hand), do not repl ace the fan dri ve. Thi s
spi n test must be performed when the engi ne i s cool .
I f the fan assembl y does not free-wheel and a
metal l i c gri ndi ng sound exi sts, repl ace the el ectroni -
cal l y control l ed fan dri ve (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR FAN - REMOVAL).
NOTE: The following test may take up to 15 minutes
to perform.
The engi ne shoul d be at normal operati ng temper-
ature.
(1) Set the parki ng brake and veri fy the transmi s-
si on i s i n park or neutral .
(2) Set ai r condi ti oner (i f equi pped) and bl ower fan
to OFF.
(3) Start and al l ow engi ne to reach normal operat-
i ng temperatures.
(4) Stop engi ne, connect the DRB I I I and sel ect
appropri ate model year and engi ne opti on.
(5) Check for and correct exi sti ng DTCs
(6) Usi ng Tool 6801, connect pi n 1 of the el ectron-
i cal l y control l ed vi scous fan dri ve connector, l ocated
at the l ower fan shroud to battery ground (Fi g. 35).
(7) Usi ng the DRB I I I , veri fy that DTC 0480 set.
(8) Start the engi ne.
(9) Go to the SENSOR screen and observe the fan
speed.
(10) Run the engi ne at 2500 rpm.
NOTE: It maybe take 15 minutes before fan speed
increases.
(11) The fan speed shoul d i ncrease accordi ng to
the tabl e bel ow.
(12) I f fan speed does not i ncrease, repl ace the
el ectroni cal l y control vi scous fan dri ve.
ELECTRONICALLY CONTROLLED VISCOUS FAN
DRIVE SPEEDS
ENGINE RPM FAN RPM (Min)
500 490
1000 950
1500 1420
2000 1850
2500 2230
3000 2440
(13) I f the fan speed does i ncrease and there i s
sti l l a concern, refer to the appropri ate Powertrai n
Di agnosi s Manual to di agnosi s the el ectroni cal l y con-
trol l ed vi scous fan dri ve control ci rcui t.
cracks or chips that could result in excessive vibra-
tion. Replace fan blade assembly if any of these
conditions are found.
Connector
1 - ELECTRONICALLY CONTROLLED VISCOUS FAN DRIVE
CONNECTOR
2 - TOOL 6801
3 - PIN 1
DR ENGINE 7 - 53
FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL (Continued)
RADIATOR-3.7L/4.7L/5.7L
DESCRIPTION
The radi ator i s a al umi num cross-fl ow desi gn wi th
hori zontal tubes through the radi ator core and verti -
cal pl asti c si de tanks (Fi g. 38).
Thi s radi ator does not contai n an i nternal trans-
mi ssi on oi l cool er.
OPERATION
The radi ator suppl i es suffi ci ent heat transfer usi ng
the cool i ng fi ns i nterl aced between the hori zontal
tubes i n the radi ator core to cool the engi ne.
COOLANT FLOW
Use the fol l owi ng procedure to determi ne i f cool ant
i s fl owi ng through the cool i ng system.
(1) I dl e engi ne unti l operati ng temperature i s
reached. I f the upper radi ator hose i s warm to the
touch, the thermostat i s openi ng and cool ant i s fl ow-
i ng to the radi ator.
CAUSE INJURY BY SCALDING. USING A RAG TO
COVER THE RADIATOR PRESSURE CAP, OPEN
RADIATOR CAP SLOWLY TO THE FIRST STOP. THIS
WILL ALLOW ANY BUILT-UP PRESSURE TO VENT
TO THE RESERVE/OVERFLOW TANK. AFTER PRES-
SURE BUILD-UP HAS BEEN RELEASED, REMOVE
CAP FROM FILLER NECK.
(2) Drai n a smal l amount of cool ant from the radi -
ator unti l the ends of the radi ator tubes are vi si bl e
through the fi l l er neck. I dl e the engi ne at normal
operati ng temperature. I f cool ant i s fl owi ng past the
exposed tubes, the cool ant i s ci rcul ati ng.
REMOVAL
(1) Di sconnect battery negati ve cabl es.
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM THE COOL-
ANT CAN OCCUR.
with a matching number or letter and the correct
width.
(3) Remove the hose cl amps and hoses from radi a-
tor.
(4) Remove the cool ant reserve/overfl ow tank hose
from the radi ator fi l l er neck.
(5) Remove the cool ant reserve/overfl ow tank from
the fan shroud (pul l strai ght up). The tank sl i ps i nto
sl ots on the fan shroud.
(6) Uncl i p the power steeri ng hoses from the fan
shroud.
(7) Di sconnect the el ectri cal connectors at the
wi ndshi el d washer reservoi r tank and remove the
tank.
(8) Remove the fan shroud mounti ng bol ts and pul l
up and out of the radi ator tank cl i ps (Fi g. 36). Posi -
ti on shroud rearward over the fan bl ades towards
engi ne.
(9) Di sconnect the transmi ssi on cool er l i nes from
the transmi ssi on cool er, then pl ug the transmi ssi on
l i nes and cool er to prevent l eakage.
(10) Di sconnect the power steeri ng l i nes from the
power steeri ng cool er, then pl ug the power steeri ng
l i nes and cool er to prevent l eakage.
Fig. 36 Fan Shroud - Gas Engine
1 - RADIATOR
2 - SCREWS
3 - FAN SHROUD
4 - SLIDE MOUNT
7 - 54 ENGINE DR
(11) Remove the two radi ator upper mounti ng
bol ts (Fi g. 37).
(12) Li ft the radi ator strai ght up and out of the
engi ne compartment. Take care not to damage cool -
i ng fi ns or tubes on the radi ator and oi l cool ers when
removi ng.
NOTE: The radiator is equipped with one alignment
dowel on the bottom of the outlet tank and one
retaining bracket on the front side of the inlet tank.
Both features have rubber insulators attached to
them that must be present. The alignment dowel fits
into a hole at the bottom of the front end sheet
metal vertical support post and the support bracket
rests on top of the lower radiator closure tube.
CLEANING
Cl ean radi ator fi ns are necessary for good heat
transfer. The radi ator and oi l cool er fi ns shoul d be
cl eaned when an accumul ati on of debri s has
occurred. Wi th the engi ne col d, appl y col d water and
compressed ai r to the back (engi ne si de) of the radi -
ator to fl ush the radi ator and/or oi l cool ers of debri s.
INSPECTION
I nspect the radi ator si de tanks for cracks, and bro-
ken or mi ssi ng fi tti ngs. I nspect the joi nt where the
tanks seam up to the radi ator core for si gns of l eak-
age and/or deteri orati ng seal s.
I nspect radi ator core for corroded, bent or mi ssi ng
cool i ng fi ns. I nspect the core for bent or damaged
cool i ng tubes.
INSTALLATION
(1) Posi ti on the fan shroud over the fan bl ades
rearward towards engi ne.
(2) I nstal l the rubber i nsul ators to the l ower radi -
ator mounti ng features (al i gnment dowel and support
bracket at the l ower part of the radi ator).
(3) Lower the radi ator i nto posi ti on whi l e gui di ng
the al i gnment dowel i nto the verti cal post bracket.
Posi ti on and seat the l ower radi ator support bracket
onto the l ower radi ator cl osure tube.
(4) I nstal l the upper radi ator mounti ng bol ts.
Ti ghten bol ts to 10 Nm (90 i n. l bs.).
(5) Connect the l ower radi ator hose and i nstal l the
cl amp i n the proper posi ti on.
(6) Connect the power steeri ng hoses to the power
steeri ng oi l cool er and i nstal l the cl amps.
(7) Connect the transmi ssi on oi l cool er l i nes to the
transmi ssi on oi l cool er and i nstal l the secondary
l atches.
(8) Posi ti on the fan shroud i nto the mounti ng cl i ps
on the radi ator tanks and secure wi th bol ts. Ti ghten
the bol ts to 8.5 Nm (75 i n. l bs.).
(9) Secure the power steeri ng hoses i nto the cl i p
on the l ower fan shroud.
(10) I nstal l the wi ndshi el d washer reservoi r tank
and connect the hose and el ectri cal connector.
(11) I nstal l cool ant reserve/overfl ow contai ner
hose(s) to radi ator fi l l er neck and secure properl y
wi th cl amps.
(12) I nstal l cool ant reserve/overfl ow contai ner or
degas contai ner to fan shroud and ti ghten the bol ts
to 8.5 Nm (75 i n. l bs.).
(13) Connect upper radi ator hose and i nstal l
cl amp.
(14) I nstal l battery negati ve cabl e.
(15) Fi l l cool i ng system wi th cool ant (Refer to 7 -
(16) Operate the engi ne unti l i t reaches normal
operati ng temperature. Check cool i ng system fl ui d
l evel s.
Fig. 37 Radiator
1 - SCREW
2 - SCREW
3 - LOWER MOUNT
4 - RADIATOR
5 - DRAINCOCK
6 -LOWER MOUNT
DR ENGINE 7 - 55
RADIATOR-3.7L/4.7L/5.7L (Continued)
RADIATOR - 5.9L DIESEL
DESCRIPTION
The radi ator i s a al umi num cross-fl ow desi gn wi th
hori zontal tubes through the radi ator core and verti -
cal pl asti c si de tanks (Fi g. 38).
Thi s radi ator does not contai n an i nternal trans-
mi ssi on oi l cool er.
OPERATION
The radi ator suppl i es suffi ci ent heat transfer usi ng
the cool i ng fi ns i nterl aced between the hori zontal
tubes i n the radi ator core to cool the engi ne.
COOLANT FLOW
Use the fol l owi ng procedure to determi ne i f cool ant
i s fl owi ng through the cool i ng system.
(1) I dl e engi ne unti l operati ng temperature i s
reached. I f the upper radi ator hose i s warm to the
touch, the thermostat i s openi ng and cool ant i s fl ow-
i ng to the radi ator.
CAUSE INJURY BY SCALDING. USING A RAG TO
COVER THE RADIATOR PRESSURE CAP, OPEN
RADIATOR CAP SLOWLY TO THE FIRST STOP. THIS
WILL ALLOW ANY BUILT-UP PRESSURE TO VENT
TO THE RESERVE/OVERFLOW TANK. AFTER PRES-
SURE BUILD-UP HAS BEEN RELEASED, REMOVE
CAP FROM FILLER NECK.
(2) Drai n a smal l amount of cool ant from the radi -
ator unti l the ends of the radi ator tubes are vi si bl e
through the fi l l er neck. I dl e the engi ne at normal
operati ng temperature. I f cool ant i s fl owi ng past the
exposed tubes, the cool ant i s ci rcul ati ng.
REMOVAL
(1) Di sconnect both battery negati ve cabl es.
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
6094). ALWAYS WEAR SAFETY GLASSES WHEN
(3) Remove ai r box and turbocharger i nl et tube.
(4) Remove cool ant tank hose, washer bottl e hose
and the posi ti ve battery cabl e from the fasteni ng
cl i ps l ocated on top of the radi ator.
(5) Remove hose cl amps and hoses from radi ator.
(6) Remove the power steeri ng cool er mounti ng
bol ts and posi ti on the power steeri ng cool er out of
the way.
(7) Di sconnect the transmi ssi on cool er l i nes at the
transmi ssi on cool er. The transmi ssi on cool er wi l l
remai n on the radi ator and can be removed as an
assembl y.
(8) Di sconnect the el ectroni c vi scous fan dri ve el ec-
tri cal connector.
(9) Usi ng a fastener removal tool , remove the two
push pi ns and the l ower shroud assembl y and el ec-
troni c vi scous fan dri ve wi ri ng from the upper shroud
assembl y. Posi ti on wi ri ng out of the way. Do not
i mpact or damage the el ectroni c vi scous fan dri ve or
pul l i ts wi ri ng.
(10) Usi ng a fastener tool , remove the wi ri ng har-
ness bracket from the upper fan shroud.
(11) Remove the two radi ator upper mounti ng
bol ts (Fi g. 38).
(12) Li ft radi ator strai ght up and out of engi ne
compartment. The bottom of the radi ator i s equi pped
wi th two al i gnment dowel s that fi t i nto hol es i n the
l ower radi ator support panel . Rubber bi scui ts (i nsu-
l ators) are i nstal l ed to these dowel s. Take care not to
damage cool i ng fi ns or tubes on the radi ator and ai r
condi ti oni ng condenser or the el ectroni c vi scous fan
connector when removi ng.
CLEANING
Cl ean radi ator fi ns are necessary for good heat
transfer. The radi ator and oi l cool er fi ns shoul d be
cl eaned when an accumul ati on of debri s has
occurred. Wi th the engi ne col d, appl y col d water and
compressed ai r to the back (engi ne si de) of the radi -
ator to fl ush the radi ator and/or oi l cool ers of debri s.
INSPECTION
I nspect the radi ator si de tanks for cracks, and bro-
ken or mi ssi ng fi tti ngs. I nspect the joi nt where the
tanks seam up to the radi ator core for si gns of l eak-
age and/or deteri orati ng seal s.
I nspect radi ator core for corroded, bent or mi ssi ng
cool i ng fi ns. I nspect the core for bent or damaged
cool i ng tubes.
7 - 56 ENGINE DR
INSTALLATION
(1) I nstal l rubber i nsul ators to al i gnment dowel s
at l ower part of radi ator.
(2) Lower the radi ator i nto posi ti on whi l e gui di ng
the two al i gnment dowel s i nto l ower radi ator sup-
port. Di fferent al i gnment hol es are provi ded i n the
l ower radi ator support for each engi ne appl i cati on.
(3) I nstal l two upper radi ator mounti ng bol ts.
Ti ghten bol ts to 11.8 Nm (105 i n. l bs.) torque.
(4) Connect both radi ator hoses and i nstal l hose
cl amps.
(5) Connect transmi ssi on cool er l i nes to transmi s-
si on cool er. I nspect qui ck connect fi tti ngs for debri s
and i nstal l unti l an audi bl e cl i ck i s heard. Pul l
apart to veri fy connecti on.
(6) Posi ti on power steeri ng cool er on the radi ator
and ti ghten nuts to 10 Nm (90 i n. l bs.)
(7) Posi ti on the el ectroni c vi scous fan wi ri ng i n the
channel i n the upper shroud (Fi g. 39). Make sure
that the grommet seats i nto the channel .
(8) I nstal l l ower radi ator shroud usi ng two push
pi ns. Make sure the wi ri ng vi scous fan dri ve wi ri ng
i s not pi nched.
(9) I nstal l the wi ri ng harness bracket to the upper
shroud.
(10) Connect the vi scous fan dri ve wi ri ng to the
wi ri ng harness.
(11) I nstal l the cool ant recovery contai ner (Refer to
7 - COOLI NG/ENGI NE/COOLANT RECOVERY
CONTAI NER - I NSTALLATI ON).
(12) Posi ti on cool ant recovery tank hose, washer
bottl e hose and the posi ti ve battery cabl e i nto the
cl i ps l ocated on the top of the radi ator.
(13) I nstal l ai r box and turbocharger i nl et hose.
Ti ghten cl amps to 4 Nm (35 i n. l bs.).
(14) Posi ti on heater control s to full heat posi ti on.
(15) Fi l l cool i ng system wi th cool ant (Refer to 7 -
(16) Operate engi ne unti l i t reaches normal tem-
perature. Check cool i ng system and automati c trans-
mi ssi on (i f equi pped) fl ui d l evel s.
RADIATOR PRESSURE CAP
DESCRIPTION
Al l cool i ng systems are equi pped wi th a pressure
cap (Fi g. 40). For 5.9L engi nes, the pressure cap i s
l ocated on top of the radi ator outl et tank. For al l
engi nes, the pressure cap i s l ocated on top of the
cool ant degas contai ner. The cap rel eases pressure at
some poi nt wi thi n a range of 97-to-124 kPa (14-to-18
psi ). The pressure rel i ef poi nt (i n pounds) i s engraved
on top of the cap
The cool i ng system wi l l operate at pressures
sl i ghtl y above atmospheri c pressure. Thi s resul ts i n a
hi gher cool ant boi l i ng poi nt al l owi ng i ncreased radi -
ator cool i ng capaci ty. The cap contai ns a spri ng-
Fig. 38 Fan Shroud Mounting - 5.9L Diesel Engine
2 - UPPER FAN SHROUD
3 - BOLTS (2)
4 - LOWER FAN SHROUD
5 - RADIATOR
Wiring
1 - UPPER SHROUD
2 - WIRING
DR ENGINE 7 - 57
RADIATOR - 5.9L DIESEL (Continued)
l oaded pressure rel i ef val ve. Thi s val ve opens when
system pressure reaches the rel ease range of 97-to-
124 kPa (14-to-18 psi ).
A rubber gasket seal s the radi ator fi l l er neck. Thi s
i s done to mai ntai n vacuum duri ng cool ant cool -down
and to prevent l eakage when system i s under pres-
sure.
OPERATION
A vent val ve i n the center of the cap wi l l remai n
shut as l ong as the cool i ng system i s pressuri zed. As
the cool ant cool s, i t contracts and creates a vacuum
i n the cool i ng system. Thi s causes the vacuum val ve
to open and cool ant i n the reserve/overfl ow contai ner
to be drawn through the recovery hose connecti ng
the fi l l er neck and reserve/overfl ow contai ner. I f the
vacuum val ve i s stuck shut, or the recovery hose i s
ki nked, radi ator hoses wi l l col l apse on cool down.
CAP-TO-FILLER NECK SEAL
The pressure cap upper gasket (seal ) pressure
rel i ef can be tested by removi ng overfl ow hose from
the radi ator fi l l er neck tube. Attach the hose of the
pressure tester tool 7700 (or equi val ent) to the tube.
I t wi l l be necessary to di sconnect hose from i ts
adapter for the fi l l er neck. Pump ai r i nto radi ator.
The pressure cap upper gasket shoul d rel i eve at 69
to 124kPa (10 to 18 psi ) and hol d pressure at a mi n-
i mum of 55 kPa (8 psi ).
WARNING: THE WARNING WORDS, DO NOT OPEN
HOT, ON RADIATOR PRESSURE CAP, ARE A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, RADIATOR CAP SHOULD
NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR
UNDER PRESSURE.
Do not remove the radi ator cap at any ti me except
for the fol l owi ng purposes:
Check and adjust anti freeze freeze poi nt.
Refi l l the system wi th new anti freeze.
Conducti ng servi ce procedures.
Checki ng for vacuum l eaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT AT LEAST 15 MINUTES BEFORE REMOVING
RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR
UPPER HOSE TO CHECK IF SYSTEM IS UNDER
PRESSURE. PLACE A RAG OVER CAP AND WITH-
OUT PUSHING CAP DOWN, ROTATE IT COUNTER-
CLOCKWISE TO FIRST STOP. ALLOW FLUID TO
ESCAPE THROUGH THE COOLANT RESERVE/
OVERFLOW HOSE INTO RESERVE/OVERFLOW
TANK. SQUEEZE RADIATOR UPPER HOSE TO
DETERMINE WHEN PRESSURE HAS BEEN
RELEASED. WHEN COOLANT AND STEAM STOP
BEING PUSHED INTO TANK AND SYSTEM PRES-
SURE DROPS, REMOVE RADIATOR CAP COM-
PLETELY.
DIAGNOSIS AND TESTING - RADIATOR CAP
Remove the cap from the radi ator. Be sure that the
seal i ng surfaces are cl ean. Moi sten the rubber gasket
wi th water and i nstal l the cap on the pressure tester
7700 or an equi val ent (Fi g. 41).
Operate the tester pump to bri ng the pressure to
104 kPa (15 psi ) on the gauge. I f the pressure cap
fai l s to hol d pressure of at l east 97 kPa (14 psi )
repl ace the cap. Refer to the fol l owi ng CAUTION.
Fig. 40 Radiator Pressure Cap - Typical
1 - FILLER NECK SEAL
2 - VACUUM VENT VALVE
3 - PRESSURE RATING
4 - PRESSURE VALVE
7 - 58 ENGINE DR
RADIATOR PRESSURE CAP (Continued)
The pressure cap may test properl y whi l e posi -
ti oned on tool 7700 (or equi val ent). I t may not hol d
pressure or vacuum when i nstal l ed on the radi ator. I f
so, i nspect the radi ator fi l l er neck and radi ator caps
top gasket for damage. Al so i nspect for di rt or di stor-
ti on that may prevent the cap from seal i ng properl y.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
CLEANING
Use onl y a mi l d soap and water to cl ean the radi -
ator cap. Usi ng any type of sol vent may cause dam-
age to the seal i n the radi ator cap.
INSPECTION
Hol d cap at eye l evel , ri ght si de up. The vent val ve
(Fi g. 42) at bottom of cap shoul d cl osed. A sl i ght
downward pul l on the vent val ve shoul d open i t. I f
the rubber gasket has swol l en and prevents vent
val ve from openi ng, repl ace cap.
Hol d cap at eye l evel , upsi de down. I f any l i ght can
be seen between vent val ve and rubber gasket,
repl ace cap. A repl acement cap must be the type
desi gned for a cool ant reserve/overfl ow system wi th a
compl etel y seal ed di aphragm spri ng and a rubber
gasket. Thi s gasket i s used to seal to radi ator fi l l er
neck top surface. Use of proper cap wi l l al l ow cool ant
return to radi ator.
WATER PUMP - 3.7L/4.7L
DESCRIPTION
DESCRIPTION - WATER PUMP
A centri fugal water pump ci rcul ates cool ant
through the water jackets, passages, i ntake mani fol d,
radi ator core, cool i ng system hoses and heater core.
The pump i s dri ven from the engi ne crankshaft by a
si ngl e serpenti ne dri ve bel t.
The water pump i mpel l er i s pressed onto the rear
of a shaft that rotates i n beari ngs pressed i nto the
housi ng. The housi ng has two smal l hol es to al l ow
seepage to escape. The water pump seal s are l ubri -
cated by the anti freeze i n the cool ant mi xture. No
addi ti onal l ubri cati on i s necessary.
Both heater hoses are connected to fi tti ngs on the
ti mi ng chai n front cover. The water pump i s al so
mounted di rectl y to the ti mi ng chai n cover and i s
equi pped wi th a non servi ceabl e i ntegral pul l ey (Fi g.
43).
DESCRIPTION - WATER PUMP BYPASS
The 3.7L and 4.7L engi ne uses an i nternal water/
cool ant bypass system. The desi gn uses gal l eri es i n
the ti mi ng chai n cover to ci rcul ate cool ant duri ng
Fig. 41 Pressure Testing Radiator Cap - Typical
1 - PRESSURE CAP
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER
Fig. 42 Radiator Pressure Cap
1 - STAINLESS-STEEL SWIVEL TOP
2 - RUBBER SEALS
3 - VENT VALVE
4 - RADIATOR TANK
5 - FILLER NECK
6 - OVERFLOW NIPPLE
7 - MAIN SPRING
8 - GASKET RETAINER
DR ENGINE 7 - 59
RADIATOR PRESSURE CAP (Continued)
engi ne warm-up preventi ng the cool ant from fl owi ng
through the radi ator (Fi g. 44).
OPERATION
OPERATION WATER PUMP
A centri fugal water pump ci rcul ates cool ant
through the water jackets, passages, i ntake mani fol d,
radi ator core, cool i ng system hoses and heater core,
thi s cool ant absorbs the heat generated when the
engi ne i s runni ng. The pump i s dri ven by the engi ne
crankshaft vi a a dri ve bel t.
OPERATION - WATER PUMP BYPASS
When the thermostat i s i n the cl osed posi ti on the
bypass gal l ery i s not obstructed al l owi ng 100% fl ow.
When the thermostat i s i n the open posi ti on the pi l l
parti al l y covers the bypass hol e, reduci ng the amount
of bypass fl ow. Thi s desi gn al l ows the cool ant to
reach operati ng temperature qui ckl y when col d,
whi l e addi ng extra cool i ng duri ng normal tempera-
ture operati on.
REMOVAL
The water pump on 3.7L/4.7L engi nes i s bol ted
di rectl y to the engi ne ti mi ng chai n case cover.
(2) Drai n cool i ng system (Refer to 7 - COOLI NG -
(3) Remove fan/vi scous fan dri ve assembl y from
water pump (Fi g. 45) (Refer to 7 - COOLI NG/EN-
GI NE/FAN DRI VE VI SCOUS CLUTCH -
REMOVAL). Do not attempt to remove fan/vi scous
fan dri ve assembl y from vehi cl e at thi s ti me.
with matching number or letter and width.
(4) I f the water pump i s bei ng repl aced, do not
unbol t the fan bl ade assembl y from the thermal vi s-
cous fan dri ve.
Fig. 43 Water Pump and Timing Chain Cover - 4.7L
1 - INTEGRAL WATER PUMP PULLEY
4 - HEATER HOSE FITTINGS
5 - WATER PUMP
Fig. 44 Water/Coolant Bypass Flow and Thermostat
1 - FROM HEATER AND DEGAS CONTAINER
2 - FROM RADIATOR
3 - TO WATER PUMP
4- THERMOSTAT
7 - 60 ENGINE DR
WATER PUMP - 3.7L/4.7L (Continued)
(5) Remove the radi ator fan (Refer to 7 - COOL-
I NG/ENGI NE/RADI ATOR FAN - REMOVAL).
(6) Remove accessory dri ve bel t (Fi g. 46) (Refer to
7 - COOLI NG/ACCESSORY DRI VE/DRI VE BELTS -
REMOVAL).
(7) Remove the l ower radi ator hose cl amp and
remove the l ower hose at the water pump.
(8) Remove the water pump mounti ng bol ts.
CAUTION: Do not pry water pump at timing chain
case/cover. The machined surfaces may be dam-
aged resulting in leaks.
(9) Remove the water pump and gasket. Di scard
gasket.
CLEANING
Cl ean the gasket mati ng surface. Use cauti on not
to damage the gasket seal i ng surface.
INSPECTION
I nspect the water pump assembl y for cracks i n the
housi ng, water l eaks from shaft seal , worn beari ng or
i mpel l er rubbi ng ei ther the pump body or ti mi ng
chai n case/cover.
INSTALLATION
The water pump on 3.7L/4.7L engi ne i s bol ted
di rectl y to the engi ne ti mi ng chai n case cover.
(1) Cl ean the gasket mati ng surfaces.
(2) Usi ng a new gasket, posi ti on water pump and
i nstal l the mounti ng bol ts. (Fi g. 47). Ti ghten the
water pump mounti ng bol ts to 58 Nm (43 ft. l bs.).
Fig. 45 Viscous Fan and Fan Drive 4.7L Engine
PINS 8346
2 - FAN
Fig. 46 Automatic Belt Tensioner4.7L
Fig. 47 Water Pump Installation3.7L/4.7L Typical
1 - WATER PUMP
DR ENGINE 7 - 61
(3) Spi n the water pump to be sure that the pump
i mpel l er does not rub agai nst the ti mi ng chai n case/
cover.
(4) Connect the radi ator l ower hose to the water
pump.
(5) Rel ax the tensi on from the bel t tensi oner (Fi g.
46). I nstal l the dri ve bel t (Refer to 7 - COOLI NG/AC-
TI ON).
drive belt, the belt must be routed correctly. If not,
rotating in the wrong direction. Refer to (Fig. 48) for
the correct belt routing. Or, refer to the Belt Routing
Label located in the engine compartment. The cor-
rect belt with correct length must be used.
(6) I nstal l the radi ator fan (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR FAN - I NSTALLATI ON).
WATER PUMP - 5.9L DIESEL
DESCRIPTION
The water pump i s mounted to the front of the
engi ne bl ock between the automati c bel t tensi oner
and the fan dri ve pul l ey.
The water pump i mpel l er i s pressed onto the rear
of a shaft that rotates i n a beari ng pressed i nto the
water pump body. The body has a smal l hol e for ven-
ti l ati on. The water pump seal s are l ubri cated by
anti freeze i n the cool ant mi xture. Addi ti onal l ubri ca-
ti on i s not necessary.
OPERATION
The di esel engi ne water pump draws cool ant from
the radi ator outl et and ci rcul ates i t through engi ne,
heater core and back to radi ator i nl et. The crank-
shaft pul l ey dri ves the water pump wi th a serpenti ne
dri ve bel t.
DIAGNOSIS AND TESTING WATER PUMP
A qui ck test to determi ne i f pump i s worki ng i s to
check i f heater warms properl y. A defecti ve water
pump wi l l not be abl e to ci rcul ate heated cool ant
through the l ong heater hose to the heater core.
REMOVAL
REMOVAL).
(4) Remove water pump mounti ng bol ts (Fi g. 49).
(5) Cl ean water pump seal i ng surface on cyl i nder
bl ock.
CLEANING
Cl ean gasket mati ng surfaces as necessary.
INSPECTION
Vi sual l y i nspect the water pump and repl ace i f i t
has any of the fol l owi ng condi ti ons:
The body i s cracked or damaged
Water l eaks from the shaft seal . Thi s i s evi dent
by traces of cool ant bel ow the vent hol e
Loose or rough turni ng beari ng.
I mpel l er rubbi ng the pump body
INSTALLATION
(1) I nstal l new O-ri ng seal i n groove on water
pump (Fi g. 50).
(2) I nstal l water pump wi th the weep hol e faci ng
downward. Ti ghten mounti ng bol ts to 24 Nm (18 ft.
l bs.) torque.
Fig. 48 Belt Routing 3.7L
2 - ACCESSORY DRIVE BELT
5 - IDLER PULLEY
6 - TENSIONER
7 - 62 ENGINE DR
LATI ON).
(5) Connect both battery cabl es.
WATER PUMP - 5.7L
REMOVAL
(1) Di sconnect negati ve battery cabl e.
(2) Drai n cool ant.
(3) Remove serpenti ne bel t.
(4) Remove fan cl utch assembl y.
(5) Remove cool ant fi l l bottl e.
(6) Di sconnect washer bottl e wi ri ng and hose.
(7) Remove fan shroud assembl y.
(8) Remove A/C compressor and generator brace.
(9) Remove i dl er pul l eys.
(10) Remove bel t tensi oner assembl y.
(11) Remove upper and l ower radi ator hoses.
(12) Remove heater hoses.
(13) Remove water pump mounti ng bol ts and
remove pump.
INSTALLATION
(1) I nstal l water pump and mounti ng bol ts.
Ti ghten moubti ng bol ts to 24 Nm (18 ft. l bs.).
(2) I nstal l heater hoses.
(3) I nstal l upper and l ower radi ator hoses.
(4) I nstal l bel t tensi oner assembl y.
(5) I nstal l i dl er pul l eys.
(6) I nstal l A/C compressor and al ternator brace.
Ti ghten bol t and nuts to 28 Nm (21 ft. l bs.).
(7) I nstal l fan shroud assembl y.
(8) Connect washer bottl e wi ri ng and hose.
(9) I nstal l cool ant fi l l bottl e.
(10) I nstal l fan cl utch assembl y.
(11) I nstal l serpenti ne bel t.
(13) Fi l l cool ant.
(14) Pressure test cool ant system
WATER PUMP - 8.0L
DIAGNOSIS AND TESTING - WATER PUMP
A qui ck test to determi ne i f pump i s worki ng i s to
check i f heater warms properl y. A defecti ve water
pump wi l l not be abl e to ci rcul ate heated cool ant
through the l ong heater hose to the heater core.
Fig. 49 Water Pump Removal/Installation
1 - O-RING SEAL (SQUARE)
2 - WATER PUMP
3 - BOLT (2)
Fig. 50 Pump O-ring Seal
1 - O-RING SEAL
2 - GROOVE
3 - WATER PUMP
DR ENGINE 7 - 63
WATER PUMP - 5.9L DIESEL (Continued)
REMOVAL
NOTE:
The water pump on all models can be removed
without discharging the air conditioning system (if
equipped).
The water pump on all gas powered engines is
bolted directly to the engine timing chain case/
cover.
On the 8.0L V-10 engine, a rubber o-ring (instead of
a gasket) is used as a seal between the water pump
and timing chain case/cover.
I f water pump i s repl aced because of beari ng/shaft
damage or l eaki ng shaft seal , the mechani cal cool i ng
fan assembl y shoul d al so be i nspected. I nspect for
fati gue cracks, l oose bl ades or l oose ri vets that coul d
have resul ted from excessi ve vi brati on. Repl ace fan i f
any of these condi ti ons are found. Al so check condi -
ti on of the thermal vi scous fan dri ve (Refer to 7 -
COOLI NG/ENGI NE/FAN DRI VE VI SCOUS
CLUTCH - DI AGNOSI S AND TESTI NG).
Do not waste reusabl e cool ant. I f sol uti on i s cl ean,
drai n cool ant i nto a cl ean contai ner for reuse.
(3) Remove wi ndshi el d washer reservoi r tank from
radi ator fan shroud.
(4) Remove the four fan shroud mounti ng bol ts at
the radi ator (Fi g. 51). Do not attempt to remove
shroud from vehi cl e at thi s ti me.
CLAMP, SUCH AS SPECIAL CLAMP TOOL NUMBER
6094. ALWAYS WEAR SAFETY GLASSES WHEN
(5) Remove radi ator upper hose at radi ator.
(6) The thermal vi scous fan dri ve i s threaded on to
the water pump hub shaft (Fi g. 53). Remove the fan/
fan dri ve assembl y from water pump by turni ng the
mounti ng nut countercl ockwi se (as vi ewed from
front). Threads on the fan dri ve are RIGHT-HAND.
A 36 MM fan wrench can be used wi th Tool 6958
Spanner Wrench and Adapter Pi ns 8346 (Fi g. 52) to
prevent the pul l ey from rotati ng.
(7) I f water pump i s bei ng repl aced, do not unbol t
fan bl ade assembl y (Fi g. 53) from the thermal control
fan dri ve.
(8) Remove fan bl ade/fan dri ve and fan shroud as
an assembl y from vehi cl e.
After removi ng fan bl ade/fan dri ve assembl y, do
not pl ace the thermal vi scous fan dri ve i n the hori -
zontal posi ti on. I f stored hori zontal l y, the si l i cone
Fig. 51 Typical Fan Shroud Mounting
2 - RADIATOR
3 - BOLTS (4)
4 - FAN SHROUD
Fig. 52 Using Special Tool 6958 Spanner Wrench
and Adapter Pins 8346
PINS 8346
2 - FAN
7 - 64 ENGINE DR
WATER PUMP - 8.0L (Continued)
fl ui d i n the vi scous dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate the beari ng l ubri cant.
REMOVAL) (Fi g. 54).
(10) Remove the radi ator l ower hose at water
pump.
(11) Remove heater hose at water pump fi tti ng.
(12) Remove the seven water pump mounti ng bol ts
(Fi g. 55).
(13) Loosen the cl amp at the water pump end of
bypass hose. Sl i p the bypass hose from the water
pump whi l e removi ng pump from vehi cl e. Do not
remove the cl amp from the bypass hose.
(14) Di scard the water pump-to-ti mi ng chai n/case
cover o-ri ng seal (Fi g. 56).
Fig. 53 Water Pump Location - Typical
Fig. 54 Belt Tensioner - 8.0L V-10 Engines
1 - PULLEY BOLT
2 - IDLER PULLEY
3 - TENSIONER PULLEY
4 - TENSIONER
5 - TENSIONER MOUNTING BOLT
Fig. 55 Water Pump Bolts - 8.0L V-10 - Typical
1 - WATER PUMP MOUNTING BOLTS (7)
Fig. 56 Water Pump O-Ring Seal - 8.0L V-10
1 - WATER PUMP
2 - O-RING SEAL
DR ENGINE 7 - 65
(15) Remove the heater hose fi tti ng from water
pump i f pump repl acement i s necessary. Note posi -
ti on (di recti on) of fi tti ng before removal . Fi tti ng must
be re-i nstal l ed to same posi ti on.
CAUTION: Do not pry the water pump at timing
chain case/cover. The machined surfaces may be
damaged resulting in leaks.
CLEANING
Cl ean gasket mati ng surfaces as necessary.
INSPECTION
Vi sual l y i nspect the water pump and repl ace i f i t
has any of the fol l owi ng condi ti ons:
The body i s cracked or damaged
Water l eaks from the shaft seal . Thi s i s evi dent
by traces of cool ant bel ow the vent hol e
Loose or rough turni ng beari ng. Al so i nspect
thermal fan dri ve
I mpel l er rubbi ng the pump body
INSTALLATION
(1) I f water pump i s bei ng repl aced, i nstal l the
heater hose fi tti ng to the pump. Ti ghten fi tti ng to 16
Nm (144 i n. l bs.) torque. After fi tti ng has been
torqued, posi ti on fi tti ng as shown i n (Fi g. 57). When
posi ti oni ng fi tti ng, do not back off (rotate counter-
cl ockwi se). Use a seal ant on the fi tti ng such as
Mopar Thread Seal ant Wi th Tefl on. Refer to the
di recti ons on the package.
CAUTION: This heater hose fitting must be installed
to pump before pump is installed to engine.
(2) Cl ean the o-ri ng mati ng surfaces at rear of
water pump and front of ti mi ng chai n/case cover.
(3) Appl y a smal l amount of petrol eum jel l y to
o-ri ng (Fi g. 56). Thi s wi l l hel p retai n o-ri ng to water
pump.
(4) I nstal l water pump to engi ne as fol l ows: Gui de
water pump fi tti ng i nto bypass hose as pump i s bei ng
i nstal l ed. I nstal l water pump bol ts (Fi g. 55). Ti ghten
water pump mounti ng bol ts to 40 Nm (30 ft. l bs.)
torque.
(5) Posi ti on bypass hose cl amp to bypass hose.
(6) Spi n water pump to be sure that pump i mpel -
l er does not rub agai nst ti mi ng chai n case/cover.
(7) Connect radi ator l ower hose to water pump.
(8) Connect heater hose and hose cl amp to heater
hose fi tti ng.
(9) I nstal l dri ve bel t (Refer to 7 - COOLI NG/AC-
TI ON).
(10) Posi ti on fan shroud and fan bl ade/vi scous fan
dri ve assembl y to vehi cl e as a compl ete uni t.
(11) I nstal l fan shroud to radi ator. Ti ghten bol ts to
6 Nm (50 i n. l bs.) torque.
(12) I nstal l fan bl ade/vi scous fan dri ve assembl y to
water pump shaft.
Fig. 57 Heater Hose Fitting Position - 8.0L V-10
1 - HEATER HOSE FITTING
2 - WATER PUMP
7 - 66 ENGINE DR
TRANSMISSION
TABLE OF CONTENTS
page page
TRANS COOLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 67
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68
TRANS COOLER - 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 68
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
REMOVAL
REMOVAL - AIR TO OIL COOLER . . . . . . . . . 69
REMOVAL - WATER TO OIL COOLER . . . . . . 69
DISASSEMBLY - 5.9L DIESEL ONLY . . . . . . . . . 70
ASSEMBLY - 5.9L DIESEL ONLY . . . . . . . . . . . 70
INSTALLATION
INSTALLATION - AIR TO OIL COOLER . . . . . 70
INSTALLATION - WATER-TO-AIR COOLER . . 70
TRANS COOLER
DESCRIPTION
An ai r-to-oi l transmi ssi on oi l cool er i s standard on
al l engi ne packages. The transmi ssi on oi l cool er i s
mounted to the front of the radi ator above the power
steeri ng cool er (Fi g. 1) and (Fi g. 2)
OPERATION
Transmi ssi on oi l i s routed through the cool er
where heat i s removed from the transmi ssi on oi l
before returni ng to the transmi ssi on.
Fig. 1 Cooling Module - 3.7L/4.7L/5.7L
1 - TRANS OIL COOLER
2 - LOCATING TABS
3 - POWER STEERING OIL COOLER
4 - POWER STEERING OIL COOLER MOUNTING BOLT
5 - TRANS OIL COOLER OUTLET
6 - TRANS OIL COOLER INLET
7 - COOLER LINE CLIP
9 - MOUNTING BOLT
10 - RADIATOR
Fig. 2 COOLING MODULE - 5.9L GAS
1 - TRANS OIL COOLER BYPASS (5.9L only)
2 - OIL COOLER THERMOSTATIC BYPASS VALVE (5.9L only)
3 -TRANS OIL COOLER
4 - OIL COOLER MOUNTING BOLT (4)
5 - POWER STEERING COOLER
6 - POWER STEERING COOLER MOUNTING BOLT(2)
7 - TRANS OIL COOLER OUTLET
8 - TRANS OIL COOLER INLET
11 - RADIATOR
DR TRANSMISSION 7 - 67
REMOVAL
(2) Pl ace a drai n pan under the oi l cool er l i nes.
(3) Di sconnect the transmi ssi on oi l cool er l i ne
qui ck-connect fi tti ng at the cool er outl et usi ng the
qui ck connect rel ease tool 6935. Pl ug the cool er l i nes
to prevent oi l l eakage.
(4) Unsnap the transmi ssi on cool er tubes from the
radi ator tank cl i ps.
(5) Remove the bol t attachi ng the transmi ssi on
cool er to the radi ator.
(6) Remove oi l cool er from the vehi cl e. Take care
not to damage the radi ator core or transmi ssi on
cool er tubes.
INSTALLATION
(1) Posi ti on the transmi ssi on cool er tubes to the
front of the radi ator by sl i di ng brackets i nto sl ots on
radi ator i nl et tank.
(2) Snap the transmi ssi on cool er tubes i nto the
cl i ps on the si de of the radi ator tank.
(3) I nstal l the transmi ssi on cool er attachi ng bol t.
Ti ghten the bol t to 16 Nm (140 i n. l bs.).
(4) I nspect the qui ck connect fi tti ngs for debri s
and i nstal l the qui ck connect fi tti ng on the cool er
tube unti l an audi bl e cl i ck i s heard. Pul l apart the
connecti on to veri fy proper i nstal l ati on and i nstal l
the secondary l atches.
(5) Connect the battery negati ve cabl e.
(6) Start the engi ne and check al l fi tti ngs for
l eaks.
(7) Check the fl ui d l evel i n the automati c trans-
mi ssi on. Refer to the appropri ate transmi ssi on sec-
ti on(Refer to 21 - TRANSMI SSI ON/TRANSAXLE/
AUTOMATI C - 45RFE/545RFE/FLUI D - STANDARD
PROCEDURE) or(Refer to 21 - TRANSMI SSI ON/
TRANSAXLE/AUTOMATI C - 46RE/FLUI D - STAN-
DARD PROCEDURE).
TRANS COOLER - 5.9L DIESEL
DESCRIPTION
Al l di esel model s equi pped wi th an automati c
transmi ssi on are equi pped wi th both a mai n water-
to-oi l cool er and a separate ai r-to-oi l cool er. Both cool -
ers are suppl i ed as standard equi pment on di esel
engi ne powered model s when equi pped wi th an auto-
mati c transmi ssi on.
The mai n water-to-oi l transmi ssi on oi l cool er i s
mounted to a bracket on the i ntake si de of the engi ne
(Fi g. 3).
The ai r-to-oi l cool er i s l ocated i n front of the radi -
ator (Fi g. 4).
Fig. 3 Transmission Water-To-Oil Cooler - Diesel
Engine - Typical
1 - TRANSMISSION WATER-TO-OIL COOLER
Fig. 4 Auxiliary Transmission Oil CoolerDiesel
Engine
1 - MOUNTING BOLTS
2 - THERMOSTATIC BYPASS VALVE
3 - RADIATOR
4 - QUICK-CONNECT FITTINGS
5 - TRANSMISSION OIL COOLER
7 - 68 TRANSMISSION DR
TRANS COOLER (Continued)
OPERATION
The transmi ssi on oi l i s routed through the mai n
cool er fi rst, then the auxi l i ary cool er where addi -
ti onal heat i s removed from the transmi ssi on oi l
before returni ng to the transmi ssi on. The auxi l i ary
cool er has an i nternal thermostat that control s fl ui d
fl ow through the cool er. When the transmi ssi on fl ui d
i s col d (l ess then operati ng temperature), the fl ui d i s
routed through the cool er bypass. When the trans-
mi ssi on fl ui d reaches operati ng temperatures and
above, the thermostat cl oses off the bypass al l owi ng
fl ui d fl ow through the cool er. The thermostat i s ser-
vi cabl e.
REMOVAL
REMOVAL - AIR TO OIL COOLER
(1) Remove Charge Ai r Cool er (Refer to 11 -
EXHAUST SYSTEM/TURBOCHARGER SYSTEM/
CHARGE AI R COOLER AND PLUMBI NG -
REMOVAL).
(2) Pl ace a drai n pan under the oi l cool er.
(4) Di sconnect the oi l cool er qui ck-connect fi tti ngs
from the transmi ssi on l i nes.
(5) Remove the charge ai r cool er-to-oi l cool er bol t
(Fi g. 5).
(6) Remove two mounti ng nuts.
(7) Remove the oi l cool er and l i ne assembl y
towards the front of vehi cl e. Cool er must be rotated
and ti l ted i nto posi ti on whi l e removi ng.
REMOVAL - WATER TO OIL COOLER
CAUTION: If a leak should occur in the water-to-oil
cooler mounted to the side of the engine block,
engine coolant may become mixed with transmis-
sion fluid. Transmission fluid may also enter engine
cooling system. Both cooling system and transmis-
sion should be drained and inspected in case of oil
cooler leakage.
(2) Remove starter (Refer to 8 - ELECTRI CAL/
STARTI NG/STARTER MOTOR - REMOVAL).
(4) Di sconnect cool ant l i nes from cool er.
(5) Di sconnect transmi ssi on oi l l i nes from cool er.
Pl ug cool er l i nes to prevent oi l l eakage.
(6) Remove cool er bracket to transmi ssi on adapter
bol t.
(7) Remove two cool er bracket to bl ock bol ts.
(8) Remove cool er assembl y from vehi cl e. (Fi g. 6)
Fig. 5 Auxiliary Transmission Oil CoolerDiesel
Engine
1 - MOUNTING BOLTS
2 - THERMOSTATIC BYPASS VALVE
3 - RADIATOR
5 - TRANSMISSION OIL COOLER
Fig. 6 Transmission Water-To- Oil Cooler - Diesel
1 - TRANSMISSION WATER-TO-OIL COOLER
DR TRANSMISSION 7 - 69
TRANS COOLER - 5.9L DIESEL (Continued)
DISASSEMBLY - 5. 9L DIESEL ONLY
NOTE: The transmission oil cooler uses an internal
thermostat to control transmission oil flow through
the cooler. This thermostat is servicable.
(1) Remove the transmi ssi on oi l cool er (Refer to 7 -
COOLI NG/TRANSMI SSI ON/TRANS COOLER -
REMOVAL).
(2) Remove the snap ri ng retai ni ng the thermostat
end pl ug (Fi g. 7).
(3) Remove the end pl ug, thermostat and spri ng
from transmi ssi on oi l cool er (Fi g. 7).
ASSEMBLY - 5. 9L DIESEL ONLY
(1) Throughl y cl ean the thermostat bore on the
transmi ssi on oi l cool er.
(2) I nstal l the new spri ng, thermostat, end pl ug
and snap ri ng.
(3) I nstal l the transmi ssi on oi l cool er (Refer to 7 -
COOLI NG/TRANSMI SSI ON/TRANS COOLER -
I NSTALLATI ON).
INSTALLATION
INSTALLATION - AIR TO OIL COOLER
(1) Careful l y posi ti on the oi l cool er assembl y to the
vehi cl e.
(2) I nstal l two nuts and one bol t. Ti ghten to 11
Nm (95 i n. l bs.) torque.
(3) Connect the qui ck-connect fi tti ngs to the trans-
mi ssi on cool er l i nes.
(4) I nstal l Charge Ai r Cool er (Refer to 11 -
EXHAUST SYSTEM/TURBOCHARGER SYSTEM/
CHARGE AI R COOLER AND PLUMBI NG -
I NSTALLATI ON).
(5) Start the engi ne and check al l fi tti ngs for
l eaks.
(6) Check the fl ui d l evel i n the automati c trans-
mi ssi on (Refer to 21 - TRANSMI SSI ON/TRANS-
AXLE/AUTOMATI C - 47RE/FLUI D - STANDARD
PROCEDURE).
INSTALLATION - WATER-TO-AIR COOLER
(1) Posi ti on oi l cool er on cyl i nder bl ock.
(2) I nstal l l ower mounti ng bol t to cool er at the cyl -
i nder bl ock. Torque bol t to 77 Nm (57 ft. l bs.)
(3) I nstal l upper mounti ng bol t at the cyl i nder
bl ock. Torque bol t to 24 Nm (19 ft. l bs.)
(4) I nstal l cool er bracket to transmi ssi on adapter
bol t. Ti ghten to 24 Nm (18 ft. l bs.).
(5) Connect transmi ssi on oi l l i nes to cool er.
(6) Connect cool ant hoses to cool er.
(7) I nstal l starter motor (Refer to 8 - ELECTRI -
CAL/STARTI NG/STARTER MOTOR - I NSTALLA-
TI ON).
(8) Connect battery negati ve cabl es.
(10) Check transmi ssi on oi l l evel and fi l l as neces-
sary (Refer to 21 - TRANSMI SSI ON/TRANSAXLE/
AUTOMATI C - 47RE/FLUI D - STANDARD
PROCEDURE).
Fig. 7 Transmission Oil Cooler Thermostat
Removal/Installation
2 - SPRING
3 - END PLUG
4 - SNAP RING
5 - THERMOSTAT
7 - 70 TRANSMISSION DR
TRANS COOLER - 5.9L DIESEL (Continued)
AUDIO/VIDEO
TABLE OF CONTENTS
page page
AUDIO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - AUDIO . . . . . . . . . . 2
AMPLIFIER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ANTENNA BODY & CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ANTENNA - NAVIGATION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTRUMENT PANEL ANTENNA CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
RADIO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RADIO NOISE SUPPRESSION GROUND STRAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOTE SWITCHES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - REMOTE
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPEAKER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - SPEAKER . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
AUDIO
DESCRIPTION
Several combi nati ons of radi o recei vers and
speaker systems are offered. The audi o system uses
an i gni ti on swi tched source of battery current so that
the system wi l l onl y operate when the i gni ti on swi tch
i s i n the RUN or ACCESSORY posi ti ons.
A opti onal navi gati on radi o (RB4) i s avai l abl e on
thi s vehi cl e. Wi th thi s system, the operator has the
opti on of choosi ng a street address, poi nt of i nterest,
tri p i ti nerary and other features outl i ned i n the oper-
ators manual .
The audi o system i ncl udes the fol l owi ng compo-
nents:
Antenna
Power ampl i fi er (wi th premi um speaker system
onl y)
Radi o noi se suppressi on components
Radi o recei ver
Remote radi o swi tches (i f equi pped)
Speakers
Certai n functi ons and features of the audi o system
rel y upon resources shared wi th other el ectroni c
modul es i n the vehi cl e over the Programmabl e Com-
muni cati on I nterface (PCI ) bus network. The data
bus network al l ows the shari ng of sensor i nforma-
ti on. For di agnosi s of these el ectroni c modul es or of
the data bus network, the use of a DRB I I I scan tool
and the proper Di agnosti c Procedures manual are
recommended.
OPERATION
The audi o system components are desi gned to pro-
vi de audi o entertai nment and i nformati on through
the recepti on, tuni ng and ampl i fi cati on of l ocal l y
broadcast radi o si gnal s i n both the Ampl i tude Modu-
l ati ng (AM) and Frequency Modul ati ng (FM) com-
merci al frequency ranges.
The audi o system components operate on battery
current recei ved through a fuse i n the I ntegrated
Power Modul e (I PM) on a fused i gni ti on swi tch out-
put (run-acc) ci rcui t so that the system wi l l onl y
operate when the i gni ti on swi tch i s i n the Run or
Accessory posi ti ons.
DR AUDIO/VIDEO 8A - 1
The opti onal navi gati on radi o system recei ves GPS
si gnal s from up to ei ght satel l i tes to di spl ay the posi -
ti on and di recti on of the vehi cl e. Map i nformati on i s
suppl i ed through a DVD-ROM. An el ectroni c gyro-
sensor and the vehi cl es speed sensor enabl e the sys-
tem to di spl ay the present vehi cl e posi ti on even i n
l ocati ons where GPS si gnal s may be bl ocked.
When a desti nati on i s sel ected, the navi gati on sys-
tem uses i nformati on from the map to qui ckl y cal cu-
l ate a route. As the vehi cl e i s dri ven al ong the chosen
route, the operator i s gui ded wi th pi ctori al di spl ays
and voi ce prompts. For compl ete operati ng i nstruc-
ti ons, refer to the manual i ncl uded wi th the vehi cl e.
On vehi cl es that are equi pped wi th the opti onal
remote radi o swi tches, the I nstrument Cl uster
recei ves hard wi red resi stor mul ti pl exed i nputs from
the remote radi o swi tches. The programmi ng i n the
I nstrument Cl uster al l ows i t to process those i nputs
and send the proper messages to the radi o recei ver
over the Programmabl e Communi cati on I nterface
(PCI ) bus network to control the radi o vol ume up or
down, stati on seek up or down, preset stati on
advance, and mode advance functi ons.
DIAGNOSIS AND TESTING - AUDIO
Any diagnosis of the Audio system should
begin with the use of the DRB III diagnostic
tool. For information on the use of the
DRB III, refer to the appropriate Diagnostic
Service Manual.
Refer to the appropri ate wi ri ng i nformati on.
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
AUDIO SYSTEM DIAGNOSIS TABLE
NO AUDIO 1. Fuse faulty. 1. Check radio fuse and Ignition-Off Draw (IOD)
fuse in the Integrated Power Module (IPM).
Replace fuses, if required.
2. Radio/amplifier (if
equipped) connector faulty.
2. Check for loose or corroded radio/amplifier
connector. Repair, if required.
3. Wiring faulty. 3. Check for shorted or open wires. Repair wiring,
if required.
equipped) ground faulty.
4. Check for continuity between radio chassis and
a known good ground. There should be
continuity. Repair ground, if required.
equipped) faulty.
5. Refer to appropriate Diagnostic Service
Manual.
6. Speakers faulty. 6. Replace speaker as necessary.
NO RADIO DISPLAY 1. Fuse faulty. 1. Check radio fuse and Ignition-Off Draw (IOD)
fuse in Integrated Power Module (IPM). Replace
fuses, if required.
2. Radio connector faulty. 2. Check for loose or corroded radio connector.
Repair, if required.
3. Wiring faulty. 3. Check for battery voltage at radio connector.
Repair wiring, if required.
4. Radio ground faulty. 4. Check for continuity between radio chassis and
5. Radio faulty. 5. Refer to appropriate Diagnostic Service
Manual.
8A - 2 AUDIO/VIDEO DR
AUDIO (Continued)
CLOCK WILL NOT KEEP
SET TIME
1. Fuse faulty. 1. Check Ignition-Off Draw (IOD) fuse in the
Integrated Power Module (IPM). Replace fuse, if
required.
2. Radio connector faulty. 2. Check for loose or corroded radio connector.
Repair, if required.
3. Wiring faulty. 3. Check for battery voltage at radio connector.
Repair wiring, if required.
Manual.
POOR RADIO RECEPTION 1. Antenna faulty. 1. (Refer to 8 - ELECTRICAL/AUDIO/ANTENNA
BODY & CABLE - DIAGNOSIS AND TESTING).
3. Radio noise suppression
faulty.
3. Repair or replace ground strap as necessary.
Manual.
NO/POOR TAPE
OPERATION
1. Faulty tape. 1. Insert known good tape and test operation.
2. Foreign objects behind
tape door.
2. Remove foreign objects and test operation.
3. Dirty cassette tape head. 3. Clean head with Mopar Cassette Head
Cleaner.
4. Faulty tape deck. 4. Exchange or replace radio, if required.
NO COMPACT DISC
OPERATION
1. Faulty CD. 1. Insert known good CD and test operation.
2. Foreign material on CD. 2. Clean CD and test operation.
3. Condensation on CD or
optics.
3. Allow temperature of vehicle interior to stabilize
and test operation.
4. Faulty CD player. 4. Refer to appropriate Diagnostic Service
Manual.
AMPLIFIER
DESCRIPTION
The opti onal I nfi ni ty premi um speaker system
i ncl udes a separate I nfi ni ty audi o power ampl i fi er.
The ampl i fi er i s a si x channel uni t and i s rated at
240 total output watts. The ampl i fi er i s l ocated
behi nd the gl ove box.
OPERATION
The power ampl i fi er el ectroni cal l y i ncreases the
frequency response of the normal audi o si gnal output
from the radi o ampl i fi er i n order to i mprove the
acousti c performance of the speakers. On vehi cl es
equi pped wi th an ampl i fi er, the ampl i fi er secti on of
the radi o becomes a pre-ampl i fi er.
The ampl i fi er recei ves audi o si gnal i nputs for
speaker channel s from the radi o, then sends ampl i -
fi ed audi o outputs through si x separate channel s
wi th dedi cated feed and return ci rcui ts to the i ndi -
vi dual speakers.
REMOVAL
cabl e.
(2) Remove gl ove box (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - REMOVAL).
AUDIO (Continued)
(3) Remove i nstrument panel center bezel (Refer to
PANEL CENTER BEZEL - REMOVAL).
(4) Remove i nstrument panel l ower ri ght center
bezel (Refer to 23 - BODY/I NSTRUMENT PANEL/I P
LOWER RI GHT CENTER BEZEL - REMOVAL).
(5) Di sconnect el ectri cal harness connector from
ampl i fi er (Fi g. 1).
(6) Remove mounti ng bol ts.
INSTALLATION
(1) Connect el ectri cal harness connector and
i nstal l ampl i fi er.
(2) I nstal l mounti ng bol ts. Ti ghten to 10 Nm (90
i n. l bs.).
(3) I nstal l i nstrument panel l ower ri ght center
LOWER RI GHT CENTER BEZEL - I NSTALLA-
TI ON).
(4) I nstal l i nstrument panel center bezel (Refer to
PANEL CENTER BEZEL - I NSTALLATI ON).
(5) I nstal l gl ove box (Refer to 23 - BODY/I NSTRU-
MENT PANEL/GLOVE BOX - I NSTALLATI ON).
ANTENNA BODY & CABLE
DESCRIPTION
The antenna body and cabl e i s secured bel ow the
fender panel by the antenna cap nut through a
mounti ng hol e i n the ri ght front fender. The pri mary
coaxi al antenna cabl e i s then routed beneath the
fender sheet metal and through a entry hol e i n the
ri ght cowl si de panel i nto the i nteri or of the vehi cl e.
I nsi de the vehi cl e, the pri mary coaxi al cabl e i s con-
nected to a secondary i nstrument panel antenna
coaxi al cabl e wi th an i n-l i ne connector that i s l ocated
behi nd the ri ght ki ck panel . The secondary coaxi al
cabl e i s then routed behi nd the i nstrument panel to
the back of the radi o.
OPERATION
The antenna body and cabl e connects the antenna
mast to the radi o. The radi o antenna i s an el ectro-
magneti c ci rcui t component used to capture radi o fre-
quency si gnal s that are broadcast by l ocal
commerci al radi o stati ons i n both the Ampl i tude
Modul ati ng (AM) and Frequency Modul ati ng (FM)
frequency ranges. These el ectromagneti c radi o fre-
quency si gnal s i nduce smal l el ectri cal modul ati ons
i nto the antenna as they move past the mast. The
antenna body transfers the weak el ectromagneti c
radi o waves i nduced i nto the ri gi d antenna mast i nto
the center conductor of the fl exi bl e pri mary antenna
coaxi al cabl e. The brai ded outer shi el d of the
antenna coaxi al cabl e i s grounded through both the
antenna body and the radi o chassi s, effecti vel y
shi el di ng the radi o waves as they are conducted to
the radi o. The radi o then tunes and ampl i fi es the
weak radi o si gnal s i nto stronger el ectri cal si gnal s i n
order to operate the audi o system speakers.
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE
The fol l owi ng four tests are used to di agnose the
antenna wi th an ohmmeter:
Test 1 - Mast to ground test
Test 2 - Ti p-of-mast to ti p-of-conductor test
Test 3 - Body ground to battery ground test
Test 4 - Body ground to antenna coaxi al cabl e
shi el d test.
INJURY.
The ohmmeter test l ead connecti ons for each test
are shown i n the i l l ustrati on (Fi g. 2).
Fig. 1 AMPLIFIER MOUNTING
1 - INSTRUMENT PANEL
2 - AMPLIFIER
3 - MOUNTING BOLTS
AMPLIFIER (Continued)
NOTE: This model has a two-piece antenna coaxial
cable. Tests 2 and 4 must be conducted in two
steps to isolate an antenna cable problem. First,
test the primary antenna cable (integral to the
antenna body and cable) from the coaxial cable
connector behind the right side kick panel to the
antenna body. Then, test the secondary antenna
cable (instrument panel antenna cable) from the
coaxial cable connector behind the right side kick
panel to the coaxial cable connector at the radio.
TEST 1
Test 1 determi nes i f the antenna mast i s i nsul ated
from ground. Proceed as fol l ows:
(1) Di sconnect and i sol ate the antenna coaxi al
cabl e connector behi nd the ri ght si de ki ck panel .
(2) Touch one ohmmeter test l ead to the ti p of the
antenna mast. Touch the other test l ead to known
ground. Check the ohmmeter readi ng for conti nui ty.
(3) There shoul d be no conti nui ty. I f OK, go to Test
2. I f not OK, repl ace the faul ty antenna body and
cabl e.
TEST 2
Test 2 checks the antenna conductor components
for an open ci rcui t. Thi s test shoul d be performed
fi rst on the enti re antenna ci rcui t, from the antenna
mast to the center conductor of the coaxi al cabl e con-
nector at the radi o. I f an open ci rcui t i s detected,
each of the three antenna conductor components
(antenna mast, antenna body and cabl e, i nstrument
panel antenna cabl e) shoul d be i sol ated and tested
i ndi vi dual l y to l ocate the exact component that i s the
source of the open ci rcui t. To begi n thi s test, proceed
as fol l ows:
(1) Di sconnect the i nstrument panel antenna cabl e
coaxi al connector from the back of the radi o.
(2) Touch one ohmmeter test l ead to the ti p of the
antenna mast. Touch the other test l ead to the center
conductor pi n of the i nstrument panel antenna cabl e
coaxi al connector for the radi o. Check the ohmmeter
readi ng for conti nui ty.
(3) There shoul d be conti nui ty. The ohmmeter
shoul d regi ster onl y a fracti on of an ohm resi stance.
Hi gh or i nfi ni te resi stance i ndi cates a damaged or
open antenna conductor. I f OK, go to Test 3. I f not
OK, i sol ate and test each of the i ndi vi dual antenna
conductor components. Repl ace onl y the faul ty
antenna conductor component.
TEST 3
Test 3 checks the condi ti on of the vehi cl e body
ground connecti on. To begi n thi s test, proceed as fol -
l ows:
(1) Thi s test must be performed wi th the battery
posi ti ve cabl e di sconnected from the battery. Di scon-
nect and i sol ate both battery cabl es, negati ve cabl e
fi rst.
(3) Touch one ohmmeter test l ead to a good cl ean
ground poi nt on the vehi cl e fender. Touch the other
test l ead to the battery negati ve termi nal post. Check
the ohmmeter readi ng for conti nui ty.
shoul d regi ster l ess than one ohm resi stance. Hi gh or
i nfi ni te resi stance i ndi cates a l oose, corroded, or
damaged connecti on between the battery negati ve
termi nal and the vehi cl e body. I f OK, go to Test 4. I f
not OK, check the battery negati ve cabl e connecti on
to the vehi cl e body and the radi o noi se suppressi on
ground strap connecti ons to the engi ne and the vehi -
cl e body for bei ng l oose or corroded. Cl ean or ti ghten
these connecti ons as requi red.
TEST 4
Test 4 checks the condi ti on of the connecti on
between the antenna coaxi al cabl e shi el d and the
vehi cl e body ground as fol l ows:
(1) Di sconnect and i sol ate the antenna coaxi al
cabl e connector behi nd the ri ght si de ki ck panel .
(2) Touch one ohmmeter test l ead to a good cl ean
ground poi nt on the vehi cl e fender. Touch the other
test l ead to the outer cri mp on the antenna coaxi al
cabl e connector. Check the ohmmeter readi ng for con-
ti nui ty.
shoul d regi ster l ess than one ohm resi stance. Hi gh or
i nfi ni te resi stance i ndi cates a l oose, corroded, or
damaged connecti on between the antenna body and
the vehi cl e body or between the antenna body and
the antenna coaxi al cabl e shi el d. I f not OK, cl ean the
Fig. 2 Antenna Tests - Typical
ANTENNA BODY & CABLE (Continued)
antenna body to fender mati ng surfaces and ti ghten
the antenna cap nut to speci fi cati ons.
(4) Check the resi stance agai n wi th an ohmmeter.
I f the resi stance i s sti l l more then one ohm, repl ace
the faul ty antenna body and cabl e.
REMOVAL
cabl e.
(2) Remove the ri ght si de ki ck panel .
(3) Di sconnect antenna body cabl e from i nstru-
ment panel cabl e.
(4) Securel y ti e a sui tabl e l ength of cord or twi ne
to the antenna hal f of the coaxi al cabl e connector.
Thi s cord wi l l be used to pul l the cabl e back i nto
posi ti on duri ng i nstal l ati on.
(5) Remove the antenna mast.
(6) Remove the antenna cap nut usi ng an antenna
nut wrench (Speci al Tool C-4816) (Fi g. 3).
(7) Remove the antenna adapter.
(8) Wi th the ri ght door open, pul l the antenna
body assembl y out through the openi ng between the
fender and body.
INSTALLATION
(1) Ti e the cord that was used duri ng the removal
procedure to the cabl e bei ng i nstal l ed.
(2) Usi ng the cord, pul l the antenna cabl e through
the hol e i n the door openi ng and seat grommet i nto
pl ace.
(3) Connect the antenna body and cabl e to the
i nstrument panel cabl e.
(4) I nstal l the ri ght si de ki ck panel .
(5) I nsert the antenna body through the hol e i n
the fender and i nstal l adapter.
(6) I nstal l the antenna cap nut. Ti ghten to 7 Nm
(65 i n. l bs.).
(7) I nstal l the antenna mast.
ANTENNA - NAVIGATION
REMOVAL
cabl e.
(2) Remove the i nstrument panel top cover (Refer
to 23 - BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL TOP COVER - REMOVAL).
(3) Remove the radi o (Refer to 8 - ELECTRI CAL/
AUDI O/RADI O - REMOVAL).
(4) Remove the antenna mounti ng fasteners (Fi g.
4).
(5) Cut each end of the cabl e and l eave remai ni ng
porti on i n the i nstrument panel (Fi g. 5).
INSTALLATION
(1) Posi ti on new antenna cabl e to wi re harness.
Secure i nto pl ace.
(2) I nstal l antenna mounti ng fasteners.
(3) I nstal l radi o (Refer to 8 - ELECTRI CAL/AU-
DI O/RADI O - I NSTALLATI ON).
(4) I nstal l i nstrument panel top cover (Refer to 23
- BODY/I NSTRUMENT PANEL/I NSTRUMENT
PANEL TOP COVER - I NSTALLATI ON).
Fig. 3 ANTENNA BODY AND CABLE
1 - NUT
2 - FENDER
3 - ANTENNA BODY AND CABLE
4 - ADAPTER
Fig. 4 NAVIGATION ANTENNA MOUNTING
ANTENNA BODY & CABLE (Continued)
INSTRUMENT PANEL
ANTENNA CABLE
REMOVAL
cabl e.
(2) Remove the gl ove box (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - REMOVAL).
(3) Remove the i nstrument panel center bezel
STRUMENT PANEL CENTER BEZEL - REMOVAL).
(4) Remove the i nstrument panel l ower ri ght cen-
ter bezel (Refer to 23 - BODY/I NSTRUMENT PAN-
EL/I P LOWER RI GHT CENTER BEZEL -
REMOVAL).
(5) Remove the radi o (Refer to 8 - ELECTRI CAL/
AUDI O/RADI O - REMOVAL).
CAUTION: Pulling the antenna cable straight out of
the radio without pulling on the locking antenna
connector could damage the cable or radio.
(6) Di sconnect the antenna cabl e by pul l i ng the
l ocki ng antenna connector away from the radi o (Fi g.
6)
(7) Remove antenna cabl e from i nstrument panel
by pul l i ng on retai ni ng fasteners (Fi g. 7).
INSTALLATION
(1) I nstal l antenna cabl e to i nstrument panel by
pressi ng retai ni ng fasteners i nto posi ti on.
(2) Connect i nstrument panel antenna cabl e to
antenna body and cabl e.
(3) I nstal l radi o (Refer to 8 - ELECTRI CAL/AU-
DI O/RADI O - I NSTALLATI ON).
(4) I nstal l the i nstrument panel l ower ri ght center
LOWER RI GHT CENTER BEZEL - I NSTALLA-
TI ON).
(5) I nstal l the i nstrument panel center bezel (Refer
Fig. 5 NAVIGATION ANTENNA ROUTING
1 - NAVIGATION ANTENNA
3 - RADIO (REAR VIEW)
Fig. 6 ANTENNA TO RADIO
1 - RADIO
2 - LOCKING ANTENNA CONNECTOR
3 - INSTRUMENT PANEL ANTENNA CABLE
Fig. 7 INSTRUMENT PANEL ANTENNA CABLE
2 - ANTENNA BODY AND CABLE
ANTENNA - NAVIGATION (Continued)
(6) I nstal l the gl ove box (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - I NSTALLA-
TI ON).
RADIO
DESCRIPTION
Avai l abl e radi o recei vers for thi s vehi cl e i ncl ude:
AM/FM/cassette wi th CD changer control fea-
ture (RBB sal es code)
AM/FM/cassette/CD/ wi th CD changer control
feature (RAZ sal es code)
AM/FM/CD wi th CD changer control feature
(RBK sal es code)
AM/FM/cassette/CD wi th CD changer control
(RBY sal es code)
AM/FM/CD wi th GPS navi gati on (RB4 sal es
code)
AM/FM/cassette/CD (RBY sal es code) - export
onl y
Al l factory-i nstal l ed radi o recei vers can communi -
cate on the Programmabl e Communi cati ons I nterface
(PCI ) data bus network. Al l factory-i nstal l ed recei v-
ers are stereo El ectroni cal l y Tuned Radi os (ETR) and
i ncl ude an el ectroni c di gi tal cl ock functi on.
OPERATION
The radi o recei ver operates on i gni ti on swi tched
battery current that i s avai l abl e onl y when the i gni -
ti on swi tch i s i n the On or Accessory posi ti ons. The
el ectroni c di gi tal cl ock functi on of the radi o operates
on fused battery current suppl i ed through the I OD
fuse, regardl ess of the i gni ti on swi tch posi ti on.
REMOVAL
cabl e.
(2) Remove center i nstrument panel bezel (Refer to
PANEL CENTER BEZEL - REMOVAL).
(3) Remove radi o mounti ng screws (Fi g. 8).
(4) Di sconnect el ectri cal harness connector.
CAUTION: Pulling the antenna cable straight out of
the radio without pulling on the locking antenna
connector could damage the cable or radio.
(5) Di sconnect the antenna cabl e by pul l i ng the
l ocki ng antenna connector away from the radi o (Fi g.
9)
INSTALLATION
(1) I nstal l antenna cabl e to radi o.
(2) Connect el ectri cal harness connector to radi o.
(3) I nstal l radi o to i nstrument panel .
(4) I nstal l i nstrument panel center bezel (Refer to
Fig. 8 RADIO
Fig. 9 ANTENNA TO RADIO
1 - RADIO
2 - LOCKING ANTENNA CONNECTOR
INSTRUMENT PANEL ANTENNA CABLE (Continued)
RADIO NOISE SUPPRESSION
GROUND STRAP
DESCRIPTION
Radi o noi se suppressi on devi ces are factory-i n-
stal l ed standard equi pment on thi s vehi cl e. Radi o
Frequency I nterference (RFI ) and El ectroMagneti c
I nterference (EMI ) can be produced by any on-board
or external source of el ectromagneti c energy. These
el ectromagneti c energy sources can radi ate el ectro-
magneti c si gnal s through the ai r, or conduct them
through the vehi cl e el ectri cal system.
When the audi o system converts RFI or EMI to an
audi bl e acousti c wave form, i t i s referred to as radi o
noi se. Thi s undesi rabl e radi o noi se i s general l y man-
i fested i n the form of buzzi ng, hi ssi ng, poppi ng,
cl i cki ng, crackl i ng, and/or whi rri ng sounds. I n
most cases, RFI and EMI radi o noi se can be sup-
pressed usi ng a combi nati on of vehi cl e and compo-
nent groundi ng, fi l teri ng and shi el di ng techni ques.
Thi s vehi cl e i s equi pped wi th factory-i nstal l ed radi o
noi se suppressi on devi ces that were desi gned to mi n-
i mi ze exposure to typi cal sources of RFI and EMI ;
thereby, mi ni mi zi ng radi o noi se compl ai nts.
Factory-i nstal l ed radi o noi se suppressi on i s accom-
pl i shed pri mari l y through ci rcui try or devi ces that
are i ntegral to the factory-i nstal l ed radi os, audi o
power ampl i fi ers and other on-board el ectri cal com-
ponents such as generators, wi per motors, bl ower
motors, and fuel pumps that have been found to be
potenti al sources of RFI or EMI . External radi o noi se
suppressi on devi ces that are used on thi s vehi cl e to
control RFI or EMI , and can be servi ced, i ncl ude the
fol l owi ng:
Engine-to-body ground strap - Thi s l ength of
brai ded ground strap has an eyel et termi nal connec-
tor cri mped to each end. One end i s secured to the
engi ne cyl i nder head(s). The other i s secured to the
pl enum at the exhaust heat shi el d forward/outer
attachi ng stud.
Resistor-type spark plugs - Thi s type of spark
pl ug has an i nternal resi stor connected i n seri es
between the spark pl ug termi nal and the center el ec-
trode to hel p reduce the producti on of el ectromag-
neti c radi ati on that can resul t i n radi o noi se.
OPERATION
There are two common strategi es that can be used
to suppress Radi o Frequency I nterference (RFI ) and
El ectroMagneti c I nterference (EMI ) radi o noi se. The
fi rst suppressi on strategy i nvol ves preventi ng the
producti on of RFI and EMI el ectromagneti c si gnal s
at thei r sources. The second suppressi on strategy
i nvol ves preventi ng the recepti on of RFI and EMI
el ectromagneti c si gnal s by the audi o system compo-
nents.
The use of brai ded ground straps i n key l ocati ons
i s part of the RFI and EMI preventi on strategy.
These ground straps ensure adequate ground paths,
parti cul arl y for hi gh current components such as
many of those found i n the starti ng, chargi ng, i gni -
ti on, engi ne control and transmi ssi on control sys-
tems. An i nsuffi ci ent ground path for any of these
hi gh current components may resul t i n radi o noi se
caused by i nduced vol tages created as the hi gh cur-
rent seeks al ternati ve ground paths through compo-
nents or ci rcui ts i ntended for use by, or i n cl ose
proxi mi ty to the audi o system components or ci rcui ts.
Preventi ng the recepti on of RFI and EMI i s accom-
pl i shed by ensuri ng that the audi o system compo-
nents are correctl y i nstal l ed i n the vehi cl e. Loose,
corroded or i mproperl y sol dered wi re harness connec-
ti ons, i mproperl y routed wi ri ng and i nadequate audi o
system component groundi ng can al l contri bute to
the recepti on of RFI and EMI . A properl y grounded
antenna body and radi o chassi s, as wel l as a shi el ded
antenna coaxi al cabl e wi th cl ean and ti ght connec-
ti ons wi l l each hel p reduce the potenti al for recepti on
of RFI and EMI .
REMOVAL
BED TO CAB
cabl e.
(2) Remove the attachi ng bol ts and strap (Fi g. 10).
Fig. 10 BED TO CAB GROUND STRAP
1 - BED
2 - CAB
3 - GROUND STRAP
4 - MOUNTING BOLTS
ENGINE TO HEAT SHIELD - 3. 7L ENGINE
cabl e.
(2) Remove the attachi ng bol ts from the cyl i nder
heads (Fi g. 11).
(3) Remove nut from heat shi el d and remove strap
(Fi g. 12).
ENGINE TO HEAT SHIELD - 4. 7L AND 5. 7L ENGINE
cabl e.
(2) Remove the attachi ng bol ts from the cyl i nder
heads (Fi g. 13).
(3) Remove nut from heat shi el d and remove strap
(Fi g. 12).
INSTALLATION
BED TO CAB
(1) I nstal l the ground strap and retai ni ng bol ts.
Ti ghten to 5 Nm (45 i n. l bs.).
ENGINE TO HEAT SHIELD
(1) I nstal l the retai ni ng nut and ground strap to
the pl enum. Ti ghten to 8 Nm (70 i n. l bs.).
(2) I nstal l the retai ni ng bol t and ground strap to
the engi ne cyl i nder heads. Ti ghten to 12 Nm (106 i n.
l bs.).
REMOTE SWITCHES
DESCRIPTION
A remote radi o control swi tch opti on i s avai l abl e on
some model s. Two rocker-type swi tches are mounted
on the back (i nstrument panel si de) of the steeri ng
wheel spokes (Fi g. 14). The swi tch on the l eft spoke
i s the seek swi tch and has seek up, seek down, and
preset stati on advance functi ons. The swi tch on the
ri ght spoke i s the vol ume control swi tch and has vol -
ume up, and vol ume down functi ons. The swi tch on
the ri ght spoke al so i ncl udes a mode control that
al l ows the dri ver to sequenti al l y sel ect AM radi o, FM
radi o, cassette pl ayer, CD pl ayer or CD changer (i f
equi pped).
Fig. 11 ENGINE GROUND STRAP - 3.7L
1 - GROUND STRAP
2 - MOUNTING BOLTS
Fig. 12 GROUND STRAP TO HEAT SHIELD
1 - STUD
2 - GROUND STRAP
3 - NUT
Fig. 13 ENGINE GROUND STRAP - 4.7L AND 5.7L
1 - GROUND STRAP
2 - MOUNTING BOLTS
RADIO NOISE SUPPRESSION GROUND STRAP (Continued)
OPERATION
The si x swi tches i n the two remote radi o swi tch
uni ts are normal l y open, resi stor mul ti pl exed
momentary swi tches that are hard wi red to the I nte-
grated Power Modul e (I PM) through the cl ockspri ng.
The I PM sends a fi ve vol t reference si gnal to both
swi tch uni ts on one ci rcui t, and senses the status of
al l of the swi tches by readi ng the vol tage drop on a
second ci rcui t.
When the I PM senses an i nput (vol tage drop) from
any one of the remote radi o swi tches, i t sends the
proper swi tch status messages on the Programmabl e
Communi cati on I nterface (PCI ) data bus network to
the radi o recei ver. The el ectroni c ci rcui try wi thi n the
radi o recei ver i s programmed to respond to these
remote radi o swi tch status messages by adjusti ng the
radi o setti ngs as requested. For di agnosi s of the I PM
or the PCI data bus, the use of a DRB I I I scan tool
recommended.
SWITCHES
Service Manual.
For compl ete ci rcui t di agrams, refer to the appro-
pri ate wi ri ng i nformati on.
INJURY.
cabl e. Remove the remote radi o swi tch(es) (Fi g. 15)
from the steeri ng wheel (Refer to 8 - ELECTRI CAL/
AUDI O/REMOTE SWI TCHES - REMOVAL).
(2) Use an ohmmeter to check the swi tch resi s-
tances as shown i n the Remote Radi o Swi tch Test
chart. I f the remote radi o swi tch resi stances check
OK, go to Step 3. I f not OK, repl ace the faul ty
swi tch.
Fig. 14 Remote Radio Switch Operational View
1 - PRESET SEEK
2 - SEEK UP
3 - VOLUME UP
4 - MODE
5 - VOLUME DOWN
6 - SEEK DOWN
Fig. 15 Remote Radio Switches
1 - BLACK (LEFT) SWITCH
2 - WHITE (RIGHT) SWITCH
REMOTE SWITCHES (Continued)
REMOTE RADIO SWITCH TEST TABLE
Switch Switch Position Resistance
Right
(White)
Volume Up
1.210 Kilohms
1%
Right
(White)
Volume Down
3.010 Kilohms
1%
Right
(White)
Mode Advance
0.0511 Kilohms
1%
Left
(Black)
Seek Up
0.261 Kilohms
1%
Left
(Black)
Seek Down
0.681 Kilohms
1%
Left
(Black)
Pre-Set Station
Advance
0.162 Kilohms
1%
(3) Reconnect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for 5 vol ts
at the radi o control mux ci rcui t cavi ti es of the steer-
i ng wheel wi re harness connectors for both remote
radi o swi tches. I f OK, go to Step 4. I f not OK, repai r
the open or shorted radi o control mux ci rcui t to the
I ntegrated Power Modul e (I PM) as requi red.
cabl e. Di sconnect the 22-way i nstrument panel wi re
harness connector from the I PM. Check for conti nu-
i ty between the remote radi o swi tch ground ci rcui t
cavi ti es of the steeri ng wheel wi re harness connec-
tors for both remote radi o swi tches and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 5. I f not OK, repai r the shorted remote radi o
swi tch ground ci rcui t to the I PM as requi red.
(5) Check for conti nui ty between the remote radi o
swi tch ground ci rcui t cavi ti es of the steeri ng wheel
wi re harness connectors for both remote radi o
swi tches and the 22-way i nstrument panel wi re har-
ness connector for the I PM. There shoul d be conti nu-
i ty. I f OK, refer to the proper Di agnosti c Procedures
manual to test the I PM and the PCI data bus. I f not
OK, repai r the open remote radi o swi tch ground ci r-
cui t as requi red.
REMOVAL
INJURY.
cabl e.
(2) Remove the dri ver ai rbag from the vehi cl e
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/DRI VER
AI RBAG - REMOVAL).
(3) Remove the speed control swi tches (Refer to 8 -
ELECTRI CAL/SPEED CONTROL/SWI TCH -
REMOVAL).
(4) Unpl ug the wi re harness connector from the
remote radi o swi tch(es).
(5) Depress the tabs on each si de of each swi tch
and push the swi tch through the rear steeri ng wheel
cover (Fi g. 16).
INSTALLATION
INJURY.
Fig. 16 REMOTE SWITCHES
1 - REMOTE SWITCH
2 - SPEED CONTROL SWITCH
3 - BOLT
(1) I nstal l remote radi o swi tch to the steeri ng
wheel .
(2) Connect the wi re harness to the remote radi o
swi tch.
(3) I nstal l the speed control swi tches (Refer to 8 -
ELECTRI CAL/SPEED CONTROL/SWI TCH -
I NSTALLATI ON).
(4) I nstal l the dri ver ai rbag
SPEAKER
DESCRIPTION
STANDARD
The standard equi pment speaker system i ncl udes
speakers i n four l ocati ons. One 15.2 X 22.8 centi me-
ter (6 X 9 i nch) ful l -range speaker i s l ocated i n each
front door. There i s al so one ful l -range 13.3 centi me-
ter (5.25 i nch) di ameter ful l -range speaker l ocated i n
each rear door.
PREMIUM
The opti onal premi um speaker system features
el even Premi um model speakers i n seven l ocati ons.
Each of the standard speakers i s repl aced wi th Pre-
mi um model speakers. One 8.8 centi meter (3.50 i nch)
di ameter speaker i s l ocated on each end of the
i nstrument panel top pad. One 6.3 centi meter (2.50
i nch) di ameter speaker i s l ocated i n the center of the
i nstrument panel top pad. One 15.2 X 22.8 centi me-
ter (6 X 9 i nch) Premi um speaker i s l ocated i n each
front door. There i s al so one coaxi al 13.3 centi meter
(5.25 i nch) di ameter Premi um ful l -range speaker
l ocated i n each rear door. The premi um speaker sys-
tem al so i ncl udes a power ampl i fi er mounted behi nd
the gl ove box. The total avai l abl e power of the pre-
mi um speaker system i s 240 watts.
OPERATION
Two wi res connected to each speaker, one feed ci r-
cui t (+) and one return ci rcui t (), al l ow the audi o
output si gnal el ectri cal current to fl ow through the
voi ce coi l . For compl ete ci rcui t di agrams, refer to the
appropri ate wi ri ng i nformati on. The wi ri ng i nforma-
ti on i ncl udes wi ri ng di agrams, proper wi re and con-
nector repai r procedures, detai l s of wi re harness
routi ng and retenti on, connector pi n-out i nformati on
and l ocati on vi ews for the vari ous wi re harness con-
nectors, spl i ces and grounds.
DIAGNOSIS AND TESTING - SPEAKER
Service Manual.
INJURY.
CAUTION: The speaker output of the radio is a
floating ground system. Do not allow any speaker
lead to short to ground, as damage to the radio
and/or amplifier may result.
(1) I f al l speakers are i noperati ve, check the fuses
i n the I ntegrated Power Modul e (I PM). I f OK, go to
Step 2. I f not OK, repai r the shorted ci rcui t or com-
ponent as requi red and repl ace the faul ty fuse.
(2) Check the ampl i fi er fuse (i f equi pped) i n the
I PM. I f OK, go to Step 3. I f not OK, repai r the
shorted ci rcui t or component as requi red and repl ace
the faul ty fuse.
(3) Turn the i gni ti on swi tch to the ON posi ti on.
Turn the radi o recei ver ON. Adjust the bal ance and
fader control control s to check the performance of
each i ndi vi dual speaker. Note the speaker l ocati ons
that are not performi ng correctl y. Go to Step 4.
(4) Turn the radi o recei ver OFF. Turn the i gni ti on
OFF. Di sconnect and i sol ate the battery negati ve
cabl e. I f vehi cl e i s not equi pped wi th a ampl i fi er,
remove the radi o recei ver. I f vehi cl e i s equi pped wi th
an ampl i fi er. di sconnect wi re harness connector at
output si de of ampl i fi er. Go to Step 5.
(5) Check both the speaker feed (+) ci rcui t and
return (-) ci rcui t cavi ti es for the i noperati ve speaker
at the radi o recei ver wi re harness connector for con-
ti nui ty to ground. There shoul d be no conti nui ty. I f
OK, go to Step 6. I f not OK, repai r the shorted
speaker feed (+) and/or return (-) ci rcui ts(s) to the
speaker as requi red.
(6) Di sconnect wi re harness connector at the i nop-
erati ve speaker. Check for conti nui ty between the
speaker feed (+) ci rcui t cavi ti es of the radi o recei ver
wi re harness connector or i f equi pped, the ampl i fi er
wi re harness connector and the speaker wi re harness
connector. Repeat the check between the speaker
return (-) ci rcui t cavi ti es of the radi o recei ver wi re
harness connector and the speaker wi re harness con-
nector. I n each case, there shoul d be conti nui ty. I f
OK, repl ace the faul ty speaker. I f not OK, repai r the
open speaker feed (+) and/or return (-) ci rcui ts(s) as
requi red.
REMOVAL
FRONT DOOR SPEAKER
cabl e.
(2) Remove front door tri m panel (Refer to 23 -
BODY/DOOR - FRONT/TRI M PANEL - REMOVAL).
(3) Remove speaker mounti ng screws (Fi g. 17).
(4) Di sconnect el ectri cal harness connector and
remove speaker.
INSTRUMENT PANEL CENTER SPEAKER
cabl e.
(2) Remove i nstrument panel top cover (Refer to
remove speaker.
INSTRUMENT PANEL END SPEAKER
cabl e.
(2) Remove i nstrument panel top cover (Refer to
(3) Remove speaker mounti ng screws (Fi g. 19)
remove speaker.
REAR CAB SIDE SPEAKER
cabl e.
(2) Remove B-pi l l ar l ower tri m (Refer to 23 -
BODY/I NTERI OR/B-PI LLAR LOWER TRI M -
REMOVAL).
remove speaker.
REAR DOOR SPEAKER
cabl e.
Fig. 17 FRONT DOOR SPEAKER
Fig. 18 INSTRUMENT PANEL CENTER SPEAKER
Fig. 19 INSTRUMENT PANEL END SPEAKER
SPEAKER (Continued)
(2) Remove rear door tri m panel (Refer to 23 -
BODY/DOORS - REAR/TRI M PANEL - REMOVAL).
remove speaker.
INSTALLATION
FRONT DOOR SPEAKER
i nstal l speaker.
(2) I nstal l front door tri m panel (Refer to 23 -
BODY/DOOR - FRONT/TRI M PANEL - I NSTALLA-
TI ON).
INSTRUMENT PANEL CENTER SPEAKER
i nstal l speaker.
INSTRUMENT PANEL END SPEAKER
i nstal l speaker.
REAR CAB SIDE SPEAKER
i nstal l speaker.
(2) I nstal l B-pi l l ar l ower tri m (Refer to 23 - BODY/
I NTERI OR/B-PI LLAR LOWER TRI M - I NSTALLA-
TI ON).
REAR DOOR SPEAKER
i nstal l speaker.
(2) I nstal l rear door tri m panel (Refer to 23 -
BODY/DOORS - REAR/TRI M PANEL - I NSTALLA-
TI ON).
Fig. 20 REAR CAB SIDE SPEAKER
Fig. 21 REAR DOOR SPEAKER
SPEAKER (Continued)
CHIME/BUZZER
TABLE OF CONTENTS
page page
CHIME WARNING SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - CHIME
WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . 3
CHIME WARNING SYSTEM
DESCRIPTION
A chi me warni ng system i s standard factory-i n-
stal l ed equi pment on thi s model . The chi me warni ng
system uses a si ngl e chi me tone generator that i s
i ntegral to the i nstrument cl uster to provi de an audi -
bl e i ndi cati on of vari ous vehi cl e condi ti ons that may
requi re the attenti on of the vehi cl e operator. The
chi me warni ng system i ncl udes the fol l owi ng major
components, whi ch are descri bed i n further detai l
el sewhere i n thi s servi ce i nformati on:
Door Ajar Switch - A door ajar swi tch i s i nte-
gral to each door l atch. Thi s swi tch provi des an i nput
to the chi me warni ng system i ndi cati ng whether the
front doors are open or cl osed.
Ignition Switch - A key-i n i gni ti on swi tch i s
i ntegral to the i gni ti on swi tch. The key-i n i gni ti on
swi tch provi des an i nput to the chi me warni ng sys-
tem i ndi cati ng whether a key i s present i n the i gni -
ti on l ock cyl i nder.
Instrument Cluster - The i nstrument cl uster
contai ns an i ntegral chi me tone generator, i ntegrated
ci rcui try, a central processi ng uni t and the program-
mi ng to provi de al l of the proper chi me warni ng sys-
tem features based upon the moni tored i nputs. The
i nstrument cl uster ci rcui try moni tors hard-wi red
swi tch i nputs, as wel l as message i nputs recei ved
from other vehi cl e el ectroni c modul es on the Pro-
grammabl e Communi cati ons I nterface (PCI ) data bus
network.
Headlamp Switch - The headl amp swi tch pro-
vi des an i nput to the chi me warni ng system i ndi cat-
i ng when the exteri or l amps are turned On or Off.
Seat Belt Switch - A seat bel t swi tch i s i nte-
gral to the dri ver seat bel t buckl e-hal f uni t. The seat
bel t swi tch provi des an i nput to the chi me warni ng
system i ndi cati ng whether the dri ver seat bel t i s fas-
tened.
Hard wi red ci rcui try connects many of the chi me
warni ng system components to each other through
the el ectri cal system of the vehi cl e. These hard wi red
ci rcui ts are i ntegral to several wi re harnesses, whi ch
are routed throughout the vehi cl e and retai ned by
many di fferent methods. Refer to the appropri ate
wi ri ng i nformati on.
The i nstrument cl uster chi me warni ng system ci r-
cui try and the i ntegral chi me tone generator cannot
be adjusted or repai red. I f the i nstrument cl uster or
the chi me tone generator are damaged or faul ty, the
i nstrument cl uster must be repl aced.
OPERATION
The chi me warni ng system i s desi gned to provi de
an audi bl e output as an i ndi cati on of vari ous condi -
ti ons that may requi re the attenti on or awareness of
the vehi cl e operator. The chi me warni ng system com-
ponents operate on battery vol tage recei ved through
the I gni ti on-Off Draw (I OD) fuse i n the Power Di stri -
buti on Center (PDC) so that the system may operate
regardl ess of the i gni ti on swi tch posi ti on.
The chi me warni ng system provi des an audi bl e
warni ng to the vehi cl e operator under the fol l owi ng
condi ti ons:
Air Bag Warning - The i nstrument cl uster
chi me tone generator wi l l generate a si ngl e chi me
tone when the ai rbag i ndi cator i s i l l umi nated for an
ai rbag system faul t condi ti on. The i nstrument cl uster
uses ai rbag i ndi cator l amp-on and l amp-off message
i nputs recei ved from the Ai rbag Control Modul e
(ACM) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus i ndi cati ng that the ai rbag
i ndi cator shoul d be i l l umi nated for an ai rbag system
faul t condi ti on.
Door Ajar Warning - The i nstrument cl uster
chi me tone generator wi l l generate a si ngl e chi mes to
announce that the hard wi red i nputs from the door
ajar swi tches and the i gni ti on swi tch as wel l as an
engi ne speed message i nput recei ved from the PCM
over the PCI data bus i ndi cate that a dri ver or pas-
senger door i s opened wi th the i gni ti on swi tch i n the
On posi ti on and vehi cl e speed present.
Engine Coolant Temperature High Warning
(Diesel Engine Only) - The i nstrument cl uster
chi me tone generator wi l l generate a si ngl e chi me
tone when the check gauges i ndi cator i s i l l umi nated
for a hi gh or cri ti cal engi ne cool ant temperature con-
di ti on. The i nstrument cl uster uses engi ne cool ant
temperature message i nputs recei ved from the di esel
DR CHIME/BUZZER 8B - 1
Engi ne Control Modul e (ECM) over the PCI data bus
to i l l umi nate the check gauges i ndi cator for a cool ant
temperature hi gh condi ti on.
Fasten Seat Belt Warning - The i nstrument
cl uster chi me tone generator wi l l generate repeti ti ve
chi mes at a sl ow rate each ti me the i gni ti on swi tch i s
turned to the On or Start posi ti ons to announce that
the hard wi red i nputs from the seat bel t swi tch and
the i gni ti on swi tch i ndi cate that the dri ver si de front
seat bel t i s not fastened. The chi mes wi l l conti nue to
sound for a durati on of about si x seconds, unti l the
dri ver si de front seat bel t i s fastened, or unti l the
i gni ti on swi tch i s turned to the Off posi ti on, whi ch-
ever occurs fi rst.
Head/Park Lamps-On Warning - The i nstru-
ment cl uster chi me tone generator wi l l generate
repeti ti ve chi mes at a sl ow rate to announce that the
hard wi red i nputs from the dri ver door ajar swi tch,
the i gni ti on swi tch, and the exteri or l i ghti ng ci rcui try
of the headl amp swi tch i ndi cate that the exteri or
l amps are turned On wi th the dri ver door opened
and the i gni ti on swi tch i n the Off posi ti on. The
chi mes wi l l conti nue to sound unti l the exteri or
l amps are turned Off, the dri ver door i s cl osed, or the
i gni ti on swi tch i s turned to the On posi ti on, or the
battery protecti on ti me-out expi res, whi chever occurs
fi rst.
Key-In-Ignition Warning - The i nstrument
chi mes at a sl ow rate to announce that the hard
wi red i nputs from the dri ver door ajar swi tch, the
i gni ti on swi tch, and the key-i n i gni ti on ci rcui try of
the i gni ti on swi tch i ndi cate that the key i s i n the
i gni ti on l ock cyl i nder wi th the dri ver door opened
and the i gni ti on swi tch i n the Off posi ti on. The
chi mes wi l l conti nue to sound unti l the key i s
removed from the i gni ti on l ock cyl i nder, the dri ver
door i s cl osed, or the i gni ti on swi tch i s turned to the
On posi ti on, whi chever occurs fi rst.
Low Fuel Warning - The i nstrument cl uster
chi me tone generator wi l l generate one chi me tone
when the l ow fuel i ndi cator i s i l l umi nated by the
i nstrument cl uster. The i nstrument cl uster uses a
percent tank ful l message i nput recei ved from the
PCM over the PCI data bus i ndi cati ng that there i s
l ess than about one-ei ghth tank of fuel remai ni ng to
i l l umi nate the l ow fuel i ndi cator. Thi s chi me feature
wi l l onl y occur once i n an i gni ti on cycl e.
Low Oil Pressure Warning (Diesel Engine
Only) - The i nstrument cl uster chi me tone generator
wi l l generate repeti ti ve chi mes at a fast rate when
the check gauges i ndi cator i s i l l umi nated for a l ow oi l
pressure condi ti on. The i nstrument cl uster uses
engi ne speed and oi l pressure message i nputs
recei ved from the di esel Engi ne Control Modul e
(ECM) over the PCI data bus i ndi cati ng that the
engi ne i s runni ng and that the oi l pressure i s l ow to
i l l umi nate the check gauges i ndi cator. The chi mes
wi l l conti nue to sound for fi ve seconds, unti l the
engi ne oi l pressure message i ndi cates that the oi l
pressure i s not l ow, or unti l the engi ne speed mes-
sage i ndi cates that the engi ne i s not runni ng, whi ch-
ever occurs fi rst. Thi s chi me tone wi l l onl y occur once
i n an i gni ti on cycl e.
Low Wash Warning - The i nstrument cl uster
chi me tone generator wi l l generate one chi me tone
when the l ow washer fl ui d i ndi cator i s i l l umi nated by
the i nstrument cl uster. The i nstrument cl uster uses a
message i nput recei ved from the Front Control Mod-
ul e (FCM) over the PCI data bus i ndi cati ng that
washer fl ui d l evel i s l ow wi thi n the washer reservoi r.
Thi s chi me feature wi l l onl y occur once i n an i gni ti on
cycl e.
Overspeed Warning - The i nstrument cl uster
chi me tone generator wi l l generate one chi me tone to
announce that a vehi cl e speed message i nput
recei ved from the PCM over the PCI data bus i ndi -
cates that the vehi cl e speed i s above a pre-programed
l i mi t.
Park Brake Reminder - The i nstrument cl us-
ter chi me tone generator wi l l generate ten repeti ti ve
wi red i nput from the park brake swi tch and a vehi cl e
speed message i nput recei ved from the PCM over the
PCI data bus i ndi cates that the park brake i s appl i ed
and the vehi cl e i s movi ng. Thi s chi me feature wi l l
repeat each ti me the i nput condi ti ons are met.
Sentry Key Immobilizer System Customer
Learn Mode Announcement - Thi s chi me feature
i s onl y acti ve on vehi cl es equi pped wi th the opti onal
Sentry Key I mmobi l i zer System (SKI S) and sol d i n
markets where the opti onal Customer Learn pro-
grammi ng feature i s avai l abl e. The i nstrument cl us-
ter chi me tone generator wi l l generate one chi me to
announce that a status message i nput recei ved from
the Sentry Key I mmobi l i zer Modul e (SKI M) over the
PCI data bus i ndi cates that the SKI S i s i n the Cus-
tomer Learn mode, whi ch i s used for programmi ng
addi ti onal sentry key transponders.
Transmission Temperature High Warning
(Automatic Transmission only) - The i nstrument
chi mes at a sl ow rate when the transmi ssi on temper-
ature i ndi cator i s i l l umi nated for a hi gh or cri ti cal
transmi ssi on fl ui d temperature condi ti on. The i nstru-
ment cl uster uses transmi ssi on temperature message
i nputs recei ved from the Transmi ssi on Control Mod-
ul e (TCM) over the PCI data bus to i l l umi nate the
i ndi cator for a transmi ssi on temperature hi gh condi -
ti on.
Turn Signal On Warning - The i nstrument
8B - 2 CHIME/BUZZER DR
CHIME WARNING SYSTEM (Continued)
wi red i nput for the ri ght or l eft turn si gnal i ndi cator
as wel l as vehi cl e di stance and speed message i nputs
recei ved from the PCM over the PCI data bus i ndi -
cate that a turn si gnal has been acti ve conti nuousl y
for 1.6 ki l ometers (1 mi l e) wi th the vehi cl e speed
greater than 22 ki l ometers-per-hour (15 mi l es-per
hour). Vehi cl es bui l t for markets other than the
Uni ted States and Canada have a revi sed di stance
threshol d of 4 ki l ometers for thi s feature. The chi me
wi l l conti nue unti l the turn si gnal i nput becomes
i nacti ve, the status changes, or unti l the vehi cl e
speed message i ndi cates that the speed i s l ess than
22 ki l ometers-per-hour (15 mi l es-per-hour), whi ch-
ever occurs fi rst. The hazard warni ng fl ashers wi l l
not acti vate thi s chi me feature.
Warning Lamp Announcement - The i nstru-
ment cl uster chi me tone generator wi l l generate a
si ngl e chi me when the check gauges i ndi cator i s i l l u-
mi nated when any cri ti cal engi ne and transmi ssi on
systems are out of thei r operati ng parameters. The
i nstrument cl uster uses system i nputs recei ved over
the PCI data bus to i l l umi nate the check gauges i ndi -
cator.
The i nstrument cl uster provi des chi me servi ce for
al l avai l abl e features i n the chi me warni ng system.
The i nstrument cl uster rel i es upon i ts i nternal pro-
grammi ng, hard wi red i nputs from numerous
swi tches, and el ectroni c message i nputs recei ved
from other el ectroni c modul es over the PCI data bus
network. Upon recei vi ng the proper i nputs, the
i nstrument cl uster acti vates the i ntegral chi me tone
generator to provi de the audi bl e chi me to the vehi cl e
operator. The chi me tone generator i n the i nstrument
cl uster i s capabl e of produci ng si ngl e chi me tones, or
repeated chi me tones at two di fferent rates: about
fi fty chi me tones per mi nute, or about 180 chi me
tones per mi nute. The i nternal programmi ng of the
i nstrument cl uster determi nes the pri ori ty of each
chi me request i nput that i s recei ved, as wel l as the
rate and durati on of each chi me that i s to be gener-
ated.
The hard wi red chi me warni ng system i nputs to
the i nstrument cl uster, as wel l as other hard wi red
ci rcui ts for thi s system may be di agnosed and tested
usi ng conventi onal di agnosti c tool s and procedures.
However, conventi onal di agnosti c methods may not
prove concl usi ve i n the di agnosi s of the i nstrument
cl uster or the PCI data bus network. The most rel i -
abl e, effi ci ent and accurate means to di agnose the
i nstrument cl uster and the PCI data bus network
i nputs for the chi me warni ng system requi res the use
of a DRBI I I scan tool . Refer to the appropri ate di ag-
nosti c i nformati on.
DIAGNOSIS AND TESTING - CHIME WARNING
SYSTEM
The chi me warni ng system features dri ven by hard
wi red i nputs to the i nstrument cl uster may be di ag-
nosed and tested usi ng conventi onal di agnosti c tool s
and procedures. However, conventi onal di agnosti c
methods may not prove concl usi ve i n the di agnosi s of
the chi me warni ng system features dri ven by mes-
sage i nputs to the i nstrument cl uster over the Pro-
grammabl e Communi cati ons I nterface (PCI ) data bus
network. The most rel i abl e, effi ci ent and accurate
means to di agnose the i nstrument cl uster and the
PCI data bus network i nputs for the chi me warni ng
system requi res the use of a DRBI I I scan tool . Refer
to the appropri ate di agnosti c and wi ri ng i nformati on.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
INJURY.
NO SEAT BELT WARNING
CHIME WITH SEAT BELT
UNBUCKLED, BUT OTHER
CHIME FEATURES OK
1. Seat belt switch ground
circuit open.
1. Check for continuity between the ground
circuit for the driver seat belt switch and a good
ground. Repair open ground circuit, if required.
2. Seat belt switch sense
circuit open.
2. Check for continuity between the seat belt
switch sense circuit for the driver seat belt switch
and the instrument cluster connector. Repair the
open seat belt switch sense circuit, if required.
3. Faulty seat belt switch. 3. Check for continuity between the ground
circuit and the driver seat belt switch sense
circuit of the seat belt switch. There should be
continuity with the seat belt unbuckled. Replace
the faulty seat belt, if required.
SEAT BELT WARNING
CHIME WITH SEAT BELT
BUCKLED
1. Seat belt switch sense
circuit shorted.
1. With the driver seat belt switch and the
instrument cluster connector disconnected, there
should be no continuity between the seat belt
switch sense circuit and a good ground. Repair
the shorted seat belt switch sense circuit, if
required.
2. Faulty seat belt switch. 2. Check for continuity between the ground
circuit cavity and the seat belt switch sense
circuit of the driver seat belt switch. There should
be no continuity with the seat belt buckled.
Replace the faulty seat belt, if required.
NO KEY-IN IGNITION
WARNING CHIME, BUT
OTHER CHIME FEATURES
OK
1. Driver door ajar switch
sense circuit open.
1. Check for continuity between the driver door
ajar switch sense circuit connector and the
instrument cluster connector. Repair the open
driver door ajar switch sense circuit, if required.
2. Key-in ignition switch
sense circuit open.
2. Check for continuity between the key-in
ignition switch sense circuit connector and
key-in ignition switch sense circuit, if required.
3. Key-in ignition switch
ground circuit open.
circuit cavity of the ignition switch connector and
a good ground. Repair the open ground circuit, if
required
4. Faulty ignition switch. 4. Check for continuity between the ground
circuit terminal and the key-in ignition switch
sense circuit terminal in the ignition switch
connector. There should be continuity with a key
in the ignition lock cylinder. Replace the faulty
ignition switch, if required.
8B - 4 CHIME/BUZZER DR
1. Driver door ajar switch
sense circuit open.
1. Check for continuity between the driver door
ajar switch sense circuit connector and the
driver door ajar switch sense circuit, if required.
2. Headlamp switch signal
circuit open.
2. Check for continuity between the headlamp
switch output circuit connector and the and the
headlamp switch signal circuit, if required.
NO CHIMES AND OTHER
INSTRUMENT CLUSTER
FEATURES ERRATIC OR
DISABLED
1. Instrument cluster ground
circuit(s) open.
circuits of the instrument cluster connector and a
good ground. Repair the open ground circuits(s),
if required.
2. Instrument cluster fused
B(+) circuit(s) open.
2. Check for battery voltage at the B(+) circuits of
the instrument cluster connector. Repair the open
fused B(+) circuit(s), if required.
3. Instrument cluster fused
ignition switch output
(run-start) circuit open.
3. With the ignition switch in the On position,
check for battery voltage at the fused ignition
switch output (run-start) circuit of the instrument
cluster connector. Repair the open fused ignition
switch output (run-start) circuit, if required.
4. Faulty instrument cluster. 4. Replace the faulty instrument cluster, if
required.
NO CHIMES, BUT ALL
OTHER INSTRUMENT
CLUSTER FEATURES OK
1. Faulty instrument cluster. 1. Replace the faulty instrument cluster, if
required.
ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
COMMUNICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CONTROLLER ANTILOCK BRAKE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DATA LINK CONNECTOR
DESCRIPTION - DATA LINK CONNECTOR . . . . . 3
OPERATION - DATA LINK CONNECTOR . . . . . . 3
ENGINE CONTROL MODULE
DESCRIPTION - ECM . . . . . . . . . . . . . . . . . . . . . 3
OPERATION - ECM . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - FRONT
CONTROL MODULE . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HEATED SEAT MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - HEATED SEAT
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
POWERTRAIN CONTROL MODULE
DESCRIPTION
DESCRIPTION - PCM . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION - MODES OF OPERATION . . . . 7
DESCRIPTION - 5 VOLT SUPPLIES . . . . . . . 10
DESCRIPTION - IGNITION CIRCUIT SENSE . 10
DESCRIPTION - POWER GROUNDS . . . . . . 10
DESCRIPTION - SENSOR RETURN . . . . . . . 10
OPERATION
OPERATION - PCM . . . . . . . . . . . . . . . . . . . . 10
OPERATION - 5 VOLT SUPPLIES . . . . . . . . . 11
OPERATION - IGNITION CIRCUIT SENSE . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
SENTRY KEY IMMOBILIZER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
TRANSFER CASE CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TRANSMISSION CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
STANDARD PROCEDURE
STANDARD PROCEDURE - TCM QUICK
LEARN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
STANDARD PROCEDURE - DRIVE LEARN . . 23
COMMUNICATION
DESCRIPTION
The Dai ml erChrysl er Programmabl e Communi ca-
ti on I nterface (PCI ) data bus system i s a si ngl e wi re
mul ti pl ex system used for vehi cl e communi cati ons on
many Dai ml erChrysl er Corporati on vehi cl es. Mul ti -
pl exi ng i s a system that enabl es the transmi ssi on of
several messages over a si ngl e channel or ci rcui t. Al l
Dai ml erChrysl er vehi cl es use thi s pri nci pl e for com-
muni cati on between vari ous mi croprocessor-based
el ectroni c control modul es. The PCI data bus exceeds
the Soci ety of Automoti ve Engi neers (SAE) J1850
Standard for Cl ass B Mul ti pl exi ng.
Many of the el ectroni c control modul es i n a vehi cl e
requi re i nformati on from the same sensi ng devi ce. I n
the past, i f i nformati on from one sensi ng devi ce was
requi red by several control l ers, a wi re from each con-
trol l er needed to be connected i n paral l el to that sen-
sor. I n addi ti on, each control l er uti l i zi ng anal og
sensors requi red an Anal og/Di gi tal (A/D) converter i n
order to read these sensor i nputs. Mul ti pl exi ng
reduces wi re harness compl exi ty, sensor current
l oads and control l er hardware because each sensi ng
devi ce i s connected to onl y one control l er, whi ch
reads and di stri butes the sensor i nformati on to the
other control l ers over the data bus. Al so, because
each control l er on the data bus can access the con-
trol l er sensor i nputs to every other control l er on the
DR ELECTRONIC CONTROL MODULES 8E - 1
data bus, more functi on and feature capabi l i ti es are
possi bl e.
I n addi ti on to reduci ng wi re harness compl exi ty,
component sensor current l oads and control l er hard-
ware, mul ti pl exi ng offers a di agnosti c advantage. A
mul ti pl ex system al l ows the i nformati on fl owi ng
between control l ers to be moni tored usi ng a di agnos-
ti c scan tool . The Dai ml erChrysl er system al l ows an
el ectroni c control modul e to broadcast message data
out onto the bus where al l other el ectroni c control
modul es can hear the messages that are bei ng sent.
When a modul e hears a message on the data bus
that i t requi res, i t rel ays that message to i ts mi cro-
processor. Each modul e i gnores the messages on the
data bus that are bei ng sent to other el ectroni c con-
trol modul es.
OPERATION
Data exchange between modul es i s achi eved by seri al
transmi ssi on of encoded data over a si ngl e wi re broad-
cast network. The wi re col ors used for the PCI data bus
ci rcui ts are yel l ow wi th a vi ol et tracer, or vi ol et wi th a
yel l ow tracer, dependi ng upon the appl i cati on. The PCI
data bus messages are carri ed over the bus i n the form
of Vari abl e Pul se Wi dth Modul ated (VPWM) si gnal s.
The PCI data bus speed i s an average 10.4 Ki l o-bi ts per
second (Kbps). By compari son, the pri or two-wi re
Chrysl er Col l i si on Detecti on (CCD) data bus system i s
desi gned to run at 7.8125 Kbps.
The vol tage network used to transmi t messages
requi res bi asi ng and termi nati on. Each modul e on
the PCI data bus system provi des i ts own bi asi ng
and termi nati on. Each modul e (al so referred to as a
node) termi nates the bus through a termi nati ng
resi stor and a termi nati ng capaci tor. There are two
types of nodes on the bus. The domi nant node termi -
nates the bus through a 1 KW resi stor and a 3300 pF
capaci tor. The Powertrai n Control Modul e (PCM) i s
the onl y domi nant node for the PCI data bus system.
A standard node termi nates the bus through an 11
KW resi stor and a 330 pF capaci tor.
The modul es bi as the bus when transmi tti ng a
message. The PCI bus uses l ow and hi gh vol tage l ev-
el s to generate si gnal s. Low vol tage i s around zero
vol ts and the hi gh vol tage i s about seven and one-
hal f vol ts. The l ow and hi gh vol tage l evel s are gener-
ated by means of vari abl e-pul se wi dth modul ati on to
form si gnal s of varyi ng l ength. The Vari abl e Pul se
Wi dth Modul ati on (VPWM) used i n PCI bus messag-
i ng i s a method i n whi ch both the state of the bus
and the wi dth of the pul se are used to encode bi t
i nformati on. A zero bi t i s defi ned as a short l ow
pul se or a l ong hi gh pul se. A one bi t i s defi ned as a
l ong l ow pul se or a short hi gh pul se. A l ow (passi ve)
state on the bus does not necessari l y mean a zero bi t.
I t al so depends upon pul se wi dth. I f the wi dth i s
short, i t stands for a zero bi t. I f the wi dth i s l ong, i t
stands for a one bi t. Si mi l arl y, a hi gh (acti ve) state
does not necessari l y mean a one bi t. Thi s too depends
upon pul se wi dth. I f the wi dth i s short, i t stands for
a one bi t. I f the wi dth i s l ong, i t stands for a zero bi t.
I n the case where there are successi ve zero or one
data bi ts, both the state of the bus and the wi dth of
the pul se are changed al ternatel y. Thi s encodi ng
scheme i s used for two reasons. Fi rst, thi s ensures
that onl y one symbol per transi ti on and one transi -
ti on per symbol exi sts. On each transi ti on, every
transmi tti ng modul e must decode the symbol on the
bus and begi n ti mi ng of the next symbol . Si nce ti m-
i ng of the next symbol begi ns wi th the l ast transi ti on
detected on the bus, al l of the modul es are re-syn-
chroni zed wi th each symbol . Thi s ensures that there
are no accumul ated ti mi ng errors duri ng PCI data
bus communi cati on.
The second reason for thi s encodi ng scheme i s to
guarantee that the zero bi t i s the domi nant bi t on
the bus. When two modul es are transmi tti ng si mul -
taneousl y on the bus, there must be some form of
arbi trati on to determi ne whi ch modul e wi l l gai n con-
trol . A data col l i si on occurs when two modul es are
transmi tti ng di fferent messages at the same ti me.
When a modul e i s transmi tti ng on the bus, i t i s read-
i ng the bus at the same ti me to ensure message
i ntegri ty. When a col l i si on i s detected, the modul e
that transmi tted the one bi t stops sendi ng messages
over the bus unti l the bus becomes i dl e.
Each modul e i s capabl e of transmi tti ng and recei v-
i ng data si mul taneousl y. The typi cal PCI bus mes-
sage has the fol l owi ng four components:
Message Header - One to three bytes i n l ength.
The header contai ns i nformati on i denti fyi ng the mes-
sage type and l ength, message pri ori ty, target mod-
ul e(s) and sendi ng modul e.
Data Byte(s) - Thi s i s the actual message that
i s bei ng sent.
Cyclic Redundancy Check (CRC) Byte - Thi s
byte i s used to detect errors duri ng a message trans-
mi ssi on.
In-Frame Response (IFR) byte(s) - I f a
response i s requi red from the target modul e(s), i t can
be sent duri ng thi s frame. Thi s functi on i s descri bed
i n greater detai l i n the fol l owi ng paragraph.
The I FR consi sts of one or more bytes, whi ch are
transmi tted duri ng a message. I f the sendi ng modul e
requi res i nformati on to be recei ved i mmedi atel y, the
target modul e(s) can send data over the bus duri ng
the ori gi nal message. Thi s al l ows the sendi ng modul e
to recei ve ti me-cri ti cal i nformati on wi thout havi ng to
wai t for the target modul e to access the bus. After
the I FR i s recei ved, the sendi ng modul e broadcasts
an End of Frame (EOF) message and rel eases control
of the bus.
8E - 2 ELECTRONIC CONTROL MODULES DR
COMMUNICATION (Continued)
The PCI data bus can be moni tored usi ng the
DRBI I I scan tool . I t i s possi bl e, however, for the bus
to pass al l DRBI I I tests and sti l l be faul ty i f the
vol tage parameters are al l wi thi n the speci fi ed range
and fal se messages are bei ng sent.
CONTROLLER ANTILOCK
BRAKE
DESCRIPTION
The Control er Anti l ock Brake (CAB) i s mounted to
the Hydraul i c Control Uni t (HCU) and operates the
ABS system (Fi g. 1).
OPERATION
The CAB vol tage source i s through the i gni ti on
swi tch i n the RUN posi ti on. The CAB contai ns a sel f
check program that i l l umi nates the ABS warni ng
l i ght when a system faul t i s detected. Faul ts are
stored i n a di agnosti c program memory and are
accessi bl e wi th the DRB I I I scan tool . ABS faul ts
remai n i n memory unti l cl eared, or unti l after the
vehi cl e i s started approxi matel y 50 ti mes. Stored
faul ts are not erased i f the battery i s di sconnected.
REMOVAL
(1) Remove the negati ve battery cabl e from the
battery.
(2) Pul l up on the CAB harness connector rel ease
and remove connector.
(3) Remove the CAB mounti ng bol ts.
(4) Remove the pump connector from the CAB.
(5) Remove the CAB from the HCU.
INSTALLATION
(1) I nstal l CAB to the HCU.
(2) I nstal l the pump connector to the CAB.
(3) I nstal l mounti ng bol ts. Ti ghten to 2 Nm (16 i n.
l bs.).
(4) I nstal l the wi ri ng harness connector to the
CAB and push down on the rel ease to secure the con-
nector.
(5) I nstal l negati ve battery cabl e to the battery.
DATA LINK CONNECTOR
DESCRIPTION - DATA LINK CONNECTOR
The Data Li nk Connector (DLC) i s l ocated at the
l ower edge of the i nstrument panel near the steeri ng
col umn.
OPERATION - DATA LINK CONNECTOR
The 16way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool or the Mopar Di agnosti c System
(MDS) wi th the Powertrai n Control Modul e (PCM).
ENGINE CONTROL MODULE
DESCRIPTION - ECM
The engi ne control modul e (ECM) for the 5.9L Di e-
sel engi ne i s bol ted to the l eft si de of the engi ne
bel ow the i ntake mani fol d.
OPERATION - ECM
The mai n functi on of the Engi ne Control Modul e
(ECM) i s to el ectri cal l y control the fuel system. The
Powertrai n Control Modul e (PCM) does not control
the fuel system.
The ECM can adapt i ts programmi ng to meet
changi ng operati ng condi ti ons. If the ECM has
been replaced, flashed or re-calibrated, the
ECM must learn the Accelerator Pedal Position
Sensor (APPS) idle voltage. Failure to learn
this voltage may result in unnecessary diagnos-
tic trouble codes. Refer to ECM Removal/Instal-
lation for learning procedures.
The ECM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
ECM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as ECM Outputs. The sensors
and swi tches that provi de i nputs to the ECM are
consi dered ECM Inputs.
Fig. 1 HYDRAULIC CONTROL UNIT
1 - HYDRAULIC CONTROL UNIT
2 - MOUNTING BOLTS
COMMUNICATION (Continued)
NOTE: ECM Inputs:
Accel erator Pedal Posi ti on Sensor (APPS) Vol ts
APPS1 Si gnal For off engi ne APPS
APPS2 Si gnal For off engi ne APPS
APPS i dl e val i dati on swi tches #1 and #2
Battery Temperature
Battery vol tage
Camshaft Posi ti on Sensor (CMP)
CCD bus (+) ci rcui ts
CCD bus (-) ci rcui ts
Crankshaft Posi ti on Sensor (CKP)
Data l i nk connecti on for DRB scan tool
Engi ne Cool ant Temperature (ECT) sensor
Fuel pressure sensor
Fan speed (engi ne cool i ng fan)
Ground ci rcui ts
I nl et ai r temperature sensor/pressure sensor
I ntake ai r temperature sensor/MAP sensor
Oi l Pressure swi tch
Power ground
Sensor return
Si gnal ground
Water-I n-Fuel (WI F) sensor
NOTE: ECM Outputs:
After i nputs are recei ved by the ECM, certai n sen-
sors, swi tches and components are control l ed or reg-
ul ated by the ECM. These are consi dered ECM
Outputs. These outputs are for:
CCD bus (+) ci rcui ts
CCD bus (-) ci rcui ts
CKP and APPS outputs to the PCM
Fan Cl utch PWM
Fi ve vol t sensor suppl y
Fuel Control Actuator
Fuel transfer (l i ft) pump
I ntake mani fol d ai r heater rel ays #1 and #2 con-
trol ci rcui ts
Mal functi on i ndi cator l amp (Check engi ne l amp)
(databus)
Oi l Pressure Swi th/warni ng l amp (databus)
Wai t-to-start warni ng l amp (databus)
Water-I n-Fuel (WI F) warni ng l amp (databus)
REMOVAL
The engi ne control modul e (ECM) i s bol ted to a
support bracket near the fuel fi l ter. The support
bracket mounts to the bl ock wi th four capscrews and
vi brati on i sol ators. A ground wi re i s fastened to the
bracket. The other end of the wi re i s fastened to the
engi ne bl ock.
(1) Record any Di agnosti c Troubl e Codes (DTCs)
found i n the ECM.
To avoi d possi bl e vol tage spi ke damage to the
ECM, i gni ti on key must be off, and both negati ve
battery cabl es must be di sconnected before unpl ug-
gi ng ECM connectors.
(2) Di sconnect both negati ve battery cabl es at both
batteri es.
(3) Remove the 50way and 60way connector
bol ts at the ECM. Note: The connector bol t i s a
femal e al l en head. As bol t i s bei ng removed, very
careful l y remove connectors from the ECM.
(4) Remove fi ve ECM mounti ng bol ts and remove
ECM from the vehi cl e (Fi g. 2).
INSTALLATION
Do not appl y pai nt to ECM or a poor ground wi l l
resul t.
(1) Posi ti on the ECM to the ECM support bracket
and i nstal l the fi ve mounti ng bol ts. Ti ghten the bol ts
to 24 Nm (18 ft. l bs.).
(2) Check pi n connectors i n ECM, 50way and
60way connectors for corrosi on or damage. Repai r
as necessary.
(3) Cl ean pi ns i n the 50way and 60way el ectri -
cal connectors wi th a el ectri cal contact cl eaner.
(4) I nstal l the 50way and 60way connectors to
ECM. Ti ghten connector bol ts to 3 Nm (27 i n. l bs.).
(5) Reconnect both negati ve battery cabl es.
(6) Use DRBI I I scan tool to erase any stored com-
pani on DTCs from ECM.
Fig. 2 Diesel ECM
1 - ENGINE CONTROL MODULE (ECM)
2 - ECM MOUNTING BOLT
3 - 50-WAY CONNECTOR
4 - SUPPORT PLATE
ENGINE CONTROL MODULE (Continued)
DESCRIPTION
The Front Control Modul e (FCM) i s a mi cro con-
trol l er based modul e l ocated i n the l eft front corner
of the engi ne compartment. On thi s model the i nte-
grated power modul e must be posi ti oned asi de i n
order to access the front control modul e. The front
control modul e mates to the power di stri buti on cen-
ter to form the I ntegrated Power Modul e (I PM). The
i ntegrated power modul e connects di rectl y to the bat-
tery and provi des the pri mary means of ci rcui t pro-
tecti on and power di stri buti on for al l vehi cl e
el ectri cal systems. The front control modul e control s
power to some of these vehi cl e systems el ectri cal and
el ectromechani cal l oads based on i nputs recei ved
from hard wi red swi tch i nputs and data recei ved on
the PCI bus ci rcui t (J1850).
For i nformati on on the Integrated Power Mod-
ule Refer to the Power Distribution Section of
the servi ce manual .
OPERATION
As messages are sent over the PCI bus ci rcui t, the
front control modul e reads these messages and con-
trol s power to some of the vehi cl es el ectri cal systems
by compl eti ng the ci rcui t to ground (l ow si de dri ver)
or compl eti ng the ci rcui t to 12 vol t power (hi gh si de
dri ver). The fol l owi ng functi ons are Controlled by
the Front Control Modul e:
Headl amp Power wi th Vol tage Regul ati on
Wi ndshi el d Wi per ON/OFF Rel ay Actuati on
Wi ndshi el d Wi per HI /LO Rel ay Actuati on
Wi ndshi el d Washer Pump Motor
Fog Lamp Rel ay Actuati on
Park Lamp Rel ay Actuati on
Horn Rel ay Actuati on
The fol l owi ng i nputs are Received/Monitored by
B+ Connecti on Detecti on
Power Ground
Ambi ent Temperature Sensi ng
I gni ti on Swi tch Run
Washer Fl ui d Level Swi tch
Wi ndshi el d Wi per Park Swi tch
PCI Bus Ci rcui t
DIAGNOSIS AND TESTING - FRONT CONTROL
MODULE
The front control modul e i s a pri nted ci rcui t board
based modul e wi th a on-board mi cro-processor. The
front control modul e i nterfaces wi th other el ectroni c
modul es i n the vehi cl e vi a the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus (J1850). I n
order to obtai n concl usi ve testi ng the Programmabl e
Communi cati ons I nterface (PCI ) data bus network
and al l of the el ectroni c modul es that provi de i nputs
to, or recei ve outputs from the front control modul e
must be checked. Al l PCI (J1850) communi cati on
faul ts must be resol ved pri or to further di agnosi ng
any front control modul e rel ated i ssues.
The front control modul e was desi gned to be di ag-
nosed wi th an appropri ate di agnosti c scan tool , such
as the DRB I I I . The most rel i abl e, effi ci ent, and
accurate means to di agnose the front control modul e
requi res the use of a DRB I I I scan tool and the
proper Body Di agnosti c Procedures manual .
Before any testi ng of the front control modul e i s
attempted, the battery shoul d be ful l y charged and
al l wi re harness and ground connecti ons i nspected
around the affected areas on the vehi cl e.
REMOVAL
(1) Di sconnect the posi ti ve and negati ve battery
cabl es from the battery.
(2) Parti al l y remove the i ntegrated power modul e
from the engi ne compartment (Refer to 8 - ELECTRI -
CAL/POWER DI STRI BUTI ON/I NTEGRATED
POWER MODULE - REMOVAL).
(3) Remove the front control modul e retai ni ng
screws.
(4) Usi ng both hands, pul l the front control modul e
straight from the i ntegrated power modul e assembl y
to di sconnect the 49-way el ectri cal connector and
remove the front control modul e from the vehi cl e.
INSTALLATION
(1) I nstal l the front control modul e on the i nte-
grated power modul e assembl y by pushi ng the
49-way el ectri cal connector strai ght i n.
(2) I nstal l the front control modul e retai ni ng
screws. Torque the screws to 7 i n. l bs.
(3) I nstal l the i ntegrated power modul e (Refer to 8
- ELECTRI CAL/POWER DI STRI BUTI ON/I NTE-
GRATED POWER MODULE - I NSTALLATI ON).
(4) Connect the posi ti ve and negati ve battery
cabl es.
HEATED SEAT MODULE
DESCRIPTION
The heated seat modul e i s al so known as the Seat
Heat I nterface Modul e. The heated seat modul e (Fi g.
3) i s l ocated under the dri vers front seat cushi on,
where i t i s secured to a mounti ng bracket. The
heated seat modul e has a si ngl e connector receptacl e
that al l ows the modul e to be connected to al l of the
requi red i nputs and outputs through the seat wi re
harness.
The heated seat modul e i s an el ectroni c mi cropro-
cessor control l ed devi ce desi gned and programmed to
use i nputs from the battery, the two heated seat
swi tches and the two heated seat sensors to operate
and control the heated seat el ements i n both front
seats and the two heated seat i ndi cator l amp Li ght-
Emi tti ng Di odes (LEDs) i n each heated seat swi tch.
The heated seat modul e i s al so programmed to per-
form sel f-di agnosi s of certai n heated seat system
functi ons and provi de feedback of that di agnosi s
through the heated seat swi tch i ndi cator l amps.
The heated seat modul e cannot be repai red. I f the
heated seat modul e i s damaged or faul ty, the enti re
modul e must be repl aced.
OPERATION
The heated seat modul e operates on fused battery
current recei ved from the i ntegrated power modul e.
I nputs to the modul e i ncl ude a resi stor mul ti pl exed
heated seat swi tch request ci rcui t for each of the two
heated seat swi tches and the heated seat sensor
i nputs from the seat cushi ons of each front seat. I n
response to those i nputs the heated seat modul e con-
trol s battery current feeds to the heated seat el e-
ments and sensors, and control s the ground for the
heated seat swi tch i ndi cator l amps.
When a heated seat swi tch (Dri ver or Passenger) i s
depressed a si gnal i s recei ved by the heated seat
modul e, the modul e energi zes the proper i ndi cator
LED (Low or Hi gh) i n the swi tch by groundi ng the
i ndi cator l amp ci rcui t to i ndi cate that the heated seat
system i s operati ng. At the same ti me, the heated
seat modul e energi zes the sel ected heated seat sensor
ci rcui t and the sensor provi des the modul e wi th an
i nput i ndi cati ng the surface temperature of the
sel ected seat cushi on.
The Low heat set poi nt i s about 36 C (96.8 F),
and the Hi gh heat set poi nt i s about 42 C (107.6 F).
I f the seat cushi on surface temperature i nput i s
bel ow the temperature set poi nt for the sel ected tem-
perature setti ng, the heated seat modul e energi zes
an N-channel Fi el d Effect Transi stor (N-FET) wi thi n
the modul e whi ch energi zes the heated seat el ements
i n the sel ected seat cushi on and back. When the sen-
sor i nput to the modul e i ndi cates the correct temper-
ature set poi nt has been achi eved, the modul e
de-energi zes the N-FET whi ch de-energi zes the
heated seat el ements. The heated seat modul e wi l l
conti nue to cycl e the N-FET as needed to mai ntai n
the sel ected temperature set poi nt.
I f the heated seat modul e detects a heated seat
sensor val ue i nput that i s out of range or a shorted
or open heated seat el ement ci rcui t, i t wi l l noti fy the
vehi cl e operator or the repai r techni ci an of thi s con-
di ti on by fl ashi ng the Hi gh and/or Low i ndi cator
l amps i n the affected heated seat swi tch. Refer to
Diagnosis and Testing Heated Seat System i n
Heated Systems for fl ashi ng LED di agnosi s and test-
i ng procedures. Refer to Diagnosis and Testing
Heated Seat Module i n thi s secti on for heated seat
modul e di agnosi s and testi ng procedures.
MODULE
I f a heated seat fai l s to heat and one or both of the
i ndi cator l amps on a heated seat swi tch fl ash, refer
to Diagnosis and Testing Heated Seat System i n
Heated Seats for the l ocati on of fl ashi ng LED heated
seat system di agnosi s and testi ng procedures. I f a
heated seat heats but one or both i ndi cator l amps on
the heated seat swi tch fai l to operate, test the heated
seat swi tch. Refer to Diagnosis and Testing
Heated Seat Switch i n Heated Seats for heated
seat swi tch di agnosi s and testi ng procedures. I f the
heated seat swi tch checks OK, proceed as fol l ows.
(1) Check the heated seat el ement (Refer to 8 -
ELECTRI CAL/HEATED SEATS/HEATED SEAT
ELEMENT - DI AGNOSI S AND TESTI NG).
Fig. 3 Heated Seat Module
1 - MOUNTING TABS (NOT USED ON DR)
2 - HEATED SEAT MODULE
3 - ELECTRICAL CONNECTOR RECEPTACLE
(2) Check the heated seat sensor (Refer to 8 -
SENSOR - DI AGNOSI S AND TESTI NG).
(3) Check the heated seat swi tch (Refer to 8 -
ELECTRI CAL/HEATED SEATS/DRI VER HEATED
SEAT SWI TCH - DI AGNOSI S AND TESTI NG).
NOTE: Refer to Wiring for the location of complete
heated seat system wiring diagrams and connector
pin-out information.
(4) Usi ng a vol tmeter, backprobe the appropri ate
heated seat modul e connector, do not di sconnect.
Check for vol tage at the appropri ate pi n cavi ti es. 12v
shoul d be present. I f OK go to Step 5, i f Not, Repai r
the open or shorted vol tage suppl y ci rcui t as
requi red.
(5) Usi ng a ohmmeter, backprobe the appropri ate
Check for proper conti nui ty to ground on the ground
pi n cavi ti es. Conti nui ty shoul d be present. I f OK
repl ace the heated seat modul e wi th a known good
uni t and retest system, i f Not OK, Repai r the open or
shorted ground ci rcui t as requi red.
REMOVAL
(1) Posi ti on the dri ver seat to the ful l rearward
and i ncl i ned posi ti on.
(2) Worki ng under the dri ver front seat, remove
the two heated seat modul e retai ni ng screws. Due to
the fact that the retai ni ng screws are i nstal l ed wi th
the seat cushi on pan removed, a smal l ri ght angl e
screwdri ver wi l l be requi red to access and remove the
screws.
(3) Di sconnect the seat wi re harness connector
from the connector receptacl e on the back of the
heated seat modul e. Depress the connector retai ni ng
tab and pul l strai ght apart.
(4) Remove the heated seat modul e from under the
front seat.
INSTALLATION
(1) Posi ti on the heated seat modul e under the
front seat.
(2) Connect the seat wi re harness connector on the
connector receptacl e on the back of the heated seat
modul e.
(3) Worki ng under the dri ver front seat, i nstal l the
heated seat modul e retai ni ng screws.
(4) Re-posi ti on the dri ver seat.
POWERTRAIN CONTROL
MODULE
DESCRIPTION
DESCRIPTION - PCM
The Powertrai n Control Modul e (PCM) i s l ocated
i n the ri ght-rear secti on of the engi ne compartment
under the cowl (Fi g. 4).
Two different PCMs are used (J TEC and
NGC). These can be easily identified. J TECs
use three 32way connectors, NGCs use four
38way connectors
DESCRIPTION - MODES OF OPERATION
As i nput si gnal s to the Powertrai n Control Modul e
(PCM) change, the PCM adjusts i ts response to the
output devi ces. For exampl e, the PCM must cal cul ate
di fferent i njector pul se wi dth and i gni ti on ti mi ng for
i dl e than i t does for wi de open throttl e (WOT).
The PCM wi l l operate i n two di fferent modes:
Open Loop and Closed Loop.
Duri ng Open Loop modes, the PCM recei ves i nput
si gnal s and responds onl y accordi ng to preset PCM
programmi ng. I nput from the oxygen (O2S) sensors
i s not moni tored duri ng Open Loop modes.
Fig. 4 POWERTRAIN CONTROL MODULE (PCM)
LOCATION
1 - COWL GRILL
2 - PCM
3 - COWL (RIGHT-REAR)
HEATED SEAT MODULE (Continued)
Duri ng Cl osed Loop modes, the PCM wi l l moni tor
the oxygen (O2S) sensors i nput. Thi s i nput i ndi cates
to the PCM whether or not the cal cul ated i njector
pul se wi dth resul ts i n the i deal ai r-fuel rati o. Thi s
rati o i s 14.7 parts ai r-to-1 part fuel . By moni tori ng
the exhaust oxygen content through the O2S sensor,
the PCM can fi ne tune the i njector pul se wi dth. Thi s
i s done to achi eve opti mum fuel economy combi ned
wi th l ow emi ssi on engi ne performance.
The fuel i njecti on system has the fol l owi ng modes
of operati on:
I gni ti on swi tch ON
Engi ne start-up (crank)
Engi ne warm-up
I dl e
Crui se
Accel erati on
Decel erati on
Wi de open throttl e (WOT)
I gni ti on swi tch OFF
The i gni ti on swi tch On, engi ne start-up (crank),
engi ne warm-up, accel erati on, decel erati on and wi de
open throttl e modes are Open Loop modes. The i dl e
and crui se modes, (wi th the engi ne at operati ng tem-
perature) are Cl osed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
Thi s i s an Open Loop mode. When the fuel system
i s acti vated by the i gni ti on swi tch, the fol l owi ng
acti ons occur:
The PCM pre-posi ti ons the i dl e ai r control (I AC)
motor.
The PCM determi nes atmospheri c ai r pressure
from the MAP sensor i nput to determi ne basi c fuel
strategy.
The PCM moni tors the engi ne cool ant tempera-
ture sensor i nput. The PCM modi fi es fuel strategy
based on thi s i nput.
I ntake mani fol d ai r temperature sensor i nput i s
moni tored.
Throttl e posi ti on sensor (TPS) i s moni tored.
The auto shutdown (ASD) rel ay i s energi zed by
the PCM for approxi matel y three seconds.
The fuel pump i s energi zed through the fuel
pump rel ay by the PCM. The fuel pump wi l l operate
for approxi matel y three seconds unl ess the engi ne i s
operati ng or the starter motor i s engaged.
The O2S sensor heater el ement i s energi zed vi a
the ASD or O2S heater rel ay. The O2S sensor i nput
i s not used by the PCM to cal i brate ai r-fuel rati o dur-
i ng thi s mode of operati on.
ENGINE START-UP MODE
Thi s i s an Open Loop mode. The fol l owi ng acti ons
occur when the starter motor i s engaged.
The PCM recei ves i nputs from:
Battery vol tage
Engi ne cool ant temperature sensor
Crankshaft posi ti on sensor
I ntake mani fol d ai r temperature sensor
Mani fol d absol ute pressure (MAP) sensor
Throttl e posi ti on sensor (TPS)
Camshaft posi ti on sensor si gnal
The PCM moni tors the crankshaft posi ti on sensor.
I f the PCM does not recei ve a crankshaft posi ti on
sensor si gnal wi thi n 3 seconds of cranki ng the
engi ne, i t wi l l shut down the fuel i njecti on system.
The fuel pump i s acti vated by the PCM through
the fuel pump rel ay.
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
The PCM determi nes the proper i gni ti on ti mi ng
accordi ng to i nput recei ved from the crankshaft posi -
ti on sensor.
ENGINE WARM-UP MODE
Thi s i s an Open Loop mode. Duri ng engi ne warm-
up, the PCM recei ves i nputs from:
Battery vol tage
Park/neutral swi tch (gear i ndi cator si gnal auto.
trans. onl y)
Ai r condi ti oni ng sel ect si gnal (i f equi pped)
Ai r condi ti oni ng request si gnal (i f equi pped)
Based on these i nputs the fol l owi ng occurs:
on and off.
The PCM adjusts engi ne i dl e speed through the
i dl e ai r control (I AC) motor and adjusts i gni ti on ti m-
i ng.
The PCM operates the A/C compressor cl utch
through the A/C compressor cl utch rel ay. Thi s i s done
i f A/C has been sel ected by the vehi cl e operator and
speci fi ed pressures are met at the hi gh and l owpres-
sure A/C swi tches. Refer to Heati ng and Ai r Condi -
ti oni ng for addi ti onal i nformati on.
When engi ne has reached operati ng tempera-
ture, the PCM wi l l begi n moni tori ng O2S sensor
i nput. The system wi l l then l eave the warm-up mode
and go i nto cl osed l oop operati on.
POWERTRAIN CONTROL MODULE (Continued)
IDLE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At i dl e speed, the PCM
recei ves i nputs from:
Battery vol tage
Battery vol tage
trans. onl y)
Oxygen sensors
Based on these i nputs, the fol l owi ng occurs:
i njecti on sequence and i njector pul se wi dth by turn-
i ng the ground ci rcui t to each i ndi vi dual i njector on
and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o by varyi ng i njector pul se wi dth.
I t al so adjusts engi ne i dl e speed through the i dl e ai r
control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by i ncreasi ng
and decreasi ng spark advance.
through the A/C compressor cl utch rel ay. Thi s i s done
i f A/C has been sel ected by the vehi cl e operator and
speci fi ed pressures are met at the hi gh and l owpres-
sure A/C swi tches. Refer to Heati ng and Ai r Condi -
ti oni ng for addi ti onal i nformati on.
CRUISE MODE
i s a Cl osed Loop mode. At crui si ng speed, the PCM
recei ves i nputs from:
Battery vol tage
trans. onl y)
Oxygen (O2S) sensors
Based on these i nputs, the fol l owi ng occurs:
ASD rel ay vi a the PCM. The PCM wi l l then adjust
the i njector pul se wi dth by turni ng the ground ci rcui t
to each i ndi vi dual i njector on and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o. I t al so adjusts engi ne i dl e
speed through the i dl e ai r control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l (s) on and off.
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
ACCELERATION MODE
Thi s i s an Open Loop mode. The PCM recogni zes
an abrupt i ncrease i n throttl e posi ti on or MAP pres-
sure as a demand for i ncreased engi ne output and
vehi cl e accel erati on. The PCM i ncreases i njector
pul se wi dth i n response to i ncreased throttl e openi ng.
DECELERATION MODE
i s an Open Loop mode. Duri ng hard decel erati on, the
PCM recei ves the fol l owi ng i nputs.
Battery vol tage
trans. onl y)
Vehi cl e speed
I f the vehi cl e i s under hard decel erati on wi th the
proper rpm and cl osed throttl e condi ti ons, the PCM
wi l l i gnore the oxygen sensor i nput si gnal . The PCM
wi l l enter a fuel cut-off strategy i n whi ch i t wi l l not
suppl y a ground to the i njectors. I f a hard decel era-
ti on does not exi st, the PCM wi l l determi ne the
proper i njector pul se wi dth and conti nue i njecti on.
Based on the above i nputs, the PCM wi l l adjust
engi ne i dl e speed through the i dl e ai r control (I AC)
motor.
ground path to the coi l on and off.
WIDE OPEN THROTTLE MODE
Thi s i s an Open Loop mode. Duri ng wi de open
throttl e operati on, the PCM recei ves the fol l owi ng
i nputs.
Battery vol tage
Duri ng wi de open throttl e condi ti ons, the fol l owi ng
occurs:
on and off. The PCM i gnores the oxygen sensor i nput
si gnal and provi des a predetermi ned amount of addi -
ti onal fuel . Thi s i s done by adjusti ng i njector pul se
wi dth.
ground path to the coi l (s) on and off.
IGNITION SWITCH OFF MODE
When i gni ti on swi tch i s turned to OFF posi ti on,
the PCM stops operati ng the i njectors, i gni ti on coi l ,
ASD rel ay and fuel pump rel ay.
DESCRIPTION - 5 VOLT SUPPLIES
Two di fferent Powertrai n Control Modul e (PCM)
fi ve vol t suppl y ci rcui ts are used; pri mary and sec-
ondary.
DESCRIPTION - IGNITION CIRCUIT SENSE
Thi s ci rcui t ti es the i gni ti on swi tch to the Power-
trai n Control Modul e (PCM).
DESCRIPTION - POWER GROUNDS
The Powertrai n Control Modul e (PCM) has 2 mai n
grounds. Both of these grounds are referred to as
power grounds. Al l of the hi gh-current, noi sy, el ectri -
cal devi ces are connected to these grounds as wel l as
al l of the sensor returns. The sensor return comes
i nto the sensor return ci rcui t, passes through noi se
suppressi on, and i s then connected to the power
ground.
The power ground i s used to control ground ci r-
cui ts for the fol l owi ng PCM l oads:
Generator fi el d wi ndi ng
Fuel i njectors
I gni ti on coi l (s)
Certai n rel ays/sol enoi ds
Certai n sensors
DESCRIPTION - SENSOR RETURN
The Sensor Return ci rcui ts are i nternal to the Pow-
ertrai n Control Modul e (PCM).
Sensor Return provi des a l ownoi se ground refer-
ence for al l engi ne control system sensors. Refer to
Power Grounds for more i nformati on.
OPERATION
OPERATION - PCM
The PCM operates the fuel system. The PCM i s a
pre-programmed, tri pl e mi croprocessor di gi tal com-
puter. I t regul ates i gni ti on ti mi ng, ai r-fuel rati o,
emi ssi on control devi ces, chargi ng system, certai n
transmi ssi on features, speed control , ai r condi ti oni ng
compressor cl utch engagement and i dl e speed. The
PCM can adapt i ts programmi ng to meet changi ng
operati ng condi ti ons.
The PCM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
PCM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as Powertrai n Control Modul e
(PCM) Outputs. The sensors and swi tches that pro-
vi de i nputs to the PCM are consi dered Powertrai n
Control Modul e (PCM) I nputs.
The PCM adjusts i gni ti on ti mi ng based upon
i nputs i t recei ves from sensors that react to: engi ne
rpm, mani fol d absol ute pressure, engi ne cool ant tem-
perature, throttl e posi ti on, transmi ssi on gear sel ec-
ti on (automati c transmi ssi on), vehi cl e speed, power
steeri ng pump pressure, and the brake swi tch.
The PCM adjusts i dl e speed based on i nputs i t
recei ves from sensors that react to: throttl e posi ti on,
vehi cl e speed, transmi ssi on gear sel ecti on, engi ne
cool ant temperature and from i nputs i t recei ves from
the ai r condi ti oni ng cl utch swi tch and brake swi tch.
Based on i nputs that i t recei ves, the PCM adjusts
i gni ti on coi l dwel l . The PCM al so adjusts the gener-
ator charge rate through control of the generator
fi el d and provi des speed control operati on.
NOTE: PCM Inputs:
ABS modul e (i f equi pped)
A/C request (i f equi pped wi th factory A/C)
A/C sel ect (i f equi pped wi th factory A/C)
A/C pressure transducer
Auto shutdown (ASD) sense
Battery temperature sensor
Battery vol tage
Brake swi tch
J1850 bus (+) ci rcui ts
J1850 bus (-) ci rcui ts
EATX modul e (i f equi pped)
Fuel l evel (through J1850 ci rcui try)
Generator (battery vol tage) output
I gni ti on ci rcui t sense (i gni ti on swi tch i n on/off/
crank/run posi ti on)
Knock sensors (2 on 3.7L engi ne)
Leak detecti on pump (swi tch) sense (i f equi pped)
Oi l pressure
Oxygen sensors
Park/neutral swi tch (auto. trans. onl y)
Power ground
Power steeri ng pressure swi tch (i f equi pped)
Sensor return
Si gnal ground
Speed control mul ti pl exed si ngl e wi re i nput
Throttl e posi ti on sensor
Transfer case swi tch (4WD range posi ti on)
Vehi cl e speed si gnal
NOTE: PCM Outputs:
A/C cl utch rel ay
Auto shutdown (ASD) rel ay
J1850 bus (+/-) ci rcui ts for: speedometer, vol tme-
ter, fuel gauge, oi l pressure gauge/l amp, engi ne temp.
gauge and speed control warn. l amp
EGR val ve control sol enoi d (i f equi pped)
EVAP cani ster purge sol enoi d
Fi ve vol t sensor suppl y (pri mary)
Fi ve vol t sensor suppl y (secondary)
Fuel i njectors
Fuel pump rel ay
Generator fi el d dri ver (-)
Generator fi el d dri ver (+)
I dl e ai r control (I AC) motor
I gni ti on coi l (s)
Leak detecti on pump (i f equi pped)
Mal functi on i ndi cator l amp (Check engi ne l amp).
Dri ven through J1850 ci rcui ts.
Oxygen sensor heater rel ays
Oxygen sensors (pul se wi dth modul ated)
Radi ator cool i ng fan rel ay (pul se wi dth modu-
l ated)
Speed control vacuum sol enoi d
Speed control vent sol enoi d
Tachometer (i f equi pped). Dri ven through J1850
ci rcui ts.
Transmi ssi on convertor cl utch ci rcui t. Dri ven
through J1850 ci rcui ts.
OPERATION - 5 VOLT SUPPLIES
Pri mary 5vol t suppl y:
suppl i es the requi red 5 vol t power source to the
Crankshaft Posi ti on (CKP) sensor.
Camshaft Posi ti on (CMP) sensor.
suppl i es a reference vol tage for the Mani fol d
Absol ute Pressure (MAP) sensor.
suppl i es a reference vol tage for the Throttl e
Posi ti on Sensor (TPS) sensor.
Secondary 5vol t suppl y:
oi l pressure sensor.
suppl i es the requi red 5 vol t power source for the
Vehi cl e Speed Sensor (VSS) (i f equi pped).
suppl i es the 5 vol t power source to the transmi s-
si on pressure sensor (certai n automati c transmi s-
si ons).
OPERATION - IGNITION CIRCUIT SENSE
The i gni ti on ci rcui t sense i nput tel l s the PCM the
i gni ti on swi tch has energi zed the i gni ti on ci rcui t.
Battery vol tage i s al so suppl i ed to the PCM
through the i gni ti on swi tch when the i gni ti on i s i n
the RUN or START posi ti on. Thi s i s referred to as
the i gni ti on sense ci rcui t and i s used to wake up
the PCM. Vol tage on the i gni ti on i nput can be as l ow
as 6 vol ts and the PCM wi l l sti l l functi on. Vol tage i s
suppl i ed to thi s ci rcui t to power the PCMs 8-vol t reg-
ul ator and to al l ow the PCM to perform fuel , i gni ti on
and emi ssi ons control functi ons.
REMOVAL
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
The PCM i s l ocated i n the engi ne compartment
attached to the dash panel (Fi g. 5).
To avoi d possi bl e vol tage spi ke damage to the
PCM, i gni ti on key must be off, and negati ve battery
cabl e must be di sconnected before unpl uggi ng PCM
connectors.
(2) Remove cover over el ectri cal connectors. Cover
snaps onto PCM.
(3) Careful l y unpl ug the three 32way connectors
(four 38way connectors i f equi pped wi th NGC) from
PCM (Fi g. 6).
(4) Remove three PCM mounti ng bol ts (Fi g. 6) and
remove PCM from vehi cl e.
INSTALLATION
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
(1) I nstal l PCM and 3 mounti ng bol ts to vehi cl e.
(2) Ti ghten bol ts. Refer to torque speci fi cati ons.
(3) Check pi n connectors i n the PCM and the three
32way connectors (four 38way connectors i f
equi pped wi th NGC) for corrosi on or damage. Al so,
the pi n hei ghts i n connectors shoul d al l be same.
Repai r as necessary before i nstal l i ng connectors.
(4) I nstal l three 32way connectors (four 38way
connectors i f equi pped wi th NGC).
(5) I nstal l cover over el ectri cal connectors. Cover
snaps onto PCM.
(6) I nstal l negati ve battery cabl e.
(7) The 5.7L V-8 engine is equipped with a
fully electronic accelerator pedal position sen-
sor. If equipped with a 5.7L, also perform the
following 3 steps:
(a) Connect negati ve battery cabl e to battery.
(b) Turn i gni ti on swi tch ON, but do not crank
engi ne.
(c) Leave i gni ti on swi tch ON for a mi ni mum of
10 seconds. Thi s wi l l al l ow PCM to l earn el ectri cal
parameters.
(d) The DRB I I I Scan Tool may al so be used to
l earn el ectri cal parameters. Go to the Mi scel l a-
neous menu, and then sel ect ETC Learn.
Fig. 5 PCM LOCATION
1 - COWL GRILL
2 - PCM
3 - COWL (RIGHT-REAR)
Fig. 6 PCM REMOVAL / INSTALLATION
1 - THREE 32-WAY CONNECTORS WITH JTEC (FOUR 38-WAY
CONNECTORS WITH NGC)
2 - PCM MOUNTING BRACKET
3 - PCM
4 - PCM MOUNTING SCREWS (3)
(8) I f the previ ous step i s not performed, a Di ag-
nosti c Troubl e Code (DTC) wi l l be set.
(9) I f necessary, use DRB I I I Scan Tool to erase
any Di agnosti c Troubl e Codes (DTCs) from PCM.
Al so use the DRB scan tool to reprogram new PCM
wi th vehi cl es ori gi nal Vehi cl e I denti fi cati on Number
(VI N) and ori gi nal vehi cl e mi l eage.
SENTRY KEY IMMOBILIZER
MODULE
DESCRIPTION
The Sentry Key I mmobi l i zer Modul e (SKI M) con-
tai ns a Radi o Frequency (RF) transcei ver and a cen-
tral processi ng uni t, whi ch i ncl udes the Sentry Key
I mmobi l i zer System (SKI S) program l ogi c. The SKI S
programmi ng enabl es the SKI M to program and
retai n i n memory the codes of at l east two, but no
more than ei ght el ectroni cal l y coded Sentry Key
transponders. The SKI S programmi ng al so enabl es
the SKI M to communi cate over the Programmabl e
Communi cati on I nterface (PCI ) bus network wi th the
Powertrai n Control Modul e (PCM) or El ectroni c Con-
trol Modul e (ECM), dependi ng on engi ne appl i cati on,
and/or the DRBI I I scan tool .
OPERATION
The SKI M transmi ts and recei ves RF si gnal s
through a tuned antenna encl osed wi thi n a mol ded
pl asti c ri ng that i s i ntegral to the SKI M housi ng.
When the SKI M i s properl y i nstal l ed on the steeri ng
col umn, the antenna ri ng i s ori ented around the i gni -
ti on l ock cyl i nder housi ng. Thi s antenna ri ng must be
l ocated wi thi n ei ght mi l l i meters (0.31 i nches) of the
Sentry Key i n order to ensure proper RF communi ca-
ti on between the SKI M and the Sentry Key tran-
sponder.
For added system securi ty, each SKI M i s pro-
grammed wi th a uni que Secret Key code and a
securi ty code. The SKI M keeps the Secret Key code
i n memory. The SKI M al so sends the Secret Key
code to each of the programmed Sentry Key tran-
sponders. The securi ty code i s used by the assembl y
pl ant to access the SKI S for i ni ti al i zati on, or by the
deal er techni ci an to access the system for servi ce.
The SKI M al so stores i n i ts memory the Vehi cl e
I denti fi cati on Number (VI N), whi ch i t l earns through
a PCI bus message from the PCM (NGC) or ECM
(Cummi ns) duri ng i ni ti al i zati on.
The SKI M and the PCM/ECM both use software
that i ncl udes a rol l i ng code al gori thm strategy, whi ch
hel ps to reduce the possi bi l i ty of unauthori zed SKI S
di sarmi ng. The rol l i ng code al gori thm ensures secu-
ri ty by preventi ng an overri de of the SKI S through
the unauthori zed substi tuti on of the SKI M or the
PCM/ECM. However, the use of thi s strategy al so
means that repl acement of ei ther the SKI M or the
PCM/ECM uni ts wi l l requi re a system i ni ti al i zati on
procedure to restore system operati on.
When the i gni ti on swi tch i s turned to the ON or
START posi ti ons, the SKI M transmi ts an RF si gnal
to exci te the Sentry Key transponder. The SKI M then
l i stens for a return RF si gnal from the transponder
of the Sentry Key that i s i nserted i n the i gni ti on l ock
cyl i nder. I f the SKI M recei ves an RF si gnal wi th
val i d Secret Key and transponder i denti fi cati on
codes, the SKI M sends a val i d key message to the
PCM/ECM over the PCI bus. I f the SKI M recei ves an
i nval i d RF si gnal or no response, i t sends i nval i d
key messages to the PCM/ECM. The PCM/ECM wi l l
enabl e or di sabl e engi ne operati on based upon the
status of the SKI M messages.
The SKI M al so sends messages to the I nstrument
Cl uster whi ch control s the VTSS i ndi cator LED. The
SKI M sends messages to the I nstrument Cl uster to
turn the LED on for about three seconds when the
i gni ti on swi tch i s turned to the ON posi ti on as a bul b
test. After compl eti on of the bul b test, the SKI M
sends bus messages to keep the LED off for a dura-
ti on of about one second. Then the SKI M sends mes-
sages to turn the LED on or off based upon the
resul ts of the SKI S sel f-tests. I f the VTSS i ndi cator
LED comes on and stays on after the bul b test, i t
i ndi cates that the SKI M has detected a system mal -
functi on and/or that the SKI S has become i nopera-
ti ve.
I f the SKI M detects an i nval i d key when the i gni -
ti on swi tch i s turned to the ON posi ti on, i t sends
messages to fl ash the VTSS i ndi cator LED. The
SKI M can al so send messages to fl ash the LED as an
i ndi cati on to the customer that the SKI S has been
pl aced i n i ts Customer Learn programmi ng mode.
See Sentry Key I mmobi l i zer System Transponder
Programmi ng i n thi s secti on for more i nformati on on
the Customer Learn programmi ng mode.
For di agnosi s or i ni ti al i zati on of the SKI M and the
PCM/ECM, a DRBI I I scan tool and the proper Pow-
ertrai n Di agnosti c Procedures manual are requi red.
The SKI M cannot be repai red and, i f faul ty or dam-
aged, the uni t must be repl aced.
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING
NOTE: There are two procedures for transfering the
secret key to the SKIM:
When ONLY the SKIM module is replaced, the
secret key is transfered from the PCM (NGC- gaso-
line engine) or ECM (Cummins - diesel engine) to
the SKIM. The ORGINAL KEYS may then be pro-
grammed to the SKIM.
When ONLY the PCM/ECM is replaced, then the
secret key is transfered from the SKIM to the PCM/
ECM. The ORGINAL KEYS may be used.
When BOTH the SKIM and the PCM/ECM are
replaced the secret key is transferred from the
SKIM to the PCM/ECM, and NEW KEYS must be
programmed.
NOTE: Before replacing the PCM/ECM (depending
on engine application), for a failed driver, control
circuit, or ground circuit, be sure to check the
related component/circuit integrity for failures not
detected due to a double fault in the circuit. Most
PCM/ECM driver/control circuit failures are caused
by internal component failures (i.e. relay and sole-
noids) and shorted circuits (i.e. pull-ups, drivers
and switched circuits). These failures are difficult to
detect when a double fault has occurred and only
one Diagnostic Trouble Code (DTC) has set.
When a PCM/ECM and the Sentry Key I mmobi -
l i zer Modul e (SKI M) are repl aced at the same ti me
perform the fol l owi ng steps i n order:
(1) Program the new PCM/ECM.
(2) Program the new SKI M.
(3) Repl ace al l i gni ti on keys and program them to
the new SKI M.
PROGRAMMING THE PCM (NGC) or ECM
(CUMMINS)
The Sentry Key I mmobi l i zer System (SKI S) Secret
Key i s an I D code that i s uni que to each SKI M. Thi s
code i s programmed and stored i n the SKI M, PCM/
ECM and transponder chi p (i gni ti on keys). When
repl aci ng the PCM/ECM i t i s necessary to program
the secret key i nto the new PCM/ECM usi ng the
DRBI I I scan tool . Perform the fol l owi ng steps to
program the secret key i nto the PCM/ECM.
(1) Turn the i gni ti on swi tch on (transmi ssi on i n
park/neutral ).
(2) Use the DRBI I I scan tool and sel ect THEFT
ALARM, SKI M then MI SCELLANEOUS.
(3) Sel ect PCM REPLACED (GAS ENGI NE) or
CUMMI NS ECM REPLACED (DI ESEL ENGI NE).
(4) Enter secured access mode by enteri ng the
vehi cl e four-di gi t PI N.
(5) Sel ect ENTER to update PCM/ECM VI N.
NOTE: If three attempts are made to enter secure
access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To
exit this lockout mode, turn the ignition to the RUN
position for one hour then enter the correct PIN.
(Ensure all accessories are turned OFF. Also moni-
tor the battery state and connect a battery charger
if necessary).
(6) Press ENTER to transfer the secret key (the
SKI M wi l l send the secret key to the PCM/ECM).
(7) Press Page Back to get to the Sel ect System
menu and sel ect ENGI NE, MI SCELLANEOUS, and
SRI MEMORY CHECK.
(8) On gasol i ne engi ne appl i cati ons (NGC), the
DRBI I I scan tool wi l l ask, I s odometer readi ng
between XX and XX? Sel ect the YES or NO button on
the DRB I I I scan tool . I f NO i s sel ected, the
DRBI I I scan tool wi l l read, Enter odometer
Readi ng<From I .P. odometer>. Enter the odometer
readi ng from the i nstrument cl uster and press
ENTER.
PROGRAMMING THE SKIM
park/neutral ).
(3) Sel ect SKI M REPLACED.
(4) Program the vehi cl e four-di gi t PI N i nto SKI M.
(5) Sel ect COUNTRY CODE and enter the correct
country.
NOTE: Be sure to enter the correct country code. If
the incorrect country code is programmed into the
SKIM, the SKIM must be replaced.
(6) Sel ect YES to update the VI N (the SKI M wi l l
l earn the VI N from the PCM/ECM).
(7) Press ENTER to transfer the secret key (the
PCM/ECM wi l l send the secret key i nformati on to
the SKI M).
(8) Program i gni ti on keys to the SKI M.
NOTE: If the PCM/ECM and the SKIM are replaced
at the same time, all vehicle keys will need to be
replaced and programmed to the new SKIM.
PROGRAMMING IGNITION KEYS TO THE SKIM
park/neutral ).
SENTRY KEY IMMOBILIZER MODULE (Continued)
(3) Sel ect PROGRAM I GNI TI ON KEYS.
(4) Enter secured access mode by enteri ng the
vehi cl e four-di gi t PI N.
NOTE: A maximum of eight keys can be learned to
each SKIM. Once a key is learned to a SKIM, it (the
key) cannot be transferred to another vehicle.
(5) I f i gni ti on key programmi ng i s unsuccessful ,
the DRBI I I scan tool wi l l di spl ay one of the fol l ow-
i ng messages:
(a) Programmi ng Not Attempted - The DRBI I I
scan tool attempts to read the programmed key
status and there are no keys programmed i nto
SKI M memory.
(b) Programmi ng Key Fai l ed (Possi bl e Used Key
From Wrong Vehi cl e) - SKI M i s unabl e to program
key due to one of the fol l owi ng:
Faul ty i gni ti on key transponder.
I gni ti on key i s programmed to another vehi cl e.
(c) 8 Keys Al ready Learned, Programmi ng Not
Done - SKI M transponder I D memory i s ful l .
(6) Obtai n i gni ti on keys to be programmed from
customer (8 keys maxi mum).
(7) Usi ng the DRBI I I scan tool , erase al l i gni ti on
keys by sel ecti ng MI SCELLANEOUS and ERASE
ALL CURRENT I GN. KEYS.
(8) Program al l i gni ti on keys.
Learned Key I n I gni ti on - I gni ti on key transponder
I D i s currentl y programmed i n SKI M memory.
REMOVAL
INJURY.
cabl e.
(2) Remove upper and l ower covers (shrouds) from
steeri ng col umn.
(3) Di sconnect the steeri ng col umn wi re harness
connector from the Sentry Key I mmobi l i zer Modul e
(SKI M)
(4) Remove the screw that secures the SKI M to
the steeri ng col umn (Fi g. 7).
(5) Rel ease the SKI M antenna ri ng retai ni ng cl i ps
from around the i gni ti on swi tch l ock cyl i nder housi ng
and remove the SKI M.
INSTALLATION
NOTE: If the SKIM is replaced with a new unit, a
DRBIII scan tool MUST be used to initialize the
new SKIM and to program at least two Sentry Key
transponders before the vehicle can be operated
(Refer to 8 - ELECTRICAL/VEHICLE THEFT SECU-
RITY - STANDARD PROCEDURE).
(1) Posi ti on the SKI M antenna ri ng around the
i gni ti on swi tch l ock cyl i nder housi ng.
(2) I nstal l the SKI M antenna ri ng retai ni ng cl i ps.
(3) I nstal l the screw that secures the SKI M to the
steeri ng col umn.
(4) Connect the steeri ng col umn wi re harness con-
nector to the SKI M.
(5) Posi ti on both the upper and l ower shrouds onto
the steeri ng col umn.
(6) I nstal l and ti ghten the screws that secure the
l ower steeri ng col umn shroud to the upper shroud.
Ti ghten the screws to 2 Nm (18 i n. l bs.).
Fig. 7 Sentry Key Immobilizer Module (SKIM)
1 - SENTRY KEY IMMOBILIZER MODULE (SKIM)
2 - STEERING COLUMN
3 - SCREW
4 - WIRING HARNES
SENTRY KEY IMMOBILIZER MODULE (Continued)
TRANSFER CASE CONTROL
MODULE
DESCRIPTION
The Transfer Case Control Modul e (TCCM) (Fi g. 8)
i s a mi croprocessor-based assembl y, control l i ng the
4X4 transfer case shi ft functi ons vi a the actuati on of
a shi ft motor and uti l i zi ng the feedback of a mode
sensor assembl y. Communi cati on i s vi a the PCI seri al
bus. I nputs i ncl ude user sel ectabl e 4X4 modes that
i ncl ude 2WD, AWD, 4HI , 4LO, and Neutral . The l ogi c
and dri ver ci rcui try i s contai ned i n a mol ded pl asti c
housi ng wi th an embedded heat-si nk and i s l ocated
behi nd the l eft si de of the l ower i nstrument panel .
OPERATION
The Transfer Case Control Modul e (TCCM) uti l i zes
the i nput from the transfer case mounted mode sen-
sor, the i nstrument panel mounted sel ector swi tch,
and the fol l owi ng i nformati on from the vehi cl es PCI
seri al bus to determi ne i f a shi ft i s al l owed.
Engi ne RPM and Vehi cl e Speed
Di agnosti c Requests
Manual Transmi ssi on and Brake Appl i ed
PRNDL
I gni ti on Status
ABS Messages
Once the TCCM determi nes that a requested shi ft
i s al l owed, i t actuates the bi -di recti onal shi ft motor
as necessary to achi eve the desi red transfer case
operati ng mode. The TCCM al so moni tors the mode
sensor whi l e control l i ng the shi ft motor to determi ne
the status of the shi ft attempt.
Several i tems can cause the requested shi ft not to
be compl eted. I f the TCCM has recogni zed a faul t
(DTC) of some vari ety, i t wi l l begi n operati on i n one
of four Functi onal i ty Level s. These l evel s are:
Level Zero - Normal Operati on.
Level One - Onl y Mode Shi fts Are Al l owed.
Level Two - Onl y Mode Shi fts and Shi fts I nto
LOW Are Al l owed (No Neutral Shi fts Are Al l owed).
Level Three - No Shi fts Are Al l owed
The TCCM can al so be operati ng i n one of three
possi bl e power modes. These power modes are:
Full Power Mode i s the normal operati onal
mode of the modul e. Thi s mode i s achi eved by normal
PCI bus traffi c bei ng present and the i gni ti on bei ng
i n the RUN posi ti on.
Reduced Power Mode wi l l be entered when
the i gni ti on has been powered off. I n thi s state, the
modul e wi l l shut down power suppl i ed to external
devi ces, and to el ectroni c i nterface i nputs and out-
puts. From thi s state the modul e can enter ei ther
Sl eep Mode or Ful l Power Mode. To enter thi s mode,
the modul e must recei ve an i gni ti on message denot-
i ng that the i gni ti on i s off, or not recei ve any mes-
sages for 5 0.5 seconds. To exi t thi s mode, the
modul e must recei ve one i gni ti on message that
denotes that the i gni ti on i s i n the RUN posi ti on.
Sleep Mode wi l l be entered, from the Reduced
Power Mode, when no PCI traffi c has been sensed for
20 1 seconds. I f duri ng Sl eep Mode the modul e
detects PCI bus traffi c, i t wi l l revert to the Reduced
Power mode whi l e moni tori ng for i gni ti on messages.
I t wi l l remai n i n thi s state as l ong as there i s traffi c
other than run or start messages, and wi l l return to
Sl eep mode i f the bus goes wi thout traffi c for 20 1
seconds.
SHIFT REQUIREMENTS
I f the TCCM i s i n ful l power mode and at functi on-
al i ty l evel zero, i t uses the fol l owi ng cri teri a to deter-
mi ne i f a shi ft i s al l owed.
I f any of the dri ver control l abl e condi ti ons are not
met once the shi ft request i s recogni zed, the TCCM
wi l l sol i dl y i l l umi nate the source posi ti ons LED and
fl ash the desi red posi ti ons LED for al l shi fts except
NEUTRAL. The NEUTRAL shi ft LED strategy wi l l
be di scussed l ater.
Mode shifts wi l l be al l owed regardl ess of trans-
mi ssi on gear or vehi cl e speed, whenever the fol l owi ng
condi ti ons are met:
Front and rear wheel speed are wi thi n 21 km/hr
(13 mph).
A change i n the Sel ector swi tch state i ndi cates
that a mode shi ft has been requested.
A val i d mode sensor si gnal i s bei ng sensed by
the TCCM.
Fig. 8 Transfer Case Control Module (TCCM)
Location
2 - TRANSFER CASE CONTROL MODULE (TCCM)
3 - TRANSFER CASE SELECTOR SWITCH
Proper transmi t/recei ve messages are occurri ng
on the PCI bus.
I gni ti on key swi tch i s i n the RUN posi ti on.
Range shifts wi l l be al l owed onl y i f al l of the fol -
l owi ng condi ti ons are met:
(13 mph).
A change i n the Sel ector Swi tch state i ndi cati ng
a range shi ft has been requested.
Transmi ssi on i n NEUTRAL si gnal must be rec-
ogni zed for at l east 1.5 seconds 100 msec. (Auto-
mati c transmi ssi ons onl y)
Proper transmi t/recei ve messages are occurri ng
on the PCI bus.
Cl utch si gnal i s recogni zed for 500 msec 50
msec (Manual transmi ssi ons onl y).
Vehi cl e speed i s l ess than or equal to 4.8 km/hr
(3 mi l es per hour).
the TCCM.
A shift into transfer case Neutral wi l l be
al l owed onl y i f al l of the fol l owi ng condi ti ons are met:
(13 mph).
The recessed Neutral Sel ecti on swi tch has been
depressed conti nuousl y for 4.0 seconds 100 msec
whi l e al l shi ft condi ti ons have been conti nuousl y met.
Transmi ssi on i n NEUTRAL si gnal recogni zed
from the bus. (Automati c transmi ssi ons onl y)
Cl utch si gnal i s recogni zed from the bus (Man-
ual transmi ssi ons onl y).
Proper message transmi ssi ons/recepti ons are
occurri ng on the PCI bus.
I gni ti on key swi tch i s i n the RUN posi ti on,
engi ne off.
Foot Brake i s appl i ed.
the TCCM.
A shift out of transfer case Neutral wi l l be
al l owed onl y i f al l of the fol l owi ng condi ti ons are met:
(13 mph).
The recessed Neutral Sel ecti on swi tch has been
depressed conti nuousl y for 1.0 seconds 100 msec
whi l e al l shi ft condi ti ons have been conti nuousl y met.
Transmi ssi on i n NEUTRAL si gnal recogni zed
from the bus.(Automati c transmi ssi ons onl y)
Cl utch si gnal i s recogni zed from the bus (Man-
ual transmi ssi ons onl y).
Proper message transmi ssi ons/recepti ons are
occurri ng on the PCI bus.
Foot Brake i s appl i ed.
the TCCM.
SHIFT SEQUENCES
Once al l the dri ver control l abl e condi ti ons for the
requested shi ft have been met, the TCCM begi ns a
shi ft ti mer wi th a maxi mum durati on of 1 second per
D channel transi ti on. I f the shi ft ti mer expi res
before the TCCM recogni zes to correct mode sensor
code, the shi ft i s consi dered to have been bl ocked.
The bl ocked shi ft wi l l i ncrement the bl ocked shi ft
counter by one. The TCCM strategy for handl i ng
bl ocked shi fts wi l l be descri bed l ater. The process the
TCCM performs for the vari ous shi fts wi l l be
descri bed fi rst.
RANGE AND MODE SHIFTS
The process for performi ng al l the range and mode
shi fts are the same. The fol l owi ng steps descri be the
process.
Al l ow ti me for Sel ector Swi tch debounce; 250
msec 50 msec.
Exti ngui sh the source gears LED whi l e fl ashi ng
desi red transfer case posi ti ons LED.
Engage the shi ft motor for a maxi mum of 1 sec-
ond 100 msec per D channel transi ti on i n the des-
ti nati on gears di recti on whi l e moni tori ng the mode
sensor channel transi ti ons.
Di sengage the shi ft motor when the correct
mode sensor code i s recogni zed.
Sol i dl y i l l umi nate the sel ected gears LED.
Transmi t a bus message that the transfer case
shi ft i s compl ete.
I f the desi red mode sensor code i s not recei ved
after the shi ft ti mer expi res (i e. a bl ocked or other
condi ti on exi sts), stop dri vi ng the motor and wai t for
200 msec 50 msec. The shi ft motor i s then reversed
i n the di recti on back toward the source gear for up to
1.0 seconds 100 msec. per D channel . The TCCM
wai ts for 2.0 seconds 50 msec. and repeats the
attempt to shi ft to the desi red posi ti on.
The excepti on to the precedi ng sequence i s when a
shi ft from 4L to 2WD/AWD i s requested. I f 2WD/
AWD i s requested from the 4L posi ti on, the transfer
case i s fi rst dri ven to the 4H posi ti on. I f the 4H posi -
ti on i s reached, the transfer case i s then dri ven back
to the 2WD/AWD posi ti on and the shi ft i s consi dered
compl ete. I f the transfer case does not reach any the
4H posi ti on, but i s i n the 2WD/AWD D channel , or
the 2WD/AWD between gear posi ti on on the 4H si de
of 2WD/AWD, the shi ft i s al so consi dered compl ete.
TRANSFER CASE CONTROL MODULE (Continued)
SHIFT OUT OF NEUTRAL
The fol l owi ng steps descri be the process for a shi ft
out of NEUTRAL.
Exti ngui sh the Neutral LED.
Engage the shi ft motor for a maxi mum of 1 sec-
ond 100 msec toward the transfer case 4H mode
posi ti on whi l e moni tori ng the mode sensor channel
transi ti ons.
Di sengage the shi ft motor when the correct
mode sensor code i s recogni zed.
Exti ngui sh the Neutral LED.
Transmi t a bus message that the transfer case
shi ft i s compl ete.
after the shi ft ti mer expi res (i e. a bl ocked or other
condi ti on exi sts), stop dri vi ng the motor and wai t for
200 msec 50 msec. The shi ft motor i s then reversed
i n the di recti on back toward the source gear for up to
1.0 seconds 100 msec. The TCCM wai ts for 2.0 sec-
onds 50 msec. and repeats the attempt to shi ft to
the desi red posi ti on.
When the Neutral button i s rel eased, i f the 4H
posi ti on i s the desi red posi ti on, the shi ft i s compl ete.
I l l umi nate the 4H LED.
Otherwi se when the Neutral button i s rel eased,
i f al l of the shi ft requi rements are bei ng met then
engage the shi ft motor towards the desi red posi ti on
for 1 second 100 msec per D channel . (i f requi re-
ments for shi fti ng are not met, i l l umi nate the 4H
LED and fl ash the desti nati on LED as an i ndi cati on
to the dri ver that al l of the dri ver control l abl e shi ft
condi ti ons are not bei ng met). I f thi s requi res
another range or mode shi ft, begi n the range/mode
shi ft process.
after the shi ft ti mer expi res (i .e. a bl ocked or other
condi ti on exi sts), refer to the secti on on Bl ocked Shi ft
Strategy.
BLOCKED SHIFT STRATEGY
When a shi ft i s commanded, the shi ft motor wi l l be
dri ven towards i ts desti nati on posi ti on, except i n the
case of shi fti ng out of Neutral i f 4L was sel ected (the
transfer case wi l l shi ft to the 4H posi ti on fi rst, before
proceedi ng to 4L). I f the shi ft i s bl ocked on the way
to the desti nati on, the TCCM may attempt to dri ve
the motor back to the ori gi nal posi ti on. Thi s process
wi l l be al l owed to occur 5 ti mes. I f the transfer case
has reached a non-NEUTRAL D channel duri ng the
shi ft re-attempts, the LED for the achi eved gear posi -
ti on i s i l l umi nated and the shi ft attempts are
stopped. To re-attempt the desi red shi ft, the sel ector
swi tch wi l l need to be rotated to the current posi ti on
unti l the swi tch debounce ti mer expi res then a shi ft
wi l l need to be requested agai n.
At the end of the 5th bl ocked attempt, the shi ft
motor i s dri ven towards the l ast known D channel
posi ti on. I f thi s motor dri ve al l ows the transfer case
to reach the 2WD/AWD D channel , or the 2WD/AWD
between gear posi ti on on the 4H si de of 2WD/AWD,
the shi ft i s consi dered compl ete and the shi ft
attempts are ended.
I f the mode sensor i s i n the NEUTRAL regi on at
the expi rati on of the shi ft ti mer, the TCCM wi l l con-
ti nue to make the shi ft attempts accordi ng to the
bl ocked shi ft strategy i ndependent of whether or not
the dri ver control l ed condi ti ons are met.
For shi fts from NEUTRAL, i f al l 5 attempts fai l to
reach the desi red posi ti on (whi ch by defaul t i s 4H),
the motor wi l l be dri ven to stal l i n the di recti on of
4H or 4L, dependi ng on the achi eved posi ti on. I f the
transfer case has reached the 2WD/AWD or 4L
between gear posi ti on nearest the NEUTRAL posi -
ti ons and the shi ft condi ti ons are no l onger bei ng
met, the transfer case wi l l be dri ven toward the cor-
respondi ng D channel . Otherwi se, the transfer case
wi l l be dri ven i n the di recti on opposi te the l ast
attempt wi th the desi red target bei ng 4H or 4L.
I f the transfer case reaches the 2WD/AWD D
channel when bei ng dri ven i n the 4H di recti on, then
one fi nal 1.0 second dri ve toward 4H i s attempted. I f
the transfer case then reaches any of the 4H posi -
ti ons, the shi ft i s consi dered compl ete and the 4H
LED i s i l l umi nated. I f the transfer case i s sti l l the
2WD/AWD posi ti on, the shi ft i s consi dered compl ete
and the 2WD/AWD LED i s i l l umi nated.
NOTE: If after the 5th blocked shift and reversal
attempt, if the transfer case position is in the NEU-
TRAL region, shift attempts will continue until a
non-NEUTRAL D channel is reached.
SHIFT REVERSAL TARGETS
I f the shi ft ti mer expi res (1 second per D channel )
and the transfer case has not reached the desi red
posi ti on, al l shi fts wi l l attempt to return to thei r
ori gi nal posi ti on wi th the excepti ons of:
I f the i ntended shi ft i s goi ng to the Hi gh rai l
from Low and cant make i t, but i t can make the
2WD/AWD posi ti on, the motor stops at that posi ti on.
The TCCM wi l l not attempt to cross back over NEU-
TRAL i f i t does not have to. Thi s means that there
was a bl ock on the fi rst attempt to go to 4H and the
transfer case has made i t through NEUTRAL to a
known good posi ti on, then the motor wi l l go back
onl y to the 2WD/4WD posi ti on and execute the
remai nder of the attempts from there.
For shi fts out of NEUTRAL, any ti me a shi ft i s
commanded out of NEUTRAL, the system needs to
get out. The TCCM shoul d never go to NEUTRAL
unl ess the dri ver i s commandi ng i t and al l requi red
condi ti ons are bei ng met
ENCODER DRIFT CORRECTION
Whenever a shi ft i s compl eted, the TCCM stores
the posi ti on i n memory as the transfer cases
i ntended posi ti on. The TCCM conti nuousl y moni tors
the mode sensor and i f the mode sensor dri fts toward
i nto a NEUTRAL regi on sensor posi ti on for 2.0 sec-
onds, the TCCM wi l l perform a motor dri ve to correct
the dri ft. The transfer case wi l l be dri ven toward the
i ntended posi ti on for 1.0 seconds 100 msec. The
TCCM wi l l wai t for 2.0 seconds 50 msec. and repeat
the attempt to shi ft to the desi red posi ti on. Thi s wi l l
conti nue unti l the i ntended posi ti on i s reached.
SHIFT MOTOR BRAKING
Two modes of shi ft motor braki ng are empl oyed to
i mprove shi ft performance, stati c and dynami c. Stati c
shi ft motor braki ng i s uti l i zed under the fol l owi ng
condi ti ons:
Whenever the transfer case i s i n the 2WD/AWD
or 4L D channel posi ti on.
Whenever an i nval i d mode sensor code i s
present.
Stati c motor braki ng i s achi eved by appl yi ng +12V
on both shi ft motor wi res.
NOTE: Static Shift Motor Braking is independent of
ignition key position.
SHIFT ATTEMPT LIMIT
To protect the transfer case system, the TCCM wi l l
i mpose a l i mi t on the number of shi fts that can occur
over a cal i brated ti me peri od. The system wi l l moni -
tor the number of D channel segment transi ti ons
that occur i n any 30 second ti me peri od. I f the num-
ber of segment transi ti ons i s 30 or greater, the sys-
tem wi l l go i nto a defaul t mode. The defaul t mode of
operati on for shi fti ng i s that the number of al l owed
D channel transi ti ons permi tted to occur wi l l be 3
over each 15 second 100 msec cal i brated wi ndow of
ti me. After 5 mi nutes 100 msec, the motor can be
assumed to have cool ed down and the system wi l l
revert to normal operati on. The fol l owi ng rul es al so
appl y to the shi ft l i mi t:
The attempt l i mi t wi l l not prevent shi fts comi ng
out of NEUTRAL, they wi l l be al l owed regardl ess of
the counter/ti mer.
Any shi ft that i s i n progress when the counter
reaches a maxi mum count i n ti me wi l l be al l owed to
compl ete before the defaul t mode i s entered. D-chan-
nel transi ti ons duri ng thi s peri od wi l l not be counted
towards the defaul t mode l i mi t.
A bl ock, regardl ess of the di recti on, whether
towards desti nati on or back towards reversal target
(shi ft ti mer expi ri ng), wi l l count as a val ue of 2 tran-
si ti ons towards the 30 segment transi ti ons to go i nto
defaul t mode as defi ned above. Current attempt l i mi t
val ues are 30 transi ti ons i n 30 seconds and defaul t
mode val ues are 3 transi ti ons every 15 seconds for 5
mi nutes.
TRANSMISSION CONTROL
MODULE
DESCRIPTION
The Transmi ssi on Control Modul e (TCM) (Fi g. 9)
may be sub-modul e wi thi n the Powertrai n Control
Modul e (PCM), Engi ne Control Modul e (ECM - Di esel
onl y) (Fi g. 10), or a standal one modul e, dependi ng on
the vehi cl e engi ne. The PCM, and TCM when
equi pped, i s l ocated at the ri ght rear of the engi ne
compartment, near the ri ght i nner fender.
OPERATION
The Transmi ssi on Control Modul e (TCM) control s
al l el ectroni c operati ons of the transmi ssi on. The
TCM recei ves i nformati on regardi ng vehi cl e opera-
ti on from both di rect and i ndi rect i nputs, and sel ects
the operati onal mode of the transmi ssi on. Di rect
i nputs are hardwi red to, and used speci fi cal l y by the
TCM. I ndi rect i nputs are shared wi th the TCM vi a
the vehi cl e communi cati on bus.
Some exampl es of direct inputs to the TCM are:
Battery (B+) vol tage
I gni ti on ON vol tage
Transmi ssi on Control Rel ay (Swi tched B+)
Throttl e Posi ti on Sensor
Crankshaft Posi ti on Sensor
Transmi ssi on Range Sensor
Pressure Swi tches
Transmi ssi on Temperature Sensor
I nput Shaft Speed Sensor
Output Shaft Speed Sensor
Li ne Pressure Sensor
Some exampl es of indirect inputs to the TCM
are:
Engi ne/Body I denti fi cati on
Mani fol d Pressure
Target I dl e
Torque Reducti on Confi rmati on
Engi ne Cool ant Temperature
Ambi ent/Battery Temperature
DRBI I I Scan Tool Communi cati on
Based on the i nformati on recei ved from these var-
i ous i nputs, the TCM determi nes the appropri ate
shi ft schedul e and shi ft poi nts, dependi ng on the
present operati ng condi ti ons and dri ver demand.
Thi s i s possi bl e through the control of vari ous di rect
and i ndi rect outputs.
Some exampl es of TCM direct outputs are:
Transmi ssi on Control Rel ay
Sol enoi ds
Torque Reducti on Request
Some exampl es of TCM indirect outputs are:
Transmi ssi on Temperature (to PCM)
PRNDL Posi ti on (to BCM)
I n addi ti on to moni tori ng i nputs and control l i ng
outputs, the TCM has other i mportant responsi bi l i -
ti es and functi ons:
Stori ng and mai ntai ni ng Cl utch Vol ume I ndexes
(CVI )
Stori ng and sel ecti ng appropri ate Shi ft Sched-
ul es
System sel f-di agnosti cs
Fig. 9 PCM/TCM Location
1 - RIGHT FENDER
2 - TRANSMISSION CONTROL MODULE
3 - POWERTRAIN CONTROL MODULE
Fig. 10 Diesel ECM
1 - ENGINE CONTROL MODULE (ECM)
2 - ECM MOUNTING BOLT
4 - SUPPORT PLATE
Di agnosti c capabi l i ti es (wi th DRBI I I scan tool )
NOTE: If the TCM has been replaced, the Quick
Learn Procedure must be performed. (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
BATTERY FEED
A fused, di rect battery feed to the TCM i s used for
conti nuous power. Thi s battery vol tage i s necessary
to retai n memory i n the TCM. When the battery (B+)
i s di sconnected, thi s memory i s l ost. When the bat-
tery (B+) i s restored, thi s memory l oss i s detected by
the TCM and a Di agnosti c Troubl e Code (DTC) i s set.
CLUTCH VOLUME INDEXES (CVI)
An i mportant functi on of the TCM i s to moni tor
Cl utch Vol ume I ndexes (CVI ). CVI s represent the vol -
ume of fl ui d needed to compress a cl utch pack.
The TCM moni tors gear rati o changes by moni tor-
i ng the I nput and Output Speed Sensors. The I nput,
or Turbi ne Speed Sensor sends an el ectri cal si gnal to
the TCM that represents i nput shaft rpm. The Out-
put Speed Sensor provi des the TCM wi th output
shaft speed i nformati on.
By compari ng the two i nputs, the TCM can deter-
mi ne transmi ssi on gear posi ti on. Thi s i s i mportant to
the CVI cal cul ati on because the TCM determi nes
CVI s by moni tori ng how l ong i t takes for a gear
change to occur (Fi g. 11).
Gear rati os can be determi ned by usi ng the
DRBI I I Scan Tool and readi ng the I nput/Output
Speed Sensor val ues i n the Moni tors di spl ay. Gear
rati o can be obtai ned by di vi di ng the I nput Speed
Sensor val ue by the Output Speed Sensor val ue.
For exampl e, i f the i nput shaft i s rotati ng at 1000
rpm and the output shaft i s rotati ng at 500 rpm,
then the TCM can determi ne that the gear rati o i s
2:1. I n di rect dri ve (3rd gear), the gear rati o changes
to 1:1. The gear rati o changes as cl utches are appl i ed
and rel eased. By moni tori ng the l ength of ti me i t
takes for the gear rati o to change fol l owi ng a shi ft
request, the TCM can determi ne the vol ume of fl ui d
used to appl y or rel ease a fri cti on el ement.
The vol ume of transmi ssi on fl ui d needed to appl y
the fri cti on el ements are conti nuousl y updated for
adapti ve control s. As fri cti on materi al wears, the vol -
ume of fl ui d need to appl y the el ement i ncreases.
Certai n mechani cal probl ems wi thi n the i nput
cl utch assembl y can cause i nadequate or out-of-range
el ement vol umes. Al so, defecti ve I nput/Output Speed
Sensors and wi ri ng can cause these condi ti ons. The
fol l owi ng chart i denti fi es the appropri ate cl utch vol -
umes and when they are moni tored/updated:
CLUTCH VOLUMES
Clutch When Updated
Proper Clutch
Volume
L/R
2-1 or 3-1
downshift
45 to 134
2C
3-2 kickdown
shift
25 to 85
OD 2-3 upshift 30 to 100
4C 3-4 upshift 30 to 85
UD
4-3 kickdown
shift
30 to 100
Fig. 11 Example of CVI Calculation
1 - OUTPUT SPEED SENSOR
2 - OUTPUT SHAFT
3 - CLUTCH PACK
4 - SEPARATOR PLATE
5 - FRICTION DISCS
6 - INPUT SHAFT
7 - INPUT SPEED SENSOR
8 - PISTON AND SEAL
TRANSMISSION CONTROL MODULE (Continued)
SHIFT SCHEDULES
As menti oned earl i er, the TCM has programmi ng
that al l ows i t to sel ect a vari ety of shi ft schedul es.
Shi ft schedul e sel ecti on i s dependent on the fol l ow-
i ng:
Shi ft l ever posi ti on
Throttl e posi ti on
Engi ne l oad
Fl ui d temperature
Software l evel
As dri vi ng condi ti ons change, the TCM appropri -
atel y adjusts the shi ft schedul e. Refer to the fol l ow-
i ng chart to determi ne the appropri ate operati on
expected, dependi ng on dri vi ng condi ti ons.
Schedule Condition Expected Operation
Extreme Cold Oil temperature below -16F -Park, Reverse, Neutral and 1st and
3rd gear only in D position, 2nd
gear only in Manual 2 or L
-No EMCC
Super Cold Oil temperature between -12F and
10F
- Delayed 2-3 upshift
- Early 4-3 coastdown shift
- High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
-Shifts at high throttle openings willl
be early.
- No EMCC
Cold Oil temperature between 10F and
36F
-Shift schedule is the same as
Super Cold except that the 2-3
upshifts are not delayed.
Warm Oil temperature between 40F and
80F
- Normal operation (upshift,
kickdowns, and coastdowns)
- No EMCC
Hot Oil temperature between 80F and
240F
- Normal operation (upshift,
kickdowns, and coastdowns)
- Normal EMCC operation
Overheat Oil temperature above 240F or
engine coolant temperature above
244F
- 3rd gear FEMCC from 30-48 mph
- 3rd gear PEMCC above 35 mph
- Above 25 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
STANDARD PROCEDURE
STANDARD PROCEDURE - TCM QUICK LEARN
The qui ck l earn procedure requi res the use of the
DRB scan tool .
Thi s program al l ows the el ectroni c transmi ssi on
system to recal i brate i tsel f. Thi s wi l l provi de the
proper transmi ssi on operati on. The qui ck l earn pro-
cedure shoul d be performed i f any of the fol l owi ng
procedures are performed:
Transmi ssi on Assembl y Repl acement
Transmi ssi on Control Modul e Repl acement
Sol enoi d Pack Repl acement
Cl utch Pl ate and/or Seal Repl acement
Val ve Body Repl acement or Recondi ti on
To perform the Qui ck Learn Procedure, the fol l ow-
i ng condi ti ons must be met:
The brakes must be appl i ed
The engi ne speed must be above 500 rpm
The throttl e angl e (TPS) must be l ess than 3
degrees
The shi ft l ever posi ti on must stay i n PARK unti l
prompted to shi ft to overdri ve
The shi ft l ever posi ti on must stay i n overdri ve
after the Shi ft to Overdri ve prompt unti l the DRB
i ndi cates the procedure i s compl ete
The cal cul ated oi l temperature must be above
60 and bel ow 200
STANDARD PROCEDURE - DRIVE LEARN
When a transmi ssi on i s repai red and a Qui ck
Learn procedure has been performed on the Trans-
mi ssi on Control Modul e (TCM), the fol l owi ng Dri ve
Learn procedure can be performed to fi ne tune any
shi fts whi ch are parti cul arl y objecti onabl e.
NOTE: It is not necessary to perform the complete
Drive Learn procedure every time the TCM is Quick
Learned. Perform only the portions which target the
objectionable shift.
LEARN A SMOOTH 1ST NEUTRAL TO DRIVE SHIFT
Perform thi s procedure onl y i f the compl ai nt i s for
a del ayed or harsh shi ft the fi rst ti me the transmi s-
si on i s put i nto gear after the vehi cl e i s al l owed to
set wi th the engi ne not runni ng for at l east 10 mi n-
utes. Use the fol l owi ng steps to have the TCM l earn
the 1st N-D UD CVI .
NOTE: The transmission oil temperature must be
between 80 - 110F (27 - 43C).
(1) Start the engi ne onl y when the engi ne and
i gni ti on have been off for at l east ten (10) mi nutes.
(2) Wi th the vehi cl e at a stop and the servi ce
brake appl i ed, record the 1st N-D UD CVI whi l e per-
formi ng a Neutral to Dri ve shi ft. The 1st N-D UD
CVI accounts for ai r entrapment i n the UD cl utch
that may occur after the engi ne has been off for a
peri od of ti me.
(3) Repeat Step 1 and Step 2 unti l the recorded 1st
N-D UD CVI val ue stabi l i zes.
NOTE: It is important that this procedure be per-
formed when the transmission temperature is
between 80 - 110F (27 - 43C). If this procedure
takes too long to complete fully for the allowed
transmission oil temperature, the vehicle may be
returned to the customer with an explanation that
the shift will improve daily during normal vehicle
usage. The TCM also learns at higher oil tempera-
tures, but these values (line pressure correction
values) are not available for viewing on the DRB
III.
LEARN A SMOOTH NEUTRAL TO DRIVE GARAGE
SHIFT
Perform thi s procedure i f the compl ai nt i s for a
del ayed or harsh shi ft when the transmi ssi on i s put
i nto gear after the vehi cl e has had i ts fi rst shi ft. Use
the fol l owi ng steps to have the TCM l earn the Norm
N-D UD CVI .
between 80 - 110F (27 - 43C) to learn the UD CVI.
Additional learning occurs at temperatures as low
as 0F and as high as 200F. This procedure may be
performed at any temperature that experiences poor
shift quality. Although the UD CVI may not change,
shift quality should improve.
(1) Start the vehi cl e engi ne and shi ft to dri ve.
(2) Move the vehi cl e forward to a speed of at l east
16 km/h (10 MPH) and come to a stop. Thi s ensures
no ai r i s present i n the UD hydraul i c ci rcui t.
(3) Perform repeated N-D shi fts at a stop whi l e
pausi ng i n Neutral for at l east 2-3 seconds and mon-
i tor Norm N-D UD CVI vol ume unti l the val ue stabi -
l i zes. The val ue wi l l change duri ng the N-D shi ft.
Thi s i s normal si nce the UD val ue i s di fferent for the
N-D shi ft then the normal val ue shown whi ch i s used
for 4-3 coastdown and ki ckdowns. Perform repeated
shi fts i n thi s temperature range unti l the Norm N-D
UD CVI val ue stabi l i zes and the N-D shi fts become
smooth.
LEARN THE 1ST 2-3 SHIFT AFTER A RESTART OR
SHIFT TO REVERSE
Use the fol l owi ng steps to have the TCM l earn the
1st 2-3 shi ft OD CVI .
above 80F (27C).
(1) Wi th the vehi cl e engi ne runni ng, sel ect reverse
gear for over 2 seconds.
(2) Shi ft the transmi ssi on to Dri ve and accel erate
the vehi cl e from a stop at a steady 15 degree throttl e
openi ng and perform a 2-3 shi ft whi l e noti ng the 1st
2-3 OD CVI .
(3) Repeat Step 1 and Step 2 unti l the 1st 2-3
upshi ft becomes smooth and the 1st 2-3 OD CVI sta-
bi l i zes.
LEARN A SMOOTH 2-3 AND 3-4 UPSHIFT
above 110F (43C).
OD and 4C CVI s.
(1) Accel erate the vehi cl e from a stop at a steady
15 degree throttl e openi ng and perform mul ti pl e 1-2,
2-3, and 3-4 upshi fts. The 2nd 2-3 shi ft fol l owi ng a
restart or shi ft to reverse wi l l be shown duri ng the
shi ft as a val ue between the 1st 2-3 OD CVI and the
normal OD CVI . Updates to the normal OD CVI wi l l
occur after the 2nd shi ft i nto 3rd gear, fol l owi ng a
restart or shi ft to reverse.
(2) Repeat Step 1 unti l the 2-3 and 3-4 shi fts
become smooth and the OD and 4C CVI become sta-
bl e.
LEARN A SMOOTH 4-3 COASTDOWN AND PART
THROTTLE 4-3 KICKDOWN
above 110F (43C).
UD shi ft vol ume.
(1) At a vehi cl e speed between 64-97 km/h (40-60
MPH), perform repeated 4-3 ki ckdown shi fts.
(2) Repeat Step 1 unti l the UD vol ume becomes
somewhat stabl e and the shi ft becomes smooth.
LEARN A SMOOTH 1-2 UPSHIFT AND 3-2
KICKDOWN
2C shi ft vol ume.
above 110F (43C).
(1) Wi th a vehi cl e speed bel ow 48 km/h (30 MPH)
and the transmi ssi on i n 3rd gear, perform mul ti pl e
3-2 ki ckdowns.
(2) Repeat Step 1 unti l the 3-2 ki ckdowns become
smooth and the 2C CVI becomes stabl e.
LEARN A SMOOTH MANUAL 2-1 PULLDOWN
SHIFT AS WELL AS A NEUTRAL TO REVERSE
SHIFT
above 110F (43C).
LR vol ume.
(1) Wi th the vehi cl e speed around 40-48 km/h
(25-30 MPH) i n Manual 2nd, perform manual pul l -
downs to Low or 1st gear at cl osed throttl e.
(2) Repeat Step 1 unti l the LR CVI becomes stabl e
and the manual 2-1 becomes smooth.
LEARN A SMOOTH NEUTRAL TO REVERSE SHIFT
above 110F (43C).
(1) Wi th the vehi cl e at a stop, perform Neutral to
Reverse shi fts unti l the shi ft i s smooth. An unl earned
Neutral to Reverse shi ft may be harsh or exhi bi t a
doubl e bump.
(2) I f any of the shi fts are sti l l not smooth after
the cl utch vol ume stabi l i zes, an i nternal transmi s-
si on probl em may be present.
LEARN A SMOOTH 4-5 UPSHIFT
above 110F (43C).
Al t 2C CVI .
(1) Accel erate the vehi cl e through 88 km/h
(55mph) at a steady 10-15 degree throttl e openi ng
and perform mul ti pl e 4-5 upshi fts.
(2) Repeat Step 1 unti l the 4-5 shi ft become
smooth and theAl t 2C CVI become stabl e. There i s a
separate 2C vol ume used and l earned for 4-5 shi fts,
2CA. I t i s i ndependent of the 2C CVI l earned on 3-2
ki ckdowns.
ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - BATTERY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS . . . . . . . 7
BATTERY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - BATTERY . . . . . . . 7
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - USING MICRO
420 BATTERY TESTER . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
BATTERY HOLDDOWN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
BATTERY CABLES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
BATTERY TRAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
BATTERY SYSTEM
DESCRIPTION
A si ngl e 12-vol t battery i s standard factory-i n-
stal l ed equi pment on gasol i ne engi ne equi pped mod-
el s. Di esel engi ne equi pped vehi cl es uti l i ze two
12-vol t batteri es connected i n paral l el . Al l of the com-
ponents of the battery system are l ocated wi thi n the
engi ne compartment of the vehi cl e. The battery sys-
tem for thi s vehi cl e, covers the fol l owi ng rel ated com-
ponents, whi ch are covered i n further detai l l ater i n
thi s secti on of the servi ce manual :
Battery - The storage battery provi des a rel i -
abl e means of stori ng a renewabl e source of el ectri cal
energy wi thi n the vehi cl e.
Battery Cables - The battery cabl es connect
the battery termi nal posts to the vehi cl e el ectri cal
system.
Battery Holddown - The battery hol ddown
hardware secures the battery i n the battery tray i n
the engi ne compartment.
Battery Tray - The battery tray provi des a
secure mounti ng l ocati on i n the vehi cl e for the bat-
tery and an anchor poi nt for the battery hol ddown
hardware.
DR ENGINE SYSTEMS 8F - 1
For battery system mai ntenance schedul es and
jump starti ng procedures, see the owners manual i n
the vehi cl e gl ove box. Opti onal l y, refer to the Lubri -
cati on and Mai ntenance secti on of thi s manual for
the proper battery jump starti ng procedure. Whi l e
battery chargi ng can be consi dered a mai ntenance
procedure, the battery chargi ng procedure and
rel ated i nformati on are l ocated l ater i n thi s secti on of
the servi ce manual . Thi s was done because the bat-
tery must be ful l y-charged before any battery system
di agnosi s or testi ng procedures can be performed.
OPERATION
The battery system i s desi gned to provi de a safe,
effi ci ent, rel i abl e and mobi l e means of del i veri ng and
stori ng el ectri cal energy. Thi s el ectri cal energy i s
requi red to operate the engi ne starti ng system, as
wel l as to operate many of the other vehi cl e acces-
sory systems for l i mi ted durati ons whi l e the engi ne
and/or the chargi ng system are not operati ng. The
battery system i s al so desi gned to provi de a reserve
of el ectri cal energy to suppl ement the chargi ng sys-
tem for short durati ons whi l e the engi ne i s runni ng
and the el ectri cal current demands of the vehi cl e
exceed the output of the chargi ng system. I n addi ti on
to del i veri ng, and stori ng el ectri cal energy for the
vehi cl e, the battery system serves as a capaci tor and
vol tage stabi l i zer for the vehi cl e el ectri cal system. I t
absorbs most abnormal or transi ent vol tages caused
by the swi tchi ng of any of the el ectri cal components
or ci rcui ts i n the vehi cl e.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starti ng, and chargi ng systems i n the
vehi cl e operate wi th one another and must be tested
as a compl ete system. I n order for the engi ne to start
and the battery to mai ntai n i ts charge properl y, al l of
the components that are used i n these systems must
perform wi thi n speci fi cati ons. I t i s i mportant that
the battery, starti ng, and chargi ng systems be thor-
oughl y tested and i nspected any ti me a battery needs
to be charged or repl aced. The cause of abnormal bat-
tery di scharge, overchargi ng or earl y battery fai l ure
must be di agnosed and corrected before a battery i s
repl aced and before a vehi cl e i s returned to servi ce.
The servi ce i nformati on for these systems has been
separated wi thi n thi s servi ce manual to make i t eas-
i er to l ocate the speci fi c i nformati on you are seeki ng.
However, when attempti ng to di agnose any of these
systems, i t i s i mportant that you keep thei r i nterde-
pendency i n mi nd.
The di agnosti c procedures used for the battery,
starti ng, and chargi ng systems i ncl ude the most
basi c conventi onal di agnosti c methods, to the more
sophi sti cated On-Board Di agnosti cs (OBD) bui l t i nto
the Powertrai n Control Modul e (PCM). Use of an
i nducti on-type mi l l i ampere ammeter, a vol t/ohmme-
ter, a battery charger, a carbon pi l e rheostat (l oad
tester), a 12-vol t test l amp and/or speci al servi ce
tool s may be requi red. Al l OBD-sensed systems are
moni tored by the PCM. Each moni tored ci rcui t i s
assi gned a Di agnosti c Troubl e Code (DTC). The PCM
wi l l store a DTC i n el ectroni c memory for any fai l ure
i t detects. Al ways check the PCM for stored troubl e
codes before returni ng the vehi cl e to servi ce. Refer to
Chargi ng System for the proper chargi ng system test
procedures. Refer to Starti ng System for the proper
starti ng system test procedures.
MICRO 420 BATTERY TESTER
The Mi cro 420 automoti ve battery tester i s
desi gned to hel p the deal ershi p techni ci an di agnose a
defecti ve battery. Fol l ow the i nstructi on manual sup-
pl i ed wi th the tester to properl y di agnose a battery.
I f the i nstructi on manual i s not avai l abl e, refer to
the standard procedure i n thi s secti on, whi ch
i ncl udes the di recti ons for usi ng the Mi cro 420 bat-
tery tester.
8F - 2 BATTERY SYSTEM DR
BATTERY SYSTEM (Continued)
BATTERY SYSTEM DIAGNOSIS
THE BATTERY SEEMS
WEAK OR DEAD WHEN
ATTEMPTING TO START
THE ENGINE.
1. The electrical system
ignition-off draw is excessive.
1. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the excessive ignition-off
draw, as required.
2. The charging system is
faulty.
2. Determine if the charging system is performing
to specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
3. The battery is discharged. 3. Determine the battery state-of-charge using the
Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Charge the faulty battery, as
required.
4. The battery terminal
connections are loose or
corroded.
4. Refer to Battery Cables for the proper battery
cable diagnosis and testing procedures. Clean
and tighten the battery terminal connections, as
required.
5. The battery has an
incorrect size or rating for
this vehicle.
5. Refer to Battery System Specifications for the
proper size and rating. Replace an incorrect
battery, as required.
6. The battery is faulty. 6. Determine the battery cranking capacity using
the Micro 420 battery tester. Refer to the
Standard Procedures in this section for additional
test procedures. Replace the faulty battery, as
required.
7. The starting system is
faulty.
7. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. The battery is physically
damaged.
8. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the damaged
DR BATTERY SYSTEM 8F - 3
BATTERY SYSTEM DIAGNOSIS
THE BATTERY STATE OF
CHARGE CANNOT BE
MAINTAINED.
1. The battery has an
incorrect size or rating for
this vehicle.
1. Refer to Battery System Specifications for the
proper specifications. Replace an incorrect
2. The battery terminal
connections are loose or
corroded.
2. Refer to Battery Cable for the proper cable
diagnosis and testing procedures. Clean and
tighten the battery terminal connections, as
required.
3. The electrical system
ignition-off draw is excessive.
3. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the faulty electrical system, as
required.
4. The battery is faulty. 4. Test the battery using the Micro 420 battery
tester. Refer to Standard Procedures for
additional test procedures. Replace the faulty
5. The starting system is
faulty.
5. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
6. The charging system is
faulty.
6. Determine if the charging system is performing
to specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
7. Electrical loads exceed the
output of the charging
system.
7. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
8. Slow driving or prolonged
idling with high-amperage
draw systems in use.
8. Advise the vehicle operator, as required.
THE BATTERY WILL NOT
ACCEPT A CHARGE.
1. The battery is faulty. 1. Test the battery using the Micro 420 battery
tester. Charge or replace the faulty battery, as
required.
ABNORMAL BATTERY DISCHARGING
Any of the fol l owi ng condi ti ons can resul t i n abnor-
mal battery di schargi ng:
1. A faul ty or i ncorrect chargi ng system compo-
nent. Refer to Chargi ng System for addi ti onal charg-
i ng system di agnosi s and testi ng procedures.
2. A faul ty or i ncorrect battery. Use Mi cro 420 bat-
tery tester and refer to Battery System for addi ti onal
battery di agnosi s and testi ng procedures.
3. A faul ty ci rcui t or component causi ng excessi ve
i gni ti on-off draw.
4. El ectri cal l oads that exceed the output of the
chargi ng system. Thi s can be due to equi pment
i nstal l ed after manufacture, or repeated short tri p
use.
5. A faul ty or i ncorrect starti ng system component.
Refer to Starti ng System for the proper starti ng sys-
tem di agnosi s and testi ng procedures.
6. Corroded or l oose battery posts and/or termi nal
cl amps.
7. Sl ow dri vi ng speeds (heavy traffi c condi ti ons) or
prol onged i dl i ng, wi th hi gh-amperage draw systems
i n use.
CLEANING
The fol l owi ng i nformati on detai l s the recommended
cl eani ng procedures for the battery and rel ated com-
ponents. I n addi ti on to the mai ntenance schedul es
found i n thi s servi ce manual and the owners man-
ual , i t i s recommended that these procedures be per-
formed any ti me the battery or rel ated components
must be removed for vehi cl e servi ce.
(1) Cl ean the battery cabl e termi nal cl amps of al l
corrosi on. Remove any corrosi on usi ng a wi re brush
or a post and termi nal cl eani ng tool , and a sodi um
bi carbonate (baki ng soda) and warm water cl eani ng
sol uti on (Fi g. 1).
(2) Cl ean the battery tray and battery hol ddown
hardware of al l corrosi on. Remove any corrosi on
usi ng a wi re brush and a sodi um bi carbonate (baki ng
soda) and warm water cl eani ng sol uti on. Pai nt any
exposed bare metal .
(3) I f the removed battery i s to be rei nstal l ed,
cl ean the outsi de of the battery case and the top
cover wi th a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on usi ng a sti ff bri stl e
parts cl eani ng brush to remove any aci d fi l m (Fi g. 2).
Ri nse the battery wi th cl ean water. Ensure that the
cl eani ng sol uti on does not enter the battery cel l s
through the vent hol es. I f the battery i s bei ng
repl aced, refer to Battery System Speci fi cati ons for
the factory-i nstal l ed battery speci fi cati ons. Confi rm
that the repl acement battery i s the correct si ze and
has the correct rati ngs for the vehi cl e.
(4) Cl ean the battery thermal guard wi th a sodi um
bi carbonate (baki ng soda) and warm water cl eani ng
sol uti on usi ng a sti ff bri stl e parts cl eani ng brush to
remove any aci d fi l m.
(5) Cl ean any corrosi on from the battery termi nal
posts wi th a wi re brush or a post and termi nal
cl eaner, and a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on (Fi g. 3).
INSPECTION
The fol l owi ng i nformati on detai l s the recommended
i nspecti on procedures for the battery and rel ated
components. I n addi ti on to the mai ntenance sched-
ul es found i n thi s servi ce manual and the owners
manual , i t i s recommended that these procedures be
performed any ti me the battery or rel ated compo-
nents must be removed for vehi cl e servi ce.
(1) I nspect the battery cabl e termi nal cl amps for
damage. Repl ace any battery cabl e that has a dam-
aged or deformed termi nal cl amp.
(2) I nspect the battery tray and battery hol ddown
hardware for damage. Repl ace any damaged parts.
(3) Sl i de the thermal guard off of the battery case
(i f equi pped). I nspect the battery case for cracks or
other damage that coul d resul t i n el ectrol yte l eaks.
Al so, check the battery termi nal posts for l ooseness.
Batteri es wi th damaged cases or l oose termi nal posts
must be repl aced.
Fig. 1 Clean Battery Cable Terminal Clamp - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
Fig. 2 Clean Battery - Typical
1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION
3 - BATTERY
(4) I nspect the battery thermal guard (i f equi pped)
for tears, cracks, deformati on or other damage.
Repl ace any battery thermal guard that has been
damaged.
(5) I nspect the battery bui l t-i n test i ndi cator si ght
gl ass (i f equi pped) for an i ndi cati on of the battery
condi ti on. I f the battery i s di scharged, charge as
requi red. Refer to Standard Procedures for the
proper battery bui l t-i n i ndi cator test procedures. Al so
refer to Standard Procedures for the proper battery
chargi ng procedures.
SPECIFICATIONS
The battery Group Si ze number, the Col d Cranki ng
Amperage (CCA) rati ng, and the Reserve Capaci ty
(RC) rati ng or Ampere-Hours (AH) rati ng can be
found on the ori gi nal equi pment battery l abel . Be
certai n that a repl acement battery has the correct
Group Si ze number, as wel l as CCA, and RC or AH
rati ngs that equal or exceed the ori gi nal equi pment
speci fi cati on for the vehi cl e bei ng servi ced. Battery
si zes and rati ngs are di scussed i n more detai l bel ow.
Group Size - The outsi de di mensi ons and ter-
mi nal pl acement of the battery conform to standards
establ i shed by the Battery Counci l I nternati onal
(BCI ). Each battery i s assi gned a BCI Group Si ze
number to hel p i denti fy a correctl y-si zed repl ace-
ment.
Cold Cranking Amperage - The Col d Crank-
i ng Amperage (CCA) rati ng speci fi es how much cur-
rent (i n amperes) the battery can del i ver for thi rty
seconds at -18 C (0 F). Termi nal vol tage must not
fal l bel ow 7.2 vol ts duri ng or after the thi rty second
di scharge peri od. The CCA requi red i s general l y
hi gher as engi ne di spl acement i ncreases, dependi ng
al so upon the starter current draw requi rements.
Reserve Capacity - The Reserve Capaci ty (RC)
rati ng speci fi es the ti me (i n mi nutes) i t takes for bat-
tery termi nal vol tage to fal l bel ow 10.5 vol ts, at a
di scharge rate of 25 amperes. RC i s determi ned wi th
the battery ful l y-charged at 26.7 C (80 F). Thi s rat-
i ng esti mates how l ong the battery mi ght l ast after a
chargi ng system fai l ure, under mi ni mum el ectri cal
l oad.
Ampere-Hours - The Ampere-Hours (AH) rat-
i ng speci fi es the current (i n amperes) that a battery
can del i ver steadi l y for twenty hours, wi th the vol t-
age i n the battery not fal l i ng bel ow 10.5 vol ts. Thi s
rati ng i s al so someti mes i denti fi ed as the twenty-
hour di scharge rati ng.
BATTERY CLASSIFICATIONS & RATINGS
Part Number
BCI Group Size
Classification
Cold Cranking
Amperage
Reserve
Capacity
Ampere -
Hours
Load Test
Amperage
56029449AB 65 600 120 Minutes 66 300
56029451AB 65 750 150 Minutes 75 375
56028450AA 65 600 120 Minutes 66 300
56028452AA 65 750 150 Minutes 75 375
56028452AB 65 700 130 Minutes 70 350
56029396AA 65 700 130 Minutes 70 350
56029382AA 65 700 130 Minutes 70 350
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS
BATTERY
DESCRIPTION
A l arge capaci ty, l ow-mai ntenance storage battery
(Fi g. 4) i s standard factory-i nstal l ed equi pment on
thi s model . Model s equi pped wi th a di esel engi ne
must uti l i ze two 12-vol t batteri es connected i n paral -
l el . Mal e post type termi nal s made of a soft l ead
materi al protrude from the top of the mol ded pl asti c
battery case to provi de the means for connecti ng the
battery to the vehi cl e el ectri cal system. The battery
posi ti ve termi nal post i s physi cal l y l arger i n di ameter
than the negati ve termi nal post to ensure proper bat-
tery connecti on. The l etters POS and NEG are al so
mol ded i nto the top of the battery case adjacent to
thei r respecti ve posi ti ve and negati ve termi nal posts
for i denti fi cati on confi rmati on. Refer to Battery
Cabl es for more i nformati on on the battery cabl es
that connect the battery to the vehi cl e el ectri cal sys-
tem.
The battery i s made up of si x i ndi vi dual cel l s that
are connected i n seri es. Each cel l contai ns posi ti vel y
charged pl ate groups that are connected wi th l ead
straps to the posi ti ve termi nal post, and negati vel y
charged pl ate groups that are connected wi th l ead
straps to the negati ve termi nal post. Each pl ate con-
si sts of a sti ff mesh framework or gri d coated wi th
l ead di oxi de (posi ti ve pl ate) or sponge l ead (negati ve
pl ate). I nsul ators or pl ate separators made of a non-
conducti ve materi al are i nserted between the posi ti ve
and negati ve pl ates to prevent them from contacti ng
or shorti ng agai nst one another. These di ssi mi l ar
metal pl ates are submerged i n a sul furi c aci d and
water sol uti on cal l ed an el ectrol yte.
The factory-i nstal l ed battery has a bui l t-i n test
i ndi cator (hydrometer). The col or vi si bl e i n the si ght
gl ass of the i ndi cator wi l l reveal the battery condi -
ti on. Refer to Standard Procedures for the proper
bui l t-i n i ndi cator test procedures. The factory-in-
stalled low-maintenance battery has non-re-
movable battery cell caps. Water cannot be added
to thi s battery. The battery i s not seal ed and has
vent hol es i n the cel l caps. The chemi cal composi ti on
of the metal coated pl ates wi thi n the l ow-mai nte-
nance battery reduces battery gassi ng and water
l oss, at normal charge and di scharge rates. There-
fore, the battery shoul d not requi re addi ti onal water
i n normal servi ce. Rapi d l oss of el ectrol yte can be
caused by an overchargi ng condi ti on.
The battery must be compl etel y charged and the
termi nal s shoul d be properl y cl eaned and i nspected
before di agnosti c procedures are performed. Refer to
Battery System Cl eani ng for the proper cl eani ng pro-
cedures, and Battery System I nspecti on for the
proper battery i nspecti on procedures. Refer to Stan-
dard Procedures for the proper battery chargi ng pro-
cedures.
Micro 420 Battery Tester
Fig. 4 Low-Maintenance Battery - Typical
1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - TEST INDICATOR (IF EQUIPPED)
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - GREEN BALL
9 - ELECTROLYTE LEVEL
10 - PLATE GROUPS
11 - LOW-MAINTENANCE BATTERY
MICRO 420 BATTERY TESTER
The Mi cro 420 automoti ve battery tester i s
desi gned to hel p the deal ershi p techni ci an di agnose
the cause of a defecti ve battery. Fol l ow the i nstruc-
ti on manual suppl i ed wi th the tester to properl y
di agnose a battery. I f the i nstructi on manual i s not
avai l abl e, refer to the standard procedure i n thi s sec-
ti on, whi ch i ncl udes the di recti ons for usi ng the
Mi cro 420 battery tester.
WARNING: IF THE BATTERY SHOWS SIGNS OF
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
WARNING: THE BATTERY CONTAINS SULFURIC
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
A battery that wi l l not accept a charge i s faul ty,
and must be repl aced. Further testi ng i s not
requi red. A ful l y-charged battery must be l oad tested
to determi ne i ts cranki ng capaci ty. A battery that i s
ful l y-charged, but does not pass the l oad test, i s
faul ty and must be repl aced. Al ways test battery
usi ng the Mi cro 420 battery tester before attempti ng
to repl ace a battery under the manufactures war-
ranty provi si ons.
NOTE: Completely discharged batteries may take
several hours to accept a charge. Refer to Standard
Procedures for the proper battery charging proce-
dures.
STANDARD PROCEDURE
STANDARD PROCEDURE - BATTERY
CHARGING
Battery chargi ng can be performed fast or sl ow, i n
terms of ti me. Slow battery chargi ng i s the best
means of restori ng a battery to ful l potenti al . Fast
battery chargi ng shoul d onl y be performed when
absol utel y necessary due to ti me restrai nts. A battery
i s ful l y-charged when:
Al l of the battery cel l s are gassi ng freel y duri ng
battery chargi ng.
A green col or i s vi si bl e i n the si ght gl ass of the
battery bui l t-i n test i ndi cator.
Three hydrometer tests, taken at one-hour i nter-
val s, i ndi cate no i ncrease i n the temperature-cor-
rected speci fi c gravi ty of the battery el ectrol yte.
Open-ci rcui t vol tage of the battery i s 12.65 vol ts
or above.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1 C [30 F] OR
LOWER) BATTERY. THE BATTERY MAY ARC INTER-
NALLY AND EXPLODE. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.
CAUTION: Always disconnect and isolate the bat-
tery negative cable before charging a battery. Do
not exceed sixteen volts while charging a battery.
Damage to the vehicle electrical system compo-
nents may result.
CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
CAUTION: The battery should not be hot to the
touch. If the battery feels hot to the touch, turn off
the charger and let the battery cool before continu-
ing the charging operation. Damage to the battery
may result.
NOTE: Models equipped with the diesel engine are
equipped with two 12-volt batteries, connected in
parallel (positive-to-positive and negative-to-nega-
tive). In order to ensure proper charging of each
battery, these batteries MUST be disconnected from
each other, as well as from the vehicle electrical
system while being charged.
Some battery chargers are equi pped wi th pol ari ty-
sensi ng ci rcui try. Thi s ci rcui try protects the battery
charger and the battery from bei ng damaged i f they
are i mproperl y connected. I f the battery state-of-
charge i s too l ow for the pol ari ty-sensi ng ci rcui try to
detect, the battery charger wi l l not operate. Thi s
makes i t appear that the battery wi l l not accept
chargi ng current. See the i nstructi ons provi ded by
the manufacturer of the battery charger for detai l s
on how to bypass the pol ari ty-sensi ng ci rcui try.
BATTERY (Continued)
After the battery has been charged to 12.4 vol ts or
greater, perform a l oad test to determi ne the battery
cranki ng capaci ty. Refer to Standard Procedures for
the proper battery l oad test procedures. I f the battery
wi l l endure a l oad test, return the battery to servi ce.
I f the battery wi l l not endure a l oad test, i t i s faul ty
and must be repl aced.
Cl ean and i nspect the battery hol d downs, tray,
termi nal s, posts, and top before compl eti ng battery
servi ce. Refer to Battery System Cl eani ng for the
proper battery system cl eani ng procedures, and Bat-
tery System I nspecti on for the proper battery system
i nspecti on procedures.
CHARGING A COMPLETELY DISCHARGED
BATTERY
The fol l owi ng procedure shoul d be used to recharge
a compl etel y di scharged battery. Unl ess thi s proce-
dure i s properl y fol l owed, a good battery may be
needl essl y repl aced.
(1) Measure the vol tage at the battery posts wi th a
vol tmeter, accurate to 1/10 (0.10) vol t (Fi g. 5). I f the
readi ng i s bel ow ten vol ts, the battery chargi ng cur-
rent wi l l be l ow. I t coul d take some ti me before the
battery accepts a current greater than a few mi l l i am-
peres. Such l ow current may not be detectabl e on the
ammeters bui l t i nto many battery chargers.
cabl e. Connect the battery charger l eads. Some bat-
tery chargers are equi pped wi th pol ari ty-sensi ng ci r-
cui try. Thi s ci rcui try protects the battery charger and
the battery from bei ng damaged i f they are i mprop-
erl y connected. I f the battery state-of-charge i s too
l ow for the pol ari ty-sensi ng ci rcui try to detect, the
battery charger wi l l not operate. Thi s makes i t
appear that the battery wi l l not accept chargi ng cur-
rent. See the i nstructi ons provi ded by the manufac-
turer of the battery charger for detai l s on how to
bypass the pol ari ty-sensi ng ci rcui try.
(3) Battery chargers vary i n the amount of vol tage
and current they provi de. The amount of ti me
requi red for a battery to accept measurabl e chargi ng
current at vari ous vol tages i s shown i n the Charge
Rate Tabl e. I f the chargi ng current i s sti l l not mea-
surabl e at the end of the chargi ng ti me, the battery
i s faul ty and must be repl aced. I f the chargi ng cur-
rent i s measurabl e duri ng the chargi ng ti me, the bat-
tery may be good and the chargi ng shoul d be
compl eted i n the normal manner.
CHARGE RATE TABLE
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
CHARGING TIME REQUIRED
The ti me requi red to charge a battery wi l l vary,
dependi ng upon the fol l owi ng factors:
Battery Capacity - A compl etel y di scharged
heavy-duty battery requi res twi ce the chargi ng ti me
of a smal l capaci ty battery.
Temperature - A l onger ti me wi l l be needed to
charge a battery at -18 C (0 F) than at 27 C (80
F). When a fast battery charger i s connected to a col d
battery, the current accepted by the battery wi l l be
very l ow at fi rst. As the battery warms, i t wi l l accept
a hi gher chargi ng current rate (amperage).
Charger Capacity - A battery charger that
suppl i es onl y fi ve amperes wi l l requi re a l onger
chargi ng ti me. A battery charger that suppl i es
twenty amperes or more wi l l requi re a shorter charg-
i ng ti me.
State-Of-Charge - A compl etel y di scharged bat-
tery requi res more chargi ng ti me than a parti al l y
di scharged battery. El ectrol yte i s nearl y pure water
i n a compl etel y di scharged battery. At fi rst, the
chargi ng current (amperage) wi l l be l ow. As the bat-
tery charges, the speci fi c gravi ty of the el ectrol yte
wi l l gradual l y ri se.
The Battery Chargi ng Ti me Tabl e gi ves an i ndi ca-
ti on of the ti me requi red to charge a typi cal battery
at room temperature based upon the battery state-of-
charge and the charger capaci ty.
Fig. 5 Voltmeter - Typical
BATTERY (Continued)
BATTERY CHARGING TIME TABLE
Charging
Amperage
5 Amps
10
Amps
20 Amps
Open Circuit
Voltage
Hours Charging @ 21C (70
F)
12.25 to 12.49 6 hours 3 hours 1.5
hours
12.00 to 12.24 10 hours 5 hours 2.5
hours
10.00 to 11.99 14 hours 7 hours 3.5
hours
Below 10.00 18 hours 9 hours 4.5
hours
STANDARD PROCEDURE - BUILT-IN
INDICATOR TEST
I f equi pped, an i ndi cator (hydrometer) bui l t i nto
the top of the battery case provi des vi sual i nforma-
ti on for battery testi ng (Fi g. 6). Li ke a hydrometer,
the bui l t-i n i ndi cator measures the speci fi c gravi ty of
the battery el ectrol yte. The speci fi c gravi ty of the
el ectrol yte reveal s the battery state-of-charge; how-
ever, i t wi l l not reveal the cranki ng capaci ty of the
battery. A l oad test must be performed to determi ne
the battery cranki ng capaci ty. Refer to Standard Pro-
cedures for the proper battery l oad test procedures.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. I n order to
obtai n correct i ndi cati ons from the bui l t-i n i ndi cator,
i t i s i mportant that the battery be l evel and have a
cl ean si ght gl ass. Addi ti onal l i ght may be requi red to
vi ew the i ndi cator. Do not use open flame as a
source of additional light.
To read the bui l t-i n i ndi cator, l ook i nto the si ght
gl ass and note the col or of the i ndi cati on (Fi g. 7). The
battery condi ti on that each col or i ndi cates i s
descri bed i n the fol l owi ng l i st:
Green - I ndi cates 75% to 100% battery state-of-
charge. The battery i s adequatel y charged for further
testi ng or return to servi ce. I f the starter wi l l not
crank for a mi ni mum of fi fteen seconds wi th a ful l y-
charged battery, the battery must be l oad tested.
Refer to Standard Procedures for the proper battery
l oad test procedures.
Black or Dark - I ndi cates 0% to 75% battery
state-of-charge. The battery i s i nadequatel y charged
and must be charged unti l a green i ndi cati on i s vi si -
bl e i n the si ght gl ass (12.4 vol ts or more), before the
battery i s tested further or returned to servi ce. Refer
to Standard Procedures for the proper battery charg-
i ng procedures. Al so refer to Di agnosi s and Testi ng
for more i nformati on on the possi bl e causes of the
di scharged battery condi ti on.
Clear or Bright - I ndi cates a l ow battery el ec-
trol yte l evel . The el ectrol yte l evel i n the battery i s
bel ow the bui l t-i n i ndi cator. A mai ntenance-free bat-
tery wi th non-removabl e cel l caps must be repl aced i f
the el ectrol yte l evel i s l ow. Water must be added to a
l ow-mai ntenance battery wi th removabl e cel l caps
before i t i s charged. Refer to Standard Procedures for
the proper battery fi l l i ng procedures. A l ow el ectro-
l yte l evel may be caused by an overchargi ng condi -
ti on. Refer to Chargi ng System for the proper
chargi ng system di agnosi s and testi ng procedures.
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
A battery open-ci rcui t vol tage (no l oad) test wi l l
show the approxi mate state-of-charge of a battery.
Thi s test can be used i n pl ace of the hydrometer test
when a hydrometer i s not avai l abl e, or for mai nte-
nance-free batteri es wi th non-removabl e cel l caps.
Before proceedi ng wi th thi s test, compl etel y charge
the battery (Refer to 8 - ELECTRI CAL/BATTERY
SYSTEM/BATTERY - STANDARD PROCEDURE).
Fig. 6 Built-In Indicator
1 - SIGHT GLASS
2 - BATTERY TOP
3 - GREEN BALL
4 - PLASTIC ROD
Fig. 7 Built-In Indicator Sight Glass Chart
BATTERY (Continued)
(1) Before measuri ng the open-ci rcui t vol tage, the
surface charge must be removed from the battery.
Turn on the headl amps for fi fteen seconds, then
al l ow up to fi ve mi nutes for the battery vol tage to
stabi l i ze.
(2) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst.
(3) Usi ng a vol tmeter connected to the battery
posts (see the i nstructi ons provi ded by the manufac-
turer of the vol tmeter), measure the open-ci rcui t vol t-
age (Fi g. 8).
See the Open-Ci rcui t Vol tage Tabl e. Thi s vol tage
readi ng wi l l i ndi cate the battery state-of-charge, but
wi l l not reveal i ts cranki ng capaci ty. I f a battery has
an open-ci rcui t vol tage readi ng of 12.4 vol ts or
greater, i t may be l oad tested to reveal i ts cranki ng
capaci ty (Refer to 8 - ELECTRI CAL/BATTERY SYS-
TEM/BATTERY - STANDARD PROCEDURE).
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST
The term I gni ti on-Off Draw (I OD) i denti fi es a nor-
mal condi ti on where power i s bei ng drai ned from the
battery wi th the i gni ti on swi tch i n the Off posi ti on. A
normal vehi cl e el ectri cal system wi l l draw from fi ve
to thi rty-fi ve mi l l i amperes (0.005 to 0.035 ampere)
wi th the i gni ti on swi tch i n the Off posi ti on, and al l
non-i gni ti on control l ed ci rcui ts i n proper worki ng
order. Up to thi rty-fi ve mi l l i amperes are needed to
enabl e the memory functi ons for the Powertrai n Con-
trol Modul e (PCM), di gi tal cl ock, el ectroni cal l y tuned
radi o, and other modul es whi ch may vary wi th the
vehi cl e equi pment.
A vehi cl e that has not been operated for approxi -
matel y twenty days, may di scharge the battery to an
i nadequate l evel . When a vehi cl e wi l l not be used for
twenty days or more (stored), remove the I OD fuse
from the I ntegrated Power Modul e (I PM). Thi s wi l l
reduce battery di schargi ng.
Excessi ve I OD can be caused by:
El ectri cal i tems l eft on.
Faul ty or i mproperl y adjusted swi tches.
Faul ty or shorted el ectroni c modul es and compo-
nents.
An i nternal l y shorted generator.
I ntermi ttent shorts i n the wi ri ng.
I f the I OD i s over thi rty-fi ve mi l l i amperes, the
probl em must be found and corrected before repl ac-
i ng a battery. I n most cases, the battery can be
charged and returned to servi ce after the excessi ve
I OD condi ti on has been corrected.
(1) Veri fy that al l el ectri cal accessori es are off.
Turn off al l l amps, remove the i gni ti on key, and cl ose
al l doors. I f the vehi cl e i s equi pped wi th an i l l umi -
nated entry system or an el ectroni cal l y tuned radi o,
al l ow the el ectroni c ti mer functi on of these systems
to automati cal l y shut off (ti me out). Thi s may take
up to three mi nutes. See the El ectroni c Modul e I gni -
ti on-Off Draw Tabl e for more i nformati on.
Fig. 8 Testing Open-Circuit Voltage - Typical
BATTERY (Continued)
ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE
Module
Time Out?
(If Yes, Interval And Wake-Up Input)
IOD
IOD After Time
Out
Radio No
1 to 3
milliamperes
N/A
Audio Power
Amplifier
No
up to 1
milliampere
N/A
Powertrain Control
Module (PCM)
No 0.95 milliampere N/A
ElectroMechanical
Instrument Cluster
(EMIC)
No 0.44 milliampere N/A
Combination Flasher No 0.08 milliampere N/A
(2) Determi ne that the underhood l amp i s operat-
i ng properl y, then di sconnect the l amp wi re harness
connector or remove the l amp bul b.
(4) Set an el ectroni c di gi tal mul ti -meter to i ts
hi ghest amperage scal e. Connect the mul ti -meter
between the di sconnected battery negati ve cabl e ter-
mi nal cl amp and the battery negati ve termi nal post.
Make sure that the doors remai n cl osed so that the
i l l umi nated entry system i s not acti vated. The mul ti -
meter amperage readi ng may remai n hi gh for up to
three mi nutes, or may not gi ve any readi ng at al l
whi l e set i n the hi ghest amperage scal e, dependi ng
upon the el ectri cal equi pment i n the vehi cl e. The
mul ti -meter l eads must be securel y cl amped to the
battery negati ve cabl e termi nal cl amp and the bat-
tery negati ve termi nal post. I f conti nui ty between the
battery negati ve termi nal post and the negati ve cabl e
termi nal cl amp i s l ost duri ng any part of the I OD
test, the el ectroni c ti mer functi on wi l l be acti vated
and al l of the tests wi l l have to be repeated.
(5) After about three mi nutes, the hi gh-amperage
I OD readi ng on the mul ti -meter shoul d become very
l ow or nonexi stent, dependi ng upon the el ectri cal
equi pment i n the vehi cl e. I f the amperage readi ng
remai ns hi gh, remove and repl ace each fuse or ci rcui t
breaker i n the I ntegrated Power Modul e (I PM), one
at a ti me unti l the amperage readi ng becomes very
l ow, or nonexi stent. Refer to the appropri ate wi ri ng
i nformati on i n thi s servi ce manual for compl ete I nte-
grated Power Modul e fuse, ci rcui t breaker, and ci r-
cui t i denti fi cati on. Thi s wi l l i sol ate each ci rcui t and
i denti fy the ci rcui t that i s the source of the hi gh-am-
perage I OD. I f the amperage readi ng remai ns hi gh
after removi ng and repl aci ng each fuse and ci rcui t
breaker, di sconnect the wi re harness from the gener-
ator. I f the amperage readi ng now becomes very l ow
or nonexi stent, refer to Chargi ng System for the
proper chargi ng system di agnosi s and testi ng proce-
dures. After the hi gh-amperage I OD has been cor-
rected, swi tch the mul ti -meter to progressi vel y l ower
amperage scal es and, i f necessary, repeat the fuse
and ci rcui t breaker remove-and-repl ace process to
i denti fy and correct al l sources of excessi ve I OD. I t i s
now safe to sel ect the l owest mi l l i ampere scal e of the
mul ti -meter to check the l ow-amperage I OD.
CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.
(6) Observe the mul ti -meter readi ng. The l ow-am-
perage I OD shoul d not exceed thi rty-fi ve mi l l i am-
peres (0.035 ampere). I f the current draw exceeds
thi rty-fi ve mi l l i amperes, i sol ate each ci rcui t usi ng the
fuse and ci rcui t breaker remove-and-repl ace process
i n Step 5. The mul ti -meter readi ng wi l l drop to
wi thi n the acceptabl e l i mi t when the source of the
excessi ve current draw i s di sconnected. Repai r thi s
ci rcui t as requi red; whether a wi ri ng short, i ncorrect
swi tch adjustment, or a component fai l ure i s at faul t.
STANDARD PROCEDURE - USING MICRO 420
BATTERY TESTER
Al ways use the Mi cro 420 I nstructi on Manual that
was suppl i ed wi th the tester as a reference. I f the
I nstructi on Manual i s not avai l abl e the fol l owi ng pro-
cedure can be used:
WARNING: ALWAYS WEAR APPROPRIATE EYE
PROTECTION AND USE EXTREME CAUTION WHEN
WORKING WITH BATTERIES.
BATTERY TESTING
(1) I f testi ng the battery OUT-OF-VEHI CLE, cl ean
the battery termi nal s wi th a wi re brush before test-
i ng. I f the battery i s equi pped wi th si de post termi -
nal s, i nstal l and ti ghten the suppl i ed l ead termi nal
stud adapters. Do not use steel bol ts. Fai l ure to prop-
BATTERY (Continued)
erl y i nstal l the stud adapters, or usi ng stud adapters
that are di rty or worn-out may resul t i n fal se test
readi ngs.
(2) I f testi ng the battery I N-THE-VEHI CLE, make
certai n al l of the vehi cl e accessory l oads are OFF,
i ncl udi ng the i gni ti on. The preferred test position
is at the battery terminal. I f the battery i s not
accessi bl e, you may test usi ng both the posi ti ve and
negati ve jumper posts. Sel ect TESTI NG AT JUMPER
POST when connecti ng to that l ocati on.
(3) Connect the tester (Fi g. 9) to the battery or
jumper posts, the red cl amp to posi ti ve (+) and the
bl ack cl amp to negati ve ().
NOTE: Multiple batteries connected in parallel must
have the ground cable disconnected to perform a
battery test. Failure to disconnect may result in
false battery test readings.
(4) Usi ng the ARROW key sel ect in or out of vehi -
cl e testi ng and press ENTER to make a sel ecti on.
(5) I f not sel ected, choose the Col d Cranki ng Amp
(CCA) battery rati ng. Or sel ect the appropri ate bat-
tery rati ng for your area (see menu). The tester wi l l
then run i ts sel f programmed test of the battery and
di spl ay the resul ts. Refer to the test resul t tabl e
noted bel ow.
CAUTION: If REPLACE BATTERY is the result of the
test, this may mean a poor connection between the
vehicles cables and battery exists. After discon-
necting the vehicles battery cables from the bat-
tery, retest the battery using the OUT-OF-VEHICLE
test before replacing.
(6) Whi l e vi ewi ng the battery test resul t, press the
CODE button and the tester wi l l prompt you for the
l ast 4 di gi ts of the VI N. Use the UP/DOWN arrow
buttons to scrol l to the correct character; then press
ENTER to sel ect and move to the next di gi t. Then
press the ENTER button to vi ew the SERVI CE
CODE. Pressi ng the CODE button a second ti me wi l l
return you to the test resul ts.
BATTERY TEST RESULTS
GOOD BATTERY Return to service
GOOD - RECHARGE Fully charge battery and
return to service
CHARGE & RETEST Fully charge battery and
retest battery
REPLACE BATTERY Replace the battery and
retest complete system
BAD-CELL REPLACE Replace the battery and
retest complete system
NOTE: The SERVICE CODE is required on every
warranty claim submitted for battery replacement.
REMOVAL
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
(2) Loosen the battery negati ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(3) Di sconnect the battery negati ve cabl e termi nal
cl amp from the battery negati ve termi nal post. I f
necessary, use a battery termi nal pul l er to remove
the termi nal cl amp from the battery post (Fi g. 10).
(4) Loosen the battery posi ti ve cabl e termi nal
cl amp pi nch-bol t hex nut.
(5) Di sconnect the battery posi ti ve cabl e termi nal
cl amp from the battery posi ti ve termi nal post. I f nec-
essary, use a battery termi nal pul l er to remove the
termi nal cl amp from the battery post (Fi g. 10).
Fig. 9 MICRO 420 BATTERY TESTER
Fig. 10 Removing Battery Cable Terminal Clamp
1 - BATTERY
2 - BATTERY TERMINAL PULLER
BATTERY (Continued)
(6) Remove the battery hol d down retai ni ng bol t.
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
GLASSES SHOULD ALSO BE WORN. IF THE BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
(7) Remove the battery from the battery tray.
INSTALLATION
(1) Cl ean and i nspect the battery.
(2) Posi ti on the battery onto the battery tray.
Ensure that the battery posi ti ve and negati ve termi -
nal posts are correctl y posi ti oned. The battery cabl e
termi nal cl amps must reach the correct battery ter-
mi nal post wi thout stretchi ng the cabl es.
(3) Posi ti on the battery hol d down and i nstal l the
retai ni ng bol t.
CAUTION: Be certain that the battery cable terminal
clamps are connected to the correct battery termi-
nal posts. Reversed battery polarity may damage
electrical components of the vehicle.
(4) Cl ean the battery cabl e termi nal cl amps and
the battery termi nal posts.
(5) Reconnect the battery posi ti ve cabl e termi nal
cl amp to the battery posi ti ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 4 Nm (35
i n. l bs.).
(6) Reconnect the battery negati ve cabl e termi nal
cl amp to the battery negati ve termi nal post. Ti ghten
the termi nal cl amp pi nch-bol t hex nut to 4 Nm (35
i n. l bs.).
(7) Appl y a thi n coati ng of petrol eum jel l y or chas-
si s grease to the exposed surfaces of the battery cabl e
termi nal cl amps and the battery termi nal posts.
(8) Obtai n a DRB I I I scan tool and check the
PCM for any stored battery di sconnect troubl e code,
i f requi red.
BATTERY HOLDDOWN
DESCRIPTION
The battery hol d down hardware i ncl udes a bol t
and a mol ded pl asti c hol d down bracket whi ch
meshes wi th the battery tray when properl y
i nstal l ed. The battery tray and hol d down hardware
combi ne to form a very stabl e and secure battery
hol d down assembl y.
OPERATION
The battery hol ddown secures the battery i n the
battery tray. Thi s hol ddown i s desi gned to prevent
battery movement duri ng the most extreme vehi cl e
operati on condi ti ons. Peri odi c removal and l ubri ca-
ti on of the battery hol ddown hardware i s recom-
mended to prevent hardware sei zure at a l ater date.
CAUTION: Never operate a vehicle without a battery
holddown device properly installed. Damage to the
vehicle, components and battery could result.
REMOVAL
(1) Loosen and remove the battery hol d down
retai ni ng bol t.
(2) Remove the battery hol d down bracket from
the battery case.
INSTALLATION
(1) Cl ean and i nspect the battery hol d down hard-
ware (Refer to 8 - ELECTRI CAL/BATTERY SYSTEM
- CLEANI NG).
(2) Posi ti on the battery hol d down bracket i n the
battery tray. Be certai n that the hol d down bracket i s
properl y posi ti oned i n the battery tray before ti ght-
eni ng the hol d down hardware.
(3) I nstal l and ti ghten the battery hol d down
retai ni ng bol t.
BATTERY CABLES
DESCRIPTION
The battery cabl es are l arge gauge, stranded cop-
per wi res sheathed wi thi n a heavy pl asti c or syn-
theti c rubber i nsul ati ng jacket. The wi re used i n the
battery cabl es combi nes excel l ent fl exi bi l i ty and rel i -
abi l i ty wi th hi gh el ectri cal current carryi ng capaci ty.
Refer to Wi ri ng for the l ocati on of the proper battery
cabl e wi re gauge i nformati on.
The battery cabl es cannot be repai red and, i f dam-
aged or faul ty they must be repl aced. Both the bat-
tery posi ti ve and negati ve cabl es are avai l abl e for
servi ce repl acement onl y as a uni t wi th the battery
posi ti ve cabl e wi re harness or the battery negati ve
cabl e wi re harness, whi ch may i ncl ude porti ons of
the wi ri ng ci rcui ts for the generator and other com-
ponents on some model s.
Most model s feature a stamped brass cl ampi ng
type femal e battery termi nal cri mped onto one end of
the battery cabl e wi re and then sol der-di pped. A
pi nch-bol t and hex nut are i nstal l ed at the open end
of the femal e battery termi nal cl amp. The battery
posi ti ve cabl e al so i ncl udes a red mol ded rubber pro-
tecti ve cover for the femal e battery termi nal cl amp.
BATTERY (Continued)
Large eyel et type termi nal s are cri mped onto the
opposi te end of the battery cabl e wi re and then sol -
der-di pped. The battery posi ti ve cabl e wi res have a
red i nsul ati ng jacket to provi de vi sual i denti fi cati on
and feature a l arger femal e battery termi nal cl amp
to al l ow connecti on to the l arger battery posi ti ve ter-
mi nal post. The battery negati ve cabl e wi res have a
bl ack i nsul ati ng jacket and a smal l er femal e battery
termi nal cl amp.
OPERATION
The battery cabl es connect the battery termi nal
posts to the vehi cl e el ectri cal system. These cabl es
al so provi de a return path for el ectri cal current gen-
erated by the chargi ng system for restori ng the vol t-
age potenti al of the battery. The femal e battery
termi nal cl amps on the ends of the battery cabl e
wi res provi de a strong and rel i abl e connecti on of the
battery cabl e to the battery termi nal posts. The ter-
mi nal pi nch bol ts al l ow the femal e termi nal cl amps
to be ti ghtened around the mal e termi nal posts on
the top of the battery. The eyel et termi nal s secured
to the ends of the battery cabl e wi res opposi te the
femal e battery termi nal cl amps provi de secure and
rel i abl e connecti on of the battery to the vehi cl e el ec-
tri cal system.
DIAGNOSIS AND TESTING - BATTERY CABLES
A vol tage drop test wi l l determi ne i f there i s exces-
si ve resi stance i n the battery cabl e termi nal connec-
ti ons or the battery cabl es. I f excessi ve resi stance i s
found i n the battery cabl e connecti ons, the connec-
ti on poi nt shoul d be di sassembl ed, cl eaned of al l cor-
rosi on or forei gn materi al , then reassembl ed.
Fol l owi ng reassembl y, check the vol tage drop for the
battery cabl e connecti on and the battery cabl e agai n
to confi rm repai r.
When performi ng the vol tage drop test, i t i s i mpor-
tant to remember that the vol tage drop i s gi vi ng an
i ndi cati on of the resi stance between the two poi nts at
whi ch the vol tmeter probes are attached. EXAM-
PLE: When testi ng the resi stance of the battery pos-
i ti ve cabl e, touch the vol tmeter l eads to the battery
posi ti ve cabl e termi nal cl amp and to the battery pos-
i ti ve cabl e eyel et termi nal at the starter sol enoi d
B(+) termi nal stud. I f you probe the battery posi ti ve
termi nal post and the battery posi ti ve cabl e eyel et
termi nal at the starter sol enoi d B(+) termi nal stud,
you are readi ng the combi ned vol tage drop i n the
battery posi ti ve cabl e termi nal cl amp-to-termi nal
post connecti on and the battery posi ti ve cabl e.
VOLTAGE DROP TEST
WARNING: MODELS EQUIPPED WITH A DIESEL
ENGINE HAVE AN AUTOMATIC SHUTDOWN (ASD)
RELAY LOCATED IN THE POWER DISTRIBUTION
CENTER (PDC). REMOVAL OF THE ASD RELAY
MAY NOT PREVENT THE DIESEL ENGINE FROM
STARTING. BE CERTAIN TO DISCONNECT THE
FUEL SHUTDOWN SOLENOID WIRE HARNESS
CONNECTOR TO PREVENT THE ENGINE FROM
STARTING. FAILURE TO DO SO MAY RESULT IN
PERSONAL INJURY.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng thi s
test, be certai n that the fol l owi ng procedures are
accompl i shed:
The battery i s ful l y-charged and tested (Refer to
8 - ELECTRI CAL/BATTERY SYSTEM/BATTERY -
Ful l y engage the parki ng brake.
I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and bl ock the cl utch pedal i n the
ful l y depressed posi ti on.
Veri fy that al l l amps and accessori es are turned
off.
To prevent a gasol i ne engi ne from starti ng,
remove the Automati c ShutDown (ASD) rel ay. The
ASD rel ay i s l ocated i n the I ntegrated Power Modul e
(I PM), i n the engi ne compartment. See the fuse and
rel ay l ayout l abel on the undersi de of the I PM cover
for ASD rel ay i denti fi cati on and l ocati on.
(1) Connect the posi ti ve l ead of the vol tmeter to
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e termi nal cl amp (Fi g. 11). Rotate and hol d the
i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f vol tage i s detected, correct the poor con-
necti on between the battery negati ve cabl e termi nal
cl amp and the battery negati ve termi nal post.
NOTE: If the vehicle is equipped with two 12v bat-
teries, step #1 must be performed twice, once for
each battery.
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
termi nal cl amp (Fi g. 12). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor connecti on
between the battery posi ti ve cabl e termi nal cl amp
and the battery posi ti ve termi nal post.
each battery.
BATTERY CABLES (Continued)
(3) Connect the vol tmeter to measure between the
battery posi ti ve cabl e termi nal cl amp and the starter
sol enoi d B(+) termi nal stud (Fi g. 13). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery posi ti ve cabl e eyel et termi nal con-
necti on at the starter sol enoi d B(+) termi nal stud.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
each battery.
(4) Connect the vol tmeter to measure between the
battery negati ve cabl e termi nal cl amp and a good
cl ean ground on the engi ne bl ock (Fi g. 14). Rotate
and hol d the i gni ti on swi tch i n the Start posi ti on.
Observe the vol tmeter. I f the readi ng i s above 0.2
vol t, cl ean and ti ghten the battery negati ve cabl e
eyel et termi nal connecti on to the engi ne bl ock.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery negati ve cabl e.
each battery.
REMOVAL
(1) Turn the i gni ti on swi tch to the Off posi ti on. Be
certai n that al l el ectri cal accessori es are turned off.
Fig. 11 Test Battery Negative Connection
Resistance - Typical
1 - VOLTMETER
2 - BATTERY
Fig. 12 Test Battery Positive Connection Resistance
- Typical
1 - VOLTMETER
2 - BATTERY
Fig. 13 Test Battery Positive Cable Resistance -
Typical
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
Fig. 14 Test Ground Circuit
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
(2) Di sconnect and i sol ate the remote battery neg-
ati ve cabl e termi nal .
(3) Remove the battery from the vehi cl e. Refer to
the procedure i n thi s group.
(4) One at a ti me, trace the battery cabl e retai ni ng
pushpi ns, fasteners and routi ng cl i ps unti l the cabl e
i s free from the vehi cl e.
(5) Remove the battery cabl e from the engi ne com-
partment.
INSTALLATION
(1) Posi ti on the battery cabl e i n the engi ne com-
partment.
(2) One at a ti me, i nstal l the battery cabl e retai n-
i ng pushpi ns, fasteners and routi ng cl i ps unti l the
cabl e i s i nstal l ed exactl y where i t was i n the vehi cl e.
Refer to Wi ri ng for i l l ustrati ons.
(3) I nstal l the battery i n the vehi cl e. Refer to the
procedure i n thi s group.
(4) Connect the battery negati ve cabl e termi nal .
BATTERY TRAY
DESCRIPTION
The mol ded pl asti c tray battery tray i s l ocated i n
the l eft front corner of the engi ne compartment. On
thi s model , the battery tray al so provi des an anchor
poi nt for the anti -l ock brake control l er, crui se control
servo (i f equi pped) and the i ntegrated power modul e
(Fi g. 15). The battery hol d down hardware i s con-
tai ned wi thi n the battery tray. A hol e i n the bottom
of the battery tray i s fi tted wi th a battery tempera-
ture sensor. Refer to Chargi ng System for more i nfor-
mati on on the battery temperature sensor.
OPERATION
The battery tray and the battery hol d down hard-
ware combi ne to secure and stabi l i ze the battery i n
the engi ne compartment, whi ch prevents battery
movement duri ng even the most extreme vehi cl e
operati on. Unrestrai ned battery movement duri ng
vehi cl e operati on coul d resul t i n damage to the vehi -
cl e, the battery, or both.
REMOVAL
LEFT SIDE
(1) Remove the battery from the battery tray
(Refer to 8 - ELECTRI CAL/BATTERY SYSTEM/BAT-
TERY - REMOVAL).
(2) Remove the i ntegrated power modul e (Refer to
8 - ELECTRI CAL/POWER DI STRI BUTI ON/I NTEL-
LI GENT POWER MODULE - REMOVAL).
(3) Di sconnect the wi re harness retai ners from the
battery tray assembl y.
(4) Remove the anti -l ock brake control l er (i f
equi pped) retai ni ng bol ts and support the brake con-
trol l er wi th mechani cs wi re. I t i s not necessary to
compl etel y remove the anti -l ock brake control uni t.
(5) Remove the l eft front wheel house spl ash shi el -
d(Refer to 23 - BODY/EXTERI OR/LF WHEEL-
HOUSE SPLASH SHI ELD - REMOVAL).
(6) Mark the l ocati on of the crui se servo (i f
equi pped) and remove the retai ni ng screws. Posi ti on
the servo out of the way.
(7) Remove the battery temperature sensor from
the battery tray (Refer to 8 - ELECTRI CAL/CHARG-
I NG/BATTERY TEMPERATURE SENSOR -
REMOVAL).
(8) Di sconnect the purge sol enoi d from i ts mount-
i ng bracket.
(9) Di sconnect the l eft front fender ground wi re.
(10) Remove the remai ni ng battery tray retai ni ng
bol ts (Fi g. 16).
(11) Remove the battery tray from the vehi cl e.
RIGHT SIDE
(1) Remove the battery from the battery tray
(Refer to 8 - ELECTRI CAL/BATTERY SYSTEM/BAT-
TERY - REMOVAL).
Fig. 15 DR Battery Tray
1 - BATTERY TRAY ASSEMBLY
2 - BATTERY TEMPERATURE SENSOR
3 - ANTI-LOCK BRAKE CONTROLLER MOUNTING LOCATION
4 - INTEGRATED POWER MODULE MOUNTING SANCTION
(2) Remove the ri ght front wheel house spl ash
shi el d.
(3) Di sconnect the ri ght front fender ground wi re.
(4) Remove fasteners from gri d heater rel ay
bracket.
(5) Remove ai r box.
(6) Remove the remai ni ng battery tray retai ni ng
bol ts (Fi g. 17).
(7) Remove the battery tray from the vehi cl e.
INSTALLATION
LEFT SIDE
(1) Posi ti on the battery tray assembl y and i nstal l
the retai ni ng bol ts.
(2) Connect the l eft front fender ground wi re.
(3) I nstal l the purge sol enoi d on i ts mounti ng
bracket.
(4) I nstal l the battery temperature sensor i n the
battery tray (Refer to 8 - ELECTRI CAL/CHARGI NG/
BATTERY TEMPERATURE SENSOR - I NSTALLA-
TI ON).
(5) I nstal l the crui se servo (i f equi pped) and
retai ni ng screws.
(6) I nstal l the l eft front wheel house spl ash shi el d
(Refer to 23 - BODY/EXTERI OR/LF WHEELHOUSE
SPLASH SHI ELD - I NSTALLATI ON).
(7) I nstal l the anti -l ock brake control l er (i f
equi pped).
(8) Connect the wi re harness retai ners on the bat-
tery tray assembl y.
- ELECTRI CAL/POWER DI STRI BUTI ON/I NTELLI -
GENT POWER MODULE - I NSTALLATI ON).
(10) I nstal l the battery (Refer to 8 - ELECTRI -
CAL/BATTERY SYSTEM/BATTERY - I NSTALLA-
TI ON).
RIGHT SIDE
(1) Posi ti on the battery tray assembl y and i nstal l
(2) Connect the ri ght front fender ground wi re.
(3) I nstal l the ai r box.
(4) I nstal l the gri d heater rel ay bracket.
(5) I nstal l the ri ght front wheel house spl ash
shi el d.
(6) I nstal l the battery (Refer to 8 - ELECTRI CAL/
BATTERY SYSTEM/BATTERY - I NSTALLATI ON).
Fig. 16 Lower Battery Tray Retaining Bolts
2 - BATTERY TRAY RETAINING BOLTS
3 - CRUISE CONTROL SERVO
Fig. 17 RIGHT SIDE BATTERY TRAY
BATTERY TRAY (Continued)
CHARGING
TABLE OF CONTENTS
page page
CHARGING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - CHARGING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS
GENERATOR RATINGS . . . . . . . . . . . . . . . . . 20
SPECIFICATIONS - TORQUE - GENERATOR
/ CHARGING SYSTEM. . . . . . . . . . . . . . . . . . 20
BATTERY TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
GENERATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
VOLTAGE REGULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CHARGING
DESCRIPTION
The chargi ng system consi sts of:
Generator
El ectroni c Vol tage Regul ator (EVR) ci rcui try
wi thi n the Powertrai n Control Modul e (PCM). El ec-
troni c Control Modul e (ECM) for di esel engi nes.
I gni ti on swi tch
Battery (refer to 8, Battery for i nformati on)
Battery temperature sensor
Check Gauges Lamp (i f equi pped)
Vol tmeter (refer to 8, I nstrument Panel and
Gauges for i nformati on)
Wi ri ng harness and connecti ons (refer to 8, Wi r-
i ng Di agrams for i nformati on)
OPERATION
The chargi ng system i s turned on and off wi th the
i gni ti on swi tch. The system i s on when the engi ne i s
runni ng and the ASD rel ay i s energi zed. When the
ASD rel ay i s on, vol tage i s suppl i ed to the ASD rel ay
sense ci rcui t at the PCM (ECM Di esel ). Thi s vol tage
i s connected through the PCM (ECM Di esel ) and sup-
pl i ed to one of the generator fi el d termi nal s (Gen.
Source +) at the back of the generator.
The amount of di rect current produced by the gen-
erator i s control l ed by the EVR (fi el d control ) ci r-
cui try contai ned wi thi n the PCM (ECM Di esel ). Thi s
ci rcui try i s connected i n seri es wi th the second rotor
fi el d termi nal and ground.
A battery temperature sensor, l ocated i n the bat-
tery tray housi ng, i s used to sense battery tempera-
ture. Thi s temperature data, al ong wi th data from
moni tored l i ne vol tage, i s used by the PCM (ECM
Di esel ) to vary the battery chargi ng rate. Thi s i s
done by cycl i ng the ground path to control the
strength of the rotor magneti c fi el d. The PCM then
compensates and regul ates generator current output
accordi ngl y.
Al l vehi cl es are equi pped wi th On-Board Di agnos-
ti cs (OBD). Al l OBD-sensed systems, i ncl udi ng EVR
(fi el d control ) ci rcui try, are moni tored by the PCM
(ECM Di esel ). Each moni tored ci rcui t i s assi gned a
Di agnosti c Troubl e Code (DTC). The PCM wi l l store a
DTC i n el ectroni c memory for certai n fai l ures i t
detects.
The Check Gauges Lamp (i f equi pped) moni tors:
charging system voltage, engi ne cool ant tempera-
ture and engi ne oi l pressure. I f an extreme condi ti on
i s i ndi cated, the l amp wi l l be i l l umi nated. Thi s i s
done as remi nder to check the three gauges. The si g-
nal to acti vate the l amp i s sent vi a the CCD bus ci r-
cui ts. The l amp i s l ocated on the i nstrument panel .
Refer to 8, I nstrument Panel and Gauges for addi -
DIAGNOSIS AND TESTING - CHARGING
SYSTEM
The fol l owi ng procedures may be used to di agnose
the chargi ng system i f:
the check gauges l amp (i f equi pped) i s i l l umi -
nated wi th the engi ne runni ng
the vol tmeter (i f equi pped) does not regi ster
properl y
an undercharged or overcharged battery condi -
ti on occurs.
Remember that an undercharged battery i s often
caused by:
accessori es bei ng l eft on wi th the engi ne not
runni ng
DR CHARGING 8F - 19
a faul ty or i mproperl y adjusted swi tch that
al l ows a l amp to stay on. Refer to I gni ti on-Off Draw
Test i n 8, Battery for more i nformati on.
INSPECTION
The PCM (Powertrai n Control Modul e), or ECM
(Di esel ) moni tors cri ti cal i nput and output ci rcui ts of
the chargi ng system, maki ng sure they are opera-
ti onal . A Di agnosti c Troubl e Code (DTC) i s assi gned
to each i nput and output ci rcui t moni tored by the
On-Board Di agnosti c (OBD) system. Some chargi ng
system ci rcui ts are checked conti nuousl y, and some
are checked onl y under certai n condi ti ons.
Refer to Di agnosti c Troubl e Codes i n; Powertrai n
Control Modul e; El ectroni c Control Modul es for more
DTC i nformati on. Thi s wi l l i ncl ude a compl ete l i st of
DTCs i ncl udi ng DTCs for the chargi ng system.
To perform a compl ete test of the chargi ng system,
refer to the appropri ate Powertrai n Di agnosti c Proce-
dures servi ce manual and the DRB scan tool . Per-
form the fol l owi ng i nspecti ons before attachi ng the
scan tool .
(1) I nspect the battery condi ti on. Refer to 8, Bat-
tery for procedures.
(2) I nspect condi ti on of battery cabl e termi nal s,
battery posts, connecti ons at engi ne bl ock, starter
sol enoi d and rel ay. They shoul d be cl ean and ti ght.
Repai r as requi red.
(3) I nspect al l fuses i n both the fusebl ock and
Power Di stri buti on Center (PDC) for ti ghtness i n
receptacl es. They shoul d be properl y i nstal l ed and
ti ght. Repai r or repl ace as requi red.
(4) I nspect generator mounti ng bol ts for ti ghtness.
Repl ace or ti ghten bol ts i f requi red. Refer to the Gen-
erator Removal /I nstal l ati on secti on of thi s group for
torque speci fi cati ons.
(5) I nspect generator dri ve bel t condi ti on and ten-
si on. Ti ghten or repl ace bel t as requi red. Refer to
Bel t Tensi on Speci fi cati ons i n 7, Cool i ng System.
(6) I nspect automati c bel t tensi oner (i f equi pped).
Refer to 7, Cool i ng System for i nformati on.
(7) I nspect generator el ectri cal connecti ons at gen-
erator fi el d, battery output, and ground termi nal (i f
equi pped). Al so check generator ground wi re connec-
ti on at engi ne (i f equi pped). They shoul d al l be cl ean
and ti ght. Repai r as requi red.
SPECIFICATIONS
GENERATOR RATINGS
TYPE PART NUMBER RATED SAE AMPS ENGINES
DENSO 56029700AA 136 3.7L / 4.7L
BOSCH 56041120AC 136 3.7L / 4.7L
DENSO 56028696AA 136 5.7L Gas/5.9L Diesel
BOSCH 56028699AA 136 5.7L Gas/5.9L Diesel
SPECIFICATIONS - TORQUE - GENERATOR /
CHARGING SYSTEM
Generator Mounting Bolts
- 5.7L
41 30 -
Generator Support
Bracket Bolt/Nuts - 5.7L
41 30 -
Generator Upper Mounting
Bolt - 5.9L Diesel Engine
41 30 -
Generator Vertical
Mounting Bolt - 3.7L / 4.7L
Engines
55 40 -
Generator (long)
Horizontal Mounting Bolt -
3.7L / 4.7L Engines
55 40 -
8F - 20 CHARGING DR
CHARGING (Continued)
Generator (short)
Horizontal Mounting Bolt -
3.7L / 4.7L Engines
74 55 -
Generator B+ Output
Cable Terminal Nut
12 - 108
BATTERY TEMPERATURE
SENSOR
DESCRIPTION
The Battery Temperature Sensor (BTS) i s attached
to the battery tray l ocated under the battery.
OPERATION
The BTS i s used to determi ne the battery temper-
ature and control battery chargi ng rate. Thi s temper-
ature data, al ong wi th data from moni tored l i ne
vol tage, i s used by the PCM (ECM Di esel ) to vary the
battery chargi ng rate. System vol tage wi l l be hi gher
at col der temperatures and i s gradual l y reduced at
warmer temperatures.
The PCM sends 5 vol ts to the sensor and i s
grounded through the sensor return l i ne. As temper-
ature i ncreases, resi stance i n the sensor decreases
and the detecti on vol tage at the PCM i ncreases.
The BTS i s al so used for OBD I I di agnosti cs. Cer-
tai n faul ts and OBD I I moni tors are ei ther enabl ed
or di sabl ed, dependi ng upon BTS i nput (for exampl e,
di sabl e purge and enabl e Leak Detecti on Pump
(LDP) and O2 sensor heater tests). Most OBD I I
moni tors are di sabl ed bel ow 20F.
REMOVAL
The battery temperature sensor i s l ocated under
the vehi cl e battery and i s attached (snapped i nto) a
mounti ng hol e on battery tray (Fi g. 1).
(1) Remove battery. Refer to 8, Battery for proce-
dures.
(2) Pry sensor strai ght up from battery tray
mounti ng hol e to gai n access to el ectri cal connector
(Fi g. 1).
(3) Di sconnect sensor from engi ne wi re harness
el ectri cal connector.
INSTALLATION
The battery temperature sensor i s l ocated under
the vehi cl e battery and i s attached (snapped i nto) a
mounti ng hol e on battery tray.
(1) Pul l el ectri cal connector up through mounti ng
hol e i n top of battery tray.
(2) Connect sensor.
(3) Snap sensor i nto battery tray.
(4) I nstal l battery. Refer to 8, Battery for proce-
dures.
GENERATOR
DESCRIPTION
The generator i s bel t-dri ven by the engi ne usi ng a
serpenti ne type dri ve bel t. I t i s servi ced onl y as a
compl ete assembl y. I f the generator fai l s for any rea-
son, the enti re assembl y must be repl aced.
OPERATION
As the energi zed rotor begi ns to rotate wi thi n the
generator, the spi nni ng magneti c fi el d i nduces a cur-
rent i nto the wi ndi ngs of the stator coi l . Once the
generator begi ns produci ng suffi ci ent current, i t al so
provi des the current needed to energi ze the rotor.
Fig. 1 BATTERY TEMPERATURE SENSOR
LOCATION
1 - BATTERY TEMP. SENSOR
2 - BATTERY
3 - SENSOR ELEC. CONNECT.
4 - BATTERY TRAY
DR CHARGING 8F - 21
CHARGING (Continued)
The stator wi ndi ng connecti ons del i ver the i nduced
al ternati ng current to 3 posi ti ve and 3 negati ve
di odes for recti fi cati on. From the di odes, recti fi ed
di rect current i s del i vered to the vehi cl e el ectri cal
system through the generator battery termi nal .
Al though the generators appear the same exter-
nal l y, di fferent generators wi th di fferent output rat-
i ngs are used on thi s vehi cl e. Be certai n that the
repl acement generator has the same output rati ng
and part number as the ori gi nal uni t. Refer to Gen-
erator Rati ngs i n the Speci fi cati ons secti on at the
back of thi s group for amperage rati ngs and part
numbers.
Noi se emi tti ng from the generator may be caused
by: worn, l oose or defecti ve beari ngs; a l oose or defec-
ti ve dri ve pul l ey; i ncorrect, worn, damaged or mi sad-
justed fan dri ve bel t; l oose mounti ng bol ts; a
mi sal i gned dri ve pul l ey or a defecti ve stator or di ode.
REMOVAL
3. 7L / 4. 7L
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO
DO SO CAN RESULT IN INJURY OR DAMAGE TO
ELECTRICAL SYSTEM.
(2) Remove generator dri ve bel t. Refer to 7, Cool -
i ng System for procedure.
(3) Unsnap pl asti c i nsul ator cap from B+ output
termi nal (Fi g. 2).
(4) Remove B+ termi nal mounti ng nut at rear of
generator (Fi g. 2). Di sconnect termi nal from genera-
tor.
(5) Di sconnect fi el d wi re connector at rear of gen-
erator (Fi g. 2) by pushi ng on connector tab.
(6) Remove 1 rear verti cal generator mounti ng bol t
(Fi g. 3).
(7) Remove 2 front hori zontal generator mounti ng
bol ts (Fi g. 3).
(8) Remove generator from vehi cl e.
5. 7L
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO
DO SO CAN RESULT IN INJURY OR DAMAGE TO
ELECTRICAL SYSTEM.
termi nal .
generator. Di sconnect termi nal from generator.
erator by pushi ng on connector tab.
Fig. 2 GENERATOR CONNECTORS - 3.7L / 4.7L
1 - GENERATOR
2 - B+ NUT
3 - PLASTIC INSULATOR CAP
4 - FIELD WIRE CONNECTOR
Fig. 3 REMOVE / INSTALL GENERATOR - 3.7L / 4.7L
1 - LOWER BOLTS
2 - REAR BOLT
3 - GENERATOR
8F - 22 CHARGING DR
GENERATOR (Continued)
(6) Remove generator support bracket nuts and
bol t (Fi g. 4) and remove support bracket.
(7) Remove 2 generator mounti ng bol ts (Fi g. 5).
5. 9L Diesel
WARNING: DISCONNECT BOTH NEGATIVE CABLES
FROM BOTH BATTERIES BEFORE REMOVING BAT-
TERY OUTPUT WIRE (B+ WIRE) FROM GENERA-
TOR. FAILURE TO DO SO CAN RESULT IN INJURY
OR DAMAGE TO ELECTRICAL SYSTEM.
batteri es.
termi nal .
generator (Fi g. 7). Di sconnect termi nal from genera-
tor.
erator by pushi ng on connector tab.
(6) Remove upper mounti ng bracket bol t (Fi g. 6).
(7) Remove l ower mounti ng bracket bol t and nut
(Fi g. 6).
Fig. 4 GENERATOR SUPPORT BRACKET- 5.7L
1 - GENERATOR
2 - SUPPORT BRACKET
3 - BRACKET NUTS
4 - BRACKET BOLT
Fig. 5 REMOVE / INSTALL GENERATOR - 5.7L
1 - MOUNTING BOLT
2 - GENERATOR
3 - MOUNTING STUD / BOLT
Fig. 6 5.9L DIESEL GENERATOR
1 - GENERATOR
2 - MOUNTING BOLTS
DR CHARGING 8F - 23
INSTALLATION
3. 7L / 4. 7L
(1) Posi ti on generator to engi ne and i nstal l 2 hor-
i zontal bol ts and 1 verti cal bol t.
(2) Ti ghten al l 3 bol ts. Refer to Torque Speci fi ca-
ti ons.
(3) Snap fi el d wi re connector i nto rear of genera-
tor.
(4) I nstal l B+ termi nal eyel et to generator output
stud. Ti ghten mounti ng nut. Refer to Torque Speci fi -
cati ons.
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump may be rotating in the wrong direction
if the belt is installed incorrectly, causing the
engine to overheat. Refer to belt routing label in
engine compartment, or refer to Belt Schematics in
7, Cooling System.
(5) I nstal l generator dri ve bel t. Refer to 7, Cool i ng
System for procedure.
(6) I nstal l negati ve battery cabl e to battery.
5. 7L
(1) Posi ti on generator to engi ne and i nstal l 2
mounti ng bol ts.
(2) Ti ghten bol ts. Refer to Torque Speci fi cati ons.
(3) Posi ti on support bracket to front of generator
and i nstal l bol t and nuts. Ti ghten bol t / nuts. Refer
to Torque Speci fi cati ons.
tor.
cati ons.
can be damaged.
7, Cooling System.
(7) I nstal l negati ve battery cabl e to battery.
5. 9L Diesel
(1) Posi ti on generator to upper and l ower mount-
i ng brackets and i nstal l upper bol t and l ower bol t /
nut.
(2) Ti ghten al l bol ts /nut. Refer to Torque Speci fi -
cati ons.
tor.
cati ons.
can be damaged.
7, Cooling System.
Fig. 7 5.9L DIESEL GENER. CONNECTORS
1 - B+ CONNECTOR
2 - GENERATOR
3 - FIELD WIRE CONNECTOR
8F - 24 CHARGING DR
(6) I nstal l both negati ve battery cabl es to both bat-
teri es.
VOLTAGE REGULATOR
DESCRIPTION
The El ectroni c Vol tage Regul ator (EVR) i s not a
separate component. I t i s actual l y a vol tage regul at-
i ng ci rcui t l ocated wi thi n the PCM (Powertrai n Con-
trol Modul e) (wi thi n the ECM for di esel engi nes). The
EVR i s not servi ced separatel y. I f repl acement i s nec-
essary, the PCM must be repl aced.
OPERATION
The amount of di rect current produced by the gen-
erator i s control l ed by EVR ci rcui try contai ned
wi thi n the PCM. Thi s ci rcui try i s connected i n seri es
wi th the generators second rotor fi el d termi nal and
i ts ground.
Vol tage i s regul ated by cycl i ng the ground path to
control the strength of the rotor magneti c fi el d. The
EVR ci rcui try moni tors system l i ne vol tage (B+) and
battery temperature (refer to Battery Temperature
Sensor for more i nformati on). I t then determi nes a
target chargi ng vol tage. I f sensed battery vol tage i s
0.5 vol ts or l ower than the target vol tage, the PCM
grounds the fi el d wi ndi ng unti l sensed battery vol t-
age i s 0.5 vol ts above target vol tage. A ci rcui t i n the
PCM cycl es the ground si de of the generator fi el d up
to 100 ti mes per second (100Hz), but has the capabi l -
i ty to ground the fi el d control wi re 100% of the ti me
(ful l fi el d) to achi eve the target vol tage. I f the charg-
i ng rate cannot be moni tored (l i mp-i n), a duty cycl e
of 25% i s used by the PCM i n order to have some
generator output. Al so refer to Chargi ng System
Operati on for addi ti onal i nformati on.
DR CHARGING 8F - 25
STARTING
TABLE OF CONTENTS
page page
STARTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DIAGNOSIS AND TESTING - STARTING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SPECIFICATIONS
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . 31
SPECIFICATIONS - TORQUE - STARTING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
STARTER MOTOR RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING - STARTER RELAY . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
STARTING
DESCRIPTION
The starti ng system consi sts of:
Starter rel ay
Starter motor (i ncl udi ng an i ntegral starter sol e-
noi d)
Other components to be consi dered as part of start-
i ng system are:
Battery
Battery cabl es
I gni ti on swi tch and key l ock cyl i nder
Cl utch pedal posi ti on swi tch (manual transmi s-
si on)
Park/neutral posi ti on swi tch (automati c trans-
mi ssi on)
Wi re harnesses and connecti ons.
The Battery, Starti ng, and Chargi ng systems oper-
ate i n conjuncti on wi th one another, and must be
tested as a compl ete system. For correct operati on of
starti ng/chargi ng systems, al l components used i n
these 3 systems must perform wi thi n speci fi cati ons.
When attempti ng to di agnose any of these systems, i t
i s i mportant that you keep thei r i nterdependency i n
mi nd.
The di agnosti c procedures used i n each of these
groups i ncl ude the most basi c conventi onal di agnosti c
methods, to the more sophi sti cated On-Board Di ag-
nosti cs (OBD) bui l t i nto the Powertrai n Control Mod-
ul e (PCM). Use of an i nducti on-type mi l l i ampere
ammeter, vol t/ohmmeter, battery charger, carbon pi l e
rheostat (l oad tester), and 12-vol t test l amp may be
requi red.
Certai n starti ng system components are moni tored
by the PCM and may produce a Di agnosti c Troubl e
Code (DTC). Refer to Di agnosti c Troubl e Codes i n
Emi ssi on Control for a l i st of codes.
OPERATION
The starti ng system components form two separate
ci rcui ts. A hi gh-amperage feed ci rcui t that feeds the
starter motor between 150 and 350 amperes (700
amperes - di esel engi ne), and a l ow-amperage control
ci rcui t that operates on l ess than 20 amperes. The
hi gh-amperage feed ci rcui t components i ncl ude the
battery, the battery cabl es, the contact di sc porti on of
the starter sol enoi d, and the starter motor. The l ow-
amperage control ci rcui t components i ncl ude the i gni -
ti on swi tch, the cl utch pedal posi ti on swi tch (manual
transmi ssi on), the park/neutral posi ti on swi tch (auto-
mati c transmi ssi on), the starter rel ay, the el ectro-
magneti c wi ndi ngs of the starter sol enoi d, and the
connecti ng wi re harness components.
I f the vehi cl e i s equi pped wi th a manual transmi s-
si on, i t has a cl utch pedal posi ti on swi tch i nstal l ed i n
seri es between the i gni ti on swi tch and the coi l bat-
tery termi nal of the starter rel ay. Thi s normal l y open
swi tch prevents the starter rel ay from bei ng ener-
gi zed when the i gni ti on swi tch i s turned to the Start
posi ti on, unl ess the cl utch pedal i s depressed. Thi s
feature prevents starter motor operati on whi l e the
cl utch di sc and the fl ywheel are engaged. The starter
rel ay coi l ground termi nal i s al ways grounded on
vehi cl es wi th a manual transmi ssi on.
8F - 26 STARTING DR
I f the vehi cl e i s equi pped wi th an automati c trans-
mi ssi on, battery vol tage i s suppl i ed through the l ow-
amperage control ci rcui t to the coi l battery termi nal
of the starter rel ay when the i gni ti on swi tch i s
turned to the Start posi ti on. The park/neutral posi -
ti on swi tch i s i nstal l ed i n seri es between the starter
rel ay coi l ground termi nal and ground. Thi s normal l y
open swi tch prevents the starter rel ay from bei ng
energi zed and the starter motor from operati ng
unl ess the automati c transmi ssi on gear sel ector i s i n
the Neutral or Park posi ti ons.
When the starter rel ay coi l i s energi zed, the nor-
mal l y open rel ay contacts cl ose. The rel ay contacts
connect the rel ay common feed termi nal to the rel ay
normal l y open termi nal . The cl osed rel ay contacts
energi ze the starter sol enoi d coi l wi ndi ngs.
The energi zed sol enoi d pul l -i n coi l pul l s i n the sol e-
noi d pl unger. The sol enoi d pl unger pul l s the shi ft
l ever i n the starter motor. Thi s engages the starter
overrunni ng cl utch and pi ni on gear wi th the starter
ri ng gear.
As the sol enoi d pl unger reaches the end of i ts
travel , the sol enoi d contact di sc compl etes the hi gh-
amperage starter feed ci rcui t and energi zes the sol e-
noi d pl unger hol d-i n coi l . Current now fl ows between
the sol enoi d battery termi nal and the starter motor,
energi zi ng the starter.
Once the engi ne starts, the overrunni ng cl utch pro-
tects the starter motor from damage by al l owi ng the
starter pi ni on gear to spi n faster than the pi ni on
shaft. When the i gni ti on swi tch i s rel eased to the On
posi ti on, the starter rel ay coi l i s de-energi zed. Thi s
causes the rel ay contacts to open. When the rel ay
contacts open, the starter sol enoi d pl unger hol d-i n
coi l i s de-energi zed.
When the sol enoi d pl unger hol d-i n coi l i s de-ener-
gi zed, the sol enoi d pl unger return spri ng returns the
pl unger to i ts rel axed posi ti on. Thi s causes the con-
tact di sc to open the starter feed ci rcui t, and the shi ft
l ever to di sengage the overrunni ng cl utch and pi ni on
gear from the starter ri ng gear.
DIAGNOSIS AND TESTING - STARTING
SYSTEM
The battery, starti ng, and chargi ng systems oper-
ate i n conjuncti on wi th one another, and must be
tested as a compl ete system. For correct starti ng/
chargi ng system operati on, al l of the components
i nvol ved i n these 3 systems must perform wi thi n
speci fi cati ons.
Starting System Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS TO
OPERATE.
1. Battery discharged or
faulty.
1. Refer to Battery. Charge or replace battery, if required.
2. Starting circuit wiring
faulty.
2. Refer to 8, Wiring Diagrams. Test and repair starter
feed and/or control circuits, if required.
3. Starter relay faulty. 3. Refer to Starter Relay in Diagnosis and Testing.
Replace starter relay if required.
4. Ignition switch faulty. 4. Refer to Ignition Switch and Key Lock Cylinder.
Replace ignition switch if required.
5. Clutch pedal position
switch faulty.
5. Refer to Clutch Pedal Position Switch.
6. Park/Neutral position
switch faulty or
misadjusted.
6. Refer to Park/Neutral Position Switch. Replace
park/neutral position switch if required.
7. Starter solenoid faulty. 7. Refer to Starter Motor. Replace starter motor assembly
if required.
8. Starter motor faulty. 8. If all other starting system components and circuits test
OK, replace starter motor.
DR STARTING 8F - 27
STARTING (Continued)
Starting System Diagnosis
STARTER ENGAGES,
FAILS TO TURN
ENGINE.
1. Battery discharged or
faulty.
1. Refer to Battery. Charge or replace battery if required.
2. Starting circuit wiring
faulty.
2. Refer to 8, Wiring Diagrams. Test and repair starter
feed and/or control circuits if required.
OK, replace starter motor assembly.
4. Engine seized. 4. Refer to Engine Diagnosis in the Diagnosis and Testing
section of 9, Engine.
STARTER ENGAGES,
SPINS OUT BEFORE
ENGINE STARTS.
1. Starter ring gear faulty. 1. Refer to Starter Motor Removal and Installation.
Remove starter motor to inspect starter ring gear.
Replace starter ring gear if required.
OK, replace starter motor assembly.
STARTER DOES NOT
DISENGAGE.
1. Starter motor
improperly installed.
1. Refer to Starter Motor Removal and Installation.
Tighten starter mounting hardware to correct torque
specifications.
2. Starter relay faulty. 2. Refer to Starter Relay Diagnosis and Testing. Replace
starter relay if required.
3. Ignition switch faulty. 3. Refer to Ignition Switch and Key Lock Cylinder.
Replace ignition switch if required.
OK, replace starter motor.
INSPECTION
For compl ete starter wi ri ng ci rcui t di agrams, refer
to 8, Wi ri ng Di agrams. Before removi ng any uni t
from starti ng system for repai r or di agnosi s, perform
the fol l owi ng i nspecti ons:
BAGS, REFER TO 8, PASSIVE RESTRAINT SYS-
TEMS, BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
Battery - Vi sual l y i nspect battery for i ndi ca-
ti ons of physi cal damage and l oose or corroded cabl e
connecti ons. Determi ne state-of-charge and cranki ng
capaci ty of battery. Charge or repl ace battery i f
requi red. Refer to Battery i n 8, Battery. Note: If
equipped with diesel engine, a dual battery sys-
tem may be used, and both batteries must be
inspected.
Ignition Switch - Vi sual l y i nspect i gni ti on
swi tch for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons. Refer to Igni-
tion Switch and Key Lock Cylinder.
Clutch Pedal Position Switch - I f equi pped
wi th manual transmi ssi on, vi sual l y i nspect cl utch
pedal posi ti on swi tch for i ndi cati ons of physi cal dam-
age and l oose or corroded wi re harness connecti ons.
Refer to Clutch Pedal Position Switch i n 6,
Cl utch.
Park/Neutral Position Switch - I f equi pped
wi th automati c transmi ssi on, vi sual l y i nspect park/
neutral posi ti on swi tch for i ndi cati ons of physi cal
damage and l oose or corroded wi re harness connec-
ti ons. Refer to Park/Neutral Position Switch i n
21, Transmi ssi on.
Starter Relay - Vi sual l y i nspect starter rel ay
for i ndi cati ons of physi cal damage and l oose or cor-
roded wi re harness connecti ons.
Starter Motor - Vi sual l y i nspect starter motor
for i ndi cati ons of physi cal damage and l oose or cor-
roded wi re harness connecti ons.
Starter Solenoid - Vi sual l y i nspect starter sol e-
noi d for i ndi cati ons of physi cal damage and l oose or
corroded wi re harness connecti ons.
Wiring - Vi sual l y i nspect wi re harnesses for
damage. Repai r or repl ace any faul ty wi ri ng, as
requi red. Refer to 8, Wi ri ng Di agrams.
8F - 28 STARTING DR
TESTING
COLD CRANKING TEST
For compl ete starter wi ri ng ci rcui t di agrams, refer
to 8, Wi ri ng Di agrams. The battery must be ful l y-
charged and l oad-tested before proceedi ng. Refer to
Battery i n 8, Battery.
(1) Connect vol t-ampere tester to battery termi nal s
(Fi g. 1). See i nstructi ons provi ded by manufacturer of
vol t-ampere tester bei ng used. Note: Certain diesel
equipped models use dual batteries. If equipped
with dual battery system, tester should be con-
nected to battery on left side of vehicle only.
Also, tester current reading must be taken from
positive battery cable lead that connects to
starter motor.
(2) Ful l y engage parki ng brake.
(3) I f equi pped wi th manual transmi ssi on, pl ace
gearshi ft sel ector l ever i n Neutral posi ti on and bl ock
cl utch pedal i n ful l y depressed posi ti on. I f equi pped
wi th automati c transmi ssi on, pl ace gearshi ft sel ector
l ever i n Park posi ti on.
(4) Veri fy that al l l amps and accessori es are
turned off.
(5) To prevent a gasol i ne engi ne from starti ng,
remove Automati c ShutDown (ASD) rel ay. To prevent
a di esel engi ne from starti ng, remove Fuel Pump
Rel ay. These rel ays are l ocated i n Power Di stri buti on
Center (PDC). Refer to l abel on PDC cover for rel ay
l ocati on.
WARNING: IF EQUIPPED WITH DIESEL ENGINE,
ATTEMPT TO START ENGINE A FEW TIMES
BEFORE PROCEEDING WITH FOLLOWING STEP.
(6) Rotate and hol d i gni ti on swi tch i n Start posi -
ti on. Note cranki ng vol tage and current (amperage)
draw readi ngs shown on vol t-ampere tester.
(a) I f vol tage reads bel ow 9.6 vol ts, refer to
Starter Motor i n Di agnosi s and Testi ng. I f starter
motor i s OK, refer to Engine Diagnosis i n 9,
Engi ne for further testi ng of engi ne. I f starter
motor i s not OK, repl ace faul ty starter motor.
(b) I f vol tage reads above 9.6 vol ts and current
(amperage) draw reads bel ow speci fi cati ons, refer
to Feed Circuit Test i n thi s secti on.
(c) I f vol tage reads 12.5 vol ts or greater and
starter motor does not turn, refer to Control Cir-
cuit Testing i n thi s secti on.
(d) I f vol tage reads 12.5 vol ts or greater and
starter motor turns very sl owl y, refer to Feed Cir-
cuit Test i n thi s secti on.
NOTE: A cold engine will increase starter current
(amperage) draw reading, and reduce battery volt-
age reading.
FEED CIRCUIT TEST
The starter feed ci rcui t test (vol tage drop method)
wi l l determi ne i f there i s excessi ve resi stance i n
hi gh-amperage feed ci rcui t. For compl ete starter wi r-
i ng ci rcui t di agrams, refer 8, Wi ri ng Di agrams.
When performi ng these tests, i t i s i mportant to
remember that vol tage drop i s gi vi ng an i ndi cati on of
resi stance between two poi nts at whi ch vol tmeter
probes are attached.
Example: When testi ng resi stance of posi ti ve bat-
tery cabl e, touch vol tmeter l eads to posi ti ve battery
cabl e cl amp and cabl e connector at starter sol enoi d.
I f you probe posi ti ve battery termi nal post and cabl e
connector at starter sol enoi d, you are readi ng com-
bi ned vol tage drop i n posi ti ve battery cabl e cl amp-to-
termi nal post connecti on and posi ti ve battery cabl e.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng tests,
be certai n that fol l owi ng procedures are accom-
pl i shed:
Battery i s ful l y-charged and l oad-tested. Refer to
Battery i n 8, Battery.
Ful l y engage parki ng brake.
I f equi pped wi th manual transmi ssi on, pl ace
gearshi ft sel ector l ever i n Neutral posi ti on and bl ock
cl utch pedal i n ful l y depressed posi ti on. I f equi pped
wi th automati c transmi ssi on, pl ace gearshi ft sel ector
l ever i n Park posi ti on.
Veri fy that al l l amps and accessori es are turned
off.
Fig. 1 VOLTS-AMPS TESTER CONNECTIONS -
TYPICAL
1 - POSITIVE CLAMP
2 - NEGATIVE CLAMP
3 - INDUCTION AMMETER CLAMP
DR STARTING 8F - 29
To prevent a gasol i ne engi ne from starti ng,
remove Automati c ShutDown (ASD) rel ay. To prevent
a di esel engi ne from starti ng, remove Fuel Pump
Rel ay. These rel ays are l ocated i n Power Di stri buti on
Center (PDC). Refer to l abel on PDC cover for rel ay
l ocati on.
(1) Connect posi ti ve l ead of vol tmeter to negati ve
battery cabl e termi nal post. Connect negati ve l ead of
vol tmeter to negati ve battery cabl e cl amp (Fi g. 2).
Rotate and hol d i gni ti on swi tch i n Start posi ti on.
Observe vol tmeter. I f vol tage i s detected, correct poor
contact between cabl e cl amp and termi nal post.
Note: Certain diesel equipped models use dual
batteries. If equipped with dual battery system,
procedure must be performed twice, once for
each battery.
(2) Connect posi ti ve l ead of vol tmeter to posi ti ve
battery termi nal post. Connect negati ve l ead of vol t-
meter to battery posi ti ve cabl e cl amp (Fi g. 3). Rotate
and hol d i gni ti on swi tch i n Start posi ti on. Observe
vol tmeter. I f vol tage i s detected, correct poor contact
between cabl e cl amp and termi nal post. Note: Cer-
tain diesel equipped models use dual batteries.
If equipped with dual battery system, this pro-
cedure must be performed twice, once for each
battery.
(3) Connect vol tmeter to measure between battery
posi ti ve termi nal post and starter sol enoi d battery
termi nal stud (Fi g. 4). Rotate and hol d i gni ti on
swi tch i n Start posi ti on. Observe vol tmeter. I f read-
i ng i s above 0.2 vol t, cl ean and ti ghten battery cabl e
connecti on at sol enoi d. Repeat test. I f readi ng i s sti l l
above 0.2 vol t, repl ace faul ty posi ti ve battery cabl e.
Note: Certain diesel equipped models use dual
batteries. If equipped with dual battery system,
this procedure must be performed on driver
side battery only.
(4) Connect vol tmeter to measure between nega-
ti ve battery termi nal post and a good cl ean ground
on engi ne bl ock (Fi g. 5). Rotate and hol d i gni ti on
swi tch i n Start posi ti on. Observe vol tmeter. I f read-
i ng i s above 0.2 vol t, cl ean and ti ghten negati ve bat-
tery cabl e attachment on engi ne bl ock. Repeat test. I f
readi ng i s sti l l above 0.2 vol t, repl ace faul ty negati ve
battery cabl e. Note: Certain diesel equipped mod-
els use dual batteries. If equipped with dual
battery system, this procedure must be per-
formed twice, once for each battery.
Fig. 2 TEST BATTERY NEGATIVE CONNECTION
RESISTANCE - TYPICAL
1 - VOLTMETER
2 - BATTERY
Fig. 3 TEST BATTERY POSITIVE CONNECTION
1 - VOLTMETER
2 - BATTERY
Fig. 4 TEST BATTERY POSITIVE CABLE
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
8F - 30 STARTING DR
(5) Connect posi ti ve l ead of vol tmeter to starter
housi ng. Connect negati ve l ead of vol tmeter to nega-
ti ve battery termi nal post (Fi g. 6). Rotate and hol d
i gni ti on swi tch i n Start posi ti on. Observe vol tmeter.
I f readi ng i s above 0.2 vol t, correct poor starter to
engi ne bl ock ground contact. Note: Certain diesel
equipped models use dual batteries. If equipped
with dual battery system, this procedure must
be performed on driver side battery only.
(6) I f equi pped wi th dual battery system (certai n
di esel equi pped model s), connect posi ti ve l ead of vol t-
meter to posi ti ve battery cabl e cl amp on battery
l ocated on l eft si de of vehi cl e. Connect negati ve l ead
of vol tmeter to posi ti ve battery termi nal post on bat-
tery l ocated on ri ght si de of vehi cl e. Rotate and hol d
i gni ti on swi tch i n Start posi ti on. Observe vol tmeter.
I f readi ng i s above 0.2 vol t, cl ean and ti ghten battery
cabl es at both batteri es. Repeat test. I f readi ng i s
sti l l above 0.2 vol t, repl ace faul ty posi ti ve battery
cabl e.
I f resi stance tests detect no feed ci rcui t probl ems,
refer to Starter Motor i n the Di agnosi s and Testi ng.
CONTROL CIRCUIT TESTING
The starter control ci rcui t components shoul d be
tested i n the order i n whi ch they are l i sted, as fol -
l ows:
Starter Relay - Refer to Starter Relay Di ag-
nosi s and Testi ng.
Starter Solenoid - Refer to Starter Motor
Di agnosi s and Testi ng.
Ignition Switch - Refer to Ignition Switch
and Key Lock Cylinder
Clutch Pedal Position Switch - I f equi pped
wi th manual transmi ssi on, refer to Clutch Pedal
Position Switch i n 6, Cl utch.
Park/Neutral Position Switch - I f equi pped
wi th automati c transmi ssi on, refer to Park/Neutral
Position Switch i n 21, Transmi ssi on.
Wire harnesses and connections - Refer to 8,
Wi ri ng Di agrams.
SPECIFICATIONS
STARTING SYSTEM
Starter Motor and Solenoid
Manufacturer Denso Denso
Part Number 56028715AD 4741012
Engine Application 3.7L / 4.7L / 5.7L 5.9L Diesel
Power Rating
1.4 Kilowatt / 1.9
Horsepower
2.7 Kilowatt / 3.6
Horsepower
Fig. 5 TEST GROUND CIRCUIT RESISTANCE -
TYPICAL
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
Fig. 6 TEST STARTER GROUND - TYPICAL
1 - STARTER MOTOR
2 - BATTERY
3 - VOLTMETER
DR STARTING 8F - 31
Starter Motor and Solenoid
Voltage 12 Volts 12 Volts
Number of Brushes 4 4
Drive Type Gear Reduction Conventional
Free Running Test Voltage 11 Volts 11 Volts
Free Running Test Amperage
Draw
73 Amperes 200 Amperes
Free Running Test Minimum
Speed
3601 rpm 3000
Solenoid Closing Maximum
Voltage Required
7.5 Volts 8.0 Volts
* Cranking Amperage Draw
Test
125 - 250 Amperes 450 - 700 Amperes
* Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter
amperage draw.
SPECIFICATIONS - TORQUE - STARTING
SYSTEM
Battery Cable Eyelet Nut
at Solenoid (large nut -
gas engines)
25 19 221
Battery Cable Eyelet Nut
at Solenoid (large nut -
diesel engine)
14 - 120
Starter Solenoid Nut
(small nut - diesel engine)
6 - 55
Starter Mounting Bolts -
Gas Engines
68 50 -
Starter Mounting Nut -
Gas Engines
68 50 -
Starter Mounting Bolts -
Diesel
43 32 -
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER MOTOR
Correct starter motor operati on can be confi rmed
by performi ng the fol l owi ng free runni ng bench test.
Thi s test can onl y be performed wi th starter motor
removed from vehi cl e. Refer to Speci fi cati ons for
starter motor speci fi cati ons.
(1) Remove starter motor from vehi cl e. Refer to
Starter Motor Removal and I nstal l ati on.
(2) Mount starter motor securel y i n a soft-jawed
bench vi se. The vi se jaws shoul d be cl amped on the
mounti ng fl ange of starter motor. Never cl amp on
starter motor by fi el d frame.
(3) Connect a sui tabl e vol t-ampere tester and a
12-vol t battery to starter motor i n seri es, and set
ammeter to 100 ampere scal e. See i nstructi ons pro-
vi ded by manufacturer of vol t-ampere tester bei ng
used.
(4) I nstal l jumper wi re from sol enoi d termi nal to
sol enoi d battery termi nal . The starter motor shoul d
operate. I f starter motor fai l s to operate, repl ace
faul ty starter motor assembl y.
(5) Adjust carbon pi l e l oad of tester to obtai n free
runni ng test vol tage. Refer to Speci fi cati ons for
starter motor free runni ng test vol tage speci fi cati ons.
8F - 32 STARTING DR
(6) Note readi ng on ammeter and compare readi ng
to free runni ng test maxi mum amperage draw. Refer
to Speci fi cati ons for starter motor free runni ng test
maxi mum amperage draw speci fi cati ons.
(7) I f ammeter readi ng exceeds maxi mum amper-
age draw speci fi cati on, repl ace faul ty starter motor
assembl y.
STARTER SOLENOID
Thi s test can onl y be performed wi th starter motor
removed from vehi cl e.
(1) Remove starter motor from vehi cl e. Refer to
Starter Motor Removal and I nstal l ati on.
(2) Di sconnect wi re from sol enoi d fi el d coi l termi -
nal .
(3) Check for conti nui ty between sol enoi d termi nal
and sol enoi d fi el d coi l termi nal wi th a conti nui ty
tester (Fi g. 7). There shoul d be conti nui ty. I f OK, go
to Step 4. I f not OK, repl ace faul ty starter motor
assembl y.
(4) Check for conti nui ty between sol enoi d termi nal
and sol enoi d case (Fi g. 8). There shoul d be conti nui ty.
I f not OK, repl ace faul ty starter motor assembl y.
REMOVAL
3. 7L / 4. 7L
(1) Di sconnect and i sol ate negati ve battery cabl e.
(3) Note: I f equi pped wi th 4WD and certai n trans-
mi ssi ons, a support bracket i s used between front
axl e and si de of transmi ssi on. Remove 2 support
bracket bol ts at transmi ssi on. Pry support bracket
sl i ghtl y to gai n access to l ower starter mounti ng bol t.
(4) Remove 1 bol t and 1 nut i f equi pped wi th a
manual transmi ssi on (Fi g. 9).
(5) Remove 2 bol ts i f equi pped wi th an automati c
transmi ssi on (Fi g. 10).
(6) Move starter motor towards front of vehi cl e far
enough for nose of starter pi ni on housi ng to cl ear
housi ng. Al ways support starter motor duri ng thi s
process, do not l et starter motor hang from wi re har-
ness.
(7) Ti l t nose downwards and l ower starter motor
far enough to access and remove nut that secures
battery posi ti ve cabl e wi re harness connector eyel et
to sol enoi d battery termi nal stud. Do not l et starter
motor hang from wi re harness.
(8) Remove battery posi ti ve cabl e wi re harness
connector eyel et from sol enoi d battery termi nal stud.
(9) Di sconnect battery posi ti ve cabl e wi re harness
connector from sol enoi d termi nal connector recepta-
cl e.
(10) Remove starter motor.
Fig. 7 CONTINUITY BETWEEN SOLENOID AND
FIELD COIL TERMINALS - TYPICAL
1 - OHMMETER
2 - SOLENOID TERMINAL
3 - FIELD COIL TERMINAL
Fig. 8 CONTINUITY BETWEEN SOLENOID
TERMINAL AND CASE - TYPICAL
1 - SOLENOID TERMINAL
2 - OHMMETER
3 - SOLENOID
Fig. 9 STARTER R/I - 3.7L/4.7L - MAN. TRANS.
1 - EYELET TERMINAL
2 - NUT
3 - BRACKET
4 - STUD
5 - STARTER MOTOR
6 - LOCK WASHER
7 - WIRE HARNESS CONNECTOR
8 - NUT
9 - SCREW AND WASHER (2)
DR STARTING 8F - 33
STARTER MOTOR (Continued)
5. 7L Gas
(3) Note: I f equi pped wi th 4WD and certai n trans-
mi ssi ons, a support bracket i s used between front
axl e and si de of transmi ssi on. Remove 2 support
bracket bol ts at transmi ssi on. Pry support bracket
sl i ghtl y to gai n access to l ower starter mounti ng bol t.
(4) Remove 2 mounti ng bol ts (Fi g. 11).
process, do not l et starter motor hang from wi re har-
ness.
far enough to access and remove nut that secures
battery posi ti ve cabl e wi re harness connector eyel et
to sol enoi d battery termi nal stud. Do not l et starter
motor hang from wi re harness.
(7) Remove battery posi ti ve cabl e wi re harness
connector eyel et from sol enoi d battery termi nal stud.
(8) Di sconnect battery posi ti ve cabl e wi re harness
connector from sol enoi d termi nal connector recepta-
cl e.
(9) Remove starter motor.
5. 9L Diesel
(1) Di sconnect and i sol ate both negati ve battery
cabl es at both batteri es.
(3) Remove 3 starter mounti ng bol ts (Fi g. 12).
process. Do not l et starter motor hang from wi re har-
ness.
far enough to access and remove nuts securi ng
starter wi ri ng harness to starter (Fi g. 13). Do not l et
starter motor hang from wi re harness.
(6) Remove starter motor from engi ne. Note: Cer-
tai n di esel engi nes use an al umi num spacer (Fi g. 12).
Note posi ti on and ori entati on of spacer before
removal .
INSTALLATION
3. 7L / 4. 7L
(1) Connect sol enoi d wi re to starter motor (snaps
on).
(2) Posi ti on battery cabl e to sol enoi d stud. I nstal l
and ti ghten battery cabl e eyel et nut. Refer to Torque
Speci fi cati ons. Do not al l ow starter motor to hang
from wi re harness.
(3) Posi ti on starter motor to transmi ssi on.
(4) I f equi pped wi th automati c transmi ssi on, sl i de
cool er tube bracket i nto posi ti on.
(5) I nstal l and ti ghten both bol ts (auto. trans.), or
1 nut and 1 bol t (man. trans.). Refer to Torque Spec-
i fi cati ons.
Fig. 10 STARTER R/I - 3.7L/4.7L - AUTO. TRANS.
1 - EYELET TERMINAL
2 - NUT
3 - SCREW AND WASHER (2)
4 - STARTER MOTOR
Fig. 11 STARTER R/I - 5.7L
1 - STARTER MOTOR
2 - MOUNTING BOLTS
8F - 34 STARTING DR
5. 7L
(1) Connect sol enoi d wi re to starter motor (snaps
on).
(2) Posi ti on battery cabl e to sol enoi d stud. I nstal l
and ti ghten battery cabl e eyel et nut. Refer to Torque
Speci fi cati ons. Do not al l ow starter motor to hang
from wi re harness.
(3) Posi ti on starter motor to engi ne.
(5) I nstal l and ti ghten both mounti ng bol ts. Refer
to Torque Speci fi cati ons.
5. 9L Diesel
(1) If Equipped: Posi ti on and hol d al umi num
spacer to rear of starter whi l e posi ti oni ng starter to
engi ne.
(2) Connect sol enoi d wi re to starter motor. Ti ghten
nut.
(3) Posi ti on battery cabl e to starter stud. I nstal l
and ti ghten battery cabl e nut. Refer to Torque Spec-
i fi cati ons. Do not al l ow starter motor to hang from
wi re harness.
(4) Posi ti on starter motor to transmi ssi on.
(6) I nstal l and ti ghten 3 starter mounti ng bol ts.
Refer to Torque Speci fi cati ons.
(8) Connect both negati ve battery cabl es to both
batteri es.
STARTER MOTOR RELAY
DESCRIPTION
The starter rel ay i s an el ectromechani cal devi ce
that swi tches battery current to the pul l -i n coi l of the
starter sol enoi d when i gni ti on swi tch i s turned to
Start posi ti on. The starter rel ay i s l ocated i n the
Power Di stri buti on Center (PDC) i n the engi ne com-
partment. See PDC cover for rel ay i denti fi cati on and
l ocati on.
The starter rel ay i s a I nternati onal Standards
Organi zati on (I SO) rel ay. Rel ays conformi ng to I SO
speci fi cati ons have common physi cal di mensi ons, cur-
rent capaci ti es, termi nal patterns, and termi nal func-
ti ons.
The starter rel ay cannot be repai red or adjusted. I f
faul ty or damaged, i t must be repl aced.
Fig. 12 STARTER R/I - 5.9L DIESEL
2 - STARTER MOTOR
3 - SPACER (CERTAIN TRANSMISSIONS)
Fig. 13 STARTER ELECTRICAL CONNECTORS -
5.9L DIESEL
1 - STARTER MOTOR
2 - BATTERY CABLE NUT
3 - SOLENOID NUT
4 - HARNESS ASSEMBLY
DR STARTING 8F - 35
OPERATION
The I SO rel ay consi sts of an el ectromagneti c coi l , a
resi stor or di ode, and three (two fi xed and one mov-
abl e) el ectri cal contacts. The movabl e (common feed)
rel ay contact i s hel d agai nst one of the fi xed contacts
(normal l y cl osed) by spri ng pressure. When el ectro-
magneti c coi l i s energi zed, i t draws the movabl e con-
tact away from normal l y cl osed fi xed contact, and
hol ds i t agai nst the other (normal l y open) fi xed con-
tact.
When el ectromagneti c coi l i s de-energi zed, spri ng
pressure returns movabl e contact to normal l y cl osed
posi ti on. The resi stor or di ode i s connected i n paral l el
wi th el ectromagneti c coi l wi thi n rel ay, and hel ps to
di ssi pate vol tage spi kes produced when coi l i s de-en-
ergi zed.
DIAGNOSIS AND TESTING - STARTER RELAY
The starter rel ay (Fi g. 14) i s l ocated i n Power Di s-
tri buti on Center (PDC). Refer to PDC cover for rel ay
i denti fi cati on and l ocati on. For compl ete starter rel ay
wi ri ng ci rcui t di agrams, refer to 8, Wi ri ng Di agrams.
(1) Remove starter rel ay from PDC.
(2) A rel ay i n de-energi zed posi ti on shoul d have
conti nui ty between termi nal s 87A and 30, and no
conti nui ty between termi nal s 87 and 30. I f OK, go to
Step 3. I f not OK, repl ace faul ty rel ay.
(3) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 5 ohms. I f OK, go to Step
4. I f not OK, repl ace faul ty rel ay.
(4) Connect 12V battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, perform Rel ay Ci rcui t Test that fol -
l ows. I f not OK, repl ace faul ty rel ay.
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r open ci r-
cui t to fuse i n PDC as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to common feed termi nal (30) i n the energi zed
posi ti on. Thi s termi nal suppl i es battery vol tage to
starter sol enoi d fi el d coi l s. There shoul d be conti nu-
i ty between cavi ty for rel ay termi nal 87 and starter
sol enoi d termi nal at al l ti mes. I f OK, go to Step 4. I f
not OK, repai r open ci rcui t to starter sol enoi d as
requi red.
(4) The coi l battery termi nal (86) i s connected to
el ectromagnet i n rel ay. I t i s energi zed when i gni ti on
swi tch i s hel d i n Start posi ti on. On vehi cl es wi th
manual transmi ssi on, cl utch pedal must be ful l y
depressed for thi s test. Check for battery vol tage at
cavi ty for rel ay termi nal 86 wi th i gni ti on swi tch i n
Start posi ti on, and no vol tage when i gni ti on swi tch i s
rel eased to On posi ti on. I f OK, go to Step 5. I f not
OK wi th automati c transmi ssi on, check for open or
short ci rcui t to i gni ti on swi tch and repai r, i f requi red.
I f ci rcui t to i gni ti on swi tch i s OK, refer to Ignition
Switch and Key Lock Cylinder. I f not OK wi th a
manual transmi ssi on, check ci rcui t between rel ay
and cl utch pedal posi ti on swi tch for open or a short.
I f ci rcui t i s OK, refer to Clutch Pedal Position
Switch i n 6 , Cl utch.
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. On vehi cl es wi th
manual transmi ssi on, i t i s grounded at al l ti mes. On
vehi cl es wi th automati c transmi ssi on, i t i s grounded
through park/neutral posi ti on swi tch onl y when gear-
shi ft sel ector l ever i s i n Park or Neutral posi ti ons.
Check for conti nui ty to ground at cavi ty for rel ay ter-
mi nal 85. I f not OK wi th manual transmi ssi on,
repai r ci rcui t to ground as requi red. I f not OK wi th
automati c transmi ssi on, check for pen or short ci rcui t
to park/neutral posi ti on swi tch and repai r, i f
requi red. I f ci rcui t to park/neutral posi ti on swi tch i s
OK, refer to Park/Neutral Position Switch i n 21,
Transmi ssi on.
Fig. 14 TYPE 1 RELAY
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
8F - 36 STARTING DR
STARTER MOTOR RELAY (Continued)
REMOVAL
The starter rel ay i s l ocated i n the Power Di stri bu-
ti on Center (PDC) (Fi g. 15). Refer to l abel on PDC
cover for rel ay l ocati on.
(2) Remove cover from Power Di stri buti on Center
(PDC) for rel ay i denti fi cati on and l ocati on.
(3) Remove starter rel ay from PDC.
(4) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(5) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
(1) Push down fi rml y on starter rel ay unti l termi -
nal s are ful l y seated i nto PDC receptacl e.
(2) I nstal l PDC cover.
(3) Connect battery cabl e.
Fig. 15 PDC LOCATION
1 - BATTERY
2 - INTEGRATED POWER MODULE (IPM)
DR STARTING 8F - 37
STARTER MOTOR RELAY (Continued)
HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . 6
HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . 7
HEATED GLASS
TABLE OF CONTENTS
page page
HEATED GLASS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER SYSTEM . . . . . . . . . . . . . . . . . . . 2
REAR WINDOW DEFOGGER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR WINDOW DEFOGGER SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR WINDOW DEFOGGER GRID
STANDARD PROCEDURE - GRID LINE AND
TERMINAL REPAIR . . . . . . . . . . . . . . . . . . . . . 4
HEATED GLASS
DESCRIPTION
CAUTION: Grid lines can be damaged or scraped off
with sharp instruments. Care should be taken in
cleaning glass or removing foreign materials, decals
or stickers. Normal glass cleaning solvents or hot
water used with rags or toweling is recommended.
The rear wi ndow defogger system consi sts of a
back gl ass wi th two verti cal el ectri cal bus bars l i nked
by a seri es of gri d l i nes fi red onto the i nsi de surface
of the opti onal heated rear wi ndow.
The rear wi ndow defogger system i s turned On or
Off by a swi tch and a ti mi ng ci rcui t i ntegral to the
A/C-heater control l ocated at the center of the i nstru-
ment panel .
Ci rcui t protecti on i s provi ded by a cartri dge fuse
l ocated i n the power di stri buti on center (PDC) for the
heated gri d ci rcui t, and a fuse l ocated i n the fuse
bl ock for the control ci rcui t.
OPERATION
The rear wi ndow defogger system i s turned on by a
momentary swi tch l ocated i n the A/C-heater control
on the i nstrument panel . When the rear wi ndow
defogger swi tch i s pressed to the On posi ti on, current
i s di rected through the rear wi ndow defogger rel ay to
the rear defogger gri d l i nes. The heated gri d l i nes
heat the rear gl ass to hel p cl ear the rear wi ndow sur-
face of fog or frost.
A yel l ow i ndi cator above the swi tch wi l l i l l umi nate
to i ndi cate when the rear wi ndow defogger system i s
turned on. The A/C-heater control contai ns the rear
wi ndow defogger system control ci rcui try.
NOTE: The rear window defogger turns off automat-
ically after approximately 10 minutes of initial oper-
ation. Each following activation cycle of the
defogger system will last approximately ten minutes
also.
The rear wi ndow defogger system wi l l be automat-
i cal l y turned off after a programmed ti me i nterval of
about ten mi nutes. After the i ni ti al ti me i nterval has
expi red, i f the defogger swi tch i s pressed to the On
posi ti on agai n duri ng the same i gni ti on cycl e, the
rear wi ndow defogger system wi l l automati cal l y turn
off after about ten mi nutes al so.
The rear wi ndow defogger system wi l l automati -
cal l y shut off i f the i gni ti on swi tch i s turned to the
Off posi ti on, or i t can be turned off manual l y by
pressi ng the defogger swi tch a second ti me.
DR HEATED SYSTEMS 8G - 1
DIAGNOSIS AND TESTING - REAR WINDOW
DEFOGGER SYSTEM
For ci rcui t descri pti ons and di agrams, refer to Rear
Wi ndow Defogger i n Wi ri ng Di agrams. The operati on
of the el ectri cal l y heated rear wi ndow defogger sys-
tem can be confi rmed i n one of the fol l owi ng man-
ners:
1. Turn the i gni ti on swi tch to the On posi ti on.
Whi l e moni tori ng the i nstrument panel vol tmeter, set
the defogger swi tch i n the On posi ti on. When the
defogger swi tch i s turned On, a di sti nct vol tmeter
needl e defl ecti on shoul d be noted.
2. Turn the i gni ti on swi tch to the On posi ti on. Set
the defogger swi tch i n the On posi ti on. The rear wi n-
dow defogger operati on can be checked by feel i ng the
rear wi ndow or outsi de rear vi ew mi rror gl ass. A di s-
ti nct di fference i n temperature between the gri d l i nes
and the adjacent cl ear gl ass or the mi rror gl ass can
be detected wi thi n three to four mi nutes of operati on.
3. Usi ng a 12-vol t DC vol tmeter, contact the rear
gl ass heati ng gri d termi nal A (ri ght si de) wi th the
negati ve l ead, and termi nal B (l eft si de) wi th the pos-
i ti ve l ead (Fi g. 1). The vol tmeter shoul d read battery
vol tage.
The above checks wi l l confi rm system operati on.
I l l umi nati on of the defogger swi tch i ndi cator l amp
means that there i s el ectri cal current avai l abl e at the
output of the rear wi ndow defogger l ogi c and ti mer
ci rcui try, but does not confi rm that the el ectri cal cur-
rent i s reachi ng the rear gl ass heati ng gri d l i nes.
I f the defogger system does not operate, the prob-
l em shoul d be i sol ated i n the fol l owi ng manner:
(1) Confi rm that the i gni ti on swi tch i s i n the On
posi ti on.
(2) Make sure that the rear gl ass heati ng gri d feed
and ground wi res are connected to the gl ass. Confi rm
that the ground wi re has conti nui ty to ground.
(3) Check the fuses i n the power di stri buti on cen-
ter (PDC) and i n the juncti on bl ock. The fuses must
be ti ght i n thei r receptacl es and al l el ectri cal connec-
ti ons must be secure.
When the above steps have been compl eted and the
rear gl ass heati ng gri d i s sti l l i noperati ve, one or
more of the fol l owi ng coul d be faul ty:
Rear wi ndow swi tch i n the A/C-heater control ..
Rear wi ndow gri d l i nes (al l gri d l i nes woul d
have to be broken or one of the feed wi res di scon-
nected for the enti re system to be i noperati ve).
I f setti ng the defogger swi tch to the On posi ti on
produces a severe vol tmeter defl ecti on, check for a
short ci rcui t between the rear wi ndow swi tch defog-
ger rel ay output and the rear gl ass heati ng gri d.
REAR WINDOW DEFOGGER
RELAY
DESCRIPTION
The rear wi ndow defogger rel ay (Fi g. 2) i s a I nter-
nati onal Standards Organi zati on (I SO) mi cro-rel ay.
Rel ays conformi ng to the I SO speci fi cati ons have
common physi cal di mensi ons, current capaci ti es, ter-
mi nal patterns, and termi nal functi ons. The I SO
mi cro-rel ay termi nal functi ons are the same as a con-
venti onal I SO rel ay. However, the I SO mi cro-rel ay
termi nal pattern (or footpri nt) i s di fferent, the cur-
rent capaci ty i s l ower, and the physi cal di mensi ons
are smal l er than those of the conventi onal I SO rel ay.
The rear wi ndow defogger rel ay i s l ocated i n the
power di stri buti on center (PDC) i n the engi ne com-
partment. Refer to the PDC l abel for rear wi ndow
defogger rel ay i denti fi cati on and l ocati on.
The bl ack, mol ded pl asti c case i s the most vi si bl e
component of the rear wi ndow defogger rel ay. Fi ve
mal e spade-type termi nal s extend from the bottom of
the base to connect the rel ay to the vehi cl e el ectri cal
system, and the I SO desi gnati on for each termi nal i s
mol ded i nto the base adjacent to each termi nal . The
I SO termi nal desi gnati ons are as fol l ows:
30 (Common Feed) - Thi s termi nal i s con-
nected to the movabl e contact poi nt of the rel ay.
85 (Coil Ground) - Thi s termi nal i s connected
to the ground feed si de of the rel ay control coi l .
86 (Coil Battery) - Thi s termi nal i s connected
to the battery feed si de of the rel ay control coi l .
87 (Normally Open) - Thi s termi nal i s con-
nected to the normal l y open fi xed contact poi nt of the
rel ay.
Fig. 1 Grid Line Test - Typical
1 - VIEW FROM INSIDE VEHICLE
2 - REAR WINDOW DEFOGGER
3 - BUS BARS
4 - VOLTAGE FEED (A)
5 - VOLTMETER
6 - MID-POINT (C)
7 - PICK-UP LEADS
8 - GROUND (B)
8G - 2 HEATED GLASS DR
HEATED GLASS (Continued)
87A (Normally Closed) - Thi s termi nal i s con-
nected to the normal l y cl osed fi xed contact poi nt of
the rel ay.
The rear wi ndow defogger rel ay cannot be adjusted
or repai red. I f the rel ay i s damaged or faul ty, i t must
be repl aced.
OPERATION
The rear wi ndow defogger rel ay i s an el ectrome-
chani cal swi tch that uses a l ow current i nput from
the i ntegrated power modul e (I PM) to control the
hi gh current output to the rear wi ndow defogger
gri d. The movabl e common feed contact poi nt i s hel d
agai nst the fi xed normal l y cl osed contact poi nt by
spri ng pressure. When the rel ay coi l i s energi zed, an
el ectromagneti c fi el d i s produced by the coi l wi nd-
i ngs. Thi s el ectromagneti c fi el d draws the movabl e
rel ay contact poi nt away from the fi xed normal l y
cl osed contact poi nt, and hol ds i t agai nst the fi xed
normal l y open contact poi nt. When the rel ay coi l i s
de-energi zed, spri ng pressure returns the movabl e
contact poi nt back agai nst the fi xed normal l y cl osed
contact poi nt. The resi stor or di ode i s connected i n
paral l el wi th the rel ay coi l i n the rel ay, and hel ps to
di ssi pate vol tage spi kes and el ectromagneti c i nterfer-
ence that can be generated as the el ectromagneti c
fi el d of the rel ay coi l col l apses.
The rear wi ndow defogger rel ay termi nal s are con-
nected to the vehi cl e el ectri cal system through a
receptacl e i n the I PM. The i nputs and outputs of the
rear wi ndow defogger rel ay i ncl ude:
The common feed termi nal (30) recei ves a bat-
tery current i nput from fuse 27 (15 amp) i n the I PM
through a fused B(+) ci rcui t at al l ti mes.
The coi l ground termi nal (87) recei ves a ground
i nput from the A/C-heater control when the A/C-
heater control el ectroni cal l y pul l s the control ci rcui t
to ground.
The coi l battery termi nal (85) recei ves a battery
current i nput from fuse 36 (10 amp) i n the I PM
through a fused B(+) ci rcui t onl y when the i gni ti on
swi tch i s i n the Run posi ti on.
The normal l y open termi nal (86) provi des a bat-
tery current output to the rear wi ndow defogger and
heated power mi rrors (when equi pped) through the
rel ay output ci rcui t onl y when the rear wi ndow
defogger rel ay coi l i s energi zed.
The normal l y cl osed termi nal (87A) i s not con-
nected to any ci rcui t i n thi s appl i cati on, but provi des
a battery current output onl y when the rear wi ndow
defogger rel ay coi l i s de-energi zed.
The rear wi ndow defogger rel ay cannot be repai red
and, i f faul ty or damaged, i t must be repl aced. Refer
to the appropri ate wi ri ng i nformati on for di agnosi s
and testi ng of the mi cro-rel ay and for compl ete rear
wi ndow defogger system wi ri ng di agrams.
REMOVAL
(1) Di sconnect and i sol ate the negati ve battery cabl e.
(2) Remove the cover from the i ntegrated power
modul e (I PM) (Fi g. 3).
(3) Refer to the fuse and rel ay l ayout map on the
i nner surface of the I PM cover for rear wi ndow defog-
ger rel ay i denti fi cati on and l ocati on.
(4) Remove the rear wi ndow defogger rel ay from
the I PM.
Fig. 2 Rear Window Defogger Relay
1 - RELAY TERMINALS
2 - RELAY CAVITIES
Fig. 3 Integrated Power Module (IPM)
1 - BATTERY
DR HEATED GLASS 8G - 3
REAR WINDOW DEFOGGER RELAY (Continued)
INSTALLATION
(1) Refer to the fuse and rel ay l ayout map on the
i nner surface of the i ntegrated power modul e (I PM)
for rear wi ndow defogger rel ay i denti fi cati on and
l ocati on.
(2) Posi ti on the rear wi ndow defogger rel ay i nto
the proper receptacl e i n the I PM.
(3) Al i gn the rear wi ndow defogger rel ay termi nal s
wi th the termi nal cavi ti es i n the I PM receptacl e.
(4) Push down fi rml y on the rear wi ndow defogger
rel ay unti l the termi nal s are ful l y seated i n the ter-
mi nal cavi ti es i n the I PM receptacl e.
(5) I nstal l the cover onto the I PM.
SWITCH
DESCRIPTION
The rear wi ndow defogger swi tch i s i ntegrated i nto
the A/C-heater control mounted i n the center of the
i nstrument panel . The rear wi ndow defogger swi tch
and the rear wi ndow defogger LED i ndi cator cannot
be repai red and, i f faul ty or damaged, the A/C-heater
control must be repl aced.
OPERATION
An LED i ndi cator wi l l i l l umi nate when the rear
wi ndow defogger swi tch i s acti vated. The swi tch
energi zes the ti mi ng ci rcui t i ntegral to the A/C-
heater control whi ch then acti vates the rear wi ndow
defogger rel ay. The rear wi ndow defogger rel ay con-
trol s the current to fl ow to the gri ds of the rear wi n-
dow defogger. The rear wi ndow defogger system wi l l
operate for approxi matel y ten mi nutes or unti l the
rear wi ndow defogger swi tch or i gni ti on swi tch i s
turned off. Refer to 8 - ELECTRI CAL/HEATED
GLASS - DI AGNOSI S AND TESTI NG for di agnosi s
and testi ng of the rear wi ndow defogger swi tch.
The rear wi ndow defogger swi tch cannot be
repai red and, i f faul ty or damaged, i t must be
repl aced. (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/CONTROLS/A/C HEATER CONTROL -
REMOVAL).
GRID
STANDARD PROCEDURE - GRID LINE AND
TERMINAL REPAIR
REAR WINDOW DEFOGGER GRID LINE REPAIR
WARNING: THE REPAIR KIT CONTAINS EPOXY
RESIN AND AMINE TYPE HARDENER WHICH MAY
CAUSE SKIN OR EYE IRRITATION AND CAN BE
HARMFUL IF SWALLOWED. USE WITH ADEQUATE
VENTILATION. DO NOT USE NEAR FIRE OR OPEN
FLAME THE CONTENTS CONTAIN FLAMMABLE
SOLVENTS. KEEP OUT OF REACH OF CHILDREN.
DO NOT TAKE INTERNALLY, IF SWALLOWED
INDUCE VOMITING AND CALL A PHYSICIAN IMME-
DIATELY.
IF SKIN CONTACT OCCURS, WASH AFFECTED
AREAS WITH SOAP AND WATER.
IF EYE CONTACT OCCURS, FLUSH WITH
PLENTY OF WATER.
The repai r of the gri d l i nes i s possi bl e usi ng the
Mopar Gri d Li ne Repai r Package or an equi val ent.
(1) Mask the repai r area so the conducti ve epoxy
can be extended onto the gri d l i ne(s) or the bus bar
(Fi g. 4).
(2) Fol l ow the i nstructi ons i n the repai r ki t for
prepari ng the damaged area.
(3) Remove the package separator cl amp and mi x
the conducti ve epoxy thoroughl y. Fol d i n hal f and cut
the center corner to di spense the epoxy.
(4) Appl y the conducti ve epoxy through the sl i t i n
the maski ng tape. Overl ap both ends of the break(s)
by 19 mm (3/4 i nch).
(5) Careful l y remove the maski ng tape from the
gri d l i ne(s).
CAUTION: To prevent the glass from fracturing, do
not allow the glass surface to exceed 204 C (400
F).
(6) Al l ow the epoxy to cure 24 hours at room tem-
perature or use a heat gun wi th a 260 to 371 C
(500 to 700 F) range for 15 mi nutes. Hol d the heat
gun approxi matel y 254 mm (10 i nches) from the
repai red area.
(7) After the conducti ve epoxy i s properl y cured,
veri fy operati on of the rear wi ndow defogger.
8G - 4 HEATED GLASS DR
REAR WINDOW DEFOGGER RELAY (Continued)
REAR WINDOW DEFOGGER GRID TERMINAL REPAIR
WARNING: THE REPAIR KIT CONTAINS EPOXY
RESIN AND AMINE TYPE HARDENER WHICH MAY
CAUSE SKIN OR EYE IRRITATION AND CAN BE
HARMFUL IF SWALLOWED. USE WITH ADEQUATE
VENTILATION. DO NOT USE NEAR FIRE OR OPEN
FLAME THE CONTENTS CONTAIN FLAMMABLE
SOLVENTS. KEEP OUT OF REACH OF CHILDREN.
DO NOT TAKE INTERNALLY, IF SWALLOWED
INDUCE VOMITING AND CALL A PHYSICIAN IMME-
DIATELY.
IF SKIN CONTACT OCCURS, WASH AFFECTED
AREAS WITH SOAP AND WATER.
IF EYE CONTACT OCCURS, FLUSH WITH
PLENTY OF WATER.
I f the rear wi ndow defogger gri d termi nal (s) i s
damaged or separated from the rear wi ndow, the
repai r of the gri d termi nal s i s possi bl e usi ng the
Mopar Gri d Li ne Repai r Package or an equi val ent.
(1) I f the gri d termi nal (s) i s broken and a porti on
of the termi nal i s sti l l attached to the heati ng gri d,
remove the porti on of the cl i p remai ni ng i n the wi re
harness connector(s).
(2) Mask the areas so the conducti ve epoxy can be
extended onto the adjacent gri d l i ne(s) as wel l as the
bus bar.
(3) Appl y a thi n l ayer of conducti ve epoxy to the
area where the termi nal (s) where fastened and to the
adjacent gri d l i ne(s).
NOTE: To prevent the terminal(s) from moving while
the epoxy is curing, a wedge or clamp must be
used.
(4) Appl y a thi n l ayer of conducti ve epoxy on the
termi nal (s) and properl y ori ent the termi nal (s) at the
desi red l ocati on(s).
CAUTION: To prevent the glass from fracturing, do
not allow the glass surface to exceed 204 C (400
F).
(5) Al l ow the epoxy to cure 24 hours at room tem-
perature or use a heat gun wi th a 260 to 371 C
(500 to 700 F) range for 15 mi nutes. Hol d the heat
gun approxi matel y 254 mm (10 i nches) from repai red
area.
NOTE: To ensure proper installation, do not attach
the wire harness connector(s) to the terminal(s)
until the epoxy is completely cured.
(6) After the conducti ve epoxy has properl y cured,
remove the wedge or cl amp from the termi nal (s),
reconnect the wi re harness connector(s) and veri fy
operati on of the rear wi ndow defogger.
Fig. 4 Grid Line Repair
1 - BREAK
2 - GRID LINE
3 - MASKING TAPE
DR HEATED GLASS 8G - 5
REAR WINDOW DEFOGGER GRID (Continued)
HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HEATED MIRRORS
DESCRIPTION
El ectri cal l y heated outsi de rear vi ew mi rrors are
an addi ti onal factory-i nstal l ed opti on on model s that
are equi pped wi th factory-i nstal l ed dual power mi r-
rors and the heated rear wi ndow defogger system.
Vehi cl es wi th thi s opti on can be vi sual l y i denti fi ed by
the I nternati onal Control and Di spl ay Symbol i con
for rear wi ndow defogger, whi ch appears on the l ower
i nboard corner of each outsi de mi rror gl ass (Fi g. 1).
The opti onal heated mi rror system operates i n con-
cert wi th the rear wi ndow defogger system, and wi l l
be automati cal l y shut off after a programmed ti me
i nterval of about ten mi nutes. After the i ni ti al ti me
i nterval has expi red, i f the defogger swi tch i s turned
on agai n duri ng the same i gni ti on cycl e, the heated
mi rror system wi l l automati cal l y shut off after about
ten mi nutes al so.
The heated mi rror system wi l l automati cal l y shut
off i f the i gni ti on swi tch i s turned to the Off posi ti on,
or i t can be shut off manual l y by pressi ng the rear
wi ndow defogger swi tch a second ti me.
OPERATION
When the rear wi ndow defogger swi tch i s i n the
On posi ti on, an el ectri c heater gri d l ocated behi nd
the gl ass of each of the outsi de rear vi ew mi rrors i s
energi zed. When energi zed, each of these heater
gri ds produce heat to hel p cl ear the outsi de rear vi ew
mi rrors of i ce, snow, or fog.
The heated mi rror system i s control l ed by a
momentary rear wi ndow defogger swi tch on the A/C-
heater control . An amber i ndi cator l amp i n the
swi tch wi l l i l l umi nate to i ndi cate when the defogger
system i s turned on.
I f the outsi de mi rror heati ng gri ds are both i noper-
ati ve, refer to DI AGNOSI S AND TESTI NG - REAR
WI NDOW DEFOGGER SYSTEM i n hi s group. I f
onl y one of the outsi de mi rror heati ng gri ds i s i nop-
erati ve, Refer to 8 - ELECTRI CAL/POWER MI R-
RORS - DI AGNOSI S AND TESTI NG.
The heati ng gri d behi nd each outsi de mi rror gl ass
cannot be repai red and, i f faul ty or damaged, the
enti re power mi rror uni t must be repl aced.
Fig. 1 Heated Mirror - Typical
1 - POWER HEATED OUTSIDE REAR VIEW MIRROR
2 - REAR WINDOW DEFOGGER ICON
8G - 6 HEATED MIRRORS DR
HEATED SEAT SYSTEM
TABLE OF CONTENTS
page page
HEATED SEAT SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HEATED SEAT ELEMENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
HEATED SEAT SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
HEATED SEAT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
HEATED SEAT MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
HEATED SEAT SYSTEM
DESCRIPTION
I ndi vi dual l y control l ed, el ectri cal l y heated front
seats are avai l abl e as a factory-i nstal l ed opti on on
some DR model s. Vehi cl es wi th thi s opti on can be
vi sual l y i denti fi ed by the l eather tri m seats and two
separate heated seat swi tches mounted i n the l ower
center of the i nstrument panel . The heated seat sys-
tem al l ows the front seat dri ver and passenger to
sel ect from two di fferent l evel s of el ectri cal seat heat-
i ng, or no seat heati ng to sui t thei r i ndi vi dual com-
fort requi rements. The heated seat system for thi s
vehi cl e i ncl udes the fol l owi ng major components,
whi ch are descri bed i n further detai l l ater i n thi s sec-
ti on:
Heated Seat Switches - Two heated seat
swi tches are used per vehi cl e. One swi tch i s used for
each front seat. The swi tches are mounted i n the
i nstrument panel , bel ow the radi o (Fi g. 1). Each
swi tch al so i ncl udes two Li ght-Emi tti ng Di ode (LED)
i ndi cator l amps and an i ncandescent back l i ghti ng
bul b.
Heated Seat Module - al so referred to as the
Seat Heat I nterface Modul e (SHI M), thi s modul e con-
tai ns the sol i d state el ectroni c control and di agnosti c
l ogi c ci rcui try for the heated seat system. One heated
seat modul e i s used per vehi cl e and i s mounted
under the dri vers front seat cushi on (Fi g. 1). Refer to
the El ectroni c Control Modul es secti on of the servi ce
manual for addi ti onal heated seat modul e i nforma-
ti on.
Heated Seat Elements - Four heated seat el e-
ments are used per vehi cl e. One el ement i s used for
each front seat back and one el ement and sensor
assembl y i s used for each front seat cushi on (Fi g. 1).
The heati ng el ements are i ntegral to the i ndi vi dual
front seat and seat back cushi ons and cannot be
removed once i nstal l ed at the factory. Repl acement
seat heati ng el ements are avai l abl e, wi thout havi ng
to repl ace the enti re seat cushi on or tri m cover. Refer
to the detai l ed procedure l ater i n thi s secti on.
Heated Seat Sensors - Two heated seat sen-
sors are used per vehi cl e. One heated seat tempera-
ture sensor i s used for each front seat cushi on. The
sensors are i ntegral to the i ndi vi dual front seat cush-
i on heati ng el ements (Fi g. 1) and cannot be removed
once i nstal l ed at the factory. Repl acement seat heat-
i ng el ements wi th the sensors are avai l abl e, wi thout
havi ng to repl ace the enti re seat cushi on or tri m
cover. Refer to the detai l ed procedure l ater i n thi s
secti on.
Fol l owi ng are general descri pti ons and operati ons
of the major components i n the heated seat system.
See the owners manual i n the vehi cl e gl ove box for
more i nformati on on the features, use and operati on
of the heated seat system. Refer to Wiring for the
l ocati on of compl ete heated seat system wi ri ng di a-
grams.
DR HEATED SEAT SYSTEM 8G - 7
OPERATION
The heated seat modul e recei ves fused battery cur-
rent through the I ntegrated Power Modul e. The
heated seat swi tches recei ve battery current from the
Cab Compartment Node (CCN) onl y when the i gni -
ti on swi tch i s i n the On posi ti on and the engi ne i s
runni ng. The heated seat modul e shares a common
ground ci rcui t wi th each of the heated seat el ements.
The heated seat system wi l l control the surface tem-
perature of the seat cushi on to wi thi n the desi gned
temperature set poi nts of the system.
The heated seat system wi l l al so automati cal l y
turn off whenever the i gni ti on swi tch i s turned to
any posi ti on except On, or i f the engi ne qui ts run-
ni ng. I f the i gni ti on swi tch i s turned to the Off posi -
ti on or i f the engi ne qui ts runni ng whi l e a heated
seat i s ON, the heated seat wi l l remai n Off after the
engi ne i s restarted unti l a heated seat swi tch i s
depressed agai n. Thi s hel ps prevent the vehi cl es bat-
tery from bei ng drai ned by the heated seat system.
The heated seat modul e moni tors i nputs from the
heated seat sensors and the heated seat swi tches. I n
response to these i nputs the heated seat modul e uses
i ts i nternal programmi ng to control 12v to the heated
seat el ements i n both front seats and to control the
heated seat LED i ndi cator l amps l ocated i n both of
the heated seat swi tches. The heated seat modul e i s
al so programmed to provi de sel f-di agnosti cs, i f a
probl em wi th the heated seat system i s detected. I f
the modul e detects certai n fai l ures wi thi n the heated
seat system, i t wi l l provi de a vi sual i ndi cati on of the
fai l ure by fl ashi ng the i ndi cator l amps i n the appro-
pri ate heated seat swi tch. The heated seat modul e
wi l l automati cal l y turn off the heated seat el ements
i f i t detects a short or open i n the heated seat el e-
ment ci rcui t or a heated seat sensor val ue that i s out
of range.
SYSTEM
HEATED SEAT SYSTEM SELF-DIAGNOSIS
The heated seat system i s capabl e of performi ng
some sel f-di agnosti cs. The fol l owi ng tabl e depi cts the
vari ous moni tored fai l ures whi ch wi l l be reported to
the vehi cl e operator or techni ci an by fl ashi ng the
i ndi vi dual heated seat swi tch Li ght Emi tti ng Di ode
(LED) i ndi cator l amps. Refer to the HEATED SEAT
SYSTEM SELF-DI AGNOSI S tabl e for fai l ure i denti -
fi cati on. The dri vers heated seat swi tch i ndi cator
l amps wi l l fl ash i f a fai l ure occurs i n the dri ver
heated seat, and the passengers heated seat swi tch
i ndi cator l amps wi l l fl ash for a passenger heated seat
fai l ure. I f a moni tored heated seat system fai l ure
occurs, the swi tch i ndi cator l amps wi l l fl ash at a
pul se rate of about one-hal f second on, fol l owed by
about one-hal f second off for a durati on of about one
mi nute after the swi tch for the faul ty heated seat i s
depressed i n ei ther the Low or Hi gh di recti on. Thi s
process wi l l repeat every ti me the faul ty heated seat
swi tch i s actuated unti l the probl em has been cor-
rected.
HEATED SEAT SYSTEM SELF-DIAGNOSIS
Monitored Failure
Switch High
Indicator Lamp
Switch Low
Indicator Lamp
Heated Seat
Element Shorted
Flashing Flashing
Heated Seat
Element Open
Flashing Off
Heated Seat
Sensor Value Out
of Range
Off Flashing
Di agnosti c l ogi c i s bui l t i nto the heated seat mod-
ul e to hel p the person tryi ng to l ocate the probl em by
the most effi ci ent means possi bl e. Anyti me a probl em
Fig. 1 DR Heated Seat System Diagram
1 - WIRE HARNESS
2 - DRIVER HEATED SEAT SWITCH
3 - PASSENGER HEATED SEAT SWITCH
4 - PASSENGER HEATED SEAT CUSHION ELEMENT
5 - SEAT CUSHION/BACK ELEMENT ELECTRICAL CONNECTOR
LOCATION
6 - DRIVER HEATED SEAT BACK ELEMENT
7 - DRIVER HEATED SEAT CUSHION ELEMENT
8G - 8 HEATED SEAT SYSTEM DR
HEATED SEAT SYSTEM (Continued)
i s suspected, l ocate the di agnosi s and testi ng proce-
dure for the component i n questi on and fol l ow the
steps unti l the speci fi c probl em i s l ocated and
resol ved. Once the probl em i s thought to be cor-
rected, veri fy correct system operati on. I f the heated
seat system i s functi oni ng correctl y return the vehi -
cl e to servi ce.
I f a probl em coul d not be veri fi ed such as not fi nd-
i ng anythi ng wrong when fol l owi ng the di agnosti c
procedure, thi s i s a good i ndi cati on that a I NTER-
MI TTENT probl em may be present. You must then
attempt to fi nd the i ntermi ttent probl em, such as
movi ng the heati ng el ement wi thi n the seat whi l e
testi ng conti nui ty or wi ggl i ng the wi re harnesss/el ec-
tri cal connectors under the seat whi l e testi ng conti -
nui ty. Al ways, el i mi nate al l other potenti al probl ems
before attempti ng to repl ace the heated seat modul e.
PRELIMINARY TEST
Refer to Wiring for the l ocati on of compl ete heated
seat system wi ri ng di agrams. Before testi ng the i ndi -
vi dual components i n the heated seat system, per-
form the fol l owi ng prel i mi nary checks:
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
CABLE, THEN WAIT TWO MINUTES FOR THE AIR-
BAG SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE AIRBAG SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
I f the heated seat swi tch back l i ghti ng and the
cl uster i l l umi nati on l amps do not i l l umi nate wi th the
headl amps or park l amps turned On, refer to the
Instrument Cluster secti on of the servi ce manual
for the l ocati on of cl uster i l l umi nati on l amp di agnosi s
and testi ng procedures. I f the heated seat swi tch
back l i ghti ng does not i l l umi nate, but the cl uster i l l u-
mi nati on l amps do i l l umi nate wi th the headl amps or
park l amps turned On, refer to Diagnosis and Test-
ing the Heated Seat Switch i n thi s secti on for the
l ocati on of the heated seat swi tch di agnosi s and test-
i ng procedures.
I f a si ngl e LED i ndi cator l amp for one heated
seat swi tch does not operate and the heated seat el e-
ments do heat, refer to Diagnosis and Testing the
Heated Seat Switch i n thi s secti on for heated seat
swi tch di agnosi s and testi ng procedures.
I f both LED i ndi cator l amps for a heated seat
swi tch operate, but the heated seat el ements do not
heat, refer to Diagnosis and Testing the Heated
Seat Module i n El ectroni c Control Modul es for
heated seat modul e di agnosi s and testi ng procedures.
I f the i ndi cator l amp on ei ther heated seat
swi tch remai ns i l l umi nated after the heated seat has
been turned Off, refer to Diagnosis and Testing
the Heated Seat Module i n El ectroni c Control
Modul es for heated seat modul e di agnosi s and test-
i ng procedures.
HEATED SEAT ELEMENT
DESCRIPTION
Vehi cl es equi pped wi th the opti onal heated seat
system have two sets of el ectri cal l y operated heati ng
el ement gri ds l ocated i n each front seat, one set for
the seat cushi on and the other set for the seat back.
Each of the heated seat el ement gri ds consi sts of a
si ngl e l ength of resi stor wi re that i s routed i n a zi g-
zag pattern and captured between a coveri ng and the
adhesi ve foam rubber backi ng. Short pi gtai l wi res
wi th connectors (Fi g. 2) are sol dered to each end of
each resi stor wi re el ement gri d, whi ch connect al l of
the el ement gri ds to the heated seat modul e through
the seat wi re harness.
One temperature sensor i s used for each front seat,
and i t i s l ocated i n the center i nsert area of the seat
cushi on el ement. The heated seat sensors and thei r
Fig. 2 Heating Element Installed on Seat Cushion
Foam
1 - SEAT BACK WIRE HARNESS
2 - HEATED SEAT WIRE HARNESS CONNECTOR
3 - HEATED SEAT CUSHION ELEMENT
HEATED SEAT SYSTEM (Continued)
pi gtai l wi res are al so captured between a coveri ng
and the adhesi ve foam rubber backi ng. The heated
seat sensors are Negati ve Thermal Coeffi ci ent (NTC)
thermi stors. The sensors for both front seats recei ve
a vol tage feed from a si ngl e output of the heated seat
modul e, but the modul e recei ves i ndi vi dual sensor
i nputs from the dri ver si de and passenger si de sen-
sors.
The heated seat el ements and sensors shoul d not
be repai red. I f damaged or faul ty, the heated seat el e-
ment assembl y must be repl aced.
OPERATION
One end of the heated seat el ement resi stor wi re i s
connected to ground at al l ti mes through a spl i ce i n
the heated seat modul e ground ci rcui t. Battery cur-
rent i s di rected to the other end of the heated seat
el ement resi stor wi re by the energi zed N-channel
Fi el d Effect Transi stor (N-FET) l ocated wi thi n the
heated seat modul e. The heated seat modul e wi l l
energi ze the N-FET onl y when the heated seat
swi tch i s i n the Low or Hi gh posi ti on and the heated
seat sensor i ndi cates that the seat cushi on surface
temperature i s bel ow the sel ected (Low or Hi gh) tem-
perature set poi nt. As el ectri cal current passes
through the heati ng el ement gri d, the resi stance of
the wi re used i n the el ement di sperses some of that
el ectri cal current i n the form of heat. The heat pro-
duced by the heated seat el ement gri d then radi ates
through the seat tri m cover, warmi ng i ts occupant.
The resi stance of the heated seat sensor i ncreases
and decreases as the surface temperature of the seat
cushi on cover changes. The heated seat modul e sup-
pl i es each sensor wi th a 5v vol tage feed, then uses
the sensor resi stance to determi ne when the heated
seat el ement gri ds need to be cycl ed on or off i n order
to mai ntai n the sel ected temperature set poi nt.
ELEMENT
The heated seat modul e wi l l sel f-di agnose shorted
or open heated seat el ement ci rcui ts and sensor ci r-
cui ts. Refer to Heated Seat System Di agnosi s and
Testi ng i n thi s secti on for addi ti onal di agnosi s and
testi ng procedures. To manual l y check the heated
seat el ement, proceed as fol l ows. The wi re harness
connectors for the seat cushi on and seat back heati ng
el ements and sensor are l ocated on the ri ght si de of
the seat, near the edge of the seat cushi on frame.
The proper connector can be i denti fi ed by the foam
wrappi ng.
NOTE: When checking heated seat elements for
continuity, be certain to move the heating element
being checked. Moving the element, such as sitting
in the seat will eliminate the possibility of an inter-
mittent open in the element which would only be
evident if the element was in a certain position.
Failure to check the element in various positions
could result in an incomplete test.
(1) Posi ti on the appropri ate seat i n the ful l for-
ward posi ti on.
(2) Make certai n the i gni ti on swi tch i s i n the OFF
posi ti on.
(3) Di sconnect the heated seat el ement connector
whi ch requi res testi ng. Check for conti nui ty between
the two heated seat el ement ci rcui t cavi ti es whi l e
movi ng the appropri ate seat cushi on. Refer to Wir-
ing for the l ocati on of compl ete heated seat system
wi ri ng di agrams. There shoul d be conti nui ty. I f OK,
the el ements wi thi n the seat assembl y test OK, go to
Step 4. I f not OK, repl ace the faul ty seat heati ng el e-
ment, refer to the procedure i n thi s secti on.
(4) Test the seat wi re harness between the heated
seat modul e connector and the appropri ate heated
seat wi re harness connector for shorted or open ci r-
cui ts. I f OK, el ement i s OK, proceed wi th testi ng the
heated seat sensor and modul e. I f not OK, repai r the
shorted or open seat wi re harness as requi red.
REMOVAL
Do not remove the heati ng el ement from the seat
or seat back cushi on. The ori gi nal el ement i s perma-
nentl y attached to the seat cushi ons and cannot be
removed wi thout damagi ng the cushi on. The repl ace-
ment heati ng el ement i s desi gned to be appl i ed
di rectl y over the ori gi nal seat heati ng el ement.
(1) Di sconnect and i sol ate the negati ve battery
cabl e.
(2) Remove the appropri ate seat cushi on or seat
back tri m cover. Refer to the Body secti on of thi s
manual for the procedures.
(3) Di sconnect the i noperati ve heated seat cushi on
or seat back el ement el ectri cal connectors.
(4) Locate the wi res l eadi ng from the i noperati ve
heati ng el ement and cut them off fl ush wi th the edge
of the ori gi nal heati ng el ement.
INSTALLATION
(1) Peel off the adhesi ve backi ng on the back of the
repl acement heati ng el ement and sti ck di rectl y over
the ori gi nal heati ng el ement (Fi g. 3).
CAUTION: During the installation of the replace-
ment heating element, be careful not to fold or
crease the element assembly. Folds or creases will
cause premature failure.
(2) Connect the new heati ng el ement el ectri cal
connectors (Fi g. 2).
(4) Veri fy heated seat system operati on.
HEATED SEAT ELEMENT (Continued)
(5) I nstal l the appropri ate seat cushi on or seat
back tri m cover. Make certai n the seat wi re harness
i s correctl y routed through the seat and seat back.
HEATED SEAT SENSOR
DESCRIPTION
The heated seat temperature sensor i s a Negati ve
Temperature Coeffi ci ent (NTC) thermi stor. One tem-
perature sensor i s used for each seat. Thi s tempera-
ture sensor i s l ocated i n the seat cushi on heati ng
el ement on al l model s.
The heated seat temperature sensor cannot be
repai red or adjusted and must be repl aced i f defec-
ti ve. The heated seat cushi on el ement must be
repl aced i f the temperature sensor i s defecti ve. Refer
to the procedure i n thi s secti on of the servi ce man-
ual .
OPERATION
When the temperature of the seat cushi on cover
ri ses, the resi stance of the sensor decreases. The
heated seat modul e suppl i es fi ve-vol ts to one si de of
each sensor, and moni tors the vol tage drop through
the sensor on a return ci rcui t. The heated seat mod-
ul e uses thi s temperature sensor i nput to moni tor
the temperature of the seat, and regul ates the cur-
rent fl ow to the seat heati ng el ements accordi ngl y.
SENSOR
NOTE: Any resistance values (OHMS ) given in the
following text are supplied using the automatic
range generated by a FLUKE automotive meter. If
another type of measuring device is used, the val-
ues generated may not be the same as the results
shown here, or may have to be converted to the
range used here.
(1) Posi ti on the dri ver seat i n the ful l rearward
posi ti on.
(2) Uncl i p the heated seat modul e from the bottom
of the dri vers seat cushi on pan.
(3) Back-probe the heated seat modul e wi re har-
ness connector, do not di sconnect. Check cavi ty (#7
for passenger, #8 for dri ver seat) for a range i n vol t-
age from approx. 1.72 3.0 vol ts. I t shoul d be wi thi n
thi s range, I f OK check the heated seat el ement. I f
NOT OK, check for the proper 5 vol t suppl y to the
heated seat sensor, from the modul e. Refer to Wi ri ng
for speci fi c i nformati on. I f 5 vol ts i s not bei ng sup-
pl i ed to the sensor from the modul e, repl ace the
heated seat modul e.
(4) Test the seat wi re harness between the heated
seat modul e connector and the heated seat wi re har-
ness connector for shorted or open ci rcui ts. I f OK,
refer to Diagnosis and Testing the Heated Seat
Module i n El ectroni c Control Modul es, for the
proper heated seat modul e di agnosi s and testi ng pro-
cedures. I f not OK, repai r the shorted or open heated
seat wi re harness as requi red.
REMOVAL
(1) For heated seat sensor repl acement procedure
(Refer to 8 - ELECTRI CAL/HEATED SEATS/
HEATED SEAT ELEMENT - REMOVAL).
HEATED SEAT SWITCH
DESCRIPTION
The momentary, bi di recti onal rocker-type heated
seat swi tch (Fi g. 4) provi des a resi stor-mul ti pl exed
si gnal to the heated seat modul e vi a a mux ci rcui t.
Each swi tch has a center neutral posi ti on and
momentary Low and Hi gh posi ti ons so that both the
dri ver and the front seat passenger can sel ect a pre-
ferred l evel of seat heati ng. Each heated seat swi tch
has two Li ght-Emi tti ng Di ode (LED) i ndi cator l amps,
whi ch i ndi cate the sel ected mode (Low or Hi gh) of
the seat heater. These i ndi cator l amps al so provi de
di agnosti c feedback for the heated seat system. Each
swi tch al so has an i ncandescent bul b, whi ch provi des
Fig. 3 Heating Element Installation
1 - ORIGINAL (INOPERATIVE) HEATING ELEMENT
2 - REPLACEMENT HEATING ELEMENT
HEATED SEAT ELEMENT (Continued)
di mmer control l ed back l i ghti ng of the swi tch when
the headl amps or park l amps are on.
The heated seat swi tches are both mounted i n the
i nstrument panel center bezel , l ocated i n the l ower
center of the i nstrument panel . The two swi tches are
snapped i nto the mounti ng hol es of the heated seat
swi tch bezel , and the heated seat swi tch bezel i s
secured wi th screws to the i nstrument panel center
bezel . The heated seat swi tches are di fferenti ated by
the keyway i n the connector receptacl e on the backs
of the swi tches and keyway on the swi tch housi ng.
The i nstrument panel wi re harness connectors for
the heated seat swi tches are keyed to match the con-
nector receptacl es on the swi tches so that the two
heated seat swi tches can onl y be connected to the
proper heated seat el ectri cal .
The two LED i ndi cator l amps and the i ncandescent
bul b i n each heated seat swi tch cannot be repai red. I f
the i ndi cator l amps or back l i ghti ng bul b are faul ty
or damaged, the i ndi vi dual heated seat swi tch must
be repl aced.
OPERATION
The heated seat swi tches recei ve battery current
through a fused i gni ti on swi tch output (run) ci rcui t
when the i gni ti on swi tch i s i n the On posi ti on.
Depressi ng the heated seat swi tch rocker to i ts
momentary Hi gh or Low posi ti on provi des a hard-
wi red resi stance si gnal to the heated seat modul e.
Thi s si gnal tel l s the modul e to energi ze the heated
seat el ement of the sel ected seat and mai ntai n the
requested temperature setti ng. I f the heated seat
swi tch i s depressed to a di fferent posi ti on (Low or
Hi gh) than the currentl y sel ected state, the heated
seat modul e wi l l change states to support the new
sel ecti on. I f a heated seat swi tch i s depressed a sec-
ond ti me, the heated seat modul e i nterprets the sec-
ond i nput as a request to turn the seat heater OFF.
The Hi gh and Low LED i ndi cator l amps i n the
heated seat swi tches recei ve battery current through
a fused i gni ti on swi tch output (run) ci rcui t when the
i gni ti on swi tch i s i n the On posi ti on. The ground si de
of each i ndi cator l amp i s control l ed by the heated
seat modul e. Thi s control of the swi tch i ndi cator
l amps al so al l ows the modul e to provi de di agnosti c
feedback to the vehi cl e operator or techni ci an to i ndi -
cate heated seat system faul ts by fl ashi ng the i ndi ca-
tor l amps on and off. One si de of the i ncandescent
back l i ghti ng bul b i n each heated seat swi tch i s con-
nected to ground at al l ti mes. The other si de of the
i ncandescent bul b i s connected to the fused panel
l amps di mmer swi tch si gnal ci rcui t. These bul bs are
energi zed when the park l amps or headl amps are
turned on, and thei r i l l umi nati on i ntensi ty i s con-
trol l ed by the panel l amps di mmer swi tch.
SWITCH
Refer to Wiring Diagrams for connector pi n-outs
and the l ocati on of compl ete heated seat system wi r-
i ng di agrams.
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE
ABLE THE AIRBAG SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
(1) I f the probl em bei ng di agnosed i nvol ves i noper-
ati ve heated seat swi tch back l i ghti ng and the cl uster
i l l umi nati on l amps operate, go to Step 2. I f the prob-
l em bei ng di agnosed i nvol ves i noperati ve heated seat
swi tch back l i ghti ng and the cl uster i l l umi nati on
l amps are al so i noperati ve, (Refer to 8 - ELECTRI -
CAL/I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). I f the probl em bei ng di agnosed i nvol ves
i noperati ve heated seat swi tch i ndi cator l amps and
the heated seat el ements do not heat, proceed. I f the
Fig. 4 HEATED SEAT SWITCH
1 - HEATED SEAT SWITCH
2 - LIGHT-EMITTING DIODE (LED) INDICATOR LAMPS
HEATED SEAT SWITCH (Continued)
probl em bei ng di agnosed i nvol ves i noperati ve heated
seat swi tch i ndi cator l amps and the heated seat el e-
ments do heat, go to Step 6. I f the probl em bei ng
di agnosed i nvol ves a heated seat swi tch i ndi cator
l amp that remai ns i l l umi nated after the heated seat
has been turned Off, (Refer to 8 - ELECTRI CAL/
ELECTRONI C CONTROL MODULES/MEMORY
HEATED SEAT/MI RROR MODULE - DI AGNOSI S
AND TESTI NG).
cabl e. Remove the heated seat swi tch and bezel uni t
from the i nstrument panel . Di sconnect the heated
seat swi tch to be tested. Check for conti nui ty
between the ground ci rcui t cavi ty of the heated seat
swi tch and a good ground. There shoul d be conti nu-
i ty. I f OK, go to Step 3. I f not OK, repai r the open
ground ci rcui t to ground as requi red.
(3) Reconnect the battery negati ve cabl e. Turn the
park l amps on wi th the headl amp swi tch. Rotate the
panel l amps di mmer thumb wheel on the headl amp
swi tch upward to just before the i nteri or l amps
detent. Check for battery vol tage at the fused panel
l amps di mmer ci rcui t cavi ty of the heated seat
swi tch. I f OK, go to Step 4. I f not OK, repai r the
open fused panel l amps di mmer swi tch si gnal ci rcui t
to the fuse i n the I ntegrated Power Modul e as
requi red.
(4) Turn the i gni ti on swi tch to the On posi ti on.
Check for battery vol tage at the fused i gni ti on swi tch
output (run) ci rcui t cavi ty of the heated seat swi tch.
I f OK, go to Step 5. I f not OK, repai r the open fused
i gni ti on swi tch output (run) ci rcui t as requi red.
(5) Check the conti nui ty and resi stance val ues of
the heated seat swi tch i n the Neutral , Low and Hi gh
posi ti ons as shown i n the Heated Seat Swi tch Conti -
nui ty chart. I f OK, refer to Step 6. I f not OK, repl ace
the faul ty heated seat swi tch.
HEATED SEAT SWITCH CONTINUITY
Switch Position
Continuity
Between
Resistance
Neutral 4 & 6 2.2 Kilohms
Low 4 & 6 .415 Kilohms
High 4 & 6 33 Ohms
(6) Repl ace the i noperati ve heated seat swi tch
wi th a known good uni t and test the operati on of the
swi tch i ndi cator l amps. I f OK, di scard the faul ty
heated seat swi tch. I f not OK, (Refer to 8 - ELEC-
TRI CAL/ELECTRONI C CONTROL MODULES/
MEMORY HEATED SEAT/MI RROR MODULE -
DI AGNOSI S AND TESTI NG).
REMOVAL
cabl e.
(2) Wai t two mi nutes for the system reserve capac-
i tor to di scharge before begi nni ng any ai rbag or
i nstrument panel servi ce.
(3) Remove the center bezel from the i nstrument
panel (Refer to 23 - BODY/I NSTRUMENT PANEL/
I NSTRUMENT PANEL CENTER BEZEL -
REMOVAL).
(4) Remove the screws that secure the heated seat
swi tch bezel to the i nstrument panel center bezel .
(5) Remove the heated seat swi tch bezel and both
swi tches from the i nstrument panel as a uni t.
(6) From the back of the heated seat swi tch bezel ,
gentl y pry the swi tch free and push the heated seat
swi tch out through the front of the bezel .
INSTALLATION
NOTE: When installing the heated seat switches, be
certain they are installed in the proper mounting
holes of the heated seat switch bezel. The heated
seat switches are differentiated by the keyway in
the connector receptacle on the backs of the
switches and keyway on the switch housing (Fig.
4).
(1) From the back of the heated seat swi tch bezel ,
gentl y push the heated seat swi tch i n through the
front of the bezel .
(2) Posi ti on the heated seat swi tch bezel to the
i nstrument panel center bezel and i nstal l the retai n-
i ng screws.
(3) I nstal l the center bezel on the i nstrument
I NSTRUMENT PANEL CENTER BEZEL - I NSTAL-
LATI ON).
(5) Veri fy vehi cl e and system operati on.
HEATED SEAT MODULE
DESCRIPTION
The heated seat modul e i s al so known as the Seat
Heat I nterface Modul e. The heated seat modul e (Fi g.
5) i s l ocated under the dri vers front seat cushi on,
where i t i s secured to a mounti ng bracket. The
heated seat modul e has a si ngl e connector receptacl e
that al l ows the modul e to be connected to al l of the
requi red i nputs and outputs through the seat wi re
harness.
HEATED SEAT SWITCH (Continued)
The heated seat modul e i s an el ectroni c mi cropro-
cessor control l ed devi ce desi gned and programmed to
use i nputs from the battery, the two heated seat
swi tches and the two heated seat sensors to operate
and control the heated seat el ements i n both front
seats and the two heated seat i ndi cator l amp Li ght-
Emi tti ng Di odes (LEDs) i n each heated seat swi tch.
The heated seat modul e i s al so programmed to per-
form sel f-di agnosi s of certai n heated seat system
functi ons and provi de feedback of that di agnosi s
through the heated seat swi tch i ndi cator l amps.
The heated seat modul e cannot be repai red. I f the
heated seat modul e i s damaged or faul ty, the enti re
modul e must be repl aced.
OPERATION
The heated seat modul e operates on fused battery
current recei ved from the i ntegrated power modul e.
I nputs to the modul e i ncl ude a resi stor mul ti pl exed
heated seat swi tch request ci rcui t for each of the two
heated seat swi tches and the heated seat sensor
i nputs from the seat cushi ons of each front seat. I n
response to those i nputs the heated seat modul e con-
trol s battery current feeds to the heated seat el e-
ments and sensors, and control s the ground for the
heated seat swi tch i ndi cator l amps.
When a heated seat swi tch (Dri ver or Passenger) i s
depressed a si gnal i s recei ved by the heated seat
modul e, the modul e energi zes the proper i ndi cator
LED (Low or Hi gh) i n the swi tch by groundi ng the
i ndi cator l amp ci rcui t to i ndi cate that the heated seat
system i s operati ng. At the same ti me, the heated
seat modul e energi zes the sel ected heated seat sensor
ci rcui t and the sensor provi des the modul e wi th an
i nput i ndi cati ng the surface temperature of the
sel ected seat cushi on.
The Low heat set poi nt i s about 36 C (96.8 F),
and the Hi gh heat set poi nt i s about 42 C (107.6 F).
I f the seat cushi on surface temperature i nput i s
bel ow the temperature set poi nt for the sel ected tem-
perature setti ng, the heated seat modul e energi zes
an N-channel Fi el d Effect Transi stor (N-FET) wi thi n
the modul e whi ch energi zes the heated seat el ements
i n the sel ected seat cushi on and back. When the sen-
sor i nput to the modul e i ndi cates the correct temper-
ature set poi nt has been achi eved, the modul e
de-energi zes the N-FET whi ch de-energi zes the
heated seat el ements. The heated seat modul e wi l l
conti nue to cycl e the N-FET as needed to mai ntai n
the sel ected temperature set poi nt.
I f the heated seat modul e detects a heated seat
sensor val ue i nput that i s out of range or a shorted
or open heated seat el ement ci rcui t, i t wi l l noti fy the
vehi cl e operator or the repai r techni ci an of thi s con-
di ti on by fl ashi ng the Hi gh and/or Low i ndi cator
l amps i n the affected heated seat swi tch. Refer to
Diagnosis and Testing Heated Seat System i n
Heated Systems for fl ashi ng LED di agnosi s and test-
i ng procedures. Refer to Diagnosis and Testing
Heated Seat Module i n thi s secti on for heated seat
modul e di agnosi s and testi ng procedures.
MODULE
I f a heated seat fai l s to heat and one or both of the
i ndi cator l amps on a heated seat swi tch fl ash, refer
to Diagnosis and Testing Heated Seat System i n
Heated Seats for the l ocati on of fl ashi ng LED heated
seat system di agnosi s and testi ng procedures. I f a
heated seat heats but one or both i ndi cator l amps on
the heated seat swi tch fai l to operate, test the heated
seat swi tch. Refer to Diagnosis and Testing
Heated Seat Switch i n Heated Seats for heated
seat swi tch di agnosi s and testi ng procedures. I f the
heated seat swi tch checks OK, proceed as fol l ows.
(1) Check the heated seat el ement (Refer to 8 -
ELEMENT - DI AGNOSI S AND TESTI NG).
(2) Check the heated seat sensor (Refer to 8 -
SENSOR - DI AGNOSI S AND TESTI NG).
(3) Check the heated seat swi tch (Refer to 8 -
ELECTRI CAL/HEATED SEATS/DRI VER HEATED
SEAT SWI TCH - DI AGNOSI S AND TESTI NG).
NOTE: Refer to Wiring for the location of complete
heated seat system wiring diagrams and connector
pin-out information.
(4) Usi ng a vol tmeter, backprobe the appropri ate
Check for vol tage at the appropri ate pi n cavi ti es. 12v
Fig. 5 Heated Seat Module
1 - MOUNTING TABS (NOT USED ON DR)
3 - ELECTRICAL CONNECTOR RECEPTACLE
shoul d be present. I f OK go to Step 5, i f Not, Repai r
the open or shorted vol tage suppl y ci rcui t as
requi red.
(5) Usi ng a ohmmeter, backprobe the appropri ate
Check for proper conti nui ty to ground on the ground
pi n cavi ti es. Conti nui ty shoul d be present. I f OK
repl ace the heated seat modul e wi th a known good
uni t and retest system, i f Not OK, Repai r the open or
shorted ground ci rcui t as requi red.
REMOVAL
(1) Posi ti on the dri ver seat to the ful l rearward
and i ncl i ned posi ti on.
(2) Worki ng under the dri ver front seat, remove
the two heated seat modul e retai ni ng screws. Due to
the fact that the retai ni ng screws are i nstal l ed wi th
the seat cushi on pan removed, a smal l ri ght angl e
screwdri ver wi l l be requi red to access and remove the
screws.
(3) Di sconnect the seat wi re harness connector
from the connector receptacl e on the back of the
heated seat modul e. Depress the connector retai ni ng
tab and pul l strai ght apart.
(4) Remove the heated seat modul e from under the
front seat.
INSTALLATION
(1) Posi ti on the heated seat modul e under the
front seat.
(2) Connect the seat wi re harness connector on the
connector receptacl e on the back of the heated seat
modul e.
(3) Worki ng under the dri ver front seat, i nstal l the
heated seat modul e retai ni ng screws.
(4) Re-posi ti on the dri ver seat.
HORN
TABLE OF CONTENTS
page page
HORN SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - HORN SYSTEM . . . 1
HORN
DIAGNOSIS AND TESTING - HORN . . . . . . . . . . 1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HORN SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - HORN SWITCH . . . 2
HORN SYSTEM
DESCRIPTION
The dual -note horn system features dual el ectro-
magneti c horn uni ts. The horn system i ncl udes the
fol l owi ng major components:
Horn - The two horns are l ocated on the l eft
si de of the engi ne compartment bel ow the I ntegrated
Power Modul e (I PM).
Horn Switch - The horn swi tch i s mol ded i nto
the dri ver ai rbag tri m cover.
OPERATION
The horn system operates on battery current
recei ved through a fuse i n the I ntegrated Power
Modul e (I PM). The horn system ci rcui t i s desi gned so
that the system wi l l remai n operati onal , regardl ess
of the i gni ti on swi tch posi ti on.
DIAGNOSIS AND TESTING - HORN SYSTEM
The most reliable, efficient, and accurate
means to diagnose the horn systemrequires the
use of a DRBIII scan tool and the proper Diag-
nostic Procedures manual.
I n most cases, any probl em i nvol vi ng conti nual l y
soundi ng horns can be qui ckl y al l evi ated by removi ng
the horn fuse from the I ntegrated Power Modul e
(I PM).
INJURY.
HORN
DIAGNOSIS AND TESTING - HORN
nostic Procedures manual. The DRBIII scan
tool can provide confirmation that the PCI data
bus is functional, that all of the electronic mod-
ules are sending and receiving the proper mes-
sages on the PCI data bus, and that the horns
are being sent the proper hard wired outputs
for them to perform their functions.
Refer to the appropri ate wi ri ng i nformati on. The
wi ri ng i nformati on i ncl udes wi ri ng di agrams, proper
wi re and connector repai r procedures, detai l s of wi re
harness routi ng and retenti on, connector pi n-out
i nformati on and l ocati on vi ews for the vari ous wi re
harness connectors, spl i ces and grounds.
INJURY.
DR HORN 8H - 1
REMOVAL
cabl e.
(2) Di sconnect the wi re harness connectors from
the horns (Fi g. 1).
(3) Remove mounti ng bol t and remove horns.
INSTALLATION
(1) Posi ti on horns and i nstal l mounti ng bol t.
Ti ghten the bol t to 10 Nm (85 i n. l bs.).
(2) Connect wi re harness connectors.
HORN SWITCH
DESCRIPTION
The horn swi tch i s mol ded i nto the dri ver ai rbag.
The horn swi tch can not be servi ced separatel y. For
servi ce procedures, (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/DRI VER AI RBAG - REMOVAL).
DIAGNOSIS AND TESTING - HORN SWITCH
nostic Procedures manual.
INJURY.
Fig. 1 HORN
1 - WIRE HARNESS CONNECTORS
2 - HORNS
3 - MOUNTING BOLT
8H - 2 HORN DR
HORN (Continued)
IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
SPECIFICATIONS - TORQUE - IGNITION . . . . 3
ENGINE FIRING ORDER - 3.7L V-6 . . . . . . . . . 4
ENGINE FIRING ORDER 4.7L V-8 . . . . . . . . 4
FIRING ORDER / CABLE ROUTING 5.7L
V-8 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPARK PLUG CABLE RESISTANCE . . . . . . . . 4
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . 4
IGNITION COIL RESISTANCE - 3.7L V-6 . . . . . 5
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . 5
AUTOMATIC SHUT DOWN RELAY
DESCRIPTION - PCM OUTPUT . . . . . . . . . . . . . 5
OPERATION
OPERATION - PCM OUTPUT . . . . . . . . . . . . . 5
OPERATION - ASD SENSE - PCM INPUT . . . . 5
DIAGNOSIS AND TESTING - ASD AND FUEL
PUMP RELAYS . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CAMSHAFT POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
IGNITION COIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
KNOCK SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPARK PLUG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CLEANING
CLEANING AND ADJUSTMENT . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
IGNITION COIL CAPACITOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPARK PLUG CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
IGNITION CONTROL
DESCRIPTION
The i gni ti on system i s control l ed by the Powertrai n
Control Modul e (PCM) on al l engi nes.
3. 7L V-6 ENGINE
The 3.7L V-6 engi ne uses a separate i gni ti on coi l
for each cyl i nder. The one-pi ece coi l bol ts di rectl y to
the cyl i nder head. Rubber boots seal the secondary
termi nal ends of the coi l s to the top of al l 6 spark
pl ugs. A separate el ectri cal connector i s used for each
coi l .
Because of coi l desi gn, spark pl ug cabl es (second-
ary cabl es) are not used. A di stri butor i s not used
wi th the 3.7L engi ne.
Two knock sensors (one for each cyl i nder bank) are
used to hel p control spark knock.
The Auto Shutdown (ASD) rel ay provi des battery
vol tage to each i gni ti on coi l .
The i gni ti on system consi sts of:
6 Spark Pl ugs
6 Separate I gni ti on Coi l s
2 Knock Sensors
Powertrai n Control Modul e (PCM)
Al so to be consi dered part of the i gni ti on system
are certai n i nputs from the Crankshaft Posi ti on,
Camshaft Posi ti on, Throttl e Posi ti on, 2 knock and
MAP Sensors
4. 7L V-8 ENGINE
The 4.7L V-8 engi ne uses a separate i gni ti on coi l
for each cyl i nder. The one-pi ece coi l bol ts di rectl y to
the cyl i nder head. Rubber boots seal the secondary
termi nal ends of the coi l s to the top of al l 8 spark
pl ugs. A separate el ectri cal connector i s used for each
coi l .
DR IGNITION CONTROL 8I - 1
ary cabl es) are not used. A di stri butor i s not used
wi th the 4.7L engi ne.
The Auto Shutdown (ASD) rel ay provi des battery
vol tage to each i gni ti on coi l .
8 Spark Pl ugs
8 Separate I gni ti on Coi l s
2 Knock Sensors
MAP Sensors
5. 7L V-8 ENGINE
For additional information, also refer to Igni-
tion Coil Description and Operation.
The 5.7L V-8 engi ne i s equi pped wi th 16 spark
pl ugs. Two pl ugs are used for each cyl i nder. The 5.7L
i s al so equi pped wi th 8 separate and i ndependent
i gni ti on coi l s. The one-pi ece coi l bol ts di rectl y to the
cyl i nder head cover and attaches the coi l s secondary
output termi nal di rectl y to a spark pl ug usi ng a rub-
ber boot seal . Each coi l i s al so equi pped wi th a sec-
ond output termi nal . Thi s second termi nal connects a
conventi onal spark pl ug cabl e di rectl y to a spark
pl ug on the opposi te cyl i nder bank. A separate pri -
mary el ectri cal connector i s used for each coi l .
Ei ght conventi onal spark pl ug cabl es are used wi th
the 5.7L. These cabl es connect a coi l on one cyl i nder
bank, di rectl y to a spark pl ug on the opposi te cyl i n-
der bank. The cabl es are pl aced and routed i n a spe-
ci al pl asti c l oom to keep them separated. Thi s l oom i s
cl i pped to the i ntake mani fol d. To prevent a mi ss-
match of cabl es, a correspondi ng spark pl ug / coi l
number i s di spl ayed on each pl ug cabl e: 1/6, 2/3, 4/7
and 5/8. These numbers can al so be found on the top
of the i ntake mani fol d to the ri ght of the throttl e
body (Fi g. 1).
The 5.7L engi ne wi l l not use a conventi onal di stri b-
utor.
16 Spark Pl ugs (2 per cyl i nder)
8 Separate, Dual -Secondary Output, I gni ti on
Coi l s
2 Knock Sensors
8 Secondary I gni ti on Cabl es
MAP Sensors
Fig. 1 FIRING ORDER / CABLE ROUTING - 5.7L V-8
ENGINE
1 - TOP OF INTAKE MANIFOLD
2 - CYLINDER FIRING ORDER (IGNITION COIL NUMBER)
3 - CORRESPONDING SPARK PLUG NUMBER
8I - 2 IGNITION CONTROL DR
IGNITION CONTROL (Continued)
SPECIFICATIONS
SPECIFICATIONS - TORQUE - IGNITION
Camshaft Position Sensor
- 3.7L V-6 Engine
12 - 106
- 4.7L V-8 Engine
12 - 106
- 5.7L V-8 Engine
12 9 105
Crankshaft Position
Sensor - 3.7L V-6 Engine
28 21 205
Crankshaft Position
28 21 205
Crankshaft Position
12 9 105
Ignition Coil Mounting -
3.7L V-6 Engine
8 - 70
4.7L V-8 Engine
8 - 70
5.7L V-8 Engine
12 9 105 ( 20)
* Knock Sensor - 3.7L V-6
Engine
20 15 176
Engine
20 15 176
Engine
20 15 176
Spark Plugs - 3.7L V-6
Engine
27 20 -
Spark Plugs - 4.7L V-8
Engine
27 20 -
** Spark Plugs - 5.7L V-8
Engine
18 ( 3) 13 ( 2) -
* Do not apply any sealant, thread-locker or adhesive to bolts. Poor sensor performance may result.
** Torque critical tapered design. Do not exceed 15 ft. lbs.
ENGINE FIRING ORDER - 3. 7L V-6
1 - 6 - 5 - 4 - 3 - 2
ENGINE FIRING ORDER 4. 7L V-8
FIRING ORDER / CABLE ROUTING 5. 7L V-8
ENGINE
Ei ght conventi onal spark pl ug cabl es are used wi th
the 5.7L. These cabl es connect a coi l on one cyl i nder
bank, di rectl y to a spark pl ug on the opposi te cyl i n-
der bank. The cabl es are pl aced and routed i n a spe-
ci al pl asti c l oom to keep them separated. Thi s l oom i s
cl i pped to the i ntake mani fol d. To prevent a mi ss-
match of cabl es, a correspondi ng spark pl ug / coi l
number i s di spl ayed on each pl ug cabl e: 1/6, 2/3, 4/7
and 5/8. These numbers can al so be found on the top
of the i ntake mani fol d to the ri ght of the throttl e
body (Fi g. 2).
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
SPARK PLUGS
ENGINE PLUG TYPE ELECTRODE GAP
3.7L V-6 ZFR6F - 11G (NGK) 1.1 (0.042 in.)
4.7L V-8 RC12MCC4 1.01 mm (.040 in.)
5.7L V-8 Champion - RE14MCC4 1.14 mm (.045 in.)
Fig. 2 FIRING ORDER / CABLE ROUTING - 5.7L V-8
ENGINE
2 - CYLINDER FIRING ORDER (IGNITION COIL NUMBER)
3 - CORRESPONDING SPARK PLUG NUMBER
IGNITION COIL RESISTANCE - 3. 7L V-6
PRIMARY RESISTANCE
21-27C (70-80F)
SECONDARY
RESISTANCE 21-27C
(70-80F)
0.6 - 0.9 Ohms 6,000 - 9,000 Ohms
PRIMARY
RESISTANCE 21-27C
(70-80F)
SECONDARY
RESISTANCE 21-27C
(70-80F)
0.6 - 0.9 Ohms 6,000 - 9,000 Ohms
PRIMARY RESISTANCE @ 21-27C (70-80F)
0.558 - 0.682 Ohms
(Plus or Minus 10% @ 70-80F)
IGNITION TIMING
I gni ti on ti mi ng i s not adjustabl e on any engi ne.
AUTOMATIC SHUT DOWN
RELAY
DESCRIPTION - PCM OUTPUT
The 5pi n, 12vol t, Automati c Shutdown (ASD)
rel ay i s l ocated i n the Power Di stri buti on Center
(PDC). Refer to l abel on PDC cover for rel ay l ocati on.
OPERATION
OPERATION - PCM OUTPUT
The ASD rel ay suppl i es battery vol tage (12+ vol ts)
to the fuel i njectors and i gni ti on coi l (s). Wi th certai n
emi ssi ons packages i t al so suppl i es 12vol ts to the
oxygen sensor heati ng el ements.
The ground ci rcui t for the coi l wi thi n the ASD
rel ay i s control l ed by the Powertrai n Control Modul e
(PCM). The PCM operates the ASD rel ay by swi tch-
i ng i ts ground ci rcui t on and off.
The ASD rel ay wi l l be shutdown, meani ng the
12vol t power suppl y to the ASD rel ay wi l l be de-ac-
ti vated by the PCM i f:
the i gni ti on key i s l eft i n the ON posi ti on. Thi s
i s i f the engi ne has not been runni ng for approxi -
matel y 1.8 seconds.
there i s a crankshaft posi ti on sensor si gnal to
the PCM that i s l ower than pre-determi ned val ues.
OPERATION - ASD SENSE - PCM INPUT
A 12 vol t si gnal at thi s i nput i ndi cates to the PCM
that the ASD has been acti vated. The rel ay i s used to
connect the oxygen sensor heater el ement, i gni ti on
coi l and fuel i njectors to 12 vol t + power suppl y.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the Powertrai n Control Modul e
(PCM) does not see 12 vol ts at thi s i nput when the
ASD shoul d be acti vated, i t wi l l set a Di agnosti c
Troubl e Code (DTC).
DIAGNOSIS AND TESTING - ASD AND FUEL
PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The termi nal s on the
bottom of each rel ay are numbered. Two di fferent
types of rel ays may be used, (Fi g. 3) or (Fi g. 4).
Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and fuel pump rel ays, termi -
nal 30 i s connected to battery vol tage at al l ti mes.
The PCM grounds the coi l si de of the rel ay
through termi nal number 85.
Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
When the PCM de-energi zes the ASD and fuel
pump rel ays, termi nal number 87A connects to termi -
nal 30. Thi s i s the Off posi ti on. I n the off posi ti on,
vol tage i s not suppl i ed to the rest of the ci rcui t. Ter-
mi nal 87A i s the center termi nal on the rel ay.
When the PCM energi zes the ASD and fuel
pump rel ays, termi nal 87 connects to termi nal 30.
Thi s i s the On posi ti on. Termi nal 87 suppl i es vol tage
to the rest of the ci rcui t.
The fol l owi ng procedure appl i es to the ASD and
fuel pump rel ays.
(1) Remove rel ay from connector before testi ng.
Fig. 3 TYPE 1 RELAY (ISO MICRO RELAY)
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be 75 ohms +/-
5 ohms.
(3) Connect the ohmmeter between termi nal s 30
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
(4) Connect the ohmmeter between termi nal s 87
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
DAMAGE TO OHMMETER MAY RESULT.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and fuel pump rel ay ci rcui ts. Refer to 8, Wi ri ng Di a-
grams.
REMOVAL
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 5). Refer to l abel on PDC cover
for rel ay l ocati on.
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
INSTALLATION
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 5). Refer to l abel on PDC cover
for rel ay l ocati on.
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
Fig. 4 ASD AND FUEL PUMP RELAY TERMINALS
TYPE 2
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 5 PDC LOCATION
1 - BATTERY
AUTOMATIC SHUT DOWN RELAY (Continued)
DESCRIPTION
3. 7L V-6
The Camshaft Posi ti on Sensor (CMP) on the 3.7L
6-cyl i nder engi ne i s bol ted to the ri ght-front si de of
the ri ght cyl i nder head.
4. 7L V-8
V-8 engi ne i s bol ted to the ri ght-front si de of the
ri ght cyl i nder head.
5. 7L V-8
V-8 engi ne i s l ocated bel ow the generator on the ti m-
i ng chai n / case cover on the ri ght/front si de of
engi ne.
5. 9L Diesel
di esel engi ne i s l ocated bel ow the fuel i njecti on
pump. I t i s bol ted to the back of the ti mi ng gear
cover.
OPERATION
3. 7L V-6
The Camshaft Posi ti on Sensor (CMP) sensor on the
3.7L V-6 engi ne contai ns a hal l effect devi ce referred
to as a sync si gnal generator. A rotati ng target wheel
(tonewheel ) for the CMP i s l ocated at the front of the
camshaft for the ri ght cyl i nder head (Fi g. 6). Thi s
sync si gnal generator detects notches l ocated on a
tonewheel . As the tonewheel rotates, the notches
pass through the sync si gnal generator. The si gnal
from the CMP sensor i s used i n conjuncti on wi th the
Crankshaft Posi ti on Sensor (CKP) to di fferenti ate
between fuel i njecti on and spark events. I t i s al so
used to synchroni ze the fuel i njectors wi th thei r
respecti ve cyl i nders.
When the l eadi ng edge of the tonewheel notch
enters the ti p of the CMP, the i nterrupti on of mag-
neti c fi el d causes the vol tage to swi tch hi gh, resul t-
i ng i n a sync si gnal of approxi matel y 5 vol ts.
When the trai l i ng edge of the tonewheel notch
l eaves then ti p of the CMP, the change of the mag-
neti c fi el d causes the sync si gnal vol tage to swi tch
l ow to 0 vol ts.
4. 7L V-8
The CMP sensor on the 4.7L engi ne contai ns a hal l
effect devi ce cal l ed a sync si gnal generator to gener-
ate a fuel sync si gnal . Thi s sync si gnal generator
detects notches l ocated on a tonewheel . The tone-
wheel i s l ocated at the front of the camshaft for the
ri ght cyl i nder head (Fi g. 7). As the tonewheel rotates,
the notches pass through the sync si gnal generator.
The pattern of the notches (vi ewed counter-cl ockwi se
from front of engi ne) i s: 1 notch, 2 notches, 3 notches,
3 notches, 2 notches 1 notch, 3 notches and 1 notch.
The si gnal from the CMP sensor i s used i n conjunc-
ti on wi th the crankshaft posi ti on sensor to di fferenti -
ate between fuel i njecti on and spark events. I t i s al so
used to synchroni ze the fuel i njectors wi th thei r
respecti ve cyl i nders.
5. 7L V-8
The CMP sensor i s used i n conjuncti on wi th the
crankshaft posi ti on sensor to di fferenti ate between
fuel i njecti on and spark events. I t i s al so used to syn-
chroni ze the fuel i njectors wi th thei r respecti ve cyl i n-
ders. The sensor generates el ectri cal pul ses. These
pul ses (si gnal s) are sent to the Powertrai n Control
Modul e (PCM). The PCM wi l l then determi ne crank-
shaft posi ti on from both the camshaft posi ti on sensor
and crankshaft posi ti on sensor.
The tonewheel i s l ocated at the front of the cam-
shaft (Fi g. 8). As the tonewheel rotates, notches (Fi g.
8) pass through the sync si gnal generator.
When the cam gear i s rotati ng, the sensor wi l l
detect the notches. I nput vol tage from the sensor to
the PCM wi l l then swi tch from a l ow (approxi matel y
0.3 vol ts) to a hi gh (approxi matel y 5 vol ts). When the
sensor detects a notch has passed, the i nput vol tage
swi tches back l ow to approxi matel y 0.3 vol ts.
Fig. 6 CMP OPERATION- 3.7L V-6
1 - NOTCHES
2 - RIGHT CYLINDER HEAD
3 - CMP
4 - TONEWHEEL (TARGET WHEEL)
5. 9L Diesel
The Camshaft Posi ti on Sensor (CMP) contai ns a
hal l effect devi ce. A rotati ng target wheel (tonewheel )
for the CMP i s l ocated on the front ti mi ng gear. Thi s
hal l effect devi ce detects notches l ocated on the tone-
wheel . As the tonewheel rotates, the notches pass the
ti p of the CMP.
passes the ti p of the CMP, the fol l owi ng occurs: The
i nterrupti on of magneti c fi el d causes the vol tage to
swi tch hi gh resul ti ng i n a si gnal of approxi matel y 5
vol ts.
passes the ti p of the CMP, the fol l owi ng occurs: The
change of the magneti c fi el d causes the si gnal vol tage
to swi tch l ow to 0 vol ts.
The CMP (Fi g. 9) provi des a si gnal to the Engi ne
Control Modul e (ECM) at al l ti mes when the engi ne
i s runni ng. The ECM uses the CMP i nformati on pri -
mari l y on engi ne start-up. Once the engi ne i s run-
ni ng, the ECM uses the CMP as a backup sensor for
engi ne speed. The Crankshaft Posi ti on Sensor (CKP)
i s the pri mary engi ne speed i ndi cator for the engi ne
after the engi ne i s runni ng.
Fig. 7 CMP AND TONEWHEEL OPERATION - 4.7L
V-8
1 - NOTCHES
3 - CAMSHAFT POSITION SENSOR
4 - TONEWHEEL
Fig. 8 CMP OPERATION - 5.7L ENGINE
2 - TONEWHEEL
3 - NOTCHES
Fig. 9 5.9L DIESEL CMP
1 - CMP
2 - FUEL INJECTION PUMP (BOTTOM)
3 - ELECTRONIC CONTROL MODULE (ECM)
4 - ECM ELEC. CONNECTOR
5 - CMP ELEC. CONNECTOR
6 - CMP MOUNTING BOLT
7 - BACK OF TIMING GEAR COVER
CAMSHAFT POSITION SENSOR (Continued)
REMOVAL
3. 7L V-6
V-6 engi ne i s bol ted to the front/top of the ri ght cyl -
i nder head (Fi g. 10).
(1) Di sconnect el ectri cal connector at CMP sensor.
(2) Remove sensor mounti ng bol t (Fi g. 10).
(3) Careful l y twi st sensor from cyl i nder head.
(4) Check condi ti on of sensor o-ri ng.
4. 7L V-8
V8 engi ne i s bol ted to the front/top of the ri ght cyl -
(2) Di sconnect el ectri cal connector at CMP sensor
(Fi g. 11).
5. 7L V-8
V-8 engi ne i s l ocated on ri ght si de of ti mi ng chai n
cover bel ow generator (Fi g. 12).
(1) Di sconnect el ectri cal connector at CMP sensor.
Fig. 10 CMP LOCATION - 3.7L
1 - RIGHT/FRONT OF RIGHT CYLINDER HEAD
3 - CMP LOCATION
Fig. 11 CMP LOCATION - 4.7L
3 - MOUNTING BOLT
4 - ELEC. CONNECTOR
Fig. 12 CMP LOCATION 5.7L
1 - GENERATOR
2 - CMP LOCATION
5. 9L Diesel
cover (Fi g. 14).
(Fi g. 14).
(2) Remove sensor mounti ng bol t.
(3) Careful l y twi st sensor from ti mi ng gear cover.
INSTALLATION
3. 7L V-6
(1) Cl ean out machi ned hol e i n cyl i nder head.
(2) Appl y a smal l amount of engi ne oi l to sensor
o-ri ng.
(3) I nstal l sensor i nto cyl i nder head wi th a sl i ght
rocki ng and twi sti ng acti on.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to cylinder head.
If sensor is not flush, damage to sensor mounting
tang may result.
(4) I nstal l mounti ng bol t and ti ghten. Refer to
4. 7L V-8
o-ri ng.
rocki ng acti on. Do not twi st sensor i nto posi ti on as
damage to o-ri ng may resul t.
be sure sensor is completely flush to cylinder head.
If sensor is not flush, damage to sensor mounting
tang may result.
Torque Speci fi cati ons.
5. 7L V-8
V-8 engi ne i s bol ted to the ri ght / front si de of the
ti mi ng chai n cover (Fi g. 12) or (Fi g. 13).
Fig. 13 CMP REMOVAL / INSTALLATION 5.7L V-8
1 - TIMING CHAIN COVER (RIGHT/FRONT)
2 - CMP SENSOR
3 - MOUNTING BOLT
1 - CMP
7 - BACK OF TIMING GEAR COVER
o-ri ng.
rocki ng acti on. Do not twi st sensor i nto posi ti on as
damage to o-ri ng may resul t.
be sure sensor is completely flush to timing chain
cover. If sensor is not flush, damage to sensor
mounting tang may result.
5. 9L Diesel
The CMP i s l ocated on the back of the ti mi ng gear
cover (Fi g. 14).
(1) Cl ean out machi ned hol e i n back of ti mi ng gear
cover.
o-ri ng.
(3) I nstal l sensor i nto ti mi ng gear cover wi th a
sl i ght rocki ng acti on. Do not twi st sensor i nto posi -
ti on as damage to o-ri ng may resul t.
be sure sensor is completely flush to back of timing
chain cover. If sensor is not flush, damage to sen-
sor mounting tang may result.
IGNITION COIL
DESCRIPTION
3. 7L V-6
The 3.7L V-6 engi ne uses 6 dedi cated, and i ndi vi d-
ual l y fi red coi l for each spark pl ug (Fi g. 15). Each
coi l i s mounted di rectl y i nto the cyl i nder head and
onto the top of each spark pl ug (Fi g. 16).
4. 7L V-8
The 4.7L V8 engi ne uses 8 dedi cated, and i ndi vi d-
ual l y fi red coi l (Fi g. 15) for each spark pl ug. Each
coi l i s mounted di rectl y to the top of each spark pl ug
(Fi g. 17).
5. 7L V-8
The 5.7L V8 engi ne uses 8 dedi cated, and i ndi vi d-
ual l y fi red coi l (Fi g. 18) for each pai r of spark pl ugs.
Each coi l i s mounted di rectl y to the top of each spark
pl ug (Fi g. 19). Each coi l i s bol ted to the val ve cover.
Fig. 15 IGNITION COIL - 3.7L V-6/ 4.7L V-8
1 - O-RING
2 - IGNITION COIL
Fig. 16 IGNITION COIL LOCATION - 3.7L V-6
1 - IGNITION COIL
2 - COIL MOUNTING NUT
OPERATION
3. 7L V-6
Battery vol tage i s suppl i ed to the 6 i ndi vi dual i gni -
ti on coi l s from the ASD rel ay. The Powertrai n Con-
trol Modul e (PCM) opens and cl oses each i gni ti on coi l
ground ci rcui t at a determi ned ti me for i gni ti on coi l
operati on.
Base ignition timing is not adjustable. By con-
trol l i ng the coi l ground ci rcui t, the PCM i s abl e to set
the base ti mi ng and adjust the i gni ti on ti mi ng
advance. Thi s i s done to meet changi ng engi ne oper-
ati ng condi ti ons.
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
ary cabl es) are not used wi th the 3.7L V-6 engi ne.
4. 7L V-8
Battery vol tage i s suppl i ed to the 8 i ndi vi dual i gni -
ti on coi l s from the ASD rel ay. The Powertrai n Con-
trol Modul e (PCM) opens and cl oses each i gni ti on coi l
ground ci rcui t at a determi ned ti me for i gni ti on coi l
operati on.
Fig. 17 IGNITION COIL LOCATION - 4.7L V-8
1 - IGNITION COIL
2 - COIL ELECTRICAL CONNECTOR
3 - COIL MOUNTING STUD/NUT
Fig. 18 IGNITION COIL - 5.7L V-8
1 - IGNITION COIL
3 - BOOT TO SPARK PLUG
Fig. 19 IGNITION COIL R/I 5.7L V-8
1 - SLIDE LOCK (SLIDE OUTWARD TO UNLOCK)
2 - SPARK PLUG CABLE (TO OPPOSITE CYLINDER BANK
SPARK PLUG)
3 - RELEASE LOCK / TAB (PUSH HERE)
4 - ELEC. CONNECTOR
5 - IGNITION COIL
6 - COIL MOUNTING BOLTS (2)
IGNITION COIL)
IGNITION COIL (Continued)
Base ignition timing is not adjustable. By con-
trol l i ng the coi l ground ci rcui t, the PCM i s abl e to set
the base ti mi ng and adjust the i gni ti on ti mi ng
advance. Thi s i s done to meet changi ng engi ne oper-
ati ng condi ti ons.
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
ary cabl es) are not used wi th the 4.7L V-8 engi ne.
5. 7L V-8
The i gni ti on system i s control l ed by the Powertrai n
Control Modul e (PCM) on al l engi nes.
A wasted spark system i s used on the 5.7L
engi ne combi ni ng pai red, or dual -fi ri ng coi l s, and 2
spark pl ugs per cyl i nder. The coi l s and spark pl ugs
are connected wi th pai red, secondary hi gh-vol tage
cabl es.
Each cyl i nder i s equi pped wi th 1 dual -output coi l .
Meani ng one coi l mounts di rectl y over one of the
dual spark pl ugs for 1 hi gh-vol tage output. A second
hi gh-vol tage output i s suppl i ed di rectl y from the
same coi l (usi ng a pl ug cabl e) to one of the dual
spark pl ugs on a correspondi ng (pai red) cyl i nder on
the opposi te cyl i nder bank.
Each coi l fi res 2 spark pl ugs si mul taneousl y on
each of the cyl i nder banks (one cyl i nder on compres-
si on stroke and one cyl i nder on exhaust stroke).
EXAMPLE : When the #1 cyl i nder i s on compressi on
stroke and ready for spark, the #1 coi l wi l l fi re one of
the dual spark pl ugs on the #1 cyl i nder (di rectl y
bel ow the coi l ). The other dual spark pl ug on the #1
cyl i nder wi l l be fi red by the #6 coi l . At the same
ti me, the #1 coi l wi l l fi re a wasted spark to one of
the dual spark pl ugs at the #6 cyl i nder as coi l #6 al so
fi res a wasted spark to one of the dual spark pl ugs
at the #6 cyl i nder.
The fi ri ng order i s pai red at cyl i nders 1/6, 2/3, 4/7,
5/8. Basi c cyl i nder fi ri ng order i s 18436572.
Battery vol tage i s suppl i ed to al l of the i gni ti on
coi l s posi ti ve termi nal s from the ASD rel ay. I f the
PCM does not see a si gnal from the crankshaft and
camshaft sensors (i ndi cati ng the i gni ti on key i s ON
but the engi ne i s not runni ng), i t wi l l shut down the
ASD ci rcui t.
Base ignition timing is not adjustable on the
5.7L V-8 engine. By control l i ng the coi l ground ci r-
cui ts, the PCM i s abl e to set the base ti mi ng and
adjust the i gni ti on ti mi ng advance. Thi s i s done to
meet changi ng engi ne operati ng condi ti ons.
The PCM adjusts i gni ti on ti mi ng based on i nputs i t
recei ves from:
The engi ne cool ant temperature sensor
The crankshaft posi ti on sensor (engi ne speed)
The camshaft posi ti on sensor (crankshaft posi -
ti on)
The mani fol d absol ute pressure (MAP) sensor
The throttl e posi ti on sensor
Transmi ssi on gear sel ecti on
REMOVAL
3. 7L V-6
An i ndi vi dual i gni ti on coi l i s used for each spark
pl ug (Fi g. 15). The coi l fi ts i nto machi ned hol es i n the
cyl i nder head. A mounti ng stud/nut secures each coi l
to the top of the i ntake mani fol d (Fi g. 16). The bot-
tom of the coi l i s equi pped wi th a rubber boot to seal
the spark pl ug to the coi l . I nsi de each rubber boot i s
a spri ng. The spri ng i s used for a mechani cal contact
between the coi l and the top of the spark pl ug. These
rubber boots and spri ngs are a permanent part of the
coi l and are not servi ced separatel y. An o-ri ng (Fi g.
15) i s used to seal the coi l at the openi ng i nto the cyl -
i nder head.
(1) Dependi ng on whi ch coi l i s bei ng removed, the
throttl e body ai r i ntake tube or i ntake box may need
to be removed to gai n access to coi l .
(2) Di sconnect el ectri cal connector from coi l by
pushi ng downward on rel ease l ock on top of connec-
tor and pul l connector from coi l .
(3) Cl ean area at base of coi l wi th compressed ai r
before removal .
(4) Remove coi l mounti ng nut from mounti ng stud
(Fi g. 16).
(5) Careful l y pul l up coi l from cyl i nder head open-
i ng wi th a sl i ght twi sti ng acti on.
(6) Remove coi l from vehi cl e.
4. 7L V-8
An i ndi vi dual i gni ti on coi l i s used for each spark
pl ug (Fi g. 15). The coi l fi ts i nto machi ned hol es i n the
cyl i nder head. A mounti ng stud/nut secures each coi l
to the top of the i ntake mani fol d (Fi g. 17). The bot-
tom of the coi l i s equi pped wi th a rubber boot to seal
the spark pl ug to the coi l . I nsi de each rubber boot i s
a spri ng. The spri ng i s used for a mechani cal contact
between the coi l and the top of the spark pl ug. These
rubber boots and spri ngs are a permanent part of the
coi l and are not servi ced separatel y. An o-ri ng (Fi g.
15) i s used to seal the coi l at the openi ng i nto the cyl -
i nder head.
(2) Di sconnect el ectri cal connector (Fi g. 17) from
coi l by pushi ng downward on rel ease l ock on top of
connector and pul l connector from coi l .
before removal .
(4) Remove coi l mounti ng nut from mounti ng stud
(Fi g. 17).
5. 7L V-8
Before removi ng or di sconnecti ng any spark pl ug
cabl es, note thei r ori gi nal posi ti on. Remove cabl es
one-at-a-ti me. To prevent i gni ti on crossfi re, spark
pl ug cabl es MUST be pl aced i n cabl e tray (routi ng
l oom) i nto thei r ori gi nal posi ti on.
An i ndi vi dual i gni ti on coi l (Fi g. 18) i s used at each
cyl i nder. The coi l mounts to the top of the val ve cover
wi th 2 bol ts (Fi g. 19). The bottom of the coi l i s
equi pped wi th a rubber boot to seal the spark pl ug to
the coi l . I nsi de each rubber boot i s a spri ng. The
spri ng i s used for a mechani cal contact between the
coi l and the top of the spark pl ug.
(2) Unl ock el ectri cal connector (Fi g. 19) by movi ng
sl i de l ock fi rst. Press on rel ease l ock (Fi g. 19) whi l e
pul l i ng el ectri cal connector from coi l .
(3) Di sconnect secondary hi gh-vol tage cabl e from
coi l wi th a twi sti ng acti on.
before removal .
(5) Remove 2 mounti ng bol ts (note that mounti ng
bol ts are retai ned to coi l ).
(8) Before i nstal l i ng spark pl ug cabl es to ei ther the
spark pl ugs or coi l s, or before i nstal l i ng a coi l to a
spark pl ug, appl y di el ectri c grease to i nsi de of boots.
INSTALLATION
3. 7L V-6
(1) Usi ng compressed ai r, bl ow out any di rt or con-
tami nants from around top of spark pl ug.
(2) Check condi ti on of coi l o-ri ng and repl ace as
necessary. To ai d i n coi l i nstal l ati on, appl y si l i cone to
coi l o-ri ng.
(3) Posi ti on i gni ti on coi l i nto cyl i nder head openi ng
and push onto spark pl ug. Do thi s whi l e gui di ng coi l
base over mounti ng stud.
(4) I nstal l coi l mounti ng stud nut. Refer to torque
speci fi cati ons.
(5) Connect el ectri cal connector to coi l by snappi ng
i nto posi ti on.
(6) I f necessary, i nstal l throttl e body ai r tube.
4. 7L V-8
(2) Check condi ti on of coi l o-ri ng and repl ace as
necessary. To ai d i n coi l i nstal l ati on, appl y si l i cone to
coi l o-ri ng.
and push onto spark pl ug. Do thi s whi l e gui di ng coi l
base over mounti ng stud.
(4) I nstal l coi l mounti ng stud nut. Refer to torque
speci fi cati ons.
i nto posi ti on.
5. 7L V-8
spark pl ugs or coi l s, or before i nstal l i ng a coi l to a
spark pl ug, appl y di el ectri c grease to i nsi de of boots.
and push onto spark pl ug. Twi st coi l i nto posi ti on.
(4) I nstal l 2 coi l mounti ng bol ts. Refer to torque
speci fi cati ons.
i nto posi ti on.
(6) I nstal l cabl e to coi l . To prevent i gni ti on cross-
fi re, spark pl ug cabl es MUST be pl aced i n cabl e tray
(routi ng l oom) i nto thei r ori gi nal posi ti on. Refer to
Spark Pl ug Cabl e Removal for a graphi c.
KNOCK SENSOR
DESCRIPTION
The sensors are used onl y wi th 3.7L V-6, 4.7L V-8
and 5.7L V-8 engi nes. On 3.7L V-6 and 4.7L V-8
engi nes, the 2 knock sensors are bol ted i nto the cyl -
i nder bl ock under the i ntake mani fol d.
On 5.7L V-8 engi nes, 2 knock sensors are al so
used. These are bol ted i nto each si de of the cyl i nder
bl ock (outsi de) under the exhaust mani fol d.
OPERATION
3. 7L V-6 / 4. 7L V-8 / 5. 7L V-8 Engines Only
Two knock sensors are used; one for each cyl i nder
bank. When the knock sensor detects a knock i n one
of the cyl i nders on the correspondi ng bank, i t sends
an i nput si gnal to the Powertrai n Control Modul e
(PCM). I n response, the PCM retards i gni ti on ti mi ng
for al l cyl i nders by a schedul ed amount.
Knock sensors contai n a pi ezoel ectri c materi al
whi ch constantl y vi brates and sends an i nput vol tage
(si gnal ) to the PCM whi l e the engi ne operates. As the
i ntensi ty of the crystal s vi brati on i ncreases, the
knock sensor output vol tage al so i ncreases.
The vol tage si gnal produced by the knock sensor
i ncreases wi th the ampl i tude of vi brati on. The PCM
recei ves the knock sensor vol tage si gnal as an i nput.
I f the si gnal ri ses above a predetermi ned l evel , the
PCM wi l l store that val ue i n memory and retard
i gni ti on ti mi ng to reduce engi ne knock. I f the knock
sensor vol tage exceeds a preset val ue, the PCM
retards i gni ti on ti mi ng for al l cyl i nders. I t i s not a
sel ecti ve cyl i nder retard.
The PCM i gnores knock sensor i nput duri ng engi ne
i dl e condi ti ons. Once the engi ne speed exceeds a
speci fi ed val ue, knock retard i s al l owed.
Knock retard uses i ts own short term and l ong
term memory program.
Long term memory stores previ ous detonati on
i nformati on i n i ts battery-backed RAM. The maxi -
mum authori ty that l ong term memory has over ti m-
i ng retard can be cal i brated.
Short term memory i s al l owed to retard ti mi ng up
to a preset amount under al l operati ng condi ti ons (as
l ong as rpm i s above the mi ni mum rpm) except at
Wi de Open Throttl e (WOT). The PCM, usi ng short
term memory, can respond qui ckl y to retard ti mi ng
when engi ne knock i s detected. Short term memory
i s l ost any ti me the i gni ti on key i s turned off.
NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors.
REMOVAL
3. 7L V-6 / 4. 7L V-8
The 2 knock sensors are bol ted i nto the cyl i nder
bl ock under the i ntake mani fol d (Fi g. 20). or (Fi g.
21).
NOTE: The left sensor is identified by an identifica-
tion tag (LEFT). It is also identified by a larger bolt
head. The Powertrain Control Module (PCM) must
have and know the correct sensor left/right posi-
tions. Do not mix the sensor locations.
(1) Di sconnect knock sensor dual pi gtai l harness
from engi ne wi ri ng harness. Thi s connecti on i s made
near rear of engi ne.
(2) Remove i ntake mani fol d. Refer to Engi ne sec-
ti on.
(3) Remove sensor mounti ng bol ts (Fi g. 20), or
(Fi g. 21). Note foam stri p on bol t threads. Thi s foam
i s used onl y to retai n the bol ts to sensors for pl ant
assembl y. I t i s not used as a seal ant. Do not appl y
any adhesi ve, seal ant or thread l ocki ng compound to
these bol ts.
(4) Remove sensors from engi ne.
5. 7L V8
Two sensors are used. Each sensor i s bol ted i nto
the outsi de of cyl i nder bl ock bel ow the exhaust man-
i fol d (Fi g. 22).
(2) Di sconnect knock sensor el ectri cal connector.
(3) Remove sensor mounti ng bol t (Fi g. 22). Note
foam stri p on bol t threads. Thi s foam i s used onl y to
retai n the bol ts to sensors for pl ant assembl y. I t i s
not used as a seal ant. Do not appl y any adhesi ve,
seal ant or thread l ocki ng compound to these bol ts.
(4) Remove sensor from engi ne.
INSTALLATION
3. 7L V-6 / 4. 7L V-8
NOTE: The left sensor is identified by an identifica-
tion tag (LEFT). It is also identified by a larger bolt
head. The Powertrain Control Module (PCM) must
have and know the correct sensor left/right posi-
tions. Do not mix the sensor locations.
Fig. 20 KNOCK SENSOR 3.7L V-6
1 - KNOCK SENSORS (2)
2 - MOUNTING BOLTS
KNOCK SENSOR (Continued)
(1) Thoroughl y cl ean knock sensor mounti ng hol es.
(2) I nstal l sensors i nto cyl i nder bl ock.
sors. The torque for the knock senor bolt is rela-
tively light for an 8mm bolt.
NOTE: Note foam strip on bolt threads. This foam is
used only to retain the bolts to sensors for plant
assembly. It is not used as a sealant. Do not apply
any adhesive, sealant or thread locking compound
to these bolts.
(3) I nstal l and ti ghten mounti ng bol ts. Refer to
torque speci fi cati on.
(4) I nstal l i ntake mani fol d. Refer to Engi ne sec-
ti on.
(5) Connect knock sensor wi ri ng harness to engi ne
harness at rear of i ntake mani fol d.
5. 7L V-8
(1) Thoroughl y cl ean knock sensor mounti ng hol e.
(2) I nstal l sensor i nto cyl i nder bl ock.
sors. The torque for the knock senor bolt is rela-
tively light for an 8mm bolt.
NOTE: Note foam strip on bolt threads. This foam is
used only to retain the bolts to sensors for plant
assembly. It is not used as a sealant. Do not apply
any adhesive, sealant or thread locking compound
to these bolts.
(3) I nstal l and ti ghten mounti ng bol t. Refer to
torque speci fi cati on.
(4) I nstal l el ectri cal connector to sensor.
Fig. 21 KNOCK SENSOR 4.7L V-8
1 - KNOCK SENSORS (2)
2 - MOUNTING BOLTS
3 - INTAKE MANIFOLD (CUTAWAY)
4 - PIGTAIL CONNECTOR
Fig. 22 5.7L KNOCK SENSOR (RIGHT SENSOR
SHOWN)
1 - KNOCK SENSOR (RIGHT SENSOR SHOWN)
2 - MOUNTING BOLT
3 - EXHAUST MANIFOLD
4 - RIGHT ENGINE MOUNT
5 - ELEC. CONNECTOR
KNOCK SENSOR (Continued)
SPARK PLUG
DESCRIPTION
Resi stor type spark pl ugs are used on al l engi nes.
Si xteen spark pl ugs (2 per cyl i nder) are used wi th
5.7L V-8 engi nes.
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS
To prevent possi bl e pre-i gni ti on and/or mechani cal
engi ne damage, the correct type/heat range/number
spark pl ug must be used.
Al ways use the recommended torque when ti ghten-
i ng spark pl ugs. I ncorrect torque can di stort the
spark pl ug and change pl ug gap. I t can al so pul l the
pl ug threads and do possi bl e damage to both the
spark pl ug and the cyl i nder head.
Remove the spark pl ugs and exami ne them for
burned el ectrodes and foul ed, cracked or broken por-
cel ai n i nsul ators. Keep pl ugs arranged i n the order
i n whi ch they were removed from the engi ne. A si n-
gl e pl ug di spl ayi ng an abnormal condi ti on i ndi cates
that a probl em exi sts i n the correspondi ng cyl i nder.
Repl ace spark pl ugs at the i nterval s recommended i n
the Lubri cati on and Mai ntenance secti on.
Spark pl ugs that have l ow mi l eage may be cl eaned
and reused i f not otherwi se defecti ve, carbon or oi l
foul ed.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
Spark pl ug resi stance val ues range from 6,000 to
20,000 ohms (when checked wi th at l east a 1000 vol t
spark pl ug tester). Do not use an ohmmeter to
check the resistance values of the spark plugs.
Inaccurate readings will result.
NORMAL OPERATING
The few deposi ts present on the spark pl ug wi l l
probabl y be l i ght tan or sl i ghtl y gray i n col or. Thi s i s
evi dent wi th most grades of commerci al gasol i ne
(Fi g. 23). There wi l l not be evi dence of el ectrode
burni ng. Gap growth wi l l not average more than
approxi matel y 0.025 mm (.001 i n) per 3200 km (2000
mi l es) of operati on. Spark pl ugs that have normal
wear can usual l y be cl eaned, have the el ectrodes
fi l ed, have the gap set and then be i nstal l ed.
Some fuel refi ners i n several areas of the Uni ted
States have i ntroduced a manganese addi ti ve (MMT)
for unl eaded fuel . Duri ng combusti on, fuel wi th MMT
causes the enti re ti p of the spark pl ug to be coated
wi th a rust col ored deposi t. Thi s rust col or can be
mi sdi agnosed as bei ng caused by cool ant i n the com-
busti on chamber. Spark pl ug performance may be
affected by MMT deposi ts.
COLD FOULING/CARBON FOULING
Col d foul i ng i s someti mes referred to as carbon
foul i ng. The deposi ts that cause col d foul i ng are basi -
cal l y carbon (Fi g. 23). A dry, bl ack deposi t on one or
two pl ugs i n a set may be caused by sti cki ng val ves
or defecti ve spark pl ug cabl es. Col d (carbon) foul i ng
of the enti re set of spark pl ugs may be caused by a
cl ogged ai r cl eaner el ement or repeated short operat-
i ng ti mes (short tri ps).
WET FOULING OR GAS FOULING
A spark pl ug coated wi th excessi ve wet fuel or oi l
i s wet foul ed. I n ol der engi nes, worn pi ston ri ngs,
l eaki ng val ve gui de seal s or excessi ve cyl i nder wear
can cause wet foul i ng. I n new or recentl y overhaul ed
engi nes, wet foul i ng may occur before break-i n (nor-
mal oi l control ) i s achi eved. Thi s condi ti on can usu-
al l y be resol ved by cl eani ng and rei nstal l i ng the
foul ed pl ugs.
OIL OR ASH ENCRUSTED
I f one or more spark pl ugs are oi l or oi l ash
encrusted (Fi g. 24), eval uate engi ne condi ti on for the
cause of oi l entry i nto that parti cul ar combusti on
chamber.
Fig. 23 NORMAL OPERATION AND COLD (CARBON)
FOULING
1 - NORMAL
2 - DRY BLACK DEPOSITS
3 - COLD (CARBON) FOULING
ELECTRODE GAP BRIDGING
El ectrode gap bri dgi ng may be traced to l oose
deposi ts i n the combusti on chamber. These deposi ts
accumul ate on the spark pl ugs duri ng conti nuous
stop-and-go dri vi ng. When the engi ne i s suddenl y
subjected to a hi gh torque l oad, deposi ts parti al l y l i q-
uefy and bri dge the gap between el ectrodes (Fi g. 25).
Thi s short ci rcui ts the el ectrodes. Spark pl ugs wi th
el ectrode gap bri dgi ng can be cl eaned usi ng standard
procedures.
SCAVENGER DEPOSITS
Fuel scavenger deposi ts may be ei ther whi te or yel -
l ow (Fi g. 26). They may appear to be harmful , but
thi s i s a normal condi ti on caused by chemi cal addi -
ti ves i n certai n fuel s. These addi ti ves are desi gned to
change the chemi cal nature of deposi ts and decrease
spark pl ug mi sfi re tendenci es. Noti ce that accumul a-
ti on on the ground el ectrode and shel l area may be
heavy, but the deposi ts are easi l y removed. Spark
pl ugs wi th scavenger deposi ts can be consi dered nor-
mal i n condi ti on and can be cl eaned usi ng standard
procedures.
CHIPPED ELECTRODE INSULATOR
A chi pped el ectrode i nsul ator usual l y resul ts from
bendi ng the center el ectrode whi l e adjusti ng the
spark pl ug el ectrode gap. Under certai n condi ti ons,
severe detonati on can al so separate the i nsul ator
from the center el ectrode (Fi g. 27). Spark pl ugs wi th
thi s condi ti on must be repl aced.
PREIGNITION DAMAGE
Prei gni ti on damage i s usual l y caused by excessi ve
combusti on chamber temperature. The center el ec-
trode di ssol ves fi rst and the ground el ectrode di s-
sol ves somewhat l atter (Fi g. 28). I nsul ators appear
rel ati vel y deposi t free. Determi ne i f the spark pl ug
has the correct heat range rati ng for the engi ne.
Determi ne i f i gni ti on ti mi ng i s over advanced or i f
other operati ng condi ti ons are causi ng engi ne over-
heati ng. (The heat range rati ng refers to the operat-
i ng temperature of a parti cul ar type spark pl ug.
Spark pl ugs are desi gned to operate wi thi n speci fi c
temperature ranges. Thi s depends upon the thi ck-
ness and l ength of the center el ectrodes porcel ai n
i nsul ator.)
Fig. 24 OIL OR ASH ENCRUSTED
Fig. 25 ELECTRODE GAP BRIDGING
1 - GROUND ELECTRODE
2 - DEPOSITS
3 - CENTER ELECTRODE
Fig. 26 SCAVENGER DEPOSITS
1 - GROUND ELECTRODE COVERED WITH WHITE OR YELLOW
DEPOSITS
SPARK PLUG (Continued)
SPARK PLUG OVERHEATING
Overheati ng i s i ndi cated by a whi te or gray center
el ectrode i nsul ator that al so appears bl i stered (Fi g.
29). The i ncrease i n el ectrode gap wi l l be consi der-
abl y i n excess of 0.001 i nch per 2000 mi l es of opera-
ti on. Thi s suggests that a pl ug wi th a cool er heat
range rati ng shoul d be used. Over advanced i gni ti on
ti mi ng, detonati on and cool i ng system mal functi ons
can al so cause spark pl ug overheati ng.
REMOVAL
3. 7L V-6
Each i ndi vi dual spark pl ug i s l ocated under each
i gni ti on coi l . Each i ndi vi dual i gni ti on coi l must be
removed to gai n access to each spark pl ug. Refer to
I gni ti on Coi l Removal /I nstal l ati on.
(1) Remove necessary ai r fi l ter tubi ng at throttl e
body.
(2) Pri or to removi ng i gni ti on coi l , spray com-
pressed ai r around coi l base at cyl i nder head.
(3) Pri or to removi ng spark pl ug, spray com-
pressed ai r i nto cyl i nder head openi ng. Thi s wi l l hel p
prevent forei gn materi al from enteri ng combusti on
chamber.
(4) Remove spark pl ug from cyl i nder head usi ng a
qual i ty socket wi th a rubber or foam i nsert. Al so
check condi ti on of i gni ti on coi l o-ri ng and repl ace as
necessary.
(5) I nspect spark pl ug condi ti on. Refer to Di agnos-
ti cs and Testi ng - Spark Pl ug Condi ti ons.
4. 7L V-8
Each i ndi vi dual spark pl ug i s l ocated under each
i gni ti on coi l . Each i ndi vi dual i gni ti on coi l must be
removed to gai n access to each spark pl ug. Refer to
I gni ti on Coi l Removal /I nstal l ati on.
body.
(2) Pri or to removi ng i gni ti on coi l , spray com-
pressed ai r around coi l base at cyl i nder head.
chamber.
qual i ty socket wi th a rubber or foam i nsert. Al so
check condi ti on of i gni ti on coi l o-ri ng and repl ace as
necessary.
5. 7L V-8
Ei ght of the 16 spark pl ugs are l ocated under an
i gni ti on coi l ; the other 8 are not. I f spark pl ug bei ng
Fig. 27 CHIPPED ELECTRODE INSULATOR
1 - GROUND ELECTRODE
3 - CHIPPED INSULATOR
Fig. 28 PREIGNITION DAMAGE
1 - GROUND ELECTRODE STARTING TO DISSOLVE
2 - CENTER ELECTRODE DISSOLVED
Fig. 29 SPARK PLUG OVERHEATING
1 - BLISTERED WHITE OR GRAY COLORED INSULATOR
removed i s under coi l , coi l must be removed to gai n
access to spark pl ug. Refer to I gni ti on Coi l Removal /
I nstal l ati on and observe al l CAUTI ONS and WARN-
I NGS.
Before removi ng or di sconnecti ng any spark pl ug
cabl es, note thei r ori gi nal posi ti on. Remove cabl es
one-at-a-ti me. To prevent i gni ti on crossfi re, spark
pl ug cabl es MUST be pl aced i n cabl e tray (routi ng
l oom) i nto thei r ori gi nal posi ti on. Refer to Spark Pl ug
Cabl e Removal for a graphi c.
Before i nstal l i ng spark pl ug cabl es to ei ther the
spark pl ugs or coi l s, appl y di el ectri c grease to i nsi de
of boots.
body.
(2) Pri or to removi ng i gni ti on coi l (i f coi l removal
i s necessary), spray compressed ai r around coi l base
at cyl i nder head cover.
chamber.
qual i ty socket wi th a rubber or foam i nsert.
CLEANING
CLEANING AND ADJUSTMENT
The pl ugs may be cl eaned usi ng commerci al l y
avai l abl e spark pl ug cl eani ng equi pment. After cl ean-
i ng, fi l e center el ectrode fl at wi th a smal l poi nt fi l e or
jewel ers fi l e before adjusti ng gap.
CAUTION: Never use a motorized wire wheel brush
to clean spark plugs. Metallic deposits will remain
on spark plug insulator and will cause plug misfire.
Adjust spark pl ug gap wi th a gap gaugi ng tool
(Fi g. 30).
INSTALLATION
3. 7L V-6
Speci al care shoul d be taken when i nstal l i ng spark
pl ugs i nto the cyl i nder head spark pl ug wel l s. Be
sure the pl ugs do not drop i nto the pl ug wel l s as el ec-
trodes can be damaged.
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap or a cracked porcel ai n
i nsul ator.
(1) Start the spark pl ug i nto the cyl i nder head by
hand to avoi d cross threadi ng.
(2) Ti ghten spark pl ugs. Refer to torque speci fi ca-
ti ons.
(3) Before i nstal l i ng i gni ti on coi l (s), check condi -
ti on of coi l o-ri ng and repl ace as necessary. To ai d i n
coi l i nstal l ati on, appl y si l i cone to coi l o-ri ng.
(4) I nstal l i gni ti on coi l (s). Refer to I gni ti on Coi l
Removal /I nstal l ati on.
4. 7L V-8
CAUTION: The 4.7L V8 engine is equipped with
copper core ground electrode spark plugs. They
must be replaced with the same type/number spark
plug as the original. If another spark plug is substi-
tuted, pre-ignition will result.
Speci al care shoul d be taken when i nstal l i ng spark
pl ugs i nto the cyl i nder head spark pl ug wel l s. Be
sure the pl ugs do not drop i nto the pl ug wel l s as el ec-
trodes can be damaged.
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on resul ti ng i n a
change i n the spark pl ug gap or a cracked porcel ai n
i nsul ator.
(1) Start the spark pl ug i nto the cyl i nder head by
hand to avoi d cross threadi ng.
(2) Ti ghten spark pl ugs. Refer to torque speci fi ca-
ti ons.
(3) Before i nstal l i ng i gni ti on coi l (s), check condi -
ti on of coi l o-ri ng and repl ace as necessary. To ai d i n
coi l i nstal l ati on, appl y si l i cone to coi l o-ri ng.
Fig. 30 SETTING SPARK PLUG GAP - TYPICAL
1 - GAUGE TOOL
2 - SPARK PLUG
(4) I nstal l i gni ti on coi l (s). Refer to I gni ti on Coi l
5. 7L V-8
(1) Speci al care shoul d be taken when i nstal l i ng
spark pl ugs i nto the cyl i nder head spark pl ug wel l s.
Be sure the pl ugs do not drop i nto the pl ug wel l s as
el ectrodes can be damaged.
(2) Start the spark pl ug i nto cyl i nder head by
hand to avoi d cross threadi ng al umi num threads. To
ai d i n i nstal l ati on, attach a pi ece of rubber hose, or
an ol d spark pl ug boot to spark pl ug.
(3) The 5.7L V-8 i s equi pped wi th torque cri ti cal
desi gn spark pl ugs. Do not exceed 15 ft. l bs. torque.
Ti ghten spark pl ugs. Refer to torque speci fi cati ons.
of boots.
(5) To prevent i gni ti on crossfi re, spark pl ug cabl es
MUST be pl aced i n cabl e tray (routi ng l oom) i nto
thei r ori gi nal posi ti on. Refer to Spark Pl ug Cabl e
Removal for a graphi c.
(6) I nstal l i gni ti on coi l (s) to necessary spark pl ugs.
Refer to I gni ti on Coi l I nstal l ati on.
(7) I nstal l spark pl ug cabl es to remai ni ng spark
pl ugs. Remember to appl y di el ectri c grease to i nsi de
of boots.
IGNITION COIL CAPACITOR
DESCRIPTION
One coi l capaci tor i s used. I t i s l ocated i n the ri ght-
rear secti on of the engi ne compartment.
OPERATION
The coi l capaci tor(s) hel p dampen the amount of
conducted el ectri cal noi se to the camshaft posi ti on
sensor, crankshaft posi ti on sensor, and throttl e posi -
ti on sensor. Thi s noi se i s generated on the 12V sup-
pl y wi re to the i gni ti on coi l s and fuel i njectors.
REMOVAL
The coi l capaci tor i s l ocated i n the ri ght-rear sec-
ti on of the engi ne compartment. I t i s attached wi th a
mounti ng stud and nut.
(1) Di sconnect el ectri cal connector at capaci tor
(Fi g. 31).
(2) Remove mounti ng nut and remove ground
strap.
(3) Remove capaci tor.
INSTALLATION
(1) Posi ti on capaci tor to mounti ng stud.
(2) Posi ti on ground strap to mounti ng stud.
(3) Ti ghten nut to 7 Nm (60 i n. l bs.) torque.
(4) Connect el ectri cal connector to coi l capaci tor.
SPARK PLUG CABLE
DESCRIPTION
Spark pl ug cabl es are someti mes referred to as sec-
ondary i gni ti on wi res, or secondary i gni ti on cabl es.
Pl ug cabl es are used onl y on the 5.7L V-8 engi ne.
OPERATION
The spark pl ug cabl es transfer el ectri cal current
from the i gni ti on coi l (s) and/or di stri butor, to i ndi vi d-
ual spark pl ugs at each cyl i nder. The resi sti ve spark
pl ug cabl es are of nonmetal l i c constructi on. The
cabl es provi de suppressi on of radi o frequency emi s-
si ons from the i gni ti on system.
Pl ug cabl es are used onl y on the 5.7L V-8 engi ne.
Fig. 31 CAPACITOR LOCATION
1 - COIL CAPACITOR
2 - MOUNTING STUD
3 - GROUND STRAP
4 - MOUNTING NUT
5 - ELEC. CONNECT.
REMOVAL
5. 7L V-8
Spark pl ug cabl es on the 5.7L engi ne are pai red on
cyl i nders 1/6, 2/3, 4/7 and 5/8. Before removi ng or
di sconnecti ng any spark pl ug cabl es, note thei r ori g-
i nal posi ti on (Fi g. 32). Remove cabl es one-at-a-ti me.
To prevent i gni ti on crossfi re, spark pl ug cabl es
MUST be pl aced i n cabl e tray (routi ng l oom) i nto
thei r ori gi nal posi ti on. The cabl e retenti on cl i ps (Fi g.
32) must al so be securl y l ocked.
Before i nstal l i ng spark pl ug cabl es to ei ther the
of boots.
I f cabl e tray removal i s necessary, rel ease the 4
tray-to-mani fol d retenti on cl i ps (Fi g. 32).
INSTALLATION
I nstal l cabl es i nto the proper engi ne cyl i nder fi ri ng
order sequence. Refer to Speci fi cati ons.
When repl aci ng the spark pl ug and coi l cabl es,
route the cabl es correctl y and secure them i n the
proper retai ners. Fai l ure to route the cabl es properl y
may cause the radi o to reproduce i gni ti on noi se. I t
coul d al so cause cross-i gni ti on of the pl ugs, or, may
short-ci rcui t the cabl es to ground.
When i nstal l i ng new cabl es, make sure a posi ti ve
connecti on i s made. A snap shoul d be fel t when a
good connecti on i s made.
5. 7L V-8
Refer to Spark Pl ug Cabl e Removal for
i nformati on.
Fig. 32 5.7L SPARK PLUG CABLE ROUTING
1 - #8 COIL-TO- #5 SPARK PLUG (MARKED 5/8) 7 - CABLE TRAY
2 - #5 COIL-TO- #8 SPARK PLUG (MARKED 5/8) 8 - CLIPS (SPARK PLUG CABLE-TO-TRAY- RETENTION)
3 - #7 COIL-TO- #4 SPARK PLUG (MARKED 4/7) 9 - #2 COIL-TO- #3 SPARK PLUG (MARKED 2/3)
6 - CLIPS (TRAY-TO-MANIFOLD RETENTION)
SPARK PLUG CABLE (Continued)
INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - INSTRUMENT
CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 14
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
ABS INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
AIRBAG INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
BRAKE/PARK BRAKE INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - BRAKE
INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CARGO LAMP INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CHECK GAUGES INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CRUISE INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DOOR AJAR INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ENGINE TEMPERATURE GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ETC INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
GEAR SELECTOR INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
HIGH BEAM INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
LAMP OUT INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
LOW FUEL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MALFUNCTION INDICATOR LAMP (MIL)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ODOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OIL PRESSURE GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SEATBELT INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
STANDARD PROCEDURE - ENHANCED
SEATBELT REMINDER PROGRAMMING . . . . 35
SECURITY INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SERVICE 4WD INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SPEEDOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TACHOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TOW/HAUL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TRANS TEMP INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TURN SIGNAL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
UPSHIFT INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
VOLTAGE GAUGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
WAIT-TO-START INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DR INSTRUMENT CLUSTER 8J - 1
WASHER FLUID INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
WATER-IN-FUEL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 45
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTRUMENT CLUSTER
DESCRIPTION
The i nstrument cl uster for thi s model i s an El ec-
troMechani cal I nstrument Cl uster (EMI C) that i s
l ocated i n the i nstrument panel above the steeri ng
col umn openi ng, di rectl y i n front of the dri ver (Fi g.
1). The remai nder of the EMI C, i ncl udi ng the mounts
and the el ectri cal connecti ons, are conceal ed wi thi n
the i nstrument panel behi nd the cl uster bezel .
Besi des anal og gauges and i ndi cators, the EMI C
modul e i ncorporates two bl ue-green di gi tal Vacuum
Fl uorescent Di spl ay (VFD) uni ts for di spl ayi ng odom-
eter/tri p odometer i nformati on, engi ne hours, auto-
mati c transmi ssi on gear sel ector posi ti on (PRNDL),
several warni ng or remi nder i ndi cati ons and certai n
di agnosti c i nformati on. The i nstrument cl uster for
thi s model al so i ncl udes the hardware and software
necessary to serve as the el ectroni c body control mod-
ul e and i s someti mes referred to as the Cab Com-
partment Node or CCN.
The EMI C gauges and i ndi cators are vi si bl e
through a dedi cated openi ng i n the cl uster bezel on
the i nstrument panel and are protected by a cl ear
pl asti c cl uster l ens (Fi g. 2) that i s i ntegral to a cl us-
ter l ens, hood and mask uni t. Just behi nd the cl uster
l ens i s the cl uster hood and an i ntegral cl uster mask,
whi ch are constructed of mol ded bl ack pl asti c. The
cl uster hood serves as a vi sor and shi el ds the face of
the cl uster from ambi ent l i ght and refl ecti ons to
reduce gl are, whi l e the cl uster mask serves to sepa-
rate and defi ne the i ndi vi dual gauges and i ndi cators
of the EMI C. A bl ack pl asti c odometer/tri p odometer
swi tch button protrudes through dedi cated hol es i n
the cl uster mask and the cl uster l ens, l ocated near
the l ower edge of the cl uster just to the l eft of the
tachometer. The mol ded pl asti c EMI C l ens, hood and
mask uni t has four i ntegral mounti ng tabs, one each
on the upper and l ower outboard corners of the uni t.
These mounti ng tabs are used to secure the EMI C to
the mol ded pl asti c i nstrument panel cl uster carri er
wi th four screws.
The rear of the cl uster housi ng and the EMI C el ec-
troni c ci rcui try are protected by a mol ded pl asti c rear
cover, whi ch i s secured to the cl uster housi ng wi th a
si ngl e screw, whi l e ei ght screws i nstal l ed around the
outsi de peri meter of the rear cover secure i t to the
cl uster l ens, hood and mask uni t. The rear cover
i ncl udes cl earance hol es for servi ce access to each of
the el even i ncandescent bul b and bul b hol der uni ts
i nstal l ed on the cl uster ci rcui t board for general i l l u-
mi nati on l i ghti ng and for the cl uster connector recep-
tacl es. The connector receptacl es on the back of the
cl uster el ectroni c ci rcui t board connect the EMI C to
the vehi cl e el ectri cal system through three take outs
wi th connectors from the i nstrument panel wi re har-
ness. The EMI C al so has an i ntegral i nterface con-
nector on the back of the cl uster ci rcui t board that
joi ns i t to the opti onal external RKE recei ver through
a connector receptacl e that i s i ntegral to that uni t.
The rear cover i ncl udes a mol ded receptacl e and two
l atch features to secure the RKE recei ver on vehi cl es
that are so equi pped.
Fig. 1 Instrument Cluster
2 - INSTRUMENT CLUSTER
Fig. 2 Instrument Cluster Components
1 - SCREW (9)
2 - REAR COVER
3 - CLUSTER HOUSING
4 - LENS, HOOD & MASK
8J - 2 INSTRUMENT CLUSTER DR
Sandwi ched between the rear cover and the l ens,
hood and mask uni t i s the cl uster housi ng. The
mol ded pl asti c cl uster housi ng serves as the carri er
for the cl uster ci rcui t board and ci rcui try, the cl uster
connector receptacl es, the RKE i nterface connector,
the gauges, a Li ght Emi tti ng Di ode (LED) for each
cl uster i ndi cator, two VFD uni ts, an audi bl e tone
generator, the cl uster overl ay, the gauge poi nters, the
odometer/tri p odometer swi tch and the swi tch button.
The cl uster overl ay i s a l ami nated pl asti c uni t. The
dark, vi si bl e, outer surface of the overl ay i s marked
wi th al l of the gauge di al faces and graduati ons, but
thi s l ayer i s al so transl ucent. The darkness of thi s
outer l ayer prevents the cl uster from appeari ng cl ut-
tered or busy by conceal i ng the cl uster i ndi cators
that are not i l l umi nated, whi l e the transl ucence of
thi s l ayer al l ows those i ndi cators and i cons that are
i l l umi nated to be readi l y vi si bl e. The underl yi ng
l ayer of the overl ay i s opaque and al l ows l i ght from
the LED for each of the vari ous i ndi cators and the
i ncandescent i l l umi nati on l amps behi nd i t to be vi si -
bl e through the outer l ayer of the overl ay onl y
through predetermi ned stenci l -l i ke cutouts. A rectan-
gul ar openi ng i n the overl ay at the base of both the
speedometer and tachometer di al faces has a smoked
cl ear l ens through whi ch the i l l umi nated VFD uni ts
can be vi ewed.
Several versi ons of the EMI C modul e are offered
on thi s model . These versi ons accommodate al l of the
vari ati ons of opti onal equi pment and regul atory
requi rements for the vari ous markets i n whi ch the
vehi cl e wi l l be offered. The mi croprocessor-based
EMI C uti l i zes i ntegrated ci rcui try and i nformati on
carri ed on the Programmabl e Communi cati ons I nter-
face (PCI ) data bus network al ong wi th several hard
wi red anal og and mul ti pl exed i nputs to moni tor sen-
sors and swi tches throughout the vehi cl e. I n response
to those i nputs, the i nternal ci rcui try and program-
mi ng of the EMI C al l ow i t to control and i ntegrate
many el ectroni c functi ons and features of the vehi cl e
through both hard wi red outputs and the transmi s-
si on of el ectroni c message outputs to other el ectroni c
modul es i n the vehi cl e over the PCI data bus. (Refer
to 8 - ELECTRI CAL/ELECTRONI C CONTROL
MODULES/COMMUNI CATI ON - DESCRI PTI ON -
PCI BUS).
Besi des typi cal i nstrument cl uster gauge and i ndi -
cator support, the el ectroni c functi ons and features
that the EMI C supports or control s i ncl ude the fol -
l owi ng:
Audible Warnings - The EMI C el ectroni c ci r-
cui t board i s equi pped wi th an audi bl e tone generator
and programmi ng that al l ows i t to provi de vari ous
audi bl e al erts to the vehi cl e operator, i ncl udi ng
chi me tones and beep tones. An el ectromechani cal
rel ay i s al so sol dered onto the ci rcui t board to pro-
duce audi bl e cl i cks that emul ate the sound of a con-
venti onal turn si gnal or hazard warni ng fl asher.
(Refer to 8 - ELECTRI CAL/CHI ME/BUZZER -
DESCRI PTI ON).
Brake Lamp Control - The EMI C provi des
el ectroni c brake l amp request messages to the Front
Control Modul e (FCM) l ocated on the I ntegrated
Power Modul e (I PM) for brake l amp control , excl ud-
i ng control of the Center Hi gh Mounted Stop Lamp
(CHMSL), whi ch remai ns control l ed by a di rect hard
wi red output of the brake l amp swi tch.
Brake Transmission Shift Interlock Control
- The EMI C moni tors i nputs from the brake l amp
swi tch, i gni ti on swi tch, and the Transmi ssi on Range
Sensor (TRS), then control s a hi gh-si de dri ver output
to operate the Brake Transmi ssi on Shi ft I nterl ock
(BTSI ) sol enoi d that l ocks and unl ocks the automati c
transmi ssi on gearshi ft sel ector l ever on the steeri ng
col umn.
Cargo Lamp Control - The EMI C provi des
di rect control of cargo l amp operati on wi th a l oad
sheddi ng (battery saver) feature whi ch wi l l automat-
i cal l y turn off the cargo l amp i f i t remai ns on after a
ti med i nterval .
Central Locking - The EMI C provi des support
for the central l ocki ng feature of the power l ock sys-
tem. Thi s feature wi l l l ock or unl ock al l doors based
upon the i nput from the door cyl i nder l ock swi tch.
Door cyl i nder l ock swi tches are used onl y on model s
equi pped wi th the opti onal Vehi cl e Theft Securi ty
System (VTSS).
Door Lock Inhibit - The EMI C i nhi bi ts l ocki ng
of the doors wi th the power l ock swi tch when the key
i s i n the i gni ti on swi tch and the dri ver si de front
door i s ajar. However, operati on of the door l ocks i s
not i nhi bi ted under the same condi ti ons when the
Lock button of the opti onal RKE transmi tter i s
depressed.
Enhanced Accident Response - The EMI C
moni tors an i nput from the Ai rbag Control Modul e
(ACM) and, fol l owi ng an ai rbag depl oyment, wi l l
i mmedi atel y di sabl e the power l ock output, unl ock al l
doors by acti vati ng the power unl ock output, then
enabl es the power l ock output. Thi s feature, l i ke al l
other enhanced acci dent response features, i s depen-
dent upon a functi onal vehi cl e el ectri cal system fol -
l owi ng the vehi cl e i mpact event.
Exterior Lighting Control - The EMI C pro-
vi des el ectroni c head l amp and/or park l amp request
messages to the Front Control Modul e (FCM) l ocated
on the I ntegrated Power Modul e (I PM) for the appro-
pri ate exteri or l amp control of standard head and
park l amps, as wel l as opti onal front fog l amps. Thi s
i ncl udes support for headl amp beam sel ecti on and
the opti cal horn feature, al so known as fl ash-to-pass.
INSTRUMENT CLUSTER (Continued)
Exterior Lighting Fail-safe - I n the absence of
a headl amp swi tch i nput, the EMI C wi l l turn on the
cl uster i l l umi nati on l amps and provi de el ectroni c
headl amp l ow beam and park l amp request messages
to the Front Control Modul e (FCM) l ocated on the
I ntegrated Power Modul e (I PM) for defaul t exteri or
l amp operati on. The FCM wi l l al so provi de defaul t
park l amp and headl amp l ow beam operati on and the
EMI C wi l l turn on the cl uster i l l umi nati on l amps i f
there i s a fai l ure of the el ectroni c data bus commu-
ni cati on between the EMI C and the FCM.
Heated Seat Control - The EMI C moni tors
i nputs from the i gni ti on swi tch and el ectroni c engi ne
speed messages from the Powertrai n Control Modul e
(PCM) to control a hi gh si de dri ver output to the
heated seat swi tch Li ght Emi tti ng Di ode (LED) i ndi -
cators. Thi s i nput al l ows the heated seat swi tches to
wake up the heated seat modul e i f the swi tch i s actu-
ated. The EMI C wi l l de-energi ze the heated seat
swi tch LED i ndi cators, whi ch deacti vates the heated
seat system, i f the i gni ti on swi tch i s turned to any
posi ti on except On or Start, or i f the engi ne speed
message i ndi cates zero. (Refer to 8 - ELECTRI CAL/
HEATED SEATS - DESCRI PTI ON).
Interior Lamp Load Shedding - The EMI C
provi des a battery saver feature whi ch wi l l automat-
i cal l y turn off al l i nteri or l amps that remai n on after
a ti med i nterval of about fi fteen mi nutes.
Interior Lamps - Enhanced Accident
Response - The EMI C moni tors i nputs from the Ai r-
bag Control Modul e (ACM) and the Powertrai n Con-
trol Modul e (PCM) to automati cal l y turn on the
i nteri or l i ghti ng after an ai rbag depl oyment event
ten seconds after the vehi cl e speed i s zero. The i nte-
ri or l i ghti ng remai ns i l l umi nated unti l the key i s
removed from the i gni ti on swi tch l ock cyl i nder, at
whi ch ti me the i nteri or l i ghti ng returns to normal
operati on and control . Thi s feature, l i ke al l other
enhanced acci dent response features, i s dependent
upon a functi onal vehi cl e el ectri cal system fol l owi ng
the vehi cl e i mpact event.
Interior Lighting Control - The EMI C moni -
tors i nputs from the i nteri or l i ghti ng swi tch, the door
ajar swi tches, the cargo l amp swi tch, the readi ng
l amp swi tches, and the Remote Keyl ess Entry (RKE)
modul e to provi de courtesy l amp control . Thi s
i ncl udes support for ti med i l l umi nated entry wi th
theater-styl e fade-to-off and courtesy i l l umi nati on
defeat features.
Lamp Out Indicator Control - The EMI C
moni tors el ectroni c l amp outage messages from the
Front Control Modul e (FCM) l ocated on the I nte-
grated Power Modul e (I PM) i n order to provi de l amp
out i ndi cator control for the headl amps (l ow and hi gh
beams), turn si gnal l amps, and the brake l amps
(excl udi ng CHMSL).
Panel Lamps Dimming Control - The EMI C
provi des a hard wi red 12-vol t Pul se-Wi dth Modul ated
(PWM) output that synchroni zes the di mmi ng l evel
of al l hard wi red panel l amps di mmer control l ed
l amps wi th that of the cl uster i l l umi nati on l amps.
Parade Mode - The EMI C provi des a parade
mode (al so known as funeral mode) that al l ows al l
Vacuum-Fl uorescent Di spl ay (VFD) uni ts i n the vehi -
cl e to be i l l umi nated at ful l (dayti me) i ntensi ty whi l e
dri vi ng duri ng dayl i ght hours wi th the exteri or
l amps turned on.
Power Locks - The EMI C moni tors i nputs from
the power l ock swi tches and the Remote Keyl ess
Entry (RKE) recei ver modul e (opti onal ) to provi de
control of the power l ock motors through hi gh si de
dri ver outputs to the power l ock motors. Thi s
i ncl udes support for rol l i ng door l ocks (al so known as
automati c door l ocks), automati c door unl ock, a door
l ock i nhi bi t mode, and central l ocki ng (wi th the
opti onal Vehi cl e Theft Securi ty System onl y). (Refer
to 8 - ELECTRI CAL/POWER LOCKS - DESCRI P-
TI ON).
Remote Keyless Entry - The EMI C supports
the opti onal Remote Keyl ess Entry (RKE) system fea-
tures, i ncl udi ng support for the RKE Lock, Unl ock
(wi th opti onal dri ver-door-onl y unl ock, and unl ock-
al l -doors), Pani c, audi bl e chi rp, opti cal chi rp, i l l umi -
nated entry modes, an RKE programmi ng mode, as
wel l as opti onal Vehi cl e Theft Securi ty System
(VTSS) armi ng (when the proper VTSS armi ng con-
di ti ons are met) and di sarmi ng.
Remote Radio Switch Interface - The EMI C
moni tors i nputs from the opti onal remote radi o
swi tches and then provi des the appropri ate el ectroni c
data bus messages to the radi o to sel ect the radi o
operati ng mode, vol ume control , preset stati on scan
and stati on seek features.
Rolling Door Locks - The EMI C provi des sup-
port for the power l ock system rol l i ng door l ocks fea-
ture (al so known as automati c door l ocks). Thi s
feature wi l l automati cal l y l ock al l unl ocked doors
each ti me the vehi cl e speed reaches twenty-four ki l o-
meters-per-hour (fi fteen mi l es-per-hour). Fol l owi ng
an automati c l ock event, i f the dri ver si de front door
i s opened fi rst after the i gni ti on i s turned to the Off
posi ti on, al l doors wi l l be automati cal l y unl ocked.
Turn Signal & Hazard Warning Lamp Con-
trol - The EMI C provi des el ectroni c turn and hazard
l amp request messages to the Front Control Modul e
(FCM) l ocated on the I ntegrated Power Modul e (I PM)
for turn and hazard l amp control . The EMI C al so
provi des an audi bl e cl i ck at one of two rates to emu-
l ate normal and bul b out turn or hazard fl asher oper-
ati on based upon el ectroni c l amp outage messages
from the FCM, and provi des an audi bl e turn si gnal
on chi me warni ng i f a turn i s si gnal l ed conti nuousl y
for more than about 1.6 ki l ometers (one mi l e) and
the vehi cl e speed remai ns greater than about twenty-
four ki l ometers-per-hour (fi fteen mi l es-per-hour).
Vacuum Fluorescent Display Synchroniza-
tion - The EMI C transmi ts el ectroni c panel l amp
di mmi ng l evel messages whi ch al l ows al l other el ec-
troni c modul es on the PCI data bus wi th Vacuum
Fl uorescent Di spl ay (VFD) uni ts to coordi nate thei r
i l l umi nati on i ntensi ty wi th that of the EMI C VFD
uni ts.
Vehicle Theft Security System - The EMI C
moni tors i nputs from the door cyl i nder l ock
swi tch(es), the door ajar swi tches, the i gni ti on
swi tch, and the Remote Keyl ess Entry (RKE) recei ver
modul e, then provi des el ectroni c horn and l i ghti ng
request messages to the Front Control Modul e (FCM)
l ocated on the I ntegrated Power Modul e (I PM) for
the appropri ate VTSS al arm output features.
Wiper/Washer System Control - The EMI C
provi des el ectroni c wi per and/or washer request mes-
sages to the Front Control Modul e (FCM) l ocated on
the I ntegrated Power Modul e (I PM) for the appropri -
ate wi per and washer system features. (Refer to 8 -
ELECTRI CAL/WI PERS/WASHERS - DESCRI P-
TI ON).
The EMI C houses si x anal og gauges and has pro-
vi si ons for up to twenty-three i ndi cators (Fi g. 3) or
(Fi g. 4). The EMI C i ncl udes the fol l owi ng anal og
gauges:
Coolant Temperature Gauge
Fuel Gauge
Oil Pressure Gauge
Speedometer
Tachometer
Voltage Gauge
Some of the EMI C i ndi cators are automati cal l y
confi gured when the EMI C i s connected to the vehi -
cl e el ectri cal system for compati bi l i ty wi th certai n
opti onal equi pment or equi pment requi red for regul a-
tory purposes i n certai n markets. Whi l e each EMI C
may have provi si ons for i ndi cators to support every
avai l abl e opti on, the confi gurabl e i ndi cators wi l l not
be functi onal i n a vehi cl e that does not have the
equi pment that an i ndi cator supports. The EMI C
i ncl udes provi si ons for the fol l owi ng i ndi cators (Fi g.
3) or (Fi g. 4):
Airbag Indicator (with Airbag System only)
Antilock Brake System (ABS) Indicator
(with ABS or Rear Wheel Anti-Lock [RWAL]
brakes only)
Brake Indicator
Cargo Lamp Indicator
Check Gauges Indicator
Cruise Indicator (with Speed Control only)
Door Ajar Indicator
Electronic Throttle Control (ETC) Indicator
(with 5.7L Gasoline Engine only)
Gear Selector Indicator (with Automatic
Transmission only)
High Beam Indicator
Lamp Out Indicator
Low Fuel Indicator
Malfunction Indicator Lamp (MIL)
Seatbelt Indicator
Security Indicator (with Sentry Key Immo-
bilizer & Vehicle Theft Security Systems only)
Service Four-Wheel Drive Indicator (with
Four-Wheel Drive only)
Tow/Haul Indicator (with Automatic Trans-
mission only)
Transmission Overtemp Indicator (with
Automatic Transmission only)
Turn Signal (Right and Left) Indicators
Upshift Indicator (with Manual Transmis-
sion only)
Washer Fluid Indicator
Wait-To-Start Indicator (with Diesel Engine
only)
Water-In-Fuel Indicator (with Diesel Engine
only)
Each i ndi cator i n the EMI C, except those l ocated
wi thi n one of the VFD uni ts, i s i l l umi nated by a ded-
i cated LED that i s sol dered onto the EMI C el ectroni c
ci rcui t board. The LED uni ts are not avai l abl e for
servi ce repl acement and, i f damaged or faul ty, the
enti re EMI C must be repl aced. Cl uster i l l umi nati on
i s accompl i shed by di mmabl e i ncandescent back
l i ghti ng, whi ch i l l umi nates the gauges for vi si bi l i ty
when the exteri or l i ghti ng i s turned on. Each of the
i ncandescent bul bs i s secured by an i ntegral bul b
hol der to the el ectroni c ci rcui t board from the back of
the cl uster housi ng.
Hard wi red ci rcui try connects the EMI C to the
el ectri cal system of the vehi cl e. These hard wi red ci r-
cui ts are i ntegral to several wi re harnesses, whi ch
many di fferent methods. These ci rcui ts may be con-
nected to each other, to the vehi cl e el ectri cal system
and to the EMI C through the use of a combi nati on of
sol dered spl i ces, spl i ce bl ock connectors, and many
di fferent types of wi re harness termi nal connectors
and i nsul ators. Refer to the appropri ate wi ri ng i nfor-
mati on. The wi ri ng i nformati on i ncl udes wi ri ng di a-
grams, proper wi re and connector repai r procedures,
further detai l s on wi re harness routi ng and reten-
ti on, as wel l as pi n-out and l ocati on vi ews for the
vari ous wi re harness connectors, spl i ces and grounds.
The EMI C modul es for thi s model are servi ced onl y
as compl ete uni ts. The EMI C modul e cannot be
adjusted or repai red. I f a gauge, an LED i ndi cator, a
VFD uni t, the el ectroni c ci rcui t board, the ci rcui t
board hardware, the cl uster overl ay, or the EMI C
housi ng are damaged or faul ty, the enti re EMI C mod-
ul e must be repl aced. The cl uster l ens, hood and
mask uni t and the i ndi vi dual i ncandescent l amp
bul bs wi th hol ders are avai l abl e for i ndi vi dual ser-
vi ce repl acement.
OPERATION
The El ectroMechani cal I nstrument Cl uster (EMI C)
i n thi s model al so i ncl udes the hardware and soft-
ware necessary to serve as the el ectroni c body control
modul e and i s someti mes referred to as the Cab
Compartment Node or CCN. The fol l owi ng i nforma-
ti on deal s pri mari l y wi th the i nstrument cl uster
functi ons of thi s uni t. Addi ti onal detai l s of the el ec-
troni c body control functi ons of thi s uni t may be
found wi thi n the servi ce i nformati on for the system
or component that the EMI C control s. For exampl e:
Addi ti onal detai l s of the audi bl e warni ng functi ons of
the EMI C are found wi thi n the Chi me/Buzzer servi ce
i nformati on.
The EMI C i s desi gned to al l ow the vehi cl e operator
to moni tor the condi ti ons of many of the vehi cl e com-
ponents and operati ng systems. The gauges and i ndi -
cators i n the EMI C provi de val uabl e i nformati on
about the vari ous standard and opti onal powertrai ns,
fuel and emi ssi ons systems, cool i ng systems, l i ghti ng
systems, safety systems and many other conveni ence
i tems. The EMI C i s i nstal l ed i n the i nstrument panel
so that al l of these moni tors can be easi l y vi ewed by
the vehi cl e operator when dri vi ng, whi l e sti l l al l ow-
i ng rel ati ve ease of access for servi ce. The mi cropro-
cessor-based EMI C hardware and software uses
vari ous i nputs to control the gauges and i ndi cators
vi si bl e on the face of the cl uster. Some of these
i nputs are hard wi red, but most are i n the form of
el ectroni c messages that are transmi tted by other
el ectroni c modul es over the Programmabl e Communi -
cati ons I nterface (PCI ) data bus network. (Refer to 8
Fig. 3 Gauges & Indicators - Gasoline Engine
1 - MALFUNCTION INDICATOR LAMP 13 - ELECTRONIC THROTTLE CONTROL (ETC) INDICATOR
2 - VOLTAGE GAUGE 14 - ENGINE TEMPERATURE GAUGE
3 - LEFT TURN INDICATOR 15 - SECURITY INDICATOR
4 - TACHOMETER 16 - GEAR SELECTOR INDICATOR DISPLAY (INCLUDES
CRUISE & UPSHIFT INDICATORS)
5 - AIRBAG INDICATOR 17 - CHECK GAUGES INDICATOR
6 - HIGH BEAM INDICATOR 18 - BRAKE INDICATOR
7 - SEATBELT INDICATOR 19 - ABS INDICATOR
8 - SPEEDOMETER 20 - ODOMETER/TRIP ODOMETER DISPLAY (INCLUDES
ENGINE HOURS, WASHER FLUID, LAMP OUTAGE, TOW/HAUL
& SERVICE 4x4 INDICATORS)
9 - RIGHT TURN INDICATOR 21 - ODOMETER/TRIP ODOMETER SWITCH BUTTON
10 - OIL PRESSURE GAUGE 22 - FUEL GAUGE
11 - CARGO LAMP INDICATOR 23 - LOW FUEL INDICATOR
12 - DOOR AJAR INDICATOR 24 - TRANSMISSION OVERTEMP INDICATOR
- ELECTRI CAL/ELECTRONI C CONTROL MOD-
ULES/COMMUNI CATI ON - OPERATI ON).
The EMI C mi croprocessor smooths the i nput data
usi ng al gori thms to provi de gauge readi ngs that are
accurate, stabl e and responsi ve to operati ng condi -
ti ons. These al gori thms are desi gned to provi de
gauge readi ngs duri ng normal operati on that are con-
si stent wi th customer expectati ons. However, when
abnormal condi ti ons exi st such as hi gh cool ant tem-
perature, the al gori thm can dri ve the gauge poi nter
to an extreme posi ti on and the mi croprocessor can
sound a chi me through the on-board audi bl e tone
generator to provi de di sti nct vi sual and audi bl e i ndi -
cati ons of a probl em to the vehi cl e operator. The
i nstrument cl uster ci rcui try may al so produce audi -
bl e warni ngs for other el ectroni c modul es i n the vehi -
cl e based upon el ectroni c tone request messages
recei ved over the PCI data bus. Each audi bl e warn-
i ng i s i ntended to provi de the vehi cl e operator wi th
an audi bl e al ert to suppl ement a vi sual i ndi cati on.
The EMI C ci rcui try operates on battery current
recei ved through a fused B(+) fuse i n the I ntegrated
Power Modul e (I PM) on a non-swi tched fused B(+)
ci rcui t, and on battery current recei ved through a
fused i gni ti on swi tch output (run-start) fuse i n the
I PM on a fused i gni ti on swi tch output (run-start) ci r-
cui t. Thi s arrangement al l ows the EMI C to provi de
some features regardl ess of the i gni ti on swi tch posi -
ti on, whi l e other features wi l l operate onl y wi th the
i gni ti on swi tch i n the On or Start posi ti ons. The
EMI C ci rcui try i s grounded through a ground ci rcui t
and take out of the i nstrument panel wi re harness
wi th an eyel et termi nal connector that i s secured by
a ground screw to a ground l ocati on near the center
of the i nstrument panel structural support.
The EMI C al so has a sel f-di agnosti c actuator test
capabi l i ty, whi ch wi l l test each of the PCI bus mes-
Fig. 4 Gauges & Indicators - Diesel Engine
1 - MALFUNCTION INDICATOR LAMP 14 - ENGINE TEMPERATURE GAUGE
2 - VOLTAGE GAUGE 15 - SECURITY INDICATOR
3 - LEFT TURN INDICATOR 16 - GEAR SELECTOR INDICATOR DISPLAY (INCLUDES
CRUISE & UPSHIFT INDICATORS)
4 - TACHOMETER 17 - WATER-IN-FUEL INDICATOR
5 - AIRBAG INDICATOR 18 - BRAKE INDICATOR
6 - HIGH BEAM INDICATOR 19 - WAIT-TO-START INDICATOR
7 - SEATBELT INDICATOR 20 - ODOMETER/TRIP ODOMETER DISPLAY (INCLUDES
ENGINE HOURS, WASHER FLUID, LAMP OUTAGE, TOW/HAUL
& SERVICE 4x4 INDICATORS)
8 - SPEEDOMETER 21 - ODOMETER/TRIP ODOMETER SWITCH BUTTON
9 - RIGHT TURN INDICATOR 22 - FUEL GAUGE
10 - OIL PRESSURE GAUGE 23 - LOW FUEL INDICATOR
11 - CARGO LAMP INDICATOR 24 - TRANSMISSION OVERTEMP INDICATOR
12 - DOOR AJAR INDICATOR 25 - CHECK GAUGES INDICATOR
13 - ABS INDICATOR
sage-control l ed functi ons of the cl uster by l i ghti ng
the appropri ate i ndi cators, posi ti oni ng the gauge nee-
dl es at several predetermi ned cal i brati on poi nts
across the gauge faces, and i l l umi nati ng al l segments
of the odometer/tri p odometer and gear sel ector i ndi -
cator Vacuum-Fl uorescent Di spl ay (VFD) uni ts.
(Refer to 8 - ELECTRI CAL/I NSTRUMENT CLUS-
TER - DI AGNOSI S AND TESTI NG). See the owners
manual i n the vehi cl e gl ove box for more i nformati on
on the features, use and operati on of the EMI C.
GAUGES
Al l gauges recei ve battery current through the
EMI C ci rcui try onl y when the i gni ti on swi tch i s i n
the On or Start posi ti ons. Wi th the i gni ti on swi tch i n
the Off posi ti on battery current i s not suppl i ed to
any gauges, and the EMI C ci rcui try i s programmed
to move al l of the gauge needl es back to the l ow end
of thei r respecti ve scal es. Therefore, the gauges do
not accuratel y i ndi cate any vehi cl e condi ti on unl ess
the i gni ti on swi tch i s i n the On or Start posi ti ons.
Al l of the EMI C gauges are ai r core magneti c
uni ts. Two fi xed el ectromagneti c coi l s are l ocated
wi thi n each gauge. These coi l s are wrapped at ri ght
angl es to each other around a movabl e permanent
magnet. The movabl e magnet i s suspended wi thi n
the coi l s on one end of a pi vot shaft, whi l e the gauge
needl e i s attached to the other end of the shaft. One
of the coi l s has a fi xed current fl owi ng through i t to
mai ntai n a constant magneti c fi el d strength. Current
fl ow through the second coi l changes, whi ch causes
changes i n i ts magneti c fi el d strength. The current
fl owi ng through the second coi l i s changed by the
EMI C ci rcui try i n response to messages recei ved over
the PCI data bus. The gauge needl e moves as the
movabl e permanent magnet al i gns i tsel f to the
changi ng magneti c fi el ds created around i t by the
el ectromagnets.
The gauges are di agnosed usi ng the EMI C sel f-di -
agnosti c actuator test. (Refer to 8 - ELECTRI CAL/
I NSTRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). Proper testi ng of the PCI data bus and
the el ectroni c data bus message i nputs to the EMI C
that control each gauge requi re the use of a DRBI I I
scan tool . Refer to the appropri ate di agnosti c i nfor-
mati on. Speci fi c operati on detai l s for each gauge may
be found el sewhere i n thi s servi ce i nformati on.
VACUUM-FLUORESCENT DISPLAYS
The Vacuum-Fl uorescent Di spl ay (VFD) uni ts are
sol dered to the EMI C el ectroni c ci rcui t board. Wi th
the i gni ti on swi tch i n the Off or Accessory posi ti ons,
the odometer di spl ay i s acti vated when the dri ver
door i s opened (Rental Car mode) and i s deacti vated
when the dri ver door i s cl osed. Otherwi se, both di s-
pl ay uni ts are acti ve when the i gni ti on swi tch i s i n
the On or Start posi ti ons, and i nacti ve when the i gni -
ti on swi tch i s i n the Off or Accessory posi ti ons.
The i l l umi nati on i ntensi ty of the VFD uni ts i s con-
trol l ed by the EMI C ci rcui try based upon an i nput
from the headl amp swi tch and a di mmi ng l evel i nput
recei ved from the headl amp di mmer swi tch. The
EMI C synchroni zes the i l l umi nati on i ntensi ty of
other VFD uni ts wi th that of the uni ts i n the EMI C
by sendi ng el ectroni c di mmi ng l evel messages to
other el ectroni c modul es i n the vehi cl e over the PCI
data bus.
The EMI C VFD uni ts have several di spl ay capabi l -
i ti es i ncl udi ng odometer, tri p odometer, engi ne hours,
gear sel ector i ndi cati on (PRNDL) for model s wi th an
automati c transmi ssi on, several warni ng or remi nder
i ndi cati ons, and vari ous di agnosti c i nformati on when
certai n faul t condi ti ons exi st. An odometer/tri p odom-
eter swi tch on the EMI C ci rcui t board i s used to con-
trol some of the di spl ay modes. Thi s swi tch i s
actuated manual l y by depressi ng the odometer/tri p
odometer swi tch button that extends through the
l ower edge of the cl uster l ens, just l eft of the tachom-
eter. Actuati ng thi s swi tch momentari l y wi th the
i gni ti on swi tch i n the On posi ti on wi l l toggl e the
VFD between the odometer and tri p odometer modes.
Depressi ng the swi tch button for about two seconds
whi l e the VFD i s i n the tri p odometer mode wi l l
reset the tri p odometer val ue to zero. Whi l e i n the
odometer mode wi th the i gni ti on swi tch i n the On
posi ti on and the engi ne not runni ng, depressi ng thi s
swi tch for about si x seconds wi l l di spl ay the engi ne
hours i nformati on. Hol di ng thi s swi tch depressed
whi l e turni ng the i gni ti on swi tch from the Off posi -
ti on to the On posi ti on wi l l i ni ti ate the EMI C sel f-di -
agnosti c actuator test. Refer to the appropri ate
di agnosti c i nformati on for addi ti onal detai l s on thi s
VFD functi on. The EMI C mi croprocessor remembers
whi ch di spl ay mode i s acti ve when the i gni ti on
swi tch i s turned to the Off posi ti on, and returns the
VFD di spl ay to that mode when the i gni ti on swi tch i s
turned On agai n.
The VFD uni ts are di agnosed usi ng the EMI C sel f-
di agnosti c actuator test. (Refer to 8 - ELECTRI CAL/
TESTI NG). Proper testi ng of the PCI data bus and
the el ectroni c data bus message i nputs to the EMI C
that control some of the VFD functi ons requi res the
use of a DRBI I I scan tool . Refer to the appropri ate
di agnosti c i nformati on. Speci fi c operati on detai l s for
the odometer, the tri p odometer, the gear sel ector
i ndi cator and the vari ous warni ng and remi nder i ndi -
cator functi ons of the VFD may be found el sewhere
i n thi s servi ce i nformati on.
INDICATORS
I ndi cators are l ocated i n vari ous posi ti ons wi thi n
the EMI C and are al l connected to the EMI C el ec-
troni c ci rcui t board. The cargo l amp i ndi cator, door
ajar i ndi cator, hi gh beam i ndi cator, and turn si gnal
i ndi cators operate based upon hard wi red i nputs to
the EMI C. The brake i ndi cator i s control l ed by PCI
data bus messages from the Control l er Anti l ock
Brake (CAB) as wel l as by hard wi red park brake
swi tch i nputs to the EMI C. The seatbel t i ndi cator i s
control l ed by the EMI C programmi ng, PCI data bus
messages from the Ai rbag Control Modul e (ACM),
and a hard wi red seat bel t swi tch i nput to the EMI C.
The Mal functi on I ndi cator Lamp (MI L) i s normal l y
control l ed by PCI data bus messages from the Pow-
ertrai n Control Modul e (PCM); however, i f the EMI C
l oses PCI data bus communi cati on, the EMI C ci r-
cui try wi l l automati cal l y turn the MI L on unti l PCI
data bus communi cati on i s restored. The EMI C uses
PCI data bus messages from the Front Control Mod-
ul e (FCM), the PCM, the di esel engi ne onl y Engi ne
Control Modul e (ECM), the ACM, the CAB, and the
Sentry Key I mmobi l i zer Modul e (SKI M) to control al l
of the remai ni ng i ndi cators.
The vari ous EMI C i ndi cators are control l ed by di f-
ferent strategi es; some recei ve fused i gni ti on swi tch
output from the EMI C ci rcui try and have a swi tched
ground, whi l e others are grounded through the EMI C
ci rcui try and have a swi tched battery feed. However,
al l i ndi cators are compl etel y control l ed by the EMI C
mi croprocessor based upon vari ous hard wi red and
el ectroni c message i nputs. Al l i ndi cators are i l l umi -
nated at a fi xed i ntensi ty, whi ch i s not affected by
the sel ected i l l umi nati on i ntensi ty of the EMI C gen-
eral i l l umi nati on l amps.
I n addi ti on, certai n i ndi cators i n thi s i nstrument
cl uster are automati cal l y confi gured or sel f-confi g-
ured. Thi s feature al l ows the confi gurabl e i ndi cators
to be enabl ed by the EMI C ci rcui try for compati bi l i ty
wi th certai n opti onal equi pment. The EMI C defaul ts
for the ABS i ndi cator and ai rbag i ndi cator are
enabl ed, and these confi gurati on setti ngs must be
programmati cal l y di sabl ed i n the EMI C usi ng a
DRBI I I scan tool for vehi cl es that do not have thi s
equi pment. The automati cal l y confi gured or sel f-con-
fi gured i ndi cators remai n l atent i n each EMI C at al l
ti mes and wi l l be acti ve onl y when the EMI C
recei ves the appropri ate PCI message i nputs for that
opti onal system or equi pment.
The hard wi red i ndi cator i nputs may be di agnosed
usi ng conventi onal di agnosti c methods. However, the
EMI C ci rcui try and PCI bus message control l ed i ndi -
cators are di agnosed usi ng the EMI C sel f-di agnosti c
actuator test. (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - DI AGNOSI S AND TESTI NG).
Proper testi ng of the PCI data bus and the el ectroni c
message i nputs to the EMI C that control an i ndi cator
requi res the use of a DRBI I I scan tool . Refer to the
appropri ate di agnosti c i nformati on. Speci fi c detai l s of
the operati on for each i ndi cator may be found el se-
where i n thi s servi ce i nformati on.
CLUSTER ILLUMINATION
The EMI C has several i l l umi nati on l amps that are
i l l umi nated when the exteri or l i ghti ng i s turned on
wi th the headl amp swi tch. The i l l umi nati on i ntensi ty
of these l amps i s adjusted when the i nteri or l i ghti ng
thumbwheel on the headl amp swi tch i s rotated (down
to di m, up to bri ghten) to one of si x avai l abl e mi nor
detent posi ti ons. The EMI C moni tors a resi stor mul -
ti pl exed i nput from the headl amp swi tch on a di m-
mer i nput ci rcui t. I n response to that i nput, the
EMI C el ectroni c ci rcui try converts a 12-vol t i nput i t
recei ves from a fuse i n the I ntegrated Power Modul e
(I PM) on a hard wi red panel l amps di mmer swi tch
si gnal ci rcui t i nto a 12-vol t Pul se Wi dth Modul ated
(PWM) output. The EMI C uses thi s PWM output to
power the cl uster i l l umi nati on l amps and the VFD
uni ts on the EMI C ci rcui t board, then provi des a syn-
chroni zed PWM output on the vari ous hard wi red
fused panel l amps di mmer swi tch si gnal ci rcui ts to
control and synchroni ze the i l l umi nati on i ntensi ty of
other i ncandescent i l l umi nati on l amps i n the vehi cl e.
The cl uster i l l umi nati on l amps are grounded at al l
ti mes.
The EMI C al so sends el ectroni c di mmi ng l evel
messages over the PCI data bus to other el ectroni c
modul es i n the vehi cl e to control and synchroni ze the
i l l umi nati on i ntensi ty of thei r VFD uni ts to that of
the EMI C VFD uni ts. I n addi ti on, the thumbwheel
on the headl amp swi tch has a Parade Mode posi ti on
to provi de a parade mode. The EMI C moni tors the
request for thi s mode from the headl amp swi tch,
then sends an el ectroni c di mmi ng l evel message over
the PCI data bus to i l l umi nate al l VFD uni ts i n the
vehi cl e at ful l (dayti me) i ntensi ty for easi er vi si bi l i ty
when dri vi ng i n dayl i ght wi th the exteri or l i ghti ng
turned on.
The hard wi red headl amp swi tch and EMI C panel
l amps di mmer i nputs and outputs may be di agnosed
usi ng conventi onal di agnosti c methods. However,
proper testi ng of the PWM output of the EMI C and
the el ectroni c di mmi ng l evel messages sent by the
EMI C over the PCI data bus requi res the use of a
DRBI I I scan tool . Refer to the appropri ate di agnos-
ti c i nformati on.
INPUT AND OUTPUT CIRCUITS
HARD WIRED INPUTS
The hard wi red i nputs to the EMI C i ncl ude the fol -
l owi ng:
Brake Lamp Switch Output
Driver Cylinder Lock Switch Sense
Driver Door Ajar Switch Sense
Driver Door Lock Switch MUX - with
Power Locks
Fused B(+) - Ignition-Off Draw
Fused B(+) - Power Lock Feed - with Power
Locks
Fused Ignition Switch Output (Accessory-
Run)
Fused Ignition Switch Output (Off-Run-
Start)
Fused Ignition Switch Output (Run-Start)
Headlamp Dimmer Switch MUX
Headlamp Switch MUX
Horn Relay Control
Key-In Ignition Switch Sense
Left Rear Door Ajar Switch Sense
Panel Lamps Dimmer Switch Signal
Park Brake Switch Sense
Passenger Door Ajar Switch Sense
Passenger Door Lock Switch MUX - with
Power Locks
Radio Control MUX
Right Rear Door Ajar Switch Sense
RKE Supply - with RKE
Seat Belt Switch Sense
Transmission Range Sensor MUX - with
Auto Trans
Turn/Hazard Switch MUX
Washer/Beam Select Switch MUX
Wiper Switch MUX
Refer to the appropri ate wi ri ng i nformati on for
addi ti onal detai l s.
HARD WIRED OUTPUTS
The hard wi red outputs of the EMI C i ncl ude the
fol l owi ng:
Accessory Switch Bank Illumination Driver
BTSI Driver - with Auto Trans
Cargo Lamp Driver
Dome/Overhead Lamp Driver
Driver Door Unlock Driver - with Power
Locks
Headlamp Switch Illumination Driver
Heated Seat Switch Indicator Driver - with
Heated Seats
Heater-A/C Control Illumination Driver
Left Door Lock Driver - with Power Locks
Left Rear Door Unlock Driver - with Power
Locks
Map/Glove Box Lamp Driver
Radio Illumination Driver
Right Door Lock Driver - with Power Locks
Right Door Unlock Driver - with Power
Locks
Transfer Case Switch Illumination Driver -
with Four-Wheel Drive
GROUNDS
The EMI C recei ves and suppl i es a ground path to
several swi tches and sensors through the fol l owi ng
hard wi red ci rcui ts:
Ground - Illumination (2 Circuits)
Ground - Power Lock - with Power Locks
Ground - Signal
Headlamp Switch Return
Multi-Function Switch Return
Transmission Range Sensor Return - with
Auto Trans
COMMUNICATION
The EMI C has provi si ons for the fol l owi ng commu-
ni cati on ci rcui ts:
PCI Data Bus
RKE Program Serial Data - with RKE
RKE Transmit Serial Data - with RKE
DIAGNOSIS AND TESTING - INSTRUMENT
CLUSTER
I f al l of the i nstrument cl uster gauges and/or i ndi -
cators are i noperati ve, refer to PRELI MI NARY
DI AGNOSI S. I f an i ndi vi dual gauge or Programma-
bl e Communi cati ons I nterface (PCI ) data bus mes-
sage-control l ed i ndi cator i s i noperati ve, refer to
ACTUATOR TEST. I f an i ndi vi dual hard wi red i ndi -
cator i s i noperati ve, refer to the di agnosi s and testi ng
i nformati on for that speci fi c i ndi cator.
CAUTION: Instrument clusters used in this model
automatically configure themselves for compatibil-
ity with the features and optional equipment in the
vehicle in which they are initially installed. The
instrument cluster is programmed to do this by
embedding the Vehicle Identification Number (VIN)
and other information critical to proper cluster
operation into electronic memory. This embedded
information is learned through electronic messages
received from other electronic modules in the vehi-
cle over the Programmable Communications Inter-
face (PCI) data bus, and through certain hard wired
inputs received when the cluster is connected to
the vehicle electrically. Once configured, the instru-
ment cluster memory may be irreparably damaged
and certain irreversible configuration errors may
occur if the cluster is connected electrically to
another vehicle; or, if an electronic module from
another vehicle is connected that provides data to
the instrument cluster (including odometer values)
that conflicts with that which was previously
learned and stored. Therefore, the practice of
exchanging (swapping) instrument clusters and
other electronic modules in this vehicle with those
removed from another vehicle must always be
avoided. Failure to observe this caution may result
in instrument cluster damage, which is not reim-
bursable under the terms of the product warranty.
Service replacement instrument clusters are pro-
vided with the correct VIN, and the certified odom-
eter and engine hours values embedded into cluster
memory, but will otherwise be automatically config-
ured for compatibility with the features and optional
equipment in the vehicle in which they are initially
installed.
NOTE: Certain indicators in this instrument cluster
are automatically configured. This feature allows
those indicators to be activated or deactivated for
compatibility with certain optional equipment. If the
problem being diagnosed involves improper illumi-
nation of the cruise indicator, the electronic throttle
control indicator, the service four-wheel drive indi-
cator, the tow/haul indicator, the transmission over-
temp indicator, the upshift indicator, the security
indicator or the gear selector indicator, disconnect
and isolate the battery negative cable. After about
five minutes, reconnect the battery negative cable
and turn the ignition switch to the On position. The
instrument cluster should automatically relearn the
equipment in the vehicle and properly configure the
configurable indicators accordingly.
PRELIMINARY DIAGNOSIS
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, IMPACT SENSOR, OR INSTRUMENT
DISCONNECT AND ISOLATE THE BATTERY NEGA-
TIVE (GROUND) CABLE, THEN WAIT TWO MINUTES
FOR THE SYSTEM CAPACITOR TO DISCHARGE
ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM.
MENT.
(1) Check the fused B(+) fuse (Fuse 51 - 20
ampere) i n the I ntegrated Power Modul e (I PM). I f
OK, go to Step 2. I f not OK, repai r the shorted ci rcui t
or component as requi red and repl ace the faul ty fuse.
(2) Check for battery vol tage at the fused B(+) fuse
(Fuse 51 - 20 ampere) i n the I PM. I f OK, go to Step
3. I f not OK, repai r the open fused B(+) ci rcui t
between the I PM and the battery as requi red.
cabl e. Remove the i nstrument cl uster. Reconnect the
battery negati ve cabl e. Check for battery vol tage at
the fused B(+) ci rcui t cavi ty of the i nstrument panel
wi re harness connector (Connector C1) for the i nstru-
ment cl uster. I f OK, go to Step 4. I f not OK, repai r
the open fused B(+) ci rcui t between the i nstrument
cl uster and the I PM as requi red.
(4) Check for conti nui ty between the si gnal ground
ci rcui t cavi ty of the i nstrument panel wi re harness
connector (Connector C1) for the i nstrument cl uster
and a good ground. There shoul d be conti nui ty. I f
OK, refer to ACTUATOR TEST. I f not OK, repai r the
open ground ci rcui t to ground (G202) as requi red.
ACTUATOR TEST
MENT.
The i nstrument cl uster actuator test wi l l put the
i nstrument cl uster i nto i ts sel f-di agnosti c mode. I n
thi s mode the i nstrument cl uster can perform a sel f-
di agnosti c test that wi l l confi rm that the i nstrument
cl uster ci rcui try, the gauges, and the i ndi cators are
capabl e of operati ng as desi gned. Duri ng the actuator
test the i nstrument cl uster ci rcui try wi l l posi ti on
each of the gauge needl es at vari ous cal i brati on
poi nts, i l l umi nate al l of the segments i n the Vacuum
Fl uorescent Di spl ay (VFD) uni ts, turn al l of the i ndi -
cators on and off agai n, di spl ay any Di agnosti c Trou-
bl e Code (DTC) i nformati on, and di spl ay the number
of i gni ti on key cycl es that have occurred si nce the
DTC was detected. I t i s suggested that a note pad
and penci l be used to wri te down any faul t i nforma-
ti on that i s di spl ayed duri ng the test for reference.
Successful compl eti on of the actuator test wi l l con-
fi rm that the i nstrument cl uster i s operati onal . How-
ever, there may sti l l be a probl em wi th the PCI data
bus, the Powertrai n Control Modul e (PCM), the
Engi ne Control Modul e (ECM), the Front Control
Modul e (FCM), the Transmi ssi on Control Modul e
(TCM), the Transfer Case Control Modul e (TCCM),
the Ai rbag Control Modul e (ACM), the Control l er
Anti -l ock Brake (CAB), or the i nputs to one of these
el ectroni c control modul es. Use a DRBI I I scan tool
to di agnose these components. Refer to the appropri -
ate di agnosti c i nformati on.
(1) Begi n the test wi th the i gni ti on swi tch i n the
Off posi ti on.
(2) Depress the odometer/tri p odometer swi tch but-
ton.
(3) Whi l e sti l l hol di ng the odometer/tri p odometer
swi tch button depressed, turn the i gni ti on swi tch to
the On posi ti on, but do not start the engi ne.
(4) Rel ease the odometer/tri p odometer swi tch but-
ton.
(5) The i nstrument cl uster wi l l si mul taneousl y
i l l umi nate al l of the operati onal segments i n both
VFD uni ts, perform a bul b check of each operati onal
LED i ndi cator. The VFD segments and LED i ndi ca-
tors remai n i l l umi nated as each gauge needl e i s
swept to several cal i brati on poi nts and back. I f a
VFD segment or an LED i ndi cator fai l s to i l l umi nate,
or i f a gauge needl e fai l s to sweep through the cal i -
brati on poi nts and back duri ng thi s test, the i nstru-
ment cl uster must be repl aced. Fol l owi ng these tests,
the actuator test wi l l proceed as descri bed i n Step 6.
(6) The text C Code i s di spl ayed i n the odometer
VFD for about three seconds. I f there i s no stored
faul t i nformati on, the di spl ay wi l l show two pai rs of
zeroes i n the format 00 00, whi ch i ndi cate that
the di spl ay of faul t i nformati on i s done. I f there i s
stored faul t i nformati on, two sets of two-di gi t al pha
and al pha-numeri c faul t codes wi l l appear i n the
odometer di spl ay for a three second i nterval . The
fi rst pai r of di gi ts represents a Di agnosti c Troubl e
Code (DTC), or faul t code for the i nstrument cl uster.
The second pai r of di gi ts i s a counter for the number
of i gni ti on key cycl es that have occurred si nce the
di spl ayed DTC was set. The i nstrument cl uster wi l l
conti nue to di spl ay addi ti onal sets of two pai rs of di g-
i ts at three second i nterval s unti l al l of the stored
codes have been di spl ayed, whi ch i s agai n si gnal ed
by a code of 00 00. Refer to the I nstrument Cl us-
ter Fai l ure Message tabl e for a descri pti on of each
faul t code that the i nstrument cl uster di spl ays. I f an
i nstrument cl uster faul t i s di spl ayed, use a DRBI I I
scan tool to di agnose the probl em. Refer to the appro-
pri ate di agnosti c i nformati on.
INSTRUMENT CLUSTER FAILURE MESSAGE
Fault Code Description Correction
01 Airbag warning indicator output circuit shorted. Refer to the appropriate diagnostic information.
02 Airbag warning indicator output circuit open. Refer to the appropriate diagnostic information.
03 ABS indicator output circuit shorted. Refer to the appropriate diagnostic information.
04 ABS indicator output circuit open. Refer to the appropriate diagnostic information.
05 MIL indicator output circuit shorted. Refer to the appropriate diagnostic information.
06 MIL indicator output circuit open. Refer to the appropriate diagnostic information.
07 Wait to start indicator circuit shorted. Refer to the appropriate diagnostic information.
08 Wait to start indicator circuit open. Refer to the appropriate diagnostic information.
0B BTSI output circuit shorted or open. Refer to the appropriate diagnostic information.
22 Headlamp switch input circuit shorted. Refer to the appropriate diagnostic information.
23 Headlamp switch input circuit open. Refer to the appropriate diagnostic information.
24 Turn hazard switch input circuit shorted. Refer to the appropriate diagnostic information.
25 Turn hazard swiitch inpot circuit open. Refer to the appropriate diagnostic information.
27 Courtesy/dome output circuit shorted or open. Refer to the appropriate diagnostic information.
28 Glovebox/map lamp output circuit shorted or
open.
Refer to the appropriate diagnostic information.
29 Cargo lamp output circuit shorted or open. Refer to the appropriate diagnostic information.
40 Wiper switch input circuit shorted. Refer to the appropriate diagnostic information.
41 Wiper switch input circuit open. Refer to the appropriate diagnostic information.
42 Wash/beam input circuit shorted. Refer to the appropriate diagnostic information.
60 Passenger door lock switch input circuit
shorted.
61 Passenger door lock switch input circuit open. Refer to the appropriate diagnostic information.
62 Passenger door lock switch input circuit stuck. Refer to the appropriate diagnostic information.
63 Driver door lock switch input circuit shorted. Refer to the appropriate diagnostic information.
64 Driver door lock switch input circuit open. Refer to the appropriate diagnostic information.
65 Driver door lock switch input circuit stuck. Refer to the appropriate diagnostic information.
66 All door lock output circuit shorted to ground
or voltage.
67 All door unlock output circuit shorted to
ground or voltage.
68 Driver door unlock output circuit shorted to
ground or voltage.
6C Driver cylinder lock switch input circuit
shorted.
6E Driver cylinder lock switch input circuit stuck. Refer to the appropriate diagnostic information.
80 Incorrect odometer value found. Refer to the appropriate diagnostic information.
81 Remote radio switch input circuit high. Refer to the appropriate diagnostic information.
82 Remote radio switch stuck. Refer to the appropriate diagnostic information.
A0 Internal module FLASH memory checksum
failure.
A1 Internal module bootloader failure. Refer to the appropriate diagnostic information.
A3 Battery voltage open. Refer to the appropriate diagnostic information.
A5 TCCM messages not received. Refer to the appropriate diagnostic information.
A7 VIN checksum error. Refer to the appropriate diagnostic information.
A8 VIN previously stored. Refer to the appropriate diagnostic information.
A9 PCI bus internal failure. Refer to the appropriate diagnostic information.
AA PCM messages not received. Refer to the appropriate diagnostic information.
AB TCM messages not received. Refer to the appropriate diagnostic information.
AC ABS messages not received. Refer to the appropriate diagnostic information.
AD FCM messages not received. Refer to the appropriate diagnostic information.
AE ACM messages not received. Refer to the appropriate diagnostic information.
AF SKIM messages not received. Refer to the appropriate diagnostic information.
B0 RKE fob batteries low. Refer to the appropriate diagnostic information.
B1 RKE module communication link. Refer to the appropriate diagnostic information.
00 Done All Diagnostic Trouble Codes (DTC) have been
displayed.
(7) The actuator test i s now compl eted. The i nstru-
ment cl uster wi l l automati cal l y exi t the sel f-di agnos-
ti c mode and return to normal operati on at the
compl eti on of the test, i f the i gni ti on swi tch i s turned
to the Off posi ti on duri ng the test, or i f a vehi cl e
speed message i ndi cati ng that the vehi cl e i s movi ng
i s recei ved from the PCM over the PCI data bus dur-
i ng the test.
(8) Go back to Step 1 to repeat the test, i f neces-
sary.
REMOVAL
MENT.
cabl e.
(2) Remove the cl uster bezel from the i nstrument
panel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(3) Remove the four screws that secure the i nstru-
ment cl uster to the i nstrument panel structural sup-
port (Fi g. 5).
(4) Pul l the i nstrument cl uster rearward far
enough to access and di sconnect the i nstrument
panel wi re harness connectors for the cl uster from
the connector receptacl es on the back of the cl uster
housi ng.
(5) Remove the i nstrument cl uster from the i nstru-
ment panel .
DISASSEMBLY
Some of the components for the i nstrument cl uster
used i n thi s vehi cl e are servi ced i ndi vi dual l y. The
servi ced components i ncl ude the i ncandescent i nstru-
ment cl uster i l l umi nati on l amp bul bs (i ncl udi ng the
i ntegral bul b hol ders), and the cl uster l ens, hood and
mask uni t. Fol l owi ng are the procedures for di sas-
sembl i ng these components from the i nstrument cl us-
ter uni t.
Fig. 5 Instrument Cluster Remove/Install
1 - WIRE HARNESS CONNECTOR (3)
3 - SCREW (4)
4 - INSTRUMENT PANEL STRUCTURAL SUPPORT
MENT.
CLUSTER BULB
Thi s procedure appl i es to each of the i ncandescent
cl uster i l l umi nati on l amp bul b and bul b hol der uni ts.
I f the vehi cl e i s equi pped wi th the opti onal Remote
Keyl ess Entry (RKE) system, the RKE recei ver mod-
ul e must be removed from the i nstrument cl uster
rear cover to access the l ower center cl uster i l l umi -
nati on l amp, whi ch i s l ocated on the ci rcui t board
di rectl y behi nd the RKE modul e. (Refer to 8 - ELEC-
TRI CAL/POWER LOCKS/REMOTE KEYLESS
ENTRY MODULE - REMOVAL).
cabl e.
ment panel . (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - REMOVAL).
(3) Turn the bul b hol der countercl ockwi se about
si xty degrees on the cl uster el ectroni c ci rcui t board
(Fi g. 6).
(4) Pul l the bul b and bul b hol der uni t strai ght
back to remove i t from the bul b mounti ng hol e i n the
cl uster el ectroni c ci rcui t board.
CLUSTER LENS, HOOD, AND MASK
cabl e.
ment panel . (Refer to 8 - ELECTRI CAL/I NSTRU-
MENT CLUSTER - REMOVAL).
(3) From the back of the i nstrument cl uster,
remove the ei ght screws around the outer peri meter
of the rear cover that secure the l ens, hood, and
mask uni t to the cl uster housi ng (Fi g. 7).
(4) Remove the l ens, hood, and mask uni t from the
face of the i nstrument cl uster.
ASSEMBLY
Some of the components for the i nstrument cl uster
used i n thi s vehi cl e are servi ced i ndi vi dual l y. The
servi ced components i ncl ude the i ncandescent i nstru-
ment cl uster i l l umi nati on l amp bul bs (i ncl udi ng the
i ntegral bul b hol ders), and the cl uster l ens, hood and
mask uni t. Fol l owi ng are the procedures for assem-
bl i ng these components to the i nstrument cl uster
uni t.
Fig. 6 Cluster Bulb Remove/Install
2 - BULB & HOLDER (11)
Fig. 7 Instrument Cluster Components
1 - SCREW (9)
2 - REAR COVER
3 - CLUSTER HOUSING
4 - LENS, HOOD & MASK
MENT.
CLUSTER BULB
Thi s procedure appl i es to each of the i ncandescent
cl uster i l l umi nati on l amp bul b and bul b hol der uni ts.
I f the vehi cl e i s equi pped wi th the opti onal Remote
Keyl ess Entry (RKE) system, and the RKE recei ver
modul e was removed from the i nstrument cl uster
rear cover to access the l ower center cl uster i l l umi -
nati on l amp, rei nstal l the RKE modul e after the bul b
i s repl aced on the ci rcui t board. (Refer to 8 - ELEC-
TRI CAL/POWER LOCKS/REMOTE KEYLESS
ENTRY MODULE - I NSTALLATI ON).
CAUTION: Always use the correct bulb size and
type for replacement. An incorrect bulb size or type
may overheat and cause damage to the instrument
cluster, the electronic circuit board and/or the
gauges.
(1) I nsert the bul b and bul b hol der uni t strai ght
i nto the correct bul b mounti ng hol e i n the cl uster
el ectroni c ci rcui t board (Fi g. 6).
(2) Wi th the bul b hol der ful l y seated agai nst the
cl uster el ectroni c ci rcui t board, turn the bul b hol der
cl ockwi se about si xty degrees to l ock i t i nto pl ace.
(3) Rei nstal l the i nstrument cl uster onto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - I NSTALLATI ON).
CLUSTER LENS, HOOD, AND MASK
(1) Posi ti on the cl uster l ens, hood, and mask uni t
over the face of the i nstrument cl uster (Fi g. 7). Be
certai n that the odometer/tri p odometer swi tch but-
ton i s i nserted through the proper cl earance hol es i n
the mask and the l ens.
(2) From the back of the i nstrument cl uster, i nstal l
and ti ghten the ei ght screws around the outer peri m-
eter of the rear cover that secure the l ens, hood, and
mask uni t to the cl uster housi ng. Ti ghten the screws
to 1 Nm (10 i n. l bs.).
(3) Rei nstal l the i nstrument cl uster onto the
i nstrument panel . (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - I NSTALLATI ON).
INSTALLATION
MENT.
(1) Posi ti on the i nstrument cl uster to the i nstru-
ment panel .
(2) Reconnect the i nstrument panel wi re harness
connectors for the cl uster to the connector receptacl es
on the back of the cl uster housi ng.
(3) Posi ti on the i nstrument cl uster i nto the i nstru-
ment panel .
(4) I nstal l and ti ghten the four screws that secure
the i nstrument cl uster to the i nstrument panel struc-
tural support (Fi g. 5). Ti ghten the screws to 4 Nm
(31 i n. l bs.).
(5) Rei nstal l the cl uster bezel onto the i nstrument
CLUSTER BEZEL - I NSTALLATI ON).
NOTE: Certain indicators in this instrument cluster
are automatically configured. This feature allows
those indicators to be activated or deactivated for
compatibility with certain optional equipment. If the
problem being diagnosed involves improper illumi-
nation of the cruise indicator, the electronic throttle
control indicator, the service four-wheel drive indi-
cator, the tow/haul indicator, the transmission over-
temp indicator, the upshift indicator, the security
indicator or the gear selector indicator, disconnect
and isolate the battery negative cable. After about
five minutes, reconnect the battery negative cable
and turn the ignition switch to the On position. The
instrument cluster should automatically relearn the
equipment in the vehicle and properly configure the
configurable indicators accordingly.
ABS INDICATOR
DESCRIPTION
An Anti l ock Brake System (ABS) i ndi cator i s stan-
dard equi pment on al l i nstrument cl usters (Fi g. 8).
However, the i nstrument cl uster can be programmed
to di sabl e thi s i ndi cator on vehi cl es that are not
equi pped wi th the ABS or Rear Wheel Anti -Lock
(RWAL) brake systems, whi ch are not avai l abl e i n
some markets. On vehi cl es equi pped wi th a gasol i ne
engi ne, the ABS i ndi cator i s l ocated near the l ower
edge of the i nstrument cl uster, between the tachom-
eter and the speedometer. On vehi cl es equi pped wi th
a di esel engi ne, the ABS i ndi cator i s l ocated on the
ri ght si de of the i nstrument cl uster, to the ri ght of
the engi ne temperature gauge. The ABS i ndi cator
consi sts of a stenci l -l i ke cutout of the I nternati onal
Control and Di spl ay Symbol i con for Fai l ure of Anti -
l ock Braki ng System i n the opaque l ayer of the
i nstrument cl uster overl ay. The dark outer l ayer of
the overl ay prevents the i ndi cator from bei ng cl earl y
vi si bl e when i t i s not i l l umi nated. An amber Li ght
Emi tti ng Di ode (LED) behi nd the cutout i n the
opaque l ayer of the overl ay causes the i con to appear
i n amber through the transl ucent outer l ayer of the
overl ay when the i ndi cator i s i l l umi nated from
behi nd by the LED, whi ch i s sol dered onto the
i nstrument cl uster el ectroni c ci rcui t board. The ABS
i ndi cator i s servi ced as a uni t wi th the i nstrument
cl uster.
OPERATION
The ABS i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the ABS system i s faul ty or i nop-
erati ve. Thi s i ndi cator i s control l ed by a transi stor on
the i nstrument cl uster ci rcui t board based upon cl us-
ter programmi ng and el ectroni c messages recei ved by
the cl uster from the Control l er Anti l ock Brake (CAB)
over the Programmabl e Communi cati ons I nterface
(PCI ) data bus. The ABS i ndi cator Li ght Emi tti ng
Di ode (LED) i s compl etel y control l ed by the i nstru-
ment cl uster l ogi c ci rcui t, and that l ogi c wi l l onl y
al l ow thi s i ndi cator to operate when the i nstrument
cl uster recei ves a battery current i nput on the fused
i gni ti on swi tch output (run-start) ci rcui t. Therefore,
the LED wi l l al ways be off when the i gni ti on swi tch
i s i n any posi ti on except On or Start. The LED onl y
i l l umi nates when i t i s provi ded a path to ground by
the i nstrument cl uster transi stor. The i nstrument
cl uster wi l l turn on the ABS i ndi cator for the fol l ow-
i ng reasons:
Bulb Test - Each ti me the i gni ti on swi tch i s
turned to the On posi ti on the ABS i ndi cator i s i l l u-
mi nated by the cl uster for about two seconds as a
bul b test.
ABS Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the CAB, the
ABS i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a
l amp-off message from the CAB, or unti l the i gni ti on
swi tch i s turned to the Off posi ti on, whi chever occurs
fi rst.
Communication Error - I f the cl uster recei ves
no l amp-on or l amp-off messages from the CAB for
three consecuti ve seconds, the ABS i ndi cator i s i l l u-
mi nated. The i ndi cator remai ns i l l umi nated unti l the
cl uster recei ves a val i d message from the CAB, or
unti l the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst.
Actuator Test - Each ti me the i nstrument cl us-
ter i s put through the actuator test, the ABS i ndi ca-
tor wi l l be turned on, then off agai n duri ng the bul b
check porti on of the test to confi rm the functi onal i ty
of the LED and the cl uster control ci rcui try.
ABS Diagnostic Test - The ABS i ndi cator i s
bl i nked on and off by l amp-on and l amp-off messages
from the CAB duri ng the performance of the ABS
di agnosti c tests.
The CAB conti nual l y moni tors the ABS ci rcui ts
and sensors to deci de whether the system i s i n good
operati ng condi ti on. The CAB then sends the proper
l amp-on or l amp-off messages to the i nstrument cl us-
ter. I f the CAB sends a l amp-on message after the
bul b test, i t i ndi cates that the CAB has detected a
system mal functi on and/or that the ABS system has
become i noperati ve. The CAB wi l l store a Di agnosti c
Troubl e Code (DTC) for any mal functi on i t detects.
Fig. 8 ABS Indicator
Each ti me the ABS i ndi cator fai l s to l i ght due to an
open or short i n the cl uster ABS i ndi cator ci rcui t, the
cl uster sends a message noti fyi ng the CAB of the
condi ti on, then the i nstrument cl uster and the CAB
wi l l each store a DTC. For proper di agnosi s of the
anti l ock brake system, the CAB, the PCI data bus, or
the el ectroni c message i nputs to the i nstrument cl us-
ter that control the ABS i ndi cator, a DRBI I I scan
tool i s requi red. Refer to the appropri ate di agnosti c
i nformati on.
AIRBAG INDICATOR
DESCRIPTION
An ai rbag i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 9). However, the i nstrument
cl uster can be programmed to di sabl e thi s i ndi cator
on vehi cl es that are not equi pped wi th the ai rbag
system, whi ch i s not avai l abl e i n some markets. The
ai rbag i ndi cator i s l ocated near the upper edge of the
i nstrument cl uster, between the tachometer and the
speedometer. The ai rbag i ndi cator consi sts of a sten-
ci l -l i ke cutout of the words AI R BAG i n the opaque
l ayer of the i nstrument cl uster overl ay. The dark
outer l ayer of the overl ay prevents the i ndi cator from
bei ng cl earl y vi si bl e when i t i s not i l l umi nated. A red
Li ght Emi tti ng Di ode (LED) behi nd the cutout i n the
opaque l ayer of the overl ay causes the AI R BAG
text to appear i n red through the transl ucent outer
l ayer of the overl ay when the i ndi cator i s i l l umi nated
from behi nd by the LED, whi ch i s sol dered onto the
i nstrument cl uster el ectroni c ci rcui t board. The ai r-
bag i ndi cator i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The ai rbag i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the ai rbag system i s faul ty or
i noperati ve. The ai rbag i ndi cator i s control l ed by a
transi stor on the i nstrument cl uster ci rcui t board
based upon cl uster programmi ng and el ectroni c mes-
sages recei ved by the cl uster from the Ai rbag Control
Modul e (ACM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The ai rbag i ndi cator
Li ght Emi tti ng Di ode (LED) i s compl etel y control l ed
by the i nstrument cl uster l ogi c ci rcui t, and that l ogi c
wi l l onl y al l ow thi s i ndi cator to operate when the
i nstrument cl uster recei ves a battery current i nput
on the fused i gni ti on swi tch output (run-start) ci r-
cui t. Therefore, the LED wi l l al ways be off when the
i gni ti on swi tch i s i n any posi ti on except On or Start.
The LED onl y i l l umi nates when i t i s provi ded a path
to ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the ai rbag i ndi cator
for the fol l owi ng reasons:
turned to the On posi ti on the ai rbag i ndi cator i s i l l u-
mi nated for about si x seconds. The enti re si x second
bul b test i s a functi on of the ACM.
ACM Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the ACM, the
ai rbag i ndi cator wi l l be i l l umi nated. The i ndi cator
remai ns i l l umi nated for about twel ve seconds or unti l
the cl uster recei ves a l amp-off message from the
ACM, whi chever i s l onger.
no ai rbag messages for three consecuti ve seconds, the
ai rbag i ndi cator i s i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a si n-
gl e l amp-off message from the ACM.
Actuator Test - Each ti me the cl uster i s put
through the actuator test, the ai rbag i ndi cator wi l l be
turned on, then off agai n duri ng the bul b check por-
ti on of the test to confi rm the functi onal i ty of the
LED and the cl uster control ci rcui try. The actuator
test i l l umi nati on of the ai rbag i ndi cator i s a functi on
of the i nstrument cl uster.
The ACM conti nual l y moni tors the ai rbag system
ci rcui ts and sensors to deci de whether the system i s
i n good operati ng condi ti on. The ACM then sends the
proper l amp-on or l amp-off messages to the i nstru-
ment cl uster. I f the ACM sends a l amp-on message
after the bul b test, i t i ndi cates that the ACM has
detected a system mal functi on and/or that the ai r-
bags and seat bel t tensi oners may not depl oy when
requi red, or may depl oy when not requi red. The ACM
wi l l store a Di agnosti c Troubl e Code (DTC) for any
mal functi on i t detects. Each ti me the ai rbag i ndi cator
fai l s to i l l umi nate due to an open or short i n the
cl uster ai rbag i ndi cator ci rcui t, the cl uster sends a
message noti fyi ng the ACM of the condi ti on, the
i nstrument cl uster and the ACM wi l l each store a
DTC, and the cl uster wi l l fl ash the seatbel t i ndi cator
on and off as a backup to noti fy the vehi cl e operator.
For proper di agnosi s of the ai rbag system, the ACM,
the PCI data bus, or the el ectroni c message i nputs to
the i nstrument cl uster that control the ai rbag i ndi ca-
tor, a DRBI I I scan tool i s requi red. Refer to the
appropri ate di agnosti c i nformati on.
Fig. 9 Airbag Indicator
ABS INDICATOR (Continued)
BRAKE/PARK BRAKE
INDICATOR
DESCRIPTION
A brake i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 10). The brake i ndi cator i s
l ocated near the l ower edge of the i nstrument cl uster,
between the tachometer and the speedometer. The
brake i ndi cator consi sts of stenci l -l i ke cutouts of the
word BRAKE and the I nternati onal Control and
Di spl ay Symbol i con for Brake Fai l ure i n the
opaque l ayer of the i nstrument cl uster overl ay. The
dark outer l ayer of the overl ay prevents the i ndi cator
from bei ng cl earl y vi si bl e when i t i s not i l l umi nated.
A red Li ght Emi tti ng Di ode (LED) behi nd the cutout
i n the opaque l ayer of the overl ay causes the
BRAKE text and the i con to appear i n red through
the transl ucent outer l ayer of the overl ay when the
i ndi cator i s i l l umi nated from behi nd by the LED,
whi ch i s sol dered onto the i nstrument cl uster el ec-
troni c ci rcui t board. The brake i ndi cator i s servi ced
as a uni t wi th the i nstrument cl uster.
OPERATION
The brake i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the parki ng brake i s appl i ed, when
there are certai n brake hydraul i c system mal func-
ti ons as i ndi cated by a l ow brake hydraul i c fl ui d l evel
condi ti on, or when the brake fl ui d l evel swi tch i s di s-
connected. The brake i ndi cator can al so gi ve an i ndi -
cati on when certai n faul ts are detected i n the
Anti l ock Brake System (ABS). Thi s i ndi cator i s con-
trol l ed by a transi stor on the i nstrument cl uster ci r-
cui t board based upon cl uster programmi ng,
el ectroni c messages recei ved by the cl uster from the
Control l er Anti l ock Brake (CAB) over the Program-
mabl e Communi cati ons I nterface (PCI ) data bus, and
a hard wi red i nput from the park brake swi tch. The
brake i ndi cator Li ght Emi tti ng Di ode (LED) i s com-
pl etel y control l ed by the i nstrument cl uster l ogi c ci r-
cui t, and that l ogi c wi l l onl y al l ow thi s i ndi cator to
operate when the i nstrument cl uster recei ves a bat-
tery current i nput on the fused i gni ti on swi tch out-
put (run-start) ci rcui t. Therefore, the LED wi l l
al ways be off when the i gni ti on swi tch i s i n any posi -
ti on except On or Start. The LED onl y i l l umi nates
when i t i s provi ded a path to ground by the i nstru-
ment cl uster transi stor. The i nstrument cl uster wi l l
turn on the brake i ndi cator for the fol l owi ng reasons:
turned to the On posi ti on the brake i ndi cator i s i l l u-
mi nated by the i nstrument cl uster for about two sec-
onds as a bul b test.
Brake Lamp-On Message - Each ti me the
cl uster recei ves a l amp-on message from the CAB,
the brake i ndi cator wi l l be i l l umi nated. The CAB can
al so send brake l amp-on messages as feedback dur-
i ng ABS di agnosti c procedures. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a
l amp-off message from the CAB, or unti l the i gni ti on
fi rst.
Park Brake Switch Input - Each ti me the
cl uster detects ground on the park brake swi tch
sense ci rcui t (park brake swi tch cl osed = park brake
appl i ed or not ful l y rel eased) whi l e the i gni ti on
swi tch i s i n the On posi ti on, the brake i ndi cator
fl ashes on and off. The i ndi cator conti nues to fl ash
unti l the park brake swi tch sense i nput to the cl uster
i s an open ci rcui t (park brake swi tch open = park
brake ful l y rel eased), or unti l the i gni ti on swi tch i s
turned to the Off posi ti on, whi chever occurs fi rst.
ter i s put through the actuator test, the brake i ndi -
cator wi l l be turned on, then off agai n duri ng the
bul b check porti on of the test to confi rm the functi on-
al i ty of the LED and the cl uster control ci rcui try.
The park brake swi tch on the park brake pedal
mechani sm provi des a hard wi red ground i nput to
the i nstrument cl uster ci rcui try through the park
brake swi tch sense ci rcui t whenever the park brake
i s appl i ed or not ful l y rel eased. The CAB conti nual l y
moni tors the ABS system ci rcui ts and sensors,
i ncl udi ng the brake fl ui d l evel swi tch on the brake
master cyl i nder reservoi r, to deci de whether the sys-
tem i s i n good operati ng condi ti on. The CAB then
sends the proper l amp-on or l amp-off messages to the
i nstrument cl uster. I f the CAB sends a l amp-on mes-
sage after the bul b test, i t i ndi cates that the CAB
has detected a brake hydraul i c system mal functi on
and/or that the ABS system has become i noperati ve.
The CAB wi l l store a Di agnosti c Troubl e Code (DTC)
for any mal functi on i t detects.
For further di agnosi s of the brake i ndi cator or the
i nstrument cl uster ci rcui try that control s the LED,
TER - DI AGNOSI S AND TESTI NG). The park brake
swi tch i nput to the i nstrument cl uster can be di ag-
nosed usi ng conventi onal di agnosti c tool s and meth-
ods. For proper di agnosi s of the brake fl ui d l evel
swi tch, the ABS, the CAB, the PCI data bus, or the
el ectroni c message i nputs to the i nstrument cl uster
that control the brake i ndi cator, a DRBI I I scan tool
i s requi red. Refer to the appropri ate di agnosti c i nfor-
mati on.
Fig. 10 Brake Indicator
DIAGNOSIS AND TESTING - BRAKE INDICATOR
The di agnosi s found here addresses an i noperati ve
brake i ndi cator condi ti on. I f there are probl ems wi th
several i ndi cators i n the i nstrument cl uster, (Refer to
8 - ELECTRI CAL/I NSTRUMENT CLUSTER - DI AG-
NOSI S AND TESTI NG). I f the brake i ndi cator stays
on wi th the i gni ti on swi tch i n the On posi ti on and
the park brake rel eased, or comes on whi l e dri vi ng,
the brake system must be di agnosed and repai red
pri or to performi ng the fol l owi ng tests. (Refer to 5 -
BRAKES - DI AGNOSI S AND TESTI NG). I f no brake
system probl em i s found, the fol l owi ng procedures
wi l l hel p to l ocate a shorted or open ci rcui t, or a
faul ty park brake swi tch i nput. Refer to the appropri -
ate wi ri ng i nformati on. The wi ri ng i nformati on
i ncl udes wi ri ng di agrams, proper wi re and connector
repai r procedures, detai l s of wi re harness routi ng
and retenti on, connector pi n-out i nformati on and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
MENT.
INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES
NOT WHEN PARK BRAKE APPLIED
cabl e. Di sconnect the body wi re harness connector for
the park brake swi tch from the swi tch termi nal .
Appl y the parki ng brake. Check for conti nui ty
between the park brake swi tch termi nal and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
2. I f not OK, repl ace the faul ty park brake swi tch.
(2) Di sconnect the i nstrument panel wi re harness
from the cl uster connector receptacl e. Check for con-
ti nui ty between the park brake swi tch sense ci rcui t
cavi ti es of the body wi re harness connector for the
park brake swi tch and the i nstrument panel wi re
harness connector for the i nstrument cl uster. There
shoul d be conti nui ty. I f not OK, repai r the open park
brake swi tch sense ci rcui t between the park brake
swi tch and the i nstrument cl uster as requi red.
INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM
CHECKS OK
the park brake swi tch from the swi tch termi nal .
Check for conti nui ty between the termi nal of the
park brake swi tch and a good ground. There shoul d
be no conti nui ty wi th the park brake rel eased, and
conti nui ty wi th the park brake appl i ed. I f OK, go to
Step 2. I f not OK, repl ace the faul ty park brake
swi tch.
from the cl uster connector receptacl e. Check for con-
ti nui ty between the park brake swi tch sense ci rcui t
cavi ty of the body wi re harness connector for the
park brake swi tch and a good ground. There shoul d
be no conti nui ty. I f not OK, repai r the shorted park
brake swi tch sense ci rcui t between the park brake
swi tch and the i nstrument cl uster as requi red.
CARGO LAMP INDICATOR
DESCRIPTION
A cargo l amp i ndi cator i s standard equi pment on
al l i nstrument cl usters (Fi g. 11). The cargo l amp
i ndi cator i s l ocated on the ri ght si de of the i nstru-
ment cl uster, to the ri ght of the oi l pressure gauge.
The cargo l amp i ndi cator consi sts of a stenci l -l i ke
cutout of the words CARGO LAMP i n the opaque
bei ng cl earl y vi si bl e when i t i s not i l l umi nated. An
amber Li ght Emi tti ng Di ode (LED) behi nd the cutout
CARGO LAMP text to appear i n amber through the
transl ucent outer l ayer of the overl ay when the i ndi -
cator i s i l l umi nated from behi nd by the LED, whi ch
i s sol dered onto the i nstrument cl uster el ectroni c ci r-
cui t board. The cargo l amp i ndi cator i s servi ced as a
uni t wi th the i nstrument cl uster.
OPERATION
The cargo l amp i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the exteri or cargo l amp i s i l l u-
mi nated. Thi s i ndi cator i s control l ed by a transi stor
on the i nstrument cl uster ci rcui t board based upon
Fig. 11 Cargo Lamp Indicator
BRAKE/PARK BRAKE INDICATOR (Continued)
cl uster programmi ng, a hard wi red mul ti pl ex i nput
recei ved by the cl uster from the headl amp panel
l amps di mmer swi tch on the headl amp di mmer
swi tch mux ci rcui t, and el ectroni c unl ock request
messages recei ved from the opti onal Remote Keyl ess
Entry (RKE) recei ver modul e. The cargo l amp i ndi ca-
tor Li ght Emi tti ng Di ode (LED) i s compl etel y con-
trol l ed by the i nstrument cl uster l ogi c ci rcui t, and
that l ogi c wi l l al l ow onl y thi s i ndi cator to operate
whenever the i nstrument cl uster recei ves a battery
current i nput on the fused i gni ti on swi tch output
(run-start) ci rcui t. Therefore, the LED wi l l al ways be
off when the i gni ti on swi tch i s i n any posi ti on except
On or Start. The LED onl y i l l umi nates when i t i s
provi ded a path to ground by the i nstrument cl uster
transi stor. The i nstrument cl uster wi l l turn on the
cargo l amp i ndi cator for the fol l owi ng reasons:
turned to the On posi ti on the cargo l amp i ndi cator i s
i l l umi nated for about two seconds as a bul b test.
Cargo Lamp-On Input - Each ti me the cl uster
detects a cargo l amp-on i nput from the headl amp
swi tch on the headl amp di mmer swi tch mux ci rcui t,
the cargo l amp and the cargo l amp i ndi cator wi l l be
i l l umi nated. The cargo l amp and i ndi cator remai n
i l l umi nated unti l the cl uster recei ves a cargo l amp-off
i nput from the headl amp swi tch, or unti l the i gni ti on
fi rst.
through the actuator test, the cargo l amp i ndi cator
wi l l be turned on, then off agai n duri ng the bul b
The i nstrument cl uster conti nual l y moni tors the
headl amp di mmer swi tch ci rcui t to determi ne the
proper i nteri or l amps features and panel l amps i l l u-
mi nati on l evel s to provi de. The cl uster then energi zes
and de-energi zes a l ow si de dri ver ci rcui t to control
the exteri or cargo l amp. Each ti me the i nstrument
cl uster energi zes the cargo l amp dri ver and the i gni -
ti on swi tch i s i n the On or start posi ti ons, the cl uster
al so turns on the cargo l amp i ndi cator. For further
di agnosi s of the cargo l amp i ndi cator or the i nstru-
ment cl uster ci rcui try that control s the i ndi cator,
TER - DI AGNOSI S AND TESTI NG). For proper
di agnosi s of the cargo l amp or the headl amp swi tch
i nputs to the i nstrument cl uster that control the
cargo l amp i ndi cator, a DRBI I I scan tool i s requi red.
Refer to the appropri ate di agnosti c i nformati on.
CHECK GAUGES INDICATOR
DESCRIPTION
A check gauges i ndi cator i s standard equi pment on
al l i nstrument cl usters (Fi g. 12). On vehi cl es
equi pped wi th a gasol i ne engi ne, the check gauges
i ndi cator i s l ocated near the l ower edge of the i nstru-
ment cl uster, between the tachometer and the speed-
ometer. On vehi cl es equi pped wi th a di esel engi ne,
the check gauges i ndi cator i s l ocated on the l eft si de
of the i nstrument cl uster, to the l eft of the vol tage
gauge. The check gauges i ndi cator consi sts of a sten-
ci l -l i ke cutout of the words CHECK GAGES i n the
CHECK GAGES text to appear i n red through the
transl ucent outer l ayer of the overl ay when the i ndi -
cator i s i l l umi nated from behi nd by the LED, whi ch
i s sol dered onto the i nstrument cl uster el ectroni c ci r-
cui t board. The check gauges i ndi cator i s servi ced as
a uni t wi th the i nstrument cl uster.
OPERATION
The check gauges i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when certai n i nstrument cl uster
gauge readi ngs refl ect a condi ti on requi ri ng i mmedi -
ate attenti on. Thi s i ndi cator i s control l ed by a tran-
si stor on the i nstrument cl uster ci rcui t board based
upon cl uster programmi ng and el ectroni c messages
recei ved by the cl uster from the Powertrai n Control
Modul e (PCM) on vehi cl es equi pped wi th a gasol i ne
engi ne, or from the Engi ne Control Modul e (ECM) on
vehi cl es equi pped wi th a di esel engi ne over the Pro-
grammabl e Communi cati ons I nterface (PCI ) data
bus. The check gauges i ndi cator Li ght Emi tti ng
cl uster wi l l turn on the check gauges i ndi cator for
the fol l owi ng reasons:
turned to the On posi ti on the check gauges i ndi cator
i s i l l umi nated for about two seconds as a bul b test.
Fig. 12 Check Gauges Indicator
CARGO LAMP INDICATOR (Continued)
Engine Temperature High Message - Each
ti me the cl uster recei ves a message from the PCM or
ECM i ndi cati ng the engi ne cool ant temperature of a
gasol i ne engi ne i s about 122 C (252 F) or hi gher, or
of a di esel engi ne i s about 112 C (233 F) or hi gher,
the check gauges i ndi cator wi l l be i l l umi nated. The
i ndi cator remai ns i l l umi nated unti l the cl uster
recei ves a message from the PCM or ECM i ndi cati ng
that the engi ne cool ant temperature of a gasol i ne
engi ne i s bel ow about 122 C (252 F), or of a di esel
engi ne i s bel ow about 112 C (233 F), or unti l the
ever occurs fi rst.
Engine Oil Pressure Low Message - Each
ECM i ndi cati ng the engi ne oi l pressure i s about 41
kPa (6 psi ) or l ower, the check gauges i ndi cator wi l l
be i l l umi nated. The i ndi cator remai ns i l l umi nated
unti l the cl uster recei ves a message from the PCM or
ECM i ndi cati ng that the engi ne oi l pressure i s above
about 41 kPa (6 psi ), or unti l the i gni ti on swi tch i s
The cl uster wi l l onl y turn the i ndi cator on i n
response to an engi ne oi l pressure l ow message i f the
engi ne speed i s greater than zero.
System Voltage Low (Charge Fail) Message
- Each ti me the cl uster recei ves a message from the
PCM or ECM i ndi cati ng the el ectri cal system vol tage
i s l ess than about 11.5 vol ts (charge fai l condi ti on),
the check gauges i ndi cator wi l l be i l l umi nated. The
the el ectri cal system vol tage i s greater than about
12.0 vol ts (but l ess than 16.0 vol ts), or unti l the i gni -
ti on swi tch i s turned to the Off posi ti on, whi chever
occurs fi rst.
System Voltage High Message - Each ti me
the cl uster recei ves a message from the PCM or ECM
i ndi cati ng the el ectri cal system vol tage i s greater
than about 16.0 vol ts, the check gauges i ndi cator wi l l
unti l the cl uster recei ves a message from the PCM or
ECM i ndi cati ng the el ectri cal system vol tage i s l ess
than about 15.5 vol ts (but greater than 11.5 vol ts), or
through the actuator test, the check gauges i ndi cator
On vehi cl es wi th a gasol i ne engi ne, the PCM con-
ti nual l y moni tors the engi ne temperature, oi l pres-
sure, and el ectri cal system vol tage, then sends the
proper messages to the i nstrument cl uster. On vehi -
cl es wi th a di esel engi ne, the ECM conti nual l y mon-
i tors the engi ne temperature, oi l pressure, and
el ectri cal system vol tage, then sends the proper mes-
sages to the i nstrument cl uster. For further di agnosi s
of the check gauges i ndi cator or the i nstrument cl us-
ter ci rcui try that control s the LED, (Refer to 8 -
ELECTRI CAL/I NSTRUMENT CLUSTER - DI AGNO-
SI S AND TESTI NG). For proper di agnosi s of the
PCM, the ECM, the PCI data bus, or the el ectroni c
message i nputs to the i nstrument cl uster that control
the check gauges i ndi cator, a DRBI I I scan tool i s
requi red. Refer to the appropri ate di agnosti c i nfor-
mati on.
CRUISE INDICATOR
DESCRIPTION
A crui se i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 13). However, on vehi cl es
not equi pped wi th the opti onal speed control system,
thi s i ndi cator i s el ectroni cal l y di sabl ed. The crui se
i ndi cator consi sts of the word CRUI SE, whi ch
appears i n the l ower porti on of the gear sel ector i ndi -
cator Vacuum-Fl uorescent Di spl ay (VFD) uni t. The
VFD i s sol dered onto the cl uster el ectroni c ci rcui t
board and i s vi si bl e through a wi ndow wi th a smoked
cl ear l ens l ocated on the l ower edge of the speedom-
eter gauge di al face of the cl uster overl ay. The dark
l ens over the VFD prevents the i ndi cator from bei ng
cl earl y vi si bl e when i t i s not i l l umi nated. The word
CRUI SE appears i n a bl ue-green col or and at the
same l i ghti ng l evel as the gear sel ector i ndi cator
i nformati on when i t i s i l l umi nated by the i nstrument
cl uster el ectroni c ci rcui t board. The crui se i ndi cator
i s servi ced as a uni t wi th the VFD i n the i nstrument
cl uster.
OPERATION
The crui se i ndi cator gi ves an i ndi cati on to the vehi -
cl e operator when the speed control system i s turned
On, regardl ess of whether the speed control i s
engaged. Thi s i ndi cator i s control l ed by the i nstru-
ment cl uster ci rcui t board based upon cl uster pro-
grammi ng and el ectroni c messages recei ved by the
cl uster from the Powertrai n Control Modul e (PCM)
(PCI ) data bus. The crui se i ndi cator i s compl etel y
control l ed by the i nstrument cl uster l ogi c ci rcui t, and
that l ogi c wi l l onl y al l ow thi s i ndi cator to operate
when the i nstrument cl uster recei ves a battery cur-
rent i nput on the fused i gni ti on swi tch output (run-
start) ci rcui t. Therefore, the i ndi cator wi l l al ways be
Fig. 13 Cruise Indicator
CHECK GAUGES INDICATOR (Continued)
off when the i gni ti on swi tch i s i n any posi ti on except
On or Start. The i ndi cator onl y i l l umi nates when i t i s
swi tched to ground by the i nstrument cl uster ci r-
cui try. The i nstrument cl uster wi l l turn on the crui se
i ndi cator for the fol l owi ng reasons:
Cruise Lamp-On Message - Each ti me the
cl uster recei ves a crui se l amp-on message from the
PCM i ndi cati ng the speed control system has been
turned On, the crui se i ndi cator i s i l l umi nated. The
recei ves a crui se l amp-off message from the PCM or
through the actuator test, the crui se i ndi cator wi l l be
turned on, then off agai n duri ng the VFD porti on of
the test to confi rm the functi onal i ty of the VFD and
the cl uster control ci rcui try.
The PCM conti nual l y moni tors the speed control
swi tches to determi ne the proper outputs to the
speed control servo. The PCM then sends the proper
crui se i ndi cator l amp-on and l amp-off messages to
the i nstrument cl uster. For further di agnosi s of the
crui se i ndi cator or the i nstrument cl uster ci rcui try
that control s the i ndi cator, (Refer to 8 - ELECTRI -
TESTI NG). For proper di agnosi s of the speed control
system, the PCM, the PCI data bus, or the el ectroni c
the crui se i ndi cator, a DRBI I I scan tool i s requi red.
DOOR AJ AR INDICATOR
DESCRIPTION
A door ajar i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 14). The door ajar i ndi cator
i s l ocated on the ri ght si de of the i nstrument cl uster,
to the ri ght of the engi ne temperature gauge. The
door ajar i ndi cator consi sts of a stenci l -l i ke cutout of
the words DOOR AJAR i n the opaque l ayer of the
i nstrument cl uster overl ay. The dark outer l ayer of
the overl ay prevents the i ndi cator from bei ng cl earl y
vi si bl e when i t i s not i l l umi nated. A red Li ght Emi t-
ti ng Di ode (LED) behi nd the cutout i n the opaque
l ayer of the overl ay causes the DOOR AJAR text to
appear i n red through the transl ucent outer l ayer of
the overl ay when the i ndi cator i s i l l umi nated from
i nstrument cl uster el ectroni c ci rcui t board. The door
ajar i ndi cator i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The door ajar i ndi cator gi ves an i ndi cati on to the
vehi cl e operator that one or more of the passenger
compartment doors may be open or not compl etel y
l atched. Thi s i ndi cator i s control l ed by a transi stor
cl uster programmi ng and hard wi red i nputs recei ved
by the cl uster from the door ajar swi tches l ocated i n
each door l atch uni t. The door ajar i ndi cator Li ght
Emi tti ng Di ode (LED) i s compl etel y control l ed by the
i nstrument cl uster l ogi c ci rcui t, and that l ogi c wi l l
al l ow thi s i ndi cator to operate whenever the i nstru-
ment cl uster recei ves a battery current i nput on the
fused i gni ti on swi tch output (run-start) ci rcui t.
Therefore, the LED wi l l al ways be off when the i gni -
ti on swi tch i s i n any posi ti on except On or Start. The
LED onl y i l l umi nates when i t i s provi ded a path to
ground by the i nstrument cl uster transi stor. The
i nstrument cl uster wi l l turn on the door ajar i ndi ca-
tor for the fol l owi ng reasons:
turned to the On posi ti on the door ajar i ndi cator i s
Door Ajar Switch Input - Each ti me the cl us-
ter detects ground on any one of the door ajar swi tch
sense ci rcui ts (door ajar swi tch cl osed = door i s open
or not compl etel y l atched) the door ajar i ndi cator wi l l
unti l al l of the door ajar swi tch sense i nputs to the
cl uster are an open ci rcui t (door ajar swi tch open =
door ful l y cl osed), or unti l the i gni ti on swi tch i s
through the actuator test, the door ajar i ndi cator wi l l
be turned on, then off agai n duri ng the bul b check
porti on of the test to confi rm the functi onal i ty of the
LED and the cl uster control ci rcui try.
door ajar swi tches to determi ne the status of the
doors. For further di agnosi s of the door ajar i ndi cator
or the i nstrument cl uster ci rcui try that control s the
i ndi cator, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). For
proper di agnosi s of the door ajar swi tches and ci r-
cui ts, (Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG
- I NTERI OR/DOOR AJAR SWI TCH - DI AGNOSI S
AND TESTI NG).
Fig. 14 Door Ajar Indicator
CRUISE INDICATOR (Continued)
ENGINE TEMPERATURE
GAUGE
DESCRIPTION
An engi ne cool ant temperature gauge i s standard
equi pment on al l i nstrument cl usters. The engi ne
cool ant temperature gauge i s l ocated i n the l ower
ri ght quadrant of the i nstrument cl uster, bel ow the
oi l pressure gauge. The engi ne cool ant temperature
gauge consi sts of a movabl e gauge needl e or poi nter
control l ed by the i nstrument cl uster ci rcui try and a
fi xed 90 degree scal e on the cl uster overl ay that
reads l eft-to-ri ght from C (or Col d) to H (or Hot)
for gasol i ne engi nes. On vehi cl es wi th a di esel
engi ne, the scal e reads from 60 C to 120 C i n
markets where a metri c i nstrument cl uster i s speci -
fi ed, or from 140 F to 245 F i n al l other mar-
kets. An I nternati onal Control and Di spl ay Symbol
i con for Engi ne Cool ant Temperature i s l ocated on
the cl uster overl ay, di rectl y bel ow the l eft end of the
gauge scal e (Fi g. 15). The engi ne cool ant temperature
gauge graphi cs are bl ack agai nst a whi te fi el d except
for two red graduati ons at the hi gh end of the gauge
scal e, maki ng them cl earl y vi si bl e wi thi n the i nstru-
ment cl uster i n dayl i ght. When i l l umi nated from
behi nd by the panel l amps di mmer control l ed cl uster
i l l umi nati on l i ghti ng wi th the exteri or l amps turned
On, the bl ack graphi cs appear bl ue and the red
graphi cs sti l l appear red. The orange gauge needl e i s
i nternal l y i l l umi nated. Gauge i l l umi nati on i s pro-
vi ded by repl aceabl e i ncandescent bul b and bul b
hol der uni ts l ocated on the i nstrument cl uster el ec-
troni c ci rcui t board. The engi ne cool ant temperature
gauge i s servi ced as a uni t wi th the i nstrument cl us-
ter.
OPERATION
The engi ne cool ant temperature gauge gi ves an
i ndi cati on to the vehi cl e operator of the engi ne cool -
ant temperature. Thi s gauge i s control l ed by the
i nstrument cl uster ci rcui t board based upon cl uster
programmi ng and el ectroni c messages recei ved by
the cl uster from the Powertrai n Control Modul e
(PCM) on vehi cl es equi pped wi th a gasol i ne engi ne,
or from the Engi ne Control Modul e (ECM) on vehi -
cl es equi pped wi th a di esel engi ne over the Program-
mabl e Communi cati ons I nterface (PCI ) data bus. The
engi ne cool ant temperature gauge i s an ai r core mag-
neti c uni t that recei ves battery current on the i nstru-
ment cl uster el ectroni c ci rcui t board through the
fused i gni ti on swi tch output (run-start) ci rcui t when-
ever the i gni ti on swi tch i s i n the On or Start posi -
ti ons. The cl uster i s programmed to move the gauge
needl e back to the l ow end of the scal e after the i gni -
ti on swi tch i s turned to the Off posi ti on. The i nstru-
ment cl uster ci rcui try control s the gauge needl e
posi ti on and provi des the fol l owi ng features:
Engine Temperature Message - Each ti me
i ndi cati ng the engi ne cool ant temperature i s between
the l ow end of normal [about 54 C (130 F) for gas-
ol i ne engi nes, or about 60 C (140 F) for di esel
engi nes] and the hi gh end of normal [about 122 C
(252 F) for gasol i ne engi nes, or about 116 C (240
F) for di esel engi nes], the gauge needl e i s moved to
the actual rel ati ve temperature posi ti on on the gauge
scal e.
Engine Temperature Low Message - Each
ECM i ndi cati ng the engi ne cool ant temperature i s
bel ow the l ow end of normal [about 54 C (130 F) for
gasol i ne engi nes, or about 60 C (140 F) for di esel
engi nes], the gauge needl e i s hel d at the graduati on
on the far l eft end of the gauge scal e. The gauge nee-
dl e remai ns at the l eft end of the gauge scal e unti l
i ndi cati ng that the engi ne temperature i s above
about 54 C (130 F) for gasol i ne engi nes, or about
60 C (140 F) for di esel engi nes, or unti l the i gni ti on
fi rst.
Engine Temperature High Message - Each
ECM i ndi cati ng the engi ne cool ant temperature i s
above about 122 C (252 F) for gasol i ne engi nes, or
about 116 C (240 F) for di esel engi nes, the gauge
needl e i s moved i nto the red zone at the far ri ght end
of gauge scal e, the check gauges i ndi cator i s i l l umi -
nated, and a si ngl e chi me tone i s sounded. The gauge
needl e remai ns i n the red zone and the check gauges
that the engi ne temperature i s bel ow about 122 C
(252 F) for gasol i ne engi nes, or about 116 C (240
F) for di esel engi nes, or unti l the i gni ti on swi tch i s
The chi me tone feature wi l l onl y repeat duri ng the
same i gni ti on cycl e i f the check gauges i ndi cator i s
cycl ed off and then on agai n by the appropri ate
engi ne temperature messages from the PCM or ECM.
Communication Error - I f the cl uster fai l s to
recei ve an engi ne temperature message, i t wi l l hol d
the gauge needl e at the l ast i ndi cati on for about fi ve
seconds or unti l the i gni ti on swi tch i s turned to the
Off posi ti on, whi chever occurs fi rst. After fi ve sec-
onds, the cl uster wi l l move the gauge needl e to the
l ow end of the gauge scal e.
Fig. 15 Engine Coolant Temperature Icon
through the actuator test, the engi ne cool ant temper-
ature gauge needl e wi l l be swept to several cal i bra-
ti on poi nts on the gauge scal e i n a prescri bed
sequence i n order to confi rm the functi onal i ty of the
gauge and the cl uster control ci rcui try.
ti nual l y moni tors the engi ne cool ant temperature
sensor to determi ne the engi ne operati ng tempera-
ture. On vehi cl es wi th a di esel engi ne, the ECM con-
ti nual l y moni tors the engi ne cool ant temperature
sensor to determi ne the engi ne operati ng tempera-
ture. The PCM or ECM then sends the proper engi ne
cool ant temperature messages to the i nstrument
cl uster. For further di agnosi s of the engi ne cool ant
temperature gauge or the i nstrument cl uster ci r-
cui try that control s the gauge, (Refer to 8 - ELEC-
TRI CAL/I NSTRUMENT CLUSTER - DI AGNOSI S
AND TESTI NG). I f the i nstrument cl uster turns on
the check gauges i ndi cator due to a hi gh engi ne tem-
perature gauge readi ng, i t may i ndi cate that the
engi ne or the engi ne cool i ng system requi res servi ce.
For proper di agnosi s of the engi ne cool ant tempera-
ture sensor, the PCM, the ECM, the PCI data bus, or
ter that control the engi ne cool ant temperature
gauge, a DRBI I I scan tool i s requi red. Refer to the
ETC INDICATOR
DESCRIPTION
An El ectroni c Throttl e Control (ETC) i ndi cator i s
standard equi pment on al l gasol i ne engi ne i nstru-
ment cl usters (Fi g. 16). However, on vehi cl es not
equi pped wi th the opti onal 5.7 l i ter gasol i ne engi ne,
thi s i ndi cator i s el ectroni cal l y di sabl ed. The ETC
i ndi cator i s l ocated on the ri ght si de of the i nstru-
ment cl uster, to the ri ght of the engi ne temperature
gauge. The ETC i ndi cator consi sts of a stenci l -l i ke
cutout of the I nternati onal Control and Di spl ay Sym-
bol i con for El ectroni c Throttl e Control i n the
i n the opaque l ayer of the overl ay causes the i con to
appear i n red through the transl ucent outer l ayer of
i nstrument cl uster el ectroni c ci rcui t board. The ETC
i ndi cator i s servi ced as a uni t wi th the i nstrument
cl uster.
OPERATION
The El ectroni c Throttl e Control (ETC) i ndi cator
gi ves an i ndi cati on to the vehi cl e operator when the
ETC system i s faul ty or i noperati ve. The ETC i ndi -
cator i s control l ed by a transi stor on the i nstrument
cl uster ci rcui t board based upon cl uster programmi ng
and el ectroni c messages recei ved by the cl uster from
the Powertrai n Control Modul e (PCM) over the Pro-
bus. The ETC i ndi cator Li ght Emi tti ng Di ode (LED)
i s compl etel y control l ed by the i nstrument cl uster
l ogi c ci rcui t, and that l ogi c wi l l onl y al l ow thi s i ndi -
cator to operate when the i nstrument cl uster recei ves
a battery current i nput on the fused i gni ti on swi tch
output (run-start) ci rcui t. Therefore, the LED wi l l
turn on the ETC i ndi cator for the fol l owi ng reasons:
turned to the On posi ti on the ETC i ndi cator i s i l l u-
mi nated for about si x seconds. The enti re si x second
bul b test i s a functi on of the PCM.
ETC Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the PCM, the
ETC i ndi cator wi l l be i l l umi nated. The i ndi cator can
be fl ashed on and off, or i l l umi nated sol i d, as di c-
tated by the PCM message. The i ndi cator remai ns
i l l umi nated sol i d or conti nues to fl ash for about
twel ve seconds or unti l the cl uster recei ves a l amp-off
message from the PCM, whi chever i s l onger. I f the
i ndi cator i s i l l umi nated sol i d wi th the engi ne run-
ni ng the vehi cl e wi l l usual l y remai n dri vabl e. I f the
i ndi cator i s fl ashi ng wi th the engi ne runni ng the
vehi cl e may requi re towi ng. A fl ashi ng i ndi cator
means the ETC system requi res i mmedi ate servi ce.
no ETC l amp messages for three consecuti ve seconds,
the ETC i ndi cator i s i l l umi nated. The i ndi cator
remai ns i l l umi nated unti l the cl uster recei ves a si n-
gl e l amp-off message from the PCM.
through the actuator test, the ETC i ndi cator wi l l be
turned on, then off agai n duri ng the bul b check por-
LED and the cl uster control ci rcui try. The actuator
test i l l umi nati on of the ETC i ndi cator i s a functi on of
the PCM.
The PCM conti nual l y moni tors the ETC system ci r-
cui ts and sensors to deci de whether the system i s i n
good operati ng condi ti on. The PCM then sends the
Fig. 16 ETC Indicator
ENGINE TEMPERATURE GAUGE (Continued)
ment cl uster. I f the PCM sends a l amp-on message
after the bul b test, i t i ndi cates that the PCM has
detected a system mal functi on and/or that the ETC
system i s i noperati ve. The PCM wi l l store a Di agnos-
ti c Troubl e Code (DTC) for any mal functi on i t
detects. Each ti me the ETC i ndi cator fai l s to i l l umi -
nate due to an open or short i n the cl uster ETC i ndi -
cator ci rcui t, the cl uster sends a message noti fyi ng
the PCM of the condi ti on, the i nstrument cl uster and
the PCM wi l l each store a DTC. For proper di agnosi s
of the ETC system, the PCM, the PCI data bus, or
ter that control the ETC i ndi cator, a DRBI I I scan
tool i s requi red. Refer to the appropri ate di agnosti c
i nformati on.
FUEL GAUGE
DESCRIPTION
A fuel gauge i s standard equi pment on al l i nstru-
ment cl usters (Fi g. 17). The fuel gauge i s l ocated i n
the l ower l eft quadrant of the i nstrument cl uster,
bel ow the vol tage gauge. The fuel gauge consi sts of a
movabl e gauge needl e or poi nter control l ed by the
i nstrument cl uster ci rcui try and a fi xed 90 degree
scal e on the cl uster overl ay that reads l eft-to-ri ght
from E (or Empty) to F (or Ful l ). An I nternati onal
Control and Di spl ay Symbol i con for Fuel i s l ocated
on the cl uster overl ay, di rectl y bel ow the ri ght end of
the gauge scal e. An arrowhead poi nted to the l eft
si de of the vehi cl e i s i mpri nted on the cl uster overl ay
next to the Fuel i con i n the fuel gauge to provi de
the dri ver wi th a remi nder as to the l ocati on of the
fuel fi l l er access. On vehi cl es equi pped wi th a di esel
engi ne, text that speci fi es DI ESEL ONLY i s l ocated
across the fuel gauge bel ow the gauge scal e, but
above the hub of the gauge needl e. The fuel gauge
graphi cs are bl ack agai nst a whi te fi el d except for a
si ngl e red graduati on at the l ow end of the gauge
scal e, maki ng them cl earl y vi si bl e wi thi n the i nstru-
ment cl uster i n dayl i ght. When i l l umi nated from
behi nd by the panel l amps di mmer control l ed cl uster
i l l umi nati on l i ghti ng wi th the exteri or l amps turned
On, the bl ack graphi cs appear bl ue and the red
graphi cs sti l l appear red. The orange gauge needl e i s
i nternal l y i l l umi nated. Gauge i l l umi nati on i s pro-
vi ded by repl aceabl e i ncandescent bul b and bul b
troni c ci rcui t board. The fuel gauge i s servi ced as a
uni t wi th the i nstrument cl uster.
OPERATION
The fuel gauge gi ves an i ndi cati on to the vehi cl e
operator of the l evel of fuel i n the fuel tank. Thi s
gauge i s control l ed by the i nstrument cl uster ci rcui t
board based upon cl uster programmi ng and el ec-
troni c messages recei ved by the cl uster from the
Powertrai n Control Modul e (PCM) on vehi cl es
equi pped wi th a gasol i ne engi ne, or from the Engi ne
Control Modul e (ECM) on vehi cl es equi pped wi th a
di esel engi ne over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The fuel gauge i s an
ai r core magneti c uni t that recei ves battery current
on the i nstrument cl uster el ectroni c ci rcui t board
through the fused i gni ti on swi tch output (run-start)
ci rcui t whenever the i gni ti on swi tch i s i n the On or
Start posi ti ons. The cl uster i s programmed to move
the gauge needl e back to the l ow end of the scal e
after the i gni ti on swi tch i s turned to the Off posi ti on.
The i nstrument cl uster ci rcui try control s the gauge
needl e posi ti on and provi des the fol l owi ng features:
Percent Tank Full Message - Each ti me the
cl uster recei ves a message from the PCM or ECM
i ndi cati ng the percent tank ful l , the cl uster program-
mi ng appl i es an al gori thm to cal cul ate the proper
gauge needl e posi ti on, then moves the gauge needl e
to the proper rel ati ve posi ti on on the gauge scal e.
The al gori thm i s used to dampen gauge needl e move-
ment agai nst the negati ve effect that fuel sl oshi ng
wi thi n the fuel tank can have on accurate i nputs
from the fuel tank sendi ng uni t to the PCM or ECM.
Less Than Twenty Percent Tank Full Mes-
sage - Each ti me the cl uster recei ves messages from
the PCM or ECM i ndi cati ng the percent tank ful l i s
about twenty percent or l ess for ten consecuti ve sec-
onds and the vehi cl e speed i s zero, or for si xty con-
secuti ve seconds and the vehi cl e speed i s greater
than zero, the gauge needl e i s moved to the one-
ei ghth graduati on or bel ow on the gauge scal e, the
l ow fuel i ndi cator i s i l l umi nated, and a si ngl e chi me
tone i s sounded. The l ow fuel i ndi cator remai ns i l l u-
mi nated unti l the cl uster recei ves messages from the
PCM or ECM i ndi cati ng that the percent tank ful l i s
greater than about twenty percent for ten consecu-
ti ve seconds and the vehi cl e speed i s zero, or for si xty
consecuti ve seconds and the vehi cl e speed i s greater
than zero, or unti l the i gni ti on swi tch i s turned to
the Off posi ti on, whi chever occurs fi rst. The chi me
tone feature wi l l onl y repeat duri ng the same i gni -
ti on cycl e i f the l ow fuel i ndi cator i s cycl ed off and
then on agai n by the appropri ate percent tank ful l
messages from the PCM or ECM.
Less Than Empty Percent Tank Full Mes-
sage - Each ti me the cl uster recei ves a message from
Fig. 17 Fuel Gauge Icon
ETC INDICATOR (Continued)
l ess than empty, the gauge needl e i s moved to the far
l eft end of the gauge scal e and the l ow fuel i ndi cator
i s i l l umi nated i mmedi atel y. Thi s message woul d i ndi -
cate that the fuel tank sender i nput to the PCM or
ECM i s a short ci rcui t.
More Than Full Percent Tank Full Message
PCM or ECM i ndi cati ng the percent tank ful l i s more
than ful l , the gauge needl e i s moved to the far l eft
end of the gauge scal e and the l ow fuel i ndi cator i s
i l l umi nated i mmedi atel y. Thi s message woul d i ndi -
cate that the fuel tank sender i nput to the PCM or
ECM i s an open ci rcui t.
recei ve a percent tank ful l message, i t wi l l hol d the
gauge needl e at the l ast i ndi cati on about fi ve seconds
or unti l the i gni ti on swi tch i s turned to the Off posi -
ti on, whi chever occurs fi rst. After fi ve seconds, the
cl uster wi l l move the gauge needl e to the l ow end of
the gauge scal e.
through the actuator test, the fuel gauge needl e wi l l
be swept to several cal i brati on poi nts on the gauge
scal e i n a prescri bed sequence i n order to confi rm the
functi onal i ty of the gauge and the cl uster control ci r-
cui try.
ti nual l y moni tors the fuel tank sendi ng uni t to deter-
mi ne the l evel of the fuel i n the fuel tank. On
vehi cl es wi th a di esel engi ne, the ECM conti nual l y
moni tors the fuel tank sendi ng uni t to determi ne the
l evel of the fuel i n the fuel tank. The PCM or ECM
then sends the proper fuel l evel messages to the
i nstrument cl uster. For further di agnosi s of the fuel
gauge or the i nstrument cl uster ci rcui try that con-
trol s the gauge, (Refer to 8 - ELECTRI CAL/I NSTRU-
For proper di agnosi s of the fuel tank sendi ng uni t,
the PCM, the ECM, the PCI data bus, or the el ec-
troni c message i nputs to the i nstrument cl uster that
control the fuel gauge, a DRBI I I scan tool i s
mati on.
GEAR SELECTOR INDICATOR
DESCRIPTION
An el ectroni c automati c transmi ssi on gear sel ector
i ndi cator i s standard factory-i nstal l ed equi pment on
thi s model . The gear sel ector i ndi cator i nformati on i s
di spl ayed i n a Vacuum-Fl uorescent Di spl ay (VFD)
uni t. The VFD i s sol dered onto the cl uster el ectroni c
ci rcui t board and i s vi si bl e through a wi ndow wi th a
smoked cl ear l ens l ocated on the l ower edge of the
speedometer gauge di al face of the cl uster overl ay.
The dark l ens over the VFD prevents the i ndi cator
The gear sel ector i ndi cator di spl ays the fol l owi ng
characters from l eft to ri ght: P, R, N, D, 2,
and 1 (Fi g. 18). Respecti vel y, these characters rep-
resent the park, reverse, neutral , dri ve, second gear,
and fi rst gear posi ti ons of the transmi ssi on gear
sel ector l ever on the steeri ng col umn. The VFD i l l u-
mi nates a rectangul ar box around the character that
represents the currentl y sel ected l ever posi ti on.
The gear sel ector i ndi cator characters and graphi cs
appear i n the same bl ue-green col or and at the same
l i ghti ng l evel as the odometer/tri p odometer i nforma-
ti on when i l l umi nated by the i nstrument cl uster el ec-
troni c ci rcui t board. Duri ng dayl i ght hours (exteri or
l amps Off) the gear sel ector i ndi cator VFD i s i l l umi -
nated at ful l bri ghtness for cl ear vi si bi l i ty. At ni ght
(exteri or l amps are On) the VFD l i ghti ng l evel i s
adjusted wi th the other cl uster i l l umi nati on l amps
usi ng the panel l amps di mmer thumbwheel on the
headl amp swi tch. However, a Parade mode posi ti on
of the panel l amps di mmer thumbwheel al l ows the
VFD to be i l l umi nated at ful l bri ghtness when the
vehi cl e i s dri ven i n dayl i ght hours wi th the exteri or
l amps turned On. The gear sel ector i ndi cator VFD i s
servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The el ectroni c gear sel ector i ndi cator gi ves an i ndi -
cati on to the vehi cl e operator of the transmi ssi on
gear that has been sel ected wi th the automati c trans-
mi ssi on gear sel ector l ever. Thi s i ndi cator i s con-
trol l ed by the i nstrument cl uster ci rcui t board based
upon cl uster programmi ng. The cl uster ci rcui try
automati cal l y confi gures i tsel f for the proper trans-
mi ssi on and automati c transmi ssi on model based
upon the hard wi red transmi ssi on range sensor mux
ci rcui t i nput to the cl uster. The gear sel ector i ndi ca-
tor i nformati on i s di spl ayed by a dedi cated Vacuum
Fl uorescent Di spl ay (VFD) uni t on the i nstrument
cl uster el ectroni c ci rcui t board, and the VFD wi l l not
di spl ay the gear sel ector i ndi cator i nformati on after
the i gni ti on swi tch i s turned to the Off posi ti on. The
i nstrument cl uster ci rcui try confi gures the gear sel ec-
tor i ndi cator VFD based upon the fol l owi ng i nputs
from the transmi ssi on range sensor:
Open Circuit - I f the cl uster i s confi gured for
an automati c transmi ssi on and the transmi ssi on
range sensor mux ci rcui t i s open, the cl uster ci rcui try
control s the gear sel ector i ndi cator di spl ay based
Fig. 18 Gear Selector Indicator
FUEL GAUGE (Continued)
upon el ectroni c messages recei ved from the el ectroni c
Transmi ssi on Control Modul e (TCM) over the Pro-
bus. I f the transmi ssi on range sensor mux ci rcui t i s
open and no el ectroni c messages are recei ved from
the TCM wi thi n two seconds, the i nstrument cl uster
ci rcui try wi l l not di spl ay any gear sel ector posi ti on
unti l the condi ti on i s resol ved or unti l the i gni ti on
fi rst.
Resolved Circuit - I f the transmi ssi on range
sensor mux ci rcui t i s resol ved, the cl uster ci rcui try
control s the gear sel ector i ndi cator di spl ay based
upon the resi stance val ue of the hard wi red i nput
from the transmi ssi on range sensor. I f the cl uster i s
confi gured for an automati c transmi ssi on wi th a
transmi ssi on range sensor i nput and detects a short
to ground or an open i n the transmi ssi on range sen-
sor mux i nput, the i nstrument cl uster ci rcui try wi l l
not di spl ay any gear sel ector posi ti on i n the VFD.
The VFD di spl ay for the short-to-ground and open
ci rcui t condi ti ons wi l l conti nue unti l the condi ti on i s
resol ved or unti l the i gni ti on swi tch i s turned to the
Off posi ti on, whi chever occurs fi rst.
through the actuator test, the gear sel ector i ndi cator
VFD wi l l di spl ay al l of i ts characters at once duri ng
the VFD porti on of the test to confi rm the functi on-
al i ty of the VFD and the cl uster control ci rcui try.
On model s wi th a TCM, the TCM conti nual l y mon-
i tors the transmi ssi on range sensor, then sends the
proper gear sel ector i ndi cator posi ti on messages to
the i nstrument cl uster. On model s wi thout a TCM,
the i nstrument cl uster conti nual l y moni tors the hard
wi red transmi ssi on range sensor mul ti pl exed i nput.
For further di agnosi s of the gear sel ector i ndi cator or
the i nstrument cl uster ci rcui try that control s thi s
functi on, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). For fur-
ther di agnosi s of the transmi ssi on range sensor on
model s wi thout a TCM, (Refer to 21 - TRANSMI S-
SI ON/TRANSAXLE/AUTOMATI C - 42RE/TRANS-
MI SSI ON RANGE SENSOR - DI AGNOSI S AND
TESTI NG) or (Refer to 21 - TRANSMI SSI ON/
TRANSAXLE/AUTOMATI C - 46RE/TRANSMI SSI ON
RANGE SENSOR - DI AGNOSI S AND TESTI NG).
On model s wi th a TCM, for proper di agnosi s of the
transmi ssi on range sensor, the TCM, the PCI data
bus, or the el ectroni c message i nputs to the i nstru-
ment cl uster that control the gear sel ector i ndi cator,
a DRBI I I scan tool i s requi red. Refer to the appro-
HIGH BEAM INDICATOR
DESCRIPTION
A hi gh beam i ndi cator i s standard equi pment on
al l i nstrument cl usters (Fi g. 19). The hi gh beam i ndi -
cator i s l ocated near the upper edge of the i nstru-
ment cl uster, between the tachometer and the
speedometer. The hi gh beam i ndi cator consi sts of a
stenci l -l i ke cutout of the I nternati onal Control and
Di spl ay Symbol i con for Hi gh Beam i n the opaque
bei ng cl earl y vi si bl e when the i t i s not i l l umi nated. A
bl ue Li ght Emi tti ng Di ode (LED) behi nd the cutout
appear i n bl ue through the transl ucent outer l ayer of
i nstrument cl uster el ectroni c ci rcui t board. The hi gh
beam i ndi cator i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The hi gh beam i ndi cator gi ves an i ndi cati on to the
vehi cl e operator whenever the headl amp hi gh beams
are i l l umi nated. Thi s i ndi cator i s control l ed by a
based upon cl uster programmi ng and a hard wi red
mul ti pl ex i nput recei ved by the cl uster from the
headl amp beam sel ect swi tch ci rcui try of the mul ti -
functi on swi tch on the washer/beam sel ect swi tch
mux ci rcui t. The hi gh beam i ndi cator Li ght Emi tti ng
ment cl uster l ogi c ci rcui t, and that l ogi c wi l l al l ow
thi s i ndi cator to operate whenever the i nstrument
B(+) ci rcui t. Therefore, the LED can be i l l umi nated
regardl ess of the i gni ti on swi tch posi ti on. The LED
onl y i l l umi nates when i t i s provi ded a path to ground
by the i nstrument cl uster transi stor. The i nstrument
cl uster wi l l turn on the hi gh beam i ndi cator for the
fol l owi ng reasons:
High Beam Headlamps-On Input - Each ti me
the cl uster detects a hi gh beam headl amps-on i nput
from the headl amp beam sel ect swi tch ci rcui try of
the mul ti -functi on swi tch on the washer/beam sel ect
swi tch mux ci rcui t, the headl amp hi gh beams and
the hi gh beam i ndi cator wi l l be i l l umi nated. The
headl amp hi gh beams and the hi gh beam i ndi cator
remai n i l l umi nated unti l the cl uster recei ves a hi gh
beam headl amps-off i nput from the mul ti -functi on
swi tch, or unti l the exteri or l amp l oad sheddi ng (bat-
Fig. 19 High Beam Indicator
GEAR SELECTOR INDICATOR (Continued)
tery saver) ti med i nterval expi res, whi chever occurs
fi rst.
through the actuator test, the hi gh beam i ndi cator
headl amp swi tch and the mul ti -functi on swi tch to
determi ne the proper headl amp l ow beam and hi gh
beam control . The i nstrument cl uster then sends the
proper l ow beam and hi gh beam l amp-on and l amp-
off messages to the Front Control Modul e (FCM) over
the Programmabl e Communi cati ons I nterface (PCI )
data bus and turns the hi gh beam i ndi cator on or off
accordi ngl y. For further di agnosi s of the hi gh beam
i ndi cator or the i nstrument cl uster ci rcui try that con-
trol s the i ndi cator, (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND
TESTI NG). For proper di agnosi s of the headl amps, or
the headl amp swi tch and mul ti -functi on swi tch
i nputs to the i nstrument cl uster that control the hi gh
beam i ndi cator, a DRBI I I scan tool i s requi red.
LAMP OUT INDICATOR
DESCRIPTION
A l amp out i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 20). The l amp out i ndi cator
consi sts of the words LAMP OUT, whi ch appear i n
the l ower porti on of the odometer/tri p odometer Vac-
uum-Fl uorescent Di spl ay (VFD) uni t. The VFD i s sol -
dered onto the cl uster el ectroni c ci rcui t board and i s
vi si bl e through a wi ndow wi th a smoked cl ear l ens
l ocated on the l ower edge of the tachometer gauge
di al face of the cl uster overl ay. The dark l ens over
the VFD prevents the i ndi cator from bei ng cl earl y
vi si bl e when i t i s not i l l umi nated. The words LAMP
OUT appear i n an amber col or and at the same
l i ghti ng l evel as the odometer/tri p odometer i nforma-
ti on when they are i l l umi nated by the i nstrument
cl uster el ectroni c ci rcui t board. The l amp out i ndi ca-
tor i s servi ced as a uni t wi th the VFD i n the i nstru-
ment cl uster.
OPERATION
The l amp out i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when an exteri or l amp has fai l ed.
Thi s i ndi cator i s control l ed by the i nstrument cl uster
ci rcui t board based upon cl uster programmi ng and
el ectroni c messages recei ved by the cl uster from the
Front Control Modul e (FCM) over the Programmabl e
Communi cati ons I nterface (PCI ) data bus. The l amp
out i ndi cator i s compl etel y control l ed by the i nstru-
the i ndi cator wi l l al ways be off when the i gni ti on
swi tch i s i n any posi ti on except On or Start. The
i ndi cator onl y i l l umi nates when i t i s swi tched to
ground by the i nstrument cl uster ci rcui try. The
i nstrument cl uster wi l l turn on the l amp out i ndi ca-
tor for the fol l owi ng reasons:
Lamp Out Indicator Lamp-On Message -
Each ti me the cl uster recei ves a l amp out i ndi cator
l amp-on message from the FCM i ndi cati ng that an
i noperati ve headl amp (l ow or hi gh beam), turn si gnal
l amp, or brake l amp (excl udi ng Center Hi gh
Mounted Stop Lamp [CHMSL]) ci rcui t has been
detected, the l amp out i ndi cator i s i l l umi nated. The
recei ves a l amp out i ndi cator l amp-off message from
the FCM or unti l the i gni ti on swi tch i s turned to the
through the actuator test, the l amp out i ndi cator wi l l
be turned on, then off agai n duri ng the VFD porti on
of the test to confi rm the functi onal i ty of the VFD
and the cl uster control ci rcui try.
The FCM moni tors each of the headl amp, turn si g-
nal l amp, and brake l amp (except CHMSL) ci rcui ts to
determi ne the condi ti on of these exteri or l amps. The
FCM then sends the proper l amp out i ndi cator
l amp-on and l amp-off messages to the i nstrument
cl uster. For further di agnosi s of the l amp out i ndi ca-
tor or the i nstrument cl uster ci rcui try that control s
the i ndi cator, (Refer to 8 - ELECTRI CAL/I NSTRU-
For proper di agnosi s of the exteri or l i ghti ng system
ci rcui ts, the FCM, the PCI data bus, or the el ectroni c
the l amp out i ndi cator, a DRBI I I scan tool i s
mati on.
Fig. 20 Lamp Out Indicator
HIGH BEAM INDICATOR (Continued)
LOW FUEL INDICATOR
DESCRIPTION
A l ow fuel i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 21). The l ow fuel i ndi cator
i s l ocated on the l eft si de of the i nstrument cl uster, to
the l eft of the fuel gauge. The l ow fuel i ndi cator con-
si sts of a stenci l -l i ke cutout of the I nternati onal Con-
trol and Di spl ay Symbol i con for Fuel i n the opaque
appear i n amber through the transl ucent outer l ayer
of the overl ay when the i ndi cator i s i l l umi nated from
i nstrument cl uster el ectroni c ci rcui t board. The l ow
fuel i ndi cator i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The l ow fuel i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the l evel of fuel i n the fuel
tank becomes l ow. Thi s i ndi cator i s control l ed by a
sages recei ved by the cl uster from the Powertrai n
Control Modul e (PCM) on vehi cl es equi pped wi th a
gasol i ne engi ne, or from the Engi ne Control Modul e
(ECM) on vehi cl es equi pped wi th a di esel engi ne over
data bus. The l ow fuel i ndi cator Li ght Emi tti ng
cl uster wi l l turn on the l ow fuel i ndi cator for the fol -
l owi ng reasons:
turned to the On posi ti on the l ow fuel i ndi cator i s
Less Than Twenty Percent Tank Full Mes-
sage - Each ti me the cl uster recei ves messages from
about twenty percent or l ess for ten consecuti ve sec-
onds and the vehi cl e speed i s zero, or for si xty con-
secuti ve seconds and the vehi cl e speed i s greater
than zero, the fuel gauge needl e i s moved to the one-
ei ghth graduati on or bel ow on the gauge scal e, the
l ow fuel i ndi cator i s i l l umi nated and a si ngl e chi me
tone i s sounded. The l ow fuel i ndi cator remai ns i l l u-
mi nated unti l the cl uster recei ves messages from the
PCM or ECM i ndi cati ng that the percent tank ful l i s
greater than about twenty percent for ten consecu-
ti ve seconds and the vehi cl e speed i s zero, or for si xty
consecuti ve seconds and the vehi cl e speed i s greater
the Off posi ti on, whi chever occurs fi rst. The chi me
tone feature wi l l onl y repeat duri ng the same i gni -
ti on cycl e i f the l ow fuel i ndi cator i s cycl ed off and
then on agai n by the appropri ate percent tank ful l
messages from the PCM or ECM.
Less Than Empty Percent Tank Full Mes-
sage - Each ti me the cl uster recei ves a message from
l ess than empty, the l ow fuel i ndi cator i s i l l umi nated
i mmedi atel y. Thi s message woul d i ndi cate that the
fuel tank sender i nput to the PCM or ECM i s a short
ci rcui t.
More Than Full Percent Tank Full Message
PCM or ECM i ndi cati ng the percent tank ful l i s more
than ful l , the l ow fuel i ndi cator i s i l l umi nated i mme-
di atel y. Thi s message woul d i ndi cate that the fuel
tank sender i nput to the PCM or ECM i s an open ci r-
cui t.
through the actuator test, the l ow fuel i ndi cator wi l l
ti nual l y moni tors the fuel tank sendi ng uni t to deter-
mi ne the l evel of fuel i n the fuel tank. On vehi cl es
wi th a di esel engi ne, the ECM conti nual l y moni tors
the fuel tank sendi ng uni t to determi ne the l evel of
fuel i n the fuel tank. The PCM or ECM then sends
the proper fuel l evel messages to the i nstrument
cl uster. For further di agnosi s of the l ow fuel i ndi cator
or the i nstrument cl uster ci rcui try that control s the
LED, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). For
proper di agnosi s of the fuel tank sendi ng uni t, the
PCM, the ECM, the PCI data bus, or the el ectroni c
the l ow fuel i ndi cator, a DRBI I I scan tool i s
mati on.
Fig. 21 Low Fuel Indicator
MALFUNCTION INDICATOR
LAMP (MIL)
DESCRIPTION
A Mal functi on I ndi cator Lamp (MI L) i s standard
equi pment on al l i nstrument cl usters (Fi g. 22). The
MI L i s l ocated on the l eft si de of the i nstrument cl us-
ter, to the l eft of the vol tage gauge. The MI L consi sts
of a stenci l -l i ke cutout of the I nternati onal Control
and Di spl ay Symbol i con for Engi ne i n the opaque
appear i n amber through the transl ucent outer l ayer
of the overl ay when the i ndi cator i s i l l umi nated from
i nstrument cl uster el ectroni c ci rcui t board. The MI L
i s servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The Mal functi on I ndi cator Lamp (MI L) gi ves an
i ndi cati on to the vehi cl e operator when the Power-
trai n Control Modul e (PCM) on vehi cl es wi th a gaso-
l i ne engi ne, or the Engi ne Control Modul e (ECM) on
vehi cl es wi th a di esel engi ne has recorded a Di agnos-
ti c Troubl e Code (DTC) for an On-Board Di agnosti cs
I I (OBDI I ) emi ssi ons-rel ated ci rcui t or component
mal functi on. The MI L i s control l ed by a transi stor on
the cl uster from the PCM or ECM over the Program-
mabl e Communi cati ons I nterface (PCI ) data bus. The
MI L Li ght Emi tti ng Di ode (LED) i s compl etel y con-
trol l ed by the i nstrument cl uster l ogi c ci rcui t, and
start) ci rcui t. Therefore, the LED wi l l al ways be off
when the i gni ti on swi tch i s i n any posi ti on except On
or Start. The LED onl y i l l umi nates when i t i s pro-
vi ded a path to ground by the i nstrument cl uster
MI L for the fol l owi ng reasons:
turned to the On posi ti on the i ndi cator i s i l l umi nated
for about two seconds as a bul b test. The enti re two
second bul b test i s a functi on of the PCM or ECM.
MIL Lamp-On Message - Each ti me the cl us-
ter recei ves a MI L l amp-on message from the PCM
or ECM, the i ndi cator wi l l be i l l umi nated. The i ndi -
cator can be fl ashed on and off, or i l l umi nated sol i d,
as di ctated by the PCM or ECM message. For some
DTCs, i f a probl em does not recur, the PCM or ECM
wi l l send a l amp-off message automati cal l y. Other
DTCs may requi re that a faul t be repai red and the
PCM or ECM be reset before a l amp-off message wi l l
be sent. For more i nformati on on the PCM, the ECM,
and the DTC set and reset parameters, (Refer to 25 -
EMI SSI ONS CONTROL - OPERATI ON).
no l amp-on message from the PCM or ECM for ten
seconds, the MI L i s i l l umi nated by the i nstrument
cl uster to i ndi cate a l oss of bus communi cati on. The
i ndi cator remai ns control l ed and i l l umi nated by the
cl uster unti l a val i d l amp-on message i s recei ved
from the PCM or ECM.
through the actuator test, the MI L i ndi cator wi l l be
turned on duri ng the bul b check porti on of the test to
confi rm the functi onal i ty of the LED and the cl uster
control ci rcui try.
ti nual l y moni tors the fuel and emi ssi ons system ci r-
cui ts and sensors to deci de whether the system i s i n
good operati ng condi ti on. On vehi cl es wi th a di esel
engi ne, the ECM conti nual l y moni tors the fuel and
emi ssi ons system ci rcui ts and sensors to deci de
whether the system i s i n good operati ng condi ti on.
The PCM or ECM then sends the proper l amp-on or
l amp-off messages to the i nstrument cl uster. For fur-
ther di agnosi s of the MI L or the i nstrument cl uster
ci rcui try that control s the LED, (Refer to 8 - ELEC-
TRI CAL/I NSTRUMENT CLUSTER - DI AGNOSI S
AND TESTI NG). I f the i nstrument cl uster turns on
the MI L after the bul b test, i t may i ndi cate that a
mal functi on has occurred and that the fuel and emi s-
si ons systems may requi re servi ce. For proper di ag-
nosi s of the fuel and emi ssi ons systems, the PCM,
the ECM, the PCI data bus, or the el ectroni c mes-
sage i nputs to the i nstrument cl uster that control the
MI L, a DRBI I I scan tool i s requi red. Refer to the
Fig. 22 Malfunction Indicator Lamp (MIL)
ODOMETER
DESCRIPTION
An odometer and tri p odometer are standard
equi pment i n al l i nstrument cl usters (Fi g. 23). The
odometer, tri p odometer, and engi ne hours i nforma-
ti on are di spl ayed i n a common el ectroni c, bl ue-green
Vacuum-Fl uorescent Di spl ay (VFD). The VFD i s sol -
dered onto the cl uster el ectroni c ci rcui t board and i s
vi si bl e through a wi ndow wi th a smoked cl ear l ens
l ocated on the l ower edge of the tachometer gauge
di al face of the cl uster overl ay. The dark l ens over
the VFD prevents i t from bei ng cl earl y vi si bl e when
i t i s not i l l umi nated. However, the odometer, tri p
odometer, and engi ne hours i nformati on are not di s-
pl ayed si mul taneousl y. The tri p odometer reset
swi tch on the i nstrument cl uster ci rcui t board toggl es
the di spl ay between odometer and tri p odometer
modes by depressi ng the odometer/tri p odometer
swi tch button that extends through the l ower edge of
the cl uster l ens, just l eft of the odometer VFD. When
the tri p odometer i nformati on i s di spl ayed, the word
TRI P i s al so i l l umi nated i n the upper ri ght corner
of the VFD i n a bl ue-green col or and at the same
l i ghti ng l evel as the tri p odometer i nformati on. The
engi ne hours i nformati on repl aces the sel ected odom-
eter or tri p odometer i nformati on whenever the i gni -
ti on swi tch i s i n the On posi ti on and the engi ne i s
not runni ng.
The odometer, tri p odometer, and engi ne hours
i nformati on i s stored i n the i nstrument cl uster mem-
ory. Thi s i nformati on can be i ncreased when the
proper i nputs are provi ded to the i nstrument cl uster,
but the i nformati on cannot be decreased. The odom-
eter can di spl ay val ues up to 999,999 ki l ometers
(999,999 mi l es). The odometer l atches at these val -
ues, and wi l l not rol l over to zero. The tri p odometer
can di spl ay val ues up to 9,999.9 ki l ometers (9,999.9
mi l es) before i t rol l s over to zero. The odometer di s-
pl ay does not have a deci mal poi nt and wi l l not show
val ues l ess than a ful l uni t (ki l ometer or mi l e), whi l e
the tri p odometer di spl ay does have a deci mal poi nt
and wi l l show tenths of a uni t (ki l ometer or mi l e).
The uni t of measure (ki l ometers or mi l es) for the
odometer and tri p odometer di spl ay i s not shown i n
the VFD. The uni t of measure for the i nstrument
cl uster odometer/tri p odometer i s sel ected at the ti me
that i t i s manufactured, and cannot be changed.
Engi ne hours are di spl ayed i n the format, hr9999.
The cl uster wi l l accumul ate val ues up to 9,999 hours
before the di spl ay rol l s over to zero.
The odometer has a Rental Car mode, whi ch wi l l
i l l umi nate the odometer i nformati on i n the VFD
whenever the dri ver si de front door i s opened wi th
the i gni ti on swi tch i n the Off or Accessory posi ti ons.
Duri ng dayl i ght hours (exteri or l amps are Off) the
VFD i s i l l umi nated at ful l bri ghtness for cl ear vi si bi l -
i ty. At ni ght (exteri or l amps are On) the VFD l i ghti ng
l evel i s adjusted wi th the other cl uster i l l umi nati on
l amps usi ng the panel l amps di mmer thumbwheel on
the headl amp swi tch. However, a Parade mode
posi ti on of the panel l amps di mmer thumbwheel
al l ows the VFD to be i l l umi nated at ful l bri ghtness i f
the exteri or l amps are turned On duri ng dayl i ght
hours.
The VFD, the tri p odometer swi tch, and the tri p
odometer swi tch button are servi ced as a uni t wi th
the i nstrument cl uster.
OPERATION
The odometer and tri p odometer gi ve an i ndi cati on
to the vehi cl e operator of the di stance the vehi cl e has
travel ed. The engi ne hours gi ve an i ndi cati on of the
cumul ati ve engi ne-on ti me. Thi s i ndi cator i s con-
trol l ed by the i nstrument cl uster ci rcui try based
Modul e (PCM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The odometer, tri p
odometer and engi ne hours i nformati on i s di spl ayed
by the i nstrument cl uster Vacuum Fl uorescent Di s-
pl ay (VFD). The VFD wi l l di spl ay the odometer i nfor-
mati on whenever any door i s opened wi th the
i gni ti on swi tch i n the Off or Accessory posi ti ons, and
wi l l di spl ay the l ast previ ousl y sel ected odometer or
tri p odometer i nformati on when the i gni ti on swi tch i s
turned to the On or Start posi ti ons. The i nstrument
cl uster ci rcui try control s the VFD and provi des the
fol l owi ng features:
Odometer/Trip Odometer Display Toggling -
Actuati ng the tri p odometer reset swi tch button
momentari l y wi th the VFD i l l umi nated wi l l toggl e
the di spl ay between the odometer and tri p odometer
i nformati on. Each ti me the VFD i s i l l umi nated wi th
the i gni ti on swi tch i n the On or Start posi ti ons, the
di spl ay wi l l automati cal l y return to the l ast mode
previ ousl y sel ected (odometer or tri p odometer).
Engine Hours Display Toggling - When the
tri p odometer reset swi tch button i s pressed and hel d
for l onger than about si x seconds wi th the i gni ti on
swi tch i n the On posi ti on and the engi ne speed mes-
sage from the PCM i s zero, the tri p odometer i nfor-
mati on wi l l be momentari l y di spl ayed, then the
engi ne hours i nformati on wi l l be di spl ayed. The VFD
must be di spl ayi ng the odometer i nformati on when
Fig. 23 Odometer Display
the tri p odometer reset swi tch button i s pressed i n
order to toggl e to the engi ne hours di spl ay. The
engi ne hours wi l l remai n di spl ayed for about thi rty
seconds, unti l the engi ne speed message i s greater
the Off posi ti on, whi chever occurs fi rst.
Trip Odometer Reset - When the tri p odome-
ter reset swi tch button i s pressed and hel d for l onger
than about two seconds wi th the i gni ti on swi tch i n
the On or Start posi ti ons, the tri p odometer wi l l be
reset to 0.0 ki l ometers (mi l es). The VFD must be di s-
pl ayi ng the tri p odometer i nformati on i n order for
the tri p odometer i nformati on to be reset.
recei ve a di stance message duri ng normal operati on,
i t wi l l hol d and di spl ay the l ast data recei ved unti l
the i gni ti on swi tch i s turned to the Off posi ti on. I f
the cl uster does not recei ve a di stance message
wi thi n one second after the i gni ti on swi tch i s turned
to the On posi ti on, i t wi l l di spl ay the l ast di stance
message stored i n the cl uster memory. I f the cl uster
i s unabl e to di spl ay di stance i nformati on due to an
error i nternal to the cl uster, the VFD di spl ay wi l l be
dashes.
through the actuator test, the odometer VFD wi l l di s-
pl ay al l of i ts segments si mul taneousl y duri ng the
VFD porti on of the test to confi rm the functi onal i ty
of each of the VFD segments and the cl uster control
ci rcui try.
The PCM conti nual l y moni tors the vehi cl e speed
pul se i nformati on recei ved from the vehi cl e speed
sensor and engi ne speed pul se i nformati on recei ved
from the crankshaft posi ti on sensor, then sends the
proper di stance and engi ne speed messages to the
i nstrument cl uster. For further di agnosi s of the
odometer/tri p odometer or the i nstrument cl uster ci r-
cui try that control s these functi ons, (Refer to 8 -
vehi cl e speed sensor, the crankshaft posi ti on sensor,
the PCM, the PCI data bus, or the el ectroni c message
odometer/tri p odometer, a DRBI I I scan tool i s
mati on.
OIL PRESSURE GAUGE
DESCRIPTION
An oi l pressure gauge i s standard equi pment on al l
i nstrument cl usters. The oi l pressure gauge i s l ocated
i n the upper ri ght quadrant of the i nstrument cl us-
ter, above the cool ant temperature gauge. The oi l
pressure gauge consi sts of a movabl e gauge needl e or
poi nter control l ed by the i nstrument cl uster ci rcui try
and a fi xed 90 degree scal e on the cl uster overl ay
that reads l eft-to-ri ght from L (or Low) to H (or
Hi gh) for gasol i ne engi nes. On vehi cl es wi th a di esel
engi ne the scal e reads from 0 kPa to 760 kPa i n
markets where a metri c i nstrument cl uster i s speci -
fi ed, or from 0 psi to 110 psi i n al l other markets.
An I nternati onal Control and Di spl ay Symbol i con for
Engi ne Oi l i s l ocated on the cl uster overl ay, di rectl y
bel ow the l eft end of the gauge scal e (Fi g. 24). The oi l
pressure gauge graphi cs are bl ack agai nst a whi te
fi el d except for two red graduati ons at the l ow end of
the gauge scal e, maki ng them cl earl y vi si bl e wi thi n
the i nstrument cl uster i n dayl i ght. When i l l umi nated
from behi nd by the panel l amps di mmer control l ed
cl uster i l l umi nati on l i ghti ng wi th the exteri or l amps
turned On, the bl ack graphi cs appear bl ue and the
red graphi cs sti l l appear red. The orange gauge nee-
dl e i s i nternal l y i l l umi nated. Gauge i l l umi nati on i s
provi ded by repl aceabl e i ncandescent bul b and bul b
troni c ci rcui t board. The oi l pressure gauge i s ser-
vi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The oi l pressure gauge gi ves an i ndi cati on to the
vehi cl e operator of the engi ne oi l pressure. Thi s
Powertrai n Control Modul e (PCM) on vehi cl es wi th a
gasol i ne engi ne, or from the Engi ne Control Modul e
(ECM) on vehi cl es equi pped wi th a di esel engi ne over
data bus. The oi l pressure gauge i s an ai r core mag-
neti c uni t that recei ves battery current on the i nstru-
ment cl uster el ectroni c ci rcui t board through the
fused i gni ti on swi tch output (run-start) ci rcui t when-
ever the i gni ti on swi tch i s i n the On or Start posi -
ti ons. The cl uster i s programmed to move the gauge
needl e back to the l ow end of the scal e after the i gni -
ti on swi tch i s turned to the Off posi ti on. The i nstru-
ment cl uster ci rcui try control s the gauge needl e
posi ti on and provi des the fol l owi ng features:
Engine Oil Pressure Message - The i nstru-
ment cl uster ci rcui try restri cts the oi l pressure gauge
needl e operati on i n order to provi de readi ngs that
are consi stent wi th customer expectati ons. Each ti me
i ndi cati ng the engi ne oi l pressure i s above about 41
kPa (6 psi ) the cl uster hol ds the gauge needl e at a
poi nt near the mi ddl e i ncrement wi thi n the normal
range on the gauge scal e.
Fig. 24 Engine Oil Icon
ODOMETER (Continued)
Engine Oil Pressure Low Message - Each
ECM i ndi cati ng the engi ne oi l pressure i s bel ow
about 41 kPa (6 psi ), the gauge needl e i s moved to
the graduati on at the far l eft end of the gauge scal e,
the check gauges i ndi cator i s i l l umi nated, and a si n-
gl e chi me tone i s generated. The gauge needl e
remai ns at the l eft end of the gauge scal e and the
check gauges i ndi cator remai ns i l l umi nated unti l the
cl uster recei ves a message from the PCM or ECM
i ndi cati ng that the engi ne oi l pressure i s above about
41 kPa (6 psi ), or unti l the i gni ti on swi tch i s turned
to the Off posi ti on, whi chever occurs fi rst. The cl us-
ter wi l l onl y turn the check gauges i ndi cator on i n
response to an engi ne oi l pressure l ow message i f the
engi ne speed message i s greater than zero.
recei ve an engi ne oi l pressure message, i t wi l l hol d
the gauge needl e at the l ast i ndi cati on about fi ve sec-
onds or unti l the i gni ti on swi tch i s turned to the Off
posi ti on, whi chever occurs fi rst. After fi ve seconds,
the cl uster wi l l move the gauge needl e to the l eft end
of the gauge scal e.
through the actuator test, the oi l pressure gauge nee-
dl e wi l l be swept to several cal i brati on poi nts on the
gauge scal e i n a prescri bed sequence i n order to con-
fi rm the functi onal i ty of the gauge and the cl uster
ti nual l y moni tors the engi ne oi l pressure sensor to
determi ne the engi ne oi l pressure. On vehi cl es wi th a
di esel engi ne, the ECM conti nual l y moni tors the
engi ne oi l pressure sensor to determi ne the engi ne oi l
pressure. The PCM or ECM then sends the proper
engi ne oi l pressure messages to the i nstrument cl us-
ter. For further di agnosi s of the oi l pressure gauge or
the i nstrument cl uster ci rcui try that control s the
gauge, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). I f the
i nstrument cl uster turns on the check gauges i ndi ca-
tor due to a l ow oi l pressure gauge readi ng, i t may
i ndi cate that the engi ne or the engi ne oi l i ng system
requi res servi ce. For proper di agnosi s of the engi ne
oi l pressure sensor, the PCM, the ECM, the PCI data
ment cl uster that control the oi l pressure gauge, a
DRBI I I scan tool i s requi red. Refer to the appropri -
SEATBELT INDICATOR
DESCRIPTION
A seatbel t i ndi cator i s standard equi pment on al l
i nstrument cl usters (Fi g. 25). The seatbel t i ndi cator
i s l ocated on the upper edge of the i nstrument cl us-
ter, between the tachometer and the speedometer.
The seatbel t i ndi cator consi sts of a stenci l -l i ke cutout
of the I nternati onal Control and Di spl ay Symbol i con
for Seat Bel t i n the opaque l ayer of the i nstrument
cl uster overl ay. The dark outer l ayer of the overl ay
prevents the i ndi cator from bei ng cl earl y vi si bl e
when i t i s not i l l umi nated. A red Li ght Emi tti ng
Di ode (LED) behi nd the cutout i n the opaque l ayer of
the overl ay causes the i con to appear i n red through
the transl ucent outer l ayer of the overl ay when the
i ndi cator i s i l l umi nated from behi nd by the LED,
whi ch i s sol dered onto the i nstrument cl uster el ec-
troni c ci rcui t board. The seatbel t i ndi cator i s servi ced
as a uni t wi th the i nstrument cl uster.
OPERATION
The seatbel t i ndi cator gi ves an i ndi cati on to the
vehi cl e operator of the status of the dri ver si de front
seatbel t. Thi s i ndi cator i s control l ed by a transi stor
cl uster programmi ng and a hard wi red i nput from
the seatbel t swi tch i n the dri ver si de front seatbel t
buckl e through the seat bel t i ndi cator dri ver ci rcui t.
The seatbel t i ndi cator al so i ncl udes a programmabl e
enhanced seatbel t remi nder or bel tmi nder feature
that i s enabl ed when the vehi cl e i s shi pped from the
factory. Thi s bel tmi nder feature can be di sabl ed and
enabl ed by the customer usi ng a speci fi c program-
mi ng event sequence, or by the deal er usi ng a
DRBI I I scan tool . The seatbel t i ndi cator Li ght Emi t-
ti ng Di ode (LED) i s compl etel y control l ed by the
onl y al l ow thi s i ndi cator to operate when the i nstru-
fused i gni ti on swi tch output (run-start) ci rcui t.
Therefore, the LED wi l l al ways be off when the i gni -
ti on swi tch i s i n any posi ti on except On or Start. The
i nstrument cl uster wi l l turn on the seatbel t i ndi cator
Seatbelt Reminder Function - Each ti me the
i gni ti on swi tch output (run-start) ci rcui t, the i ndi ca-
tor wi l l be i l l umi nated as a seatbel t remi nder for
about si x seconds, or unti l the i gni ti on swi tch i s
Thi s remi nder functi on wi l l occur regardl ess of the
status of the seatbel t swi tch i nput to the cl uster.
Driver Side Front Seatbelt Not Buckled -
Beltminder Active - Fol l owi ng the seatbel t
Fig. 25 Seatbelt Indicator
OIL PRESSURE GAUGE (Continued)
remi nder functi on, each ti me the cl uster detects an
open ci rcui t on the seat bel t i ndi cator dri ver ci rcui t
(seatbel t swi tch open = seatbel t unbuckl ed) wi th the
i gni ti on swi tch i n the Start or On posi ti ons, the i ndi -
cator wi l l be i l l umi nated. I n addi ti on, i f the dri ver
si de front seat bel t remai ns unbuckl ed about si xty
seconds after the concl usi on of the seatbel t remi nder
functi on wi th the vehi cl e speed greater than about 13
ki l ometers-per-hour (8 mi l es-per-hour), the seatbel t
i ndi cator wi l l begi n to cycl e between fl ashi ng on and
off for fi ve seconds, then l i ghti ng sol i d for three sec-
onds. The seatbel t i ndi cator wi l l conti nue to cycl e
between fl ashi ng and sol i d i l l umi nati on for twel ve
compl ete cycl es, unti l the seat bel t i ndi cator dri ver
i nput to the cl uster i s cl osed to ground (seatbel t
swi tch cl osed = seatbel t buckl ed), or unti l the i gni -
ti on swi tch i s turned to the Off posi ti on, whi chever
occurs fi rst.
Driver Side Front Seatbelt Not Buckled -
Beltminder Inactive - Fol l owi ng the seatbel t
remi nder functi on, each ti me the cl uster detects an
open ci rcui t on the seat bel t i ndi cator dri ver ci rcui t
(seatbel t swi tch open = seatbel t unbuckl ed) wi th the
i gni ti on swi tch i n the Start or On posi ti ons, the i ndi -
cator wi l l be i l l umi nated. The seatbel t i ndi cator
remai ns i l l umi nated unti l the seat bel t i ndi cator
dri ver i nput to the cl uster i s cl osed to ground (seat-
bel t swi tch cl osed = seatbel t buckl ed), or unti l the
ever occurs fi rst.
Airbag Indicator Backup - I f the i nstrument
cl uster detects a faul t i n the ai rbag i ndi cator ci rcui t
i t wi l l send a message i ndi cati ng the faul t to the Ai r-
bag Control Modul e (ACM), store a Di agnosti c Trou-
bl e Code (DTC) i n the cl uster memory, then fl ash the
seatbel t i ndi cator on and off. The cl uster wi l l con-
ti nue to fl ash the seatbel t i ndi cator unti l the ai rbag
i ndi cator ci rcui t faul t i s resol ved, or unti l the i gni ti on
fi rst.
through the actuator test, the seatbel t i ndi cator wi l l
The seatbel t swi tch i s connected i n seri es between
ground and the seat bel t i ndi cator dri ver i nput to the
i nstrument cl uster. The seatbel t swi tch i nput to the
i nstrument cl uster ci rcui try may be di agnosed usi ng
conventi onal di agnosti c tool s and methods. For fur-
ther di agnosi s of the seatbel t i ndi cator or the i nstru-
ment cl uster ci rcui try that control s the LED, (Refer
to 8 - ELECTRI CAL/I NSTRUMENT CLUSTER -
STANDARD PROCEDURE - ENHANCED
SEATBELT REMINDER PROGRAMMING
The seatbel t i ndi cator al so i ncl udes a programma-
bl e enhanced seatbel t remi nder or bel tmi nder fea-
ture that i s enabl ed when the vehi cl e i s shi pped from
the factory. Thi s bel tmi nder feature provi des
extended and modi fi ed vi sual seatbel t i ndi cator and
audi bl e chi me warni ng responses to an unbuckl ed
dri ver si de front seat bel t. The bel tmi nder feature
may be di sabl ed or enabl ed by the customer usi ng
the programmi ng sequence that fol l ows, or by the
deal er usi ng a DRBI I I scan tool . The fol l owi ng
sequence of events must occur wi thi n si xty (60) sec-
onds of the i gni ti on swi tch bei ng pl aced i n the On
posi ti on i n order for the programmi ng to be com-
pl eted successful l y.
(1) Wi th the i gni ti on swi tch i n any posi ti on except
On or Start, buckl e the dri ver si de front seat bel t.
(2) Turn the i gni ti on swi tch to the On posi ti on and
wai t for the seatbel t i ndi cator remi nder functi on to
concl ude (about si x seconds).
(3) Unbuckl e and buckl e the dri ver si de front seat
bel t three or more ti mes, endi ng wi th the bel t buck-
l ed.
(4) Turn the i gni ti on swi tch to any posi ti on except
On or Start to toggl e the bel tmi nder feature from i ts
current setti ng (from acti ve to i nacti ve, or from i nac-
ti ve to acti ve). A si ngl e chi me tone wi l l provi de an
audi bl e confi rmati on that the programmi ng sequence
has been successful l y compl eted.
SECURITY INDICATOR
DESCRIPTION
A securi ty i ndi cator i s standard equi pment on al l
not equi pped wi th the opti onal Vehi cl e Theft Securi ty
System (VTSS), thi s i ndi cator i s el ectroni cal l y di s-
abl ed. The securi ty i ndi cator i s l ocated i n the l ower
ri ght quadrant of the i nstrument cl uster, between the
speedometer and the cool ant temperature gauge. The
securi ty i ndi cator consi sts of a smal l round cutout i n
the opaque l ayer of the i nstrument cl uster overl ay.
The dark outer l ayer of the overl ay prevents the i ndi -
cator from bei ng cl earl y vi si bl e when i t i s not i l l umi -
nated. A red Li ght Emi tti ng Di ode (LED) behi nd the
cutout i n the opaque l ayer of the overl ay causes the
i ndi cator to appear i n red through the transl ucent
outer l ayer of the overl ay when i t i s i l l umi nated from
Fig. 26 Security Indicator
SEATBELT INDICATOR (Continued)
i nstrument cl uster el ectroni c ci rcui t board. The secu-
ri ty i ndi cator i s servi ced as a uni t wi th the i nstru-
ment cl uster.
OPERATION
The securi ty i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the Vehi cl e Theft Securi ty Sys-
tem (VTSS) i s armi ng or i s armed. On model s
equi pped wi th the Sentry Key I mmobi l i zer System
(SKI S), the securi ty i ndi cator al so gi ves an i ndi cati on
to the vehi cl e operator of the status of the SKI S. Thi s
i ndi cator i s control l ed by a transi stor on the i nstru-
ment cl uster ci rcui t board based upon cl uster pro-
grammi ng, hard wi red i nputs to the cl uster from the
vari ous securi ty system components, el ectroni c mes-
sages recei ved by the cl uster from the Remote Key-
l ess Entry (RKE) recei ver modul e over a dedi cated
seri al bus, and el ectroni c messages recei ved by the
cl uster from the Sentry Key I mmobi l i zer Modul e
(SKI M) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The securi ty i ndi cator Li ght
Emi tti ng Di ode (LED) i s compl etel y control l ed by the
al l ow thi s i ndi cator to operate whenever the i nstru-
fused B(+) ci rcui t. Therefore, the LED can be i l l umi -
nated regardl ess of the i gni ti on swi tch posi ti on. The
i nstrument cl uster wi l l turn on the securi ty i ndi cator
turned to the On posi ti on, the SKI M tel l s the cl uster
to i l l umi nate the SKI S i ndi cator for about two sec-
VTSS Indication - Duri ng the si xteen second
VTSS armi ng functi on, the cl uster wi l l fl ash the
securi ty i ndi cator on and off repeatedl y at a steady,
fast rate to i ndi cate that the VTSS i s i n the process
of armi ng. Fol l owi ng successful VTSS armi ng, the
cl uster fl ashes the securi ty i ndi cator on and off con-
ti nuousl y at a sl ower rate to i ndi cate that the VTSS
i s armed. The securi ty i ndi cator conti nues fl ashi ng at
the sl ower rate unti l the VTSS i s di sarmed or tri g-
gered. I f the VTSS has al armed and rearmed, the
cl uster wi l l fl ash the securi ty i ndi cator at a steady,
sl ow rate for about thi rty seconds after the VTSS i s
di sarmed.
SKIM Lamp-On Message - Each ti me the cl us-
ter recei ves a l amp-on message from the SKI M, the
securi ty i ndi cator wi l l be i l l umi nated. The i ndi cator
can be fl ashed on and off, or i l l umi nated sol i d, as di c-
tated by the SKI M message. The i ndi cator remai ns
i l l umi nated sol i d or conti nues to fl ash unti l the cl us-
ter recei ves a l amp-off message from the SKI M, or
whi chever occurs fi rst. For more i nformati on on the
SKI S and the securi ty i ndi cator control parameters,
(Refer to 8 - ELECTRI CAL/VEHI CLE THEFT SECU-
RI TY/SENTRY KEY I MMOBI LI ZER SYSTEM -
OPERATI ON).
no SKI S l amp-on or l amp-off messages from the
SKI M for twenty consecuti ve seconds, the SKI S i ndi -
cator i s i l l umi nated by the i nstrument cl uster. The
i ndi cator remai ns control l ed and i l l umi nated by the
cl uster unti l a val i d SKI S l amp-on or l amp-off mes-
sage i s recei ved from the SKI M.
ter i s put through the actuator test, the securi ty i ndi -
cator wi l l be turned on, then off agai n duri ng the
bul b check porti on of the test to confi rm the functi on-
al i ty of the LED and the cl uster control ci rcui try.
The i nstrument cl uster ci rcui try control s the secu-
ri ty i ndi cator whenever the i gni ti on swi tch i s i n the
Off posi ti on and the VTSS i s armi ng, armed, or
al armi ng. Whenever the i gni ti on swi tch i s i n the On
or Start posi ti ons, the SKI M performs a sel f-test to
deci de whether the SKI S i s i n good operati ng condi -
ti on and whether a val i d key i s present i n the i gni -
ti on l ock cyl i nder. The SKI M then sends the proper
l amp-on or l amp-off messages to the i nstrument cl us-
ter. For further di agnosi s of the securi ty i ndi cator or
the i nstrument cl uster ci rcui try that control s the
i ndi cator, (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). I f the
i nstrument cl uster fl ashes the SKI S i ndi cator upon
i gni ti on On, or turns on the SKI S i ndi cator sol i d
after the bul b test, i t i ndi cates that a SKI S mal func-
ti on has occurred or that the SKI S i s i noperati ve. For
proper di agnosi s of the VTSS, the SKI S, the SKI M,
the PCI data bus, or the el ectroni c message i nputs to
the i nstrument cl uster that control the securi ty i ndi -
cator, a DRBI I I scan tool i s requi red. Refer to the
SERVICE 4WD INDICATOR
DESCRIPTION
A servi ce 4WD i ndi cator i s standard equi pment on
al l i nstrument cl usters (Fi g. 27). However, on vehi -
cl es not equi pped wi th the opti onal four-wheel dri ve
system and el ectroni cal l y shi fted transfer case, thi s
i ndi cator i s el ectroni cal l y di sabl ed. The servi ce 4WD
i ndi cator consi sts of the text SERV 4WD, whi ch
Fig. 27 Service 4WD Indicator
SECURITY INDICATOR (Continued)
appears i n the l ower porti on of the odometer/tri p
odometer Vacuum Fl uorescent Di spl ay (VFD) uni t.
The VFD i s sol dered onto the cl uster el ectroni c ci r-
cui t board and i s vi si bl e through a wi ndow wi th a
tachometer gauge di al face of the cl uster overl ay. The
dark l ens over the VFD prevents the i ndi cator from
bei ng cl earl y vi si bl e when i t i s not i l l umi nated. The
text SERV 4WD appears i n an amber col or and at
the same l i ghti ng l evel as the odometer/tri p odometer
i nformati on when they are i l l umi nated by the i nstru-
ment cl uster el ectroni c ci rcui t board. The servi ce
4WD i ndi cator i s servi ced as a uni t wi th the VFD i n
OPERATION
The servi ce 4WD i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when the Transfer Case Control
Modul e (TCCM) has recorded a Di agnosti c Troubl e
Code (DTC) for an el ectroni c transfer case ci rcui t or
component mal functi on. Thi s i ndi cator i s control l ed
by a transi stor on the i nstrument cl uster ci rcui t
TCCM over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The servi ce 4WD i ndi cator
i s compl etel y control l ed by the i nstrument cl uster
l ogi c ci rcui t, and that l ogi c wi l l onl y al l ow thi s i ndi -
cator to operate when the i nstrument cl uster recei ves
a battery current i nput on the fused i gni ti on swi tch
output (run-start) ci rcui t. Therefore, the i ndi cator
wi l l al ways be off when the i gni ti on swi tch i s i n any
posi ti on except On or Start. The i ndi cator onl y i l l u-
mi nates when i t i s swi tched to ground by the i nstru-
ment cl uster ci rcui try. The i nstrument cl uster wi l l
turn on the servi ce 4WD i ndi cator for the fol l owi ng
reasons:
Service 4WD Lamp-On Message - Each ti me
the cl uster recei ves a servi ce 4WD l amp-on message
from the TCCM, the i ndi cator wi l l be i l l umi nated.
The i ndi cator remai ns i l l umi nated unti l the cl uster
recei ves a servi ce 4WD l amp-off message from the
TCCM, or unti l the i gni ti on swi tch i s turned to the
no messages from the TCCM for fi ve seconds, the
servi ce 4WD i ndi cator i s i l l umi nated by the i nstru-
ment cl uster to i ndi cate a l oss of TCCM communi ca-
ti on. The i ndi cator remai ns control l ed and
i l l umi nated by the cl uster unti l a val i d message i s
recei ved from the TCCM.
through the actuator test, the servi ce 4WD i ndi cator
wi l l be turned on, then off agai n duri ng the VFD por-
VFD and the cl uster control ci rcui try.
The TCCM conti nual l y moni tors the el ectroni c
transfer case swi tch and ci rcui ts to determi ne the
condi ti on of the system. The TCCM then sends the
ment cl uster. For further di agnosi s of the servi ce
4WD i ndi cator or the i nstrument cl uster ci rcui try
that control s the VFD, (Refer to 8 - ELECTRI CAL/
TESTI NG). For proper di agnosi s of the TCCM, the
PCI data bus, or the el ectroni c message i nputs to the
i nstrument cl uster that control the servi ce 4WD i ndi -
cator, a DRBI I I scan tool i s requi red. Refer to the
SPEEDOMETER
DESCRIPTION
A speedometer i s standard equi pment on al l i nstru-
ment cl usters. The speedometer i s l ocated next to the
tachometer, just to the ri ght of center i n the i nstru-
ment cl uster. The speedometer consi sts of a movabl e
gauge needl e or poi nter control l ed by the i nstrument
cl uster ci rcui try and a fi xed 210 degree pri mary scal e
on the gauge di al face that reads l eft-to-ri ght ei ther
from 0 to 120 mph, or from 0 to 200 km/h,
dependi ng upon the market for whi ch the vehi cl e i s
manufactured. Each versi on al so has a secondary
i nner scal e on the gauge di al face that provi des the
equi val ent opposi te uni ts from the pri mary scal e.
Text appeari ng on the cl uster overl ay just bel ow the
hub of the speedometer needl e abbrevi ates the uni t
of measure for the pri mary scal e (i .e.: MPH or km/h),
fol l owed by the uni t of measure for the secondary
scal e (Fi g. 28). The speedometer graphi cs are bl ack
(pri mary scal e) and bl ue (secondary scal e) agai nst a
whi te fi el d, maki ng them cl earl y vi si bl e wi thi n the
i nstrument cl uster i n dayl i ght. When i l l umi nated
turned On, the bl ack graphi cs appear dark bl ue and
the bl ue graphi cs appear l i ght bl ue. The orange
gauge needl e i s i nternal l y i l l umi nated. Gauge i l l umi -
nati on i s provi ded by repl aceabl e i ncandescent bul b
and bul b hol der uni ts l ocated on the i nstrument cl us-
ter el ectroni c ci rcui t board. The speedometer i s ser-
OPERATION
The speedometer gi ves an i ndi cati on to the vehi cl e
operator of the vehi cl e road speed. Thi s gauge i s con-
Fig. 28 Speedometer Text
SERVICE 4WD INDICATOR (Continued)
Modul e (PCM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The speedometer i s an
ai r core magneti c uni t that recei ves battery current
on the i nstrument cl uster el ectroni c ci rcui t board
through the fused i gni ti on swi tch output (run-start)
ci rcui t whenever the i gni ti on swi tch i s i n the On or
Start posi ti ons. The cl uster i s programmed to move
the gauge needl e back to the l ow end of the scal e
after the i gni ti on swi tch i s turned to the Off posi ti on.
The i nstrument cl uster ci rcui try control s the gauge
needl e posi ti on and provi des the fol l owi ng features:
Vehicle Speed Message - Each ti me the cl us-
ter recei ves a vehi cl e speed message from the PCM i t
wi l l cal cul ate the correct vehi cl e speed readi ng and
posi ti on the gauge needl e at that rel ati ve speed posi -
ti on on the gauge scal e. The cl uster wi l l recei ve a
new vehi cl e speed message and reposi ti on the gauge
poi nter accordi ngl y about every 88 mi l l i seconds. The
gauge needl e wi l l conti nue to be posi ti oned at the
actual vehi cl e speed posi ti on on the gauge scal e unti l
the i gni ti on swi tch i s turned to the Off posi ti on.
recei ve a speedometer message, i t wi l l hol d the gauge
needl e at the l ast i ndi cati on for about three seconds,
ti on, whi chever occurs fi rst. After three seconds, the
gauge needl e wi l l return to the l eft end of the gauge
scal e.
through the actuator test, the speedometer needl e
wi l l be swept to several cal i brati on poi nts on the
The PCM conti nual l y moni tors the vehi cl e speed
sensor to determi ne the vehi cl e road speed. The PCM
then sends the proper vehi cl e speed messages to the
i nstrument cl uster. For further di agnosi s of the
speedometer or the i nstrument cl uster ci rcui try that
control s the gauge, (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND TEST-
I NG). For proper di agnosi s of the vehi cl e speed
sensor, the PCM, the PCI data bus, or the el ectroni c
the speedometer, a DRBI I I scan tool i s requi red.
TACHOMETER
DESCRIPTION
A tachometer i s standard equi pment on al l i nstru-
ment cl usters. The tachometer i s l ocated to the l eft of
the speedometer, just to the l eft of center i n the
i nstrument cl uster. The tachometer consi sts of a
scal e on the gauge di al face that reads l eft-to-ri ght
from 0 to 7 for gasol i ne engi nes. On vehi cl es wi th
a di esel engi ne, the scal e reads from 0 to 5. The
text RPM X 1000 i mpri nted on the cl uster overl ay
di rectl y bel ow the hub of the tachometer needl e i den-
ti fi es that each number on the tachometer scal e i s to
be mul ti pl i ed by 1000 rpm (Fi g. 29). The tachometer
graphi cs are bl ack agai nst a whi te fi el d, maki ng
them cl earl y vi si bl e wi thi n the i nstrument cl uster i n
dayl i ght. When i l l umi nated from behi nd by the panel
l amps di mmer control l ed cl uster i l l umi nati on l i ghti ng
wi th the exteri or l amps turned On, the bl ack graph-
i cs appear bl ue. The orange gauge needl e i s i nter-
nal l y i l l umi nated. Gauge i l l umi nati on i s provi ded by
repl aceabl e i ncandescent bul b and bul b hol der uni ts
l ocated on the i nstrument cl uster el ectroni c ci rcui t
board. The tachometer i s servi ced as a uni t wi th the
i nstrument cl uster.
OPERATION
The tachometer gi ves an i ndi cati on to the vehi cl e
operator of the engi ne speed. Thi s gauge i s control l ed
by the i nstrument cl uster ci rcui t board based upon
cl uster programmi ng and el ectroni c messages
Modul e (PCM) on vehi cl es wi th a gasol i ne engi ne, or
from the Engi ne Control Modul e (ECM) on vehi cl es
equi pped wi th a di esel engi ne over the Programma-
bl e Communi cati ons I nterface (PCI ) data bus. The
tachometer i s an ai r core magneti c uni t that recei ves
battery current on the i nstrument cl uster el ectroni c
ci rcui t board through the fused i gni ti on swi tch out-
put (run-start) ci rcui t whenever the i gni ti on swi tch i s
i n the On or Start posi ti ons. The cl uster i s pro-
grammed to move the gauge needl e back to the l ow
end of the scal e after the i gni ti on swi tch i s turned to
the Off posi ti on. The i nstrument cl uster ci rcui try
control s the gauge needl e posi ti on and provi des the
Engine Speed Message - Each ti me the cl uster
recei ves an engi ne speed message from the PCM or
ECM i t wi l l cal cul ate the correct engi ne speed read-
i ng and posi ti on the gauge needl e at that rel ati ve
speed posi ti on on the gauge scal e. The cl uster wi l l
recei ve a new engi ne speed message and reposi ti on
the gauge poi nter accordi ngl y about every 88 mi l l i -
seconds. The gauge needl e wi l l conti nual l y be reposi -
Fig. 29 Tachometer Text
SPEEDOMETER (Continued)
ti oned at the rel ati ve engi ne speed posi ti on on the
gauge scal e unti l the engi ne stops runni ng, or unti l
the i gni ti on swi tch i s turned to the Off posi ti on,
recei ve an engi ne speed message, i t wi l l hol d the
gauge needl e at the l ast i ndi cati on for about three
seconds, or unti l the i gni ti on swi tch i s turned to the
Off posi ti on, whi chever occurs fi rst. After three sec-
onds, the gauge needl e wi l l return to the l eft end of
the gauge scal e.
through the actuator test, the tachometer needl e wi l l
be swept to several cal i brati on poi nts on the gauge
scal e i n a prescri bed sequence i n order to confi rm the
functi onal i ty of the gauge and the cl uster control ci r-
cui try.
ti nual l y moni tors the crankshaft posi ti on sensor to
determi ne the engi ne speed. On vehi cl es wi th a di e-
sel engi ne, the ECM conti nual l y moni tors the engi ne
speed sensor to determi ne the engi ne speed. The
PCM or ECM then sends the proper engi ne speed
messages to the i nstrument cl uster. For further di ag-
nosi s of the tachometer or the i nstrument cl uster ci r-
cui try that control s the gauge, (Refer to 8 -
crankshaft posi ti on sensor, the engi ne speed sensor,
the PCM, the ECM, the PCI data bus, or the el ec-
control the tachometer, a DRBI I I scan tool i s
mati on.
TOW/HAUL INDICATOR
DESCRIPTION
A tow/haul i ndi cator i s standard equi pment on al l
not equi pped wi th the opti onal overdri ve automati c
transmi ssi on, thi s i ndi cator i s el ectroni cal l y di sabl ed.
The tow/haul i ndi cator consi sts of the text TOW/
HAUL, whi ch appears i n the l ower porti on of the
odometer/tri p odometer i ndi cator Vacuum Fl uores-
cent Di spl ay (VFD) uni t. The VFD i s sol dered onto
the cl uster el ectroni c ci rcui t board and i s vi si bl e
through a wi ndow wi th a smoked cl ear l ens l ocated
on the l ower edge of the tachometer gauge di al face
of the cl uster overl ay. The dark l ens over the VFD
prevents the i ndi cator from bei ng cl earl y vi si bl e
when i t i s not i l l umi nated. The text TOW/HAUL
appear i n an amber col or and at the same l i ghti ng
l evel as the odometer/tri p odometer i nformati on
when they are i l l umi nated by the i nstrument cl uster
el ectroni c ci rcui t board. The tow/haul i ndi cator i s ser-
vi ced as a uni t wi th the VFD i n the i nstrument cl us-
ter.
OPERATION
The tow/haul i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the Off posi ti on of the tow/
haul swi tch has been sel ected, di sabl i ng the el ectron-
i cal l y control l ed overdri ve feature of the automati c
transmi ssi on. Thi s i ndi cator i s control l ed by the
(PCM) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The tow/haul i ndi cator i s
compl etel y control l ed by the i nstrument cl uster l ogi c
ci rcui t, and that l ogi c wi l l onl y al l ow thi s i ndi cator to
put (run-start) ci rcui t. Therefore, the i ndi cator wi l l
ti on except On or Start. The i ndi cator onl y i l l umi -
nates when i t i s swi tched to ground by the
i nstrument cl uster ci rcui try. The i nstrument cl uster
wi l l turn on the tow/haul off i ndi cator for the fol l ow-
i ng reasons:
Tow/Haul Lamp-On Message - Each ti me the
cl uster recei ves a tow/haul l amp-on message from the
PCM i ndi cati ng that the Off posi ti on of the tow/haul
swi tch has been sel ected, the tow/haul i ndi cator wi l l
unti l the cl uster recei ves a tow/haul l amp-off mes-
sage from the PCM, or unti l the i gni ti on swi tch i s
through the actuator test, the tow/haul i ndi cator wi l l
The PCM conti nual l y moni tors the tow/haul swi tch
to determi ne the proper outputs to the automati c
transmi ssi on. The PCM then sends the proper tow/
haul l amp-on and l amp-off messages to the i nstru-
ment cl uster. For further di agnosi s of the tow/haul
TESTI NG). For proper di agnosi s of the overdri ve con-
trol system, the PCM, the PCI data bus, or the el ec-
control the tow/haul i ndi cator, a DRBI I I scan tool i s
Fig. 30 Tow/Haul Indicator
TACHOMETER (Continued)
mati on.
TRANS TEMP INDICATOR
DESCRIPTION
A transmi ssi on over-temperature i ndi cator i s stan-
dard equi pment on al l i nstrument cl usters (Fi g. 31).
However, on vehi cl es not equi pped wi th an opti onal
automati c transmi ssi on, thi s i ndi cator i s el ectroni -
cal l y di sabl ed. The transmi ssi on over-temperature
i ndi cator i s l ocated on the l eft si de of the i nstrument
cl uster, to the l eft of the fuel gauge. The transmi ssi on
over-temperature i ndi cator consi sts of a stenci l -l i ke
cutout of the words TRANS TEMP i n the opaque
bei ng cl earl y vi si bl e when i t i s not i l l umi nated. A red
opaque l ayer of the overl ay causes the TRANS
TEMP text to appear i n red through the transl ucent
outer l ayer of the overl ay when the i ndi cator i s i l l u-
mi nated from behi nd by the LED, whi ch i s sol dered
onto the i nstrument cl uster el ectroni c ci rcui t board.
The transmi ssi on over-temperature i ndi cator i s ser-
OPERATION
The transmi ssi on over-temperature i ndi cator gi ves
an i ndi cati on to the vehi cl e operator when the trans-
mi ssi on fl ui d temperature i s excessi ve, whi ch may
l ead to accel erated transmi ssi on component wear or
fai l ure. Thi s i ndi cator i s control l ed by a transi stor on
(PCM) over the Programmabl e Communi cati ons
I nterface (PCI ) data bus. The transmi ssi on over-tem-
perature i ndi cator Li ght Emi tti ng Di ode (LED) i s
turn on the transmi ssi on over-temperature i ndi cator
turned to the On posi ti on the transmi ssi on over-tem-
perature i ndi cator i s i l l umi nated for about two sec-
Trans Over-Temp Lamp-On Message - Each
ti me the cl uster recei ves a trans over-temp l amp-on
message from the PCM i ndi cati ng that the transmi s-
si on fl ui d temperature i s 135 C (275 F) or hi gher,
the i ndi cator wi l l be i l l umi nated and a si ngl e chi me
tone i s sounded. The i ndi cator remai ns i l l umi nated
unti l the cl uster recei ves a trans over-temp l amp-off
message from the PCM, or unti l the i gni ti on swi tch
i s turned to the Off posi ti on, whi chever occurs fi rst.
The chi me tone feature wi l l onl y repeat duri ng the
same i gni ti on cycl e i f the transmi ssi on over-tempera-
ture i ndi cator i s cycl ed off and then on agai n by the
appropri ate trans over-temp messages from the PCM.
through the actuator test, the transmi ssi on over-tem-
perature i ndi cator wi l l be turned on, then off agai n
duri ng the bul b check porti on of the test to confi rm
the functi onal i ty of the LED and the cl uster control
ci rcui try.
The PCM conti nual l y moni tors the transmi ssi on
temperature sensor to determi ne the transmi ssi on
operati ng condi ti on. The PCM then sends the proper
trans over-temp l amp-on or l amp-off messages to the
i nstrument cl uster. I f the i nstrument cl uster turns on
the transmi ssi on over-temperature i ndi cator due to a
hi gh transmi ssi on oi l temperature condi ti on, i t may
i ndi cate that the transmi ssi on and/or the transmi s-
si on cool i ng system are bei ng overl oaded or that they
requi re servi ce. For further di agnosi s of the trans-
mi ssi on over-temperature i ndi cator or the i nstrument
cl uster ci rcui try that control s the LED, (Refer to 8 -
transmi ssi on temperature sensor, the PCM, the PCI
data bus, or the el ectroni c message i nputs to the
i nstrument cl uster that control the transmi ssi on
over-temperature i ndi cator, a DRBI I I scan tool i s
mati on.
TURN SIGNAL INDICATOR
DESCRIPTION
Two turn si gnal i ndi cators, one ri ght and one l eft,
are standard equi pment on al l i nstrument cl usters
(Fi g. 32). The turn si gnal i ndi cators are l ocated near
Fig. 31 Transmission Overtemp Indicator
Fig. 32 Turn Signal Indicators
TOW/HAUL INDICATOR (Continued)
the upper edge of the i nstrument cl uster, between
the speedometer and the tachometer. Each turn si g-
nal i ndi cator consi sts of a stenci l -l i ke cutout of the
I nternati onal Control and Di spl ay Symbol i con for
Turn Warni ng i n the opaque l ayer of the i nstru-
ment cl uster overl ay. The dark outer l ayer of the
overl ay prevents these i cons from bei ng cl earl y vi si -
bl e when they are not i l l umi nated. A green Li ght
Emi tti ng Di ode (LED) behi nd each turn si gnal i ndi -
cator cutout i n the opaque l ayer of the overl ay causes
the i con to appear i n green through the transl ucent
outer l ayer of the overl ay when the i ndi cator i s i l l u-
mi nated from behi nd by the LED, whi ch i s sol dered
onto the i nstrument cl uster el ectroni c ci rcui t board.
The turn si gnal i ndi cators are servi ced as a uni t wi th
OPERATION
The turn si gnal i ndi cators gi ve an i ndi cati on to the
vehi cl e operator that the turn si gnal (l eft or ri ght
i ndi cator fl ashi ng) or hazard warni ng (both l eft and
ri ght i ndi cators fl ashi ng) have been sel ected and are
operati ng. These i ndi cators are control l ed by transi s-
tors on the i nstrument cl uster el ectroni c ci rcui t board
based upon the cl uster programmi ng, a hard wi red
mul ti pl ex i nput recei ved by the cl uster from the turn
si gnal and hazard warni ng swi tch ci rcui try of the
mul ti -functi on swi tch on the turn/hazard swi tch mux
ci rcui t, and el ectroni c messages recei ved from the
Front Control Modul e (FCM) over the Programmabl e
Communi cati ons I nterface (PCI ) data bus. Each turn
si gnal i ndi cator Li ght Emi tti ng Di ode (LED) i s com-
cui t, and that l ogi c wi l l al l ow thi s i ndi cator to
operate whenever the i nstrument cl uster recei ves a
battery current i nput on the fused B(+) ci rcui t.
Therefore, each LED can be i l l umi nated regardl ess of
the i gni ti on swi tch posi ti on. The LED onl y i l l umi -
nates when i t i s provi ded a path to ground by the
i nstrument cl uster transi stor. The i nstrument cl uster
wi l l turn on the turn si gnal i ndi cators for the fol l ow-
i ng reasons:
Turn Signal-On Input - Each ti me the cl uster
detects a turn si gnal -on i nput from the turn si gnal
swi tch ci rcui try of the mul ti -functi on swi tch on the
turn/hazard swi tch mux ci rcui t, the requested turn
si gnal l amps and turn si gnal i ndi cator wi l l be fl ashed
on and off, and an el ectromechani cal rel ay sol dered
onto the cl uster el ectroni c ci rcui t board wi l l produce
a cl i cki ng sound to emul ate a conventi onal turn si g-
nal fl asher. The turn si gnal s and the turn si gnal
i ndi cators conti nue to fl ash on and off unti l the cl us-
ter recei ves a turn si gnal -off i nput from the mul ti -
functi on swi tch, or unti l the i gni ti on swi tch i s turned
to the Off posi ti on, whi chever occurs fi rst.
Hazard Warning-On Input - Each ti me the
cl uster detects a hazard warni ng-on i nput from the
hazard warni ng swi tch ci rcui try of the mul ti -functi on
swi tch on the turn/hazard swi tch mux ci rcui t, al l of
the turn si gnal l amps and both turn si gnal i ndi cators
wi l l be fl ashed on and off, and an el ectromechani cal
rel ay sol dered onto the cl uster el ectroni c ci rcui t
board wi l l produce a cl i cki ng sound to emul ate a con-
venti onal hazard warni ng fl asher. The turn si gnal s
and the turn si gnal i ndi cators conti nue to fl ash on
and off unti l the cl uster recei ves a hazard warni ng-
off i nput from the mul ti -functi on swi tch.
Lamp Out Mode - The i nstrument cl uster al so
sends el ectroni c turn si gnal on and off messages to
the FCM over the PCI data bus, and the FCM
fl ashes the appropri ate exteri or turn si gnal l amps. I f
the FCM detects an i noperati ve turn si gnal l amp or
ci rcui t, i t i ncreases the fl ash rate for the remai ni ng
operati ve turn si gnal s and sends an el ectroni c mes-
sage back to the i nstrument cl uster. The i nstrument
cl uster then i ncreases the fl ash rate of the turn si g-
nal i ndi cator(s) and the cl i cki ng rate of the el ectro-
mechani cal rel ay to provi de an i ndi cati on of the
probl em to the vehi cl e operator.
through the actuator test, the turn si gnal i ndi cators
of each LED and the cl uster control ci rcui try.
mul ti -functi on swi tch and el ectroni c messages from
the FCM to determi ne the proper turn si gnal and
hazard warni ng system control . For further di agnosi s
of the turn si gnal i ndi cators or the i nstrument cl us-
ter ci rcui try that control s the i ndi cators, (Refer to 8 -
turn si gnal and hazard warni ng system, the mul ti -
functi on swi tch, the FCM, the PCI data bus, or the
that control the turn si gnal i ndi cators, a DRBI I I
scan tool i s requi red. Refer to the appropri ate di ag-
UPSHIFT INDICATOR
DESCRIPTION
An upshi ft i ndi cator i s standard equi pment on al l
not equi pped wi th a manual transmi ssi on, thi s i ndi -
Fig. 33 Upshift Indicator
TURN SIGNAL INDICATOR (Continued)
cator i s el ectroni cal l y di sabl ed. The upshi ft i ndi cator
consi sts of an upward poi nted arrow i con, whi ch
appears on the ri ght si de of the el ectroni c gear sel ec-
tor i ndi cator Vacuum Fl uorescent Di spl ay (VFD)
uni t. The VFD i s sol dered onto the cl uster el ectroni c
ci rcui t board and i s vi si bl e through a wi ndow wi th a
speedometer gauge di al face of the cl uster overl ay.
The dark l ens over the VFD prevents the i ndi cator
The i con appears i n a bl ue-green col or and at the
same l i ghti ng l evel as the odometer/tri p odometer
cl uster el ectroni c ci rcui t board. The upshi ft i ndi cator
i s servi ced as a uni t wi th the i nstrument cl uster.
OPERATION
The upshi ft i ndi cator gi ves an i ndi cati on to the
vehi cl e operator when the manual transmi ssi on
shoul d be shi fted to the next hi ghest gear i n order to
achi eve the best fuel economy. Thi s i ndi cator i s con-
Modul e (PCM) on vehi cl es wi th a gasol i ne engi ne, or
from the Engi ne Control Modul e (ECM) on vehi cl es
wi th a di esel engi ne over the Programmabl e Commu-
ni cati ons I nterface (PCI ) data bus. The upshi ft i ndi -
cator i s compl etel y control l ed by the i nstrument
cl uster l ogi c ci rcui t, and that l ogi c wi l l onl y al l ow
thi s i ndi cator to operate when the i nstrument cl uster
recei ves a battery current i nput on the fused i gni ti on
swi tch output (run-start) ci rcui t. Therefore, the i ndi -
cator wi l l al ways be off when the i gni ti on swi tch i s i n
any posi ti on except On or Start. The i ndi cator onl y
i l l umi nates when i t i s swi tched to ground by the
wi l l turn on the upshi ft i ndi cator for the fol l owi ng
reasons:
Upshift Lamp-On Message - Each ti me the
cl uster recei ves an upshi ft l amp-on message from the
PCM or ECM i ndi cati ng the engi ne speed and l oad
condi ti ons are ri ght for a transmi ssi on upshi ft to
occur, the upshi ft i ndi cator i s i l l umi nated. The i ndi -
cator remai ns i l l umi nated unti l the cl uster recei ves
an upshi ft l amp-off message from the PCM or ECM,
ti on, whi chever occurs fi rst. The PCM or ECM wi l l
normal l y send an upshi ft l amp-off message three to
fi ve seconds after a l amp-on message, i f an upshi ft i s
not performed. The i ndi cator wi l l then remai n off
unti l the vehi cl e stops accel erati ng and i s brought
back i nto the range of i ndi cator operati on, or unti l
the transmi ssi on i s shi fted i nto another gear.
through the actuator test, the upshi ft i ndi cator wi l l
ti nual l y moni tors the engi ne speed and l oad condi -
ti ons to determi ne the proper fuel and i gni ti on
requi rements. On vehi cl es wi th a di esel engi ne, the
ECM conti nual l y moni tors the engi ne speed and l oad
condi ti ons to determi ne the proper fuel requi rements.
The PCM or ECM then sends the proper upshi ft i ndi -
cator l amp-on and l amp-off messages to the i nstru-
ment cl uster. For further di agnosi s of the upshi ft
TESTI NG). For proper di agnosi s of the PCM, the
ECM, the PCI data bus, or the el ectroni c message
upshi ft i ndi cator, a DRBI I I scan tool i s requi red.
VOLTAGE GAUGE
DESCRIPTION
A vol tage gauge i s standard equi pment on al l
i nstrument cl usters. The vol tage gauge i s l ocated i n
the upper l eft quadrant of the i nstrument cl uster,
above the fuel gauge. The vol tage gauge consi sts of a
scal e on the cl uster overl ay that reads l eft-to-ri ght
from L (or Low) to H (or Hi gh) for gasol i ne
engi nes. On vehi cl es wi th a di esel engi ne, the scal e
reads from 8 to 18 vol ts. An I nternati onal Control
and Di spl ay Symbol i con for Battery Chargi ng Con-
di ti on i s l ocated on the cl uster overl ay, di rectl y
bel ow the ri ght end of the gauge scal e (Fi g. 34). The
vol tage gauge graphi cs are bl ack agai nst a whi te
fi el d except for a si ngl e red graduati on at each end of
the gauge scal e, maki ng them cl earl y vi si bl e wi thi n
the i nstrument cl uster i n dayl i ght. When i l l umi nated
turned On, the bl ack graphi cs appear bl ue and the
red graphi cs sti l l appear red. The orange gauge nee-
dl e i s i nternal l y i l l umi nated. Gauge i l l umi nati on i s
provi ded by repl aceabl e i ncandescent bul b and bul b
troni c ci rcui t board. The vol tage gauge i s servi ced as
a uni t wi th the i nstrument cl uster.
Fig. 34 Battery Charging Condition Icon
UPSHIFT INDICATOR (Continued)
OPERATION
The vol tage gauge gi ves an i ndi cati on to the vehi -
cl e operator of the el ectri cal system vol tage. Thi s
Powertrai n Control Modul e (PCM) on vehi cl es
equi pped wi th a gasol i ne engi ne, or from the Engi ne
Control Modul e (ECM) on vehi cl es equi pped wi th a
di esel engi ne over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The vol tage gauge i s
an ai r core magneti c uni t that recei ves battery cur-
rent on the i nstrument cl uster el ectroni c ci rcui t
board through the fused i gni ti on swi tch output (run-
start) ci rcui t whenever the i gni ti on swi tch i s i n the
On or Start posi ti ons. The cl uster i s programmed to
move the gauge needl e back to the l eft end of the
scal e after the i gni ti on swi tch i s turned to the Off
posi ti on. The i nstrument cl uster ci rcui try control s
the gauge needl e posi ti on and provi des the fol l owi ng
features:
System Voltage Message - Each ti me the cl us-
ter recei ves a system vol tage message from the PCM
or ECM i ndi cati ng the system vol tage i s between
about 9.5 vol ts and about 15 vol ts, the gauge needl e
i s moved to the rel ati ve vol tage posi ti on on the gauge
scal e.
System Voltage Low (Charge Fail) Message
- Each ti me the cl uster recei ves three consecuti ve
messages from the PCM or ECM i ndi cati ng the el ec-
tri cal system vol tage i s l ess than about 9 vol ts
(charge fai l condi ti on), the gauge needl e i s moved to
the graduati on on the far l eft end of the gauge scal e
and the check gauges i ndi cator i s i l l umi nated. The
gauge needl e remai ns at the far l eft end of the gauge
scal e and the check gauges i ndi cator remai ns i l l umi -
nated unti l the cl uster recei ves a si ngl e message
from the PCM or ECM i ndi cati ng the el ectri cal sys-
tem vol tage i s greater than about 9.5 vol ts (but l ess
than about 15.5 vol ts), or unti l the i gni ti on swi tch i s
turned to the Off posi ti on, whi chever occurs fi rst. On
vehi cl es equi pped wi th the opti onal di esel engi ne, the
ECM i s programmed to restri ct the vol tage gauge
needl e to a posi ti on above the graduati on on the far
l eft end of the gauge scal e and suppress the check
engi ne i ndi cator operati on unti l after the engi ne
i ntake mani fol d ai r heater has compl eted a pre-heat
or post-heat cycl e.
System Voltage High Message - Each ti me
the cl uster recei ves three consecuti ve messages from
the PCM or ECM i ndi cati ng the el ectri cal system
vol tage i s greater than about 15.5 vol ts, the gauge
needl e i s moved to the graduati on on the far ri ght
end of the gauge scal e and the check gauges i ndi ca-
tor i s i l l umi nated. The gauge needl e remai ns at the
ri ght end of the gauge scal e and the check gauges
the el ectri cal system vol tage i s l ess than about 15.0
vol ts (but greater than about 9.5 vol ts), or unti l the
ever occurs fi rst.
recei ve a system vol tage message, i t wi l l hol d the
gauge needl e at the l ast i ndi cati on for about fi ve sec-
onds or unti l the i gni ti on swi tch i s turned to the Off
posi ti on, whi chever occurs fi rst. After fi ve seconds,
the cl uster wi l l move the gauge needl e to the far l eft
end of the gauge scal e.
through the actuator test, the vol tage gauge needl e
wi l l be swept to several cal i brati on poi nts on the
ti nual l y moni tors the system vol tage to control the
generator output. On vehi cl es wi th a di esel engi ne,
the ECM conti nual l y moni tors the system vol tage to
control the generator output. The PCM or ECM then
sends the proper system vol tage messages to the
i nstrument cl uster. For further di agnosi s of the vol t-
age gauge or the i nstrument cl uster ci rcui try that
control s the gauge, (Refer to 8 - ELECTRI CAL/I N-
STRUMENT CLUSTER - DI AGNOSI S AND TEST-
I NG). I f the i nstrument cl uster turns on the check
gauges i ndi cator due to a charge fai l or vol tage hi gh
condi ti on, i t may i ndi cate that the chargi ng system
requi res servi ce. For proper di agnosi s of the chargi ng
system, the PCM, the ECM, the PCI data bus, or the
that control the vol tage gauge, a DRBI I I scan tool i s
mati on.
VOLTAGE GAUGE (Continued)
WAIT-TO-START INDICATOR
DESCRIPTION
A wai t-to-start i ndi cator i s onl y found i n the
i nstrument cl usters for vehi cl es equi pped wi th an
opti onal di esel engi ne (Fi g. 35). The wai t-to-start
ometer. The wai t-to-start i ndi cator consi sts of stenci l -
l i ke cutout of the I nternati onal Control and Di spl ay
Symbol i con for Di esel Preheat i n the opaque l ayer
of the i nstrument cl uster overl ay. The dark outer
l ayer of the overl ay prevents the i ndi cator from bei ng
cl earl y vi si bl e when i t i s not i l l umi nated. An amber
i n amber through the transl ucent outer l ayer of the
i nstrument cl uster el ectroni c ci rcui t board. The wai t-
to-start i ndi cator i s servi ced as a uni t wi th the
OPERATION
The wai t-to-start i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when the ai r temperature wi thi n
the di esel engi ne i ntake mani fol d i s too cool for effi -
ci ent and rel i abl e engi ne starti ng, and that the
i ntake ai r heater gri ds are energi zed i n thei r pre-
heat operati ng mode. Thi s i ndi cator i s control l ed by a
sages recei ved by the cl uster from the Engi ne Control
Modul e (ECM) over the Programmabl e Communi ca-
ti ons I nterface (PCI ) data bus. The wai t-to-start i ndi -
cator Li ght Emi tti ng Di ode (LED) i s compl etel y
control l ed by the i nstrument cl uster l ogi c ci rcui t, and
start) ci rcui t. Therefore, the LED wi l l al ways be off
when the i gni ti on swi tch i s i n any posi ti on except On
or Start. The LED onl y i l l umi nates when i t i s pro-
vi ded a path to ground by the i nstrument cl uster
wai t-to-start i ndi cator for the fol l owi ng reasons:
Wait-To-Start Lamp-On Message - Each ti me
the cl uster recei ves a wai t-to-start l amp-on message
from the ECM i ndi cati ng that the ai r temperature
wi thi n the i ntake mani fol d i s too cool for effi ci ent
and rel i abl e engi ne starti ng, the wai t-to-start i ndi ca-
tor wi l l be i l l umi nated. The i ndi cator remai ns i l l umi -
nated unti l the cl uster recei ves a wai t-to-start l amp-
off message, unti l the ECM detects that the engi ne i s
runni ng or unti l the i gni ti on swi tch i s turned to the
through the actuator test, the wai t-to-start i ndi cator
The ECM conti nual l y moni tors the engi ne i ntake
ai r temperature sensor to determi ne when the i ntake
ai r heater gri ds shoul d be energi zed i n thei r pre-heat
operati ng mode. The ECM then sends the proper
wai t-to-start l amp-on and l amp-off messages to the
i nstrument cl uster. For further di agnosi s of the wai t-
to-start i ndi cator or the i nstrument cl uster ci rcui try
that control s the i ndi cator, (Refer to 8 - ELECTRI -
TESTI NG). For proper di agnosi s of the engi ne i ntake
ai r temperature sensor, the i ntake ai r heater gri d
control ci rcui ts, the ECM, the PCI data bus, or the
that control the wai t-to-start i ndi cator, a DRBI I I
WASHER FLUID INDICATOR
DESCRIPTION
A washer fl ui d i ndi cator i s standard equi pment on
al l i nstrument cl usters. The washer fl ui d i ndi cator
consi sts of the words LOW WASH, whi ch appear i n
the l ower porti on of the odometer/tri p odometer Vac-
uum-Fl uorescent Di spl ay (VFD) uni t (Fi g. 36). The
VFD i s sol dered onto the cl uster el ectroni c ci rcui t
board and i s vi si bl e through a wi ndow wi th a smoked
cl ear l ens l ocated on the l ower edge of the tachome-
ter gauge di al face of the cl uster overl ay. The dark
l ens over the VFD prevents the i ndi cator from bei ng
cl earl y vi si bl e when i t i s not i l l umi nated. The LOW
WASH text appears i n an amber col or and at the
same l i ghti ng l evel as the odometer/tri p odometer
cl uster el ectroni c ci rcui t board. The washer fl ui d
i ndi cator i s servi ced as a uni t wi th the VFD i n the
OPERATION
The washer fl ui d i ndi cator gi ves an i ndi cati on to
the vehi cl e operator that the fl ui d l evel i n the washer
Fig. 35 Wait-To-Start Indicator
Fig. 36 Washer Fluid Indicator
reservoi r i s l ow. Thi s i ndi cator i s control l ed by the
the cl uster from the Front Control Modul e (FCM)
(PCI ) data bus. The washer fl ui d i ndi cator i s com-
cui t, and that l ogi c wi l l onl y al l ow thi s i ndi cator to
put (run-start) ci rcui t. Therefore, the i ndi cator wi l l
ti on except On or Start. The i ndi cator onl y i l l umi -
nates when i t i s swi tched to ground by the
wi l l turn on the washer fl ui d i ndi cator for the fol l ow-
i ng reasons:
Washer Fluid Indicator Lamp-On Message -
Each ti me the cl uster recei ves a washer fl ui d i ndi ca-
tor l amp-on message from the FCM i ndi cati ng that a
l ow washer condi ti on has been detected for si xty con-
secuti ve seconds, the washer fl ui d i ndi cator i s i l l umi -
nated and a si ngl e chi me tone i s sounded. The
recei ves a washer fl ui d i ndi cator l amp-off message
for si xty consecuti ve seconds from the FCM or unti l
the i gni ti on swi tch i s turned to the Off posi ti on,
whi chever occurs fi rst. The chi me tone feature wi l l
onl y repeat duri ng the same i gni ti on cycl e i f the
washer fl ui d i ndi cator i s cycl ed off and then on agai n
by the appropri ate washer fl ui d l amp messages from
the FCM.
through the actuator test, the washer fl ui d i ndi cator
wi l l be turned on, then off agai n duri ng the VFD por-
VFD and the cl uster control ci rcui try.
The FCM conti nual l y moni tors the washer fl ui d
l evel swi tch i n the washer reservoi r to determi ne the
l evel of the washer fl ui d. The FCM then sends the
proper washer fl ui d i ndi cator l amp-on and l amp-off
messages to the i nstrument cl uster. For further di ag-
nosi s of the washer fl ui d i ndi cator or the i nstrument
cl uster ci rcui try that control s the i ndi cator, (Refer to
8 - ELECTRI CAL/I NSTRUMENT CLUSTER - DI AG-
NOSI S AND TESTI NG). For proper di agnosi s of the
washer fl ui d l evel swi tch, the FCM, the PCI data
ment cl uster that control the washer fl ui d i ndi cator,
a DRBI I I scan tool i s requi red. Refer to the appro-
WATER-IN-FUEL INDICATOR
DESCRIPTION
A water-i n-fuel i ndi cator i s onl y found i n the
i nstrument cl usters for vehi cl es equi pped wi th an
opti onal di esel engi ne (Fi g. 37). The water-i n-fuel
ometer. The water-i n-fuel i ndi cator consi sts of stenci l -
l i ke cutout of the I nternati onal Control and Di spl ay
Symbol i con for Water I n Fuel i n the opaque l ayer
of the i nstrument cl uster overl ay. The dark outer
l ayer of the overl ay prevents the i ndi cator from bei ng
cl earl y vi si bl e when i t i s not i l l umi nated. A red Li ght
Emi tti ng Di ode (LED) behi nd the cutout i n the
i n red through the transl ucent outer l ayer of the
i nstrument cl uster el ectroni c ci rcui t board. The
water-i n-fuel i ndi cator i s servi ced as a uni t wi th the
OPERATION
The water-i n-fuel i ndi cator gi ves an i ndi cati on to
the vehi cl e operator when there i s excessi ve water i n
the fuel system. Thi s i ndi cator i s control l ed by a
based upon the cl uster programmi ng and el ectroni c
messages recei ved by the cl uster from the Engi ne
Control Modul e (ECM) over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus. The water-i n-
fuel i ndi cator Li ght Emi tti ng Di ode (LED) i s
turn on the water-i n-fuel i ndi cator for the fol l owi ng
reasons:
turned to the On posi ti on the water-i n-fuel i ndi cator
i s i l l umi nated for about two seconds as a bul b test.
Water-In-Fuel Lamp-On Message - Each ti me
the cl uster recei ves a water-i n-fuel l amp-on message
from the ECM i ndi cati ng that there i s excessi ve
Fig. 37 Water-In-Fuel Indicator
WASHER FLUID INDICATOR (Continued)
water i n the di esel fuel system, the water-i n-fuel
i ndi cator wi l l be i l l umi nated. The i ndi cator remai ns
i l l umi nated unti l the cl uster recei ves a water-i n-fuel
l amp-off message, or unti l the i gni ti on swi tch i s
through the actuator test, the water-i n-fuel i ndi cator
The ECM conti nual l y moni tors the water-i n-fuel
sensor to determi ne whether there i s excessi ve water
i n the di esel fuel system. The ECM then sends the
proper water-i n-fuel l amp-on and l amp-off messages
to the i nstrument cl uster. For further di agnosi s of
the water-i n-fuel i ndi cator or the i nstrument cl uster
ci rcui try that control s the i ndi cator, (Refer to 8 -
water-i n-fuel sensor, the ECM, the PCI data bus, or
ter that control the water-i n-fuel i ndi cator, a
DRBI I I scan tool i s requi red. Refer to the appropri -
WATER-IN-FUEL INDICATOR (Continued)
LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . . . . . 1 LAMPS/LIGHTING - INTERIOR. . . . . . . . . . . . . . . 26
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - LAMPS/
LIGHTING - EXTERIOR . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . 7
BACKUP LAMP
REMOVAL
REMOVAL - WITH CARGO BOX . . . . . . . . . . . 7
REMOVAL - WITHOUT CARGO BOX . . . . . . . . 7
INSTALLATION
INSTALLATION - WITH CARGO BOX . . . . . . . . 7
INSTALLATION - WITHOUT CARGO BOX . . . . 8
BACKUP LAMP SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - BACKUP LAMP
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BRAKE LAMP
REMOVAL
REMOVAL - WITH CARGO BOX . . . . . . . . . . . 9
REMOVAL - WITHOUT CARGO BOX . . . . . . . . 9
INSTALLATION
INSTALLATION - WITH CARGO BOX . . . . . . . . 9
INSTALLATION - WITHOUT CARGO BOX . . . . 9
BRAKE LAMP SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
CENTER HIGH MOUNTED STOP LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
CENTER HIGH MOUNTED STOP LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
CAB CLEARANCE LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
FOG LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
FOG LAMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
HAZARD SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HEADLAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
HEADLAMP SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
HEADLAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 16
LICENSE PLATE LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
LICENSE PLATE LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
DR LAMPS 8L - 1
MARKER LAMP UNIT
REMOVAL
REMOVAL - FENDER MARKER LAMP . . . . . . 17
REMOVAL - TAILGATE MARKER LAMP . . . . . 18
INSTALLATION
INSTALLATION - FENDER MARKER LAMP . . 18
INSTALLATION - TAILGATE MARKER LAMP . 18
MULTI-FUNCTION SWITCH
DESCRIPTION - TURN SIGNAL SYSTEM . . . . . 18
OPERATION - TURN SIGNAL SYSTEM . . . . . . . 18
DIAGNOSIS AND TESTING - MULTI-
FUNCTION SWITCH . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
PARK LAMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - PARK LAMP
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
PARK/TURN SIGNAL LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
TAIL LAMP
REMOVAL
REMOVAL - WITH CARGO BOX . . . . . . . . . . 22
REMOVAL - WITHOUT CARGO BOX . . . . . . . 22
INSTALLATION
INSTALLATION - WITH CARGO BOX . . . . . . . 22
INSTALLATION - WITHOUT CARGO BOX . . . 22
TAIL LAMP UNIT
REMOVAL
INSTALLATION
TRAILER TOW WIRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
TURN LAMP
REMOVAL
INSTALLATION
UNDERHOOD LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
UNDERHOOD LAMP UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
DESCRIPTION
The exteri or l i ghti ng system for thi s model i ncl ude
the fol l owi ng components:
Backup Lamps
Brake Lamps
Dayti me Runni ng Lamps
Front Fog Lamps
Hazard Warni ng Lamps
Headl amps
Park Lamps
Turn Si gnal Lamps
Other components of the exteri or l i ghti ng system
for thi s model i ncl ude:
Backup Lamp Swi tch
Brake Lamp Swi tch
Front Control Modul e
Front Fog Lamp Rel ay
Hazard Swi tch
Mul ti -Functi on Swi tch
Park Lamp Rel ay
Trai l er Tow Connectors
Some of the i nteri or and exteri or l i ghti ng functi ons
are governed by the front control modul e. The head-
l amp, dome, and door ajar swi tchs provi de si gnal s to
the i nstrument cl uster. The i nstrument cl uster sends
a J1850 message to the front control modul e to
enabl e the necessary components for i l l umi nati on.
Hard wi red ci rcui try connects the exteri or l i ghti ng
system components to the el ectri cal system of the
vehi cl e. Refer to the appropri ate wi ri ng i nformati on.
OPERATION
DAYTIME RUNNING LAMPS
Power i s reduced usi ng pul se-wi dth modul ati on to
the hi gh beams, where by the power i s swi tched on
and off rapi dl y i nstead of remai ni ng on conti nuousl y.
The durati on and i nterval of the power pul ses i s pro-
grammed i nto the Front Control Modul e (FCM).
HEADLAMP SYSTEM
The i nstrument cl uster moni tors both the mul ti -
pl exed headl amp and mul ti functi on swi tches. The
i nstrument cl uster transmi ts a J1850 bus message to
the front control modul e (FCM) to acti vate the head-
l amps. The headl amp system wi l l defaul t to head-
l amps ON posi ti on when i gni ti on swi tch i s ON and
when an open or short ci rcui t fai l ure occurs on the
headl amp swi tch i nput to the i nstrument cl uster. The
system wi l l return to normal operati on when the
open or short i s repai red. A faul t wi l l be reported by
the I nstrument Cl uster when a fai l ure occurs on the
di mmer or headl amp swi tch i nput.
I f the exteri or l amps are ON, and the headl amp
swi tch i s i n any posi ti on other than OFF, wi th the
i gni ti on swi tch OFF (LOCK) after 5 mi nutes, the
8L - 2 LAMPS/LIGHTING - EXTERIOR DR
I nstrument Cl uster transmi ts a message vi a J1850
i nformi ng the the FCM. The FCM wi l l then turn off
the headl amps, park l amps and fog l amps. Thi s fea-
ture (l oad shed) prevents the vehi cl e battery from
bei ng di scharged when the vehi cl e l i ghts have been
l eft ON.
HEADLAMP TIME DELAY SYSTEM
The headl amp ti me del ay system i s acti vated by
turni ng the headl amps ON (hi gh or l ow beam) whi l e
the engi ne i s runni ng, turni ng the i gni ti on swi tch
OFF, and then turni ng the headl amp swi tch OFF
wi thi n 45 seconds. The system wi l l not acti vate i f
more than 45 seconds el apse between i gni ti on swi tch
OFF and headl amp swi tch OFF. The FCM wi l l al l ow
the headl amps to remai n ON for 60 seconds (confi g-
urabl e) before they automati cal l y turn off (I f the key
i s i n the i gni ti on duri ng the headl amp ti me del ay
mode, then the headl amps i ncl udi ng panel di mmi ng
wi l l be ON).
LAMP OUTAGE
I f one or more of the fol l owi ng l amps (Low and/or
Hi gh beams, Brake and/or Turn Si gnal ) are out, then
a l amps out i ndi cator l ocated i n the cl uster wi l l
i l l umi nate.
OPTICAL HORN/HIGH BEAMS
When the mul ti pl exed mul ti functi on swi tch i s
pul l ed to the fi rst detent (opti cal horn) si gnal , the
headl amps are ON, the I nstrument Cl uster shal l
send a message vi a J1850 to the FCM to turn on the
headl amps dri vers to i l l umi nate al l four fi l aments
(Low and Hi gh beams). When the mul ti functi on
swi tch i s pul l ed to the second detent (hi gh beam) si g-
nal and the headl amps are ON, the I nstrument Cl us-
ter shal l send a message vi a J1850 to the FCM to
turn on the headl amps dri vers. The Hi gh Beams are
i l l umi nated and the Low Beams and Fog Lamps (i f
ON) are exti ngui shed. I f the headl amps were i n the
hi gh beam confi gurati on when power was removed
from the headl amps, the headl amps wi l l return to
thei r l ast state pri or to bei ng shut off.
DIAGNOSIS AND TESTING - LAMPS/LIGHTING
- EXTERIOR
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result. Do not use bulbs other than
those indicated in the Bulb Application table. Dam-
age to lamp and/or Daytime Running Lamp Module
can result. Do not use fuses, circuit breakers or
relays having greater amperage value than indi-
cated on the fuse panel or in the Owners Manual.
When a vehi cl e experi ences probl ems wi th the
headl amp system, veri fy the condi ti on of the battery
connecti ons, fuses, chargi ng system, headl amp bul bs,
wi re connectors, rel ay, mul ti functi on swi tch, and
headl amp swi tch. Refer to the appropri ate wi ri ng
i nformati on.
Each vehi cl e i s equi pped wi th vari ous l amp assem-
bl i es. A good ground i s necessary for proper l i ghti ng
operati on. Groundi ng i s provi ded by the l amp socket
when i t comes i n contact wi th the metal body, or
through a separate ground wi re.
When changi ng l amp bul bs check the socket for
l oose pi n connecti ons and corrosi on. Repai r as neces-
sary.
When i t i s necessary to remove components to ser-
vi ce another, i t shoul d not be necessary to appl y
excessi ve force or bend a component to remove i t.
Before damagi ng a tri m component, veri fy hi dden
fasteners or captured edges are not hol di ng the com-
ponent i n pl ace.
DR LAMPS/LIGHTING - EXTERIOR 8L - 3
LAMPS/LIGHTING - EXTERIOR (Continued)
HEADLAMP DIAGNOSIS
HEADLAMPS ARE DIM
WITH ENGINE IDLING
OR IGNITION TURNED
OFF
1. Loose or corroded battery
cables.
1. Clean and secure battery cable clamps and
posts.
2. Loose or worn generator drive
belt.
2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Electrical, Charging
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical, Battery
System.
6. Poor lighting circuit ground. 6. Test for voltage drop across ground circuits,
refer to Electrical, Wiring Diagram Information.
HEADLAMP BULBS
BURN OUT
FREQUENTLY
1. Integrated Control Module (ICM)
not controlling voltage.
1. Test and repair Integrated Control Module.
2. Loose or corroded terminals or
splices in circuit.
2. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
HEADLAMPS ARE DIM
WITH ENGINE
RUNNING ABOVE IDLE
1. Charging system output too low. 1. Test and repair charging system, refer to
Electrical, Wiring Information.
2. Poor lighting circuit ground. 2. Test for voltage drop across ground circuits,
refer to Electrical, Wiring Information.
3. High resistance in headlamp
circuit.
3. Test amperage draw of headlamp circuit.
HEADLAMPS FLASH
RANDOMLY
1. Poor lighting circuit ground. 1. Test for voltage drop across ground
locations, refer to Electrical, Wiring Information.
2. Variable resistance in headlamp
circuit.
2. Test amperage draw of headlamp circuit.
splices in circuit.
3. Inspect and repair all connectors and splices,
refer to Electrical, Wiring Information.
4. Faulty headlamp switch. 4. Replace headlamp switch.
5. Front Control Module
Malfunction.
5. Refer to appropriate ICM/FCM diagnostics.
HEADLAMPS DO NOT
ILLUMINATE
1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to
Electrical, Wiring Information.
2. No ground at headlamps. 2. Repair circuit ground, refer to Electrical,
Wiring Information.
3. Broken connector terminal or
wire splice in headlamp circuit.
3. Repair connector terminal or wire splice.
4. Faulty or burned out bulb. 4. Replace headlamp bulb(s).
5. Integrated Control Module
malfunction.
5. Refer to appropriate Body Control Module
diagnostics.
6. J1850 Bus Communication 6. Verify messages being transmitted by
Instrument Cluster and received by FCM.
Malfunction.
HEADLAMPS ON WITH
IGNITION IN RUN, WITH
HEADLAMP SWITCH
OFF
1. Faulty headlamp switch. 1. Replace headlamp switch (review Instrument
Cluster logged faults).
2. Diagnostic tool indicates (4.7 -
5.0V) on headlamp switch input to
Instrument Cluster.
2. Inspect and repair terminals, connectors and
open circuits.
3. J1850 Bus Communication. 3. Verify messages being transmitted by
Instrument Cluster and received by FCM.
Malfunction.
FOG LAMP DIAGNOSIS
FOG LAMPS ARE DIM
WITH ENGINE IDLING
OR IGNITION TURNED
OFF.
1. Loose or corroded battery
cables.
1. Clean and secure battery cable clamps and
posts.
2. Loose or worn generator drive
belt.
2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Electrical, Charging,
4. Battery has insufficient charge. 4. Test battery state-of-charge. Refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Electrical, Battery
System.
locations. Refer to Electrical, Wiring
Information.
FOG LAMP BULBS
BURN OUT
FREQUENTLY
1. Charging system output too
high.
1. Test and repair charging system. Refer to
Electrical, Charging.
splices in circuit.
FOG LAMPS ARE DIM
WITH ENGINE
RUNNING ABOVE IDLE
1. Charging system output too low. 1. Test and repair charging system. Refer to
Electrical, Charging.
Information.
3. High resistance in fog lamp
circuit.
3. Test amperage draw of fog lamp circuit.
FOG LAMPS FLASH
RANDOMLY
Information.
2. Variable resistance in fog lamp
circuit.
2. Test amperage draw of fog lamp circuit.
3. Faulty fog lamp switch (part of
headlamp switch).
3. Replace headlamp switch.
splices in circuit.
5. Is relay engaging properly? 5. Verify function of fog lamp relay in IPM.
6. J1850 Bus Communication. 6. Verify J1850 message (fog lamp info)
transmitted from Instrument Cluster and
received by FCM.
FOG LAMPS DO NOT
ILLUMINATE
1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Electrical, Wiring
Information.
2. No ground at fog lamps. 2. Repair circuit ground. Refer to Electrical,
Wiring Information.
3. Faulty fog lamp switch (part of
headlamp switch).
3. Replace headlamp switch.
4. Broken connector terminal or
wire splice in fog lamp circuit.
4. Repair connector terminal or wire splice.
5. Faulty or burned out bulb. 5. Replace bulb.
6. Is relay engaging? 6. Verify function of fog lamp relay in IPM.
7. J1850 Bus Communication. 7. Verify J1850 message (fog lamp info)
transmitted from Instrument Cluster and
received by FCM.
DAYTIME RUNNING LAMP (CANADA ONLY) DIAGNOSIS
DAYTIME RUNNING
LAMPS DO NOT
OPERATE
1. Parking brake engaged. 1. Disengage parking brake.
2. Parking brake circuit shorted
to ground.
2. Check cluster telltale, refer to the appropriate
wiring information.
3. Headlamp circuit shorted to
ground.
3. Refer to the appropriate wiring information.
4. FCM, Instrument Cluster not
programed with Canadian
country code.
4. Check country code.
STANDARD PROCEDURE
SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.Do not use bulbs with higher
candle power than indicated in the Bulb Application
table . Damage to lamp and/or Daytime Running
Lamp Module can result.Do not use fuses, circuit
breakers or relays having greater amperage value
than indicated on the fuse panel or in the Owners
Manual.
When i t i s necessary to remove components to ser-
vi ce another, i t shoul d not be necessary to appl y
excessi ve force or bend a component to remove i t.
Before damagi ng a tri m component, veri fy hi dden
fasteners or captured edges are not hol di ng the com-
ponent i n pl ace.
SPECIFICATIONS
EXTERIOR LAMPS
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the Bulb Applica-
tion Table. Damage to lamp can result. Do not touch
halogen bulbs with fingers or other oily surfaces.
Bulb life will be reduced.
The fol l owi ng Bul b Appl i cati on Tabl e l i sts the l amp
ti tl e on the l eft si de of the col umn and trade number
or part number on the ri ght.
BULB APPLICATION TABLE
LAMP BULB
Backup - w/cargo box 3057
Backup - w/box off 1156
Center High Mounted
Stop lamp
912
Fog lamp 9006LL
Front Park/Turn Signal 3157NA
Head lamp 9007
License Plate 168
Tail, Brake, Turn Signal -
w/cargo box
3057
LAMP BULB
Tail, Brake, Turn Signal -
w/box off
1157
Side Marker, Tail Gate,
Cab Clearance
168
BACKUP LAMP
REMOVAL
REMOVAL - WITH CARGO BOX
(1) Remove and i sol ate the negati ve battery cabl e.
(2) Remove the tai l l amp uni t (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/TAI L
LAMP UNI T - REMOVAL).
(3) Remove the l amp back pl ate from the tai l l amp
uni t.
(4) Rel ease the backup l amp bul b l ocki ng tabs and
remove the bul b from the back pl ate.
REMOVAL - WITHOUT CARGO BOX
cabl e.
(2) Remove the four screws that secure the tai l
l amp l ens to the tai l l amp housi ng (Fi g. 1).
(3) Separate the tai l l amp l ens from the tai l l amp
housi ng.
(4) Push the backup l amp bul b i nward and rotate
i t counter-cl ockwi se.
(5) Remove the backup l amp bul b from the backup
l amp socket.
INSTALLATION
INSTALLATION - WITH CARGO BOX
(1) I nstal l the backup l amp bul b i nto the l amp
back pl ate.
Fig. 1 Tail Lamp Lens
(2) I nstal l the l amp back pl ate onto the tai l l amp
uni t.
(3) I nstal l the tai l l amp uni t (Refer to 8 - ELEC-
LAMP UNI T - I NSTALLATI ON).
INSTALLATION - WITHOUT CARGO BOX
(1) I nstal l the backup l amp bul b i nto the backup
l amp socket by pushi ng i nward and rotati ng i t cl ock-
wi se.
NOTE: Install the tail lamp lens with the clear por-
tion (back-up lens) at the top of the housing. Make
sure that the gasket is correctly in place and not
twisted or torn.
(2) Posi ti on the tai l l amp l ens and gasket onto the
tai l l amp uni t.
NOTE: Do not overtighten the tail lamp lens screws
or damage to the tail lamp lens may result.
(3) I nstal l the four screws that secure the tai l
l amp l ens to the tai l l amp uni t. Ti ghten the screws
securel y.
BACKUP LAMP SWITCH
DESCRIPTION
Vehi cl es equi pped wi th a manual transmi ssi on
have a normal l y open, spri ng-l oaded pl unger type
back-up l amp swi tch (Fi g. 2). The backup l amp
swi tch i s l ocated i n a threaded hol e on the si de of the
manual transmi ssi on housi ng. The backup l amp
swi tch has a threaded body and a hex formati on near
the pl unger end of the swi tch, and an i ntegral con-
nector at the opposi te end of the swi tch. When
i nstal l ed, onl y the connector and the hex formati on
are vi si bl e on the outsi de of the transmi ssi on hous-
i ng. Vehi cl es wi th an opti onal el ectroni c automati c
transmi ssi on have a Transmi ssi on Range Sensor
(TRS) that i s used to perform several functi ons,
i ncl udi ng that of the backup l amp swi tch. The TRS i s
descri bed i n further detai l el sewhere i n thi s servi ce
i nformati on. The backup l amp swi tch cannot be
adjusted or repai red and, i f faul ty or damaged, the
enti re swi tch uni t must be repl aced.
OPERATION
The backup l amp swi tch control s the fl ow of bat-
tery vol tage to the backup l amp bul bs through an
output on the back-up l amp feed ci rcui t. The swi tch
pl unger i s mechani cal l y actuated by the gearshi ft
mechani sm wi thi n the transmi ssi on, whi ch wi l l
depress the swi tch pl unger and cl ose the swi tch con-
tacts whenever the reverse gear has been sel ected.
The swi tch recei ves battery vol tage through a fuse i n
the I ntegrated Power Modul e (I PM) on a fused i gni -
ti on swi tch output (run) ci rcui t whenever the i gni ti on
swi tch i s i n the On posi ti on. A take out of the engi ne
wi re harness connects the backup l amp swi tch to the
vehi cl e el ectri cal system. The backup l amp swi tch
and ci rcui ts can be tested usi ng conventi onal di ag-
nosti c tool s and methods.
DIAGNOSIS AND TESTING - BACKUP LAMP
SWITCH
cabl e.
(3) Locate and di sconnect the engi ne wi re harness
connector for the backup l amp swi tch.
(4) Check for conti nui ty between the two termi nal
pi ns i n the backup l amp swi tch connector.
(a) Wi th the gear sel ector l ever i n the Reverse
posi ti on, there shoul d be conti nui ty.
(b) Wi th the gear sel ector l ever i n any posi ti on
other than Reverse, there shoul d be no conti nui ty.
Fig. 2 Backup Lamp Switch - Typical
1 - MANUAL TRANSMISSION
2 - BACKUP LAMP SWITCH
3 - ENGINE WIRE HARNESS
BACKUP LAMP (Continued)
BRAKE LAMP
REMOVAL
cabl e.
uni t.
(4) Rel ease the brake l amp bul b l ocki ng tabs and
cabl e.
housi ng.
(4) Push the brake l amp bul b i nward and rotate i t
counter-cl ockwi se.
(5) Remove the brake l amp bul b from the brake
l amp socket.
INSTALLATION
(1) I nstal l the brake l amp bul b i nto the l amp back
pl ate.
uni t.
(1) I nstal l the brake l amp bul b i nto the brake
l amp socket by pushi ng i nward and rotati ng i t cl ock-
wi se.
twisted or torn.
tai l l amp uni t.
securel y.
BRAKE LAMP SWITCH
DESCRIPTION
The pl unger type brake l amp swi tch i s mounted on
a bracket attached to the base of the steeri ng col -
umn, under the i nstrument panel .
CAUTION: The switch can only be adjusted during
initial installation. If the switch is not adjusted prop-
erly a new switch must be installed.
OPERATION
The brake l amp swi tch i s hard wi red to the Center
Hi gh Mount Stop Lamp (CHMSL) and al so moni -
tored by the I nstrument Cl uster for use by the brake
l amp, speed control brake sensor ci rcui ts and el ec-
troni c brake di stri buti on (EBD). The brake l amp ci r-
cui t i s open unti l the pl unger i s depressed. The speed
control and brake sensor ci rcui ts are cl osed unti l the
pl unger i s depressed. When the brake l amp swi tch
transi ti ons, the CHMSL transi ti ons and i nstrument
cl uster transmi ts a brake appl i ed/rel eased message
on the bus. The I ntegrated Power Modul e (I PM) wi l l
then transi ti on the brake l amps.
When the brake l i ght swi tch i s acti vated, the Pow-
ertrai n Control Modul e (PCM) recei ves an i nput i ndi -
cati ng that the brakes are bei ng appl i ed. After
recei vi ng thi s i nput, the PCM mai ntai ns i dl e speed to
a schedul ed rpm through control of the I dl e Ai r Con-
trol (I AC) motor. The brake swi tch i nput i s al so used
to di sabl e vent and vacuum sol enoi d output si gnal s
to the speed control servo.
Vehi cl es equi pped wi th the speed control opti on use
a dual functi on brake l amp swi tch. The PCM moni -
tors the state of the dual functi on brake l amp swi tch.
The brake swi tch i s equi pped wi th three sets of
contacts, one normal l y open and the other two nor-
mal l y cl osed (brakes di sengaged). The PCM sends a
12 vol t si gnal to one of the normal l y cl osed contacts
i n the brake swi tch, whi ch i s returned to the PCM as
a brake swi tch state si gnal . Wi th the contacts cl osed,
the 12 vol t si gnal i s pul l ed to ground causi ng the si g-
nal to go l ow. The l ow vol tage si gnal , moni tored by
the PCM, i ndi cates that the brakes are not appl i ed.
When the brakes are appl i ed, the contacts open,
causi ng the PCMs output brake si gnal to go hi gh,
di sengagi ng the speed control , cutti ng off PCM power
to the speed control sol enoi ds.
The second set of normal l y cl osed contacts suppl i es
12 vol ts from the PCM any ti me speed control i s
turned on. Through the brake swi tch, vol tage i s
routed to the speed control servo sol enoi ds. The
speed control sol enoi ds (vacuum, vent and dump) are
provi ded thi s vol tage any ti me the speed control i s
ON and the brakes are di sengaged.
When the dri ver appl i es the brakes, the contacts
open and vol tage i s i nterrupted to the sol enoi ds. The
normal l y open contacts are fed battery vol tage. When
the brakes are appl i ed, battery vol tage i s suppl i ed to
the brake l amps.
The brake l amp swi tch can onl y be adjusted once.
That i s at the i ni ti al i nstal l ati on of the swi tch. I f the
swi tch i s not adjusted properl y or has been removed,
a new swi tch must be i nstal l ed and adjusted.
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH
The brake l amp swi tch can be tested wi th an ohm-
meter. The ohmmeter i s used to check conti nui ty
between the pi n termi nal s (Fi g. 4).
SWITCH CIRCUIT IDENTIFICATION
Termi nal s 1 and 2: brake l amp ci rcui t
Termi nal s 3 and 4: RWAL/ABS modul e and Pow-
ertrai n Control Modul e (PCM) ci rcui t
Termi nal s 5 and 6: speed control ci rcui t
SWITCH CONTINUITY TEST
NOTE: Disconnect switch harness before testing
switch continuity.
Wi th swi tch pl unger extended, attach test l eads to
pi ns 1 and 2. Repl ace swi tch i f meter i ndi cates no
conti nui ty.
Wi th swi tch pl unger retracted, attach test l eads to
conti nui ty.
Wi th swi tch pl unger retracted, attach test l eads to
conti nui ty.
REMOVAL
(1) Di sconnect the swi tch harness (Fi g. 5).
(2) Press and hol d the brake pedal i n appl i ed posi -
ti on.
(3) Rotate the swi tch countercl ockwi se about 30 to
al i gn the swi tch l ock tab wi th the notch i n bracket.
(4) Pul l the swi tch rearward out of the mounti ng
bracket and rel ease the brake pedal .
Fig. 4 Brake Lamp Switch Terminal Identification
1 - TERMINAL PINS
2 - PLUNGER TEST POSITIONS
Fig. 5 Brake Lamp Switch & Bracket
1 - RELEASE LEVER
2 - BRACKET
3 - BRAKE PEDAL SUPPORT
4 - BRAKE LAMP SWITCH
BRAKE LAMP SWITCH (Continued)
INSTALLATION
(1) Press and hol d the brake pedal down.
(2) Al i gn the tab on the new swi tch wi th the notch
i n the swi tch bracket. I nsert the swi tch i n the
bracket and turn i t cl ockwi se about 30 to l ock i t i n
pl ace.
(3) Connect the harness wi res to the swi tch.
(4) Rel ease the brake pedal .
(5) Move the rel ease l ever on the swi tch paral l el
wi th the connector to engage the swi tch pl unger. The
swi tch i s now adjusted and can not be adjusted
agai n.
CENTER HIGH MOUNTED
STOP LAMP
REMOVAL
cabl e.
(2) Remove the CHMSL from the roof panel . Refer
to (Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG -
EXTERI OR/CENTER HI GH MOUNTED STOP
LAMP UN - REMOVAL).
(3) Turn the bul b socket 1/4 turn countercl ockwi se.
(4) Separate the socket from the l amp.
(5) Remove the bul b.
INSTALLATION
(1) Posi ti on the bul b i n the socket and press i nto
pl ace.
(2) Posi ti on the socket i n the l amp.
(3) Turn the bul b socket 1/4 turn cl ockwi se.
(4) I nstal l the CHMSL. Refer to (Refer to 8 -
CENTER HI GH MOUNTED STOP LAMP UN -
I NSTALLATI ON).
CENTER HIGH MOUNTED
STOP LAMP UNIT
REMOVAL
cabl e.
(2) Remove screws hol di ng CHMSL to roof panel
(Fi g. 6).
(3) Separate CHMSL from roof.
(4) Di sengage wi re connector from body wi re har-
ness.
(5) Separate CHMSL from vehi cl e.
INSTALLATION
(1) Posi ti on l amp at cab roof and connect wi re con-
nector.
(2) I nstal l screws hol di ng CHMSL to roof panel .
Ti ghten securel y.
CAB CLEARANCE LAMP
REMOVAL
(1) Remove both retai ni ng screws and separate the
l amp from the roof.
(2) Quarter turn counter cl ockwi se to separate
bul b socket from l amp.
Fig. 6 Center High Mount Stop Lamp - Typical
1 - CHMSL CARGO LAMP HOUSING
2 - CHMSL
3 - CARGO LAMPS
4 - SCREW
5 - CLIP
6 - CAB
BRAKE LAMP SWITCH (Continued)
INSTALLATION
(1) Quarter twi st the bul b socket cl ockwi se i nto
the l amp housi ng.
(2) Posi ti on the l amp assembl y onto the roof and
i nstal l retai ni ng screws. (Fi g. 7)
FOG LAMP
REMOVAL
NOTE: The fog lamps are serviced from the rear-
ward side of the front bumper.
cabl e.
(2) Di sengage fog l amp harness connector.
(3) Remove the bol ts attachi ng the fog l amp to the
bumper (Fi g. 8).
(4) Separate fog l amp from bumper.
INSTALLATION
(1) Posi ti on fog l amp i n bumper.
(2) I nstal l the bol ts attachi ng the fog l amp to the
bumper.
(3) Connect fog l amp harness connector.
(5) Check for proper operati on and beam al i gn-
ment.
FOG LAMP RELAY
DESCRIPTION
The front fog l amp rel ay i s l ocated i n the Power
Di stri buti on Center (PDC) i n the engi ne compart-
Fig. 7 Clearance Lamp
1 - NUT
2 - CAB ROOF
3 - BULB SOCKET
4 - CLEARANCE LAMP
5 - SCREW
6 - BULB
Fig. 8 Fog Lamp
1 - SCREW
2 - FOG LAMP UNIT
3 - CONNECTOR
Fig. 9 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
CAB CLEARANCE LAMP (Continued)
ment of the vehi cl e. The front fog l amp rel ay i s a
conventi onal I nternati onal Standards Organi zati on
(I SO) mi cro rel ay (Fi g. 9). Rel ays conformi ng to the
I SO speci fi cati ons have common physi cal di mensi ons,
current capaci ti es, termi nal patterns, and termi nal
functi ons. The rel ay i s contai ned wi thi n a smal l , rect-
angul ar, mol ded pl asti c housi ng and i s connected to
al l of the requi red i nputs and outputs by fi ve i ntegral
mal e spade-type termi nal s that extend from the bot-
tom of the rel ay base.
The front fog l amp rel ay cannot be adjusted or
repai red and, i f faul ty or damaged, the uni t must be
repl aced.
OPERATION
The front fog l amp rel ay i s an el ectromechani cal
swi tch that uses a l ow current i nput from the Front
Control Modul e (FCM) to control a hi gh current out-
put to the front fog l amps. The movabl e common feed
contact poi nt i s hel d agai nst the fi xed normal l y
cl osed contact poi nt by spri ng pressure. When the
rel ay coi l i s energi zed, an el ectromagneti c fi el d i s
produced by the coi l wi ndi ngs. Thi s el ectromagneti c
fi el d draws the movabl e rel ay contact poi nt away
from the fi xed normal l y cl osed contact poi nt, and
hol ds i t agai nst the fi xed normal l y open contact
poi nt. When the rel ay coi l i s de-energi zed, spri ng
pressure returns the movabl e contact poi nt back
agai nst the fi xed normal l y cl osed contact poi nt. A
resi stor i s connected i n paral l el wi th the rel ay coi l i n
the rel ay, and hel ps to di ssi pate vol tage spi kes and
el ectromagneti c i nterference that can be generated as
the el ectromagneti c fi el d of the rel ay coi l col l apses.
The front fog l amp rel ay termi nal s are connected
to the vehi cl e el ectri cal system through a connector
receptacl e i n the Power Di stri buti on Center (PDC).
The i nputs and outputs of the front fog l amp rel ay
i ncl ude:
Common Feed Terminal - The common feed
termi nal (30) recei ves battery vol tage at al l ti mes
from a fuse i n the PDC through a fused B(+) ci rcui t.
Coil Ground Terminal - The coi l ground termi -
nal (85) i s connected to a control output of the Front
Control Modul e (FCM) through a front fog l amp rel ay
control ci rcui t. The FCM control s front fog l amp oper-
ati on by control l i ng a ground path through thi s ci r-
cui t.
Coil Battery Terminal - The coi l battery ter-
mi nal (86) recei ves battery vol tage at al l ti mes from
a fuse i n the PDC through a fused B(+) ci rcui t.
Normally Open Terminal - The normal l y open
termi nal (87) i s connected to the front fog l amps
through a front fog l amp rel ay output ci rcui t and
provi des battery vol tage to the front fog l amps when-
ever the rel ay i s energi zed.
Normally Closed Terminal - The normal l y
cl osed termi nal (87A) i s not connected i n thi s appl i -
cati on.
The front fog l amp rel ay can be di agnosed usi ng
conventi onal di agnosti c tool s and methods. Refer to
the appropri ate wi ri ng i nformati on for di agnosi s and
testi ng of the front fog l amp mi cro-rel ay and for com-
pl ete wi ri ng di agrams.
REMOVAL
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
cabl e.
(2) Remove the cover for the Power Di stri buti on
Center (PDC).
(3) Remove the front fog l amp rel ay by graspi ng i t
fi rml y and pul l i ng i t strai ght out from the receptacl e
i n the PDC.
INSTALLATION
PERSONAL INJURY.
FOG LAMP RELAY (Continued)
(1) Posi ti on the front fog l amp rel ay to the proper
(2) Al i gn the front fog l amp rel ay termi nal s wi th
the termi nal cavi ti es i n the PDC.
(3) Press fi rml y and evenl y on the top of the front
fog l amp rel ay unti l the termi nal s are ful l y seated i n
the PDC.
HAZARD SWITCH
DESCRIPTION
The hazard swi tch i s acti vated by a push button
l ocated i n the mul ti functi on swi tch on the top of the
steeri ng col umn between the steeri ng wheel and
The hazard warni ng system al l ows the vehi cl e
operator to provi de other vehi cl e operators i n the
near proxi mi ty an opti cal i ndi cati on that the vehi cl e
i s di sabl ed or an obstacl e to traffi c fl ow. The hazard
warni ng system has battery vol tage at al l ti mes,
regardl ess of i gni ti on posi ti on.
OPERATION
The i nstrument cl uster moni tors the mul ti pl exed
mul ti functi on swi tch operati on. When the hazard
warni ng swi tch i s acti vated, the i nstrument cl uster
wi l l send a J1850 bus message to the Front Control
Modul e (FCM), then acti vate the two turn si gnal
i ndi cators and audi bl e cl i ck i n the i nstrument cl us-
ter.
The FCM wi l l then acti vate the necessary rel ays i n
the Power Di stri buti on Center (PDC) to begi n fl ash-
i ng both the front and rear turn si gnal i ndi cator
l amps.
HEADLAMP
REMOVAL
(1) Di sconnect and i sol ate the negi ti ve battery
cabl e.
(2) Remove the headl amp uni t (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/HEAD-
(3) Seperate the socket from the headl amp uni t.
INSTALLATION
CAUTION: Do Not Touch the bulb glass with fingers
or other oily surfaces. Reduced bulb life will result.
(1) I nstal l the socket i nto the headl amp uni t.
(2) I nstal l the headl amp uni t (Refer to 8 - ELEC-
(3) Connect the negi ti ve battery cabl e.
HEADLAMP SWITCH
DESCRIPTION
The mul ti pl exed headl amp swi tch i s l ocated on the
i nstrument panel . The headl amp swi tch control s the
parki ng l amps, fog l amps and the headl amps. A sep-
arate swi tch i n the modul e control s the i nteri or
l amps and i nstrument cl uster i l l umi nati on. Thi s
swi tch al so contai ns a rheostat for control l i ng the
i l l umi nati on l evel of the cl uster l amps.
OPERATION
The mul ti pl exed headl amp swi tch has an off, park-
i ng l amp, fog l amp and a headl amp on posi ti on. Hi gh
beams are control l ed by the mul ti pl exed mul ti func-
ti on swi tch on the steeri ng col umn. The fog l amps
are i l l umi nated by pul l i ng back on the headl amp
swi tch knob when i n the parki ng l amp or headl amp
ON posi ti on.The headl amp swi tch cannot be
repai red. I t must be repl aced.
The I nstrument Cl uster moni tors the headl amp
and mul ti functi on swi tch operati on. When the head-
l amp swi tch i s rotated to the parki ng l amp or On
posi ti on the I nstrument Cl uster sends a J1850 mes-
sage to the Front Control Modul e, whi ch i s mated to
the power di stri buti on center to become the I nte-
grated Control Modul e, to i l l umi nate the appropri ate
bul bs. When the mul ti functi on swi tch i s acti vated to
the opti cal horn or hi gh beam posi ti on the I nstru-
ment Cl uster i l l umi nates the hi gh beam i ndi cator
and sends a J1850 message to the Front Control
Modul e to i l l umi nate the appropri ate bul bs.
REMOVAL
INJURY.
cabl e.
FOG LAMP RELAY (Continued)
(2) Remove the l eft i nstrument panel bezel . (Refer
to 23 - BODY/I NSTRUMENT PANEL/CLUSTER
BEZEL - REMOVAL).
(3) Di sconnect the harness connector.
(4) Remove the screws that secure the headl amp
swi tch to the i nstrument panel bezel (Fi g. 10).
(5) Remove the headl amp swi tch from the i nstru-
ment panel bezel .
INSTALLATION
INJURY.
(1) Posi ti on the headl amp swi tch to the l eft i nstru-
ment panel bezal and secure wi th screws.Ti ghten the
screws to 2.2 Nm (20 i n. l bs.).
connector for the headl amp swi tch.
(3) Posi ti on the l eft i nstrument panel bezal on to
the i nstrument panel .
(4) I nstal l the cl uster bezel onto the i nstrument
panel (Fi g. 10).
HEADLAMP UNIT
REMOVAL
cabl e.
(2) Remove the push pi ns attachi ng the seal to the
fender.
(3) Remove the bol ts attachi ng the headl amp uni t
to the fender (Fi g. 11).
(4) Remove the bul b sockets from the headl amp
uni t
(5) Separate headl amp uni t from vehi cl e.
INSTALLATION
CAUTION: Do not touch the bulb glass with fingers
or other oily surfaces. Reduced bulb life will result.
(1) I nstal l the bul b sockets for the front park/turn
si gnal and headl amp.
(2) Posi ti on headl amp uni t i n i nner fender panel .
Fig. 10 Headlamp Switch Removal
1 - DASH BOARD
2 - HEADLAMP SWITCH
3 - INSTRUMENT PANEL BEZAL
Fig. 11 Headlamp - Typical
1 - SEAL
2 - PUSH PIN
3 - SCREW
4 - HEADLAMP UNIT
HEADLAMP SWITCH (Continued)
(3) I nstal l the bol ts attachi ng headl amp uni t to the
fender (Fi g. 11).
(4) Al i gn the seal and i nstal l the push pi ns.
ADJUSTMENTS
Headl amps can be al i gned usi ng the screen method
provi ded i n thi s secti on.
LAMP ALIGNMENT SCREEN PREPARATION
(1) Posi ti on vehi cl e on a l evel surface perpendi cu-
l ar to a fl at wal l 7.62 meters (25 ft) away from front
of headl amp l ens (Fi g. 12).
(2) I f necessary, tape a l i ne on the fl oor 7.62
meters (25 ft) away from and paral l el to the wal l .
(3) Up 1.27 meters (5 feet) from the fl oor, tape a
l i ne on the wal l at the centerl i ne of the vehi cl e. Si ght
al ong the centerl i ne of the vehi cl e (from rear of vehi -
cl e forward) to veri fy accuracy of the l i ne pl acement.
(4) Rock vehi cl e si de-to-si de three ti mes to al l ow
suspensi on to stabi l i ze.
(5) Jounce front suspensi on three ti mes by pushi ng
downward on front bumper and rel easi ng.
(6) Measure the di stance from the center of head-
l amp l ens to the fl oor. Transfer measurement to the
al i gnment screen (wi th tape). Use thi s l i ne for
up/down adjustment reference.
(7) Measure di stance from the centerl i ne of the
vehi cl e to the center of each headl amp bei ng al i gned.
Transfer measurements to screen (wi th tape) to each
si de of vehi cl e centerl i ne. Use these l i nes for l eft/
ri ght adjustment reference.
VEHICLE PREPARATION FOR HEADLAMP
ALIGNMENT
(1) Veri fy headl amp di mmer swi tch and hi gh beam
i ndi cator operati on.
(2) Correct defecti ve components that coul d hi nder
proper headl amp al i gnment.
(3) Veri fy proper ti re i nfl ati on.
(4) Cl ean headl amp l enses.
(5) Veri fy that l uggage area i s not heavi l y l oaded.
(6) Fuel tank shoul d be FULL. Add 2.94 kg (6.5
l bs.) of wei ght over the fuel tank for each esti mated
gal l on of mi ssi ng fuel .
HEADLAMP ALIGNMENT
A properl y ai med l ow beam headl amp wi l l project
top edge of hi gh i ntensi ty pattern on screen from 50
mm (2 i n.) above to 50 mm (2 i n.) bel ow headl amp
Fig. 12 Headlamp Alignment Screen - Typical
1 - CENTER OF VEHICLE
2 - CENTER OF HEADLAMP
3 - 7.62 METERS (25 FT.)
4 - FRONT OF HEADLAMP
HEADLAMP UNIT (Continued)
centerl i ne. The si de-to-si de outboard edge of hi gh
i ntensi ty pattern shoul d be from 150 mm (6 i n.) l eft
to 150 mm (6 i n.) ri ght of headl amp centerl i ne (Fi g.
12). The preferred headlamp alignment is 1
down for the up/down adjustment and 0 for the
left/right adjustment. The hi gh beam pattern
shoul d be correct when the l ow beams are al i gned
properl y.
To adjust l ow beam headl amp, rotate verti cal al i gn-
ment screw to achi eve the speci fi ed ai m.
LICENSE PLATE LAMP
REMOVAL
cabl e.
(2) Grasp l i cense pl ate bul b socket and 1/4 turn
l eft to rel ease from the l i cense pl ate l amp uni t.
(3) Pul l bul b from l i cense pl ate l amp socket.
INSTALLATION
(1) I nstal l the bul b i n the socket.
(2) I nstal l the socket i n to the l i cense pl ate l amp
uni t and 1/4 turn to l ock.
LICENSE PLATE LAMP UNIT
REMOVAL
cabl e.
(2) Di sconnect the harness connector.
(3) Remove the retai ni ng cl i p. (Fi g. 13).
(4) Separate l i cense pl ate l amp from vehi cl e.
INSTALLATION
(1) Posi ti on l i cense pl ate l amp on the bumper.
(2) I nstal l the cl i p.
(3) Reconnect the harness connector.
MARKER LAMP UNIT
REMOVAL
REMOVAL - FENDER MARKER LAMP
(1) Grasp the l ens assembl y fi rml y and push i t
rearward to remove the l ens assembl y from the
fender (Fi g. 14).
(2) Turn the bul b socket countercl ockwi se a quar-
ter turn and remove the bul b socket from the l ens
assembl y.
Fig. 13 License Plate Lamp Panel
1 - REAR BUMPER
2 - WIRING CONNECTOR
3 - CLIP
4 - LICENSE PLATE LAMP UNIT
Fig. 14 Fender Extension And Marker Lamp
Assembly
1 - WIRING HARNESS AND BULB SOCKET
2 - MARKER LAMP LENS ASSEMBLY
HEADLAMP UNIT (Continued)
REMOVAL - TAILGATE MARKER LAMP
(1) Remove the two screws that secure the l ens
assembl y to the tai l gate (Fi g. 15).
(2) Turn the bul b sockets countercl ockwi se a quar-
ter turn and remove the bul b sockets from the l ens
assembl y.
INSTALLATION
INSTALLATION - FENDER MARKER LAMP
(1) I nstal l the bul b socket to the l ens assembl y.
Turn the bul b socket a quarter turn cl ockwi se.
(2) Posi ti on the l ens assembl y agai nst the fender.
Usi ng fi rm pressure, push the l ens assembl y i nto the
fender.
INSTALLATION - TAILGATE MARKER LAMP
(1) I nstal l the bul b sockets i nto the l ens assembl y.
Turn the bul b sockets a quarter turn cl ockwi se.
(2) Posi ti on the l ens assembl y to the tai l gate.
I nstal l and ti ghten the two screws securel y.
MULTI-FUNCTION SWITCH
DESCRIPTION - TURN SIGNAL SYSTEM
The mul ti -functi on swi tch i s a resi sti ve MUX
swi tch that i s moni tored by the I nstrument Cl uster.
The turn si gnal s are actuated wi th the l ever on
Mul ti -Functi on Swi tch. The si gnal s are automati cal l y
turned off by a cancel i ng cam (two l obes mol ded to
the back of the cl ock spri ng mechani sm). The cam
comes i n contact wi th the cancel actuator on the turn
si gnal (mul ti -functi on) swi tch assembl y. Ei ther cam
l obe, pushi ng on the cancel actuator, returns the
swi tch to the OFF posi ti on.
OPERATION - TURN SIGNAL SYSTEM
The I nstrument Cl uster moni tors the mul ti pl exed
mul ti functi on swi tch. I n a turni ng event the I nstru-
ment Cl uster senses a change i n the turn si gnal
l ever and i l l umi nates the appropri ate turn si gnal
i ndi cator. At the same ti me, the I nstrument Cl uster
wi l l send a J1850 message on the PCI bus to the
Front Control Modul e (FCM). The FCM wi l l respond
by acti vati ng the appropri ate rel ay i n the Power Di s-
tri buti on Center.
A chi me wi l l sound after the turn i s compl eted i f
vehi cl e has travel ed a di stance of approxi matel y 1.0
mi l e and a speed of 15 mph, wi th the turn si gnal ON.
DIAGNOSIS AND TESTING - MULTI-FUNCTION
SWITCH
To test the turn si gnal , headl amp beam sel ect and
opti cal horn porti on of the mul ti -functi on swi tch:
(1) Remove the mul ti -functi on swi tch, refer to
El ectri cal , Lamps/Li ghti ng - Exteri or, Mul ti -Functi on
Swi tch, Removal , and I nstal l ati on.
(2) Usi ng an ohmmeter check the resi stance read-
i ngs between mul ti -functi on swi tch pi ns. Refer to
Wi ri ng Di agrams for proper pi n numbers and the
MULTI -FUNCTI ON SWI TCH TESTS tabl e.
MULTI-FUNCTION SWITCH TESTS
EXTERIOR LIGHTING FUNCTIONS
SWITCH POSITION CONNECTOR PINS RESISTANCE (OHMS)
Off 1 - 2 Open
Headlamp High Beams On 1 - 2 518 - 575
Hazard 3 - 2 115 - 128
Fig. 15 Tailgate Marker Lamp Housing
1 - RETAINING NUT (2)
2 - TAILGATE
3 - WIRING HARNESS AND BULB SOCKET
4 - SCREW (2)
5 - LENS ASSEMBLY
MARKER LAMP UNIT (Continued)
EXTERIOR LIGHTING FUNCTIONS
Optical Horn (Flash-to-Pass) On 1 - 2 1257 - 1397
Off 3 - 2 2643 - 2937
Turn Signal Left 3 - 2 345 - 384
Turn Signal Right 3 - 2 786 - 873
FRONT WIPER FUNCTIONS
SWITCH POSITION CONNECTOR PINS RESISTANCE (OHMS) 10%
Front Wiper Off 2 - 4 6910 - 7678
Delay 1 2 - 4 2128 - 2365
Delay 2 2 - 4 1089 - 1210
Delay 3 2 - 4 627 - 697
Delay 4 2 - 4 388 - 431
Delay 5 2 - 4 234 - 261
Front Wiper Low 2 - 4 125 - 140
Front Wiper High 2 - 4 50 - 56
Wash 1 - 2 2584 - 2871
REMOVAL
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO THE ELECTRICAL RESTRAINT
SYSTEM FOR SERVICE PROCEDURES. FAILURE
TO DO SO MAY RESULT IN ACCIDENTAL DEPLOY-
MENT OF THE AIRBAG AND POSSIBLE PERSONAL
INJURY
(1) Di sconnect and i sol ate battery negati ve cabl e.
(2) Remove the steeri ng wheel and the upper and
l ower steeri ng col umn shrouds. Refer to Steeri ng,
Col umn, Shroud, Removal .
(3) Di sconnect the wi re connector from the back of
the mul ti -functi on swi tch.
(4) Remove the screws retai ni ng the mul ti -functi on
swi tch to the steeri ng col umn adapter col l ar (Fi g. 16).
(5) Remove the mul ti -functi on swi tch.
(6) Remove the screws retai ni ng the cl ock spri ng
to the mul ti functi on swi tch.
INSTALLATION
ARMED. REFER TO THE ELECTRICAL RESTRAINT
SYSTEM FOR SERVICE PROCEDURES. FAILURE
TO DO SO MAY RESULT IN ACCIDENTAL DEPLOY-
MENT OF THE AIRBAG AND POSSIBLE PERSONAL
INJURY.
(1) I nstal l the cl ock spri ng on the mul ti functi on
swi tch.
(2) Posi ti on the swi tch on to the steeri ng col umn.
(3) I nstal l the retai ni ng screws.
(4) Connect the wi re harness connector.
(5) I nstal l the upper, l ower steeri ng col umn
shrouds and the steeri ng wheel . Refer to Steeri ng,
Col umn, Shroud, I nstal l ati on.
Fig. 16 Multifunction Switch
1 - SCREW
2 - COLUMN
3 - CLOCK SPRING
4 - MULTI - FUNCTION SWITCH
MULTI-FUNCTION SWITCH (Continued)
PARK LAMP RELAY
DESCRIPTION
The park l amp rel ay i s l ocated i n the Power Di s-
tri buti on Center (PDC) of the vehi cl e. The park l amp
rel ay i s a conventi onal I nternati onal Standards
Organi zati on (I SO) mi cro rel ay (Fi g. 17). Rel ays con-
formi ng to the I SO speci fi cati ons have common phys-
i cal di mensi ons, current capaci ti es, termi nal
patterns, and termi nal functi ons.
The park l amp rel ay cannot be adjusted or
repl aced.
OPERATION
The park l amp rel ay i s an el ectromechani cal
put to the park l amps. The movabl e common feed
The park l amp rel ay termi nal s are connected to
the vehi cl e el ectri cal system through a connector i n
the Juncti on Bl ock (JB). The i nputs and outputs of
the headl amp l ow beam rel ay i ncl ude:
termi nal (30) i s connected to the park l amps through
the park l amp rel ay output ci rcui t and provi des
ground to the park l amps when the rel ay i s de-ener-
gi zed, and battery current to the park l amps when-
Control Modul e (FCM) through a park l amp rel ay
control ci rcui t. The FCM control s park l amp opera-
ti on by control l i ng a ground path through thi s ci r-
cui t.
mi nal (86) recei ves battery current at al l ti mes from
a fuse i n the PDC through a fused B(+) ci rcui t.
termi nal (87) recei ves battery current at al l ti mes
from a fuse i n the Power Di stri buti on Center (PDC)
through a fused B(+) ci rcui t.
cl osed termi nal (87A) i s connected to ground at al l
ti mes.
The park l amp rel ay can be di agnosed usi ng con-
venti onal di agnosti c tool s and methods.
DIAGNOSIS AND TESTING - PARK LAMP
RELAY
The park l amp rel ay (Fi g. 18) i s l ocated i n the
Power Di stri buti on Center (PDC). Refer to the appro-
PERSONAL INJURY.
(1) Remove the park l amp rel ay from the PDC.
(2) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 3. I f not OK, repl ace the faul ty rel ay.
4. I f not OK, repl ace the faul ty rel ay.
(4) Connect a battery to termi nal s 85 and 86.
and 30. I f OK, rei nstal l the rel ay and use a DRBI I I
scan tool to perform further testi ng. Refer to the
REMOVAL
PERSONAL INJURY.
cabl e.
(2) Remove the Power Di stri buti on Center (PDC)
cover.
(3) Remove the park l amp rel ay by graspi ng i t
i n the PDC.
INSTALLATION
PERSONAL INJURY.
(1) Posi ti on the park l amp rel ay to the proper
(2) Al i gn the park l amp rel ay termi nal s wi th the
termi nal cavi ti es i n the PDC.
(3) Press fi rml y and evenl y on the top of the park
l amp rel ay unti l the termi nal s are ful l y seated i n the
PDC.
(4) I nstal l the PDC cover.
PARK/TURN SIGNAL LAMP
REMOVAL
cabl e.
(2) Remove the headl amp uni t.(Refer to 8 - ELEC-
(3) Remove the bul b socket from the headl amp
uni t.
(4) Rel ease the front park/turn si gnal bul b l ocki ng
tabs and remove the bul b from the socket (Fi g. 19).
INSTALLATION
(1) I nstal l the front park/turn si gnal bul b i nto the
bul b socket.
(2) I nstal l the bul b socket i nto the headl amp uni t.
(3) I nstal l the headl amp uni t (Refer to 8 - ELEC-
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
PARK LAMP RELAY (Continued)
TAIL LAMP
REMOVAL
cabl e.
uni t.
(4) Rel ease the tai l l amp bul b l ocki ng tabs and
cabl e.
housi ng.
(4) Push the tai l l amp bul b i nward and rotate i t
(5) Remove the tai l l amp bul b from the tai l l amp
socket.
INSTALLATION
(1) I nstal l the tai l l amp bul b i nto the l amp back
pl ate.
uni t.
(1) I nstal l the tai l l amp bul b i nto the tai l l amp
socket by pushi ng i nward and rotati ng i t cl ockwi se.
twisted or torn.
tai l l amp uni t.
securel y.
TAIL LAMP UNIT
REMOVAL
cabl e.
(2) Lower the tai l gate.
(3) Remove the two screws that secure the tai l
l amp uni t to the cargo box.
(4) Remove the tai l l amp uni t from the cargo box.
(5) Di sconnect the body wi re harness connector
from the l amp back pl ate connector (Fi g. 21).
Fig. 19 Park Turn Signal Bulb
1 - BULB SOCKET
2 - BULB
PARK/TURN SIGNAL LAMP (Continued)
cabl e.
(2) Di sconnect the body wi re harness connector
from the tai l l amp wi re harness connector (Fi g. 22).
(3) Remove the tai l l amp uni t connector from the
frame rai l .
(4) Remove the two nuts that secure the tai l l amp
housi ng to the mounti ng bracket.
(5) Remove the tai l l amp uni t from the mounti ng
bracket whi l e routi ng the wi re harness through the
bracket.
INSTALLATION
(1) Connect the body wi re harness connector to the
l amp back pl ate connector.
(2) Posi ti on the tai l l amp uni t i nto the cargo box.
(3) I nstal l the two screws that secure the tai l l amp
uni t to the cargo box.
(4) Rai se the tai l gate.
(1) Posi ti on the tai l l amp uni t onto the mounti ng
bracket whi l e routi ng the wi re harness through the
bracket.
(2) I nstal l the two nuts that secure the tai l l amp
housi ng to the mounti ng bracket.
(3) Connect the tai l l amp wi re harness connector
to the body wi re harness connector.
(4) I nstal l the tai l l amp connector retai ner to the
frame rai l .
Fig. 21 Tail Lamp Unit
1 - SCREW (2)
3 - TAIL LAMP UNIT
Fig. 22 Tail Lamp Unit - RH Side Shown, LH Side
Typical
1 - TAIL LAMP UNIT
3 - TRAILER HITCH BRACKET
4 - WIRE HARNESS
5 - NUT (2)
TAIL LAMP UNIT (Continued)
TRAILER TOW WIRING
DESCRIPTION
Vehi cl es equi pped wi th an opti onal factory-i n-
stal l ed trai l er towi ng package have a rear body wi re
harness that i ncl udes an i ntegral trai l er tow wi ri ng
take out that connects to a heavy duty, seal ed, 7-pi n
trai l er tow connector l ocated i n the rear bumper (Fi g.
23). Thi s harness i ncl udes an adapter harness that
adapts the 7-pi n trai l er tow connector to a standard,
l i ght-duty, 4-pi n trai l er tow connector. Refer to the
appropri ate wi ri ng i nformati on.
TURN LAMP
REMOVAL
cabl e.
uni t.
(4) Rel ease the turn si gnal bul b l ocki ng tabs and
cabl e.
housi ng.
(4) Push the turn si gnal bul b i nward and rotate i t
(5) Remove the turn si gnal bul b from the tai l l amp
socket.
INSTALLATION
(1) I nstal l the turn si gnal bul b i nto the l amp back
pl ate.
uni t.
(1) I nstal l the turn si gnal bul b i nto the tai l l amp
socket by pushi ng i nward and rotati ng i t cl ockwi se.
twisted or torn.
tai l l amp uni t.
securel y.
Fig. 23 Trailer Tow Wiring
1 - RETAINER CLIP (4)
2 - REAR BODY HARNESS (TRAILER TOW TAKE OUT)
3 - RETAINER CLIP (2)
UNDERHOOD LAMP
REMOVAL
cabl e.
(2) I nsert a smal l fl at bl ade i n the access sl ot
between the l amp base and l amp l ens.
(3) Pry the l amp l ens upward and remove the
l amp l ens (Fi g. 25).
(4) Depress the bul b termi nal i nward (Fi g. 26) to
rel ease the bul b.
INSTALLATION
(1) Engage the repl acement bul b wi re l oop to the
termi nal cl osest to the l amp base wi re connector (Fi g.
26).
(2) Depress the opposi te termi nal i nward and
engage the remai ni ng bul b wi re l oop.
(3) Posi ti on the l amp l ens on the l amp base and
press i nto pl ace (Fi g. 25).
UNDERHOOD LAMP UNIT
REMOVAL
cabl e.
(2) Di sconnect the wi re harness connector from the
l amp.
(3) Remove l amp l ens.
(4) Remove bul b.
(5) Remove screw attachi ng underhood l amp to the
i nner hood panel (Fi g. 27).
(6) Separate underhood l amp from vehi cl e.
INSTALLATION
(1) I nstal l bul b.
(2) I nstal l l amp l ens.
(3) Posi ti on the underhood l amp on the hood i nner
panel .
(4) I nstal l the attachi ng screw through the l amp
and i nto the hood panel (Fi g. 27). Ti ghten the screw
securel y.
(5) Fol d l amp housi ng over and fi rml y press onto
base to snap i nto pl ace.
(6) Connect the wi re harness connector to the
l amp.
Fig. 25 Underhood Lamp Lens
1 - LAMP
2 - LAMP LENS
Fig. 26 Underhood Lamp Bulb
1 - BULB
2 - DEPRESS TERMINAL INWARD
3 - BULB WIRE LOOP
4 - LAMP BASE
Fig. 27 Underhood Lamp
1 - UNDER HOOD LAMP
2 - HOOD
3 - CONNECTOR
LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
DOME LAMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
DOOR AJAR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
GLOVE BOX LAMP/SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
READING LAMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
DOME LAMP
DESCRIPTION
The dome l amp i s control l ed by the i nstrument
cl uster whi ch provi des power at al l ti mes, regardl ess
of the i gni ti on swi tch posi ti on. The ground ci rcui t for
the l amp i s swi tched through the i ntegral dome l amp
swi tch or through the door ajar swi tches vi a the
The dome l amp l ens and bul b are avai l abl e for ser-
vi ce repl acement. I f ei ther of the l amp swi tch or bul b
hol ders i s faul ty or damaged, the dome l amp assem-
bl y must be repl aced.
For servi ce of the dome l amp bul b, refer to the
appropri ate wi ri ng i nformati on.
OPERATION
The dome l amp i s acti vated by the door ajar
swi tches vi a the i nstrument cl uster. When al l of the
doors are cl osed, the l amp can be acti vated by
depressi ng the l ens. When any door i s open, depress-
i ng the l amp l ense to acti vate the l amp swi tch wi l l
not turn the l amps off.
The i nstrument cl uster moni tors the door ajar
swi tches. When a door i s open the i nstrument cl uster
grounds the l ow si de dri vers to turn on the l amp.
Upon cl osi ng al l doors, the i nstrument cl uster i ni -
ti ates a 30 second ti mer. I f any of the doors are
opened duri ng the ti me out cycl e, the i nstrument
cl uster wi l l reset the ti mer unti l al l doors are cl osed.
The i nstrument cl uster wi l l fai d to off when the doors
are cl osed and the i gni ti on i s turned ON, the ti me
out expi res or the power l ocks are acti vated.
REMOVAL
(1) Usi ng a smal l fl at bl ade, pry the l eft si de (dri v-
ers si de) of the dome l amp l ens downward from
dome l amp.
(2) Al l ow the l ens to hang down (Fi g. 1), thi s wi l l
di sengage the ri ght si de of the l amp (passengers
si de) from the headl i ner.
(3) Pul l the ri ght si de of the l amp down and sl i de
the l amp to the ri ght (Fi g. 2).
(4) Separate the l amp from the headl i ner.
(5) Di sengage dome l amp wi re connector from body
wi re harness.
(6) Separate dome l amp from vehi cl e.
INSTALLATION
(1) Posi ti on dome l amp at headl i ner.
(2) Connect dome l amp wi re connector to body
wi re harness.
(3) Posi ti on the l eft si de of the l amp i n the head-
l i ner openi ng and sl i de l amp to the l eft (Fi g. 1).
Fig. 1 Dome Lamp Lens
1 - HEADLINER
2 - CONNECTOR
3 - DOME LAMP
4 - LENS
5 - BULB
8L - 26 LAMPS/LIGHTING - INTERIOR DR
(4) Push the ri ght si de of the l amp i n the head-
l i ner openi ng and push the l amp l ens up i nto the
l amp to secure (Fi g. 1).
DOOR AJ AR SWITCH
DESCRIPTION
The door ajar swi tches are i ntegral to the door
l atches on each door. The swi tches cl ose a path to
ground for the I nstrument Cl uster when a door i s
opened.
The door ajar swi tches cannot be repai red and, i f
faul ty or damaged, the door l atch uni t must be
repl aced. Refer to the Body secti on under Doors for
the removal and i nstal l ati on procedure.
OPERATION
The door ajar swi tches cl ose a path to ground for
the I nstrument Cl uster when a door i s opened. The
passenger front door i s connected i n a paral l el -seri es
ci rcui t between ground and the I nstrument Cl uster,
whi l e the dri ver si de front door ajar swi tch i s con-
nected i n seri es between ground and the I nstrument
Cl uster to provi de a uni que i nput. The I nstrument
Cl uster reads the swi tch status, then sends the
proper swi tch status messages to other el ectroni c
modul es over the Programmabl e Communi cati ons
I nterface (PCI ) data bus network. The door ajar
swi tches can be di agnosed usi ng conventi onal di ag-
nosti c tool s and methods. Refer to the Body secti on
under Doors for the Removal and I nstal l ati on proce-
dures.
GLOVE BOX LAMP/SWITCH
REMOVAL
cabl e.
(2) Remove the gl ove box from the i nstrument
GLOVE BOX - REMOVAL) for the procedures.
(3) Reach through the gl ove box openi ng and
behi nd the gl ove box l amp and swi tch mounti ng
bracket to access the i nstrument panel wi re harness
connector on the gl ove box l amp and swi tch (Fi g. 3).
connector from the connector receptacl e on the back
of the gl ove box l amp and swi tch uni t.
bracket to depress the retai ni ng tabs on the top and
bottom of the gl ove box l amp and swi tch housi ng.
(6) Whi l e hol di ng the retai ni ng tabs depressed,
push the gl ove box l amp and swi tch uni t out through
the hol e i n the mounti ng bracket on the i nstrument
panel gl ove box openi ng upper rei nforcement.
(7) Remove the gl ove box l amp and swi tch uni t
from the i nstrument panel .
Fig. 2 Dome Lamp
1 - SLIDE LAMP
Fig. 3 Glove Box Lamp and Switch Remove/Install
2 - DASH BOARD
3 - GLOVE BOX SWITCH/LIGHT
DR LAMPS/LIGHTING - INTERIOR 8L - 27
DOME LAMP (Continued)
INSTALLATION
bracket to feed the i nstrument panel wi re harness
connectors out through the hol e i n the gl ove box
l amp and swi tch housi ng mounti ng bracket.
(2) Posi ti on the gl ove box l amp and swi tch uni t to
the i nstrument panel .
connector to the connector receptacl e on the back of
the gl ove box l amp and swi tch uni t.
(4) Push the gl ove box l amp and swi tch uni t i nto
the hol e i n the mounti ng bracket on the i nstrument
panel gl ove box openi ng upper rei nforcement.
(5) I nstal l the gl ove box onto the i nstrument panel .
(Refer to 23 - BODY/I NSTRUMENT PANEL/GLOVE
BOX - I NSTALLATI ON) for the procedures.
(6) Cl ose the gl ove box.
READING LAMP
DESCRIPTION
The overhead consol e i n thi s vehi cl e i s equi pped
wi th two i ndi vi dual readi ng and courtesy l amps. The
l amp l enses are the onl y vi si bl e components of these
l amps. Each l amp has i ts own swi tch, bul b, refl ector
and l ens wi thi n the overhead consol e.
The overhead consol e readi ng and courtesy l amps
are control l ed by the i nstrument cl uster whi ch pro-
vi des power at al l ti mes, regardl ess of the i gni ti on
swi tch posi ti on. The ground ci rcui t for the l amps i s
swi tched through the i ntegral readi ng and courtesy
l amp swi tches or through the door ajar swi tches.
Each l amp i s desi gned and ai med to provi de i l l umi -
nati on that wi l l be di rected onl y to that si de of the
vehi cl e on whi ch the l amp i s l ocated.
The readi ng and courtesy l amp l enses and bul bs
are avai l abl e for servi ce repl acement. The readi ng
and courtesy l amp swi tches, bul b hol ders and wi ri ng
are onl y avai l abl e as part of the overhead consol e
wi re harness. I f ei ther of the l amp swi tches or bul b
hol ders i s faul ty or damaged, the enti re overhead
consol e wi re harness assembl y must be repl aced.
For servi ce of the readi ng and courtesy l amp bul bs,
refer to the appropri ate wi ri ng i nformati on.
OPERATION
Al l readi ng and courtesy l amps l ocated i n the over-
head consol e are acti vated by the door ajar swi tches
vi a the i nstrument cl uster. When al l of the doors are
cl osed, these l amps can be i ndi vi dual l y acti vated by
depressi ng the correspondi ng l ens. When any door i s
open, depressi ng the l amp l enses to acti vate the l amp
swi tches wi l l not turn the l amps off.
The i nstrument cl uster moni tors the door ajar
swi tches. When a door i s open the i nstrument cl uster
grounds the l ow si de dri vers to turn on the l amps.
Upon cl osi ng al l doors, the i nstrument cl uster i ni -
ti ates a 30 second ti mer. I f any of the doors are
opened duri ng the ti me out cycl e, the i nstrument
cl uster wi l l reset the ti mer unti l al l doors are cl osed.
The i nstrument cl uster wi l l fai d to off when the doors
are cl osed and the i gni ti on i s turned ON, the ti me
out expi res or the power l ocks are acti vated.
REMOVAL
cabl e.
(2) I nsert a l ong, narrow, fl at-bl aded tool between
the curved (outboard) edge of the readi ng and cour-
tesy l amp l ens and the overhead consol e housi ng
(Fi g. 4).
(3) Gentl y pry i nward and downward agai nst the
l ens unti l the l atch tab i n the center of the outboard
edge of the readi ng and courtesy l amp l ens i s di sen-
gaged from the overhead consol e housi ng.
(4) Pul l fi rml y on the l ens toward the outboard
si de of the vehi cl e to di sengage the two pi vot tabs on
the i nboard edge of the readi ng and courtesy l amp
l ens are di sengaged from the overhead consol e hous-
i ng.
(5) Remove the readi ng and courtesy l amp l ens
from the overhead consol e housi ng.
Fig. 4 Overhead Console Reading Lamp Bulb
Removal
1 - LENS
2 - FLAT BLADE
3 - CONSOLE
8L - 28 LAMPS/LIGHTING - INTERIOR DR
GLOVE BOX LAMP/SWITCH (Continued)
INSTALLATION
(1) Posi ti on the readi ng and courtesy l amp l ens
onto the overhead consol e housi ng.
(2) Al i gn the two pi vot tabs on the i nboard edge of
the readi ng and courtesy l amp l ens wi th the two
pi vot hol es i n the overhead consol e housi ng.
(3) Push fi rml y on the l ens toward the i nboard
si de of the vehi cl e to i nsert the two pi vot tabs on the
i nboard edge of the readi ng and courtesy l amp l ens
i nto the two pi vot hol es i n the overhead consol e hous-
i ng.
(4) Pi vot the l ens back up i nto posi ti on and press
upward fi rml y unti l the l atch tab i n the center of the
outboard edge of the readi ng and courtesy l amp l ens
snaps back i nto the overhead consol e housi ng.
DR LAMPS/LIGHTING - INTERIOR 8L - 29
READING LAMP (Continued)
MESSAGE SYSTEMS
TABLE OF CONTENTS
page page
OVERHEAD CONSOLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - OVERHEAD
CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - READING/
COURTESY LAMP REPLACEMENT . . . . . . . . . 3
STANDARD PROCEDURE - MODULE LENS
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE - MODULE LAMP
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE - COMPASS
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . 3
DEMAGNETIZING . . . . . . . . . . . . . . . . . . . . . . 4
VARIATION ADJUSTMENT. . . . . . . . . . . . . . . . 5
REMOVAL
OVERHEAD CONSOLE REMOVAL . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
COMPASS/MINI-TRIP COMPUTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - COMPASS
MINI-TRIP COMPUTER . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRONIC VEHICLE INFO CENTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - ELECTRONIC
VEHICLE INFORMATION CENTER . . . . . . . . . 8
STANDARD PROCEDURE - ELECTRONIC
VEHICLE INFORMATION CENTER
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AMBIENT TEMP SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR . . . . . . . . . . . . . . . 10
TEMPERATURE SENSOR CIRCUIT . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
UNIVERSAL TRANSMITTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - UNIVERSAL
TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE
STANDARD PROCEDURE - ERASING
TRANSMITTER CODES . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - SETTING
TRANSMITTER CODES . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OVERHEAD CONSOLE
DESCRIPTION
Two di fferent overhead consol es are avai l abl e on
DR model s. The El ectroni c Vehi cl e I nformati on Cen-
ter (EVI C) (Fi g. 1) or Compass Mi ni -Tri p Computer
(CMTC). Al l consol es are equi pped wi th two readi ng/
courtesy l amps. The overhead consol e i s mounted
wi th screws and two snap cl i ps to a mol ded pl asti c
retai ner bracket l ocated above the headl i ner.
COMPASS DISPLAY
Al l the avai l abl e overhead consol es on thi s model
i ncl ude Compass i nformati on. Whi l e i n the compass/
temperature mode, the compass wi l l di spl ay the
di recti on i n whi ch the vehi cl e i s poi nted usi ng the
ei ght major compass headi ngs (Exampl es: north i s N,
northeast i s NE). The sel f-cal i brati ng compass uni t
requi res no adjusti ng i n normal use. The onl y cal i -
brati on that may prove necessary i s to dri ve the vehi -
cl e at 5 to 8 ki l ometers-per-hour (3 to 5 mi l es-per-
hour), on l evel ground i n a square shaped pattern.
Thi s wi l l reori ent the compass uni t to i ts vehi cl e.
DR MESSAGE SYSTEMS 8M - 1
The compass uni t al so wi l l compensate for magne-
ti sm the body of the vehi cl e may acqui re duri ng nor-
mal use. However, avoi d pl aci ng anythi ng magneti c
di rectl y on the roof of the vehi cl e. Magneti c mounts
for an antenna, a repai r order hat, or a funeral pro-
cessi on fl ag can exceed the compensati ng abi l i ty of
the compass uni t i f pl aced on the roof panel . Mag-
neti c bi t dri vers used on the fasteners that hol d the
overhead consol e assembl y to the roof header can
al so affect compass operati on. I f the vehi cl e roof
shoul d become magneti zed, the demagneti zi ng and
cal i brati on procedures found i n thi s secti on may be
requi red to restore proper compass operati on.
TEMPERATURE DISPLAY
Al l the avai l abl e overhead consol es on thi s model
i ncl ude Temperature i nformati on. The temperature
di spl ays the outsi de ambi ent temperature i n whol e
degrees. The temperature di spl ay can be toggl ed
from Fahrenhei t to Cel si us by sel ecti ng the desi red
U.S./Metri c opti on from the customer programmabl e
features. The di spl ayed temperature i s not an i nstant
readi ng of condi ti ons, but an average temperature. I t
may take the temperature di spl ay several mi nutes to
respond to a major temperature change, such as dri v-
i ng out of a heated garage i nto wi nter temperatures.
When the i gni ti on swi tch i s turned to the Off posi -
ti on, the l ast di spl ayed temperature readi ng stays i n
the el ectroni c control modul es, (CMTC, EVI C) mem-
ory. When the i gni ti on swi tch i s turned to the On
posi ti on agai n, the el ectroni c modul e wi l l di spl ay the
memory temperature for one mi nute; then update the
di spl ay to the current average temperature readi ng
wi thi n fi ve mi nutes.
The temperature functi on i s supported by an ambi -
ent temperature sensor. Thi s sensor i s mounted out-
si de the passenger compartment near the front and
center of the vehi cl e, and i s hard wi red to the Front
Control Modul e (FCM). The FCM sends temperature
status messages to the modul e over the J1850 PCI
data bus ci rcui t. For more i nformati on on the ambi -
ent temperature sensor, refer to Ambi ent Tempera-
ture Sensor l ater i n thi s secti on.
Fol l owi ng are general descri pti ons of the major
components used i n the overhead consol e. Refer to
Wi ri ng Di agrams for compl ete ci rcui t schemati cs.
OPERATION
Refer to the vehi cl e Owners Manual for speci fi c
operati on of each overhead consol e and i ts systems.
DIAGNOSIS AND TESTING - OVERHEAD
CONSOLE
I f the probl em wi th the overhead consol e i s an
i naccurate or scrambl ed di spl ay, refer to SELF-DI-
AGNOSTIC TEST l ater i n thi s text. I f the probl em
wi th the overhead consol e i s i ncorrect Vacuum Fl uo-
rescent Di spl ay (VFD) di mmi ng l evel s, use a DRB
I I I scan tool and the proper Di agnosti c Procedures
manual to test for the correct di mmi ng message
i nputs bei ng recei ved from the Body Control Modul e
(BCM) or Front Control Modul e (FCM) over the
J1850 Programmabl e Communi cati ons I nterface
(PCI ) data bus ci rcui t. I f the probl em i s a no-di spl ay
condi ti on, use the fol l owi ng procedure. For compl ete
ci rcui t di agrams, refer to Overhead Console i n the
Wi ri ng Di agrams secti on of the servi ce manual .
(1) Remove the overhead consol e from the head-
l i ner (Refer to 8 - ELECTRI CAL/OVERHEAD CON-
SOLE - REMOVAL).
(2) Check for battery vol tage at the overhead con-
sol e el ectri cal connector. Refer to Wi ri ng for connec-
tor i nformati on. I f OK, go to Step 3. I f not OK, Check
for battery vol tage at the appropri ate B(+) fuse i n the
i ntegrated power modul e, repai r the open fused B(+)
ci rcui t as requi red.
Check the fused i gni ti on swi tch output ci rcui t(s) at
the overhead consol e el ectri cal connector. I f OK, go to
Step 4. I f not OK, repai r the open or shorted ci rcui t
as requi red.
(4) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Check for conti nui ty between the ground ci rcui t cav-
i ty of the overhead consol e el ectri cal connector and a
good ground. There shoul d be conti nui ty. I f OK, refer
to SELF-DIAGNOSTIC TEST bel ow for further
di agnosi s of the el ectroni cs modul e and the J1850
PCI data bus ci rcui t. I f not OK, repai r the open
ground ci rcui t as requi red.
Fig. 1 DR OVERHEAD CONSOLE EVIC
8M - 2 MESSAGE SYSTEMS DR
OVERHEAD CONSOLE (Continued)
SELF-DIAGNOSTIC TEST
A sel f-di agnosti c test i s bui l t-i n to the modul e to
determi ne that the el ectroni cs modul e i s operati ng
properl y, and that al l the J1850 PCI data bus mes-
sages are bei ng recei ved for proper operati on. To per-
form the sel f-di agnosti c test proceed as fol l ows:
(1) Wi th the i gni ti on swi tch i n the Off posi ti on,
si mul taneousl y depress and hol d the STEP and
RESET buttons.
(3) Fol l owi ng compl eti on of the test, the el ectroni cs
modul e wi l l di spl ay one of the fol l owi ng messages:
a. Pass Self Test (EVIC only), PASS (CMTC) -
The el ectroni cs modul e i s worki ng properl y.
b. Failed Self Test (EVIC only), FAIL (CMTC) -
The el ectroni cs modul e has an i nternal fai l ure. The
el ectroni cs modul e i s faul ty and must be repl aced.
c. Failed J 1850 Communication (EVIC only),
BUS (CMTC) - The el ectroni cs modul e i s not recei v-
i ng proper message i nput through the J1850 PCI
data bus ci rcui t. Thi s can resul t from one or more
faul ty el ectroni c modul es i n the vehi cl e, or from a
faul ty PCI data bus. The use of a DRB I I I scan tool
requi red for further di agnosi s.
NOTE: If the compass functions, but accuracy is
suspect, it may be necessary to perform a variation
adjustment. This procedure allows the compass
unit to accommodate variations in the earths mag-
netic field strength, based on geographic location.
Refer to Compass Variation Adjustment in the Stan-
dard Procedures section of this group.
NOTE: If the compass reading displays dashes, and
only CAL appears in the display, demagnetizing
may be necessary to remove excessive residual
magnetic fields from the vehicle. Refer to Compass
Demagnetizing in the Standard Procedures section
of this group.
STANDARD PROCEDURE
STANDARD PROCEDURE - READING/
COURTESY LAMP REPLACEMENT
(1) Open hood, di sconnect and i sol ate the negati ve
battery cabl e.
(2) Remove the readi ng/courtesy l amp l ens. Usi ng
a tri m sti ck, gentl y pry the forward edge of the read-
i ng/courtesy l amp l ens outward.
(3) Remove the readi ng/courtesy l amp socket from
the overhead consol e. Rotate the readi ng/courtesy
l amp socket one quarter turn counter cl ockwi se.
(4) Remove the l amp and socket assembl y.
(5) Reverse the above procedure to i nstal l .
STANDARD PROCEDURE - MODULE LENS
REPLACEMENT
(1) Remove the overhead consol e (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE -
REMOVAL).
(2) Remove the el ectroni cs modul e from the over-
head consol e. Refer to the procedure l ater i n thi s sec-
ti on.
(3) Unsnap the l ens from the modul e and repl ace
l ens as necessary.
STANDARD PROCEDURE - MODULE LAMP
REPLACEMENT
(1) Remove the overhead consol e (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE -
REMOVAL).
(2) Usi ng a fl at bl ade screwdri ver twi st out socket/
l amp (Fi g. 2).
(3) Repl ace l amp(s) as necessary.
CALIBRATION
CAUTION: Do not place any external magnets, such
as magnetic roof mount antennas, in the vicinity of
the compass. Do not use magnetic tools when ser-
vicing the overhead console.
Fig. 2 Top of Overhead Console
1 - OVERHEAD CONSOLE HOUSING
2 - EVIC/CMTC MODULE
3 - ILLUMINATION LAMPS
4 - MODULE RETAINING SCREWS
The el ectroni c compass uni t features a sel f-cal i -
brati ng desi gn, whi ch si mpl i fi es the cal i brati on pro-
cedure. Thi s feature automati cal l y updates the
compass cal i brati on whi l e the vehi cl e i s bei ng dri ven.
Thi s al l ows the compass uni t to compensate for smal l
changes i n the resi dual magneti sm that the vehi cl e
may acqui re duri ng normal use. I f the compass read-
i ngs appear to be errati c or out of cal i brati on, per-
form the fol l owi ng cal i brati on procedure. Al so, new
servi ce repl acement El ectroni c Modul es (EVI C,
CMTC) must have thei r compass cal i brated usi ng
thi s procedure. Do not attempt to cal i brate the com-
pass near l arge metal objects such as other vehi cl es,
l arge bui l di ngs, or bri dges; or, near overhead or
underground power l i nes.
NOTE: Whenever the compass is calibrated manu-
ally, the variance number must also be reset. Refer
to Compass Variation Adjustment in this group.
To cal i brate the compass manual l y proceed as fol -
l ows:
(1) Turn the i gni ti on swi tch to the On posi ti on. I f
the compass/temperature data i s not currentl y bei ng
di spl ayed, momentari l y depress and rel ease the C/T
push button to reach the compass/temperature di s-
pl ay.
(2) Depress the RESET push button and hol d the
button down unti l CAL appears i n the di spl ay. Thi s
takes about ten seconds, and appears about fi ve sec-
onds after VAR = XX i s di spl ayed.
(3) Rel ease the RESET push button.
(4) Dri ve the vehi cl e on a l evel surface, away from
l arge metal objects and power l i nes, through three or
more compl ete turns at between fi ve and ei ght ki l o-
meters-per-hour (three and fi ve mi l es-per-hour) i n
not l ess than 48 seconds. The CAL message wi l l
di sappear from the di spl ay to i ndi cate that the com-
pass i s now cal i brated.
NOTE: If the CAL message remains in the display,
either there is excessive magnetism near the com-
pass, or the unit is faulty. Repeat the calibration
procedure one more time.
NOTE: If the wrong direction is still indicated in the
compass display, the area selected for calibration
may be too close to a strong magnetic field. Repeat
the calibration procedure in another location.
DEMAGNETIZING
A degaussi ng tool (Speci al Tool 6029) i s used to
demagneti ze, or degauss, the overhead consol e for-
ward mounti ng screw and the roof panel above the
overhead consol e. Equi val ent uni ts must be rated as
conti nuous duty for 110/115 vol ts and 60 Hz. They
must al so have a fi el d strength of over 350 gauss at 7
mi l l i meters (0.25 i nch) beyond the ti p of the probe.
To demagneti ze the roof panel and the overhead
consol e forward mounti ng screw, proceed as fol l ows:
(1) Be certai n that the i gni ti on swi tch i s i n the Off
posi ti on, before you begi n the demagneti zi ng proce-
dure.
(2) Connect the degaussi ng tool to an el ectri cal
outl et, whi l e keepi ng the tool at l east 61 centi meters
(2 feet) away from the compass uni t.
(3) Sl owl y approach the head of the overhead con-
sol e mounti ng screw wi th the degaussi ng tool con-
nected.
(4) Contact the head of the screw wi th the pl asti c
coated ti p of the degaussi ng tool for about two sec-
onds.
(5) Wi th the degaussi ng tool sti l l energi zed, sl owl y
back i t away from the screw. When the ti p of the tool
i s at l east 61 centi meters (2 feet) from the screw
head, di sconnect the tool .
(6) Pl ace a pi ece of paper approxi matel y 22 by 28
centi meters (8.5 by 11 i nches), ori ented on the vehi cl e
l engthwi se from front to rear, on the center l i ne of
the roof at the wi ndshi el d header (Fi g. 3). The pur-
pose of the paper i s to protect the roof panel from
scratches, and to defi ne the area to be demagneti zed.
(7) Connect the degaussi ng tool to an el ectri cal
outl et, whi l e keepi ng the tool at l east 61 centi meters
(2 feet) away from the compass uni t.
(8) Sl owl y approach the center l i ne of the roof
panel at the wi ndshi el d header, wi th the degaussi ng
tool connected.
(9) Contact the roof panel wi th the pl asti c coated
ti p of the degaussi ng tool . Be sure that the templ ate
i s i n pl ace to avoi d scratchi ng the roof panel . Usi ng a
sl ow, back-and-forth sweepi ng moti on, and al l owi ng
13 mi l l i meters (0.50 i nch) between passes, move the
tool at l east 11 centi meters (4 i nches) to each si de of
the roof center l i ne, and 28 centi meters (11 i nches)
back from the wi ndshi el d header.
(10) Wi th the degaussi ng tool sti l l energi zed,
sl owl y back i t away from the roof panel . When the
ti p of the tool i s at l east 61 centi meters (2 feet) from
the roof panel , di sconnect the tool .
(11) Cal i brate the compass and adjust the compass
vari ance (Refer to 8 - ELECTRI CAL/OVERHEAD
CONSOLE - STANDARD PROCEDURE).
VARIATION ADJUSTMENT
Compass vari ance, al so known as magneti c decl i -
nati on, i s the di fference i n angl e between magneti c
north and true geographi c north. I n some geographi c
l ocati ons, the di fference between magneti c and geo-
graphi c north i s great enough to cause the compass
to gi ve fal se readi ngs. I f thi s probl em occurs, the
compass vari ance setti ng may need to be changed.
To set the compass vari ance:
(1) Usi ng the Vari ance Setti ngs map, fi nd your
geographi c l ocati on and note the zone number (Fi g.
4).
(2) Turn the i gni ti on swi tch to the On posi ti on. I f
the compass/temperature data i s not currentl y bei ng
di spl ayed, momentari l y depress and rel ease the C/T
push button to reach the compass/temperature di s-
pl ay.
(3) Depress the RESET push button and hol d the
button down unti l VAR = XX appears i n the di spl ay.
Thi s takes about fi ve seconds.
(4) Rel ease the RESET push button. VAR =XX
wi l l remai n i n the di spl ay. XX equal s the current
vari ance zone setti ng.
(5) Depress and rel ease the STEP push button to
step through the zone numbers, unti l the zone num-
ber for your geographi c l ocati on appears i n the di s-
pl ay.
Fig. 4 Variance Settings
Fig. 3 Roof Demagnetizing Pattern
(6) Depress and rel ease the RESET push button
to enter the di spl ayed zone number i nto the EVI C/
CMTC modul e memory.
(7) Confi rm that the correct di recti ons are now
i ndi cated by the compass.
REMOVAL
OVERHEAD CONSOLE REMOVAL
cabl e.
(2) Remove the overhead consol e retai ni ng screws,
l ocated i n the sungl ass storage bi n.
(3) Usi ng your fi ngerti ps, grasp the si des of the
overhead consol e and pul l strai ght down evenl y to
di sengage the two snap cl i ps at the front of the uni t.
(4) Lower the overhead consol e far enough to
access the wi re harness connectors.
(5) Di sconnect the EVI C, CMTC el ectroni c modul e
and the readi ng/courtesy l amps el ectri cal connectors.
(6) Remove the overhead consol e from the vehi cl e.
INSTALLATION
(1) Posi ti on the overhead consol e i n the vehi cl e.
(2) Connect the EVI C, CMTC el ectroni c modul e
and the readi ng/courtesy l amps el ectri cal connectors.
(3) Grasp the si des of the overhead consol e and
push strai ght up evenl y to engage the two snap cl i ps
at the rear of the uni t.
(4) I nstal l the overhead consol e retai ni ng screw,
l ocated i n the front of consol e. Torque the screw to
1.2 Nm (10 i n. l bs.).
COMPASS/MINI-TRIP
COMPUTER
DESCRIPTION
The Compass Mi ni -Tri p Computer (CMTC) i s a
modul e l ocated i n the overhead consol e. The CMTC i s
equi pped wi th a mi ni -tri p feature. The CMTC con-
si sts of a el ectroni c control modul e wi th a vacuum
fl uorescent di spl ay (VFD) and functi on swi tches. The
CMTC consi sts of a el ectroni c modul e that di spl ays
compass, tri p computer, and temperature features.
Actuati ng the STEP push button wi l l cause the
CMTC to change mode of operati on when the i gni ti on
i s ON. Exampl e:
Average mi l es per gal l on (ECO)
Di stance to empty (DTE)
Tri p odometer (ODO)
El apsed ti me (ET)
Off
Actuati ng the C/T push button wi l l cause the
CMTC to change to Compass/Temperature di spl ay.
OPERATION
The Compass Mi ni -Tri p Computer modul e i n the
overhead consol e has buttons used to sel ect vari ous
functi ons. The CMTC sel ector buttons wi l l not oper-
ate unti l the i gni ti on i s i n the RUN posi ti on.
When the i gni ti on swi tch i s fi rst turned to the
RUN posi ti on the CMTC di spl ay;
Returns to the l ast mode setti ng sel ected before
the i gni ti on was l ast swi tched OFF.
DIAGNOSIS AND TESTING - COMPASS
MINI-TRIP COMPUTER
Compass Mi ni -Tri p Computer (CMTC) data i s
obtai ned from other el ectroni c modul es (CCN, FCM
and JTEC) on the J1850 Data Bus ci rcui t. The
CMTC wi l l di spl ay dashes (- -) for any of the screens
i t di d not recei ve the bus messages. The l abel corre-
spondi ng to the mi ssi ng i nformati on wi l l be l i t. I f no
compass mi ni -tri p computer data i s di spl ayed, check
the J1850 Data Bus ci rcui t communi cati ons and the
other modul es.
Refer to Overhead Consol e Di agnosi s and Testi ng
for i nstructi ons on performi ng a CMTC modul e Sel f-
Di agnosti c Test. The DRB I I I i s recommended for
checki ng the J1850 Data Bus ci rcui t and the other
modul es. Perform the CMTC sel f di agnosi s before
repl aci ng the CMTC modul e.
REMOVAL
cabl e.
(2) Remove the overhead consol e from the headl i n-
er.(Refer to 8 - ELECTRI CAL/OVERHEAD CON-
SOLE - REMOVAL).
(3) Remove the screws hol di ng Compass Mi ni -Tri p
Computer modul e i n the overhead consol e (Fi g. 5).
(4) Di sconnect the CMTC modul e el ectri cal connec-
tor. Depress the retai ni ng tab and pul l strai ght
apart.
(5) Remove CMTC modul e from consol e assembl y.
INSTALLATION
(1) Posi ti on the compass mi ni -tri p computer mod-
ul e i n the overhead consol e.
(2) I nstal l the screws hol di ng the compass mi ni -
tri p computer modul e i n the overhead consol e.
(3) Connect the modul e el ectri cal connector.
(4) I nstal l the overhead consol e on the headl i n-
er(Refer to 8 - ELECTRI CAL/OVERHEAD CON-
SOLE - I NSTALLATI ON).
(6) Check CMTC modul e functi on.
NOTE: If a new module has been installed, the com-
pass will have to be calibrated and the variance set.
Refer to Compass Variation Adjustment and Com-
pass Calibration in the Standard Procedures sec-
tion of this group for the procedures.
ELECTRONIC VEHICLE INFO
CENTER
DESCRIPTION
The El ectroni c Vehi cl e I nformati on Center (EVI C)
i s a modul e l ocated i n the overhead consol e on some
model s. The EVI C modul e features a l arge Vacuum
Fl uorescent Di spl ay (VFD) screen for di spl ayi ng
i nformati on, and back-l i t push button swi tches
l abel ed C/T (compass/temperature), RESET, STEP,
and MENU.
The EVI C modul e contai ns a central processi ng
uni t and i nterfaces wi th other el ectroni c modul es i n
the vehi cl e over the Programmabl e Communi cati ons
I nterface (PCI ) J1850 data bus ci rcui t. The PCI data
bus ci rcui t al l ows the shari ng of sensor i nformati on.
Thi s hel ps to reduce wi re harness compl exi ty, reduce
i nternal control l er hardware, and reduce component
sensor current l oads. At the same ti me, thi s system
provi des i ncreased rel i abi l i ty, enhanced di agnosti cs,
and al l ows the addi ti on of many new feature capabi l -
i ti es.
The EVI C Menu push button provi des the vehi cl e
operator wi th a user i nterface, whi ch al l ows the
sel ecti on of several opti onal customer programmabl e
el ectroni c features to sui t i ndi vi dual preferences.
Refer to ELECTRONIC VEHICLE INFORMA-
TION CENTER PROGRAMMING i n the Standard
Procedures secti on of thi s group for more i nformati on
on the customer programmabl e feature opti ons.
I f the vehi cl e i s equi pped wi th the opti onal uni ver-
sal transmi tter transcei ver, the EVI C wi l l al so di s-
pl ay messages and an i con i ndi cati ng when the
uni versal transmi tter transcei ver i s bei ng trai ned,
whi ch of the three transmi tter buttons i s transmi t-
ti ng, and when the transcei ver i s cl eared.
Data i nput for al l EVI C functi ons, i ncl udi ng VFD
di mmi ng l evel , i s recei ved through the J1850 PCI
data bus ci rcui t. The EVI C modul e uses i ts i nternal
programmi ng and al l of i ts data i nputs to cal cul ate
and di spl ay the requested data. I f the data di spl ayed
i s i ncorrect, perform the sel f-di agnosti c tests as
descri bed i n thi s group. I f these tests prove i nconcl u-
si ve, the use of a DRB I I I scan tool and the proper
Di agnosti c Procedures manual are recommended for
further testi ng of the EVI C modul e and the J1850
PCI data bus ci rcui t.
The EVI C modul e cannot be repai red, and i s avai l -
abl e for servi ce onl y as a uni t. I f any part i s faul ty or
damaged, the compl ete EVI C modul e must be
repl aced.
OPERATION
The El ectroni c Vehi cl e I nformati on Center i s wi red
to both constant 12v and i gni ti on swi tched sources of
battery current so that some of i ts features remai n
operati onal at any ti me, whi l e others may onl y oper-
ate wi th the i gni ti on swi tch i n the On posi ti on. When
the i gni ti on swi tch i s turned to the On posi ti on, the
EVI C modul e di spl ay wi l l return to the l ast functi on
bei ng di spl ayed before the i gni ti on was turned to the
Off posi ti on.
The compass/temperature di spl ay i s the normal
EVI C di spl ay. Wi th the i gni ti on swi tch i n the On
posi ti on, momentari l y depressi ng and rel easi ng the
C/T (compass/temperature) push button swi tch wi l l
cause the EVI C to return to the compass/tempera-
ture di spl ay mode from any other mode. Whi l e i n the
compass/temperature di spl ay mode, momentari l y
depressi ng and rel easi ng the Step push button wi l l
step through the avai l abl e tri p computer di spl ay
opti ons.
The EVI C tri p computer features several functi ons
that can be reset. The functi ons that can be reset
are: average fuel economy, tri p odometer and el apsed
ti me. Wi th the i gni ti on swi tch i n the On posi ti on and
wi th one of the functi ons of the tri p computer that
can be reset currentl y di spl ayed, depressi ng the
Fig. 5 OVERHEAD CONSOLE MODULE REMOVAL
1 - COMPASS MINI-TRIP COMPUTER MODULE
2 - OVERHEAD CONSOLE
COMPASS/MINI-TRIP COMPUTER (Continued)
Reset push button twi ce wi thi n three seconds wi l l
perform a gl obal reset, and al l of the tri p computer
i nformati on that can be reset wi l l be reset to zero.
Wi th the i gni ti on swi tch i n the On posi ti on and the
functi on that i s to be reset currentl y di spl ayed,
momentari l y depressi ng and rel easi ng the Reset
push button once wi l l perform a l ocal reset, and onl y
the val ue of the di spl ayed functi on wi l l be reset to
zero. A gl obal or l ocal reset wi l l onl y occur i f the
functi on currentl y di spl ayed i s a functi on that can be
reset. The di stance to servi ce functi on can al so be
reset usi ng the l ocal reset method, but i t wi l l reset
back to the Servi ce I nterval di stance that i s set i n
the EVI C programmabl e features mode. Refer to
ELECTRONIC VEHICLE INFORMATION CEN-
TER PROGRAMMING i n the Standard Procedures
secti on of thi s group for more i nformati on on setti ng
the Servi ce I nterval .
For more i nformati on on the features, control func-
ti ons and setti ng procedures for the EVI C modul e,
see the owners manual i n the vehi cl e gl ove box.
DIAGNOSIS AND TESTING - ELECTRONIC
El ectroni c Vehi cl e I nformati on Center (EVI C) data
i s obtai ned from other el ectroni c modul es (CCN,
FCM, JTEC) on the J1850 Data Bus ci rcui t. The
EVI C wi l l di spl ay dashes (- -) for any of the screens
i t di d not recei ve the bus messages. The l abel corre-
spondi ng to the mi ssi ng i nformati on wi l l be l i t. I f no
EVI C data i s di spl ayed, check the J1850 Data Bus
ci rcui t communi cati ons and the other modul es. I f the
bri ghtness l evel i s i mproper check the J1850 Data
Bus ci rcui t.
Refer to Overhead Consol e Di agnosi s and Testi ng
for i nstructi ons on performi ng a EVI C modul e Sel f-
Di agnosti c Test. The DRB I I I i s recommended for
checki ng the J1850 Data Bus ci rcui t and other mod-
ul es. Perform the EVI C sel f di agnosi s before repl ac-
i ng the EVI C modul e.
STANDARD PROCEDURE - ELECTRONIC
PROGRAMMING
EVIC PROGRAMMING MODE
Some vehi cl es are equi pped wi th a El ectroni c Vehi -
cl e I nformati on Center (EVI C) equi pped overhead
consol e. The El ectroni c Vehi cl e I nformati on Center
(EVI C) provi des the vehi cl e operator wi th a user
i nterface, whi ch al l ows the sel ecti on of several
opti onal customer programmabl e el ectroni c features
to sui t i ndi vi dual preferences. The EVI C must be
pl aced i nto i ts programmi ng mode i n order to vi ew or
change the programmabl e features. To enter the
EVI C programmi ng mode and to vi ew or change the
sel ected programmabl e features opti ons, proceed as
fol l ows:
(2) Momentari l y depress and rel ease the Menu
push button to step through the programmabl e fea-
tures l i st. Each programmabl e feature and i ts cur-
rentl y sel ected opti on wi l l appear on the EVI C
di spl ay i n the sequence shown i n the Programmabl e
Features l i st that fol l ows.
(3) Momentari l y depress and rel ease the Step push
button to step through the avai l abl e opti ons for the
programmabl e feature bei ng di spl ayed.
(4) The opti on that l ast appears i n the di spl ay
wi th a programmabl e feature before exi ti ng the pro-
grammi ng mode, becomes the newl y sel ected pro-
grammabl e feature opti on.
(5) The EVI C exi ts the programmi ng mode and
returns to i ts normal operati ng mode when the C/T
push button i s depressed or when the end of the pro-
grammabl e features menu l i st i s reached, whi chever
occurs fi rst.
PROGRAMMABLE FEATURES
LANGUAGE? - The opti ons i ncl ude Engl i sh,
Francai se, Deutsch, I tal i ana, or Espanol . The defaul t
i s Engl i sh. Al l EVI C di spl ay nomencl ature, i ncl udi ng
the tri p computer functi ons, warni ng messages and
the programmabl e features appear i n the sel ected
l anguage.
DISPLAY U.S. OR METRIC? - The opti ons
i ncl ude U.S. and M. The defaul t i s U.S. Thi s feature
toggl es the tri p computer temperature, fuel economy
and odometer di spl ay readi ngs between U.S. and
metri c uni ts of measure.
SERVICE INTV. = - The opti ons i ncl ude from
3200 to 12000 ki l ometers i n 800 ki l ometer i ncre-
ments (2000 to 6000 mi l es i n 500 mi l e i ncrements).
The defaul t i s 12000 ki l ometers (6000 mi l es). The
sel ected di stance becomes the i nterval at whi ch the
Perform Servi ce warni ng message wi l l be di spl ayed
by the EVI C. I f a new di stance i s sel ected, a second
programmabl e feature appears, RESET SERVICE
DISTANCE? - The opti ons i ncl ude No and Yes. The
defaul t i s Yes. When Yes i s sel ected, the accumul ated
di stance si nce the l ast previ ous Perform Servi ce
warni ng message wi l l be reset to zero because the
servi ce i nterval has been changed. When No i s
sel ected, the di stance unti l the next Perform Servi ce
warni ng message i s reduced by the accumul ated di s-
tance si nce the l ast previ ous message.
AUTO DOOR LOCKS? - The opti ons i ncl ude
Yes and No. The defaul t i s Yes. When Yes i s sel ected,
al l doors l ock automati cal l y when vehi cl e speed
reaches 25 ki l ometers-per-hour (15 mi l es-per-hour). I f
YES i s sel ected, a second programmabl e feature
ELECTRONIC VEHICLE INFO CENTER (Continued)
appears, AUTO UNLOCK ON EXIT? - The opti ons
agai n i ncl ude Yes and No. The defaul t i s No. When
Yes i s sel ected, fol l owi ng each Auto Door Lock event
al l doors wi l l automati cal l y unl ock when the dri ver
door i s opened, i f the vehi cl e i s stopped and the
transmi ssi on gear sel ector i s i n Park or Neutral . The
Auto Door Unl ock event wi l l onl y occur once fol l ow-
i ng each Auto Door Lock event.
REMOTE UNLOCK - The opti ons i ncl ude
Dri ver Door 1st and Al l Doors. The defaul t i s Dri ver
Door 1st. When Di ver Door 1st i s sel ected, onl y the
dri ver door unl ocks when the Unl ock button of the
Remote Keyl ess Entry (RKE) transmi tter i s
depressed once. The Unl ock button of the RKE trans-
mi tter must be depressed twi ce to unl ock al l doors.
When Al l Doors i s sel ected, al l doors unl ock when the
Unl ock button of the RKE transmi tter i s depressed
once.
SOUND HORN ON LOCK? - The opti ons
i ncl ude On and Off. The defaul t i s No. When Yes i s
sel ected, a short horn chi rp wi l l provi de an audi bl e
confi rmati on when the RKE recei ver recogni zes a
val i d Lock si gnal from an RKE transmi tter. When No
i s sel ected, no horn chi rp wi l l occur wi th the RKE
Lock event. Thi s feature may be sel ected i ndepen-
dent of the FLASH LIGHTS WITH LOCKS? pro-
grammabl e feature.
FLASH LIGHTS WITH LOCKS? - The opti ons
i ncl ude Yes and No. The defaul t i s Yes. When Yes i s
sel ected, a si ngl e fl ash of the hazard warni ng l amps
wi l l provi de an opti cal confi rmati on when the RKE
recei ver recogni zes a val i d Lock si gnal from an RKE
transmi tter, and two fl ashes of the same l amps wi l l
occur when the RKE recei ver recogni zes a val i d
Unl ock si gnal from an RKE transmi tter. When No i s
sel ected, no l amp fl ash wi l l occur wi th the RKE Lock
or Unl ock event. Thi s feature may be sel ected i nde-
pendent of the SOUND HORN ON LOCK? pro-
grammabl e feature.
HEADLAMP DELAY = - The opti ons i ncl ude
Off, 30 Sec, 60 Sec, and 90 Sec. The defaul t i s 90 Sec.
When a ti me i nterval i s sel ected, the headl amps wi l l
remai n on for that l ength of ti me when the head-
l amps are turned off after the i gni ti on i s turned off,
or i f the Auto mode i s sel ected on vehi cl es wi th the
Auto Headl amps opti on. When Off i s sel ected, the
headl amp del ay feature i s di sabl ed.
TRAIN REMOTE - When thi s feature i s
sel ected the dri ver can choose to trai n up to four
remote keyl ess entry transmi tters. The opti ons
i ncl ude Yes and No. The defaul t i s No. When Yes i s
sel ected and the MENU button i s pressed the EVI C
wi l l di spl ay PRESS REMOTE LOCK & UNLOCK
THEN PRESS UNLOCK, fol l owed by a chi me to
i ndi cate the trai ni ng sequence can commence. You
have approxi matel y 30 seconds to trai n up to four
transmi tters, after each transmi tter i s trai ned a
chi me wi l l sound i ndi cati ng that the trai ni ng was
successful . I f remote l i nk to memory i s YES , the
fi rst transmi tter trai ned wi l l be associ ated wi th
memory setti ng 1 and the second transmi tter trai ned
wi l l be associ ated wi th memory setti ng 2. Addi ti onal
transmi tters wi l l not be associ ated wi th a memory
setti ng. When you have fi ni shed trai ni ng the trans-
mi tters, press the menu button agai n and the EVI C
wi l l di spl ay TRAI N DONE X TRAI NED. I f no
transmi tters are trai ned wi thi n approxi matel y 30
seconds the EVI C wi l l di spl ay TRAI N TI MEOUT.
REMOVAL
cabl e.
(2) Remove the overhead consol e from the headl i n-
er.(Refer to 8 - ELECTRI CAL/OVERHEAD CON-
SOLE - REMOVAL).
(3) Di sconnect the EVI C modul e el ectri cal connec-
tor. Depress the retai ni ng tab and pul l strai ght
apart.
(4) Remove the screws hol di ng the EVI C modul e i n
the overhead consol e (Fi g. 6).
(5) Remove EVI C modul e from consol e assembl y.
INSTALLATION
(1) Posi ti on the EVI C modul e i n the overhead con-
sol e.
Fig. 6 OVERHEAD CONSOLE MODULE REMOVAL
1 - ELECTRONIC VEHICLE INFORMATION MODULE
2 - OVERHEAD CONSOLE
(2) I nstal l the screws hol di ng the EVI C modul e i n
the overhead consol e.
(3) Connect the EVI C modul e el ectri cal connector.
(4) I nstal l the overhead consol e on the headl i n-
er(Refer to 8 - ELECTRI CAL/OVERHEAD CON-
SOLE - I NSTALLATI ON).
(6) Check EVI C modul e functi on.
NOTE: If a new EVIC module has been installed, the
compass will have to be calibrated and the variance
set. Refer to Compass Variation Adjustment and
Compass Calibration in the Standard Procedures
section of this group for the procedures.
AMBIENT TEMP SENSOR
DESCRIPTION
Ambi ent ai r temperature i s moni tored by the over-
head consol e. The ambi ent temperature messages are
recei ved from the Front Control Modul e (FCM) over
J1850 data bus ci rcui t. The FCM recei ves a hard
wi red i nput from the ambi ent temperature sensor
(Fi g. 7). The ambi ent temperature sensor i s a vari -
abl e resi stor mounted to the undersi de of the hood,
i n the engi ne compartment.
For more i nformati on on the front control modul e,
refer to Front Control Module i n the El ectroni c
Control Modul es secti on of thi s manual . For compl ete
ci rcui t di agrams, refer to Wiring. The ambi ent tem-
perature sensor cannot be adjusted or repai red and,
i f faul ty or damaged, i t must be repl aced.
OPERATION
The ambi ent temperature sensor i s a vari abl e
resi stor that operates on a fi ve-vol t reference si gnal
sent to i t by the Front Control Modul e. The resi s-
tance i n the sensor changes as temperature changes,
changi ng the temperature sensor si gnal ci rcui t vol t-
age to the Front Control Modul e. Based upon the
resi stance i n the sensor, the Front Control Modul e
senses a speci fi c vol tage on the temperature sensor
si gnal ci rcui t, whi ch i t i s programmed to correspond
to a speci fi c temperature. The Front Control Modul e
then sends the proper ambi ent temperature mes-
sages to the EVI C, CMTC over the PCI J1850 data
bus.
The temperature functi on i s supported by the
ambi ent temperature sensor, a wi ri ng ci rcui t, the
Front Control Modul e, the Programmabl e Communi -
cati ons I nterface (PCI ) data bus, and a porti on of the
El ectroni cs modul e. I f any porti on of the ambi ent
temperature sensor ci rcui t fai l s, the Front Control
Modul e wi l l sel f-di agnose the ci rcui t.
For compl ete ci rcui t di agrams, refer to Wiring.
TEMPERATURE SENSOR
Di sconnect the ambi ent temperature sensor wi re har-
ness connector.
(2) Measure the resi stance of the ambi ent temper-
ature sensor. At 24 C (75 F), the sensor resi stance
shoul d be approxi matel y 10.3 ki l ohms. At 30 C (86
F), the sensor resi stance shoul d be approxi matel y
7.57 ki l ohms. The sensor resi stance shoul d decrease
as the temperature ri ses. I f OK, refer to Diagnosis
and Testing - Ambient Temperature Sensor Cir-
cuit i n thi s group. I f not OK, repl ace the faul ty
ambi ent temperature sensor.
NOTE: The ambient temperature sensor is a very
sensitive device. When testing, be certain the tem-
perature sensor has had time to stabilize (room
temperature) before attempting to read the sensor
resistance. Failure to let the ambient temperature
sensor temperature stabilize could result in a mis-
leading test.
TEMPERATURE SENSOR CIRCUIT
Di sconnect the ambi ent temperature sensor wi re har-
ness connector and the Front Control Modul e wi re
harness connector.
(2) Connect a jumper wi re between the two termi -
nal s of the ambi ent temperature sensor wi re harness
connector.
(3) Check for conti nui ty between the sensor return
ci rcui t and the ambi ent temperature sensor si gnal
ci rcui t cavi ti es of the Front Control Modul e wi re har-
Fig. 7 Ambient Temperature Sensor - Typical
ness connector. There shoul d be conti nui ty. I f OK, go
to Step 4. I f not OK, repai r the open sensor return or
si gnal ci rcui t as requi red.
(4) Remove the jumper wi re from the ambi ent tem-
perature sensor wi re harness connector. Check for
conti nui ty between the sensor return ci rcui t cavi ty of
the Front Control Modul e wi re harness connector
and a good ground. There shoul d be no conti nui ty. I f
OK, go to Step 5. I f not OK, repai r the shorted sen-
sor return ci rcui t as requi red.
(5) Check for conti nui ty between the ambi ent tem-
perature sensor si gnal ci rcui t cavi ty of the Front
Control Modul e wi re harness connector and a good
ground. There shoul d be no conti nui ty. I f OK, refer to
Diagnosis and Testing - Overhead Console i n
thi s group. I f not OK, repai r the shorted ambi ent
temperature sensor si gnal ci rcui t as requi red.
REMOVAL
(1) Open the hood.
cabl e.
(3) Worki ng on the undersi de of the hood, remove
screw hol di ng sensor to hood panel .
(4) Di sconnect the sensor el ectri cal connector and
remove sensor from vehi cl e.
INSTALLATION
(1) Connect the sensor el ectri cal connector.
(2) Worki ng on the undersi de of the hood, i nstal l
screw hol di ng sensor to hood panel .
(4) Cl ose the hood.
UNIVERSAL TRANSMITTER
DESCRIPTION
Some DR model s are equi pped wi th a uni versal
transmi tter transcei ver. The uni versal transmi tter i s
i ntegral to the El ectroni c Vehi cl e I nformati on Center
(EVI C) and the Compass Mi ni -Tri p Computer
(CMTC), whi ch i s l ocated i n the overhead consol e.
The onl y vi si bl e component of the uni versal transmi t-
ter are the three transmi tter push buttons centered
between the modul es push buttons l ocated just rear-
ward of the di spl ay screen i n the overhead consol e.
The three uni versal transmi tter push buttons are
i denti fi ed wi th one, two or three l i ght i ndi cators so
that they be easi l y i denti fi ed.
Each of the three uni versal transmi tter push but-
tons control an i ndependent radi o transmi tter chan-
nel . Each of these three channel s can be trai ned to
transmi t a di fferent radi o frequency si gnal for the
remote operati on of garage door openers, motori zed
gate openers, home or offi ce l i ghti ng, securi ty sys-
tems or just about any other devi ce that can be
equi pped wi th a radi o recei ver i n the 286 to 399
MegaHertz (MHz) frequency range for remote opera-
ti on. The uni versal transmi tter i s capabl e of operat-
i ng systems usi ng ei ther rol l i ng code or non-rol l i ng
code technol ogy.
The el ectroni cs modul e di spl ays messages and a
smal l house-shaped i con wi th one, two or three dots
correspondi ng to the three transmi tter buttons to
i ndi cate the status of the uni versal transmi tter. The
EVI C messages are:
Clearing Channels - I ndi cates that al l of the
transmi tter codes stored i n the uni versal transmi tter
have been successful l y cl eared.
Channel XTraining - I ndi cates that the uni -
versal transmi tter i s i n i ts transmi tter l earni ng
mode.
Channel X Trained - I ndi cates that the uni -
versal transmi tter has successful l y acqui red a new
transmi tter code.
Channel X Transmitting - I ndi cates that a
trai ned uni versal transmi tter button has been
depressed and that the uni versal transmi tter i s
transmi tti ng.
The uni versal transmi tter cannot be repai red, and
i s avai l abl e for servi ce onl y as a uni t wi th the EVI C
or CMTC modul es. I f any part of the uni versal trans-
mi tter i s faul ty or damaged, the compl ete EVI C or
CMTC modul e must be repl aced.
OPERATION
The uni versal transmi tter operates on a non-
swi tched source of battery current so the uni t wi l l
remai n functi onal , regardl ess of the i gni ti on swi tch
posi ti on. For more i nformati on on the features, pro-
grammi ng procedures and operati on of the uni versal
transmi tter, see the owners manual i n the vehi cl e
gl ove box.
DIAGNOSIS AND TESTING - UNIVERSAL
TRANSMITTER
I f the Uni versal Transmi tter i s i noperati ve, but the
El ectroni c Vehi cl e I nformati on Center (EVI C) i s oper-
ati ng normal l y, see the owners manual i n the vehi cl e
gl ove box for i nstructi ons on trai ni ng the Transmi t-
ter. Retrai n the Transmi tter wi th a known good
transmi tter as i nstructed i n the owners manual and
test the Transmi tter operati on agai n. I f the uni t i s
sti l l i noperati ve, test the uni versal transmi tter wi th
Radi o Frequency Detector speci al tool . I f both the
Transmi tter and the EVI C modul e are i noperati ve,
refer to Electronic Vehicle Information Center
Diagnosis and Testing i n thi s group for further
di agnosi s. For compl ete ci rcui t di agrams, refer to
Wiring Diagrams. (Fi g. 8) as descri bed bel ow:
AMBIENT TEMP SENSOR (Continued)
(1) Turn the Radi o Frequency (RF) Detector ON. A
chi rp wi l l sound and the green power LED wi l l
l i ght. I f the green LED does not l i ght, repl ace the
battery.
(2) Hol d the RF detector wi thi n one i nch of the
TRAI NED uni versal transmi tter and press any of the
transmi tters buttons.
(3) The red si gnal detecti on LEDs wi l l l i ght and
the tool wi l l beep i f a radi o si gnal i s detected. Repeat
thi s test three ti mes.
STANDARD PROCEDURE
STANDARD PROCEDURE - ERASING
TRANSMITTER CODES
To erase the uni versal transmi tter codes, si mpl y
hol d down the two outsi de buttons unti l the di spl ay
confi rms the operati on.
NOTE: Individual channels cannot be erased. Eras-
ing the transmitter codes will erase ALL pro-
grammed codes.
STANDARD PROCEDURE - SETTING
TRANSMITTER CODES
(1) Turn off the engi ne.
(2) Erase the codes by pressi ng the two outsi de
buttons. Rel ease the buttons when the di spl ay con-
fi rms the operati on (about 20 seconds).
(3) Choose one of the three buttons to trai n. Pl ace
the hand-hel d transmi tter wi thi n one i nch of the uni -
versal transmi tter and push the buttons on both
transmi tters.
(4) Rel ease both buttons. Your uni versal transmi t-
ter i s now trai ned. To trai n the other buttons,
repeat Step 3 and Step 4. Be sure to keep your hand-
hel d transmi tter i n case you need to retrai n the uni -
versal transmi tter.
REMOVAL
(1) For uni versal transmi tter removal and i nstal l a-
ti on procedure, (Refer to 8 - ELECTRI CAL/OVER-
HEAD CONSOLE/COMPASS/MI NI -TRI P
COMPUTER - REMOVAL and I NSTALLATI ON).
Fig. 8 RADIO FREQUENCY DETECTOR
1 - SIGNAL DETECTION LEDS
2 - POWER LED
3 - ON/OFF SWITCH
4 - 9V BATTERY
UNIVERSAL TRANSMITTER (Continued)
POWER SYSTEMS
TABLE OF CONTENTS
page page
POWER LOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . 10
POWER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
POWER WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . 19
POWER LOCKS
TABLE OF CONTENTS
page page
POWER LOCKS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - POWER LOCKS . . 3
POWER LOCK SWITCH
DIAGNOSIS AND TESTING - POWER LOCK
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DOOR LOCK MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - DOOR LOCK
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DRIVER DOOR MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - DRIVER DOOR
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOTE KEYLESS ENTRY MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
KEYLESS ENTRY MODULE . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOTE KEYLESS ENTRY TRANSMITTER
KEYLESS ENTRY TRANSMITTER . . . . . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - RKE
TRANSMITTER BATTERIES . . . . . . . . . . . . . . 8
TRANSMITTER CUSTOMER
PREFERENCES . . . . . . . . . . . . . . . . . . . . . . . 8
TRANSMITTER PROGRAMING . . . . . . . . . . . . 9
SPECIFICATIONS - REMOTE KEYLESS
ENTRY TRANSMITTER . . . . . . . . . . . . . . . . . . 9
POWER LOCKS
DESCRIPTION
POWER LOCKS
The power l ock system al l ows al l of the doors to be
l ocked or unl ocked el ectri cal l y by operati ng a swi tch
on ei ther front door tri m panel . The power l ock sys-
tem recei ves non-swi tched battery current through a
fuse i n the I ntegrated Power Modul e (I PM), so that
the power l ocks remai n operati onal , regardl ess of the
i gni ti on swi tch posi ti on.
The i nstrument cl uster l ocks the doors automati -
cal l y when the vehi cl e i s dri ven beyond the speed of
25.7 Km/h (15 mph), al l doors are cl osed and the
accel erator pedal i s depressed. The rol l i ng door l ock
feature can be di sabl ed i f desi red.
Thi s vehi cl e al so offers several customer program-
mabl e features, whi ch al l ows the sel ecti on of several
opti onal el ectroni c features to sui t i ndi vi dual prefer-
ences.
The power l ock system for thi s vehi cl e can al so be
operated remotel y usi ng the avai l abl e Remote Key-
l ess Entry (RKE) system radi o frequency transmi t-
ters, i f equi pped.
DR POWER SYSTEMS 8N - 1
Certai n functi ons and features of the power l ock
system rel y upon resources shared wi th other el ec-
troni c modul es i n the vehi cl e over the Programmabl e
Communi cati ons I nterface (PCI ) data bus network.
For proper di agnosi s of these el ectroni c modul es or of
the PCI data bus network, the use of a DRB I I I
scan tool and the appropri ate di agnosti c i nformati on
are requi red.
CENTRAL LOCKING/UNLOCKING
The i nstrument cl uster wi l l l ock al l doors when a
cyl i nder l ock swi tch i s acti vated i n the l ock posi -
ti on. When the i nstrument cl uster recei ves an unl ock
command from one of the cyl i nder l ock swi tches, i t
wi l l unl ock onl y that door. I f the i nstrument cl uster
recei ves a second command wi thi n a 5 second peri od,
i t wi l l unl ock al l the remai ni ng doors. The i l l umi -
nated entry wi l l acti vate duri ng door unl ock.
ENHANCED ACCIDENT RESPONSE
Upon detecti on of an ai rbag depl oyment by way of
the PCI bus, the i nstrument cl uster wi l l :
I mmedi atel y di sabl e the power door l ock output.
Unl ock al l doors by acti vati ng the door unl ock
output for approxi matel y 300 mi l l i seconds.
After actuati ng the door unl ock output, al l ow
the door l ock motors to be acti vated i f the door l ock
i nput has been i nacti ve (not errati c) for 2 seconds
si nce the recepti on of the ai rbag depl oyment mes-
sage.
REMOTE KEYLESS ENTRY
A Radi o Frequency (RF) type Remote Keyl ess
Entry (RKE) system i s an avai l abl e factory-i nstal l ed
opti on on thi s model . The RKE system al l ows the use
of a remote battery-powered radi o transmi tter to si g-
nal the i nstrument cl uster to actuate the power l ock
system. The RKE recei ver operates on non-swi tched
battery current through a fuse i n the I ntegrated
Power Modul e (I PM), so that the system remai ns
operati onal , regardl ess of the i gni ti on swi tch posi ti on.
The RKE transmi tters are al so equi pped wi th a
Pani c button. I f the Pani c button on the RKE trans-
mi tter i s depressed, the horn wi l l sound and the
exteri or l i ghts wi l l fl ash on the vehi cl e for about
three mi nutes, or unti l the Pani c button i s depressed
a second ti me. A vehi cl e speed of about 25.7 ki l ome-
ters-per-hour (15 mi l es-per-hour) wi l l al so cancel the
pani c event.
The RKE system can al so perform other functi ons
on thi s vehi cl e. I f the vehi cl e i s equi pped wi th the
opti onal Vehi cl e Theft Securi ty System (VTSS), the
RKE transmi tter wi l l arm the VTSS when the Lock
button i s depressed, and di sarm the VTSS when the
Unl ock button i s depressed.
The RKE system i ncl udes two transmi tters when
the vehi cl e i s shi pped from the factory, but the system
can retai n the vehi cl e access codes of up to a total of
four transmi tters. The transmi tter codes are retai ned
i n the RKE modul e memory, even i f the battery i s di s-
connected. I f an RKE transmi tter i s faul ty or l ost,
new transmi tter vehi cl e access codes can be pro-
grammed i nto the system usi ng a DRB I I I scan tool .
Thi s vehi cl e al so offers several customer program-
mabl e features, whi ch al l ows the sel ecti on of several
opti onal el ectroni c features to sui t i ndi vi dual prefer-
ences. Customer programmabl e feature opti ons
affecti ng the RKE system i ncl ude:
Remote Unlock Sequence - Al l ows the opti on
of havi ng onl y the dri ver si de front door unl ock when
the RKE transmi tter Unl ock button i s depressed the
fi rst ti me. The remai ni ng doors unl ock when the but-
ton i s depressed a second ti me wi thi n 5 seconds of
the fi rst unl ock press. Another opti on i s havi ng al l
doors unl ock upon the fi rst depressi on of the RKE
transmi tter Unl ock button.
Sound Horn on Lock - Al l ows the opti on of
havi ng the horn sound a short chi rp as an audi bl e
veri fi cati on that the RKE system recei ved a val i d
Lock request from the RKE transmi tter, or havi ng no
audi bl e veri fi cati on.
Flash Lights with Lock and Unlock - Al l ows
the opti on of havi ng the park l amps fl ash as an opti -
cal veri fi cati on that the RKE system recei ved a val i d
Lock request or Unl ock request from the RKE trans-
mi tter, or havi ng no opti cal veri fi cati on.
Programming Additional Transmitters -
Al l ows up to a total of four transmi tter vehi cl e access
codes to be stored i n the recei ver memory.
Certai n functi ons and features of the RKE system
rel y upon resources shared wi th other el ectroni c
modul es i n the vehi cl e over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus network. For
di agnosi s of these el ectroni c modul es or of the PCI
data bus network, the use of a DRB I I I scan tool
and the appropri ate di agnosti c i nformati on are
requi red.
OPERATION
POWER LOCKS
The i nstrument cl uster l ocks or unl ocks the doors
when an actuati on i nput si gnal from a door l ock
swi tch or Remote Keyl ess Entry Modul e (RKE) i s
recei ved. The i nstrument cl uster turns on the output
dri vers and provi des a vol tage l evel to the door l ock
motor for a speci fi ed ti me. Al l passenger doors can be
l ocked or unl ocked usi ng a mechani cal button
mounted on the door tri m panel . The front passenger
doors can be l ocked or unl ocked by usi ng the key cyl -
i nder.
8N - 2 POWER LOCKS DR
POWER LOCKS (Continued)
AUTOMATIC DOOR LOCKS
When the automati c door l ocks are ENABLED the
door l ocks wi l l l ock when the vehi cl e i s movi ng at
about 25.7 Km/h (15 mph), al l doors are cl osed and
the accel erator pedal i s depressed. Thi s feature can
be swi tched ON or OFF as desi red. When the system
i s DI SABLED the door l ocks wi l l operate normal l y,
but wi l l not l ock automati cal l y when the vehi cl e i s
rol l i ng. Once the automati c door l ocks have been
actuated, they wi l l not try to l ock the doors agai n
unti l a door i s opened.
DOOR LOCK INHIBIT
I f the key i s i n the i gni ti on, i n any posi ti on, and
ei ther front door i s ajar, the doors can not be l ocked,
but the unl ock functi on sti l l operates. Pressi ng the
RKE l ock/unl ock button under these condi ti ons wi l l
resul t i n a normal l ock/unl ock acti vati on.
After the key i s removed from the i gni ti on swi tch,
or the doors are cl osed, the power door l ocks wi l l
operate normal l y.
DOOR LOCK CIRCUIT PROTECTION
I f the door l ock swi tch i s actuated conti nuousl y for
more than fi ve seconds the i nstrument cl uster wi l l
turn the output dri ver OFF (the i nstrument cl uster
woul d consi der the swi tch stuck). Each l ock motor i s
protected wi th a Posi ti ve Temperature Coeffi ci ent
devi ce that prevents motor burn out.
LOCK: Pressi ng the LOCK button l ocks al l
doors, sounds horn (chi rp) once i f enabl ed, fl ashes the
park l amps once i f enabl ed, and arms the Vehi cl e
Theft Securi ty System (VTSS), i f enabl ed. The chi rp
veri fi es that the RKE modul e has sent a message to
the i nstrument cl uster for door l ock operati on. I f a
door has not been cl osed before pressi ng the LOCK
button, the vehi cl e may not be secured and the VTSS
(i f equi pped) wi l l not arm unti l the door i s cl osed.
UNLOCK: Pressi ng the UNLOCK button once
wi l l unl ock the dri vers door fi rst i f enabl ed, fl ashes
the park l amps twi ce i f enabl ed, acti vates the i l l umi -
nated entry system, and di sarms the Vehi cl e Theft
Securi ty System (VTSS), i f equi pped. Pressi ng the
UNLOCK button twi ce wi thi n fi ve seconds wi l l
unl ock al l doors, i f dri vers door fi rst i s enabl ed.
PANIC: Pressi ng the PANI C button sounds the
horns at hal f second i nterval s, fl ashes the exteri or
l amps, and turns ON the i nteri or l amps. The pani c
al arm wi l l remai n on for three mi nutes, or unti l the
PANI C button i s actuated agai n or the vehi cl e speed
exceeds 25.7 Km/h (15 mph) wi l l cancel the pani c event.
The Remote Keyl ess Entry Modul e i s capabl e of
retai ni ng the transmi tter Vehi cl e Access Code(s) i n i ts
memory even after vehi cl e power has been i nterrupted.
DIAGNOSIS AND TESTING - POWER LOCKS
means to diagnose the power lock system
requires the use of a DRBIII scan tool and the
proper Diagnostic Procedures manual.
Fol l owi ng are tests that wi l l hel p to di agnose the
hard wi red components and ci rcui ts of the power l ock
system. However, these tests may not prove concl u-
si ve i n the di agnosi s of thi s system. I n order to
obtai n concl usi ve testi ng of the power l ock system,
data bus network and al l of the el ectroni c modul es
that provi de i nputs to, or recei ve outputs from the
power l ock system components must be checked.
The i nstrument cl uster wi l l set Di agnosti c Troubl e
Codes (DTC) for the power l ock system.
PRELIMINARY DIAGNOSIS
As a prel i mi nary di agnosi s for the power l ock sys-
tem, note the system operati on whi l e you actuate
both the Lock and Unl ock functi ons wi th the power
l ock swi tches and wi th the Remote Keyl ess Entry
(RKE) transmi tter. Then, proceed as fol l ows:
I f the enti re power l ock system fai l s to functi on
wi th ei ther the power l ock swi tches or the RKE
transmi tter, check the fused B(+) fuse i n the I nte-
grated Power Modul e (I PM).
I f the power l ock system functi ons wi th both
power l ock swi tches, but not wi th the RKE transmi t-
ter, proceed to di agnosi s of the Remote Keyl ess Entry
(RKE) system. (Refer to 8 - ELECTRI CAL/POWER
LOCKS/KEYLESS ENTRY TRANSMI TTER - DI AG-
NOSI S AND TESTI NG) or (Refer to 8 - ELECTRI -
CAL/POWER LOCKS/REMOTE KEYLESS ENTRY
MODULE - DI AGNOSI S AND TESTI NG).
I f the power l ock system functi ons wi th the RKE
transmi tter, but not wi th one or both power l ock
swi tches, proceed to di agnosi s of the door l ock
swi tches. (Refer to 8 - ELECTRI CAL/POWER
LOCKS/POWER LOCK SWI TCH - DI AGNOSI S AND
TESTI NG).
I f the dri ver si de power l ock swi tch operates
onl y the dri ver si de front door power l ock motor, but
al l other power l ock motors operate wi th the passen-
ger si de power l ock swi tch or the RKE transmi tter,
use a DRBI I I scan tool and the appropri ate di agnos-
ti c i nformati on to di agnose the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus.
I f onl y one power l ock motor fai l s to operate
wi th both power l ock swi tches and the RKE trans-
mi tter, proceed to di agnosi s of the power l ock motor.
(Refer to 8 - ELECTRI CAL/POWER LOCKS/POWER
LOCK MOTOR - DI AGNOSI S AND TESTI NG).
DR POWER LOCKS 8N - 3
POWER LOCKS (Continued)
POWER LOCK SWITCH
DIAGNOSIS AND TESTING - POWER LOCK
SWITCH
The Li ght-Emi tti ng Di ode (LED) i l l umi nati on l amp
of the power l ock swi tch recei ves battery current
through a fuse i n the I ntegrated Power Modul e (I PM)
on a fused i gni ti on swi tch output (run) ci rcui t. The
power l ock swi tch on the dri ver si de front door tri m
panel i s i ntegral to the dri ver door modul e. (Refer to
8 - ELECTRI CAL/POWER LOCKS/DOOR MODULE
- DI AGNOSI S AND TESTI NG). I f the power l ock
swi tch operates, but the LED i s i noperati ve, check
for battery current at the swi tch wi th the i gni ti on
swi tch i n the On posi ti on. I f OK, repl ace the faul ty
swi tch. Refer to the appropri ate wi ri ng i nformati on.
cabl e. Remove the power l ock swi tch from the door
tri m panel . Di sconnect the door wi re harness connec-
tor for the power l ock swi tch from the swi tch connec-
tor receptacl e.
(2) Test the power l ock swi tch resi stance. See the
Power Lock Swi tch Test chart to determi ne i f the
resi stance i s correct for the swi tch i n each swi tch
posi ti on (Fi g. 1). I f not OK, repl ace the faul ty power
l ock swi tch as requi red.
POWER LOCK SWITCH TEST TABLE
SWITCH POSITION RESISTANCE BETWEEN
PINS 1 & 5
NEUTRAL 10 KILOHMS 1%
LOCK 820 OHMS 5%
UNLOCK 330 OHMS 5%
REMOVAL
The power l ock swi tch on the dri ver si de front door
tri m panel i s i ntegral to the dri ver door modul e.
(Refer to 8 - ELECTRI CAL/POWER LOCKS/DOOR
MODULE - REMOVAL).
cabl e.
(2) Remove the door tri m panel (Refer to 23 -
(3) Remove the swi tch from the tri m panel bezel .
INSTALLATION
(1) I nsert swi tch to tri m panel bezel .
(2) I nstal l door tri m panel (Refer to 23 - BODY/
DOOR - FRONT/TRI M PANEL - I NSTALLATI ON).
DOOR LOCK MOTOR
DESCRIPTION
The l ock mechani sms are actuated by a reversi bl e
el ectri c motor mounted wi thi n each door. The power
l ock motors are i ntegral to the door l atch uni ts.
The power l ock motors cannot be adjusted or
repai red and, i f faul ty or damaged, the door l atch
uni t must be repl aced.
OPERATION
The door l ock motors are control l ed by the i nstru-
ment cl uster. A posi ti ve and negati ve battery connec-
ti on to the two motor termi nal s wi l l cause the motor
to move i n one di recti on. Reversi ng the current wi l l
cause the motor to move i n the opposi te di recti on.
DIAGNOSIS AND TESTING - DOOR LOCK
MOTOR
The most rel i abl e, effi ci ent, and accurate means to
di agnose the power l ock system requi res the use of a
DRBI I I scan tool and the proper Di agnosti c Proce-
dures manual .
Fig. 1 Power Lock Switch Connector Receptacle
DRIVER DOOR MODULE
DESCRIPTION
A Dri ver Door Modul e (DDM) i s used on al l model s
equi pped wi th power l ocks, power wi ndows, and
power mi rrors. The DDM houses the fol l owi ng
swi tches:
Power Lock Switch - The DDM i ncl udes a
two-way, momentary, resi stor mul ti pl exed swi tch to
control the power l ock system.
Power Mirror Selector Switch - A three-posi -
ti on rocker swi tch i n the DDM sel ects the ri ght or
l eft power mi rror for adjustment, or turns the power
mi rror system Off.
Power Mirror Adjustment Switches - Four
momentary, arrowhead shaped, di recti onal swi tches
al l ow the dri ver to adjust the sel ected power mi rror
i n the Up, Down, Ri ght, or Left di recti ons.
Power Window Lockout Switch - A two-way,
l atchi ng, push-button swi tch i n the DDM al l ows the
vehi cl e operator to l ock out the power wi ndow
swi tches on each passenger door so that the passen-
ger door power wi ndows may be operated onl y from
the master swi tches i n the DDM.
Power Window Switches - The DDM houses a
two-way, momentary power wi ndow swi tch for the
dri ver si de front door. Thi s swi tch al so has a second
detent i n the Down di recti on and i nternal ci rcui try to
provi de an Auto-Down feature for the dri ver si de
front door power wi ndow. I n addi ti on to the power
wi ndow swi tch for i ts own door, the DDM houses
i ndi vi dual master swi tches for each passenger door
power wi ndow.
The DDM al so i ncorporates several green Li ght-
Emi tti ng Di odes (LEDs) that i l l umi nate the power
l ock and power wi ndow swi tch paddl es, and the
power mi rror swi tch di recti onal buttons to i mprove
swi tch vi si bi l i ty i n dark ambi ent l i ghti ng condi ti ons.
The DDM cannot be adjusted or repai red and, i f
faul ty or damaged, the enti re DDM uni t must be
repl aced.
OPERATION
The Dri ver Door Modul e (DDM) combi nes a power
l ock swi tch, a dri ver power wi ndow swi tch wi th an
Auto-down feature, master swi tches for each passen-
ger door power wi ndow, a power wi ndow l ockout
swi tch, a power mi rror sel ector swi tch, and four
power mi rror adjustment swi tches i n a si ngl e uni t.
The swi tches i n the DDM can be di agnosed usi ng
conventi onal di agnosti c tool s and methods.
Power Lock Switch
The DDM power l ock swi tch ci rcui try i s connected
i n seri es between ground and the dri ver door swi tch
mux i nput of the i nstrument cl uster. Each power l ock
swi tch posi ti on (Lock, Unl ock, and Neutral ) provi des
a di fferent resi stance val ue to the i nstrument cl uster
i nput, whi ch al l ows the i nstrument cl uster to sense
the swi tch posi ti on. Based upon the power l ock
swi tch i nput, the i nstrument cl uster control s the bat-
tery and ground feed outputs to the i ndi vi dual power
l ock motors to l ock or unl ock the door l atches. The
Li ght-Emi tti ng Di ode (LED) i n the DDM power l ock
swi tch i s connected to battery current through the
power wi ndow ci rcui t breaker i n the I ntegrated
Power Modul e (I PM) on a fused i gni ti on swi tch out-
put (run-acc) ci rcui t so that the swi tch wi l l be i l l umi -
nated whenever the i gni ti on swi tch i s i n the On or
Accessory posi ti ons.
Power Window Switches
The DDM power wi ndow swi tch ci rcui try i s con-
nected to battery current through a ci rcui t breaker i n
the I ntegrated Power Modul e (I PM) on a fused i gni -
ti on swi tch output (run-acc) ci rcui t so that the power
wi ndows wi l l operate whenever the i gni ti on swi tch i s
i n the On or Accessory posi ti ons. Each two-way,
momentary master passenger power wi ndow swi tch
i n the DDM provi des battery current and ground to
the i ndi vi dual power wi ndow swi tches on each pas-
senger door so that the power wi ndow swi tch control s
the battery current and ground feeds to i ts respecti ve
power wi ndow motor. The DDM swi tch for the dri ver
si de front door power wi ndow i s l abel ed Auto and
i ncl udes an auto-down feature. When thi s swi tch i s
depressed to a second momentary detent posi ti on and
rel eased, the dri ver door power wi ndow i s automati -
cal l y operated through an i nternal ci rcui t and rel ay
to i ts ful l y l owered posi ti on. The Auto-down event i s
cancel l ed i f the swi tch paddl e i s depressed a second
ti me i n ei ther the Up or Down di recti on. When the
two posi ti on wi ndow l ockout swi tch i n the DDM i s
depressed and l atched i n the l ockout posi ti on, the
battery current feed to each of the i ndi vi dual passen-
ger power wi ndow swi tches i s i nterrupted so that the
passenger door power wi ndows can onl y be operated
from the master swi tches i n the DDM. The wi ndow
l ockout swi tch al so control s the battery current feed
for the LED i n each passenger power wi ndow swi tch
so that the swi tch wi l l not be i l l umi nated when i t i s
l ocked out.
Power Mirror Switches
The DDM power mi rror swi tch ci rcui try i s con-
nected to battery current through a fuse i n the I PM
on a fused B(+) ci rcui t so that the power mi rrors
remai n operati onal regardl ess of the i gni ti on swi tch
posi ti on. A rocker type sel ector swi tch has three posi -
ti ons, one to sel ect the ri ght mi rror, one to sel ect the
l eft mi rror, and a neutral Off posi ti on. After the ri ght
or l eft mi rror i s sel ected, one of four di recti onal but-
tons i s depressed to move the sel ected mi rror Up,
Down, Ri ght or Left. The DDM power mi rror swi tch
ci rcui try control s the battery current and ground
feeds to each of the four (two i n each mi rror head)
power mi rror motors. The Li ght-Emi tti ng Di ode
(LED) i n the DDM power mi rror swi tch i s connected
to battery current through the power wi ndow ci rcui t
breaker i n the I PM on a fused i gni ti on swi tch output
(run-acc) ci rcui t so that the swi tch di recti onal but-
tons wi l l be i l l umi nated whenever the i gni ti on swi tch
i s i n the On or Accessory posi ti ons.
DIAGNOSIS AND TESTING - DRIVER DOOR
MODULE
The Li ght-Emi tti ng Di ode (LED) i l l umi nati on
l amps for al l of the Dri ver Door Modul e (DDM)
power wi ndow, power l ock, and power mi rror
swi tches recei ve battery current through the power
wi ndow ci rcui t breaker i n the I ntegrated Power Mod-
ul e (I PM). I f al l of the LEDs are i noperati ve i n the
DDM, be certai n to di agnose the power wi ndow sys-
tem before repl aci ng the swi tch uni t. (Refer to 8 -
ELECTRI CAL/POWER WI NDOWS - DI AGNOSI S
AND TESTI NG). I f onl y one LED i n the DDM i s
i noperati ve, repl ace the faul ty DDM. I f the dri ver
si de front door power wi ndow operates i n a normal
manner, but the Auto-Down feature i s i noperati ve,
repl ace the faul ty DDM. Refer to the appropri ate wi r-
i ng i nformati on.
cabl e. Remove the DDM from the door tri m panel .
Di sconnect the door wi re harness connectors for the
DDM from the DDM connector receptacl es.
(2) Test the DDM swi tch conti nui ty. See the Dri ver
Door Modul e Swi tch Tests chart to determi ne i f the
conti nui ty i s correct for the suspect swi tches i n each
swi tch posi ti on (Fi g. 2) and/or (Fi g. 3). I f not OK,
repl ace the faul ty DDM as requi red.
DRIVER DOOR MODULE SWITCH TESTS
POWER LOCK SWITCH
SWITCH POSITION
RESISTANCE BETWEEN
CONNECTOR C-1 PINS
7 & 11
NEUTRAL 10 KILOHMS 1%
LOCK 820 OHMS 5%
UNLOCK 330 OHMS 5%
POWER MIRROR SWITCH
SWITCH POSITION
CONTINUITY BETWEEN
PINS OF CONNECTOR
C-2
LEFT MIRROR SELECTED
UP PINS 1 & 3
DOWN PINS 2 & 3
RIGHT PINS 2 & 3
LEFT PINS 3 & 6
RIGHT MIRROR SELECTED
UP PINS 3 & 7
DOWN PINS 2 & 3
RIGHT PINS 2 & 3
LEFT PINS 3 & 4
POWER WINDOW SWITCH
SWITCH POSITION CONTINUITY BETWEEN
PINS OF CONNECTOR
C-1
NEUTRAL PINS 1 & 8, PINS 2 & 8,
PINS 3 & 8, PINS 4 & 8,
PINS 5 & 8, PINS 6 & 8,
PINS 8 & 10, PINS 8 &
12
LEFT FRONT UP PINS 5 & 9
Fig. 2 Driver Door Module Connector C1 Receptacle
Fig. 3 Driver Door Module Connector C2 Receptacle
DRIVER DOOR MODULE (Continued)
DRIVER DOOR MODULE SWITCH TESTS
LEFT FRONT DOWN PINS 9 & 12
RIGHT FRONT UP PINS 3 & 9
RIGHT FRONT DOWN PINS 6 & 9
LEFT REAR UP PINS 4 & 9
LEFT REAR DOWN PINS 9 & 10
RIGHT REAR UP PINS 2 & 9
RIGHT REAR DOWN PINS 1 & 9
POWER WINDOW LOCKOUT SWITCH
OFF (SWITCH BUTTON
RAISED - NOT
DEPRESSED)
PIN 9 OF CONNECTOR
C-1 & PIN 8 OF
CONNECTOR C-2
REMOVAL
cabl e.
(3) Remove the dri ver door modul e from the tri m
panel bezel .
INSTALLATION
(1) I nstal l dri ver door modul e to tri m panel bezel .
MODULE
DESCRIPTION
When an RKE l ock message i s sent to the i nstru-
ment cl uster, the i nstrument cl uster actuates the
door l ocks, the i nteri or l i ghti ng i s turned off, the
horn chi rps (i f thi s feature i s enabl ed), the park
l amps fl ash (i f thi s feature i s enabl ed) and, i f the
vehi cl e i s so equi pped, the Vehi cl e Theft Securi ty
System (VTSS) i s armed. When an RKE unl ock mes-
sage i s sent to the i nstrument cl uster, the i nstrument
cl uster actuates the dri ver si de front door (or al l
doors i f thi s feature i s enabl ed) unl ock, the i nteri or
l i ghti ng i s turned on and, i f the vehi cl e i s so
equi pped, the VTSS i s di sarmed.
When an RKE pani c message i s sent to the i nstru-
ment cl uster, the i nstrument cl uster actuates the
dri ver si de front door (or al l doors i f thi s feature i s
enabl ed) unl ock, the i nteri or l i ghti ng i s turned on
and, i f the vehi cl e i s so equi pped, the VTSS i s di s-
armed. The pani c message wi l l al so cause the exte-
ri or l amps (i ncl udi ng the headl i ghts) to fl ash, and
the horn to sound for about three mi nutes, or unti l a
second pani c message i s sent to the i nstrument cl us-
ter. A vehi cl e speed of about 25.7 ki l ometers-per-hour
(15 mi l es-per-hour) wi l l al so cancel the pani c event.
Refer to the owners manual for more i nformati on
on the features, use and operati on of the RKE sys-
tem.
OPERATION
Whenever the vehi cl e battery power i s i nterrupted,
the Remote Keyl ess Modul e (RKE) Modul e wi l l retai n
al l vehi cl e access codes i n i ts memory. When repl ac-
i ng or addi ng a key fob transmi tter (maxi mum of 4) a
DRB I I I scan tool i s requi red to program the RKE
Modul e to accept the new Vehi cl e Access Code i f a
customer owned transmi tter i s not avai l abl e.
I f a functi oni ng transmi tter i s avai l abl e, (Refer to 8
- ELECTRI CAL/POWER LOCKS/KEYLESS ENTRY
TRANSMI TTER - STANDARD PROCEDURE)
DIAGNOSIS AND TESTING - REMOTE KEYLESS
ENTRY MODULE
di agnose the power l ock system requi res the use of a
DRBI I I scan tool and the proper Di agnosti c Proce-
dures manual .
REMOVAL
cabl e.
(2) Remove the i nstrument cl uster (Refer to 8 -
ELECTRI CAL/I NSTRUMENT CLUSTER -
REMOVAL).
(3) Remove remote keyl ess entry modul e from
i nstrument cl uster (Fi g. 4).
Fig. 4 REMOTE KEYLESS ENTRY MODULE
2 - REMOTE KEYLESS ENTRY MODULE
DRIVER DOOR MODULE (Continued)
INSTALLATION
(1) I nstal l remote keyl ess entry modul e to i nstru-
ment cl uster.
(2) I nstal l i nstrument cl uster (Refer to 8 - ELEC-
TRI CAL/I NSTRUMENT CLUSTER - I NSTALLA-
TI ON).
TRANSMITTER
DIAGNOSIS AND TESTING - REMOTE KEYLESS
ENTRY TRANSMITTER
Usi ng speci al tool 9001, fi rst test to ensure that
the transmi tter i s functi oni ng. Typi cal testi ng di s-
tance i s 2.5 centi meters (1 i nch) for Asi an transmi t-
ters and 30.5 centi meters (12 i nches) for al l others.
To test, posi ti on the transmi tter as shown (Fi g. 5).
Press any transmi tter button, then test each button
i ndi vi dual l y. The tool wi l l beep i f a radi o si gnal
strength that l i ghts fi ve or more LEDs i s detected.
Repeat thi s test three ti mes. I f transmi tter fai l s any
of the test refer to the Di agnosti c Procedures man-
ual .
STANDARD PROCEDURE
STANDARD PROCEDURE - RKE TRANSMITTER
BATTERIES
NOTE: Do not disturb the metal terminal near the
batteries. Avoid touching the new batteries. Skin
oils may cause battery deterioration. If batteries are
touched, clean with rubbing alcohol.
The Remote Keyl ess Entry (RKE) transmi tter case
snaps open and shut for battery access. To repl ace
the RKE transmi tter batteri es:
(1) Usi ng a thi n coi n, gentl y pry at the notch i n
the center seam of the RKE transmi tter case hal ves
near the key ri ng unti l the two hal ves unsnap. Be
careful not to damage the rubber gasket when sepa-
rati ng the case hal ves.
(2) Li ft the back hal f of the transmi tter case off of
the RKE transmi tter.
(3) Remove the two batteri es from the RKE trans-
mi tter.
(4) Repl ace the two batteri es wi th new 3V l i thi um
2016 cel l . I nstal l the batteri es wi th the posi ti ve ter-
mi nal up. Reference the + SI DE UP on the i nsi de of
the bottom hal f of the transmi tter case.
(5) Al i gn the two RKE transmi tter case hal ves
wi th each other, and squeeze them fi rml y and evenl y
together unti l they snap back i nto pl ace. Test trans-
mi tter operati on.
CUSTOMER PREFERENCES
AUTOMATIC (ROLLING) LOCKS
The rol l i ng l ocks feature can be toggl ed ON/OFF
by usi ng the DRB I I I onl y.
HORN CHIRP DISABLING / ENABLING
The horn chi rp can be toggl ed usi ng a DRB I I I or
by usi ng the Remote Keyl ess Entry (RKE) transmi t-
ter that i s al ready programmed to the vehi cl e.
To DI SABLE (cancel ) the horn chi rp feature:
(1) Enter the vehi cl e and cl ose al l doors.
(2) Fasten the seat bel t (thi s wi l l cancel the seat
bel t chi me).
(3) Turn the i gni ti on to the ON posi ti on.
(4) Press and hol d the LOCK button for 4 seconds.
Wi thi n 6 seconds wi th the LOCK button sti l l
depressed, press the UNLOCK button. When a si ngl e
chi me i s heard, rel ease both buttons.
(5) Turn the i gni ti on OFF.
(6) Turn the i gni ti on ON or wai t 60 seconds.
(7) Test the horn chi rp feature by pressi ng the
LOCK button.
I f a chi me i s not heard, program mode was can-
cel ed before the feature coul d be di sabl ed. I f neces-
sary, repeat the procedure.
To ENABLE the horn chi rp feature, repeat the
above procedure.
OPTICAL CHIRP (FLASH) DISABLING / ENABLING
The opti cal chi rp can be toggl ed usi ng a DRB I I I
or by usi ng the Remote Keyl ess Entry (RKE) trans-
mi tter that i s al ready programmed to the vehi cl e.
To DI SABLE (cancel ) the opti cal chi rp feature:
Fig. 5 TRANSMITTER DIAGNOSIS
REMOTE KEYLESS ENTRY MODULE (Continued)
bel t chi me).
(4) Press and hol d the LOCK button for 4 seconds.
Wi thi n 6 seconds wi th the LOCK button sti l l
depressed, press the PANI C button. When a si ngl e
chi me i s heard, rel ease both buttons.
(7) Test the opti cal chi rp feature by pressi ng the
LOCK button.
To ENABLE the opti cal chi rp feature, repeat the
above procedure.
UNLOCK SEQUENCE
The unl ock sequence can be toggl ed usi ng a DRB
I I I or by usi ng the Remote Keyl ess Entry (RKE)
transmi tter that i s al ready programmed to the vehi -
cl e.
To toggl e between Dri ver door fi rst and Unl ock al l
doors functi on:
bel t chi me).
(4) Press and hol d the UNLOCK button for 4 sec-
onds. Wi thi n 6 seconds wi th the UNLOCK button
sti l l depressed, press the LOCK button. When a si n-
gl e chi me i s heard, rel ease both buttons.
To toggl e thi s feature, repeat the above procedure.
PROGRAMING
New Remote Keyl ess Entry (RKE) transmi tters can
be programed usi ng the DRB I I I scan tool and the
proper Di agnosti c Procedures manual . The DRB I I I
scan tool can provi de confi rmati on that the PCI data
bus i s functi onal , and that al l of the el ectroni c mod-
ul es are sendi ng and recei vi ng the proper messages
on the PCI data bus.
The fol l owi ng procedure can be used as l ong as one
programmed transmi tter i s avai l abl e:
NOTE: When entering program mode using that
programmed fob, ALL currently programmed fobs
will be erased and they will have to be repro-
grammed for the vehicle. If program mode is
entered and no action is performed, the previously
programmed fobs will continue to function.
bel t chi me). Turn the i gni ti on to the RUN posi ti on.
(3) Press and hol d the UNLOCK button on a pro-
grammed transmi tter for 4 to 10 seconds. Wi thi n the
4 to 10 seconds wi th the UNLOCK button sti l l
depressed, press the PANI C button for one second.
When a si ngl e chi me i s heard, rel ease both button-
s.The chi me i ndi cates the system i s i n program
mode.
(4) Press and rel ease both the LOCK and
UNLOCK buttons si mul taneousl y on a fob to be pro-
grammed. A si ngl e chi me wi l l be heard, thi s i ndi cates
the fob has been recogni zed.
(5) Press and rel ease any button on the same fob.
A si ngl e chi me wi l l be heard, thi s i ndi cates the fob
has been programmed.
(6) Repeat steps 4 and 5 for up to a total of 4 fobs.
The vehi cl e wi l l remai n i n program mode for up to
60 seconds from when the ori gi nal chi me (step 3) was
heard. After 60 seconds, al l programmed transmi tters
wi l l functi on normal l y.
SPECIFICATIONS - REMOTE KEYLESS ENTRY
TRANSMITTER
RANGE
Normal operati on range i s up to a di stance of 3 to
7 meters (10 to 23 ft.) of the vehi cl e. Range may be
better or worse dependi ng on the envi ronment
around the vehi cl e.
REMOTE KEYLESS ENTRY TRANSMITTER (Continued)
POWER MIRRORS
TABLE OF CONTENTS
page page
POWER MIRRORS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING - POWER
MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
AUTOMATIC DAY / NIGHT MIRROR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - AUTOMATIC DAY
/ NIGHT MIRROR . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
POWER MIRROR SWITCH
DIAGNOSIS AND TESTING - POWER MIRROR
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SIDEVIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
POWER MIRRORS
DESCRIPTION
AUTOMATIC DAY/NIGHT MIRROR
The automati c day/ni ght mi rror system i s abl e to
automati cal l y change the refl ectance of the i nsi de
rear vi ew mi rror i n order to reduce the gl are of head-
l amps approachi ng the vehi cl e from the rear. The
automati c day/ni ght rear vi ew mi rror recei ves bat-
tery current through a fuse i n the I ntegrated Power
Modul e (I PM) onl y when the i gni ti on swi tch i s i n the
On posi ti on.
OUTSIDE REAR VIEW MIRROR
The power operated outsi de rear vi ew mi rrors
al l ow the dri ver to adjust both outsi de mi rrors el ec-
tri cal l y from the dri ver si de front seat posi ti on by
operati ng a swi tch on the dri ver si de front door tri m
panel . The power mi rrors recei ve a non-swi tched bat-
tery feed through a fuse i n the I ntegrated Power
Modul e (I PM) so that the system wi l l remai n opera-
ti onal , regardl ess of the i gni ti on swi tch posi ti on.
OPERATION
AUTOMATIC DAY/NIGHT MIRROR
A swi tch l ocated on the bottom of the automati c
day/ni ght mi rror housi ng al l ows the vehi cl e operator
to sel ect whether the automati c di mmi ng feature i s
operati onal . When the automati c day/ni ght mi rror i s
turned on, the mi rror swi tch i s l i ghted by an i ntegral
Li ght-Emi tti ng Di ode (LED). The mi rror wi l l auto-
mati cal l y di sabl e i ts sel f-di mmi ng feature whenever
the vehi cl e i s bei ng dri ven i n reverse.
OUTSIDE REAR VIEW MIRROR
The heated mi rrors i ncl ude an el ectri c heati ng gri d
behi nd the mi rror gl ass i n each outsi de mi rror, whi ch
can cl ear the mi rror gl ass of i ce, snow, or fog. (Refer
to 8 - ELECTRI CAL/HEATED MI RRORS -
DESCRI PTI ON) for more i nformati on.
DIAGNOSIS AND TESTING - POWER MIRRORS
WIRING VOLTAGE TEST
The fol l owi ng wi ri ng test determi nes whether or
not vol tage i s conti nuous through the body harness
to swi tch.
(1) Remove the power mi rror swi tch (Refer to 8 -
ELECTRI CAL/POWER LOCKS/DOOR MODULE -
REMOVAL).
(2) Di sconnect wi re harness connector from back of
power mi rror swi tch.
(3) Connect the cl i p end of a 12 vol t test l i ght to
Pi n 5 i n the mi rror swi tch harness connector. Touch
the test l i ght probe to Pi n 3.
I f the test l i ght i l l umi nates, the wi ri ng ci rcui t
between the battery and swi tch i s OK.
I f the l amp does not i l l umi nate, fi rst check fuse i n
the I ntegrated Power Modul e (I PM). I f fuse i s OK,
then check for a broken wi re.
POWER MIRROR MOTOR TEST
I f the power mi rror swi tch i s recei vi ng proper cur-
rent and ground and mi rrors do not operate, proceed
wi th power mi rror motor test. Refer to the appropri -
ate wi ri ng i nformati on.
(1) Remove the power mi rror swi tch (Refer to 8 -
REMOVAL).
8N - 10 POWER MIRRORS DR
(2) Di sconnect wi re harness connector to power
mi rror swi tch (Fi g. 1).
(3) Usi ng two jumper wi res:
Connect one to a 12 vol t source
Connect the other to a good body ground
Refer to the Mi rror Motor Test Chart for proper
wi re connecti ons at the swi tch connector
MIRROR MOTOR TEST CHART
12 VOLTS GROUND MIRROR REACTION
SWITCH CONNECTOR RIGHT LEFT
PIN 1 PIN 2 - UP
PIN 6 PIN 2 - LEFT
PIN 2 PIN 1 - DOWN
PIN 2 PIN 6 - RIGHT
PIN 7 PIN 2 UP -
PIN 4 PIN 2 LEFT -
PIN 2 PIN 7 DOWN -
PIN 2 PIN 4 RIGHT -
(4) I f resul ts shown i n tabl e are not obtai ned,
check for open or shorted ci rcui t. Repl ace mi rror
assembl y as necessary.
AUTOMATIC DAY / NIGHT
MIRROR
DESCRIPTION
The automati c day/ni ght mi rror uses a thi n l ayer
of el ectrochromi c materi al between two pi eces of con-
ducti ve gl ass to make up the face of the mi rror.
When the mi rror swi tch i s i n the On posi ti on, two
photocel l sensors are used by the mi rror ci rcui try to
moni tor external l i ght l evel s and adjust the refl ec-
tance of the mi rror.
OPERATION
The ambi ent photocel l sensor i s l ocated on the for-
ward-faci ng (wi ndshi el d si de) of the rear vi ew mi rror
housi ng, and detects the ambi ent l i ght l evel s outsi de
of the vehi cl e. The headl amp photocel l sensor i s
l ocated i nsi de the rear vi ew mi rror housi ng behi nd
the mi rror gl ass and faces rearward, to detect the
l evel of the l i ght bei ng recei ved at the rear wi ndow
si de of the mi rror. When the ci rcui try of the auto-
mati c day/ni ght mi rror detects that the di fference
between the two l i ght l evel s i s too great (the l i ght
l evel recei ved at the rear of the mi rror i s much
hi gher than that at the front of the mi rror), i t begi ns
to darken the mi rror.
The automati c day/ni ght mi rror ci rcui try al so mon-
i tors the transmi ssi on usi ng an i nput from the
backup l amp ci rcui t. The mi rror ci rcui try i s pro-
grammed to automati cal l y di sabl e i ts sel f-di mmi ng
feature whenever i t senses that the transmi ssi on
backup l amp ci rcui t i s energi zed.
The automati c day/ni ght mi rror i s a compl etel y
sel f-contai ned uni t and cannot be repai red. I f faul ty
or damaged, the enti re mi rror assembl y must be
repl aced.
DIAGNOSIS AND TESTING - AUTOMATIC DAY /
NIGHT MIRROR
(1) Check the fuse i n the I ntegrated Power Modul e
(I PM). I f OK, go to Step 2. I f not OK, repai r the
shorted ci rcui t or component as requi red and repl ace
the faul ty fuse.
Check for battery vol tage at the fuse i n the I PM. I f
OK, go to Step 3. I f not OK, repai r the open ci rcui t to
the i gni ti on swi tch as requi red.
Unpl ug the wi re harness connector from the auto-
mati c day/ni ght mi rror (Fi g. 2). Connect the battery
negati ve cabl e. Turn the i gni ti on swi tch to the On
posi ti on. Check for battery vol tage at the fused i gni -
ti on swi tch output (run/start) ci rcui t cavi ty of the
automati c day/ni ght mi rror wi re harness connector. I f
OK, go to Step 4. I f not OK, repai r the open ci rcui t to
the I PM as requi red.
i ty of the automati c day/ni ght mi rror wi re harness
connector and a good ground. There shoul d be conti -
nui ty. I f OK, go to Step 5. I f not OK, repai r the ci r-
cui t to ground as requi red.
Fig. 1 POWER MIRROR SWITCH CONNECTOR
DR POWER MIRRORS 8N - 11
POWER MIRRORS (Continued)
(5) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Set the parki ng
brake. Pl ace the transmi ssi on gear sel ector l ever i n
the Reverse posi ti on. Check for battery vol tage at the
backup l amp swi tch output ci rcui t cavi ty of the auto-
mati c day/ni ght mi rror wi re harness connector. I f
OK, go to Step 6. I f not OK, repai r the open ci rcui t
as requi red.
Di sconnect the battery negati ve cabl e. Pl ug i n the
automati c day/ni ght mi rror wi re harness connector.
Connect the battery negati ve cabl e. Turn the i gni ti on
swi tch to the On posi ti on. Pl ace the transmi ssi on
gear sel ector l ever i n the Neutral posi ti on. Pl ace the
mi rror swi tch i n the On (the LED i n the mi rror
swi tch i s l i ghted) posi ti on. Cover the forward faci ng
ambi ent photocel l sensor to keep out any ambi ent
l i ght.
NOTE: The ambient photocell sensor must be cov-
ered completely, so that no light reaches the sen-
sor. Use a finger pressed tightly against the sensor,
or cover the sensor completely with electrical tape.
(7) Shi ne a l i ght i nto the rearward faci ng head-
l amp photocel l sensor. The mi rror gl ass shoul d
darken. I f OK, go to Step 8. I f not OK, repl ace the
faul ty automati c day/ni ght mi rror uni t.
(8) Wi th the mi rror gl ass darkened, pl ace the
transmi ssi on gear sel ector l ever i n the Reverse posi -
ti on. The mi rror shoul d return to i ts normal refl ec-
tance. I f not OK, repl ace the faul ty automati c day/
ni ght mi rror uni t.
REMOVAL
For removal procedures, (Refer to 23 - BODY/I N-
TERI OR/REAR VI EW MI RROR - REMOVAL).
POWER MIRROR SWITCH
DIAGNOSIS AND TESTING - POWER MIRROR
SWITCH
The power mi rror swi tch i s i ncl uded wi th the
Dri ver Door Modul e. (Refer to 8 - ELECTRI CAL/
POWER LOCKS/DOOR MODULE - DI AGNOSI S
AND TESTI NG).
REMOVAL
The power mi rror swi tch i s i ncl uded wi th the
Dri ver Door Modul e. (Refer to 8 - ELECTRI CAL/
POWER LOCKS/DOOR MODULE - REMOVAL).
SIDEVIEW MIRROR
REMOVAL
(Refer to 23 - BODY/EXTERI OR/SI DE VI EW MI R-
ROR - REMOVAL).
Fig. 2 Automatic Day/Night Mirror
1 - REAR FACING SENSOR
2 - CONNECTOR
3 - FORWARD FACING SENSOR
4 - SWITCH
8N - 12 POWER MIRRORS DR
AUTOMATIC DAY / NIGHT MIRROR (Continued)
POWER SEATS
TABLE OF CONTENTS
page page
POWER SEATS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - POWER SEAT
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DRIVER SEAT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING - DRIVER SEAT
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
PASSENGER SEAT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - PASSENGER
SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
POWER SEAT TRACK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
LUMBAR CONTROL SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LUMBAR MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING - LUMBAR MOTOR . 18
POWER SEATS
DESCRIPTION
The power seat system opti on al l ows the dri ver or
passenger to el ectri cal l y adjust the seat posi ti on for
opti mum control and comfort usi ng the power seat
swi tches l ocated on the outboard seat cushi on si de
shi el d. The power seat system al l ows the seati ng
posi ti on to be adjusted forward, rearward, front up,
front down, rear up, or rear down. The power seat
system recei ves battery current through a fuse i n the
I ntegrated Power Modul e, regardl ess of the i gni ti on
swi tch posi ti on. The power seat system i ncl udes the
fol l owi ng components:
Dri ver Power Seat Swi tch
Passenger Power Seat Swi tch
Dri ver Power Seat Track
Passenger Power Seat Track
Power Lumbar Adjuster(s)
Some model s equi pped wi th the power seat opti on
al so feature a power operated l umbar support i n the
seat back. The power l umbar support al l ows the user
to i nfl ate or defl ate a bl adder l ocated i n the l ower
seat back to achi eve opti mum comfort and support i n
the l ower l umbar regi on of the spi nal col umn. The
power l umbar support shares the battery feed ci rcui t
of the power seat system.
components i n the power seat system. Refer to
Heated Seat System for i nformati on on the i ndi vi d-
ual l y control l ed heated front seats. Refer to the own-
ers manual i n the vehi cl e gl ove box for more
i nformati on on the features, use and operati on of the
power seat system.
OPERATION
The power seat system al l ows the dri ver and/or
front passenger seati ng posi ti ons to be adjusted el ec-
tri cal l y and i ndependentl y usi ng the separate power
seat swi tches found on the outboard seat cushi on
si de shi el d of each front seat. See the owners manual
i n the vehi cl e gl ove box for more i nformati on on the
features, use and operati on of the power seat system.
SYSTEM
Before any testi ng of the power seat system i s
attempted, the battery shoul d be ful l y-charged and
al l wi re harness connecti ons and pi ns checked to
ensure proper conti nui ty and grounds. For ci rcui t
descri pti ons and di agrams, refer to Wi ri ng Di agrams.
Wi th the dome l amp on, appl y the power seat
swi tch i n the di recti on of the fai l ure. I f the dome
l amp di ms, the seat may be jammi ng. Check under
and behi nd the seat for bi ndi ng or obstructi ons. I f
the dome l amp does not di m, proceed wi th testi ng of
the i ndi vi dual components and ci rcui ts.
DR POWER SEATS 8N - 13
DRIVER SEAT SWITCH
DESCRIPTION
The power seat on thi s model can be adjusted i n
ei ght di fferent di recti ons, up, down, front up, front
down, rear up, rear down, rearward and forward.
The power seat swi tch (Fi g. 1) on thi s model has an
addi ti onal swi tch knob for adjusti ng the power l um-
bar support. The power seat swi tch i s l ocated on the
outboard si de of the seat cushi on on the seat cushi on
si de shi el d. Refer to the owners manual i n the vehi -
cl e gl ove box for more i nformati on on the power seat
swi tch functi ons and the seat adjusti ng procedures.
The i ndi vi dual swi tches i n the power seat swi tch
assembl y cannot be repai red. I f one swi tch i s dam-
aged or faul ty, the enti re power seat swi tch assembl y
must be repl aced.
OPERATION
When a power swi tch control knob or knobs are
actuated, a battery feed and a ground path are
appl i ed through the swi tch contacts to the power seat
track or recl i ner adjuster motor. The sel ected
adjuster motor operates to move the seat track or
recl i ner through i ts dri ve uni t i n the sel ected di rec-
ti on unti l the swi tch i s rel eased, or unti l the travel
l i mi t of the adjuster i s reached. When the swi tch i s
moved i n the opposi te di recti on, the battery feed and
ground path to the motor are reversed through the
swi tch contacts. Thi s causes the adjuster motor to
run i n the opposi te di recti on.
No power seat swi tch shoul d be hel d appl i ed i n any
di recti on after the adjuster has reached i ts travel
l i mi t. The power seat adjuster motors each contai n a
sel f-resetti ng ci rcui t breaker to protect them from
overl oad. However, consecuti ve or frequent resetti ng
of the ci rcui t breaker must not be al l owed to con-
ti nue, or the motor may be damaged.
DIAGNOSIS AND TESTING - DRIVER SEAT
SWITCH
For ci rcui t descri pti ons and di agrams, refer to Wi r-
i ng.
cabl e.
(2) Remove the power seat swi tch from the power
seat.
(3) Use an ohmmeter to test the conti nui ty of the
power seat swi tches i n each posi ti on. See the Power
Seat Swi tch Conti nui ty chart (Fi g. 2). I f OK, refer to
Power Seat Track Di agnosi s and Testi ng i n thi s
group. I f not OK, repl ace the faul ty power seat
swi tch.
DRIVER POWER SEAT SWITCH TEST TABLE
DRIVER SWITCH
POSITION
CONTINUITY BETWEEN
OFF B-N, B-J, B-M
B-E, B-L, B-K
VERTICAL UP A-E, A-M, B-N, B-J
VERTICAL DOWN A-J, A-N, B-M, B-E
Fig. 1 DR Power Seat Switch
1 - POWER SEAT SWITCH ASSEMBLY
2 - FRONT SEAT CUSHION ADJUSTMENT BUTTON
3 - COMPLETE SEAT ADJUSTMENT BUTTON
4 - REAR SEAT CUSHION ADJUSTMENT BUTTON
5 - LUMBAR ADJUSTMENT BUTTON
Fig. 2 Testing Driver Power Seat Switch
8N - 14 POWER SEATS DR
DRIVER POWER SEAT SWITCH TEST TABLE
DRIVER SWITCH
POSITION
CONTINUITY BETWEEN
HORIZONTAL
FORWARD
A-L, B-K
HORIZONTAL
REARWARD
A-K, B-L
FRONT TILT UP A-M, B-N
FRONT TILT DOWN A-N, B-M
REAR TILT UP A-E, B-J
REAR TILT DOWN A-J, B-E
LUMBAR OFF O-P, O-R, P-R
LUMPAR UP (INFLATE) O-P, Q-R
LUMBAR DOWN
(DEFLATE)
O-R, P-Q
REMOVAL
cabl e.
(2) Remove the seat cushi on si de shi el d from the
seat. Refer to the Body secti on of the servi ce manual
for the procedure.
(3) Pul l the swi tch bezel or si de shi el d uni t out
from the seat far enough to access the swi tch wi re
harness connector. Gentl y pry the l ocki ng tabs of the
swi tch away from the wi re harness connector and
careful l y unpl ug the connector from the power seat
swi tch modul e.
(4) Remove the screws that secure the power seat
swi tch.
INSTALLATION
(1) Posi ti on the power seat swi tch on the seat
cushi on si de shi el d and i nstal l the screws that secure
the power seat swi tch to seat cushi on si de shi el d.
(2) Connect the el ectri cal connector.
(3) I nstal l the seat cushi on si de shi el d on the seat.
Refer to the Body secti on of the servi ce manual for
the procedure.
(4) I f equi pped, i nstal l the screw that secures the
recl i ner l ever to the recl i ner mechani sm rel ease shaft
on the outboard si de of the front seat.
PASSENGER SEAT SWITCH
DESCRIPTION
The power seat on thi s model can be adjusted i n
ei ght di fferent di recti ons, up, down, front up, front
down, rear up, rear down, rearward and forward.
The power seat swi tch (Fi g. 3) on thi s model has an
addi ti onal swi tch knob for adjusti ng the power l um-
bar support. The power seat swi tch i s l ocated on the
outboard si de of the seat cushi on on the seat cushi on
si de shi el d. Refer to the owners manual i n the vehi -
cl e gl ove box for more i nformati on on the power seat
swi tch functi ons and the seat adjusti ng procedures.
The i ndi vi dual swi tches i n the power seat swi tch
assembl y cannot be repai red. I f one swi tch i s dam-
aged or faul ty, the enti re power seat swi tch assembl y
must be repl aced.
OPERATION
When a power swi tch control knob or knobs are
actuated, a battery feed and a ground path are
appl i ed through the swi tch contacts to the power seat
track or recl i ner adjuster motor. The sel ected
adjuster motor operates to move the seat track or
recl i ner through i ts dri ve uni t i n the sel ected di rec-
swi tch contacts. Thi s causes the adjuster motor to
run i n the opposi te di recti on.
No power seat swi tch shoul d be hel d appl i ed i n any
di recti on after the adjuster has reached i ts travel
l i mi t. The power seat adjuster motors each contai n a
sel f-resetti ng ci rcui t breaker to protect them from
overl oad. However, consecuti ve or frequent resetti ng
of the ci rcui t breaker must not be al l owed to con-
ti nue, or the motor may be damaged.
Fig. 3 DR Power Seat Switch
1 - POWER SEAT SWITCH ASSEMBLY
2 - FRONT SEAT CUSHION ADJUSTMENT BUTTON
3 - COMPLETE SEAT ADJUSTMENT BUTTON
4 - REAR SEAT CUSHION ADJUSTMENT BUTTON
5 - LUMBAR ADJUSTMENT BUTTON
DRIVER SEAT SWITCH (Continued)
DIAGNOSIS AND TESTING - PASSENGER SEAT
SWITCH
For ci rcui t descri pti ons and di agrams, refer to Wi r-
i ng.
cabl e.
(2) Remove the power seat swi tch from the power
seat.
(3) Use an ohmmeter to test the conti nui ty of the
power seat swi tches i n each posi ti on. See the Power
Seat Swi tch Conti nui ty chart (Fi g. 4). I f OK, refer to
Power Seat Track Di agnosi s and Testi ng i n thi s
group. I f not OK, repl ace the faul ty power seat
swi tch.
PASSENGER SEAT SWITCH TEST TABLE
PASSENGER SWITCH
POSITION
CONTINUITY BETWEEN
OFF B-N, B-J, B-M
B-E, B-L, B-K
VERTICAL DOWN A-E, A-M, B-N, B-E
VERTICAL UP A-J, A-N, B-M, B-E
HORIZONTAL
FORWARD
A-L, B-K
HORIZONTAL
REARWARD
A-K, B-L
FRONT TILT DOWN A-M, B-N
FRONT TILT UP A-N, B-M
REAR TILT DOWN A-E, B-J
REAR TILT UP A-J, B-E
LUMBAR OFF O-P, O-R, P-R
LUMPAR UP (DEFLATE) O-P, Q-R
LUMBAR DOWN
(INFLATE)
O-R, P-Q
REMOVAL
cabl e.
(2) Remove the seat cushi on si de shi el d from the
for the procedure.
(3) Pul l the swi tch bezel or si de shi el d uni t out
from the seat far enough to access the swi tch wi re
harness connector. Gentl y pry the l ocki ng tabs of the
swi tch away from the wi re harness connector and
careful l y unpl ug the connector from the power seat
swi tch modul e.
(4) Remove the screws that secure the power seat
swi tch.
INSTALLATION
(1) Posi ti on the power seat swi tch on the seat
cushi on bezel and i nstal l the screws that secure the
power seat swi tch to seat cushi on si de bezel .
(3) I nstal l the seat cushi on swi tch bezel on the
for the procedure.
(4) I f equi pped, i nstal l the screw that secures the
recl i ner l ever to the recl i ner mechani sm rel ease shaft
on the outboard si de of the front seat.
POWER SEAT TRACK
DESCRIPTION
The ei ght-way power seat opti on i ncl udes a power
seat track assembl y l ocated under each front seat
(Fi g. 5). The power seat track assembl y repl aces the
standard manual l y operated seat tracks. The l ower
hal f of the power seat track i s secured at the front
wi th two bol ts to the fl oor panel seat cross member,
and at the rear wi th two bol ts to the fl oor panel .
Four nuts secure the bottom of the seat cushi on
frame to the upper hal f of the power seat track uni t.
The power seat track assembl y cannot be repai red,
and i s servi ced onl y as a compl ete assembl y. I f any
component i n thi s assembl y i s faul ty or damaged, the
enti re power seat track must be repl aced.
OPERATION
The power seat track uni t i ncl udes three reversi bl e
el ectri c motors that are secured to the upper hal f of
the track uni t. Each motor moves the seat adjuster
through a combi nati on of worm-dri ve gearboxes and
screw-type dri ve uni ts.
The front and rear of the seat are operated by two
separate verti cal adjustment motors. These motors
can be operated i ndependentl y of each other, ti l ti ng
the enti re seat assembl y forward or rearward; or,
Fig. 4 Testing Passenger Power Seat Switch
PASSENGER SEAT SWITCH (Continued)
they can be operated i n uni son by sel ecti ng the
proper power seat swi tch functi ons, whi ch wi l l rai se
or l ower the enti re seat assembl y. The thi rd motor i s
the hori zontal adjustment motor, whi ch moves the
seat track i n the forward and rearward di recti ons.
TRACK
For compl ete power seat ci rcui t descri pti ons and
di agrams, refer to Wi ri ng Di agrams.
Operate the power seat swi tch to move al l three
seat motors i n each di recti on. The seat shoul d move
i n each of the sel ected di recti ons. I f the power seat
track fai l s to operate i n onl y one di recti on, move the
seat track a short di stance i n the opposi te di recti on
and test agai n to be certai n that the track i s not at
i ts travel l i mi t. I f the power seat track sti l l fai l s to
operate i n onl y one di recti on, refer to Di agnosi s and
Testi ng of the Power Seat Swi tch i n thi s secti on. I f
the power seat track fai l s to operate i n more than
one di recti on, proceed as fol l ows:
(1) Check the power seat fuse i n the power di stri -
buti on center. I f OK, go to Step 2. I f not OK, repl ace
the faul ty fuse.
(2) Remove the power seat swi tch from the seat.
Check for battery vol tage at the fused B(+) ci rcui t
cavi ty of the power seat swi tch wi re harness connec-
tor. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t to the power di stri buti on center as requi red.
(3) Check for conti nui ty between the ground ci r-
cui t cavi ty of the power seat swi tch wi re harness con-
nector and a good ground. There shoul d be
conti nui ty. I f OK, go to Step 4. I f not OK, repai r the
open ci rcui t to ground as requi red.
(4) Test the power seat swi tch as descri bed i n thi s
group. I f the swi tch tests OK, check the wi re harness
between the power seat swi tch and the motor for
shorts or opens. I f the ci rcui ts check OK, repl ace the
faul ty power seat track (adjuster) assembl y. I f the
ci rcui ts are not OK, repai r the wi re harness as
requi red.
REMOVAL
(1) Remove the appropri ate seat from the vehi cl e.
(Refer to 23 - BODY/SEATS/SEAT - REMOVAL).
(2) Remove the power seat swi tch from the seat.
Refer to the procedure i n thi s secti on of the servi ce
manual .
(3) Remove four seat track mounti ng nuts from
cushi on pan.
(4) Di sconnect the power seat el ectri cal and
remove the seat track from the seat cushi on.
(5) Remove the necessary components that must
be transferred to the repl acement seat track (seat
bel t buckl es, wi re harness, etc.).
INSTALLATION
(1) I nstal l the necessary components that must be
transferred to the repl acement seat track (seat bel t
buckl es, wi re harness, etc.).
(2) Posi ti on the seat track and i nstal l the retai ni ng
nuts on the seat cushi on pan studs. Torque the bol ts
to 25 Nm.
(3) Route and connect the power seat el ectri cal on
the seat track and cushi on pan.
(4) I nstal l the power seat swi tch on the seat. Refer
to the procedure i n thi s secti on of the servi ce man-
ual .
(5) I nstal l the seat i n the vehi cl e (Refer to 23 -
BODY/SEATS/SEAT - I NSTALLATI ON).
LUMBAR CONTROL SWITCH
DESCRIPTION
The power l umbar seat opti on i ncl udes an el ectri -
cal l y operated l umbar support mechani sm. A si ngl e
two-way momentary power l umbar swi tch i s i ntegral
wi th the power seat swi tches. The power l umbar
swi tch i s secured to the back of the seat cushi on si de
shi el d wi th screws, and the swi tch paddl e protrudes
through a hol e to the outsi de of the shi el d. The
swi tch paddl e i s l ocated i n a shal l ow depressi on
mol ded i nto the outer surface of the seat cushi on si de
Fig. 5 DR Driver Power Seat Track
1 - POWER SEAT TRACK ASSEMBLY
2 - SEAT TRACK WIRE HARNESS
3 - SEAT BELT BUCKLE ASSEMBLIES
POWER SEAT TRACK (Continued)
shi el d that hel ps to shroud i t from uni ntenti onal
actuati on when enteri ng or l eavi ng the vehi cl e.
The power l umbar swi tches cannot be adjusted or
repai red and, i f faul ty or damaged, the seat swi tch
assembl y must be repl aced.
OPERATION
When the power l umbar swi tch paddl e i s actuated,
a battery feed and a ground path are appl i ed through
the swi tch contacts to the power l umbar adjuster
motor. The motor operates to move the l umbar
adjuster through i ts dri ve uni t i n the sel ected di rec-
swi tch contacts. Thi s causes the motor to run i n the
opposi te di recti on.
The power l umbar swi tch shoul d not be hel d
appl i ed i n ei ther di recti on after the adjuster has
reached i ts travel l i mi t. The power l umbar adjuster
motor contai ns a sel f-resetti ng ci rcui t breaker to pro-
tect i t from overl oad. However, consecuti ve or fre-
quent resetti ng of the ci rcui t breaker must not be
al l owed to conti nue, or the motor may be damaged.
REMOVAL
The power l umbar swi tch i s i ntegral wi th the other
power seat swi tches. Refer to the appropri ate dri ver
or passenger power front seat swi tch removal and/or
i nstal l ati on procedure.
LUMBAR MOTOR
DESCRIPTION
The power l umbar seat opti on i ncl udes an el ectri -
cal l y operated l umbar support mechani sm. The onl y
vi si bl e evi dence of thi s opti on i s the separate power
l umbar swi tch control paddl e that i s l ocated on the
outboard seat cushi on swi tch bezel , next to the other
power seat swi tch control knobs. The power l umbar
adjuster and motor are conceal ed beneath the seat
back tri m cover and paddi ng, where they are secured
to a mol ded pl asti c back panel and to the seat back
frame.
The power l umbar adjuster cannot be repai red, and
i s servi ced onl y as a uni t wi th the seat back frame. I f
the power l umbar adjuster or the seat back frame
are damaged or faul ty, the enti re seat back frame
uni t must be repl aced (Refer to 23 - BODY/SEATS/
SEAT BACK - REMOVAL).
OPERATION
The power l umbar adjuster mechani sm i ncl udes a
reversi bl e el ectri c motor that i s secured to the
i nboard si de of the seat back panel and i s connected
to a worm-dri ve gearbox. The motor and gearbox
operate the l umbar adjuster mechani sm i n the center
of the seat back dri vi ng a nut up or down a fi xed
dri ve screw. The acti on of thi s nut extends or con-
tracts the pl asti c l umbar support band. The more
thi s band i s contracted, the more outward pressure i s
appl i ed agai nst the center of the seat back paddi ng,
provi di ng addi ti onal l umbar support.
DIAGNOSIS AND TESTING - LUMBAR MOTOR
Actuate the power l umbar swi tch to move the
power l umbar adjuster i n each di recti on. The power
l umbar adjuster shoul d move i n both di recti ons. I t
shoul d be noted that the power l umber adjuster nor-
mal l y operates very qui etl y and exhi bi ts l i ttl e vi si bl e
movement. I f the power l umbar adjuster fai l s to oper-
ate i n onl y one di recti on, move the adjuster a short
di stance i n the opposi te di recti on and test agai n to be
certai n that the adjuster i s not at i ts travel l i mi t. I f
the power l umbar adjuster fai l s to operate i n onl y
one di recti on, Test the appropri ate power seat swi tch
as descri bed i n thi s group. I f the power l umbar
adjuster fai l s to operate i n ei ther di recti on, perform
the fol l owi ng tests. For compl ete ci rcui t di agrams,
refer to Wiring.
(1) Check the power seat ci rcui t breaker. I f OK, go
to Step 2. I f not OK, repl ace the faul ty power seat
ci rcui t breaker.
(2) Check for battery vol tage at the power seat ci r-
cui t breaker. I f OK, go to Step 3. I f not OK, repai r
the open fused B(+) ci rcui t to the fuse i n the I nte-
grated Power Modul e as requi red.
(3) Remove the outboard seat cushi on si de shi el d
from the seat. Di sconnect the seat wi re harness con-
nector from the power l umbar swi tch connector
receptacl e. Check for battery vol tage at the fused
B(+) ci rcui t cavi ty of the power seat wi re harness
connector for the power l umbar swi tch. I f OK, go to
Step 4. I f not OK, repai r the open fused B(+) ci rcui t
to the power seat as requi red.
cui t cavi ty of the power seat wi re harness connector
for the power l umbar swi tch and a good ground.
There shoul d be conti nui ty. I f OK, go to Step 5. I f not
OK, repai r the open ground ci rcui t to ground as
requi red.
(5) Test the power l umbar swi tch. . I f the swi tch
tests OK, test the ci rcui ts of the power seat wi re har-
ness between the power l umbar adjuster motor and
the power l umbar swi tch for shorts or opens. I f the
ci rcui ts check OK, repl ace the faul ty seat back frame
assembl y. I f the ci rcui ts are not OK, repai r the power
seat wi re harness as requi red.
LUMBAR CONTROL SWITCH (Continued)
POWER WINDOWS
TABLE OF CONTENTS
page page
POWER WINDOWS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
WINDOW MOTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
WINDOW SWITCH
DIAGNOSIS AND TESTING - WINDOW
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
POWER WINDOWS
DESCRIPTION
The power wi ndow system al l ows each of the door
wi ndows to be rai sed and l owered el ectri cal l y by
actuati ng a swi tch on each door panel . A master
swi tch on the dri vers door al l ows the dri ver to rai se
or l ower each of the passenger door wi ndows and to
l ock out the i ndi vi dual swi tches on the passenger
doors from operati on. The power wi ndow system
recei ves battery feed through a fuse i n the I ntegrated
Power Modul e (I PM) and a ci rcui t breaker l ocated i n
the i nstrument panel wi ri ng harness near the park
brake pedal , onl y when the i gni ti on swi tch i s i n the
RUN or ACCESSORY posi ti on.
OPERATION
WINDOW SWITCH
The power wi ndow swi tches control the battery
and ground feeds to the power wi ndow motors. The
passenger door power wi ndow swi tches recei ve thei r
battery and ground feeds through the ci rcui try of the
dri vers wi ndow swi tch. When the power wi ndow l ock-
out swi tch i s i n the Lock posi ti on, the battery feed
for the passenger door wi ndow swi tches i s i nter-
rupted.
WINDOW MOTOR
Wi ndow motors use permanent type magnets. The
B+ and ground appl i ed at the motor termi nal pi ns
wi l l cause the motor to rotate i n one di recti on.
Reversi ng current through the motor termi nal s wi l l
cause the motor to rotate i n the opposi te di recti on.
WINDOWS
WIRING VOLTAGE TEST
The fol l owi ng wi ri ng test determi nes whether or
not vol tage i s conti nuous through the body harness
to the front swi tch.
(1) Remove the Dri ver Door Modul e (Refer to 8 -
REMOVAL).
(2) Di sconnect wi re connector from back of power
wi ndow swi tch.
(3) Swi tch i gni ti on to the ON posi ti on.
(4) Connect the cl i p end of a 12 vol t test l i ght to
Pi n 14 of the wi ndow swi tch harness connector.
Touch the test l i ght probe to Pi n 10.
I f the test l i ght i l l umi nates, the wi ri ng ci rcui t
between the battery and swi tch i s OK.
I f the l amp does not i l l umi nate, fi rst check the
fuse i n the I ntegrated Power Modul e (I PM). Check
the ci rcui t breaker l ocated near the park brake
pedal . I f fuse and ci rcui t breaker are OK, then check
for a broken wi re.
POWER WINDOW MOTOR TEST
I f the power wi ndow motor i s recei vi ng proper cur-
rent and ground and does not operate, proceed wi th
motor test.
(1) Remove front door tri m panel as necessary to
gai n access to power wi ndow motor wi re connector
(Refer to 23 - BODY/DOOR - FRONT/TRI M PANEL -
REMOVAL).
(2) Di sconnect power wi ndow motor wi re connector
from door harness.
(3) Usi ng two jumper wi res, connect one to a bat-
tery (+) source and the other to a good ground (-).
(4) Connect the Negati ve (-) jumper probe to one of
the motor connector termi nal s.
DR POWER WINDOWS 8N - 19
(5) Momentari l y touch the Posi ti ve (+) jumper
probe to the other motor connector termi nal .
When posi ti ve probe i s connected the motor shoul d
rotate i n one di recti on to ei ther move wi ndow up or
down. I f wi ndow i s al l the way up or down the motor
wi l l grunt and the i nner door panel wi l l fl ex when
actuated i n that one di recti on.
(6) Reverse jumper probes at the motor connector
termi nal s and wi ndow shoul d now move i n opposi te
di recti on. I f wi ndow does not move or grunt, repl ace
the motor.
I f wi ndow moved compl etel y up or down, reverse
the jumper probes and cycl e wi ndow to the opposi te
posi ti on to veri fy ful l operati on.
I f motor grunts and does not move, veri fy that reg-
ul ator i s not bi ndi ng.
WINDOW MOTOR
REMOVAL
The wi ndow motor i s servi ced wi th the wi ndow
regul ator (Refer to 23 - BODY/DOOR - FRONT/WI N-
DOW REGULATOR - REMOVAL) or (Refer to 23 -
BODY/DOORS - REAR/WI NDOW REGULATOR -
REMOVAL).
WINDOW SWITCH
DIAGNOSIS AND TESTING - WINDOW SWITCH
The Li ght-Emi tti ng Di ode (LED) i l l umi nati on
l amps for al l of the power wi ndow and l ock swi tch
and bezel uni t swi tch paddl es recei ve battery current
through the power wi ndow ci rcui t breaker i n the
juncti on bl ock. I f al l of the LEDs are i noperati ve i n
both the power wi ndow and l ock swi tch uni ts and the
power wi ndows are i noperati ve, (Refer to 8 - ELEC-
TRI CAL/POWER WI NDOWS - DI AGNOSI S AND
TESTI NG). I f the power wi ndows operate, but any or
al l of the LEDs are i noperati ve, the power wi ndow
and l ock swi tch uni ts wi th the i noperati ve LED(s) i s
faul ty and must be repl aced. For compl ete ci rcui t di a-
grams, refer to the appropri ate wi ri ng i nformati on.
(1) Check the fuse i n the I ntegrated Power Modul e
(I PM) and the ci rcui t breaker l ocated near the park
brake pedal . I f OK, go to Step 2. I f not OK, repl ace
the faul ty fuse or ci rcui t breaker.
Check for battery vol tage at the fuse i n the I nte-
grated Power Modul e (I PM). I f OK, turn the i gni ti on
swi tch to the Off posi ti on and go to Step 3. I f not OK,
check ci rcui t breaker and repai r the ci rcui t to the
i gni ti on swi tch as requi red.
cabl e. Remove the power wi ndow swi tch uni t from
the door tri m panel (passenger doors). The dri vers
door swi tch i s i ncl uded wi th the Dri ver Door Modul e
(Refer to 8 - ELECTRI CAL/POWER LOCKS/DOOR
MODULE - DI AGNOSI S AND TESTI NG) for servi ce
procedures. Unpl ug the wi re harness connector from
the swi tch uni t.
(4) Test the power wi ndow swi tch conti nui ty. See
the Power Wi ndow Swi tch Conti nui ty charts to deter-
mi ne i f the conti nui ty i s correct i n the Off, Up and
Down swi tch posi ti ons (Fi g. 1). I f OK, (Refer to 8 -
ELECTRI CAL/POWER WI NDOWS - DI AGNOSI S
AND TESTI NG). I f not OK, repl ace the faul ty swi tch.
POWER WINDOW SWITCH CONTINUITY
CHART
NEUTRAL PIN 2 AND 5, PIN 4 AND
1
UP (FRONT
PASSENGER)
PIN 6 AND 5
UP (REAR
PASSENGER)
PIN 6 AND 1
DOWN (FRONT
PASSENGER)
PIN 6 AND 1
DOWN (REAR
PASSENGER)
PIN 6 AND 5
REMOVAL
FRONT PASSENGER
cabl e.
(3) Remove the swi tch from the tri m panel bezel .
Fig. 1 PASSENGER DOOR SWITCH
8N - 20 POWER WINDOWS DR
POWER WINDOWS (Continued)
REAR PASSENGER
cabl e.
BODY/DOORS - REAR/TRI M PANEL - REMOVAL).
(3) Gentl y pry swi tch from door tri m panel .
INSTALLATION
FRONT PASSENGER
(1) I nsert swi tch to tri m panel bezel .
REAR PASSENGER
(1) I nstal l swi tch to door tri m panel
DOORS - REAR/TRI M PANEL - I NSTALLATI ON).
DR POWER WINDOWS 8N - 21
WINDOW SWITCH (Continued)
RESTRAINTS
TABLE OF CONTENTS
page page
RESTRAINTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WARNING
WARNINGS - RESTRAINT SYSTEM . . . . . . . . 5
DIAGNOSIS AND TESTING - SUPPLEMENTAL
RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - SERVICE
AFTER A SUPPLEMENTAL RESTRAINT
DEPLOYMENT. . . . . . . . . . . . . . . . . . . . . . . . . 7
STANDARD PROCEDURE - VERIFICATION
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ACM COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
AIRBAG CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
AUTOMATIC LOCKING RETRACTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHILD RESTRAINT ANCHOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
CLOCKSPRING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
STANDARD PROCEDURE - CLOCKSPRING
CENTERING . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
DRIVER AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 25
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
FRONT CENTER SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
FRONT CENTER SEAT BELT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
FRONT OUTBOARD SEAT BELT &
RETRACTOR
REMOVAL
REMOVAL - STANDARD CAB . . . . . . . . . . . . 32
REMOVAL - QUAD CAB . . . . . . . . . . . . . . . . 33
INSTALLATION
INSTALLATION - STANDARD CAB . . . . . . . . . 35
INSTALLATION - QUAD CAB . . . . . . . . . . . . . 36
FRONT OUTBOARD SEAT BELT BUCKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
PASSENGER AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
PASSENGER AIRBAG ON/OFF SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
REAR CENTER SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
REAR OUTBOARD SEAT BELT & RETRACTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
REAR SEAT BELT BUCKLE
REMOVAL
REMOVAL - CENTER & LEFT OUTBOARD . . 48
REMOVAL - CENTER ANCHOR & RIGHT
OUTBOARD. . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION
INSTALLATION - CENTER & LEFT
OUTBOARD. . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION - CENTER ANCHOR &
RIGHT OUTBOARD . . . . . . . . . . . . . . . . . . . . 50
SEAT BELT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 51
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DIAGNOSIS AND TESTING - SEAT BELT
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SEAT BELT TENSIONER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DR RESTRAINTS 8O - 1
SEAT BELT TENSION REDUCER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 53
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
TENSION REDUCER . . . . . . . . . . . . . . . . . . . 54
SEAT BELT TURNING LOOP ADJUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
SIDE CURTAIN AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 56
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
SIDE IMPACT SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 59
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
REMOVAL
REMOVAL - STANDARD CAB . . . . . . . . . . . . 59
REMOVAL - QUAD CAB . . . . . . . . . . . . . . . . 60
INSTALLATION
INSTALLATION - STANDARD CAB . . . . . . . . . 61
INSTALLATION - QUAD CAB . . . . . . . . . . . . . 61
RESTRAINTS
DESCRIPTION
An occupant restrai nt system i s standard factory-
i nstal l ed safety equi pment on thi s model . Avai l abl e
occupant restrai nts for thi s model i ncl ude both acti ve
and passi ve types. Acti ve restrai nts are those whi ch
requi re the vehi cl e occupants to take some acti on to
empl oy, such as fasteni ng a seat bel t; whi l e passi ve
restrai nts requi re no acti on by the vehi cl e occupants
to be empl oyed (Fi g. 1).
ACTIVE RESTRAINTS
The acti ve restrai nts for thi s model i ncl ude:
Front Seat Belts - Both outboard front seati ng
posi ti ons are equi pped wi th three-poi nt seat bel t sys-
tems empl oyi ng a l ower B-pi l l ar mounted i nerti a
l atch-type emergency l ocki ng retractor, hei ght-adjust-
abl e upper B-pi l l ar mounted turni ng l oops, a fi xed
l ower seat bel t anchor secured to the l ower B-pi l l ar
(standard cab) or fl oor panel adjacent to the B-pi l l ar
(quad cab), and a travel i ng end-rel ease seat bel t
buckl e secured to the i nboard seat track. The dri ver
si de retractor for standard cab model s i ncl udes an
el ectri cal l y actuated seat bel t tensi on reducer. The
passenger si de front seat retractor for al l model s i s
al so swi tchabl e from an emergency l ocki ng retractor
to an automati c l ocki ng retractor. The front seat bel t
buckl e for the dri ver si de of al l model s i ncl udes an
i ntegral seat bel t swi tch that detects whether i ts seat
bel t has been fastened. The center front seati ng posi -
ti on for standard cab model s i s al so equi pped wi th a
three-poi nt seat bel t empl oyi ng a fl oor panel
mounted i nerti a l atch-type retractor, a routi ng
bracket and bezel near the top of the cab back panel ,
and two fi xed end-rel ease buckl es secured to the cen-
ter seat cushi on frame. The center front seati ng posi -
ti on for quad cab model s i s equi pped wi th a fi xed l ap
bel t and an end-rel ease buckl e secured to the center
seat cushi on frame.
Rear Seat Belts - Al l three rear seati ng posi -
ti ons are equi pped wi th three-poi nt seat bel t sys-
tems. The outboard seati ng posi ti on bel ts empl oy a
l ower C-pi l l ar mounted i nerti a l atch-type emergency
l ocki ng retractor, a fi xed posi ti on upper C-pi l l ar
mounted turni ng l oop, and a fi xed l ower seat bel t
anchor secured to the l ower C-pi l l ar. The rear seat
center seati ng posi ti on bel t has a rear fl oor panel
mounted i nerti a l atch-type emergency l ocki ng retrac-
tor and a routi ng bracket and bezel on the top of the
cab back panel . The end-rel ease buckl e uni ts for the
ri ght outboard seati ng posi ti on and the center seat-
i ng posi ti on l ower anchor are i ntegral to the center
retractor mounti ng bracket on the rear fl oor panel .
The end-rel ease buckl e uni ts for the center and l eft
outboard seati ng posi ti ons are i ndi vi dual l y secured to
the rear fl oor panel on model s wi th the standard
equi pment rear bench seat, or secured wi th the rear
seat mounti ng hardware on model s wi th the opti onal
60/40 spl i t rear bench seat.
Child Restraint Anchors - Al l standard cab
model s are equi pped wi th two, fi xed-posi ti on, chi l d
seat upper tether anchors that are i ntegral to the
upper cab back panel rei nforcement and conceal ed
behi nd i ndi vi dual tri m cover and bezel uni ts that are
i ntegral to the cab back tri m panel . Al l quad cab
model s are equi pped wi th three chi l d seat upper
tether anchor straps that are secured to the upper
cab back panel rei nforcement, behi nd the upri ght
rear seat back. Two l ower anchors are al so provi ded
for the front outboard seati ng posi ti on of standard
cab model s, and for each rear outboard seati ng posi -
ti on on quad cab model s. These l ower anchors are
accessed from the front of the seat where the seat
back meets the seat cushi on. The chi l d seat tether
and l ower anchors for the front seat are del eted on
quad cab model s.
PASSIVE RESTRAINTS
The passi ve restrai nts avai l abl e for thi s model
i ncl ude the fol l owi ng:
Dual Front Airbags - Mul ti stage dri ver and
front passenger ai rbags are avai l abl e for thi s model .
Thi s ai rbag system i s a passi ve, i nfl atabl e, Suppl e-
mental Restrai nt System (SRS) and vehi cl es wi th
thi s equi pment can be readi l y i denti fi ed by the SRS
- AI RBAG l ogo mol ded i nto the dri ver ai rbag tri m
cover i n the center of the steeri ng wheel and al so
8O - 2 RESTRAINTS DR
i nto the passenger ai rbag door on the i nstrument
panel above the gl ove box (Fi g. 2). Vehi cl es wi th the
ai rbag system can al so be i denti fi ed by the ai rbag
i ndi cator, whi ch wi l l i l l umi nate i n the i nstrument
cl uster for about si x seconds as a bul b test each ti me
the i gni ti on swi tch i s turned to the On posi ti on. A
pyrotechni c-type seat bel t tensi oner i s i ntegral to the
front outboard seat bel t retractors mounted on each
l ower B-pi l l ar of al l model s equi pped wi th dual front
ai rbags.
Side Curtain Airbags - Opti onal si de curtai n
ai rbags are avai l abl e for thi s model when i t i s al so
equi pped wi th dual front ai rbags. Thi s ai rbag system
i s a passi ve, i nfl atabl e, Suppl emental Restrai nt Sys-
tem (SRS) and vehi cl es wi th thi s equi pment can be
readi l y i denti fi ed by a mol ded i denti fi cati on tri m but-
ton wi th the SRS - AI RBAG l ogo l ocated on the
headl i ner above each B-pi l l ar (Fi g. 2).
The suppl emental restrai nt system i ncl udes the
fol l owi ng major components, whi ch are descri bed i n
further detai l el sewhere i n thi s servi ce i nformati on:
Airbag Control Module - The Ai rbag Control
Modul e (ACM) i s al so someti mes referred to as the
Occupant Restrai nt Control l er (ORC). The ACM i s
l ocated on a mount on the fl oor panel transmi ssi on
tunnel , bel ow the center of the i nstrument panel .
Fig. 1 Supplemental Restraint System
1 - AIRBAG CONTROL MODULE
2 - PASSENGER AIRBAG
3 - PASSENGER AIRBAG ON/OFF SWITCH (STD CAB ONLY)
4 - DRIVER AIRBAG
5 - SIDE CURTAIN AIRBAG (2)
6 - SIDE IMPACT SENSOR (2 - W/SIDE CURTAIN AIRBAGS
ONLY)
7 - SEAT BELT TENSIONER (2)
RESTRAINTS (Continued)
Airbag Indicator - The ai rbag i ndi cator i s i nte-
gral to the El ectroMechani cal I nstrument Cl uster
(EMI C), whi ch i s l ocated on the i nstrument panel i n
front of the dri ver.
Clockspring - The cl ockspri ng i s l ocated near
the top of the steeri ng col umn, di rectl y beneath the
steeri ng wheel .
Driver Airbag - The dri ver ai rbag i s l ocated i n
the center of the steeri ng wheel , beneath the dri ver
ai rbag tri m cover.
Driver Knee Blocker - The dri ver knee bl ocker
i s a structural uni t secured to the back si de of and
i ntegral to the i nstrument panel steeri ng col umn
openi ng cover.
Passenger Airbag - The passenger ai rbag i s
l ocated on the i nstrument panel , beneath the passen-
ger ai rbag door on the i nstrument panel above the
gl ove box on the passenger si de of the vehi cl e.
Passenger Airbag On/Off Switch - Standard
cab model s wi thout a rear seat are equi pped wi th a
passenger ai rbag on/off swi tch, whi ch i s l ocated on
the ri ght si de of the i nstrument panel center bezel .
Passenger Knee Blocker - The passenger knee
bl ocker i s a structural rei nforcement that i s i ntegral
to and conceal ed wi thi n the gl ove box door.
Seat Belt Tensioner - The seat bel t tensi oner
i s i ntegral to the front outboard seat bel t retractor
uni ts on vehi cl es equi pped wi th dual front ai rbags.
Side Impact Sensor - Two si de i mpact sensors
are used on vehi cl es equi pped wi th the opti onal si de
curtai n ai rbags, one l eft si de and one ri ght si de. One
sensor i s l ocated behi nd the B-pi l l ar tri m near the
base of each B-pi l l ar.
Side Curtain Airbag - I n vehi cl es equi pped
wi th thi s opti on, a si de curtai n ai rbag i s l ocated on
each i nsi de roof si de rai l above the headl i ner, and
extends from the A-pi l l ar to the B-pi l l ar on standard
cab model s, and from the A-pi l l ar to the C-pi l l ar on
quad cab model s.
The ACM and the EMI C each contai n a central
processi ng uni t and programmi ng that al l ow them to
communi cate wi th each other usi ng the Programma-
bl e Communi cati ons I nterface (PCI ) data bus net-
work. Thi s method of communi cati on i s used by the
ACM for control of the ai rbag i ndi cator on al l model s
equi pped wi th dual front ai rbags. (Refer to 8 - ELEC-
TRI CAL/ELECTRONI C CONTROL MODULES/
COMMUNI CATI ON - DESCRI PTI ON).
Hard wi red ci rcui try connects the suppl emental
restrai nt system components to each other through
the el ectri cal system of the vehi cl e. These hard wi red
ci rcui ts are i ntegral to several wi re harnesses, whi ch
many di fferent methods. These ci rcui ts may be con-
nected to each other, to the vehi cl e el ectri cal system,
and to the suppl emental restrai nt system compo-
nents through the use of a combi nati on of sol dered
spl i ces, spl i ce bl ock connectors, and many di fferent
types of wi re harness termi nal connectors and i nsu-
l ators. Refer to the appropri ate wi ri ng i nformati on.
The wi ri ng i nformati on i ncl udes wi ri ng di agrams,
proper wi re and connector repai r procedures, further
detai l s on wi re harness routi ng and retenti on, as wel l
as pi n-out and l ocati on vi ews for the vari ous wi re
OPERATION
ACTIVE RESTRAINTS
The pri mary passenger restrai nts i n thi s or any
other vehi cl e are the standard equi pment factory-i n-
stal l ed seat bel ts and chi l d restrai nt anchors. Seat
bel ts and chi l d restrai nt anchors are referred to as
an acti ve restrai nt because the vehi cl e occupants are
requi red to physi cal l y fasten and properl y adjust
these restrai nts i n order to benefi t from them. See
the owners manual i n the vehi cl e gl ove box for more
i nformati on on the features, use and operati on of al l
of the factory-i nstal l ed acti ve restrai nts.
PASSIVE RESTRAINTS
The passi ve restrai nts are referred to as a suppl e-
mental restrai nt system because they were desi gned
and are i ntended to enhance the protecti on for the
occupants of the vehi cl e only when used i n conjunc-
ti on wi th the seat bel ts. They are referred to as pas-
si ve restrai nts because the vehi cl e occupants are not
requi red to do anythi ng to make them operate; how-
ever, the vehi cl e occupants must be weari ng thei r
seat bel ts i n order to obtai n the maxi mum safety
benefi t from the factory-i nstal l ed suppl emental
restrai nt system.
The suppl emental restrai nt system el ectri cal ci r-
cui ts are conti nuousl y moni tored and control l ed by a
mi croprocessor and software contai ned wi thi n the
Fig. 2 SRS Logo
Ai rbag Control Modul e (ACM). An ai rbag i ndi cator i n
the El ectroMechani cal I nstrument Cl uster (EMI C)
i l l umi nates for about si x seconds as a bul b test each
ti me the i gni ti on swi tch i s turned to the On or Start
posi ti ons. Fol l owi ng the bul b test, the ai rbag i ndi ca-
tor i s turned on or off by the ACM to i ndi cate the
status of the suppl emental restrai nt system. I f the
ai rbag i ndi cator comes on at any ti me other than
duri ng the bul b test, i t i ndi cates that there i s a prob-
l em i n the suppl emental restrai nt system el ectri cal
ci rcui ts. Such a probl em may cause ai rbags not to
depl oy when requi red, or to depl oy when not
requi red.
Depl oyment of the suppl emental restrai nts
depends upon the angl e and severi ty of an i mpact.
Depl oyment i s not based upon vehi cl e speed; rather,
depl oyment i s based upon the rate of decel erati on as
measured by the forces of gravi ty (G force) upon the
i mpact sensors. When an i mpact i s severe enough,
the mi croprocessor i n the ACM si gnal s the i nfl ator of
the appropri ate ai rbag uni ts to depl oy thei r ai rbag
cushi ons. The outboard front seat bel t tensi oners are
provi ded wi th a depl oyment si gnal by the ACM i n
conjuncti on wi th the dri ver and passenger front ai r-
bags. Duri ng a frontal vehi cl e i mpact, the knee bl ock-
ers work i n concert wi th properl y fastened and
adjusted seat bel ts to restrai n both the dri ver and
the front seat passenger i n the proper posi ti on for an
ai rbag depl oyment. The knee bl ockers al so absorb
and di stri bute the crash energy from the dri ver and
the front seat passenger to the structure of the
i nstrument panel . The seat bel t tensi oner removes
the sl ack from the outboard front seat bel ts to pro-
vi de further assurance that the dri ver and front seat
passenger are properl y posi ti oned and restrai ned for
an ai rbag depl oyment.
Typi cal l y, the vehi cl e occupants recal l more about
the events precedi ng and fol l owi ng a col l i si on than
they do of an ai rbag depl oyment i tsel f. Thi s i s
because the ai rbag depl oyment and defl ati on occur
very rapi dl y. I n a typi cal 48 ki l ometer-per-hour (30
mi l e-per-hour) barri er i mpact, from the moment of
i mpact unti l the ai rbags are ful l y i nfl ated takes
about 40 mi l l i seconds. Wi thi n one to two seconds
from the moment of i mpact, the ai rbags are al most
enti rel y defl ated. The ti mes ci ted for these events are
approxi mati ons, whi ch appl y onl y to a barri er i mpact
at the gi ven speed. Actual ti mes wi l l vary somewhat,
dependi ng upon the vehi cl e speed, i mpact angl e,
severi ty of the i mpact, and the type of col l i si on.
When the ACM moni tors a probl em i n any of the
suppl emental restrai nt system ci rcui ts or compo-
nents, i ncl udi ng the seat bel t tensi oners, i t stores a
faul t code or Di agnosti c Troubl e Code (DTC) i n i ts
memory ci rcui t and sends an el ectroni c message to
the EMI C to turn on the ai rbag i ndi cator. Proper
testi ng of the suppl emental restrai nt system compo-
nents, the Programmabl e Communi cati ons I nterface
(PCI ) data bus, the el ectroni c message i nputs to and
outputs from the EMI C or the ACM, as wel l as the
retri eval or erasure of a DTC from the ACM or EMI C
more i nformati on on the features, use and operati on
of al l of the factory-i nstal l ed passi ve restrai nts.
WARNING
WARNINGS - RESTRAINT SYSTEM
DEATH, DURING AND FOLLOWING ANY SEAT BELT
OR CHILD RESTRAINT ANCHOR SERVICE, CARE-
FULLY INSPECT ALL SEAT BELTS, BUCKLES,
MOUNTING HARDWARE, RETRACTORS, TETHER
STRAPS, AND ANCHORS FOR PROPER INSTALLA-
TION, OPERATION, OR DAMAGE. REPLACE ANY
BELT THAT IS CUT, FRAYED, OR TORN.
STRAIGHTEN ANY BELT THAT IS TWISTED.
TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY
BELT THAT HAS A DAMAGED OR INOPERATIVE
BUCKLE OR RETRACTOR. REPLACE ANY BELT
THAT HAS A BENT OR DAMAGED LATCH PLATE
OR ANCHOR PLATE. REPLACE ANY CHILD
RESTRAINT ANCHOR OR THE UNIT TO WHICH THE
ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR
DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT
BELT OR CHILD RESTRAINT COMPONENT.
ALWAYS REPLACE DAMAGED OR FAULTY SEAT
BELT AND CHILD RESTRAINT COMPONENTS WITH
THE CORRECT, NEW AND UNUSED REPLACEMENT
PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR
PARTS CATALOG.
MENT.
DEATH ON VEHICLES EQUIPPED WITH AIRBAGS,
BEFORE PERFORMING ANY WELDING OPERA-
TIONS DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE AND DISCONNECT
ALL WIRE HARNESS CONNECTORS FROM THE
AIRBAG CONTROL MODULE (ACM). FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND OTHER POSSIBLE DAMAGE TO THE SUPPLE-
MENTAL RESTRAINT SYSTEM CIRCUITS AND COM-
PONENTS.
DEATH, DO NOT ATTEMPT TO DISMANTLE AN AIR-
BAG UNIT OR TAMPER WITH ITS INFLATOR. DO
NOT PUNCTURE, INCINERATE, OR BRING INTO
CONTACT WITH ELECTRICITY. DO NOT STORE AT
TEMPERATURES EXCEEDING 93 C (200 F). AN
AIRBAG INFLATOR UNIT MAY CONTAIN SODIUM
AZIDE AND POTASSIUM NITRATE. THESE MATERI-
ALS ARE POISONOUS AND EXTREMELY FLAMMA-
BLE. CONTACT WITH ACID, WATER, OR HEAVY
METALS MAY PRODUCE HARMFUL AND IRRITAT-
ING GASES (SODIUM HYDROXIDE IS FORMED IN
THE PRESENCE OF MOISTURE) OR COMBUSTIBLE
COMPOUNDS. AN AIRBAG INFLATOR UNIT MAY
ALSO CONTAIN A GAS CANISTER PRESSURIZED
TO OVER 2500 PSI.
DEATH, WHEN HANDLING A SEAT BELT TEN-
SIONER RETRACTOR, PROPER CARE SHOULD BE
EXERCISED TO KEEP FINGERS OUT FROM UNDER
THE RETRACTOR COVER AND AWAY FROM THE
SEAT BELT WEBBING WHERE IT EXITS FROM THE
RETRACTOR COVER.
DEATH, REPLACE ALL RESTRAINT SYSTEM COM-
PONENTS ONLY WITH PARTS SPECIFIED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
SUBSTITUTE PARTS MAY APPEAR INTERCHANGE-
ABLE, BUT INTERNAL DIFFERENCES MAY RESULT
IN INFERIOR OCCUPANT PROTECTION.
DEATH, THE FASTENERS, SCREWS, AND BOLTS
ORIGINALLY USED FOR THE RESTRAINT SYSTEM
COMPONENTS MUST NEVER BE REPLACED WITH
ANY SUBSTITUTES. THESE FASTENERS HAVE
SPECIAL COATINGS AND ARE SPECIFICALLY
DESIGNED FOR THE RESTRAINT SYSTEM. ANY
TIME A NEW FASTENER IS NEEDED, REPLACE IT
WITH THE CORRECT FASTENERS PROVIDED IN
THE SERVICE PACKAGE OR SPECIFIED IN THE
DAIMLERCHRYSLER MOPAR PARTS CATALOG.
DEATH, WHEN A STEERING COLUMN HAS AN AIR-
BAG UNIT ATTACHED, NEVER PLACE THE COL-
UMN ON THE FLOOR OR ANY OTHER SURFACE
WITH THE STEERING WHEEL OR AIRBAG UNIT
FACE DOWN.
DIAGNOSIS AND TESTING - SUPPLEMENTAL
RESTRAINT SYSTEM
Proper di agnosi s and testi ng of the suppl emental
restrai nt system components, the Programmabl e
Communi cati ons I nterface (PCI ) data bus, the data
bus el ectroni c message i nputs to and outputs from
the El ectroMechani cal I nstrument Cl uster (EMI C),
the Ai rbag Control Modul e (ACM), as wel l as the
retri eval or erasure of a Di agnosti c Troubl e Code
(DTC) from the ACM requi res the use of a DRBI I I
mati on.
MENT.
STANDARD PROCEDURE
STANDARD PROCEDURE - HANDLING
NON-DEPLOYED SUPPLEMENTAL RESTRAINTS
At no ti me shoul d any source of el ectri ci ty be per-
mi tted near the i nfl ator on the back of a non-de-
pl oyed ai rbag or seat bel t tensi oner. When carryi ng a
non-depl oyed ai rbag, the tri m cover or ai rbag cushi on
si de of the uni t shoul d be poi nted away from the
body to mi ni mi ze i njury i n the event of an acci dental
depl oyment. I f the ai rbag uni t i s pl aced on a bench or
any other surface, the tri m cover or ai rbag cushi on
si de of the uni t shoul d be face up to mi ni mi ze move-
ment i n the event of an acci dental depl oyment. When
handl i ng a non-depl oyed seat bel t tensi oner, take
proper care to keep fi ngers out from under the
retractor cover and away from the seat bel t webbi ng
where i t exi ts from the retractor cover. I n addi ti on,
the suppl emental restrai nt system shoul d be di s-
armed whenever any steeri ng wheel , steeri ng col -
umn, seat bel t tensi oner, ai rbag, i mpact sensor, or
i nstrument panel components requi re di agnosi s or
servi ce. Fai l ure to observe thi s warni ng coul d resul t
i n acci dental ai rbag depl oyment and possi bl e per-
sonal i njury.
Al l damaged, faul ty or non-depl oyed ai rbags and
seat bel t tensi oners whi ch are repl aced on vehi cl es
are to be handl ed and di sposed of properl y. I f an ai r-
bag or seat bel t tensi oner uni t i s faul ty or damaged
and non-depl oyed, refer to the Hazardous Substance
Control System for proper di sposal . Di spose of al l
non-depl oyed and depl oyed ai rbags and seat bel t ten-
si oners i n a manner consi stent wi th state, provi nci al ,
l ocal and federal regul ati ons.
SUPPLEMENTAL RESTRAINT STORAGE
Ai rbags and seat bel t tensi oners must be stored i n
thei r ori gi nal , speci al contai ner unti l they are used
for servi ce. Al so, they must be stored i n a cl ean, dry
envi ronment; away from sources of extreme heat,
sparks, and hi gh el ectri cal energy. Al ways pl ace or
store any ai rbag on a surface wi th i ts tri m cover or
ai rbag cushi on si de faci ng up, to mi ni mi ze movement
i n case of an acci dental depl oyment.
STANDARD PROCEDURE - SERVICE AFTER A
SUPPLEMENTAL RESTRAINT DEPLOYMENT
Any vehi cl e whi ch i s to be returned to use fol l ow-
i ng a suppl emental restrai nt depl oyment, must have
the depl oyed restrai nts repl aced. I n addi ti on, i f the
dri ver ai rbag has been depl oyed, the cl ockspri ng
must be repl aced. I f the passenger ai rbag i s
depl oyed, the passenger ai rbag door must be
repl aced. The seat bel t tensi oners are depl oyed by
the same si gnal that depl oys the dri ver and passen-
ger ai rbags and must al so be repl aced i f ei ther front
ai rbag has been depl oyed. I f a si de curtai n ai rbag
has been depl oyed, the compl ete ai rbag uni t, the
headl i ner, as wel l as the upper A, B, and C-pi l l ar
tri m must be repl aced. These components are not
i ntended for reuse and wi l l be damaged or weakened
as a resul t of a suppl emental restrai nt depl oyment,
whi ch may or may not be obvi ous duri ng a vi sual
i nspecti on.
I t i s al so cri ti cal that the mounti ng surfaces and/or
mounti ng brackets for the Ai rbag Control Modul e
(ACM) and the si de i mpact sensors be cl osel y
i nspected and restored to thei r ori gi nal condi ti ons fol -
l owi ng any vehi cl e i mpact damage. Because the ACM
and each i mpact sensor are used by the suppl emental
restrai nt system to moni tor or confi rm the di recti on
and severi ty of a vehi cl e i mpact, i mproper ori entati on
or i nsecure fasteni ng of these components may cause
ai rbags not to depl oy when requi red, or to depl oy
when not requi red.
Al l other vehi cl e components shoul d be cl osel y
i nspected fol l owi ng any suppl emental restrai nt
depl oyment, but are to be repl aced onl y as requi red
by the extent of the vi si bl e damage i ncurred.
AIRBAG SQUIB STATUS
Mul ti stage ai rbags wi th mul ti pl e i ni ti ators (squi bs)
must be checked to determi ne that al l squi bs were
used duri ng the depl oyment event. The dri ver and
passenger ai rbags i n thi s model are depl oyed by el ec-
tri cal si gnal s generated by the Ai rbag Control Mod-
ul e (ACM) through the dri ver or passenger squi b 1
and squi b 2 ci rcui ts to the two i ni ti ators i n the ai r-
bag i nfl ators. Typi cal l y, both i ni ti ators are used and
al l potenti al l y hazardous chemi cal s are burned dur-
i ng an ai rbag depl oyment event. However, i t i s possi -
bl e for onl y one i ni ti ator to be used due to an ai rbag
system faul t; therefore, i t i s al ways necessary to con-
fi rm that both i ni ti ators have been used i n order to
avoi d the i mproper handl i ng or di sposal of poten-
ti al l y l i ve pyrotechni c or hazardous materi al s. The
fol l owi ng procedure shoul d be performed usi ng a
DRBI I I scan tool to veri fy the status of both ai rbag
squi bs before ei ther depl oyed ai rbag i s removed from
the vehi cl e for di sposal .
CAUTION: Deployed front airbags having two initia-
tors (squibs) in the airbag inflator may or may not
have live pyrotechnic material within the inflator. Do
not dispose of these airbags unless you are sure of
complete deployment. Refer to the Hazardous Sub-
stance Control System for proper disposal proce-
dures. Dispose of all non-deployed and deployed
airbags in a manner consistent with state, provin-
cial, local, and federal regulations.
(1) Be certai n that the DRBI I I scan tool contai ns
the l atest versi on of the proper DRBI I I software.
Connect the DRBI I I to the 16-way Data Li nk Con-
nector (DLC). The DLC i s l ocated on the dri ver si de
l ower edge of the i nstrument panel , outboard of the
steeri ng col umn.
(3) Usi ng the DRBI I I , read and record the acti ve
(current) Di agnosti c Troubl e Code (DTC) data.
Usi ng the acti ve DTC i nformati on, refer to the Air-
bag Squib Status tabl e to determi ne the status of
both dri ver and/or passenger ai rbag squi bs.
AIRBAG SQUIB STATUS
IF the Active DTC is: Conditions Squib Status
Driver or Passenger Squib 1
open
AND the stored DTC minutes for both Driver or
Passenger squibs are within 15 minutes of each
other
Both Squib 1 and 2 were
used.
open
open
AND the stored DTC minutes for Driver or
Passenger Squib 2 open is GREATER than the
stored DTC minutes for Driver or Passenger
Squib 1 by 15 minutes or more
Squib 1 was used; Squib 2 is
live.
open
open
AND the stored DTC minutes for Driver or
Passenger Squib 1 open is GREATER than the
stored DTC minutes for Driver or Passenger
Squib 2 by 15 minutes or more
Squib 1 is live; Squib 2 was
used.
open
open
AND Driver or Passenger Squib 2 open is NOT
an active code
Squib 1 was used; Squib 2 is
live.
open
AND Driver or Passenger Squib 1 open is NOT
an active code
Squib 1 is live; Squib 2 was
used.
If none of the Dri ver or Passenger Squi b 1 or 2
open are acti ve codes, the status of the ai rbag squi bs
i s unknown. I n thi s case the ai rbag shoul d be han-
dl ed and di sposed of as i f the squi bs were both l i ve.
CLEANUP PROCEDURE
Fol l owi ng a suppl emental restrai nt depl oyment,
the vehi cl e i nteri or wi l l contai n a powdery resi due.
Thi s resi due consi sts pri mari l y of harml ess parti cu-
l ate by-products of the smal l pyrotechni c charge that
i ni ti ates the propel l ant used to depl oy a suppl emen-
tal restrai nt. However, thi s resi due may al so contai n
traces of sodi um hydroxi de powder, a chemi cal
by-product of the propel l ant materi al that i s used to
generate the i nert gas that i nfl ates the ai rbag. Si nce
sodi um hydroxi de powder can i rri tate the ski n, eyes,
nose, or throat, be certai n to wear safety gl asses,
rubber gl oves, and a l ong-sl eeved shi rt duri ng
cl eanup (Fi g. 3).
DEATH, IF YOU EXPERIENCE SKIN IRRITATION
DURING CLEANUP, RUN COOL WATER OVER THE
AFFECTED AREA. ALSO, IF YOU EXPERIENCE
IRRITATION OF THE NOSE OR THROAT, EXIT THE
VEHICLE FOR FRESH AIR UNTIL THE IRRITATION
CEASES. IF IRRITATION CONTINUES, SEE A PHYSI-
CIAN.
(1) Begi n the cl eanup by usi ng a vacuum cl eaner
to remove any resi dual powder from the vehi cl e i nte-
ri or. Cl ean from outsi de the vehi cl e and work your
way i nsi de, so that you avoi d kneel i ng or si tti ng on a
non-cl eaned area.
(2) Be certai n to vacuum the heater and ai r condi -
ti oni ng outl ets as wel l (Fi g. 4). Run the heater and
ai r condi ti oner bl ower on the l owest speed setti ng
and vacuum any powder expel l ed from the outl ets.
Fig. 3 Wear Safety Glasses and Rubber Gloves -
Typical
CAUTION: Deployed front airbags having two initia-
tors (squibs) in the airbag inflator may or may not
have live pyrotechnic material within the inflator. Do
not dispose of these airbags unless you are sure of
complete deployment. Refer to AIRBAG SQUIB STA-
TUS. All damaged, faulty, or non-deployed supple-
mental restraints which are replaced on vehicles
are to be handled and disposed of properly. If an
airbag or seat belt tensioner unit is faulty or dam-
aged and non-deployed, refer to the Hazardous
Substance Control System for proper disposal. Be
certain to dispose of all non-deployed and deployed
supplemental restraints in a manner consistent with
state, provincial, local and federal regulations.
(3) Next, remove the depl oyed suppl emental
restrai nts from the vehi cl e. Refer to the appropri ate
servi ce removal procedures.
(4) You may need to vacuum the i nteri or of the
vehi cl e a second ti me to recover al l of the powder.
STANDARD PROCEDURE - VERIFICATION TEST
The fol l owi ng procedure shoul d be performed usi ng
a DRBI I I scan tool to veri fy proper suppl emental
restrai nt system operati on fol l owi ng the servi ce or
repl acement of any suppl emental restrai nt system
component.
MENT.
(1) Duri ng the fol l owi ng test, the battery negati ve
cabl e remai ns di sconnected and i sol ated, as i t was
duri ng the suppl emental restrai nt system component
removal and i nstal l ati on procedures.
(2) Be certai n that the DRBI I I scan tool contai ns
the l atest versi on of the proper DRBI I I software.
Connect the DRBI I I to the 16-way Data Li nk Con-
nector (DLC). The DLC i s l ocated on the dri ver si de
l ower edge of the i nstrument panel , outboard of the
steeri ng col umn (Fi g. 5).
(3) Turn the i gni ti on swi tch to the On posi ti on and
exi t the vehi cl e wi th the DRBI I I scan tool .
(4) Check to be certai n that nobody i s i n the vehi -
cl e, then reconnect the battery negati ve cabl e.
(5) Usi ng the DRBI I I , read and record the acti ve
(current) Di agnosti c Troubl e Code (DTC) data.
(6) Next, use the DRBI I I to read and record any
stored (hi stori cal ) DTC data.
(7) I f any DTC i s found i n Step 5 or Step 6, refer
to the appropri ate di agnosti c i nformati on.
(8) Use the DRBI I I to erase the stored DTC data.
I f any probl ems remai n, the stored DTC data wi l l not
erase. Refer to the appropri ate di agnosti c i nforma-
ti on to di agnose any stored DTC that wi l l not erase.
Fig. 4 Vacuum Heater and A/C Outlets - Typical
Fig. 5 16-Way Data Link Connector - Typical
1 - 16-WAY DATA LINK CONNECTOR
2 - BOTTOM OF INSTRUMENT PANEL
I f the stored DTC i nformati on i s successful l y erased,
go to Step 9.
(9) Turn the i gni ti on swi tch to the Off posi ti on for
about fi fteen seconds, and then back to the On posi -
ti on. Observe the ai rbag i ndi cator i n the i nstrument
cl uster. I t shoul d i l l umi nate for si x to ei ght seconds,
and then go out. Thi s i ndi cates that the suppl emen-
tal restrai nt system i s functi oni ng normal l y and that
the repai rs are compl ete. I f the ai rbag i ndi cator fai l s
to l i ght, or l i ghts and stays on, there i s sti l l an acti ve
suppl emental restrai nt system faul t or mal functi on.
Refer to the appropri ate di agnosti c i nformati on to
di agnose the probl em.
ACM COVER
REMOVAL
The Ai rbag Control Modul e (ACM) cover i s used
onl y on model s wi th an automati c transmi ssi on. Mod-
el s wi th a manual transmi ssi on requi re that the fl oor
consol e be removed to access the ACM for servi ce.
(Refer to 23 - BODY/I NTERI OR/FLOOR CONSOLE -
REMOVAL).
MENT.
cabl e. Wai t two mi nutes for the system capaci tor to
di scharge before further servi ce.
fl at-bl aded tool , gentl y pry each si de of the ACM
cover away from the i nstrument panel at each si de of
the center bracket on the fl oor panel transmi ssi on
tunnel far enough to di sengage the two snap cl i p
retai ners from the i nstrument panel receptacl es (Fi g.
6).
(3) Remove the ACM cover from the i nstrument
panel .
INSTALLATION
The Ai rbag Control Modul e (ACM) cover i s used
onl y on model s wi th an automati c transmi ssi on. Mod-
el s wi th a manual transmi ssi on requi re that the fl oor
consol e be rei nstal l ed fol l owi ng ACM servi ce. (Refer
to 23 - BODY/I NTERI OR/FLOOR CONSOLE -
I NSTALLATI ON).
MENT.
(1) Posi ti on the ACM cover to the i nstrument
panel (Fi g. 6).
(2) Al i gn the snap cl i p retai ner on each si de of the
ACM cover wi th the i nstrument panel receptacl e at
each si de of the center bracket on the fl oor panel
transmi ssi on tunnel .
(3) Usi ng hand pressure, press fi rml y and evenl y
on the outsi de of the ACM cover over each snap cl i p
retai ner l ocati on unti l each retai ner i s ful l y engaged
i n i ts i nstrument panel receptacl e.
Fig. 6 ACM Cover Remove/Install
1 - INSTRUMENT PANEL RECEPTACLE (2)
2 - ACM COVER
AIRBAG CONTROL MODULE
DESCRIPTION
The Ai rbag Control Modul e (ACM) i s al so some-
ti mes referred to as the Occupant Restrai nt Control -
l er (ORC) (Fi g. 7). The ACM i s conceal ed bel ow the
i nstrument panel center stack i n the passenger com-
partment of the vehi cl e, where i t i s secured by three
screws to a stamped steel mounti ng bracket wel ded
onto the top of the fl oor panel transmi ssi on tunnel
just forward of the i nstrument panel center support
bracket. Conceal ed wi thi n a hol l ow i n the center of
the di e cast al umi num ACM housi ng i s the el ectroni c
ci rcui try of the ACM whi ch i ncl udes a mi croproces-
sor, an el ectroni c i mpact sensor, an el ectroni c safi ng
sensor, and an energy storage capaci tor. A stamped
metal cover pl ate i s secured to the bottom of the
ACM housi ng wi th four screws to encl ose and protect
the i nternal el ectroni c ci rcui try and components.
An arrow pri nted on the l abel on the top of the
ACM housi ng provi des a vi sual veri fi cati on of the
proper ori entati on of the uni t, and shoul d al ways be
poi nted toward the front of the vehi cl e. The ACM
housi ng has i ntegral mounti ng fl anges on three cor-
ners. The mounti ng fl ange to the l eft of the connector
receptacl e has an i ntegral l ocati ng pi n on i ts l ower
surface. Both l eft si de fl anges have round mounti ng
hol es, whi l e the fl ange on the ri ght si de has a sl otted
mounti ng hol e. A mol ded pl asti c el ectri cal connector
wi th two receptacl es, one contai ni ng twenty-four ter-
mi nal pi ns and the other contai ni ng thi rty-two termi -
nal pi ns, exi ts the rearward faci ng si de of the ACM
housi ng. These termi nal pi ns connect the ACM to the
vehi cl e el ectri cal system through two dedi cated take
outs and connectors of the i nstrument panel wi re
harness.
The i mpact sensor and safi ng sensor i nternal to
the ACM are cal i brated for the speci fi c vehi cl e, and
are onl y servi ced as a uni t wi th the ACM. I n addi -
ti on, there are uni que versi ons of the ACM for l i ght
and heavy-duty model s, and for vehi cl es wi th or
wi thout the opti onal si de curtai n ai rbags. The ACM
cannot be repai red or adjusted and, i f damaged or
faul ty, i t must be repl aced.
OPERATION
The mi croprocessor i n the Ai rbag Control Modul e
(ACM) contai ns the suppl emental restrai nt system
l ogi c ci rcui ts and control s al l of the suppl emental
restrai nt system components. The ACM uses
On-Board Di agnosti cs (OBD) and can communi cate
wi th other el ectroni c modul es i n the vehi cl e as wel l
as wi th the DRBI I I scan tool usi ng the Programma-
bl e Communi cati ons I nterface (PCI ) data bus net-
work. Thi s method of communi cati on i s used for
control of the ai rbag i ndi cator i n the El ectroMechani -
cal I nstrument Cl uster (EMI C) and for suppl emental
restrai nt system di agnosi s and testi ng through the
16-way data l i nk connector l ocated on the dri ver si de
l ower edge of the i nstrument panel . (Refer to 8 -
ELECTRI CAL/I NSTRUMENT CLUSTER/AI RBAG
I NDI CATOR - OPERATI ON).
The ACM mi croprocessor conti nuousl y moni tors al l
of the suppl emental restrai nt system el ectri cal ci r-
cui ts to determi ne the system readi ness. I f the ACM
detects a moni tored system faul t, i t sets an acti ve
and stored Di agnosti c Troubl e Code (DTC) and sends
el ectroni c messages to the EMI C over the PCI data
bus to turn on the ai rbag i ndi cator. An acti ve faul t
onl y remai ns for the durati on of the faul t, or i n some
cases for the durati on of the current i gni ti on swi tch
cycl e, whi l e a stored faul t causes a DTC to be stored
i n memory by the ACM. For some DTCs, i f a faul t
does not recur for a number of i gni ti on cycl es, the
ACM wi l l automati cal l y erase the stored DTC. For
other i nternal faul ts, the stored DTC i s l atched for-
ever.
I n standard cab model s, the ACM al so moni tors a
resi stor mul ti pl exed i nput from the passenger ai rbag
on/off swi tch and provi des a control output for the
Off i ndi cator i n the swi tch through a passenger ai r-
bag i ndi cator dri ver ci rcui t. I f the passenger ai rbag
on/off swi tch i s set to the Off posi ti on, the ACM turns
on the passenger ai rbag on/off swi tch Off i ndi cator
and wi l l i nternal l y di sabl e the passenger ai rbag from
bei ng depl oyed. The ACM al so turns on the on/off
swi tch Off i ndi cator for about seven seconds each
ti me the i gni ti on swi tch i s turned to the On posi ti on
as a bul b test. Fol l owi ng the bul b test, the ACM con-
trol s the status of the Off i ndi cator based upon the
Fig. 7 Airbag Control Module
2 - ORIENTATION ARROW
3 - LABEL
4 - CONNECTOR RECEPTACLE (2)
resi stance of the i nput from the on/off swi tch. The
ACM wi l l al so set and/or store a DTC for faul ts i t
detects i n the passenger ai rbag on/off swi tch ci rcui ts,
and wi l l turn on the ai rbag i ndi cator i n the EMI C i f
a faul t has been detected.
The ACM recei ves battery current through two ci r-
cui ts; a fused i gni ti on swi tch output (run) ci rcui t
through a fuse i n the I ntegrated Power Modul e
(I PM), and a fused i gni ti on swi tch output (run-start)
ci rcui t through a second fuse i n the I PM. The ACM
recei ves ground through a ground ci rcui t and take
out of the i nstrument panel wi re harness. Thi s take
out has a si ngl e eyel et termi nal connector that i s
secured by a ground screw to the i nstrument panel
support structure. These connecti ons al l ow the ACM
to be operati onal whenever the i gni ti on swi tch i s i n
the Start or On posi ti ons.
The ACM al so contai ns an energy-storage capaci -
tor. When the i gni ti on swi tch i s i n the Start or On
posi ti ons, thi s capaci tor i s conti nual l y bei ng charged
wi th enough el ectri cal energy to depl oy the suppl e-
mental restrai nt components for up to one second fol -
l owi ng a battery di sconnect or fai l ure. The purpose of
the capaci tor i s to provi de backup suppl emental
restrai nt system protecti on i n case there i s a l oss of
battery current suppl y to the ACM duri ng an i mpact.
Two sensors are contai ned wi thi n the ACM, an
el ectroni c i mpact sensor and a safi ng sensor. The
el ectroni c i mpact sensors are accel erometers that
sense the rate of vehi cl e decel erati on, whi ch provi de
veri fi cati on of the di recti on and severi ty of an
i mpact. On model s equi pped wi th opti onal si de cur-
tai n ai rbags, the ACM al so moni tors i nputs from two
remote si de i mpact sensors l ocated wi thi n both the
l eft and ri ght B-pi l l ars to control depl oyment of the
si de curtai n ai rbag uni ts.
The safi ng sensor i s an el ectroni c accel erometer
sensor wi thi n the ACM that provi des an addi ti onal
l ogi c i nput to the ACM mi croprocessor. The safi ng
sensor i s used to veri fy the need for a suppl emental
restrai nt depl oyment by detecti ng i mpact energy of a
l esser magni tude than that of the pri mary el ectroni c
i mpact sensors, and must exceed a safi ng threshol d
i n order for the ai rbags to depl oy. Vehi cl es equi pped
wi th opti onal si de curtai n ai rbags feature a second
safi ng sensor wi thi n the ACM to provi de confi rma-
ti on to the ACM mi croprocessor of si de i mpact forces.
Thi s second safi ng sensor i s a bi -di recti onal uni t that
detects i mpact forces from ei ther si de of the vehi cl e.
Pre-programmed deci si on al gori thms i n the ACM
mi croprocessor determi ne when the decel erati on rate
as si gnal ed by the i mpact sensors and the safi ng sen-
sors i ndi cate an i mpact that i s severe enough to
requi re suppl emental restrai nt system protecti on
and, based upon the severi ty of the moni tored i mpact
and the status of the passenger ai rbag on/off swi tch
i nput, determi nes the l evel of front ai rbag depl oy-
ment force requi red for each front seati ng posi ti on.
When the programmed condi ti ons are met, the ACM
sends the proper el ectri cal si gnal s to depl oy the dual
mul ti stage front ai rbags at the programmed force
l evel s, the front seat bel t tensi oners and, i f the vehi -
cl e i s so equi pped, ei ther si de curtai n ai rbag uni t.
The hard wi red i nputs and outputs for the ACM
may be di agnosed and tested usi ng conventi onal
di agnosti c tool s and procedures. However, conven-
ti onal di agnosti c methods wi l l not prove concl usi ve i n
the di agnosi s of the ACM, the PCI data bus network,
or the el ectroni c message i nputs to and outputs from
the ACM. The most rel i abl e, effi ci ent, and accurate
means to di agnose the ACM, the PCI data bus net-
work, and the el ectroni c message i nputs to and out-
puts from the ACM requi res the use of a DRBI I I
mati on.
REMOVAL
MENT.
DEATH, NEVER STRIKE OR DROP THE AIRBAG
CONTROL MODULE, AS IT CAN DAMAGE THE
IMPACT SENSOR OR AFFECT ITS CALIBRATION.
THE AIRBAG CONTROL MODULE CONTAINS THE
IMPACT SENSOR, WHICH ENABLES THE SYSTEM
TO DEPLOY THE SUPPLEMENTAL RESTRAINTS. IF
AN AIRBAG CONTROL MODULE IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER SUPPLEMENTAL RESTRAINT DEPLOY-
MENT.
AIRBAG CONTROL MODULE (Continued)
(2) On model s wi th a manual transmi ssi on,
remove the fl oor consol e from the top of the fl oor
panel transmi ssi on tunnel . (Refer to 23 - BODY/I N-
TERI OR/FLOOR CONSOLE - REMOVAL).
(3) On model s wi th an automati c transmi ssi on,
remove the ACM cover from the i nstrument panel .
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/ACM
COVER - REMOVAL).
(4) Reach through the rearward faci ng openi ng
bel ow the i nstrument panel center stack support
bracket on the top of the fl oor panel transmi ssi on
tunnel to access and di sconnect the two i nstrument
panel wi re harness connectors for the Ai rbag Control
Modul e (ACM) from the ACM connector receptacl es
l ocated on the rearward faci ng si de of the modul e
(Fi g. 8). To di sconnect the wi re harness connectors
from the ACM, depress the rel ease tab and l i ft the
l ever arm on each connector.
(5) From the l eft si de of the fl oor panel transmi s-
si on tunnel , reach behi nd the modul e to access and
l oosen the screw that secures the ri ght si de of the
ACM to the bracket on the fl oor panel transmi ssi on
tunnel . Loosen the screw about 7 mi l l i meters (0.25
i nch).
si on tunnel , remove the two screws that secure the
l eft si de of the ACM to the bracket on the fl oor panel
transmi ssi on tunnel .
(7) Sti l l worki ng from the l eft si de of the fl oor
panel transmi ssi on tunnel , l i ft the ACM upward far
enough to di sengage the l ocati ng pi n on the bottom of
the ACM mounti ng fl ange from the l ocati ng hol e i n
the mounti ng bracket, then sl i de the ACM toward
the l eft far enough to di sengage the sl otted hol e i n
the ri ght ACM mounti ng fl ange from under the head
of the previ ousl y l oosened ri ght mounti ng screw.
(8) Remove the ACM from the l eft si de of the fl oor
panel transmi ssi on tunnel .
INSTALLATION
WARNING: TO AVOID PERSONAL INJURY OR DEATH,
ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE
THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE
COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT
SENSOR, OR INSTRUMENT PANEL COMPONENT
THEN WAIT TWO MINUTES FOR THE SYSTEM
CAPACITOR TO DISCHARGE BEFORE PERFORMING
FURTHER DIAGNOSIS OR SERVICE. THIS IS THE
ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL
DENTAL AIRBAG DEPLOYMENT.
NEVER STRIKE OR DROP THE AIRBAG CONTROL
MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR
OR AFFECT ITS CALIBRATION. THE AIRBAG CON-
TROL MODULE CONTAINS THE IMPACT SENSOR,
WHICH ENABLES THE SYSTEM TO DEPLOY THE
SUPPLEMENTAL RESTRAINTS. IF AN AIRBAG CON-
TROL MODULE IS ACCIDENTALLY DROPPED DUR-
ING SERVICE, THE MODULE MUST BE SCRAPPED
AND REPLACED WITH A NEW UNIT. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER SUPPLEMEN-
TAL RESTRAINT DEPLOYMENT.
(1) Posi ti on the Ai rbag Control Modul e (ACM) to
the l eft si de of the fl oor panel transmi ssi on tunnel
near the ACM bracket (Fi g. 8). When the ACM i s cor-
rectl y posi ti oned, the arrow on the ACM l abel wi l l be
poi nted forward i n the vehi cl e.
si on tunnel , sl i de the ACM toward the ri ght far
enough to engage the sl otted hol e i n the ri ght ACM
mounti ng fl ange under the head of the previ ousl y
l oosened ri ght mounti ng screw, then engage the
l ocati ng pi n on the bottom of the l eft ACM mounti ng
fl ange i nto the l ocati ng hol e i n the bracket.
(3) Sti l l worki ng from the l eft si de of the fl oor
panel transmi ssi on tunnel , i nstal l and ti ghten the
two screws that secure the l eft ACM mounti ng
fl anges to the bracket that i s wel ded onto the fl oor
Fig. 8 Airbag Control Module Remove/Install
2 - SCREW (3)
3 - BODY WIRE HARNESS CONNECTOR
4 - INSTRUMENT PANEL WIRE HARNESS CONNECTOR
5 - FLOOR PANEL TRANSMISSION TUNNEL
panel transmi ssi on tunnel . Ti ghten the screws to 12
Nm (9 ft. l bs.).
si on tunnel , reach behi nd the modul e to access and
ti ghten the screw that secures the ri ght si de of the
ACM to the bracket on the fl oor panel transmi ssi on
tunnel . Ti ghten the screw to 12 Nm (9 ft. l bs.).
(5) Reach through the rearward faci ng openi ng
bel ow the i nstrument panel center stack support
bracket on the top of the fl oor panel transmi ssi on
tunnel to access and reconnect the two i nstrument
panel wi re harness connectors for the ACM to the
ACM connector receptacl e l ocated on the rearward
faci ng si de of the modul e. Be certai n that the l atches
on the connectors are each ful l y engaged.
(6) On model s wi th an automati c transmi ssi on,
rei nstal l the ACM cover onto the i nstrument panel .
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/ACM
COVER - I NSTALLATI ON).
(7) On model s wi th a manual transmi ssi on, rei n-
stal l the fl oor consol e onto the top of the fl oor panel
transmi ssi on tunnel . (Refer to 23 - BODY/I NTERI -
OR/FLOOR CONSOLE - I NSTALLATI ON).
(8) Do not reconnect the battery negati ve cabl e at
thi s ti me. The suppl emental restrai nt system veri fi -
cati on test procedure shoul d be performed fol l owi ng
servi ce of any suppl emental restrai nt system compo-
nent. (Refer to 8 - ELECTRI CAL/RESTRAI NTS -
STANDARD PROCEDURE - VERI FI CATI ON TEST).
AUTOMATIC LOCKING
RETRACTOR
DESCRIPTION
The seat bel t retractors used i n al l seati ng posi -
ti ons i ncl ude an i nerti a-type, emergency l ocki ng
mechani sm as standard equi pment (Fi g. 9). However,
the retractor l ocki ng mechani sm for the passenger
si de front seati ng posi ti on i s mechani cal l y swi tchabl e
from an emergency l ocki ng retractor to an automati c
l ocki ng retractor. The pri mary functi on of thi s fea-
ture i s to securel y accommodate a chi l d seat i n the
passenger si de front seati ng posi ti on of the vehi cl e
wi thout the need for a sel f-ci nchi ng seat bel t ti p hal f
l atch pl ate uni t or another suppl emental devi ce that
woul d be requi red to prevent the seat bel t webbi ng
from unwi ndi ng freel y from the retractor spool of an
i nerti a-type emergency l ocki ng retractor mechani sm.
The automati c l ocki ng mechani sm i s i ntegral to the
passenger si de front seat bel t and retractor uni t and
i s conceal ed beneath a mol ded pl asti c cover l ocated
on the same si de of the retractor spool as the seat
bel t tensi oner housi ng. The retractor i s secured to
the i nner B-pi l l ar on the ri ght si de of the vehi cl e and
i s conceal ed beneath the mol ded pl asti c i nner B-pi l -
l ar tri m. The automati c l ocki ng mechani sm cannot be
enti re passenger si de front seat bel t and retractor
uni t must be repl aced.
OPERATION
The automati c l ocki ng mode of the retractor i s
engaged and the retractor i s swi tched from operati ng
as a standard i nerti a-type emergency l ocki ng retrac-
tor by fi rst buckl i ng the combi nati on l ap and shoul -
der bel t buckl e. Then grasp the shoul der bel t and
pul l al l of the webbi ng out of the retractor. Once al l
of the bel t webbi ng i s extracted from the spool , the
retractor wi l l automati cal l y become engaged i n the
pre-l ocked automati c l ocki ng mode and wi l l make an
audi bl e cl i cki ng or ratcheti ng sound as the shoul der
bel t i s al l owed to retract to confi rm that the auto-
mati c l ocki ng mode i s now engaged. Once the auto-
mati c l ocki ng mode i s engaged, the retractor wi l l
remai n l ocked and the bel t wi l l remai n ti ght around
whatever i t i s restrai ni ng.
The retractor i s returned to standard emergency
l ocki ng mode by unbuckl i ng the combi nati on l ap and
shoul der bel t buckl e and al l owi ng the bel t webbi ng to
be al most ful l y retracted onto the retractor spool . The
emergency l ocki ng mode i s confi rmed by the absence
of the audi bl e cl i cki ng or ratcheti ng sound as the bel t
webbi ng retracts. Thi s mode wi l l al l ow the bel t to
unwi nd from and wi nd onto the retractor spool freel y
unl ess and unti l a predetermi ned i nerti a l oad i s
sensed, or unti l the retractor i s agai n swi tched to the
automati c l ocki ng mode.
Fig. 9 Automatic Locking Retractor
1 - TENSIONER HOUSING OR CHAMBER
2 - GAS GENERATOR
3 - TENSIONER PIGTAIL WIRE
4 - SPOOL
5 - TENSION REDUCER (DRIVER SIDE ON STANDARD CAB
ONLY)
6 - REDUCER CONNECTOR RECEPTACLE
7 - RETRACTOR LOCKING MECHANISM COVER
CHILD RESTRAINT ANCHOR
DESCRIPTION
Fig. 10 Child Restraint Anchor Location - Standard Cab
1 - LOWER ANCHOR (PROVIDED FOR OUTBOARD SEATING
POSITION ONLY)
2 - TETHER ANCHOR (PROVIDED FOR CENTER AND
OUTBOARD SEATING POSITIONS)
Fig. 11 Child Restraint Anchor Location - Quad Cab
1 - LOWER ANCHOR (PROVIDED FOR REAR OUTBOARD
SEATING POSITIONS ONLY)
2 - TETHER ANCHOR (PROVIDED FOR REAR CENTER AND
OUTBOARD SEATING POSITIONS)
Thi s model i s equi pped wi th a Lower Anchors and
Tether for CHi l dren, or LATCH chi l d restrai nt
anchorage system (Fi g. 10) or (Fi g. 11). The LATCH
system provi des for the i nstal l ati on of sui tabl e chi l d
restrai nts i n certai n seati ng posi ti ons wi thout usi ng
the standard equi pment seat bel t provi ded for that
seati ng posi ti on. Standard cab model s are equi pped
wi th a fi xed-posi ti on chi l d restrai nt upper tether
anchor for the front center and outboard seati ng posi -
ti ons, and chi l d restrai nt l ower anchors for the front
outboard seati ng posi ti on. Quad cab model s are
equi pped wi th a fi xed-posi ti on chi l d restrai nt upper
tether anchor strap for the rear center and both rear
outboard seati ng posi ti ons, and chi l d restrai nt l ower
anchors for both rear outboard seati ng posi ti ons. Al l
front seat chi l d restrai nt anchors are del eted on quad
cab model s.
The two upper tether anchors for standard cab
model s are i ntegral to the upper cab back panel rei n-
forcement and are conceal ed behi nd i ndi vi dual tri m
cover and bezel uni ts that are i ntegral to the cab
back tri m panel (Fi g. 12). These upper tether anchors
cannot be adjusted or repai red and, i f faul ty or dam-
aged, they must be repl aced as a uni t wi th the upper
cab back panel rei nforcement. The upper tether
anchor tri m covers and bezel s are servi ced as a uni t
wi th the cab back tri m panel .
The three upper tether anchor straps for quad cab
model s are secured to the upper cab back panel rei n-
forcement wi th screws (Fi g. 13). These anchor straps
are conceal ed behi nd the upri ght rear seat back. The
upper tether anchor straps are avai l abl e for i ndi vi d-
ual servi ce repl acement.
The l ower anchors for al l model s are i ntegral to
thei r respecti ve front or rear seat cushi on frame (Fi g.
14) or (Fi g. 15). Round markers wi th an i mpri nted
chi l d seat i con on the standard cab front seat back
tri m cover hel ps i denti fy the anchor l ocati ons for that
appl i cati on because they may be otherwi se di ffi cul t to
see wi th the seat back i n the upri ght posi ti on. These
l ower anchors are each constructed from round steel
bar stock that i s formed i nto a U-shape, then
securel y wel ded at each end to the seat cushi on
frame. They are each accessed from the front of thei r
respecti ve seats, at each si de where the seat back
meets the seat cushi on. These l ower anchors cannot
be adjusted or repai red and, i f faul ty or damaged,
they must be repl aced as a uni t wi th the seat cush-
i on frame. On quad cab model s, i f the l ower anchors
have been bent or broken as a resul t of a vehi cl e col -
l i si on, the l atch for the affected rear seat cushi on
frame uni t must al so be repl aced.
Fig. 12 Child Tether Anchor - Standard Cab
1 - COVER & BEZEL (2)
2 - CAB BACK TRIM PANEL
3 - ANCHOR (2)
Fig. 13 Child Tether Strap - Quad Cab
1 - TETHER STRAP (3)
2 - CAB BACK PANEL
3 - SCREW (3)
CHILD RESTRAINT ANCHOR (Continued)
WARNING: DURING AND FOLLOWING ANY SEAT
BELT OR CHILD RESTRAINT ANCHOR SERVICE,
CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES,
PARTS CATALOG.
OPERATION
more i nformati on on the proper use of al l of the fac-
tory-i nstal l ed chi l d restrai nt anchors.
REMOVAL
The fol l owi ng procedure appl i es onl y to the rear
seat upper chi l d tether straps used on quad cab mod-
el s. The chi l d restrai nt anchors used i n other model s
and l ocati ons are i ntegral to other components and
cannot be servi ced separatel y.
PARTS CATALOG.
(1) Remove the rear seat from the vehi cl e. (Refer
to 23 - BODY/SEATS/SEAT - REAR - REMOVAL).
(2) Remove the screw that secures the chi l d tether
strap to the upper cab back panel rei nforcement (Fi g.
16).
(3) Remove the chi l d tether strap from the upper
cab back panel rei nforcement.
Fig. 14 Child Restraint Lower Anchor - Standard
Cab Front Seat
1 - FRONT SEAT BACK
2 - LOWER ANCHOR (2) - PASSENGER SIDE OUTBOARD
SEATING POSITION ONLY
3 - LOWER ANCHOR MARKER (2)
4 - FRONT SEAT CUSHION
Fig. 15 Child Restraint Lower Anchor - Quad Cab
Rear Seat
1 - REAR SEAT BACK
2 - LOWER ANCHOR (2 PER OUTBOARD REAR SEATING
POSITION)
3 - REAR SEAT CUSHION
INSTALLATION
The fol l owi ng procedure appl i es onl y to the rear
seat upper chi l d tether straps used on quad cab mod-
el s. The chi l d restrai nt anchors used i n other model s
and l ocati ons are i ntegral to other components and
cannot be servi ced separatel y.
PARTS CATALOG.
(1) Posi ti on the chi l d tether strap onto the upper
cab back panel rei nforcement (Fi g. 16).
(2) I nstal l and ti ghten the screw that secures the
chi l d tether strap to the upper cab back panel rei n-
forcement. Ti ghten the screw to 14 Nm (10 ft. l bs.).
(3) Rei nstal l the rear seat i nto the vehi cl e. (Refer
to 23 - BODY/SEATS/SEAT - REAR - I NSTALLA-
TI ON).
CLOCKSPRING
DESCRIPTION
The cl ockspri ng assembl y i s secured wi th two
screws onto the mul ti -functi on swi tch mounti ng
housi ng near the top of the steeri ng col umn behi nd
the steeri ng wheel (Fi g. 17). The cl ockspri ng consi sts
of a fl at, round mol ded pl asti c case wi th a stubby tai l
that hangs bel ow the steeri ng col umn (Fi g. 18). The
tai l contai ns two connector receptacl es that face
toward the i nstrument panel . Wi thi n the pl asti c case
i s a spool -l i ke mol ded pl asti c rotor wi th a l arge
exposed hub. The upper surface of the rotor hub has
a l arge center hol e, two l arge fl ats, an engagement
dowel wi th a yel l ow rubber boot, two short pi gtai l
wi res wi th connectors, and two connector receptacl es
that face toward the steeri ng wheel .
The l ower surface of the rotor hub has a mol ded
pl asti c turn si gnal cancel cam wi th two l obes that i s
keyed to the rotor and i s secured there wi th four
i ntegral snap features. Wi thi n the pl asti c case and
wound around the rotor spool i s a l ong ri bbon-l i ke
tape that consi sts of several thi n copper wi re l eads
sandwi ched between two thi n pl asti c membranes.
The outer end of the tape termi nates at the connector
Fig. 16 Child Tether Strap - Quad Cab
1 - TETHER STRAP (3)
2 - CAB BACK PANEL
3 - SCREW (3)
Fig. 17 Clockspring
1 - PIGTAIL WIRE (2)
2 - LOCATING TAB
3 - LOCKING PIN
4 - MOUNTING TAB (2)
5 - UPPER CONNECTOR RECEPTACLE (2)
6 - LABEL
7 - ENGAGEMENT DOWEL & BOOT
8 - CASE
9 - CENTERING ARROWS
10 - ROTOR
receptacl es that face the i nstrument panel , whi l e the
i nner end of the tape termi nates at the pi gtai l wi res
and connector receptacl es on the hub of the cl ock-
spri ng rotor that face the steeri ng wheel .
Servi ce repl acement cl ockspri ngs are shi pped pre-
centered and wi th a mol ded pl asti c l ocki ng pi n that
snaps i nto a receptacl e on the rotor and i s engaged
between two tabs on the upper surface of the rotor
case. The l ocki ng pi n secures the centered cl ock-
spri ng rotor to the cl ockspri ng case duri ng shi pment
and handl i ng, but must be removed from the cl ock-
spri ng after i t i s i nstal l ed on the steeri ng col umn.
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/CLOCK-
SPRI NG - STANDARD PROCEDURE - CLOCK-
SPRI NG CENTERI NG).
The cl ockspri ng cannot be repai red. I f the cl ock-
spri ng i s faul ty, damaged, or i f the dri ver ai rbag has
been depl oyed, the cl ockspri ng must be repl aced.
OPERATION
The cl ockspri ng i s a mechani cal el ectri cal ci rcui t
component that i s used to provi de conti nuous el ectri -
cal conti nui ty between the fi xed i nstrument panel
wi re harness and the el ectri cal components mounted
on or i n the rotati ng steeri ng wheel . On thi s model
the rotati ng el ectri cal components i ncl ude the dri ver
ai rbag, the horn swi tch, the speed control swi tches,
and the remote radi o swi tches, i f the vehi cl e i s so
equi pped. The cl ockspri ng case i s posi ti oned and
secured to the mul ti -functi on swi tch mounti ng hous-
i ng near the top of the steeri ng col umn. The connec-
tor receptacl es on the tai l of the fi xed cl ockspri ng
case connect the cl ockspri ng to the vehi cl e el ectri cal
system through two take outs wi th connectors from
the i nstrument panel wi re harness.
The cl ockspri ng rotor i s movabl e and i s keyed by
an engagement dowel that i s mol ded onto the rotor
hub between two fi ns that are cast i nto the l ower
surface of the steeri ng wheel armature. A yel l ow rub-
ber boot i s i nstal l ed over the engagement dowel to
el i mi nate contact noi se between the dowel and the
steeri ng wheel . The two l obes on the turn si gnal can-
cel cam on the l ower surface of the cl ockspri ng rotor
hub contact a turn si gnal cancel actuator of the
mul ti -functi on swi tch to provi de automati c turn si g-
nal cancel l ati on.
Two short, yel l ow-sl eeved pi gtai l wi res on the
upper surface of the cl ockspri ng rotor connect the
cl ockspri ng to the dri ver ai rbag, whi l e a steeri ng
wheel wi re harness connects the two connector recep-
tacl es on the upper surface of the cl ockspri ng rotor to
the horn swi tch feed pi gtai l wi re connector and, i f
the vehi cl e i s so equi pped, to the opti onal speed con-
trol and remote radi o swi tches on the steeri ng wheel .
Li ke the cl ockspri ng i n a ti mepi ece, the cl ockspri ng
tape has travel l i mi ts and can be damaged by bei ng
wound too ti ghtl y duri ng ful l stop-to-stop steeri ng
wheel rotati on. To prevent thi s from occurri ng, the
cl ockspri ng i s centered when i t i s i nstal l ed on the
steeri ng col umn. Centeri ng the cl ockspri ng i ndexes
the cl ockspri ng tape to the movabl e steeri ng compo-
nents so that the tape can operate wi thi n i ts
desi gned travel l i mi ts. However, i f the cl ockspri ng i s
removed from the steeri ng col umn or i f the steeri ng
shaft i s di sconnected from the steeri ng gear, the
cl ockspri ng spool can change posi ti on rel ati ve to the
movabl e steeri ng components. The cl ockspri ng must
be re-centered fol l owi ng compl eti on of thi s servi ce or
the tape may be damaged.
Servi ce repl acement cl ockspri ngs are shi pped pre-
centered and wi th a pl asti c l ocki ng pi n i nstal l ed.
Thi s l ocki ng pi n shoul d not be removed unti l the
cl ockspri ng has been i nstal l ed on the steeri ng col -
umn. I f the l ocki ng pi n i s removed before the cl ock-
spri ng i s i nstal l ed on a steeri ng col umn, the
cl ockspri ng centeri ng procedure must be performed.
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/CLOCK-
SPRI NG - STANDARD PROCEDURE - CLOCK-
SPRI NG CENTERI NG).
STANDARD PROCEDURE - CLOCKSPRING
CENTERING
The cl ockspri ng i s desi gned to wi nd and unwi nd
when the steeri ng wheel i s rotated, but i s onl y
desi gned to rotate the same number of turns (about
fi ve compl ete rotati ons) as the steeri ng wheel can be
turned from stop to stop. Centeri ng the cl ockspri ng
i ndexes the cl ockspri ng tape to other steeri ng compo-
nents so that i t can operate wi thi n i ts desi gned
travel l i mi ts. The rotor of a centered cl ockspri ng can
be rotated two and one-hal f turns i n ei ther di recti on
Fig. 18 Turn Signal Cancel Cam
1 - LOCKING PIN
2 - CLOCKSPRING CASE
3 - CANCEL CAM
4 - LOWER CONNECTOR RECEPTACLE (2)
CLOCKSPRING (Continued)
from the centered posi ti on, wi thout damagi ng the
cl ockspri ng tape.
However, i f the cl ockspri ng i s removed for servi ce
or i f the steeri ng col umn i s di sconnected from the
steeri ng gear, the cl ockspri ng tape can change posi -
ti on rel ati ve to the other steeri ng components. The
cl ockspri ng must then be re-centered fol l owi ng com-
pl eti on of such servi ce or the cl ockspri ng tape may be
damaged. Servi ce repl acement cl ockspri ngs are
shi pped pre-centered, wi th a mol ded pl asti c l ocki ng
pi n i nstal l ed (Fi g. 19). Thi s l ocki ng pi n shoul d not be
removed unti l the cl ockspri ng has been i nstal l ed on
the steeri ng col umn. I f the l ocki ng pi n i s removed
before the cl ockspri ng i s i nstal l ed on a steeri ng col -
umn, the cl ockspri ng centeri ng procedure must be
performed.
MENT.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
(1) Pl ace the front wheel s i n the strai ght-ahead
posi ti on.
(2) Remove the cl ockspri ng from the steeri ng col -
umn. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
CLOCKSPRI NG - REMOVAL).
(3) Rotate the cl ockspri ng rotor cl ockwi se to the
end of i ts travel . Do not apply excessive torque.
(4) From the end of the cl ockwi se travel , rotate the
rotor about two and one-hal f turns countercl ockwi se.
The engagement dowel and yel l ow rubber boot
shoul d end up at the bottom, and the arrows on the
cl ockspri ng rotor and case shoul d be i n al i gnment.
(5) The cl ockspri ng i s now centered. Secure the
cl ockspri ng rotor to the cl ockspri ng case to mai ntai n
cl ockspri ng centeri ng unti l i t i s rei nstal l ed on the
steeri ng col umn.
(6) The front wheel s shoul d sti l l be i n the strai ght-
ahead posi ti on. Rei nstal l the cl ockspri ng onto the
steeri ng col umn. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/CLOCKSPRI NG - I NSTALLATI ON).
REMOVAL
The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the dri ver ai rbag
has been depl oyed.
MENT.
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
Fig. 19 Clockspring and Multi-Function Switch
1 - PIGTAIL WIRE (2)
2 - LOCATING TAB
3 - LOCKING PIN
5 - UPPER CONNECTOR RECEPTACLE (2)
6 - LABEL
7 - ENGAGEMENT DOWEL & BOOT
8 - CASE
9 - CENTERING ARROWS
10 - ROTOR
(1) Pl ace the front wheel s i n the strai ght ahead
posi ti on.
(2) Remove the dri ver ai rbag from the steeri ng
wheel . (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - REMOVAL).
(3) Di sconnect the steeri ng wheel wi re harness
connectors from the upper cl ockspri ng connector
receptacl es.
CAUTION: Be certain that the screws that secure
the steering wheel puller to the steering wheel are
fully engaged in the steering wheel armature with-
out passing through the steering wheel and damag-
ing the clockspring.
(4) Remove the steeri ng wheel from the steeri ng
col umn. (Refer to 19 - STEERI NG/COLUMN/STEER-
I NG WHEEL - REMOVAL).
(5) Remove the steeri ng col umn openi ng cover
from the i nstrument panel . (Refer to 23 - BODY/I N-
I NG COVER - REMOVAL).
(6) I f the vehi cl e i s so equi pped, grasp the steeri ng
col umn ti l t knob fi rml y and pul l i t strai ght rearward
to remove i t from the ti l t adjuster mechani sm l ever
l ocated on the l eft si de of the col umn just bel ow the
mul ti -functi on swi tch control stal k.
(7) From bel ow the steeri ng col umn, remove the
two outboard screws that secure the upper shroud to
the l ower shroud.
(8) Usi ng hand pressure, push gentl y i nward on
both si des of the upper shroud near the parti ng l i ne
between the upper and l ower shrouds to rel ease the
snap features that secure i t to the l ower shroud.
(9) Remove the upper shroud from the l ower
shroud.
(10) From bel ow the steeri ng col umn, remove the
one center screw that secures the l ower shroud to the
steeri ng col umn l ock housi ng.
(11) Remove the l ower shroud from the steeri ng
col umn.
(12) Di sconnect the two i nstrument panel wi re
harness connectors for the cl ockspri ng from the two
connector receptacl es bel ow the steeri ng col umn on
the back of the cl ockspri ng housi ng.
(13) Remove the two screws that secure the cl ock-
spri ng to the mul ti -functi on swi tch mounti ng housi ng
(Fi g. 20).
(14) Remove the cl ockspri ng from the mul ti -func-
ti on swi tch mounti ng housi ng. The cl ockspri ng can-
not be repai red. I t must be repl aced i f faul ty or
damaged, or i f the dri ver ai rbag has been depl oyed.
(15) I f the removed cl ockspri ng i s to be reused, be
certai n to secure the cl ockspri ng rotor to the cl ock-
spri ng case to mai ntai n cl ockspri ng centeri ng unti l i t
i s rei nstal l ed on the steeri ng col umn. I f cl ockspri ng
centeri ng i s not mai ntai ned, the cl ockspri ng must be
centered agai n before i t i s rei nstal l ed. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/CLOCKSPRI NG -
STANDARD PROCEDURE - CLOCKSPRI NG CEN-
TERI NG).
INSTALLATION
The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the dri ver ai rbag
has been depl oyed.
I f the cl ockspri ng i s not properl y centered i n rel a-
ti on to the steeri ng wheel , steeri ng shaft and steer-
i ng gear, i t may be damaged. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/CLOCKSPRI NG -
STANDARD PROCEDURE - CLOCKSPRI NG CEN-
TERI NG). Servi ce repl acement cl ockspri ngs are
shi pped pre-centered and wi th a l ocki ng pi n
i nstal l ed. Thi s l ocki ng pi n shoul d not be removed
unti l the cl ockspri ng has been i nstal l ed on the steer-
i ng col umn. I f the l ocki ng pi n i s removed before the
cl ockspri ng i s i nstal l ed on a steeri ng col umn, the
cl ockspri ng centeri ng procedure must be performed.
Fig. 20 Clockspring Remove/Install
1 - CLOCKSPRING
2 - LOCATING PIN
3 - SCREW (2)
4 - LOCKING PIN
5 - ENGAGEMENT DOWEL BOOT
MENT.
NOTE: Before starting this procedure, be certain
that the front wheels are still in the straight-ahead
position.
(1) Whi l e hol di ng the centered cl ockspri ng rotor
and case stati onary i n rel ati on to each other, care-
ful l y sl i de the cl ockspri ng down over the steeri ng col -
umn upper shaft.
(2) Al i gn and seat the hol e i n the l ocati ng tab at
the el even ocl ock posi ti on on the cl ockspri ng case
over the l ocati ng pi n on the mul ti -functi on swi tch
mounti ng housi ng (Fi g. 20).
(3) I nstal l and ti ghten the two screws that secure
the cl ockspri ng to the mul ti -functi on swi tch mount-
i ng housi ng. Ti ghten the screws to 2 Nm (20 i n.
l bs.).
(4) Reconnect the two i nstrument panel wi re har-
ness connectors for the cl ockspri ng to the two connec-
tor receptacl es bel ow the steeri ng col umn on the back
of the cl ockspri ng housi ng.
(5) Posi ti on the l ower shroud onto the steeri ng col -
umn.
(6) From bel ow the steeri ng col umn, i nstal l and
ti ghten the one center screw that secures the l ower
shroud to the steeri ng col umn l ock housi ng. Ti ghten
the screw to 2 Nm (20 i n. l bs.).
(7) Posi ti on the upper shroud onto the steeri ng col -
umn. I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, be certai n to engage the gearshi ft l ever
gap hi der i nto the openi ngs i n the ri ght si de of the
upper and l ower shrouds.
(8) Al i gn the snap features on the upper shroud
wi th the receptacl es on the l ower shroud and appl y
hand pressure to snap them together.
(9) From bel ow the steeri ng col umn, i nstal l and
ti ghten the two screws that secure the upper shroud
to the l ower shroud. Ti ghten the screws to 2 Nm (20
i n. l bs.).
(10) I f the vehi cl e i s equi pped wi th the opti onal ti l t
steeri ng col umn, al i gn the steeri ng col umn ti l t knob
wi th the ti l t adjuster mechani sm l ever l ocated on the
l eft si de of the col umn just bel ow the mul ti -functi on
swi tch control stal k and, usi ng hand pressure, push
the knob fi rml y onto the l ever.
(11) Rei nstal l the steeri ng col umn openi ng cover
onto the i nstrument panel . (Refer to 23 - BODY/I N-
I NG COVER - I NSTALLATI ON).
(12) I f a new cl ockspri ng has been i nstal l ed,
remove the pl asti c l ocki ng pi n that i s securi ng the
cl ockspri ng rotor to the cl ockspri ng case to mai ntai n
cl ockspri ng centeri ng.
NOTE: When reinstalling the steering wheel, be cer-
tain to index the yellow rubber booted engagement
dowel on the upper surface of the clockspring rotor
between the two fins cast into the lower surface of
the steering wheel armature hub.
(13) Rei nstal l the steeri ng wheel onto the steeri ng
col umn. (Refer to 19 - STEERI NG/COLUMN/STEER-
I NG WHEEL - I NSTALLATI ON).
(14) Reconnect the steeri ng wheel wi re harness
connectors to the upper cl ockspri ng connector recep-
tacl es. Be certai n that the steeri ng wheel wi re har-
ness i s routed between the steeri ng wheel back tri m
cover and the steeri ng wheel armature.
(15) Rei nstal l the dri ver ai rbag onto the steeri ng
wheel . (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - I NSTALLATI ON).
DRIVER AIRBAG
DESCRIPTION
The col or-keyed, i njecti on mol ded, thermopl asti c
dri ver ai rbag protecti ve tri m cover i s the most vi si bl e
part of the dri ver ai rbag (Fi g. 21). The dri ver ai rbag
i s l ocated i n the center of the steeri ng wheel , where
i t i s secured wi th two screws to the armature of the
four-spoke steeri ng wheel . Al l model s have a chrome
Dodge Ram embl em i n the center of the tri m cover.
Conceal ed beneath the dri ver ai rbag tri m cover are
the horn swi tch, the fol ded ai rbag cushi on, the ai rbag
cushi on retai ner, the ai rbag housi ng, the ai rbag i nfl a-
tor, and the retai ners that secure the i nfl ator to the
ai rbag housi ng.
The ai rbag cushi on, housi ng, and i nfl ator are
secured wi thi n an i ntegral receptacl e mol ded i nto the
back of the tri m cover. The four verti cal wal l s of thi s
receptacl e have a total of twel ve smal l wi ndows wi th
bl ocki ng tabs that are engaged by twel ve hook forma-
ti ons around the peri meter of the ai rbag housi ng.
Each hook i s i nserted through one of the wi ndows
and the bl ocki ng tab i n each wi ndow keeps the hook
properl y engaged wi th the tri m cover, l ocki ng the
tri m cover securel y i nto pl ace on the ai rbag housi ng.
The resi sti ve membrane-type horn swi tch i s
secured wi th heat stakes to the i nsi de surface of the
dri ver ai rbag tri m cover, between the tri m cover and
the fol ded ai rbag cushi on. The horn swi tch ground
pi gtai l wi re has an eyel et termi nal connector that i s
captured beneath a fl anged nut on the upper ri ght
i nfl ator mounti ng stud on the back of the housi ng
(Fi g. 22). The horn swi tch feed pi gtai l wi re has a
bl ack, mol ded pl asti c i nsul ator that i s secured by an
i ntegral retai ner i n a l ocator hol e near the upper
ri ght corner of the ai rbag housi ng and i s connected to
the vehi cl e el ectri cal system through a dedi cated
take out and connector of the steeri ng wheel wi re
harness. Both horn swi tch wi res are routed through
an i ntegral notch i n the center of the upper edge of
the ai rbag housi ng stampi ng.
The ai rbag used i n thi s model i s a mul ti stage, Next
Generati on-type that compl i es wi th revi sed federal
ai rbag standards to depl oy wi th l ess force than those
used i n some pri or model s. A 71 centi meter (28 i nch)
di ameter, radi al depl oyi ng fabri c cushi on wi th i nter-
nal tethers i s used. The ai rbag i nfl ator i s a dual -i ni -
ti ator, non-azi de, pyrotechni c-type uni t wi th four
mounti ng studs and i s secured to the stamped metal
ai rbag housi ng by four fl anged hex nuts. Two keyed
and col or-coded connector receptacl es on the dri ver
ai rbag i nfl ator connect the two i nfl ator i ni ti ators to
the vehi cl e el ectri cal system through two yel l ow-jack-
eted, two-wi re pi gtai l harnesses of the cl ockspri ng.
The dri ver ai rbag uni t cannot be repai red, and
must be repl aced i f depl oyed or i n any way damaged.
The dri ver ai rbag tri m cover and horn swi tch uni t
may be di sassembl ed from the dri ver ai rbag uni t,
and i s avai l abl e for separate servi ce repl acement.
OPERATION
The mul ti stage dri ver ai rbag i s depl oyed by el ectri -
cal si gnal s generated by the Ai rbag Control Modul e
(ACM) through the dri ver ai rbag squi b 1 and squi b 2
ci rcui ts to the two i ni ti ators i n the ai rbag i nfl ator. By
usi ng two i ni ti ators, the ai rbag can be depl oyed at
mul ti pl e l evel s of force. The force l evel i s control l ed
Fig. 21 Driver Airbag Trim Cover
1 - STEERING WHEEL
2 - TRIM COVER
Fig. 22 Driver Airbag Housing
1 - HORN SWITCH FEED WIRE
2 - HORN SWITCH GROUND WIRE
3 - INFLATOR
4 - TRIM COVER
5 - HOUSING
by the ACM to sui t the moni tored i mpact condi ti ons
by provi di ng one of three del ay i nterval s between the
el ectri cal si gnal s provi ded to the two i ni ti ators. The
l onger the del ay between these si gnal s, the l ess force-
ful l y the ai rbag wi l l depl oy.
When the ACM sends the proper el ectri cal si gnal s
to each i ni ti ator, the el ectri cal energy generates
enough heat to i ni ti ate a smal l pyrotechni c charge
whi ch, i n turn i gni tes chemi cal pel l ets wi thi n the
i nfl ator. Once i gni ted, these chemi cal pel l ets burn
rapi dl y and produce a l arge quanti ty of i nert gas.
The i nfl ator i s seal ed to the back of the ai rbag hous-
i ng and a di ffuser i n the i nfl ator di rects al l of the
i nert gas i nto the ai rbag cushi on, causi ng the cushi on
to i nfl ate. As the cushi on i nfl ates, the dri ver ai rbag
tri m cover wi l l spl i t at predetermi ned breakout l i nes,
then fol d back out of the way al ong wi th the horn
swi tch uni t. Fol l owi ng an ai rbag depl oyment, the ai r-
bag cushi on qui ckl y defl ates by venti ng the i nert gas
towards the i nstrument panel through vent hol es
wi thi n the fabri c used to construct the back (steeri ng
wheel si de) panel of the ai rbag cushi on.
Some of the chemi cal s used to create the i nert gas
may be consi dered hazardous whi l e i n thei r sol i d
state before they are burned, but they are securel y
seal ed wi thi n the ai rbag i nfl ator. Typi cal l y, both i ni -
ti ators are used and al l potenti al l y hazardous chem-
i cal s are burned duri ng an ai rbag depl oyment event.
However, i t i s possi bl e for onl y one i ni ti ator to be
used duri ng a depl oyment due to an ai rbag system
faul t; therefore, i t i s necessary to al ways confi rm
that both i ni ti ators have been used i n order to avoi d
the i mproper di sposal of potenti al l y l i ve pyrotechni c
or hazardous materi al s. (Refer to 8 - ELECTRI CAL/
RESTRAI NTS - STANDARD PROCEDURE - SER-
VI CE AFTER A SUPPLEMENTAL RESTRAI NT
DEPLOYMENT).
The i nert gas that i s produced when the chemi cal s
are burned i s harml ess. However, a smal l amount of
resi due from the burned chemi cal s may cause some
temporary di scomfort i f i t contacts the ski n, eyes, or
breathi ng passages. I f ski n or eye i rri tati on i s noted,
ri nse the affected area wi th pl enty of cool , cl ean
water. I f breathi ng passages are i rri tated, move to
another area where there i s pl enty of cl ean, fresh ai r
to breath. I f the i rri tati on i s not al l evi ated by these
acti ons, contact a physi ci an.
REMOVAL
The fol l owi ng procedure i s for repl acement of a
faul ty or damaged dri ver ai rbag. I f the ai rbag i s
faul ty or damaged, but not depl oyed, revi ew the rec-
ommended procedures for handl i ng non-depl oyed
suppl emental restrai nts. (Refer to 8 - ELECTRI CAL/
RESTRAI NTS - STANDARD PROCEDURE - HAN-
DLI NG NON-DEPLOYED SUPPLEMENTAL
RESTRAI NTS). I f the dri ver ai rbag has been
depl oyed, revi ew the recommended procedures for
servi ce after a suppl emental restrai nt depl oyment
before removi ng the ai rbag from the vehi cl e. (Refer to
8 - ELECTRI CAL/RESTRAI NTS - STANDARD PRO-
CEDURE - SERVI CE AFTER A SUPPLEMENTAL
RESTRAI NT DEPLOYMENT).
MENT.
DEATH, WHEN REMOVING A DEPLOYED AIRBAG,
RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG CUSHION AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
(2) From the undersi de of the steeri ng wheel ,
remove the two screws that secure the dri ver ai rbag
to the steeri ng wheel armature (Fi g. 23).
(3) Pul l the dri ver ai rbag away from the steeri ng
wheel far enough to access the three el ectri cal con-
necti ons on the back of the ai rbag housi ng (Fi g. 24).
(4) Di sconnect the steeri ng wheel wi re harness
connector for the horn swi tch from the horn swi tch
feed pi gtai l wi re connector, whi ch i s l ocated on the
back of the dri ver ai rbag housi ng.
CAUTION: Do not pull on the clockspring pigtail
wires or pry on the connector insulator to disen-
gage the connector from the driver airbag inflator
connector receptacle. Improper removal of these
pigtail wires and their connector insulators can
result in damage to the airbag circuits or connector
insulators.
DRIVER AIRBAG (Continued)
(5) The cl ockspri ng dri ver ai rbag pi gtai l wi re con-
nectors are secured by i ntegral l atches to the ai rbag
i nfl ator connector receptacl es, whi ch are l ocated on
the back of the dri ver ai rbag housi ng. Depress the
l atches on each si de of the connector i nsul ator and
pul l the i nsul ators strai ght out from the ai rbag i nfl a-
tor to di sconnect them from the connector recepta-
cl es.
wheel .
(7) I f the dri ver ai rbag has been depl oyed, the
cl ockspri ng must be repl aced. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS/CLOCKSPRI NG - REMOVAL).
DISASSEMBLY
The fol l owi ng procedures can be used to repl ace
the dri ver ai rbag tri m cover and horn swi tch uni t for
servi ce. I f the dri ver ai rbag i s faul ty or depl oyed, the
enti re dri ver ai rbag, tri m cover and horn swi tch must
be repl aced as a uni t.
MENT.
DEATH, SERVICE OF THIS UNIT SHOULD BE PER-
FORMED ONLY BY DAIMLERCHRYSLER-TRAINED
AND AUTHORIZED DEALER SERVICE TECHNI-
CIANS. FAILURE TO TAKE THE PROPER PRECAU-
TIONS OR TO FOLLOW THE PROPER
PROCEDURES COULD RESULT IN ACCIDENTAL,
INCOMPLETE, OR IMPROPER AIRBAG DEPLOY-
MENT AND POSSIBLE OCCUPANT INJURIES.
DEATH, USE EXTREME CARE TO PREVENT ANY
FOREIGN MATERIAL FROM ENTERING THE DRIVER
AIRBAG, OR BECOMING ENTRAPPED BETWEEN
THE DRIVER AIRBAG CUSHION AND THE DRIVER
AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
Fig. 23 Driver Airbag Remove/Install
1 - DRIVER AIRBAG
2 - STEERING WHEEL
3 - SCREW (2)
Fig. 24 Driver Airbag Connections
1 - DRIVER AIRBAG
2 - HORN SWITCH PIGTAIL WIRE CONNECTOR
3 - CLOCKSPRING PIGTAIL WIRE CONNECTOR (2)
4 - STEERING WHEEL WIRE HARNESS CONNECTOR
DEATH, THE DRIVER AIRBAG TRIM COVER MUST
NEVER BE PAINTED. REPLACEMENT TRIM COV-
ERS ARE SERVICED IN THE ORIGINAL COLORS.
PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TRIM COVER RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
wheel (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
(3) Pl ace the dri ver ai rbag on a sui tabl e cl ean and
dry work surface wi th the tri m cover faci ng down. I f
the tri m cover wi l l be reused, be certai n to take the
proper precauti ons to prevent the tri m cover from
recei vi ng cosmeti c damage duri ng the fol l owi ng pro-
cedures.
(4) Careful l y pry the horn swi tch feed pi gtai l wi re
connector away from the back of the dri ver ai rbag
housi ng far enough to di sengage the i ntegral connec-
tor retai ner from the l ocator hol e just above the
upper ri ght i nfl ator mounti ng stud (Fi g. 25).
(5) Remove the nut that secures the horn swi tch
ground pi gtai l wi re eyel et termi nal to the upper ri ght
i nfl ator stud on the back of the dri ver ai rbag hous-
i ng.
(6) Remove the horn swi tch ground pi gtai l wi re
eyel et termi nal from the upper ri ght i nfl ator stud on
the back of the dri ver ai rbag housi ng.
(7) Di sengage each of the twel ve hooks of the ai r-
bag housi ng from the twel ve wi ndows i n the verti cal
wal l s of the tri m cover, one wal l at a ti me. Start by
di sengagi ng the upper wal l , then do each of the two
si de wal l s, and fi ni sh wi th the l ower wal l . To di sen-
gage the hooks, use hand pressure to push fi rml y
and evenl y downward i nto the receptacl e on the adja-
cent edge of the ai rbag housi ng, whi l e at the same
ti me pushi ng outward on the upper edge of the
receptacl e wal l .
(8) Wi th al l of the hooks di sengaged, l i ft the hous-
i ng, i nfl ator, and cushi on as a uni t from the recepta-
cl e on the back of the dri ver ai rbag tri m cover.
ASSEMBLY
The fol l owi ng procedures can be used to repl ace
the dri ver ai rbag tri m cover and horn swi tch uni t for
servi ce. I f the dri ver ai rbag i s faul ty or depl oyed, the
enti re dri ver ai rbag, tri m cover and horn swi tch must
be repl aced as a uni t.
MENT.
DEATH, SERVICE OF THIS UNIT SHOULD BE PER-
FORMED ONLY BY DAIMLERCHRYSLER-TRAINED
AND AUTHORIZED DEALER SERVICE TECHNI-
CIANS. FAILURE TO TAKE THE PROPER PRECAU-
TIONS OR TO FOLLOW THE PROPER
PROCEDURES COULD RESULT IN ACCIDENTAL,
INCOMPLETE, OR IMPROPER AIRBAG DEPLOY-
MENT AND POSSIBLE OCCUPANT INJURIES.
Fig. 25 Driver Airbag Disassembly
1 - HORN SWITCH FEED CONNECTOR
2 - HORN SWITCH GROUND EYELET TERMINAL
3 - HOUSING
4 - TRIM COVER
5 - HOOK (4 LOWER EDGE, 4 UPPER EDGE)
6 - HOOK (2 ON EACH SIDE)
NEVER BE PAINTED. REPLACEMENT TRIM COV-
ERS ARE SERVICED IN THE ORIGINAL COLORS.
PAINT MAY CHANGE THE WAY IN WHICH THE
MATERIAL OF THE TRIM COVER RESPONDS TO AN
AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
THIS WARNING COULD RESULT IN OCCUPANT
INJURIES UPON AIRBAG DEPLOYMENT.
(1) Pl ace the dri ver ai rbag on a sui tabl e work sur-
face wi th the ai rbag cushi on faci ng up.
(2) Fol d the two fl aps of cushi on materi al up
around the si des and over the top of the ai rbag cush-
i on retai ner strap (Fi g. 26).
(3) Posi ti on the new dri ver ai rbag tri m cover over
the ai rbag cushi on, then push the receptacl e of the
tri m cover down evenl y over the cushi on. Be certai n
that the cushi on materi al fl aps remai n ori ented over
the cushi on retai ner strap as they were i n Step 2.
(4) Turn the dri ver ai rbag and the new dri ver ai r-
bag tri m cover over as a uni t, and pl ace the uni t on a
sui tabl e cl ean and dry work surface wi th the ai rbag
cushi on faci ng down. Be certai n to take the proper
precauti ons to prevent the tri m cover from recei vi ng
cosmeti c damage duri ng the fol l owi ng procedures.
(5) Be certai n that the horn swi tch feed and
ground pi gtai l wi res are routed through the cl earance
notch at the top of the ai rbag housi ng, between the
housi ng and the upper verti cal wal l of the tri m cover
receptacl e (Fi g. 25).
(6) Work around the peri meter of the uni t engag-
i ng each of the twel ve hooks on the dri ver ai rbag
housi ng through the wi ndows i n the wal l s of the tri m
cover receptacl e.
(7) After each of the twel ve hooks on the dri ver
ai rbag housi ng has been engaged i n a wi ndow of the
tri m cover receptacl e, try pul l i ng the tri m cover and
the ai rbag housi ng away from each other. Thi s acti on
wi l l ful l y seat the edges of the wi ndows i nto the cra-
dl es of the hooks.
(8) After al l of the wi ndows i n the wal l s of the
tri m cover receptacl e have been ful l y seated i n the
cradl es of the hooks on the ai rbag housi ng, check
that the bl ocki ng tabs i n each of the tri m cover wi n-
dows i s ori ented over the ai rbag housi ng hooks as
(9) I nstal l the horn swi tch ground pi gtai l wi re eye-
l et termi nal over the upper ri ght i nfl ator stud on the
back of the dri ver ai rbag housi ng.
(10) I nstal l and ti ghten the nut that secures the
horn swi tch ground pi gtai l wi re eyel et termi nal to
the upper ri ght i nfl ator stud on the back of the
Fig. 26 Driver Airbag Flaps
1 - FLAP (2)
2 - RETAINER STRAP
Fig. 27 Driver Airbag Trim Cover Blocking Tabs
1 - BLOCKING TAB (12)
2 - DRIVER AIRBAG TRIM COVER
3 - HORN SWITCH
4 - AIRBAG HOUSING HOOK (12)
dri ver ai rbag housi ng. Ti ghten the nut to 7 Nm (65
i n. l bs.).
(11) Usi ng hand pressure, push the i ntegral
retai ner of the horn swi tch feed pi gtai l wi re connec-
tor i nto the l ocator hol e just above the upper ri ght
i nfl ator mounti ng stud on the back of the dri ver ai r-
bag.
(12) Rei nstal l the dri ver ai rbag onto the steeri ng
wheel (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
DRI VER AI RBAG - I NSTALLATI ON).
INSTALLATION
faul ty or damaged dri ver ai rbag. I f the ai rbag i s
RESTRAI NTS). I f the dri ver ai rbag has been
MENT.
NEVER BE PAINTED. REPLACEMENT AIRBAGS
ARE SERVICED WITH TRIM COVERS IN THE ORIG-
INAL COLORS. PAINT MAY CHANGE THE WAY IN
WHICH THE MATERIAL OF THE TRIM COVER
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Posi ti on the dri ver ai rbag cl ose enough to the
steeri ng wheel to reconnect the three el ectri cal con-
necti ons on the back of the ai rbag housi ng (Fi g. 24).
(2) When i nstal l i ng the dri ver ai rbag, reconnect
the two cl ockspri ng dri ver ai rbag pi gtai l wi re connec-
tors to the ai rbag i nfl ator connector receptacl es by
pressi ng strai ght i n on the connector. Be certai n to
engage each keyed and col or-coded connector to the
matchi ng connector receptacl e. You can be certai n
that each connector i s ful l y engaged i n i ts receptacl e
by l i steni ng careful l y for a di sti nct, audi bl e cl i ck as
the connector l atches snap i nto pl ace.
(3) Reconnect the steeri ng wheel wi re harness con-
nector for the horn swi tch to the horn swi tch feed
pi gtai l wi re connector, whi ch i s l ocated on the back of
the dri ver ai rbag housi ng.
(4) Careful l y posi ti on the dri ver ai rbag i n the
steeri ng wheel (Fi g. 23). Be certai n that the cl ock-
spri ng pi gtai l wi res and the steeri ng wheel wi re har-
ness i n the steeri ng wheel hub area are not pi nched
between the dri ver ai rbag and the steeri ng wheel
armature.
(5) From the undersi de of the steeri ng wheel ,
i nstal l and ti ghten the two screws that secure the
dri ver ai rbag to the steeri ng wheel armature.
Ti ghten the screws to 10 Nm (90 i n. l bs.).
FRONT CENTER SEAT BELT &
RETRACTOR
REMOVAL
A front center seat bel t and retractor i s used onl y
on standard cab model s. Quad cab model s have a l ap
bel t i n the front center seati ng posi ti on. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/FRONT CENTER
SEAT BELT - REMOVAL).
PARTS CATALOG.
(1) Reach between the center of the front seat
cushi on and front seat back to access and unbuckl e
the front center seat bel t l ower anchor l atch pl ate
from the uni que bl ack, keyed l ower anchor buckl e.
Use an i gni ti on key or a smal l screwdri ver to depress
the smal l whi te rel ease button on the anchor buckl e.
(2) Move the front seat to i ts most forward posi ti on
for easi est access to the front center seat bel t and
retractor uni t.
fl at-bl aded tool , gentl y pry at each si de of the front
center seat bel t bezel on the cab back tri m panel to
rel ease the snap features that secure the bezel to the
panel (Fi g. 28).
(4) Remove the bezel from the webbi ng of the front
center seat bel t.
(5) Remove the tri m from the cab back panel .
(Refer to 23 - BODY/I NTERI OR/REAR CAB BACK
PANEL TRI M - REMOVAL).
(6) Remove the two screws that secure the bel t
bracket of the front center seat bel t to the body
bracket on the upper cab back panel rei nforcement
(Fi g. 29).
(7) Remove the bel t bracket of the front center
seat bel t from the body bracket on the upper cab
back panel rei nforcement.
(8) Remove the two screws that secure the front
center seat bel t retractor bracket to the fl oor panel
near the base of the cab back panel .
(9) Remove the front center seat bel t and retractor
uni t from the fl oor panel .
INSTALLATION
A front center seat bel t and retractor i s used onl y
on standard cab model s. Quad cab model s have a l ap
bel t i n the front center seati ng posi ti on. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/FRONT CENTER
SEAT BELT - I NSTALLATI ON).
Fig. 28 Front Center Seat Belt Bezel
1 - TRIM PANEL
2 - BODY BRACKET
3 - SEAT BELT BRACKET
4 - SEAT BELT
5 - BEZEL
PARTS CATALOG.
(1) Posi ti on the front center seat bel t and retractor
uni t to the fl oor panel at the base of the cab back
panel to the ri ght of center (Fi g. 29).
the front center seat bel t retractor bracket to the
fl oor panel near the base of the cab back panel .
Ti ghten the screws to 40 Nm (29 ft. l bs.).
(3) Posi ti on the bel t bracket of the front center
seat bel t to the body bracket on the upper cab back
panel rei nforcement.
the bel t bracket of the front center seat bel t to the
body bracket on the upper cab back panel rei nforce-
ment. Ti ghten the screws to 20 Nm (15 ft. l bs.).
(5) Rei nstal l the tri m onto the cab back panel .
(Refer to 23 - BODY/I NTERI OR/REAR CAB BACK
PANEL TRI M - I NSTALLATI ON).
(6) Route the webbi ng of the front center seat bel t
through the bezel and posi ti on the bezel to the bel t
openi ng near the top of the cab back tri m panel (Fi g.
28).
on each si de of the front center seat bel t bezel unti l i t
snaps i nto pl ace on the cab back tri m panel .
(8) Move the front seat back to i ts rearward posi -
ti on.
(9) Reach between the center of the front seat
cushi on and front seat back to access and buckl e the
front center seat bel t l ower anchor l atch pl ate to the
uni que bl ack, keyed l ower anchor buckl e.
FRONT CENTER SEAT BELT
REMOVAL
A fi xed posi ti on front center seat bel t buckl e i s
l ocated on the l eft si de of the front center seat sec-
ti on (20 percent) used on al l model s. Standard cab
model s al so have a uni que fi xed posi ti on bl ack, keyed
front center seat bel t l ower anchor buckl e for the
three-poi nt center seat bel t l ower anchor l ocated on
the ri ght si de of the front center seat secti on. The fol -
l owi ng procedure al so appl i es to the fi xed posi ti on
front center seat l ap bel t l ocated on the ri ght si de of
the front center seat secti on of al l quad cab model s.
The three-poi nt front center seat bel t and retractor
uni t i s onl y used on standard cab model s. (Refer to 8
- ELECTRI CAL/RESTRAI NTS/FRONT CENTER
SEAT BELT & RETRACTOR - REMOVAL).
Fig. 29 Front Center Seat Belt & Retractor Remove/
Install
1 - BODY BRACKET
2 - BELT BRACKET
3 - SCREW (2)
4 - SCREW (2)
5 - RETRACTOR
6 - FLOOR PANEL
7 - SEAT BELT
8 - CAB BACK PANEL
FRONT CENTER SEAT BELT & RETRACTOR (Continued)
PARTS CATALOG.
(1) Move the adjacent ri ght or l eft front outboard
seat secti on (40 percent) to i ts most forward posi ti on
for easi est access to the front center seat bel t buckl e,
l ap bel t l ower anchor, or uni que bl ack, keyed front
center seat bel t l ower anchor buckl e (Fi g. 30).
(2) From behi nd the front seat, remove the screw
that secures the front center seat bel t buckl e, l ap bel t
l ower anchor, or uni que bl ack, keyed front center
seat bel t l ower anchor buckl e to the center seat sup-
port bracket.
(3) From the front of the front seat, reach between
the center seat cushi on and the adjacent ri ght or l eft
front outboard seat cushi on to access and remove the
front center seat bel t buckl e, l ap bel t uni t, or uni que
bl ack, keyed front center seat bel t l ower anchor
buckl e through the el asti c strap on the si de of the
center seat cushi on.
(4) Remove the front center seat bel t buckl e, l ap
bel t uni t, or uni que bl ack, keyed front center seat
bel t l ower anchor buckl e from the front seat.
INSTALLATION
A fi xed posi ti on front center seat bel t buckl e i s
l ocated on the l eft si de of the front center seat sec-
ti on (20 percent) used on al l model s. Standard cab
model s al so have a uni que fi xed posi ti on bl ack, keyed
front center seat bel t l ower anchor buckl e for the
three-poi nt center seat bel t l ower anchor l ocated on
the ri ght si de of the front center seat secti on. The fol -
l owi ng procedure al so appl i es to the fi xed posi ti on
front center seat l ap bel t l ocated on the ri ght si de of
the front center seat secti on of al l quad cab model s.
The three-poi nt front center seat bel t and retractor
uni t i s onl y used on standard cab model s. (Refer to 8
- ELECTRI CAL/RESTRAI NTS/FRONT CENTER
SEAT BELT & RETRACTOR - I NSTALLATI ON).
PARTS CATALOG.
Fig. 30 Front Center Seat Belt Remove/Install
1 - FRONT CENTER SEAT BELT
2 - ELASTIC STRAP
3 - CENTER SEAT SUPPORT BRACKET
4 - INBOARD FRONT SEAT TRACK
5 - SCREW
6 - CENTER SEAT SECTION
FRONT CENTER SEAT BELT (Continued)
(1) From the front of the front seat, posi ti on the
front center seat bel t buckl e, l ap bel t uni t, or uni que
buckl e between the center seat cushi on and the adja-
cent ri ght or l eft front outboard seat cushi on.
front outboard seat cushi on to route the front center
seat bel t buckl e, l ap bel t uni t l ower anchor, or uni que
buckl e through the el asti c strap on the si de of the
center seat cushi on (Fi g. 30).
(3) From behi nd the front seat, posi ti on the front
center seat bel t buckl e, l ap bel t l ower anchor, or
uni que bl ack, keyed front center seat bel t l ower
anchor buckl e to the center seat support bracket.
front center seat bel t buckl e, l ap bel t l ower anchor, or
uni que bl ack, keyed front center seat bel t l ower
anchor buckl e to the center seat support bracket.
Ti ghten the screw to 40 Nm (29 ft. l bs.).
(5) Move the adjacent ri ght or l eft front outboard
seat secti on (40 percent) back to i ts rearward posi -
ti on.
FRONT OUTBOARD SEAT
BELT & RETRACTOR
REMOVAL
REMOVAL - STANDARD CAB
faul ty or damaged front outboard seat bel t and
retractor uni t, whi ch i ncl udes a seat bel t tensi oner
for thi s model .(Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/SEAT BELT TENSI ONER - DESCRI P-
TI ON). The onl y component of thi s seat bel t and
retractor uni t that i s avai l abl e for i ndi vi dual servi ce
repl acement i s the pl asti c web stop button that pre-
vents the l atch pl ate from fal l i ng to the fl oor whi l e i n
the stored posi ti on. Refer to the i nstructi ons suppl i ed
wi th the servi ce ki t for the proper web stop button
repl acement procedures.
The seat bel t retractor on the dri vers si de of stan-
dard cab model s onl y al so i ncl udes a tensi on reducer.
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/TENSI ON
REDUCER - DESCRI PTI ON). The seat bel t retractor
on the passengers si de of al l model s i ncl udes a swi t-
chabl e automati c l ocki ng mechani sm. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/AUTOMATI C LOCK-
I NG RETRACTOR - DESCRI PTI ON).
I f the seat bel t or retractor i s faul ty or damaged,
but the seat bel t tensi oner i s not depl oyed, revi ew
the recommended procedures for handl i ng non-de-
pl oyed suppl emental restrai nts. (Refer to 8 - ELEC-
TRI CAL/RESTRAI NTS - STANDARD PROCEDURE
- HANDLI NG NON-DEPLOYED SUPPLEMENTAL
RESTRAI NTS). I f the seat bel t tensi oner has been
before removi ng the front outboard seat bel t and
retractor from the vehi cl e. (Refer to 8 - ELECTRI -
CAL/RESTRAI NTS - STANDARD PROCEDURE -
SERVI CE AFTER A SUPPLEMENTAL RESTRAI NT
DEPLOYMENT).
MENT.
PARTS CATALOG.
for easi est access to the l ower seat bel t anchor and
the B-pi l l ar tri m.
FRONT CENTER SEAT BELT (Continued)
(3) Remove the screw that secures the l ower seat
bel t anchor to the l ower i nner B-pi l l ar (Fi g. 31).
(4) Remove the l ower seat bel t anchor from the
l ower i nner B-pi l l ar.
(5) Unsnap and remove the tri m cover from the
front outboard seat bel t turni ng l oop to access the
screw that secures the turni ng l oop to the hei ght
adjuster on the upper i nner B-pi l l ar. Di scard the
removed turni ng l oop tri m cover as i t i s not i ntended
for reuse.
(6) Remove the screw that secures the seat bel t
turni ng l oop to the hei ght adjuster.
(7) Remove the seat bel t turni ng l oop from the
hei ght adjuster.
(8) Remove the upper and l ower tri m from the
i nner B-pi l l ar. (Refer to 23 - BODY/I NTERI OR/B-
PI LLAR UPPER TRI M - REMOVAL) and (Refer to
23 - BODY/I NTERI OR/B-PI LLAR LOWER TRI M -
REMOVAL).
web gui de to the i nner B-pi l l ar near the bel t l i ne.
(10) Remove the seat bel t web gui de from the
i nner B-pi l l ar.
(11) On the dri ver si de onl y, di sconnect the body
wi re harness take out and whi te connector from the
connector receptacl e for the seat bel t tensi on reducer
l ocated near the bottom of the retractor.
(12) Di sengage the seat bel t tensi oner pi gtai l wi re
retai ner from the hol e i n the i nner B-pi l l ar sheet
metal .
(13) Di sconnect the yel l ow seat bel t tensi oner pi g-
tai l wi re connector from the body wi re harness take
out and connector for the tensi oner.
(14) Remove the screw that secures the l ower
retractor bracket to the l ower i nner B-pi l l ar bel ow
the retractor mounti ng hol e.
(15) Di sengage the hooks on the upper retractor
bracket from the sl ots i n the l ower i nner B-pi l l ar
above the retractor mounti ng hol e.
(16) Remove the front outboard seat bel t and
retractor from the retractor mounti ng hol e i n the
REMOVAL - QUAD CAB
for thi s model . (Refer to 8 - ELECTRI CAL/RE-
The seat bel t retractor on the passengers si de of
al l model s i ncl udes a swi tchabl e automati c l ocki ng
mechani sm. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/AUTOMATI C LOCKI NG RETRACTOR -
DESCRI PTI ON).
Fig. 31 Front Outboard Seat Belt & Retractor
Remove/Install - Standard Cab
1 - ADJUSTER
2 - UPPER TRIM PANEL
3 - TURNING LOOP
4 - SCREW
5 - TRIM COVER
6 - LOWER TRIM PANEL
7 - LOWER ANCHOR
8 - SCREW
9 - SCREW
10 - RETRACTOR
12 - SCREW
13 - WEB GUIDE
14 - B-PILLAR
FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued)
DEPLOYMENT).
MENT.
PARTS CATALOG.
for easi est access to the l ower seat bel t anchor and
the B-pi l l ar tri m.
bel t anchor to the fl oor panel near the base of the
i nner B-pi l l ar (Fi g. 32).
fl oor panel near the base of the i nner B-pi l l ar.
for reuse.
hei ght adjuster.
REMOVAL).
Fig. 32 Front Outboard Seat Belt & Retractor
Remove/Install - Quad Cab
1 - ADJUSTER
2 - UPPER TRIM PANEL
3 - B-PILLAR
4 - TURNING LOOP
5 - SCREW
6 - TRIM COVER
7 - SEAT BELT
8 - LOWER TRIM PANEL
9 - SCREW
10 - LOWER ANCHOR
11 - SCREW
12 - RETRACTOR
14 - SCREW
15 - WEB GUIDE
web gui de to the i nner B-pi l l ar near the bel t l i ne.
(10) Remove the seat bel t web gui de from the
i nner B-pi l l ar.
(11) Di sengage the seat bel t tensi oner pi gtai l wi re
retai ner from the hol e i n the i nner B-pi l l ar sheet
metal .
(12) Di sconnect the yel l ow seat bel t tensi oner pi g-
tai l wi re connector from the body wi re harness take
out and connector for the tensi oner.
retractor bracket to the l ower i nner B-pi l l ar bel ow
(14) Di sengage the hooks on the upper retractor
bracket from the sl ots i n the l ower i nner B-pi l l ar
(15) Remove the front outboard seat bel t and
INSTALLATION
INSTALLATION - STANDARD CAB
The seat bel t retractor on the dri vers si de of stan-
dard cab model s onl y al so i ncl udes a tensi on reducer.
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/TENSI ON
REDUCER - DESCRI PTI ON). The seat bel t retractor
on the passengers si de of al l model s i ncl udes a swi t-
chabl e automati c l ocki ng mechani sm. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/AUTOMATI C LOCK-
I NG RETRACTOR - DESCRI PTI ON).
DEPLOYMENT).
MENT.
PARTS CATALOG.
(1) Posi ti on the front outboard seat bel t and
retractor to the retractor mounti ng hol e i n the l ower
(2) Engage the hooks on the upper retractor
bracket i nto the sl ots i n the l ower i nner B-pi l l ar
l ower retractor bracket to the l ower i nner B-pi l l ar
bel ow the retractor mounti ng hol e. Ti ghten the screw
to 40 Nm (29 ft. l bs.).
(4) Reconnect the yel l ow seat bel t tensi oner pi gtai l
wi re connector to the body wi re harness take out and
connector for the tensi oner.
(5) Engage the seat bel t tensi oner pi gtai l wi re
retai ner i nto the hol e i n the i nner B-pi l l ar sheet
metal .
(6) On the dri ver si de onl y, reconnect the body
wi re harness take out and whi te connector to the
seat bel t tensi on reducer connector receptacl e near
the bottom of the retractor.
(7) Posi ti on the seat bel t web gui de to i ts mount-
i ng l ocati on on the i nner B-pi l l ar near the bel t l i ne.
seat bel t web gui de to the i nner B-pi l l ar. Ti ghten the
(9) Rei nstal l the upper and l ower tri m onto the
PI LLAR UPPER TRI M - I NSTALLATI ON) and
(Refer to 23 - BODY/I NTERI OR/B-PI LLAR LOWER
TRI M - I NSTALLATI ON).
(10) Posi ti on the seat bel t turni ng l oop onto the
hei ght adjuster on the upper i nner B-pi l l ar.
seat bel t turni ng l oop to the hei ght adjuster. Ti ghten
the screw to 40 Nm (29 ft. l bs.).
(12) Engage the l ower snap features of the new
tri m cover over the front outboard seat bel t turni ng
l oop and, usi ng hand pressure, press fi rml y and
evenl y on the top of the tri m cover unti l i t snaps i nto
pl ace.
(13) Posi ti on the l ower seat bel t anchor to the
l ower seat bel t anchor to the B-pi l l ar. Ti ghten the
screw to 40 Nm (29 ft. l bs.).
ti on.
INSTALLATION - QUAD CAB
The seat bel t retractor on the passengers si de of
al l model s i ncl udes a swi tchabl e automati c l ocki ng
mechani sm. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/AUTOMATI C LOCKI NG RETRACTOR -
DESCRI PTI ON).
DEPLOYMENT).
MENT.
PARTS CATALOG.
(1) Posi ti on the front outboard seat bel t and
retractor to the retractor mounti ng hol e i n the l ower
(2) Engage the hooks on the upper retractor
bracket i nto the sl ots i n the l ower i nner B-pi l l ar
l ower retractor bracket to the l ower i nner B-pi l l ar
to 40 Nm (29 ft. l bs.).
(4) Reconnect the yel l ow seat bel t tensi oner pi gtai l
wi re connector to the body wi re harness take out and
connector for the tensi oner.
(5) Engage the seat bel t tensi oner pi gtai l wi re
retai ner i nto the hol e i n the i nner B-pi l l ar sheet
metal .
(6) Posi ti on the seat bel t web gui de to i ts mount-
i ng l ocati on on the i nner B-pi l l ar near the bel t l i ne.
seat bel t web gui de to the i nner B-pi l l ar. Ti ghten the
(Refer to 23 - BODY/I NTERI OR/B-PI LLAR LOWER
(11) Engage the l ower snap features of the new
tri m cover over the front outboard seat bel t turni ng
l oop and, usi ng hand pressure, press fi rml y and
evenl y on the top of the tri m cover unti l i t snaps i nto
pl ace.
(12) Posi ti on the l ower seat bel t anchor to the fl oor
panel near the base of the i nner B-pi l l ar.
l ower seat bel t anchor to the fl oor panel near the
base of the i nner B-pi l l ar. Ti ghten the screw to 40
Nm (29 ft. l bs.).
ti on.
FRONT OUTBOARD SEAT
BELT BUCKLE
REMOVAL
A travel i ng front outboard seat bel t buckl e i s
l ocated on the i nboard si de of each front outboard
seat secti on (40 percent) used on al l model s. The seat
bel t buckl e on the dri vers si de front seat for al l mod-
el s al so i ncl udes a seat bel t swi tch. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/SEAT BELT SWI TCH -
DESCRI PTI ON).
PARTS CATALOG.
(1) Move the ri ght or l eft front outboard seat sec-
ti on (40 percent) to i ts most rearward posi ti on and
ti l t the seat back forward for easi est access to the
front outboard seat bel t buckl e l ower anchor.
(2) For easi est access to the front outboard seat
bel t buckl e l ower anchor on standard cab model s,
al so move the outboard seat secti on (40 percent)
opposi te the si de from whi ch the buckl e i s to be
removed to i ts most forward posi ti on and ti l t the seat
back forward.
(3) On standard cab model s onl y, remove the stow-
age tray from the rear fl oor panel behi nd the seat.
(Refer to 23 - BODY/I NTERI OR/REAR FLOOR
STOWAGE TRAY - REMOVAL).
(4) From behi nd the front seat on the dri ver si de
onl y, di sconnect the seat bel t swi tch pi gtai l wi re con-
nector from the seat wi re harness take out and con-
nector for the swi tch l ocated bel ow the i nboard edge
of the dri ver si de i nboard seat track just forward of
the buckl e l ower anchor (Fi g. 33).
(5) From behi nd the front seat, remove the screw
that secures the front outboard seat bel t buckl e l ower
anchor to the bracket on the i nboard seat track.
front outboard seat cushi on to access and remove the
front outboard seat bel t buckl e from the seat.
INSTALLATION
A travel i ng front outboard seat bel t buckl e i s
l ocated on the i nboard si de of each front outboard
seat secti on (40 percent) used on al l model s. The seat
bel t buckl e on the dri vers si de front seat for al l mod-
el s al so i ncl udes a seat bel t swi tch. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/SEAT BELT SWI TCH -
DESCRI PTI ON).
PARTS CATALOG.
front outboard seat cushi on to posi ti on the front out-
board seat bel t buckl e to the seat (Fi g. 33).
(2) From behi nd the front seat, i nstal l and ti ghten
the screw that secures the front outboard seat bel t
buckl e l ower anchor to the bracket on the i nboard
seat track. Ti ghten the screw to 25 Nm (18 ft. l bs.).
(3) From behi nd the front seat on the dri ver si de
onl y, reconnect the seat bel t swi tch pi gtai l wi re con-
nector to the seat wi re harness take out and connec-
tor for the swi tch l ocated bel ow the i nboard edge of
the dri ver si de i nboard seat track just forward of the
buckl e l ower anchor.
(4) On standard cab model s onl y, rei nstal l the
stowage tray onto the rear fl oor panel behi nd the
seat. (Refer to 23 - BODY/I NTERI OR/REAR FLOOR
STOWAGE TRAY - I NSTALLATI ON).
(5) On standard cab model s, move the outboard
seat secti on (40 percent) opposi te the si de from whi ch
the buckl e was repl aced to i ts most rearward posi ti on
and ti l t the seat back to i ts upri ght posi ti on.
Fig. 33 Front Outboard Seat Belt Buckle Remove/
Install
1 - DRIVER SIDE FRONT OUTBOARD SEAT BELT BUCKLE
2 - SEAT CUSHION
3 - PIGTAIL WIRE
4 - INBOARD SEAT TRACK
5 - SCREW
FRONT OUTBOARD SEAT BELT BUCKLE (Continued)
PASSENGER AIRBAG
DESCRIPTION
The rearward faci ng surface of the i njecti on
mol ded, thermopl asti c passenger ai rbag door i s the
most vi si bl e part of the passenger ai rbag (Fi g. 34).
The passenger ai rbag door i s l ocated above the gl ove
box openi ng on the i nstrument panel i n front of the
front seat passenger seati ng posi ti on. The upper and
outboard edges of the ai rbag door are secured wi th
seven i ntegral snap features to the i nstrument panel
base tri m, whi l e two screws secure the i ntegral
i nboard mounti ng fl ange to the base tri m, and four
screws secure the l ower mounti ng fl ange to the upper
gl ove box openi ng rei nforcement i ntegral to the
i nstrument panel structural support. The passenger
ai rbag door i ncl udes an ai r condi ti oni ng panel outl et
and housi ng. The panel outl et housi ng features four
snap features that secure i t to the back of the ai rbag
door and a mounti ng tab that i s al so secured wi th
one screw to the upper gl ove box openi ng rei nforce-
ment.
Located behi nd the passenger ai rbag door wi thi n
the i nstrument panel i s the passenger ai rbag uni t
(Fi g. 35). The passenger ai rbag housi ng fi ts i nto a
mol ded receptacl e on the back of the ai rbag door,
where si x stamped hook formati ons on the upper and
l ower edges of the ai rbag housi ng are engaged i n si x
smal l wi ndow openi ngs on the upper and l ower
fl anges of the receptacl e to secure the ai rbag door to
the ai rbag housi ng. The i nboard ai rbag door fasten-
ers and mounti ng fl ange are conceal ed beneath the
i nstrument panel center bezel , whi l e the l ower fas-
teners and mounti ng fl ange are conceal ed beneath
the i nstrument panel l ower surround. The passenger
ai rbag uni t i s secured by four screws through four
brackets (two front and two rear) that are i ntegral to
the base of the ai rbag housi ng to the i nstrument
panel structural support.
The passenger ai rbag uni t used i n thi s model i s a
mul ti stage, Next Generati on-type that compl i es wi th
revi sed federal ai rbag standards to depl oy wi th l ess
force than those used i n some pri or model s. The pas-
senger ai rbag uni t consi sts of a stamped and wel ded
metal housi ng, the ai rbag cushi on, the ai rbag i nfl a-
tor, and a stamped metal ai rbag and i nfl ator retai ner
pl ate that i s secured to the ai rbag housi ng wi th si x
studs and nuts. The ai rbag housi ng contai ns the ai r-
bag i nfl ator and the fol ded ai rbag cushi on. An
approxi matel y 80 centi meter (31.5 i nch) wi de by 90
centi meter (35.5 i nch) hi gh rectangul ar fabri c cush-
i on i s used.
The ai rbag i nfl ator i s a non-azi de, pyrotechni c-type
uni t that i s secured to and seal ed wi thi n the ai rbag
housi ng. A short four-wi re pi gtai l harness wi th a
keyed, yel l ow connector i nsul ator connects the two
i nfl ator i ni ti ators to the vehi cl e el ectri cal system
through a dedi cated take out and connector of the
i nstrument panel wi re harness.
The passenger ai rbag i ncl udes the ai rbag door and
the panel outl et housi ng. Thi s uni t cannot be
repai red, and must be repl aced i f depl oyed, faul ty, or
i n any way damaged.
Fig. 34 Passenger Airbag Door
1 - PASSENGER AIRBAG DOOR
2 - PANEL OUTLET
3 - GLOVE BOX DOOR
Fig. 35 Passenger Airbag Unit
1 - DOOR
2 - PANEL OUTLET HOUSING
3 - SNAP FEATURE (7)
4 - REAR BRACKET (2)
5 - PIGTAIL WIRE CONNECTOR
6 - INITIATOR (2)
7 - FRONT BRACKET (2)
8 - HOUSING
OPERATION
The mul ti stage passenger ai rbag i s depl oyed by
el ectri cal si gnal s generated by the Ai rbag Control
Modul e (ACM) through the passenger ai rbag squi b 1
and squi b 2 ci rcui ts to the two i ni ti ators i n the ai r-
bag i nfl ator. By usi ng two i ni ti ators, the ai rbag can
be depl oyed at mul ti pl e l evel s of force. The force l evel
i s control l ed by the ACM to sui t the moni tored
i mpact condi ti ons by provi di ng one of four del ay
i nterval s between the el ectri cal si gnal s provi ded to
the two i ni ti ators. The l onger the del ay between
these si gnal s, the l ess forceful l y the ai rbag wi l l
depl oy.
When the ACM sends the proper el ectri cal si gnal s to
each i ni ti ator, the el ectri cal energy generates enough
heat to i ni ti ate a smal l pyrotechni c charge whi ch, i n
turn i gni tes chemi cal pel l ets wi thi n the i nfl ator. Once
i gni ted, these chemi cal pel l ets burn rapi dl y and pro-
duce a l arge quanti ty of i nert gas. The i nfl ator i s
seal ed to the ai rbag cushi on and a di ffuser i n the i nfl a-
tor di rects al l of the i nert gas i nto the ai rbag cushi on,
causi ng the cushi on to i nfl ate. As the cushi on i nfl ates,
the passenger ai rbag door wi l l spl i t at predetermi ned
tear seam l i nes conceal ed on the i nsi de surface of the
door, then the door wi l l pi vot up over the top of the
i nstrument panel and out of the way. Fol l owi ng an ai r-
bag depl oyment, the ai rbag cushi on qui ckl y defl ates by
venti ng the i nert gas through vent hol es wi thi n the
fabri c used to construct the back (i nstrument panel
si de) of the ai rbag cushi on.
Typi cal l y, both i ni ti ators are used duri ng an ai rbag
depl oyment event. However, i t i s possi bl e for onl y one
i ni ti ator to be used duri ng a depl oyment due to an
ai rbag system faul t; therefore, i t i s necessary to
al ways confi rm that both i ni ti ators have been used i n
order to avoi d the i mproper di sposal of potenti al l y
l i ve pyrotechni c materi al s. (Refer to 8 - ELECTRI -
DEPLOYMENT).
REMOVAL
faul ty or damaged passenger ai rbag. I f the ai rbag i s
RESTRAI NTS). I f the passenger ai rbag has been
MENT.
MAY BE DEPOSITS ON THE AIRBAG UNIT AND
SKIN AND EYES.
(2) Remove the l ower surround from the i nstru-
ment panel . (Refer to 23 - BODY/I NSTRUMENT
PANEL/LOWER SURROUND - REMOVAL).
(3) Remove the screw that secures the mounti ng
tab of the panel outl et housi ng to the upper gl ove box
openi ng rei nforcement (Fi g. 36).
(4) Remove the si x screws that secure the i nboard
and l ower fl anges of the passenger ai rbag door to the
i nstrument panel .
Fig. 36 Passenger Airbag Door Screws
2 - PANEL OUTLET SCREW (1)
3 - GLOVE BOX OPENING UPPER REINFORCEMENT
4 - DOOR SCREW (6)
PASSENGER AIRBAG (Continued)
(5) Reach through and above the gl ove box openi ng
to access and remove the two screws that secure the
passenger ai rbag rear brackets to the upper gl ove
box openi ng rei nforcement (Fi g. 37).
to access and remove the two screws that secure the
passenger ai rbag front brackets to the i nstrument
panel structural support.
fl at-bl aded tool , gentl y pry the upper and outboard
edges of the passenger ai rbag door away from the
i nstrument panel far enough to di sengage the seven
snap features on the door from the receptacl es i n the
i nstrument panel base tri m (Fi g. 38).
(8) Pul l the passenger ai rbag housi ng and door
uni t strai ght back from the i nstrument panel far
enough to access the i nstrument panel wi re harness
take out and connector for the ai rbag l ocated on the
i nboard si de of the ai rbag housi ng.
(9) Di sconnect the passenger ai rbag pi gtai l wi re
connector from the i nstrument panel wi re harness
connector for the ai rbag. To di sconnect the connector:
(a) Sl i de the red Connector Posi ti on Assurance
(CPA) l ock on the connector toward the si de of the
connector.
(b) Depress the connector l atch tab and pul l the
two hal ves of the connector strai ght away from
each other.
(10) Remove the passenger ai rbag and ai rbag door
from the i nstrument panel as a uni t.
INSTALLATION
faul ty or damaged passenger ai rbag. I f the ai rbag i s
RESTRAI NTS). I f the passenger ai rbag has been
MENT.
SKIN AND EYES.
Fig. 37 Passenger Airbag Remove/Install
2 - UPPER GLOVE BOX OPENING REINFORCEMENT
3 - FRONT BRACKET SCREW (2)
4 - REAR BRACKET SCREW (2)
Fig. 38 Passenger Airbag Door Disengage
1 - TRIM STICK
DEATH, THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT PASSENGER
AIRBAG UNITS ARE SERVICED WITH DOORS IN
THE ORIGINAL COLORS. PAINT MAY CHANGE THE
WAY IN WHICH THE MATERIAL OF THE AIRBAG
DOOR RESPONDS TO AN AIRBAG DEPLOYMENT.
RESULT IN OCCUPANT INJURIES UPON AIRBAG
DEPLOYMENT.
FOREIGN MATERIAL FROM ENTERING THE PAS-
SENGER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Careful l y posi ti on the passenger ai rbag and
ai rbag door to the i nstrument panel as a uni t.
(2) Reconnect the passenger ai rbag pi gtai l wi re
connector to the i nstrument panel wi re harness con-
nector for the ai rbag. Thi s connector i s secured to the
i nboard si de of the ai rbag housi ng. Be certain that
the latch on the connector and the red Connec-
tor Position Assurance (CPA) lock are each
fully engaged.
(3) Posi ti on the passenger ai rbag housi ng and door
uni t i nto the i nstrument panel .
over each of the seven snap features on the upper
and outboard edges of the passenger ai rbag door
unti l they snap i nto thei r receptacl es i n the i nstru-
ment panel base tri m.
to i nstal l and ti ghten the two screws that secure the
passenger ai rbag front brackets to the i nstrument
panel structural support (Fi g. 37). Ti ghten the screws
to 6 Nm (55 i n. l bs.).
to i nstal l and ti ghten the two screws that secure the
passenger ai rbag rear brackets to the upper gl ove
box openi ng rei nforcement. Ti ghten the screws to 6
Nm (55 i n. l bs.).
(7) I nstal l and ti ghten the si x screws that secure
the i nboard and l ower fl anges of the passenger ai r-
bag door to the i nstrument panel (Fi g. 36). Ti ghten
the screws to 2 Nm (20 i n. l bs.).
mounti ng tab of the panel outl et housi ng to the
upper gl ove box openi ng rei nforcement. Ti ghten the
(9) Rei nstal l the l ower surround onto the i nstru-
ment panel . (Refer to 23 - BODY/I NSTRUMENT
PANEL/LOWER SURROUND - I NSTALLATI ON).
PASSENGER AIRBAG ON/OFF
SWITCH
DESCRIPTION
The passenger ai rbag on/off swi tch i s standard
equi pment on al l standard cab versi ons of thi s model
when they are equi pped wi th the dual front ai rbag
system (Fi g. 39). Thi s swi tch i s a two-posi ti on, resi s-
tor mul ti pl exed swi tch wi th a si ngl e i ntegral red
Li ght-Emi tti ng Di ode (LED), and a non-coded key
cyl i nder-type actuator. The swi tch i s l ocated i n the
l ower ri ght corner of i nstrument panel center bezel ,
near the center of i nstrument panel to make the Off
i ndi cator vi si bl e to al l front seat occupants. When the
swi tch i s i n i ts i nstal l ed posi ti on, the onl y compo-
nents vi si bl e through the dedi cated openi ng of the
cl uster bezel are the swi tch face pl ate and nomencl a-
ture, and the key cyl i nder actuator. The Off posi ti on
of the swi tch i s i l l umi nated when thi s swi tch posi ti on
i s sel ected, whi l e the On posi ti on of the swi tch i s
desi gnated by text i mpri nted upon the face pl ate of
the swi tch, but i s not i l l umi nated. The remai nder of
the swi tch i s conceal ed behi nd the swi tch face pl ate
and the i nstrument panel center bezel .
Fig. 39 Passenger Airbag On/Off Switch
1 - SWITCH
2 - FACE PLATE
3 - OFF INDICATOR
4 - KEY CYLINDER ACTUATOR
The passenger ai rbag on/off swi tch housi ng i s con-
structed of mol ded pl asti c and has three i ntegral
mounti ng tabs. These mounti ng tabs are used to
secure the swi tch to the back of the mol ded pl asti c
swi tch face pl ate wi th three smal l screws. The
mol ded pl asti c face pl ate al so has three i ntegral
mounti ng tabs that are used to secure the swi tch and
face pl ate uni t to the i nstrument panel center bezel
wi th three addi ti onal screws. A mol ded pl asti c con-
nector receptacl e on the back of the swi tch housi ng
connects the swi tch to the vehi cl e el ectri cal system
through a dedi cated take out and connector of the
i nstrument panel wi re harness. The mol ded pl asti c
harness connector i nsul ator i s keyed and l atched to
ensure proper and secure swi tch el ectri cal connec-
ti ons. The passenger ai rbag on/off swi tch cannot be
swi tch must be repl aced.
OPERATION
The passenger ai rbag on/off swi tch al l ows the cus-
tomer to turn the passenger ai rbag functi on On or
Off to accommodate certai n uses of the ri ght front
seati ng posi ti on where ai rbag protecti on may not be
desi red. See the owners manual i n the vehi cl e gl ove
box for speci fi c recommendati ons on when to enabl e
or di sabl e the passenger ai rbag. The Off i ndi cator of
the swi tch wi l l be i l l umi nated whenever the swi tch i s
turned to the Off posi ti on and the i gni ti on swi tch i s
i n the On posi ti on.
The i gni ti on key i s the onl y key or object that
shoul d ever be i nserted i nto the key cyl i nder actuator
of the swi tch. The on/off swi tch requi res onl y a par-
ti al key i nserti on to ful l y depress a spri ng-l oaded
l ocki ng pl unger. The spri ng-l oaded l ocki ng pl unger
prevents the user from l eavi ng the key i n the swi tch.
The key wi l l be automati cal l y ejected when force i s
not appl i ed. To actuate the passenger ai rbag on/off
swi tch, i nsert the i gni ti on key i nto the swi tch key
actuator far enough to ful l y depress the pl unger, then
rotate the actuator to the desi red swi tch posi ti on.
When the swi tch key actuator i s rotated to i ts cl ock-
wi se stop (the key actuator sl ot wi l l be al i gned wi th
the Off i ndi cator), the Off i ndi cator i s i l l umi nated
and the passenger ai rbag i s di sabl ed. When the
swi tch i s rotated to i ts countercl ockwi se stop (the key
actuator sl ot wi l l be i n a verti cal posi ti on), the Off
i ndi cator wi l l be exti ngui shed and the passenger ai r-
bag i s enabl ed.
The passenger ai rbag on/off swi tch connects one of
two i nternal resi stors i n seri es between the passen-
ger ai rbag mux swi tch sense and passenger ai rbag
mux swi tch return ci rcui ts of the Ai rbag Control
Modul e (ACM). The ACM conti nual l y moni tors the
resi stance i n these ci rcui ts to determi ne the swi tch
posi ti on that has been sel ected. When the swi tch i s
i n the Off posi ti on, the ACM provi des a ground i nput
to the swi tch through the passenger ai rbag i ndi cator
dri ver ci rcui t, whi ch energi zes the Li ght-Emi tti ng
Di ode (LED) that i l l umi nates the Off i ndi cator of the
swi tch.
The ACM wi l l al so i l l umi nate the Off i ndi cator of
the swi tch for about seven seconds each ti me the
i gni ti on swi tch i s turned to the On posi ti on as a bul b
test. The ACM wi l l store a Di agnosti c Troubl e Code
(DTC) for any faul t i t detects i n the passenger ai rbag
on/off swi tch or Off i ndi cator ci rcui ts, and wi l l i l l umi -
nate the ai rbag i ndi cator i n the i nstrument cl uster i f
a faul t i s detected. For proper di agnosi s of the pas-
senger ai rbag on/off swi tch or the ACM, a DRBI I I
REMOVAL
MENT.
REMOVAL).
(3) From the back of the center bezel , remove the
three screws that secure the passenger ai rbag on/off
swi tch and face pl ate uni t to the back of the bezel
(Fi g. 40).
(4) Remove the passenger ai rbag on/off swi tch and
face pl ate from the center bezel as a uni t.
PASSENGER AIRBAG ON/OFF SWITCH (Continued)
INSTALLATION
MENT.
(1) Posi ti on the passenger ai rbag on/off swi tch and
face pl ate uni t to the back of the center bezel (Fi g.
40).
(2) I nstal l and ti ghten the three screws that secure
the passenger ai rbag on/off swi tch face pl ate to the
back of the center bezel . Ti ghten the screws to 2 Nm
(17 i n. l bs.).
(3) Rei nstal l the center bezel onto the i nstrument
I NSTRUMENT PANEL CENTER BEZEL - I NSTAL-
LATI ON).
REAR CENTER SEAT BELT &
RETRACTOR
REMOVAL
The rear center seat bel t retractor i s secured wi th
a si ngl e screw to a mounti ng bracket that i ncl udes
the uni que bl ack, keyed center seat bel t l ower anchor
buckl e and the ri ght outboard occupant buckl e, but
can be removed from the mounti ng bracket and i s
servi ced separatel y from the two buckl es. The center
anchor buckl e and the ri ght outboard occupant
buckl e are servi ced as a uni t wi th thei r mounti ng
bracket. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
REAR SEAT BELT BUCKLE - REMOVAL - CEN-
TER ANCHOR & RI GHT OUTBOARD).
PARTS CATALOG.
(1) Reach between the rear seat cushi on and the
rear seat back to access and unbuckl e the center seat
bel t l ower anchor l atch pl ate from the uni que bl ack,
keyed l ower anchor buckl e. Use an i gni ti on key or a
smal l screwdri ver to depress the smal l whi te rel ease
button on the anchor buckl e.
(2) Remove the rear seat from the vehi cl e. On
model s wi th the opti onal 60/40 spl i t rear bench, onl y
the 60 percent secti on (ri ght si de) of the rear seat
must be removed. (Refer to 23 - BODY/SEATS/SEAT
- REAR - REMOVAL).
Fig. 40 Passenger Airbag On/Off Switch Remove/
Install
1 - CENTER BEZEL
2 - SCREW (3)
3 - SWITCH & PLATE UNIT
PASSENGER AIRBAG ON/OFF SWITCH (Continued)
(3) Li ft upward on the forward edge of the rear
center seat bel t bezel at the top of the cab back panel
to rel ease the snap features that secure the bezel to
the bel t bracket (Fi g. 41).
(4) Remove the bezel from the webbi ng of the rear
center seat bel t.
(5) Li ft the rear center seat bel t cover off of the
bel t bracket at the top of the cab back panel and
remove the cover from the webbi ng of the rear center
seat bel t.
(6) Remove the two screws that secure the bel t
bracket of the rear center seat bel t to the body
bracket on the upper cab back panel rei nforcement.
(7) Remove the bel t bracket of the rear center seat
bel t from the body bracket.
(8) Remove the screw that secures the rear center
seat bel t retractor to the center anchor/ri ght out-
board occupant buckl e and mounti ng bracket uni t on
the rear fl oor panel near the cab back panel (Fi g. 42).
(9) Remove the rear center seat bel t retractor from
the center anchor/ri ght outboard occupant buckl e and
mounti ng bracket uni t.
(10) Remove the rear center seat bel t and retractor
uni t from the vehi cl e.
INSTALLATION
The rear center seat bel t retractor i s secured wi th
a si ngl e screw to a mounti ng bracket that i ncl udes
the uni que bl ack, keyed center seat bel t l ower anchor
buckl e and the ri ght outboard occupant buckl e, but
can be removed from the mounti ng bracket and i s
servi ced separatel y from the two buckl es. The center
bracket. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
REAR SEAT BELT BUCKLE - I NSTALLATI ON -
CENTER ANCHOR & RI GHT OUTBOARD).
Fig. 41 Rear Center Seat Belt & Retractor Remove/
Install
1 - CAB BACK PANEL
2 - CENTER SEAT BELT
3 - BEZEL
4 - COVER
5 - BELT BRACKET
6 - SCREW (2)
7 - BODY BRACKET
8 - RETRACTOR
9 - SCREW (2)
10 - CENTER ANCHOR/RIGHT OUTBOARD OCCUPANT BUCKLE
& BRACKET UNIT
11 - REAR FLOOR PANEL
12 - LOWER ANCHOR LATCH PLATE
Fig. 42 Rear Center Retractor & Mounting Bracket
1 - RIGHT OUTBOARD OCCUPANT BUCKLE
2 - REAR CENTER SEAT BELT
3 - REAR CENTER SEAT BELT RETRACTOR
5 - CENTER ANCHOR BUCKLE
6 - SCREW (1)
REAR CENTER SEAT BELT & RETRACTOR (Continued)
PARTS CATALOG.
(1) Posi ti on the rear center seat bel t and retractor
uni t onto the center anchor/ri ght outboard occupant
buckl e and mounti ng bracket uni t on the rear fl oor
panel near the base of the cab back panel (Fi g. 42).
rear center seat bel t retractor bracket to the center
anchor/ri ght outboard occupant buckl e and mounti ng
bracket uni t. Ti ghten the screw to 40 Nm (29 ft.
l bs.).
(3) Posi ti on the bel t bracket of the rear center seat
bel t onto the body bracket on the upper cab back
panel rei nforcement (Fi g. 41).
the bel t bracket of the rear center seat bel t to the
body bracket. Ti ghten the screws to 20 Nm (15 ft.
l bs.).
(5) Li ft the webbi ng of the rear center seat bel t
and sl i de the cover over the bel t bracket at the top of
the cab back panel unti l i t i s ful l y seated.
(6) Route the rear center seat bel t bezel over the
webbi ng of the rear center seat bel t.
(7) Posi ti on the rear center seat bel t bezel over the
cover and bel t bracket at the top of the cab back
panel and engage the rearward snap features of the
bezel wi th the bel t bracket. Usi ng hand pressure,
press fi rml y and evenl y downward on the front of the
bezel unti l i t snaps i nto pl ace over the cover and bel t
bracket.
(8) Rei nstal l the rear seat i nto the vehi cl e. On
must be rei nstal l ed. (Refer to 23 - BODY/SEATS/
SEAT - REAR - I NSTALLATI ON).
rear seat back to buckl e the rear center seat bel t
l ower anchor l atch pl ate to the uni que bl ack, keyed
l ower anchor buckl e.
REAR OUTBOARD SEAT BELT
& RETRACTOR
REMOVAL
The onl y component of thi s seat bel t and retractor
uni t that i s avai l abl e for i ndi vi dual servi ce repl ace-
ment i s the pl asti c web stop button that prevents the
l atch pl ate from fal l i ng to the fl oor whi l e i n the
stored posi ti on. Refer to the i nstructi ons suppl i ed
PARTS CATALOG.
(1) Remove the rear seat from the vehi cl e. (Refer
to 23 - BODY/SEATS/SEAT - REAR - REMOVAL).
bel t anchor to the base of the i nner C-pi l l ar (Fi g. 43).
base of the i nner C-pi l l ar.
rear outboard seat bel t turni ng l oop to access the
screw that secures the turni ng l oop to the upper
i nner C-pi l l ar. Di scard the removed turni ng l oop tri m
cover as i t i s not i ntended for reuse.
turni ng l oop to the C-pi l l ar.
REAR CENTER SEAT BELT & RETRACTOR (Continued)
upper i nner C-pi l l ar.
i nner C-pi l l ar. (Refer to 23 - BODY/I NTERI OR/C-
23 - BODY/I NTERI OR/C-PI LLAR LOWER TRI M -
REMOVAL).
web gui de to the i nner C-pi l l ar near the bel t l i ne.
(9) Remove the seat bel t web gui de from the i nner
C-pi l l ar.
retractor bracket to the l ower i nner C-pi l l ar bel ow
(11) Di sengage the hook on the upper retractor
bracket from the sl ot i n the l ower i nner C-pi l l ar
(12) Remove the rear outboard seat bel t and
l ower i nner C-pi l l ar.
INSTALLATION
The onl y component of thi s seat bel t and retractor
uni t that i s avai l abl e for i ndi vi dual servi ce repl ace-
ment i s the pl asti c web stop button that prevents the
l atch pl ate from fal l i ng to the fl oor whi l e i n the
stored posi ti on. Refer to the i nstructi ons suppl i ed
PARTS CATALOG.
(1) Posi ti on the rear outboard seat bel t and retrac-
tor to the retractor mounti ng hol e i n the l ower i nner
C-pi l l ar (Fi g. 43).
(2) Engage the hook on the upper retractor bracket
i nto the sl ot i n the l ower i nner C-pi l l ar above the
retractor mounti ng hol e.
l ower retractor bracket to the l ower i nner C-pi l l ar
to 40 Nm (29 ft. l bs.).
(4) Posi ti on the seat bel t web gui de to the i nner
C-pi l l ar near the bel t l i ne.
seat bel t web gui de to the i nner C-pi l l ar. Ti ghten the
i nner C-pi l l ar. (Refer to 23 - BODY/I NTERI OR/C-
(Refer to 23 - BODY/I NTERI OR/C-PI LLAR LOWER
upper i nner C-pi l l ar.
Fig. 43 Rear Outboard Seat Belt & Retractor
Remove/Install
1 - C-PILLAR
2 - TRIM PANEL
3 - TURNING LOOP
4 - SCREW
5 - TRIM COVER
6 - SEAT BELT
7 - SCREW
8 - LOWER ANCHOR
9 - SCREW
10 - SCREW
11 - RETRACTOR
12 - WEB GUIDE
REAR OUTBOARD SEAT BELT & RETRACTOR (Continued)
seat bel t turni ng l oop to the C-pi l l ar. Ti ghten the
screw to 40 Nm (29 ft. l bs.).
(9) Engage the l ower snap features of the new tri m
cover over the rear outboard seat bel t turni ng l oop
and, usi ng hand pressure, press fi rml y and evenl y on
the top of the tri m cover unti l i t snaps i nto pl ace.
(10) Posi ti on the l ower seat bel t anchor to the base
of the i nner C-pi l l ar.
l ower seat bel t anchor to the base of the i nner C-pi l -
l ar. Ti ghten the screw to 40 Nm (29 ft. l bs.).
(12) Rei nstal l the rear seat i nto the vehi cl e. (Refer
to 23 - BODY/SEATS/SEAT - REAR - I NSTALLA-
TI ON).
REAR SEAT BELT BUCKLE
REMOVAL
REMOVAL - CENTER & LEFT OUTBOARD
PARTS CATALOG.
(1) Li ft up the rear seat cushi on i nto i ts stowed
posi ti on agai nst the rear seat back.
(2) Remove the screw that secures ei ther the cen-
ter or the l eft outboard occupant buckl e uni t to the
rear fl oor panel near the base of the cab back panel
(Fi g. 44). On model s wi th the opti onal 60/40 spl i t
rear bench, the screw that secures the buckl e uni t
al so secures one of the rear seat mounti ng brackets
to the rear fl oor panel .
(3) Remove the center or the l eft outboard occu-
pant buckl e uni t from the rear fl oor panel or from
the rear seat mounti ng bracket.
Fig. 44 Rear Seat Belt Buckle Remove/Install
1 - CAB BACK PANEL
2 - CENTER SEAT BELT RETRACTOR
3 - SCREW (4)
4 - LEFT OUTBOARD OCCUPANT BUCKLE UNIT
5 - CENTER OCCUPANT BUCKLE UNIT
& BRACKET UNIT
REAR OUTBOARD SEAT BELT & RETRACTOR (Continued)
REMOVAL - CENTER ANCHOR & RIGHT
OUTBOARD
The uni que bl ack, keyed center seat bel t l ower
bracket. The rear center seat bel t retractor i s al so
secured to the mounti ng bracket wi th these two
buckl es, but can be removed from the mounti ng
bracket and i s servi ced separatel y from the two buck-
l es. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/REAR
CENTER SEAT BELT & RETRACTOR - REMOVAL).
PARTS CATALOG.
rear seat back to access and unbuckl e the rear center
seat bel t l ower anchor l atch pl ate from the uni que
bl ack, keyed l ower anchor buckl e. Use an i gni ti on
key or a smal l screwdri ver to depress the smal l whi te
rel ease button on the anchor buckl e.
(2) Remove the rear seat from the vehi cl e. On
must be removed. (Refer to 23 - BODY/SEATS/SEAT
- REAR - REMOVAL).
(3) Remove the screw that secures the rear center
seat bel t retractor to the center anchor/ri ght out-
board occupant buckl e and mounti ng bracket uni t on
the rear fl oor panel near the cab back panel (Fi g. 45).
(4) Remove the rear center seat bel t retractor from
mounti ng bracket uni t.
(5) Remove the two screws that secure the center
anchor/ri ght outboard occupant buckl e and mounti ng
bracket uni t to the rear fl oor panel near the base of
the cab back panel (Fi g. 46).
(6) Remove the center anchor/ri ght outboard occu-
pant buckl e and mounti ng bracket uni t from the rear
fl oor panel .
Fig. 45 Rear Center Retractor & Mounting Bracket
1 - RIGHT OUTBOARD OCCUPANT BUCKLE
2 - REAR CENTER SEAT BELT
3 - REAR CENTER SEAT BELT RETRACTOR
5 - CENTER ANCHOR BUCKLE
6 - SCREW (1)
REAR SEAT BELT BUCKLE (Continued)
INSTALLATION
INSTALLATION - CENTER & LEFT OUTBOARD
PARTS CATALOG.
(1) Posi ti on the center or the l eft outboard occu-
pant buckl e uni t onto the rear fl oor panel or onto the
rear seat mounti ng bracket near the base of the cab
back panel (Fi g. 44). On model s wi th the opti onal
60/40 spl i t rear bench, the screw that secures the
buckl e uni t al so secures one of the rear seat mount-
i ng brackets to the rear fl oor panel .
center or the l eft outboard occupant buckl e uni t to
the rear fl oor panel . Ti ghten the screw to 40 Nm (29
ft. l bs.).
(3) Lower the rear seat cushi on back to i ts normal
seati ng posi ti on.
INSTALLATION - CENTER ANCHOR & RIGHT
OUTBOARD
The uni que bl ack, keyed center seat bel t l ower
bracket. The rear center seat bel t retractor i s al so
secured to the mounti ng bracket wi th these two
buckl es, but can be removed from the mounti ng
bracket and i s servi ced separatel y from the two buck-
l es. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/REAR
CENTER SEAT BELT & RETRACTOR - I NSTALLA-
TI ON).
PARTS CATALOG.
Fig. 46 Rear Seat Belt Buckle Remove/Install
1 - CAB BACK PANEL
2 - CENTER SEAT BELT RETRACTOR
3 - SCREW (4)
4 - LEFT OUTBOARD OCCUPANT BUCKLE UNIT
5 - CENTER OCCUPANT BUCKLE UNIT
& BRACKET UNIT
(1) Posi ti on the center anchor/ri ght outboard occu-
pant buckl e and mounti ng bracket uni t onto the rear
fl oor panel near the base of the cab back panel (Fi g.
46).
mounti ng bracket uni t to the rear fl oor panel .
Ti ghten the screws to 40 Nm (29 ft. l bs.).
(3) Posi ti on the rear center seat bel t retractor onto
mounti ng bracket uni t (Fi g. 45).
rear center seat bel t retractor to the center anchor/
ri ght outboard occupant buckl e and mounti ng
bracket uni t. Ti ghten the screw to 40 Nm (29 ft.
l bs.).
(5) Rei nstal l the rear seat i nto the vehi cl e. On
must be rei nstal l ed. (Refer to 23 - BODY/SEATS/
SEAT - REAR - I NSTALLATI ON).
rear seat back to access and buckl e the rear center
seat bel t l ower anchor l atch pl ate to the uni que
bl ack, keyed l ower anchor buckl e.
SEAT BELT SWITCH
DESCRIPTION
The seat bel t swi tch i s a smal l , normal l y open, si n-
gl e pol e, si ngl e throw, l eaf contact, momentary
swi tch. Onl y one seat bel t swi tch i s i nstal l ed i n the
vehi cl e, and i t i s i ntegral to the buckl e of the dri ver
si de front seat bel t buckl e-hal f, l ocated on the
i nboard si de of the dri ver si de front seat track (Fi g.
47). The seat bel t swi tch i s connected to the vehi cl e
el ectri cal system through a two-wi re pi gtai l wi re and
connector on the seat bel t buckl e-hal f, whi ch i s con-
nected to a wi re harness connector and take out of
the seat wi re harness routed beneath the dri ver si de
front seat cushi on i n the passenger compartment.
The seat bel t swi tch cannot be adjusted or repai red
and, i f faul ty or damaged, the enti re dri ver si de front
seat bel t buckl e-hal f uni t must be repl aced.
OPERATION
The seat bel t swi tch i s desi gned to control a path
to ground for the seat bel t swi tch sense i nput of the
El ectroMechani cal I nstrument Cl uster (EMI C). When
the dri ver si de front seat bel t ti p-hal f i s i nserted i nto
the seat bel t buckl e, the swi tch cl oses the path to
ground; and, when the dri ver si de front seat bel t ti p-
hal f i s removed from the seat bel t buckl e, the swi tch
opens the ground path. The swi tch i s actuated by the
l atch mechani sm wi thi n the seat bel t buckl e.
The seat bel t swi tch i s connected i n seri es between
ground and the seat bel t swi tch sense i nput of the
i nstrument cl uster. The seat bel t swi tch recei ves
ground at al l ti mes through i ts pi gtai l wi re connec-
ti on to the seat wi re harness from a take out of the
body wi re harness. An eyel et termi nal connector on
the body wi re harness ground take out i s secured
beneath a ground screw on the l eft cowl si de i nner
panel , beneath the i nstrument panel . The seat bel t
swi tch may de di agnosed usi ng conventi onal di agnos-
ti c tool s and methods.
SWITCH
Fig. 47 Seat Belt Switch
1 - DRIVER SIDE FRONT OUTBOARD SEAT BELT BUCKLE
2 - SEAT CUSHION
3 - PIGTAIL WIRE
4 - INBOARD SEAT TRACK
5 - SCREW
MENT.
cabl e. Di sconnect the seat bel t swi tch pi gtai l wi re
connector from the seat wi re harness connector for
the seat bel t swi tch on the i nboard si de of the dri ver
si de front seat forward of the seat bel t buckl e-hal f
anchor. Check for conti nui ty between the seat bel t
swi tch sense ci rcui t and the ground ci rcui t cavi ti es of
the seat bel t swi tch pi gtai l wi re connector. There
shoul d be conti nui ty wi th the seat bel t buckl ed, and
no conti nui ty wi th the seat bel t unbuckl ed. I f OK, go
to Step 2. I f not OK, repl ace the faul ty front seat bel t
buckl e-hal f assembl y.
cui t cavi ty i n the seat wi re harness connector for the
seat bel t swi tch and a good ground. There shoul d be
conti nui ty. I f OK, go to Step 3. I f not OK, repai r the
open ground ci rcui t to ground (G301) as requi red.
ment panel . Check for conti nui ty between the seat
bel t swi tch sense ci rcui t cavi ty of the seat wi re har-
ness connector for the seat bel t swi tch and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 4. I f not OK, repai r the shorted seat bel t swi tch
sense ci rcui t between the seat bel t swi tch and the
i nstrument cl uster as requi red.
(4) Check for conti nui ty between the seat bel t
swi tch sense ci rcui t cavi ti es of the seat wi re harness
connector for the seat bel t swi tch and the i nstrument
panel wi re harness connector (Connector C2) for the
i nstrument cl uster. There shoul d be conti nui ty. I f
OK, test and repl ace the faul ty i nstrument cl uster as
requi red. (Refer to 8 - ELECTRI CAL/I NSTRUMENT
CLUSTER - DI AGNOSI S AND TESTI NG). I f not OK,
repai r the open seat bel t swi tch sense ci rcui t between
the seat bel t swi tch and the i nstrument cl uster as
requi red.
SEAT BELT TENSIONER
DESCRIPTION
Front outboard seati ng posi ti on seat bel t tensi on-
ers suppl ement the dri ver and passenger ai rbags for
al l versi ons of thi s model (Fi g. 48). The seat bel t ten-
si oner i s i ntegral to the front outboard seat bel t and
retractor uni ts, whi ch are secured to the i nner B-pi l -
l ar on the ri ght and l eft si des of the vehi cl e. The
retractor i s conceal ed beneath the mol ded pl asti c
i nner B-pi l l ar tri m. The seat bel t tensi oner consi sts
pri mari l y of a di e cast al umi num tensi oner housi ng
or chamber, a mechani cal cl utch uni t, a tape-l i ke
metal stri p, a pai r of cutters, a pyrotechni cal l y acti -
vated gas generator, and a short pi gtai l wi re. Al l of
these components are l ocated on one si de of the
retractor spool on the outsi de of the retractor hous-
i ng. The seat bel t tensi oners are control l ed by the
Ai rbag Control Modul e (ACM) and are connected to
the vehi cl e el ectri cal system through a dedi cated
take out of the body wi re harness by a keyed and
l atchi ng mol ded pl asti c connector i nsul ator to ensure
a secure connecti on.
The seat bel t tensi oners cannot be repai red and, i f
faul ty or damaged, the enti re outboard front seat bel t
and retractor uni t must be repl aced. I f the front ai r-
bags have been depl oyed, the seat bel t tensi oners
have al so been depl oyed. The seat bel t tensi oners are
not i ntended for reuse and must be repl aced fol l ow-
i ng any front ai rbag depl oyment. A l ocked retractor
that wi l l not al l ow the seat bel t webbi ng to be
Fig. 48 Seat Belt Tensioner
2 - GAS GENERATOR
4 - SPOOL
ONLY)
7 - RETRACTOR LOCKING MECHANISM COVER
SEAT BELT SWITCH (Continued)
retracted or extracted i s a sure i ndi cati on that the
seat bel t tensi oner has been depl oyed and requi res
repl acement. (Refer to 8 - ELECTRI CAL/RE-
STRAI NTS/FRONT OUTBOARD SEAT BELT &
RETRACTOR - REMOVAL).
OPERATION
The seat bel t tensi oners are depl oyed by a si gnal
generated by the Ai rbag Control Modul e (ACM)
through the dri ver and passenger seat bel t tensi oner
l i ne 1 and l i ne 2 (or squi b) ci rcui ts. When the ACM
sends the proper el ectri cal si gnal to the tensi oners,
the el ectri cal energy generates enough heat to i ni -
ti ate a smal l pyrotechni c gas generator. The gas gen-
erator i s i nstal l ed at the top of the tensi oner housi ng
whi ch contai ns a l ong metal tape that i s routed
through two chambers wi thi n the housi ng. Each end
of the tape i s wound around the outer sl eeve of a
mechani cal cl utch mechani sm secured to one end of
the torsi on bar upon whi ch the retractor spool i s
secured. As the gas expands, i t i s di rected agai nst
the metal tape wi thi n the two chambers of the hous-
i ng causi ng the tape to unwi nd from the cl utch
sl eeve. As the cl utch rotates i t engages the torsi on
bar, whi ch dri ves the seat bel t retractor spool causi ng
the sl ack to be removed from the seat bel t.
Once a seat bel t tensi oni ng sequence has been
compl eted, the forward momentum of the occupant
resul ts i n deformati on of the torsi on bar. As the tor-
si on bar deforms i t al l ows the seat bel t webbi ng to
unwi nd from the retractor spool , whi ch causes the
metal tape to be wound back onto the cl utch sl eeve
unti l i t i s pul l ed ti ght agai nst two cutter bl ades
wi thi n the housi ng, whi ch i mmedi atel y cut the metal
tape.
Removi ng excess sl ack from the seat bel t not onl y
keeps the occupant properl y posi ti oned for an ai rbag
depl oyment fol l owi ng a frontal i mpact of the vehi cl e,
but al so hel ps to reduce i njuri es that the occupant
mi ght experi ence i n these si tuati ons as a resul t of a
harmful contact wi th the steeri ng wheel , steeri ng col -
umn, i nstrument panel and/or wi ndshi el d. The tor-
si on bar i s desi gned to deform i n order to control the
l oadi ng bei ng appl i ed to the occupant by the seat bel t
duri ng a frontal i mpact, further reduci ng the poten-
ti al for occupant i njuri es.
The ACM moni tors the condi ti on of the seat bel t
tensi oners through ci rcui t resi stance. The ACM wi l l
i l l umi nate the ai rbag i ndi cator i n the El ectroMe-
chani cal I nstrument Cl uster (EMI C) and store a
Di agnosti c Troubl e Code (DTC) for any faul t that i s
detected. For proper di agnosi s of the seat bel t ten-
si oners, a DRBI I I scan tool i s requi red. Refer to the
SEAT BELT TENSION
REDUCER
DESCRIPTION
A seat bel t tensi on reducer i s standard equi pment
for the dri ver si de front outboard seat bel t on stan-
dard cab versi ons of thi s model (Fi g. 49). The tensi on
reducer i s i ntegral to the dri ver si de front outboard
seat bel t and retractor uni t, whi ch i s secured to the
i nner B-pi l l ar on the l eft si de of the vehi cl e. The
retractor i s conceal ed beneath the mol ded pl asti c
i nner B-pi l l ar tri m. The seat bel t tensi on reducer
consi sts pri mari l y of a 12-vol t Di rect Current (DC)
sol enoi d and an i ntegral connector receptacl e that i s
l ocated on the forward faci ng end housi ng of the
retractor. The seat bel t tensi on reducer i s control l ed
by a battery current output of the i gni ti on swi tch and
a ground path provi ded by the seat bel t swi tch, and
i s connected to the vehi cl e el ectri cal system through
a dedi cated take out of the body wi re harness by a
keyed and l atchi ng mol ded pl asti c connector i nsul a-
tor to ensure a secure connecti on.
The seat bel t tensi on reducer cannot be repai red
and, i f faul ty or damaged, the enti re dri ver si de front
outboard seat bel t and retractor uni t must be
repl aced. (Refer to 8 - ELECTRI CAL/RESTRAI NTS/
FRONT OUTBOARD SEAT BELT & RETRACTOR -
REMOVAL).
Fig. 49 Seat Belt Tension Reducer
2 - GAS GENERATOR
4 - SPOOL
ONLY)
SEAT BELT TENSIONER (Continued)
OPERATION
The seat bel t tensi on reducer i s control l ed by a
ground si gnal recei ved from the seat bel t swi tch on
the seat bel t swi tch sense ci rcui t and a battery cur-
rent si gnal recei ved from the i gni ti on swi tch on the
fused i gni ti on swi tch output (run-accessory) ci rcui t.
When the seat bel t swi tch i s cl osed (the dri ver si de
front seat bel t i s fastened) and the i gni ti on swi tch i s
i n the On or Accessory posi ti ons, the seat bel t tensi on
reducer sol enoi d i s energi zed. When the sol enoi d i s
energi zed, i t actuates a mechani sm wi thi n the dri ver
si de front outboard seat bel t retractor to reduce the
normal recoi l spri ng tensi on exerted by the retractor
spool , whi ch i s desi gned to reel i n the seat bel t web-
bi ng onto the spool . When the dri ver si de seat bel t i s
unbuckl ed or i f the i gni ti on swi tch i s turned to any
posi ti on except On or Accessory, the tensi on reducer
sol enoi d i s de-energi zed and the normal recoi l spri ng
tensi on of the retractor i s restored.
The acti on of the seat bel t tensi on reducer resul ts
i n i mproved seat bel t comfort for the dri ver. Reduci ng
the seat bel t retractor recoi l spri ng tensi on i s desi r-
abl e on standard cab model s of thi s vehi cl e and not
on the quad cab model due to the di fferent mounti ng
posi ti on requi red for the seat bel t turni ng l oop on the
B-pi l l ar rel ati ve to the dri vers seat posi ti on on the
standard cab model . The seat bel t tensi on reducer
may be di agnosed usi ng conventi onal di agnosti c tool s
and methods.
TENSION REDUCER
MENT.
the seat bel t tensi on reducer from the tensi on
reducer connector receptacl e on the dri ver si de front
outboard seat bel t and retractor uni t. Usi ng an ohm-
meter, measure the resi stance between the seat bel t
swi tch sense ci rcui t termi nal pi n and the fused i gni -
ti on swi tch output (run-accessory) ci rcui t termi nal
pi n i n the tensi on reducer connector receptacl e on
the retractor. Resi stance through the tensi on reducer
sol enoi d coi l shoul d be 53 ohms at 20 C (68 F). I f
OK, go to Step 2. I f not OK, repl ace the faul ty dri ver
si de front outboard seat bel t and retractor uni t.
(2) Check for conti nui ty between the seat bel t
swi tch sense ci rcui t cavi ty of the body wi re harness
connector for the seat bel t tensi on reducer and a good
ground. There shoul d be conti nui ty wi th the dri ver
si de front seat bel t buckl ed, and no conti nui ty wi th
the dri ver si de front seat bel t unbuckl ed. I f OK, go to
Step 3. I f not OK, repai r the shorted or open seat
bel t swi tch sense ci rcui t between the tensi on reducer
and the seat bel t swi tch as requi red.
(3) Reconnect the battery negati ve cabl e. Check for
battery current at the fused i gni ti on swi tch output
(run-accessory) ci rcui t of the body wi re harness con-
nector for the seat bel t tensi on reducer. There shoul d
be battery current wi th the i gni ti on swi tch i n the On
or Accessory posi ti ons, and no battery current wi th
the i gni ti on swi tch i n any other posi ti on. I f not OK,
repai r the shorted or open fused i gni ti on swi tch out-
put (run-accessory) ci rcui t between the tensi on
reducer and the i gni ti on swi tch as requi red.
SEAT BELT TENSION REDUCER (Continued)
SEAT BELT TURNING LOOP
ADJ USTER
REMOVAL
PARTS CATALOG.
for reuse.
(3) Remove the front seat bel t turni ng l oop from
the hei ght adjuster.
(4) Remove the upper tri m from the i nner B-pi l l ar.
(Refer to 23 - BODY/I NTERI OR/B-PI LLAR UPPER
TRI M - REMOVAL).
(5) Loosen the two screws that secure the seat bel t
turni ng l oop hei ght adjuster far enough to remove
the adjuster from the upper B-pi l l ar (Fi g. 50).
(6) Di sengage the tab near the l ower end of the
seat bel t turni ng l oop hei ght adjuster from the sl ot i n
the sheet metal and remove the adjuster from the
i nner B-pi l l ar.
INSTALLATION
DURING AND FOLLOWING ANY SEAT BELT OR
CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY
INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING
HARDWARE, RETRACTORS, TETHER STRAPS, AND
ANCHORS FOR PROPER INSTALLATION, OPERA-
TION, OR DAMAGE. REPLACE ANY BELT THAT IS
CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT
THAT IS TWISTED. TIGHTEN ANY LOOSE FASTEN-
ERS. REPLACE ANY BELT THAT HAS A DAMAGED
OR INOPERATIVE BUCKLE OR RETRACTOR.
REPLACE ANY BELT THAT HAS A BENT OR DAM-
AGED LATCH PLATE OR ANCHOR PLATE. REPLACE
ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO
WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN
BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A
SEAT BELT OR CHILD RESTRAINT COMPONENT.
PARTS CATALOG.
(1) Posi ti on the front seat bel t turni ng l oop
adjuster to the i nner B-pi l l ar (Fi g. 50).
(2) Engage the tab near the l ower end of the seat
bel t turni ng l oop hei ght adjuster i nto the sl ot i n the
sheet metal of the i nner B-pi l l ar.
(3) Hand ti ghten the l ower of the two screws that
secure the seat bel t turni ng l oop hei ght adjuster to
the upper B-pi l l ar far enough to keep the tab on the
l ower end of the adjuster engaged i n the B-pi l l ar sl ot.
Fig. 50 Seat Belt Turning Loop Adjuster Remove/
Install
1 - B-PILLAR
2 - ADJUSTER
3 - SCREW (2)
4 - GRAB HANDLE BRACKET (QUAD CAB ONLY)
(4) I nstal l the upper screw that secures the seat
bel t turni ng l oop hei ght adjuster to the upper B-pi l -
l ar, then ti ghten both the upper and l ower screws to
40 Nm (29 ft. l bs.).
(5) Rei nstal l the upper tri m onto the i nsi de of the
B-pi l l ar. (Refer to 23 - BODY/I NTERI OR/B-PI LLAR
UPPER TRI M - I NSTALLATI ON).
(8) Engage the l ower snap features of the new tri m
cover over the front outboard seat bel t turni ng l oop
and, usi ng hand pressure, press fi rml y and evenl y on
the top of the tri m cover unti l i t snaps i nto pl ace.
SIDE CURTAIN AIRBAG
DESCRIPTION
Opti onal si de curtai n ai rbags are avai l abl e for thi s
model when i t i s al so equi pped wi th dual front ai r-
bags. These ai rbags are passi ve, i nfl atabl e, Suppl e-
mental Restrai nt System (SRS) components, and
vehi cl es wi th thi s equi pment can be readi l y i denti fi ed
by a mol ded i denti fi cati on tri m button wi th the SRS
- AI RBAG l ogo l ocated on the headl i ner above each
A-pi l l ar, and above each B-pi l l ar on quad cab model s
(Fi g. 51). Thi s system i s desi gned to reduce i njuri es
to the vehi cl e occupants i n the event of a si de i mpact
col l i si on.
Vehi cl es equi pped wi th si de curtai n ai rbags have
two i ndi vi dual l y control l ed curtai n ai rbag uni ts.
These ai rbag uni ts are conceal ed and mounted above
the headl i ner where they are each secured to one of
the roof si de rai l s (Fi g. 52). Each fol ded ai rbag cush-
i on i s contai ned wi thi n a l ong extruded pl asti c chan-
nel that extends al ong the roof rai l from the A-pi l l ar
at the front of the vehi cl e to just behi nd the B-pi l l ar
on standard cab model s, and to just behi nd the C-pi l -
l ar on quad cab model s. A tether extends down the
A-pi l l ar from the front of the ai rbag cushi on, where i t
i s retai ned to the pi l l ar wi th pl asti c push-i n routi ng
cl i ps and i t i s secured to the base of the A-pi l l ar near
the bel t l i ne wi th a screw.
The hybri d-type i nfl ator for each ai rbag i s secured
to the roof rai l at the rear of the ai rbag uni t behi nd
the B-pi l l ar (standard cab) or C-pi l l ar (quad cab), and
i s connected to the ai rbag cushi on by a l ong tubul ar
mani fol d. The i nfl ator bracket and the extruded ai r-
bag cushi on channel are l ocated wi th pl asti c push-i n
fasteners to the roof rai l , then secured wi th screws to
spri ng nuts l ocated i n the roof rai l . A two-wi re take
out of the body wi re harness wi th a keyed and
l atched connector i nsul ator connects di rectl y to an
i ntegral receptacl e on the i nfl ator i ni ti ator.
The si de curtai n ai rbag uni t cannot be adjusted or
repai red and must be repl aced i f depl oyed, faul ty, or
i n any way damaged. Once a si de curtai n ai rbag has
been depl oyed, the compl ete ai rbag uni t, the head-
l i ner, the upper A, B, and C-pi l l ar tri m, and al l other
vi si bl y damaged components must be repl aced.
OPERATION
Each si de curtai n ai rbag i s depl oyed i ndi vi dual l y
by an el ectri cal si gnal generated by the Ai rbag Con-
trol Modul e (ACM) to whi ch i t i s connected through
l eft or ri ght curtai n ai rbag l i ne 1 and l i ne 2 (or
squi b) ci rcui ts. The hybri d-type i nfl ator assembl y for
each ai rbag contai ns a smal l cani ster of hi ghl y com-
Fig. 51 SRS Logo
Fig. 52 Side Curtain Airbag
2 - B-PILLAR (STD CAB) OR C-PILLAR (QUAD CAB)
3 - INFLATOR
4 - MANIFOLD
5 - ROOF SIDE RAIL
6 - A-PILLAR
7 - TETHER
8 - CHANNEL
SEAT BELT TURNING LOOP ADJ USTER (Continued)
pressed i nert gas. When the ACM sends the proper
el ectri cal si gnal to the ai rbag i nfl ator, the el ectri cal
energy creates enough heat to i gni te chemi cal pel l ets
wi thi n the i nfl ator. Once i gni ted, these chemi cal s
burn rapi dl y and produce the pressure necessary to
rupture a contai nment di sk i n the i nert gas cani ster.
The i nfl ator and i nert gas cani ster are seal ed and
connected to a tubul ar mani fol d so that al l of the
rel eased gas i s di rected i nto the fol ded si de curtai n
ai rbag cushi on, causi ng the cushi on to i nfl ate.
As the ai rbag cushi on i nfl ates i t wi l l drop down
from the roof rai l between the edge of the headl i ner
and the si de gl ass/body pi l l ars to form a curtai n-l i ke
cushi on to protect the vehi cl e occupants duri ng a si de
i mpact col l i si on. The front tether keeps the front por-
ti on of the si de curtai n bag taut, thus ensuri ng that
the bag wi l l depl oy i n the proper posi ti on. Fol l owi ng
the ai rbag depl oyment, the ai rbag cushi on qui ckl y
defl ates by venti ng the i nert gas through the l oose
weave of the cushi on fabri c, and the defl ated cushi on
hangs down l oosel y from the roof rai l .
REMOVAL
faul ty or damaged si de curtai n ai rbag. I f the ai rbag
i s faul ty or damaged, but not depl oyed, revi ew the
recommended procedures for handl i ng non-depl oyed
RESTRAI NTS). I f the si de curtai n ai rbag has been
MENT.
SKIN AND EYES.
FOREIGN MATERIAL FROM ENTERING THE SIDE
CURTAIN AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE SIDE CURTAIN AIRBAG CUSHION
AND THE HEADLINER. FAILURE TO OBSERVE THIS
(2) Remove the headl i ner from the vehi cl e. (Refer
to 23 - BODY/I NTERI OR/HEADLI NER -
REMOVAL).
(3) Remove the screw that secures the si de curtai n
ai rbag tether retai ner to the base of the A-pi l l ar near
the bel t l i ne (Fi g. 53).
(4) Di sengage the two si de curtai n ai rbag tether
pl asti c retai ner cl i ps from the A-pi l l ar.
Fig. 53 Side Curtain Airbag Remove/Install - Typical
1 - ROOF SIDE RAIL
2 - SPRING NUT (4 - STD CAB/6 - QUAD CAB)
3 - SCREW (4 - STD CAB/6 - QUAD CAB)
4 - CLIP (2)
5 - RIVET NUT
6 - SCREW
7 - SIDE CURTAIN AIRBAG
8 - RETAINER (3 - STD CAB/5 - QUAD CAB)
SIDE CURTAIN AIRBAG (Continued)
(5) Di sconnect the body wi re harness connector for
the si de curtai n ai rbag from the connector receptacl e
at the back of the ai rbag i nfl ator.
(6) Remove the four screws (standard cab) or si x
screws (quad cab) that secure the si de curtai n ai rbag
i nfl ator and mani fol d tube brackets to the nuts i n the
roof rai l .
(7) Grasp the extruded pl asti c si de curtai n ai rbag
channel fi rml y and pul l i t strai ght away from the
roof rai l far enough to di sengage al l three (standard
cab) or fi ve (quad cab) pl asti c push-i n fasteners that
secure i t.
(8) Remove the si de curtai n ai rbag from the vehi -
cl e as a uni t.
INSTALLATION
faul ty or damaged si de curtai n ai rbag. I f the ai rbag
i s faul ty or damaged, but not depl oyed, revi ew the
recommended procedures for handl i ng non-depl oyed
RESTRAI NTS). I f the si de curtai n ai rbag has been
MENT.
SKIN AND EYES.
FOREIGN MATERIAL FROM ENTERING THE SIDE
CURTAIN AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE SIDE CURTAIN AIRBAG CUSHION
AND THE HEADLINER. FAILURE TO OBSERVE THIS
(1) Posi ti on the si de curtai n ai rbag i nto the vehi cl e
as a uni t.
(2) Al i gn al l three (standard cab) or fi ve (quad cab)
pl asti c push-i n fasteners that secure the extruded
pl asti c si de curtai n ai rbag channel wi th thei r hol es
i n the roof si de rai l and push them strai ght i nto the
roof rai l unti l they are ful l y seated (Fi g. 53).
(3) Worki ng from the rear of the vehi cl e to the
front, i nstal l and ti ghten the four screws (standard
cab) or si x screws (quad cab) that secure the si de cur-
tai n ai rbag i nfl ator and mani fol d tube brackets to the
nuts i n the roof rai l . Ti ghten the screws to 5 Nm (40
i n. l bs.).
(4) Reconnect the body wi re harness connector for
the si de curtai n ai rbag to the connector receptacl e at
the back of the ai rbag i nfl ator. Be certai n the connec-
tor i s ful l y engaged and l atched.
(5) Engage the two si de curtai n ai rbag tether pl as-
ti c retai ner cl i ps i nto the A-pi l l ar.
si de curtai n ai rbag tether retai ner to the base of the
A-pi l l ar near the bel t l i ne. Ti ghten the screw to 6
Nm (55 i n. l bs.).
(7) Rei nstal l the headl i ner i nto the vehi cl e. (Refer
to 23 - BODY/I NTERI OR/HEADLI NER - I NSTALLA-
TI ON).
SIDE CURTAIN AIRBAG (Continued)
SIDE IMPACT SENSOR
DESCRIPTION
On vehi cl es equi pped wi th the opti onal si de curtai n
ai rbags, two si de i mpact sensors are used, one each
for the l eft and ri ght si des of the vehi cl e (Fi g. 54).
These sensors are mounted remotel y from the bi -di -
recti onal safi ng sensor that i s i nternal to the Ai rbag
Control Modul e (ACM). The si de i mpact sensors are
secured wi thi n the ri ght and l eft B-pi l l ars just above
the front seat bel t retractors and behi nd the l ower
B-pi l l ar tri m i n the passenger compartment.
The i mpact sensor housi ng has an i ntegral connec-
tor receptacl e, an i ntegral mounti ng stud, and an
i ntegral l ocati ng tab. A cavi ty i n the center of the
mol ded bl ack pl asti c i mpact sensor housi ng contai ns
the el ectroni c ci rcui try of the sensor, whi ch i ncl udes
an el ectroni c communi cati on chi p and an el ectroni c
i mpact sensor. Potti ng materi al fi l l s the cavi ty to seal
and protect the i nternal el ectroni c ci rcui try and com-
ponents. The si de i mpact sensors are each connected
to the vehi cl e el ectri cal system through a dedi cated
take out and connector of the body wi re harness.
The si de i mpact sensors cannot be repai red or
adjusted and, i f damaged or faul ty, they must be
repl aced.
OPERATION
The si de i mpact sensors are el ectroni c accel erome-
ters that sense the rate of vehi cl e decel erati on, whi ch
provi des veri fi cati on of the di recti on and severi ty of
an i mpact. Each sensor al so contai ns an el ectroni c
communi cati on chi p that al l ows the uni t to commu-
ni cate the sensor status as wel l as sensor faul t i nfor-
mati on to the mi croprocessor i n the Ai rbag Control
Modul e (ACM). The ACM mi croprocessor conti nu-
ousl y moni tors al l of the passi ve restrai nt system
el ectri cal ci rcui ts to determi ne the system readi ness.
I f the ACM detects a moni tored system faul t, i t sets
a Di agnosti c Troubl e Code (DTC) and control s the
ai rbag i ndi cator operati on accordi ngl y.
The i mpact sensors each recei ve battery current
and ground through dedi cated l eft and ri ght sensor
pl us and mi nus ci rcui ts from the ACM. The i mpact
sensors and the ACM communi cate by modul ati ng
the vol tage i n the sensor pl us ci rcui t. The hard wi red
ci rcui ts between the si de i mpact sensors and the
ACM may be di agnosed and tested usi ng conven-
ti onal di agnosti c tool s and procedures. However, con-
venti onal di agnosti c methods wi l l not prove
concl usi ve i n the di agnosi s of the ACM or the i mpact
sensors. The most rel i abl e, effi ci ent, and accurate
means to di agnose the i mpact sensors, the ACM, and
the el ectroni c message communi cati on between the
sensors and the ACM requi res the use of a DRBI I I
mati on.
REMOVAL
REMOVAL - STANDARD CAB
MENT.
Fig. 54 Side Impact Sensor
1 - SENSOR
2 - CONNECTOR RECEPTACLE
3 - STUD
DEATH, NEVER STRIKE OR DROP THE SIDE
IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT
SENSOR OR AFFECT ITS CALIBRATION. THE SIDE
IMPACT SENSOR ENABLES THE SYSTEM TO
DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN
IMPACT SENSOR IS ACCIDENTALLY DROPPED
DURING SERVICE, THE MODULE MUST BE
SCRAPPED AND REPLACED WITH A NEW UNIT.
MENT.
(1) Adjust the front seat to i ts most forward posi -
ti on for easi est access to the l ower B-pi l l ar tri m.
(3) Remove the front outboard seat bel t and retrac-
tor from the i nsi de of the B-pi l l ar. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/FRONT OUTBOARD
SEAT BELT & RETRACTOR - REMOVAL - STAN-
DARD CAB).
(4) Remove the nut that secures the si de i mpact
sensor stud to the i nner B-pi l l ar (Fi g. 55).
(5) Reach through the retractor mounti ng hol e i n
the i nner B-pi l l ar to access the si de i mpact sensor
and di sengage the l ocati ng pi n and mounti ng stud
from the hol es i n the i nner B-pi l l ar.
(6) Pul l the si de i mpact sensor out of the B-pi l l ar
far enough to access and di sconnect the body wi re
harness connector for the sensor from the sensor con-
nector receptacl e.
(7) Remove the si de i mpact sensor from the B-pi l -
l ar.
REMOVAL - QUAD CAB
MENT.
MENT.
(1) Adjust the front seat to i ts most forward posi -
ti on for easi est access to the l ower B-pi l l ar tri m.
(3) Remove the nut that secures the si de i mpact
sensor stud to the i nner B-pi l l ar (Fi g. 56).
(4) Reach through the l arge hol e above the retrac-
tor mounti ng hol e i n the i nner B-pi l l ar to access the
si de i mpact sensor and di sengage the l ocati ng pi n
and mounti ng stud from the hol es i n the i nner B-pi l -
l ar.
Fig. 55 Side Impact Sensor Remove/Install -
Standard Cab
1 - SIDE IMPACT SENSOR
3 - B-PILLAR
4 - NUT
SIDE IMPACT SENSOR (Continued)
(5) Pul l the si de i mpact sensor out through the
l arge hol e i n the B-pi l l ar far enough to access and
di sconnect the body wi re harness connector for the
sensor from the sensor connector receptacl e.
(6) Remove the si de i mpact sensor from the B-pi l -
l ar.
INSTALLATION
INSTALLATION - STANDARD CAB
MENT.
MENT.
(1) Posi ti on the si de i mpact sensor to the retractor
mounti ng hol e i n the i nner B-pi l l ar (Fi g. 55).
the si de i mpact sensor to the sensor connector recep-
tacl e.
(3) Reach through the retractor mounti ng hol e i n
the i nner B-pi l l ar to posi ti on and engage the l ocati ng
pi n and the stud on the si de i mpact sensor to the
l ocati ng sl ot and mounti ng hol e from the i nsi de of
the B-pi l l ar.
si de i mpact sensor stud to the i nner B-pi l l ar. Ti ghten
the nut to 8 Nm (70 i n. l bs.).
(5) Rei nstal l the front outboard seat bel t and
retractor to the i nsi de of the B-pi l l ar. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/FRONT OUTBOARD
SEAT BELT & RETRACTOR - I NSTALLATI ON -
STANDARD CAB).
INSTALLATION - QUAD CAB
MENT.
Fig. 56 Side Impact Sensor Remove/Install - Quad
Cab
1 - B-PILLAR
2 - SIDE IMPACT SENSOR
3 - NUT
MENT.
(1) Posi ti on the si de i mpact sensor to the l arge
hol e above the retractor mounti ng hol e i n the i nner
B-pi l l ar (Fi g. 56).
the si de i mpact sensor to the sensor connector recep-
tacl e.
(3) Reach through the l arge hol e above the retrac-
tor mounti ng hol e i n the i nner B-pi l l ar to posi ti on
and engage the l ocati ng pi n and the stud on the si de
i mpact sensor to the l ocati ng sl ot and mounti ng hol e
from the i nsi de of the B-pi l l ar.
si de i mpact sensor stud to the i nner B-pi l l ar. Ti ghten
the nut to 8 Nm (70 i n. l bs.).
SPEED CONTROL
TABLE OF CONTENTS
page page
SPEED CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - VACUUM
SUPPLY TEST . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - ROAD TEST . . . . 3
SPECIFICATIONS
TORQUE - SPEED CONTROL . . . . . . . . . . . . . 3
CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VACUUM RESERVOIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPEED CONTROL
DESCRIPTION
All 3. 7L/4. 7LGas Engines and/or Diesel With
Automatic Trans.
The speed control system i s operated by the use of
a cabl e and a vacuum control l ed servo. On al l
engi nes except di esel s, el ectroni c control of the speed
control system i s i ntegrated i nto the Powertrai n Con-
trol Modul e (PCM). I f equi pped wi th a di esel engi ne,
el ectroni c control of the speed control system i s i nte-
grated i nto the Engi ne Control Modul e (ECM). The
control s consi st of two steeri ng wheel mounted
swi tches. The swi tches are l abel ed: ON/OFF, RES/
ACCEL, SET, COAST, and CANCEL.
The system i s desi gned to operate at speeds above
30 mph (50 km/h).
WARNING: THE USE OF SPEED CONTROL 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 SLIP-
PERY.
5. 7L Gas
The speed control system i s ful l y el ectroni cal l y con-
trol l ed by the Powertrai n Control Modul e (PCM). A
cable and a vacuum controlled servo are not
used. This is a servo-less system. The control s
consi st of two steeri ng wheel mounted swi tches. The
swi tches are l abel ed: ON/OFF, RES/ACCEL, SET,
COAST, and CANCEL.
30 mph (50 km/h).
PERY.
DR SPEED CONTROL 8P - 1
5. 9L Diesel With Manual Trans.
The speed control system i s ful l y el ectroni cal l y con-
trol l ed by the Engi ne Control Modul e (ECM). A
cable and a vacuum controlled servo are not
used if the vehicle is equipped with a manual
transmission and a diesel engine. This is a ser-
vo-less system. The control s consi st of two steeri ng
wheel mounted swi tches. The swi tches are l abel ed:
ON/OFF, RES/ACCEL, SET, COAST, and CANCEL.
30 mph (50 km/h).
PERY.
OPERATION
When speed control i s sel ected by depressi ng the
ON swi tch, the PCM (the ECM wi th a di esel engi ne)
al l ows a set speed to be stored i n i ts RAM for speed
control . To store a set speed, depress the SET swi tch
whi l e the vehi cl e i s movi ng at a speed between 35
and 85 mph. I n order for the speed control to engage,
the brakes cannot be appl i ed, nor can the gear sel ec-
tor be i ndi cati ng the transmi ssi on i s i n Park or Neu-
tral .
The speed control can be di sengaged manual l y by:
Steppi ng on the brake pedal
Depressi ng the OFF swi tch
Depressi ng the CANCEL swi tch.
Depressi ng the cl utch pedal (i f equi pped).
NOTE: Depressing the OFF switch or turning off the
ignition switch will erase the set speed stored in
the PCM (the ECM with a diesel engine).
For added safety, the speed control system i s pro-
grammed to di sengage for any of the fol l owi ng condi -
ti ons:
An i ndi cati on of Park or Neutral
A rapi d i ncrease rpm (i ndi cates that the cl utch
has been di sengaged)
Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
The speed si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the coeffi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
The speed si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
Once the speed control has been di sengaged,
depressi ng the RES/ACCEL swi tch (when speed i s
greater than 30 mph) restores the vehi cl e to the tar-
get speed that was stored i n the PCM (the ECM wi th
a di esel engi ne).
Whi l e the speed control i s engaged, the dri ver can
i ncrease the vehi cl e speed by depressi ng the RES/AC-
CEL swi tch. The new target speed i s stored i n the
PCM (the ECM wi th a di esel engi ne) when the RES/
ACCEL i s rel eased. The PCM (the ECM wi th a di esel
engi ne) al so has a tap-up feature i n whi ch vehi cl e
speed i ncreases at a rate of approxi matel y 2 mph for
each momentary swi tch acti vati on of the RES/AC-
CEL swi tch.
A tap down feature i s used to decel erate wi thout
di sengagi ng the speed control system. To decel erate
from an exi sti ng recorded target speed, momentari l y
depress the COAST swi tch. For each swi tch acti va-
ti on, speed wi l l be l owered approxi matel y 1 mph.
DIAGNOSIS AND TESTING - VACUUM SUPPLY
TEST
3. 7L / 4. 7L Gas Powered Engines
3.7L/4.7L gas powered engi nes: actual engi ne vac-
uum, a vacuum reservoi r, a one-way check val ve and
vacuum l i nes are used to suppl y vacuum to the speed
control servo.
(1) Di sconnect vacuum hose at speed control servo
and i nstal l a vacuum gauge i nto the di sconnected
hose.
(2) Start engi ne and observe gauge at i dl e. Vac-
uum gauge shoul d read at l east ten i nches of mer-
cury.
(3) I f vacuum i s l ess than ten i nches of mercury,
determi ne source of l eak. Check vacuum l i ne to
engi ne for l eaks. Al so check actual engi ne i ntake
mani fol d vacuum. I f mani fol d vacuum does not meet
thi s requi rement, check for poor engi ne performance
and repai r as necessary.
(4) I f vacuum l i ne to engi ne i s not l eaki ng, check
for l eak at vacuum reservoi r. To l ocate and gai n
access to reservoi r, refer to Vacuum Reservoi r Remov-
al /I nstal l ati on i n thi s group. Di sconnect vacuum l i ne
at reservoi r and connect a hand-operated vacuum
pump to reservoi r fi tti ng. Appl y vacuum. Reservoi r
vacuum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace reservoi r.
8P - 2 SPEED CONTROL DR
SPEED CONTROL (Continued)
(5) Veri fy operati on of one-way check val ve and
check i t for l eaks.
(a) Locate one-way check val ve. The val ve i s
l ocated i n vacuum l i ne between vacuum reservoi r
and engi ne vacuum source. Di sconnect vacuum
hoses (l i nes) at each end of val ve.
(b) Connect a hand-operated vacuum pump to
reservoi r end of check val ve. Appl y vacuum. Vac-
uum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace one-way check val ve.
(c) Connect a hand-operated vacuum pump to
vacuum source end of check val ve. Appl y vacuum.
Vacuum shoul d fl ow through val ve. I f vacuum i s
not fl owi ng, repl ace one-way check val ve. Seal the
fi tti ng at opposi te end of val ve wi th a fi nger and
appl y vacuum. I f vacuum wi l l not hol d, di aphragm
wi thi n check val ve has ruptured. Repl ace val ve.
5. 7 Gas
Vacuum i s not used for any part of the speed con-
trol system i f equi pped wi th a 5.7L V-8 engi ne.
5. 9L Diesel Engine With Manual Trans.
Vacuum i s not used for any part of the speed con-
trol system i f equi pped wi th a di esel engi ne and a
manual transmi ssi on.
5. 9L Diesel Engines With Automatic Trans.
I f equi pped wi th a di esel powered engi ne and an
automati c transmi ssi on, an el ectri c vacuum pump
and vacuum l i nes are used to suppl y vacuum to the
speed control servo. A vacuum reservoi r i s not used.
DIAGNOSIS AND TESTING - ROAD TEST
Perform a vehi cl e road test to veri fy reports of
speed control system mal functi on. The road test
shoul d i ncl ude attenti on to the speedometer. Speed-
ometer operati on shoul d be smooth and wi thout fl ut-
ter at al l speeds.
Fl utter i n the speedometer i ndi cates a probl em
whi ch mi ght cause surgi ng i n the speed control sys-
tem. The cause of any speedometer probl ems shoul d
be corrected before proceedi ng. Refer to I nstrument
Cl uster for speedometer di agnosi s.
I f a road test veri fi es a system probl em and the
speedometer operates properl y, check for:
A Di agnosti c Troubl e Code (DTC). I f a DTC
exi sts, conduct tests per the Powertrai n Di agnosti c
Procedures servi ce manual .
A mi sadjusted brake (stop) l amp swi tch. Thi s
coul d al so cause an i ntermi ttent probl em.
Loose, damaged or corroded el ectri cal connec-
ti ons at the servo (i f used). Corrosi on shoul d be
removed from el ectri cal termi nal s and a l i ght coati ng
of Mopar Mul ti Purpose Grease, or equi val ent,
appl i ed.
Leaki ng vacuum reservoi r (i f used).
Loose or l eaki ng vacuum hoses or connecti ons (i f
used).
Defecti ve one-way vacuum check val ve (i f used).
Secure attachment of both ends of the speed con-
trol servo cabl e (i f used).
Smooth operati on of throttl e l i nkage (i f used)
and throttl e body ai r val ve.
Fai l ed speed control servo (i f used). Do the servo
vacuum test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
SPECIFICATIONS
TORQUE - SPEED CONTROL
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Servo Mounting Bracket-
to-Servo Nuts
7 - 60
Servo Mounting Bracket-
to-Battery Tray Screws
4 - 30
Speed Control Switch
Mounting Screws
1.7 - 15
Vacuum Reservoir
Mounting Nuts
3 - 20
SPEED CONTROL (Continued)
CABLE
DESCRIPTION
The speed control servo cabl e i s connected between
the speed control vacuum servo di aphragm and the
throttl e body control l i nkage. Thi s cabl e i s used wi th
3.7L/4.7L gas powered engi nes onl y. I t i s al so used i f
equi pped wi th a 5.9L di esel engi ne equi pped wi th an
automati c transmi ssi on.
A speed control servo cabl e is not used i f equi pped
wi th ei ther a 5.9L di esel engi ne equi pped wi th a
manual transmi ssi on, or any 5.7L engi ne/transmi s-
si on combi nati ons.
OPERATION
Thi s cabl e causes the throttl e control l i nkage to
open or cl ose the throttl e val ve i n response to move-
ment of the vacuum servo di aphragm.
REMOVAL
3. 7L / 4. 7L GAS
(2) Remove ai r i ntake tube at top of throttl e body.
The accel erator cabl e must be parti al l y removed to
gai n access to speed control cabl e.
(3) Hol d throttl e i n wi de open posi ti on. Whi l e hel d
i n thi s posi ti on, sl i de throttl e cabl e pi n (Fi g. 1) from
throttl e body bel l crank.
(4) Usi ng a pi ck or smal l screwdri ver, press rel ease
tab (Fi g. 2) to rel ease pl asti c cabl e mount from
bracket. Press on tab only enough to release
cable from bracket. If tab is pressed too much,
it will be broken. Sl i de pl asti c mount (Fi g. 2)
towards ri ght si de of vehi cl e to remove throttl e cabl e
from throttl e body bracket.
(5) Usi ng fi nger pressure onl y, di sconnect servo
cabl e connector (Fi g. 3) at throttl e body bel l crank pi n
by pushi ng connector off bel l crank pi n towards front
of vehi cl e. DO NOT try to pull connector off per-
pendicular to the bellcrank pin. Connector will
be broken.
(6) Sl i de speed control cabl e pl asti c mount towards
ri ght of vehi cl e to remove cabl e from throttl e body
bracket (Fi g. 4).
(7) Remove servo cabl e from servo. Refer to Servo
5. 9L Diesel Auto. Trans.
batteri es.
(2) Remove cabl e/l ever/l i nkage cover. Refer to
Speed Control Servo Removal /I nstal l ati on.
(3) Remove (di sconnect) servo cabl e from servo.
Refer to Speed Control Servo Removal /I nstal l ati on.
(4) Usi ng fi nger pressure onl y, di sconnect end of
servo cabl e from throttl e l ever pi n by pul l i ng forward
on connector whi l e hol di ng l ever rearward (Fi g. 5).
DO NOT try to pull connector off perpendicular
to lever pin. Connector will be broken.
(5) Squeeze 2 pi nch tabs (Fi g. 5) on si des of speed
control cabl e at mounti ng bracket and push cabl e
rearward out of bracket.
Fig. 1 THROTTLE CABLE PIN - 3.7L / 4.7L
1 - THROTTLE CABLE PIN
2 - THROTTLE BODY BELLCRANK
3 - PUSH UP HERE
Fig. 2 THROTTLE CABLE RELEASE TAB - 3.7L /
4.7L
1 - THROTTLE CABLE
2 - RELEASE TAB
3 - PICK OR SCREWDRIVER
4 - PLASTIC CABLE MOUNT
(6) Remove cabl e from vehi cl e.
INSTALLATION
3. 7L / 4. 7L Gas
(1) I nstal l end of cabl e to speed control servo.
Refer to Servo Removal /I nstal l ati on.
(2) Sl i de speed control cabl e pl asti c mount i nto
throttl e body bracket.
(3) I nstal l speed control cabl e connector onto throt-
tl e body bel l crank pi n (push rearward to snap i nto
l ocati on).
(4) Sl i de throttl e (accel erator) cabl e pl asti c mount
i nto throttl e body bracket. Conti nue sl i di ng unti l
cabl e rel ease tab i s al i gned to hol e i n throttl e body
mounti ng bracket.
(5) Whi l e hol di ng throttl e to wi de open posi ti on,
pl ace throttl e cabl e pi n i nto throttl e body bel l crank.
(6) I nstal l ai r i ntake tube to top of throttl e body.
(7) Connect negati ve battery cabl e at battery.
(8) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
5. 9L Diesel Auto. Trans.
(1) I nstal l (connect) end of speed control servo
cabl e to speed control servo. Refer to Speed Control
Servo Removal /I nstal l ati on.
(2) I nstal l cabl e through mounti ng hol e on mount-
i ng bracket. Cabl e snaps i nto bracket.
(3) Connect servo cabl e to throttl e l ever by push-
i ng cabl e connector rearward onto l ever pi n whi l e
hol di ng l ever forward.
(4) Connect negati ve battery cabl es to both batter-
i es.
Fig. 3 SPEED CONTROL CABLE AT BELLCRANK -
3.7L / 4.7L
2 - SPEED CONTROL CABLE CONNECTOR
Fig. 4 SPEED CONTROL CABLE AT BRACKET - 3.7L
/ 4.7L
1 - THROTTLE CABLE BRACKET
3 - SPEED CONTROL CABLE
Fig. 5 SERVO CABLE AT THROTTLE LEVER 5.9L
DIESEL
1 - PINCH (2) TABS
2 - CABLE MOUNTING BRACKET
3 - PINCH TABS (2)
4 - OFF
5 - THROTTLE CABLE
6 - THROTTLE LEVER
7 - THROTTLE LEVER PIN
8 - OFF
9 - CONNECTOR
CABLE (Continued)
(6) I nstal l cabl e/l ever cover.
SERVO
DESCRIPTION
A speed control servo is not used with any
5.7L V-8 engine, or with the 5.9L diesel engine
when equipped with a manual transmission.
The speed control servo i s attached to the bottom
of the battery tray.
The servo uni t consi sts of a sol enoi d val ve body,
and a vacuum chamber. The sol enoi d val ve body con-
tai ns three sol enoi ds:
Vacuum
Vent
Dump
The vacuum chamber contai ns a di aphragm wi th a
cabl e attached to control the throttl e l i nkage.
OPERATION
A speed control servo is not used with any
5.7L V-8 engine, or with the 5.9L diesel engine
when equipped with a manual transmission.
The following information applies only to
vehicles equipped with a mechanical servo.
When/i f a servo i s used on gasol i ne powered vehi -
cl es, the Powertrai n Control Modul e (PCM) control s
the sol enoi d val ve body. When/i f a servo i s used on
certai n di esel powered vehi cl es, the Engi ne Control
Modul e (ECM) control s the sol enoi d val ve body. The
sol enoi d val ve body control s the appl i cati on and
rel ease of vacuum to the di aphragm of the vacuum
servo. The servo uni t cannot be repai red and i s ser-
vi ced onl y as a compl ete assembl y.
Power i s suppl i ed to the servos by the PCM/ECM
through the brake swi tch. The PCM/ECM control s
the ground path for the vacuum and vent sol enoi ds.
The dump sol enoi d i s energi zed anyti me i t recei ves
power. I f power to the dump sol enoi d i s i nterrupted,
the sol enoi d dumps vacuum i n the servo. Thi s pro-
vi des a safety backup to the vent and vacuum sol e-
noi ds.
The vacuum and vent sol enoi ds must be grounded
at the PCM/ECM to operate. When the PCM/ECM
grounds the vacuum servo sol enoi d, the sol enoi d
al l ows vacuum to enter the servo and pul l open the
throttl e pl ate usi ng the cabl e. When the PCM/ECM
breaks the ground, the sol enoi d cl oses and no more
vacuum i s al l owed to enter the servo. The PCM/ECM
al so operates the vent sol enoi d vi a ground. The vent
sol enoi d opens and cl oses a passage to bl eed or hol d
vacuum i n the servo as requi red.
The PCM/ECM duty cycl es the vacuum and vent
sol enoi ds to mai ntai n the set speed, or to accel erate
and decel erate the vehi cl e. To i ncrease throttl e open-
i ng, the PCM/ECM grounds the vacuum and vent
sol enoi ds. To decrease throttl e openi ng, the PCM/
ECM removes the grounds from the vacuum and
vent sol enoi ds. When the brake i s rel eased, i f vehi cl e
speed exceeds 30 mph to resume, 35 mph to set, and
the RES/ACCEL swi tch has been depressed, ground
for the vent and vacuum ci rcui ts i s restored.
REMOVAL
The speed control servo assembl y i s attached to the
bottom of the battery tray (Fi g. 6).
(1) Di sconnect negati ve battery cabl e at battery
(both cabl es at both batteri es i f di esel ).
(2) To gai n access to servo, remove pl asti c wheel -
house spl ash shi el d over l eft-front wheel .
(3) Di sconnect vacuum l i ne at servo (Fi g. 6).
(4) Di sconnect el ectri cal connector at servo (Fi g. 6).
(5) Remove 3 servo mounti ng screws (Fi g. 6).
Dependi ng on engi ne appl i cati on, di fferent sets of
mounti ng l ugs (Fi g. 6) are used to support servo to
battery tray. Whi l e removi ng, note proper l ugs.
(6) Di sconnect servo cabl e at throttl e body. Refer to
Servo Cabl e Removal /I nstal l ati on.
(7) Remove 2 mounti ng nuts hol di ng servo cabl e
sl eeve to bracket (Fi g. 7).
(8) Pul l speed control cabl e sl eeve and servo away
from servo mounti ng bracket to expose cabl e retai n-
i ng cl i p (Fi g. 7) and remove cl i p. Note: The servo
mounti ng bracket di spl ayed i n (Fi g. 7) i s a typi cal
bracket and may/may not be appl i cabl e to thi s model
vehi cl e.
(9) Remove servo from mounti ng bracket. Whi l e
removi ng, note ori entati on of servo to bracket.
INSTALLATION
(1) Posi ti on servo to mounti ng bracket (Fi g. 7).
(2) Al i gn hol e i n cabl e connector wi th hol e i n servo
pi n. I nstal l cabl e-to-servo retai ni ng cl i p (Fi g. 7).
(3) I nsert servo mounti ng studs through hol es i n
servo mounti ng bracket.
(4) I nstal l 2 servo-to-mounti ng bracket nuts and
ti ghten. Refer to torque speci fi cati ons.
(5) Posi ti on servo assembl y to correct mounti ng
l ugs on battery tray (Fi g. 6) and i nstal l 3 screws.
Ti ghten 3 screws. Refer to torque speci fi cati ons.
(6) Connect vacuum l i ne at servo.
(7) Connect el ectri cal connector at servo.
(8) Connect servo cabl e to throttl e body. Refer to
servo Cabl e Removal /I nstal l ati on.
(9) I nstal l l eft-front wheel -wel l l i ner.
(10) Connect negati ve battery cabl e to battery
(connect both cabl es i f di esel ).
CABLE (Continued)
SWITCH
DESCRIPTION
Two separate swi tch pods operate the speed control
system. The steeri ng-wheel -mounted swi tches use
mul ti pl exed ci rcui ts to provi de i nputs to the PCM (to
the ECM for di esel ) for ON, OFF, RESUME, ACCEL-
ERATE, SET, DECEL and CANCEL modes. Refer to
the owners manual for more i nformati on on speed
control swi tch functi ons and setti ng procedures.
The i ndi vi dual swi tches cannot be repai red. I f one
swi tch fai l s, the enti re swi tch modul e must be
repl aced.
Depending on engine control computer (J TEC
having a 3 plug connector or NGC having a 4
plug connector), 2 types of switches are used.
Both types of switches are internally and exter-
nally different. The switch used with the NGC
system has an attached pigtail lead. The switch
used with the J TEC system does not have an
attached pigtail lead.
OPERATION
When speed control i s sel ected by depressi ng the
ON, OFF swi tch, the PCM (ECM for diesel) al l ows
a set speed to be stored i n i ts RAM for speed control .
To store a set speed, depress the SET swi tch whi l e
the vehi cl e i s movi ng at a speed between approxi -
matel y 35 and 85 mph. I n order for the speed control
to engage, the brakes cannot be appl i ed, nor can the
gear sel ector be i ndi cati ng the transmi ssi on i s i n
Park or Neutral .
The speed control can be di sengaged manual l y by:
Steppi ng on the brake pedal
Depressi ng the OFF swi tch
Depressi ng the CANCEL swi tch.
The speed control can be di sengaged al so by any of
the fol l owi ng condi ti ons:
An i ndi cati on of Park or Neutral (auto. trans.)
The VSS si gnal i ncreases at a rate of 10 mph
per second (i ndi cates that the co-effi ci ent of fri cti on
between the road surface and ti res i s extremel y l ow)
Depressi ng the cl utch pedal (manual trans.).
Excessi ve engi ne rpm (i ndi cates that the trans-
mi ssi on may be i n a l ow gear)
The VSS si gnal decreases at a rate of 10 mph
per second (i ndi cates that the vehi cl e may have
decel erated at an extremel y hi gh rate)
I f the actual speed i s not wi thi n 20 mph of the
set speed
Fig. 6 SPEED CONTROL SERVO LOCATION
1 - BATTERY TRAY
2 - MOUNTING LUGS
3 - SERVO
4 - ELEC. CONNEC.
5 - MOUNTING SCREWS (3)
7 - VACUUM LINE
Fig. 7 SERVO CABLE CLIP REMOVE/INSTALL
TYPICAL
1 - SERVO MOUNTING NUTS (2)
2 - SERVO
3 - CABLE RETAINING CLIP
4 - SERVO CABLE AND SLEEVE
SERVO (Continued)
The previ ous di sengagement condi ti ons are pro-
grammed for added safety.
Once the speed control has been di sengaged,
depressi ng the ACCEL swi tch restores the vehi cl e to
the target speed that was stored i n the PCMs RAM
(ECM for diesel).
NOTE: Depressing the OFF switch will erase the set
speed stored in the PCMs/ECMs RAM.
I f, whi l e the speed control i s engaged, the dri ver
wi shes to i ncrease vehi cl e speed, the PCM (ECM for
diesel) i s programmed for an accel erati on feature.
Wi th the ACCEL swi tch hel d cl osed, the vehi cl e
accel erates sl owl y to the desi red speed. The new tar-
get speed i s stored i n the PCMs/ECMs RAM when
the ACCEL swi tch i s rel eased. The PCM/ECM al so
has a tap-up feature i n whi ch vehi cl e speed
i ncreases at a rate of approxi matel y 2 mph for each
momentary swi tch acti vati on of the ACCEL swi tch.
The PCM/ECM al so provi des a means to decel erate
wi thout di sengagi ng speed control . To decel erate from
an exi sti ng recorded target speed, depress and hol d
the COAST swi tch unti l the desi red speed i s reached.
Then rel ease the swi tch. The ON, OFF swi tch oper-
ates two components: the PCMs/ECMs ON, OFF
i nput, and the battery vol tage to the brake swi tch.
REMOVAL
Depending on engine control computer (J TEC
having a 3plug connector or 5.7L V-8 NGC hav-
ing a 4plug connector), 2 types of switches are
used. Both types of switches are internally and
externally different. The switches used with the
NGC systemhave attached pigtail leads (Fig. 9).
The switch used with the J TEC systemdoes not
have an attached pigtail lead.
(1) Remove swi tch mounti ng screw (Fi g. 8). or
(Fi g. 9)
(2) Pul l swi tch from steeri ng wheel .
(3) Unpl ug el ectri cal connector from swi tch (Fi g.
8), or, swi tch pi gtai l wi re harness from steeri ng
wheel wi re harness (Fi g. 9) and remove swi tch.
INSTALLATION
(1) Pl ug el ectri cal connector i nto swi tch (Fi g. 8), or
connect pi gtai l wi re harness to steeri ng wheel wi re
harness (Fi g. 9). Be sure wi res are not pi nched.
(2) Posi ti on swi tch to steeri ng wheel .
(3) I nstal l swi tch mounti ng screw and ti ghten.
Refer to torque speci fi cati ons.
Fig. 8 SPEED CONTROL SWITCHES (EXCEPT 5.7L
V-8 ENGINE)
1 - ELECTRICAL CONNECTORS
2 - MOUNTING SCREWS
3 - RIGHT SWITCH
4 - LEFT SWITCH
Fig. 9 SPEED CONTROL SWITCHES (WITH 5.7L V-8
ENGINE)
1 - MOUNTING SCREWS
2 - RIGHT SWITCH
3 - LEFT SWITCH
4 - PIGTAIL LEADS
SWITCH (Continued)
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoi r i s a pl asti c storage tank con-
nected to an engi ne vacuum source by vacuum l i nes.
A vacuum reservoi r i s not used wi th di esel engi nes or
the 5.7L gas powered engi ne.
OPERATION
The vacuum reservoi r i s used to suppl y the vac-
uum needed to mai ntai n proper speed control opera-
ti on when engi ne vacuum drops, such as i n cl i mbi ng
a grade whi l e dri vi ng. A one-way check val ve i s used
i n the vacuum l i ne between the reservoi r and the
vacuum source. Thi s check val ve i s used to trap
engi ne vacuum i n the reservoi r. On certai n vehi cl e
appl i cati ons, thi s reservoi r i s shared wi th the heat-
i ng/ai r-condi ti oni ng system. The vacuum reservoi r
cannot be repai red and must be repl aced i f faul ty.
RESERVOIR
(1) Di sconnect vacuum hose at speed control servo
and i nstal l a vacuum gauge i nto the di sconnected
hose.
(2) Start engi ne and observe gauge at i dl e. Vac-
uum gauge shoul d read at l east ten i nches of mer-
cury.
(3) I f vacuum i s l ess than ten i nches of mercury,
determi ne source of l eak. Check vacuum l i ne to
engi ne for l eaks. Al so check actual engi ne i ntake
mani fol d vacuum. I f mani fol d vacuum does not meet
thi s requi rement, check for poor engi ne performance
and repai r as necessary.
(4) I f vacuum l i ne to engi ne i s not l eaki ng, check
for l eak at vacuum reservoi r. To l ocate and gai n
access to reservoi r, refer to Vacuum Reservoi r Remov-
al /I nstal l ati on i n thi s group. Di sconnect vacuum l i ne
at reservoi r and connect a hand-operated vacuum
pump to reservoi r fi tti ng. Appl y vacuum. Reservoi r
vacuum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace reservoi r.
(5) Veri fy operati on of one-way check val ve and
check i t for l eaks. Certain models may be
equipped with 2 check-valves.
(a) Locate one-way check val ve. The val ve i s
l ocated i n vacuum l i ne between vacuum reservoi r
and engi ne vacuum source. Di sconnect vacuum
hoses (l i nes) at each end of val ve.
(b) Connect a hand-operated vacuum pump to
reservoi r end of check val ve. Appl y vacuum. Vac-
uum shoul d not bl eed off. I f vacuum i s bei ng l ost,
repl ace one-way check val ve.
(c) Connect a hand-operated vacuum pump to
vacuum source end of check val ve. Appl y vacuum.
Vacuum shoul d fl ow through val ve. I f vacuum i s
not fl owi ng, repl ace one-way check val ve. Seal the
fi tti ng at opposi te end of val ve wi th a fi nger and
appl y vacuum. I f vacuum wi l l not hol d, di aphragm
wi thi n check val ve has ruptured. Repl ace val ve.
REMOVAL
The vacuum reservoi r i s l ocated i n the engi ne com-
partment under the fresh ai r cowl gri l l panel (Fi g.
10).
(1) Remove wi per bl ades and arms. Refer to Wi per
Arm Removal / I nstal l ati on i n the Wi pers / Washers
secti on.
(2) Remove fresh ai r cowl gri l l . Refer to Cowl Gri l l
Removal / I nstal l ati on.
(3) Di sconnect vacuum l i ne at reservoi r (Fi g. 11).
(4) Remove 2 reservoi r mounti ng nuts (Fi g. 11).
(5) Remove reservoi r from cowl .
Fig. 10 VACUUM RESERVOIR LOCATION
1 - COWL GRILL
2 - WIPER ARMS / BLADES
3 - VACUUM RESERVOIR
INSTALLATION
(1) Posi ti on reservoi r onto 2 wel d studs (Fi g. 11).
(2) I nstal l 2 mounti ng nuts and ti ghten. Refer to
(3) Connect vacuum l i ne to reservoi r fi tti ng.
(4) I nstal l cowl gri l l . Refer to Cowl Gri l l Removal /
I nstal l ati on.
(5) I nstal l wi per arms /bl ades. Refer to Wi per Arm
Removal / I nstal l ati on.
Fig. 11 VACUUM RESERVOIR REMOVAL /
INSTALLATION
1 - COWL (BELOW WIPER ARMS)
2 - VACUUM LINE CONNECTION
3 - MOUNTING NUTS (2)
4 - VACUUM RESERVOIR
5 - WELDED STUDS
VACUUM RESERVOIR (Continued)
VEHICLE THEFT SECURITY
TABLE OF CONTENTS
page page
DESCRIPTION
DESCRIPTION - VEHICLE THEFT/
SECURITY SYSTEM . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - SENTRY KEY
IMMOBILIZER SYSTEM (SKIS) . . . . . . . . . . . . 1
DESCRIPTION SENTRY KEY
IMMOBILIZER MODULE (SKIM) . . . . . . . . . . . . 1
OPERATION
OPERATION - VEHICLE THEFT/SECURITY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION - SENTRY KEY IMMOBILIZER
SYSTEM (SKIS) . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION SENTRY KEY IMMOBILIZER
MODULE (SKIM) . . . . . . . . . . . . . . . . . . . . . . . 2
VEHICLE THEFT SECURITY SYSTEM . . . . . . 3
STANDARD PROCEDURE
CONFIGURING A NEW MODULE / SWITCH
OPERATING MODES. . . . . . . . . . . . . . . . . . . . 3
SENTRY KEY IMMOBILIZER SYSTEM
INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSPONDER PROGRAMMING. . . . . . . . . . 4
INDICATOR LAMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DESCRIPTION
DESCRIPTION - VEHICLE THEFT/SECURITY
SYSTEM
The Vehi cl e Theft/Securi ty System (VTSS) i s
desi gned to protect agai nst whol e vehi cl e theft. The
system moni tors the vehi cl e doors and i gni ti on for
unauthori zed operati on.
The VTSS acti vates:
Soundi ng of the horn
Fl ashi ng of the park l amps
Fl ashi ng of the head l amps
The Remote Keyl ess Entry (RKE) has 1 mode of
operati on, CUSTOMER USAGE mode. The cus-
tomer usage mode provi des ful l functi onal i ty of the
modul e and i s the mode i n whi ch the RKE modul e
shoul d be operati ng when used by the customer.
DESCRIPTION - SENTRY KEY IMMOBILIZER
SYSTEM (SKIS)
The Sentry Key I mmobi l i zer System (SKI S) i s
desi gned to provi de passi ve protecti on agai nst unau-
thori zed vehi cl e use by preventi ng the engi ne from
operati ng whi l e the system i s armed. The pri mary
components of thi s system are the Sentry Key I mmo-
bi l i zer Modul e (SKI M), the Sentry Key transponder,
the Vehi cl e Theft/Securi ty System (VTSS) i ndi cator
LED, and the Powertrai n Control Modul e (PCM).
The SKI M i s i nstal l ed on the steeri ng col umn near
the i gni ti on l ock cyl i nder. The transponder i s l ocated
under the mol ded rubber cap on the head of the i gni -
ti on key. The VTSS i ndi cator LED i s l ocated i n the
DESCRIPTION SENTRY KEY IMMOBILIZER
MODULE (SKIM)
The Sentry Key I mmobi l i zer Modul e (SKI M) con-
tai ns a Radi o Frequency (RF) transcei ver and a cen-
tral processi ng uni t, whi ch i ncl udes the Sentry Key
I mmobi l i zer System (SKI S) program l ogi c. The SKI S
programmi ng enabl es the SKI M to program and
retai n i n memory the codes of at l east two, but no
more than ei ght el ectroni cal l y coded Sentry Key
transponders. The SKI S programmi ng al so enabl es
the SKI M to communi cate over the Programmabl e
Communi cati on I nterface (PCI ) bus network wi th the
Powertrai n Control Modul e (PCM), and/or the
DRBI I I scan tool .
OPERATION
OPERATION - VEHICLE THEFT/SECURITY
SYSTEM
When i n the Customer Usage mode of operati on,
the system i s armed when the vehi cl e i s l ocked usi ng
the:
Power Door Lock Swi tches
Remote Keyl ess Entry (RKE) Transmi tter
Key Cyl i nder Swi tches
DR VEHICLE THEFT SECURITY 8Q - 1
After the vehi cl e i s l ocked and the l ast door i s
cl osed, the VTSS i ndi cator i n the i nstrument cl uster
wi l l fl ash qui ckl y for 16 seconds, i ndi cati ng that the
armi ng i s i n process. After 16 seconds, the LED wi l l
conti nue to fl ash at a sl ower rate i ndi cati ng that the
system i s armed.
VTSS di sarmi ng occurs upon normal vehi cl e entry
by unl ocki ng ei ther door vi a the key cyl i nder or RKE
transmi tter, or by starti ng the vehi cl e wi th a val i d
Sentry Key. Thi s di sarmi ng wi l l al so hal t the al arm
once i t has been acti vated.
A tamper al ert exi sts to noti fy the dri ver that the
system has been acti vated. Thi s al ert consi sts of 3
horn pul ses and the securi ty tel l tal e fl ashi ng for 30
seconds when the vehi cl e i s di sarmed. The tamper
al ert wi l l not occur i f di sarmed whi l e al armi ng.
The VTSS wi l l not arm by mechani cal l y l ocki ng the
vehi cl e doors. Thi s wi l l manual l y overri de the sys-
tem.
OPERATION - SENTRY KEY IMMOBILIZER
SYSTEM (SKIS)
The SKI S i ncl udes two val i d Sentry Key transpon-
ders from the factory. These two Sentry Keys can be
used to program addi ti onal non-coded bl ank Sentry
Keys. These bl ank keys can be cut to match a val i d
i gni ti on key, but the engi ne wi l l not start unl ess the
key transponder i s al so programmed to the vehi cl e.
The SKI S wi l l recogni ze no more than ei ght val i d
Sentry Key transponders at any one ti me.
The SKI S performs a sel f-test each ti me the i gni -
ti on swi tch i s turned to the ON posi ti on, and wi l l
store Di agnosti c Troubl e Codes (DTCs) i f a system
mal functi on i s detected. The SKI S can be di agnosed,
and any stored DTC can be retri eved usi ng a
DRBI I I scan tool as descri bed i n the proper Power-
trai n Di agnosti c Procedures manual .
OPERATION SENTRY KEY IMMOBILIZER
MODULE (SKIM)
The SKI M transmi ts and recei ves RF si gnal s
through a tuned antenna encl osed wi thi n a mol ded
pl asti c ri ng formati on that i s i ntegral to the SKI M
housi ng. When the SKI M i s properl y i nstal l ed on the
steeri ng col umn, the antenna ri ng i s ori ented around
the ci rcumference of the i gni ti on l ock cyl i nder hous-
i ng. Thi s antenna ri ng must be l ocated wi thi n ei ght
mi l l i meters (0.31 i nches) of the Sentry Key i n order
to ensure proper RF communi cati on between the
SKI M and the Sentry Key transponder.
For added system securi ty, each SKI M i s pro-
grammed wi th a uni que Secret Key code and a
securi ty code. The SKI M keeps the Secret Key code
i n memory. The SKI M al so sends the Secret Key
code to each of the programmed Sentry Key tran-
sponders. The securi ty code i s used by the assembl y
pl ant to access the SKI S for i ni ti al i zati on, or by the
deal er techni ci an to access the system for servi ce.
The SKI M al so stores i n i ts memory the Vehi cl e
I denti fi cati on Number (VI N), whi ch i t l earns through
a PCI bus message from the PCM duri ng i ni ti al i za-
ti on.
The SKI M and the PCM both use software that
i ncl udes a rol l i ng code al gori thm strategy, whi ch
hel ps to reduce the possi bi l i ty of unauthori zed SKI S
di sarmi ng. The rol l i ng code al gori thm ensures secu-
ri ty by preventi ng an overri de of the SKI S through
the unauthori zed substi tuti on of the SKI M or the
PCM. However, the use of thi s strategy al so means
that repl acement of ei ther the SKI M or the PCM
uni ts wi l l requi re a system i ni ti al i zati on procedure to
restore system operati on.
When the i gni ti on swi tch i s turned to the ON or
START posi ti ons, the SKI M transmi ts an RF si gnal
to exci te the Sentry Key transponder. The SKI M then
l i stens for a return RF si gnal from the transponder
of the Sentry Key that i s i nserted i n the i gni ti on l ock
cyl i nder. I f the SKI M recei ves an RF si gnal wi th
val i d Secret Key and transponder i denti fi cati on
codes, the SKI M sends a val i d key message to the
PCM over the PCI bus. I f the SKI M recei ves an
i nval i d RF si gnal or no response, i t sends i nval i d
key messages to the PCM. The PCM wi l l enabl e or
di sabl e engi ne operati on based upon the status of the
SKI M messages.
The SKI M al so sends messages to the I nstrument
Cl uster whi ch control s the VTSS i ndi cator. The
SKI M sends messages to the I nstrument Cl uster to
turn the i ndi cator on for about three seconds when
the i gni ti on swi tch i s turned to the ON posi ti on as a
bul b test. After compl eti on of the bul b test, the
SKI M sends bus messages to keep the i ndi cator off
for a durati on of about one second. Then the SKI M
sends messages to turn the i ndi cator on or off based
upon the resul ts of the SKI S sel f-tests. I f the VTSS
i ndi cator comes on and stays on after the bul b test,
i t i ndi cates that the SKI M has detected a system
mal functi on and/or that the SKI S has become i noper-
ati ve.
I f the SKI M detects an i nval i d key when the i gni -
ti on swi tch i s turned to the ON posi ti on, i t sends
messages to fl ash the VTSS i ndi cator. The SKI M can
al so send messages to fl ash the i ndi cator to serve as
an i ndi cati on to the customer that the SKI S has been
pl aced i n i ts Customer Learn programmi ng mode.
See Sentry Key I mmobi l i zer System Transponder
Programmi ng i n thi s secti on for more i nformati on on
the Customer Learn programmi ng mode.
For di agnosi s or i ni ti al i zati on of the SKI M and the
PCM, a DRBI I I scan tool and the proper Powertrai n
Di agnosti c Procedures manual are requi red. The
8Q - 2 VEHICLE THEFT SECURITY DR
VEHICLE THEFT SECURITY (Continued)
SKI M cannot be repai red and, i f faul ty or damaged,
the uni t must be repl aced.
VEHICLE THEFT SECURITY SYSTEM
BAGS, REFER TO RESTRAINT SYSTEMS BEFORE
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PERSONAL INJURY.
NOTE: The most reliable, efficient, and accurate
means to diagnose the Vehicle Theft Security Sys-
tem (VTSS) and Sentry Key Immobilizer System
(SKIS) involves the use of a DRBlll scan tool and
the proper Powertrain Diagnostic Procedures man-
ual.
The Vehi cl e Theft Securi ty System (VTSS), Sentry
Key I mmobi l i zer System (SKI S) and the Programma-
bl e Communi cati on I nterface (PCI ) bus network
shoul d be di agnosed usi ng a DRBI I I scan tool . The
DRBI I I wi l l al l ow confi rmati on that the PCI bus i s
functi onal , that the Sentry Key I mmobi l i zer Modul e
(SKI M) i s pl aci ng the proper messages on the PCI
bus, and that the Powertrai n Control Modul e (PCM)
and the I nstrument Cl uster are recei vi ng the PCI
bus messages. Refer to the proper Powertrai n or
Body Di agnosti c Procedures manual .
Vi sual l y i nspect the rel ated wi ri ng harness connec-
tors. Look for broken, bent, pushed out or corroded
termi nal s. I f any of the condi ti ons are present, repai r
as necessary. Refer to Wi ri ng Di agrams for compl ete
ci rcui t descri pti ons and di agrams. Refer to 8 - ELEC-
TRI CAL/ELECTRONI C CONTROL MODULES/SEN-
TRY KEY I MMOBI LI ZER MODULE - REMOVAL for
SKI M repl acement.
STANDARD PROCEDURE
CONFIGURING A NEW MODULE / SWITCH
OPERATING MODES
To confi gure a new modul e or to swi tch operati ng
modes, a DRBI I I scan tool must be used.
(1) Hook up the DRBI I I scan tool to the Data
Li nk Connector (DLC).
(2) Wi th the key i n the i gni ti on, turn the key to
the RUN posi ti on.
(3) After the DRBI I I scan tool i ni ti al i zati on, per-
form the fol l owi ng:
(a) Sel ect Theft Al arm.
(b) Sel ect VTSS.
(c) Sel ect Mi scel l aneous.
(4) Once i n the Mi scel l aneous screen:
(a) I f you wi sh to confi gure a new modul e, sel ect
Confi gure Modul e.
(b) I f you wi sh to put the modul e i nto customer
usage mode, sel ect Enabl e VTSS.
(c) I f you wi sh to put the modul e i nto deal er l ot
mode, sel ect Deal er Lot.
INITIALIZATION
The Sentry Key I mmobi l i zer System (SKI S) i ni ti al -
i zati on shoul d be performed fol l owi ng a Sentry Key
I mmobi l i zer Modul e (SKI M) repl acement.
I t can be summari zed by the fol l owi ng:
(1) Obtai n the vehi cl es uni que PI N number
assi gned to i ts ori gi nal SKI M from the vehi cl e
owner, the vehi cl es i nvoi ce or from Chrysl ers Cus-
tomer Center.
(2) Wi th the DRBI I I scan tool , sel ect Theft
Al arm, SKI M, Mi scel l aneous. Sel ect SKI M Mod-
ul e Repl aced functi on and the DRBI I I wi l l prompt
you through the fol l owi ng steps.
(3) Enter secured access mode usi ng the uni que
four di gi t PI N number.
(4) Program the vehi cl es VI N number i nto the
SKI Ms memory.
(5) Program the country code i nto the SKI Ms
memory (U.S.).
(6) Transfer the vehi cl es uni que Secret Key data
from the PCM. Thi s process wi l l requi re the SKI M to
be i n secured access mode. The PI N number must
be entered i nto the DRBI I I before the SKI M wi l l
enter secured access mode. Once secured access
mode i s acti ve, the SKI M wi l l remai n i n that mode
for 60 seconds.
(7) Program al l customer keys i nto the SKI Ms
memory. Thi s requi red that the SKI M be i n secured
access mode The SKI M wi l l i mmedi atel y exi t
secured access mode after each key i s pro-
grammed.
NOTE: If a PCM is replaced, the unique Secret
Key data must be transferred from the SKIM to the
PCM. This procedure requires the SKIM to be
placed in SECURED ACCESS MODE using the four
digit PIN code.
TRANSPONDER PROGRAMMING
Two programmed Sentry Key transponders are
i ncl uded wi th the Sentry Key I mmobi l i zer System
(SKI S) when i t i s shi pped from the factory. The Sen-
try Key I mmobi l i zer Modul e (SKI M) can be pro-
grammed to recogni ze up to si x addi ti onal
transponders, for a total of ei ght Sentry Keys. The
fol l owi ng Customer Learn programmi ng procedure
for the programmi ng of addi ti onal transponders
requi res access to at l east two of the val i d Sentry
Keys. I f two val i d Sentry Keys are not avai l abl e, Sen-
try Key programmi ng wi l l requi re the use of a
DRBI I I scan tool .
CUSTOMER LEARN PROGRAMMING
(1) Obtai n the addi ti onal Sentry Key transponder
bl ank(s) that are to be programmed for the vehi cl e.
Cut the addi ti onal Sentry Key transponder bl anks to
match the i gni ti on l ock cyl i nder mechani cal key
codes.
(2) I nsert one of the two val i d Sentry Key tran-
sponders i nto the i gni ti on swi tch and turn the i gni -
ti on swi tch to the ON posi ti on.
(3) After the i gni ti on swi tch has been i n the ON
posi ti on for about three seconds, but no more than
fi fteen seconds, cycl e the i gni ti on swi tch back to the
OFF posi ti on. Repl ace the fi rst val i d Sentry Key i n
the i gni ti on l ock cyl i nder wi th the second val i d Sen-
try Key and turn the i gni ti on swi tch back to the ON
posi ti on. Both operati ons must be performed wi thi n
15 seconds.
(4) I n approxi matel y ten seconds the VTSS i ndi ca-
tor LED wi l l start to fl ash to i ndi cate that the sys-
tem has entered the Customer Learn programmi ng
mode.
(5) Wi thi n approxi matel y si xty seconds of enteri ng
the Customer Learn programmi ng mode, turn the
i gni ti on swi tch to the OFF posi ti on, repl ace the val i d
Sentry Key wi th a bl ank Sentry Key transponder,
and turn the i gni ti on swi tch back to the ON posi ti on.
(6) I n approxi matel y ten seconds, the VTSS i ndi ca-
tor LED wi l l stop fl ashi ng and stay on sol i d for
approxi matel y three seconds and then turn OFF to
i ndi cate that the bl ank Sentry Key transponder has
been successful l y programmed. The SKI S wi l l i mme-
di atel y return to normal system operati on fol l owi ng
exi t from the Customer Learn programmi ng mode.
(7) Repeat thi s process for each addi ti onal Sentry
Key transponder bl ank to be programmed.
I f any of the above steps i s not compl eted i n the
proper sequence, or wi thi n the al l otted ti me, the
SKI S wi l l automati cal l y exi t the Customer Learn
programmi ng mode. The SKI S wi l l al so automati cal l y
exi t the Customer Learn programmi ng mode i f i t
sees a non-bl ank Sentry Key transponder when i t
shoul d see a bl ank, i f i t has al ready programmed
ei ght val i d Sentry Keys, or i f the i gni ti on swi tch i s
turned to the OFF posi ti on for more than about fi fty
seconds.
NOTE: While in Customer Learn mode (LED flash-
ing), the engine will not START and RUN.
PROGRAMMING BLANK SENTRY KEY
TRANSPONDERS WITH A DRBIII SCAN TOOL
When programmi ng a bl ank Sentry Key transpon-
der, the key bl ank must fi rst be cut to match the
i gni ti on l ock cyl i nder. I t wi l l al so be necessary to
enter the vehi cl es four di gi t PI N code i nto the
DRBI I I scan tool to enter the Sentry Key I mmobi -
l i zer Modul es (SKI Ms) secured access mode.
NOTE: Once a Sentry Key is programmed to a par-
ticular vehicle, it cannot be transferred to another
vehicle.
I nsert the bl ank key i nto the i gni ti on and turn i t to
the RUN posi ti on. Usi ng the DRBI I I scan tool ,
sel ect Theft Al arm, then SKI M, then Mi scel l a-
neous. Sel ect Program New Key. Enter the four
di gi t PI N code usi ng the DRBI I I . When program-
mi ng i s compl eted, the SKI M wi l l exi t secured access
mode and the DRBI I I wi l l di spl ay the status of the
key. One of fi ve di fferent status messages may be di s-
pl ayed as fol l ows:
Programmi ng Successful i s di spl ayed i f SKI M
Sentry Key programmi ng succeeds.
Learned Key i n I gni ti on i s di spl ayed i f the key
i n the i gni ti on has al ready been programmed i nto
that vehi cl es SKI M.
8 Keys Al ready Learned (At The Maxi mum)
Programmi ng Not Done i s di spl ayed i f ei ght keys
have al ready been programmed i nto the SKI M. I n
thi s case, i f a new key needs to be added due to a
l ost or defecti ve key, the Erase Al l Keys functi on
(requi res enteri ng secured access mode) has to be
performed. Then the customers seven keys pl us the
new key MUST be reprogrammed i nto the SKI M.
Programmi ng Not Attempted i s di spl ayed after
an Erase Al l Keys functi on i s executed.
Programmi ng Key Fai l ed i s di spl ayed i f fur-
ther di agnosi s i s requi red.
To l earn addi ti onal keys, turn the i gni ti on OFF,
remove the l earned key, and i nsert the next new
bl ank key. Turn i gni ti on to the RUN posi ti on and re-
enter the secured access mode functi on and repeat
the Program New Key procedure outl i ned above.
8Q - 4 VEHICLE THEFT SECURITY DR
SENTRY KEY IMMOBILIZER
SYSTEM INDICATOR LAMP
DESCRIPTION
The Sentry Key I mmobi l i zer System (SKI S) uses
the Vehi cl e Theft Securi ty System (VTSS) i ndi cator
i n the i nstrument cl uster to gi ve an i ndi cati on when
the SKI S i s faul ty or when the vehi cl e has been
i mmobi l i zed due to the use of an i nval i d key. The
i ndi cator i s control l ed by the i nstrument cl uster
based upon messages recei ved from the Sentry Key
I mmobi l i zer Modul e (SKI M).
OPERATION
The SKI M sends PCI Bus messages to the i nstru-
ment cl uster, to turn on the Securi ty i ndi cator for
about 3 seconds when the i gni ti on i s turned to the
ON posi ti on, as a Bul b test. After compl eti on of the
Bul b test, the SKI M sends a PCI bus messages to
keep the LED off for 1 second. Then the SKI M sends
messages to the i nstrument cl uster to turn the LED
off based upon the resul ts i f the SKI S sel f - test. I f
the i ndi cator i l l umi nates and remai ns i l l umi nated
after the bul b test, i t i ndi cates that the SKI M has
detected a system mal functi on and/or the system has
become i noperati ve. I f the SKI M detects a i nval i d
key when the i gni ti on swi tch i s turned on, i t sends a
message to the i nstrument cl uster to fl ash the Secu-
ri ty i ndi cator.
The SKI M can al so send messages to the cl uster to
fl ash the LED and generate a chi me. These functi ons
serve as an i ndi cati on to the customer that the SKI M
i s i n the Customer Learn programmi ng mode. See
Sentry Key I mmobi l i zer System Transponder Pro-
grammi ng i n thi s group for more i nformati on on the
Customer Learn programmi ng Mode.
I f the VTSS i ndi cator remai ns on after the Bul b
test, the system shoul d be di agnosed usi ng the
DRBI I I scan tool and the proper Powertrai n Di ag-
nosti c Procedures manual .
WIPERS/WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - WIPER &
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . 6
CLEANING - WIPER & WASHER SYSTEM . . . . . 6
INSPECTION - WIPER & WASHER SYSTEM . . . 7
CHECK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WASHER FLUID LEVEL SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
WASHER HOSES/TUBES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WASHER NOZZLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
WASHER PUMP/MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
WASHER RESERVOIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL
REMOVAL - EXCEPT DIESEL ENGINE . . . . . 15
REMOVAL - DIESEL ENGINE . . . . . . . . . . . . 16
INSTALLATION
INSTALLATION - EXCEPT DIESEL ENGINE . . 17
INSTALLATION - DIESEL ENGINE . . . . . . . . . 17
WIPER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
WIPER BLADE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
WIPER HIGH/LOW RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - WIPER HIGH/
LOW RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
WIPER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
WIPER ON/OFF RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING - WIPER ON/OFF
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
WIPERS/WASHERS
DESCRIPTION
An el ectri cal l y operated i ntermi ttent wi per and
washer system i s standard factory-i nstal l ed safety
equi pment on thi s model (Fi g. 1). The wi per and
washer system i ncl udes the fol l owi ng major compo-
nents, whi ch are descri bed i n further detai l el se-
where i n thi s servi ce i nformati on:
Check Valve - The washer system check val ve
i s i ntegral to the wye fi tti ng l ocated i n the washer
pl umbi ng between the cowl pl enum washer hose and
the washer nozzl es, and i s conceal ed beneath the
cowl pl enum cover/gri l l e panel at the base of the
wi ndshi el d.
Front Control Module - The Front Control
Modul e (FCM) i s i ntegral to the I ntegrated Power
Modul e (I PM). The I PM i s l ocated i n the engi ne com-
partment, near the battery. (Refer to 8 - ELECTRI -
POWER MODULE - DESCRI PTI ON).
Instrument Cluster - I n thi s model , the i nstru-
ment cl uster i s al so someti mes referred to as the Cab
Control Node (CCN). The i nstrument cl uster i s
l ocated i n the i nstrument panel above the steeri ng
DR WIPERS/WASHERS 8R - 1
col umn openi ng, di rectl y i n front of the dri ver. (Refer
to 8 - ELECTRI CAL/I NSTRUMENT CLUSTER -
DESCRI PTI ON).
Multi-Function Switch - The mul ti -functi on
swi tch i s l ocated on the top of the steeri ng col umn,
just bel ow the steeri ng wheel . The mul ti -functi on
swi tch i ncl udes a control stal k that extends through
an openi ng on the l eft si de of the steeri ng col umn
shrouds and a control knob on the end of the stal k i s
dedi cated to provi di ng al l of the dri ver control s for
the wi per and washer systems. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - EXTERI OR/MULTI -
FUNCTI ON SWI TCH - DESCRI PTI ON).
Washer Fluid Level Switch - The washer fl ui d
l evel swi tch i s l ocated i n a dedi cated hol e on the out-
board si de of the washer reservoi r i n the engi ne com-
partment.
Washer Nozzle - Two fl ui di c washer nozzl es are
secured wi th i ntegral snap features to dedi cated
openi ngs i n the cowl pl enum cover/gri l l e panel
l ocated near the base of the wi ndshi el d.
Washer Plumbing - The pl umbi ng for the
washer system consi sts of rubber hoses and mol ded
pl asti c fi tti ngs. The pl umbi ng i s routed al ong the
ri ght si de of the engi ne compartment from the
washer reservoi r, and through a trough near the
ri ght end of the cowl pl enum cover/gri l l e panel i nto
the cowl pl enum to the washer nozzl e fi tti ngs.
Washer Pump/Motor - The el ectri c washer
pump/motor uni t i s l ocated i n a dedi cated hol e on the
rearward faci ng surface of the washer reservoi r i n
the engi ne compartment.
Washer Reservoir - On al l model s except those
wi th an opti onal di esel engi ne, the washer reservoi r
Fig. 1 Wiper & Washer System
1 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL
SWITCH (EXCEPT DIESEL ENGINE)
2 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL
SWITCH (DIESEL ENGINE ONLY)
3 - WIPER MODULE
4 - WASHER NOZZLE (2)
5 - WIPER ARM & BLADE (2)
6 - MULTI-FUNCTION (WIPER, WASHER, & LIGHTING) SWITCH
8R - 2 WIPERS/WASHERS DR
WIPERS/WASHERS (Continued)
i s secured by i ntegral mounti ng tabs and a snap fea-
ture to sl ots i n the ri ght si de of the cool i ng modul e
shroud i n the engi ne compartment. On model s wi th
an opti onal di esel engi ne, the washer reservoi r i s
secured by screws to the back of the upri ght l eft ver-
ti cal member of the radi ator support i n the engi ne
compartment. The washer reservoi r fi l l er neck i s
accessed from the engi ne compartment.
Wiper Arm - The two wi per arms are secured
wi th i ntegral l atches to the serrated ends of the two
wi per pi vot shafts, whi ch extend through the cowl
pl enum cover/gri l l e panel l ocated near the base of the
wi ndshi el d.
Wiper Blade - The two wi per bl ades are
secured to the two wi per arms wi th an i ntegral l atch,
and are parked on the gl ass near the bottom of the
wi ndshi el d when the wi per system i s not i n opera-
ti on.
Wiper High/Low Relay - The wi per hi gh/l ow
rel ay i s an I nternati onal Standards Organi zati on
(I SO) mi cro rel ay l ocated i n the I ntegrated Power
Modul e (I PM) i n the engi ne compartment near the
battery.
Wiper Module - The wi per pi vot shafts are the
onl y vi si bl e components of the wi per modul e. The
remai nder of the modul e i s conceal ed wi thi n the cowl
pl enum area beneath the cowl pl enum cover/gri l l e
panel . The wi per modul e i ncl udes the wi per modul e
bracket, four rubber-i sol ated wi per modul e mounts,
the wi per motor, the wi per motor crank arm, the two
wi per dri ve l i nks, and the two wi per pi vots.
Wiper On/Off Relay - The wi per on/off rel ay i s
an I nternati onal Standards Organi zati on (I SO) mi cro
rel ay l ocated i n the I ntegrated Power Modul e (I PM)
i n the engi ne compartment near the battery.
Hard wi red ci rcui try connects the wi per and
washer system components to the el ectri cal system of
the vehi cl e. These hard wi red ci rcui ts are i ntegral to
several wi re harnesses, whi ch are routed throughout
the vehi cl e and retai ned by many di fferent methods.
These ci rcui ts may be connected to each other, to the
vehi cl e el ectri cal system and to the wi per and washer
system components through the use of a combi nati on
of sol dered spl i ces, spl i ce bl ock connectors, and many
di fferent types of wi re harness termi nal connectors
and i nsul ators. Refer to the appropri ate wi ri ng i nfor-
mati on. The wi ri ng i nformati on i ncl udes wi ri ng di a-
grams, proper wi re and connector repai r procedures,
further detai l s on wi re harness routi ng and reten-
ti on, as wel l as pi n-out and l ocati on vi ews for the
vari ous wi re harness connectors, spl i ces and grounds.
OPERATING MODES
The components of the wi per and washer system
are desi gned to work i n concert to provi de the fol l ow-
i ng operati ng modes:
Continuous Wipe Mode - The control knob on
the control stal k of the mul ti -functi on swi tch has two
conti nuous wi pe posi ti ons, Low and Hi gh. When
sel ected, these swi tch posi ti ons wi l l cause the two-
speed wi per motor to operate i n a conti nuous l ow or
hi gh speed cycl e.
Intermittent Wipe Mode - The control knob on
the control stal k of the mul ti -functi on swi tch has fi ve
mi nor detent i ntermi ttent wi pe posi ti ons. When
sel ected, these swi tch posi ti ons wi l l cause the wi per
system to operate wi th one of fi ve del ay i nterval s
between compl ete wi pe cycl es. The i ntermi ttent wi pe
del ay i nterval s are speed sensi ti ve and wi l l be dou-
bl ed when the vehi cl e speed i s about si xteen ki l ome-
ters-per-hour (ten mi l es-per-hour) or l ess.
Pulse Wipe Mode - When the control knob on
the control stal k of the mul ti -functi on swi tch i s
depressed to the momentary Wash posi ti on for l ess
than about one-hal f second, the wi per system wi l l
operate the wi pers for one compl ete l ow speed cycl e,
then wi l l park the wi per bl ades near the base of the
wi ndshi el d.
Washer Mode - When the control knob on the
control stal k of the mul ti -functi on swi tch i s
depressed to the momentary Wash posi ti on for more
than about one-hal f second wi th the wi per system
turned Off, the washer pump/motor and the wi pers
wi l l operate for as l ong as the washer swi tch i s hel d
cl osed up to about thi rty seconds, then the wi pe-af-
ter-wash mode i s i nvoked when the control knob i s
rel eased. When the Wash posi ti on i s sel ected wi th
the wi per system operati ng i n a conti nuous wi pe
mode, washer fl ui d wi l l be di spensed onto the wi nd-
shi el d gl ass through the washer nozzl es for as l ong
as the washer swi tch i s hel d cl osed up to about thi rty
seconds. When the Wash posi ti on i s sel ected wi th the
wi per system operati ng i n an i ntermi ttent wi pe
mode, washer fl ui d i s sti l l di spensed unti l the control
knob i s rel eased; however, the wi pers wi l l operate i n
a l ow speed conti nuous cycl e from the ti me the
washer swi tch i s cl osed unti l several wi pe cycl es
after the swi tch i s rel eased, before returni ng to the
sel ected i ntermi ttent wi pe i nterval . I f the control
knob i s hel d i n the depressed Wash posi ti on for more
than about thi rty seconds, washer system operati on
wi l l be suspended unti l the control knob i s rel eased
for about two seconds then cycl ed back to the Wash
posi ti on.
Wipe-After-Wash Mode - When the control
knob on the control stal k of the mul ti -functi on swi tch
i s depressed to the momentary Wash posi ti on for
more than about one-hal f second wi th the wi per sys-
tem turned Off, the washer pump/motor and the wi p-
ers wi l l operate for as l ong as the washer swi tch i s
hel d cl osed up to about thi rty seconds, then provi de
several addi ti onal wi pe cycl es after the control knob
i s rel eased before parki ng the wi per bl ades near the
base of the wi ndshi el d. I f the control knob i s hel d i n
the depressed Wash posi ti on for more than about
thi rty seconds, washer system operati on wi l l be sus-
pended unti l the control knob i s rel eased for about
two seconds then cycl ed back to the Wash posi ti on.
OPERATION
The wi per and washer system i s desi gned to pro-
vi de the vehi cl e operator wi th a conveni ent, safe, and
rel i abl e means of mai ntai ni ng vi si bi l i ty through the
wi ndshi el d gl ass. The vari ous components of thi s sys-
tem are desi gned to convert el ectri cal energy pro-
duced by the vehi cl e el ectri cal system i nto the
mechani cal acti on of the wi per bl ades to wi pe the
outsi de surface of the gl ass, as wel l as i nto the
hydraul i c acti on of the washer system to appl y
washer fl ui d stored i n an on-board reservoi r to the
area of the gl ass to be wi ped. When combi ned, these
components provi de the means to effecti vel y mai n-
tai n cl ear vi si bi l i ty for the vehi cl e operator by remov-
i ng excess accumul ati ons of rai n, snow, bugs, mud, or
other mi nor debri s from the outsi de wi ndshi el d gl ass
surface that mi ght be encountered whi l e dri vi ng the
vehi cl e under numerous types of i ncl ement operati ng
condi ti ons.
The vehi cl e operator i ni ti ates al l wi per and washer
system functi ons wi th the control knob on the end of
the control stal k of the mul ti -functi on swi tch that
extends from the l eft si de of the steeri ng col umn, just
bel ow the steeri ng wheel . Rotati ng the control knob
on the end of the control stal k, sel ects the Off, Del ay,
Low, or Hi gh wi per system operati ng modes. I n the
Del ay mode, the control knob al so al l ows the vehi cl e
operator to sel ect from one of fi ve i ntermi ttent wi pe
Del ay i nterval s. Depressi ng the control knob towards
the steeri ng col umn actuates the momentary washer
system swi tch, whi ch sel ects the Wash, Wi pe-After-
Wash, and Pul se Wi pe Modes dependi ng upon when
and how l ong the swi tch i s hel d cl osed. The mul ti -
functi on swi tch provi des hard wi red resi stor mul ti -
pl exed i nputs to the i nstrument cl uster for al l of the
wi per and washer system functi ons. The i nstrument
cl uster then sends el ectroni c messages to the Front
Control Modul e (FCM) over the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus requesti ng the
appropri ate wi per and washer system operati ng
modes.
Wi per and washer system operati on are compl etel y
control l ed by the i nstrument cl uster and FCM l ogi c
ci rcui ts, and that l ogi c wi l l onl y al l ow these systems
to operate when the i gni ti on swi tch i s i n the Acces-
sory or On posi ti ons. Battery current i s di rected from
a B(+) fuse i n the I ntegrated Power Modul e (I PM) to
the wi per on/off rel ay and the wi per hi gh/l ow rel ay i n
the I PM through a fused B(+) ci rcui t. The FCM uses
l ow si de dri vers to control wi per system operati on by
energi zi ng or de-energi zi ng the wi per hi gh/l ow and
wi per on/off rel ays. The FCM uses a hi gh si de dri ver
to control the operati on of the washer pump motor
uni t. The mul ti -functi on swi tch ci rcui try recei ves a
cl ean ground output from the i nstrument cl uster on a
mul ti -functi on swi tch return ci rcui t, then provi des
resi stor mul ti pl exed i nputs to the i nstrument cl uster
on an i ntermi ttent wi pe mux ci rcui t to i ndi cate the
sel ected wi per system mode and on a wash/beam
sel ect mux ci rcui t to i ndi cate the sel ected washer sys-
tem mode.
The hard wi red ci rcui ts and components of the
wi per and washer system may be di agnosed and
tested usi ng conventi onal di agnosti c tool s and proce-
dures. However, conventi onal di agnosti c methods
may not prove concl usi ve i n the di agnosi s of the
i nstrument cl uster, the FCM, or the el ectroni c mes-
sage i nputs to or outputs from the i nstrument cl uster
or FCM that control the wi per and washer system
operati ng modes. The most rel i abl e, effi ci ent, and
accurate means to di agnose the i nstrument cl uster or
the FCM i nputs and outputs rel ated to the vari ous
wi per and washer system operati ng modes requi res
the use of a DRBI I I scan tool . Refer to the appro-
OPERATING MODES
Fol l owi ng are paragraphs that bri efl y descri be the
operati on of each of the wi per and washer system
operati ng modes.
CONTINUOUS WIPE MODE
When the Low posi ti on of the control knob on the
control stal k of the mul ti -functi on swi tch i s sel ected
the i nstrument cl uster sends an el ectroni c wi per
swi tch l ow message to the FCM, then the FCM ener-
gi zes the wi per on/off rel ay. Thi s di rects battery cur-
rent through the normal l y open contacts of the
energi zed wi per on/off rel ay and the normal l y cl osed
contacts of the de-energi zed wi per hi gh/l ow rel ay to
the l ow speed brush of the wi per motor, causi ng the
wi pers to cycl e at l ow speed.
When the Hi gh posi ti on of the control knob i s
sel ected the i nstrument cl uster sends an el ectroni c
wi per swi tch hi gh message to the FCM, then the
FCM energi zes both the wi per on/off rel ay and the
wi per hi gh/l ow rel ay. Thi s di rects battery current
through the normal l y open contacts of the energi zed
wi per on/off rel ay and the normal l y open contacts of
the energi zed wi per hi gh/l ow rel ay to the hi gh speed
brush of the wi per motor, causi ng the wi pers to cycl e
at hi gh speed.
When the Off posi ti on of the mul ti -functi on swi tch
control knob i s sel ected, the i nstrument cl uster sends
an el ectroni c wi per swi tch off message to the FCM. I f
the wi per motor was operati ng at hi gh speed, the
FCM i mmedi atel y de-energi zes the wi per hi gh/l ow
rel ay causi ng the wi per motor to return to l ow speed
operati on. Then one of two events wi l l occur. The
event that occurs depends upon the posi ti on of the
wi per bl ades on the wi ndshi el d at the moment that
the control knob Off posi ti on i s sel ected.
I f the wi per bl ades are i n the down posi ti on on the
wi ndshi el d when the Off posi ti on i s sel ected, the
park swi tch that i s i ntegral to the wi per motor i s
cl osed to ground and provi des a hard wi red park
swi tch sense i nput to the FCM. The FCM then de-en-
ergi zes the wi per on/off rel ay and the wi per motor
ceases to operate. I f the wi per bl ades are not i n the
down posi ti on on the wi ndshi el d at the moment the
Off posi ti on i s sel ected, the park swi tch i s an open
ci rcui t and the FCM keeps the wi per on/off rel ay
energi zed, whi ch causes the wi per motor to conti nue
runni ng at l ow speed unti l the wi per bl ades are i n
the down posi ti on on the wi ndshi el d and the park
swi tch i nput to the FCM i s agai n cl osed to ground.
INTERMITTENT WIPE MODE
When the control knob on the control stal k of the
mul ti -functi on swi tch i s moved to one of the Del ay
i nterval posi ti ons the i nstrument cl uster sends an
el ectroni c wi per swi tch del ay message to the FCM,
then the FCM el ectroni c i ntermi ttent wi pe l ogi c ci r-
cui t responds by cal cul ati ng the correct l ength of
ti me between wi per sweeps based upon the sel ected
del ay i nterval i nput. The FCM moni tors the changi ng
state of the wi per motor park swi tch through a hard
wi red park swi tch sense i nput. Thi s i nput al l ows the
FCM to determi ne the proper i nterval s at whi ch to
energi ze and de-energi ze the wi per on/off rel ay to
operate the wi per motor i ntermi ttentl y for one l ow
speed cycl e at a ti me.
The FCM l ogi c i s al so programmed to provi de vehi -
cl e speed sensi ti vi ty to the sel ected i ntermi ttent wi pe
del ay i nterval s. I n order to provi de thi s feature the
FCM moni tors el ectroni c vehi cl e speed messages
from the Powertrai n Control Modul e (PCM) and dou-
bl es the sel ected del ay i nterval whenever the vehi cl e
speed i s about si xteen ki l ometers-per-hour (ten mi l es-
per-hour) or l ess.
PULSE WIPE MODE
mul ti -functi on swi tch i s depressed to the momentary
Wash posi ti on for l ess than about one-hal f second,
the i nstrument cl uster sends an el ectroni c washer
swi tch message to the FCM, then the FCM the ener-
gi zes the wi per on/off rel ay for one compl ete wi pe
cycl e. The FCM de-energi zes the rel ay when the state
of the park swi tch sense changes to ground, parki ng
the wi per bl ades near the base of the wi ndshi el d.
WASH MODE
Wash posi ti on for more than about one-hal f second,
the i nstrument cl uster sends an el ectroni c washer
swi tch message to the FCM, then the FCM di rects
battery current to the washer pump/motor uni t. Thi s
wi l l cause the washer pump/motor uni t to be ener-
gi zed for as l ong as the Wash swi tch i s hel d cl osed up
to about thi rty seconds, and to de-energi ze when the
front Wash swi tch i s rel eased.
When the control knob i s depressed to the momen-
tary Wash posi ti on whi l e the wi per system i s operat-
i ng i n one of the Del ay i nterval posi ti ons, the washer
pump/motor operati on i s the same. However, the
FCM al so energi zes the wi per on/off rel ay to overri de
the sel ected del ay i nterval and operate the wi per
motor i n a conti nuous l ow speed mode for as l ong as
the control knob i s hel d depressed, then de-energi zes
the rel ay and reverts to the sel ected del ay mode
i nterval several wi pe cycl es after the control knob i s
rel eased. I f the control knob i s hel d depressed for
more than about thi rty seconds, the FCM wi l l sus-
pend washer pump/motor operati on unti l the knob i s
rel eased for about two seconds, then cycl ed back to
the Wash posi ti on.
WIPE-AFTER-WASH MODE
Wash posi ti on for more than about one-hal f second
whi l e the wi per system i s not operati ng, the i nstru-
ment cl uster sends an el ectroni c washer swi tch mes-
sage to the FCM, then the FCM the di rects battery
current to the washer pump/motor uni t and energi zes
the wi per on/off rel ay. Thi s wi l l cause the washer
pump/motor uni t to be energi zed and operate the
wi per motor i n a conti nuous l ow speed mode for as
l ong as the Wash swi tch i s hel d cl osed up to about
thi rty seconds. When the control knob i s rel eased,
the FCM de-energi zes the washer pump/motor uni t,
but al l ows the wi per motor to operate for several
addi ti onal wi pe cycl es before i t de-energi zes the
wi per on/off rel ay and parks the wi per bl ades near
the base of the wi ndshi el d.
I f the control knob i s hel d depressed for more than
about thi rty seconds, the FCM wi l l suspend washer
pump/motor operati on unti l the knob i s rel eased for
about two seconds, then cycl ed back to the Wash
posi ti on; however, the wi pers wi l l conti nue to operate
for as l ong as the Wash swi tch i s hel d cl osed. The
FCM moni tors the changi ng state of the wi per motor
park swi tch through a hard wi red wi per park swi tch
sense ci rcui t i nput. Thi s i nput al l ows the FCM to
count the number of wi pe cycl es that occur after the
Wash swi tch i s rel eased, and to determi ne the proper
i nterval at whi ch to de-energi ze the wi per on/off
rel ay to compl ete the wi pe-after-wash mode cycl e.
DIAGNOSIS AND TESTING - WIPER &
WASHER SYSTEM
I f the wi per motor operates, but the wi pers do not
move on the wi ndshi el d, repl ace the faul ty wi per
modul e. I f the washer pump/motor operates, but no
washer fl ui d i s di spensed on the gl ass; or, i f the wi p-
ers operate, but chatter, l i ft, or do not cl ear the gl ass,
cl ean and i nspect the wi per and washer system com-
ponents as requi red. (Refer to 8 - ELECTRI CAL/
WI PERS/WASHERS - CLEANI NG) and (Refer to 8 -
ELECTRI CAL/WI PERS/WASHERS - I NSPECTI ON).
For di agnosi s and testi ng of the mul ti -functi on
swi tch (Refer to 8 - ELECTRI CAL/LAMPS/LI GHT-
I NG - EXTERI OR/MULTI -FUNCTI ON SWI TCH -
DI AGNOSI S AND TESTI NG). Refer to the appropri -
ate wi ri ng i nformati on. The wi ri ng i nformati on
i ncl udes wi ri ng di agrams, proper wi re and connector
repai r procedures, detai l s of wi re harness routi ng
and retenti on, connector pi n-out i nformati on and
l ocati on vi ews for the vari ous wi re harness connec-
tors, spl i ces and grounds.
The hard wi red ci rcui ts and components of the
wi per and washer system may be di agnosed and
tested usi ng conventi onal di agnosti c tool s and proce-
dures. However, conventi onal di agnosti c methods
may not prove concl usi ve i n the di agnosi s of the
i nstrument cl uster, the Front Control Modul e (FCM),
or the el ectroni c message i nputs to or outputs from
the i nstrument cl uster and the FCM that control the
vari ous wi per and washer system operati ng modes.
di agnose the i nstrument cl uster, the FCM, or the
el ectroni c message i nputs and outputs rel ated to the
vari ous wi per and washer system operati ng modes
MENT.
CLEANING - WIPER & WASHER SYSTEM
WIPER SYSTEM
The squeegees of wi per bl ades exposed to the el e-
ments for a l ong ti me tend to l ose thei r wi pi ng effec-
ti veness. Peri odi c cl eani ng of the squeegees i s
suggested to remove any deposi ts of sal t or road fi l m.
The wi per bl ades, arms, and wi ndshi el d gl ass shoul d
onl y be cl eaned usi ng a sponge or soft cl oth and
wi ndshi el d washer fl ui d, a mi l d detergent, or a non-
abrasi ve cl eaner. I f the wi per bl ades conti nue to
l eave streaks, smears, hazi ng, or beadi ng on the
gl ass after thorough cl eani ng of the squeegees and
the gl ass, the enti re wi per bl ade assembl y must be
repl aced.
CAUTION: Protect the rubber squeegees of the
wiper blades from any petroleum-based cleaners,
solvents, or contaminants. These products can rap-
idly deteriorate the rubber squeegees.
WASHER SYSTEM
I f the washer system i s contami nated wi th forei gn
materi al , drai n the washer reservoi r by removi ng the
washer pump/motor from the reservoi r. Cl ean forei gn
materi al from the i nsi de of the washer pump/motor
i nl et fi l ter screen and the washer reservoi r usi ng
cl ean washer fl ui d, a mi l d detergent, or a non-abra-
si ve cl eaner. Fl ush forei gn materi al from the washer
system pl umbi ng by fi rst di sconnecti ng the washer
hoses from the washer nozzl es, then runni ng the
washer pump/motor to run cl ean washer fl ui d or
water through the system. Pl ugged or restri cted
washer nozzl es shoul d be careful l y back-fl ushed
usi ng compressed ai r. I f the washer nozzl e obstruc-
ti on cannot be cl eared, repl ace the washer nozzl e.
CAUTION: Never introduce petroleum-based clean-
ers, solvents, or contaminants into the washer sys-
tem. These products can rapidly deteriorate the
rubber seals and hoses of the washer system, as
well as the rubber squeegees of the wiper blades.
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbing
components and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
INSPECTION - WIPER & WASHER SYSTEM
WIPER SYSTEM
The wi per bl ades and wi per arms shoul d be
i nspected peri odi cal l y, not just when wi per perfor-
mance probl ems are experi enced. Thi s i nspecti on
shoul d i ncl ude the fol l owi ng poi nts:
(1) I nspect the wi per arms for any i ndi cati ons of
damage, or contami nati on. I f the wi per arms are con-
tami nated wi th any forei gn materi al , cl ean them as
requi red. (Refer to 8 - ELECTRI CAL/WI PERS/
WASHERS - CLEANI NG). I f a wi per arm i s damaged
or corrosi on i s evi dent, repl ace the wi per arm wi th a
new uni t. Do not attempt to repai r a wi per arm that
i s damaged or corroded.
(2) Careful l y l i ft the wi per bl ade off of the gl ass.
Note the acti on of the wi per arm hi nge. The wi per
arm shoul d pi vot freel y at the hi nge, but wi th no l at-
eral l ooseness evi dent. I f there i s any bi ndi ng evi dent
i n the wi per arm hi nge, or there i s evi dent l ateral
pl ay i n the wi per arm hi nge, repl ace the wi per arm.
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(3) Once proper hi nge acti on of the wi per arm i s
confi rmed, check the hi nge for proper spri ng tensi on.
Remove the wi per bl ade from the wi per arm. Ei ther
pl ace a smal l postal scal e between the bl ade end of
the wi per arm and the gl ass, or careful l y l i ft the
bl ade end of the arm away from the gl ass usi ng a
smal l fi sh scal e. Compare the scal e readi ngs between
the ri ght and l eft wi per arms. Repl ace a wi per arm i f
i t has comparati vel y l ower spri ng tensi on, as evi -
denced by a l ower scal e readi ng.
(4) I nspect the wi per bl ades and squeegees for any
i ndi cati ons of damage, contami nati on, or rubber dete-
ri orati on (Fi g. 2). I f the wi per bl ades or squeegees
are contami nated wi th any forei gn materi al , cl ean
them and the gl ass as requi red. (Refer to 8 - ELEC-
TRI CAL/WI PERS/WASHERS - CLEANI NG). After
cl eani ng the wi per bl ade and the gl ass, i f the wi per
bl ade sti l l fai l s to cl ear the gl ass wi thout smeari ng,
streaki ng, chatteri ng, hazi ng, or beadi ng, repl ace the
wi per bl ade. Al so, i f a wi per bl ade i s damaged or the
squeegee rubber i s damaged or deteri orated, repl ace
the wi per bl ade wi th a new uni t. Do not attempt to
repai r a wi per bl ade that i s damaged.
WASHER SYSTEM
The washer system components shoul d be
i nspected peri odi cal l y, not just when washer perfor-
mance probl ems are experi enced. Thi s i nspecti on
shoul d i ncl ude the fol l owi ng poi nts:
(1) Check for i ce or other forei gn materi al i n the
washer reservoi r. I f contami nated, cl ean and fl ush
the washer system. (Refer to 8 - ELECTRI CAL/WI P-
ERS/WASHERS - CLEANI NG).
(2) I nspect the washer pl umbi ng for pi nched, l eak-
i ng, deteri orated, or i ncorrectl y routed hoses and
damaged or di sconnected hose fi tti ngs. Repl ace dam-
aged or deteri orated hoses and hose fi tti ngs. Leaki ng
washer hoses can someti mes be repai red by cutti ng
the hose at the l eak and spl i ci ng i t back together
usi ng an i n-l i ne connector fi tti ng. Si mi l arl y, secti ons
of deteri orated hose can be cut out and repl aced by
spl i ci ng i n new secti ons of hose usi ng i n-l i ne connec-
tor fi tti ngs. Whenever routi ng a washer hose or a
wi re harness contai ni ng a washer hose, i t must be
routed away from hot, sharp, or movi ng parts. Al so,
sharp bends that mi ght pi nch the washer hose must
be avoi ded.
CHECK VALVE
DESCRIPTION
A si ngl e washer system check val ve i s standard
equi pment on thi s model , and i s i nstal l ed i n the
Fig. 2 Wiper Blade Inspection
1 - WORN OR UNEVEN EDGES
2 - ROAD FILM OR FOREIGN MATERIAL DEPOSITS
3 - HARD, BRITTLE, OR CRACKED
4 - DEFORMED OR FATIGUED
5 - SPLIT
6 - DAMAGED SUPPORT COMPONENTS
washer system pl umbi ng (Fi g. 3). The check val ve i s
i ntegral to the washer nozzl e pl umbi ng wye fi tti ng
l ocated i n the cowl pl enum area beneath the cowl
pl enum cover/gri l l e panel near the base of the wi nd-
shi el d. The check val ve consi sts of a mol ded pl asti c
body wi th a rai sed arrowhead mol ded i nto i ts center
secti on that i ndi cates the di recti on of the fl ow
through the val ve, and three barbed hose ni ppl es
formed i n a wye confi gurati on on the outsi de ci rcum-
ference of the center secti on of the val ve body. The
check val ve cannot be adjusted or repai red and, i f
OPERATION
The check val ve provi des more than one functi on
i n thi s appl i cati on. I t serves as a wye connector fi t-
ti ng between the engi ne compartment and washer
nozzl e secti ons of the washer suppl y hose. I t prevents
washer fl ui d from drai ni ng out of the washer suppl y
hoses back to the washer reservoi r. Thi s drai n-back
woul d resul t i n a l engthy del ay from when the
washer swi tch i s actuated unti l washer fl ui d was di s-
pensed through the washer nozzl es, because the
washer pump woul d have to refi l l the washer pl umb-
i ng from the reservoi r to the nozzl es. Such a drai n-
back condi ti on coul d al so resul t i n water, di rt, or
other outsi de contami nants bei ng si phoned i nto the
washer system through the washer nozzl e ori fi ce.
Thi s water coul d subsequentl y freeze and pl ug the
nozzl e, whi l e other contami nants coul d i nterfere wi th
proper nozzl e operati on and cause i mproper nozzl e
spray patterns. I n addi ti on, the check val ve prevents
washer fl ui d from si phoni ng through the washer noz-
zl es after the washer system i s turned Off.
When the washer pump pressuri zes and pumps
washer fl ui d from the reservoi r through the washer
pl umbi ng, the fl ui d pressure unseats a di aphragm
from over a sump wel l wi thi n the val ve by overri di ng
the spri ng pressure appl i ed to i t by a pi ston (Fi g. 4).
Wi th the di aphragm unseated, washer fl ui d i s
al l owed to fl ow toward the two washer nozzl es. When
the washer pump stops operati ng, the spri ng pres-
sure on the pi ston seats the di aphragm over the
sump wel l i n the val ve and fl ui d fl ow i n ei ther di rec-
ti on wi thi n the washer pl umbi ng i s prevented. The
check val ve cannot be adjusted or repai red and, i f
REMOVAL
(1) Remove both wi per arms from the wi per pi vots.
(Refer to 8 - ELECTRI CAL/WI PERS/WASHERS/
WI PER ARM - REMOVAL).
(2) Unl atch and open the hood.
(3) Remove the cowl pl enum cover/gri l l e panel
from over the cowl pl enum. (Refer to 23 - BODY/EX-
TERI OR/COWL GRI LLE - REMOVAL).
(4) From the undersi de of the cowl pl enum cover/
gri l l e panel , di sconnect the cowl pl enum and washer
nozzl e hoses from the three barbed ni ppl es of the
check val ve (Fi g. 5).
(5) Remove the check val ve from the undersi de of
the cowl pl enum cover/gri l l e panel .
INSTALLATION
(1) Posi ti on the check val ve to the undersi de of the
cowl pl enum cover/gri l l e panel (Fi g. 5). Be certai n
that the fl ow di recti on arrow mol ded i nto the check
val ve body i s ori ented towards the washer nozzl es.
Fig. 3 Check Valve
1 - INLET NIPPLE
2 - CHECK VALVE
3 - OUTLET NIPPLE (2)
4 - FLOW DIRECTION ARROW
Fig. 4 Check Valve
1 - SPRING
2 - PISTON
3 - DIAPHRAGM
4 - TO WASHER NOZZLE
5 - FROM WASHER PUMP
CHECK VALVE (Continued)
gri l l e panel , reconnect the cowl pl enum and washer
nozzl e hoses to the three barbed ni ppl es of the check
val ve.
(3) Rei nstal l the cowl pl enum cover/gri l l e panel
over the cowl pl enum. (Refer to 23 - BODY/EXTERI -
OR/COWL GRI LLE - I NSTALLATI ON).
(4) Cl ose and l atch the hood.
(5) Rei nstal l both wi per arms onto the wi per pi v-
ots. (Refer to 8 - ELECTRI CAL/WI PERS/WASHERS/
WI PER ARM - I NSTALLATI ON).
WASHER FLUID LEVEL
SWITCH
DESCRIPTION
The washer fl ui d l evel swi tch i s a si ngl e pol e, si n-
gl e throw reed-type swi tch mounted on the outboard
si de of the of the washer reservoi r i n the engi ne com-
partment (Fi g. 6). Onl y the mol ded pl asti c swi tch
mounti ng fl ange and the i ntegral connector recepta-
cl e are vi si bl e when the swi tch i s i nstal l ed i n the res-
ervoi r. A short ni ppl e formati on extends from the
i nner surface of the swi tch mounti ng fl ange, and a
barb on the ni ppl e near the swi tch mounti ng fl ange
i s pressed through a rubber grommet seal i nstal l ed
i n the mounti ng hol e of the reservoi r.
A smal l , mol ded pl asti c fl oat has two pi vot pi ns
near i ts center that are snapped i nto two receptacl es
near the ends of two stanchi ons that extend toward
the fl oat from the swi tch ni ppl e formati on. A smal l
magnet i s secured wi thi n the end of the fl oat nearest
the swi tch ni ppl e formati on, and a reed swi tch i s con-
ceal ed wi thi n the ni ppl e. A di agnosti c resi stor i s con-
nected between the two swi tch termi nal s wi thi n the
swi tch mounti ng fl ange. The washer fl ui d l evel
swi tch cannot be adjusted or repai red. I f faul ty or
damaged, the swi tch must be repl aced.
OPERATION
The washer fl ui d l evel swi tch uses a pi voti ng,
obl ong fl oat to moni tor the l evel of the washer fl ui d
i n the washer reservoi r. The fl oat contai ns a smal l
magnet. When the fl oat pi vots, the proxi mi ty of thi s
magnet to a stati onary reed swi tch wi thi n the ni ppl e
formati on of the swi tch changes. When the fl ui d l evel
i n the washer reservoi r i s at or above the fl oat l evel ,
the fl oat moves to a verti cal posi ti on, the i nfl uence of
the fl oat magneti c fi el d i s removed from the reed
swi tch, and the normal l y open reed swi tch contacts
open. When the fl ui d l evel i n the washer reservoi r
fal l s bel ow the l evel of the pi voti ng fl oat, the fl oat
moves to a hori zontal posi ti on, the i nfl uence of the
fl oat magneti c fi el d i s appl i ed to the reed swi tch, and
the contacts of the normal l y open reed swi tch cl ose.
The washer fl ui d l evel swi tch i s connected to the
vehi cl e el ectri cal system through a dedi cated take
out and connector of the ri ght (except di esel engi nes)
or l eft (di esel engi nes onl y) headl amp and dash wi re
harness. The swi tch i s connected i n seri es between a
cl ean ground output of the Front Control Modul e
Fig. 5 Check Valve Remove/Install
1 - WASHER NOZZLE HOSE (RIGHT)
2 - CHECK VALVE
3 - ROUTING CLIP
4 - COWL PLENUM WASHER HOSE
5 - COWL PLENUM COVER/GRILLE PANEL (UNDERSIDE)
6 - WASHER NOZZLE HOSE (LEFT)
Fig. 6 Washer Fluid Level Switch
1 - MOUNTING FLANGE
2 - BARBED NIPPLE
3 - FLOAT
4 - RESERVOIR
5 - GROMMET SEAL
6 - PIVOT
7 - MAGNET
CHECK VALVE (Continued)
(FCM) on a sensor return ci rcui t and the washer
fl ui d swi tch sense i nput to the FCM. When the
swi tch cl oses, the FCM senses the ground on the
washer fl ui d swi tch sense ci rcui t. The FCM i s pro-
grammed to respond to thi s i nput by sendi ng an el ec-
troni c washer fl ui d i ndi cator l amp-on message to the
i nstrument cl uster over the Programmabl e Commu-
ni cati ons I nterface (PCI ) data bus. The i nstrument
cl uster responds to thi s message by i l l umi nati ng the
washer fl ui d i ndi cator and by soundi ng an audi bl e
chi me tone warni ng.
The washer fl ui d l evel swi tch may be di agnosed
and tested usi ng conventi onal di agnosti c tool s and
procedures. However, conventi onal di agnosti c meth-
ods may not prove concl usi ve i n the di agnosi s of the
and the FCM that control the operati on of the
washer fl ui d vi sual and/or audi bl e i ndi cators. The
most rel i abl e, effi ci ent, and accurate means to di ag-
nose the washer fl ui d l evel i ndi cator, the i nstrument
cl uster, the FCM, or the el ectroni c message i nputs
and outputs rel ated to the washer fl ui d i ndi cator
REMOVAL
The washer fl ui d l evel swi tch can be removed from
the washer reservoi r wi thout removi ng the reservoi r
from the vehi cl e.
cabl e.
(3) Di sconnect the washer hose from the barbed
outl et ni ppl e of the washer pump/motor uni t and
al l ow the washer fl ui d to drai n i nto a cl ean contai ner
for reuse.
(4) Di sconnect the ri ght (except di esel engi ne) or
l eft (di esel engi ne onl y) headl amp and dash wi re har-
ness connector for the washer fl ui d l evel swi tch from
the swi tch connector receptacl e (Fi g. 7) or (Fi g. 8).
NOTE: The pivoting float of the washer fluid level
switch must be in a horizontal position within the
reservoir in order to be removed. With the reservoir
empty and in an upright position, the pivoting float
will orient itself to the horizontal position when the
switch connector receptacle is pointed straight
upwards.
fl at-bl aded tool , gentl y pry the barbed ni ppl e of the
washer fl ui d l evel swi tch out of the rubber grommet
seal on the reservoi r sump. Care must be taken not
to damage the reservoi r.
(6) Remove the washer fl ui d l evel swi tch from the
washer reservoi r.
(7) Remove the rubber grommet seal from the
washer fl ui d l evel swi tch mounti ng hol e i n the
washer reservoi r and di scard.
Fig. 7 Washer Fluid Level Switch Remove/Install -
Except Diesel Engine
1 - WASHER HOSE
2 - WASHER RESERVOIR
3 - WASHER FLUID LEVEL SWITCH
4 - WIRE HARNESS
5 - WASHER PUMP/MOTOR
Fig. 8 Washer Fluid Level Switch Remove/Install -
Diesel Engine
1 - WIRE HARNESS
4 - WASHER HOSE
WASHER FLUID LEVEL SWITCH (Continued)
INSTALLATION
(1) I nstal l a new rubber grommet seal i nto the
washer fl ui d l evel swi tch mounti ng hol e i n the
washer reservoi r. Al ways use a new rubber grommet
seal on the reservoi r.
(2) I nsert the fl oat of the washer fl ui d l evel swi tch
through the rubber grommet seal and i nto the
washer reservoi r. The connector receptacl e of the
washer fl ui d l evel swi tch shoul d be poi nted upward.
on the washer fl ui d l evel swi tch mounti ng fl ange
unti l the barbed ni ppl e i s ful l y seated i n the rubber
grommet seal i n the washer reservoi r mounti ng hol e.
(4) Reconnect the ri ght (except di esel engi ne) or
ness connector for the washer fl ui d l evel swi tch to
the swi tch connector receptacl e (Fi g. 7) or (Fi g. 8).
(5) Reconnect the removed washer hose to the
barbed outl et ni ppl e of the washer pump/motor uni t.
(6) Refi l l the washer reservoi r wi th the washer
fl ui d drai ned from the reservoi r duri ng the removal
procedure.
WASHER HOSES/TUBES
DESCRIPTION
The washer pl umbi ng consi sts of a smal l di ameter
rubber reservoi r washer hose that i s routed from the
barbed outl et ni ppl e of the el ectri c washer pump/mo-
tor uni t on the washer reservoi r through a trough
mol ded i nto the back of the reservoi r above the
washer pump and to the engi ne compartment washer
hose (Fi g. 9). On model s equi pped wi th an opti onal
di esel engi ne, the reservoi r washer hose i s routed
through routi ng cl i ps on the top of the radi ator fan
shroud from the washer reservoi r on the l eft si de of
the radi ator to the engi ne compartment washer hose
on the ri ght si de of the radi ator. The engi ne compart-
ment washer hose i s contai ned wi thi n the ri ght head-
l amp and dash wi re harness, whi ch i s routed through
the engi ne compartment al ong the top of the ri ght
front fender wheel house to the dash panel .
The engi ne compartment washer hose i s connected
to the washer reservoi r washer hose and to the cowl
pl enum washer hose wi th mol ded pl asti c i n-l i ne fi t-
ti ngs that have a barbed ni ppl e on each end. The
cowl pl enum washer hose i s routed from the engi ne
compartment i nto the cowl pl enum area through a
trough formati on l ocated near the ri ght end of the
cowl pl enum cover/gri l l e panel . The cowl pl enum
washer hose i s connected to the washer system check
val ve/wye fi tti ng on the undersi de of the cowl pl enum
cover/gri l l e panel . The cowl pl enum washer hose and
the two washer nozzl e hoses are routed through i nte-
gral routi ng cl i ps on the undersi de of the cowl pl e-
num cover/gri l l e panel . The cowl pl enum washer hose
i s connected to one ni ppl e on the wye fi tti ng and the
two washer nozzl e hoses are connected to the other
two wye fi tti ng ni ppl es. The washer nozzl e hoses are
then routed al ong the undersi de of the cowl pl enum
cover/gri l l e panel to the two washer nozzl es.
Washer hose i s avai l abl e for servi ce onl y as rol l
stock, whi ch must then be cut to l ength. The mol ded
pl asti c washer hose fi tti ngs cannot be repai red. I f
these fi tti ngs are faul ty or damaged, they must be
repl aced.
OPERATION
Washer fl ui d i n the washer reservoi r i s pressuri zed
and fed by the washer pump/motor through the
washer system pl umbi ng and fi tti ngs to the two
washer nozzl es. Whenever routi ng the washer hose
or a wi re harness contai ni ng a washer hose, i t must
be routed away from hot, sharp, or movi ng parts;
and, sharp bends that mi ght pi nch the hose must be
avoi ded.
WASHER NOZZLE
DESCRIPTION
The two washer nozzl es have i ntegral snap fea-
tures and an anti -rotati on tab that secure them i n
dedi cated hol es i n the cowl pl enum cover/gri l l e panel
l ocated near the base of the wi ndshi el d (Fi g. 10). The
Fig. 9 Engine Compartment Washer Hose
1 - RIGHT FENDER
2 - RIGHT HEADLAMP & DASH WIRE HARNESS
3 - ENGINE COMPARTMENT WASHER HOSE (TO COWL
PLENUM)
5 - ENGINE COMPARTMENT WASHER HOSE (TO WASHER
RESERVOIR)
WASHER FLUID LEVEL SWITCH (Continued)
domed upper surface of the washer nozzl e i s vi si bl e
on the top of the pl enum cover/gri l l e panel , and the
nozzl e ori fi ce i s ori ented towards the wi ndshi el d
gl ass. The washer pl umbi ng fi tti ngs for the washer
nozzl es are conceal ed beneath the cowl pl enum cover/
gri l l e panel . These fl ui di c washer nozzl es are con-
structed of mol ded pl asti c. The cowl pl enum cover/
gri l l e panel must be removed from the vehi cl e to
access the nozzl es for servi ce. The washer nozzl es
cannot be adjusted or repai red. I f faul ty or damaged,
they must be repl aced.
OPERATION
The two washer nozzl es are desi gned to di spense
washer fl ui d i nto the wi per pattern area on the out-
si de of the wi ndshi el d gl ass. Pressuri zed washer fl ui d
i s fed to each nozzl e from the washer reservoi r by the
washer pump/motor uni t through a si ngl e hose,
whi ch i s attached to a barbed ni ppl e on each washer
nozzl e bel ow the cowl pl enum cover/gri l l e panel . A
fl ui di c matri x wi thi n the washer nozzl e causes the
pressuri zed washer fl ui d to be emi tted from the noz-
zl e ori fi ce as an osci l l ati ng stream to more effecti vel y
cover a l arger area of the gl ass to be cl eaned.
REMOVAL
gri l l e panel , di sconnect the washer nozzl e hose from
the barbed ni ppl e of the washer nozzl e (Fi g. 11).
gri l l e panel , rel ease the i ntegral snap features of the
washer nozzl e and push the nozzl e out through the
mounti ng hol e toward the top si de of the cowl pl e-
num cover/gri l l e panel .
(6) Remove the washer nozzl e from the top of the
cowl pl enum cover/gri l l e panel .
INSTALLATION
(1) From the top of the cowl pl enum cover/gri l l e
panel , posi ti on the ni ppl e end of the washer nozzl e
through the mounti ng hol e and engage the anti -rota-
ti on tab of the ni ppl e i nto the anti -rotati on notch i n
the mounti ng hol e.
(2) Usi ng hand pressure, push fi rml y and evenl y
on the top of the washer nozzl e unti l the i ntegral
snap features l ock i nto pl ace on the undersi de of the
cowl pl enum cover/gri l l e panel .
gri l l e panel , reconnect the washer hose to the barbed
ni ppl e of the washer nozzl e (Fi g. 11).
(4) Rei nstal l the washer hose for the washer noz-
zl e i nto i ts routi ng cl i ps on the undersi de of the cowl
pl enum cover/gri l l e panel .
Fig. 10 Washer Nozzle
1 - HOOD
2 - LATCH (2)
3 - NIPPLE
4 - ANTI-ROTATION TAB
5 - ORIFICE
Fig. 11 Washer Nozzle Remove/Install
1 - COWL PLENUM COVER/GRILLE PANEL (UNDERSIDE)
2 - ANTI-ROTATION TAB (LARGE)
3 - NIPPLE
4 - ANTI-ROTATION TAB (SMALL)
5 - PLIERS
6 - LATCH (2)
WASHER NOZZLE (Continued)
WI PER ARM - I NSTALLATI ON).
WASHER PUMP/MOTOR
DESCRIPTION
The washer pump/motor uni t (Fi g. 12) i s l ocated on
the rearward faci ng surface of the washer reservoi r,
i n the ri ght (except di esel engi ne) or l eft (di esel
engi ne onl y) front corner of the engi ne compartment.
A smal l permanentl y l ubri cated and seal ed el ectri c
motor i s coupl ed to the rotor-type washer pump. A
seal fl ange wi th a barbed i nl et ni ppl e on the pump
housi ng passes through a rubber grommet seal
i nstal l ed i n a dedi cated mounti ng hol e of the washer
reservoi r. When the pump i s i nstal l ed i n the reser-
voi r a barbed outl et ni ppl e on the pump housi ng con-
nects the uni t to the washer system through a short
washer reservoi r hose.
The washer pump/motor uni t i s retai ned on the
reservoi r by the i nterference fi t between the barbed
pump i nl et ni ppl e and the grommet seal , whi ch i s a
l i ght press fi t. The top of the washer pump i s al so
secured to the washer reservoi r by the use of a snap
post on the motor housi ng and a snap post receptacl e
mol ded i nto the reservoi r that al l ows for mounti ng of
the washer pump wi thout the use of fasteners. An
i ntegral connector receptacl e on the top of the motor
housi ng connects the uni t to the vehi cl e el ectri cal
system. The washer pump/motor uni t cannot be
repai red. I f faul ty or damaged, the enti re washer
pump/motor uni t must be repl aced.
OPERATION
The washer pump/motor uni t features a smal l
Di rect Current (DC) el ectri c motor. The motor i s con-
nected to the vehi cl e el ectri cal system through a si n-
gl e take out and two-cavi ty connector of the ri ght
(except di esel engi ne) or l eft (di esel engi ne onl y)
headl amp and dash wi re harness. The motor i s
grounded at al l ti mes through another take out of
the ri ght (except di esel engi ne) or l eft (di esel engi ne
onl y) headl amp and dash wi re harness. On model s
wi thout the di esel engi ne, a si ngl e eyel et termi nal
connector i s secured by a nut to a ground stud
l ocated on the ri ght front fender i nner shi el d i n the
engi ne compartment. On model s wi th a di esel engi ne,
an eyel et termi nal connector i s secured by a ground
screw to the l eft front fender i nner shi el d i n the
engi ne compartment. The motor recei ves battery cur-
rent on a washer pump/motor control ci rcui t.
The washer pump/motor control ci rcui t i s energi zed
through a hi gh si de dri ver wi thi n the Front Control
Modul e (FCM) whenever the FCM recei ves an el ec-
troni c message requesti ng washer system operati on
from the i nstrument cl uster over the Programmabl e
Communi cati ons I nterface (PCI ) data bus. The
i nstrument cl uster moni tors a resi stor mul ti pl exed
hard wi red i nput from the momentary washer swi tch
contacts wi thi n the mul ti -functi on swi tch on the
steeri ng col umn to determi ne when i t shoul d i ssue
the el ectroni c message requesti ng washer system
operati on.
Washer fl ui d i s gravi ty-fed from the washer reser-
voi r to the i nl et si de of the washer pump. When the
pump motor i s energi zed, the motor spi ns the rotor
wi thi n the washer pump. The spi nni ng pump rotor
pressuri zes the washer fl ui d and forces i t through
the pump outl et ni ppl e, the washer pl umbi ng, and
the washer nozzl es onto the wi ndshi el d gl ass.
The washer pump/motor uni t may be di agnosed
usi ng conventi onal di agnosti c tool s and methods.
However, conventi onal di agnosti c methods may not
prove concl usi ve i n the di agnosi s of the i nstrument
cl uster, the FCM, or the el ectroni c message i nputs to
or outputs from the i nstrument cl uster and the FCM
that control the operati on of the washer pump/motor
uni t. The most rel i abl e, effi ci ent, and accurate means
to di agnose the washer pump/motor uni t, the i nstru-
ment cl uster, the FCM, or the el ectroni c message
Fig. 12 Washer Pump/Motor
1 - MOTOR
2 - SNAP POST
4 - PUMP
5 - OUTLET NIPPLE
6 - INLET NIPPLE
7 - FILTER SCREEN
WASHER NOZZLE (Continued)
i nputs and outputs rel ated to the washer pump/mo-
tor uni t operati on requi res the use of a DRBI I I scan
tool . Refer to the appropri ate di agnosti c i nformati on.
REMOVAL
The washer pump/motor uni t can be removed from
the washer reservoi r wi thout removi ng the reservoi r
from the vehi cl e.
cabl e.
(3) Di sconnect the washer hose from the barbed
outl et ni ppl e of the washer pump/motor uni t and
al l ow the washer fl ui d to drai n i nto a cl ean contai ner
for reuse.
(4) Di sconnect the ri ght (except di esel engi ne) or
ness connector for the washer pump/motor uni t from
the motor connector receptacl e (Fi g. 13).
(5) Fi rml y grasp the top of the washer pump/motor
housi ng.
(6) Pul l l i ghtl y outward on the top of the washer
pump/motor housi ng away from the washer reservoi r
far enough to di sengage the snap post on the top of
the motor from the receptacl e i n the reservoi r.
(7) Pul l the washer pump/motor uni t strai ght out
from the washer reservoi r far enough to di sengage
the barbed pump i nl et ni ppl e from the rubber grom-
met seal i n the reservoi r.
(8) Di sconnect the reservoi r washer hose from the
washer pump/motor uni t outl et ni ppl e.
(9) Remove washer pump/motor uni t from the back
of the washer reservoi r.
(10) Remove the rubber grommet seal from the
washer reservoi r and di scard.
INSTALLATION
(1) I nstal l a new rubber grommet seal i nto the
washer pump mounti ng hol e i n the washer reservoi r.
Al ways use a new rubber grommet seal on the reser-
voi r.
(2) Posi ti on the barbed i nl et ni ppl e of the washer
pump to the rubber grommet seal i n the washer res-
ervoi r (Fi g. 13).
(3) Usi ng hand pressure, press on the washer
pump/motor uni t fi rml y and evenl y unti l the barbed
i nl et ni ppl e i s ful l y seated i n the rubber grommet
seal i n the washer reservoi r mounti ng hol e.
(4) Al i gn the washer pump/motor snap post on the
top of the motor housi ng wi th the snap post recepta-
cl e i n the washer reservoi r.
on the top of washer pump/motor uni t unti l the snap
post snaps i nto the washer reservoi r receptacl e.
(6) Reconnect the washer reservoi r hose to the
barbed outl et ni ppl e of the washer pump.
(7) Reconnect the ri ght (except di esel engi ne) or
ness connector for the washer pump/motor uni t to
the motor connector receptacl e.
procedure.
WASHER RESERVOIR
DESCRIPTION
Except on model s equi pped wi th an opti onal di esel
engi ne, the mol ded pl asti c washer fl ui d reservoi r i s
mounted on the ri ght rearward faci ng surface of the
cool i ng modul e radi ator shroud i n the engi ne com-
partment (Fi g. 14). On model s wi th the di esel engi ne,
the mol ded pl asti c washer fl ui d reservoi r i s mounted
on the rearward faci ng surface of the l eft verti cal
member of the radi ator support i n the engi ne com-
partment. The reservoi r i s a mol ded uni t constructed
of a transl ucent pl asti c that al l ows the washer fl ui d
l evel to be i nspected wi thout removi ng the washer
Fig. 13 Washer Pump/Motor Remove/Install
2 - SNAP POST
3 - SNAP POST RECEPTACLE
4 - GROMMET SEAL
7 - INLET NIPPLE
8 - OUTLET NIPPLE
WASHER PUMP/MOTOR (Continued)
reservoi r cap. The most vi si bl e component of the
washer reservoi r i s the fi l l er cap uni t, whi ch i s
secured to and hi nges on a hook feature that i s i nte-
gral to the fi l l er neck near the top of the reservoi r.
The bri ght yel l ow pl asti c fi l l er cap snaps over the
fi l l er neck openi ng and seal s the reservoi r openi ng
wi th an i ntegral rubber gasket. The fi l l er cap i s
l abel ed wi th an I nternati onal Control and Di spl ay
Symbol i con for Wi ndshi el d Washer and the text
Washer Fl ui d Onl y that are mol ded i nto i t and
hi ghl i ghted i n bl ack agai nst the yel l ow pl asti c cap for
vi si bi l i ty.
There are dedi cated hol es near the bottom of the
rearward faci ng si de of the reservoi r provi ded for the
mounti ng of the washer pump/motor uni t and the
washer fl ui d l evel swi tch. A snap post receptacl e
mol ded i nto the reservoi r al l ows for mounti ng of the
washer pump wi thout the use of fasteners. The res-
ervoi r al so features an i ntegral hose routi ng trough
on i ts rearward faci ng si de. Except on model s wi th a
di esel engi ne, the washer reservoi r i s secured to the
cool i ng modul e radi ator shroud wi th three i ntegral
tabs, two at the bottom and one at the top. The two
bottom tabs are i nserted i nto two sl ots near the bot-
tom of the shroud, whi l e the upper tab sl i des i nto an
i ntegral channel -l i ke sl ot near the top of the shroud.
A mol ded l ock feature on the forward faci ng surface
of the reservoi r engages a mol ded depressi on on the
rearward faci ng surface of the radi ator shroud when
the reservoi r i s ful l y seated on the shroud, l ocki ng
the uni t securel y i n pl ace. On model s wi th a di esel
engi ne, the washer reservoi r i s secured wi th two
screws through i ntegral mounti ng tabs to the l eft
verti cal member of the radi ator support. On many
model s, a mol ded pl asti c cool ant recovery contai ner
or a cool ant pressure contai ner must be detached
from the top of the cool i ng modul e and moved asi de
to access the washer fl ui d reservoi r for servi ce. Thi s
may be accompl i shed wi thout openi ng or drai ni ng the
engi ne cool i ng system.
OPERATION
The washer fl ui d reservoi r provi des a secure,
on-vehi cl e storage l ocati on for a l arge reserve of
washer fl ui d for operati on of the washer system. The
washer reservoi r fi l l er neck provi des a cl earl y
marked and readi l y accessi bl e poi nt from whi ch to
add washer fl ui d to the reservoi r. The washer/pump
motor uni t i s l ocated i n a sump area near the bottom
of the reservoi r to be certai n that washer fl ui d wi l l
be avai l abl e to the pump as the fl ui d l evel i n the res-
ervoi r becomes depl eted. The washer pump/motor
uni t i s mounted i n the l owest posi ti on i n the sump.
The washer fl ui d l evel swi tch i s mounted just above
the sump area of the reservoi r so that there wi l l be
adequate warni ng to the vehi cl e operator that the
washer fl ui d l evel i s l ow, wel l before the washer sys-
tem wi l l no l onger operate.
REMOVAL
REMOVAL - EXCEPT DIESEL ENGINE
cabl e.
(3) Remove the fasteners securi ng the cool ant
recovery contai ner or the cool ant pressure contai ner
to the top of the cool i ng modul e and move the con-
tai ner asi de. I t i s not necessary to open or drai n the
engi ne cool i ng system. (Refer to 7 - COOLI NG/EN-
GI NE/COOLANT RECOVERY CONTAI NER -
REMOVAL) or (Refer to 7 - COOLI NG/ENGI NE/
COOLANT RECOVERY PRESSURE CONTAI NER -
REMOVAL).
barbed ni ppl e of the i nl i ne fi tti ng at the engi ne com-
partment washer hose i n the ri ght headl amp and
dash wi re harness and al l ow the washer fl ui d to
Fig. 14 Washer Reservoir - except Diesel Engine
1 - TOP TAB
2 - HOOK FEATURE
3 - CAP
4 - RESERVOIR
5 - TROUGH
6 - HOSE
7 - LOCK FEATURE
10 - BOTTOM TAB (2)
WASHER RESERVOIR (Continued)
drai n from the reservoi r i nto a cl ean contai ner for
reuse (Fi g. 15).
(5) Di sconnect the ri ght headl amp and dash wi re
harness connector for the washer fl ui d l evel swi tch
from the swi tch connector receptacl e.
(6) Di sconnect the ri ght headl amp and dash wi re
harness connector for the washer pump/motor uni t
from the motor connector receptacl e.
(7) Grasp the bottom of the washer reservoi r
fi rml y wi th both hands and pul l the uni t sharpl y
upward to di sengage the l ocki ng feature on the
washer reservoi r from the depressi on i n the radi ator
shroud.
(8) Conti nue l i fti ng the washer reservoi r upward
far enough to di sengage the three mounti ng tabs (one
at the top and two at the bottom) from the channel -
l i ke sl ot at the top and the two sl ots at the bottom of
the radi ator shroud.
(9) Remove the washer reservoi r from the ri ght
si de of the engi ne compartment.
REMOVAL - DIESEL ENGINE
cabl e.
(3) Di sengage the reservoi r washer hose from the
i ntegral routi ng cl i ps on the top of the radi ator fan
shroud (Fi g. 16).
dash wi re harness and al l ow the washer fl ui d to
drai n from the reservoi r i nto a cl ean contai ner for
reuse.
(5) Di sconnect the l eft headl amp and dash wi re
harness connector for the washer fl ui d l evel swi tch
from the swi tch connector receptacl e.
harness connector for the washer pump/motor uni t
from the motor connector receptacl e.
(7) Remove the two screws that secure the washer
reservoi r to the l eft verti cal member of the radi ator
support (Fi g. 17).
(8) Remove the washer reservoi r from the l eft si de
of the engi ne compartment.
Fig. 15 Washer Reservoir Remove/Install
1 - TOP TAB
2 - RADIATOR SHROUD
3 - TOP SLOT
4 - RIGHT HEADLAMP & DASH WIRE HARNESS
5 - ENGINE COMPARTMENT WASHER HOSE
6 - BOTTOM SLOT (2)
7 - RESERVOIR WASHER HOSE
8 - BOTTOM TAB (2)
12 - LOCK FEATURE
Fig. 16 Washer Reservoir Connections - Diesel
Engine
1 - WIRE HARNESS
4 - WASHER HOSE
INSTALLATION
INSTALLATION - EXCEPT DIESEL ENGINE
(1) Posi ti on the washer reservoi r i nto the ri ght
si de of the engi ne compartment.
(2) Al i gn and i nsert the three mounti ng tabs (one
at the top and two at the bottom) i nto the two sl ots
at the bottom and the channel -l i ke sl ot at the top of
the radi ator shroud (Fi g. 15).
(3) Pl ace both hands on the top of the washer res-
ervoi r and push the uni t downward far enough for
the l ocki ng feature on the washer reservoi r to snap
i nto the depressi on i n the radi ator shroud.
(4) Reconnect the ri ght headl amp and dash wi re
harness connector for the washer pump/motor uni t to
the motor connector receptacl e.
(5) Reconnect the ri ght headl amp and dash wi re
harness connector for the washer fl ui d l evel swi tch to
the swi tch connector receptacl e.
(6) Reconnect the reservoi r washer hose to the
dash wi re harness.
(7) Reposi ti on the cool ant recovery contai ner or the
cool ant pressure contai ner to the top of the cool i ng
modul e and rei nstal l the fasteners that secure i t
there. (Refer to 7 - COOLI NG/ENGI NE/COOLANT
RECOVERY CONTAI NER - I NSTALLATI ON) or
(Refer to 7 - COOLI NG/ENGI NE/COOLANT RECOV-
ERY PRESSURE CONTAI NER - I NSTALLATI ON).
procedure.
INSTALLATION - DIESEL ENGINE
(1) Posi ti on the washer reservoi r i nto the l eft si de
of the engi ne compartment (Fi g. 17).
the washer reservoi r to the l eft verti cal member of
the radi ator support. Ti ghten the screws to 10 Nm
(85 i n. l bs.).
(3) Reconnect the l eft headl amp and dash wi re
harness connector for the washer pump/motor uni t to
the motor connector receptacl e (Fi g. 16).
harness connector for the washer fl ui d l evel swi tch to
the swi tch connector receptacl e.
(5) Reconnect the reservoi r washer hose to the
dash wi re harness.
(6) Engage the reservoi r washer hose i nto the i nte-
gral routi ng cl i ps on the top of the radi ator fan
shroud.
procedure.
WIPER ARM
DESCRIPTION
The wi per arms are the ri gi d members l ocated
between the wi per pi vots that protrude from the cowl
Fig. 17 Washer Reservoir
Remove/Install - Diesel Engine
1 - RESERVOIR WASHER HOSE
3 - SCREW (2)
Fig. 18 Wiper Arm
1 - HOOK
2 - STRAP
3 - PIVOT END
4 - KEY
5 - LATCH
6 - HINGE PIN
7 - TENSION SPRING
8 - CHANNEL
pl enum cover/gri l l e panel near the base of the wi nd-
shi el d and the wi per bl ades on the wi ndshi el d gl ass
(Fi g. 18). These wi per arms feature an over-center
hi nge that al l ows easy access to the wi ndshi el d gl ass
for cl eani ng. The wi per arm has a di e cast metal
pi vot end wi th a l arge i nternal l y serrated socket for-
mati on at one end. A key wi thi n the socket formati on
i ndexes the wi per arm to a keyway i n the pi vot shaft
of the wi per modul e to provi de wi per al i gnment, and
a spri ng-l oaded l atch on the undersi de of the wi per
arm pi vot end l ocks the uni t to the pi vot shaft when
i t i s ful l y i nstal l ed. The ri ght and l eft wi per arms for
thi s model are not i nterchangeabl e, as the ri ght
wi per arm i s sl i ghtl y l onger than the l eft one.
The wi de end of a tapered, stamped steel channel
hi nges on and i s secured wi th a hi nge pi n to the
bl ade end of the wi per arm pi vot end. One end of a
l ong, ri gi d, stamped steel strap, wi th a smal l hol e
near i ts pi vot end, i s ri veted and cri mped wi thi n the
narrow end of the stamped steel channel . The ti p of
the wi per bl ade end of thi s strap i s bent back under
i tsel f to form a smal l hook. Conceal ed wi thi n the
stamped steel channel , one end of a l ong spri ng i s
engaged wi th a wi re hook on the undersi de of the di e
cast pi vot end, whi l e the other end of the spri ng i s
hooked through the smal l hol e i n the steel strap. The
enti re wi per arm has a sati n bl ack fi ni sh appl i ed to
al l of i ts vi si bl e surfaces.
A wi per arm cannot be adjusted or repai red. I f
damaged or faul ty, the enti re wi per arm uni t must be
repl aced.
OPERATION
The wi per arms are desi gned to mechani cal l y
transmi t the moti on from the wi per pi vots to the
wi per bl ades. The wi per arm must be properl y
i ndexed to the wi per pi vot i n order to mai ntai n the
proper wi per bl ade travel on the gl ass. The serrated
and keyed socket formati on i n the wi per arm pi vot
end i nterl ocks wi th the serrati ons and keyway on the
outer ci rcumference of the wi per pi vot shaft, provi d-
i ng posi ti ve engagement and al i gnment of thi s con-
necti on. The l atch posi ti vel y l ocks the wi per arm to
the wi per pi vot shaft when the arm i s ful l y i nstal l ed.
The spri ng-l oaded wi per arm hi nge control s the
down-force appl i ed through the ti p of the wi per arm
to the wi per bl ade on the gl ass. The hook formati on
on the ti p of the wi per arm provi des a cradl e for
securi ng and l atchi ng the wi per bl ade pi vot bl ock to
the wi per arm.
REMOVAL
(1) Li ft the wi per arm to i ts over-center posi ti on to
hol d the wi per bl ade off of the gl ass and rel i eve the
spri ng tensi on on the wi per arm to wi per pi vot shaft
connecti on.
(2) Pul l the l atch on the pi vot end of the wi per
arm outward (Fi g. 19).
(3) Remove the wi per arm pi vot end from the
wi per pi vot shaft.
INSTALLATION
The ri ght and l eft wi per arms are not i nterchange-
abl e. The ri ght wi per arm i s sl i ghtl y l onger than the
l eft. Be certai n that each wi per arm i s i nstal l ed on
the proper wi per pi vot.
(1) Pl ace the wi per arm hi nge i n i ts over-center
posi ti on pri or to attempti ng i nstal l ati on.
(2) The wi per arms are i ndexed to the wi per pi vot
shafts wi th i ntegral keys i n the wi per arm pi vot ends
and keyways i n the wi per pi vot shafts. Al i gn the key
of the wi per arm to the keyway on the wi per pi vot
shaft.
(3) Once the wi per bl ade i s al i gned, push the pi vot
of the wi per arm down fi rml y and evenl y over the
wi per pi vot shaft unti l i t i s ful l y engaged. When the
wi per arm i s ful l y engaged on the wi per pi vot, the
spri ng-l oaded l atch (Fi g. 19) wi l l snap back i nto pl ace
agai nst the wi per arm pi vot end.
(4) Gentl y l ower the wi per arm unti l the wi per
bl ade i s i n posi ti on on the wi ndshi el d gl ass.
WIPER BLADE
DESCRIPTION
Each wi per bl ade i s secured by an i ntegral l atchi ng
pi vot bl ock to the hook formati on on the ti p of each
wi per arm, and rests on the gl ass near the base of
the wi ndshi el d when the wi pers are not i n operati on
(Fi g. 20). The wi per bl ade consi sts of the fol l owi ng
components:
Fig. 19 Wiper Arm Remove/Install
1 - WIPER ARM PIVOT END
2 - LATCH
WIPER ARM (Continued)
Superstructure - The superstructure i ncl udes
several stamped steel bri dges and l i nks wi th cl aw
formati ons that gri p the wi per bl ade el ement. Al so
i ncl uded i n thi s uni t i s the l atchi ng, mol ded pl asti c
pi vot bl ock that secures the superstructure to the
wi per arm. Al l of the metal components of the wi per
bl ade have a sati n bl ack fi ni sh appl i ed.
Element - The wi per el ement or squeegee i s the
resi l i ent rubber member of the wi per bl ade that con-
tacts the gl ass.
Flexor - The fl exor i s a ri gi d metal component
runni ng al ong the l ength of each si de of the wi per
el ement where i t i s gri pped by the cl aws of the
superstructure.
Al l model s have two 60.00 centi meter (23.62 i nch)
l ong wi per bl ades wi th non-repl aceabl e rubber el e-
ments (squeegees). The wi per bl ades cannot be
adjusted or repai red. I f faul ty, worn, or damaged the
enti re wi per bl ade uni t must be repl aced.
OPERATION
The wi per bl ades are moved back and forth across
the gl ass by the wi per arms when the wi pers are
bei ng operated. The wi per bl ade superstructure i s
the fl exi bl e frame that gri ps the wi per bl ade el ement
and evenl y di stri butes the force of the spri ng-l oaded
wi per arm al ong the l ength of the el ement. The com-
bi nati on of the wi per arm force and the fl exi bi l i ty of
the superstructure makes the el ement conform to
and mai ntai n proper contact wi th the gl ass, even as
the bl ade i s moved over the vari ed curvature that
may be encountered across the gl ass surface. The
wi per el ement fl exor provi des the cl aws of the bl ade
superstructure wi th a ri gi d, yet fl exi bl e component
on the el ement whi ch can be gri pped. The rubber el e-
ment i s desi gned to be sti ff enough to mai ntai n an
even cl eani ng edge as i t i s drawn across the gl ass,
yet resi l i ent enough to conform to the gl ass surface
and fl i p from one cl eani ng edge to the other each
ti me the wi per bl ade changes di recti ons.
REMOVAL
NOTE: The notched end of the wiper element flexor
should always be oriented towards the end of the
wiper blade that is nearest to the wiper pivot.
(1) Li ft the wi per arm to rai se the wi per bl ade and
el ement off of the gl ass, unti l the wi per arm hi nge i s
i n i ts over-center posi ti on.
(2) To remove the wi per bl ade from the wi per arm,
depress the pi vot bl ock l atch rel ease tab under the
ti p of the arm and sl i de the bl ade away from the ti p
towards the pi vot end of the arm far enough to di s-
engage the pi vot bl ock from the hook formati on on
the end of the arm (Fi g. 21).
(3) Extract the hook formati on on the ti p of the
wi per arm through the openi ng i n the wi per bl ade
superstructure just ahead of the wi per bl ade pi vot
bl ock/l atch uni t.
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(4) Gentl y l ower the ti p of the wi per arm onto the
gl ass.
Fig. 20 Wiper Blade
1 - SUPERSTRUCTURE
2 - ELEMENT
3 - PIVOT BLOCK
4 - RELEASE TAB
5 - PIVOT PIN
6 - CLAWS
7 - FLEXOR
Fig. 21 Wiper Blade Remove/Install
1 - SUPERSTRUCTURE
2 - WIPER ARM
3 - PIVOT BLOCK
4 - RELEASE TAB
5 - HOOK
6 - ELEMENT
WIPER BLADE (Continued)
INSTALLATION
NOTE: The notched end of the wiper element flexor
should always be oriented towards the end of the
wiper blade that is nearest to the wiper pivot.
(1) Li ft the wi per arm off of the wi ndshi el d gl ass,
unti l the wi per arm hi nge i s i n i ts over-center posi -
ti on.
(2) Posi ti on the wi per bl ade near the hook forma-
ti on on the ti p of the arm wi th the notched end of the
wi per el ement fl exor ori ented towards the end of the
wi per arm that i s nearest to the wi per pi vot.
(3) I nsert the hook formati on on the ti p of the
wi per arm through the openi ng i n the wi per bl ade
superstructure ahead of the wi per bl ade pi vot bl ock/
l atch uni t far enough to engage the pi vot bl ock i nto
the hook (Fi g. 21).
(4) Sl i de the wi per bl ade pi vot bl ock/l atch up i nto
the hook formati on on the ti p of the wi per arm unti l
the l atch rel ease tab snaps i nto i ts l ocked posi ti on.
Latch engagement wi l l be accompani ed by an audi bl e
cl i ck.
(5) Gentl y l ower the wi per bl ade onto the gl ass.
WIPER HIGH/LOW RELAY
DESCRIPTION
The wi per hi gh/l ow rel ay i s l ocated i n the I nte-
grated Power Modul e (I PM) i n the engi ne compart-
ment near the battery. The wi per hi gh/l ow rel ay i s a
conventi onal I nternati onal Standards Organi zati on
(I SO) mi cro rel ay (Fi g. 22). Rel ays conformi ng to the
I SO speci fi cati ons have common physi cal di mensi ons,
current capaci ti es, termi nal patterns, and termi nal
functi ons. The rel ay i s contai ned wi thi n a smal l , rect-
angul ar, mol ded pl asti c housi ng and i s connected to
al l of the requi red i nputs and outputs by fi ve i ntegral
mal e spade-type termi nal s that extend from the bot-
tom of the rel ay base.
The wi per hi gh/l ow rel ay cannot be adjusted or
repl aced.
OPERATION
The wi per hi gh/l ow rel ay i s an el ectromechani cal
put to the wi per motor. The movabl e common feed
The wi per hi gh/l ow rel ay termi nal s are connected
to the vehi cl e el ectri cal system through a connector
receptacl e i n the I ntegrated Power Modul e (I PM).
The i nputs and outputs of the wi per hi gh/l ow rel ay
i ncl ude:
termi nal (30) i s connected to the output of the wi per
on/off rel ay at al l ti mes through the wi per on/off
rel ay output ci rcui t.
Control Modul e (FCM) through a wi per hi gh/l ow
rel ay control ci rcui t. The FCM control s wi per motor
operati on by control l i ng a ground path through thi s
ci rcui t.
mi nal (86) recei ves battery current when the i gni ti on
swi tch i s i n the On or Accessory posi ti ons from a fuse
i n the I ntegrated Power Modul e (I PM) through a
fused i gni ti on swi tch output (run-acc) ci rcui t.
termi nal (87) i s connected to the hi gh speed brush of
the wi per motor through a wi per hi gh/l ow rel ay hi gh
speed output ci rcui t, and i s connected to the hi gh
speed brush whenever the rel ay i s energi zed.
cl osed termi nal (87A) i s connected to the l ow speed
brush of the wi per motor through a wi per hi gh/l ow
rel ay l ow speed output ci rcui t, and i s connected to
the l ow speed brush whenever the rel ay i s de-ener-
gi zed.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
WIPER BLADE (Continued)
The wi per hi gh/l ow rel ay can be di agnosed usi ng
conventi onal di agnosti c tool s and methods. However,
conventi onal di agnosti c methods may not prove con-
cl usi ve i n the di agnosi s of the i nstrument cl uster, the
Front Control Modul e (FCM), or the el ectroni c mes-
and the FCM that control the operati on of the wi per
hi gh/l ow rel ay. The most rel i abl e, effi ci ent, and accu-
rate means to di agnose the wi per hi gh/l ow rel ay, the
sage i nputs and outputs rel ated to the wi per hi gh/l ow
rel ay operati on requi res the use of a DRBI I I scan
tool . Refer to the appropri ate di agnosti c i nformati on.
DIAGNOSIS AND TESTING - WIPER HIGH/LOW
RELAY
The wi per hi gh/l ow rel ay (Fi g. 23) i s l ocated i n the
I ntegrated Power Modul e (I PM) i n the engi ne com-
partment near the battery. Refer to the appropri ate
wi ri ng i nformati on. The wi ri ng i nformati on i ncl udes
wi ri ng di agrams, proper wi re and connector repai r
procedures, detai l s of wi re harness routi ng and
retenti on, connector pi n-out i nformati on and l ocati on
vi ews for the vari ous wi re harness connectors, spl i ces
and grounds.
(1) Remove the wi per hi gh/l ow rel ay from the I PM.
WI PER HI GH/LOW RELAY - REMOVAL).
REMOVAL
cabl e.
(2) Remove the cover from the I ntegrated Power
Modul e (I PM) (Fi g. 24).
(3) Remove the wi per hi gh/l ow rel ay by graspi ng i t
i n the I PM.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
Fig. 24 Integrated Power Module
1 - 15 - CARTRIDGE FUSE
16 - 53 - BLADE FUSE
54 - HEATED MIRROR RELAY
55 - WIPER ON/OFF RELAY
56 - A/C CONDENSER FAN RELAY
57 - ENGINE CONTROL RELAY
58 - FUEL PUMP RELAY
59 - TRANSMISSION RELAY
60 - WIPER HIGH/LOW RELAY
61 - SPARE
62 - FOG LAMP RELAY
63 - ADJUSTABLE PEDAL RELAY
64 - A/C CLUTCH RELAY
65 - SPARE
66 - O2 RELAY
67 - SPARE
68 - SPARE
69 - SPARE
70 - SPARE
71 - SPARE
72 - STARTER RELAY
73 - PARK LAMP RELAY
WIPER HIGH/LOW RELAY (Continued)
INSTALLATION
(1) Posi ti on the wi per hi gh/l ow rel ay to the proper
receptacl e i n the I ntegrated Power Modul e (I PM)
(Fi g. 24).
(2) Al i gn the wi per hi gh/l ow rel ay termi nal s wi th
the termi nal cavi ti es i n the I PM receptacl e.
(3) Push fi rml y and evenl y on the top of the wi per
hi gh/l ow rel ay unti l the termi nal s are ful l y seated i n
the termi nal cavi ti es i n the I PM receptacl e.
(4) Rei nstal l the cover onto the I PM.
WIPER MODULE
DESCRIPTION
The wi per motor bracket i s secured wi th two
screws bel ow the wi per motor through two rubber
i nsul ators to the bottom of the cowl pl enum panel
beneath the cowl pl enum cover/gri l l e panel (Fi g. 25).
Two screws secure the top of the wi per modul e
bracket to the cowl pl enum panel through rubber
i nsul ators l ocated on the outboard end of each pi vot
bracket. The ends of the wi per pi vot shafts that pro-
trude through dedi cated openi ngs i n the cowl pl enum
cover/gri l l e panel to dri ve the wi per arms and bl ades
are the onl y vi si bl e components of the wi per modul e.
The wi per modul e consi sts of the fol l owi ng major
components:
Bracket - The wi per modul e bracket consi sts of
a l ong tubul ar steel mai n member that has a di e cast
pi vot bracket formati on near each end where the two
wi per pi vots are secured. A stamped steel cl amp
secures the center of the tubul ar member to the di e
cast bracket i ntegral to the wi per motor wi th two
screws.
Crank Arm - The wi per motor crank arm i s a
stamped steel uni t wi th a sl otted hol e on the dri ven
end that i s secured to the wi per motor output shaft
wi th a nut, and has a bal l stud secured to the dri ve
end.
Linkage - Two stamped steel dri ve l i nks con-
nect the wi per motor crank arm to the wi per pi vot
l ever arms. The l eft si de dri ve l i nk has a pl asti c sock-
et-type bushi ng on each end. The ri ght si de dri ve
l i nk has a pl asti c socket-type bushi ng on one end,
and a pl asti c sl eeve-type bushi ng on the other end.
The socket-type bushi ng on one end of each dri ve
l i nk i s snap-fi t over the bal l stud on the l ever arm of
i ts respecti ve pi vot. The ri ght si de dri ve l i nk sl eeve-
type bushi ng end i s then fi t over the motor crank
arm bal l stud, and the other socket-type bushi ng of
the l eft si de dri ve l i nk i s snap-fi t over the exposed
end of the wi per motor crank arm bal l stud.
Motor - The wi per motor features an i ntegral
di e cast bracket to whi ch the wi per modul e bracket i s
secured wi th a stamped steel cl amp and two screws
near the top and whi ch has two rubber i nsul ated
mounti ng ears at the bottom. Thi s di e casti ng al so
serves as the wi per motor transmi ssi on housi ng from
whi ch the wi per motor output shaft exi ts. A nut
secures the wi per motor crank arm to the motor out-
put shaft. The two-speed permanent magnet wi per
motor features an i ntegral transmi ssi on, an i nternal
park swi tch, and an i nternal automati c resetti ng ci r-
cui t breaker.
Pivots - The two front wi per pi vots are secured
wi thi n the di e cast pi vot brackets on the outboard
ends of the wi per modul e mai n member. The l ever
arms that extend from the center of the pi vot shafts
each have a bal l stud on thei r end. The upper end of
each pi vot shaft where the wi per arms wi l l be fas-
tened each has a serrated dri ver wi th a keyway. The
l ower ends of the pi vot shafts are i nstal l ed through
l ubri cated bushi ngs i n the pi vot brackets and are
secured wi th snap ri ngs.
The wi per modul e cannot be adjusted or repai red.
I f any component of the modul e i s faul ty or damaged,
the enti re wi per modul e uni t must be repl aced.
Fig. 25 Wiper Module
1 - PIVOT BRACKET (2)
2 - TUBE
3 - CLAMP
4 - PIVOT SHAFT (2)
5 - INSULATOR (4)
6 - LINKAGE BUSHING (4)
7 - DRIVE LINK (2)
8 - PIVOT CRANK ARM (2)
9 - PIGTAIL WIRE CONNECTOR
10 - MOTOR CRANK ARM
11 - WIPER MOTOR
WIPER HIGH/LOW RELAY (Continued)
OPERATION
The wi per modul e operati on i s control l ed by the
battery current i nputs recei ved by the wi per motor
through the wi per on/off and wi per hi gh/l ow rel ays.
The wi per motor speed i s control l ed by current fl ow
to ei ther the l ow speed or the hi gh speed set of
brushes. The park swi tch i s a si ngl e pol e, si ngl e
throw, momentary swi tch wi thi n the wi per motor
that i s mechani cal l y actuated by the wi per motor
transmi ssi on components. The park swi tch al ter-
natel y opens and cl oses the wi per park swi tch sense
ci rcui t to ground, dependi ng upon the posi ti on of the
wi pers on the gl ass. Thi s feature al l ows the motor to
compl ete i ts current wi pe cycl e after the wi per sys-
tem has been turned Off, and to park the wi per
bl ades i n the l owest porti on of the wi pe pattern. The
automati c resetti ng ci rcui t breaker protects the
motor from overl oads. The wi per motor crank arm,
the two wi per l i nkage members, and the two wi per
pi vots mechani cal l y convert the rotary output of the
wi per motor to the back and forth wi pi ng moti on of
the wi per arms and bl ades on the gl ass.
REMOVAL
cabl e.
harness connector for the wi per motor from the
motor pi gtai l wi re connector (Fi g. 26).
(6) Remove the two screws that secure the wi per
modul e to the top of the cowl pl enum panel at the
pi vot brackets.
(7) Remove the two screws that secure the wi per
modul e to the bottom of the cowl pl enum panel .
(8) Remove the wi per modul e from the cowl pl e-
num panel as a uni t.
INSTALLATION
(1) Posi ti on the wi per modul e i nto the cowl pl e-
num as a uni t (Fi g. 26).
(2) I nstal l the two screws that secure the wi per
modul e to the top of the cowl pl enum panel at the
pi vot brackets. Ti ghten the screw on the dri ver si de,
fol l owed by the screw on the passenger si de. Ti ghten
the screws to 7 Nm (60 i n. l bs.).
(3) I nstal l and ti ghten the screws that secure the
wi per modul e to the bottom of the cowl pl enum
panel . Ti ghten the screw on the passenger si de, fol -
l owed by the screw on the dri ver si de. Ti ghten the
screws to 7 Nm (60 i n. l bs.).
harness connector for the wi per motor to the motor
pi gtai l wi re connector.
WI PER ARMS - I NSTALLATI ON).
WIPER MODULE (Continued)
WIPER ON/OFF RELAY
DESCRIPTION
The wi per on/off rel ay i s l ocated i n the I ntegrated
Power Modul e (I PM) i n the engi ne compartment near
the battery. The wi per on/off rel ay i s a conventi onal
I nternati onal Standards Organi zati on (I SO) mi cro
rel ay (Fi g. 27). Rel ays conformi ng to the I SO speci fi -
cati ons have common physi cal di mensi ons, current
capaci ti es, termi nal patterns, and termi nal functi ons.
The rel ay i s contai ned wi thi n a smal l , rectangul ar,
mol ded pl asti c housi ng and i s connected to al l of the
requi red i nputs and outputs by fi ve i ntegral mal e
spade-type termi nal s that extend from the bottom of
the rel ay base.
Fig. 26 Wiper Module Remove/Install
2 - PLASTIC FASTENER (6)
3 - SCREW (2)
4 - WIPER ARM & BLADE (2)
5 - COWL PLENUM COVER/GRILLE PANEL
6 - WIPER MODULE
8 - PLENUM PANEL
9 - SCREW (4)
10 - ENGINE COMPARTMENT WASHER HOSE
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
WIPER MODULE (Continued)
The wi per on/off rel ay cannot be adjusted or
repl aced.
OPERATION
The wi per on/off rel ay i s an el ectromechani cal
put to the wi per motor. The movabl e common feed
The wi per on/off rel ay termi nal s are connected to
the vehi cl e el ectri cal system through a connector
receptacl e i n the I ntegrated Power Modul e (I PM).
The i nputs and outputs of the wi per on/off rel ay
i ncl ude:
termi nal (30) i s connected to the common feed termi -
nal of the wi per hi gh/l ow rel ay at al l ti mes through
the wi per on/off rel ay output ci rcui t.
Control Modul e (FCM) through a wi per on/off rel ay
control ci rcui t. The FCM control s wi per motor opera-
ti on by control l i ng a ground path through thi s ci r-
cui t.
mi nal (86) recei ves battery current at al l ti mes from
a fuse i n the I PM through a fused i gni ti on swi tch
output (run-acc) ci rcui t.
termi nal (87) recei ves battery current at al l ti mes
from a fuse i n the I PM through a fused i gni ti on
swi tch output (run-acc) ci rcui t, and provi des battery
current to the wi per on/off rel ay output ci rcui t when-
cl osed termi nal (87A) i s connected to ground at al l
ti mes through a take out of the l eft headl amp and
dash wi re harness wi th an eyel et termi nal connector
that i s secured by a screw to the front end sheet
metal , and i s connected to the wi per on/off rel ay out-
put ci rcui t whenever the rel ay i s de-energi zed.
The wi per on/off rel ay may be di agnosed usi ng con-
venti onal di agnosti c tool s and methods. However,
conventi onal di agnosti c methods may not prove con-
cl usi ve i n the di agnosi s of the i nstrument cl uster, the
Front Control Modul e (FCM), or the el ectroni c mes-
and the FCM that control the operati on of the wi per
on/off rel ay. The most rel i abl e, effi ci ent, and accurate
means to di agnose the wi per on/off rel ay, the i nstru-
ment cl uster, the FCM, or the el ectroni c message
i nputs and outputs rel ated to the wi per on/off rel ay
operati on requi res the use of a DRBI I I scan tool .
DIAGNOSIS AND TESTING - WIPER ON/OFF
RELAY
The wi per on/off rel ay (Fi g. 28) i s l ocated i n the
I ntegrated Power Modul e (I PM) i n the engi ne com-
partment near the battery. Refer to the appropri ate
wi ri ng i nformati on. The wi ri ng i nformati on i ncl udes
wi ri ng di agrams, proper wi re and connector repai r
procedures, detai l s of wi re harness routi ng and
retenti on, connector pi n-out i nformati on and l ocati on
vi ews for the vari ous wi re harness connectors, spl i ces
and grounds.
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
WIPER ON/OFF RELAY (Continued)
(1) Remove the wi per on/off rel ay from the I PM.
WI PER ON/OFF RELAY - REMOVAL).
REMOVAL
cabl e.
(2) Remove the cover from the I ntegrated Power
Modul e (I PM) (Fi g. 29).
(3) Remove the wi per on/off rel ay by graspi ng i t
i n the I PM.
INSTALLATION
(1) Posi ti on the wi per on/off rel ay to the proper
receptacl e i n the I ntegrated Power Modul e (I PM)
(Fi g. 29).
(2) Al i gn the wi per on/off rel ay termi nal s wi th the
termi nal cavi ti es i n the I PM receptacl e.
(3) Push fi rml y and evenl y on the top of the wi per
on/off rel ay unti l the termi nal s are ful l y seated i n the
termi nal cavi ti es i n the I PM receptacl e.
(4) Rei nstal l the cover onto the I PM.
Fig. 29 Integrated Power Module
1 - 15 - CARTRIDGE FUSE
16 - 53 - BLADE FUSE
54 - HEATED MIRROR RELAY
55 - WIPER ON/OFF RELAY
56 - A/C CONDENSER FAN RELAY
57 - ENGINE CONTROL RELAY
58 - FUEL PUMP RELAY
59 - TRANSMISSION RELAY
60 - WIPER HIGH/LOW RELAY
61 - SPARE
62 - FOG LAMP RELAY
63 - ADJUSTABLE PEDAL RELAY
64 - A/C CLUTCH RELAY
65 - SPARE
66 - O2 RELAY
67 - SPARE
68 - SPARE
69 - SPARE
70 - SPARE
71 - SPARE
72 - STARTER RELAY
73 - PARK LAMP RELAY
WIPER ON/OFF RELAY (Continued)
NAVIGATION/TELECOMMUNICATION
TABLE OF CONTENTS
page page
NAVIGATION/TELECOMMUNICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HANDS FREE MODULE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
NAVIGATION/
TELECOMMUNICATION
DESCRIPTION
TELECOMMUNICATIONS
The hands-free cel l ul ar system on thi s vehi cl e uses
Bl uetooth technol ogy to provi de wi rel ess communi -
cati on between the operators compati bl e cel l ul ar
tel ephone and the vehi cl es on-board recei ver.
The system uses voi ce recogni ti on technol ogy to
control operati on. The i ncomi ng voi ce i s broadcast
through the vehi cl es radi o speakers, automati cal l y
overri di ng any other audi o si gnal s on the front
speakers when the hands-free system i s i n use. A
mi crophone i n the rearvi ew mi rror pi cks up vehi cl e
occupants voi ces. I f a cal l i s i n progress when the
i gni ti on i s swi tched off, the hands-free system wi l l
conti nue to operate for up to 45 seconds as part of
the Accessory Rel ay Del ay functi on. Thereafter, the
cal l can conti nue on the hand-hel d tel ephone.
The system wi l l communi cate wi th a tel ephone
that i s anywhere wi thi n the vehi cl e. However, cover-
i ng the hand hel d phone or the hands-free phone
modul e wi th a metal object may bl ock the si gnal . The
system wi l l recogni ze up to seven tel ephones, each of
whi ch i s gi ven a spoken i denti fi cati on by the user
duri ng the setup process. The system i ncl udes Span-
i sh and French voi ce recogni ti on i n addi ti on to
Engl i sh.
Two buttons on the rearvi ew mi rror, i denti fi ed wi th
I SO i cons, control the system: A phone button turns
the system on and off; a voi ce recogni ti on (or voi ce
command) button prompts the hands-free system to
l i sten for a voi ce command.
OPERATION
TELECOMMUNICATION
Two buttons on the rearvi ew mi rror, i denti fi ed wi th
I SO i cons, control the system: A phone button turns
the system on and off; a voi ce recogni ti on (or voi ce
command) button prompts the hands-free system to
l i sten for a voi ce command. The system i ncl udes the
Phone book - Stores tel ephone numbers for l ater
recal l by name or other verbal i denti fi cati on, cal l ed a
voi ce tag, and memory l ocati on.
Four memory l ocati ons - Home, Work, Cel l ul ar
and Pager. A maxi mum of 32 uni que names or voi ce
tags may be stored at the same ti me, wi th a di fferent
number i n each of the four memory l ocati ons.
Voi ce tag di al i ng - Di al s the number associ ated
wi th a voi ce tag and memory l ocati on.
Di gi t di al i ng - Di al s the tel ephone number by
recogni zi ng the names of the di gi ts as they are spo-
ken.
Recei vi ng cal l s - A voi ce prompt noti fi es the user
of an i ncomi ng cal l . A voi ce response accepts or
rejects the cal l wi thout manual i nterventi on.
Pri vacy Mode - Swi tches the cal l to the hand-
hel d tel ephone and the hands-free system and back
agai n usi ng the voi ce recogni ti on (or voi ce com-
mand) button and a voi ce command, i f desi red.
DR NAVIGATION/TELECOMMUNICATION 8T - 1
HANDS FREE MODULE
REMOVAL
cabl e.
(2) Remove the i nstrument panel ri ght si de end
cap.
(3) Remove the mounti ng fasteners (Fi g. 1).
(4) Di sconnect the el ectri cal harness connector and
remove modul e.
INSTALLATION
(1) Connect the el ectri cal harness connector and
posi ti on modul e.
(2) I nstal l and ti ghten the mounti ng fasteners.
(3) I nstal l the i nstrument panel ri ght si de end cap.
Fig. 1 HANDS FREE MODULE
8T - 2 NAVIGATION/TELECOMMUNICATION DR
WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION. . . . . . . 8W-01-1
COMPONENT INDEX. . . . . . . . . . . . . . . . . . 8W-02-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-10-1
GROUND DISTRIBUTION . . . . . . . . . . . . . . 8W-15-1
BUS COMMUNICATIONS . . . . . . . . . . . . . . 8W-18-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 8W-20-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . . 8W-21-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . 8W-30-1
TRANSMISSION CONTROL SYSTEM . . . . . 8W-31-1
VEHICLE SPEED CONTROL . . . . . . . . . . . . 8W-33-1
REAR WHEEL ANTILOCK BRAKES. . . . . . . 8W-34-1
ALL WHEEL ANTILOCK BRAKES . . . . . . . . 8W-35-1
VEHICLE THEFT SECURITY SYSTEM . . . . . 8W-39-1
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING . . . . . . . . . . . . . . . . . . 8W-42-1
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . 8W-43-1
INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . 8W-44-1
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . 8W-47-1
REAR WINDOW DEFOGGER. . . . . . . . . . . . 8W-48-1
OVERHEAD CONSOLE. . . . . . . . . . . . . . . . . 8W-49-1
FRONT LIGHTING. . . . . . . . . . . . . . . . . . . . 8W-50-1
REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . 8W-51-1
TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . 8W-52-1
WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
TRAILER TOW. . . . . . . . . . . . . . . . . . . . . . . 8W-54-1
NAVIGATION/TELECOMMUNICATION . . . . . 8W-55-1
POWER WINDOWS. . . . . . . . . . . . . . . . . . . 8W-60-1
POWER DOOR LOCKS . . . . . . . . . . . . . . . . 8W-61-1
POWER MIRRORS . . . . . . . . . . . . . . . . . . . 8W-62-1
POWER SEATS . . . . . . . . . . . . . . . . . . . . . . 8W-63-1
SPLICE INFORMATION . . . . . . . . . . . . . . . . 8W-70-1
CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . 8W-80-1
CONNECTOR/GROUND/SPLICE
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . 8W-91-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-97-1
DR WIRING 8W - 1
8W-01 WIRING DIAGRAM INFORMATION
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - CIRCUIT INFORMATION . . . . 5
DESCRIPTION - CIRCUIT FUNCTIONS . . . . . . 6
DESCRIPTION - SECTION IDENTIFICATION
AND INFORMATION . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - CONNECTOR, GROUND
AND SPLICE INFORMATION . . . . . . . . . . . . . . 7
WARNING
WARNINGS - GENERAL . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - WIRING
HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STANDARD PROCEDURE
STANDARD PROCEDURE -
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL. . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - TESTING FOR
CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND . . . . . . . . . . . . . . . . . . . 9
SHORT TO GROUND ON FUSES
POWERING SEVERAL LOADS . . . . . . . . . . . 10
VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . 10
CONNECTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIODE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
TERMINAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
WIRE
STANDARD PROCEDURE - WIRE SPLICING . . 15
WIRING DIAGRAM
INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS
Dai ml erChrysl er Corporati on wi ri ng di agrams are
desi gned to provi de i nformati on regardi ng the vehi -
cl es wi ri ng content. I n order to effecti vel y use the
wi ri ng di agrams to di agnose and repai r
Dai ml erChrysl er Corporati on vehi cl es, i t i s i mportant
to understand al l of thei r features and characteri s-
ti cs.
Di agrams are arranged such that the power (B+)
si de of the ci rcui t i s pl aced near the top of the page,
and the ground (B-) si de of the ci rcui t i s pl aced near
the bottom of the page (Fi g. 1).
Al l swi tches, components, and modul es are shown
i n the at rest posi ti on wi th the doors cl osed and the
key removed from the i gni ti on (Fi g. 2).
Components are shown two ways. A sol i d l i ne
around a component i ndi cates that the component i s
compl ete. A dashed l i ne around the component i ndi -
cates that the component i s bei ng shown i s not com-
pl ete. I ncompl ete components have a reference
number to i ndi cate the page where the component i s
shown compl ete.
I t i s i mportant to real i ze that no attempt i s made
on the di agrams to represent components and wi ri ng
as they appear on the vehi cl e. For exampl e, a short
pi ece of wi re i s treated the same as a l ong one. I n
addi ti on, swi tches and other components are shown
as si mpl y as possi bl e, wi th regard to functi on onl y.
SYMBOLS
I nternati onal symbol s are used throughout the wi r-
i ng di agrams. These symbol s are consi stent wi th
those bei ng used around the worl d (Fi g. 3).
DR 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1
Fig. 1 WIRING DIAGRAM EXAMPLE 1
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION DR
WIRING DIAGRAM INFORMATION (Continued)
Fig. 2 WIRING DIAGRAM EXAMPLE 2
Fig. 3 WIRING DIAGRAM SYMBOLS
TERMINOLOGY
Thi s i s a l i st of terms and defi ni ti ons used i n the
wi ri ng di agrams.
LHD . . . . . . . . . . . . . . . . . Left Hand Dri ve Vehi cl es
RHD . . . . . . . . . . . . . . . Ri ght Hand Dri ve Vehi cl es
ATX . . Automati c Transmi ssi ons-Front Wheel Dri ve
MTX . . . Manual Transmi ssi ons-Front Wheel Dri ve
AT. . . . Automati c Transmi ssi ons-Rear Wheel Dri ve
MT . . . . . Manual Transmi ssi ons-Rear Wheel Dri ve
SOHC . . . . . . . . . . . Si ngl e Over Head Cam Engi ne
DOHC . . . . . . . . . . Doubl e Over Head Cam Engi ne
Export . . Vehi cl es Bui l t For Sal e I n Markets Other
Than North Ameri ca
Except Export . . . . Vehi cl es Bui l t For Sal e I n North
Ameri ca
DESCRIPTION - CIRCUIT INFORMATION
Each wi re shown i n the di agrams contai ns a code
whi ch i denti fi es the mai n ci rcui t, part of the mai n
ci rcui t, gage of wi re, and col or (Fi g. 4).
WIRE COLOR CODE CHART
COLOR CODE COLOR
BL BLUE
BK BLACK
BR BROWN
DB DARK BLUE
DG DARK GREEN
GY GRAY
LB LIGHT BLUE
LG LIGHT GREEN
OR ORANGE
PK PINK
RD RED
TN TAN
VT VIOLET
WT WHITE
YL YELLOW
* WITH TRACER
Fig. 4 WIRE CODE IDENTIFICATION
1 - COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER
2 - GAGE OF WIRE (18 GAGE)
3 - PART OF MAIN CIRCUIT (VARIES DEPENDING ON
EQUIPMENT)
4 - MAIN CIRCUIT IDENTIFICATION
DESCRIPTION - CIRCUIT FUNCTIONS
Al l ci rcui ts i n the di agrams use an al pha/numeri c
code to i denti fy the wi re and i ts functi on. To i denti fy
whi ch ci rcui t code appl i es to a system, refer to the
Ci rcui t I denti fi cati on Code Chart. Thi s chart shows
the mai n ci rcui ts onl y and does not show the second-
ary codes that may appl y to some model s.
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION
CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS
(GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL
MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY
FEED)
Q POWER OPTIONS (IGNITION
FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/
WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
DESCRIPTION - SECTION IDENTIFICATION AND
INFORMATION
The wi ri ng di agrams are grouped i nto i ndi vi dual
secti ons. I f a component i s most l i kel y found i n a par-
ti cul ar group, i t wi l l be shown compl ete (al l wi res,
connectors, and pi ns) wi thi n that group. For exam-
pl e, the Auto Shutdown Rel ay i s most l i kel y to be
found i n Group 30, so i t i s shown there compl ete. I t
can, however, be shown parti al l y i n another group i f
i t contai ns some associ ated wi ri ng.
Spl i ce di agrams i n Secti on 8W-70 show the enti re
spl i ce and provi de references to other secti ons the
spl i ces serves. Secti on 8W-70 onl y contai ns spl i ce di a-
grams that are not shown i n thei r enti rety some-
where el se i n the wi ri ng di agrams.
Secti on 8W-80 shows each connector and the ci r-
cui ts i nvol ved wi th that connector. The connectors
are i denti fi ed usi ng the name/number on the di a-
gram pages.
WIRING SECTION CHART
GROUP TOPIC
8W-01 thru
8W-09
General information and Diagram
Overview
8W-10 thru
8W-19
Main Sources of Power and
Vehicle Grounding
8W-20 thru
8W-29
Starting and Charging
8W-30 thru
8W-39
Powertrain/Drivetrain Systems
8W-40 thru
8W-49
Body Electrical items and A/C
8W-50 thru
8W-59
Exterior Lighting, Wipers and
Trailer Tow
8W-60 thru
8W-69
Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-91 Connector, Ground and Splice
Locations
DESCRIPTION - CONNECTOR, GROUND AND
SPLICE INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
I n-l i ne connectors are i denti fi ed by a number, as
fol l ows:
I n-l i ne connectors l ocated i n the engi ne compart-
ment are C100 seri es numbers
I n-l i ne connectors l ocated i n the I nstrument
Panel area are C200 seri es numbers.
I n-l i ne connectors l ocated i n the body are C300
seri es numbers.
Jumper harness connectors are C400 seri es
numbers.
Grounds and ground connectors are i denti fi ed
wi th a G and fol l ow the same seri es numberi ng as
the i n-l i ne connectors.
Spl i ces are i denti fi ed wi th an S and fol l ow the
same seri es numberi ng as the i n-l i ne connectors.
Component connectors are i denti fi ed by the com-
ponent name i nstead of a number. Mul ti pl e connec-
tors on a component use a C1, C2, etc. i denti fi er.
LOCATIONS
Secti on 8W-91 contai ns connector/ground/spl i ce
l ocati on i l l ustrati ons. The i l l ustrati ons contai n the
connector name (or number)/ground number/spl i ce
number and component i denti fi cati on. Connector/
ground/spl i ce l ocati on charts i n secti on 8W-91 refer-
ence the fi gure numbers of the i l l ustrati ons.
The abbrevi ati on T/O i s used i n the component
l ocati on secti on to i ndi cate a poi nt i n whi ch the wi r-
i ng harness branches out to a component. The abbre-
vi ati on N/S means Not Shown i n the i l l ustrati ons
WARNING
WARNINGS - GENERAL
WARNINGS provi de i nformati on to prevent per-
sonal i njury and vehi cl e damage. Bel ow i s a l i st of
general warni ngs that shoul d be fol l owed any ti me a
vehi cl e i s bei ng servi ced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
CLOTHING.
DIAGNOSIS AND TESTING - WIRING HARNESS
TROUBLESHOOTING TOOLS
When di agnosi ng a probl em i n an el ectri cal ci rcui t
there are several common tool s necessary. These tool s
are l i sted and expl ai ned bel ow.
Jumper Wi re - Thi s i s a test wi re used to con-
nect two poi nts of a ci rcui t. I t can be used to bypass
an open i n a ci rcui t.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
Vol tmeter - Used to check for vol tage on a ci r-
cui t. Al ways connect the bl ack l ead to a known good
ground and the red l ead to the posi ti ve si de of the
ci rcui t.
CAUTION: Most of the electrical components used
in todays vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 -
megohm or greater impedance rating.
Ohmmeter - Used to check the resi stance
between two poi nts of a ci rcui t. Low or no resi stance
i n a ci rcui t means good conti nui ty.
CAUTION: Most of the electrical components used
in todays vehicles are Solid State. When checking
resistance in these circuits use a meter with a 10 -
megohm or greater impedance rating. In addition,
make sure the power is disconnected from the cir-
cuit. Circuits that are powered up by the vehicles
electrical system can cause damage to the equip-
ment and provide false readings.
Probi ng Tool s - These tool s are used for probi ng
termi nal s i n connectors (Fi g. 5). Sel ect the proper
si ze tool from Speci al Tool Package 6807, and i nsert
i t i nto the termi nal bei ng tested. Use the other end
of the tool to i nsert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most i ntermi ttent el ectri cal probl ems are caused
by faul ty el ectri cal connecti ons or wi ri ng. I t i s al so
possi bl e for a sti cki ng component or rel ay to cause a
probl em. Before condemni ng a component or wi ri ng
assembl y, check the fol l owi ng i tems.
Connectors are ful l y seated
Spread termi nal s, or termi nal push out
Termi nal s i n the wi ri ng assembl y are ful l y seated
i nto the connector/component and l ocked i nto posi ti on
Di rt or corrosi on on the termi nal s. Any amount
of corrosi on or di rt coul d cause an i ntermi ttent prob-
l em
Damaged connector/component casi ng exposi ng
the i tem to di rt or moi sture
Wi re i nsul ati on that has rubbed through causi ng
a short to ground
Some or al l of the wi ri ng strands broken i nsi de
of the i nsul ati on
Wi ri ng broken i nsi de of the i nsul ati on
TROUBLESHOOTING WIRING PROBLEMS
When troubl eshooti ng wi ri ng probl ems there are
si x steps whi ch can ai d i n the procedure. The steps
are l i sted and expl ai ned bel ow. Al ways check for non-
factory i tems added to the vehi cl e before doi ng any
di agnosi s. I f the vehi cl e i s equi pped wi th these i tems,
di sconnect them to veri fy these add-on i tems are not
the cause of the probl em.
(1) Veri fy the probl em.
(2) Veri fy any rel ated symptoms. Do thi s by per-
formi ng operati onal checks on components that are
i n the same ci rcui t. Refer to the wi ri ng di agrams.
(3) Anal yze the symptoms. Use the wi ri ng di a-
grams to determi ne what the ci rcui t i s doi ng, where
the probl em most l i kel y i s occurri ng and where the
di agnosi s wi l l conti nue.
(4) I sol ate the probl em area.
(5) Repai r the probl em area.
(6) Veri fy the proper operati on. For thi s step,
check for proper operati on of al l i tems on the
repai red ci rcui t. Refer to the wi ri ng di agrams.
STANDARD PROCEDURE
STANDARD PROCEDURE - ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE DEVICES
Al l ESD sensi ti ve components are sol i d state and a
symbol (Fi g. 6) i s used to i ndi cate thi s. When han-
dl i ng any component wi th thi s symbol , compl y wi th
the fol l owi ng procedures to reduce the possi bi l i ty of
el ectrostati c charge bui l d up on the body and i nad-
vertent di scharge i nto the component. I f i t i s not
known whether the part i s ESD sensi ti ve, assume
that i t i s.
(1) Al ways touch a known good ground before han-
dl i ng the part. Thi s shoul d be repeated whi l e han-
dl i ng the part and more frequentl y after sl i di ng
across a seat, si tti ng down from a standi ng posi ti on,
or wal ki ng a di stance.
(2) Avoi d touchi ng el ectri cal termi nal s of the part,
unl ess i nstructed to do so by a wri tten procedure.
(3) When usi ng a vol tmeter, be sure to connect the
ground l ead fi rst.
(4) Do not remove the part form i ts protecti ve
packi ng unti l i t i s ti me to i nstal l the part.
(5) Before removi ng the part from i ts pakage,
ground the pakage to a known good ground on the
vehi cl e.
Fig. 5 PROBING TOOL
2 - PROBING END
Fig. 6 ELECTROSTATIC DISCHARGE SYMBOL
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL
(1) Connect the ground l ead of a vol tmeter to a
known good ground (Fi g. 7).
(2) Connect the other l ead of the vol tmeter to the
sel ected test poi nt. The vehi cl e i gni ti on may need to
be turned ON to check vol tage. Refer to the appropri -
ate test procedure.
STANDARD PROCEDURE - TESTING FOR
CONTINUITY
(1) Remove the fuse for the ci rcui t bei ng checked
or, di sconnect the battery.
(2) Connect one l ead of the ohmmeter to one si de
of the ci rcui t bei ng tested (Fi g. 8).
(3) Connect the other l ead to the other end of the
ci rcui t bei ng tested. Low or no resi stance means good
conti nui ty.
SHORT TO GROUND
(1) Remove the fuse and di sconnect al l i tems
i nvol ved wi th the fuse.
(2) Connect a test l i ght or a vol tmeter across the
termi nal s of the fuse.
(3) Starti ng at the fuse bl ock, wi ggl e the wi ri ng
harness about si x to ei ght i nches apart and watch
the vol tmeter/test l amp.
(4) I f the vol tmeter regi sters vol tage or the test
l amp gl ows, there i s a short to ground i n that gen-
eral area of the wi ri ng harness.
Fig. 7 TESTING FOR VOLTAGE POTENTIAL
Fig. 8 TESTING FOR CONTINUITY
1 - FUSE REMOVED FROM CIRCUIT
SHORT TO GROUND ON FUSES POWERING
SEVERAL LOADS
(1) Refer to the wi ri ng di agrams and di sconnect or
i sol ate al l i tems on the suspected fused ci rcui ts.
(2) Repl ace the bl own fuse.
(3) Suppl y power to the fuse by turni ng ON the
i gni ti on swi tch or re-connecti ng the battery.
(4) Start connecti ng or energi zi ng the i tems i n the
fuse ci rcui t one at a ti me. When the fuse bl ows the
ci rcui t wi th the short to ground has been i sol ated.
VOLTAGE DROP
the si de of the ci rcui t cl osest to the battery (Fi g. 9).
(2) Connect the other l ead of the vol tmeter to the
other si de of the swi tch, component or ci rcui t.
(3) Operate the i tem.
(4) The vol tmeter wi l l show the di fference i n vol t-
age between the two poi nts.
SPECIAL TOOLS
WIRING/TERMINAL
Fig. 9 TESTING FOR VOLTAGE DROP
PROBING TOOL PACKAGE 6807
TERMINAL PICK TOOL SET 6680
TERMINAL REMOVING TOOLS 6932 AND 8638
TERMINAL REMOVING TOOL 6934
CONNECTOR
REMOVAL
(1) Di sconnect battery.
(2) Rel ease Connector Lock (Fi g. 10).
(3) Di sconnect the connector bei ng repai red from
i ts mati ng hal f/component.
(4) Remove the dress cover (i f appl i cabl e) (Fi g. 10).
(5) Rel ease the Secondary Termi nal Lock, i f
requi red (Fi g. 11).
(6) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper speci al tool . Pul l on
the wi re to remove the termi nal from the connector
(Fi g. 12).
INSTALLATION
(1) I nsert the removed termi nal i n the same cavi ty
on the repai r connector.
(2) Repeat steps for each termi nal i n the connec-
tor, bei ng sure that al l wi res are i nserted i nto the
proper cavi ti es. For addi ti onal connector pi n-out
i denti fi cati on, refer to the wi ri ng di agrams.
(3) When the connector i s re-assembl ed, the sec-
ondary termi nal l ock must be pl aced i n the l ocked
posi ti on to prevent termi nal push out.
(4) Repl ace dress cover (i f appl i cabl e).
(5) Connect connector to i ts mati ng hal f/compo-
nent.
(6) Connect battery and test al l affected systems.
Fig. 10 REMOVAL OF DRESS COVER
1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS
1 - Secondary Terminal Lock
CONNECTOR (Continued)
Fig. 12 TERMINAL REMOVAL
1 - TYPICAL CONNECTOR
2 - PICK FROM SPECIAL TOOL KIT 6680
3 - APEX CONNECTOR
4 - PICK FROM SPECIAL TOOL KIT 6680
5 - AUGAT CONNECTOR
7 - MOLEX CONNECTOR
9 - THOMAS AND BETTS CONNECTOR
11 - TYCO CONNECTOR
CONNECTOR (Continued)
DIODE
REMOVAL
(1) Di sconnect the battery.
(2) Locate the di ode i n the harness, and remove
the protecti ve coveri ng.
(3) Remove the di ode from the harness, pay atten-
ti on to the current fl ow di recti on (Fi g. 13).
INSTALLATION
(1) Remove the i nsul ati on from the wi res i n the
harness. Onl y remove enough i nsul ati on to sol der i n
the new di ode.
(2) I nstal l the new di ode i n the harness, maki ng
sure current fl ow i s correct. I f necessary, refer to the
appropri ate wi ri ng di agram for current fl ow (Fi g. 13).
(3) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(4) Tape the di ode to the harness usi ng el ectri cal
tape. Make sure the di ode i s compl etel y seal ed from
the el ements.
(5) Re-connect the battery and test affected sys-
tems.
TERMINAL
REMOVAL
(1) Fol l ow steps for removi ng termi nal s descri bed
i n the connector removal secti on.
(2) Cut the wi re 6 i nches from the back of the con-
nector.
INSTALLATION
(1) Sel ect a wi re from the termi nal repai r ki t that
best matches the col or and gage of the wi re bei ng
repai red.
(2) Cut the repai r wi re to the proper l ength and
remove onehal f (1/2) i nch of i nsul ati on.
(3) Spl i ce the repai r wi re to the wi re harness (see
wi re spl i ci ng procedure).
(4) I nsert the repai red wi re i nto the connector.
(5) I nstal l the connector l ocki ng wedge, i f requi red,
and reconnect the connector to i ts mati ng hal f/compo-
nent.
(6) Re-tape the wi re harness starti ng at 11/2
i nches behi nd the connector and 2 i nches past the
repai r.
(7) Connect battery and test al l affected systems.
Fig. 13 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
WIRE
STANDARD PROCEDURE - WIRE SPLICING
When spl i ci ng a wi re, i t i s i mportant that the cor-
rect gage be used as shown i n the wi ri ng di agrams.
(1) Remove one-hal f (1/2) i nch of i nsul ati on from
each wi re that needs to be spl i ced.
(2) Pl ace a pi ece of adhesi ve l i ned heat shri nk tub-
i ng on one si de of the wi re. Make sure the tubi ng wi l l
be l ong enough to cover and seal the enti re repai r
area.
(3) Pl ace the strands of wi re overl appi ng each
other i nsi de of the spl i ce cl i p (Fi g. 14).
(4) Usi ng cri mpi ng tool , Mopar p/n 05019912AA,
cri mp the spl i ce cl i p and wi res together (Fi g. 15).
(5) Sol der the connecti on together usi ng rosi n core
type sol der onl y (Fi g. 16).
CAUTION: DO NOT USE ACID CORE SOLDER.
(6) Center the heat shri nk tubi ng over the joi nt
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng (Fi g. 17).
Fig. 14 SPLICE BAND
1 - SPLICE BAND
Fig. 15 CRIMPING TOOL
1 - CRIMPING TOOL
Fig. 16 SOLDER SPLICE
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
Fig. 17 HEAT SHRINK TUBE
1 - SEALANT
2 - HEAT SHRINK TUBE
8W-02 COMPONENT INDEX
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . 8W-42
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . 8W-42
A/C Pressure Transducer . . . . . . . . . . . . . . . . 8W-42
A/C-Heater Control . . . . . . . . . . . . . . . . . . . . 8W-42
Accel erator Pedal Posi ti on Sensor . . . . . . . . . 8W-30
Adjustabl e Pedal Motor . . . . . . . . . . . . . . . . . 8W-30
Adjustabl e Pedal Rel ay . . . . . . . . . . . . . . . . . 8W-30
Adjustabl e Pedal Swi tch . . . . . . . . . . . . . . . . 8W-30
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . 8W-43
Ai rbag-Squi bs . . . . . . . . . . . . . . . . . . . . . . . . 8W-43
Ai rbag-Curtai ns . . . . . . . . . . . . . . . . . . . . . . . 8W-43
Ai rbag-Passenger On/Off Swi tch . . . . . . . . . . 8W-43
Ambi ent Temperature Sensor . . . . . . . . . . . . 8W-49
Ampl i fi er Audi o . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Ashtray Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Auto Shut Down Rel ay . . . . . . . . . . . . . . . . . 8W-30
Automati c Day/Ni ght Mi rror . . . . . . . . . . 8W-49, 55
Auxi l i ary Battery . . . . . . . . . . . . . . . . . . . . . 8W-20
Backup Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-51
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Battery Temperature Sensor . . . . . . . . . . . . . 8W-30
Bl end Door Actuators . . . . . . . . . . . . . . . . . . 8W-42
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . . . 8W-42
Brake Fl ui d Level Swi tch . . . . . . . . . . . . 8W-34, 35
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-33
Brake Transmi ssi on Shi ft I nterl ock
Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . . 8W-30
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Center Hi gh Mounted Stop Lamp-
Aftermarket . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Center Hi gh Mounted Stop Lamp/Cargo
Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44, 51
Ci gar Li ghter Outl et . . . . . . . . . . . . . . . . . . . 8W-41
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Cl earance Lamps . . . . . . . . . . . . . . . . . . . . . . 8W-50
Cl ockspri ng . . . . . . . . . . . . . . . . . 8W-33, 41, 43, 47
Cl utch I nterl ock Brake Swi tch . . . . . . . . . . . 8W-21
Coi l On Pl ugs . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Compass/Mi ni -Tri p Computer . . . . . . . . . . . . 8W-49
Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Condenser Fan Rel ay . . . . . . . . . . . . . . . . . . 8W-42
Control l er Anti l ock Brake . . . . . . . . . . . . 8W-34, 35
Crankshaft Posi ti on Sensor . . . . . . . . . . . . . . 8W-30
Cyl i nder Lock Swi tch-Dri ver . . . . . . . . . . . . . 8W-61
Data Li nk Connector . . . . . . . . . . . . . . . . . . . 8W-18
Data Li nk Connector-Engi ne . . . . . . . . . . . . . 8W-18
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-44, 49
Door Ajar Swi tches . . . . . . . . . . . . . . . . . . . . 8W-40
Door Lock Motor/Ajar Swi tches . . . . . . . . 8W-40, 61
Door Lock Swi tch-Passenger . . . . . . . . . . . . . 8W-61
Component Page
Door Modul e . . . . . . . . . . . . . . . . . . . 8W-60, 61, 62
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
El ectri c Backl i ght . . . . . . . . . . . . . . . . . . . . . 8W-48
El ectri c Brake Provi si on . . . . . . . . . . . . . . . . 8W-54
El ectroni c Throttl e Control Modul e . . . . . . . . 8W-30
Engi ne Control Modul e . . . . . . . . . . . . . . . . . 8W-30
Engi ne Cool ant Temperature Sensor . . . . . . . 8W-30
Engi ne Oi l Pressure Swi tch . . . . . . . . . . . . . . 8W-30
EVAP/Purge Sol enoi d . . . . . . . . . . . . . . . . . . 8W-30
Evaporator Temperature Sensor . . . . . . . . . . 8W-42
Fender Lamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-50
Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Front Control Modul e . . . . . . . . . . . . . . . . . . 8W-10
Fuel Control Actuator . . . . . . . . . . . . . . . . . . 8W-30
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel I njector Packs . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel I njectors . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Motor . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 33
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Gl ove Box Lamp And Swi tch . . . . . . . . . . . . . 8W-44
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15
Hands Free Modul e . . . . . . . . . . . . . . . . . . . . 8W-55
Headl amp Swi tch . . . . . . . . . . . . . . . . . . 8W-40, 50
Headl amps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Heated Mi rror Rel ay . . . . . . . . . . . . . . . . . . . 8W-62
Heated Seat Cushi ons . . . . . . . . . . . . . . . . . . 8W-63
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Horn-Hi gh Note . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Horn-Low Note . . . . . . . . . . . . . . . . . . . . . . . 8W-41
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . . . 8W-30
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-10
I nl et Ai r Temperature Sensor . . . . . . . . . . . . 8W-30
I nput Speed Sensor . . . . . . . . . . . . . . . . . . . . 8W-31
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . 8W-40
I ntake Ai r Heater Rel ays . . . . . . . . . . . . . . . 8W-30
I ntake Ai r Temperature Sensor . . . . . . . . . . . 8W-30
I ntake Ai r Temperature/Mani fol d Absol ute
Pressure Sensor . . . . . . . . . . . . . . . . . . . . . 8W-30
I ntegrated Power Modul e . . . . . . . . . . . . . . . 8W-10
Knock Sensosr . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Li cense Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Li ft Pump Motor . . . . . . . . . . . . . . . . . . . . . . 8W-30
Li ne Pressure Sensor . . . . . . . . . . . . . . . . 8W-30, 31
Lumbar Motors . . . . . . . . . . . . . . . . . . . . . . . 8W-63
Lumbar Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-63
DR 8W-02 COMPONENT INDEX 8W - 02 - 1
Component Page
Mani fol d Absol ute Pressure Sensor . . . . . . . . 8W-30
Mode Door Actuators . . . . . . . . . . . . . . . . . . . 8W-42
Mul ti -Functi on Swi tch . . . . . . . . . . . . 8W-40, 52, 53
Natural Vacuum Leak Detecti on Assembl y . . 8W-30
Output Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-31
Overhead Map/Readi ng Lamp . . . . . . . . . 8W-44, 49
Oxygen Sensor Downstream Rel ay . . . . . . . . 8W-30
Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . . 8W-40
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . 8W-50, 52
Park/Turn Si gnal Lamps . . . . . . . . . . . . . 8W-50, 52
Power Mi rrors . . . . . . . . . . . . . . . . . . . . . . . . 8W-62
Power Outl ets . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Power Seat Motors . . . . . . . . . . . . . . . . . . . . 8W-63
Power Seat Swi tches . . . . . . . . . . . . . . . . . . . 8W-63
Power Steeri ng Pressure Swi tch . . . . . . . . . . 8W-30
Power Wi ndow Ci rcui t Breaker . . . . . . . . . . . 8W-10
Power Wi ndow Motors . . . . . . . . . . . . . . . . . . 8W-60
Power Wi ndow Swi tches . . . . . . . . . . . . . . . . 8W-60
Powertrai n Control Modul e . . . . . . . . . . . . . . 8W-30
PTCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10
PTO Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . 8W-48
Reci rcul ati on Door Actuator . . . . . . . . . . . . . 8W-42
Remote Radi o Swi tches . . . . . . . . . . . . . . . . . 8W-47
Seat Bel t Pretensi oners . . . . . . . . . . . . . . . . . 8W-43
Seat Bel t Swi tch-Dri ver . . . . . . . . . . . . . . . . 8W-40
Seat Bel t Tensi oner Reducer . . . . . . . . . . . . . 8W-40
Seat Heater I nterface Modul e . . . . . . . . . . . . 8W-63
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . 8W-39
Si de I mpact Sensors . . . . . . . . . . . . . . . . . . . 8W-43
Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Component Page
Speed Control Servo . . . . . . . . . . . . . . . . . . . 8W-33
Speed Control Swi tches . . . . . . . . . . . . . . . . . 8W-33
Spl i ces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . 8W-21
Starter Motor Rel ay . . . . . . . . . . . . . . . . . . . 8W-21
Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-52
Tai l /Stop/Turn Si gnal Lamps . . . . . . . . . . 8W-51, 52
Tai l /Turn Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-52
Tai l gate Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . . 8W-30
Tow/Haul Overdri ve Swi tch . . . . . . . . . . . 8W-30, 31
Trai l er Tow Connectors . . . . . . . . . . . . . . . . . 8W-54
Trai l er Tow Rel ays . . . . . . . . . . . . . . . . . . . . 8W-54
Transfer Case Control Modul e . . . . . . . . . . . . 8W-31
Transfer Case Mode Sensor . . . . . . . . . . . . . . 8W-31
Transfer Case Sel ector Swi tch . . . . . . . . . . . . 8W-31
Transfer Case Shi ft Motor . . . . . . . . . . . . . . . 8W-31
Transmi ssi on Control Rel ay . . . . . . . . . . . . . 8W-31
Transmi ssi on Range Sensor . . . . . . . . . . . . . . 8W-31
Transmi ssi on Sol enoi d Assembl y . . . . . . . . . . 8W-31
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . . 8W-31
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-44
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Vi stroni c Fan Dri ve . . . . . . . . . . . . . . . . . 8W-30, 70
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . . 8W-53
Washer Pump Motor-Front . . . . . . . . . . . . . . 8W-53
Water I n Fuel Sensor . . . . . . . . . . . . . . . . . . 8W-30
Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . 8W-35
Wi per Hi gh/Low Rel ay . . . . . . . . . . . . . . . . . 8W-53
Wi per Motor-Front . . . . . . . . . . . . . . . . . . . . 8W-53
Wi per On/Off Rel ay . . . . . . . . . . . . . . . . . . . . 8W-53
8W - 02 - 2 8W-02 COMPONENT INDEX DR
8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . . . . 8W-10-17, 40
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . . . . . . 8W-10-17, 40
A/C-Heater Control . . . . . . . . . . . . . . . . . . . . 8W-10-42, 43, 49
Adjustabl e Pedal Rel ay . . . . . . . . . . . . . . . . . . . . 8W-10-15, 32
Adjustabl e Pedal Swi tch . . . . . . . . . . . . . . . . . . 8W-10-15, 32, 42
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . . . . 8W-10-42, 44
Ai rbag-Passenger On/Off Swi tch . . . . . . . . . . . . . . . . . 8W-10-42
Ambi ent Temperature Sensor . . . . . . . . . . . . . . . . . 8W-10-48, 50
Ampl i fi er Audi o . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31
Ashtray Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-35
Auto Shut Down Rel ay . . . . . . . . . . . . . . . . . . . . 8W-10-12, 19
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . . . . . . 8W-10-41, 48
Auxi l i ary Battery . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Backup Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-10-44, 49
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 19
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-52
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-10-14, 30, 40
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
Ci gar Li ghter Outl et . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-46
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-52
Cl earance Lamp No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-35
Cl utch I nterl ock Brake Swi tch . . . . . . . . . . . . . . . . . . 8W-10-37
Coi l On Pl ug No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 23
Coi l On Pl ug No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21, 22
Coi l On Pl ug No. 3 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 23
Coi l On Pl ug No. 4 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21, 22
Coi l On Pl ug No. 5 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 23
Coi l On Pl ug No. 6 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21, 22
Coi l On Pl ug No. 7 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 23
Coi l On Pl ug No. 8 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21, 22
Compass/Mi ni -Tri p Computer . . . . . . . . . . . . . . . 8W-10-31, 39, 41
Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18, 45
Condenser Fan Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-10-18, 45
Control l er Anti l ock Brake . . . . . . . . . . . . . . . . . 8W-10-14, 28, 44
Data Li nk Connector . . . . . . . . . . . . . . . . . . . . . . 8W-10-30, 50
Door Lock Swi tch-Passenger . . . . . . . . . . . . . . . . . . . . 8W-10-41
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . . . 8W-10-15, 32, 52
El ectri c Backl i ght . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-49
El ectri c Brake Provi si on . . . . . . . . . . . . . . . . . . . . 8W-10-12, 19
Engi ne Control Modul e . . . . . . . . . . . . . . . . 8W-10-12, 26, 38, 40
Fender Lamp-Front Left . . . . . . . . . . . . . . . . . . . . . . 8W-10-35
Fender Lamp-Front Ri ght . . . . . . . . . . . . . . . . . . . . . 8W-10-35
Fender Lamp-Rear Left . . . . . . . . . . . . . . . . . . . . . . 8W-10-35
Fender Lamp-Rear Ri ght . . . . . . . . . . . . . . . . . . . . . 8W-10-35
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 36
Fog Lamp-Left . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-36
Fog Lamp-Ri ght . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-36
Front Control Modul e . 8W-10-13, 26, 29, 30, 32, 33, 34, 36, 47, 48, 50, 51
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-53
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-10-18, 40, 53
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23, 24
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 39
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 39, 40
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 19
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 13, 19
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 25
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 25
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 13, 14, 26, 27
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 28
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 28
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 29
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 25
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 25
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 30
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18, 45, 53
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 30
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 37
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 17, 34
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 40
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 18, 39
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 30
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 31
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 25
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 31
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 31
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 31
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 30
Component Page
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 31
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-49
Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 18, 43
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-40, 41
Fuse 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-46
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 34
Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 34
Fuse 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 34
Fuse 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-44
Fuse 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-43
Fuse 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-44
Fuse 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-43, 44
Fuse 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 16, 32
Fuse 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 36
Fuse 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 32
Fuse 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 32
Fuse 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 17, 36
Fuse 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 16, 33
Fuse 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 33
Fuse 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 32
Fuse 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 19
Fuse 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 40
Fuse 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 15, 30
Fuse 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-43, 44
Fuse 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-41
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
G104 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27, 29, 47, 48, 53
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-25
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-36
Headl amp-Left . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-51
Headl amp-Ri ght . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-51
Heated Mi rror Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-10-18, 43
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 36
Horn-Hi gh Note . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-36
Horn-Low Note . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-36
I gni ti on Swi tch . . . . . . . . . . . . . . . 8W-10-13, 25, 37, 41, 44, 46, 52
I nstrument Cl uster . . . . . . . . . . . . 8W-10-14, 25, 30, 31, 41, 46, 52
I ntegrated Power Modul e . . 8W-10-3, 4, 12, 13, 14, 15, 16, 17, 18, 19, 25,
26, 27, 28, 29, 30, 31, 32, 33, 34, 36, 37, 39, 40, 41, 42, 43, 44, 45, 46,
47, 48, 49, 50, 51, 53
Li cense Lamp-Left . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-34
Li cense Lamp-Ri ght . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-34
Oxygen Sensor Downstream Rel ay . . . . . . . . . . . . . . 8W-10-12, 19
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 34
Park/Turn Si gnal Lamp-Left Front . . . . . . . . . . . . . . 8W-10-34, 47
Park/Turn Si gnal Lamp-Ri ght Front . . . . . . . . . . . . . 8W-10-34, 47
Passenger Lumbar Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-10-28
Power Mi rror-Left . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-43
Power Mi rror-Ri ght . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-43
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 31
Power Outl et-Consol e . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 32
Power Seat Swi tch-Dri ver . . . . . . . . . . . . . . . . . . . . . 8W-10-28
Power Seat Swi tch-Passenger . . . . . . . . . . . . . . . . . . . 8W-10-28
Power Wi ndow Ci rcui t Breaker . . . . . . . . . . . . . . . . . . 8W-10-52
Powertrai n Control Modul e . . 8W-10-18, 19, 22, 27, 31, 37, 39, 40, 45, 52
PTC No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-39, 40, 41
PTC No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-46
PTC No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-33
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30, 46
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . . . . . . . . 8W-10-49
Seat Bel t Tensi oner Reducer . . . . . . . . . . . . . . . . . . . . 8W-10-46
Seat Heater I nterface Modul e . . . . . . . . . . . . . . . . . . . 8W-10-32
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . . . . . 8W-10-31, 39, 40
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 37
Starter Motor Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 37
Tai l /Stop/Turn Si gnal Lamp-Left . . . . . . . . . . . 8W-10-34, 47, 48, 50
Tai l /Stop/Turn Si gnal Lamp-Ri ght . . . . . . . . . . 8W-10-35, 47, 48, 50
Tai l gate Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-34
Trai l er Tow Connector . . . . . . . . . . . . . . . . . 8W-10-16, 17, 33, 34
Trai l er Tow Connector-Add On . . . . . . . . . . 8W-10-14, 31, 33, 34, 48
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . . . . . . . . 8W-10-16, 33
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . . . . . . . . 8W-10-16, 33
Transfer Case Control Modul e . . . . . . . . . . . . . . . 8W-10-14, 32, 37
Transfer Case Sel ector Swi tch . . . . . . . . . . . . . . . . . . . 8W-10-41
Transmi ssi on Control Rel ay . . . . . . . . . . . . . . . . 8W-10-13, 26, 27
Transmi ssi on Range Sensor . . . . . . . . . . . . . . . . 8W-10-38, 44, 49
Transmi ssi on Sol enoi d Assembl y . . . . . . . . . . . . . . . . . 8W-10-26
Transmi ssi on Sol enoi d/TRS Assembl y . . . . . . . . . . . 8W-10-27, 44, 49
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
Vi stroni c Fan Dri ve . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-43
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . . . . . . . . 8W-10-48
Washer Pump Motor-Front . . . . . . . . . . . . . . . . . . . . 8W-10-48
Wi per Hi gh/Low Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 29
Wi per Motor-Front . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29, 48
Wi per On/Off Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 29
DR 8W-10 POWER DISTRIBUTION 8W - 10 - 1
8W-15 GROUND DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . 8W-15-5, 8
A/C-Heater Control . . . . . . . . . . . . . . . . . . 8W-15-9, 12
Adjustabl e Pedal Swi tch . . . . . . . . . . . . . . . . 8W-15-12
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . 8W-15-15
Ampl i fi er Audi o . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
Ashtray Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
Automati c Day/Ni ght Mi rror . . . . . . . . . . . . . . 8W-15-9
Auxi l i ary Battery . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-15-9
Brake Transmi ssi on Shi ft I nterl ock Sol enoi d . . 8W-15-14
Center Hi gh Mounted Stop Lamp/Cargo Lamp . 8W-15-14
Ci gar Li ghter Outl et . . . . . . . . . . . . . . . . . . . 8W-15-12
Cl earance Lamp No. 1 . . . . . . . . . . . . . . . . . . 8W-15-13
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
Cl utch I nterl ock Brake Swi tch . . . . . . . . . . . . . 8W-15-3
Compass/Mi ni -Tri p Computer . . . . . . . . . . . . . . 8W-15-9
Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
Cyl i nder Lock Swi tch-Dri ver . . . . . . . . . . . . . 8W-15-17
Data Li nk Connector . . . . . . . . . . . . . . . . . . . . 8W-15-9
Data Li nk Connector-Engi ne . . . . . . . . . . . . . . 8W-15-8
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
Door Ajar Swi tch-Dri ver . . . . . . . . . . . . . . . . 8W-15-17
Door Ajar Swi tch-Left Rear . . . . . . . . . . . . . . 8W-15-16
Door Ajar Swi tch-Passenger . . . . . . . . . . . . . . 8W-15-17
Door Ajar Swi tch-Ri ght Rear . . . . . . . . . . . . . 8W-15-16
Door Lock Motor/Ajar Swi tch-Dri ver . . . . . . . . 8W-15-17
Door Lock Motor/Ajar Swi tch-Left Rear . . . . . . 8W-15-16
Door Lock Motor/Ajar Swi tch-Passenger . . . . . 8W-15-17
Door Lock Motor/Ajar Swi tch-Ri ght Rear . . . . . 8W-15-16
Door Lock Swi tch-Passenger . . . . . . . . . . . . . . 8W-15-17
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . . 8W-15-18
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
El ectri c Brake Provi si on . . . . . . . . . . . . . . . . . 8W-15-4
Engi ne Control Modul e . . . . . . . . . . . . . . . . . . 8W-15-8
Fender Lamp-Front Left . . . . . . . . . . . . . . . . . 8W-15-2
Fender Lamp-Front Ri ght . . . . . . . . . . . . . . . . 8W-15-2
Fender Lamp-Rear Left . . . . . . . . . . . . . . . . . . 8W-15-2
Fender Lamp-Rear Ri ght . . . . . . . . . . . . . . . . . 8W-15-2
Fog Lamp-Left . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
Fog Lamp-Ri ght . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . . 8W-15-4
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3, 4, 15
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5, 6
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
G109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
G114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
G120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9, 10
Component Page
G202 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11, 12, 14
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 8
Gl ove Box Lamp And Swi tch . . . . . . . . . . . . . 8W-15-12
Hands Free Modul e . . . . . . . . . . . . . . . . . . . . 8W-15-11
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-15-14
Headl amp-Left . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
Headl amp-Ri ght . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
Heated Seat Cushi on-Dri ver . . . . . . . . . . . . . . 8W-15-18
Heated Seat Cushi on-Passenger . . . . . . . . . . . 8W-15-19
Heated Seat Swi tch-Dri ver . . . . . . . . . . . . . . . 8W-15-12
Heated Seat Swi tch-Passenger . . . . . . . . . . . . 8W-15-12
Horn-Hi gh Note . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
Horn-Low Note . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
I nstrument Cl uster . . . . . . . . . . . . . . . . . 8W-15-10, 14
I ntake Ai r Heater Rel ay No. 1 . . . . . . . . . . . . . 8W-15-7
I ntegrated Power Modul e . . . . . . . . . . . . . . . 8W-15-3, 4
Li cense Lamp-Left . . . . . . . . . . . . . . . . . . . . . 8W-15-2
Li cense Lamp-Ri ght . . . . . . . . . . . . . . . . . . . . 8W-15-2
Li ft Pump Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
Natural Vacuum Leak Detecti on Assembl y . . . . . 8W-15-6
Overhead Map/Readi ng Lamp . . . . . . . . . . . . 8W-15-14
Oxygen Sensor 1/1 Upstream . . . . . . . . . . . . . . 8W-15-6
Oxygen Sensor 1/2 Downstream . . . . . . . . . . . . 8W-15-6
Oxygen Sensor 2/1 Upstream . . . . . . . . . . . . . . 8W-15-6
Oxygen Sensor 2/2 Downstream . . . . . . . . . . . . 8W-15-6
Park/Turn Si gnal Lamp-Left Front . . . . . . . . . . 8W-15-4
Park/Turn Si gnal Lamp-Ri ght Front . . . . . . . . . 8W-15-7
Passenger Lumbar Swi tch . . . . . . . . . . . . . . . 8W-15-19
Power Mi rror-Left . . . . . . . . . . . . . . . . . . . . . 8W-15-18
Power Mi rror-Ri ght . . . . . . . . . . . . . . . . . . . . 8W-15-18
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12
Power Outl et-Consol e . . . . . . . . . . . . . . . . 8W-15-15, 19
Power Seat Swi tch-Dri ver . . . . . . . . . . . . . . . 8W-15-18
Power Seat Swi tch-Passenger . . . . . . . . . . . . . 8W-15-19
Power Steeri ng Pressure Swi tch . . . . . . . . . . . . 8W-15-5
Powertrai n Control Modul e . . . . . . . . . . . . . 8W-15-5, 6
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
Seat Bel t Swi tch-Dri ver . . . . . . . . . . . . . . . . . 8W-15-16
Seat Heater I nterface Modul e . . . . . . . . . . . . . 8W-15-16
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . . 8W-15-10
Speed Control Servo . . . . . . . . . . . . . . . . . . . . 8W-15-3
Tai l /Stop/Turn Si gnal Lamp-Left . . . . . . . . . . . 8W-15-2
Tai l /Stop/Turn Si gnal Lamp-Ri ght . . . . . . . . . . 8W-15-2
Tai l gate Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
Tow/Haul Overdri ve Swi tch . . . . . . . . . . . . . . . 8W-15-9
Trai l er Tow Connector . . . . . . . . . . . . . . . . . . . 8W-15-4
Trai l er Tow Connector-Add On . . . . . . . . . . . . . 8W-15-4
Transfer Case Control Modul e . . . . . . . . . . . . 8W-15-15
Transfer Case Sel ector Swi tch . . . . . . . . . . . 8W-15-4, 15
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . . 8W-15-3, 7
Washer Pump Motor-Front . . . . . . . . . . . . . . . 8W-15-7
Wi per Motor-Front . . . . . . . . . . . . . . . . . . . . . 8W-15-4
DR 8W-15 GROUND DISTRIBUTION 8W - 15 - 1
8W-18 BUS COMMUNICATIONS
Component Page
A/C-Heater Control . . . . . . . . . . . . . . . . . . . 8W-18-5
Ai rbag Control Modul e . . . . . . . . . . . . . . . . 8W-18-5
Ampl i fi er Audi o . . . . . . . . . . . . . . . . . . . . . 8W-18-5
Compass/Mi ni -Tri p Computer . . . . . . . . . . . 8W-18-5
Control l er Anti l ock Brake . . . . . . . . . . . . . . 8W-18-6
Data Li nk Connector . . . . . . . . . . . 8W-18-2, 3, 4, 5
Data Li nk Connector-Engi ne . . . . . . . . . . . 8W-18-4
Engi ne Control Modul e . . . . . . . . . . . . . . . . 8W-18-4
Front Control Modul e . . . . . . . . . . . . . . . . . 8W-18-6
Fuse 51 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 4
Component Page
G120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-4
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2, 4
Hands Free Modul e . . . . . . . . . . . . . . . . . . 8W-18-6
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-18-5
I ntegrated Power Modul e . . . . . . . . . . 8W-18-2, 4, 6
Powertrai n Control Modul e . . . . . . . . . . 8W-18-2, 3
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5
Sentry Key I mmobi l i zer Modul e . . . . . . . . . 8W-18-6
Transfer Case Control Modul e . . . . . . . . . . 8W-18-6
DR 8W-18 BUS COMMUNICATIONS 8W - 18 - 1
8W-20 CHARGING SYSTEM
Component Page
Auxi l i ary Battery . . . . . . . . . . . . . . . . . . . . 8W-20-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Engi ne Control Modul e . . . . . . . . . . . . . . 8W-20-3, 4
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-3
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Component Page
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-3
G109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-3
G120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-3
Generator . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
Powertrai n Control Modul e . . . . . . . . . . . . 8W-20-2
Starter Motor . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3
DR 8W-20 CHARGING SYSTEM 8W - 20 - 1
8W-21 STARTING SYSTEM
Component Page
Auxi l i ary Battery . . . . . . . . . . . . . . . . . . . . 8W-21-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3
Cl utch I nterl ock Brake Swi tch . . . . . . . . . . 8W-21-4
Engi ne Control Modul e . . . . . . . . . . . . . . . . 8W-21-4
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-4
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3
Component Page
Starter Motor . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3
Starter Motor Rel ay . . . . . . . . . . . . . . . . 8W-21-2, 3
Transfer Case Control Modul e . . . . . . . . . . 8W-21-4
Transmi ssi on Range Sensor . . . . . . . . . . . . 8W-21-4
DR 8W-21 STARTING SYSTEM 8W - 21 - 1
8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . 8W-30-9, 58
A/C Pressure Transducer . . . . . . . . . 8W-30-23, 28, 29, 45
Accel erator Pedal Posi ti on Sensor . . . 8W-30-29, 47, 64, 65
Adjustabl e Pedal Motor . . . . . . . . . . . . . . . . . 8W-30-61
Adjustabl e Pedal Rel ay . . . . . . . . . . . . . . . . . . 8W-30-61
Adjustabl e Pedal Swi tch . . . . . . . . . . . . . . . . . 8W-30-61
Ambi ent Temperature Sensor . . . . . . . . . . . . . 8W-30-30
Auto Shut Down Rel ay . . . . . . . . . . . . . . . . . . . 8W-30-4
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-52
Battery Temperature Sensor . . . . . . . . . . . . 8W-30-12, 56
Brake Lamp Swi tch . . . . . . . . . . . . . 8W-30-8, 36, 57, 63
Camshaft Posi ti on Sensor . . . . . . . . 8W-30-10, 29, 45, 46
Capaci tor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-13
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . 8W-30-8, 36, 59
Coi l On Pl ug No. 1 . . . . . . . . . . . . . . . . . . 8W-30-14, 39
Coi l On Pl ug No. 2 . . . . . . . . . . . . . . . . . . 8W-30-15, 37
Coi l On Pl ug No. 3 . . . . . . . . . . . . . . . . . . 8W-30-14, 39
Coi l On Pl ug No. 4 . . . . . . . . . . . . . . . . . . 8W-30-15, 37
Coi l On Pl ug No. 5 . . . . . . . . . . . . . . . . . . 8W-30-16, 39
Coi l On Pl ug No. 6 . . . . . . . . . . . . . . . . . . 8W-30-13, 37
Coi l On Pl ug No. 7 . . . . . . . . . . . . . . . . . . 8W-30-16, 39
Coi l On Pl ug No. 8 . . . . . . . . . . . . . . . . . . 8W-30-13, 37
Condenser Fan Rel ay . . . . . . . . . . . . . . . . . . . . 8W-30-9
Control l er Anti l ock Brake . . . . . . . . . . . . 8W-30-6, 11, 57
Crankshaft Posi ti on Sensor . . . . . . . . . . . . 8W-30-10, 46
Data Li nk Connector . . . . . . . . . . . . . . . 8W-30-9, 22, 55
Data Li nk Connector-Engi ne . . . . . . . . . . . . . . 8W-30-51
EGR Sol enoi d . . . . . . . . . . . . . . . . . . . 8W-30-28, 29, 32
El ectroni c Throttl e Control Modul e . . . . . . . . . . 8W-30-35
Engi ne Control Modul e . . . . . . . 8W-30-42, 43, 44, 45, 46,
47, 48, 49, 50, 51, 52, 53, 54,
55, 56, 57, 58, 59, 60, 62, 63, 64, 65
Engi ne Cool ant Temperature Sensor . . . . 8W-30-23, 41, 47
Engi ne Oi l Pressure Swi tch . . . . . . . . . . 8W-30-2, 53, 56
EVAP/Purge Sol enoi d . . . . . . . . . . . . . . . . . . . 8W-30-12
Front Control Modul e . . . . . . . . . . . . . . . . . . . 8W-30-61
Fuel Control Actuator . . . . . . . . . . . . . . . . . . . 8W-30-50
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-60
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-30-60
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . 8W-30-14, 40
Fuel I njector Pack No. 1 . . . . . . . . . . . . . . . . . 8W-30-42
Fuel I njector Pack No. 2 . . . . . . . . . . . . 8W-30-42, 43, 44
Fuel I njector Pack No. 3 . . . . . . . . . . . . . . . . . 8W-30-44
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . 8W-30-3, 58
Fuel Pump Motor . . . . . . . . . . . . . . . . . . . . . . 8W-30-48
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-25, 62
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-60
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-52
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
Component Page
Fuse 36 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-54, 61
Fuse 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-61
Fuse 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4
Fuse 50 . . . . . . . . . . . . . . . . . . . . . 8W-30-2, 55, 58, 62
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-52
G104 . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3, 8, 25, 60
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-56, 58
G107 . . . . . . . . . . . 8W-30-2, 7, 15, 18, 19, 20, 21, 30, 32
G114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-53
G120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-51, 60
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-6
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-61
Generator . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-7, 51
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . . . . 8W-30-9
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-30-6, 22
I nl et Ai r Temperature Sensor . . . . . . . . . . . . . 8W-30-49
I nput Speed Sensor . . . . . . . . . . . . . . . . . . . . 8W-30-24
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . 8W-30-30
I ntake Ai r Temperature Sensor . . . . . . . . . . 8W-30-23, 41
Pressure Sensor . . . . . . . . . . . . . . . . . . . . . 8W-30-50
I ntegrated Power Modul e . . . . 8W-30-2, 3, 4, 9, 25, 52, 54,
55, 58, 60, 61, 62, 64
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-31
Knock Sensor-Left . . . . . . . . . . . . . . . . . . . . . 8W-30-33
Knock Sensor-Ri ght . . . . . . . . . . . . . . . . . . . . 8W-30-33
Li ft Pump Motor . . . . . . . . . . . . . . . . . . . . . . 8W-30-51
Li ne Pressure Sensor . . . . . . . . . . . . . . . . . . . 8W-30-17
Mani fol d Absol ute Pressure Sensor . . . . . 8W-30-23, 29, 41
Natural Vacuum Leak Detecti on Assembl y . . . . . 8W-30-7
Output Speed Sensor . . . . . . . . . . . . . . . . . 8W-30-24, 62
Oxygen Sensor 1/1 Upstream . . . . . . . . . . . 8W-30-20, 21
Oxygen Sensor 1/2 Downstream . . . . . . . . . 8W-30-18, 19
Oxygen Sensor 2/1 Upstream . . . . . . . . . . . 8W-30-20, 21
Oxygen Sensor 2/2 Downstream . . . . . . . . . 8W-30-18, 19
Oxygen Sensor Downstream Rel ay . . . . . . . . . . . 8W-30-4
Power Steeri ng Pressure Swi tch . . . . . . . . . . . . 8W-30-7
Powertrai n Control Modul e . . . . . . . 8W-30-2, 3, 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, 14, 15, 16,
17, 18, 19, 20, 21, 22, 23, 24,
25, 26, 27, 28, 29, 30, 31, 32,
33, 35, 36, 37, 38, 39, 40, 41
PTC No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3, 9, 58
Pto Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-6
Speed Control Servo . . . . . . . . . . . . . . . . . . 8W-30-8, 63
Speed Control Swi tch-Left . . . . . . . . . . . . . 8W-30-36, 59
Speed Control Swi tch-Ri ght . . . . . . . . . . . . 8W-30-36, 59
Starter Motor Rel ay . . . . . . . . . . . . . . . . . . 8W-30-2, 64
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . . . 8W-30-17
Tow/Haul Overdri ve Swi tch . . . . . . . . . . . . . 8W-30-6, 64
Transmi ssi on Control Rel ay . . . . . . . . . . . . 8W-30-25, 62
Transmi ssi on Range Sensor . . . . . . . . . . . . . . . 8W-30-64
Transmi ssi on Sol enoi d Assembl y . . . . . . . . . 8W-30-54, 62
Transmi ssi on Sol enoi d/TRS Assembl y . 8W-30-5, 25, 26, 27
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-58
Vi stroni c Fan Dri ve . . . . . . . . . . . . . . . . . . . . 8W-30-54
Water I n Fuel Sensor . . . . . . . . . . . . . . . . 8W-30-47, 48
DR 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1
8W-31 TRANSMISSION CONTROL SYSTEM
Component Page
Automati c Day/Ni ght Mi rror . . . . . . . . . . . 8W-31-7
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-31-9
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . 8W-31-6
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-10
Cl utch I nterl ock Brake Swi tch . . . . . . . . . 8W-31-11
Data Li nk Connector . . . . . . . . . . . . . . . . 8W-31-16
Engi ne Control Modul e . . . . . . . . . 8W-31-7, 8, 9, 10
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 8
Fuse 38 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 7
Fuse 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-11
Fuse 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-8
G104 . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 11, 14, 16
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-14
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3, 10
I nput Speed Sensor . . . . . . . . . . . . . . . . . . 8W-31-5
I nstrument Cl uster . . . . . . . . . . . . . . . . 8W-31-7, 14
I ntegrated Power Modul e . . . . . . . 8W-31-2, 7, 8, 11
Component Page
Li ne Pressure Sensor . . . . . . . . . . . . . . . . . 8W-31-6
Output Speed Sensor . . . . . . . . . . . . . . . 8W-31-5, 8
Powertrai n Control Modul e . . . . . 8W-31-2, 3, 4, 5, 6
Speed Control Servo . . . . . . . . . . . . . . . . . . 8W-31-9
Speed Control Swi tch-Left . . . . . . . . . . . . 8W-31-10
Speed Control Swi tch-Ri ght . . . . . . . . . . . 8W-31-10
Starter Motor Rel ay . . . . . . . . . . . . . . . . . 8W-31-11
Tow/Haul Overdri ve Swi tch . . . . . . . . . 8W-31-3, 10
Transfer Case Control
Modul e . . . . . . . . . . . . . . 8W-31-11, 12, 13, 14, 16
Transfer Case Mode Sensor . . . . . . . . 8W-31-12, 13
Transfer Case Sel ector Swi tch . . . . . . . . . 8W-31-14
Transfer Case Shi ft Motor . . . . . . . . . . . . 8W-31-16
Transmi ssi on Control Rel ay . . . . . . . . . . 8W-31-2, 8
Transmi ssi on Sol enoi d Assembl y . . . . . . . . 8W-31-8
Transmi ssi on Sol enoi d/TRS Assembl y . 8W-31-2, 3, 4
DR 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
8W-33 VEHICLE SPEED CONTROL
Component Page
Brake Lamp Swi tch . . . . . . . . . . . . . . 8W-33-2, 4, 5
Aftermarket . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . 8W-33-6, 7, 8
Control l er Anti l ock Brake . . . . . . . . . . . . . . 8W-33-3
El ectri c Brake Provi si on . . . . . . . . . . . . . . . 8W-33-2
Engi ne Control Modul e . . . . . . . . . . . . 8W-33-3, 5, 8
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Component Page
Fuse 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-4
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-4, 5
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
I ntegrated Power Modul e . . . . . . . . . . . . 8W-33-2, 4
Powertrai n Control Modul e . . . . . . . . 8W-33-3, 4, 8
PTC No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-4
Speed Control Servo . . . . . . . . . . . . . . . . 8W-33-4, 5
Speed Control Swi tch-Left . . . . . . . . . . . 8W-33-6, 7
Speed Control Swi tch-Ri ght . . . . . . . . . . 8W-33-6, 7
DR 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1
8W-34 REAR WHEEL ANTILOCK BRAKES
Component Page
Brake Fl ui d Level Swi tch . . . . . . . . . . . . . . 8W-34-2
Control l er Anti l ock Brake . . . . . . . . . . . . 8W-34-2, 3
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-34-2
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-34-2
Component Page
Fuse 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-34-2
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-34-2
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-34-3
I ntegrated Power Modul e . . . . . . . . . . . . . . 8W-34-2
Wheel Speed Sensor-Rear . . . . . . . . . . . . . . 8W-34-3
DR 8W-34 REAR WHEEL ANTILOCK BRAKES 8W - 34 - 1
8W-35 ALL WHEEL ANTILOCK BRAKES
Component Page
Brake Fl ui d Level Swi tch . . . . . . . . . . . . . . 8W-35-2
Control l er Anti l ock Brake . . . . . . . . . . . . 8W-35-2, 3
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Fuse 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Component Page
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
Wheel Speed Sensor-Left Front . . . . . . . . . 8W-35-3
Wheel Speed Sensor-Rear . . . . . . . . . . . . . . 8W-35-3
Wheel Speed Sensor-Ri ght Front . . . . . . . . 8W-35-3
DR 8W-35 ALL WHEEL ANTILOCK BRAKES 8W - 35 - 1
8W-39 VEHICLE THEFT SECURITY SYSTEM
Component Page
Cyl i nder Lock Swi tch-Dri ver . . . . . . . . . . . 8W-39-5
Door Lock Motor/Ajar Swi tch-Dri ver . . . . . 8W-39-5
Door Lock Motor/Ajar Swi tch-Left Rear . . . 8W-39-5
Door Lock Motor/Ajar Swi tch-Passenger . . 8W-39-4
Door Lock Motor/Ajar Swi tch-Ri ght Rear . . 8W-39-4
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Fuse 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Fuse 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Fuse 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
Component Page
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5
Headl amp-Left . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Headl amp-Ri ght . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
I nstrument Cl uster . . . . . . . . . . . . . . . 8W-39-2, 4, 5
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-39-3
Sentry Key I mmobi l i zer Modul e . . . . . . . . . 8W-39-2
DR 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1
8W-40 INSTRUMENT CLUSTER
Component Page
A/C-Heater Control . . . . . . . . . . . . . . . . . . 8W-40-12
Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-10
Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5, 11
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . 8W-40-10, 14
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-40-11
Door Ajar Swi tch-Dri ver . . . . . . . . . . . . . . 8W-40-13
Door Ajar Swi tch-Left Rear . . . . . . . . . . . 8W-40-13
Door Ajar Swi tch-Passenger . . . . . . . . . . . 8W-40-13
Door Ajar Swi tch-Ri ght Rear . . . . . . . . . . 8W-40-13
Door Lock Motor/Ajar
Swi tch-Passenger . . . . . . . . . . . . . . . . 8W-40-6, 8
Swi tch-Ri ght Rear . . . . . . . . . . . . . . . 8W-40-7, 8
Door Lock Swi tch-Passenger . . . . . . . . . . . 8W-40-6
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . 8W-40-8
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Fog Lamp-Left . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Fog Lamp-Ri ght . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5
Fuse 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5
Component Page
Fuse 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3, 12
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-10
G301 . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 6, 7, 13
Gl ove Box Lamp And Swi tch . . . . . . . . . . 8W-40-12
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-40-3
Heated Seat Swi tch-Dri ver . . . . . . . . . . 8W-40-8, 12
Heated Seat Swi tch-Passenger . . . . . . . 8W-40-8, 12
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-40-14
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . 8W-40-5, 14
I nstrument Cl uster . . . . . . . . 8W-40-2, 3, 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, 14
I ntegrated Power Modul e . . . . . . . . 8W-40-2, 3, 5, 9
Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . . 8W-40-4
Overhead Map/Readi ng Lamp . . . . . . . . . 8W-40-11
Park Brake Swi tch . . . . . . . . . . . . . . . . . . 8W-40-14
Powertrai n Control Modul e . . . . . . . . . . . 8W-40-14
PTC No. 2 . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 9
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-9, 11
Remote Radi o Swi tch-Left . . . . . . . . . . . . 8W-40-10
Remote Radi o Swi tch-Ri ght . . . . . . . . . . . 8W-40-10
Seat Bel t Swi tch-Dri ver . . . . . . . . . . . . . . . 8W-40-2
Seat Bel t Tensi oner Reducer . . . . . . . . . . . 8W-40-2
Transfer Case Sel ector Swi tch . . . . . . . . . . 8W-40-9
DR 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
Component Page
Ci gar Li ghter Outl et . . . . . . . . . . . . . . . . . . 8W-41-3
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4
Fuse 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Component Page
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4
Horn-Hi gh Note . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Horn-Low Note . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Power Outl et-Consol e . . . . . . . . . . . . . . . 8W-41-3, 4
DR 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1
8W-42 AIR CONDITIONING
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . 8W-42-7
A/C Compressor Cl utch Rel ay . . . . . . . . . . 8W-42-7
A/C Pressure Transducer . . . . . . . . . . . . 8W-42-8, 9
A/C-Heater Control . . . . . . . . . . . 8W-42-2, 3, 4, 5, 6
Bl end Door Actuator . . . . . . . . . . . . . . . . . . 8W-42-6
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . 8W-42-2
Condenser Fan . . . . . . . . . . . . . . . . . . . . . 8W-42-10
Condenser Fan Rel ay . . . . . . . . . . . . . . . . 8W-42-10
Data Li nk Connector . . . . . . . . . . . . . 8W-42-3, 4, 8
Dri ver Bl end Door Actuator . . . . . . . . . . . . 8W-42-5
EVAPorator Temperature Sensor . . . . . . . . 8W-42-4
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-10
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7
Component Page
Fuse 36 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3, 4
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-10
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7
G120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4
Heated Mi rror Rel ay . . . . . . . . . . . . . . . 8W-42-3, 4
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-42-2
I ntegrated Power Modul e . . . . . . . 8W-42-3, 4, 7, 10
Mode Door Actuator 1 . . . . . . . . . . . . . . . 8W-42-5, 6
Mode Door Actuator 2 . . . . . . . . . . . . . . . 8W-42-5, 6
Passenger Bl end Door Actuator . . . . . . . . . 8W-42-5
Powertrai n Control Modul e . . . . . . . . 8W-42-7, 8, 10
PTC No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7
Reci rcul ati on Door Actuator . . . . . . . . . . 8W-42-5, 6
DR 8W-42 AIR CONDITIONING 8W - 42 - 1
8W-43 AIRBAG SYSTEM
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . 8W-43-2, 3, 4
Ai rbag-Dri ver Squi b 1 . . . . . . . . . . . . . . . . 8W-43-3
Ai rbag-Dri ver Squi b 2 . . . . . . . . . . . . . . . . 8W-43-3
Ai rbag-Left Curtai n . . . . . . . . . . . . . . . . . . 8W-43-4
Ai rbag-Passenger On/Off Swi tch . . . . . . . . 8W-43-2
Ai rbag-Passenger Squi b . . . . . . . . . . . . . . . 8W-43-3
Ai rbag-Ri ght Curtai n . . . . . . . . . . . . . . . . . 8W-43-4
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
Component Page
Fuse 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Fuse 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
G204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Seat Bel t Pretensi oner-Dri ver . . . . . . . . . . 8W-43-3
Seat Bel t Pretensi oner-Passenger . . . . . . . . 8W-43-3
Si de I mpact Sensor-Left . . . . . . . . . . . . . . . 8W-43-4
Si de I mpact Sensor-Ri ght . . . . . . . . . . . . . . 8W-43-4
DR 8W-43 AIRBAG SYSTEM 8W - 43 - 1
8W-44 INTERIOR LIGHTING
Component Page
Ashtray Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
Door Ajar Swi tch-Dri ver . . . . . . . . . . . . . . . 8W-44-3
Door Ajar Swi tch-Left Rear . . . . . . . . . . . . 8W-44-3
Door Ajar Swi tch-Passenger . . . . . . . . . . . . 8W-44-4
Door Ajar Swi tch-Ri ght Rear . . . . . . . . . . . 8W-44-4
Door Lock Motor/Ajar Swi tch-Passenger . . 8W-44-4
Component Page
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
Fuse 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 4
Gl ove Box Lamp And Swi tch . . . . . . . . . . . 8W-44-2
Overhead Map/Readi ng Lamp . . . . . . . . . . 8W-44-2
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-44-4
Underhood Lamp . . . . . . . . . . . . . . . . . . . . 8W-44-3
DR 8W-44 INTERIOR LIGHTING 8W - 44 - 1
8W-47 AUDIO SYSTEM
Component Page
Ampl i fi er Audi o . . . . . . . . . . . . . . . . . . . 8W-47-4, 5
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-7
Data Li nk Connector . . . . . . . . . . . . . . . 8W-47-2, 5
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-7
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 5
Radi o . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 4, 7
Component Page
Remote Radi o Swi tch-Left . . . . . . . . . . . . . 8W-47-7
Remote Radi o Swi tch-Ri ght . . . . . . . . . . . . 8W-47-7
Speaker-Center I nstrument Panel . . . . . . . 8W-47-4
Speaker-Left Front Door . . . . . . . . . . . . . 8W-47-3, 6
Speaker-Left I nstrument Panel . . . . . . . . . 8W-47-4
Speaker-Left Rear . . . . . . . . . . . . . . . . . 8W-47-3, 6
Speaker-Ri ght Front Door . . . . . . . . . . . 8W-47-3, 6
Speaker-Ri ght I nstrument Panel . . . . . . . . 8W-47-4
Speaker-Ri ght Rear . . . . . . . . . . . . . . . . 8W-47-3, 6
DR 8W-47 AUDIO SYSTEM 8W - 47 - 1
8W-48 REAR WINDOW DEFOGGER
Component Page
El ectri c Backl i ght . . . . . . . . . . . . . . . . . . . . 8W-48-2
Fuse 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
Component Page
Heated Mi rror Rel ay . . . . . . . . . . . . . . . . . 8W-48-2
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . 8W-48-2
DR 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1
8W-49 OVERHEAD CONSOLE
Component Page
Ambi ent Temperature Sensor . . . . . . . . . 8W-49-3, 4
Backup Lamp Swi tch . . . . . . . . . . . . . . . . . 8W-49-2
Compass/Mi ni -Tri p Computer . . . . . . . . . . . 8W-49-2
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2
Component Page
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3
Overhead Map/Readi ng Lamp . . . . . . . . . . 8W-49-3
Transmi ssi on Sol enoi d/TRS Assembl y . . . . 8W-49-2
DR 8W-49 OVERHEAD CONSOLE 8W - 49 - 1
8W-50 FRONT LIGHTING
Component Page
Cl earance Lamp No. 1 . . . . . . . . . . . . . . . . 8W-50-6
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-50-5
Fog Lamp-Left . . . . . . . . . . . . . . . . . . . . . . 8W-50-5
Fog Lamp-Ri ght . . . . . . . . . . . . . . . . . . . . . 8W-50-5
Front Control Modul e . . . . . . . . . . . 8W-50-2, 3, 4, 5
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
Fuse 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4
Fuse 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-5
Component Page
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 4, 5
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 4
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-5
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-6
Headl amp Swi tch . . . . . . . . . . . . . . . . . . 8W-50-2, 5
Headl amp-Left . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
Headl amp-Ri ght . . . . . . . . . . . . . . . . . . . . . 8W-50-3
I ntegrated Power Modul e . . . . . . . . 8W-50-2, 3, 4, 5
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-50-4
Park/Turn Si gnal Lamp-Left Front . . . . . . . 8W-50-4
Park/Turn Si gnal Lamp-Ri ght Front . . . . . 8W-50-4
DR 8W-50 FRONT LIGHTING 8W - 50 - 1
8W-51 REAR LIGHTING
Component Page
Backup Lamp Swi tch . . . . . . . . . . . . . . . 8W-51-3, 5
Aftermarket . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
Fender Lamp-Front Left . . . . . . . . . . . . . . . 8W-51-4
Fender Lamp-Front Ri ght . . . . . . . . . . . . . 8W-51-4
Fender Lamp-Rear Left . . . . . . . . . . . . . . . 8W-51-4
Fender Lamp-Rear Ri ght . . . . . . . . . . . . . . 8W-51-4
Front Control Modul e . . . . . . . . . 8W-51-2, 3, 5, 6, 7
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 3, 7
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3
Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
Fuse 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2
Fuse 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3
Component Page
G104 . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 4, 5, 6
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
I ntegrated Power Modul e . . . . . . 8W-51-2, 3, 5, 6, 7
Li cense Lamp-Left . . . . . . . . . . . . . . . . . . . 8W-51-2
Li cense Lamp-Ri ght . . . . . . . . . . . . . . . . . . 8W-51-2
Park Lamp Rel ay . . . . . . . . . . . . . . . . 8W-51-2, 3, 7
Tai l /Stop/Turn Si gnal Lamp-Left . . . . . . 8W-51-2, 5
Tai l /Stop/Turn Si gnal Lamp-Ri ght . . . . . . . 8W-51-6
Tai l gate Lamp . . . . . . . . . . . . . . . . . . . . 8W-51-2, 4
Trai l er Tow Connector . . . . . . . . . . . . . . . . 8W-51-7
Trai l er Tow Connector-Add On . . . . . . . . 8W-51-5, 7
Transmi ssi on Sol enoi d/TRS Assembl y . . . . 8W-51-5
DR 8W-51 REAR LIGHTING 8W - 51 - 1
8W-52 TURN SIGNALS
Component Page
Front Control Modul e . . . . . . . . . 8W-52-2, 3, 4, 5, 6
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
Fuse 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
Fuse 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
Fuse 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-6
Fuse 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-6
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 4, 5
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
I ntegrated Power Modul e . . . . . . 8W-52-2, 3, 4, 5, 6
Component Page
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . . . 8W-52-3
Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . 8W-52-4, 5
Tai l /Stop/Turn Si gnal Lamp-Left . . . . . . 8W-52-3, 4
Tai l /Stop/Turn Si gnal Lamp-Ri ght . . . . . . . 8W-52-5
Tai l /Turn Lamp . . . . . . . . . . . . . . . . . . . 8W-52-4, 5
Trai l er Tow Connector . . . . . . . . . . . . . . . . 8W-52-6
Trai l er Tow Connector-Add On . . . . . . . . . . 8W-52-6
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . . 8W-52-6
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . . 8W-52-6
DR 8W-52 TURN SIGNALS 8W - 52 - 1
8W-53 WIPERS
Component Page
Front Control Modul e . . . . . . . . . . . . . 8W-53-2, 3, 4
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3, 4
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4
Component Page
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . 8W-53-4
Washer Pump Motor-Front . . . . . . . . . . . . . 8W-53-4
Wi per Hi gh/Low Rel ay . . . . . . . . . . . . . . 8W-53-3, 4
Wi per Motor-Front . . . . . . . . . . . . . . . . . 8W-53-3, 4
Wi per On/Off Rel ay . . . . . . . . . . . . . . . . . . 8W-53-3
DR 8W-53 WIPERS 8W - 53 - 1
8W-54 TRAILER TOW
Component Page
El ectri c Brake Provi si on . . . . . . . . . . . . . . . 8W-54-5
Front Control Modul e . . . . . . . . . . . . . 8W-54-2, 3, 5
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-5
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2, 3
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-5
Fuse 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-5
Fuse 33 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2, 3
Fuse 46 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2, 3
Component Page
Fuse 47 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2, 3
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2, 4, 5
Park Lamp Rel ay . . . . . . . . . . . . . . . . . . 8W-54-2, 3
PTC No. 5 . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2, 3
Trai l er Tow Connector . . . . . . . . . . . . 8W-54-2, 3, 4
Trai l er Tow Connector-Add On . . . . . . 8W-54-3, 4, 5
Trai l er Tow Left Turn Rel ay . . . . . . . . . . 8W-54-2, 3
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . 8W-54-2, 3
DR 8W-54 TRAILER TOW 8W - 54 - 1
8W-55 NAVIGATION/TELECOMMUNICATION
Component Page
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-2
Component Page
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-2
DR 8W-55 NAVIGATION/TELECOMMUNICATION 8W - 55 - 1
8W-60 POWER WINDOWS
Component Page
Ci rcui t Breaker . . . . . . . . . . . . . . . . . . . 8W-60-2, 4
Dri ver Door Modul e . . . . . . . . 8W-60-2, 3, 4, 5, 6, 7
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 4
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-60-2
Power Wi ndow Ci rcui t Breaker . . . . . . . 8W-60-2, 4
Power Wi ndow Motor-Dri ver . . . . . . . . . 8W-60-2, 4
Component Page
Power Wi ndow Motor-Left Rear . . . . . . . . . 8W-60-7
Power Wi ndow Motor-Passenger . . . . . . . 8W-60-3, 5
Power Wi ndow Motor-Ri ght Rear . . . . . . . . 8W-60-6
Power Wi ndow Swi tch-Left Rear . . . . . . 8W-60-4, 7
Power Wi ndow Swi tch-Passenger . . . . 8W-60-3, 4, 5
Power Wi ndow Swi tch-Ri ght Rear . . . . . 8W-60-4, 6
DR 8W-60 POWER WINDOWS 8W - 60 - 1
8W-61 POWER DOOR LOCKS
Component Page
Swi tch-Passenger . . . . . . . . . . . . . . . . 8W-61-3, 4
Door Lock Swi tch-Passenger . . . . . . . . . 8W-61-3, 4
Component Page
Dri ver Door Modul e . . . . . . . . . . . . . . . . . . 8W-61-2
Fuse 28 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-3, 4
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3, 4
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2
DR 8W-61 POWER DOOR LOCKS 8W - 61 - 1
8W-62 POWER MIRRORS
Component Page
Dri ver Door Modul e . . . . . . . . . . . . . . . . 8W-62-2, 3
Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-3
Fuse 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-3
Fuse 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2
Component Page
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3
Heated Mi rror Rel ay . . . . . . . . . . . . . . . . . 8W-62-3
Power Mi rror-Left . . . . . . . . . . . . . . . . . . 8W-62-2, 3
Power Mi rror-Ri ght . . . . . . . . . . . . . . . . . . 8W-62-3
DR 8W-62 POWER MIRRORS 8W - 62 - 1
8W-63 POWER SEATS
Component Page
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2
Fuse 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-6
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-5
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-7
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 3, 4
Heated Seat Cushi on-Dri ver . . . . . . . . . . . . 8W-63-7
Heated Seat Cushi on-Passenger . . . . . . . . . 8W-63-7
Heated Seat Swi tch-Dri ver . . . . . . . . . . . 8W-63-5, 6
Heated Seat Swi tch-Passenger . . . . . . . . 8W-63-5, 6
Lumbar Motor-Dri ver . . . . . . . . . . . . . . . . . 8W-63-2
Lumbar Motor-Passenger . . . . . . . . . . . . 8W-63-3, 4
Component Page
Passenger Lumbar Swi tch . . . . . . . . . . . . . 8W-63-3
Power Seat Motor-Dri ver Front Verti cal . . . 8W-63-2
Power Seat Motor-Dri ver Hori zontal . . . . . 8W-63-2
Power Seat Motor-Dri ver Rear Verti cal . . . 8W-63-2
Power Seat Motor-Passenger Front
Verti cal . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4
Power Seat Motor-Passenger Hori zontal . . 8W-63-4
Power Seat Motor-Passenger Rear
Verti cal . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4
Power Seat Swi tch-Dri ver . . . . . . . . . . . . . 8W-63-2
Power Seat Swi tch-Passenger . . . . . . . . . . . 8W-63-4
Seat Heater I nterface Modul e . . . . . . . . . 8W-63-6, 7
DR 8W-63 POWER SEATS 8W - 63 - 1
8W-70 SPLICE INFORMATION
Component Page
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-34
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-36
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-34
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-36
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-36
S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31
S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-48
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-37
S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-4
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-4
S125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3, 4
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3, 4
S133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-6
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-5
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-40
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-43
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22, 24
S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-6
S145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
S148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-16, 23
S149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23
S150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-5
S154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-29
S155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 34
S157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-47
S158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-43
S159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-42
S160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-21, 42
S161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
S162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20
S163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21
S164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
S165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4, 12
S166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4, 12
S168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-18, 21
S169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20
S170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-44
S171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-42
S172 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-8
S173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-7
S174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-44
S175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-44
S176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
S177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-43
S187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-19
S191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-45
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-41
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-41
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-6, 7
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-6, 7
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-5
Component Page
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-52
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-46
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-5
S217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4
S218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4
S219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-7
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-7
S221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31
S222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-42
S224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2
S225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-42
S226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-5, 6
S228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-7
S230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5
S231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-6
S232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-6
S240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31
S241 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-35
S243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
S245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30
S300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32
S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-3
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-39
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-35
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-41
S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
S308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28
S318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4, 28
S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
S320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
S321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-7
S322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-34
S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-48
S326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3, 35
S327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-34
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-7
S330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-33
S331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-33
S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2
S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-4
S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-43
S335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14, 19
S336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
S337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
S340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
S341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
S342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-35
S343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-35
S351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
DR 8W-70 SPLICE INFORMATION 8W - 70 - 1
8W-80 CONNECTOR PIN-OUTS
Component Page
4WD Swi tch (Manual Transfer Case) . . . . . 8W-80-5
A/C Compressor Cl utch (Di esel ) . . . . . . . . . 8W-80-5
A/C Compressor Cl utch (Gas) . . . . . . . . . . . 8W-80-5
A/C Heater Control C1 . . . . . . . . . . . . . . . . 8W-80-5
A/C Heater Control C2 . . . . . . . . . . . . . . . . 8W-80-6
A/C Pressure Transducer (Di esel ) . . . . . . . . 8W-80-6
A/C Pressure Transducer (NGC) . . . . . . . . . 8W-80-6
Accel erator Pedal Posi ti on Sensor (5.7L) . . 8W-80-6
Accel erator Pedal Posi ti on Sensor
(Di esel M/T) . . . . . . . . . . . . . . . . . . . . . . 8W-80-7
Accel erator Pedel Posi ti on Sensor
(Di esel A/T) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-7
Adjustabl e Pedal Motor (Except Memory) . 8W-80-7
Adjustabl e Pedal Swi tch (Except Memory) . 8W-80-8
Ai rbag Control Modul e C1 . . . . . . . . . . . . . 8W-80-8
Ai rbag Control Modul e C2 . . . . . . . . . . . . . 8W-80-9
Ai rbag-Left Curtai n . . . . . . . . . . . . . . . . . . 8W-80-9
Ai rbag-Passenger On/Off Swi tch . . . . . . . 8W-80-10
Ai rbag-Passenger Squi b . . . . . . . . . . . . . . 8W-80-10
Ai rbag-Ri ght Curtai n . . . . . . . . . . . . . . . . 8W-80-10
Ambi ent Temperature Sensor . . . . . . . . . . 8W-80-10
Ampl i fi er Audi o C1 (Premi um) . . . . . . . . . 8W-80-11
Ampl i fi er Audi o C2 (Premi um) . . . . . . . . . 8W-80-11
Ashtray Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-80-11
Automati c Day/Ni ght Mi rror C1 (Except
Base) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
Automati c Day/Ni ght Mi rror C2
(Tel emati cs) . . . . . . . . . . . . . . . . . . . . . 8W-80-12
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . 8W-80-12
Battery Temperature Sensor . . . . . . . . . . . 8W-80-12
Bl end Door Actuator (Si ngl e Zone) . . . . . . 8W-80-13
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . 8W-80-13
Bl ower Motor Resi stor Bl ock . . . . . . . . . . 8W-80-13
Brake Fl ui d Level Swi tch . . . . . . . . . . . . . 8W-80-13
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . 8W-80-13
Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C102 (NGC) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C106 (5.7L A/T) . . . . . . . . . . . . . . . . . . . . 8W-80-14
C106 (5.7L A/T) . . . . . . . . . . . . . . . . . . . . 8W-80-15
C107 (5.7L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C107 (5.7L) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C108 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C108 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-16
C109 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C109 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C110 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-17
C110 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C112 (Di esel M/T) . . . . . . . . . . . . . . . . . . . 8W-80-18
C112 (Di esel M/T) . . . . . . . . . . . . . . . . . . . 8W-80-18
C112 (Di esel A/T) . . . . . . . . . . . . . . . . . . . 8W-80-18
Component Page
C112 (Di esel A/T) . . . . . . . . . . . . . . . . . . . 8W-80-19
C130 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
C131 (4.7L El ectroni c Transfer Case) . . . . 8W-80-20
C131 (4.7L El ectroni c Transfer Case) . . . . 8W-80-20
C131 (5.7L/Di esel ) . . . . . . . . . . . . . . . . . . 8W-80-20
C131 (5.7L/Di esel ) . . . . . . . . . . . . . . . . . . 8W-80-21
C131 (3.7L/4.7L Except El ectroni c
Transfer Case) . . . . . . . . . . . . . . . . . . . 8W-80-21
C131 (3.7L/4.7L Except El ectroni c
Transfer Case) . . . . . . . . . . . . . . . . . . . 8W-80-22
C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
C201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
C201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
C216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
C216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
C217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
C217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
C218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
C218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27
C219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27
C219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-29
C220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-30
C220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-31
C250 (Hands Free) . . . . . . . . . . . . . . . . . . 8W-80-31
C250 (Hands Free) . . . . . . . . . . . . . . . . . . 8W-80-32
C301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-32
C301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-32
C301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
C302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
C302 (SLT) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
C304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
C304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
C305 (SLT) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35
C305 (SLT) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35
C306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-36
C306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-36
C308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-36
C308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-37
C309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-37
C309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-37
C311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-38
C311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-38
C313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-38
C313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-39
C315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-39
DR 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1
Component Page
C315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-39
C316 (Heated Seats) . . . . . . . . . . . . . . . . . 8W-80-39
C316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-40
C319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-40
C319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-40
C320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-40
C320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
C322 (Except Heated Seats) . . . . . . . . . . . 8W-80-41
C322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-41
C323 (Heated Seats) . . . . . . . . . . . . . . . . . 8W-80-42
C323 (Heated Seats) . . . . . . . . . . . . . . . . . 8W-80-43
C327 (Dual Rear Wheel s) . . . . . . . . . . . . . 8W-80-43
Camshaft Posi ti on Sensor (NGC) . . . . . . . 8W-80-44
Camshaft Posi ti on Sensor (Di esel ) . . . . . . 8W-80-44
Capaci tor (3.7L/4.7L) . . . . . . . . . . . . . . . . 8W-80-44
Center Hi gh Mounted Stop Lamp/cargo
Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-45
Ci gar Li ghter Outl et . . . . . . . . . . . . . . . . . 8W-80-45
Cl earance Lamp No. 1 (Heavy Duty) . . . . 8W-80-45
Cl ockspri ng C1 . . . . . . . . . . . . . . . . . . . . . 8W-80-46
Cl ockspri ng C2 . . . . . . . . . . . . . . . . . . . . . 8W-80-47
Cl ockspri ng C3 . . . . . . . . . . . . . . . . . . . . . 8W-80-47
Cl ockspri ng C4 . . . . . . . . . . . . . . . . . . . . . 8W-80-47
Cl utch I nterl ock Brake Swi tch . . . . . . . . . 8W-80-47
Coi l On Pl ug No. 1 (3.7L/4.7L) . . . . . . . . . 8W-80-47
Coi l On Pl ug No. 1 (5.7L) . . . . . . . . . . . . . 8W-80-48
Coi l On Pl ug No. 2 (5.7L) . . . . . . . . . . . . . 8W-80-48
Coi l On Pl ug No. 3 (5.7L) . . . . . . . . . . . . . 8W-80-49
Coi l On Pl ug No. 4 (5.7L) . . . . . . . . . . . . . 8W-80-49
Coi l On Pl ug No. 5 (5.7L) . . . . . . . . . . . . . 8W-80-50
Coi l On Pl ug No. 6 (5.7L) . . . . . . . . . . . . . 8W-80-50
Coi l On Pl ug No. 7 (4.7L) . . . . . . . . . . . . . 8W-80-50
Coi l On Pl ug No. 7 (5.7L) . . . . . . . . . . . . . 8W-80-51
Coi l On Pl ug No. 8 (4.7L) . . . . . . . . . . . . . 8W-80-51
Coi l On Pl ug No. 8 (5.7L) . . . . . . . . . . . . . 8W-80-51
Compass/Mi ni -Tri p Computer (Except
Base) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-51
Condenser Fan (NGC) . . . . . . . . . . . . . . . 8W-80-52
Control l er Ani tl ock Brake C1 . . . . . . . . . . 8W-80-52
Control l er Anti l ock Brake C2 (ABS) . . . . . 8W-80-52
Component Page
Crankshaft Posi ti on Sensor (3.7L) . . . . . . 8W-80-52
Crankshaft Posi ti on Sensor (Di esel ) . . . . . 8W-80-53
Cyl i nder Lock Swi tch-Dri ver (Premi um) . . 8W-80-53
Data Li nk Connector . . . . . . . . . . . . . . . . 8W-80-53
Data Li nk Connector-Engi ne (Di esel ) . . . . 8W-80-54
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-80-54
Door Ajar Swi tch-Dri ver . . . . . . . . . . . . . . 8W-80-54
Door Ajar Swi tch-Left Rear . . . . . . . . . . . 8W-80-54
Door Ajar Swi tch-Passenger . . . . . . . . . . . 8W-80-55
Door Ajar Swi tch-Ri ght Rear . . . . . . . . . . 8W-80-55
Door Lock Motor/Ajar Swi tch-Dri ver . . . . 8W-80-55
Door Lock Motor/Ajar Swi tch-Left Rear . . 8W-80-55
Door Lock Motor/Ajar Swi tch-Passenger . 8W-80-56
Door Lock Motor/Ajar Swi tch-Ri ght Rear . 8W-80-56
Door Lock Swi tch-Passenger . . . . . . . . . . . 8W-80-56
Dri ver Bl end Door Actuator (Dual Zone) . 8W-80-56
Dri ver Door Modul e C1 . . . . . . . . . . . . . . 8W-80-57
Dri ver Door Modul e C2 . . . . . . . . . . . . . . 8W-80-57
EGR Sol enoi d (4.7L/5.7L) . . . . . . . . . . . . . 8W-80-57
El ectri c Brake Provi si on . . . . . . . . . . . . . . 8W-80-58
El ectri c Throttl e Control Modul e . . . . . . . 8W-80-58
Engi ne Control Modul e C1 (Di esel ) . . . . . 8W-80-58
Engi ne Control Modul e C2 (Di esel ) . . . . . 8W-80-60
Engi ne Cool ant Temperature Sensor
(Di esel ) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-61
Engi ne Cool ant Temperature Sensor
(Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-61
Engi ne Oi l Pressure Swi tch . . . . . . . . . . . 8W-80-61
EVAP/Purge Sol enoi d (NGC) . . . . . . . . . . 8W-80-61
Evaporator Temperature Sensor . . . . . . . . 8W-80-62
Fender Lamp-Front Left (Dual Rear
Wheel s) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-62
Fender Lamp-Front Ri ght (Dual Rear
Wheel s) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-62
Fender Lamp-Rear Left (Dual Rear
Wheel s) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-62
Fender Lamp-Rear Ri ght (Dual Rear
Wheel s) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-62
Fog Lamp-Left . . . . . . . . . . . . . . . . . . . . . 8W-80-63
Fog Lamp-Ri ght . . . . . . . . . . . . . . . . . . . . 8W-80-63
Fuel Control Actuator (Di esel ) . . . . . . . . . 8W-80-63
Fuel Heater (Di esel ) . . . . . . . . . . . . . . . . . 8W-80-63
Fuel I njector No. 1 (Gas) . . . . . . . . . . . . . 8W-80-63
Fuel I njector Pack No. 1 (Di esel ) . . . . . . . 8W-80-65
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS DR
Component Page
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . 8W-80-66
Fuel Pump Motor (Di esel ) . . . . . . . . . . . . 8W-80-66
Generator . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-67
Gl ove Box Lamp And Swi tch . . . . . . . . . . 8W-80-67
Hands Free Modul e (Tel emati cs) . . . . . . . 8W-80-67
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . 8W-80-68
Headl amp-Left . . . . . . . . . . . . . . . . . . . . . 8W-80-68
Headl amp-Ri ght . . . . . . . . . . . . . . . . . . . . 8W-80-68
Heated Seat Cushi on-Dri ver . . . . . . . . . . . 8W-80-68
Heated Seat Cushi on-Passenger . . . . . . . . 8W-80-69
Heated Seat Swi tch-Dri ver . . . . . . . . . . . . 8W-80-69
Heated Seat Swi tch-Passenger . . . . . . . . . 8W-80-69
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-80-69
Horn-Hi gh Note . . . . . . . . . . . . . . . . . . . . 8W-80-70
Horn-Low Note . . . . . . . . . . . . . . . . . . . . . 8W-80-70
I dl e Ai r Control Motor (3.7L/4.7L) . . . . . . 8W-80-70
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-80-70
I nl et Ai r Temperature Sensor . . . . . . . . . . 8W-80-71
I nput Speed Sensor (45RFE) . . . . . . . . . . 8W-80-71
I nstrument Cl uster C1 . . . . . . . . . . . . . . . 8W-80-71
I ntake Ai r Temperature Sensor (Gas) . . . . 8W-80-73
Pressure Sensor (Di esel ) . . . . . . . . . . . . 8W-80-73
I ntegrated Power Modul e C1 . . . . . . . . . . 8W-80-73
Knock Sensor (3.7L) . . . . . . . . . . . . . . . . . 8W-80-77
Knock Sensor-Left (5.7L) . . . . . . . . . . . . . 8W-80-77
Knock Sensor-Ri ght (5.7L) . . . . . . . . . . . . 8W-80-77
Li cense Lamp-Left . . . . . . . . . . . . . . . . . . 8W-80-77
Li cense Lamp-Ri ght . . . . . . . . . . . . . . . . . 8W-80-77
Li ft Pump Motor (Di esel ) . . . . . . . . . . . . . 8W-80-78
Li ne Pressure Sensor (NGC) . . . . . . . . . . . 8W-80-78
Lumbar Motor-Dri ver . . . . . . . . . . . . . . . . 8W-80-78
Lumbar Motor-Passenger . . . . . . . . . . . . . 8W-80-78
Mani fol d Absol ute Pressure Sensor
(NGC) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-79
Mode Door Actuator 1 (Panel To Fl oor) . . . 8W-80-79
Mode Door Actuator 2 (Defrost To Fl oor) . 8W-80-79
Mul ti -Functi on Swi tch . . . . . . . . . . . . . . . 8W-80-79
Natural Vacuum Leak Detecti on Assembl y
(NGC) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-80
Output Speed Sensor (45RFE) . . . . . . . . . 8W-80-80
Output Speed Sensor (47RE) . . . . . . . . . . 8W-80-80
Overhead Map/readi ng Lamp (Except
Base) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-80
Oxygen Sensor 1/1 Upstream (NGC) . . . . 8W-80-81
Oxygen Sensor 1/2 Downstream (NGC) . . 8W-80-81
Component Page
Oxygen Sensor 2/1 Upstream (NGC) . . . . 8W-80-81
Oxygen Sensor 2/2 Downstream (NGC) . . 8W-80-81
Park/Turn Si gnal Lamp-Left Front . . . . . . 8W-80-82
Park/Turn Si gnal Lamp-Ri ght Front . . . . 8W-80-82
Passenger Bl end Door Actuator (Dual -
Zone) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-82
Passenger Lumbar Swi tch . . . . . . . . . . . . 8W-80-82
Power Mi rror-Left . . . . . . . . . . . . . . . . . . . 8W-80-82
Power Mi rror-Ri ght . . . . . . . . . . . . . . . . . 8W-80-83
Power Outl et . . . . . . . . . . . . . . . . . . . . . . 8W-80-83
Power Outl et-Consol e (Except Base) . . . . . 8W-80-83
Power Seat Motor-Dri ver Front Verti cal . . 8W-80-83
Power Seat Motor-Dri ver Hori zontal . . . . 8W-80-84
Power Seat Motor-Dri ver Rear Verti cal . . 8W-80-84
Power Seat Motor-Passenger Front
Verti cal . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-84
Power Seat Motor-Passenger Hori zontal . 8W-80-84
Power Seat Motor-Passenger Rear
Verti cal . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-84
Power Seat Swi tch-Dri ver . . . . . . . . . . . . 8W-80-85
Power Seat Swi tch-Passenger . . . . . . . . . . 8W-80-85
Power Steeri ng Pressure Swi tch (NGC) . . 8W-80-85
Power Wi ndow Ci rcui t Breaker . . . . . . . . 8W-80-86
Power Wi ndow Motor-Dri ver . . . . . . . . . . 8W-80-86
Power Wi ndow Motor-Left Rear . . . . . . . . 8W-80-86
Power Wi ndow Motor-Passenger . . . . . . . . 8W-80-86
Power Wi ndow Motor-Ri ght Rear . . . . . . . 8W-80-87
Power Wi ndow Swi tch-Left Rear . . . . . . . 8W-80-87
Power Wi ndow Swi tch-Passenger . . . . . . . 8W-80-87
Power Wi ndow Swi tch-Ri ght Rear . . . . . . 8W-80-87
Powertrai n Control Modul e C1 (NGC) . . . 8W-80-88
Radi o C1 (Except I nfi ni ty) . . . . . . . . . . . . 8W-80-92
Radi o C1 (I nfi ni ty) . . . . . . . . . . . . . . . . . . 8W-80-92
Radi o C2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-93
Reci rcul ati on Door Actuator . . . . . . . . . . . 8W-80-93
Remote Radi o Swi tch-Left . . . . . . . . . . . . 8W-80-93
Remote Radi o Swi tch-Ri ght . . . . . . . . . . . 8W-80-93
Seat Bel t Swi tch-Dri ver . . . . . . . . . . . . . . 8W-80-94
Seat Bel t Tensi oner Reducer (Standard
Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-94
Seat Bel t Tensi oner-Dri ver . . . . . . . . . . . . 8W-80-94
Seat Bel t Tensi oner-Passenger . . . . . . . . . 8W-80-94
Seat Heater I nterface Modul e . . . . . . . . . . 8W-80-94
Sentry Key I mmobi l i zer Modul e (SKI M) . . 8W-80-95
Si de I mpact Sensor-Left . . . . . . . . . . . . . . 8W-80-95
Si de I mpact Sensor-Ri ght . . . . . . . . . . . . . 8W-80-95
Speaker-Center I nstrument Panel . . . . . . 8W-80-95
Speaker-Left Front Door . . . . . . . . . . . . . . 8W-80-95
Speaker-Left I nstrument Panel . . . . . . . . 8W-80-96
Speaker-Left Rear . . . . . . . . . . . . . . . . . . 8W-80-96
Speaker-Ri ght Front Door . . . . . . . . . . . . 8W-80-96
Component Page
Speaker-Ri ght I nstrument Panel . . . . . . . 8W-80-96
Speaker-Ri ght Rear . . . . . . . . . . . . . . . . . 8W-80-96
Speed Control Servo (Di esel A/T/NGC) . . . 8W-80-97
Speed Control Swi tch-Left (ETC) . . . . . . . 8W-80-97
Speed Control Swi tch-Left
(Except ETC) . . . . . . . . . . . . . . . . . . . . 8W-80-97
Speed Control Swi tch-Ri ght (ETC) . . . . . . 8W-80-97
Speed Control Swi tch-Ri ght (Except
ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-97
Tai l /Stop/Turn Si gnal Lamp-Left . . . . . . . 8W-80-98
Tai l /Stop/Turn Si gnal Lamp-Ri ght . . . . . . 8W-80-98
Tai l gate Lamp . . . . . . . . . . . . . . . . . . . . . 8W-80-98
Throttl e Posi ti on Sensor (3.7L) . . . . . . . . . 8W-80-98
Throttl e Posi ti on Sensor (4.7L) . . . . . . . . . 8W-80-99
Tow/haul Overdri ve Swi tch . . . . . . . . . . . . 8W-80-99
Trai l er Tow Connector . . . . . . . . . . . . . . . 8W-80-99
Trai l er Tow Connector-Add On . . . . . . . . . 8W-80-99
Transfer Case Control Modul e C1 (El ectri c
4x4) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-100
Transfer Case Control Modul e C2 (El ectri c
4x4) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-100
Component Page
Transfer Case Control Modul e C3
(El ectri c 4x4) . . . . . . . . . . . . . . . . . . . 8W-80-101
Transfer Case Mode Sensor . . . . . . . . . . 8W-80-101
Transfer Case Sel ector Swi tch . . . . . . . . 8W-80-101
Transfer Case Shi ft Motor . . . . . . . . . . . 8W-80-101
Transmi ssi on Range Sensor . . . . . . . . . . 8W-80-102
Transmi ssi on Sol enoi d Assembl y
(48RE) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-102
Transmi ssi on Sol enoi d/TRS Assembl y
(NGC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-102
Vacuum Pump (Di esel ) . . . . . . . . . . . . . . 8W-80-103
Vi stroni c Fan Dri ve (Di esel ) . . . . . . . . . . 8W-80-103
Washer Fl ui d Level Swi tch . . . . . . . . . . . 8W-80-103
Washer Pump Motor-Front . . . . . . . . . . . 8W-80-103
Water I n Fuel Sensor . . . . . . . . . . . . . . . 8W-80-103
Wheel Speed Sensor-Left Front . . . . . . . 8W-80-104
Wheel Speed Sensor-Rear . . . . . . . . . . . . 8W-80-104
Wheel Speed Sensor-Ri ght Front . . . . . . 8W-80-104
Wi per Motor . . . . . . . . . . . . . . . . . . . . . . 8W-80-104
4WD SWITCH (MANUAL TRANSFER CASE) - 2 WAY
CAV CIRCUIT FUNCTION
1 K77 18BR/WT TRANSFER CASE POSITION SENSOR INPUT
2 Z901 18BK GROUND
A/C COMPRESSOR CLUTCH (DIESEL) - BLACK 2 WAY
1 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Z816 18BK GROUND
A/C COMPRESSOR CLUTCH (GAS) - BLACK 2 WAY
1 C3 20DB/YL A/C CLUTCH RELAY OUTPUT
2 Z153 18BK/GY GROUND
A/C HEATER CONTROL C1 - BLACK 16 WAY
1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN)
2 Z24 18BK/OR GROUND
3 C121 20DB/DG SENSOR GROUND
4 C29 20DB MODE DOOR 2 DRIVER
5 - -
6 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL
7 - -
8 E16 20OR/GY PANEL LAMPS DRIVER
9 C61 20DB/LG BLEND DOOR DRIVER
10 C801 20DB/OR MODE DOOR 1 DRIVER
11 C34 20DB/LB COMMON DOOR DRIVER
12 C32 20DB/TN RECIRCULATION DOOR DRIVER
13 C33 20LB/BR (DUAL ZONE) PASSENGER BLEND DOOR DRIVER
14 - -
15 C110 20DB/LB DEFOGGER RELAY CONTROL
16 D25 20WT/VT PCI BUS
A/C HEATER CONTROL C2 - BLACK 10 WAY
1 - -
2 C71 16DB/BR BLOWER MOTOR LOW DRIVER
3 C73 14DB/VT BLOWER MOTOR M2 DRIVER
4 - -
5 Z134 10BK/LG GROUND
6 - -
7 C72 16DB/OR BLOWER MOTOR M1 DRIVER
8 - -
9 - -
10 C70 10DB/YL BLOWER MOTOR HIGH DRIVER
A/C PRESSURE TRANSDUCER (DIESEL) - BLACK 4 WAY
1 K916 18BR/OR SENSOR GROUND
2 F855 18PK/YL 5 VOLT SUPPLY
3 C918 18BK/LB A/C PRESSURE SENSOR GROUND
4 - -
A/C PRESSURE TRANSDUCER (NGC) - 4 WAY
1 K900 18DB/DG SENSOR GROUND
3 C918 18BK/LB A/C PRESSURE SIGNAL
4 - -
ACCELERATOR PEDAL POSITION SENSOR (5.7L) - 6 WAY
1 K29 20WT/BR APPS NO. 2 SIGNAL
2 F856 20YL/PK 5 VOLT SUPPLY
4 K400 20BR/VT APPS NO.2 RETURN
5 K23 20BR/WT APPS NO. 1 SIGNAL
6 K167 20BR/YL APPS NO.1 RETURN
ACCELERATOR PEDAL POSITION SENSOR (DIESEL M/T) - 6 WAY
1 K29 20WT/BR APPS NO. 2 SIGNAL
2 K854 20VT/BR APPS NO. 2 5 VOLT SUPPLY
3 K852 20BR/LB APPS NO. 1 5 VOLT SUPPLY
4 K400 20BR/VT APPS NO. 2 RETURN
5 K23 20BR/WT APPS NO. 1 SIGNAL
6 K167 20BR/YL APPS NO. 1 RETURN
ACCELERATOR PEDEL POSITION SENSOR (DIESEL A/T) - 6 WAY
1 K914 18RD/WT SENSOR GROUND
2 K556 18OR/BR NOT IDLE SWITCH
3 K22 18BR/WT TP SIGNAL
4 K922 18LG/OR THROTTLE POSITION SENSOR RETURN
5 K851 18VT/PK 5-VOLT SUPPLY
6 K565 18OR IDLE SWITCH
ADJ USTABLE PEDAL MOTOR (EXCEPT MEMORY) - 2 WAY
1 P206 18LG/LB ADJ USTABLE PEDALS MOTOR REVERSE
2 P205 18LG/WT ADJ USTABLE PEDALS MOTOR FORWARD
ADJ USTABLE PEDAL SWITCH (EXCEPT MEMORY) - BLUE 6 WAY
1 P206 18LG/LB ADJ USTABLE PEDALS MOTOR REVERSE
2 A72 18RD/OR ADJ USTABLE PEDAL RELAY OUTPUT
3 - -
4 Z146 18BK GROUND
6 P205 18LG/WT ADJ USTABLE PEDALS MOTOR FORWARD
AIRBAG CONTROL MODULE C1 - 24 WAY
1 - -
2 - -
4 - -
6 G104 20VT/GY PASSENGER AIRBAG INDICATOR DRIVER
7 R104 20LB/LG PASSENGER AIRBAG MUX SWITCH RETURN
8 R106 20LG/LB PASSENGER AIRBAG MUX SWITCH SENSE
9 - -
10 - -
11 - -
12 - -
13 - -
14 - -
15 - -
16 - -
17 R43 20LG/BR DRIVER SQUIB 1 LINE 1
18 R45 20LG/OR DRIVER SQUIB 1 LINE 2
19 R44 20LB/OR PASSENGER SQUIB 1 LINE 2
20 R42 20LB/BR PASSENGER SQUIB 1 LINE 1
21 R61 20LG/VT DRIVER SQUIB 2 LINE 1
22 R63 20LG/WT DRIVER SQUIB 2 LINE 2
23 R64 20LB/WT PASSENGER SQUIB 2 LINE 1
24 R62 20LB/VT PASSENGER SQUIB 2 LINE 2
AIRBAG CONTROL MODULE C2 - 32 WAY
1 - -
2 - -
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2
10 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1
11 R56 20LB/DG PASSENGER SEAT BELT TENSIONER LINE 1
12 R54 20LB/YL PASSENGER SEAT BELT TENSIONER LINE 2
13 R1 18LB/WT (LIGHT DUTY) LEFT CURTAIN SQUIB 1 LINE 2
14 R3 18LB/OR (LIGHT DUTY) LEFT CURTAIN SQUIB 1 LINE 1
15 R4 18OR/LB (LIGHT DUTY) RIGHT CURTAIN SQUIB 1 LINE 1
16 R2 18WT/LB (LIGHT DUTY) RIGHT CURTAIN SQUIB 1 LINE 2
17 F201 18PK/OR FUSED IGNITION SWITCH OUTPUT (RUN-START)
18 F100 18PK/VT FUSED IGNITION SWITCH OUTPUT (RUN)
19 - -
20 - -
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 R14 20TN/LG (LIGHT DUTY) RIGHT SIDE IMPACT SENSOR 1 SIGNAL
28 R16 20BR/LG (LIGHT DUTY) RIGHT SIDE IMPACT SENSOR 1 GROUND
29 R15 20LG/BR (LIGHT DUTY) LEFT SIDE IMPACT SENSOR 1 GROUND
30 R13 20LG/TN (LIGHT DUTY) LEFT SIDE IMPACT SENSOR 1 SIGNAL
31 - -
32 - -
AIRBAG-LEFT CURTAIN - YELLOW 2 WAY
1 R3 18LB/OR LEFT CURTAIN SQUIB 1 LINE 1
2 R1 18LB/WT LEFT CURTAIN SQUIB 1 LINE 2
AIRBAG-PASSENGER ON/OFF SWITCH - 6 WAY
1 R106 20LG/LB PASSENGER AIRBAG MUX SWITCH SENSE
2 R104 20LB/LG PASSENGER AIRBAG MUX SWITCH RETURN
3 G104 20VT/GY PASSENGER AIRBAG INDICATOR DRIVER
4 F201 18PK/OR FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 - -
6 - -
AIRBAG-PASSENGER SQUIB - 4 WAY
1 R44 20LB/OR PASSENGER SQUIB 1 LINE 2
2 R42 20LB/BR PASSENGER SQUIB 1 LINE 1
3 R64 20LB/WT PASSENGER SQUIB 2 LINE 1
4 R62 20LB/VT PASSENGER SQUIB 2 LINE 2
AIRBAG-RIGHT CURTAIN - YELLOW 2 WAY
1 R4 18OR/LB RIGHT CURTAIN SQUIB 1 LINE 1
2 R2 18WT/LB RIGHT CURTAIN SQUIB 1 LINE 2
AMBIENT TEMPERATURE SENSOR - 2 WAY
1 G31 20VT/LG AAT SIGNAL
AMPLIFIER AUDIO C1 (PREMIUM) - GRAY 12 WAY
1 X53 20DG LEFT FRONT SPEAKER (+)
2 X55 20DG/BR LEFT FRONT SPEAKER (-)
3 X57 20DG/OR LEFT REAR SPEAKER (-)
4 Z513 18BK GROUND
5 X11 20DG RADIO 12 VOLT OUTPUT
6 X56 20GY/BR RIGHT FRONT SPEAKER (-)
7 X54 20GY RIGHT FRONT SPEAKER (+)
8 X51 20DG/DB LEFT REAR SPEAKER (+)
9 X58 20GY/OR RIGHT REAR SPEAKER (-)
10 X52 20GY/DB RIGHT REAR SPEAKER (+)
11 Z907 18BK GROUND
AMPLIFIER AUDIO C2 (PREMIUM) - GRAY 18 WAY
1 A116 18YL/RD FUSED B(+)
2 - -
3 - -
4 X295 18GY/DG LEFT REAR SPEAKER (-)
5 X154 18GY/YL RIGHT FRONT DOOR SPEAKER (+)
6 X153 18DG/YL LEFT FRONT DOOR SPEAKER (+)
7 X208 18GY/DG RIGHT INSTRUMENT PANEL SPEAKER (+)
8 X299 18GY/YL LEFT INSTRUMENT PANEL SPEAKER (-)
10 - -
11 - -
12 X205 18GY/LG LEFT REAR SPEAKER (+)
13 X296 18DG/GY RIGHT REAR SPEAKER (-)
14 X206 18DG/LG RIGHT REAR SPEAKER (+)
15 X156 18GY/LB RIGHT FRONT DOOR SPEAKER (-)
16 X155 18DG/LB LEFT FRONT DOOR SPEAKER (-)
17 X298 18GY/LG RIGHT INSTRUMENT PANEL SPEAKER (-)
18 X209 18GY/OR LEFT INSTRUMENT PANEL SPEAKER (+)
ASHTRAY LAMP - 2 WAY
1 L70 18WT/GY FUSED PARK LAMP RELAY OUTPUT
2 Z923 18BK GROUND
AUTOMATIC DAY/NIGHT MIRROR C1 (EXCEPT BASE) - 7 WAY
1 F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 Z13 20BK/WT GROUND
3 L1 20WT/LG BACKUP LAMP FEED
4 - -
5 - -
6 - -
7 - -
AUTOMATIC DAY/NIGHT MIRROR C2 (TELEMATICS) - 12 WAY
1 - -
2 - -
3 - -
4 X722 20LB/DG MICROPHONE 2 IN (+)
5 X735 20BR HANDSFREE MICROPHONE SHIELD
6 X712 20DG/LB MICROPHONE 1 IN (+)
7 X793 20DG/YL HANDSFREE MICROPHONE HSD FEED
8 - -
9 X730 20GY/YL VOICE RECOGNITION/PHONE SWITCH SIGNAL
10 - -
11 X835 20OR/GY SENSOR GROUND
12 X792 20LB/DG MICROPHONE IN (-)
BACKUP LAMP SWITCH - BLACK 2 WAY
A L1 18WT/LG BACKUP LAMP FEED
B L10 18WT/GY FUSED IGNITION SWITCH OUTPUT (RUN)
BATTERY TEMPERATURE SENSOR - BLACK 2 WAY
1 K25 18DB/VT BATT TEMP SIGNAL
BLEND DOOR ACTUATOR (SINGLE ZONE) - 2 WAY
BLOWER MOTOR - BLACK 2 WAY
2 C7 10DB BLOWER MOTOR FEED
BLOWER MOTOR RESISTOR BLOCK - BLACK 4 WAY
1 C72 16DB/OR BLOWER MOTOR M1 DRIVER
3 C71 16DB/BR BLOWER MOTOR LOW DRIVER
4 C73 14DB/VT BLOWER MOTOR M2 DRIVER
BRAKE FLUID LEVEL SWITCH - BLACK 2 WAY
1 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
BRAKE LAMP SWITCH - 6 WAY
1 A103 18GY/RD FUSED B(+)
2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
3 V30 20VT/WT S/C BRAKE SWITCH OUTPUT
3 V30 20VT/WT (5.7L) FUSED IGNITION SWITCH (RUN-START)
4 V32 20VT/YL SPEED CONTROL SUPPLY
4 V32 20VT/YL (5.7L) BRAKE SWITCH NO. 2 SIGNAL
6 B29 20DG/WT BRAKE SWITCH SIGNAL
6 B29 20DG/WT (5.7L) BRAKE SWITCH NO. 1 SIGNAL
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - BLACK 2 WAY
1 K32 18DB/YL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
2 Z101 18BK/VT GROUND
C102 (NGC) - (AMBIENT TEMPERATURE SEN-
SOR SIDE)
CAV CIRCUIT
1 G31 20VT/LG
2 K900 20DB/DG
C103 - (HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 Z470 20BK/LB
2 A114 18GY/RD
C106 (5.7L A/T) - (ENGINE SIDE)
CAV CIRCUIT
1 K11 18BR/YL
2 K12 18BR/DB
3 K13 18BR/LB
4 K14 18BR/TN
5 K38 18BR/OR
6 K58 18BR/VT
7 K26 18BR/YL
8 K28 18BR/LB
9 K19 18DB/DG
10 K17 18DB/TN
11 K18 18DB/OR
12 K15 18DB/GY
13 K16 18DB/YL
14 K10 18DB/OR
15 K97 18BR
16 K98 18DB/YL
C106 (5.7L A/T) - (INTAKE AIR FUEL MODULE
SIDE)
CAV CIRCUIT
1 K11 18BR/YL
2 K12 18BR/DB
3 K13 18BR/LB
4 K14 18BR/TN
5 K38 18BR/OR
6 K58 18BR/VT
7 K26 18BR/YL
8 K28 18BR/LB
9 K19 18DB/DG
10 K17 18DB/TN
11 K18 18DB/OR
12 K15 18DB/GY
13 K16 18DB/YL
14 K10 18DB/OR
15 K97 18BR
16 K98 18DB/YL
C107 (5.7L) - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 K900 18DB/DG
2 K1 18VT/BR
3 K21 18DB/LG
4 K922 18BR/DB
5 F856 18YL/PK
6 K447 18TN/YL
7 K342 16BR/WT
8 F855 18PK/YL
9 K2 18VT/OR
10 K122 18BR/DG
11 K22 18BR/OR
12 -
13 K448 18TN/OR
14 K342 16BR/WT
C107 (5.7L) - BLACK (INTAKE AIR FUEL MOD-
ULE SIDE)
CAV CIRCUIT
1 K900 18DB/DG
2 K1 18VT/BR
3 K21 18DB/LG
4 K922 18BR/DB
5 F856 18YL/PK
6 K447 18TN/YL
7 K342 16BR/WT
8 F855 18PK/YL
9 K2 18VT/OR
10 K122 18BR/DG
11 K22 18BR/OR
12 -
13 K448 18TN/OR
14 K342 16BR/WT
C108 (DIESEL) - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 B22 18DG/YL
2 C13 18LB/OR
3 A961 14RD
4 K25 18DB/VT
5 N4 18DB/WT
6 D25 18WT/VT
7 -
8 V32 18VT/YL (M/T)
9 K174 18BR/YL
10 -
11 K176 18BR/OR
12 K23 18BR/WT (M/T)
13 K852 18BR/VT (M/T)
14 K167 18BR/YL (M/T)
C108 (DIESEL) - BLACK (TRANSMISSION SIDE)
CAV CIRCUIT
1 B22 20DG/YL
2 C13 20LB/OR
3 A961 14RD
4 K25 18DB/VT
5 N4 18DB/WT
6 D25 20WT/VT
7 -
8 V32 20VT/YL (M/T)
9 K174 18BR/YL
10 -
11 K176 18BR/OR
12 K23 20BR/WT (M/T)
13 K852 20BR/LB (M/T)
14 K167 20BR/YL (M/T)
C109 (DIESEL) - LT GRAY (ENGINE SIDE)
CAV CIRCUIT
1 V35 18VT/OR
2 V32 18VT/YL
3 T41 18YL/DB
4 T6 18DG
5 T118 18DG
6 T9 18DG/TN
7 -
8 T38 18YL/BR
9 T75 18YL/LB
10 T54 18DG/OR
11 T515 18YL/DB
12 V36 18VT/YL
13 T14 18DG/BR
14 T13 18DG/VT
C109 (DIESEL) - LT GRAY (TRANSMISSION
SIDE)
CAV CIRCUIT
1 V35 20VT/OR
2 V32 20VT/YL
3 T41 20YL/DB
4 T6 20DG
5 T118 18DG
6 T9 18DG/TN
7 -
8 T38 18YL/BR
9 T75 18YL/LB
10 T54 18DG/OR
11 T515 20YL/DB
12 V36 20VT/YL
13 T14 18DG/BR
14 T13 18DG/VT
C110 (DIESEL) - BLACK (ENGINE SIDE)
CAV CIRCUIT
1 C3 18DB/YL
2 B29 18DG/WT
3 -
4 K900 18DB/DG
5 V37 18VT
6 K160 18BR/OR
7 K161 18BR/LB
8 F856 18YL/PK
9 D20 18WT/LG
10 D21 18WT/BR
10 D21 18PK
11 F202 18PK/GY
12 K29 18WT/BR (M/T)
13 K854 18VT/BR (M/T)
14 K400 18BR/VT (M/T)
C110 (DIESEL) - BLACK (TRANSMISSION SIDE)
CAV CIRCUIT
1 C3 20DB/YL
2 B29 20DG/WT
3 -
4 K900 20DB/DG
5 V37 20VT
6 K160 18BR/OR
7 K161 18BR/LB
8 F856 18YL/PK
9 D20 20WT/LG
10 D21 20WT/BR
11 F202 20PK/GY
12 K29 20WT/BR (M/T)
13 K854 20VT/BR (M/T)
14 K400 20BR/VT (M/T)
C112 (DIESEL A/T) - (ENGINE SIDE)
CAV CIRCUIT
1 C3 18DB/YL
2 A961 14RD
3 K615 18VT/WT
4 K616 18BR/YL
C112 (DIESEL A/T) - (TRANSMISSION SIDE)
CAV CIRCUIT
1 C3 18DB/YL
2 A961 14RD
3 K615 18VT/WT
4 K616 18BR/YL
C112 (DIESEL M/T) - (ENGINE SIDE)
CAV CIRCUIT
1 C3 18DB/YL
2 A961 14RD
3 K615 18BR/WT
4 K616 18BR/YL
5 K167 18BR/YL
6 K23 18BR/WT
7 K852 18BR/VT
8 K29 18WT/BR
C112 (DIESEL M/T) - (TRANSMISSION SIDE)
CAV CIRCUIT
1 C3 18DB/YL
2 A961 14RD
3 K615 18BR/WT
4 K616 18BR/YL
5 K167 18BR/YL
6 K23 18BR/WT
7 K852 18BR/VT
8 K29 18WT/BR
C130 (DIESEL) - (TRANSMISSION SIDE)
CAV CIRCUIT
A1 -
A2 C3 20DB/YL
A3 T41 20YL/DB (A/T)
A4 K400 20BR/VT (M/T)
A5 K900 20DB/DG
A6 K29 20WT/BR (M/T)
A7 K852 20BR/LB (M/T)
A8 Z901 18BK (MANUAL TRANSFER
CASE)
B1 T16 18YL/OR (A/T)
B2 L1 18WT/LG
B3 L10 18WT/GY
B4 F202 20PK/GY
B5 B22 20DG/YL
B6 T515 20YL/DB (A/T)
B7 K77 18BR/WT (MANUAL TRANSFER
CASE)
B8 N4 18DB/WT
C1 K174 18BR/YL
C2 C13 20LB/OR
C3 D25 20WT/VT
C4 K854 20VT/BR (M/T)
C5 K167 20BR/YL (M/T)
C6 K23 20BR/WT (M/T)
C7 T6 20DG (A/T)
C8 K176 18BR/OR
C131 (3.7L/4.7L EXCEPT ELECTRONIC TRANS-
FER CASE) - (HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 D20 20WT/LG
2 D21 20WT/BR
3 -
4 -
C131 (3.7L/4.7L EXCEPT ELECTRONIC TRANS-
FER CASE) - DK GRAY (ENGINE SIDE)
CAV CIRCUIT
1 D20 18WT/LG
2 D21 18WT/BR
3 -
4 -
C131 (4.7L ELECTRONIC TRANSFER CASE) -
(ENGINE SIDE)
CAV CIRCUIT
1 T316 16YL/GY
2 D200 20WT/LG
3 T313 20YL/LG
4 D202 20WT/VT
5 T885 20YL/GY
6 D201 20WT/DG
7 D203 20WT/BR
8 T315 16YL/BR
9 D20 18WT/LG (4.7L)
10 D21 18WT/BR (4.7L)
11
12
C131 (4.7L ELECTRONIC TRANSFER CASE) -
(HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 T316 16YL/GY
2 D200 20WT/LG
3 T313 20YL/LG
4 D202 20WT/VT
5 T885 20YL/GY
6 D201 20WT/DG
7 D203 20WT/BR
8 T315 16YL/BR
9 D20 20WT/LG (4.7L)
10 D21 20WT/BR (4.7L)
11
12
C131 (5.7L/DIESEL) - GRAY (ENGINE SIDE)
CAV CIRCUIT
A1 T316 16YL/GY (ELECTRONIC TRANS-
FER CASE)
A2 D200 20WT/LG (ELECTRONIC TRANS-
FER CASE)
A3 T313 20YL/LG (ELECTRONIC TRANS-
FER CASE)
A4 D202 20WT/VT (ELECTRONIC TRANS-
FER CASE)
FER CASE)
A6 D201 20WT/DG (ELECTRONIC TRANS-
FER CASE)
A7 D203 20WT/BR (ELECTRONIC TRANS-
FER CASE)
A8 T315 16YL/BR (ELECTRONIC TRANS-
FER CASE)
B1 -
B2 D20 20WT/LG
B3 D21 20WT/BR
B4 V32 20VT/YL (DIESEL)
B5 T117 20DG/YL (DIESEL A/T)
B6 V36 20VT/YL (DIESEL A/T)
B7 T917 20YL/TN (DIESEL A/T)
B8 -
C1 A961 14RD (DIESEL)
C2 B22 20DG/WT (5.7L)
C3 F855 18PK/YL (5.7L)
C3 B29 20DG/WT (DIESEL)
C4 F856 18YL/PK (5.7L)
C5 K160 18BR/OR (DIESEL)
C6 K161 18BR/LB (DIESEL)
C7 V37 20VT (DIESEL)
C8 K25 18DB/VT (DIESEL)
C131 (5.7L/DIESEL) - GRAY (HEADLAMP AND
DASH SIDE)
CAV CIRCUIT
FER CASE)
A2 D200 20WT/LG (ELECTRONIC TRANS-
FER CASE)
A3 T313 20YL/LG (ELECTRONIC TRANS-
FER CASE)
A4 D202 20WT (ELECTRONIC TRANSFER
CASE)
FER CASE)
A6 D201 20WT/DG (ELECTRONIC TRANS-
FER CASE)
A7 D203 20WT/BR (ELECTRONIC TRANS-
FER CASE)
A8 T315 16YL/BR (ELECTRONIC TRANS-
FER CASE)
B1 -
B2 D20 20WT/LG
B3 D21 20WT/BR
B4 V32 20VT/YL (DIESEL)
B5 T117 20DG/YL (DIESEL A/T)
B6 V36 20VT/YL (DIESEL A/T)
B7 T917 20YL/TN (DIESEL A/T)
B8 -
C1 A961 14RD (DIESEL)
C2 B22 20DG/WT (5.7L)
C2 V35 20VT/OR (DIESEL A/T)
C3 F855 20PK/YL (5.7L)
C3 B29 20DG/WT (DIESEL)
C4 F856 20YL/PK (5.7L)
C4 F856 18YL/PK (DIESEL)
C5 K160 18BR/OR (DIESEL)
C6 K161 18BR/LB (DIESEL)
C7 V37 20VT (DIESEL)
C8 K25 18DB/VT (DIESEL)
C200 - (HVAC SIDE)
CAV CIRCUIT
1 C70 10DB/YL
2 C34 20DB/LB
3 C71 16DB/BR
4 C32 20DB/TN
5 C73 14DB/VT
6 C72 16DB/OR
7 C7 10DB
8 C29 20DB
9 C21 20DB/LG (EXCEPT BASE A/C)
10 C121 20DB/DG
11 C33 20LB/BR
12 C61 20DB/LG
12 C33 20LB/BR (DUAL ZONE)
13 C801 20DB/OR
C200 - (I/P SIDE)
CAV CIRCUIT
1 C70 10DB/YL
2 C34 20DB/LB
3 C71 16DB/BR
4 C32 20DB/TN
5 C73 14DB/VT
6 C72 16DB/OR
7 C7 10DB
8 C29 20DB
9 C21 20DB/LG
10 C121 20DB/DG
11 C61 20DB/LG
12 C33 20LB/BR (SLT)
13 C801 20DB/OR
C201 - WHITE (HEADLINER SIDE)
CAV CIRCUIT
1 D25 20WT/VT (PREMIUM)
2 Z13 20BK/WT (PREMIUM)
3 L50 20WT/TN
4 Z350 20BK/TN
5 A919 20RD (PREMIUM)
6 F21 20PK/DG (PREMIUM)
7 L14 20WT/TN
8 Z964 20BK
9 M20 20YL/LB
10 M22 20YL/OR (PREMIUM)
11 L1 20WT/LG (PREMIUM)
12 M288 20YL/GY (PREMIUM)
C201 - WHITE (I/P SIDE)
CAV CIRCUIT
1 D25 20WT/VT (PREMIUM)
2 Z13 18BK/WT
3 L50 18WT/TN
4 Z350 18BK/TN
5 A919 20RD (PREMIUM)
6 F21 20PK/DG
7 L14 20WT/TN
8 Z964 18BK
9 M20 20YL/LB
10 M22 20YL/OR
11 L1 20WT/LG
12 M288 18YL/GY
C202 - BLACK (FRONT FASCIA SIDE)
CAV CIRCUIT
1 L89 18WT/YL
2 Z926 18BK
C202 - BLACK (HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 L89 18WT/YL
2 Z926 18BK
C206 - (CLEARANCE LAMPS SIDE)
CAV CIRCUIT
1 L70 20WT/GY
2 Z946 20BK
C206 - (I/P SIDE)
CAV CIRCUIT
1 L70 18WT/GY
2 Z946 18BK
CAV CIRCUIT
1 A34 16RD/WT
2 E11 20OR/DB
3 F21 20PK/DG
4 T315 16YL/BR
5 D25 20VT/DB
6 T885 20YL/GY
7 D200 20WT/LG
8 T316 16YL/GY
9 D202 20WT/VT
10 D201 20WT/DG
11 T41 20YL/DB
12 T313 20YL/LG
13 D203 20WT/BR
14 Z905 16BK
C207 - (TRANSFER CASE CONTROL MODULE
SIDE)
CAV CIRCUIT
1 A34 16RD/WT
2 E11 20OR/DB
3 F21 20PK/DG
4 T315 16YL/BR
5 D25 20VT/DB
6 T885 20YL/GY
7 D200 20WT/LG
8 T316 16YL/GY
9 D202 20WT/VT
10 D201 20WT/DG
11 T41 20YL/DB
12 T313 20YL/LG
13 D203 20WT/BR
14 Z905 16BK
C216 - (CHASSIS SIDE)
CAV CIRCUIT
1 B4 18DG/GY
2 B3 18DG/YL
3 L678 18BR
4 L53 18DG/WT
5 L62 18WT/YL
6 K900 18DB/DG
8 L70 18WT/GY
CAV CIRCUIT
1 B4 20DG/GY
2 B3 20DG/YL
3 L678 18BR
4 L53 18DG/WT
5 L62 18WT/YL
6 K900 20DB/DG
7 N4 18DB/WT
8 L70 18WT/GY
C217 - BLACK (CHASSIS SIDE)
CAV CIRCUIT
1 L673 18YL
2 B40 14DG (TRAILER TOW)
3 A100 14RD/VT (TRAILER TOW)
4 L7 18WT/YL
5 A109 14OR/RD
6 L50 18WT/TN
7 Z927 12BK/OR
8 -
9 -
10 L54 18WT/LG
11 L63 18WT/DG
12 L1 18WT/LG
13 L674 18LG
14 Z928 16BK
C217 - BLACK (HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 L673 18YL
2 B40 14DG (TRAILER TOW)
3 A100 14RD/VT (TRAILER TOW)
4 L7 18WT/YL
5 A109 16OR/RD (GAS)
6 L50 18WT/TN
7 Z927 14BK/OR
8 -
9 -
10 L54 18WT/LG
11 L63 18WT/DG
12 L1 18WT/LG
13 L674 18LG
14 Z928 16BK
C218 - (BODY SIDE)
CAV CIRCUIT
1 -
2 A405 18RD/DB
3 C16 16DB/GY (SLT)
4 A930 18RD (SLT)
5 -
6 -
7 -
8 -
9 A210 12OR/RD (SLT)
10 -
11 -
12 C15 16DB/WT (SLT)
C218 - NATURAL (HEADLAMP AND DASH SIDE)
CAV CIRCUIT
1 -
2 A405 18RD/DB
3 C16 16DB/GY (EXCEPT 3.7L BASE)
4 A930 18RD (EXCEPT 3.7L BASE)
5 -
6 -
7 -
8 -
9 A210 12OR/RD (EXCEPT 3.7L BASE)
10 -
11 -
12 C15 16DB/WT (EXCEPT 3.7L BASE)
CAV CIRCUIT
1 C110 20DB/LB (TRAILER TOW)
2 D15 18WT/DG (NGC)
3 L50 18WT/TN
4 F1 16PK/WT (NGC)
5 D21 20WT/BR
6 A103 18GY/RD
7 T751 16YL
8 D20 20WT/LG
9 E11 20OR/DB (ELECTRONIC TRANSFER
CASE)
10 A970 10RD
11 A991 10RD (TRAILER TOW)
12 -
13 -
14 -
15 -
16 V38 20VT/OR (5.7L)
17 V37 20VT
18 T6 20DG (GAS/DIESEL A/T)
19 L70 18WT/GY
20 F21 20PK/DG
21 V32 20VT/YL
22 -
23 A921 16RD
24 B25 20DG/WT
25 F202 20PK/GY (5.7L)
25 V30 20VT/WT (GAS EXCEPT 5.7L/DIE-
SEL A/T)
26 A114 18GY/RD
27 L1 18WT/LG
28 -
29 -
30 V937 20VT/BR (5.7L)
30 K900 20DB/DG (EXCEPT 5.7L)
31 A944 20RD
32 F504 20GY/PK
33 A941 18RD
34 -
CAV CIRCUIT
35 -
36 F984 18PK/YL
37 -
38 F951 16PK/LG
39 T917 20YL/TN (DIESEL A/T)
40 -
41 A951 16RD
42 F202 20PK/GY
43 A72 18RD/OR (TRAILER TOW)
44 D16 18WT/OR (GAS)
45 -
46 K77 18BR/WT (MAUAL TRANSFER
CASE)
47 T117 20DG/YL (MANUAL TRANSFER
CASE EXCEPT NGC)
48 A205 18RD/OR
49 A116 18YL/RD
50 -
51 -
52 -
53 R79 20LB/VT (NGC EXCEPT 5.7L ABS)
54 R81 20LB/WT (NGC EXCEPT 5.7L ABS)
55 -
56 F100 18PK/VT
57 R80 20VT/LB (NGC EXCEPT 5.7L ABS)
58 R82 20WT/LB (NGC EXCEPT 5.7L ABS)
59 -
60 A981 14RD
61 F982 14PK/YL
62 -
63 -
64 -
65 -
66 F922 16PK/YL
67 F201 18PK/OR
68 L89 18WT/YL (TRAILER TOW)
69 B29 20DG/WT
70 A919 20RD
71 -
72 D25 20VT/PK
73 F983 20PK/YL
74 -
C219 - (I/P SIDE)
CAV CIRCUIT
1 C110 20DB/LB (EXCEPT BASE)
2 D15 18WT/DG
3 L50 18WT/TN
4 F1 16PK/WT
5 D21 18WT/BR
6 A103 18GY/RD
7 T751 16YL
8 D20 20WT/LG
9 E11 20OR/DB (EXCEPT BASE)
10 A970 10RD
11 A991 10RD
12 -
13 -
14 -
15 -
16 -
16 V38 20VT/OR
17 V37 20VT
18 T6 20DG
19 L70 18WT/GY
20 F21 20PK/DG
21 V32 20VT/YL
22 -
23 A921 16RD
24 B25 20DG/WT
25 V30 20VT/WT
26 A114 18GY/RD
27 L1 20WT/LG
28 -
29 -
30 V937 20VT/BR
31 A944 20RD
32 F504 20GY/PK
33 A941 18RD
34 -
35 -
36 F984 18PK/YL
37 -
38 F951 16PK/LG
39 T917 20YL/TN
40 -
41 A951 16RD
42 F202 20PK/GY (EXCEPT BASE)
43 A72 18RD/OR (EXCEPT BASE)
44 D16 18WT/OR
45 -
46 K77 18BR/WT
47 T117 20DG/YL
48 A205 18RD/OR
49 A116 18YL/RD
50 -
51 -
52 -
53
C219 - (I/P SIDE)
CAV CIRCUIT
54
55 -
56 F100 18PK/VT
57
58
59 -
60 A981 14RD
61 F982 14PK/YL
62 -
63 -
64 -
65 -
66 F922 16PK/YL
67 F201 18PK/OR
68 L89 20WT/YL (EXCEPT BASE)
69 B29 20DG/WT
70 A919 20RD
71 -
72 D25 20WT/VT
73 F983 20PK/YL
74 -
C220 - (I/P SIDE)
CAV CIRCUIT
1 F983 20PK/YL
2 X295 18GY/DG
3 -
4 X153 18DG/YL
5 G75 20VT
6 G77 20VT/GY
7 X155 18DG/LB
8 G10 20VT/LG
9 G163 20VT/LB (SLT)
10 X205 18GY/LG
11 P5 18TN/OR (SLT)
12 F100 18PK/VT
13 F201 18PK/OR
14 -
15 -
16 -
17 P393 18LG (SLT)
18 G161 20VT/DG (SLT)
19 -
20 P1 18TN/LG (SLT)
21 -
22 F30 12PK/YL (SLT)
23 -
24 -
C220 - NATURAL (BODY SIDE)
CAV CIRCUIT
1 F983 20PK/YL
2 X295 18GY/DG
3 -
4 X153 18DG/YL
5 G75 20VT
6 G77 20VT/OR
7 X155 18DG/LB
8 G10 20VT/LG
10 X205 18GY/LG
11 P5 18TN/OR (SLT)
12 F100 18PK/VT
13 F201 18PK/OR
14 -
15 -
16 -
17 P393 18LG (SLT)
18 G161 20VT/DG (SLT)
19 -
20 P1 18TN/LG (SLT)
21 -
22 F30 12PK/YL (SLT)
23 -
24 -
C250 (HANDS FREE) - (I/P SIDE)
CAV CIRCUIT
1 X712 18DG/LB
2 X735 22NA
3 X792 18LB/DG
4 X835 18OR/GY
5 X730 18GY/YL
6 X793 18DG/YL
7 X722 18LB/DG
8 -
C250 (HANDS FREE) - BLACK (HEADLINER
SIDE)
CAV CIRCUIT
1 X712 20DG/LB
2 X735 20BR
3 X792 20LB/DG
4 X835 20OR/GY
5 X730 20GY/YL
6 X793 20DG/YL
7 X722 20LB/DG
8 -
C301 - (BODY SIDE)
CAV CIRCUIT
1 G74 20VT/WT
2 P195 18LG/YL (SLT)
3 P72 18TN/GY (SLT)
4 X154 18GY/YL
5 X156 18GY/LB
6 P74 18TN/OR (SLT)
7 Q15 12OR/LB (SLT)
8 -
9 -
10 Z74 20BK/WT
C301 - (BODY SIDE)
CAV CIRCUIT
1 G74 20VT/WT
3 P72 18TN/GY (SLT)
4 X154 18GY/YL
5 X156 18GY/LB
6 P74 18TN/OR (SLT)
7 Q15 14OR/LB (SLT)
8 -
9 -
10 Z74 20BK/WT (BASE)
10 Z461 20BK/DG (SLT)
C301 - (PASSENGER DOOR SIDE)
CAV CIRCUIT
1 G74 20VT/WT
2 P195 18LG/YL (POWER WINDOWS/
LOCKS)
3 P72 18TN/GY (POWER WINDOWS/
LOCKS)
4 X154 18GY/YL
5 X156 18GY/LB
6 P74 18TN/OR (POWER WINDOWS/
LOCKS)
7 Q15 14OR/LB (POWER WINDOWS/
LOCKS)
8 -
9 -
10 Z74 20BK/WT (EXCEPT POWER WIN-
DOWS/LOCKS)
10 Z461 20BK/DG (POWER WINDOWS/
LOCKS)
C302 (SLT) - (BODY SIDE)
CAV CIRCUIT
1 F21 20PK/DG
2 -
3 -
4 G778 18VT/LB
5 -
6 G160 20VT/LG
7 Q16 14OR/TN
8 Q26 14OR/GY
9 G162 20VT/LB
10 P392 18LG/DB
11 Z216 18BK/DB
12 -
13 C16 18DB/GY
14 -
15 -
16 -
C302 - BLACK (PASSENGER DOOR SIDE)
CAV CIRCUIT
1 F21 20PK/DG
2 -
3 -
4 G778 18VT/LB
5 -
6 G160 20VT/LG
7 Q16 14OR/TN
8 Q26 14OR/GY
9 -
10 P392 18LG/DB
11 Z216 20BK/DB
12 -
13 C16 18DB/GY
14 -
15 -
16 -
C304 - (BODY SIDE)
CAV CIRCUIT
1 G75 20VT
3 P72 18TN/GY (SLT)
4 X153 18DG/YL
5 X155 18DG/LB
6 P74 18TN/OR (SLT)
7 F30 12PK/YL (SLT)
8 Q15 12OR/LB (SLT)
9 A930 18RD (SLT)
10 Z75 20BK/VT
C304 - (DRIVER DOOR SIDE)
CAV CIRCUIT
1 G75 20VT
2 P195 18LG/YL (POWER WINDOW/
LOCKS)
3 P72 20TN/GY (POWER WINDOW/
LOCKS EXCEPT SECURITY)
3 P72 18 TN/GY (SECURITY)
4 X153 18DG/YL
5 X155 18DG/LB
6 P74 18TN/OR (POWER WINDOW/
LOCKS)
7 F30 14PK/YL (POWER WINDOW/
LOCKS)
8 Q15 14OR/LB (POWER WINDOW/
LOCKS)
9 A930 18RD (POWER WINDOW/LOCKS)
10 Z75 20BK/VT (EXCEPT SECURITY)
10 Z463 20BK/LB (SECURITY)
C305 (SLT) - (BODY SIDE)
CAV CIRCUIT
1 C16 18DB/GY
2 Q16 14OR/TN
3 Q26 14OR/GY
4 P393 18LG
5 -
6 P1 18TN/LG
7 Z461 14BK/DG
8 Q612 14OR/DB
9 -
10 G161 20VT/DG
11 G163 20VT/LB
12 Q412 14OR/LB
13 Q611 14OR/GY
14 Q411 14OR/WT
15 -
16 -
C305 (SLT) - BLACK (DRIVER DOOR SIDE)
CAV CIRCUIT
1 C16 18DB/GY
2 Q16 14OR/TN
3 Q26 14OR/GY
4 P393 18LG
5 -
6 P1 18TN/LG
7 Z461 14BK/DG
8 Q612 14OR/DB
9 -
10 G161 20VT/DG
11 G163 20VT/LB
12 Q412 14OR/LB
13 Q611 14OR/GY
14 Q411 14OR/WT
15 -
16 -
C306 - (REAR DOOR SIDE)
CAV CIRCUIT
1 Z79 20LG/BK
2 G77 20VT/GY
3 P393 18LG (POWER WINDOW/LOCKS)
4 P5 18TN/OR (POWER WINDOW/LOCKS)
5 Q15 14OR/LB (POWER WINDOW/
LOCKS)
6 Q411 14OR/WT (POWER WINDOW/
LOCKS)
7 Q611 14OR/GY (POWER WINDOW/
LOCKS)
8 X295 18GY/DG
9 X205 18GY/LG
10 -
CAV CIRCUIT
1 Z79 20LG/BK
2 G77 20VT/OR
3 P393 18LG (SLT)
4 P5 18TN/OR (SLT)
5 Q15 14OR/LB (SLT)
6 Q411 14OR/WT (SLT)
7 Q611 14OR/GY (SLT)
8 X295 18GY/DG
9 X205 18GY/LG
10 -
C308 - (BODY SIDE)
CAV CIRCUIT
1 G74 20VT/WT
3 D25 20WT/VT
4 X154 18GY/YL
5 G160 20VT/LG (SLT)
6 G76 20TN/YL
7 F201 18PK/OR
8 P392 18LG/DB (SLT)
10 F21 20PK/DG (SLT)
11 -
12 -
13 -
14 X206 18DG/LG
15 X296 18DG/GY
16 -
17 -
18 Z105 18BK
19 X156 18GY/LB
C308 - (I/P SIDE)
CAV CIRCUIT
1 G74 20VT/WT
2 -
3 -
4 X154 18GY/YL
5 G160 20VT/LG (SLT)
6 G76 20VT/YL
7 -
8 P392 18LG/DB (SLT)
10 F21 20PK/DG
11 -
12 -
13 -
14 X206 18DG/LG
15 X296 18DG/GY
16 -
17 -
18 -
19 X156 18GY/LB
CAV CIRCUIT
1 -
2 P7 20LG/DG
3 P81 20TN/LB
4 -
5 P84 20TN/VT
6 P8 20LG/WT
7 P82 20TN/DG
8 P83 20TN/WT
C309 - NATURAL (I/P SIDE)
CAV CIRCUIT
1 -
2 P7 20LG/DG
3 P81 20TN/LB
4 -
5 P84 20TN/VT
6 P8 20LG/WT
7 P82 20TN/DG
8 P83 20TN/WT
C311 - (BODY SIDE)
CAV CIRCUIT
1 Z918 14BK (BASE)
1 Z939 14BK (EXCEPT BASE)
2 A210 12OR/RD (EXCEPT BASE)
3 G10 20VT/LG
3 G10 20LG/RD
4 A405 18RD/DB
5 Z951 20BK
6
C311 - (DRIVER SEAT SIDE)
CAV CIRCUIT
1 Z939 14BK
2 A210 12OR/RD
3 G10 20VT/LG
4 A405 12RD/DB
5 Z951 20BK
6 -
CAV CIRCUIT
1 P105 12LG
2 P13 12LG/OR
3 P21 12LG/TN
4 P15 12LG/BR
5 P107 12LG/WT
6 P11 12LG/YL
7 A210 12OR/RD
8 Z939 14BK
9 P17 12LG/DG
10 P19 12LG/LB
11 -
12 -
C313 - (DRIVER SEAT SWITCH SIDE)
CAV CIRCUIT
1 P105 12LG
2 P13 12LG/OR
3 P21 12LG/TN
4 P15 12LG/BR
5 P107 12LG/WT
6 P11 12LG/YL
7 A210 12OR/RD
8 Z939 14BK
9 P17 12LG/DG
10 P19 12LG/LB
11 -
12 -
CAV CIRCUIT
1 A405 12RD/DB
2 P54 20OR/LG (HEATED SEATS)
3 A210 12OR/RD
4 Z939 14BK
5 P188 18LG/VT (HEATED SEATS)
6 P89 20LG/OR (HEATED SEATS)
C315 - (J UMPER SIDE)
CAV CIRCUIT
1 A405 12RD/DB
2 P54 20OR/LG (HEATED SEATS)
3 A210 12OR/RD
4 Z939 14BK
5 P188 18LG/VT (HEATED SEATS)
6 P89 18LG/OR (HEATED SEATS)
C316 (HEATED SEATS) - (J UMPER SIDE)
CAV CIRCUIT
1 P89 20LG/OR
2 P54 20OR/LG
3 A210 12OR/RD
4 Z939 14BK
5 P188 18LG/VT
6 -
C316 - (PASSENGER SEAT SIDE)
CAV CIRCUIT
1 P89 20LG/OR
2 P54 20OR/LG
3 A210 12OR/RD
4 Z939 14BK
5 P188 18LG/VT
6 -
C319 - (CENTER CONSOLE SIDE)
CAV CIRCUIT
1 Z939 18BK
2 A405 18RD/DB
C319 - (SEAT J UMPER SIDE)
CAV CIRCUIT
1 A405 12RD/DB (EXCEPT HEATED SEAT)
1 Z939 14BK (HEATED SEAT)
2 Z939 14BK (EXCEPT HEATED SEAT)
2 A405 12RD/DB (HEATED SEAT)
C320 - (RIGHT REAR DOOR SIDE)
CAV CIRCUIT
1 Z72 20LG/BK
2 G76 20VT/GY
3 P392 18LG (POWER WINDOW/LOCKS)
4 G778 18TN/OR (POWER WINDOW/
LOCKS)
5 Q15 14TN/LG (POWER WINDOW/
LOCKS)
6 Q412 14OR/WT (POWER WINDOW/
LOCKS)
7 Q612 14OR/GY (POWER WINDOW/
LOCKS)
8 X296 18GY/DG
9 X206 18GY/LG
10 -
CAV CIRCUIT
1 Z72 20LG/BK
2 G76 20TN/YL
3 P392 18LG/DB (EXCEPT BASE)
4 G778 18VT/LB (EXCEPT BASE)
5 Q15 14OR/LB (EXCEPT BASE)
6 Q412 14OR/LB (EXCEPT BASE)
7 Q612 14OR/DB (EXCEPT BASE)
8 X296 18DG/GY
9 X206 18DG/LG
10 -
C322 (EXCEPT HEATED SEATS) - (DRIVER SEAT
SIDE)
CAV CIRCUIT
1 A930 18RD
2 P81 20TN/LB
3 P7 20LG/DG
4 G10 20VT/LG
5 P83 20TN/WT
6 P82 20TN/DG
7 Z939 14BK
8 A210 12OR/RD
9 P8 20LG/WT
10 P84 20TN/VT
11 -
12 Z951 20BK
13 -
14 A405 12RD/DB
C322 - (BODY SIDE)
CAV CIRCUIT
1 A930 18RD
2 P81 20TN/LB
3 P7 20LG/DG
4 G10 20VT/LG
5 P83 20TN/WT
6 P82 20TN/DG
7 Z939 14BK
8 A210 12OR/RD
9 P8 20LG/WT
10 P84 20TN/VT
11 -
12 Z951 18BK
13 -
14 A405 12RD/DB
C323 (EXCEPT HEATED SEATS) - (PASSENGER
SEAT SIDE)
CAV CIRCUIT
1 P18 12LG/DG
2 P14 12LG/OR
3 P10 12LG/TN
4 P12 12LG/YL
5 P16 12LG/BR
6 P20 12LG/LB
7 P104 12LG
8 P106 12LG/WT
9 A210 12OR/RD
10 Z939 14BK
11 -
12 -
C323 (EXCEPT HEATED SEATS) - (PASSENGER
SEAT SWITCH SIDE)
CAV CIRCUIT
1 P18 12LG/DG
2 P14 12LG/OR
3 P10 12LG/TN
4 P12 12LG/YL
5 P16 12LG/BR
6 P20 12LG/LB
7 P104 12LG
8 P106 12LG/WT
9 A210 12OR/RD
10 Z939 14BK
11 -
12 -
C323 (HEATED SEATS) - (PASSENGER SEAT
SIDE)
CAV CIRCUIT
1 P104 12LG
2 P106 12LG/WT
3 A210 12OR/RD
4 Z939 14BK
5 -
6 -
C323 (HEATED SEATS) - (SEAT J UMPER SIDE)
CAV CIRCUIT
1 P104 12LG
2 P106 12LG/WT
3 A210 12OR/RD
4 Z939 14BK
5 -
6 -
C327 (DUAL REAR WHEELS) - (CHASSIS SIDE)
CAV CIRCUIT
1 L7 18WT/YL
2 Z948 20BK
C327 (DUAL REAR WHEELS) - (DRW LAMP
SIDE)
CAV CIRCUIT
1 L7 18WT/YL
2 Z947 18BK
C328 (DUAL REAR WHEELS) - (CHASSIS SIDE)
CAV CIRCUIT
1 L70 18WT/GY
2 Z948 20BK
C328 (DUAL REAR WHEELS) - (DRW LAMP
SIDE)
CAV CIRCUIT
1 L70 18WT/YL
2 Z948 18BK
CAMSHAFT POSITION SENSOR (DIESEL) - 3 WAY
3 K44 18DB/GY CMP SIGNAL
CAMSHAFT POSITION SENSOR (NGC) - GRAY 3 WAY
CAPACITOR (3.7L/4.7L) - BLACK 2 WAY
1 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT
2 - -
CENTER HIGH MOUNTED STOP LAMP/CARGO LAMP - 4 WAY
1 L14 20WT/TN CARGO LAMP DRIVER
2 Z964 20BK GROUND
3 Z350 20BK/TN GROUND
CIGAR LIGHTER OUTLET - RED 3 WAY
1 F984 18PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 - -
3 Z736 18BK/YL GROUND
CLEARANCE LAMP NO. 1 (HEAVY DUTY) - 2 WAY
2 Z946 20BK GROUND
2 Z946 20BK GROUND
2 Z946 20BK GROUND
2 Z946 20BK GROUND
2 Z946 20BK GROUND
CLOCKSPRING C1 - 6 WAY
1 Z909 20BK (DSAB ETC) GROUND
2 X20 20GY/WT (DSAB ETC) RADIO CONTROL MUX
3 V38 20VT/OR S/C SWITCH NO. 2 SIGNAL
4 V37 20VT S/C SWITCH NO. 1 SIGNAL
5 V937 20VT/BR S/C SWITCH RETURN
6 X3 20DG/VT HORN SWITCH SENSE
CLOCKSPRING C2 - YELLOW 4 WAY
1 R61 20LG/VT DRIVER SQUIB 2 LINE 1
2 R63 20LG/WT DRIVER SQUIB 2 LINE 2
3 R43 20LG/BR DRIVER SQUIB 1 LINE 1
4 R45 20LG/OR DRIVER SQUIB 1 LINE 2
CLOCKSPRING C3 - BLACK 4 WAY
4 V38 20VT/OR (DSAB ETC) S/C SWITCH NO. 2 SIGNAL
CLOCKSPRING C4 - 2 WAY
1 Z909 22BK GROUND
2 X20 22GY/WT RADIO CONTROL MUX
CLUTCH INTERLOCK BRAKE SWITCH - 2 WAY
1 T41 20YL/DB TRS T41 SENSE
2 Z911 18BK GROUND
COIL ON PLUG NO. 1 (3.7L/4.7L) - BLACK 3 WAY
1 K19 18DB/DG COIL CONTROL NO. 1
2 K342 16BR/WT ASD RELAY OUTPUT
3 - -
COIL ON PLUG NO. 1 (5.7L) - 2 WAY
1 K17 18DB/TN COIL CONTROL NO. 2
3 - -
1 K18 18DB/OR COIL CONTROL NO. 3
3 - -
1 K15 18DB/GY COIL CONTROL NO. 4
3 - -
1 K16 18DB/YL COIL CONTROL NO. 5
3 - -
3 - -
COIL ON PLUG NO. 7 (4.7L) - BLACK 3 WAY
3 - -
2 K97 18BR COIL CONTROL NO. 7
COIL ON PLUG NO. 8 (4.7L) - BLACK 3 WAY
3 - -
COMPASS/MINI-TRIP COMPUTER (EXCEPT BASE) - BLACK 6 WAY
1 - -
4 A919 20RD FUSED B(+)
6 - -
CONDENSER FAN (NGC) - BLACK 2 WAY
1 Z823 16BK/DG GROUND
2 C123 16LB/WT CONDENSER FAN RELAY OUTPUT
CONTROLLER ANITLOCK BRAKE C1 - BLACK 14 WAY
1 B4 20DG/GY REAR WHEEL SPEED SENSOR (+)
2 B222 20DG/WT (ETC) VEHICLE SPEED SIGNAL NO. 2
4 F500 20DG/PK FUSED IGNITION SWITCH OUTPUT (RUN)
5 B9 20DG/LG (ETC) LEFT FRONT WHEEL SPEED SENSOR (+)
7 A111 14DG/RD FUSED B(+)
8 B3 20DG/YL REAR WHEEL SPEED SENSOR (-)
10 B8 20DG/TN (ETC) LEFT FRONT WHEEL SPEED SENSOR (-)
11 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
12 B22 20DG/YL VEHICLE SPEED SIGNAL NO. 1
13 Z127 12BK/DG (ABS) GROUND
14 A111 14DG/RD (ABS) FUSED B(+)
CONTROLLER ANTILOCK BRAKE C2 (ABS) - BLACK 4 WAY
1 B9 20DG/LG LEFT FRONT WHEEL SPEED SENSOR (+)
2 B8 20DG/TN LEFT FRONT WHEEL SPEED SENSOR (-)
3 B6 20DG/WT RIGHT FRONT WHEEL SPEED SENSOR (-)
4 B7 20DG/VT RIGHT FRONT WHEEL SPEED SENSOR (+)
CRANKSHAFT POSITION SENSOR (3.7L) - 3 WAY
1 K24 20BR/LB CKP SIGNAL
CRANKSHAFT POSITION SENSOR (DIESEL) - 3 WAY
1 K853 18DB/BR 5 VOLT SUPPLY
2 K975 18BR/BK SENSOR GROUND
3 K24 18LB/BR CKP SIGNAL
CYLINDER LOCK SWITCH-DRIVER (PREMIUM) - 2 WAY
1 G163 20VT/LB DRIVER CYLINDER LOCK SWITCH MUX
2 Z463 20BK/LB GROUND
DATA LINK CONNECTOR - BLACK 16 WAY
1 - -
3 - -
6 - -
7 D21 18WT/BR SCI TRANSMIT (PCM)
8 - -
9 D16 18WT/OR SCI RECEIVE (TCM)
10 - -
11 - -
DATA LINK CONNECTOR - BLACK 16 WAY
12 D20 20WT/LG SCI RECEIVE (PCM)
13 - -
14 - -
15 D15 18WT/DG SCI TRANSMIT (TCM)
DATA LINK CONNECTOR-ENGINE (DIESEL) - 3 WAY
1 D72 18WT/LB CCD BUS (+)
2 D71 18WT/DB CCD BUS (-)
3 Z816 14BK (A/T) GROUND
3 Z11 14BK/LG (M/T) GROUND
DOME LAMP - BLACK 3 WAY
1 - -
2 M20 20YL/LB COURTESY LAMPS DRIVER
3 Z964 20BK GROUND
DOOR AJ AR SWITCH-DRIVER - BLACK 2 WAY
1 G75 20VT DRIVER DOOR AJ AR SWITCH SENSE
DOOR AJ AR SWITCH-LEFT REAR - BLACK 2 WAY
1 G77 20VT/GY LEFT REAR DOOR AJ AR SWITCH SENSE
2 Z79 20LG/BK GROUND
DOOR AJ AR SWITCH-PASSENGER - BLACK 2 WAY
1 G74 20VT/WT PASSENGER DOOR AJ AR SWITCH SENSE
DOOR AJ AR SWITCH-RIGHT REAR - BLACK 2 WAY
1 G76 20VT/GY RIGHT REAR DOOR AJ AR SWITCH SENSE
DOOR LOCK MOTOR/AJ AR SWITCH-DRIVER - BLACK 4 WAY
3 P1 18TN/LG DOOR UNLOCK DRIVER LEFT FRONT
4 P393 18LG DOOR LOCK DRIVER LEFT DOORS
DOOR LOCK MOTOR/AJ AR SWITCH-LEFT REAR - BLACK 4 WAY
3 P5 18TN/OR DOOR UNLOCK DRIVER LEFT REAR
4 P393 18LG DOOR LOCK DRIVER LEFT DOORS
DOOR LOCK MOTOR/AJ AR SWITCH-PASSENGER - BLACK 4 WAY
3 G778 18VT/LB DOOR UNLOCK DRIVER RIGHT DOORS
4 P392 18LG/DB DOOR LOCK DRIVER RIGHT DOORS
DOOR LOCK MOTOR/AJ AR SWITCH-RIGHT REAR - BLACK 4 WAY
1 G76 20VT/GY (VIRTUAL) RIGHT REAR DOOR AJ AR SWITCH SENSE
2 Z72 20LG/BK (VIRTUAL) GROUND
3 G778 18TN/OR (VIRTUAL) DOOR UNLOCK DRIVER RIGHT DOORS
4 P392 18LG (VIRTUAL) DOOR LOCK DRIVER RIGHT DOORS
DOOR LOCK SWITCH-PASSENGER - 6 WAY
1 G160 20VT/LG PASSENGER DOOR LOCK SWITCH MUX
3 - -
4 - -
6 - -
DRIVER BLEND DOOR ACTUATOR (DUAL ZONE) - 2 WAY
DRIVER DOOR MODULE C1 - BLUE 12 WAY
1 Q612 14OR/DB RIGHT REAR WINDOW DRIVER (DOWN)
2 Q412 14OR/LB RIGHT REAR WINDOW DRIVER (UP)
3 Q16 14OR/TN MASTER WINDOW SWITCH RIGHT FRONT (UP)
4 Q411 14OR/WT LEFT REAR WINDOW DRIVER (UP)
5 Q11 14OR/LG LEFT FRONT WINDOW DRIVER (UP)
6 Q26 14OR/GY MASTER WINDOW SWITCH RIGHT FRONT (DOWN)
7 G161 20VT/DG DRIVER DOOR LOCK SWITCH MUX
8 Z421 14BK/BR GROUND
10 Q611 14OR/GY LEFT REAR WINDOW DRIVER (DOWN)
11 Z941 20BK GROUND
12 Q21 14OR/WT LEFT FRONT WINDOW DRIVER (DOWN)
DRIVER DOOR MODULE C2 - BLUE 8 WAY
1 P71 18TN/DG LEFT MIRROR UP DRIVER
2 P195 18LG/YL LEFT MIRROR COMMON DRIVER (RIGHT/DOWN)
4 P74 18TN/OR RIGHT MIRROR LEFT DRIVER
6 P75 18TN/LG LEFT MIRROR LEFT DRIVER
7 P72 18TN/GY RIGHT MIRROR UP DRIVER
8 Q15 14OR/LB POWER WINDOW SWITCH FEED
EGR SOLENOID (4.7L/5.7L) - 6 WAY
1 K34 18DB/LG EGR SENSOR SIGNAL
5 - -
6 K35 18DB/VT EGR SOLENOID CONTROL
ELECTRIC BRAKE PROVISION - 4 WAY
A A400 14TN/RD FUSED B(+)
B B40 14DG TRAILER TOW BRAKE B(+)
C L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
D Z998 18BK GROUND
ELECTRIC THROTTLE CONTROL MODULE - BLACK 6 WAY
1 K22 18BR/OR TP NO. 1 SIGNAL
3 K447 18TN/YL ETC MOTOR (+)
4 K122 18BR/DG TP NO. 2 SIGNAL
5 K448 18TN/OR ETC MOTOR (-)
6 K922 18BR/DB TP SENSOR RETURN
ENGINE CONTROL MODULE C1 (DIESEL) - 60 WAY
1 - -
2 - -
3 - -
4 D72 18WT/LB CCD BUS (+)
5 D71 18WT/DB CCD BUS (-)
6 K65 18BR/LB FUEL PUMP RELAY RETURN
7 K20 18BR/GY GEN FIELD CONTROL
8 - -
9 - -
10 - -
11 K2 18TN/BK (A/T) ECT SIGNAL
11 K2 18VT/OR (M/T) ECT SIGNAL
12 K181 18BR/YL FUEL PUMP DRIVER
13 - -
14 K22 18BR/WT (A/T) TP SIGNAL
14 K23 18DB/WT (M/T) APPS NO. 1 SIGNAL
15 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 - -
16 K29 18WT/BR (M/T) APPS NO. 2 SIGNAL
17 - -
18 - -
19 K31 18BR FUEL PUMP RELAY CONTROL
20 - -
21 - -
22 K24 18LB/BR (A/T) CKP SIGNAL
22 K24 18BR/LB (M/T) CKP SIGNAL
23 K914 18RD/WT (A/T) SENSOR GROUND
23 K914 18BR/WT (M/T) SENSOR GROUND
25 K668 18LG (A/T) SUPPLY VOLTAGE
25 K688 18BR (M/T) SUPPLY VOLTAGE
26 C918 18BK/LB A/C PRESSURE SENSOR GROUND
27 K853 18DB/BR 5 VOLT SUPPLY
28 - -
29 K690 18DG/YL (A/T) INLET AIR TEMPERATURE/PRESSURE RETURN
29 K690 18BR/YL (M/T) INLET AIR TEMPERATURE/PRESSURE RETURN
30 K11 16WT/DB (A/T) INJ ECTOR CONTROL NO. 1
30 K11 16BR/YL (M/T) INJ ECTOR CONTROL NO.1
31 G123 18VT/LG WATER IN FUEL SENSOR SIGNAL
33 K922 18LG/OR (A/T) THROTTLE POSITION SENSOR RETURN
33 K167 18BR/YL (M/T) APPS NO. 1 RETURN
34 K565 18OR IDLE SWITCH
35 - -
36 K14 16BR/TN INJ ECTOR CONTROL NO. 4
37 - -
38 - -
39 - -
40 K13 16TN (A/T) INJ ECTOR CONTROL NO. 3
40 K13 16BR/LB (M/T) INJ ECTOR CONTROL NO.3
41 - -
42 K851 18VT/PK (A/T) 5-VOLT SUPPLY
42 K852 18BR/VT (M/T) APPS 1 5-VOLT SUPPLY
43 K37 18LB (A/T) BOOST PRESSURE SENSOR SIGNAL
43 K37 18BR/OR (M/T) BOOST PRESSURE SENSOR SIGNAL
44 K556 18OR/BR NOT IDLE SWITCH
45 N2 18DB/YL LIFT PUMP FEED
46 K58 16BR/VT INJ ECTOR CONTROL NO. 6
47 - -
48 - -
49 - -
50 K12 16BR/DB INJ ECTOR CONTROL NO. 2
51 - -
52 K975 18BR/BK (A/T) SENSOR GROUND
52 K975 18BR/OR (M/T) SENSOR GROUND
53 K915 18VT/RD FUEL RAIL SENSOR RETURN
55 - -
56 K38 16GY (A/T) INJ ECTOR CONTROL NO. 5
56 K38 16BR/OR (M/T) INJ ECTOR CONTROL NO. 5
57 K229 16TN/PK (A/T) ENG-INJ ECTOR HIGH SIDE DRIVER-BANK 2
57 K229 16BR/LB (M/T) ENG-INJ ECTOR HIGH SIDE DRIVER-BANK 2
58 - -
59 K227 16BR/LG ENG-INJ ECTOR HIGH SIDE DRIVER-BANK 1
60 - -
1 - -
2 - -
3 K615 18VT/WT INLET AIR TEMPERATURE SENSE
3 K615 18BR/WT (M/T) INLET AIR TEMPERATURE SENSE
4 V35 18VT/OR (A/T) S/C VENT CONTROL
5 K176 18BR/OR INTAKE AIR HEATER RELAY NO 2 CONTROL
6 K174 18BR/YL INTAKE AIR HEATER RELAY NO 1 CONTROL
7 V32 18VT/YL (A/T) SPEED CONTROL SUPPLY
8 - -
9 T41 18YL/DB (A/T) PARK/NEUTRAL POSITION SWITCH SENSE (T41)
10 K161 18BR/LB FAN SPEED SENSOR
11 B22 18DG/YL VEHICLE SPEED SENSOR SIGNAL NO. 1
12 G6 18VT/GY OIL PRESSURE SIGNAL
13 T6 18DG (A/T) TOW/HAUL OVERDRIVE OFF SWITCH SENSE
14 T118 18DG (A/T) GOVERNOR PRESSURE SOLENOID CONTROL
15 T9 18DG/TN (A/T) 3-4 SOLENIOD CONTROL
16 D21 18WT/BR SCI TRANSMIT (PCM)
16 D21 18PK (M/T) SCI TRANSMIT
17 - -
18 T38 18YL/BR (A/T) GOVERNOR PRESSURE SENSOR SIGNAL
19 D20 18WT/LG SCI RECEIVE (PCM)
20 A209 16RD FUSED B(+)
21 Z902 16BK GROUND
22 - -
25 T75 18YL/LB (A/T) TORQUE CONVERTER CLUTCH SOLENOID CONTROL
26 N4 18DB/WT FUEL LEVEL SENSOR SIGNAL
27 - -
29 T54 18DG/OR (A/T) TRANSMISSION TEMPERATURE SENSOR SIGNAL
30 A209 16RD FUSED B(+)
31 T515 18YL/DB (A/T) TRANSMISSION CONTROL RELAY CONTROL
32 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
33 K854 18VT/BR (M/T) 5 VOLT SUPPLY
34 V36 18VT/YL (A/T) S/C VACUUM CONTROL
35 K616 18BR/YL INLET AIR PRESSURE SENSE
36 V32 18VT/YL (M/T) SPEED CONTROL SUPPLY
38 - -
39 - -
40 A209 16RD FUSED B(+)
41 C13 18LB/OR A/C CLUTCH RELAY CONTROL
42 - -
43 K160 18BR/OR PARK LOCKOUT SOLENOID CONTROL
44 T14 18DG/BR (A/T) OUTPUT SPEED SENSOR SIGNAL
45 T13 18DG/VT (A/T) SENSOR GROUND
48 K400 18BR/VT (M/T) APPS NO.2 RETURN
49 Z902 16BK GROUND
50 Z902 16BK GROUND
ENGINE COOLANT TEMPERATURE SENSOR (DIESEL) - 2 WAY
A K914 18RD/WT SENSOR GROUND
A K914 18BR/WT SENSOR GROUND
B K2 18TN/BK ECT SIGNAL
B K2 18VT/OR ECT SIGNAL
ENGINE COOLANT TEMPERATURE SENSOR (GAS) - BLACK 2 WAY
2 K2 18VT/OR ECT SIGNAL
ENGINE OIL PRESSURE SWITCH - 2 WAY
2 - -
EVAP/PURGE SOLENOID (NGC) - 2 WAY
1 K52 18DB/WT EVAP PURGE CONTROL
2 K70 18DB/BR EVAP PURGE RETURN
EVAPORATOR TEMPERATURE SENSOR - 2 WAY
1 C121 20DB/DG SENSOR GROUND
2 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL
FENDER LAMP-FRONT LEFT (DUAL REAR WHEELS) - 2 WAY
1 L7 18WT/YL FUSED PARK LAMP RELAY OUTPUT
2 Z947 18BK GROUND
FENDER LAMP-FRONT RIGHT (DUAL REAR WHEELS) - 2 WAY
2 Z948 18BK GROUND
FENDER LAMP-REAR LEFT (DUAL REAR WHEELS) - 2 WAY
2 Z947 18BK GROUND
FENDER LAMP-REAR RIGHT (DUAL REAR WHEELS) - 2 WAY
2 Z948 18BK GROUND
FOG LAMP-LEFT - GRAY 2 WAY
A Z926 18BK GROUND
B L89 18WT/YL FOG LAMP RELAY OUTPUT
FOG LAMP-RIGHT - WHITE 2 WAY
A Z926 18BK GROUND
B L89 18WT/YL FOG LAMP RELAY OUTPUT
FUEL CONTROL ACTUATOR (DIESEL) - 3 WAY
1 K915 18VT/RD FUEL RAIL SENSOR RETURN
2 K181 18BR/YL FUEL PUMP DRIVER
FUEL HEATER (DIESEL) - 2 WAY
A Z816 14BK GROUND
B A961 14RD FUEL HEATER RELAY OUTPUT
FUEL INJ ECTOR NO. 1 (GAS) - 2 WAY
1 K11 18BR/YL INJ ECTOR CONTROL NO. 1
1 K13 18BR/LB INJ ECTOR CONTROL NO. 3
1 K38 18BR/OR INJ ECTOR CONTROL NO. 5
FUEL INJ ECTOR PACK NO. 1 (DIESEL) - 4 WAY
1 K227 14BR/LG ENG - INJ ECTOR HIGH SIDE DRIVER - BANK 1
4 K11 14WT/DB INJ ECTOR CONTROL NO. 1
1 K229 14BR/LB ENG - INJ ECTOR HIGH SIDE DRIVER - BANK 2
1 K229 14TN/PK ENG - INJ ECTOR HIGH SIDE DRIVER - BANK 2
4 K13 14TN INJ ECTOR CONTROL NO. 3
4 K38 14GY INJ ECTOR CONTROL NO. 5
FUEL PUMP MODULE - LT GRAY 4 WAY
3 N4 18DB/WT FUEL LEVEL SENSOR SIGNAL
4 A109 14OR/RD FUEL PUMP RELAY OUTPUT
FUEL PUMP MOTOR (DIESEL) - 2 WAY
2 K65 18BR/LB FUEL PUMP RELAY RETURN
GENERATOR - BLACK 2 WAY
2 Z816 18BK (DIESEL) GROUND
2 Z20 18BR/BK (NGC) GROUND
GLOVE BOX LAMP AND SWITCH - BLACK 2 WAY
2 M228 18YL/LB COURTESY LAMP DRIVER
HANDS FREE MODULE (TELEMATICS) - 22 WAY
3 - -
4 - -
5 X722 18LB/DG MICROPHONE 2 IN (+)
6 - -
7 - -
8 X703 18DG/OR LEFT AUDIO OUTPUT
9 X704 18DG/YL RIGHT AUDIO OUTPUT
10 X795 18DG HANDS FREE AUDIO OUTPUT COMMON
11 - -
12 - -
13 - -
15 X730 18GY/YL VOICE RECOGNITION/PHONE SWITCH SIGNAL
16 X712 18DG/LB MICROPHONE 1 IN (+)
17 X792 18LB/DG MICROPHONE IN (-)
18 X735 22NA HANDSFREE MICROPHONE SHIELD
19 - -
20 X793 18DG/YL HANDSFREE MICROPHONE HSD FEED
21 X835 18OR/GY SENSOR GROUND
22 Z970 18BK GROUND
HEADLAMP SWITCH - BLACK 8 WAY
1 - -
2 - -
3 E19 20OR/BR PANEL LAMPS DIMMER SIGNAL
5 L89 20WT/YL (FOG LAMPS) FOG LAMP RELAY OUTPUT
7 L115 20WT/YL HEADLAMP SWITCH RETURN
8 L116 20WT/LG HEADLAMP SWITCH SIGNAL
HEADLAMP-LEFT - BLUE 3 WAY
A L43 18WT/DB LEFT LOW BEAM OUTPUT
B Z345 18BK/LB GROUND
C L33 18WT/LG LEFT HIGH BEAM OUTPUT
HEADLAMP-RIGHT - BLUE 3 WAY
A L44 18WT/TN RIGHT LOW BEAM OUTPUT
B Z346 18BK/LG GROUND
C L34 18WT/GY RIGHT HIGH BEAM OUTPUT
HEATED SEAT CUSHION-DRIVER - BLUE 4 WAY
1 P187 18LG/BR DRIVER SEAT TEMPERATURE SENSOR INPUT
2 Z939 20BK GROUND
3 P53 20LG/OR DRIVER SEAT TEMPERATURE 5 VOLT SUPPLY
4 P89 20LG/OR SEAT HEATER DRIVER
HEATED SEAT CUSHION-PASSENGER - BLUE 4 WAY
1 P188 18LG/VT PASSENGER SEAT TEMPERATURE SENSOR INPUT
2 Z939 20BK GROUND
3 P54 20OR/LG PASSENGER SEAT TEMPERATURE 5 VOLT SUPPLY
HEATED SEAT SWITCH-DRIVER - 6 WAY
1 P81 20TN/LB DRIVER SEAT LOW HEAT LED DRIVER
2 P301 20LG/OR PANEL LAMPS DRIVER
3 Z301 20TN/BK GROUND
4 P85 20LG/WT HEATED SEAT SWITCH SUPPLY
5 P83 20TN/WT DRIVER SEAT HIGH HEAT LED DRIVER
6 P7 20LG/DG DRIVER SEAT HEATER MUX SWITCH
HEATED SEAT SWITCH-PASSENGER - 6 WAY
1 P82 20TN/DG PASSENGER SEAT LOW HEAT LED DRIVER
2 P301 20LG/OR PANEL LAMPS DRIVER
4 P85 20LG/WT HEATED SEAT SWITCH SUPPLY
5 P84 20TN/VT PASSENGER SEAT HIGH HEAT LED DRIVER
6 P8 20LG/WT PASSENGER SEAT HEATER MUX SWITCH
HORN SWITCH - WHITE 2 WAY
2 - -
HORN-HIGH NOTE - 2 WAY
1 X2 18DG/OR HORN RELAY OUTPUT
HORN-LOW NOTE - 2 WAY
2 Z298 18BK/DB GROUND
IDLE AIR CONTROL MOTOR (3.7L/4.7L) - BLACK 2 WAY
1 K961 18BR/VT IAC RETURN
2 K61 18VT/GY IAC MOTOR CONTROL
IGNITION SWITCH - BLACK 14 WAY
2 F1 16PK/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START)
3 F951 16PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 G15 20VT/TN KEY IN IGNITION SWITCH SENSE
6 Z943 20BK GROUND
8 C7 10DB BLOWER MOTOR FEED
10 F991 10PK/YL (POWER WINDOWS) FUSED IGNITION SWITCH OUTPUT (RUN-START)
11 A981 14RD FUSED B(+)
12 A991 10RD (POWER WINDOWS) FUSED B(+)
13 T751 16YL FUSED IGNITION SWITCH OUTPUT (START)
14 F922 16PK/YL FUSED IGNITION SWITCH OUTPUT (RUN)
INLET AIR TEMPERATURE SENSOR - 4 WAY
1 K690 18BR/YL (A/T) INLET AIR TEMPERATURE/PRESSURE RETURN
1 K690 18DG/YL (M/T) INLET AIR TEMPERATURE/PRESSURE RETURN
2 K615 18VT/WT (A/T) INLET AIR TEMPERATURE SENSE
2 K615 18BR/WT (M/T) INLET AIR TEMPERATURE SENSE
3 K668 18BR (A/T) SUPPLY VOLTAGE
3 K668 18LG (M/T) SUPPLY VOLTAGE
4 K616 18BR/YL INLET AIR PRESSURE SENSE
INPUT SPEED SENSOR (45RFE) - BLACK 2 WAY
1 T52 18DG/OR INPUT SPEED SENSOR SIGNAL
2 T13 18DG/VT SPEED SENSOR GROUND
INSTRUMENT CLUSTER C1 - WHITE 26 WAY
1 P1 18TN/LG (SLT) DOOR UNLOCK DRIVER LEFT FRONT
3 K32 18DB/YL BTSI SOLENOID CONTROL
4 - -
5 - -
6 - -
7 E16 20OR/GY PANEL LAMPS DRIVER
8 E14 20OR/TN PANEL LAMPS DRIVER
10 P393 18LG (SLT) DOOR LOCK DRIVER LEFT DOORS
11 P392 18LG/DB (SLT) DOOR LOCK DRIVER RIGHT DOORS
12 - -
13 Z921 18BK GROUND
15 M288 18YL/GY FUSED B(+)
16 P85 20LG/WT (SLT+) HEATED SEAT SWITCH SUPPLY
17 M228 18YL/LB (SLT) COURTESY LAMP DRIVER
18 L14 20WT/TN CARGO LAMP DRIVER
19 P301 20LG/OR (SLT+) PANEL LAMPS DRIVER
20 E11 20OR/DB (SLT) PANEL LAMPS DRIVER
21 M20 20YL/LB COURTESY LAMPS DRIVER
22 M22 20YL/OR COURTESY LAMPS DRIVER
23 P5 18TN/OR (SLT) DOOR UNLOCK DRIVER LEFT REAR
24 G778 18VT/LB (SLT) DOOR UNLOCK DRIVER RIGHT DOORS
25 A944 20RD FUSED B(+)
26 A944 20RD FUSED B(+)
INSTRUMENT CLUSTER C2 - GRAY 16 WAY
1 G194 20VT/LG WASH/BEAM SELECT SWITCH SIGNAL
2 G160 20VT/LG (SLT) PASSENGER DOOR LOCK SWITCH MUX
3 G161 20VT/DG (SLT) DRIVER DOOR LOCK SWITCH MUX
5 L116 20WT/LG HEADLAMP SWITCH SIGNAL
6 - -
7 G163 20VT/LB (SLT) DRIVER CYLINDER LOCK SWITCH MUX
8 L12 20WT/OR TURN LAMPS SWITCH SIGNAL
9 - -
10 W52 20BR/YL INTERMITTENT WIPER SWITCH SIGNAL
11 T117 20DG/YL TRANS RANGE SENSOR ELECTRONIC CLUSTER 5
VOLT SUPPLY
12 X20 20GY/WT (SLT PREMIUM RADIO) RADIO CONTROL MUX
13 - -
14 - -
15 - -
16 - -
INSTRUMENT CLUSTER C3 - GRAY 26 WAY
3 G76 20VT/YL RIGHT REAR DOOR AJ AR SWITCH SENSE
5 - -
6 - -
7 K77 18BR/WT TRANSFER CASE POSITION SENSOR INPUT
8 L900 20WT/YL WIPER/TURN/BEAM SELECT SWITCH RETURN
9 L115 20WT/YL HEADLAMP SWITCH RETURN
10 T917 20YL/TN TRANS RANGE SENSOR ELECTRONIC CLUSTER MUX
11 - -
12 - -
16 G15 20VT/TN KEY IN IGNITION SWITCH SENSE
17 - -
18 - -
20 G10 20VT/LG SEAT BELT SWITCH SENSE
21 - -
22 B25 20DG/WT PARK BRAKE SWITCH SENSE
INTAKE AIR TEMPERATURE SENSOR (GAS) - BLACK 2 WAY
2 K21 18DB/LG IAT SIGNAL
INTAKE AIR TEMPERATURE/MANIFOLD ABSOLUTE PRESSURE SENSOR (DIESEL) - 4 WAY
A K916 18BR/OR SENSOR GROUND
B K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
C F855 18PK/YL 5 VOLT SUPPLY
D K37 18LB (A/T) BOOST PRESSURE SENSOR SIGNAL
D K37 18BR/OR (M/T) BOOST PRESSURE SENSOR SIGNAL
INTEGRATED POWER MODULE C1 - 26 WAY
1 A960 14RD (DIESEL) FUSED B(+)
1 A16 16RD/BR (NGC) FUSED B(+)
3 - -
4 F500 20DG/PK FUSED IGNITION SWITCH OUTPUT (RUN)
5 L673 18YL TRAILER TOW LEFT TURN RELAY OUTPUT
6 - -
7 L674 18LG TRAILER TOW RIGHT TURN RELAY OUTPUT
11 F951 16PK/LG FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 A941 18RD FUSED B(+)
13 A919 20RD FUSED B(+)
15 - -
17 L678 18BR PARK LAMP RELAY OUTPUT
18 - -
20 - -
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
INTEGRATED POWER MODULE C2 - WHITE 15 WAY
2 A34 16RD/WT (ELECTRONIC TRANS-
FERCASE))
FUSED B(+)
3 A405 18RD/DB FUSED B(+)
4 - -
5 A210 12OR/RD FUSED B(+)
7 A100 14RD/VT FUSED B(+)
8 A111 14DG/RD FUSED B(+)
9 A205 18RD/OR FUSED B(+)
10 A921 16RD FUSED B(+)
11 - -
14 A951 16RD FUSED B(+)
15 - -
1 W10 20BR WASHER PUMP MOTOR CONTROL
2 L62 18WT/YL RIGHT REAR TURN LAMP DRIVER
4 G31 20VT/LG (DIESEL) AAT SIGNAL
5 Z118 18BK/YL GROUND
7 - -
8 - -
9 - -
10 D25 20VT/PK PCI BUS
11 - -
12 L61 18WT/LG LEFT FRONT TURN LAMP DRIVER
13 L53 18DG/WT LEFT STOP LAMP FEED
14 L63 18WT/DG LEFT REAR TURN LAMP DRIVER
15 L60 18WT/TN RIGHT FRONT TURN LAMP DRIVER
16 G180 20VT/YL (DIESEL) SENSOR GROUND
2 L54 18WT/LG RIGHT STOP LAMP FEED
3 W1 20BR/TN WASHER FLUID SWITCH SENSE
4 - -
5 - -
6 F941 20PK/LG (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START)
7 W7 20BR/GY WIPER PARK SWITCH SENSE
8 - -
9 - -
1 F922 16PK/YL FUSED IGNITION SWITCH OUTPUT (RUN)
2 F941 20PK/LG (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 Z912 20BK (GAS) GROUND
3 - -
4 L10 18WT/GY FUSED IGNITION SWITCH OUTPUT (RUN)
5 - -
6 - -
7 - -
8 Z920 12BK GROUND
10 - -
12 - -
13 - -
14 Z114 20BK/LG (DIESEL) GROUND
14 K173 18BR/VT (NGC) CONDENSER FAN RELAY CONTROL
15 F202 20PK/GY (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START)
16 T515 20YL/DB TRANSMISSION CONTROL RELAY CONTROL
17 C16 16DB/GY HEATED MIRROR RELAY OUTPUT
18 C3 20DB/YL A/C CLUTCH RELAY OUTPUT
19 - -
20 - -
22 W4 16BR/OR WIPER RELAY HIGH SPEED OUTPUT
23 F100 18PK/VT FUSED IGNITION SWITCH OUTPUT (RUN)
24 F201 18PK/OR FUSED IGNITION SWITCH OUTPUT (RUN)
25 - -
INTEGRATED POWER MODULE C6 - BLACK 15 WAY
1 - -
2 A400 14TN/RD FUSED B(+)
3 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 A961 14RD (DIESEL) FUEL HEATER RELAY OUTPUT
10 C123 16LB/WT (NGC) CONDENSER FAN RELAY OUTPUT
11 A960 14RD (DIESEL) FUSED B(+)
13 - -
14 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
15 - -
INTEGRATED POWER MODULE C7 - GRAY 26 WAY
1 T750 14YL/GY STARTER MOTOR RELAY OUTPUT
2 W3 16BR/WT WIPER RELAY LOW SPEED OUTPUT
5 - -
6 L43 18WT/DB LEFT LOW BEAM OUTPUT
7 L34 18WT/GY RIGHT HIGH BEAM OUTPUT
8 - -
9 A109 16OR/RD (GAS) FUEL PUMP RELAY OUTPUT
10 - -
11 K51 20BR/WT (GAS) ASD RELAY CONTROL
13 - -
14 - -
15 L33 18WT/LG LEFT HIGH BEAM OUTPUT
16 - -
16 A72 18RD/OR ADJ USTABLE PEDAL RELAY OUTPUT
17 - -
17 C15 16DB/WT REAR WINDOW DEFOGGER RELAY OUTPUT
18 - -
20 - -
20 L89 18WT/YL (FOG LAMPS) FOG LAMP RELAY OUTPUT
22 L44 18WT/TN RIGHT LOW BEAM OUTPUT
23 T41 20YL/DB (EXCEPT NGC) TRS T41 SENSE
23 T752 20DG/OR (NGC) STARTER RELAY CONTROL
24 A944 20RD FUSED B(+)
26 - -
KNOCK SENSOR (3.7L) - BLACK 4 WAY
1 K42 18DB/YL KNOCK SENSOR NO. 1 SIGNAL
2 K942 18BR/LG KNOCK SENSOR NO. 1 RETURN
3 K242 18BR/WT KNOCK SENSOR NO. 2 SIGNAL
4 K924 18WT/BR KNOCK SENSOR NO. 2 RETURN
KNOCK SENSOR-LEFT (5.7L) - 2 WAY
1 K42 18DB/YL KNOCK SENSOR NO. 1 SIGNAL
2 K942 18BR/LG KNOCK SENSOR NO. 1 RETURN
KNOCK SENSOR-RIGHT (5.7L) - 2 WAY
1 K242 18BR/WT KNOCK SENSOR NO. 2 SIGNAL
2 K924 18WT/BR KNOCK SENSOR NO. 2 RETURN
LICENSE LAMP-LEFT - 2 WAY
LICENSE LAMP-RIGHT - 2 WAY
LIFT PUMP MOTOR (DIESEL) - 2 WAY
1 N2 18DB/YL LIFT PUMP FEED
2 Z816 18BK GROUND
LINE PRESSURE SENSOR (NGC) - 4 WAY
3 T38 18YL/BR LINE PRESSURE SENSOR SIGNAL
4 - -
LUMBAR MOTOR-DRIVER - 2 WAY
1 P105 12LG LUMBAR MOTOR FORWARD
2 P107 12LG/WT LUMBAR MOTOR REARWARD
LUMBAR MOTOR-PASSENGER - 2 WAY
2 P106 12LG/WT RIGHT SEAT REAR UP
MANIFOLD ABSOLUTE PRESSURE SENSOR (NGC) - GRAY 3 WAY
1 K1 18VT/BR MAP SIGNAL
MODE DOOR ACTUATOR 1 (PANEL TO FLOOR) - 2 WAY
2 C801 20DB/OR MODE DOOR 1 DRIVER
MODE DOOR ACTUATOR 2 (DEFROST TO FLOOR) - 2 WAY
2 C29 20DB MODE DOOR 2 DRIVER
MULTI-FUNCTION SWITCH - BLACK 4 WAY
1 G194 20VT/LG WASH/BEAM SELECT SWITCH SIGNAL
2 L900 20WT/YL WIPER/TURN/BEAM SELECT SWITCH RETURN
3 L12 20WT/OR TURN LAMPS SWITCH SIGNAL
4 W52 20BR/YL INTERMITTENT WIPER SWITCH SIGNAL
NATURAL VACUUM LEAK DETECTION ASSEMBLY (NGC) - BLACK 3 WAY
1 Z910 18BK GROUND
2 K107 18VT/WT NVLD SWITCH SIGNAL
3 K106 18VT/LB NVLD SOLENOID CONTROL
OUTPUT SPEED SENSOR (45RFE) - DK BLUE 2 WAY
1 T14 18DG/BR OUTPUT SPEED SENSOR SIGNAL
OUTPUT SPEED SENSOR (47RE) - 2 WAY
OVERHEAD MAP/READING LAMP (EXCEPT BASE) - 3 WAY
1 M288 20YL/GY FUSED B(+)
2 Z964 20BK GROUND
3 M22 20YL/OR COURTESY LAMPS DRIVER
OXYGEN SENSOR 1/1 UPSTREAM (NGC) - BLACK 4 WAY
1 K99 18BR/LG O2 1/1 HEATER CONTROL
3 K902 18BR/DG O2 RETURN (UP)
4 K41 18DB/LB O2 1/1 SIGNAL
OXYGEN SENSOR 1/2 DOWNSTREAM (NGC) - 4 WAY
1 K299 18BR/WT O2 1/2 HEATER CONTROL
3 K904 18DB/DG O2 RETURN (DOWN)
4 K141 18DB/YL O2 1/2 SIGNAL
OXYGEN SENSOR 2/1 UPSTREAM (NGC) - 4 WAY
1 K199 18BR/VT O2 2/1 HEATER CONTROL
2 Z934 18BK GROUND
4 K43 18DB/LG O2 2/1 SIGNAL
OXYGEN SENSOR 2/2 DOWNSTREAM (NGC) - 4 WAY
1 K399 18BR/GY O2 2/2 HEATER CONTROL
2 Z992 18BK GROUND
4 K243 18BR O2 2/2 SIGNAL
PARK/TURN SIGNAL LAMP-LEFT FRONT - BROWN 3 WAY
1 L61 18WT/LG LEFT FRONT TURN LAMP DRIVER
PARK/TURN SIGNAL LAMP-RIGHT FRONT - BROWN 3 WAY
1 L60 18WT/TN RIGHT FRONT TURN LAMP DRIVER
PASSENGER BLEND DOOR ACTUATOR (DUAL-ZONE) - 2 WAY
2 C33 20LB/BR PASSENGER BLEND DOOR DRIVER
PASSENGER LUMBAR SWITCH - 5 WAY
1 Z939 14BK GROUND
2 P106 12LG/WT RIGHT SEAT REAR UP
3 A210 12OR/RD FUSED B(+)
5 Z939 14BK GROUND
POWER MIRROR-LEFT - BLACK 8 WAY
3 P75 18TN/LG LEFT MIRROR LEFT DRIVER
4 P71 18TN/DG LEFT MIRROR UP DRIVER
6 - -
7 - -
8 - -
POWER MIRROR-RIGHT - BLACK 8 WAY
3 P74 18TN/OR RIGHT MIRROR LEFT DRIVER
4 P72 18TN/GY RIGHT MIRROR UP DRIVER
5 Z216 20BK/DB GROUND
6 - -
7 - -
8 - -
POWER OUTLET - RED 3 WAY
1 A205 18RD/OR FUSED B(+)
2 - -
POWER OUTLET-CONSOLE (EXCEPT BASE) - 3 WAY
1 A405 18RD/DB FUSED B(+)
2 - -
3 Z939 18BK GROUND
POWER SEAT MOTOR-DRIVER FRONT VERTICAL - RED 2 WAY
1 P21 12LG/TN LEFT SEAT FRONT DOWN
2 P19 12LG/LB LEFT SEAT FRONT UP
POWER SEAT MOTOR-DRIVER HORIZONTAL - 2 WAY
1 P17 12LG/DG DRIVER SEAT HORIZONTAL FORWARD DRIVER
2 P15 12LG/BR DRIVER SEAT HORIZONTAL REARWARD DRIVER
POWER SEAT MOTOR-DRIVER REAR VERTICAL - 2 WAY
1 P13 12LG/OR DRIVER SEAT REAR DOWN
2 P11 12LG/YL LEFT SEAT REAR UP
POWER SEAT MOTOR-PASSENGER FRONT VERTICAL - 2 WAY
1 P20 12LG/LB RIGHT SEAT FRONT UP
2 P18 12LG/DG RIGHT SEAT FRONT DOWN
POWER SEAT MOTOR-PASSENGER HORIZONTAL - 2 WAY
1 P16 12LG/BR RIGHT SEAT HORIZONTAL REARWARD
2 P14 12LG/OR RIGHT SEAT HORIZONTAL FORWARD
POWER SEAT MOTOR-PASSENGER REAR VERTICAL - 2 WAY
1 P12 12LG/YL RIGHT SEAT REAR UP
2 P10 12LG/TN RIGHT SEAT REAR DOWN
POWER SEAT SWITCH-DRIVER - 12 WAY
A A210 12OR/RD FUSED B(+)
B Z939 14BK GROUND
C P105 12LG LUMBAR MOTOR FORWARD
D P13 12LG/OR DRIVER SEAT REAR DOWN
E P107 12LG/WT LUMBAR MOTOR REARWARD
F Z939 14BK GROUND
G A210 12OR/RD FUSED B(+)
H P11 12LG/YL LEFT SEAT REAR UP
I P17 12LG/DG DRIVER SEAT HORIZONTAL FORWARD DRIVER
J P15 12LG/BR DRIVER SEAT HORIZONTAL REARWARD DRIVER
K P21 12LG/TN LEFT SEAT FRONT DOWN
L P19 12LG/LB LEFT SEAT FRONT UP
POWER SEAT SWITCH-PASSENGER - 12 WAY
A A210 12OR/RD FUSED B(+)
B Z939 14BK GROUND
C P106 12LG/WT RIGHT SEAT REAR UP
D P10 12LG/TN RIGHT SEAT REAR DOWN
E P104 12LG LUMBAR MOTOR FORWARD
F Z939 14BK GROUND
G A210 12OR/RD FUSED B(+)
H P12 12LG/YL RIGHT SEAT REAR UP
I P16 12LG/BR RIGHT SEAT HORIZONTAL REARWARD
J P14 12LG/OR RIGHT SEAT HORIZONTAL FORWARD
K P18 12LG/DG RIGHT SEAT FRONT DOWN
L P20 12LG/LB RIGHT SEAT FRONT UP
POWER STEERING PRESSURE SWITCH (NGC) - BLACK 2 WAY
1 Z988 20BK GROUND
2 K66 18DB/WT P/S SWITCH SIGNAL
POWER WINDOW CIRCUIT BREAKER - 2 WAY
1 F991 10PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
POWER WINDOW MOTOR-DRIVER - 2 WAY
A Q21 14OR/WT LEFT FRONT WINDOW DRIVER (DOWN)
B Q11 14OR/LG LEFT FRONT WINDOW DRIVER (UP)
POWER WINDOW MOTOR-LEFT REAR - 2 WAY
A Q211 14TN/LB DRIVER REAR WINDOW DRIVER (DOWN)
B Q111 14TN/YL DRIVER REAR WINDOW DRIVER (UP)
POWER WINDOW MOTOR-PASSENGER - 2 WAY
A Q22 14OR/VT RIGHT FRONT WINDOW DRIVER (DOWN)
B Q12 14OR/BR RIGHT FRONT WINDOW DRIVER (UP)
POWER WINDOW MOTOR-RIGHT REAR - 2 WAY
A Q212 14TN/LB PASSENGER REAR WINDOW DRIVER (DOWN)
B Q112 14TN/YL PASSENGER REAR WINDOW DRIVER (UP)
POWER WINDOW SWITCH-LEFT REAR - BLUE 6 WAY
1 Q111 14TN/YL DRIVER REAR WINDOW DRIVER (UP)
2 Q611 14OR/GY LEFT REAR WINDOW DRIVER (DOWN)
3 - -
4 Q411 14OR/WT LEFT REAR WINDOW DRIVER (UP)
5 Q211 14TN/LB DRIVER REAR WINDOW DRIVER (DOWN)
POWER WINDOW SWITCH-PASSENGER - BLUE 6 WAY
1 Q12 14OR/BR RIGHT FRONT WINDOW DRIVER (UP)
2 Q26 14OR/GY MASTER WINDOW SWITCH RIGHT FRONT (DOWN)
3 - -
4 Q16 14OR/TN MASTER WINDOW SWITCH RIGHT FRONT (UP)
5 Q22 14OR/VT RIGHT FRONT WINDOW DRIVER (DOWN)
POWER WINDOW SWITCH-RIGHT REAR - BLUE 6 WAY
1 Q112 14TN/YL PASSENGER REAR WINDOW DRIVER (UP)
2 Q612 14OR/GY RIGHT REAR WINDOW DRIVER (DOWN)
3 - -
4 Q412 14OR/WT RIGHT REAR WINDOW DRIVER (UP)
5 Q212 14TN/LB PASSENGER REAR WINDOW DRIVER (DOWN)
6 Q15 14TN/LG POWER WINDOW SWITCH FEED
POWERTRAIN CONTROL MODULE C1 (NGC) - BLACK 38 WAY
1 K98 18DB/YL (EXCEPT 3.7L) COIL CONTROL NO. 8
2 - -
3 K97 18BR/YL (4.7L) COIL CONTROL NO. 7
3 K97 18BR (5.7L) COIL CONTROL NO. 7
4 K28 18BR/LB (EXCEPT 3.7L) INJ ECTOR CONTROL NO. 8
5 K26 18BR/YL (EXCEPT 3.7L) INJ ECTOR CONTROL NO. 7
6 - -
7 - -
8 B222 20DG/WT VEHICLE SPEED SIGNAL NO. 2
10 - -
13 B22 20DG/YL VEHICLE SPEED SIGNAL NO. 1
14 - -
15 - -
16 - -
17 - -
19 - -
21 C918 18BK/LB A/C PRESSURE SIGNAL
22 G31 18VT/LG AAT SIGNAL
23 - -
24 - -
25 D20 20WT/LG (5.7L) SCI RECEIVE (PCM)
25 D20 17WT/LG (EXCEPT 5.7L) SCI RECEIVE (PCM)
26 D16 18WT/OR (EXCEPT 3.7L M/T) SCI RECEIVE (TCM)
28 - -
29 A919 20RD FUSED B(+)
31 K141 18DB/YL O2 1/2 SIGNAL
33 K243 18BR O2 2/2 SIGNAL
34 - -
35 - -
36 D21 20WT/BR (5.7L) SCI TRANSMIT (PCM)
36 D21 18WT/BR (EXCEPT 5.7L) SCI TRANSMIT (PCM)
37 D15 18WT/DG (EXCEPT 3.7L) SCI TRANSMIT (TCM)
POWERTRAIN CONTROL MODULE C2 (NGC) - ORANGE 38 WAY
6 K447 18TN/YL (5.7L) ETC MOTOR (+)
8 K35 18DB/VT (5.7L LIGHT DUTY) EGR SOLENOID CONTROL
15 K922 18BR/DB (5.7L) THROTTLE POSITION SENSOR GROUND
16 - -
17 K199 18BR/VT O2 2/1 HEATER CONTROL
18 K99 18BR/LG O2 1/1 HEATER CONTROL
20 K2 18VT/OR ECT SIGNAL
22 K34 18DB/LG (5.7L LIGHT DUTY) EGR SENSOR SIGNAL
23 K1 18VT/BR MAP SIGNAL
24 K942 18BR/LG (EXCEPT 4.7L) KNOCK SENSOR NO. 1 RETURN
25 K42 18DB/YL (EXCEPT 4.7L) KNOCK SENSOR NO. 1 SIGNAL
26 - -
28 K122 18BR/DG (5.7L) TP NO. 2 SIGNAL
28 K961 18BR/VT (EXCEPT 5.7L) IAC RETURN
30 K21 18DB/LG IAT SIGNAL
31 K41 18DB/LB O2 1/1 SIGNAL
33 K43 18DB/LG O2 2/1 SIGNAL
36 K242 18BR/WT (EXCEPT 4.7L) KNOCK SENSOR NO. 2 SIGNAL
37 K924 18WT/BR (EXCEPT 4.7L) KNOCK SENSOR NO. 2 RETURN
38 K448 18TN/OR (5.7L) ETC MOTOR (-)
38 K61 18VT/GY (EXCEPT 5.7L) IAC MOTOR CONTROL
POWERTRAIN CONTROL MODULE C3 (NGC) - WHITE 38 WAY
1 - -
2 - -
3 K51 20BR/WT ASD RELAY CONTROL
4 - -
5 V35 20VT/OR (4.7L) S/C VENT CONTROL
6 K173 18BR/VT CONDENSER FAN RELAY CONTROL
7 V32 20VT/YL (4.7L) S/C POWER SUPPLY
8 K106 18VT/LB NVLD SOLENOID CONTROL
9 K299 18BR/WT O2 1/2 HEATER CONTROL
10 K399 18BR/GY O2 2/2 HEATER CONTROL
12 V36 20VT/YL (4.7L) S/C VACUUM CONTROL
13 - -
14 V32 20VT/YL (5.7L) BRAKE SWITCH NO. 2 SIGNAL
15 V937 20VT/BR (5.7L) S/C SWITCH RETURN
16 K167 20BR/YL (5.7L) APPS NO. 1 RETURN
17 K400 20BR/VT (5.7L) APPS NO. 2 RETURN
18 V38 20VT/OR (5.7L) S/C SWITCH NO. 2 SIGNAL
20 K52 18DB/WT EVAP PURGE CONTROL
22 G113 18VT PTO SWITCH SENSE
24 - -
25 K23 20BR/WT (5.7L) APPS NO. 1 SIGNAL
26 - -
27 - -
29 K70 18DB/BR EVAP PURGE RETURN
30 K66 18DB/WT P/S SWITCH SIGNAL
31 - -
33 N4 18DB/WT (3.7L/4.7L) FUEL LEVEL SENSOR SIGNAL
33 N4 20DB/WT (5.7L) FUEL LEVEL SENSOR SIGNAL
35 K107 18VT/WT NVLD SWITCH SIGNAL
36 K29 20WT/BR (5.7L) APPS NO. 2 SIGNAL
38 T752 20DG/OR STARTER RELAY CONTROL
POWERTRAIN CONTROL MODULE C4 (NGC) - GREEN 38 WAY
1 T60 18YL/GY OVERDRIVE SOLENOID CONTROL
2 T259 18YL/DG 4C SOLENOID CONTROL
3 - -
4 T118 18DG MS SOLENOID CONTROL
5 - -
6 T219 18YL/LG 2C SOLENOID CONTROL
7 - -
8 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL
9 - -
10 T20 18DG/WT L/R SOLENOID CONTROL
11 T140 18YL/GY PRESSURE CONTROL SOLENOID CONTROL
12 Z908 18BK GROUND
13 Z977 18BK GROUND
14 Z904 18BK (A/T) GROUND
15 T1 18DG/LB TRS T1 SENSE
16 T3 18DG/DB TRS T3 SENSE
17 T6 18DG TOW/HAUL OVERDRIVE OFF SWITCH SENSE
18 T515 20YL/DB TRANSMISSION CONTROL RELAY CONTROL
20 T48 18BR/YL 4C PRESSURE SWITCH SENSE
21 T29 18YL/WT UNDERDRIVE PRESSURE SWITCH SENSE
22 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE
23 - -
24 - -
25 - -
27 - -
29 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE
30 T147 18DG/YL 2C PRESSURE SWITCH SENSE
31 T38 18YL/BR LINE PRESSURE SENSOR SIGNAL
33 T52 18DG/OR INPUT SPEED SENSOR SIGNAL
35 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL
36 - -
37 T42 18DG/YL TRS T42 SENSE
RADIO C1 (EXCEPT INFINITY) - GRAY 22 WAY
4 - -
5 - -
6 - -
13 - -
15 - -
16 - -
17 - -
20 X296 18DG/GY RIGHT REAR SPEAKER (-)
21 X206 18DG/LG RIGHT REAR SPEAKER (+)
22 Z515 18BK GROUND
RADIO C1 (INFINITY) - GRAY 22 WAY
4 - -
5 - -
6 - -
7 X56 20GY/BR RIGHT FRONT SPEAKER (+)
8 X54 20GY RIGHT FRONT SPEAKER (-)
9 X55 20DG/BR LEFT FRONT SPEAKER (-)
10 X53 20DG LEFT FRONT SPEAKER (+)
13 X11 20DG RADIO 12 VOLT OUTPUT
15 - -
16 - -
17 - -
18 X51 20DG/DB LEFT REAR SPEAKER (+)
19 X57 20DG/OR LEFT REAR SPEAKER (-)
20 X58 20GY/OR RIGHT REAR SPEAKER (-)
21 X52 20GY/DB RIGHT REAR SPEAKER (+)
22 Z515 18BK GROUND
RADIO C2 - 10 WAY
1 X704 18DG/YL RIGHT AUDIO OUTPUT
2 X795 18DG HANDS FREE AUDIO OUTPUT COMMON
3 - -
4 - -
5 - -
6 X703 18DG/OR LEFT AUDIO OUTPUT
7 - -
8 - -
9 - -
10 - -
RECIRCULATION DOOR ACTUATOR - 2 WAY
2 C32 20DB/TN RECIRCULATION DOOR DRIVER
REMOTE RADIO SWITCH-LEFT - BLACK 2 WAY
2 Z909 22BK GROUND
REMOTE RADIO SWITCH-RIGHT - BLACK 2 WAY
2 Z909 22BK GROUND
SEAT BELT SWITCH-DRIVER - 2 WAY
1 Z951 20BK GROUND
SEAT BELT TENSIONER REDUCER (STANDARD CAB) - 2 WAY
SEAT BELT TENSIONER-DRIVER - 2 WAY
1 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1
2 R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2
SEAT BELT TENSIONER-PASSENGER - 2 WAY
1 R54 20LB/YL PASSENGER SEAT BELT TENSIONER LINE 2
2 R56 20LB/DG PASSENGER SEAT BELT TENSIONER LINE 1
SEAT HEATER INTERFACE MODULE - GREEN 14 WAY
1 P7 20LG/DG DRIVER SEAT HEATER MUX SWITCH
3 P188 18LG/VT PASSENGER SEAT TEMPERATURE SENSOR INPUT
5 P187 18LG/BR DRIVER SEAT TEMPERATURE SENSOR INPUT
7 P54 20OR/LG PASSENGER SEAT TEMPERATURE 5 VOLT SUPPLY
8 P53 20LG/OR DRIVER SEAT TEMPERATURE 5 VOLT SUPPLY
9 P8 20LG/WT PASSENGER SEAT HEATER MUX SWITCH
10 P82 20TN/DG PASSENGER SEAT LOW HEAT LED DRIVER
11 P84 20TN/VT PASSENGER SEAT HIGH HEAT LED DRIVER
12 P81 20TN/LB DRIVER SEAT LOW HEAT LED DRIVER
13 Z951 20BK GROUND
14 P83 20TN/WT DRIVER SEAT HIGH HEAT LED DRIVER
SENTRY KEY IMMOBILIZER MODULE (SKIM) - BLACK 6 WAY
1 - -
3 - -
SIDE IMPACT SENSOR-LEFT - 4 WAY
1 R13 20LG/TN LEFT SIDE IMPACT SENSOR 1 SIGNAL
2 R15 20LG/BR LEFT SIDE IMPACT SENSOR 1 GROUND
3 - -
4 - -
SIDE IMPACT SENSOR-RIGHT - 4 WAY
1 R14 20TN/LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL
2 R16 20BR/LG RIGHT SIDE IMPACT SENSOR 1 GROUND
3 - -
4 - -
SPEAKER-CENTER INSTRUMENT PANEL - 2 WAY
SPEAKER-LEFT FRONT DOOR - WHITE 3 WAY
2 - -
SPEAKER-LEFT INSTRUMENT PANEL - BLACK 2 WAY
1 X209 18GY/OR LEFT INSTRUMENT PANEL SPEAKER (+)
SPEAKER-LEFT REAR - WHITE 3 WAY
2 - -
SPEAKER-RIGHT FRONT DOOR - WHITE 3 WAY
2 - -
SPEAKER-RIGHT INSTRUMENT PANEL - BLACK 2 WAY
2 X298 18GY/LG RIGHT INSTRUMENT PANEL SPEAKER (-)
SPEAKER-RIGHT REAR - WHITE 3 WAY
1 X206 18GY/LG RIGHT REAR SPEAKER (+)
2 - -
3 X296 18GY/DG RIGHT REAR SPEAKER (-)
SPEED CONTROL SERVO (DIESEL A/T/NGC) - 4 WAY
1 V36 20VT/YL S/C VACUUM CONTROL
2 V35 20VT/OR S/C VENT CONTROL
3 V30 20VT/WT S/C BRAKE SWITCH OUTPUT
4 Z913 20BK GROUND
SPEED CONTROL SWITCH-LEFT (ETC) - 3 WAY
SPEED CONTROL SWITCH-LEFT (EXCEPT ETC) - 2 WAY
A V37 20VT S/C SWITCH NO. 1 SIGNAL
B V937 20VT/BR S/C SWITCH RETURN
SPEED CONTROL SWITCH-RIGHT (ETC) - 3 WAY
SPEED CONTROL SWITCH-RIGHT (EXCEPT ETC) - 2 WAY
TAIL/STOP/TURN SIGNAL LAMP-LEFT - 6 WAY
2 - -
3 Z928 18BK GROUND
4 L53 18DG/WT LEFT STOP LAMP FEED
5 L63 18WT/DG LEFT REAR TURN LAMP DRIVER
TAIL/STOP/TURN SIGNAL LAMP-RIGHT - BLACK 6 WAY
2 - -
3 Z928 18BK GROUND
4 L54 18DG/WT RIGHT STOP LAMP FEED
4 L54 18WT/LG RIGHT STOP LAMP FEED
5 L62 18WT/YL RIGHT REAR TURN LAMP DRIVER
5 L62 18WT/DG RIGHT REAR TURN LAMP DRIVER
TAILGATE LAMP - 2 WAY
2 Z942 20BK GROUND
THROTTLE POSITION SENSOR (3.7L) - 3 WAY
THROTTLE POSITION SENSOR (4.7L) - 3 WAY
TOW/HAUL OVERDRIVE SWITCH - WHITE 2 WAY
1 T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SENSE
2 Z71 20LB/BK GROUND
TRAILER TOW CONNECTOR - 4 WAY
1 Z999 14BK GROUND
TRAILER TOW CONNECTOR-ADD ON - 10 WAY
1 - -
4 A100 14RD/VT FUSED B(+)
6 - -
7 B40 14DG TRAILER TOW BRAKE B(+)
8 Z999 14BK GROUND
9 Z999 14BK GROUND
TRANSFER CASE CONTROL MODULE C1 (ELECTRIC 4x4) - 16 WAY
A1 D25 20VT/DB PCI BUS
A2 - -
A3 - -
A4 G92 20VT/OR 4WD LOW INDICATOR
A5 G91 20VT/WT 4WD HIGH INDICATOR
A6 K977 20BR/WT MODE SELECT
A7 T885 20YL/GY MODE SENSOR GROUND
A8 Z905 18BK GROUND
A9 - -
A10 - -
A11 - -
A12 G95 20VT/BR NEUTRAL INDICATOR
A13 G2 20BR/WT IGNITION SWITCH SENSE
A14 D200 20WT/LG MODE SENSOR D
A15 - -
A16 Z905 20BK GROUND
B1 D202 20WT/VT MODE SENSOR B
B2 D201 20WT/DG MODE SENSOR A
B3 - -
B4 - -
B5 - -
B6 T41 20YL/DB TRS T41 SENSE
B7 - -
B8 T313 20YL/LG 5 VOLT MODE SENSOR SUPPLY
B9 - -
B10 D203 20WT/BR MODE SENSOR C
B11 - -
B12 - -
B13 - -
B14 - -
B15 - -
B16 T322 20DG/GY 5 VOLT SELECTOR SWITCH SUPPLY
A Z905 16BK GROUND
B A34 16RD/WT FUSED B(+)
C T315 16YL/BR SHIFT MOTOR CONTROL A
D T316 16YL/GY SHIFT MOTOR CONTROL B
TRANSFER CASE MODE SENSOR - 6 WAY
1 D200 20WT/LG MODE SENSOR D
2 T313 20YL/LG 5 VOLT MODE SENSOR SUPPLY
3 D202 20WT/VT MODE SENSOR B
4 T885 20YL/GY MODE SENSOR GROUND
5 D201 20WT/DG MODE SENSOR A
6 D203 20WT/BR MODE SENSOR C
TRANSFER CASE SELECTOR SWITCH - 12 WAY
1 T322 20DG/GY 5 VOLT SELECTOR SWITCH SUPPLY
2 G2 20BR/WT IGNITION SWITCH SENSE
3 - -
4 G95 20VT/BR NEUTRAL INDICATOR
5 K977 20BR/WT MODE SELECT
6 E11 20OR/DB PANEL LAMPS DRIVER
8 G92 20VT/OR 4WD LOW INDICATOR
9 G91 20VT/WT 4WD HIGH INDICATOR
10 - -
11 Z905 20BK GROUND
12 - -
TRANSFER CASE SHIFT MOTOR - 2 WAY
1 T316 16YL/GY SHIFT MOTOR CONTROL B
2 T315 16YL/BR SHIFT MOTOR CONTROL A
TRANSMISSION RANGE SENSOR - 6 WAY
2 T117 20DG/YL TRANS RANGE SENSOR ELECTRONIC CLUSTER 5
VOLT SUPPLY
3 - -
5 T917 20YL/TN TRANS RANGE SENSOR ELECTRONIC CLUSTER MUX
6 T41 20YL/DB PARK NEUTRAL POSITION SWITCH SENSE (T41)
6 T41 18YL/DB PARK NEUTRAL POSITION SWITCH SENSE (T41)
TRANSMISSION SOLENOID ASSEMBLY (48RE) - 8 WAY
4 T38 18YL/BR GOVERNOR PRESSURE SENSOR SIGNAL
5 T118 18DG GOVERNOR PRESSURE SOLENOID CONTROL
6 T9 18DG/TN 3-4 SHIFT SOLENOID
7 T75 18YL/LB TORQUE CONVERTER CLUTCH SOLENOID CONTROL
TRANSMISSION SOLENOID/TRS ASSEMBLY (NGC) - 23 WAY
2 T20 18DG/WT L/R SOLENOID CONTROL
3 - -
5 T42 18DG/YL TRS T42 SENSE
7 T60 18YL/GY OVERDRIVE SOLENOID CONTROL
8 T3 18DG/DB TRS T3 SENSE
11 T48 18BR/YL 4C PRESSURE SWITCH SENSE
12 T140 18YL/GY PRESSURE CONTROL SOLENIOD CONTROL
14 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE
15 T147 18DG/YL 2C PRESSURE SWITCH SENSE
16 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE
17 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL
18 T29 18YL/WT UNDERDRIVE PRESSURE SWITCH SENSE
19 T259 18YL/DG 4C SOLENOID CONTROL
20 T219 18YL/LG 2C SOLENOID CONTROL
21 T118 18DG MS SOLENOID CONTROL
VACUUM PUMP (DIESEL) - 4 WAY
1 - -
3 - -
4 Z936 18BK GROUND
VISTRONIC FAN DRIVE (DIESEL) - 6 WAY
1 K160 18BR/OR PARK LOCKOUT SOLENOID CONTROL
3 K161 18BR/LB FAN SPEED SENSOR
4 - -
WASHER FLUID LEVEL SWITCH - 2 WAY
1 Z932 20BK GROUND
2 W1 20BR/TN WASHER FLUID SWITCH SENSE
WASHER PUMP MOTOR-FRONT - BLACK 2 WAY
1 Z945 20BK GROUND
2 W10 20BR WASHER PUMP MOTOR CONTROL
WATER IN FUEL SENSOR - 2 WAY
A K914 18RD/WT (A/T) SENSOR GROUND
A K914 18BR/WT (M/T) SENSOR GROUND
B G123 18VT/LG WATER IN FUEL SENSOR SIGNAL
WHEEL SPEED SENSOR-LEFT FRONT - 2 WAY
1 B8 20DG/TN LEFT FRONT WHEEL SPEED SENSOR (-)
2 B9 20DG/LG LEFT FRONT WHEEL SPEED SENSOR (+)
WHEEL SPEED SENSOR-REAR - 2 WAY
1 B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR SIGNAL
2 B4 18DG/GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
WHEEL SPEED SENSOR-RIGHT FRONT - 2 WAY
1 B6 20DG/WT RIGHT FRONT WHEEL SPEED SENSOR (-)
2 B7 20DG/VT RIGHT FRONT WHEEL SPEED SENSOR (+)
WIPER MOTOR - 4 WAY
A W7 20BR/GY WIPER PARK SWITCH SENSE
B Z103 18BK/WT GROUND
C W3 16BR/WT WIPER RELAY LOW SPEED OUTPUT
D W4 16BR/OR WIPER RELAY HIGH SPEED OUTPUT
8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng con-
nector, ground, and spl i ce l ocati ons i n the vehi cl e.
Connector, ground, and spl i ce i ndexes are provi ded.
Use the wi ri ng di agrams i n each secti on for connec-
tor, ground, and spl i ce i denti fi cati on. Refer to the
i ndex for the proper fi gure number. For i tems that
are not shown i n thi s secti on N/S i s pl aced i n the
Fi g. col umn.
CONNECTORS
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
4WD Switch (Manual Transfer
Case)
BK Near T/O for Backup Lamp Switch 16, 17, 19
A/C Compressor Clutch BK At A/C Compressor 3, 6, 7, 10
A/C Pressure Transducer BK Left Side of A/C Compressor 6, 7, 10
A/C-Heater Control C1 BK Center of Instrument Panel 34, 35, 36
A/C-Heater Control C2 BK Center of Instrument Panel 34, 35
Accelerator Pedal Position Sensor Under Battery Tray 22, 27
Adjustable Pedal Motor WT Left of Instrument Panel 31
Adjustable Pedal Switch BL Left of Instrument Panel 35, 38
Airbag Control Module C1 YL Lower Center of Instrument Panel 35, 36
Airbag Control Module C2 YL Lower Center of Instrument Panel 44, 46
Airbag Control Module-Left Side
Impact
YL Left B-Pillar 44, 46
Airbag Control Module-Right Side
Impact
YL Right B-Pillar 45, 47
Airbag-Driver Squib 1 YL On Steering Wheel N/S
Airbag-Left Curtain YL Top Left B-Pillar 44, 46
Airbag-Passenger YL Right Front of Instrument Panel 35, 39
Airbag-Right Curtain YL Top Right B-Pillar 45, 47
Ambient Temperature Sensor BK Left Rear of Hood 23, 29
Amplifier Audio C1 GY Top Center of Instrument Panel 35, 39
Amplifier Audio C2 GY Top Center of Instrument Panel 35, 39
Ashtray Lamp Center Stack 35
Automatic Day/Night Mirror (Except
Base)
BK Top Center of Windshield N/S
Backup Lamp Switch BK Left Rear of Transmission 12, 13, 17, 19
DR 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1
Battery Temperature Sensor BK Below Battery Tray 22, 25, 26, 28
Blend Door Actuator (Single Zone) BK Behind Right Side of Instrument
Panel
N/S
Blower Motor BK Behind Right Side of Instrument
Panel
N/S
Blower Motor Resistor Block BK Behind Right Side of Instrument
Panel
N/S
Brake Lamp Switch BK Top of Brake Pedal Arm 30, 35, 38
Brake Transmission Shift Interlock
Solenoid
BK Near Steering Column 31, 35, 38
C102 Near Integrated Power Module 25
C106 BK Left Rear Engine 7
C107 (5.7L) BK Left Rear Engine 7
C112 (Diesel) BK Near T/O for Water In Fuel Sensor N/S
C113 BK Left Side Engine 10
C114 BK Left side Engine 10
C115 (Diesel) BK Left Side Engine 10
C130 BK Left Rear of Engine 4, 8, 21
C131 Right Rear Engine Compartment 4, 8, 21
C200 GY Under Instrument Panel 39
C201 WT Near Left Instrument Panel
Speaker
35, 38
C202 BK Left Rear Side of Engine
Compartment
27
C206 BK Right Instrument Panel 35, 39, 48
C207 Rear Engine Compartment 22
C216 BK Middle Left Frame 22, 25, 50
C217 BK Middle Left Frame 22, 25, 50
C218 WT Left Side of Instrument Panel 22, 24, 40, 44, 46
C219 GY Left Side of Instrument Panel 22, 24, 31, 35, 38, 40,
44
C250 Seft Side Instrument Panel 35
C301 WT Right Kick Panel 40, 42, 45, 47
C302 BK Left Front Door 40, 42, 45, 47
C304 WT Left Side of Instrument Panel 41, 44, 46
C305 BK At Left Front Door 41, 44, 46
C306 WT Middle Front of Door 43, 46
C308 WT Under Instrument Panel 39, 40, 45, 47
C311 BK Left Rear of Frame 44, 46
C312 WT Under Seat 47
C313 DK GY At Driver Seat N/S
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION DR
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
C316 BK At Passenger Seat N/S
C317 BK At Passenger Seat N/S
C319 BK Bottom Left of Left Door N/S
C320 Right Rear Door 43
C322 DK GY Left Rear of Frame 44, 46
C323 BK Left Side of Instrument Panel N/S
C327 BK Right Rear Fender 50, 51
C328 BK Left Rear Fender 50, 51, 52
Camshaft Position Sensor GY Right Front Side of Engine 3, 9
Capacitor Left Rear of Engine Compartment 4
Center High Mounted Stop
Lamp/Cargo Lamp
BK Rear of Cab 49
Cigar Lighter Outlet NAT Rear of Cigar Lighter 32, 35, 36
Clearance Lamp No. 1 BK Left Roof 48
Clearance Lamp No. 2 BK Left-Center Roof 48
Clearance Lamp No. 3 BK Center Roof 48
Clearance Lamp No. 4 BK Right-Center Roof 48
Clearance Lamp No. 5 BK Right Roof 48
Clockspring C1 BK Steering Column 31
Clockspring C2 YL Steering Column 31
Clockspring C3 BK Steering Column N/S
Clockspring C4 BK Steering Column N/S
Clutch Interlock Brake Switch BK At Clutch Pedal 22, 24
Coil On Plug No.1 BK Left Top Side of Intake Manifold 6
Coil On Plug No.2 BK Right Top Side of Intake Manifold 3
Coil On Plug No.5 BK Left Top Side of Intake Manifold 5, 6
Compass/Mini-Trip Computer BK In Overhead Console N/S
Condenser Fan BK Near Condenser 23, 24
Controller Anti-Lock Brake C1 BK Left Fender Side Shield 22, 24, 25
Controller Anti-Lock Brake C2
(ABS)
BK Left Fender Side Shield 22, 25
Crankshaft Position Sensor BK Right Rear of Engine Block 3, 9
Cylinder Lock Switch-Driver
(Premium)
BK In Left Front Door 41
Cylinder Lock Switch-Passenger
(Premium)
LT GY In Right Front Door N/S
Data Link Connector BK Left Bottom of Instrument Panel 35, 38
Data Link Connector - Engine
(Diesel)
BK Near T/O for Water In Fuel Sensor N/S
Dome Lamp BK Center of Headliner N/S
Door Ajar Switch-Driver (Base) BK Left Front Door 41
Door Ajar Switch-Left Rear (Base) BK Left Rear Door 43
Door Ajar Switch-Right Rear (Base) BK Right Rear Door 43
Door Lock Motor/Ajar Switch-Driver
(Except Base)
BK Left Front Door 41
Door Lock Motor/Ajar Switch-Left
Rear (Except Base)
BK Left Rear Door 43
Door Lock Motor/Ajar Switch-
Passenger
BK Right Front Door 42
Door Lock Motor/Ajar Switch-Right
Rear (Except Base)
BK Right Rear Door 43
Door Lock Switch-Passenger BL In Right Front Door 42
Driver Airbag Squib BK In Steering Column N/S
Driver Blend Door Actuator (Dual
Zone)
BK Right Side of HVAC N/S
Driver Door Module C1 BL In Left Front Door 41
Driver Door Module C2 BL In Left Front Door 41
EGR Solenoid Right Front Engine 9
Electric Brake Provision Rear of Engine 22, 24
Engine Control Module C1 BK Left Engine 10
Engine Control Module C2 BK Left Engine 10
Engine Coolant Temperature
Sensor
BK Near Generator 6
Engine Oil Pressure Switch BK Lower Left Side of Engine 6, 9
Evap/Purge Solenoid BK Left Fender Side Shield 23, 25
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Fog Lamp-Left WT Left Front Facia N/S
Fog Lamp-Right WT Right Front Facia N/S
Fuel Control Actuator (Diesel) BK Left Rear Engine N/S
Fuel Heater (Diesel) BK Left Side Engine 10
Fuel Injector No. 1 BK At Fuel Injector 6
Fuel Pump Module LT GY At Fuel Tank 50
Fuel Pump Motor (Diesel) BK Left Side Engine 10
Generator BK Front of Engine 6, 9, 10
Glove Box Lamp and Switch BK At Glove Box 35, 39
Governor Pressure Sensor BK Left Rear of Transmission N/S
Hands Free Module Right Instrument Panel 39
Headlamp Switch BK Left Side of Instrument Panel 32, 35, 38
Headlamp-Left BL At Headlamp 23, 28, 29
Headlamp-Right BL At Headlamp 1, 21, 26
Heated Seat Cushion - Driver BL Under Driver Seat N/S
Heated Seat Cushion - Passenger BL Under Passenger Seat N/S
Heated Seat Switch-Driver RD Center of Instrument Panel 33, 35, 36
Heated Seat Switch-Passenger BL Center of Instrument Panel 33, 35, 36
Horn Switch WT In Steering Wheel N/S
Horn-High Note BK Left Front Fender 23, 28, 29
Horn-Low Note BK Left Front Fender 23, 29
Idle Air Control Motor BK On Throttle Body 6
Ignition Coil GY Left Rear of Engine N/S
Ignition Switch BK Steering Column 31
Inlet Air Temperature/Pressure
Sensor
BK Right Side Engine 10
Input Speed Sensor BK At Transmission 15, 16
Instrument Cluster C1 GY Rear of Instrument Cluster 35
Instrument Cluster C2 GY Rear of Instrument Cluster 35
Instrument Cluster C3 WT Rear of Instrument Cluster 35
Intake Air Heater Relay Right Engine Compartment 2
Intake Air Temperature/Manifold
Absolute Pressure Sensor (Diesel)
BK Left rear Engine N/S
Intake Air Temperature Sensor BK On Intake Manifold 5
Integrated Power Module C1 BK Left Front Fender 26, 28
Integrated Power Module C2 WT Left Front Fender 26, 28
Integrated Power Module C3 GR Left Front Fender 26, 28
Integrated Power Module C4 WT Left Front Fender 26, 28
Integrated Power Module C5 BK Left Front Fender 26, 28
Integrated Power Module C6 BK Left Front Fender 25, 26, 28
Integrated Power Module C7 GY Left Front Fender 26, 28
Integrated Power Module FCM BK In IPM N/S
Knock Sensor BK Left Rear of Engine 5, 7, 9
License Lamp-Left BK At Rear Bumper 50, 51
License Lamp-Right BK At Rear Bumper 50, 51
Lift Pump Motor BK Near T/O for WIF Sensor N/S
Line Pressure Sensor BK Right Rear of Transmission 15, 18
Lumbar Motor-Driver DK GY At Driver Seat N/S
Lumbar Motor-Passenger BK At Passenger Seat N/S
Manifold Absolute Pressure Sensor GY Left Front of Intake Manifold 6
Mode Door Actuator 1 BK Right Side of HVAC N/S
Mode Door Actuator 2 BK Right Side of HVAC N/S
Multi-Function Switch BK On Steering Column 31
Natural Vacuum Leak Detection
Assembly
BK Rear of Transmission 18, 50
Output Speed Sensor DB Left Side of Transmission 11, 14, 15, 16
Overdrive Switch WT Center of Instrument Panel 35
Overhead Map/Reading Lamp
(Except Base)
NAT Center of Headliner N/S
Oxygen Sensor 1/1 Upstream BK Left Front of Side of Transmission 15, 16, 17, 19
Oxygen Sensor 1/2 Downstream NAT Left Rear of Side of Transmission 15, 16, 17, 19
Oxygen Sensor 2/1 Upstream BK Right Front Side of Transmission 15, 17, 18
Oxygen Sensor 2/2 Downstream BK Right Rear Side of Transmission 15, 17, 18
Park Brake Switch At Park Brake 22, 24
Park/Turn Signal Lamp-Left Front BK At Lamp 23, 28, 29
Park/Turn Signal Lamp-Right Front BK At Lamp 1, 21, 26
Passenger Airbag On/Off Switch Right Side of Instrument Panel 33, 35, 39
Passenger Blend Door Actuator
(Dual Zone)
BK Right Side of HVAC N/S
Passenger Lumbar Switch At Passenger Seat N/S
Power Mirror-Left BK At Mirror 41
Power Mirror-Right BK At Mirror 42
Power Outlet RD Center of Instrument Panel 35
Power Outlet-Console BK Center of Instrument Panel N/S
Power Seat Motor-Driver Front
Vertical
RD At Driver Seat N/S
Power Seat Motor-Driver Horizontal BK At Driver Seat N/S
Power Seat Motor-Driver Rear
Vertical
BK At Driver Seat N/S
Power Seat Switch-Driver BK At Driver Seat N/S
Power Seat Switch-Passenger BK At Passenger Seat N/S
Power Steering Pressure Switch BK Near Power Steering Pump 7
Power Window Circuit Breaker Under Instrument Panel 31, 35, 38
Power Window Motor-Driver BK In Driver Door at Motor 41
Power Window Motor-Left Rear BK In Door at Motor 43
Power Window Motor-Passenger BK In Passenger Door at Motor 42
Power Window Motor-Right Rear BK In Door at Motor 43
Power Window Switch-Left Rear BL In Door 43
Power Window Switch-Passenger Passenger Door 42
Power Window Switch-Right Rear BL In Door 43
Powertrain Control Module C1 BK Right Rear Engine Compartment 4, 8
Powertrain Control Module C2 WT Right Rear Engine Compartment 4, 8
Powertrain Control Module C3 GY Right Rear Engine Compartment 21
Powertrain Control Module C4 GN Right Rear Engine Compartment 4, 8
PTO Switch Near G107 N/S
Radio C1 (Base) GY Rear of Radio 35, 36
Radio C1 (Premium) BK Rear of Radio 36
Radio C2 (Premium) BK Rear of Radio 36
Radio Antenna - At Antenna Base 37
Radio Antenna Cable - Right Kick Panel 36, 37
Recirculation Door Actuator BK Right Side of HVAC N/S
Red Brake Warning Indicator
Switch
BK Near Master Cylinder 22, 25, 29
Remote Radio Switch-Left BK At Steering Wheel N/S
Remote Radio Switch-Right BK At Steering Wheel N/S
Seat Belt Pretensioner-Left YL Left B-Pillar 44, 46
Seat Belt Pretensioner-Right YL Right B-Pillar 45, 47
Seat Belt Switch-Driver DK GY Left B-Pillar N/S
Seat Belt Tension Reducer
(Standard Cab)
YL Left B-Pillar 44
Seat Heater Interface Module GN Under Driver Seat N/S
Sentry Key Immobilizer Module BK On Steering Column 30
Side Marker - Left Front (Dual
Wheels)
BK Front of Left Rear Fender 52
Side Marker - Left Rear (Dual
Wheels)
BK Rear of Left Rear Fender 52
Side Marker - Right Front (Dual
Wheels)
BK Front of Right Rear Fender 52
Side Marker - Right Rear (Dual
Wheels)
BK Rear of Right Rear Fender 52
Speaker-Center Instrument Panel WT Center of Instrument Panel 35, 36
Speaker-Left Front Door WT In Left Front Door 41
Speaker-Left Instrument Panel BK Left Side of Instrument Panel 35, 38
Speaker-Left Rear (Standard Cab) WT In Lower Left B-Pillar 44
Speaker-Left Rear Door (Quad
Cab)
WT In Left Rear Door 43
Speaker-Right Front Door WT In Right Front Door 42
Speaker-Right Instrument Panel BK Right Side of Instrument Panel 35, 39
Speaker-Right Rear (Standard
Cab)
BK In Lower Right B-Pillar 45
Speaker-Right Rear Door (Quad
Cab)
BK In Right Rear Door 43
Speed Control Servo BK Left Front Side of Engine
Compartment
23, 25
Speed Control Switch - Left
(Except ETC)
GN Steering Wheel N/S
Speed Control Switch - Right
(Except ETC)
GN Steering Wheel N/S
Speed Control Switch-Left (ETC) WT At Steering Wheel N/S
Speed Control Switch-Right (ETC) WT At Steering Wheel N/S
Starter Solenoid Left Engine 23
Tail/Stop/Turn Signal Lamp-Left BK At Lamp 50, 51
Tail/Stop/Turn Signal Lamp-Right BK At Lamp 50, 51
Throttle Position Sensor NAT Throttle Body 6
Trailer Tow Connector BK At Trailer Hitch 51
Trailer Tow Connector-Add On BK At Trailer Hitch 51, 53
Transfer Case Control Module C1 BK Left Side of Instrument Panel 35, 38
Transfer Case Control Module C2 GY Left Side of Instrument Panel 35, 38
Transfer Case Control Module C3 BK Left Side of Instrument Panel 35, 38
Transfer Case Mode Sensor BK Left Front Side of Transfer Case 13, 14, 16, 20
Transfer Case Position Sensor BK Front Middle of Transfer Case 20
Transfer Case Selector Switch BK Center of Instrument Panel 11, 12, 33, 35, 36
Transfer Case Shift Motor BK Left Rear of Transmission 13, 14, 20
Transmission Range Sensor BK Left side of Transmission 11, 14
Transmission Solenoid Assembly BK Left Side of Transmission 14, 11
Transmission Solenoid/TRS
Assembly (3.7L/4.7L)
BK Left Side of Transmission 15, 16
Underhood Lamp BK Underside of Hood 29
Vacuum Pump (Diesel) Right Rear Engine Compartment 21
Vistronic Fan Drive Front Engine Compartment 28
Washer Fluid Level Switch BK At Reservoir 21, 23, 26, 28
Washer Pump Motor-Front BK At Washer Fluid Reservoir 21, 23, 26, 28
Water In Fuel Sensor (Diesel) BK Right Side Engine 10
Wheel Speed Sensor-Left Front BK Left Rear Lower Side of Engine
Compartment
22, 29
Wheel Speed Sensor-Rear BK Right Rear of Body 51
Wheel Speed Sensor-Right Front GY Right Rear Lower Side of Engine
Compartment
21
Wiper Motor-Front BK Left Side of Cowl 22, 25
GROUNDS
GROUND
NUMBER
LOCATION FIG.
G100 Battery Ground - Left Front Engine N/S
G101 Battery Ground - Left Front Engine N/S
G102 Battery Ground - Left Front Chassis N/S
G103 Left Front Engine Compartment 22
G104 Left Front Engine Compartment N/S
G105 Right Front Chassis 21
G106 Left Rear Engine Compartment 22, 29
G107 (Gas) Right Rear Engine Compartment 4, 8, 10
G108 Diesel Auxiliary Battery Ground N/S
G109 Diesel Auxiliary Battery Ground N/S
G114 (Diesel) Right Side Engine Compartment 10
G120 Left Side Engine 10
G201 Right Side of Instrument Panel 38
G202 Center of Instrument Panel 35, 36
G203 Center of Instrument Panel 35, 36
G204 Right Side of Instrument Panel 35
G301 Left Front Body 40, 44, 46
G302 Left Front Body 40, 44, 46
SPLICES
SPLICE
NUMBER
LOCATION FIG.
S101 Left Front Fender 21
S103 Left Rear of Engine Compartment 22, 25
S104 Front Facia 35
S105 Front Facia N/S
S106 Left Rear of Engine Compartment 22
S108 Headlamp and Dash, Left Side 22, 25
S111 Center Rear of Engine Compartment N/S
S112 Right Rear of Engine 3
S115 Left Rear of Engine Compartment N/S
S117 Left Rear of Engine Compartment N/S
SPLICE
NUMBER
LOCATION FIG.
S123 Left Front Fender 22, 23
S124 Center Rear of Engine Compartment N/S
S125 Right Rear of Engine Compartment 4, 8
S130 Top Front of Transmission 3, 9
S133 Left Rear of Engine 4, 9
S135 Headlamp and Dash, Left Side N/S
S138 Left Rear of Engine N/S
S139 Right Front of Transmission N/S
S140 Right Rear Engine Compartment 22
S142 Left Side of Engine 3
S143 Left Side of Engine Compartment N/S
S144 Top Front of Transmission N/S
S148 Top Front of Transmission 3
S149 Left Rear of Engine 6
S150 Top Center of Engine 3, 9
S153 Rear Engine Compartment N/S
S154 Left Top Engine N/S
S155 Left Rear Engine Compartment near T/O for Fuel Control Actuator 9
S157 Near T/O for Camshaft Position Sensor N/S
S158 Near T/O for C114 10
S159 Near T/O for Engine Control Module N/S
S160 Top Left Engine 10
S162 Left Side Engine N/S
S163 Right Side Engine N/S
S164 Near Engine Control Module C2 10
S165 Near Engine Control Module C2 10
S166 In Battery Positive Harness N/S
S168 Right Rear of Engine 3
S169 Right Rear of Engine 3, 7
S170 Left Engine 10
S171 Top Left Engine 10
S172 In T/O for Fuel Control Actuator N/S
S174 Near T/O for C114 N/S
SPLICE
NUMBER
LOCATION FIG.
S176 Left Side Engine Near T/O for Fuel Control Actuator N/S
S187 Rear of Engine 7
S191 Near Integrated Power Module 23
S203 Right Side Engine Compartment 23
S204 Left Side of Instrument Panel 35
S205 Left Side of Instrument Panel 35
S206 At Steering Column N/S
S209 Center of Instrument Panel 35
S210 Center of Instrument Panel 35, 38
S212 Left Side of Instrument Panel 31, 38
S214 Left Side of Instrument Panel 31, 38
S217 Left Side of Instrument Panel N/S
S218 Left Side of Instrument Panel N/S
S219 Center of Instrument Panel N/S
S220 Center of Instrument Panel N/S
S224 Right Side of HVAC N/S
S226 Right Side of HVAC N/S
S230 Right Instrument Panel 35
S231 Left Instrument Panel 38
S232 Right Engine Compartment 23
S240 Steering Column 31, 38
S241 Center Instrument Panel 35, 36
S243 Right Engine Compartment 23
S245 Left Instrument Panel 35
S300 Left Kick Panel 40, 44, 46
S301 Center of Headliner N/S
S303 Middle of Roof 48
S305 Middle of Roof 48
S306 Left Side of Frame N/S
S308 Left Rear Chassis 50, 51
S309 Center Rear of Chassis 51
S311 Left Front of Body 44, 46
SPLICE
NUMBER
LOCATION FIG.
S312 Right Door 42
S313 Left Front Door 41
S314 Left Rear Frame Rail N/S
S315 Left Front Body 40, 44, 46
S316 At Driver Seat N/S
S318 At Passenger Seat N/S
S320 Center of Body 44
S321 Left Front Body 44
S322 Left Front Body 45, 47
S323 Left Front Body 45, 47
S324 Left Rear Chassis 51
S326 Left Rear Chassis N/S
S335 Left Front Body N/S
S336 Passenger Seat N/S
S337 Passenger Seat N/S
S340 Left Rear Fender 52
S341 Right Rear Fender 52
S342 Left Rear Fender 52
S343 Right Rear Fender 52
S351 Driver Seat N/S
Fig. 1 RIGHT SIDE FRONT LIGHTING
Fig. 2 LEFT FRONT BUMPER AND RIGHT BATTERY TRAY
F
i
g
.
3
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Fig. 4 RIGHT REAR ENGINE COMPARTMENT
F
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.
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Fig. 8 RIGHT REAR ENGINE COMPARTMENT (5.7L)
F
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Fig. 12 MANUAL TRANSMISSION (DIESEL)
Fig. 13 FRONT MANUAL TRANSMISSION (DIESEL)
F
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.
1
4
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Fig. 16 1LEFT TRANSMISSION 45RFE (5.7L)
F
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.
1
7
M
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(
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L
)
Fig. 19 MANUAL TRANSMISSION (5.7L/DIESEL)
F
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.
2
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Fig. 27 27 LEFT FRONT FACIA AND BATTERY TRAY
F
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.
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8
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Fig. 30 STEERING COLUMN
F
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Fig. 37 RADIO ANTENNA
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Fig. 45 STANDARD CAB RIGHT SIDE BODY
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Fig. 47 QUAD CAB RIGHT SIDE BODY
Fig. 48 ROOF
Fig. 49 REAR BODY
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8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS . . . . . . . . . 2
CIGAR LIGHTER OUTLET
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTEGRATED POWER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - FRONT
CONTROL MODULE . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
IOD FUSE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
POWER OUTLET
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
POWER DISTRIBUTION
DESCRIPTION
Thi s group covers the vari ous standard and
opti onal power di stri buti on components used on thi s
model . The power di stri buti on system for thi s vehi cl e
consi sts of the fol l owi ng components:
I ntegrated Power Modul e (I PM)
Front Control Modul e (FCM)
Power Di stri buti on Center (PDC)
Power Outl ets
Ci gar Li ghter Outl ets
Rel ays
Refer to Wi ri ng Di agrams for compl ete ci rcui t sche-
mati cs.
The power di stri buti on system al so i ncorporates
vari ous types of ci rcui t control and protecti on fea-
tures, i ncl udi ng:
Automati c resetti ng ci rcui t breakers
Bl ade-type fuses
Cartri dge fuses
Rel ays
components i n the power di stri buti on system. See the
owners manual i n the vehi cl e gl ove box for more
i nformati on on the features and use of al l of the
power di stri buti on system components.
OPERATION
The power di stri buti on system for thi s vehi cl e i s
desi gned to provi de safe, rel i abl e, and central i zed di s-
tri buti on poi nts for the el ectri cal current requi red to
operate al l of the many standard and opti onal facto-
ry-i nstal l ed el ectri cal and el ectroni c powertrai n,
chassi s, safety, securi ty, comfort and conveni ence sys-
tems. At the same ti me, the power di stri buti on sys-
tem was desi gned to provi de ready access to these
el ectri cal di stri buti on poi nts for the vehi cl e techni -
ci an to use when conducti ng di agnosi s and repai r of
faul ty ci rcui ts. The power di stri buti on system can
al so prove useful for the sourci ng of addi ti onal el ec-
tri cal ci rcui ts that may be requi red to provi de the
el ectri cal current needed to operate many accessori es
that the vehi cl e owner may choose to have i nstal l ed
i n the aftermarket.
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
CIGAR LIGHTER OUTLET
DESCRIPTION
On model s equi pped a ci gar l i ghter outl et i s
i nstal l ed to the l eft of the center stack area i n the
l ower i nstrument panel . The ci gar l i ghter outl et i s
secured by a snap fi t wi thi n the bezel .
The ci gar l i ghter outl et, pl asti c cap and the knob
and heati ng el ement uni t are avai l abl e for servi ce
repl acement. These components cannot be repai red
and, i f faul ty or damaged, they must be repl aced.
OPERATION
The ci gar l i ghter consi sts of two major components:
a knob and heati ng el ement uni t, and the ci gar
l i ghter base or outl et shel l . The receptacl e shel l i s
connected to ground, and an i nsul ated contact i n the
bottom of the shel l i s connected to battery current.
The ci gar l i ghter recei ves battery vol tage from a fuse
i n the juncti on bl ock when the i gni ti on swi tch i s i n
the Accessory or Run posi ti ons.
The ci gar l i ghter knob and heati ng el ement are
encased wi thi n a spri ng-l oaded housi ng, whi ch al so
features a sl i di ng protecti ve heat shi el d. When the
knob and heati ng el ement are i nserted i n the outl et
shel l , the heati ng el ement resi stor coi l i s grounded
through i ts housi ng to the outl et shel l . I f the ci gar
l i ghter knob i s pushed i nward, the heat shi el d sl i des
up toward the knob exposi ng the heati ng el ement,
and the heati ng el ement extends from the housi ng
toward the i nsul ated contact i n the bottom of the
outl et shel l .
Two smal l spri ng-cl i p retai ners are l ocated on
ei ther si de of the i nsul ated contact i nsi de the bottom
of the outl et shel l . These cl i ps engage and hol d the
heati ng el ement agai nst the i nsul ated contact l ong
enough for the resi stor coi l to heat up. When the
heati ng el ement i s engaged wi th the contact, battery
current can fl ow through the resi stor coi l to ground,
causi ng the resi stor coi l to heat.
When the resi stor coi l becomes suffi ci entl y heated,
excess heat radi ates from the heati ng el ement caus-
i ng the spri ng-cl i ps to expand. Once the spri ng-cl i ps
expand far enough to rel ease the heati ng el ement,
the spri ng-l oaded housi ng forces the knob and heat-
i ng el ement to pop back outward to thei r rel axed
posi ti on. When the ci gar l i ghter knob and el ement
are pul l ed out of the outl et shel l , the protecti ve heat
shi el d sl i des downward on the housi ng so that the
heati ng el ement i s recessed and shi el ded around i ts
ci rcumference for safety.
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET
For compl ete ci rcui t di agrams, refer to Wiring
Diagrams.
(1) Check the fused B(+) fuse i n the i ntegrated
power modul e. I f OK, go to Step 2. I f not OK, repai r
the shorted ci rcui t or component as requi red and
repl ace the faul ty fuse.
(2) Turn the i gni ti on swi tch to the Run posi ti on.
Check for battery vol tage at the fused B(+) fuse i n
the i ntegrated power modul e. I f OK, go to Step 3. I f
not OK, repai r the open or short as requi red.
(3) Remove the ci gar l i ghter knob and el ement
from the ci gar l i ghter outl et shel l . Check for conti nu-
i ty between the i nsi de ci rcumference of the ci gar
l i ghter outl et shel l and a good ground. there shoul d
be conti nui ty. I f OK, go to Step 4. I f not OK, go to
Step 5.
(4) Turn the i gni ti on swi tch to the Run posi ti on.
Check for battery vol tage at the i nsul ated contact
l ocated at the back of the ci gar l i ghter outl et shel l . I f
OK, repl ace the faul ty ci gar l i ghter knob and el e-
ment. I f not OK, go to Step 5.
i ty of the ci gar l i ghter wi re harness connector and a
good ground. There shoul d be conti nui ty. I f OK, go to
Step 6. I f not OK, repai r the open ground ci rcui t to
ground as requi red.
(6) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the Accessory or Run posi ti ons.
Check for battery vol tage at the fused B(+) ci rcui t
cavi ty of the ci gar l i ghter wi re harness connector. I f
OK, repl ace the faul ty ci gar l i ghter outl et. I f not OK,
repai r the open fused B(+) ci rcui t to the i ntegrated
power modul e fuse as requi red.
Terminal Pick Kit 6680
8W - 97 - 2 8W-97 POWER DISTRIBUTION DR
POWER DISTRIBUTION (Continued)
INTEGRATED POWER MODULE
DESCRIPTION
The I ntegrated Power Modul e (I PM) (Fi g. 1) i s a
combi nati on of the Power Di stri buti on Center (PDC)
and the Front Control Modul e (FCM). The I PM i s
l ocated i n the engi ne compartment, next to the bat-
tery on thi s model . The power di stri buti on center
mates di rectl y wi th the Front Control Modul e (FCM)
to form the I ntegrated Power Modul e Fuse and Rel ay
Center. The power di stri buti on center (PDC) i s a
pri nted ci rcui t board based modul e that contai ns
fuses and rel ays, whi l e the front control modul e con-
tai ns the el ectroni cs control l i ng the i ntegrated power
modul e and other functi ons. Thi s i ntegrated power
modul e connects di rectl y to the battery posi ti ve vi a a
stud l ocated on top of the uni t. The ground connec-
ti on i s vi a el ectri cal connectors. The i ntegrated power
modul e provi des the pri mary means of vol tage di stri -
buti on and protecti on for the enti re vehi cl e.
The mol ded pl asti c i ntegrated power modul e hous-
i ng i ncl udes a base and cover. The i ntegrated power
modul e cover i s easi l y opened or removed for servi ce
access by unscrewi ng the cover retai ni ng nut and has
a fuse and rel ay l ayout map i ntegral to the i nsi de
surface of the cover. Thi s i ntegrated power modul e
housi ng base and cover are secured i n pl ace vi a bol ts
to the l eft front fender support assembl y.
Repl aceabl e components of the i ntegrated power
modul e assembl y are broken down i nto the fol l owi ng
components: the Power Di stri buti on Center (PDC),
the i ntegrated power modul e cover, the Front Control
Modul e (FCM) and the I ntegrated Power Modul e
Assembl y whi ch i ncl udes the power di stri buti on cen-
ter, the cover and FCM. Refer to the Front Con-
trol Module in the Electronic Control Module
section of thi s servi ce manual for i nformati on on the
front control modul e.
OPERATION
Al l of the current from the battery and the gener-
ator output enters the i ntegrated power modul e vi a a
stud on the top of the modul e. The i ntegrated power
modul e cover i s removed to access the fuses or rel ays.
I nternal connecti ons of al l of the power di stri buti on
center ci rcui ts i s accompl i shed by a combi nati on of
bus bars and a pri nted ci rcui t board. Refer to the
Wi ri ng secti on of the servi ce manual for compl ete
i ntegrated power modul e ci rcui t schemati cs.
REMOVAL
(1) Di sconnect the negati ve and posi ti ve battery
cabl es.
(2) Unsnap cover and remove the B+ termi nal nut
from the i ntegrated power modul e B+ termi nal .
Remove the B+ cabl e from the i ntegrated power mod-
ul e.
(3) Di sconnect the gray connector from the i nte-
grated power modul e.
Fig. 1 DR INTEGRATED POWER MODULE
1 - POWER DISTRIBUTION CENTER HOUSING
2 - FRONT CONTROL MODULE ELECTRICAL CONNECTOR
Fig. 2 DR INTEGRATED POWER MODULE
1 - COVER RETAINING BOLT
2 - INTEGRATED POWER MODULE RETAINING BOLT
3 - RETAINING SCREW
4 - INTEGRATED POWER MODULE COVER
(4) Remove the i ntegrated power modul e retai ni ng
bol t and screw (Fi g. 2).
(5) Grasp the i ntegrated power modul e wi th two
hands and sl i de the assembl y i n the di recti on shown
(Fi g. 3) to free the modul e from i ts mounti ng bracket.
Posi ti on the assembl y upsi de down to access the el ec-
tri cal connectors l ocated on the bottom of the uni t.
(6) Di sconnect the el ectri cal connectors by depress-
i ng the l ocki ng tab and rotati ng the connector arm
outboard, unti l the connector i s free from the modul e
assembl y. Be certai n to pul l the connectors strai ght
off.
(7) Posi ti on the i ntegrated power modul e on a
bench and remove the four front control modul e
retai ni ng screws.
(8) Di sconnect the front control modul e by pul l i ng
i t strai ght off the i ntegrated power modul e.
LLATI ON
INSTALLATION
(1) Connect the front control modul e by pushi ng i t
strai ght on the i ntegrated power modul e el ectri cal
receptacl e.
(2) I nstal l the four front control modul e retai ni ng
screws. Torque to 30 i n. l bs. +/-5.
NOTE: Integrated power module electrical connec-
tors are color coded to ease location reference (Fig.
4).
Fig. 3 REMOVING INTEGRATED POWER MODULE
Fig. 4 INTEGRATED POWER MODULE ELECTRICAL
CONNECTIONS
1 - RETAINING LATCH
2 - GRAY CONNECTOR
3 - GREEN CONNECTOR
4 - GREEN CONNECTOR
5 - BLUE CONNECTOR
6 - WHITE CONNECTOR
7 - BLACK CONNECTOR
8 - BLACK CONNECTOR
INTEGRATED POWER MODULE (Continued)
(3) Connect the el ectri cal connectors by pushi ng
strai ght on and rotati ng the connector arm i nboard,
unti l the connector i s fi rml y l ocked i n pl ace on the
modul e assembl y.
(4) Grasp the i ntegrated power modul e wi th two
hands and i nstal l the assembl y on the battery tray
(Fi g. 5).
(5) I nstal l the i ntegrated power modul e retai ni ng
bol t and screw.
(6) Connect the gray connector on the i ntegrated
power modul e housi ng.
(7) I nstal l the B+ termi nal cabl e and nut on the
i ntegrated power modul e B+ termi nal . Snap the
cover i n pl ace.
(8) Connect the negati ve and posi ti ve battery
cabl es.
DESCRIPTION
The Front Control Modul e (FCM) i s a mi cro con-
trol l er based modul e l ocated i n the l eft front corner
of the engi ne compartment. On thi s model the i nte-
grated power modul e must be posi ti oned asi de i n
order to access the front control modul e. The front
control modul e mates to the power di stri buti on cen-
ter to form the I ntegrated Power Modul e (I PM). The
i ntegrated power modul e connects di rectl y to the bat-
tery and provi des the pri mary means of ci rcui t pro-
tecti on and power di stri buti on for al l vehi cl e
el ectri cal systems. The front control modul e control s
power to some of these vehi cl e systems el ectri cal and
el ectromechani cal l oads based on i nputs recei ved
from hard wi red swi tch i nputs and data recei ved on
the PCI bus ci rcui t (J1850).
For i nformati on on the Integrated Power Mod-
ule Refer to the Power Distribution Section of
the servi ce manual .
OPERATION
As messages are sent over the PCI bus ci rcui t, the
front control modul e reads these messages and con-
trol s power to some of the vehi cl es el ectri cal systems
by compl eti ng the ci rcui t to ground (l ow si de dri ver)
or compl eti ng the ci rcui t to 12 vol t power (hi gh si de
dri ver). The fol l owi ng functi ons are Controlled by
Headl amp Power wi th Vol tage Regul ati on
Wi ndshi el d Wi per ON/OFF Rel ay Actuati on
Wi ndshi el d Wi per HI /LO Rel ay Actuati on
Wi ndshi el d Washer Pump Motor
Fog Lamp Rel ay Actuati on
Park Lamp Rel ay Actuati on
Horn Rel ay Actuati on
The fol l owi ng i nputs are Received/Monitored by
B+ Connecti on Detecti on
Power Ground
Ambi ent Temperature Sensi ng
I gni ti on Swi tch Run
Washer Fl ui d Level Swi tch
Wi ndshi el d Wi per Park Swi tch
PCI Bus Ci rcui t
DIAGNOSIS AND TESTING - FRONT CONTROL
MODULE
The front control modul e i s a pri nted ci rcui t board
based modul e wi th a on-board mi cro-processor. The
front control modul e i nterfaces wi th other el ectroni c
modul es i n the vehi cl e vi a the Programmabl e Com-
muni cati ons I nterface (PCI ) data bus (J1850). I n
order to obtai n concl usi ve testi ng the Programmabl e
Communi cati ons I nterface (PCI ) data bus network
and al l of the el ectroni c modul es that provi de i nputs
to, or recei ve outputs from the front control modul e
must be checked. Al l PCI (J1850) communi cati on
faul ts must be resol ved pri or to further di agnosi ng
any front control modul e rel ated i ssues.
The front control modul e was desi gned to be di ag-
nosed wi th an appropri ate di agnosti c scan tool , such
as the DRB I I I . The most rel i abl e, effi ci ent, and
accurate means to di agnose the front control modul e
Fig. 5 INTEGRATED POWER MODULE MOUNTING
TABS
1 - INTEGRATED POWER MODULE MOUNTING HOLES
3 - FRONT CONTROL MODULE
INTEGRATED POWER MODULE (Continued)
requi res the use of a DRB I I I scan tool and the
proper Body Di agnosti c Procedures manual .
Before any testi ng of the front control modul e i s
attempted, the battery shoul d be ful l y charged and
al l wi re harness and ground connecti ons i nspected
around the affected areas on the vehi cl e.
REMOVAL
(1) Di sconnect the posi ti ve and negati ve battery
cabl es from the battery.
(2) Parti al l y remove the i ntegrated power modul e
from the engi ne compartment (Refer to 8 - ELECTRI -
POWER MODULE - REMOVAL).
(3) Remove the front control modul e retai ni ng
screws.
(4) Usi ng both hands, pul l the front control modul e
straight from the i ntegrated power modul e assembl y
to di sconnect the 49-way el ectri cal connector and
remove the front control modul e from the vehi cl e.
INSTALLATION
(1) I nstal l the front control modul e on the i nte-
grated power modul e assembl y by pushi ng the
49-way el ectri cal connector strai ght i n.
(2) I nstal l the front control modul e retai ni ng
screws. Torque the screws to 7 i n. l bs.
- ELECTRI CAL/POWER DI STRI BUTI ON/I NTE-
GRATED POWER MODULE - I NSTALLATI ON).
(4) Connect the posi ti ve and negati ve battery
cabl es.
IOD FUSE
DESCRIPTION
Al l vehi cl es are equi pped wi th an I gni ti on-Off
Draw (I OD) fuse that i s di sconnected wi thi n the I nte-
grated Power Modul e when the vehi cl e i s shi pped
from the factory. Deal er personnel are to reconnect
the I OD fuse i n the I ntegrated Power Modul e as part
of the preparati on procedures performed just pri or to
new vehi cl e del i very.
A l aser pri nted fuse l ayout map i s i ntegral to the
I ntegrated Power Modul e cover to ensure proper fuse
i denti fi cati on. The I OD fuse i s a 20 ampere mi ni
bl ade-type fuse, l ocated i n fuse cavi ty #51 (Fi g. 6).
The fuse i s secured wi thi n a bl ack mol ded pl asti c
fuse hol der and pul l er uni t that serves both as a tool
for di sconnecti ng and reconnecti ng the fuse i n i ts
I ntegrated Power Modul e cavi ty, and as a fuse hol der
that conveni entl y stores the fuse i n the same I nte-
grated Power Modul e cavi ty after i t has been di scon-
nected.
CIRCUITS INCLUDED WITH IOD FUSE
Cl uster (CCN)
Di agnosti c Connector
Map Lamps
Gl ove Box Lamp
Courtesy Lamps
Radi o
Underhood Lamp
OPERATION
The term i gni ti on-off draw i denti fi es a normal con-
di ti on where power i s bei ng drai ned from the battery
wi th the i gni ti on swi tch i n the Off posi ti on. The I OD
fuse feeds the memory and sl eep mode functi ons for
some of the el ectroni c modul es i n the vehi cl e as wel l
as vari ous other accessori es that requi re battery cur-
rent when the i gni ti on swi tch i s i n the Off posi ti on.
The onl y reason the I OD fuse i s di sconnected i s to
reduce the normal I OD of the vehi cl e el ectri cal sys-
tem duri ng new vehi cl e transportati on and pre-del i v-
ery storage to reduce battery depl eti on, whi l e sti l l
al l owi ng vehi cl e operati on so that the vehi cl e can be
l oaded, unl oaded and moved as needed by both vehi -
cl e transportati on company and deal er personnel .
The I OD fuse i s di sconnected from I ntegrated
Power Modul e fuse cavi ty #51 when the vehi cl e i s
shi pped from the assembl y pl ant. Deal er personnel
must reconnect the I OD fuse when the vehi cl e i s
bei ng prepared for del i very i n order to restore ful l
el ectri cal system operati on. Once the vehi cl e i s pre-
pared for del i very, the I OD functi on of thi s fuse
Fig. 6 IOD FUSE LOCATION
1 - IOD FUSE
FRONT CONTROL MODULE (Continued)
becomes transparent and the fuse that has been
assi gned the I OD desi gnati on becomes onl y another
Fused B(+) ci rcui t fuse.
The I OD fuse can be used by the vehi cl e owner as
a conveni ent means of reduci ng battery depl eti on
when a vehi cl e i s to be stored for peri ods not to
exceed about thi rty days. However, i t must be
remembered that di sconnecti ng the I OD fuse wi l l not
el i mi nate I OD, but onl y reduce thi s normal condi ti on.
I f a vehi cl e wi l l be stored for more than about thi rty
days, the battery negati ve cabl e shoul d be di scon-
nected to el i mi nate normal I OD; and, the battery
shoul d be tested and recharged at regul ar i nterval s
duri ng the vehi cl e storage peri od to prevent the bat-
tery from becomi ng di scharged or damaged.
REMOVAL
The I gni ti on-Off Draw (I OD) fuse i s di sconnected
from I ntegrated Power Modul e fuse cavi ty #51 when
the vehi cl e i s shi pped from the assembl y pl ant.
Deal er personnel must reconnect the I OD fuse when
the vehi cl e i s bei ng prepared for del i very i n order to
restore ful l el ectri cal system operati on.
(2) Remove the I ntegrated Power Modul e cover.
(3) Grasp the outer tabs of the I OD fuse hol der
uni t i n fuse cavi ty #51 between the thumb and fore-
fi nger and pul l the uni t fi rml y upward.
(4) I nstal l the I ntegrated Power Modul e cover.
INSTALLATION
(2) Remove the I ntegrated Power Modul e cover.
(3) To i nstal l the I OD fuse, use a thumb to press
the I OD fuse hol der uni t i n fuse cavi ty #51 fi rml y
i nto the I ntegrated Power Modul e.
(4) I nstal l the I ntegrated Power Modul e cover.
POWER OUTLET
DESCRIPTION
Two power outl ets are uti l i zed on thi s model . One
i n the i nstrument panel center l ower bezel and the
other i n the center consol e. The power outl et bases
are secured by a snap fi t wi thi n the i nstrument
panel or tri m panel . A pl asti c protecti ve cap snaps
i nto the power outl et base when the power outl et i s
not bei ng used, and hangs from the power outl et base
mount by an i ntegral bai l strap whi l e the power out-
l et i s i n use.
The power outl et receptacl e uni t and the accessory
power outl et protecti ve cap are avai l abl e for servi ce.
The power outl et receptacl e cannot be repai red and,
i f faul ty or damaged, i t must be repl aced.
OPERATION
The power outl et base or receptacl e shel l i s con-
nected to ground, and an i nsul ated contact i n the
bottom of the shel l i s connected to battery current.
The power outl et recei ves battery vol tage from a fuse
i n the i ntegrated power modul e at al l ti mes.
Whi l e the power outl et i s very si mi l ar to a ci gar
l i ghter base uni t, i t does not i ncl ude the two smal l
spri ng-cl i p retai ners i nsi de the bottom of the recepta-
cl e shel l that are used to secure the ci gar l i ghter
heati ng el ement to the i nsul ated contact.
DIAGNOSIS AND TESTING - POWER OUTLET
For compl ete ci rcui t di agrams, refer to Wiring
Diagrams.
(1) Check the fused B(+) fuse i n the i ntegrated
power modul e. I f OK, go to Step 2. I f not OK, repai r
the shorted ci rcui t or component as requi red and
repl ace the faul ty fuse.
(2) Check for battery vol tage at the fused B(+) fuse
i n the i ntegrated power modul e. I f OK, go to Step 3.
I f not OK, repai r the open fused B(+) ci rcui t to the
battery as requi red.
(3) Remove the pl asti c protecti ve cap from the
power outl et receptacl e. Check for conti nui ty between
the i nsi de ci rcumference of the power outl et recepta-
cl e and a good ground. There shoul d be conti nui ty. I f
OK, go to Step 4. I f not OK, go to Step 5.
(4) Check for battery vol tage at the i nsul ated con-
tact l ocated at the back of the power outl et recepta-
cl e. I f not OK, go to Step 5.
cabl e. Remove the power outl et receptacl e from the
i nstrument panel . Di sconnect the wi re harness con-
nector from the power outl et receptacl e. Check for
conti nui ty between the ground ci rcui t cavi ty of the
power outl et wi re harness connector and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
6. I f not OK, repai r the open ground ci rcui t to ground
as requi red.
(6) Connect the battery negati ve cabl e. Check for
battery vol tage at the fused B(+) ci rcui t cavi ty of the
power outl et wi re harness connector. I f OK, repl ace
the faul ty power outl et receptacl e. I f not OK, repai r
the open fused B(+) ci rcui t to the i ntegrated power
modul e fuse as requi red.
IOD FUSE (Continued)
REMOVAL
cabl e.
(2) Pul l the ci gar l i ghter knob and el ement out of
the ci gar l i ghter receptacl e base, or unsnap the pro-
tecti ve cap from the power outl et receptacl e base.
(3) Look i nsi de the ci gar l i ghter or power outl et
receptacl e base and note the posi ti on of the rectangu-
l ar retai ni ng bosses of the mount that secures the
receptacl e base to the panel (Fi g. 7).
(4) I nsert a pai r of external snap ri ng pl i ers i nto
the ci gar l i ghter or power outl et receptacl e base and
engage the ti ps of the pl i ers wi th the retai ni ng
bosses of the mount.
(5) Squeeze the pl i ers to di sengage the mount
retai ni ng bosses from the receptacl e base and, usi ng
a gentl e rocki ng moti on, pul l the pl i ers and the
receptacl e base out of the mount.
(6) Pul l the receptacl e base away from the i nstru-
ment panel far enough to access the i nstrument
panel wi re harness connector.
connector from the ci gar l i ghter or power outl et
receptacl e base connector receptacl e.
(8) Remove the ci gar l i ghter or power outl et mount
from the i nstrument panel .
INSTALLATION
connector to the ci gar l i ghter or power outl et recep-
tacl e base connector receptacl e.
(2) I nstal l the ci gar l i ghter or power outl et mount
i nto the i nstrument panel .
(3) Al i gn the spl i nes on the outsi de of the ci gar
l i ghter or power outl et receptacl e base connector
receptacl e wi th the grooves on the i nsi de of the
mount.
(4) Press fi rml y on the ci gar l i ghter or power out-
l et receptacl e base unti l the retai ni ng bosses of the
mount are ful l y engaged i n thei r receptacl es.
(5) I nstal l the ci gar l i ghter knob and el ement i nto
the ci gar l i ghter receptacl e base, or the protecti ve cap
i nto the power outl et receptacl e base.
Fig. 7 Cigar Lighter and Power Outlet Remove/
Install
1 - KNOB AND ELEMENT
2 - RETAINING BOSSES-ENGAGE PLIERS HERE
3 - BASE
4 - PARTIALLY REMOVED
5 - EXTERNAL SNAP-RING PLIERS
6 - MOUNT
7 - BASE
POWER OUTLET (Continued)
ENGINE
TABLE OF CONTENTS
page page
ENGINE - 3. 7L . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE - 4. 7L . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
ENGINE - 5. 7L . . . . . . . . . . . . . . . . . . . . . . . . . . 180
ENGINE 5. 9L DIESEL . . . . . . . . . . . . . . . . . . . . . 230
ENGINE - 3.7L
TABLE OF CONTENTS
page page
ENGINE - 3.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION . . . . . . . . . . . . 4
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . . 4
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . . 6
DIAGNOSIS - LUBRICATION . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE . . . . . . . . . . . . . . 8
COMBUSTION PRESSURE LEAKAGE. . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS . . . . . . . . . . 9
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS . . . . . . . . . . 9
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION. . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
SPECIFICATIONS - 3.7L ENGINE . . . . . . . . . 12
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 17
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
CYLINDER HEAD - LEFT
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
CAMSHAFT(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
CYLINDER HEAD COVER(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
STANDARD PROCEDURE - REFACING . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
ROCKER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
VALVE GUIDE SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
CYLINDER HEAD - RIGHT
LASH ADJUSTER . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
CAMSHAFT(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
ROCKER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
VALVE GUIDE SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
DR ENGINE 9 - 1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
ENGINE BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
STANDARD PROCEDURE - CYLINDER BORE
HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE
MAIN BEARING FITTING . . . . . . . . . . . . . . . . 44
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
FLEX PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 48
STANDARD PROCEDURE
CONNECTING ROD BEARING FITTING . . . . 49
STANDARD PROCEDURE - PISTON FITTING . . 51
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56
STRUCTURAL COVER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 57
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 59
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 61
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . 65
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . 65
OIL PAN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 66
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 67
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 68
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 72
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS . . . . . . . . . . . . . . . . . . . . . 72
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 74
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 74
VALVE TIMING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 76
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
STANDARD PROCEDURE
MEASURING TIMING CHAIN WEAR . . . . . . . 77
SERVICE PROCEDURE - TIMING
VERIFICATION. . . . . . . . . . . . . . . . . . . . . . . . 77
BALANCE SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
IDLER SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 81
TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 81
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
9 - 2 ENGINE - 3. 7L DR
ENGINE - 3.7L
DESCRIPTION
The 3.7 l i ter (226 CI D) si x-cyl i nder engi ne i s an
90 si ngl e overhead camshaft engi ne (Fi g. 1). The
cast i ron cyl i nder bl ock i s made up of two di fferent
components; the fi rst component i s the cyl i nder bore
and upper bl ock, the second component i s the bed-
pl ate that compri ses the l ower porti on of the cyl i nder
bl ock and houses the l ower hal f of the crankshaft
mai n beari ngs. The cyl i nders are numbered from
front to rear wi th the l eft bank bei ng numbered 1,3,
and 5 and the ri ght bank bei ng numbered 2,4, and 6.
The fi ri ng order i s 165432. The engi ne seri al
number i s l ocated at the ri ght front si de of the
engi ne bl ock
Fig. 1 3.7 L ENGINE
DR ENGINE - 3. 7L 9 - 3
DIAGNOSIS - INTRODUCTION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne mai ntenance.
These mal functi ons may be cl assi fi ed as ei ther per-
formance (e.g., engi ne i dl es rough and stal l s) or
mechani cal (e.g., a strange noi se).
(Refer to 9 - ENGI NE - DI AGNOSI S AND TEST-
I NG) - PERFORMANCE and (Refer to 9 - ENGI NE -
DI AGNOSI S AND TESTI NG)MECHANI CAL for
possi bl e causes and correcti ons of mal functi ons.
(Refer to 14 - FUEL SYSTEM/FUEL DELI VERY -
DI AGNOSI S AND TESTI NG) and (Refer to 14 -
FUEL SYSTEM/FUEL I NJECTI ON - DI AGNOSI S
AND TESTI NG) for the fuel system di agnosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng di agnosi s:
Cyl i nder Compressi on Pressure Test (Refer to 9 -
ENGI NE - DI AGNOSI S AND TESTI NG).
Cyl i nder Combusti on Pressure Leakage Test
I NG).
Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s
(Refer to 9 - ENGI NE/CYLI NDER HEAD - DI AGNO-
SI S AND TESTI NG).
I ntake Mani fol d Leakage Di agnosi s (Refer to 9 -
ENGI NE/MANI FOLDS/I NTAKE MANI FOLD -
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary.
2. Corroded or loose battery
connections.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to the terminals.
3. Faulty starter. 3. (Refer to 8 - ELECTRICAL/
STARTING - DIAGNOSIS AND
TESTING).
4. Faulty coil or control unit. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
5. Incorrect spark plug gap. 5. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
- CLEANING).
6. Incorrect right bank cam timing. 6. Refer to engine timing in this
section.
7. Dirt or water in fuel system. 7. Clean system and replace fuel
filter.
8.Faulty fuel pump, relay or wiring. 8.Repair or replace as necessary.
9. Faulty cam or crank sensor 9. Refer to Ignition system.
ENGINE STALLS OR ROUGH IDLE 1. Vacuum leak. 1. Inspect intake manifold and
vacuum hoses, repair or replace as
necessary.
2. Faulty crank position sensor 2. Replace crank position sensor.
3. Faulty coil. 3. (Refer to 8 - ELECTRICAL/
COIL - REMOVAL).
9 - 4 ENGINE - 3. 7L DR
ENGINE - 3.7L (Continued)
4. Incorrect cam timing. 4. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD
PROCEDURE).
1. ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped spark
plugs.
- CLEANING).
filter.
3. Faulty fuel pump. 3. (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL PUMP -
4. Blown cylinder head gasket. 4. Replace cylinder head gasket.
5. Low compression. 5. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING), repair
as necessary.
6. Burned, warped or pitted valves. 6. Replace as necessary.
7. Plugged or restricted exhaust
system.
necessary.
COIL - REMOVAL).
9. Incorrect cam timing. 9. Refer to Engine TIming in this
section.
1. ENGINE MISSES ON
ACCELERATION
1. Spark plugs dirty or incorrectly
gapped.
- CLEANING).
2. Dirt in fuel system. 2. Clean fuel system.
3. Burned, warped or pitted valves. 3. Replcae as necessary.
COIL - REMOVAL).
1. ENGINE MISSES AT HIGH
SPEED
gapped.
- CLEANING).
COIL - REMOVAL).
filter.
DR ENGINE - 3. 7L 9 - 5
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTIONS
NOISY VALVES 1. High or low oil level in
crankcase.
MAINTENANCE -
SPECIFICATIONS)
2. Thin or diluted oil. 2. Change oil and filter.
3. Low oil pressure. 3. Check oil pump, if Ok, check rod
and main bearings for excessive
wear.
4. Dirt in lash adjusters. 4. Replace as necessary.
5. Worn rocker arms. 5. Replace as necessary.
6. Worn lash adjusters 6. Replace as necessary.
7. Worn valve guides. 7. (Refer to 9 - ENGINE/CYLINDER
HEAD/INTAKE/EXHAUST VALVES
& SEATS - STANDARD
PROCEDURE)
8. Excessive runout of valve seats
on valve faces.
8. (Refer to 9 - ENGINE/CYLINDER
& SEATS - STANDARD
PROCEDURE)
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
wear.
4. Excessive bearing clearance. 4. Replace as necessary.
5. Connecting rod journal
out-of-round.
5. Service or replace crankshaft.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. (Refer to LUBRICATION &
MAINTENANCE -
SPECIFICATIONS)
wear.
5. Excessive end play. 5. Check thrust washers for wear.
6. Crankshaft journal out-of round. 6. Service or replace crankshaft.
7. Loose flywheel or torque
converter.
7. Tighten to correct torque
9 - 6 ENGINE - 3. 7L DR
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION
OIL LEAKS 1. Gaskets and O-Rings. 1.
(a) Misaligned or damaged. (a) Replace as necessary.
(b) Loose fasteners, broken or
porous metal parts.
(b) Tighten fasteners, Repair or
replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary (Refer to 9
- ENGINE/ENGINE BLOCK/
CRANKSHAFT OIL SEAL - REAR -
REMOVAL).
3. Crankshaft seal flange.
Scratched, nicked or grooved.
3. Polish or replace crankshaft.
4. Oil pan flange cracked. 4. Replace oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
5. Timing chain cover seal,
damaged or misaligned.
5. Replace seal (Refer to 9 -
ENGINE/ENGINE BLOCK/
- REMOVAL).
6. Scratched or damaged vibration
damper hub.
6. Polish or replace damper.
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.
2. Faulty oil pressure sending unit. 2. Replace sending unit (Refer to 9
- ENGINE/LUBRICATION/OIL
PRESSURE SENSOR/SWITCH -
REMOVAL).
3. Low oil pressure. 3. Check oil pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER
- REMOVAL).
5. Worn oil pump. 5. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
8. Oil pump relief valve stuck. 8. Replace oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP
- REMOVAL).
9. Oil pick up tube loose, damaged
or clogged.
9. Replace as necessary.
DR ENGINE - 3. 7L 9 - 7
OIL PUMPING AT RINGS; SPARK
PLUGS FOULING
1. Worn or damaged rings. 1. Hone cylinder bores and replace
rings.
2. Carbon in oil ring slots. 2. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
3. Incorrect ring size installed. 3. Replace rings (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON
RINGS - STANDARD
PROCEDURE).
4. Worn valve guides. 4. Ream guides and replace valves
(Refer to 9 - ENGINE/CYLINDER
& SEATS - STANDARD
PROCEDURE).
5. Leaking valve guide seals. 5. Replace valve guide seals.
COMPRESSION PRESSURE
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed
ai r.
(2) Remove the spark pl ugs.
(3) Di sabl e the fuel system (Refer to 14 - FUEL
SYSTEM/FUEL DELI VERY - DESCRI PTI ON).
(4) Remove the ASD rel ay (Refer to 8 - ELECTRI -
CAL/I GNI TI ON CONTROL/AUTO SHUT DOWN
RELAY - REMOVAL).
(5) I nsert a compressi on pressure gauge and rotate
the engi ne wi th the engi ne starter motor for three
revol uti ons.
(6) Record the compressi on pressure on the 3rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
(7) (Refer to 9 - ENGI NE - SPECI FI CATI ONS) for
the correct engi ne compressi on pressures.
COMBUSTION PRESSURE LEAKAGE
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
Exhaust and i ntake val ve l eaks (i mproper seat-
i ng).
Leaks between adjacent cyl i nders or i nto water
jacket.
Any causes for combusti on/compressi on pressure
l oss.
(1) Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
(2) Start and operate the engi ne unti l i t attai ns
normal operati ng temperature, then turn the engi ne
OFF.
(4) Remove the oi l fi l l er cap.
(5) Remove the ai r cl eaner hose.
(6) Cal i brate the tester accordi ng to the manufac-
turers i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
(7) Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturers i nstructi ons.
Set pi ston of cyl i nder to be tested at TDC compres-
si on,Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Refer to CYLI NDER COMBUSTI ON PRESSURE
LEAKAGE DI AGNOSI S CHART.
9 - 8 ENGINE - 3. 7L DR
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
AIR ESCAPES THROUGH
THROTTLE BODY
Intake valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
TAILPIPE
Exhaust valve bent, burnt, or not
seated properly
necessary.
AIR ESCAPES THROUGH
RADIATOR
Head gasket leaking or cracked
cylinder head or block
Remove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
Head gasket leaking or crack in
cylinder head or block between
adjacent cylinders
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
Stuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wall
Inspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
Dri l l i ng out worn or damaged threads.
Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous pl aces where form-i n-pl ace
gaskets are used on the engi ne. Care must be taken
when appl yi ng form-i n-pl ace gaskets to assure
obtai ni ng the desi red resul ts. Do not use form-in-
place gasket material unless specified. Bead si ze,
conti nui ty, and l ocati on are of great i mportance. Too
thi n a bead can resul t i n l eakage whi l e too much can
resul t i n spi l l -over whi ch can break off and obstruct
fl ui d feed l i nes. A conti nuous bead of the proper
wi dth i s essenti al to obtai n a l eak-free gasket.
There are numerous types of form-i n-pl ace gasket
materi al s that are used i n the engi ne area. Mopar
Engi ne RTV GEN I I , Mopar ATF-RTV, and Mopar
Gasket Maker gasket materi al s, each have di fferent
properti es and can not be used i n pl ace of the other.
MOPAR ENGINE RTV GEN II
Mopar Engi ne RTV GEN I I i s used to seal com-
ponents exposed to engi ne oi l . Thi s materi al i s a spe-
ci al l y desi gned bl ack si l i cone rubber RTV that
retai ns adhesi on and seal i ng properti es when
exposed to engi ne oi l . Moi sture i n the ai r causes the
materi al to cure. Thi s materi al i s avai l abl e i n three
ounce tubes and has a shel f l i fe of one year. After one
year thi s materi al wi l l not properl y cure. Al ways
i nspect the package for the expi rati on date before
use.
MOPAR ATF RTV
Mopar ATF RTV i s a speci fi cal l y desi gned bl ack
si l i cone rubber RTV that retai ns adhesi on and seal -
i ng properti es to seal components exposed to auto-
mati c transmi ssi on fl ui d, engi ne cool ants, and
moi sture. Thi s materi al i s avai l abl e i n three ounce
tubes and has a shel f l i fe of one year. After one year
thi s materi al wi l l not properl y cure. Al ways i nspect
the package for the expi rati on date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker i s an anaerobi c type gasket
materi al . The materi al cures i n the absence of ai r
when squeezed between two metal l i c surfaces. I t wi l l
not cure i f l eft i n the uncovered tube. The anaerobi c
materi al i s for use between two machi ned surfaces.
Do not use on fl exi bl e metal fl anges.
MOPAR GASKET SEALANT
Mopar Gasket Seal ant i s a sl ow dryi ng, perma-
nentl y soft seal er. Thi s materi al i s recommended for
seal i ng threaded fi tti ngs and gaskets agai nst l eakage
DR ENGINE - 3. 7L 9 - 9
of oi l and cool ant. Can be used on threaded and
machi ned parts under al l temperatures. Thi s mate-
ri al i s used on engi nes wi th mul ti -l ayer steel (MLS)
cyl i nder head gaskets. Thi s materi al al so wi l l pre-
vent corrosi on. Mopar Gasket Seal ant i s avai l abl e i n
a 13 oz. aerosol can or 4oz./16 oz. can w/appl i cator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care but i ts easi er than usi ng precut gas-
kets.
Mopar Gasket Maker materi al shoul d be appl i ed
spari ngl y 1 mm (0.040 i n.) di ameter or l ess of seal ant
to one gasket surface. Be certai n the materi al sur-
rounds each mounti ng hol e. Excess materi al can eas-
i l y be wi ped off. Components shoul d be torqued i n
pl ace wi thi n 15 mi nutes. The use of a l ocati ng dowel
i s recommended duri ng assembl y to prevent smear-
i ng materi al off the l ocati on.
Mopar Engi ne RTV GEN I I or ATF RTV gasket
materi al shoul d be appl i ed i n a conti nuous bead
approxi matel y 3 mm (0.120 i n.) i n di ameter. Al l
mounti ng hol es must be ci rcl ed. For corner seal i ng, a
3.17 or 6.35 mm (1/8 or 1/4 i n.) drop i s pl aced i n the
center of the gasket contact area. Uncured seal ant
may be removed wi th a shop towel . Components
shoul d be torqued i n pl ace whi l e the seal ant i s sti l l
wet to the touch (wi thi n 10 mi nutes). The usage of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng materi al off the l ocati on.
Mopar Gasket Seal ant i n an aerosol can shoul d be
appl i ed usi ng a thi n, even coat sprayed compl etel y
over both surfaces to be joi ned, and both si des of a
gasket. Then proceed wi th assembl y. Materi al i n a
can w/appl i cator can be brushed on evenl y over the
seal i ng surfaces. Materi al i n an aerosol can shoul d be
used on engi nes wi th mul ti -l ayer steel gaskets.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engi ne gasket seal i ng, proper surface
preparati on must be performed, especi al l y wi th the
use of al umi num engi ne components and mul ti -l ayer
steel cyl i nder head gaskets.
Never use the fol l owi ng to cl ean gasket surfaces:
Metal scraper
Abrasi ve pad or paper to cl ean cyl i nder bl ock
and head
Hi gh speed power tool wi th an abrasi ve pad or a
wi re brush (Fi g. 2)
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Onl y use the fol l owi ng for cl eani ng gasket surfaces:
Sol vent or a commerci al l y avai l abl e gasket
remover
Pl asti c or wood scraper (Fi g. 2)
Dri l l motor wi th 3M Rol oc Bri stl e Di sc (whi te
or yel l ow) (Fi g. 2)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
REMOVAL
(2) Remove hood. Mark hood hi nge l ocati on for
rei nstal l ati on.
(3) Remove ai r cl eaner assembl y.
(4) Remove radi ator core support bracket.
(5) Remove fan shroud wi th vi scous fan assembl y.
(6) Remove dri ve bel t.
(7) Remove A/C compressor and secure away from
engi ne.
(8) Remove generator and secure away from
engi ne.
NOTE: Do NOT remove the phenolic pulley from the
P/S pump. It is not required for P/S pump removal.
(9) Remove power steeri ng pump wi th l i nes
attached and secure away from engi ne.
(10) Drai n cool i ng system.
(11) Di sconnect the heater hoses from the engi ne.
Fig. 2 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOC BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
9 - 10 ENGINE - 3. 7L DR
(12) Di sconnect heater hoses from heater core and
remove hose assembl y.
(13) Di sconnect throttl e and speed control cabl es.
(14) Remove upper radi ator hose from engi ne.
(15) Remove l ower radi ator hose from engi ne.
(16) Remove radi ator/cool i ng modul e assembl y.
(17) Di sconnect the engi ne to body ground straps
at the l eft si de of cowl .
(18) Di sconnect the engi ne wi ri ng harness at the
fol l owi ng poi nts:
I ntake ai r temperature (I AT) sensor
Fuel I njectors
Throttl e Posi ti on (TPS) Swi tch
I dl e Ai r Control (I AC) Motor
Engi ne Oi l Pressure Swi tch
Engi ne Cool ant Temperature (ECT) Sensor
Mani fol d Absol ute Pressure MAP) Sensor
Camshaft Posi ti on (CMP) Sensor
Coi l Over Pl ugs
(19) Remove coi l over pl ugs.
(20) Rel ease fuel rai l pressure.
(21) Remove fuel rai l and secure away from
engi ne.
NOTE: It is not necessary to release the quick con-
nect fitting from the fuel supply line for engine
removal.
(22) Remove the PCV hose.
(23) Remove the breather hoses.
(24) Remove the vacuum hose for the power brake
booster.
(25) Di sconnect knock sensors.
(26) Remove engi ne oi l di psti ck tube.
(27) Remove i ntake mani fol d.
(28) I nstal l engi ne l i fti ng fi xture,speci al tool #8247,
usi ng ori gi nal fasteners from the removed i ntake
mani fol d, and fuel rai l . Torque to factory speci fi ca-
ti ons.
NOTE: Recheck bolt torque for engine lift plate
before removing engine.
(29) Secure the l eft and ri ght engi ne wi ri ng har-
nesses away from engi ne.
(31) Di sconnect oxygen sensor wi ri ng.
(32) Di sconnect crankshaft posti on sensor.
(33) Di sconnect the engi ne bl ock heater power
cabl e, i f equi pped.
(34) Di sconnect the front propshaft at the front
di fferenti al and secure out of way.
NOTE: It is necessary to disconnect the front prop-
shaft for access to the starter and left side exhaust
flange.
(35) Remove the starter.
(36) Remove the ground straps from the l eft and
ri ght si de of the bl ock.
(37) Di sconnect the ri ght and l eft exhaust pi pes at
the mani fol ds and from the crossover, and remove
from the vehi cl e.
NOTE: The exhaust clamps at the manifolds cannot
be reused. New clamps must be used or leaks may
occur.
(38) Remove the structural cover.
(39) Remove torque convertor bol ts, and mark
l ocati on for reassembl y.
(40) Remove transmi ssi on bel l housi ng to engi ne
bol ts.
(41) Remove l eft and ri ght engi ne mount thru
bol ts.
(43) Support the transmi ssi on wi th a sui tabl e jack.
(44) Connect a sui tabl e engi ne hoi st to the engi ne
l i ft pl ate.
(45) Remove engi ne from vehi cl e.
INSTALLATION
(1) Posi ti on the engi ne i n the vehi cl e.
(2) I nstal l both l eft and ri ght si de engi ne mounts
onto engi ne.
(4) I nstal l the transmi ssi on bel l housi ng to engi ne
mounti ng bol ts. Ti ghten the bol ts to 41 Nm (30ft.
l bs.).
(5) Ti ghten the engi ne mount thru bol ts.
(6) I nstal l the torque convertor bol ts.
(7) Connect the ground straps on the l eft and ri ght
si de of the engi ne.
(8) I nstal l the starter.
(9) Connect the crankshaft posi ti on sensor.
(10) I nstal l the engi ne bl ock heater power cabl e, i f
equi pped.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(11) I nstal l the structural cover.
NOTE: New clamps must be used on exhaust man-
ifold flanges. Failure to use new clamps may result
in exhaust leaks.
(12) I nstal l the l eft and ri ght exhaust pi pes.
(13) Connect the l eft and ri ght oxygen sensors.
(15) Remove the engi ne l i ft pl ate.
(16) Connect the knock sensors.
DR ENGINE - 3. 7L 9 - 11
(17) Connect the engi ne to body ground straps at
the l eft si de of the cowl .
(18) I nstal l the i ntake mani fol d.
(19) I nstal l the engi ne oi l di psti ck tube.
(20) I nstal l the power brake booster vacuum hose.
(21) I nstal l the breather hoses.
(22) I nstal l the PCV hose.
(23) I nstal l the fuel rai l .
(24) I nstal l the coi l over pl ugs.
(25) Connect the engi ne wi ri ng harness at the fol -
l owi ng poi nts:
I ntake ai r temperature (I AT) sensor
Fuel I njectors
Mani fol d Absol ute Pressure MAP) Sensor
Coi l Over Pl ugs
(26) Rei nstal l the radi ator/cool i ng modul e assem-
bl y.
(27) Connect l ower radi ator hose.
(28) Connect upper radi ator hose.
(29) Connect throttl e and speed control cabl es.
(30) I nstal l the heater hose assembl y.
(31) I nstal l cool ant recovery bottl e.
(32) I nstal l the power steeri ng pump.
(33) I nstal l the generator.
(34) I nstal l the A/C compressor.
(35) I nstal l the dri ve bel t.
(36) I nstal l the fan shroud wi th the vi scous fan
assembl y.
(37) I nstal l the radi ator core support bracket.
(38) I nstal l the ai r cl eaner assembl y.
(39) Refi l l the engi ne cool i ng system.
(40) Recharge the ai r condi ti oni ng.
(41) I nstal l the hood.
(42) Check and fi l l engi ne oi l .
(44) Start the engi ne and check for l eaks.
SPECIFICATIONS
SPECIFICATIONS - 3. 7L ENGINE
GENERAL SPECIFICATIONS
Type 90SOHC V6 12 Valve
Number of
Cylinders
4
Firing Order 1-6-5-4-3-2
Lead Cylinder No. 1 Left Bank
Compression
Ratio
9.1:1
Max. Variation
Between
Cylinders
25%
Metric Standard
Displacement 3.7 Liters 226 Cubic
Inches
Bore 93.0 mm 3.66 in.
Stroke 90.8 mm 3.40 in.
Horsepower 210@5200 RPM
Torque 225ft. lbs.@4200 PRM
Compression
Pressure
1172-1551 kPa 170-225 psi
CYLINDER BLOCK
Metric Standard
Bore Diameter 93.0 .0075
mm
3.6619 0.0003
in.
Out of Round
(MAX)
0.076 mm 0.003 in.
Taper (MAX) 0.051 mm 0.002 in.
9 - 12 ENGINE - 3. 7L DR
PISTONS
Metric Standard
Diameter 92.975 mm 3.6605 in.
Weight 367.5 grams 12.96 oz
Ring Groove
Diameter
No. 1 83.73 - 83.13
mm
3.296 - 3.273 in
No. 2 82.833 - 83.033
mm
3.261 - 3.310 in.
No. 3 83.88 - 84.08
mm
3.302 - 3.310 in.
PISTON PINS
Metric Standard
Clearance In
Piston
0.006 - 0.015
mm
0.0002 - 0.0005
in.
Diameter 24.017 - 24.020
mm
0.9455 - 0.9456
in.
PISTON RINGS
Metric Standard
Ring Gap
Top
Compression
Ring
0.20 - 0.36 mm 0.0079 - 0.0142
in.
Second
Compression
Ring
0.37 - 0.63 mm 0.0146 - 0.0249
in.
Oil Control
(Steel Rails)
0.25 - 0.76 mm 0.0099 - 0.30 in.
Side Clearance
Top
Compression
Ring
.051 - .094 mm 0.0020 - 0.0037
in.
Second
Compression
Ring
0.040 - 0.080
mm
0.0016 - 0.0031
in.
Oil Ring (Steel
Ring)
.019 - .229 mm .0007 - .0091 in.
Metric Standard
Ring Width
Top
Compression
Ring
1.472 - 1.490
mm
0.057 - 0.058 in.
Second
Compression
Ring
1.472 - 1.490
mm
0.057 - 0.058 in.
Oil Ring (Steel
Rails)
0.445 - 0.470
mm
0.017 - 0.018 in.
CONNECTING RODS
Metric Standard
Bearing
Clearance
0.015 - 0.055
mm
0.0006 - 0.0022
in.
Side Clearance 0.10 - 0.35 mm 0.004 - 0.0138
in.
Piston Pin
Clearance
.015 - .028 mm 0.0006 - 0.0011
in.
Bearing Bore
Out of Round
(MAX)
0.004 mm 0.0002 in.
Total Weight
(Less Bearing)
612 grams 21.588 ounces
DR ENGINE - 3. 7L 9 - 13
CRANKSHAFT
Metric Standard
Main Bearing
Journal
Diameter
63.488 - 63.512
mm
2.4996 - 2.5005
in.
Bearing
Clearance
0.002 - 0.034
mm
-
Out of Round
(MAX)
0.005 mm 0.0002 in.
Taper (MAX) 0.006 mm 0.0004 in.
End Play 0.052 - 0.282
mm
0.0021 - 0.0112
in.
End Play (MAX) 0.282 mm 0.0112 in.
Connecting Rod
Journal
Diameter
57.908 - 57.892
mm
-
Bearing
Clearance
0.015 - 0.055 -
Out of Round
(MAX)
0.005 mm 0.0002 in.
Taper (MAX) 0.006 mm 0.0002 in.
CAMSHAFT
Metric Standard
Bore Diameter 26.02 - 26.04
mm
1.0245 - 1.0252
in.
Bearing Journal
Diameter
25.975 - 25.995
mm
1.0227 - 1.0235
in.
Bearing
Clearance
0.025 - 0.065
mm
0.001 - 0.0026
in.
Bearing
Clearance
(MAX)
0.065 mm 0.0026 in.
End Play .075 - .200 mm 0.003 - 0.0079
in.
End Play (MAX) .200 mm 0.0079 in.
VALVE TIMING
Intake
Opens (ATDC) 0.0
Closes (ATDC) 236
Duration 236
Exhaust
Opens (BTDC) 233
Closes (ATDC) 17
Duration 250
Valve Overlap 17
VALVES
Metric Standard
Face Angle 45- 45.5
Head Diameter
Intake 48.52 - 48.78
mm
1.9103 - 1.9205
in.
Exhaust 36.87 - 37.13
mm
1.4516 - 1.4618
in.
Length (Overall)
Intake 113.45 - 114.21
mm
4.4666 - 4.4965
in.
Exhaust 114.92 - 115.68
mm
4.5244 - 4.5543
in.
Stem Diameter
Intake 6.931 - 6.957
mm
0.2729 - 0.2739
in.
Exhaust 6.902 - 6.928
mm
0.2717 - 0.2728
in.
Stem-to-Guide
Clearance
Intake 0.018 - 0.069
mm
0.0008 - 0.0028
in.
Exhaust 0.047 - 0.098
mm
0.0019 - 0.0039
in.
Max. Allowable
Stem-to-Guide
Clearance
(Rocking Method)
Intake 0.069 mm 0.0028 in.
Exhaust 0.098 mm 0.0039 in.
Valve Lift (Zero
Lash)
Intake 12.00 mm () 0.472 in.
Exhaust 10.90 mm 0.4292 in.
9 - 14 ENGINE - 3. 7L DR
VALVE SPRING
Metric Standard
Free Length
(Approx)
Intake 48.92 mm 1.9260 in.
Exhaust -
w/damper
48.2 mm 1.897 in.
Spring Force
(Valve Closed)
Intake 361.0 - 390.0 N
@ 40.12 mm
81.15 - 87.67
lbs. @ 1.5795
in.
Exhaust -
(without
damper)
356 - 394 N @
39.12 mm
80.031 - 88.57
lbs. @ 1.54 in.
Spring Force
(Valve Open)
Intake 984.0 - 1040.0
N @ 27.12 mm
221.2 - 233.8
lbs. @ 1.107 in.
Exhaust -
without damper
974 - 956 N @
28.12 mm
196.48 - 214.91
lbs. @ 1.107 in.
Number of Coils
Intake 7.30
Exhaust 7.15
Wire Diameter
Intake 4.77 3.80mm 0.1878 0.1496
in.
Exhaust 4.66 3.72mm 0.1843 .1464
in.
Installed Height
(Spring Seat to
Bottom of
Retainer)
Nominal
Intake 40.12 mm 1.579 in.
Exhaust -
w/damper
40.12 mm 1.579 in.
CYLINDER HEAD
Metric Standard
Gasket
Thickness
(Compressed)
0.7 mm (0.0276 in.)
Valve Seat
Angle
44.5- 45.0
Valve Seat
Runout (MAX)
0.051 mm 0.002 in.
Valve Seat
Width
Intake 1.75 - 2.36 mm 0.0698 - 0.0928
in.
Exhaust 1.71 - 2.32 mm 0.0673 - 0.0911
in.
Guide Bore
Diameter (Std.)
6.975 - 7.00
mm
0.2747 - 0.2756
in.
Cylinder Head
Warpage
(Flatness)
0.0508 mm 0.002 in.
OIL PUMP
Metric Standard
Clearance Over
Rotors/End
Face (MAX)
0.095 mm 0.0038 in.
Cover Out - of
-Flat (MAX)
0.025 mm 0.001 in.
Inner and Outer
Rotor Thickness
12.02 mm 0.4731 in.
Outer Rotor to
pocket
(Diametral)
clearance
(MAX)
.235 mm .0093 in.
Outer Rotor
Diameter (MIN)
85.925 mm 0.400 in.
Tip Clearance
Between Rotors
(MAX)
0.150 mm 0.006 in.
DR ENGINE - 3. 7L 9 - 15
OIL PRESSURE
SPECIFICATION SPECIFICATION
Metric Standard
At Curb Idle
Speed (MIN)*
25 kPa 4 psi
@ 3000 rpm 170 - 758 kPa 25 - 110 psi
* CAUTION: If pressure is zero at curb idle, DO
NOT run engine at 3000 rpm.
TORQUE
DESCRIPTION Nm Ft.
Lbs.
In.
Lbs.
Camshaft
Non - Oiled Sprocket Bolt 122 90 -
Bearing Cap Bolts 11 - 100
Counterbalance shaft
retaining bolt
28 - 250
Timing Chain Cover-Bolts 58 43 -
Connecting Rod Cap-Bolts 27 20 -
PLUS 90TURN
Bed Plate-Bolts Refer to Procedure
Crankshaft Damper-Bolt 175 130 -
Cylinder Head-Bolts
M11 Bolts Refer To Procedure
M8 Bolts Refer To Procedure
Cylinder Head Cover-Bolts 12 - 105
Exhaust Manifold-Bolts 25 18 -
Exhaust Manifold Heat
Shield-Nuts
8 - 72
Then loosen 45
DESCRIPTION Nm Ft.
Lbs.
In.
Lbs.
Flexplate-Bolts 95 70 -
Engine Mount Bracket to
Block-Bolts
61 45 -
Rear Mount to Transmission-
Bolts
46 34 -
Generator Mounting-Bolts
M10 Bolts 54 40 -
M8 Bolts 28 - 250
Intake Manifold-Bolts 12 - 105
Refer to Procedure
for Tightening
Sequence
Oil Pan-Bolts 15 - 130
Oil Pan-Drain Plug 34 25 -
Oil Pump-Bolts 28 - 250
Oil Pump Cover-Bolts 12 - 105
Oil Pickup Tube-Bolt and Nut 28 - 250
Oil Dipstick Tube to Engine
Block-Bolt
15 - 130
Oil Fill Tube-Bolts 12 - 105
Timing Chain Guide-Bolts 28 - 250
Timing Chain Tensioner Arm 28 - 250
Hydraulic Tensioner-Bolts 28 - 250
Timing Chain Primary
Tensioner-Bolts
28 - 250
Timing Drive Idler Sprocket-
Bolt
34 25 -
Thermostat Housing-Bolts 12 - 105
Water Pump-Bolts 58 43 -
9 - 16 ENGINE - 3. 7L DR
SPECIAL TOOLS
Spanner Wrench 6958
Adapter Pins 8346
Front Crankshaft Seal Remover 8511
Front Crankshaft Seal Installer 8348
Handle C-4171
Rear Crankshaft Seal Installer 8349
Rear Crankshaft Seal Remover 8506
Connecting Rod Guides 8507
DR ENGINE - 3. 7L 9 - 17
Crankshaft Damper Installer 8512
Puller 1026
Crankshaft Damper Removal Insert 8513
Chain Tensioner Wedge 8379
Chain Tensioner Pins 8514
VALVE SPRING COMPRESSOR 8426
ENGINE LIFTING FIXTURE 8427
CAMSHAFT HOLDER 8428
9 - 18 ENGINE - 3. 7L DR
HOLDER SECONDARY CAMSHAFT CHAIN 8429
Remover, Rocker Arm 8516
Idler Shaft Remover 8517
Valve Spring Compressor Adapters 8519
INSTALLER - REMOVER - COUNTER BALANCE
SHAFT 8641
Valve Spring Tester C-647
Dial Indicator C-3339
Valve Spring Compressor C-3422-B
DR ENGINE - 3. 7L 9 - 19
Bore Size Indicator C-119
Oil Pressure Gauge C-3292
Piston Ring Compressor C-385
Pressure Tester Kit 7700
BlocChekKit C-3685A
ENGINE SUPPORT FIXTURE 8534
9 - 20 ENGINE - 3. 7L DR
AIR CLEANER ELEMENT
REMOVAL
Filter Element Only
Housi ng removal i s not necessary for el ement (fi l -
ter) repl acement.
(1) Loosen cl amp (Fi g. 3) and di sconnect ai r duct
at ai r cl eaner cover.
(2) Pry over 4 spri ng cl i ps (Fi g. 3) from housi ng
cover (spri ng cl i ps retai n cover to housi ng).
(3) Rel ease housi ng cover from l ocati ng tabs on
housi ng (Fi g. 3) and remove cover.
(4) Remove ai r cl eaner el ement (fi l ter) from hous-
i ng.
(5) Cl ean i nsi de of housi ng before repl aci ng el e-
ment.
Housing Assembly
(2) Li ft enti re housi ng assembl y from 4 l ocati ng
pi ns (Fi g. 4).
INSTALLATION
(1) I nstal l fi l ter el ement i nto housi ng.
(2) Posi ti on housi ng cover i nto housi ng l ocati ng
tabs (Fi g. 3).
(3) Pry up 4 spri ng cl i ps (Fi g. 3) and l ock cover to
housi ng.
(4) I nstal l ai r duct to ai r cl eaner cover and ti ghten
hose cl amp to 3 Nm (30 i n. l bs.) torque.
(5) I f any other hose cl amps were removed from
ai r i ntake system, ti ghten them to 3.4 Nm (30 i n.
l bs.) torque.
(6) I f any bol ts were removed from ai r resonator
housi ng or ai r i ntake tubi ng, ti ghten them to 4.5 Nm
(40 i n. l bs.) torque.
CYLINDER HEAD - LEFT
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET
A cyl i nder head gasket l eak can be l ocated between
adjacent cyl i nders or between a cyl i nder and the
adjacent water jacket.
Possi bl e i ndi cati ons of the cyl i nder head gasket
l eaki ng between adjacent cyl i nders are:
Loss of engi ne power
Engi ne mi sfi ri ng
Poor fuel economy
l eaki ng between a cyl i nder and an adjacent water
jacket are:
Engi ne overheati ng
Loss of cool ant
Fig. 3 AIR CLEANER HOUSING COVER
1 - CLAMP
2 - AIR DUCT
3 - AIR CLEANER COVER
4 - LOCATING TABS
5 - CLIPS (4)
Fig. 4 AIR CLEANER HOUSING
1 - AIR CLEANER HOUSING ASSEMBLY
2 - LOCATING PINS (4)
DR ENGINE - 3. 7L 9 - 21
Excessi ve steam (whi te smoke) emi tti ng from
exhaust
Cool ant foami ng
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders, fol l ow the proce-
dures i n Cyl i nder Compressi on Pressure Test (Refer
to 9 - ENGI NE - DI AGNOSI S AND TESTI NG). An
engi ne cyl i nder head gasket l eaki ng between adja-
cent cyl i nders wi l l resul t i n approxi matel y a 50 - 70%
reducti on i n compressi on pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
Wi th the engi ne cool , remove the cool ant pressure
cap. Start the engi ne and al l ow i t to warm up unti l
thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
I nstal l Cool i ng System Tester 7700 or equi val ent to
pressure cap neck. Start the engi ne and observe the
testers pressure gauge. I f gauge pul sates wi th every
power stroke of a cyl i nder a combusti on pressure
l eak i s evi dent.
CHEMICAL TEST METHOD
Combusti on l eaks i nto the cool i ng system can al so
be checked by usi ng Bl oc-Chek Ki t C-3685-A or
equi val ent. Perform test fol l owi ng the procedures
suppl i ed wi th the tool ki t.
REMOVAL
(1) Di sconnect the negati ve cabl e from the battery.
(3) Di sconnect the exhaust pi pe at the l eft si de
exhaust mani fol d.
(4) Drai n the engi ne cool ant(Refer to 7 - COOL-
(6) Remove the i ntake mani fol d(Refer to 9 -
REMOVAL).
(7) Remove the master cyl i nder and booster assem-
bl y(Refer to 5 - BRAKES/HYDRAULI C/MECHANI -
CAL/POWER BRAKE BOOSTER - REMOVAL).
(8) Remove the cyl i nder head cover(Refer to 9 -
ENGI NE/CYLI NDER HEAD/CYLI NDER HEAD
COVER(S) - REMOVAL).
(9) Remove the fan shroud and fan bl ade assem-
bl y(Refer to 7 - COOLI NG/ENGI NE/RADI ATOR FAN
- REMOVAL).
(10) Remove accessory dri ve bel t(Refer to 7 -
REMOVAL).
(11) Remove the power steeri ng pump and set
asi de.
(12) Rotate the crankshaft unti l the damper ti m-
i ng mark i s al i gned wi th TDC i ndi cator mark (Fi g.
5).
(13) Veri fy the V6 mark on the camshaft sprocket
i s at the 12 ocl ock posi ti on (Fi g. 6). Rotate the crank-
shaft one turn i f necessary.
(14) Remove the crankshaft damper(Refer to 9 -
ENGI NE/ENGI NE BLOCK/VI BRATI ON DAMPER -
REMOVAL).
(15) Remove the ti mi ng chai n cover(Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT / CHAI N
Fig. 5 Engine Top Dead Center
2 - CRANKSHAFT TIMING MARKS
9 - 22 ENGINE - 3. 7L DR
CYLINDER HEAD - LEFT (Continued)
(16) Lock the secondary ti mi ng chai ns to the i dl er
sprocket usi ng Speci al Tool 8429 Ti mi ng Chai n Hol d-
i ng Fi xture (Fi g. 7).
NOTE: Mark the secondary timing chain prior to
removal to aid in installation.
(17) Mark the secondary ti mi ng chai n, one l i nk on
each si de of the V6 mark on the camshaft dri ve gear.
(18) Remove the l eft si de secondary chai n ten-
si oner. Refer to Ti mi ng Chai n and Sprockets.
(19) Remove the cyl i nder head access pl ug (Fi g. 8).
Fig. 6 CAMSHAFT SPROCKET V6 MARKS (#1 TDC, Exhaust stroke)
1 - LEFT CYLINDER HEAD
Fig. 7 Using Special Tool 8429
2 - CAMSHAFT CHAIN
3 - CRANKSHAFT TIMING GEAR
Fig. 8 Cylinder Head Access Plugs
1 - RIGHT CYLINDER HEAD ACCESS PLUG
2 - LEFT CYLINDER HEAD ACCESS PLUG
DR ENGINE - 3. 7L 9 - 23
(20) Remove the l eft si de secondary chai n
gui de(Refer to 9 - ENGI NE/VALVE TI MI NG/TI MI NG
BELT/CHAI N AND SPROCKETS - REMOVAL).
(21) Remove the retai ni ng bol t and the camshaft
dri ve gear.
CAUTION: Do not allow the engine to rotate. Severe
damage to the valve train can occur.
CAUTION: Do not overlook the four smaller bolts at
the front of the cylinder head. Do not attempt to
remove the cylinder head without removing these
four bolts.
NOTE: The cylinder head is attached to the cylinder
block with twelve bolts.
(22) Remove the cyl i nder head retai ni ng bol ts.
(23) Remove the cyl i nder head and gasket. Di scard
the gasket.
CAUTION: Do not lay the cylinder head on its gas-
ket sealing surface, due to the design of the cylin-
der head gasket any distortion to the cylinder head
sealing surface may prevent the gasket from prop-
erly sealing resulting in leaks.
INSTALLATION
NOTE: The cylinder head bolts are tightened using
a torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are necked
down the bolts should be replaced.
Necki ng can be checked by hol di ng a strai ght edge
agai nst the threads. I f al l the threads do not contact
the scal e, the bol t shoul d be repl aced (Fi g. 9).
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
only a wooden or plastic scraper.
(1) Cl ean the cyl i nder head and cyl i nder bl ock
mati ng surfaces (Fi g. 10).
(2) Posi ti on the new cyl i nder head gasket on the
l ocati ng dowel s.
CAUTION: When installing cylinder head, use care
not damage the tensioner arm or the guide arm.
(3) Posi ti on the cyl i nder head onto the cyl i nder
bl ock. Make sure the cyl i nder head seats ful l y over
the l ocati ng dowel s.
NOTE: The four smaller cylinder head mounting
bolts require sealant to be added to them before
installing. Failure to do so may cause leaks.
(4) Lubri cate the cyl i nder head bol t threads wi th
cl ean engi ne oi l and i nstal l the ei ght M11 bol ts.
(5) Coat the four M8 cyl i nder head bol ts wi th
Mopar Lock and Seal Adhesive then i nstal l the
bol ts.
an angle torque procedure, however, the bolts are
not a torque-to-yield design.
(6) Ti ghten the bol ts i n sequence usi ng the fol l ow-
i ng steps and torque val ues:
Fig. 9 Checking Cylinder Head Bolts for Stretching
(Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
9 - 24 ENGINE - 3. 7L DR
Step 1: Ti ghten bol ts 1-8, 27 Nm (20 ft. l bs.).
Step 2: Veri fy that bol ts 1-8, al l reached 27 Nm
(20 ft. l bs.), by repeati ng step 1 wi thout l ooseni ng the
bol ts. Ti ghten bol ts 9 thru 12 to 14 Nm (10 ft. l bs.).
Step 3: Ti ghten bol ts 1-8, 90 degrees (Fi g. 11).
Step 4: Ti ghten bol ts 1-8, 90 degrees, agai n.
Ti ghten bol ts 9-12, 26 Nm (19 ft. l bs.)
(7) Posi ti on the secondary chai n onto the camshaft
dri ve gear, maki ng sure one marked chai n l i nk i s on
ei ther si de of the V6 mark on the gear then usi ng
Speci al Tool 8428 Camshaft Wrench, posi ti on the
gear onto the camshaft.
CAUTION: Remove excess oil from camshaft
sprocket retaining bolt before reinstalling bolt. Fail-
ure to do so may cause over-torqueing of bolt
resulting in bolt failure.
(8) I nstal l the camshaft dri ve gear retai ni ng bol t.
(9) I nstal l the l eft si de secondary chai n gui de(Re-
fer to 9 - ENGI NE/VALVE TI MI NG/TI MI NG BELT/
CHAI N AND SPROCKETS - I NSTALLATI ON).
(10) I nstal l the cyl i nder head access pl ug.
(11) Re-set and i nstal l the l eft si de secondary
chai n tensi oner(Refer to 9 - ENGI NE/VALVE TI M-
I NG/TI MI NG BELT/CHAI N AND SPROCKETS -
I NSTALLATI ON).
(12) Remove Speci al Tool 8429.
(13) I nstal l the ti mi ng chai n cover(Refer to 9 -
COVER(S) - I NSTALLATI ON).
(14) I nstal l the crankshaft damper(Refer to 9 -
I NSTALLATI ON). Ti ghten damper bol t 175 Nm (130
Ft. Lbs.).
(16) I nstal l the fan bl ade assembl y and fan shrou-
d(Refer to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
I NSTALLATI ON).
(17) I nstal l the cyl i nder head cover(Refer to 9 -
(18) I nstal l the master cyl i nder and booster assem-
bl y(Refer to 5 - BRAKES/HYDRAULI C/MECHANI -
CAL/POWER BRAKE BOOSTER - I NSTALLATI ON).
(19) I nstal l the i ntake mani fol d(Refer to 9 -
I NSTALLATI ON).
(20) Refi l l the cool i ng system(Refer to 7 - COOL-
(22) I nstal l the exhaust pi pe onto the l eft exhaust
mani fol d.
(24) Connect the negati ve cabl e to the battery.
CAMSHAFT(S)
DESCRIPTION
The camshafts consi st of powdered metal steel
l obes whi ch are si nter-bonded to a steel tube. Four
beari ng journal s are machi ned i nto the camshaft.
Camshaft end pl ay i s control l ed by two thrust wal l s
that border the nose pi ece journal . Engi ne oi l enters
the hol l ow camshafts at the thi rd journal and l ubri -
cates every i ntake l obe rocker through a dri l l ed pas-
sage i n the i ntake l obe.
REMOVAL
CAUTION: When the timing chain is removed and
the cylinder heads are still installed, DO NOT force-
fully rotate the camshafts or crankshaft indepen-
dently of each other. Severe valve and/or piston
damage can occur.
CAUTION: When removing the cam sprocket, timing
chains or camshaft, Failure to use Special Tool
8379 will result in hydraulic tensioner ratchet over
extension, requiring timing chain cover removal to
reset the tensioner ratchet.
(1) Remove cyl i nder head cover(Refer to 9 -
Fig. 11 Cylinder head Tightening Sequence
* - INDICATES SEALANT ON THREADS
DR ENGINE - 3. 7L 9 - 25
(2) Set engi ne to TDC cyl i nder #1, camshaft
sprocket V6 marks at the 12 ocl ock posi ti on.
(3) Mark one l i nk on the secondary ti mi ng chai n
on both si des of the V6 mark on the camshaft
sprocket to ai d i n i nstal l ati on.
CAUTION: Do not hold or pry on the camshaft tar-
get wheel (Located on the right side camshaft
sprocket) for any reason, Severe damage will occur
to the target wheel resulting in a vehicle no start
condition.
(4) Loosen but DO NOT remove the camshaft
sprocket retai ni ng bol t. Leave the bol t snug agai nst
the sprocket.
NOTE: The timing chain tensioners must be
secured prior to removing the camshaft sprockets.
Failure to secure tensioners will allow the tension-
ers to extend, requiring timing chain cover removal
in order to reset tensioners.
CAUTION: Do not force wedge past the narrowest
point between the chain strands. Damage to the
tensioners may occur.
(5) Posi ti on Speci al Tool 8379 ti mi ng chai n wedge
between the ti mi ng chai n strands, tap the tool to
securel y wedge the ti mi ng chai n agai nst the ten-
si oner arm and gui de (Fi g. 12).
(6) Hol d the camshaft wi th Speci al Tool 8428 Cam-
shaft Wrench, whi l e removi ng the camshaft sprocket
bol t and sprocket (Fi g. 13).
(7) Usi ng Speci al Tool 8428 Camshaft Wrench,
gentl y al l ow the camshaft to rotate 5 cl ockwi se unti l
the camshaft i s i n the neutral posi ti on (no val ve
l oad).
(8) Starti ng at the outsi de worki ng i nward, l oosen
the camshaft beari ng cap retai ni ng bol ts 1/2 turn at
a ti me. Repeat unti l al l l oad i s off the beari ng caps.
CAUTION: DO NOT STAMP OR STRIKE THE CAM-
SHAFT BEARING CAPS. SEVERE DAMAGE WILL
OCCUR TO THE BEARING CAPS.
NOTE: When the camshaft is removed the rocker
arms may slide downward, mark the rocker arms
before removing camshaft.
(9) Remove the camshaft beari ng caps and the
camshaft.
Fig. 12 SECURING TIMING CHAIN TENSIONERS
USING TIMING CHAIN WEDGE - Typical
2 - CAMSHAFT SPROCKET
3 - CAMSHAFT SPROCKET BOLT
4 - CYLINDER HEAD
Fig. 13 Special Tool 8428
1 - Camshaft hole
2 - Special Tool 8428
9 - 26 ENGINE - 3. 7L DR
CAMSHAFT(S) (Continued)
INSTALLATION
(1) Lubri cate camshaft journal s wi th cl ean engi ne
oi l .
NOTE: Position the left side camshaft so that the
camshaft sprocket dowel is near the 1 oclock posi-
tion, This will place the camshaft at the neutral
position easing the installation of the camshaft
bearing caps.
(2) Posi ti on the camshaft i nto the cyl i nder head.
(3) I nstal l the camshaft beari ng caps, hand ti ghten
NOTE: Caps should be installed so that the
stamped numbers on the caps are in numerical
order, ( 1 thru 4 ) from the front to the rear of the
engine. All caps should be installed so that the
stamped arrows on the caps point toward the front
of the engine.
(4) Worki ng i n 1/2 turn i ncrements, ti ghten the
beari ng cap retai ni ng bol ts starti ng wi th the mi ddl e
cap worki ng outward (Fi g. 14).
(5) Torque the camshaft beari ng cap retai ni ng
bol ts to 11 Nm (100 i n. l bs.).
(6) Posi ti on the camshaft dri ve gear i nto the ti m-
i ng chai n al i gni ng the V6 mark between the two
marked chai n l i nks (Two l i nks marked duri ng
removal ).
rotate the camshaft unti l the camshaft sprocket
dowel i s al i gned wi th the sl ot i n the camshaft
sprocket. I nstal l the sprocket onto the camshaft.
sprocket bolt. Failure to do so can cause bolt over-
torque resulting in bolt failure.
(8) Remove excess oi l from bol t, then i nstal l the
camshaft sprocket retai ni ng bol t and hand ti ghten.
(9) Remove Speci al Tool 8379 ti mi ng chai n wedge.
(10) Usi ng Speci al Tool 6958 spanner wrench wi th
adapter pi ns 8346, torque the camshaft sprocket
retai ni ng bol t to 122 Nm (90 ft. l bs.).
DESCRIPTION
The cyl i nder head covers are made of si ngl e l ayer
stamped steel , and are not i nterchangabl e from si de-
to-si de (Fi g. 15).
Fig. 14 CAMSHAFT BEARING CAPS TIGHTENING
Fig. 15 CYLINDER HEAD COVERS
1 - LEFT SIDE CYLINDER HEAD COVER
2 - RIGHT SIDE CYLINDER HEAD COVER
DR ENGINE - 3. 7L 9 - 27
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) Remove the resonator assembl e and ai r i nl et hose.
(3) Di sconnect i njector connectors and un-cl i p the
i njector harness.
(4) Route i njector harness i n front of cyl i nder head
cover.
(5) Di sconnect the l eft si de breather tube and
remove the breather tube.
(6) Remove the cyl i nder head cover mounti ng bol ts
(Fi g. 16).
(7) Remove cyl i nder head cover and gasket.
NOTE: The gasket may be used again, providing no
cuts, tears, or deformation has occurred.
INSTALLATION
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
NOTE: The gasket may be used again, provided no
(1) Cl ean cyl i nder head cover and both seal i ng sur-
faces. I nspect and repl ace gasket as necessary.
(2) Ti ghten cyl i nder head cover bol ts and doubl e
ended studs to 12 Nm (105 i n. l bs.).
(3) I nstal l l eft si de breather and connect breather
tube.
(4) Connect i njector el ectri cal connectors and i njec-
tor harness retai ni ng cl i ps.
(5) I nstal l the resonator and ai r i nl et hose.
(6) Connect negati ve cabl e to battery.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The val ves are made of heat resi stant steel and
have chrome pl ated stems to prevent scuffi ng. Each
val ve i s actuated by a rol l er rocker arm whi ch pi vots
on a stati onary l ash adjuster. Al l val ves use three
bead l ock keepers to retai n the spri ngs and promote
val ve rotati on.
STANDARD PROCEDURE - REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
NOTE: When refacing valves and valve seats, it is
important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.
(1) Usi ng a sui tabl e di al i ndi cator measure the
center of the val ve seat Total run out must not
exceed 0.051 mm (0.002 i n).
(2) Appl y a smal l amount of Prussi an bl ue to the
val ve seat, i nsert the val ve i nto the cyl i nder head,
whi l e appl yi ng l i ght pressure on the val ve rotate the
val ve. Remove the val ve and exami ne the val ve face.
I f the bl ue i s transferred bel ow the top edge of the
val ve face, l ower the val ve seat usi ng a 15 degree
stone. I f the bl ue i s transferred to the bottom edge of
the val ve face, rai se the val ve seat usi ng a 65 degree
stone.
(3) When the seat i s properl y posi ti oned the wi dth
of the i ntake seat must be 1.75 - 2.36 mm (0.0689 -
0.0928 i n.) and the exhaust seat must be 1.71 - 2.32
mm (0.0673 - 0.0911 i n.).
(4) Check the val ve spri ng i nstal l ed hei ght after
refaci ng the val ve and seat. The i nstal l ed hei ght for
both i ntake and exhaust val ve spri ngs must not
exceed 40.74 mm (1.6039 i n.).
Fig. 16 CYLINDER HEAD COVER - TYPICAL
1 - SCREWS
2 - CYLINDER HEAD COVER
9 - 28 ENGINE - 3. 7L DR
CYLINDER HEAD COVER(S) (Continued)
(5) The val ve seat and val ve face must mai ntai n a
face angl e of 44.5 - 45 angl e (Fi g. 17).
REMOVAL
NOTE: The cylinder heads must be removed in
order to perform this procedure.
(1) Remove rocker arms and l ash adjusters(Refer
to 9 - ENGI NE/CYLI NDER HEAD/ROCKER ARM /
ADJUSTER ASSY - REMOVAL). (Fi g. 18).
camshaft.
NOTE: All six valve springs and valves are removed
in the same manner; this procedure only covers
one valve and valve spring.
(3) Usi ng Speci al Tool C-3422B or C-3422C
Val ve Spri ng Compressor and Speci al tool 8519
Adapter, compress the val ve spri ng.
NOTE: It may be necessary to tap the top of the
valve spring to loosen the spring retainers locks
enough to be removed.
(4) Remove the two spri ng retai ner l ock hal ves.
NOTE: the valve spring is under tension use care
when releasing the valve spring compressor.
(5) Remove the val ve spri ng compressor.
(6) Remove the spri ng retai ner, and the spri ng.
NOTE: Check for sharp edges on the keeper
grooves. Remove any burrs from the valve stem
before removing the valve from the cylinder head.
(7) Remove the val ve from the cyl i nder head.
NOTE: The valve stem seals are common between
intake and exhaust.
(8) Remove the val ve stem seal . Mark the val ve for
proper i nstal l ati on.
Fig. 17 Valve Assembly Configuration
1 - VALVE LOCKS (3BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 18 Rocker Arm Removal
1 - CAMSHAFT
DR ENGINE - 3. 7L 9 - 29
INTAKE/EXHAUST VALVES & SEATS (Continued)
TESTING VALVE SPRINGS
NOTE: Whenever the valves are removed from the
cylinder head it is recommended that the valve
springs be inspected and tested for reuse.
I nspect the val ve spri ngs for physi cal si gns of wear or
damage. Turn tabl e of tool C-647 unti l surface i s i n l i ne
wi th the 40.12 mm (1.579 i n.) mark on the threaded
stud and the zero mark on the front. Pl ace spri ng over
the stud on the tabl e and l i ft compressi ng l ever to set
tone devi ce. Pul l on torque wrench unti l a Pi ng i s
heard. Take readi ng on torque wrench at thi s i nstant.
Mul ti pl y thi s readi ng by two. Thi s wi l l gi ve the spri ng
l oad at test l ength. Fracti onal measurements are i ndi -
cated on the tabl e for fi ner adjustments. Refer to Spec-
i fi cati ons Secti on to obtai n speci fi ed hei ght and
al l owabl e tensi ons. Repl ace any spri ngs that do not
meet speci fi cati ons (Fi g. 19).
INSTALLATION
(1) coat the val ve stem wi th cl ean engi ne oi l and
i nsert i t i nto the cyl i nder head.
(2) I nstal l the val ve stem seal . make sure the seal
i s ful l y seated and that the garter spri ng at the top
of the seal i s i ntact.
(3) I nstal l the spri ng and the spri ng retai ner (Fi g.
20).
(4) Usi ng the val ve spri ng compressor, compress
the spri ng and i nstal l the two val ve spri ng retai ner
hal ves.
(5) Rel ease the val ve spri ng compressor and make
sure the two spri ng retai ner hal ves and the spri ng
retai ner are ful l y seated.
(6) l ubri cate the camshaft journal wi th cl ean
engi ne oi l then Posi ti on the camshaft (wi th the
sprocket dowel on the l eft camshaft at 11 ocl ock and
the ri ght camshaft at 12 ocl ock), then posi ti on the
camshaft beari ng caps.
(7) I nstal l the camshaft beari ng cap retai ni ng
bol ts. Ti ghten the bol ts 9-13 Nm (100 i n. l bs.) i n 1/2
turn i ncrements i n the sequence shown (Fi g. 21).
(8) Posi ti on the hydraul i c l ash adjusters and rocker
arms(Refer to 9 - ENGI NE/CYLI NDER HEAD/ROCKER
ARM /ADJUSTER ASSY - I NSTALLATI ON).
Fig. 19 Testing Valve Springs
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 21 Camshaft Bearing Caps Tightening
Sequence
9 - 30 ENGINE - 3. 7L DR
ROCKER ARM
DESCRIPTION
The rocker arms are steel stampi ngs wi th an i nte-
gral rol l er beari ng. The rocker arms i ncorporate a 2.8
mm (0.11 i nch) oi l hol e i n the l ash adjuster socket for
rol l er and camshaft l ubri cati on.
REMOVAL
NOTE: Disconnect the battery negative cable to pre-
vent accidental starter engagement.
(1) Remove the cyl i nder head cover (Refer to 9 -
(2) For rocker arm removal on cyl i nder No. 4,
Rotate the crankshaft unti l cyl i nder No. 1 i s at BDC
i ntake stroke.
combusti on stroke.
(4) For rocker arm removal on cyl i nders No. 3 and
No. 5, Rotate the crankshaft unti l cyl i nder No. 1 i s at
TDC exhaust stroke.
TDC i gni ti on stroke.
(6) Usi ng speci al tool 8516 Rocker Arm Remover,
press downward on the val ve spri ng, remove rocker
arm (Fi g. 22).
INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil
prior to installation.
(1) For rocker arm i nstal l ati on on cyl i nders No. 4,
i ntake stroke.
(2) For rocker arm i nstal l ati on on cyl i nder No. 1,
combusti on stroke.
(3) For rocker arm i nstal l ati on on cyl i nders No. 3
and No. 5, Rotate the crankshaft unti l cyl i nder No. 1
i s at TDC exhaust stroke.
(4) For rocker arm i nstal l ati on on cyl i nders No. 2
and No. 6, Rotate the crankshaft unti l cyl i nder No. 1
i s at TDC i gni ti on stroke.
(5) Usi ng speci al tool 8516 press downward on the
val ve spri ng, i nstal l rocker arm (Fi g. 23).
(6) I nstal l the cyl i nder head cover (Refer to 9 -
Fig. 22 Rocker Arm - Removal
1 - CAMSHAFT
Fig. 23 Rocker Arm - Installation
1 - CAMSHAFT
DR ENGINE - 3. 7L 9 - 31
VALVE GUIDE SEALS
DESCRIPTION
The val ve gui de seal s are made of rubber and
i ncorporate an i ntegral steel val ve spri ng seat. The
i ntegral garter spri ng mai ntai ns consi stent l ubri ca-
ti on control to the val ve stems.
VALVE SPRINGS
DESCRIPTION
The val ve spri ngs are made from hi gh strength
chrome si l i con steel . The spri ngs are NOT common
for i ntake and exhaust appl i cati ons. The exhaust
spri ng has an external damper. The val ve spri ng seat
i s i ntegral wi th the val ve stem seal , whi ch i s a posi -
ti ve type seal to control l ubri cati on.
REMOVAL
(2) Usi ng Speci al Tool 8516 Val ve Spri ng Compres-
sor, remove the rocker arms and the hydraul i c l ash
adjusters.
(3) Remove the spark pl ug for the cyl i nder the
val ve spri ng and seal are to be removed from.
(4) Appl y shop ai r to the cyl i nder to hol d the
val ves i n pl ace when the spri ng i s removed.
NOTE: All six valve springs and seals are removed
one valve seal and valve spring.
sor, compress the val ve spri ng.
NOTE: The valve springs are NOT common between
intake and exhaust.
(9) Remove the val ve stem seal .
intake and exhaust.
INSTALLATION
val ves i n pl ace whi l e the spri ng i s i nstal l ed.
intake and exhaust.
(2) I nstal l the val ve stem seal .
intake and exhaust.
(3) I nstal l the spri ng retai ner, and the spri ng.
(5) I nstal l the two spri ng retai ner l ock hal ves.
(7) Di sconnect the shop ai r to the cyl i nder.
(8) I nstal l the spark pl ug for the cyl i nder the val ve
spri ng and seal was i nstal l ed on.
sor, i nstal l the rocker arms and the hydraul i c l ash
adjusters.
CYLINDER HEAD - RIGHT
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER
A tappet-l i ke noi se may be produced from several
i tems. Check the fol l owi ng i tems.
(1) Engi ne oi l l evel too hi gh or too l ow. Thi s may
cause aerated oi l to enter the adjusters and cause
them to be spongy.
(2) I nsuffi ci ent runni ng ti me after rebui l di ng cyl i n-
der head. Low speed runni ng up to 1 hour may be
requi red.
(3) Turn engi ne off and l et set for a few mi nutes
before restarti ng. Repeat thi s several ti mes after
engi ne has reached normal operati ng temperature.
(4) Low oi l pressure.
(5) The oi l restri ctor i n cyl i nder head gasket or the
oi l passage to the cyl i nder head i s pl ugged wi th
debri s.
9 - 32 ENGINE - 3. 7L DR
(6) Ai r i ngested i nto oi l due to broken or cracked
oi l pump pi ck up.
(7) Worn val ve gui des.
(8) Rocker arm ears contacti ng val ve spri ng
retai ner.
(9) Rocker arm l oose, adjuster stuck or at maxi -
mum extensi on and sti l l l eaves l ash i n the system.
(10) Oi l l eak or excessi ve cam bore wear i n cyl i n-
der head.
(11) Faul ty l ash adjuster.
a. Check l ash adjusters for spongi ness whi l e
i nstal l ed i n cyl i nder head and cam on camshaft at
base ci rcl e. Depress part of rocker arm over adjuster.
Normal adjusters shoul d feel very fi rm. Spongy
adjusters can be bottomed out easi l y.
b. Remove suspected l ash adjusters, and repl ace.
c. Before i nstal l ati on, make sure adjusters are at
l east parti al l y ful l of oi l . Thi s can be veri fi ed by l i ttl e
or no pl unger travel when l ash adjuster i s depressed.
REMOVAL
(1) Di sconnect battery negati ve cabl e.
(3) Di sconnect the exhaust pi pe at the ri ght si de
exhaust mani fol d.
(4) Drai n the engi ne cool ant(Refer to 7 - COOL-
(6) Remove the i ntake mani fol d(Refer to 9 -
REMOVAL).
ENGI NE/CYLI NDER HEAD - REMOVAL).
(8) Remove the fan shroud(Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR FAN - REMOVAL).
(9) Remove oi l fi l l housi ng from cyl i nder head.
(10) Remove accessory dri ve bel t(Refer to 7 -
REMOVAL).
(11) Rotate the crankshaft unti l the damper ti mi ng
mark i s al i gned wi th TDC i ndi cator mark.
i s at the 12 ocl ock posi ti on. Rotate the crankshaft
one turn i f necessary.
(13) Remove the crankshaft damper(Refer to 9 -
REMOVAL).
sprocket usi ng Speci al Tool 8429 Ti mi ng Chai n Hol d-
i ng Fi xture.
each si de of the V6 mark on the camshaft dri ve gear.
(17) Remove the ri ght si de secondary chai n ten-
si oner(Refer to 9 - ENGI NE/VALVE TI MI NG/TI M-
I NG BELT/CHAI N AND SPROCKETS - REMOVAL).
(18) Remove the cyl i nder head access pl ug.
(19) Remove the ri ght si de secondary chai n
gui de(Refer to 9 - ENGI NE/VALVE TI MI NG/TI MI NG
CAUTION: The nut on the right side camshaft
sprocket should not be removed for any reason, as
the sprocket and camshaft sensor target wheel is
serviced as an assembly. If the nut was removed,
torque nut to 5 Nm (44 in. lbs.).
dri ve gear.
CAUTION: Do not allow the engine to rotate. severe
four bolts.
get wheel for any reason. A damaged target wheel
can result in a vehicle no start condition.
block with twelve bolts.
the gasket.
ket sealing surface, do to the design of the cylinder
head gasket any distortion to the cylinder head
DR ENGINE - 3. 7L 9 - 33
CYLINDER HEAD - RIGHT (Continued)
INSTALLATION
agai nst the threads (Fi g. 24). I f al l the threads do not
contact the scal e, the bol t shoul d be repl aced.
l ocati ng dowel s.
NOTE: The four M8 cylinder head mounting bolts
require sealant to be added to them before install-
ing. Failure to do so may cause leaks.
cl ean engi ne oi l and i nstal l the ei ght M10 bol ts.
(5) Coat the four M8 cyl i nder head bol ts wi th Mopar
Lock and Seal Adhesive then i nstal l the bol ts.
(6) Ti ghten the bol ts i n sequence usi ng the fol l ow-
i ng steps and torque val ues:
Step 1: Ti ghten bol ts 1-8, 27 Nm (20 ft. l bs.).
Step 2: Veri fy that bol ts 1-8, al l reached 27 Nm
(20 ft. l bs.), by repeati ng step 1 wi thout l ooseni ng the
bol ts. Ti ghten bol ts 9 thru 12 to 14 Nm (10 ft. l bs.).
Step 3: Ti ghten bol ts 1-8, 90 (Fi g. 26).
Step 4: Ti ghten bol ts 1-8, 90 , agai n. Ti ghten
bol ts 9-12, 26 Nm (19 ft. l bs.)
(Necking)
1 - STRETCHED BOLT
Fig. 26 Cylinder Head Tightening Sequence
* - INDICATES SEALANT ON THREADS
9 - 34 ENGINE - 3. 7L DR
CAUTION: The nut on the right side camshaft
sprocket should not be removed for any reason, as
the sprocket and camshaft sensor target wheel is
serviced as an assembly. If the nut was removed,
torque nut to 5 NM ( 60 in. lbs.).
ei ther si de of the V6 mark on the gear then usi ng
Speci al Tool 8428 Camshaft Wrench, posi ti on the
gear onto the camshaft.
ure to do so may cause over-torquing of bolt result-
ing in bolt failure.
(9) I nstal l the ri ght si de secondary chai n gui de(Re-
fer to 9 - ENGI NE/VALVE TI MI NG/TI MI NG BELT/
(10) I nstal l the cyl i nder head access pl ug.
(11) Re-set and i nstal l the ri ght si de secondary
chai n tensi oner(Refer to 9 - ENGI NE/VALVE TI M-
I NSTALLATI ON).
(14) I nstal l the crankshaft damper(Refer to 9 -
I NSTALLATI ON). Ti ghten damper bol t 175 Nm (130
Ft. Lbs.).
(15) I nstal l accessory dri ve bel t(Refer to 7 - COOL-
LATI ON).
(16) I nstal l the fan shroud(Refer to 7 - COOLI NG/
(18) I nstal l the i ntake mani fol d(Refer to 9 -
I NSTALLATI ON).
(19) I nstal l oi l fi l l housi ng onto cyl i nder head.
(20) Refi l l the cool i ng system(Refer to 7 - COOL-
(22) I nstal l the exhaust pi pe onto the ri ght
exhaust mani fol d.
(24) Reconnect battery negati ve cabl e.
CAMSHAFT(S)
DESCRIPTION
l obes whi ch are si nter-bonded to a steel tube. Four
beari ng journal s are machi ned i nto the camshaft.
that border the nose pi ece journal . Engi ne oi l enters
the hol l ow camshafts at the thi rd journal and l ubri -
cates every i ntake l obe rocker through a dri l l ed pas-
sage i n the i ntake l obe.
REMOVAL
damage can occur.
chains or camshaft, Failure to use special tool 8379
will result in hydraulic tensioner ratchet over exten-
sion, Requiring timing chain cover removal to re-set
the tensioner ratchet.
(2) Set engi ne to TDC cyl i nder No. 1, camshaft
get wheel for any reason, Severe damage will occur
to the target wheel. A damaged target wheel could
cause a vehicle no start condition.
sprocket retai ni ng bol t. Leave bol t snug agai nst
sprocket.
DR ENGINE - 3. 7L 9 - 35
between the ti mi ng chai n strands. Tap the tool to
si oner arm and gui de.
(6) Remove the camshaft posi ti on sensor.
(7) Hol d the camshaft wi th Speci al Tool 8428 Cam-
shaft Wrench, whi l e removi ng the camshaft sprocket
bol t and sprocket.
camshaft.
INSTALLATION
oi l .
NOTE: Position the right side camshaft so that the
camshaft sprocket dowel is near the 10 oclock
position, This will place the camshaft at the neutral
bearing caps.
NOTE: Caps should be installed so that the
stamped numbers on the caps are in numerical
order, ( 1 thru 4 ) from the front to the rear of the
engine. All caps should be installed so that the
stamped arrows on the caps point toward the front
of the engine.
removal ).
rotate the camshaft unti l the camshaft sprocket
dowel i s al i gned wi th the sl ot i n the camshaft
sprocket . I nstal l the sprocket onto the camshaft.
(8) Remove excess oi l from camshaft sprocket bol t,
then i nstal l the camshaft sprocket retai ni ng bol t and
hand ti ghten.
(9) Remove ti mi ng chai n wedge speci al tool 8379.
adapter pi ns 8346, torque the camshaft sprocket
(11) I nstal l the camshaft posi ti on sensor.
Fig. 27 CAMSHAFT BEARING CAPS TIGHTENING
9 - 36 ENGINE - 3. 7L DR
REMOVAL
(2) Remove ai r cl eaner assembl y, resonator assem-
bl y and ai r i nl et hose.
(3) Drai n cool i ng system, bel ow the l evel of the
heater hoses(Refer to 7 - COOLI NG - STANDARD
PROCEDURE).
(4) Remove accessory dri ve bel t(Refer to 7 - COOL-
I NG/ACCESSORY DRI VE/DRI VE BELTS - REMOVAL).
(5) Remove ai r condi ti oni ng compressor retai ni ng
bol ts and move compressor to the l eft.
(7) Di sconnect i njector and i gni ti on coi l connectors.
(8) Di sconnect and remove posi ti ve crankcase ven-
ti l ati on (PCV) hose.
(9) Remove oi l fi l l tube.
(10) Un-cl i p i njector and i gni ti on coi l harness and
move away from cyl i nder head cover.
(11) Remove ri ght rear breather tube and fi l ter
assembl y.
(12) Remove cyl i nder head cover retai ni ng bol ts.
(13) Remove cyl i nder head cover.
INSTALLATION
may occur.
ended studs to 12 Nm (105 i n. l bs).
(3) I nstal l ri ght rear breather tube and fi l ter
assembl y.
(4) Connect i njector, i gni ti on coi l el ectri cal connec-
tors and harness retai ni ng cl i ps.
(5) I nstal l the oi l fi l l tube.
(6) I nstal l PCV hose.
(8) I nstal l ai r condi ti oni ng compressor retai ni ng
bol ts.
(9) I nstal l accessory dri ve bel t(Refer to 7 - COOL-
LATI ON).
(10) Fi l l Cool i ng system(Refer to 7 - COOLI NG -
(11) I nstal l ai r cl eaner assembl y, resonator assem-
ROCKER ARM
DESCRIPTION
REMOVAL
i ntake stroke.
combusti on stroke.
TDC exhaust stroke.
TDC i gni ti on stroke.
arm (Fi g. 28).
Fig. 28 Rocker Arm - Removal
1 - CAMSHAFT
DR ENGINE - 3. 7L 9 - 37
VALVE GUIDE SEALS
DESCRIPTION
VALVE SPRINGS
DESCRIPTION
chrome si l i con steel . There are di fferent spri ngs for
i ntake and exhaust appl i cati ons. The exhaust spri ng
has an external damper. The val ve spri ng seat i s
i ntegral wi th the val ve stem seal , whi ch i s a posi ti ve
type seal to control l ubri cati on.
REMOVAL
sor, remove the rocker arms and the hydraul i c l ash
adjusters.
val ves i n pl ace when the spri ng i s removed.
intake and exhaust.
intake and exhaust.
INSTALLATION
val ves i n pl ace whi l e the spri ng i s i nstal l ed.
intake and exhaust.
(2) I nstal l the val ve stem seal .
intake and exhaust.
(3) I nstal l the spri ng retai ner, and the spri ng.
(5) I nstal l the two spri ng retai ner l ock hal ves.
(7) Di sconnect the shop ai r to the cyl i nder.
(8) I nstal l the spark pl ug for the cyl i nder the val ve
spri ng and seal was i nstal l ed on.
sor, i nstal l the rocker arms and the hydraul i c l ash
adjusters.
ENGINE BLOCK
DESCRIPTION
The cyl i nder bl ock i s made of cast i ron. The bl ock
i s a cl osed deck desi gn wi th the l eft bank forward. To
provi de hi gh ri gi di ty and i mproved NVH an
enhanced compacted graphi te bedpl ate i s bol ted to
the bl ock. The bl ock desi gn al l ows cool ant fl ow
between the cyl i nders bores, and an i nternal cool ant
bypass to a si ngl e poppet i nl et thermostat i s i ncl uded
i n the cast al umi num front cover.
HONING
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823, equi pped wi th 220 gri t stones, i s the best tool
9 - 38 ENGINE - 3. 7L DR
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round, as wel l as removi ng l i ght
scuffi ng, scori ng and scratches. Usual l y, a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). about 20-60
strokes, dependi ng on the bore condi ti on, wi l l be suf-
fi ci ent to provi de a sati sfactory surface. Usi ng honi ng
oi l C-3501-3880, or a l i ght honi ng oi l , avai l abl e from
major oi l di stri butors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 50 to 60
for proper seati ng of ri ngs (Fi g. 29).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50 to 60
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
The gal l ey at the oi l fi l ter adaptor hol e.
The front and rear oi l gal l ey hol es.
The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Locti te PST pi pe seal ant wi th Tefl on 592 to the
threads of the front and rear oi l gal l ey pl ugs. Ti ghten
the 1/4 i nch NPT pl ugs to 20 Nm (177 i n. l bs.)
torque. Ti ghten the 3/8 i nch NPT pl ugs to 27 Nm
INSPECTION
(1) I t i s mandatory to use a di al bore gauge to
measure each cyl i nder bore di ameter. To correctl y
sel ect the proper si ze pi ston, a cyl i nder bore gauge,
capabl e of readi ng i n 0.003 mm (.0001 i n.) I NCRE-
MENTS i s requi red. I f a bore gauge i s not avai l abl e,
do not use an i nsi de mi crometer (Fi g. 30).
Fig. 29 CYLINDER BORE CROSSHATCH PATTERN
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
Fig. 30 BORE GAUGE-TYPICAL
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM (1.5 in)
DR ENGINE - 3. 7L 9 - 39
ENGINE BLOCK (Continued)
(2) Measure the i nsi de di ameter of the cyl i nder
bore at three l evel s bel ow top of bore. Start perpen-
di cul ar (across or at 90 degrees) to the axi s of the
crankshaft and then take two addi ti onal readi ng.
(3) Measure the cyl i nder bore di ameter crosswi se
to the cyl i nder bl ock near the top of the bore. Repeat
the measurement near the mi ddl e of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determi ne taper by subtracti ng the smal l er
di ameter from the l arger di ameter.
(5) Rotate measuri ng devi ce 90 and repeat steps
above.
(6) Determi ne out-of-roundness by compari ng the
di fference between each measurement.
(7) I f cyl i nder bore taper does not exceed 0.025
mm (0.001 i nch) and out-of-roundness does not
exceed 0.025 mm (0.001 i nch), the cyl i nder bore can
be honed. I f the cyl i nder bore taper or out- of-round
condi ti on exceeds these maxi mum l i mi ts, the cyl i nder
bl ock must be repl aced. A sl i ght amount of taper
al ways exi sts i n the cyl i nder bore after the engi ne
has been i n use for a peri od of ti me.
CRANKSHAFT
DESCRIPTION
The crankshaft i s constructed of nodul ar cast i ron.
The crankshaft i s a three throw spl i t pi n desi gn wi th
si x counterwei ghts for bal anci ng purposes. The
crankshaft i s supported by four sel ect fi t mai n bear-
i ngs wi th the No. 2 servi ng as the thrust washer
l ocati on. The mai n journal s of the crankshaft are
cross dri l l ed to i mprove rod beari ng l ubri cati on. The
No. 6 counterwei ght has provi si ons for crankshaft
posi ti on sensor target wheel mounti ng. The sel ect fi t
mai n beari ng marki ngs are l ocated on the rear si de
of the target wheel (Fi g. 31). The crankshaft oi l seal s
are one pi ece desi gn. The front oi l seal i s retai ned i n
the ti mi ng chai n cover, and the rear seal i s pressed
i n to a bore formed by the cyl i nder bl ock and the
bedpl ate assembl y.
REMOVAL
NOTE: To remove the crankshaft from the engine,
the engine must be removed from the vehicle.
(1) Remove the engi ne(Refer to 9 - ENGI NE -
REMOVAL).
(2) Remove the engi ne oi l pump(Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PUMP - REMOVAL).
CAUTION: DO NOT pry on the oil pan gasket when
removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when removing oil pan.
Gasket can not be removed with oil pan.
(3) Remove the bedpl ate mounti ng bol ts. Note the
l ocati on of the two stud bol ts for i nstal l ati on.
(4) Remove the connecti ng rods from the crank-
shaft.
CAUTION: The bedplate to cylinder block mating
surface is a critical sealing surface. Do not pry on
or damage this surface in anyway.
NOTE: The bedplate contains the lower main bear-
ing halves. Use care when handling bedplate as not
to drop or damage bearing halves. Installing main
bearing halves in the wrong position will cause
severe damage to the crankshaft.
Fig. 31 CRANKSHAFT AND TARGET RING
1 - CRANKSHAFT
2 - CRANKSHAFT POSITION SENSOR TARGET RING
9 - 40 ENGINE - 3. 7L DR
NOTE: The bedplate has pry points cast into it. Use
these points only. The pry points are shown below.
(5) Careful l y pry on the pry poi nts (Fi g. 32) to
l oosen the bedpl ate then remove the bedpl ate.
CAUTION: When removing the crankshaft, use care
not to damage bearing surfaces on the crankshaft.
(6) Remove the crankshaft.
(7) Remove the crankshaft tone wheel .
INSPECTION
NOTE: Thoroughly inspect the connecting rod bear-
ing bores and main bearing bores for scoring, blue-
ing or severe scratches. Further disassembly may
be required.
I f connecti ng rod beari ng bores show damage, the
cyl i nder heads must be removed to servi ce the pi ston
and rod assembl i es. I f the bedpl ate or the cyl i nder
bl ock mai n beari ng bores show damage the engi ne
must be repl aced.
(1) I f requi red, remove the mai n beari ng hal ves
from the cyl i nder bl ock and bedpl ate.
(2) Thoroughl y cl ean the bedpl ate to cyl i nder bl ock
seal i ng surfaces and mai n beari ng bores. Remove al l
oi l and seal ant resi due.
(3) I nspect the bedpl ate mai n beari ng bores for
cracks, scori ng or severe bl uei ng. I f ei ther condi ti on
exi sts the engi ne must be repl aced.
(4) I nspect the crankshaft thrust washers for scor-
i ng, scratches, wear or bl uei ng. I f ei ther condi ti on
exi st repl ace the thrust washers.
(5) I nspect the oi l pan gasket/wi ndage tray for
spl i ts, tears or cracks i n the gasket seal i ng surfaces.
Repl ace gasket as necessary.
Fig. 32 BEDPLATE PRY POINT LOCATION
DR ENGINE - 3. 7L 9 - 41
CRANKSHAFT (Continued)
INSTALLATION
CAUTION: Main bearings are select fit. Refer to
Crankshaft Main Bearings in this section for proper
bearing selections.
CAUTION: When installing crankshaft, use care not
to damage bearing surfaces on the crankshaft.
NOTE: Apply sealant to the tone wheel retaining
screws prior to installation.
(1) Lubri cate upper mai n beari ng hal ves wi th
cl ean engi ne oi l .
(2) I nstal l the crankshaft tone wheel . Torque the
mounti ng screws to 15 Nm (11 ft. l bs.).
(3) Posi ti on crankshaft i n cyl i nder bl ock.
(4) I nstal l the thrust washers (Fi g. 33).
surface must be coated with Mopar Engine RTV
sealant prior to installation. Failure to do so will
cause severe oil leaks.
NOTE: Make sure that the bedplate and cylinder block
sealing surfaces are clean and free of oil or other con-
taminants. Contaminants on the sealing surfaces may
cause main bearing distortion and/or oil leaks.
(5) Appl y a 2.5mm (0.100 i nch) bead of Mopar
Engi ne RTV seal ant to the cyl i nder bl ock-to-bedpl ate
mati ng surface as shown (Fi g. 34).
(6) Coat the crankshaft mai n beari ng journal s
wi th cl ean engi ne oi l and posi ti on the bedpl ate onto
the cyl i nder bl ock.
Fig. 33 Crankshaft Thrust Washer Installation
1 - CRANKSHAFT THRUST WASHER
Fig. 34 BEDPLATE SEALANT
1 - CYLINDER BLOCK
2 - SEALENT
3 - SEALANT
9 - 42 ENGINE - 3. 7L DR
NOTE: Lubricate the bedplate retaining bolts with
clean engine oil prior to installation.
(7) I nstal l the bedpl ate retai ni ng bol ts, maki ng
sure to pl ace the stud bol ts i n the correct l ocati on,
Torque the bol ts i n the sequence shown (Fi g. 35).
Hand ti ghten bol ts 1D,1G and 1F unti l the bed-
pl ate contacts the bl ock.
Ti ghten bol ts 1A - 1J to 54 Nm (40 ft. l bs.)
Ti ghten bol ts 1 - 8 to 7 Nm (5 ft. l bs.)
Turn bol ts 1 - 8 an addi ti onal 90.
Ti ghten bol ts A - E 27 Nm ( 20 ft. l bs.).
(8) Measure crankshaft end pl ay.
(9) I nstal l the connecti ng rods and measure si de cl ear-
ance(Refer to 9 - ENGI NE/ENGI NE BLOCK/PI STON &
CONNECTI NG ROD - STANDARD PROCEDURE).
(10) I nstal l oi l pump(Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L PUMP - I NSTALLATI ON).
(11) I nstal l the engi ne(Refer to 9 - ENGI NE -
I NSTALLATI ON).
Fig. 35 BEDPLATE TIGHTENING SEQUENCE
DR ENGINE - 3. 7L 9 - 43
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE
MAIN BEARING FITTING
SELECT FIT IDENTIFICATION
The mai n beari ngs are sel ect fi t to achi eve proper
oi l cl earances. For mai n beari ng sel ecti on, the crank-
shaft posi ti on sensor target wheel has grade i denti fi -
cati on marks stamped i nto i t (Fi g. 36). These marks
are read from l eft to ri ght, correspondi ng wi th jour-
nal number 1, 2, 3, 4. The crankshaft posi ti on sensor
target wheel i s mounted to the number 6 counter
wei ght on the crankshaft.
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cyl i nder bl ock(Re-
fer to 9 - ENGI NE/ENGI NE BLOCK/CRANKSHAFT
- REMOVAL).
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90
apart at each end of the journal .
The maxi mum al l owabl e taper i s 0.008mm (0.0004
i nch.) and maxi mum out of round i s 0.005mm (0.002
i nch). Compare the measured di ameter wi th the jour-
nal di ameter speci fi cati on (Mai n Beari ng Fi tti ng
Chart). Sel ect i nserts requi red to obtai n the speci fi ed
beari ng-to-journal cl earance.
I nstal l the crankshaft i nto the cyl i nder bl ock(Refer
to 9 - ENGI NE/ENGI NE BLOCK/CRANKSHAFT -
I NSPECTI ON).
Check crankshaft end pl ay.
Fig. 36 MARKINGS ON TARGET WHEEL
1 - REARMOST CRANKSHAFT COUNTER WEIGHT
2 - TARGET WHEEL
3 - MAIN BEARING SELECT FIT MARKINGS
9 - 44 ENGINE - 3. 7L DR
CRANKSHAFT MAIN BEARING SELECTION
(1) Servi ce mai n beari ngs are avai l abl e i n four
grades. The chart bel ow i denti fi es the four servi ce
grades avai l abl e.
Crankshaft
Marking
JOURNAL SIZE
SIZE mm (in.)
R Size 63.488 - 63.496 mm
(2.4995 - 2.4998 in.)
S Size 63.496 - 63.500 mm (2.4998 - 2.4999
in.)
T Size 63.500 - 63.504 mm (2.4999 - 2.501
in.)
U Size 63.504 - 63.512 mm (2.5001 - 2.5004
in.)
Bearing size
Bearing
Code
Size Application
Upper Bearing
A .2.443 - 2.447
mm
Use with crankshaft
size R
(.0961 - .0963
in.)
B 2.439 - 2.443
mm
Use with crankshaft
S, T
(0.960 - .0961
in.)
C 2.435 - 2.439
mm
Use with crankshaft
U
(.0958 - .0960
in.)
Lower Bearing Main 1 and 4
1 2.441 - 2.447
mm
Use with crankshaft
R, S
(.0961 -.0963
in.)
2 2.435 - 2.441
mm
Use with crankshaft
T, U
(.0958 - .0962
in.)
Crankshaft
Marking
JOURNAL SIZE
SIZE mm (in.)
Lower Main Bearing 2 and 3
3 2.429 - 2.435
mm
Use with crankshaft
R, S
(.0956 - .0958
in.)
4 2.423 - 2.429
mm
Use with crankshaft
T, U
(.0953 - .0956
in.)
Bearing Clearances
Main 1, 4
Crankshaft
R
.004 - .034 mm ( .00015 - .0013 in.)
Crankshaft
S
.004 - .030 mm ( .00015 - .0011 in.)
Crankshaft
T
.006 - .032 mm (.0002 - .0012 in.)
Crankshaft
U
.002 - .032 mm (.00007 -. 0012 in.)
Main 2, 3
Crankshaft
R
.016 - .046 mm (.0006 - .0018 in.)
Crankshaft
S
.016 - .042 mm (.00062 - .016 in.)
Crankshaft
T
.018 - .044 mm (.0007 - .0017 in.)
Crankshaft
U
.014 - .044 mm (.0005 - .0017 in.)
DR ENGINE - 3. 7L 9 - 45
CRANKSHAFT MAIN BEARINGS (Continued)
REMOVAL
REMOVAL).
(3) Remove A/C compressor mouni ng fasteners and
set asi de.
(5) Remove upper radi ator hose.
(6) Di sconnect el ectri cal connector for fan mounted
i nsi de radi ator shroud.
(7) Remove radi ator shroud attachi ng fasteners.
NOTE: Transmission cooler line snaps into shroud
lower right hand corner.
(8) Remove radi ator cool i ng fan and shroud (Refer to
7 - COOLI NG/ENGI NE/RADI ATOR FAN - REMOVAL).
(9) Remove crankshaft damper bol t.
(10) Remove damper usi ng Speci al Tool s 8513
I nsert and 1026 Three Jaw Pul l er (Fi g. 37).
(11) Usi ng Speci al Tool 8511, remove crankshaft
front seal (Fi g. 38).
INSTALLATION
CAUTION: To prevent severe damage to the Crank-
shaft, Damper or Special Tool 8512, thoroughly
clean the damper bore and the crankshaft nose
before installing Damper.
(1) Usi ng Speci al Tool 8348 and 8512, i nstal l
crankshaft front seal (Fi g. 39).
(2) I nstal l vi brati on damper (Refer to 9 - ENGI NE/
ENGI NE BLOCK/VI BRATI ON DAMPER - I NSTAL-
LATI ON).
Fig. 37 Crankshaft Damper Removal
1 - SPECIAL TOOL 8513 INSERT
Fig. 39 Crankshaft Front Seal Installation
Fig. 38 Crankshaft Front Seal Removal
9 - 46 ENGINE - 3. 7L DR
(3) I nstal l radi ator cool i ng fan and shroud (Refer
to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
I NSTALLATI ON).
(4) I nstal l upper radi ator hose.
(5) I nstal l A/C compressor and ti ghten fasteners to
54 Nm (40 ft. l bs.).
(6) I nstal l accessory dri ve bel t refer (Refer to 7 -
I NSTALLATI ON).
(7) Refi l l cool i ng system (Refer to 7 - COOLI NG -
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
NOTE: This procedure can be performed in vehicle.
(1) I f bei ng preformed i n vehi cl e, remove the
transmi ssi on.
(2) Remove the fl expl ate (Refer to 9 - ENGI NE/
ENGI NE BLOCK/FLEX PLATE - REMOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused
after removal.
NOTE: The crankshaft rear oil seal remover Special
Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Usi ng Speci al Tool 8506 (Fi g. 40), remove the
crankshaft rear oi l seal .
INSTALLATION
(1) Lubri cate the crankshaft fl ange wi th engi ne oi l .
(2) Posi ti on the magneti c seal gui de Speci al Tool
8349-2 (Fi g. 41) onto the crankshaft rear face. Then
posi ti on the crankshaft rear oi l seal onto the gui de.
Fig. 40 Crankshaft Rear Oil Seal Removal
1 - REAR CRANKSHAFT SEAL
Fig. 41 Crankshaft Rear Oil Seal Guide Special Tool
8349-2 and Oil
2 - SPECIAL TOOL 8349-2 GUIDE
DR ENGINE - 3. 7L 9 - 47
CRANKSHAFT OIL SEAL - FRONT (Continued)
(3) Usi ng Speci al Tool s 8349 Crankshaft Rear Oi l
Seal I nstal l er and C-4171 Dri ver Handl e (Fi g. 42),
wi th a hammer, tap the seal i nto pl ace. Conti nue to
tap on the dri ver handl e unti l the seal i nstal l er seats
agai nst the cyl i nder bl ock crankshaft bore.
(4) I nstal l the fl expl ate.
(5) I nstal l the transmi ssi on.
FLEX PLATE
REMOVAL
(1) Remove the transmi ssi on.
(2) Remove the bol ts and fl expl ate.
INSTALLATION
(1) Posi ti on the fl expl ate onto the crankshaft and
i nstal l the bol ts hand ti ght.
(2) Ti ghten the fl expl ate retai ni ng bol ts to 95 Nm
(70 ft. l bs.) i n the sequence shown (Fi g. 43).
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.
The pi stons are made of a hi gh strength al umi num
al l oy. The connecti ng rods are made of forged pow-
dered metal , wi th a fractured cap desi gn. A ful l
fl oati ng pi ston pi n i s used to attach the pi ston to the
connecti ng rod (Fi g. 44).
Fig. 42 Crankshaft Rear Oil Seal Installation
2 - SPECIAL TOOL 8349-1 INSTALLER
3 - SPECIAL TOOL C-4171 HANDLE
Fig. 43 Flexplate Tightening Sequence
1 - FLEXPLATE
Fig. 44 PISTON AND ROD ASSEMBLY
1 - CONNECTING ROD
2 - PISTON
3 - PISTON PIN
4 - OIL SLINGER SLOT
9 - 48 ENGINE - 3. 7L DR
CRANKSHAFT OIL SEAL - REAR (Continued)
STANDARD PROCEDURE
CONNECTING ROD BEARING FITTING
I nspect the connecti ng rod beari ngs for scori ng.
Check the beari ngs for normal wear patterns, scor-
i ng, groovi ng, fati gue and pi tti ng (Fi g. 45). Repl ace
any beari ng that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs (Fi g. 46).
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Lubri cate the upper beari ng i nsert and posi ti on
i n connecti ng rod. Center beari ng i nsert i n connect-
i ng rod (Fi g. 47)
Fig. 45 Connecting Rod Bearing Inspection
1 - UPPER BEARING HALF
2 - MATING EDGES
3 - GROOVES CAUSED BY ROD BOLTS SCRATCHING JOURNAL
DURING INSTALLATION
4 - WEAR PATTERN - ALWAYS GREATER ON UPPER BEARING
Fig. 46 Scoring Caused by Insufficient Lubrication
or Damaged Crankshaft Journal
Fig. 47 Bearing Insert Location
1 - Connecting Rod
2 - Bearing Insert
- A, B less then .50 mm (.0196 in.)
DR ENGINE - 3. 7L 9 - 49
PISTON & CONNECTING ROD (Continued)
(3) Use pi ston ri ng compressor and Gui de Pi ns
Speci al Tool 8507 (Fi g. 48) to i nstal l the rod and pi s-
ton assembl i es. The oi l sl i nger sl ots i n the rods must
face front of the engi ne. The Fs near the pi ston
wri st pi n bore shoul d poi nt to the front of the engi ne.
(4) I nstal l the l ower beari ng i nsert i n the beari ng
cap. Center beari ng i nsert i n connecti ng rod (Fi g. 47).
The l ower i nsert must be dry. Pl ace stri p of Pl asti -
gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(5) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten bol ts to 27 Nm (20 ft. l bs.) pl us a
90 turn. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(6) Remove the beari ng cap and determi ne amount
of beari ng-to-journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 49). Refer to
Engi ne Speci fi cati ons for the proper cl earance. Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(7) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(8) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, determi n whi ch servi ces beari ng set to
use the beari ng si zes are as fol l ows:
Bearing
Mark
SIZE USED WITH
JOURNAL SIZE
.025 US .025 mm 57.883-57.867 mm
(.001 in.) (2.2788-2.2783 in.)
Std. STANDARD 57.908-57.892 mm
(2.2798-2.2792 in.)
.250 US .250 mm 57.658-57.646 mm
(.010 in.) (2.2700-2.2695 in.)
CAUTION: Connecting Rod Bolts are Torque to
Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened
or removed.
(9) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
Fig. 48 Piston and Connecting Rod -Installation -
Typical
1 - F TOWARD FRONT OF ENGINE
3 - RING COMPRESSOR
Fig. 49 Measuring Bearing Clearance with
Plastigage
1 - PLASTIGAGE SCALE
2 - COMPRESSED PLASTIGAGE
9 - 50 ENGINE - 3. 7L DR
(10) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 27 Nm (20 ft. l bs.) pl us a 90 turn.
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 50).
Refer to Engi ne Speci fi cati ons for the proper cl ear-
ance. Repl ace the connecti ng rod i f the si de cl earance
i s not wi thi n speci fi cati on.
STANDARD PROCEDURE - PISTON FITTING
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm (
.0001 i n.) I NCREMENTS i s requi red. I f a bore gauge
i s not avai l abl e, do not use an i nsi de mi crometer.
bore at a poi nt 38.0 mm (1.5 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 52).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 51). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
REMOVAL
(2) Remove the fol l owi ng components:
Oi l pan and gasket/wi ndage tray (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
Cyl i nder head covers (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CYLI NDER HEAD COVER(S) -
REMOVAL) and (Refer to 9 - ENGI NE/CYLI NDER
HEAD/CYLI NDER HEAD COVER(S) - REMOVAL).
Fig. 50 Checking Connecting Rod Side Clearance -
Typical
Fig. 51 DO NOT MEASURE MOLY COATED PISTON
1 - MOLY COATED
2 - MOLY COATED
Fig. 52 BORE GAUGE - TYPICAL
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM (1.5 in)
DR ENGINE - 3. 7L 9 - 51
Ti mi ng chai n cover (Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT / CHAI N COVER(S)
- REMOVAL).
Cyl i nder head(s) (Refer to 9 - ENGI NE/CYLI N-
DER HEAD - REMOVAL) and (Refer to 9 - ENGI NE/
CYLI NDER HEAD - REMOVAL).
(3) I f necessary, remove top ri dge of cyl i nder bores
wi th a rel i abl e ri dge reamer before removi ng pi stons
from cyl i nder bl ock. Be sure to keep tops of pis-
tons covered during this operation. Pi stons and
connecti ng rods must be removed from top of cyl i nder
bl ock. When removi ng pi ston and connecti ng rod
assembl i es from the engi ne, rotate crankshaft so the
each connecti ng rod i s centered i n cyl i nder bore.
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods or caps, as damage to
connecting rods could occur
NOTE: Connecting rods and bearing caps are not
interchangeable and should be marked before
removing to ensure correct reassembly.
(4) Mark connecti ng rod and beari ng cap posi ti ons
usi ng a permanent i nk marker or scri be tool .
CAUTION: Care must be taken not to damage the
fractured rod and cap joint face surfaces, as engine
damage may occur.
(5) Remove connecti ng rod cap. I nstal l Speci al Tool
8507 Connecti ng Rod Gui des i nto the connecti ng rod
bei ng removed. Remove pi ston from cyl i nder bore.
Repeat thi s procedure for each pi ston bei ng removed.
CAUTION: Care must be taken not to nick crank-
shaft journals, as engine damage may occur
(6) I mmedi atel y after pi ston and connecti ng rod
removal , i nstal l beari ng cap on the mati ng connect-
i ng rod to prevent damage to the fractured cap and
rod surfaces.
CLEANING
CAUTION: DO NOT use a wire wheel or other abra-
sive cleaning devise to clean the pistons or con-
necting rods. The pistons have a Moly coating, this
coating must not be damaged.
(1) Usi ng a sui tabl e cl eani ng sol vent cl ean the pi s-
tons i n warm water and towel dry.
(2) Use a wood or pl asti c scraper to cl ean the ri ng
l and grooves.
CAUTION: DO NOT remove the piston pin from the
piston and connecting rod assembly.
INSPECTION
Check the connecti ng rod journal for excessi ve
wear, taper and scori ng (Refer to 9 - ENGI NE/EN-
GI NE BLOCK/CONNECTI NG ROD BEARI NGS -
Check the connecti ng rod for si gns of twi st or bend-
i ng.
Check the pi ston for taper and el l i pti cal shape
before i t i s fi tted i nto the cyl i nder bore (Refer to 9 -
ENGI NE/ENGI NE BLOCK/PI STON & CONNECT-
I NG ROD - STANDARD PROCEDURE).
Check the pi ston for scori ng, or scrapi ng marks i n
the pi ston ski rts. Check the ri ng l ands for cracks
and/or deteri orati on.
INSTALLATION
(1) Before i nstal l i ng pi ston and connecti ng rod
assembl i es i nto the bore, i nstal l the pi ston ri ngs.
(2) I mmerse the pi ston head and ri ngs i n cl ean
engi ne oi l . Posi ti on a ri ng compressor over the pi ston
and ri ngs. Ti ghten ri ng compressor. Ensure posi-
tion of rings do not change during this opera-
tion.
(3) Posi ti on beari ng onto connecti ng rod. Ensure
that hol e i n beari ng shel l al i gns wi th hol e i n connect-
i ng rod. Lubri cate beari ng surface wi th cl ean engi ne
oi l .
(4) I nstal l Speci al Tool 8507 Connecti ng Rod
Gui des i nto connecti ng rod bol t threads (Fi g. 53).
(5) The pi stons are marked on the pi ston pi n bore
surface wi th an rai sed F i ndi cati ng i nstal l ati on
posi ti on. Thi s mark must be poi nti ng toward the
front of engi ne on both cyl i nder banks. The connect-
i ng rod oi l sl i nger sl ot faces the front of the engi ne
(Fi g. 54).
(6) Wi pe cyl i nder bore cl ean and l ubri cate wi th
engi ne oi l .
(7) Rotate crankshaft unti l connecti ng rod journal
i s on the center of cyl i nder bore. I nsert rod and pi s-
ton i nto cyl i nder bore and careful l y posi ti on connect-
i ng rod gui des over crankshaft journal .
(8) Tap pi ston down i n cyl i nder bore usi ng a ham-
mer handl e. Whi l e at the same ti me, gui de connect-
i ng rod i nto posi ti on on rod journal .
or removed.
(9) Lubri cate rod bol ts and beari ng surfaces wi th
engi ne oi l . I nstal l connecti ng rod cap and beari ng.
Ti ghten bol ts to 27 Nm (20 ft. l bs.) pl us 90.
(10) I nstal l the fol l owi ng components:
Cyl i nder head(s). (Refer to 9 - ENGI NE/CYLI N-
DER HEAD - I NSTALLATI ON).
9 - 52 ENGINE - 3. 7L DR
Ti mi ng chai n and cover. (Refer to 9 - ENGI NE/
- I NSTALLATI ON).
I NSTALLATI ON).
Oi l pan and gasket/wi ndage tray. (Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
(11) Fi l l crankcase wi th proper engi ne oi l to cor-
rect l evel .
PISTON RINGS
FITTING
Before rei nstal l i ng used ri ngs or i nstal l i ng new
ri ngs, the ri ng cl earances must be checked.
(1) Wi pe the cyl i nder bore cl ean.
(2) I nsert the ri ng i n the cyl i nder bore.
NOTE: The ring gap measurement must be made
with the ring positioned at least 12mm (0.50 inch.)
from bottom of cylinder bore.
(3) Usi ng a pi ston, to ensure that the ri ng i s
squared i n the cyl i nder bore, sl i de the ri ng downward
i nto the cyl i nder.
(4) Usi ng a feel er gauge check the ri ng end gap
(Fi g. 55). Repl ace any ri ngs not wi thi n speci fi cati on.
Fig. 53 PISTON AND CONNECTING ROD
INSTALLATION
3 - RING COMPRESSOR
ORIENTATION
1 - MAJOR THRUST SIDE OF PISTON
Fig. 55 Ring End Gap Measurement - Typical
1 - FEELER GAUGE
DR ENGINE - 3. 7L 9 - 53
PISTON RING SIDE CLEARANCE
NOTE: Make sure the piston ring grooves are clean
and free of nicks and burrs.
(5) Measure the ri ng si de cl earance as shown (Fi g.
56) make sure the feel er gauge fi ts snugl y between
the ri ng l and and the ri ng. Repl ace any ri ng not
wi thi n speci fi cati on.
(6) Rotate the ri ng around the pi ston, the ri ng
must rotate i n the groove wi th out bi ndi ng.
PISTON RING SPECIFICATION CHART
Ring Position Groove
Clearance
Maximum
Clearance
Upper Ring .051-.094 mm 0.11 mm
(0.0020-.0037
in.)
(0.004 in.)
Intermediate
Ring
0.04-0.08 mm 0.10 mm
(0.0016-0.0031
in.)
(0.004 in.)
Oil Control Ring .019-.229 mm .25 mm
(Steel Rails) (.0007-.0090
in.)
(0.010 in.)
Ring Position Ring Gap Wear Limit
Upper Ring 0.20-0.36 mm 0.43 mm
(0.0079-0.0142
in.)
(0.0017 in.)
Intermediate
Ring
0.37-0.63 mm 0.74 mm
(0.0146-0.0249
in.)
(0.029 in.)
Oil Control Ring 0.025-0.76 mm 1.55 mm
(Steel Rail) (0.0099- 0.03
in.)
(0.061 in.)
(7) The No. 1 and No. 2 pi ston ri ngs have a di ffer-
ent cross secti on. Ensure No. 2 ri ng i s i nstal l ed wi th
manufacturers I .D. mark (Dot) faci ng up, towards top
of the pi ston.
NOTE: Piston rings are installed in the following
order:
Oil ring expander.
Upper oil ring side rail.
Lower oil ring side rail.
No. 2 Intermediate piston ring.
No. 1 Upper piston ring.
Fig. 56 Measuring Piston Ring Side Clearance
1 - FEELER GAUGE
9 - 54 ENGINE - 3. 7L DR
PISTON RINGS (Continued)
(8) I nstal l the oi l ri ng expander.
(9) I nstal l upper si de rai l (Fi g. 57) by pl aci ng one
end between the pi ston ri ng groove and the expander
ri ng. Hol d end fi rml y and press down the porti on to
be i nstal l ed unti l si de rai l i s i n posi ti on. Repeat thi s
step for the l ower si de rai l .
(10) I nstal l No. 2 i ntermedi ate pi ston ri ng usi ng a
pi ston ri ng i nstal l er (Fi g. 58).
(11) I nstal l No. 1 upper pi ston ri ng usi ng a pi ston
ri ng i nstal l er (Fi g. 58).
(12) Posi ti on pi ston ri ng end gaps as shown i n
(Fi g. 59). I t i s i mportant that expander ri ng gap i s at
l east 45 from the si de rai l gaps, but not on the pi s-
ton pi n center or on the thrust di recti on.
VIBRATION DAMPER
REMOVAL
REMOVAL).
(4) Remove radi ator upper hose.
(5) Remove upper fan shroud.
(6) Usi ng Speci al Tool s 6958 Spanner wi th Adapter
Pi ns 8346, l oosen fan and vi scous assembl y from
water pump (Fi g. 60).
(7) Remove fan and vi scous assembl y.
Fig. 57 Side Rail - Installation
1 - SIDE RAIL END
Fig. 58 Upper and Intermediate Rings - Installation
Fig. 59 Piston Ring End Gap Position
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 60 FAN ASSEMBLY - REMOVAL/ASSEMBLY
PINS 8346
2 - FAN
DR ENGINE - 3. 7L 9 - 55
INSTALLATION
shaft, Damper or Special Tool 8512A, thoroughly
(1) Al i gn crankshaft damper sl ot wi th key i n
crankshaft. Sl i de damper onto crankshaft sl i ghtl y.
CAUTION: Special Tool 8512A, is assembled in a
specific sequence. Failure to assemble this tool in
this sequence can result in tool failure and severe
damage to either the tool or the crankshaft.
(2) Assembl e Speci al Tool 8512A as fol l ows, The
nut i s threaded onto the shaft fi rst. Then the rol l er
beari ng i s pl aced onto the threaded rod (The hard-
ened beari ng surface of the beari ng MUSTface the
nut). Then the hardened washer sl i des onto the
threaded rod (Fi g. 62). Once assembl ed coat the
threaded rods threads wi th Mopar Ni ckel Anti -
Sei ze or equi val ent.
(3) Usi ng Speci al Tool 8512A, press damper onto
crankshaft (Fi g. 63).
(4) I nstal l then ti ghten crankshaft damper bol t to
175 Nm (130 ft. l bs.).
Fig. 61 CRANKSHAFT DAMPER - REMOVAL
Fig. 62 PROPER ASSEMBLY METHOD FOR
SPECIAL TOOL 8512A
1 - BEARING
2 - NUT
3 - THREADED ROD
4 - BEARING HARDENED SURFACE (FACING NUT)
5 - HARDENED WASHER
Fig. 63 Crankshaft Damper Installation
9 - 56 ENGINE - 3. 7L DR
VIBRATION DAMPER (Continued)
(5) I nstal l fan bl ade assembl y (Refer to 7 - COOL-
I NG/ENGI NE/FAN DRI VE VI SCOUS CLUTCH -
I NSTALLATI ON).
(6) I nstal l radi ator upper shroud and ti ghten fas-
teners to 11 Nm (95 i n. l bs.).
(7) Connect el ectri cal connector for shroud fan.
(8) I nstal l radi ator upper hose.
LATI ON).
STRUCTURAL COVER
DESCRIPTION
The structural dust cover i s made of di e cast al u-
mi num and joi ns the l ower hal f of the transmi ssi on
bel l housi ng to the engi ne bedpl ate.
OPERATION
The structural cover provi des addi ti onal power-
trai n sti ffness and reduces noi se and vi brati on.
REMOVAL
(1) Rai se vehi cl e on hoi st.
(2) Remove the l eft hand exhaust pi pe from
exhaust mani fol d.
(3) Loosen the ri ght hand exhaust mani fol d-to-ex-
haust pi pe retai ni ng bol ts.
(4) Remove the ei ght bol ts retai ni ng structural
cover (Fi g. 64) i n the sequence shown.
(5) Pi vot the exhaust pi pe downward and remove
the structural cover.
INSTALLATION
CAUTION: The structural cover must be installed as
described in the following steps. Failure to do so
will cause severe damage to the cover.
(1) Posi ti on the structural cover i n the vehi cl e.
(2) I nstal l al l four bol ts retai ni ng the cover-to-en-
gi ne. DO NOT ti ghten the bol ts at thi s ti me.
(3) I nstal l the four cover-to-transmi ssi on bol ts. Do
NOT ti ghten at thi s ti me.
CAUTION: The structural cover must be held tightly
against both the engine and the transmission bell
housing during tightening sequence. Failure to do
so may cause damage to the cover.
(4) Starti ng wi th the two rear cover-to-engi ne
bol ts, ti ghten bol ts (1) (Fi g. 65) to 54 Nm (40 ft. l bs.),
then ti ghten bol ts (2) (Fi g. 65) and (3) to 54 Nm ( 40
ft. l bs.) i n the sequence shown.
(5) I nstal l the exhaust pi pe on l eft hand exhaust
mani fol d.
(6) Ti ghten exhaust mani fol d-to-exhaust pi pe
retai ni ng bol ts to 2026 Nm (1520 ft. l bs.).
Fig. 64 Structural Cover
1 - BOLT
2 - BOLT
3 - BOLT
1 - BOLT
2 - BOLT
3 - BOLT
DR ENGINE - 3. 7L 9 - 57
FRONT MOUNT
REMOVAL
2WD
CAUTION: Remove the viscous fan before raising
engine. Failure to do so may cause damage to the
fan blade, fan clutch and fan shroud.
(2) Remove the vi scous fan (Refer to 7 - COOL-
REMOVAL).
(4) Remove the engi ne oi l fi l ter.
(5) Remove the oi l drai n trough.
(6) Support the engi ne wi th a sui tabl e jack and a
bl ock of wood across the ful l wi dth of the engi ne oi l pan.
(7) Support the front axl e wi th a sui tabl e jack.
(8) Remove the (4) bol ts that attach the engi ne
mounts to the front axl e.
(9) Remove the (3) bol ts that attach the front axl e
to the l eft engi ne bracket.
(10) Lower the front axl e.
(11) Remove the through bol ts
(12) Rai se the engi ne far enough to be abl e to
remove the l eft and ri ght engi ne mounts.
(13) Remove the (8) mount to engi ne attachi ng
bol ts
(14) Remove the engi ne mounts.
4WD
REMOVAL).
(4) Remove the ski d pl ate.
(5) Remove the front crossmember.
bl ock of wood across the ful l wi dth of the engi ne oi l
pan.
mounts to the front axl e (Fi g. 66).
Fig. 66 ENGINE INSULATOR MOUNTS 4X4
1 - RH INSULATOR TO AXLE BOLT
2 - NUT
3 - PINION SUPPORT MOUNT
4 - LH INSULATOR MOUNT
5 - LH INSULATOR TO AXLE BOLT
6 - FRONT AXLE
7 - NUT
8 - RH INSULATOR MOUNT
9 - 58 ENGINE - 3. 7L DR
(13) Remove the (6) through bol ts
remove the l eft (Fi g. 67) and ri ght (Fi g. 68) engi ne
mounts.
INSTALLATION
2WD
NOTE: For mount to engine block and left engine
bracket to front axle bolts, apply Mopar Lock and
Seal Adhesive, Medium Strength Threadlocker.
(1) I nstal l the ri ght and l eft si de engi ne mounts to
the engi ne bl ock wi th (8) bol ts. Torque bol ts to 54
Nm (40 ft. l bs.).
(2) I nsert the (2) through bol ts i nto the ri ght and
l eft si de engi ne mounts and l oose assembl e the two
nuts onto the through bol ts.
(3) Lower the engi ne unti l the through bol ts rest
onto the sl ots i n the frame brackets.
(4) Ti ghten the through bol t nuts to 94 Nm (70 ft.
l bs.).
(5) I nstal l the oi l drai n trough.
(6) I nstal l the engi ne oi l fi l ter.
(8) I nstal l the vi scous fan (Refer to 7 - COOLI NG/
ENGI NE/FAN DRI VE VI SCOUS CLUTCH -
REMOVAL).
4WD
the front axl e. Torque nuts to 94 Nm (70 ft. l bs.).
(2) Rai se the front axl e i nto the frame and i nstal l
the l eft and ri ght si de through bol ts. Torque nuts to
94 Nm (70 ft. l bs.).
(3) I nsert the two upper through bol ts i nto the
ri ght and l eft si de engi ne mounts and l oose assembl e
the two nuts onto the through bol ts.
(4) Lower the engi ne unti l the l eft and ri ght si de
engi ne brackets rest on the through bol ts, and the
l ower engi ne bracket through hol es al i gn wi th the
engi ne mounts, and the l eft engi ne bracket hol es
al i gn wi th the front axl e sl ots (Fi g. 69).
(5) Loose assembl e the (3) bol ts that attach the
front axl e to the l eft engi ne bracket.
Fig. 67 ENGINE MOUNT SUPPORT BRACKET
1 - BOLT
2 - ENGINE MOUNT SUPPORT BRACKET
3 - BOLT
Fig. 68 ENGINE MOUNT SUPPORT BRACKET RH
1 - BOLT
DR ENGINE - 3. 7L 9 - 59
FRONT MOUNT (Continued)
(6) Loose assembl e the l ower through bol ts.
(7) Torque the nuts for the (4) through bol ts to 101
Nm (75 ft. l bs.).
(8) Torque the (3) bol ts that attach the front axl e
to the l eft engi ne bracket to 101 Nm (75 ft. l bs.).
(11) I nstal l the front crossmember.
(12) I nstal l the ski d pl ate.
(14) I nstal l the vi scous fan (Refer to 7 - COOL-
REMOVAL).
2 - NUT
6 - FRONT AXLE
7 - NUT
9 - 60 ENGINE - 3. 7L DR
REAR MOUNT
REMOVAL
(2) Usi ng a sui tabl e jack, support transmi ssi on.
(3) Remove the nuts from the transmi ssi on mount
(Fi g. 70).
(4) Remove the two bol ts that attach the transmi s-
si on mount to the engi ne bracket.
(5) Rai se the transmi ssi on enough to remove the
mount from the crossmember.
(6) Remove the mount.
INSTALLATION
NOTE: Threadlocking compound must be applied to
the bolts before installation.
(1) I nstal l the two bol ts that attach the transmi s-
si on mount to the transmi ssi on bracket.
(2) Torque the bol ts to 61Nm (45 ft.l bs.) torque.
(3) Lower the transmi ssi on so the transmi ssi on
mount rests on the crossmember, and the studs of
the transmi ssi on mount are al i gned i n the sl ots i n
the crossmember.
(4) I nstal l the nuts onto the transmi ssi on mount
studs through the crossmember access sl ot.
(5) Torque the nuts to 54Nm (40 ft. l bs.).
LUBRICATION
DESCRIPTION
The l ubri cati on system i s a ful l fl ow fi l trati on pres-
sure feed type.
OPERATION
Oi l from the oi l pan i s pumped by a gerotor type oi l
pump di rectl y mounted to the crankshaft nose. Oi l
pressure i s control l ed by a rel i ef val ve mounted
i nsi de the oi l pump housi ng. For l ubri cati on fl ow
refer to (Fi g. 71)
The camshaft exhaust val ve l obes and rocker arms
are l ubri cated through a smal l hol e i n the rocker
arm; oi l fl ows through the l ash adjuster then through
the rocker arm and onto the camshaft l obe. Due to
the ori entati on of the rocker arm, the camshaft
i ntake l obes are not l ubed i n the same manner as the
exhaust l obes. The i ntake l obes are l ubed through
i nternal passages i n the camshaft. Oi l fl ows through
a bore i n the No. 3 camshaft beari ng bore, and as the
camshaft turns, a hol e i n the camshaft al i gns wi th
the hol e i n the camshaft bore al l owi ng engi ne oi l to
enter the camshaft tube. The oi l then exi ts through
1.6mm (0.063 i n.) hol es dri l l ed i nto the i ntake l obes,
l ubri cati ng the l obes and the rocker arms.
Fig. 70 TRANSMISSION MOUNT
1 - MOUNT
2 - CROSSMEMBER
3 - NUT
4 - BOLT
DR ENGINE - 3. 7L 9 - 61
ENGINE LUBRICATION FLOW CHART - BLOCK: TABLE 1
FROM TO
Oil Pickup Tube Oil Pump
Oil Pump Oil Filter
Oil Filter Block Main Oil Gallery
Block Main Oil Gallery 1. Crankshaft Main Journal
2. Left Cylinder Head*
3. Right Cylinder Head*
4. Counterbalance Shaft Rear Journal
Crankshaft Main Journals Crankshaft Rod Journals
Crankshaft Number One Main Journal 1. Front Timing Chain Idler Shaft
2. Counterbalance Shaft - Front Journal
3. Both Secondary Chain Tensioners
Left Cylinder Head Refer to Engine Lubrication Flow Chart - Cylinder
Heads: Table 2
Right Cylinder Head Refer to Engine Lubrication Flow Chart - Cylinder
Heads: Table 2
* The cylinder head gaskets have an oil restricter to control oil flow to the cylinder heads
ENGINE LUBRICATION FLOW CHART - CYLINDER HEADS: TABLE 2
FROM TO
Cylinder Head Oil Port (in bolt hole) Diagonal Cross Drilling to Main Oil Gallery
Main Oil Gallery (drilled through head from rear to
front)
1. Base of Camshaft Towers
2. Lash Adjuster Towers
Base of Camshaft Towers Vertical Drilling Through Tower to Camshaft Bearings**
Lash Adjuster Towers Diagonal Drillings to Hydraulic Lash Adjuster Pockets
** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake
lobes, which have oil passages drilled into them to lubricate the rocker arms.
9 - 62 ENGINE - 3. 7L DR
LUBRICATION (Continued)
Fig. 71 LUBRICATION OIL FLOW
1 - OIL FLOW TO RIGHT CYLINDER HEAD
2 - CYLINDER BLOCK MAIN OIL GALLERY
3 - LEFT CYLINDER HEAD OIL GALLERY
4 - OIL FLOW TO BOTH SECONDARY TENSIONERS
5 - OIL FLOW TO LEFT CYLINDER HEAD
6 - OIL PRESSURE SENSOR LOCATION
7 - OIL FLOW TO COUNTER BALANCE SHAFT
8 - OIL PUMP OUTLET TO CYLINDER BLOCK
9 - OIL PUMP
10 - OIL FLOW TO CRANKSHAFT MAIN JOURNALS
11 - CRANKSHAFT MAIN BEARING JOURNALS
12 - RIGHT CYLINDER HEAD OIL GALLERY
DR ENGINE - 3. 7L 9 - 63
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begi n wi th a thorough vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24 km (15 mi l es), and
repeat i nspecti on.I f the oi l l eak source i s not posi -
ti vel y i denti fi ed at thi s ti me, proceed wi th the ai r
l eak detecti on test method.
Air Leak Detection Test Method
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the PCV val ve from the cyl i nder head
cover. Cap or pl ug the PCV val ve grommet.
(3) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kPa (3 PSI) of test pressure.
(4) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
(5) I f the l eakage occurs at the rear oi l seal area,
refer to the secti on, I nspecti on for Rear Seal Area
Leak.
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, di stri butor seal ,
camshaft bore cup pl ugs oi l gal l ey pi pe pl ugs, oi l
fi l ter runoff, and mai n beari ng cap to cyl i nder
bl ock mati ng surfaces.
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed.
9 - 64 ENGINE - 3. 7L DR
ENGINE OIL PRESSURE
(1) Remove oi l pressure sendi ng uni t (Fi g. 72)and
i nstal l gauge assembl y C-3292.
(2) Run engi ne unti l thermostat opens.
(3) Oi l Pressure:
Curb I dl e - 25 kPa (4 psi ) mi ni mum
3000 rpm - 170 - 758 kPa (25 - 110 psi )
(4) I f oi l pressure i s 0 at i dl e, shut off engi ne.
Check for a cl ogged oi l pi ck-up screen or a pressure
rel i ef val ve stuck open.
DIAGNOSIS AND TESTING - REAR SEAL AREA
LEAKS
area:
possi bl e causes are a porous bl ock, camshaft bore
cup pl ugs, oi l gal l ey pi pe pl ugs, oi l fi l ter runoff,
and mai n beari ng cap to cyl i nder bl ock mati ng sur-
faces. See Engi ne, for proper repai r procedures of
these i tems.
(4) I f no l eaks are detected, pressuri zed the crank-
case as outl i ned i n the secti on, I nspecti on (Engi ne oi l
Leaks i n general )
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
seal.
assembl ed. (Refer to 9 - ENGI NE - DI AGNOSI S AND
TESTI NG), under the Oi l Leak row, for components
i nspecti ons on possi bl e causes and correcti ons.
(7) After the oi l l eak root cause and appropri ate
correcti ve acti on have been i denti fi ed, (Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT OI L
SEAL - REAR - REMOVAL).
Fig. 72 OIL PRESSURE SENDING UNIT -TYPICAL
1 - BELT
2 - OIL PRESSURE SENSOR
3 - OIL FILTER
4 - ELEC. CONNECTOR
DR ENGINE - 3. 7L 9 - 65
OIL PAN
DESCRIPTION
The engi ne oi l pan i s made of l ami nated steel and
has a si ngl e pl ane seal i ng surface. The sandwi ch
styl e oi l pan gasket has an i ntegrated wi ndage tray
and steel carri er (Fi g. 73). The seal i ng area of the
gasket i s mol ded wi th rubber and i s desi gned to be
reused as l ong as the gasket i s not cut, torn or
ri pped.
REMOVAL
(2) I nstal l engi ne support fi xture speci al tool #
8534. Do not raise engine at this time.
(3) Loosen both l eft and ri ght si de engi ne mount
through bol ts. Do not remove bol ts.
(4) Remove the structural dust cover, i f equi pped.
(5) Drai n engi ne oi l .
(6) Remove the front crossmember(Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT CROSS-
MEMBER - REMOVAL).
CAUTION: Only raise the engine enough to provide
clearance for oil pan removal. Check for proper
clearance at fan shroud to fan and cowl to intake
manifold.
(7) Rai se engi ne usi ng speci al tool 8534 to provi de
cl earance to remove oi l pan.
NOTE: Do not pry on oil pan or oil pan gasket. Gas-
ket is integral to engine windage tray and does not
come out with oil pan.
(8) Remove the oi l pan mounti ng bol ts and oi l pan.
(9) Unbol t oi l pump pi ckup tube and remove tube.
(10) I nspect the i ntegral wi ndage tray (Fi g. 73)
and gasket and repl ace as needed.
CLEANING
(1) Cl ean oi l pan i n sol vent and wi pe dry wi th a
cl ean cl oth.
(2) Cl ean the oi l pan gasket surface. DO NOT use
a gri nder wheel or other abrasi ve tool to cl ean seal -
i ng surface.
(3) Cl ean oi l screen and tube thoroughl y i n cl ean
sol vent.
INSPECTION
(1) I nspect oi l drai n pl ug and pl ug hol e for
stri pped or damaged threads. Repai r as necessary.
(2) I nspect the oi l pan mounti ng fl ange for bends
or di storti on. Strai ghten fl ange, i f necessary.
INSTALLATION
(1) Cl ean the oi l pan gasket mati ng surface of the
bedpl ate and oi l pan.
(2) I nspect i ntegrated oi l pan gasket, and repl ace
as necessary.
(3) Posi ti on the i ntegrated oi l pan gasket/wi ndage
tray assembl y.
(4) I nstal l the oi l pi ckup tube
(5) I nstal l the mounti ng bol t and nuts. Ti ghten
nuts to 28 Nm (20 ft. l bs.).
(6) I f removed, i nstal l stud at posi ti on No. 9. (Fi g.
74).
(7) Posi ti on the oi l pan and i nstal l the mounti ng
bol ts and nut. Ti ghten the mounti ng bol ts and nut to
15 Nm (11 ft. l bs.) i n the sequence shown (Fi g. 74).
(8) Lower the engi ne i nto mounts usi ng speci al
tool 8534.
(9) I nstal l both the l eft and ri ght si de engi ne
mount through bol ts. Ti ghten the nuts to 68 Nm (50
ft. l bs.).
(10) Remove speci al tool 8534.
(11) I nstal l structural dust cover, i f equi pped.
Fig. 73 Oil Pan And Gasket
1 - OIL PAN
2 - WINDAGE TRAY AND INTEGRATED OIL PAN GASKET
9 - 66 ENGINE - 3. 7L DR
(12) I nstal l the front crossmember(Refer to 13 -
(13) Fi l l engi ne oi l .
(15) Start engi ne and check for l eaks.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 3 wi re, sol i d-state engi ne oi l pressure sensor
(sendi ng uni t) i s l ocated i n an engi ne oi l pressure
gal l ery.
OPERATION
The oi l pressure sensor uses three ci rcui ts. They
are:
A 5 vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM)
A sensor ground through the PCMs sensor
return
A si gnal to the PCM rel ati ng to engi ne oi l pres-
sure
The oi l pressure sensor has a 3 wi re el ectri cal
functi on very much l i ke the Mani fol d Absol ute Pres-
sure (MAP) sensor. Meani ng di fferent pressures
rel ate to di fferent output vol tages.
A 5 vol t suppl y i s sent to the sensor from the PCM
to power up the sensor. The sensor returns a vol tage
si gnal back to the PCM rel ati ng to engi ne oi l pres-
sure. Thi s si gnal i s then transferred (bussed) to the
i nstrument panel on ei ther a CCD or PCI bus ci rcui t
(dependi ng on vehi cl e l i ne) to operate the oi l pressure
gauge and the check gauges l amp. Ground for the
sensor i s provi ded by the PCM through a l ow-noi se
sensor return.
REMOVAL
(3) Remove front spl ash shi el d.
(4) Di sconnect oi l pressure sender wi re (Fi g. 75).
(5) Remove the pressure sender (Fi g. 75).
INSTALLATION
(1) I nstal l oi l pressure sender.
(2) Connect oi l pressure sender wi re.
(3) I nstal l front spl ash shi el d.
OIL PUMP
REMOVAL
(1) Remove the oi l pan and pi ck-up tube (Refer to
9 - ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
(2) Remove the ti mi ng chai n cover (Refer to 9 -
Fig. 74 Oil Pan Mounting Bolt Sequence
Fig. 75 OIL PRESSURE SENDING UNIT
1 - BELT
3 - OIL FILTER
4 - ELEC. CONNECTOR
DR ENGINE - 3. 7L 9 - 67
OIL PAN (Continued)
(3) Remove the ti mi ng chai ns and tensi oners
(Refer to 9 - ENGI NE/VALVE TI MI NG/TI MI NG
(4) Remove the four bol ts, pri mary ti mi ng chai n
tensi oner and the oi l pump.
DISASSEMBLY
(1) Remove oi l pump cover screws and l i ft off cover
pl ate.
(2) Remove pump i nner and outer rotors.
NOTE: Once the oil pressure relief valve, cup plug,
and pin are removed, the pump assembly must be
replaced.
(3) I f i t i s necessary to remove the pressure rel i ef
val ve, dri ve the rol l pi n from pump housi ng and
remove cup pl ug, spri ng and val ve.
INSPECTION
CAUTION: Oil pump pressure relief valve and spring
should not be removed from the oil pump. If these com-
ponents are disassembled and or removed from the
pump the entire oil pump assembly must be replaced.
(1) Cl ean al l parts thoroughl y. Mati ng surface of
the oi l pump housi ng shoul d be smooth. I f the pump
cover i s scratched or grooved the oi l pump assembl y
(2) Lay a strai ght edge across the pump cover sur-
face (Fi g. 76). I f a 0.025 mm (0.001 i n.) feel er gauge
can be i nserted between the cover and the strai ght
edge the oi l pump assembl y shoul d be repl aced.
(3) Measure the thi ckness of the outer rotor (Fi g.
77). I f the outer rotor thi ckness measures at 12.005
mm (0.472 i n.) or l ess the oi l pump assembl y must be
repl aced.
(4) Measure the di ameter of the outer rotor. I f the
outer rotor di ameter measures at 85.925 mm (3.382
i n.) or l ess the oi l pump assembl y must be repl aced.
(5) Measure the thi ckness of the i nner rotor (Fi g.
78). I f the i nner rotor thi ckness measures at 12.005
mm (0.472 i n.) or l ess then the oi l pump assembl y
must be repl aced.
Fig. 76 Checking Oil Pump Cover Flatness
1 - STRAIGHT EDGE
2 - FEELER GAUGE
3 - OIL PUMP COVER
Fig. 77 Measuring Outer Rotor Thickness
Fig. 78 Measuring Inner Rotor Thickness
9 - 68 ENGINE - 3. 7L DR
OIL PUMP (Continued)
(6) Sl i de outer rotor i nto the body of the oi l pump.
Press the outer rotor to one si de of the oi l pump body
and measure cl earance between the outer rotor and
the body (Fi g. 79). I f the measurement i s 0.235mm
(0.009 i n.) or more the oi l pump assembl y must be
repl aced.
(7) I nstal l the i nner rotor i n the i nto the oi l pump
body. Measure the cl earance between the i nner and
outer rotors (Fi g. 80). I f the cl earance between the
rotors i s .150 mm (0.006 i n.) or more the oi l pump
(8) Pl ace a strai ght edge across the body of the oi l
pump (between the bol t hol es), i f a feel er gauge of
.095 mm (0.0038 i n.) or greater can be i nserted
between the strai ghtedge and the rotors, the pump
must be repl aced (Fi g. 81).
NOTE: The 3.7 Oil pump is released as an assem-
bly. There are no DaimlerChrysler part numbers for
Sub-Assembly components. In the event the oil
pump is not functioning or out of specification it
ASSEMBLY
(1) Wash al l parts i n a sui tabl e sol vent and i nspect
careful l y for damage or wear.
(2) I nstal l i nner and outer rotors
(3) I nstal l oi l pump cover pl ate and i nstal l cover
bol ts and ti ghten them to 12 Nm (105 i n. l bs.).
(4) Pri me oi l pump before i nstal l ati on by fi l l i ng
rotor cavi ty wi th engi ne oi l .
(5) I f oi l pressure i s l ow and pump i s wi thi n spec-
i fi cati ons, i nspect for worn engi ne beari ngs or other
causes for oi l pressure l oss.
INSTALLATION
(1) Posi ti on the oi l pump onto the crankshaft and
i nstal l one oi l pump retai ni ng bol ts.
(2) Posi ti on the pri mary ti mi ng chai n tensi oner
and i nstal l three retai ni ng bol ts.
(3) Ti ghten the oi l pump and pri mary ti mi ng chai n
tensi oner retai ni ng bol ts to 28 Nm (250 i n. l bs.) i n
the sequence shown (Fi g. 82).
(4) I nstal l the secondary ti mi ng chai n tensi oners
and ti mi ng chai ns (Refer to 9 - ENGI NE/VALVE
TI MI NG/TI MI NG BELT/CHAI N AND SPROCKETS -
I NSTALLATI ON).
Fig. 79 Measuring Outer Rotor Clearance
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 80 Measuring Clearance Between Rotors
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
Fig. 81 Measuring Clearance Over Rotors
1 - STRAIGHT EDGE
2 - FEELER GAUGE
DR ENGINE - 3. 7L 9 - 69
(5) I nstal l the ti mi ng chai n cover (Refer to 9 -
(6) I nstal l the pi ck-up tube and oi l pan (Refer to 9
- ENGI NE/LUBRI CATI ON/OI L PAN - I NSTALLA-
TI ON).
OIL FILTER
REMOVAL
Al l engi nes are equi pped wi th a hi gh qual i ty ful l -
fl ow, di sposabl e type oi l fi l ter. Dai ml erChrysl er Cor-
porati on recommends a Mopar or equi val ent oi l
fi l ter be used.
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se (Fi g. 83)
to remove i t from the cyl i nder bl ock oi l fi l ter boss.
(4) When fi l ter separates from cyl i nder bl ock oi l
fi l ter boss, ti p gasket end upward to mi ni mi ze oi l
spi l l . Remove fi l ter from vehi cl e.
NOTE: Make sure filter gasket was removed with fil-
ter.
(5) Wi th a wi pi ng cl oth, cl ean the gasket seal i ng
surface of oi l and gri me.
INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l .
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 84) hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
Fig. 82 Oil Pump And Primary Timing Chain
Tensioner Tightening Sequence
Fig. 83 OIL FILTER
1 - ENGINE OIL FILTER
Fig. 84 Oil Filter Sealing Surface-Typical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
9 - 70 ENGINE - 3. 7L DR
OIL
SERVICE
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
Use an engi ne oi l that i s API Servi ce Grade Certi -
fi ed. MOPAR provi des engi ne oi l s that conform to
thi s servi ce grade.
SAE VISCOSITY
pl e vi scosi ti es such as 5W-30 or 10W-30 i n the 3.7L
engi nes. These are speci fi ed wi th a dual SAE vi scos-
i ty grade whi ch i ndi cates the col d-to-hot temperature
vi scosi ty range. Sel ect an engi ne oi l that i s best
sui ted to your parti cul ar temperature range and vari -
ati on (Fi g. 85).
tai ner.
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 86).
OIL LEVEL INDICATOR (DIPSTICK)
The engi ne oi l l evel i ndi cator i s l ocated at the ri ght
rear of the engi ne on the 3.7L engi nes. (Fi g. 87).
Fig. 85 TEMPERATURE/ENGINE OIL VISCOSITY -
3.7L ENGINE
Fig. 86 Engine Oil Container Standard Notations
Fig. 87 ENGINE OIL DIPSTICK 3.7L ENGINE
1 - TRANSMISSION DIPSTICK
2 - ENGINE OIL DIPSTICK
3 - ENGINE OIL FILL CAP
DR ENGINE - 3. 7L 9 - 71
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
pressure loss or oil foaming can result.
I nspect engi ne oi l l evel approxi matel y every 800
ki l ometers (500 mi l es). Unl ess the engi ne has exhi b-
i ted l oss of oi l pressure, run the engi ne for about fi ve
mi nutes before checki ng oi l l evel . Checki ng engi ne oi l
l evel on a col d engi ne i s not accurate.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck.
(1) Posi ti on vehi cl e on l evel surface.
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
(5) Remove di psti ck, wi th handl e hel d above the
ti p, take oi l l evel readi ng.
(6) Add oi l onl y i f l evel i s bel ow the ADD mark on
di psti ck.
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Mai ntenance Schedul es.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(2) Hoi st and support vehi cl e on safety stands.
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
(8) I nstal l oi l fi l l cap.
(9) Start engi ne and i nspect for l eaks.
(10) Stop engi ne and i nspect oi l l evel .
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
secti on.
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d (Fi g. 88) i s made of a compos-
i te materi al and features 300 mm (11.811 i n.) l ong
runners whi ch maxi mi zes l ow end torque. The i ntake
mani fol d uses si ngl e pl ane seal i ng whi ch consi st of
si x i ndi vi dual press i n pl ace port gaskets to prevent
l eaks. The throttl e body attaches di rectl y to the
i ntake mani fol d. Ei ght studs and two bol ts are used
to fasten the i ntake to the head.
MANIFOLD LEAKS
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
Fig. 88 Intake Manifold
1 - THROTTLE BODY
2 - INTAKE MANIFOLD
3 - INTAKE PORT GASKETS
9 - 72 ENGINE - 3. 7L DR
OIL (Continued)
(2) Spray a smal l stream of water (spray bottl e) at
the suspected l eak area.
(3) I f engi ne RPMS change, the area of the sus-
pected l eak has been found.
(4) Repai r as requi red.
REMOVAL
(2) Remove resonator assembl y and ai r i nl et hose.
(4) Di sconnect el ectri cal connectors for the fol l ow-
i ng components: Refer to FUEL SYSTEM for compo-
nent l ocati ons.
Mani fol d Absol ute Pressure (MAP) Sensor
I ntake Ai r Temperature (I AT) Sensor
Throttl e Posi ti on (TPS) Sensor
Cool ant Temperature (CTS) Sensor
(5) Di sconnect vapor purge hose, brake booster
hose, speed control servo hose, posi ti ve crankcase
venti l ati on (PCV) hose.
(6) Di sconnect generator el ectri cal connecti ons.
(7) Di sconnect ai r condi ti oni ng compressor el ectri -
cal connecti ons.
(8) Di sconnect l eft and ri ght radi o suppressor
straps.
(9) Di sconnect and remove i gni ti on coi l towers.
(10) Remove top oi l di psti ck tube retai ni ng bol t
and ground strap.
(11) Bl eed fuel system (Refer to 14 - FUEL SYS-
TEM/FUEL DELI VERY - STANDARD PROCE-
DURE).
(12) Remove fuel rai l .
(13) Remove throttl e body assembl y and mounti ng
bracket.
(14) Drai n cool i ng system bel ow cool ant tempera-
ture l evel (Refer to 7 - COOLI NG - STANDARD
PROCEDURE).
(15) Remove the heater hoses from the engi ne
front cover and the heater core.
(16) Uncl i p and remove heater hoses and tubes
from i ntake mani fol d.
(17) Remove cool ant temperature sensor (Refer to
7 - COOLI NG/ENGI NE/ENGI NE COOLANT TEMP
SENSOR - REMOVAL).
(18) Remove i ntake mani fol d retai ni ng fasteners i n
reverse order of ti ghteni ng sequence.
INSTALLATION
(1) I nstal l i ntake mani fol d gaskets.
(2) I nstal l i ntake mani fol d.
(3) I nstal l i ntake mani fol d retai ni ng bol ts and
ti ghten i n sequence shown i n to 12 Nm (105 i n. l bs.)
(Fi g. 89).
(4) I nstal l l eft and ri ght radi o suppressor straps.
(5) I nstal l throttl e body assembl y.
(6) Connect throttl e cabl e and speed control cabl e
to throttl e body.
(7) I nstal l fuel rai l .
(8) I nstal l i gni ti on coi l towers.
(9) Posi ti on and i nstal l heater hoses and tubes
onto i ntake mani fol d.
(10) I nstal l the heater hoses to the heater core and
engi ne front cover.
(11) Connect el ectri cal connectors for the fol l owi ng
components:
I gni ti on coi l towers
Fuel i njectors
(12) I nstal l top oi l di psti ck tube retai ni ng bol t and
ground strap.
(13) Connect generator el ectri cal connecti ons.
(14) Connect Vapor purge hose, Brake booster
hose, Speed control servo hose, Posi ti ve crankcase
venti l ati on (PCV) hose.
(16) I nstal l resonator assembl y and ai r i nl et hose.
Fig. 89 Intake Manifold Tightening Sequence
DR ENGINE - 3. 7L 9 - 73
INTAKE MANIFOLD (Continued)
EXHAUST MANIFOLD
DESCRIPTION
The exhaust mani fol ds (Fi g. 90) are l og styl e wi th
a patented fl ow enhanci ng desi gn to maxi mi ze perfor-
mance. The exhaust mani fol ds are made of hi gh si l i -
con mol ybdenum cast i ron. A perforated core graphi te
exhaust mani fol d gasket i s used to i mprove seal i ng
to the cyl i nder head. The exhaust mani fol ds are cov-
ered by a three l ayer l ami nated heat shi el d for ther-
mal protecti on and noi se reducti on. The heat shi el ds
(Fi g. 91) are fastened wi th a torque prevai l i ng nut
that i s backed off sl i ghtl y to al l ow for the thermal
expansi on of the exhaust mani fol d.
REMOVAL
RIGHT EXHAUST MANIFOLD
(3) Remove the bol ts and nuts attachi ng the
exhaust pi pe to the engi ne exhaust mani fol d.
(5) Remove the exhaust heat shi el d (Fi g. 92).
(6) Remove bol ts, nuts and washers attachi ng
mani fol d to cyl i nder head.
(7) Remove mani fol d and gasket from the cyl i nder
head.
LEFT EXHAUST MANIFOLD
(3) Remove the bol ts and nuts attachi ng the
exhaust pi pe to the engi ne exhaust mani fol d.
(5) Remove the exhaust heat shi el ds (Fi g. 93).
(6) Remove bol ts, nuts and washers attachi ng
mani fol d to cyl i nder head.
(7) Remove mani fol d and gasket from the cyl i nder
head.
INSTALLATION
CAUTION: If the studs came out with the nuts when
removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends.
Water leaks may develop at the studs if this precau-
tion is not taken.
Fig. 90 EXHAUST MANIFOLDS
1 - LEFT SIDE EXHAUST MANIFOLD
2 - RIGHT SIDE EXHAUST MANIFOLD
Fig. 91 Exhaust Manifold Heat Shields
1 - RIGHT SIDE EXHAUST MANIFOLD HEAT SHIELD
2 - RIGHT SIDE EXHAUST MANIFOLD FLANGE
3 - LEFT SIDE EXHAUST MANIFOLD HEAT SHIELD
4 - LEFT SIDE EXHAUST MANIFOLD FLANGE
9 - 74 ENGINE - 3. 7L DR
(1) Posi ti on the engi ne exhaust mani fol d and gas-
ket on the two studs l ocated on the cyl i nder head.
I nstal l coni cal washers and nuts on these studs .
(2) I nstal l remai ni ng coni cal washers. Starti ng at
the center arm and worki ng outward, ti ghten the
bol ts and nuts to 25 Nm (18 ft. l bs.) torque.
(3) I nstal l the exhaust heat shi el ds.
CAUTION: Over tightening heat shield fasteners,
may cause shield to distort and/or crack.
(5) Assembl e exhaust pi pe to mani fol d and secure
wi th bol ts, nuts and retai ners. Ti ghten the bol ts and
nuts to 34 Nm (25 ft. l bs.) torque.
CAUTION: If the studs came out with the nuts when
removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends.
Water leaks may develop at the studs if this precau-
tion is not taken.
(1) Posi ti on the engi ne exhaust mani fol d and gas-
ket on the two studs l ocated on the cyl i nder head.
I nstal l coni cal washers and nuts on these studs .
(2) I nstal l remai ni ng coni cal washers. Starti ng at
the center arm and worki ng outward, ti ghten the
bol ts and nuts to 25 Nm (18 ft. l bs.) torque.
(3) I nstal l the exhaust heat shi el ds.
(5) Assembl e exhaust pi pe to mani fol d and secure
wi th bol ts, nuts and retai ners. Ti ghten the bol ts and
Fig. 92 Exhaust Manifold Right
1 - HEAT SHIELD
2 - NUTS
3 - MANIFOLD FLANGE
Fig. 93 Exhaust Manifold left
1 - HEAT SHIELD
2 - NUTS
3 - MANIFOLD FLANGE
DR ENGINE - 3. 7L 9 - 75
EXHAUST MANIFOLD (Continued)
VALVE TIMING
DESCRIPTION
The ti mi ng dri ve system has been desi gned to pro-
vi de qui et performance and rel i abi l i ty to support a
non-free wheeling engi ne. Speci fi cal l y the i ntake
val ves are non-free wheel i ng and can be easi l y dam-
aged wi th forceful engi ne rotati on i f camshaft-to-
crankshaft ti mi ng i s i ncorrect. The ti mi ng dri ve
system consi sts of a pri mary chai n, two secondary
ti mi ng chai n dri ves (Fi g. 94) and a counterbal ance
shaft dri ve.
OPERATION
The pri mary ti mi ng chai n i s a si ngl e i nverted tooth
chai n type. The pri mary chai n dri ves the l arge 50
tooth i dl er sprocket di rectl y from a 25 tooth crank-
shaft sprocket. Pri mary chai n moti on i s control l ed by
a pi voti ng l eaf spri ng tensi oner arm and a fi xed
gui de. The arm and the gui de both use nyl on pl asti c
wear faces for l ow fri cti on and l ong wear. The pri -
mary chai n recei ves oi l spl ash l ubri cati on from the
secondary chai n dri ve and desi gned oi l pump l eak-
age. The i dl er sprocket assembl y connects the pri -
mary chai n dri ve, secondary chai n dri ves, and the
counterbal ance shaft. The i dl er sprocket assembl y
consi sts of two i ntegral 26 tooth sprockets a 50 tooth
sprocket and a hel i cal gear that i s press-fi t to the
assembl y. The spl i ne joi nt for the 50 tooth sprocket i s
a non servi ceabl e press fi t anti rattl e type. A spi ral
ri ng i s i nstal l ed on the outboard si de of the 50 tooth
sprocket to prevent spl i ne di sengagement. The i dl er
sprocket assembl y spi ns on a stati onary i dl er shaft.
The i dl er shaft i s a l i ght press-fi t i nto the cyl i nder
Fig. 94 Timing Drive System
1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN
2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT
SIDE NOT INTERCHANGEABLE)
3 - SECONDARY TENSIONER ARM
4 - LEFT CAMSHAFT SPROCKET AND SECONDARY CHAIN
5 - CHAIN GUIDE (LEFT AND RIGHT SIDE ARE NOT
INTERCHANGEABLE)
6 - PRIMARY CHAIN
7 - IDLER SPROCKET
8 - CRANKSHAFT SPROCKET
9 - PRIMARY CHAIN TENSIONER
9 - 76 ENGINE - 3. 7L DR
bl ock. A l arge washer on the i dl er shaft bol t and the
rear fl ange of the i dl er shaft are used to control
sprocket thrust movement. Pressuri zed oi l i s routed
through the center of the i dl er shaft to provi de l ubri -
cati on for the two bushi ngs used i n the i dl er sprocket
assembl y.
There are two secondary dri ve chai ns, both are
rol l er type, one to dri ve the camshaft i n each SOHC
cyl i nder head. There are no shaft speed changes i n
the secondary chai n dri ve system. Each secondary
chai n dri ves a 26 tooth cam sprocket di rectl y from
the 26 tooth sprocket on the i dl er sprocket assembl y.
A fi xed chai n gui de and a hydraul i c oi l damped ten-
si oner are used to mai ntai n tensi on i n each second-
ary chai n system. The hydraul i c tensi oners for the
secondary chai n systems are fed pressuri zed oi l from
oi l reservoi r pockets i n the bl ock. Each tensi oner
i ncorporates a control l ed l eak path through a devi ce
known as a vent di sc l ocated i n the nose of the pi ston
to manage chai n l oads. Each tensi oner al so has a
mechani cal ratchet system that l i mi ts chai n sl ack i f
the tensi oner pi ston bl eeds down after engi ne shut
down. The tensi oner arms and gui des al so uti l i ze
nyl on wear faces for l ow fri cti on and l ong wear. The
secondary ti mi ng chai ns recei ve l ubri cati on from a
smal l ori fi ce i n the tensi oners. Thi s ori fi ce i s pro-
tected from cl oggi ng by a fi ne mesh screen whi ch i s
l ocated on the back of the hydraul i c tensi oners.
STANDARD PROCEDURE
MEASURING TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed.
ENGI NE/VALVE TI MI NG/TI MI NG BELT/CHAI N
AND SPROCKETS - REMOVAL).
(2) To determi ne i f the secondary ti mi ng chai ns
are worn, rotate the engi ne cl ockwi se unti l maxi mum
tensi oner pi ston extensi on i s obtai ned. Measure the
di stance between the secondary ti mi ng chai n ten-
si oner housi ng and the step l edge on the pi ston. The
measurement at poi nt (A) must be l ess than 15mm
(.5906 i nches) (Fi g. 95).
(3) I f the measurement exceeds the speci fi cati on
the secondary ti mi ng chai ns are worn and requi re
repl acement (Refer to 9 - ENGI NE/VALVE TI MI NG/
TI MI NG BELT/CHAI N AND SPROCKETS -
REMOVAL).
SERVICE PROCEDURE - TIMING VERIFICATION
CAUTION: The 3.7L is a non free-wheeling design
engine. Therefore, correct engine timing is critical.
NOTE: Components referred to as left hand or right
hand are as viewed from the drivers position inside
the vehicle.
NOTE: The blue link plates on the chains and the
dots on the camshaft drive sprockets may not line
up during the timing verification procedure. The
blue link plates are lined up with the sprocket dots
only when re-timing the complete timing drive.
Once the timing drive is rotated blue link-to-dot
alignment is no longer valid.
Engi ne base ti mi ng can be veri fi ed by the fol l owi ng
procedure:
(1) Remove the cyl i nder head covers. Refer to the
procedure i n thi s secti on.
Fig. 95 Measuring Secondary Timing Chains For
Wear
2 - SECONDARY CHAIN TENSIONER PISTON
DR ENGINE - 3. 7L 9 - 77
VALVE TIMING (Continued)
(2) Usi ng a mi rror, l ocate the TDC arrow on the
front cover (Fi g. 96). Rotate the crankshaft unti l the
mark on the crankshaft damper i s al i gned wi th the
TDC arrow on the front cover. The engi ne i s now at
TDC.
(3) Note the l ocati on of the V6 mark stamped i nto
the camshaft dri ve gears. I f the V6 mark on each
camshaft dri ve gear i s at the twel ve ocl ock posi ti on,
the engi ne i s at TDC on the exhaust stroke. I f the V6
mark on each gear i s at the si x ocl ock posi ti on, the
engi ne i s at TDC on the compressi on stroke. (Fi g.
100)
(4) I f both of the camshaft dri ve gears are off i n
the same or opposi te di recti ons, the pri mary chai n or
both secondary chai ns are at faul t. Refer to Ti mi ng
Chai n and Sprockets procedure i n thi s secti on.
(5) I f onl y one of the camshaft dri ve gears i s off
and the other i s correct, the probl em i s confi ned to
one secondary chai n. Refer to Si ngl e camshaft ti m-
i ng, i n thi s procedure.
(6) I f both camshaft dri ve gear V6 marks are at
the twel ve ocl ock or the si x ocl ock posi ti on the
engi ne base ti mi ng i s correct. Rei nstal l the cyl i nder
head covers.
COUNTER BALANCE SHAFT TIMING
(1) Ensure that the engi ne i s at TDC wi th both
camshaft sprocket V6 marks i n the 12 ocl ock posi -
ti on. (Fi g. 100)
(2) Look down the l eft cyl i nder head chai n cavi ty.
The ti mi ng dot on the counter bal ance shaft dri ve
gear shoul d be i n the 6 ocl ock posi ti on (Fi g. 97).
TIMING - SINGLE CAMSHAFT
NOTE: to adjust the timing on one camshaft, pre-
form the following procedure.
(1) Usi ng Chai n Tensi oner Wedge (Fi g. 99), Speci al
Tool 8379, stabi l i ze the secondary chai n dri ve. For
reference purposes, mark the chai n-to-sprocket posi -
ti on. (Fi g. 98)
(2) Remove the camshaft dri ve gear retai ni ng bol t.
(3) Careful l y remove the camshaft dri ve gear from
the camshaft.
(4) Re-i ndex the camshaft dri ve gear i n the chai n
unti l the V6 mark i s at the same posi ti on as the V6
mark on the opposi te camshaft dri ve gear.
rotate the camshaft unti l the al i gnment dowel on the
camshaft i s al i gned wi th the sl ot i n the camshaft
dri ve gear.
Fig. 96 Engine Top Dead Center (TDC) Indicator
Mark
Fig. 97 COUNTERBALANCE SHAFT ALIGNMENT
MARKS
1 - COUNTERBALANCE SHAFT GEAR
2 - TIMING MARK
3 - IDLER SPROCKET GEAR
9 - 78 ENGINE - 3. 7L DR
(6) Posi ti on the camshaft dri ve gear onto the cam-
shaft, remove oi l from bol t then i nstal l the retai ni ng
bol t. Usi ng Speci al Tool s, Spanner Wrench 6958 wi th
Adapter Pi ns 8346 and a sui tabl e torque wrench,
Ti ghten retai ni ng bol t to 122 Nm (90 ft. Lbs.).
Fig. 98 SECURING TIMING CHAIN TENSIONER
USING TIMING CHAIN WEDGE
1 - CYLINDER HEAD
2 -SPECIAL TOOL 8379
3 - TIMING CHAIN
Fig. 99 CAMSHAFT DRIVE GEAR REMOVAL/
INSTALLATION
1 - SPECIAL TOOL 8379 TIMING CHAIN WEDGE
2 - CAMSHAFT DRIVE GEAR
3 - RETAINING BOLT
4 - CYLINDER HEAD
Fig. 100 CAMSHAFT SPROCKET V6 MARKS (#1 TDC, Exhaust stroke)
DR ENGINE - 3. 7L 9 - 79
(8) Rotate the crankshaft two ful l revol uti ons, then
veri fy that the camshaft dri ve gear V6 marks are i n
fact al i gned.
(9) I nstal l the cyl i nder head covers. Refer to Cyl i n-
der Head Cover i n thi s secti on.
BALANCE SHAFT
REMOVAL
(1) Remove the pri mary and secondary ti mi ng
chai ns. Refer to TI MI NG CHAI N and SPROCKET.
NOTE: The balance shaft and gear are serviced as
an assembly. Do not attempt to remove the gear
from the balance shaft.Remove the retaining bolt
from the counterbalance shaft thrust plate (Fig.
101).
(2) Usi ng Speci al Tool 8641 Counterbal ance shaft
remover/i nstal l er tool , remove the counterbal ance
shaft from the engi ne (Fi g. 102).
INSTALLATION
NOTE: The balance shaft and gear are serviced as
an assembly. Do not attempt to remove the gear
from the balance shaft.
(1) Coat counterbal ance shaft beari ng journal s
wi th cl ean engi ne oi l .
NOTE: The balance shaft is heavy, and care should
be used when installing shaft, so bearings are not
damaged.
(2) Usi ng Speci al Tool 8641 Counterbal ance shaft
remover/i nstal l er tool , careful l y i nstal l counterbal -
ance shaft i nto engi ne.
(3) I nstal l Counterbal ance shaft thrust pl ate
retai ni ng bol t fi nger ti ght.Do not ti ghten bol t at thi s
ti me.
(4) Posi ti on the ri ght si de of the thrust pl ate wi th
the ri ght chai n gui de bol t, i nstal l bol t fi nger ti ght.
(5) Torque the thrust pl ate retai ni ng bol t to 28
Nm (250 i n. l bs.).
(6) Remove the chai n gui de bol t so that gui de can
be i nstal l ed.
Fig. 101 Counterbalance Shaft Retaining Plate
1 - IDLER SHAFT
2 - COUNTERBALANCE SHAFT THRUST PLATE
3 - COUNTERBALANCE SHAFT DRIVE GEAR
4 - RETAINING BOLT
Fig. 102 Counterbalance Shaft Removal/Installation
Tool
1 - COUNTERBALANCE SHAFT REMOVAL AND INSTALLATION
TOOL
2 - COUNTERBALANCE SHAFT THRUST PLATE
9 - 80 ENGINE - 3. 7L DR
IDLER SHAFT
REMOVAL
chai ns and sprockets. Refer to procedure i n thi s sec-
ti on.
NOTE: To remove the idler shaft, it is necessary to
tap threads into the shaft, to install the removal
tool.
(2) Usi ng a 12 mm X 1.75 tap, cut threads i n the
i dl er shaft center bore.
(3) Cover the radi ator core wi th a sui tabl e cover.
CAUTION: Use care when removing the idler shaft,
Do not strike the radiator cooling fins with the slide
hammer.
(4) Usi ng Speci al Tool 8517 Sl i de Hammer, remove
the i dl er shaft.
INSTALLATION
(1) Thoroughl y cl ean the i dl er shaft bore.
(2) Posi ti on the i dl er shaft i n the bore.
NOTE: The two lubrication holes in the idler shaft
do not require any special alignment.
NOTE: Before using the retaining bolt to install the
idler shaft, coat the threads and the pilot on the
idler shaft, with clean engine oil.
(3) Usi ng the pri mary i dl er sprocket retai ni ng bol t
and washer, careful l y draw the i dl er shaft i nto the
bore unti l ful l y seated.
(4) Coat the i dl er shaft wi th cl ean engi ne oi l .
(5) I nstal l the ti mi ng chai ns and sprockets. Refer
to procedure i n thi s secti on.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(3) Remove el ectri c cool i ng fan and fan shroud
assembl y.
(4) Remove fan and fan dri ve assembl y (Refer to 7
- COOLI NG/ENGI NE/FAN DRI VE VI SCOUS
CLUTCH - REMOVAL).
(5) Di sconnect both heater hoses at ti mi ng cover.
(6) Di sconnect l ower radi ator hose at engi ne.
(7) Remove accessory dri ve bel t tensi oner assembl y
(Fi g. 103).
(8) Remove crankshaft damper (Refer to 9 -
REMOVAL).
(9) Remove the generator (Refer to 8 - ELECTRI -
CAL/CHARGI NG/GENERATOR - REMOVAL).
(10) Remove A/C compressor (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C COM-
PRESSOR - REMOVAL).
CAUTION: The 3.7L engine uses an anerobic sealer
instead of a gasket to seal the front cover to the
engine block, from the factory. For service, Mopar
Engine RTV sealant must be substituted.
NOTE: It is not necessary to remove the water
pump for timing cover removal.
(11) Remove the bol ts hol di ng the ti mi ng cover to
engi ne bl ock (Fi g. 104).
(12) Remove the ti mi ng cover.
INSTALLATION
CAUTION: Do not use oil based liquids to clean tim-
ing cover or block surfaces. Use only rubbing alco-
hol, along with plastic or wooden scrapers. Use no
wire brushes or abrasive wheels or metal scrapers,
or damage to surfaces could result.
Fig. 103 ACCESSORY DRIVE BELT TENSIONER
1 - TENSIONER ASSEMBLY
2 - FASTENER TENSIONER TO FRONT COVER
DR ENGINE - 3. 7L 9 - 81
(1) Cl ean ti mi ng chai n cover and bl ock surface
usi ng rubbi ng al cohol .
CAUTION: The 3.7L uses a special anerobic sealer
instead of a gasket to seal the timing cover to the
engine block, from the factory. For service repairs,
Mopar Engine RTV must be used as a substitute.
(2) I nspect the water passage o-ri ngs for any dam-
age, and repl ace as necessary.
(3) Appl y Mopar Engi ne RTV seal er to front cover
fol l owi ng the path bel ow usi ng a 3 to 4mm thi ck
bead (Fi g. 105).
(4) I nstal l cover. Ti ghten fasteners i n sequence as
shown i n to 58 Nm (43 ft. l bs.) (Fi g. 106).
(5) I nstal l crankshaft damper (Refer to 9 -
I NSTALLATI ON).
(6) I nstal l the A/C compressor (Refer to 24 - HEAT-
PRESSOR - I NSTALLATI ON).
(7) I nstal l the generator (Refer to 8 - ELECTRI -
CAL/CHARGI NG/GENERATOR - I NSTALLATI ON).
(8) I nstal l accessory dri ve bel t tensi oner assembl y
(Refer to 7 - COOLI NG/ACCESSORY DRI VE/BELT
TENSI ONERS - I NSTALLATI ON).
(9) I nstal l radi ator upper and l ower hoses.
(10) I nstal l both heater hoses.
(11) I nstal l el ectri c fan shroud and vi scous fan
dri ve assembl y (Refer to 7 - COOLI NG/ENGI NE/FAN
DRI VE VI SCOUS CLUTCH - I NSTALLATI ON).
Fig. 104 TIMING CHAIN COVER FASTENERS
Fig. 105 TIMING COVER SEALANT
2 - WATER PASSAGE ORING
3 - MOPAR ENGINE RTV SEALER
Fig. 106 TIMING CHAIN COVER FASTENERS
9 - 82 ENGINE - 3. 7L DR
TIMING BELT / CHAIN COVER(S) (Continued)
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(2) Drai n cool i ng system(Refer to 7 - COOLI NG -
(3) Remove ri ght and l eft cyl i nder head covers(Re-
fer to 9 - ENGI NE/CYLI NDER HEAD/CYLI NDER
HEAD COVER(S) - REMOVAL).
(4) Remove radi ator fan shroud(Refer to 7 - COOL-
(5) Rotate engi ne unti l ti mi ng mark on crankshaft
damper al i gns wi th TDC mark on ti mi ng chai n cover
(Fi g. 108) and the camshaft sprocket V6 marks are
at the 12 ocl ock posi ti on (No. 1 TDC exhaust stroke)
(Fi g. 107).
(6) Remove power steeri ng pump(Refer to 19 -
STEERI NG/PUMP - REMOVAL).
Fig. 107 CAMSHAFT SPROCKET V6 MARKS, (#1 TDC EXHAUST STROKE)
Fig. 108 Engine Top Dead Center
DR ENGINE - 3. 7L 9 - 83
(7) Remove access pl ug from l eft and ri ght cyl i nder
heads for access to chai n gui de fasteners (Fi g. 109).
(8) Remove the oi l fi l l housi ng to gai n access to the
ri ght si de tensi oner arm fastener.
REMOVAL) and ti mi ng chai n cover(Refer to 9 -
(10) Col l apse and pi n pri mary chai n tensi oner.
CAUTION: Plate behind left secondary chain ten-
sioner could fall into oil pan. Therefore, cover pan
opening.
(11) Remove secondary chai n tensi oners.
(12) Remove camshaft posi ti on sensor (Fi g. 110).
CAUTION: Care should be taken not to damage
camshaft target wheel. Do not hold target wheel
while loosening or tightening camshaft sprocket.
Do not place the target wheel near a magnetic
source of any kind. A damaged or magnetized tar-
get wheel could cause a vehicle no start condition.
CAUTION: Do not forcefully rotate the camshafts or
crankshaft independently of each other. Damaging
intake valve to piston contact will occur. Ensure
negative battery cable is disconnected to guard
against accidental starter engagement.
(13) Remove l eft and ri ght camshaft sprocket bol ts.
(14) Whi l e hol di ng the l eft camshaft steel tube
wi th Speci al Tool 8428 Camshaft Wrench, remove the
l eft camshaft sprocket. Sl owl y rotate the camshaft
approxi matel y 5 degrees cl ockwi se to a neutral posi -
ti on.
(15) Whi l e hol di ng the ri ght camshaft steel tube
wi th Speci al Tool 8428 Camshaft Wrench, remove the
ri ght camshaft sprocket.
(16) Remove i dl er sprocket assembl y bol t.
(17) Sl i de the i dl er sprocket assembl y and crank
sprocket forward si mul taneousl y to remove the pri -
mary and secondary chai ns.
(18) Remove both pi voti ng tensi oner arms and
chai n gui des.
(19) Remove pri mary chai n tensi oner.
INSPECTION
I nspect the fol l owi ng components:
Sprockets for excessi ve tooth wear. Some tooth
marki ngs are normal and not a cause for sprocket
repl acement.
I dl er sprocket assembl y bushi ng and shaft for
excessi ve wear.
I dl er sprocket assembl y spl i ne joi nt. The joi nt
shoul d be ti ght wi th no backl ash or axi al movement.
Chai n gui des and tensi oner arms. Repl ace these
parts i f groovi ng i n pl asti c face i s more than 1 mm
(0.039 i n.) deep. I f pl asti c face i s severel y grooved or
mel ted, the tensi oner l ube jet may be cl ogged. The
tensi oner shoul d be repl aced.
Secondary chai n tensi oner pi ston and ratcheti ng
devi ce. I nspect for evi dence of heavy contact between
tensi oner pi ston and tensi oner arm. I f thi s condi ti on
exi st the tensi oner tensi oner arm and chai n shoul d
be repl aced.
Fig. 110 Camshaft Position Sensor
1 - CYLINDER HEAD
2 - CAMSAHFT POSITION SENSOR
3 - SCREW
9 - 84 ENGINE - 3. 7L DR
TIMING BELT/CHAIN AND SPROCKETS (Continued)
Pri mary chai n tensi oner pl asti c faces. Repl ace as
requi red.
INSTALLATION
(1) Usi ng a vi se, l i ghtl y compress the secondary
chai n tensi oner pi ston unti l the pi ston step i s fl ush
wi th the tensi oner body. Usi ng a pi n or sui tabl e tool ,
rel ease ratchet pawl by pul l i ng pawl back agai nst
spri ng force through access hol e on si de of tensi oner.
Whi l e conti nui ng to hol d pawl back, Push ratchet
devi ce to approxi matel y 2 mm from the tensi oner
body. I nstal l Speci al Tool 8514 l ock pi n i nto hol e on
front of tensi oner (Fi g. 111). Sl owl y open vi se to
transfer pi ston spri ng force to l ock pi n.
(2) Posi ti on pri mary chai n tensi oner over oi l pump
and i nsert bol ts i nto l ower two hol es on tensi oner
bracket. Ti ghten bol ts to 28 Nm (250 i n. l bs.).
(3) I nstal l ri ght si de chai n tensi oner arm. I nstal l
Torx bol t. Ti ghten Torx bol t to 28 Nm (250 i n.
l bs.).
CAUTION: The silver bolts retain the guides to the
cylinder heads and the black bolts retain the guides
to the engine block.
(4) I nstal l the l eft si de chai n gui de. Ti ghten the
(5) I nstal l l eft si de chai n tensi oner arm, and Torx
bol t. Ti ghten Torx bol t to 28 Nm (250 i n. l bs.).
(6) I nstal l the ri ght si de chai n gui de. Ti ghten the
(7) I nstal l both secondary chai ns onto the i dl er
sprocket. Al i gn two pl ated l i nks on the secondary
chai ns to be vi si bl e through the two l ower openi ngs
on the i dl er sprocket (4 ocl ock and 8 ocl ock). Once
the secondary ti mi ng chai ns are i nstal l ed, posi ti on
speci al tool 8429 to hol d chai ns i n pl ace for i nstal l a-
ti on.
(8) Al i gn pri mary chai n doubl e pl ated l i nks wi th
the ti mi ng mark at 12 ocl ock on the i dl er sprocket.
Al i gn the pri mary chai n si ngl e pl ated l i nk wi th the
ti mi ng mark at 6 ocl ock on the crankshaft sprocket.
(9) Lubri cate i dl er shaft and bushi ngs wi th cl ean
engi ne oi l .
NOTE: The idler sprocket must be timed to the
counterbalance shaft drive gear before the idler
sprocket is fully seated.
(10) I nstal l al l chai ns, crankshaft sprocket, and
i dl er sprocket as an assembl y (Fi g. 112). After gui d-
i ng both secondary chai ns through the bl ock and cyl -
i nder head openi ngs, affi x chai ns wi th a el asti c strap
or equi val ent. Thi s wi l l mai ntai n tensi on on chai ns to
ai d i n i nstal l ati on. Al i gn the ti mi ng mark on the
i dl er sprocket gear to the ti mi ng mark on the coun-
terbal ance shaft dri ve gear, then seat i dl er sprocket
ful l y (Fi g. 113). Before i nstal l i ng i dl er sprocket bol t,
l ubri cate washer wi th oi l , and ti ghten i dl er sprocket
assembl y retai ni ng bol t to 34 Nm (25 ft. l bs.).
Fig. 111 RESETTING SECONDARY CHAIN
TENSIONERS
1 - VISE
2 - INSERT LOCK PIN
3 - RATCHET PAWL
4 - RATCHET
5 - PISTON
Fig. 112 INSTALLING IDLER GEAR, PRIMARY AND
SECONDARY TIMING CHAINS
2 - PRIMARY CHAIN IDLER SPROCKET
DR ENGINE - 3. 7L 9 - 85
NOTE: It will be necessary to slightly rotate cam-
shafts for sprocket installation.
(11) Al i gn l eft camshaft sprocket L dot to pl ated
l i nk on chai n.
(12) Al i gn ri ght camshaft sprocket R dot to
pl ated l i nk on chai n.
CAUTION: Remove excess oil from the camshaft
sprocket bolt. Failure to do so can result in over-
torque of bolt resulting in bolt failure.
(13) Remove Speci al Tool 8429, then attach both
sprockets to camshafts. Remove excess oi l from bol ts,
then I nstal l sprocket bol ts, but do not ti ghten at thi s
ti me.
(14) Veri fy that al l pl ated l i nks are al i gned wi th
the marks on al l sprockets and the V6 marks on
camshaft sprockets are at the 12 ocl ock posi ti on.
CAUTION: Ensure the plate between the left sec-
ondary chain tensioner and block is correctly
installed.
(15) I nstal l both secondary chai n tensi oners.
NOTE: Left and right secondary chain tensioners
are not common.
(16) Remove al l l ocki ng pi ns (3) from tensi oners.
CAUTION: After pulling locking pins out of each
tensioner, DO NOT manually extend the tensioner(s)
ratchet. Doing so will over tension the chains,
resulting in noise and/or high timing chain loads.
(17) Usi ng Speci al Tool 6958, Spanner wi th Adap-
tor Pi ns 8346, ti ghten l eft (Fi g. 114) and ri ght (Fi g.
115). camshaft sprocket bol ts to 122 Nm (90 ft. l bs.).
(18) Rotate engi ne two ful l revol uti ons. Veri fy ti m-
i ng marks are at the fol l ow l ocati ons:
pri mary chai n i dl er sprocket dot i s at 12 ocl ock
pri mary chai n crankshaft sprocket dot i s at 6
ocl ock
secondary chai n camshaft sprockets V6 marks
are at 12 ocl ock
counterbal ancer shaft dri ve gear dot i s al i gned
to the i dl er sprocket gear dot
(19) Lubri cate al l three chai ns wi th engi ne oi l .
(20) After i nstal l i ng al l chai ns, i t i s recommended
that the i dl er gear end pl ay be checked. The end pl ay
Fig. 113 COUNTERBALANCE SHAFT ALIGNMENT
MARKS
1 - COUNTERBALANCE SHAFT GEAR
2 - TIMING MARK
3 - IDLER SPROCKET GEAR
Fig. 114 TIGHTENING LEFT SIDE CAMSHAFT
SPROCKET BOLT
1 - TORQUE WRENCH
4 - SPECIAL TOOL 6958 SPANNER WITH ADAPTER PINS 8346
9 - 86 ENGINE - 3. 7L DR
must be wi thi n 0.10 -0.25 mm (0.004 - 0.010 i n.). I f
not wi thi n speci fi cati on, the i dl er gear must be
repl aced (Fi g. 116).
(21) I nstal l ti mi ng chai n cover and crankshaft
damper. Refer to procedures.
(22) I nstal l cyl i nder head covers(Refer to 9 -
NOTE: Before installing threaded plug in right cylin-
der head, the plug must be coated with sealant to
prevent leaks.
(23) Coat the l arge threaded access pl ug wi th
Mopar Thread Sealant with Teflon, then i nstal l
i nto the ri ght cyl i nder head and ti ghten to 81 Nm
(60 ft. l bs.).
(24) I nstal l the oi l fi l l housi ng.
(25) I nstal l access pl ug i n l eft cyl i nder head.
(26) I nstal l power steeri ng pump(Refer to 19 -
STEERI NG/PUMP - I NSTALLATI ON).
(27) Fi l l cool i ng system(Refer to 7 - COOLI NG -
Fig. 115 TIGHTENING RIGHT SIDE CAMSHAFT
SPROCKET BOLT
1 - TORQUE WRENCH
2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346
3 - LEFT CAMSHAFT SPROCKET
4 - RIGHT CAMSHAFT SPROCKET
Fig. 116 MEASURING IDLER GEAR END PLAY
1 - IDLER SPROCKET ASSEMBLY
2 - DIAL INDICATOR
DR ENGINE - 3. 7L 9 - 87
ENGINE - 4.7L
TABLE OF CONTENTS
page page
ENGINE - 4.7L
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . 90
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . 92
COMPRESSION PRESSURE . . . . . . . . . . . . . 93
COMBUSTION PRESSURE LEAKAGE . . . . . . 93
DIAGNOSIS - INTRODUCTION . . . . . . . . . . . 94
STANDARD PROCEDURE
DAMAGED OR WORN THREADS . . . . . . . . . 94
PLACE GASKETS AND SEALERS . . . . . . . . . 94
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 97
SPECIFICATIONS
SPECIFICATIONS - 4.7L ENGINE . . . . . . . . . 99
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
SPECIAL TOOLS
4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 103
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 107
CYLINDER HEAD
DESCRIPTION
DESCRIPTION - CYLINDER HEAD . . . . . . . 107
DESCRIPTION - VALVE GUIDES . . . . . . . . . 107
REMOVAL
REMOVAL - LEFT CYLINDER HEAD . . . . . . 108
REMOVAL - RIGHT CYLINDER HEAD . . . . . 110
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 111
INSTALLATION
INSTALLATION - LEFT CYLINDER HEAD . . . 112
INSTALLATION - RIGHT CYLINDER HEAD . 113
CAMSHAFT(S) - LEFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 114
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 116
CAMSHAFT(S) - RIGHT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 119
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 120
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 122
REMOVAL
REMOVAL - RIGHT SIDE . . . . . . . . . . . . . . . 122
REMOVAL - LEFT SIDE . . . . . . . . . . . . . . . . 122
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
INSTALLATION
INSTALLATION - RIGHT SIDE . . . . . . . . . . . 123
INSTALLATIONLEFT SIDE . . . . . . . . . . . . 123
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 123
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124
ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 125
LASH ADJUSTER . . . . . . . . . . . . . . . . . . . . . 125
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 126
VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 126
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 127
VALVE STEM SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 127
ENGINE BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 128
HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 128
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING . . . . . . . . . . . . . . . 129
CORE PLUGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 131
CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 131
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 132
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 132
STANDARD PROCEDURECRANKSHAFT
MAIN BEARING - FITTING . . . . . . . . . . . . . . 134
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 135
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 136
9 - 88 ENGINE - 4. 7L DR
AREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 137
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 138
FLEX PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 138
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 139
STANDARD PROCEDURE - PISTON FITTING . 139
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 140
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 140
PISTON RINGS
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 144
STRUCTURAL COVER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 145
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 145
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 145
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 147
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 149
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 150
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 150
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . 152
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
OIL
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 155
OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 155
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 156
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 156
OPERATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 156
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 156
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 156
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 157
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 157
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 159
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 159
DIAGNOSIS AND TESTINGINTAKE
MANIFOLD LEAKAGE . . . . . . . . . . . . . . . . . 159
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 160
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 160
EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 161
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 163
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 164
VALVE TIMING
DESCRIPTIONTIMING DRIVE SYSTEM . . . . 166
OPERATION - TIMING DRIVE SYSTEM . . . . . 166
STANDARD PROCEDURE
STANDARD PROCEDUREMEASURING
TIMING CHAIN WEAR . . . . . . . . . . . . . . . . . 167
STANDARD PROCEDURE - ENGINE TIMING
- VERIFICATION . . . . . . . . . . . . . . . . . . . . . 167
TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 171
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 174
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 176
IDLER SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 179
DR ENGINE - 4. 7L 9 - 89
ENGINE - 4.7L
connections.
TESTING).
COIL - REMOVAL).
- CLEANING).
filter.
7. Faulty fuel pump, relay or wiring. 7. Repair or replace as necessary.
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low. 1. (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/IDLE AIR
CONTROL MOTOR - REMOVAL).
2. Idle mixture too lean or too rich. 2. Refer to Powertrain Diagnosis
Information.
3. Vacuum leak. 3. Inspect intake manifold and
necessary.
COIL - REMOVAL).
5. Incorrect engine timing. 5. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD
PROCEDURE).
9 - 90 ENGINE - 4. 7L DR
plugs.
- CLEANING).
filter.
system.
necessary.
COIL - REMOVAL).
1. ENGINE MISSES ON
ACCELERATION
gapped.
- CLEANING).
COIL - REMOVAL).
1. ENGINE MISSES AT HIGH
SPEED
gapped.
- CLEANING).
COIL - REMOVAL).
filter.
DR ENGINE - 4. 7L 9 - 91
crankcase.
MAINTENANCE -
SPECIFICATIONS)
wear.
& SEATS - STANDARD
PROCEDURE)
on valve faces.
& SEATS - STANDARD
PROCEDURE)
MAINTENANCE -
SPECIFICATIONS)
wear.
out-of-round.
MAINTENANCE -
SPECIFICATIONS)
wear.
converter.
9 - 92 ENGINE - 4. 7L DR
ti ons.
ai r.
RELAY - REMOVAL).
revol uti ons.
(6) Record the compressi on pressure on the 3rd revo-
l uti on. Conti nue the test for the remai ni ng cyl i nders.
Exhaust and i ntake val ve l eaks (i mproper seati ng).
jacket.
l oss.
OFF.
mended.
AIR ESCAPES THROUGH
THROTTLE BODY
seated properly
necessary.
AIR ESCAPES THROUGH
TAILPIPE
Exhaust valve bent, burnt, or not
seated properly
necessary.
AIR ESCAPES THROUGH
RADIATOR
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
adjacent cylinders
necessary
Stuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wall
DR ENGINE - 4. 7L 9 - 93
I NG).
SI S AND TESTI NG).
STANDARD PROCEDURE
OR WORN THREADS
equi val ent.
GASKETS AND SEALERS
use.
MOPAR ATF RTV
MOPAR GASKET MAKER
APPLICATION
kets.
9 - 94 ENGINE - 4. 7L DR
REMOVAL
NOTE: This procedure applies to both the 4X2 and
4X4 vehicles, steps that apply to the 4X4 vehicle
only, are identified.
(1) Di sconnect the battery negati ve and posi ti ve
cabl es.
(2) Remove the battery and the battery tray.
(4) Remove exhaust crossover pi pe from exhaust
mani fol ds.
(5) 4X4 vehicles Di sconnect axl e vent tube from
l eft si de engi ne mount.
(6) Remove the through bol t retai ni ng nut and bol t
from both the l eft and ri ght si de engi ne mounts.
(7) 4X4 vehicles Remove l ocknut from l eft and
ri ght si de engi ne mount brackets.
(8) Di sconnect two ground straps from the l ower
l eft hand si de and one ground strap from the l ower
ri ght hand si de of the engi ne.
(9) Di sconnect crankshaft posi ti on sensor. (Fi g. 1)
NOTE: The following step applies to 4X4 vehicles
equipped with automatic transmission only.
(10) 4X4 vehicles Remove the axl e i sol ator
bracket from the engi ne, transmi ssi on and the axl e.
(11) Remove structural cover (Refer to 9 -
ENGI NE/ENGI NE BLOCK/STRUCTURAL COVER -
REMOVAL).
(12) Remove starter (Refer to 8 - ELECTRI CAL/
STARTI NG/STARTER MOTOR - REMOVAL).
(14) Remove torque converter bol ts (Automati c
Transmi ssi on Onl y).
(15) Remove transmi ssi on to engi ne mounti ng
bol ts.
(16) Di sconnect the engi ne bl ock heater power
cabl e from the bl ock heater, i f equi pped.
(18) Remove throttl e body resonator assembl y and
ai r i nl et hose.
Fig. 1 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
4 - RIGHT SIDE CYLINDER BLOCK
DR ENGINE - 4. 7L 9 - 95
(20) Di sconnect tube from both the l eft and ri ght
si de crankcase breathers (Fi g. 2). Remove breathers
(21) Di scharge A/C system (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/REFRI G-
ERANT - STANDARD PROCEDURE).
PRESSOR - REMOVAL).
(23) Remove shroud, fan assembl y (Refer to 7 -
COOLI NG/ENGI NE/FAN DRI VE VI SCOUS
CLUTCH - REMOVAL) and accessory dri ve bel t
(Refer to 7 - COOLI NG/ACCESSORY DRI VE/DRI VE
BELTS - REMOVAL).
(24) Di sconnect transmi ssi on oi l cool er l i nes at the
radi ator.
(25) Di sconnect radi ator upper and l ower hoses.
(26) Remove radi ator (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR - REMOVAL), A/C condenser
(Refer to 24 - HEATI NG & AI R CONDI TI ONI NG/
PLUMBI NG/A/C CONDENSER - REMOVAL) and
transmi ssi on oi l cool er.
(27) Remove generator (Refer to 8 - ELECTRI CAL/
CHARGI NG/GENERATOR - REMOVAL).
(28) Di sconnect the two heater hoses from the ti m-
i ng chai n cover and heater core.
from the i ntake mani fol d.
(30) Di sconnect engi ne harness at the fol l owi ng
poi nts :
I ntake ai r temperature (I AT) sensor (Fi g. 3)
Fuel I njectors
Mani fol d absol ute pressure (MAP) Sensor
Coi l Over Pl ugs
(31) Di sconnect the vacuum l i nes at the throttl e
body and i ntake mani fol d.
(32) Rel ease fuel rai l pressure (Refer to 14 - FUEL
SYSTEM/FUEL DELI VERY - STANDARD PROCE-
DURE) then di sconnect the fuel suppl y qui ck connect
fi tti ng at the fuel rai l (Refer to 14 - FUEL SYSTEM/
FUEL DELI VERY/QUI CK CONNECT FI TTI NG -
(33) Remove power steeri ng pump and posi ti on out
of the way.
(34) I nstal l Speci al Tool s 8400 Li fti ng Studs, i nto
the cyl i nder heads.
(35) I nstal l Engi ne Li fti ng Fi xture Speci al Tool
8347 (Fi g. 4) fol l owi ng these steps.
Hol di ng the l i fti ng fi xture at a sl i ght angl e, sl i de
the l arge bore i n the front pl ate over the hex porti on
of the l i fti ng stud.
Posi ti on the two remai ni ng fi xture arms onto
the two Speci al Tool s 8400 Li fti ng Studs, i n the cyl -
i nder heads.
Pul l foward and upward on the l i fti ng fi xture so
that the l i fti ng stud rest i n the sl otted area bel ow the
l arge bore.
Fig. 2 Crankcase Breather Connection Points
1 - CRANKCASE BREATHERS
Fig. 3 Throttle Body Connection Points
1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR
4 - IAT SENSOR
5 - MOUNTING SCREWS
9 - 96 ENGINE - 4. 7L DR
Secure the l i fti ng fi xture to the three studs
usi ng three 7/16 14 N/C l ocknuts.
Make sure the l i fti ng l oop i n the l i fti ng fi xture i s
i n the l ast hol e (cl osest to the throttl e body) to mi n-
i mi ze the angl e of engi ne duri ng removal .
(36) Di sconnect body ground strap at the ri ght si de
cowl (Fi g. 5).
(37) Di sconnect body ground strap at the l eft si de
cowl (Fi g. 6).
NOTE: It will be necessary to support the transmis-
sion in order to remove the engine.
(38) Posi ti on a sui tabl e jack under the transmi s-
si on.
(39) Remove engi ne from the vehi cl e.
INSTALLATION
(1) Posi ti on engi ne i n the vehi cl e.
Fig. 4 Engine Lifting Fixture Attachment Locations
1 - ATTACHING LOCATION
2 - ADJUSTABLE HOOK
3 - SPECIAL TOOL 8347 ENGINE LIFT FIXTURE
4 - ATTACHING LOCATIONS
Fig. 5 Body Ground StrapRight Side Removal /
Installation
1 - NUT
2 - A/C ACCUMULATOR
3 - GROUND STRAP
Fig. 6 Body Ground StrapLeft Side Removal /
Installation
1 - NUT
2 - GROUND STRAP
3 - BRAKE BOOSTER
DR ENGINE - 4. 7L 9 - 97
Posi ti on both the l eft and ri ght si de engi ne mount
brackets and i nstal l the through bol ts and nuts.
Ti ghten nuts to 4X2 vehicles 95 Nm (70 ft. l bs.).
4X4 vehicles 102 Nm (75 ft. l bs.).
(2) 4X4 vehicles I nstal l l ocknuts onto the engi ne
mount brackets. Ti ghten l ocknuts to 41 Nm (30 ft.
l bs.).
(3) Remove jack from under the transmi ssi on.
(4) Remove Engi ne Li fti ng Fi xture Speci al Tool
8347 (Fi g. 4).
(5) Remove Speci al Tool s 8400 Li fti ng Studs.
(6) Posi ti on generator wi ri ng behi nd the oi l di p-
sti ck tube, then i nstal l the oi l di psti ck tube upper
mounti ng bol t.
(7) Connect both l eft and ri ght si de body ground
straps.
(8) I nstal l power steeri ng pump.
(9) Connect fuel suppl y l i ne qui ck connect fi tti ng
(Refer to 14 - FUEL SYSTEM/FUEL DELI VERY/
QUI CK CONNECT FI TTI NG - STANDARD PROCE-
DURE).
(10) Connect the vacuum l i nes at the throttl e body
and i ntake mani fol d.
(11) Connect engi ne harness at the fol l owi ng
poi nts (Fi g. 3):
Fuel I njectors
Coi l Over Pl ugs
(13) I nstal l the heater hoses onto the heater core
and the engi ne front cover.
(14) I nstal l generator (Refer to 8 - ELECTRI CAL/
CHARGI NG/GENERATOR - I NSTALLATI ON).
(15) I nstal l A/C condenser (Refer to 24 - HEATI NG
& AI R CONDI TI ONI NG/PLUMBI NG/A/C CON-
DENSER - I NSTALLATI ON), radi ator (Refer to 7 -
COOLI NG/ENGI NE/RADI ATOR - I NSTALLATI ON)
and transmi ssi on oi l cool er.
(16) Connect radi ator upper and l ower hoses.
(17) Connect the transmi ssi on oi l cool er l i nes to
the radi ator.
(18) I nstal l accessory dri ve bel t (Refer to 7 -
I NSTALLATI ON), fan assembl y and shroud (Refer to
7 - COOLI NG/ENGI NE/FAN DRI VE VI SCOUS
CLUTCH - I NSTALLATI ON).
(19) I nstal l A/C compressor (Refer to 24 - HEAT-
(20) I nstal l both breathers. Connect tube to both
crankcase breathers (Fi g. 2).
(21) Connect throttl e and speed control cabl es.
(22) I nstal l throttl e body resonator assembl y and
ai r i nl et hose. Ti ghten cl amps 4 Nm (35 i n. l bs.).
(24) I nstal l transmi ssi on to engi ne mounti ng bol ts.
Ti ghten the bol ts to 41 Nm (30 ft. l bs.).
(25) I nstal l torque converter bol ts (Automati c
Transmi ssi on Onl y).
(26) Connect crankshaft posi ti on sensor (Fi g. 1).
(27) 4X4 vehicles Posi ti on and i nstal l the axl e
i sol ator bracket onto the axl e, transmi ssi on and
engi ne bl ock. Ti ghten bol ts to speci fi cati on (Refer to 9
- ENGI NE - SPECI FI CATI ONS).
(28) I nstal l starter (Refer to 8 - ELECTRI CAL/
STARTI NG/STARTER MOTOR - I NSTALLATI ON).
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(29) I nstal l structural cover (Refer to 9 - ENGI NE/
ENGI NE BLOCK/STRUCTURAL COVER - I NSTAL-
LATI ON).
(30) I nstal l exhaust crossover pi pe.
(31) I nstal l engi ne bl ock heater power cabl e, I f
equi pped.
(32) 4X4 vehicles Connect axl e vent tube to l eft
si de engi ne mount.
(34) Check and fi l l engi ne oi l .
(35) Recharge the A/C system (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG/REFRI G-
ERANT - STANDARD PROCEDURE).
(36) Refi l l the engi ne cool i ng system (Refer to 7 -
(37) I nstal l the battery tray and battery.
(38) Connect the battery posi ti ve and negati ve
cabl es.
9 - 98 ENGINE - 4. 7L DR
SPECIFICATIONS
SPECIFICATIONS - 4. 7L ENGINE
GENERAL DESCRIPTION
Engine Type 90SOHC V-8 16-Valve
Displacement 4.7 Liters / 4701 cc
287 ( Cubic Inches)
Bore 93.0 mm (3.66 in.)
Stroke 86.5 mm (3.40 in.)
Compression Ratio 9.0:1
Horsepower 235 BHP @ 4800 RPM
Torque 295 LB-FT @ 3200 RPM
Lead Cylinder #1 Left Bank
Firing Order 1-8-4-3-6-5-7-2
CYLINDER BLOCK
Metric Standard
Bore Diameter 93.010 .0075
mm
3.6619 0.0003
in.
Out of Round
(MAX)
0.076 mm 0.003 in.
Taper (MAX) 0.051 mm 0.002 in.
PISTONS
Metric Standard
Diameter 92.975 mm 3.6605 in.
Weight 366 grams 12.9 oz
Ring Groove
Diameter
No. 1 83.37 - 83.13
mm
3.282 - 3.273 in
No. 2 82.833 - 83.033
mm
3.261 - 3.310 in.
No. 3 83.88 - 84.08
mm
3.302 - 3.310 in.
PISTON PINS
Metric Standard
Clearance In
Piston
0.010 - 0.019
mm
0.0004 - 0.0008
in.
Diameter 24.013 - 24.016
mm
0.9454 - 0.9455
in.
PISTON RINGS
Metric Standard
Ring Gap
Top
Compression
Ring
0.20 - 0.36 mm 0.0079 - 0.0142
in.
Second
Compression
Ring
0.37 - 0.63 mm 0.0146 - 0.0249
in.
Oil Control
(Steel Rails)
0.25 - 0.76 mm 0.0099 - 0.30 in.
Side Clearance
Top
Compression
Ring
.051 - .094 mm 0.0020 - 0.0037
in.
Second
Compression
Ring
0.040 - 0.080
mm
0.0016 - 0.0031
in.
Oil Ring (Steel
Ring)
.019 - .229 mm .0007 - .0091 in.
Ring Width
Top
Compression
Ring
1.472 - 1.490
mm
0.057 - 0.058 in.
Second
Compression
Ring
1.472 - 1.490
mm
0.057 - 0.058 in.
Oil Ring (Steel
Rails)
0.445 - 0.470
mm
0.017 - 0.018 in.
DR ENGINE - 4. 7L 9 - 99
CONNECTING RODS
Metric Standard
Bearing
Clearance
0.015 - 0.055
mm
0.0006 - 0.0022
in.
in.
Piston Pin Bore
Diameter
.025 - .048 mm
(Interference
Fit)
0.001 - 0.0019
in.
Bearing Bore
Out of Round
(MAX)
0.004 mm 0.0002 in.
Total Weight
(Less Bearing)
555 grams 19.5771 ounces
CRANKSHAFT
Metric Standard
Main Bearing
Journal
Diameter
63.488 - 63.512
mm
2.4996 - 2.5005
in.
Bearing
Clearance
0.018 - 0.052
mm
0.0008 - 0.0021
in.
Out of Round
(MAX)
0.005 mm 0.0004 in.
Taper (MAX) 0.008 mm 0.0004 in.
End Play 0.052 - 0.282
mm
0.0021 - 0.0112
in.
Connecting Rod
Journal
Diameter
50.992 - 51.008
mm
2.0076 - 2.0082
in.
Bearing
Clearance
0.015 - 0.055 0.0006 - 0.0022
in.
Out of Round
(MAX)
0.005 mm 0.0002 in.
Taper (MAX) 0.008 mm 0.0004 in.
CAMSHAFT
Metric Standard
Bore Diameter 26.02 - 26.04
mm
1.0245 - 1.0252
in.
Bearing Journal
Diameter
25.975 - 25.995
mm
1.0227 - 1.0235
in.
Bearing
Clearance
0.025 - 0.065
mm
0.001 - 0.0026
in.
Bearing
Clearance
(MAX)
0.065 mm 0.0026 in.
End Play .075 - .200 mm 0.003 - 0.0079
in.
End Play (MAX) .200 mm 0.0079 in.
VALVE TIMING
Intake
Opens (BTDC) 4.4
Closes (ATDC) 239.1
Duration 243.5
Exhaust
Opens (BTDC) 240.5
Closes (ATDC) 13.2
Duration 253.70
Valve Overlap 17.6
9 - 100 ENGINE - 4. 7L DR
VALVES
Face Angle 45- 45.5
Head Diameter
Intake 48.52 - 48.78 mm
(1.9103 - 1.9205 in.)
Exhaust 36.87 - 37.13 mm
(1.4516 - 1.4618 in.)
Length (Overall)
Intake 113.45 - 114.21 mm
(4.4666 - 4.4965)
Exhaust 114.92 - 115.68 mm
(4.5244 - 4.5543 in.)
Stem Diameter
Intake 6.931 - 6.957 mm
(0.2729 - 0.2739 in.)
Exhaust 6.902 - 6.928 mm
(0.2717 - 0.2728 in.)
Stem - to - Guide
Clearance
Intake 0.018 - 0.069 mm
(0.0008 - 0.0028 in.)
Exhaust 0.047 - 0.098 mm
(0.0019 - 0.0039 in.)
Max. Allowable Stem - to
- Guide Clearance
(Rocking Method)
Intake 0.069 mm (0.0028 in.)
Exhaust 0.098 mm (0.0039 in.)
Valve Lift (Zero Lash)
Intake 11.25 mm (0.443 in.)
Exhaust 10.90 mm (0.4292 in.)
VALVE SPRING
Free Length (Approx)
Intake 49.0 mm (1.9291 in.)
Exhaust 49.0 mm (1.9291 in.)
Spring Force (Valve
Closed)
Intake and Exhaust 313.0 - 354.0 N @ 40.12
mm
(70.365 - 79.582 lbs. @
1.5795 in.)
Spring Force (Valve
Open)
Intake and Exhaust 776.0 - 870.0 N @ 28.88
mm
(174.451 - 195.583 lbs.
@ 1.137 in.)
Number of Coils
Intake 7.3
Exhaust 7.3
Wire Diameter
Intake and Exhaust 4.6 3.67mm
(0.1811 - 0.1445 in.)
Installed Height (Spring
Seat to Bottom of
Retainer)
Nominal
Intake 40.12 mm (1.579 in.)
Exhaust 40.12 mm (1.579 in.)
DR ENGINE - 4. 7L 9 - 101
CYLINDER HEAD
Gasket Thickness
(Compressed)
0.7 mm (0.0276 in.)
Valve Seat Angle 44.5- 45.0
Valve Seat Runout (MAX) 0.051 mm (0.002 in.)
Valve Seat Width
Intake 1.75 - 2.36 mm
(0.0698 - 0.0928 in.)
Exhaust 1.71 - 2.32 mm
(0.0673 - 0.0911 in.)
Guide Bore Diameter
(Std.)
6.975 - 7.00 mm
(0.2747 - 0.2756 in.)
Cylinder Head Warpage
(Flatness)
0.0508 mm (0.002 in.)
OIL PUMP
Clearance Over
Rotors/End Face (MAX)
0.095 mm (0.0038 in.)
Cover Out - of -Flat
(MAX)
0.025 mm (0.001 in.)
Inner and Outer Rotor
Thickness
12.02 mm (0.4731 in.)
Outer Rotor to pocket
(Diametral) clearance
(MAX)
.235 mm (.0093 in.)
Outer Rotor Diameter
(MIN)
85.925 mm (0.400 in.)
Tip Clearance Between
Rotors (MAX)
0.150 mm (0.006 in.)
OIL PRESSURE
At Curb Idle Speed
(MIN)*
48 kPa (7 psi)
@ 3000 rpm 240 - 725 kPa (35 - 105
psi)
NOT run engine at 3000 rpm.
TORQUE
DESCRIPTION Nm Ft. In.
Lbs. Lbs.
Camshaft
Non - Oiled Sprocket Bolt 122 90
Bearing Cap Bolts 11 100
Timing Chain CoverBolts 58 43
Connecting Rod CapBolts 27 20
PLUS 90TURN
Bed PlateBolts Refer to Procedure
Crankshaft DamperBolt 175 130
Cylinder HeadBolts
M11 Bolts 81 60
M8 Bolts 26 19
Cylinder Head CoverBolts 12 105
Exhaust ManifoldBolts 25 18
Exhaust Manifold Heat
ShieldNuts
8 72
Then loosen 45
FlexplateBolts 60 45
Engine Mount Bracket to
BlockBolts
61 45
Rear Mount to
TransmissionBolts
46 34
Generator MountingBolts
M10 Bolts 54 40
M8 Bolts 28 250
Intake ManifoldBolts 12 105
Refer to Procedure
for
Tightening Sequence
Oil PanBolts 15 130
Oil PanDrain Plug 34 25
Oil PumpBolts 28 250
Oil Pump CoverBolts 12 105
Oil Pickup TubeBolt and
Nut
28 250
Oil Dipstick Tube to Engine
BlockBolt 15 130
Oil Fill TubeBolts 12 105
Timing Chain GuideBolts 28 250
Timing Chain Tensioner
ArmSpecial
9 - 102 ENGINE - 4. 7L DR
Lbs. Lbs.
Pin Bolt 17 150
Hydraulic TensionerBolts 28 250
Timing Chain Primary
TensionerBolts
28 250
Timing Drive Idler Sprocket
Bolt
34 25
Thermostat HousingBolts 13 115
Water PumpBolts 58 43
SPECIAL TOOLS
4. 7L ENGINE
Spanner Wrench 6958
Adapter Pins 8346
Engine Lifting Studs 8400
Engine Lift Fixture 8347
Front Crankshaft Seal Remover 8511
Front Crankshaft Seal Installer 8348
Handle C-4171
DR ENGINE - 4. 7L 9 - 103
Connecting Rod Guides 8507
Puller 1026
Crankshaft Damper Removal Insert 8513
Chain Tensioner Wedge 8379
Chain Tensioner Pins 8514
9 - 104 ENGINE - 4. 7L DR
Secondary Chain Holder 8515
Remover, Rocker Arm 8516
Valve Spring Compressor 8387
Idler Shaft Remover 8517
Valve Spring Compressor Adapters 8519
DR ENGINE - 4. 7L 9 - 105
BlocChekKit C-3685A
9 - 106 ENGINE - 4. 7L DR
AIR CLEANER ELEMENT
REMOVAL
Filter Element Only
ter) repl acement.
i ng.
ment.
Housing Assembly
pi ns (Fi g. 8).
INSTALLATION
tabs (Fi g. 7).
housi ng.
l bs.) torque.
CYLINDER HEAD
DESCRIPTION
DESCRIPTION - CYLINDER HEAD
The cyl i nder heads are made of an al umi num al l oy.
The cyl i nder head features two val ves per cyl i nder
wi th pressed i n powdered metal val ve gui des. The
cyl i nder heads al so provi de encl osures for the ti mi ng
chai n drai n, necessi tati ng uni que l eft and ri ght cyl i n-
der heads.
DESCRIPTION - VALVE GUIDES
The val ve gui des are made of powered metal and
are pressed i nto the cyl i nder head. The gui des are
not repl aceabl e or servi ceabl e, and val ve gui de ream-
i ng i s not recommended. I f the gui des are worn
beyond acceptabl e l i mi ts, repl ace the cyl i nder heads.
1 - CLAMP
2 - AIR DUCT
4 - LOCATING TABS
5 - CLIPS (4)
DR ENGINE - 4. 7L 9 - 107
REMOVAL
REMOVAL - LEFT CYLINDER HEAD
(3) Di sconnect the exhaust pi pe at the l eft si de
exhaust mani fol d.
(4) Drai n the engi ne cool ant. Refer to COOLI NG
SYSTEM.
(6) Remove the i ntake mani fol d (Refer to 9 -
REMOVAL).
(7) Remove the master cyl i nder and booster assem-
bl y. Refer to secti on 5 brakes.
(9) Remove the fan shroud and fan bl ade assembl y
(Refer to 7 - COOLI NG/ENGI NE/FAN DRI VE VI S-
COUS CLUTCH - REMOVAL).
REMOVAL).
asi de.
(12) Rotate the crankshaft unti l the damper ti m-
i ng mark i s al i gned wi th TDC i ndi cator mark (Fi g.
9).
i s at the 12 ocl ock posi ti on (Fi g. 11). Rotate the
crankshaft one turn i f necessary.
(14) Remove the crankshaft damper (Refer to 9 -
REMOVAL).
sprocket usi ng Speci al Tool 8515 (Fi g. 10).
Fig. 9 Engine Top Dead Center (TDC) Indicator Mark
Fig. 10 Using Special Tool 8515 to Hold Chains to
Idler Sprocket.
1 - LOCK ARM
2 - RIGHT CAMSHAFT CHAIN
3 - SECONDARY CHAINS RETAINING PINS (4)
4 - IDLER SPROCKET
5 - LEFT CAMSHAFT CHAIN
9 - 108 ENGINE - 4. 7L DR
CYLINDER HEAD (Continued)
each si de of the V8 mark on the camshaft dri ve gear
(Fi g. 11).
(18) Remove the l eft si de secondary chai n ten-
si oner (Refer to 9 - ENGI NE/VALVE TI MI NG/TI M-
(19) Remove the cyl i nder head access pl ug (Fi g.
12).
(20) Remove the l eft si de secondary chai n gui de
dri ve gear.
CAUTION: Do not allow the engine to rotate. Severe
four bolts.
block with fourteen bolts.
the gasket.
ket sealing surface, due to the design of the cylin-
der head gasket any distortion to the cylinder head
Fig. 11 Camshaft Sprocket V8 Marks
DR ENGINE - 4. 7L 9 - 109
REMOVAL - RIGHT CYLINDER HEAD
(1) Di sconnect battery negi ti ve cabl e.
(3) Di sconnect the exhaust pi pe at the ri ght si de
exhaust mani fol d.
(4) Drai n the engi ne cool ant (Refer to 7 - COOL-
(6) Remove the i ntake mani fol d (Refer to 9 -
REMOVAL).
(8) Remove the fan shroud (Refer to 7 - COOLI NG/
REMOVAL).
(9) Remove oi l fi l l housi ng from cyl i nder head.
REMOVAL).
(11) Rotate the crankshaft unti l the damper ti mi ng
mark i s al i gned wi th TDC i ndi cator mark (Fi g. 13).
i s at the 12 ocl ock posi ti on (Fi g. 14). Rotate the
crankshaft one turn i f necessary.
REMOVAL).
Mark
9 - 110 ENGINE - 4. 7L DR
sprocket usi ng Speci al Tool 8515 (Fi g. 15).
each si de of the V8 mark on the camshaft dri ve gear
(Fi g. 14).
(17) Remove the ri ght si de secondary chai n ten-
si oner (Refer to 9 - ENGI NE/VALVE TI MI NG/TI M-
(18) Remove the cyl i nder head access pl ug (Fi g.
16).
(19) Remove the ri ght si de secondary chai n gui de
dri ve gear.
CAUTION: Do not allow the engine to rotate. severe
four bolts.
get wheel for any reason. A damaged target wheel
can result in a vehicle no start condition.
block with fourteen bolts.
the gasket.
ket sealing surface, do to the design of the cylinder
head gasket any distortion to the cylinder head
CLEANING
To ensure engi ne gasket seal i ng, proper surface
preparati on must be performed, especi al l y wi th the
use of al umi num engi ne components. (Refer to 9 -
ENGI NE - STANDARD PROCEDURE)
INSPECTION
(1) I nspect the cyl i nder head for out-of-fl atness,
usi ng a strai ghtedge and a feel er gauge. I f tol erances
exceed 0.0508 mm (0.002 i n.) repl ace the cyl i nder
head.
(2) I nspect the val ve seats for damage. Servi ce the
val ve seats as necessary.
(3) I nspect the val ve gui des for wear, cracks or
l ooseness. I f ei ther condi ti on exi st, repl ace the cyl i n-
der head.
Fig. 15 Using Special Tool 8515 to Hold Chains to
Idler Sprocket.
1 - LOCK ARM
4 - IDLER SPROCKET
DR ENGINE - 4. 7L 9 - 111
INSTALLATION
INSTALLATION - LEFT CYLINDER HEAD
l ocati ng dowel s.
cl ean engi ne oi l and i nstal l the ten M11 bol ts.
bol ts.
(6) Ti ghten the bol ts i n sequence (Fi g. 19) usi ng
the fol l owi ng steps and torque val ues:
Step 1: Ti ghten bol ts 110, 20 Nm (15 ft. l bs.).
Ti ghten bol ts 1114, 25 Nm (18 ft. l bs.).
Step 3: Ti ghten bol ts 110, 90 degrees. Ti ghten
bol ts 1114, 30 Nm (22 ft. l bs.).
ei ther si de of the V8 mark on the gear and posi ti on
the gear onto the camshaft.
(Necking)
1 - STRETCHED BOLT
Fig. 18 Proper Tool Usage for
9 - 112 ENGINE - 4. 7L DR
(9) I nstal l the l eft si de secondary chai n gui de
BELT/CHAI N AND SPROCKETS - I NSTALLA-
TI ON).
(10) I nstal l the cyl i nder head access pl ug (Fi g. 20).
(11) Re-set and I nstal l the l eft si de secondary
chai n tensi oner (Refer to 9 - ENGI NE/VALVE TI M-
I NSTALLATI ON).
(14) I nstal l the crankshaft damper (Refer to 9 -
I NSTALLATI ON).
(16) I nstal l the fan bl ade assembl y and fan shroud
(Refer to 7 - COOLI NG/ENGI NE/FAN DRI VE VI S-
COUS CLUTCH - I NSTALLATI ON).
(18) Rei nstal l the master cyl i nder and booster
assembl y. Refer to secti on 5 brakes.
(19) I nstal l the i ntake mani fol d (Refer to 9 -
I NSTALLATI ON).
(20) Refi l l the cool i ng system (Refer to 7 - COOL-
(22) I nstal l the exhaust pi pe onto the l eft exhaust
mani fol d.
INSTALLATION - RIGHT CYLINDER HEAD
l ocati ng dowel s.
cl ean engi ne oi l and i nstal l the ten M10 bol ts.
bol ts.
(Necking)
1 - STRETCHED BOLT
DR ENGINE - 4. 7L 9 - 113
(6) Ti ghten the bol ts i n sequence (Fi g. 23) usi ng
the fol l owi ng steps and torque val ues:
Ti ghten bol ts 1114, 25 Nm (18 ft. l bs.).
Step 3: Ti ghten bol ts 110, 90 degrees. Ti ghten
bol ts 1114, 30 Nm (22 ft. l bs.).
ei ther si de of the V8 mark on the gear and posi ti on
the gear onto the camshaft.
(9) I nstal l the ri ght si de secondary chai n gui de
BELT / CHAI N COVER(S) - I NSTALLATI ON).
(10) I nstal l the ri ght si de cyl i nder head access
pl ug (Fi g. 24).
(11) Re-set and i nstal l the ri ght si de secondary
chai n tensi oner.
(14) I nstal l the crankshaft damper (Refer to 9 -
I NSTALLATI ON).
I NSTALLATI ON).
(18) I nstal l the i ntake mani fol d (Refer to 9 -
I NSTALLATI ON).
(19) I nstal l oi l fi l l housi ng onto cyl i nder head.
(22) I nstal l the exhaust pi pe onto the ri ght
exhaust mani fol d.
(24) Reconnect battery negi ti ve cabl e.
CAMSHAFT(S) - LEFT
DESCRIPTION
l obes whi ch are si nter-bonded to a steel tube. A steel
post or nose pi ece i s fri cti on-wel ded to the steel cam-
shaft tube. Fi ve beari ng journal s are machi ned i nto
Fig. 22 Proper Tool Usage for
9 - 114 ENGINE - 4. 7L DR
the camshaft, four on the steel tube and one on the
steel nose pi ece. Camshaft end pl ay i s control l ed by
two thrust wal l s that border the nose pi ece journal .
Engi ne oi l enters the hol l ow camshafts at the thi rd
journal and l ubri cates every i ntake l obe rocker
through a dri l l ed passage i n the i ntake l obe.
REMOVAL
damage can occur.
chains or camshaft, Failure to use Special Tool
8350 will result in hydraulic tensioner ratchet over
extension, requiring timing chain cover removal to
reset the tensioner ratchet.
(1) Remove cyl i nder head cover (Refer to 9 -
get wheel (Located on the right side camshaft
sprocket) for any reason, Severe damage will occur
to the target wheel resulting in a vehicle no start
condition.
sprocket retai ni ng bol t. Leave the bol t snug agai nst
the sprocket.
between the ti mi ng chai n strands, tap the tool to
NOTE: When gripping the camshaft, place the pliers
on the tube portion of the camshaft only. Do not
grip the lobes or the sprocket areas.
Fig. 25 Securing Timing Chain Tensioners Using Timing Chain Wedge
3 - SPECIAL TOOL 8350 WEDGE
DR ENGINE - 4. 7L 9 - 115
CAMSHAFT(S) - LEFT (Continued)
(6) Hol d the camshaft wi th adjustabl e pl i ers whi l e
removi ng the camshaft sprocket bol t and sprocket
(Fi g. 26).
(7) Usi ng the pl i ers, gentl y al l ow the camshaft to
rotate 15 cl ockwi se unti l the camshaft i s i n the neu-
tral posi ti on (no val ve l oad).
camshaft.
INSTALLATION
oi l .
NOTE: Position the left side camshaft so that the
camshaft sprocket dowel is near the 1 oclock posi-
tion, This will place the camshaft at the neutral
bearing caps.
(4) Worki ng i n
1
2 turn i ncrements, ti ghten the
Fig. 26 Camshaft Sprocket and Chain
1 - CAMSHAFT SPROCKET AND CHAIN
3 - CAMSHAFT
Sequence
9 - 116 ENGINE - 4. 7L DR
removal ) (Fi g. 28).
(7) Usi ng the adjustabl e pl i ers, rotate the cam-
shaft unti l the camshaft sprocket dowel i s al i gned
wi th the sl ot i n the camshaft sprocket. I nstal l the
sprocket onto the camshaft (Fi g. 29).
Fig. 28 Timing Chain to Sprocket Alignment
Fig. 29 Camshaft Sprocket Installation
2 - CAMSHAFT DOWEL
DR ENGINE - 4. 7L 9 - 117
(8) Remove excess oi l from bol t, then i nstal l the
camshaft sprocket retai ni ng bol t and hand ti ghten.
(9) Remove Speci al Tool 8350 ti mi ng chai n wedge
(Fi g. 30).
adapter pi ns 8346 (Fi g. 31), torque the camshaft
sprocket retai ni ng bol t to 122 Nm (90 ft. l bs.).
(11) I nstal l the cyl i nder head cover.
Fig. 30 SPECIAL TOOL 8350
Fig. 31 Tightening Left Side Cam Sprocket
Retaining Bolt
1 - TORQUE WRENCH
9 - 118 ENGINE - 4. 7L DR
CAMSHAFT(S) - RIGHT
DESCRIPTION
The camshafts consi st of powdered metal steel l obes
whi ch are si nter-bonded to a steel tube. A steel post or
nose pi ece i s fri cti on-wel ded to the steel camshaft tube.
Fi ve beari ng journal s are machi ned i nto the camshaft,
four on the steel tube and one on the steel nose pi ece.
that border the nose pi ece journal . Engi ne oi l enters the
hol l ow camshafts at the thi rd journal and l ubri cates
every i ntake l obe rocker through a dri l l ed passage i n
the i ntake l obe.
REMOVAL
damage can occur.
chains or camshaft, Failure to use special tool 8350
will result in hydraulic tensioner ratchet over exten-
sion, Requiring timing chain cover removal to re-set
the tensioner ratchet.
(1) Remove the cyl i nder head covers (Refer to 9 -
get wheel for any reason, Severe damage will occur
to the target wheel. A damaged target wheel could
cause a vehicle no start condition.
sprocket retai ni ng bol t. Leave bol t snug agai nst sprocket.
between the ti mi ng chai n strands. Tap the tool to
DR ENGINE - 4. 7L 9 - 119
(6) Remove the camshaft posi ti on sensor (Fi g. 33).
(7) Hol d the camshaft wi th adjustabl e pl i ers whi l e
removi ng the camshaft sprocket bol t and sprocket
(Fi g. 34).
(8) Usi ng the pl i ers, gentl y al l ow the camshaft to
rotate 45 counter-cl ockwi se unti l the camshaft i s i n
the neutral posi ti on (no val ve l oad).
camshaft.
INSTALLATION
oi l .
NOTE: Position the right side camshaft so that the
camshaft sprocket dowel is near the 10 oclock
position, This will place the camshaft at the neutral
bearing caps.
Fig. 33 Camshaft Position Sensor
Fig. 34 Camshaft Sprocket and Chain
2 - SPROCKET BOLT
4 - CAMSHAFT
9 - 120 ENGINE - 4. 7L DR
CAMSHAFT(S) - RIGHT (Continued)
removal ) (Fi g. 36).
(7) Usi ng the adjustabl e pl i ers, rotate the cam-
shaft unti l the camshaft sprocket dowel i s al i gned
wi th the sl ot i n the camshaft sprocket. I nstal l the
sprocket onto the camshaft (Fi g. 37).
(8) Remove excess oi l from camshaft sprocket bol t,
then i nstal l the camshaft sprocket retai ni ng bol t and
hand ti ghten.
(9) Remove ti mi ng chai n wedge speci al tool 8350
(Fi g. 32).
Fig. 36 Timing Chain to Sprocket Alignment
Sequence
DR ENGINE - 4. 7L 9 - 121
adapter pi ns 8346 (Fi g. 38), torque the camshaft
sprocket retai ni ng bol t to 122 Nm (90 ft. l bs.).
(11) I nstal l the camshaft posi ti on sensor (Fi g. 33).
DESCRIPTION
The cyl i nder head covers are made of i njecti on
mol ded thermo-set pl asti c, and are not i nterchange-
abl e from si de-to-si de. I t i s i mperati ve that nothi ng
rest on the cyl i nder head covers. Prol onged contact
wi th other i tems may wear a hol e i n the cyl i nder
head cover.
REMOVAL
REMOVAL - RIGHT SIDE
REMOVAL).
(5) Remove ai r condi ti oni ng compressor retai ni ng
bol ts and move compressor to the l eft.
(7) Di sconnect i njector and i gni ti on coi l connectors.
(8) Di sconnect and remove posi ti ve crankcase ven-
ti l ati on (PCV) hose.
(9) Remove oi l fi l l tube.
(10) Un-cl i p i njector and i gni ti on coi l harness and
move away from cyl i nder head cover.
(11) Remove ri ght rear breather tube and fi l ter
assembl y.
(12) Remove cyl i nder head cover retai ni ng bol ts.
REMOVAL - LEFT SIDE
(2) Remove the resonator assembl e and ai r i nl et
hose.
(3) Di sconnect i njector connectors and un-cl i p the
i njector harness.
(4) Route i njector harness i n front of cyl i nder head
cover.
(5) Di sconnect the l eft si de breather tube and
remove the breather tube.
(6) Remove the cyl i nder head cover mounti ng
bol ts.
Fig. 37 Camshaft Sprocket Installation
2 - CAMSHAFT DOWEL
Fig. 38 Tightening Right Side Cam Sprocket
Retaining Bolt
1 - TORQUE WRENCH
9 - 122 ENGINE - 4. 7L DR
(7) Remove cyl i nder head cover and gasket.
CLEANING
Cl ean cyl i nder head cover gasket surface.
Cl ean head rai l , i f necessary.
INSTALLATION
INSTALLATION - RIGHT SIDE
may occur.
(2) I nstal l cyl i nder head cover and hand start al l
fasteners. Veri fy that al l doubl e ended studs are i n
the correct l ocati on shown i n (Fi g. 39).
ended studs to 12 Nm (105 i n. l bs).
(4) I nstal l ri ght rear breather tube and fi l ter
assembl y.
(5) Connect i njector, i gni ti on coi l el ectri cal connec-
tors and harness retai ni ng cl i ps.
(6) I nstal l the oi l fi l l tube.
(9) I nstal l ai r condi ti oni ng compressor retai ni ng
bol ts.
I NSTALLATI ON).
(11) Fi l l Cool i ng system (Refer to 7 - COOLI NG -
INSTALLATION LEFT SIDE
may occur.
(2) I nstal l cyl i nder head cover and hand start al l
fasteners. Veri fy that al l studs are i n the correct l oca-
ti on shown i n (Fi g. 40).
ended studs to 12 Nm (105 i n. l bs.).
(4) I nstal l l eft si de breather and connect breather
tube.
(5) Connect i njector el ectri cal connectors and i njec-
tor harness retai ni ng cl i ps.
(6) I nstal l the resonator and ai r i nl et hose.
SEATS
DESCRIPTION
The val ves are made of heat resi stant steel and
have chrome pl ated stems to prevent scuffi ng. Each
val ve i s actuated by a rol l er rocker arm whi ch pi vots
on a stati onary l ash adjuster. Al l val ves use three
bead l ock keepers to retai n the spri ngs and promote
val ve rotati on.
Fig. 39 Cylinder Head CoverRight
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 Nm (105 in. lbs.)
Fig. 40 Cylinder Head Cover-Left
ITEM DESCRIPTION TORQUE
1 Cover Fasteners 12 Nm (105 in. lbs.)
DR ENGINE - 4. 7L 9 - 123
CYLINDER HEAD COVER(S) (Continued)
REMOVAL
NOTE: The cylinder heads must be removed in
order to perform this procedure.
(1) Remove rocker arms and l ash adjusters(Refer
to 9 - ENGI NE/CYLI NDER HEAD/ROCKER ARM /
ADJUSTER ASSY - REMOVAL). (Fi g. 41).
camshaft.
NOTE: All six valve springs and valves are removed
one valve and valve spring.
(3) Usi ng Speci al Tool C-3422B or C-3422C
Val ve Spri ng Compressor and Speci al tool 8519
Adapter, compress the val ve spri ng.
NOTE: Check for sharp edges on the keeper
grooves. Remove any burrs from the valve stem
before removing the valve from the cylinder head.
(7) Remove the val ve from the cyl i nder head.
intake and exhaust.
(8) Remove the val ve stem seal . Mark the val ve for
proper i nstal l ati on.
TESTING VALVE SPRINGS
NOTE: Whenever the valves are removed from the
cylinder head it is recommended that the valve
springs be inspected and tested for reuse.
I nspect the val ve spri ngs for physi cal si gns of wear
or damage. Turn tabl e of tool C-647 unti l surface i s
i n l i ne wi th the 40.12 mm (1.579 i n.) mark on the
threaded stud and the zero mark on the front. Pl ace
spri ng over the stud on the tabl e and l i ft compress-
i ng l ever to set tone devi ce. Pul l on torque wrench
unti l a Pi ng i s heard. Take readi ng on torque wrench
at thi s i nstant. Mul ti pl y thi s readi ng by two. Thi s
wi l l gi ve the spri ng l oad at test l ength. Fracti onal
measurements are i ndi cated on the tabl e for fi ner
adjustments. Refer to Speci fi cati ons Secti on to obtai n
speci fi ed hei ght and al l owabl e tensi ons. Repl ace any
spri ngs that do not meet speci fi cati ons (Fi g. 42).
INSTALLATION
i nsert i t i nto the cyl i nder head.
(2) I nstal l the val ve stem seal . make sure the seal
i s ful l y seated and that the garter spri ng at the top
of the seal i s i ntact.
Fig. 41 Rocker Arm Removal
1 - CAMSHAFT
Fig. 42 Testing Valve Springs
9 - 124 ENGINE - 4. 7L DR
43).
(4) Usi ng the val ve spri ng compressor, compress
the spri ng and i nstal l the two val ve spri ng retai ner
hal ves.
(6) l ubri cate the camshaft journal wi th cl ean
engi ne oi l then Posi ti on the camshaft (wi th the
sprocket dowel on the l eft camshaft at 11 ocl ock and
the ri ght camshaft at 12 ocl ock), then posi ti on the
camshaft beari ng caps.
(7) I nstal l the camshaft beari ng cap retai ni ng
bol ts. Ti ghten the bol ts 913 Nm (100 i n. l bs.) i n
1
2
turn i ncrements i n the sequence shown (Fi g. 44).
(8) Posi ti on the hydraul i c l ash adjusters and
rocker arms.
ROCKER ARM / ADJ USTER
ASSEMBLY
DESCRIPTION
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER
A tappet-l i ke noi se may be produced from several
i tems. Check the fol l owi ng i tems.
(1) Engi ne oi l l evel too hi gh or too l ow. Thi s may
cause aerated oi l to enter the adjusters and cause
them to be spongy.
(2) I nsuffi ci ent runni ng ti me after rebui l di ng cyl i n-
der head. Low speed runni ng up to 1 hour may be
requi red.
(3) Turn engi ne off and l et set for a few mi nutes
before restarti ng. Repeat thi s several ti mes after
engi ne has reached normal operati ng temperature.
(4) Low oi l pressure.
(5) The oi l restri ctor i n cyl i nder head gasket or the
oi l passage to the cyl i nder head i s pl ugged wi th
debri s.
(6) Ai r i ngested i nto oi l due to broken or cracked
oi l pump pi ck up.
(7) Worn val ve gui des.
(8) Rocker arm ears contacti ng val ve spri ng
retai ner.
(9) Rocker arm l oose, adjuster stuck or at maxi -
mum extensi on and sti l l l eaves l ash i n the system.
(10) Oi l l eak or excessi ve cam bore wear i n cyl i n-
der head.
(11) Faul ty l ash adjuster.
a. Check l ash adjusters for spongi ness whi l e
i nstal l ed i n cyl i nder head and cam on camshaft at
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Sequence
DR ENGINE - 4. 7L 9 - 125
base ci rcl e. Depress part of rocker arm over adjuster.
Normal adjusters shoul d feel very fi rm. Spongy
adjusters can be bottomed out easi l y.
b. Remove suspected l ash adjusters, and repl ace.
c. Before i nstal l ati on, make sure adjusters are at
l east parti al l y ful l of oi l . Thi s can be veri fi ed by l i ttl e
or no pl unger travel when l ash adjuster i s depressed.
REMOVAL
(2) For rocker arm removal on cyl i nders 3 and 5
Rotate the crankshaft unti l cyl i nder #1 i s at TDC
exhaust stroke.
compressi on stroke.
arm (Fi g. 45).
INSTALLATION
CAUTION: Make sure the rocker arms are installed
with the concave pocket over the lash adjusters.
Failure to do so may cause severe damage to the
rocker arms and/or lash adjusters.
NOTE: Coat the rocker arms with clean engine oil
prior to installation.
(1) For rocker arm i nstal l ati on on cyl i nders 3 and
5 Rotate the crankshaft unti l cyl i nder #1 i s at TDC
exhaust stroke.
(5) Usi ng speci al tool 8516 press downward on the
val ve spri ng, i nstal l rocker arm (Fi g. 45).
VALVE SPRINGS
DESCRIPTION
chrome si l i con steel . The spri ngs are common for
i ntake and exhaust appl i cati ons. The val ve spri ng
seat i s i ntegral wi th the val ve stem seal , whi ch i s a
posi ti ve type seal to control l ubri cati on.
REMOVAL
(2) Usi ng Speci al Tool 8516 Rocker Arm Remover,
remove the rocker arms and the hydraul i c l ash
adjusters (Fi g. 46).
val ves i n pl ace when the spri ng i s removed
(5) Remove the camshaft (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: All eight valve springs and seals are
removed in the same manner; this procedure only
covers one valve seal and valve spring.
Fig. 45 Rocker ArmRemoval
1 - CAMSHAFT
9 - 126 ENGINE - 4. 7L DR
ROCKER ARM / ADJ USTER ASSEMBLY (Continued)
intake and exhaust.
INSTALLATION
i nstal l the val ve stem seal . Make sure the seal i s
ful l y seated and that the garter spri ng at the top of
the seal i s i ntact.
47).
sor, compress the spri ng and i nstal l the two val ve
spri ng retai ner hal ves.
(5) I nstal l the camshaft (Refer to 9 - ENGI NE/
CYLI NDER HEAD/CAMSHAFT(S) - I NSTALLA-
TI ON).
(6) Posi ti on the hydraul i c l ash adjusters and
rocker arms (Fi g. 46).
VALVE STEM SEALS
DESCRIPTION
The val ve stem seal s are made of rubber and i ncor-
porate an i ntegral steel val ve spri ng seat. The i nte-
gral garter spri ng mai ntai ns consi stent l ubri cati on
control to the val ve stems.
Fig. 46 Rocker ArmRemoval
1 - CAMSHAFT
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
DR ENGINE - 4. 7L 9 - 127
VALVE SPRINGS (Continued)
ENGINE BLOCK
DESCRIPTION
The cyl i nder bl ock i s made of cast i ron. The bl ock
i s a cl osed deck desi gn wi th the l eft bank forward. To
provi de hi gh ri gi di ty and i mproved NVH an
enhanced compacted graphi te bedpl ate i s bol ted to
the bl ock. The bl ock desi gn al l ows cool ant fl ow
between the cyl i nders bores, and an i nternal cool ant
bypass to a si ngl e poppet i nl et thermostat i s i ncl uded
i n the cast al umi num front cover.
HONING
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823, equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round, as wel l as removi ng l i ght
scuffi ng, scori ng and scratches. Usual l y, a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). about 20-60
strokes, dependi ng on the bore condi ti on, wi l l be suf-
fi ci ent to provi de a sati sfactory surface. Usi ng honi ng
oi l C-3501-3880, or a l i ght honi ng oi l , avai l abl e from
major oi l di stri butors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 50 to 60
for proper seati ng of ri ngs (Fi g. 48).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50 to 60
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
CLEANING
ket surfaces.
INSPECTION
Fig. 48 CYLINDER BORE CROSSHATCH PATTERN
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
9 - 128 ENGINE - 4. 7L DR
above.
STANDARD PROCEDURE - CONNECTING ROD
BEARING FITTING
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 50). Check the beari ngs for
normal wear patterns, scori ng, groovi ng, fati gue and
pi tti ng (Fi g. 51). Repl ace any beari ng that shows
abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(3) Use pi ston ri ng compressor and Gui de Pi ns
Speci al Tool 8507 (Fi g. 52) to i nstal l the rod and pi s-
ton assembl i es. The oi l sl i nger sl ots i n the rods must
face front of the engi ne. The Fs near the pi ston
wri st pi n bore shoul d poi nt to the front of the engi ne.
(4) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(5) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten bol ts to 27 Nm (20 ft. l bs.) pl us a
90 turn. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM (1.5 in)
Fig. 50 Locking Tab Inspection
1 - ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 51 Scoring Caused by Insufficient Lubrication
or Damaged Crankshaft Journal
DR ENGINE - 4. 7L 9 - 129
(6) Remove the beari ng cap and determi ne amount of
beari ng-to-journal cl earance by measuri ng the wi dth of
compressed Pl asti gage (Fi g. 53). Refer to Engi ne Speci -
fi cati ons for the proper cl earance. Plastigage should
indicate the same clearance across the entire
width of the insert. If the clearance varies, it may
be caused by either a tapered journal, bent con-
necting rod or foreign material trapped between
the insert and cap or rod.
(7) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(8) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, determi n whi ch servi ces beari ng set to
use the beari ng si zes are as fol l ows:
Bearing
Mark
SIZE USED WITH
JOURNAL SIZE
.025 US .025 mm 50.983-50.967 mm
(.001 in.) (2.0073-2.0066 in.)
Std. STANDARD 50.992-51.008 mm
(2.0076-2.0082 in.)
.250 US .250 mm 50.758-50.742 mm
(.010 in.) (1.9984-1.9978 in.)
(9) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(10) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
bol ts to 27 Nm (20 ft. l bs.) pl us a 90 turn.
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 54).
Refer to Engi ne Speci fi cati ons for the proper cl ear-
ance. Repl ace the connecti ng rod i f the si de cl earance
i s not wi thi n speci fi cati on.
Fig. 53 Measuring Bearing Clearance with Plastigage
1 - PLASTIGAGE SCALE
2 - COMPRESSED PLASTIGAGE
Fig. 52 Piston and Connecting Rod - Installation
3 - RING COMPRESSOR
Fig. 54 Checking Connecting Rod Side Clearance -
Typical
9 - 130 ENGINE - 4. 7L DR
CONNECTING ROD BEARINGS (Continued)
CORE PLUGS
REMOVAL
(2) Usi ng a bl unt tool such as a dri ft or a screw
dri ver and a hammer, stri ke the bottom edge of the
cup pl ug (Fi g. 55)
(3) Usi ng a sui tabl e pai r of pl i ers, grasp the core
pl ug and remove.
INSTALLATION
NOTE: Thoroughly clean core plug bore, remove all
of the old sealer.
(1) Coat the edges of the engi ne core pl ug and the
core pl ug bore wi th Mopar Gasket Maker, or equi va-
l ent.
NOTE: It is not necessary to wait for the sealant to
cure on the core plugs. The cooling system can be
filled and the vehicle returned to service immedi-
ately.
(2) Usi ng proper pl ug dri ver, dri ve core pl ug i nto
the core pl ug bore. The sharp edge of the core pl ug
shoul d be at l east 0.50 mm (0.020 i n.) i nsi de the l ead
i n chamfer.
CRANKSHAFT
DESCRIPTION
The crankshaft i s constructed of nodul ar cast i ron.
The crankshaft i s a crosshaped four throw desi gn
wi th ei ght counterwei ghts for bal anci ng purposes.
The crankshaft i s supported by fi ve sel ect fi t mai n
beari ngs wi th the number three servi ng as the thrust
washer l ocati on. The mai n journal s of the crankshaft
are cross dri l l ed to i mprove rod beari ng l ubri cati on.
The number ei ght counterwei ght has provi si ons for
crankshaft posi ti on sensor target wheel mounti ng.
The sel ect fi t mai n beari ng marki ngs are l ocated on
the rear si de of the target wheel . The crankshaft oi l
seal s are one pi ece desi gn. The front oi l seal i s
retai ned i n the ti mi ng chai n cover, and the rear seal
i s pressed i n to a bore formed by the cyl i nder bl ock
and the bedpl ate assembl y.
REMOVAL
NOTE: To remove the crankshaft from the engine,
the engine must be removed from the vehicle.
(1) Remove the engi ne. (Refer to 9 - ENGI NE -
REMOVAL).
(2) Remove the engi ne oi l pump.(Refer to 9 -
ENGI NE/LUBRI CATI ON/OI L PUMP - REMOVAL).
CAUTION: DO NOT pry on the oil pan gasket when
removing the oil pan, The oil pan gasket is mounted
to the cylinder block in three locations and will
remain attached to block when removing oil pan.
Gasket can not be removed with oil pan.
(3) Remove oi l pan. (Refer to 9 - ENGI NE/LUBRI -
CATI ON/OI L PAN - REMOVAL).
(4) Remove the oi l pump pi ckup tube and oi l pan
gasket /wi ndage tray.
(5) Remove the bedpl ate mounti ng bol ts. Note the
l ocati on of the three stud bol ts for i nstal l ati on.
(6) Remove the connecti ng rods from the crank-
shaft.
surface is a critical sealing surface. Do not pry on
or damage this surface in anyway.
NOTE: The bedplate contains the lower main bear-
ing halves. Use care when handling bedplate as not
to drop or damage bearing halves. Installing main
bearing halves in the wrong position will cause
sever damage to the crankshaft.
Fig. 55 Engine Core Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
DR ENGINE - 4. 7L 9 - 131
NOTE: The bedplate has pry points cast into it. Use
these points only. The pry points are on both the
left and right sides, only the left side is shown.
(7) Careful l y pry on the pry poi nts (Fi g. 56) to
l oosen the bedpl ate then remove the bedpl ate.
CAUTION: When removing the crankshaft, use care
not to damage bearing surfaces on the crankshaft.
(8) Remove the crankshaft.
(9) Remove the crankshaft target wheel .
INSPECTION
NOTE: Thoroughly inspect the connecting rod bear-
ing bores and main bearing bores for scoring, blue-
ing or severe scratches. Further disassembly may
be required.
I f connecti ng rod beari ng bores show damage, the
cyl i nder heads must be removed to servi ce the pi ston
and rod assembl i es. I f the bedpl ate or the cyl i nder
bl ock mai n beari ng bores show damage the engi ne
must be repl aced.
(1) I f requi red, remove the mai n beari ng hal ves
from the cyl i nder bl ock and bedpl ate.
(2) Thoroughl y cl ean the bedpl ate to cyl i nder bl ock
seal i ng surfaces and mai n beari ng bores. Remove al l
oi l and seal ant resi due.
(3) I nspect the bedpl ate mai n beari ng bores for
cracks, scori ng or severe bl uei ng. I f ei ther condi ti on
exi sts the engi ne must be repl aced.
(4) I nspect the crankshaft thrust washers for scor-
i ng, scratches, wear or bl uei ng. I f ei ther condi ti on
exi st repl ace the thrust washer.
(5) I nspect the oi l pan gasket/wi ndage tray for
spl i ts, tears or cracks i n the gasket seal i ng surfaces.
Repl ace gasket as necessary.
INSTALLATION
CAUTION: Main bearings are select fit. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE) for proper
bearing selections.
(1) Lubri cate upper mai n beari ng hal ves wi th
cl ean engi ne oi l .
CAUTION: When installing crankshaft, use care not
to damage bearing surfaces on the crankshaft.
NOTE: Apply sealant to the target wheel retaining
screws prior to installation.
(2) I nstal l the crankshaft target wheel . Torque the
mounti ng screws to 15 Nm (12 ft. l bs.).
(3) Posi ti on crankshaft i n cyl i nder bl ock.
(4) I nstal l the thrust washers (Fi g. 57).
Fig. 56 Bedplate Pry Point Location
1 - CYLINDER BLOCK
2 - BEDPLATE
3 - PRY POINT
Fig. 57 Crankshaft Thrust Washer Installation
1 - CRANKSHAFT THRUST WASHER
9 - 132 ENGINE - 4. 7L DR
CAUTION: The bedplate to cylinder block mateing
surface must be coated with sealant prior to instal-
lation. Failure to do so will cause severe oil leaks.
NOTE: The installation time to install the bedplate
after the sealant has been applied is critical.
NOTE: Make sure that the bedplate and cylinder
block sealing surfaces are clean and free of oil or
other contaminants. Contaminants on the sealing
surfaces may cause main bearing distortion and/or
oil leaks.
(5) Appl y a 2.5mm (0.100 i nch) (Fi g. 58) bead of
Mopar Gen I I Si l i cone Rubber Adhesi ve seal ant to
the cyl i nder bl ock-to-bedpl ate mati ng surface as
shown (Fi g. 59).
(6) Coat the crankshaft mai n beari ng journal s
wi th cl ean engi ne oi l and posi ti on the bedpl ate onto
the cyl i nder bl ock.
NOTE: Lubricate the bedplate retaining bolts with
clean engine oil prior to installation.
(7) I nstal l the bedpl ate retai ni ng bol ts, maki ng
sure to pl ace the stud bol ts i n the correct l ocati on,
Torque the bol ts i n the sequence shown (Fi g. 60).
Ti ghten bol ts A L to 54 Nm (40 ft. l bs.)
Ti ghten bol ts 110 to 2.8 Nm (25 i n. l bs.)
Turn bol ts 110 an addi ti onal 90.
Ti ghten bol ts A1 A6 to 27 Nm (20 ft. l bs.)
(8) Measure crankshaft end pl ay. (Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT - STAN-
DARD PROCEDURE).
(9) I nstal l the connecti ng rods and measure si de
cl earance. (Refer to 9 - ENGI NE/ENGI NE BLOCK/
CONNECTI NG ROD BEARI NGS - STANDARD
PROCEDURE).
Fig. 58 Cutting Aplicator to Achieve 2.5mm (0.100
in.) Bead
1 - CUT HERE
Fig. 59 Cylinder Block-to-Bedplate Sealent Bead
Location
1 - CYLINDER BLOCK
2 - SEALANT BEAD LOCATION
DR ENGINE - 4. 7L 9 - 133
(10) Posi ti on the oi l pan gasket/wi ndage tray,
usi ng a new o-ri ng, i nstal l the oi l pi ckup tube.
Torque the bol t to 28Nn (20 ft. l bs.) torque the nuts
to 28Nm (20 ft. l bs.).
(11) I nstal l the oi l pan. Torque the retai ni ng bol ts
to 15 Nm (11 ft. l bs.) i n the sequence shown (Fi g.
61).
(12) I nstal l the engi ne (Refer to 9 - ENGI NE -
I NSTALLATI ON).
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE CRANKSHAFT MAIN
BEARING - FITTING
Crankshaft removed from the cyl i nder bl ock.
shaft posi ti on sensor target wheel has grade i denti fi -
cati on marks stamped i nto i t (Fi g. 62). These marks
are read from l eft to ri ght, correspondi ng wi th jour-
Fig. 60 Bedplate Tightening Sequence
1 - BEDPLATE
2 - CYLINDER BLOCK
Fig. 61 Oil Pan Tightening Sequence
9 - 134 ENGINE - 4. 7L DR
nal number 1, 2, 3, 4 and 5. The crankshaft posi ti on
sensor target wheel i s mounted to the number 8
counter wei ght on the crankshaft.
NOTE: Service main bearings are coded. These
codes identify what size (grade) the bearing is.
MAIN BEARING SELECTION CHART4.7L
GRADE SIZE mm
(in.)
FOR USE WITH
MARKING JOURNAL SIZE
A 0.008 mm
U/S
63.48863.496 mm
(0.0004 in.)
U/S
(2.49962.4999 in.)
B NOMINAL 63.49663.504 mm
(2.49992.5002 in.)
C 0.008 mm
O/S
63.50463.512 mm
(0.0004 in.)
O/S
(2.50022.5005 in.)
INSPECTION
wear patterns are i l l ustrated (Fi g. 63).
NOTE: If any of the crankshaft journals are scored,
the crankshaft must be repaired or replaced.
FRONT
REMOVAL
REMOVAL).
(3) Remove A/C compressor mouni ng fasteners and
set asi de.
(8) Remove radi ator cool i ng fan and shroud (Refer
REMOVAL).
Fig. 62 Main Bearing Markings on Target Wheel
1 - REARMOST CRANKSHAFT COUNTER WEIGHT
2 - TARGET WHEEL
3 - MAIN BEARING SELECT FIT MARKINGS
Fig. 63 Main Bearing Wear Patterns
1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
DR ENGINE - 4. 7L 9 - 135
front seal (Fi g. 65).
INSTALLATION
shaft, Damper or Special Tool 8512, thoroughly
(1) Usi ng Speci al Tool 8348 and 8512, i nstal l
crankshaft front seal (Fi g. 66).
LATI ON).
I NSTALLATI ON).
(5) I nstal l A/C compressor and ti ghten fasteners to
54 Nm (40 ft. l bs.).
I NSTALLATI ON).
Fig. 64 Crankshaft Damper Removal
Fig. 65 Crankshaft Front Seal Removal
Fig. 66 Crankshaft Front Seal Installation
9 - 136 ENGINE - 4. 7L DR
REAR
LEAKS
area:
these i tems.
Leaks i n general )
seal.
REMOVAL
transmi ssi on.
after removal.
(3) Usi ng Speci al Tool 8506 (Fi g. 67), remove the
crankshaft rear oi l seal .
Fig. 67 Crankshaft Rear Oil Seal Removal
DR ENGINE - 4. 7L 9 - 137
INSTALLATION
(1) Lubri cate the crankshaft fl ange wi th engi ne oi l .
(2) Posi ti on the magneti c seal gui de Speci al Tool
8349-2 (Fi g. 68) onto the crankshaft rear face. Then
posi ti on the crankshaft rear oi l seal onto the gui de.
Seal I nstal l er and C-4171 Dri ver Handl e (Fi g. 69),
wi th a hammer, tap the seal i nto pl ace. Conti nue to
tap on the dri ver handl e unti l the seal i nstal l er seats
FLEX PLATE
REMOVAL
INSTALLATION
(1) Posi ti on the fl expl ate onto the crankshaft and
i nstal l the bol ts hand ti ght.
(2) Ti ghten the fl expl ate retai ni ng bol ts to 60 Nm
(45 ft. l bs.) i n the sequence shown (Fi g. 70).
Fig. 68 Crankshaft Rear Oil Seal Guide Special Tool
8349-2 and Oil
2 - SPECIAL TOOL 8349-2 GUIDE
Fig. 69 Crankshaft Rear Oil Seal Installation
2 - SPECIAL TOOL 8349-1 INSTALLER
3 - SPECIAL TOOL C-4171 HANDLE
Fig. 70 Flexplate Tightening Sequence
1 - FLEXPLATE
9 - 138 ENGINE - 4. 7L DR
DESCRIPTION
or a scratch awl.
al l oy. The anodi zed top ri ng groove and crown has
been repl aced wi th a coated top ri ng that i s bl ue i n
col or on the bottom surface. Pi ston ski rts are coated
wi th a sol i d l ubri cant (Mol ykote) to reduce fri cti on
and provi de scuff resi stance. The connecti ng rods are
made of forged powdered metal , wi th a fractured
cap desi gn. A pressed fi t pi ston pi n i s used to attach
the pi ston and connecti ng rod.
STANDARD PROCEDURE - PISTON FITTING
B (Fi g. 72).
pi ston pi n and connecti ng rod pre-assembl ed.
requi red.
REMOVAL
- REMOVAL).
Fig. 71 DO NOT MEASURE MOLY COATED PISTON
1 - MOLY COATED
2 - MOLY COATED
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM (1.5 in)
DR ENGINE - 4. 7L 9 - 139
usi ng a permanent i nk marker or scri be tool (Fi g.
73).
damage may occur.
rod surfaces.
(7) Careful l y remove pi ston ri ngs from pi ston(s),
starti ng from the top ri ng down.
CLEANING
l and grooves.
INSPECTION
i ng.
INSTALLATION
assembl i es i nto the bore, i nstal l the pi ston ri ngs.
tion.
(3) Posi ti on beari ng onto connecti ng rod. Ensure
that hol e i n beari ng shel l al i gns wi th hol e i n connect-
i ng rod. Lubri cate beari ng surface wi th cl ean engi ne
oi l .
Fig. 73 Identify Connecting Rod to Cylinder
PositionTypical
9 - 140 ENGINE - 4. 7L DR
Gui des i nto connecti ng rod bol t threads (Fi g. 74).
surface wi th an rai sed F i ndi cati ng i nstal l ati on
posi ti on. Thi s mark must be poi nti ng toward the
front of engi ne on both cyl i nder banks. The connect-
i ng rod oi l sl i nger sl ot faces the front of the engi ne
(Fi g. 75).
engi ne oi l .
or removed.
Ti ghten bol ts to 27 Nm (20 ft. l bs.) pl us 90.
Ti mi ng chai n and cover. (Refer to 9 - ENGI NE/
- I NSTALLATI ON).
I NSTALLATI ON).
TI ON).
rect l evel .
INSTALLATION
3 - RING COMPRESSOR
ORIENTATION
1 - MAJOR THRUST SIDE OF PISTON
DR ENGINE - 4. 7L 9 - 141
PISTON RINGS
FITTING
77) make sure the feel er gauge fi ts snugl y between
Ring Position Groove
Clearance
Maximum
Clearance
Upper Ring .051-.094 mm 0.11 mm
(0.0020-.0037
in.)
(0.004 in.)
Intermediate
Ring
0.04-0.08 mm 0.10 mm
(0.0016-0.0031
in.)
(0.004 in.)
Oil Control Ring .019-.229 mm .25 mm
(Steel Rails) (.0007-.0090
in.)
(0.010 in.)
Upper Ring 0.20-0.36 mm 0.43 mm
(0.0079-0.0142
in.)
(0.0017 in.)
Intermediate
Ring
0.37-0.63 mm 0.74 mm
(0.0146-0.0249
in.)
(0.029 in.)
Oil Control Ring 0.025-0.76 mm 1.55 mm
(Steel Rail) (0.0099- 0.03
in.)
(0.061 in.)
Fig. 76 Ring End Gap Measurement - Typical
1 - FEELER GAUGE
1 - FEELER GAUGE
9 - 142 ENGINE - 4. 7L DR
of the pi ston.
order:
Oil ring expander.
Fig. 78 Side Rail - Installation
1 - SIDE RAIL END
Fig. 79 Upper and Intermediate Rings - Installation
Fig. 80 Piston Ring End Gap Position
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
DR ENGINE - 4. 7L 9 - 143
VIBRATION DAMPER
REMOVAL
REMOVAL).
water pump (Fi g. 81).
INSTALLATION
(1) Al i gn crankshaft damper sl ot wi th key i n
crankshaft. Sl i de damper onto crankshaft sl i ghtl y.
ened beari ng surface of the beari ng MUSTface the
Sei ze or equi val ent.
crankshaft (Fi g. 84).
175 Nm (130 ft. l bs.).
I NSTALLATI ON).
(7) Connect el ectri cal connector for shroud fan.
Fig. 81 FAN ASSEMBLY - REMOVAL/ASSEMBLY
PINS 8346
2 - FAN
Fig. 82 CRANKSHAFT DAMPER - REMOVAL
9 - 144 ENGINE - 4. 7L DR
LATI ON).
STRUCTURAL COVER
DESCRIPTION
bel l housi ng to the engi ne bedpl ate.
OPERATION
REMOVAL
(2) Remove the l eft hand exhaust pi pe from
exhaust mani fol d.
(3) Loosen the ri ght hand exhaust mani fol d-to-ex-
haust pi pe retai ni ng bol ts.
(4) Remove the ei ght bol ts retai ni ng structural
cover (Fi g. 85) i n the sequence shown.
(5) Pi vot the exhaust pi pe downward and remove
the structural cover.
INSTALLATION
Fig. 83 PROPER ASSEMBLY METHOD FOR
SPECIAL TOOL 8512A
1 - BEARING
2 - NUT
3 - THREADED ROD
5 - HARDENED WASHER
Fig. 84 Crankshaft Damper Installation
1 - BOLT
2 - BOLT
3 - BOLT
DR ENGINE - 4. 7L 9 - 145
mani fol d.
FRONT MOUNT
REMOVAL
2WD
REMOVAL).
pan.
mounts to the front axl e.
(11) Remove the through bol ts
(13) Remove the (8) mount to engi ne attachi ng
bol ts
4WD
(2) Remove the vi scous fan.
(5) Remove the front crossmember.
pan.
1 - BOLT
2 - BOLT
3 - BOLT
9 - 146 ENGINE - 4. 7L DR
STRUCTURAL COVER (Continued)
remove the l eft (Fi g. 89) and ri ght (Fi g. 88) engi ne
mounts.
INSTALLATION
2WD
the engi ne bl ock wi th (8) bol ts. Torque bol ts to 54
Nm (40 ft. l bs.).
(2) I nsert the (2) through bol ts i nto the ri ght and
l eft si de engi ne mounts and l oose assembl e the two
nuts onto the through bol ts.
(3) Lower the engi ne unti l the through bol ts rest
onto the sl ots i n the frame brackets.
(4) Ti ghten the through bol t nuts to 94 Nm (70 ft.
l bs.).
2 - NUT
6 - FRONT AXLE
7 - NUT
Fig. 88 ENGINE MOUNT SUPPORT BRACKET RH
1 - BOLT
DR ENGINE - 4. 7L 9 - 147
(8) I nstal l the vi scous fan (Refer to 7 - COOLI NG/
REMOVAL).
4WD
94 Nm (70 ft. l bs.).
(4) Lower the engi ne unti l the l eft and ri ght si de
Fig. 89 ENGINE MOUNT SUPPORT BRACKET
1 - BOLT
3 - BOLT
2 - NUT
6 - FRONT AXLE
7 - NUT
9 - 148 ENGINE - 4. 7L DR
Nm (75 ft. l bs.).
(11) I nstal l the front crossmember.
(14) I nstal l the vi scous fan (Refer to 7 - COOL-
REMOVAL).
REAR MOUNT
REMOVAL
(Fi g. 91).
INSTALLATION
the crossmember.
1 - MOUNT
2 - CROSSMEMBER
3 - NUT
4 - BOLT
DR ENGINE - 4. 7L 9 - 149
LUBRICATION
DESCRIPTION
The l ubri cati on system (Fi g. 92) i s a ful l fl ow fi l -
trati on pressure feed type.
OPERATION
Oi l from the oi l pan i s pumped by a gerotor type oi l
pump di rectl y mounted to the crankshaft nose. Oi l
pressure i s control l ed by a rel i ef val ve mounted
i nsi de the oi l pump housi ng. For l ubri cati on fl ow
refer to (Fi g. 92).
Fig. 92 Engine Oil Lubrication System
1 - LEFT CYLINDER HEAD OIL GALLERY
2 - OIL PRESSURE SENSOR LOCATION
3 - TO LEFT CYLINDER HEAD
4 - OIL FEED TO IDLER SHAFT
5 - OIL PUMP OUTLET TO BLOCK
6 - OIL PUMP
7 - TO CRANKSHAFT MAIN JOURNALS
8 - RIGHT CYLINDER HEAD OIL GALLERY
9 - TO RIGHT CYLINDER HEAD
10 - CYLINDER BLOCK MAIN GALLERY
11 - OIL FEED TO BOTH SECONDARY TENSIONERS
9 - 150 ENGINE - 4. 7L DR
The camshaft exhaust val ve l obes and rocker arms
are l ubri cated through a smal l hol e i n the rocker
arm; oi l fl ows through the l ash adjuster then through
the rocker arm and onto the camshaft l obe. Due to
the orentati on of the rocker arm, the camshaft i ntake
l obes are not l ubed i n the same manner as the
exhaust l obes. The i ntake l obes are l ubed through
i nternal passages i n the camshaft. Oi l fl ows through
a bore i n the number 3 camshaft beari ng bore, and
as the camshaft turns, a hol e i n the camshaft al i gns
wi th the hol e i n the camshaft bore al l owi ng engi ne
oi l to enter the camshaft tube. The oi l then exi ts
through 1.6mm (0.063 i n.) hol es dri l l ed i nto the
i ntake l obes, l ubri cati ng the l obes and the rocker
arms.
ENGINE LUBRICATION FLOW CHARTBLOCK: TABLE 1
FROM TO
Oil Pickup Tube Oil Pump
Oil Pump Oil Filter
Oil Filter Block Main Oil Gallery
Block Main Oil Gallery 1. Crankshaft Main Journal
2. Left Cylinder Head*
3. Right Cylinder Head*
Crankshaft Main Journals Crankshaft Rod Journals
Crankshaft Number One Main Journal 1.Front Timing Chain Idler Shaft
2.Both Secondary Chain Tensioners
Left Cylinder Head See Table 2
Right Cylinder Head See Table 2
* The cylinder head gaskets have an oil restricter to control oil flow to the cylinder heads.
ENGINE LUBRICATION FLOW CHARTCYLINDER HEADS: TABLE 2
FROM TO
Cylinder Head Oil Port (in bolt hole) Diagonal Cross Drilling to Main Oil Gallery
Main Oil Gallery (drilled through head from rear to
front)
1. Base of Camshaft Towers
2. Lash Adjuster Towers
Base of Camshaft Towers Vertical Drilling Through Tower to Camshaft Bearings**
Lash Adjuster Towers Diagonal Drillings to Hydraulic Lash Adjuster Pockets
** The number three camshaft bearing journal feeds oil into the hollow camshaft tubes. Oil is routed to the intake
lobes, which have oil passages drilled into them to lubricate the rocker arms.
DR ENGINE - 4. 7L 9 - 151
ENGINE OIL PRESSURE
(1) Remove oi l pressure sendi ng uni t (Fi g. 93)and
i nstal l gauge assembl y C-3292.
(3) Oi l Pressure:
Curb I dl e - 25 kPa (4 psi ) mi ni mum
3000 rpm - 170 - 758 kPa (25 - 110 psi )
repeat i nspecti on.I f the oi l l eak source i s not posi -
ti vel y i denti fi ed at thi s ti me, proceed wi th the ai r
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the PCV val ve from the cyl i nder head
cover. Cap or pl ug the PCV val ve grommet.
procedures.
Leak.
I nstal l the PCV val ve and breather cap hose.
area:
Fig. 93 OIL PRESSURE SENDING UNIT -TYPICAL
1 - BELT
3 - OIL FILTER
4 - ELEC. CONNECTOR
9 - 152 ENGINE - 4. 7L DR
i n general )
seal.
assembl ed.
OIL
SERVICE
PROPERLY.
SAE VISCOSITY
pl e vi scosi ti es such as 5W-30 or 10W-30 i n the 3.7L
engi nes. These are speci fi ed wi th a dual SAE vi scos-
i ty grade whi ch i ndi cates the col d-to-hot temperature
vi scosi ty range. Sel ect an engi ne oi l that i s best
sui ted to your parti cul ar temperature range and vari -
ati on (Fi g. 94).
tai ner.
cans (Fi g. 95).
Fig. 94 TEMPERATURE/ENGINE OIL VISCOSITY -
3.7L ENGINE
Fig. 95 Engine Oil Container Standard Notations
DR ENGINE - 4. 7L 9 - 153
The engi ne oi l l evel i ndi cator i s l ocated at the ri ght
rear of the engi ne on the 3.7L engi nes. (Fi g. 96).
i ted l oss of oi l pressure, run the engi ne for about fi ve
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
(4) I nstal l di psti ck and veri fy i t i s seated i n the tube.
di psti ck.
ENGINE OIL CHANGE
descri bed i n Mai ntenance Schedul es.
perature.
engi ne off.
(4) Pl ace a sui tabl e drai n pan under crankcase drai n.
(5) Remove drai n pl ug from crankcase and al l ow oi l
to drai n i nto pan. I nspect drai n pl ug threads for stretch-
i ng or other damage. Repl ace drai n pl ug i f damaged.
(6) I nstal l drai n pl ug i n crankcase.
type and amount of engi ne oi l descri bed i n thi s secti on.
Care shoul d be exerci sed when di sposi ng used engi ne
oi l after i t has been drai ned from a vehi cl e engi ne.
Refer to the WARNI NG at begi nni ng of thi s secti on.
OIL FILTER
REMOVAL
Al l engi nes are equi pped wi th a hi gh qual i ty ful l -fl ow,
di sposabl e type oi l fi l ter. Dai ml erChrysl er Corporati on
recommends a Mopar or equi val ent oi l fi l ter be used.
(3) Rotate the oi l fi l ter countercl ockwi se (Fi g. 97)to
remove i t from the cyl i nder bl ock oi l fi l ter boss.
Fig. 96 ENGINE OIL DIPSTICK 3.7L ENGINE
1 - TRANSMISSION DIPSTICK
2 - ENGINE OIL DIPSTICK
3 - ENGINE OIL FILL CAP
Fig. 97 Oil Filter - 4.7L Engine
1 - ENGINE OIL FILTER
9 - 154 ENGINE - 4. 7L DR
OIL (Continued)
ter.
INSTALLATION
oi l .
ti ghten fi l ter one ful l turn, do not over ti ghten.
OIL PAN
REMOVAL
(4)
MEMBER - REMOVAL).
manifold.
(8) Rai se engi ne usi ng speci al tool #8534 to pro-
vi de cl earance to remove oi l pan.
(10) Unbol t oi l pump pi ckup tube and remove
tube.
(11) I nspect the i ntegral wi ndage tray and gasket
and repl ace as needed.
INSTALLATION
bedpl ate and oi l pan.
(2) Posi ti on the oi l pan gasket and pi ckup tube
wi th new o-ri ng. I nstal l the mounti ng bol t and nuts.
Ti ghten bol t and nuts to 28 Nm (20 ft. l bs.).
bol ts. Ti ghten the mounti ng bol ts to 15 Nm (11 ft.
l bs.) i n the sequence shown (Fi g. 99).
tool #8534.
ft. l bs.).
(6) Remove speci al tool #8534.
Fig. 98 Oil Filter Sealing Surface-Typical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
Fig. 99 Oil Pan Mounting Bolts and Oil Pan
DR ENGINE - 4. 7L 9 - 155
OIL FILTER (Continued)
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
DESCRIPTION
The 3 wi re, sol i d-state engi ne oi l pressure sensor
(sendi ng uni t) i s l ocated i n an engi ne oi l pressure
gal l ery.
DESCRIPTION
The 3wi re, el ectri cal /mechani cal engi ne oi l pres-
sure sensor (sendi ng uni t) i s l ocated i n an engi ne oi l
pressure gal l ery.
OPERATION
OPERATION
The oi l pressure sensor uses three ci rcui ts. They
are:
A 5 vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM)
return
sure
The oi l pressure sensor has a 3 wi re el ectri cal
functi on very much l i ke the Mani fol d Absol ute Pres-
sure (MAP) sensor. Meani ng di fferent pressures
rel ate to di fferent output vol tages.
A 5 vol t suppl y i s sent to the sensor from the PCM
to power up the sensor. The sensor returns a vol tage
si gnal back to the PCM rel ati ng to engi ne oi l pres-
sure. Thi s si gnal i s then transferred (bussed) to the
i nstrument panel on ei ther a CCD or PCI bus ci rcui t
(dependi ng on vehi cl e l i ne) to operate the oi l pressure
gauge and the check gauges l amp. Ground for the
sensor i s provi ded by the PCM through a l ow-noi se
sensor return.
OPERATION
The oi l pressure sensor uses two ci rcui ts. They are:
sure
return
The oi l pressure sensor returns a vol tage si gnal
back to the PCM rel ati ng to engi ne oi l pressure. Thi s
si gnal i s then transferred (bussed) to the i nstrument
panel on a CCD bus ci rcui t to operate the oi l pres-
sure gauge and the check gauges l amp. Ground for
the sensor i s provi ded by the PCM through a l ow-
noi se sensor return.
REMOVAL
(3) Remove front spl ash shi el d.
(4) Di sconnect oi l pressure sender wi re (Fi g. 100).
(5) Remove the pressure sender (Fi g. 100).
INSTALLATION
(1) I nstal l oi l pressure sender.
(2) Connect oi l pressure sender wi re.
(3) I nstal l front spl ash shi el d.
OIL PUMP
REMOVAL
(1) Remove the oi l pan and pi ck-up tube (Refer to
(3) Remove the ti mi ng chai ns and tensi oners
(4) Remove the four bol ts, pri mary ti mi ng chai n
tensi oner and the oi l pump.
Fig. 100 OIL PRESSURE SENDING UNIT
1 - BELT
3 - OIL FILTER
4 - ELEC. CONNECTOR
9 - 156 ENGINE - 4. 7L DR
DISASSEMBLY
(1) Remove oi l pump cover screws and l i ft off cover
pl ate.
(2) Remove pump i nner and outer rotors.
NOTE: Once the oil pressure relief valve, cup plug,
and pin are removed, the pump assembly must be
replaced.
(3) I f i t i s necessary to remove the pressure rel i ef
val ve, dri ve the rol l pi n from pump housi ng and
remove cup pl ug, spri ng and val ve.
CLEANING
(1) Wash al l parts i n a sui tabl e sol vent.
INSPECTION
CAUTION: Oil pump pressure relief valve and
spring should not be removed from the oil pump. If
these components are disassembled and or
removed from the pump the entire oil pump assem-
bly must be replaced.
(2) Lay a strai ght edge across the pump cover sur-
face (Fi g. 101). I f a 0.025 mm (0.001 i n.) feel er gauge
can be i nserted between the cover and the strai ght
edge the oi l pump assembl y shoul d be repl aced.
(3) Measure the thi ckness of the outer rotor (Fi g.
102). I f the outer rotor thi ckness measures at 12.005
mm (0.472 i n.) or l ess the oi l pump assembl y must be
repl aced.
(4) Measure the di ameter of the outer rotor. I f the
outer rotor di ameter measures at 85.925 mm (3.382
i n.) or l ess the oi l pump assembl y must be repl aced.
(5) Measure the thi ckness of the i nner rotor (Fi g.
103). I f the i nner rotor thi ckness measures at 12.005
mm (0.472 i n.) or l ess then the oi l pump assembl y
must be repl aced.
Fig. 101 Checking Oil Pump Cover Flatness
1 - STRAIGHT EDGE
2 - FEELER GAUGE
3 - OIL PUMP COVER
Fig. 102 Measuring Outer Rotor Thickness
Fig. 103 Measuring Inner Rotor Thickness
DR ENGINE - 4. 7L 9 - 157
repl aced.
ASSEMBLY
(1) Wash al l parts i n a sui tabl e sol vent and i nspect
careful l y for damage or wear.
(2) I nstal l i nner and outer rotors
(3) I nstal l oi l pump cover pl ate and i nstal l cover
bol ts and ti ghten them to 12 Nm (105 i n. l bs.).
(4) Pri me oi l pump before i nstal l ati on by fi l l i ng
rotor cavi ty wi th engi ne oi l .
(5) I f oi l pressure i s l ow and pump i s wi thi n spec-
i fi cati ons, i nspect for worn engi ne beari ngs or other
causes for oi l pressure l oss.
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 105 Measuring Clearance Between Rotors
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
Fig. 106 Measuring Clearance Over Rotors
1 - STRAIGHT EDGE
2 - FEELER GAUGE
9 - 158 ENGINE - 4. 7L DR
INSTALLATION
i nstal l one oi l pump retai ni ng bol ts.
(2) Posi ti on the pri mary ti mi ng chai n tensi oner
and i nstal l three retai ni ng bol ts.
(3) Ti ghten the oi l pump and pri mary ti mi ng chai n
tensi oner retai ni ng bol ts to 28 Nm (250 i n. l bs.) i n
the sequence shown (Fi g. 107).
(4) I nstal l the secondary ti mi ng chai n tensi oners
and ti mi ng chai ns (Refer to 9 - ENGI NE/VALVE
I NSTALLATI ON).
(6) I nstal l the pi ck-up tube and oi l pan (Refer to 9
TI ON).
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d i s made of a composi te mate-
ri al and features l ong runners whi ch maxi mi zes l ow
end torque. The i ntake mani fol d uses si ngl e pl ane
seal i ng whi ch consi st of ei ght i ndi vi dual press i n
pl ace port gaskets to prevent l eaks. Ei ght studs and
two bol ts are used to fasten the i ntake to the head.
DIAGNOSIS AND TESTING INTAKE
MANIFOLD LEAKAGE
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
REMOVAL
i ng components:
(5) Di sconnect brake booster hose and posi ti ve
crankcase venti l ati on (PCV) hose.
(6) Di sconnect generator el ectri cal connecti ons.
(7) Di sconnect ai r condi ti oni ng compressor el ectri -
cal connecti ons.
(8) Di sconnect l eft and ri ght radi o suppressor
straps.
(9) Di sconnect and remove i gni ti on coi l towers
(Refer to 8 - ELECTRI CAL/I GNI TI ON CONTROL/
I GNI TI ON COI L - REMOVAL).
(10) Remove top oi l di psti ck tube retai ni ng bol t
and ground strap.
DURE).
(12) Remove fuel rai l (Refer to 14 - FUEL SYS-
TEM/FUEL DELI VERY/FUEL RAI L - REMOVAL).
(13) Remove throttl e body assembl y and mounti ng
bracket.
(14) Drai n cool i ng system bel ow cool ant tempera-
ture l evel (Refer to 7 - COOLI NG - STANDARD
PROCEDURE).
(15) Remove the heater hoses from the engi ne
front cover and the heater core.
Fig. 107 Oil Pump And Primary Timing Chain
Tensioner Tightening Sequence
DR ENGINE - 4. 7L 9 - 159
from i ntake mani fol d (Fi g. 108).
(17) Remove cool ant temperature sensor (Refer to
7 - COOLI NG/ENGI NE/ENGI NE COOLANT TEM-
PERATURE SENSO - REMOVAL).
reverse order of ti ghteni ng sequence (Fi g. 109).
CLEANING
NOTE: There is NO approved repair procedure for the
intake manifold. If severe damage is found during
inspection, the intake manifold must be replaced.
Before i nstal l i ng the i ntake mani fol d thoroughl y
cl ean the mati ng surfaces. Use a sui tabl e cl eani ng
sol vent, then ai r dry.
INSPECTION
(1) I nspect the i ntake seal i ng surface for cracks,
ni cks and di storti on.
(2) I nspect the i ntake mani fol d vacuum hose fi t-
ti ngs for l ooseness or bl ockage.
(3) I nspect the mani fol d to throttl e body mati ng
surface for cracks, ni cks and di storti on.
INSTALLATION
(1) I nstal l i ntake mani fol d gaskets.
(2) Posi ti on i ntake mani fol d.
(3) I nstal l i ntake mani fol d retai ni ng bol ts and
ti ghten i n sequence shown i n (Fi g. 109) to 12 Nm
(105 i n. l bs.).
(4) I nstal l l eft and ri ght radi o suppressor straps.
(5) I nstal l throttl e body assembl y.
(6) I nstal l throttl e cabl e bracket.
(7) Connect throttl e cabl e and speed control cabl e
to throttl e body.
(8) I nstal l fuel rai l (Refer to 14 - FUEL SYSTEM/
FUEL DELI VERY/FUEL RAI L - I NSTALLATI ON).
(9) I nstal l i gni ti on coi l towers (Refer to 8 - ELEC-
TRI CAL/I GNI TI ON CONTROL/I GNI TI ON COI L -
I NSTALLATI ON).
(11) I nstal l the heater hoses to the heater core and
engi ne front cover.
components:
I gni ti on coi l towers
Fuel i njectors
(13) I nstal l top oi l di psti ck tube retai ni ng bol t and
ground strap.
(14) Connect generator el ectri cal connecti ons.
(15) Connect Brake booster hose and Posi ti ve
Fig. 108 Heater Hoses and Tubes Removal /
Installation
1 - HEATER HOSES AND TUBES
2 - ROUTING/RETAINING CLIPS
Fig. 109 Intake Manifold Tightening Sequence
9 - 160 ENGINE - 4. 7L DR
EXHAUST MANIFOLD
DESCRIPTION
The exhaust mani fol ds are l og styl e wi th a pat-
ented fl ow enhanci ng desi gn to maxi mi ze perfor-
mance. The exhaust mani fol ds are made of hi gh
si l i con mol ybdenum cast i ron. A perforated core
graphi te exhaust mani fol d gasket i s used to i mprove
seal i ng to the cyl i nder head. The exhaust mani fol ds
are covered by a three l ayer l ami nated heat shi el d
for thermal protecti on and noi se reducti on. The heat
shi el ds are fastened wi th a torque prevai l i ng nut
REMOVAL
(1) Di sconnect negati ve cabl e for battery.
REMOVAL).
PRESSOR - REMOVAL).
(5) Remove A/C accumul ator support bracket fas-
tener.
(6) Drai n cool ant bel ow heater hose l evel (Refer to
7 - COOLI NG - STANDARD PROCEDURE).
(7) Remove heater hoses at engi ne.
(8) Remove fasteners attachi ng exhaust mani fol d
heat shi el d.
(9) Remove heat shi el d.
(10) Remove upper exhaust mani fol d attachi ng fas-
teners.
(12) Di sconnect exhaust pi pe from mani fol d.
(13) Remove fasteners attachi ng starter. Move
starter asi de.
(14) Remove l ower exhaust mani fol d attachi ng fas-
teners.
(15) Remove exhaust mani fol d and gasket (Fi g.
110). Mani fol d i s removed from bel ow the engi ne
compartment.
DR ENGINE - 4. 7L 9 - 161
Fig. 110 Exhaust ManifoldRight
ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE
1 Stud (Qty 2)
25 Nm (18 ft. lbs.)
4 Nut (Qty 2) 8 Nm (72 in. lbs.),
then loosen 45
degrees
2 Bolt (Qty 4) 5 Nut (Qty 2)
3 Stud (Qty 2)
9 - 162 ENGINE - 4. 7L DR
(1) Di sconnect negati ve cabl e for battery.
(2) Hoi st vehi cl e.
(3) Di sconnect exhaust pi pe at mani fol d.
(5) Remove the front two exhaust heat shi el d
retai ni ng fasteners. Rai se vehi cl e and remove the
fasteners at rear of heat shi el d.
(6) Remove heat shi el d (Fi g. 111).
(7) Lower vehi cl e and remove the upper exhaust
mani fol d retai ni ng bol ts (Fi g. 111).
(8) Rai se vehi cl e and remove the l ower exhaust
mani fol d retai ni ng bol ts (Fi g. 111).
(9) Remove exhaust mani fol d and gasket (Fi g.
111). Mani fol d i s removed from bel ow the engi ne
compartment.
CLEANING
(1) Cl ean the exhaust mani fol d usi ng a sui tabl e
cl eani ng sol vent, then al l ow to ai r dry.
(2) Cl ean al l gasket resi due from the mani fol d
mati ng surface.
INSPECTION
(1) I nspect the exhaust mani fol d for cracks i n the
mati ng surface and at every mounti ng bol t hol e.
(2) Usi ng a strai ght edge and a feel er gauge, check
the mati ng surface for warp and twi st.
(3) I nspect the mani fol d to exhaust pi pe mati ng
surface for cracks, gouges, or other damage that
woul d prevent seal i ng.
Fig. 111 Exhaust ManifoldLeft
1 Stud (Qty 2)
25 Nm (18 ft. lbs.)
4 Nut (Qty 2) 8 Nm (72 in. lbs.),
then loosen 45
degrees
3 Stud (Qty 2)
DR ENGINE - 4. 7L 9 - 163
INSTALLATION
(1) I nstal l exhaust mani fol d and gasket (Fi g. 112)
from bel ow engi ne compartment.
(2) I nstal l l ower exhaust mani fol d fasteners. DO
NOT ti ghten unti l al l fasteners are i n pl ace.
(3) Lower vehi cl e and i nstal l upper exhaust mani -
fol d fasteners. Ti ghten al l mani fol d bol ts starti ng at
center and worki ng outward to 25 Nm (18 ft. l bs.).
(4) I nstal l exhaust mani fol d heat shi el d. Ti ghten fas-
teners to 8 Nm (72 i n. l bs.), then l oosen 45 degrees.
(5) I nstal l starter and fasteners.
(6) Connect exhaust pi pe to mani fol d.
(7) Connect heater hoses at engi ne.
(8) I nstal l fastener attachi ng A/C accumul ator.
(9) I nstal l A/C compressor and fasteners.
I NSTALLATI ON).
(12) I nstal l battery and connect cabl es.
Fig. 112 Exhaust ManifoldRight
1 Stud (Qty 2)
25 Nm (18 ft. lbs.)
4 Nut (Qty 2) 8 Nm (72 in. lbs.),
then loosen 45
degrees
3 Stud (Qty 2)
9 - 164 ENGINE - 4. 7L DR
(1) I nstal l exhaust mani fol d and gasket from bel ow
engi ne compartment.
(2) I nstal l l ower exhaust mani fol d fasteners (Fi g.
113). DO NOT ti ghten unti l al l fasteners are i n pl ace.
(3) Lower vehi cl e and i nstal l upper exhaust mani -
fol d fasteners (Fi g. 113). Ti ghten al l mani fol d bol ts
starti ng at center and worki ng outward to 25 Nm
(18 ft. l bs.).
(4) I nstal l exhaust mani fol d heat shi el d (Fi g.
113). Ti ghten fasteners to 8 Nm (72 i n. l bs.), then
l oosen 45 degrees.
(5) Connect exhaust pi pe to mani fol d.
Fig. 113 Exhaust ManifoldLeft
1 Stud (Qty 2)
25 Nm (18 ft. lbs.)
4 Nut (Qty 2) 8 Nm (72 in. lbs.),
then loosen 45
degrees
3 Stud (Qty 2)
DR ENGINE - 4. 7L 9 - 165
VALVE TIMING
DESCRIPTION TIMING DRIVE SYSTEM
The ti mi ng dri ve system (Fi g. 114) has been
desi gned to provi de qui et performance and rel i abi l i ty
to support a non-free wheeling engi ne. Speci fi cal l y
the i ntake val ves are non-free wheel i ng and can be
easi l y damaged wi th forceful engi ne rotati on i f cam-
shaft-to-crankshaft ti mi ng i s i ncorrect. The ti mi ng
dri ve system consi sts of a pri mary chai n and two sec-
ondary ti mi ng chai n dri ves.
OPERATION - TIMING DRIVE SYSTEM
The pri mary ti mi ng chai n i s a si ngl e i nverted tooth
type. The pri mary chai n dri ves the l arge fi fty tooth
i dl er sprocket di rectl y from a 25 tooth crankshaft
sprocket. Pri mary chai n moti on i s control l ed by a
pi voti ng l eaf spri ng tensi oner arm and a fi xed gui de.
The arm and the gui de both use nyl on pl asti c wear
faces for l ow fri cti on and l ong wear. The pri mary
chai n recei ves oi l spl ash l ubri cati on from the second-
ary chai n dri ve and oi l pump l eakage. The i dl er
sprocket assembl y connects the pri mary and second-
ary chai n dri ves. The i dl er sprocket assembl y con-
si sts of two i ntegral thi rty tooth sprockets and a fi fty
tooth sprocket that i s spl i ned to the assembl y. The
spl i ne joi nt i s a non servi ceabl e press fi t anti rattl e
type. The i dl er sprocket assembl y spi ns on a stati on-
ary i dl er shaft. The i dl er shaft i s press-fi t i nto the
cyl i nder bl ock. A l arge washer on the i dl er shaft bol t
and the rear fl ange of the i dl er shaft are used to con-
trol sprocket thrust movement. Pressuri zed oi l i s
routed through the center of the i dl er shaft to pro-
vi de l ubri cati on for the two bushi ngs used i n the
i dl er sprocket assembl y.
There are two secondary dri ve chai ns, both are
i nverted tooth type, one to dri ve the camshaft i n each
SOHC cyl i nder head. There are no shaft speed
changes i n the secondary chai n dri ve system. Each
secondary chai n dri ves a thi rty tooth cam sprocket
di rectl y from the thi rty tooth sprocket on the i dl er
Fig. 114 Timing Drive System
SIDE NOT COMMON)
5 - CHAIN GUIDE
6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN
7 - PRIMARY CHAIN
8 - IDLER SPROCKET
11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
9 - 166 ENGINE - 4. 7L DR
sprocket assembl y. A fi xed chai n gui de and a hydrau-
l i c oi l damped tensi oner are used to mai ntai n tensi on
i n each secondary chai n system. The hydraul i c ten-
si oners for the secondary chai n systems are fed pres-
suri zed oi l from oi l reservoi r pockets i n the bl ock.
Each tensi oner al so has a mechani cal ratchet system
that l i mi ts chai n sl ack i f the tensi oner pi ston bl eeds
down after engi ne shut down. The tensi oner arms
and gui des al so uti l i ze nyl on wear faces for l ow fri c-
ti on and l ong wear. The secondary ti mi ng chai ns
recei ve l ubri cati on from a smal l ori fi ce i n the ten-
si oners. Thi s ori fi ce i s protected from cl oggi ng by a
fi ne mesh screen whi ch i s l ocated on the back of the
hydraul i c tensi oners.
STANDARD PROCEDURE
STANDARD PROCEDURE MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed.
(1) Remove the ti mi ng chai n cover. (Refer to 9 -
(2) To determi ne i f the secondary ti mi ng chai ns
are worn, rotate the engi ne cl ockwi se unti l maxi mum
tensi oner pi ston extensi on i s obtai ned. Measure the
di stance between the secondary ti mi ng chai n ten-
si oner housi ng and the step l edge on the pi ston (Fi g.
115). The measurement at poi nt (A) must be l ess
than 15mm (0.5906 i nches).
(3) I f the measurement exceeds the speci fi cati on
the secondary ti mi ng chai ns are worn and requi re
repl acement. (Refer to 9 - ENGI NE/VALVE TI MI NG/
TI MI NG BELT/CHAI N AND SPROCKETS -
REMOVAL).
NOTE: If the secondary chains are to be replaced
the primary chain must also be replaced.
STANDARD PROCEDURE - ENGINE TIMING -
VERIFICATION
CAUTION: The 4.7L is a non free-wheeling design
engine. Therefore, correct engine timing is critical.
NOTE: Components referred to as left hand or right
hand are as viewed from the drivers position inside
the vehicle.
NOTE: The blue link plates on the chains and the
dots on the camshaft drive sprockets may not line
up during the timing verification procedure. The
blue link plates are lined up with the sprocket dots
only when re-timing the complete timing drive.
Once the timing drive is rotated blue link-to-dot
alignment is no longer valid.
Engi ne base ti mi ng can be veri fi ed by the fol l owi ng
procedure:
(1) Remove the cyl i nder head covers (Refer to 9 -
Fig. 115 Measuring Secondary Timing Chains For
Wear
2 - SECONDARY CHAIN TENSIONER PISTON
DR ENGINE - 4. 7L 9 - 167
(2) Usi ng a mi rror, l ocate the TDC arrow on the
front cover (Fi g. 116). Rotate the crankshaft unti l the
mark on the crankshaft damper i s al i gned wi th the
TDC arrow on the front cover. The engi ne i s now at
TDC.
(3) Note the l ocati on of the V8 mark stamped i nto
the camshaft dri ve gears (Fi g. 117). I f the V8 mark
on each camshaft dri ve gear i s at the twel ve ocl ock
posi ti on, the engi ne i s at TDC (cyl i nder #1) on the
exhaust stroke. I f the V8 mark on each gear i s at the
si x ocl ock posi ti on, the engi ne i s at TDC (cyl i nder
#1) on the compressi on stroke.
(4) I f both of the camshaft dri ve gears are off i n
the same or opposi te di recti ons, the pri mary chai n or
both secondary chai ns are at faul t. Refer to Ti mi ng
Chai n and Sprockets procedure i n thi s secti on.
(5) I f onl y one of the camshaft dri ve gears i s off
and the other i s correct, the probl em i s confi ned to
one secondary chai n. Refer to Si ngl e camshaft ti m-
i ng, i n thi s procedure.
(6) I f both camshaft dri ve gear V8 marks are at
the twel ve ocl ock or the si x o cl ock posi ti on the
engi ne base ti mi ng i s correct. Rei nstal l the cyl i nder
head covers.
Mark
9 - 168 ENGINE - 4. 7L DR
SINGLE CAMSHAFT TIMING
NOTE: to adjust the timing on one camshaft, pre-
form the following procedure.
(1) Usi ng Chai n Tensi oner Wedge, speci al tool
8350, stabi l i ze the secondary chai n dri ve (Fi g. 118).
For reference purposes, mark the chai n-to-sprocket
posi ti on (Fi g. 118).
(2) Remove the camshaft dri ve gear retai ni ng bol t.
(3) Careful l y remove the camshaft dri ve gear from
the camshaft.
(4) Re-i ndex the camshaft dri ve gear i n the chai n
unti l the V8 mark i s at the same posi ti on as the V8
mark on the opposi te camshaft dri ve gear.
(5) Usi ng a sui tabl e pai r of adjustabl e pl i ers,
rotate the camshaft unti l the al i gnment dowel on the
camshaft i s al i gned wi th the sl ot i n the camshaft
dri ve gear (Fi g. 119).
Fig. 119 Camshaft Dowel
2 - CAMSHAFT DOWEL
DR ENGINE - 4. 7L 9 - 169
(6) Posi ti on the camshaft dri ve gear onto the camshaft,
remove oi l from bol t then i nstal l the retai ni ng bol t. Usi ng
Speci al Tool s, Spanner Wrench 6958 wi th Adapter Pi ns
8346 and a sui tabl e torque wrench, Ti ghten retai ni ng bol t
to 122Nm (90 ft. Lbs.) (Fi g. 120) (Fi g. 121).
(7) Remove speci al tool 8350.
(8) Rotate the crankshaft two ful l revol uti ons, then
reveri fy that the camshaft dri ve gear V8 marks are
i n fact al i gned.
(9) I nstal l the cyl i nder head covers (Refer to 9 -
TIMING BELT / CHAIN
COVER(S)
REMOVAL
REMOVAL).
(6) Remove accessory dri ve bel t tensi oner assembl y
(Fi g. 122).
Fig. 120 Camshaft Sprocket Left Cylinder Head
1 - TORQUE WRENCH
Fig. 121 Camshaft Sprocket InstallationRight
Cylinder Head
1 - TORQUE WRENCH
Fig. 122 Accessory Drive Belt Tensioner
1 - TENSIONER ASSEMBLY
2 - FASTENER TENSIONER TO FRONT COVER
9 - 170 ENGINE - 4. 7L DR
(7) Remove the generator and A/C compressor.
CAUTION: The 4.7L engine uses an RTV sealer
instead of a gasket to seal the front cover to the
engine block, from the factory. For service, Mopar
Engine RTV sealant must be substituted.
NOTE: It is not necessary to remove the water
pump for timing cover removal.
(8) Remove the bol ts hol di ng the ti mi ng cover to
engi ne bl ock. (Fi g. 123).
(9) Remove cover (Fi g. 123).
INSTALLATION
CAUTION: Do not use oil based liquids to clean tim-
ing cover or block surfaces. Use only rubbing alco-
hol, along with plastic or wooden scrapers. Use no
wire brushes or abrasive wheels or metal scrapers,
or damage to surfaces could result.
(1) Cl ean ti mi ng chai n cover and bl ock surface
usi ng rubbi ng al cohol .
CAUTION: The 4.7L can use a special RTV sealer
instead of a carrier gasket to seal the timing cover
to the engine block, from the factory. For service
repairs, Mopar Engine RTV must be used as a sub-
stitute, if RTV is present.
(2) I nspect the water passage o-ri ngs for any dam-
age, and repl ace as necessary.
(3) Appl y Mopar Engi ne RTV seal er to the front
cover fol l owi ng the path bel ow, usi ng a 3 to 4mm
thi ck bead (Fi g. 124).
(4) I nstal l cover. Ti ghten fl ange head fasteners i n
sequence as shown i n (Fi g. 125) to 58 Nm (43 ft.
l bs.).
(5) I nstal l the A/C compressor and generator.
(6) I nstal l crankshaft damper (Refer to 9 -
I NSTALLATI ON).
(7) I nstal l accessory dri ve bel t tensi oner assembl y.
Ti ghten fastener to 54 Nm (40 ft. l bs.).
Fig. 123 Timing Chain Cover Fasteners
Fig. 124 Timing Cover Sealant
2 - WATER PASSAGE ORING
3 - MOPAR ENGINE RTV SEALER
Fig. 125 Timing Chain Cover Fasteners
DR ENGINE - 4. 7L 9 - 171
(8) I nstal l l ower radi ator hose.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(3) Remove ri ght and l eft cyl i nder head covers
(Refer to 9 - ENGI NE/CYLI NDER HEAD/CYLI N-
DER HEAD COVER(S) - REMOVAL).
(4) Remove radi ator fan shroud.
(5) Rotate engi ne unti l ti mi ng mark on crankshaft
damper al i gns wi th TDC mark on ti mi ng chai n cover
(Fi g. 126) (#1 cyl i nder exhaust stroke) and the cam-
shaft sprocket V8 marks are at the 12 ocl ock posi -
ti on (Fi g. 127).
(6) Remove power steeri ng pump (Refer to 19 -
Mark
9 - 172 ENGINE - 4. 7L DR
(7) Remove access pl ugs (2) from l eft and ri ght cyl -
i nder heads for access to chai n gui de fasteners (Fi g.
128).
(8) Remove the oi l fi l l housi ng to gai n access to the
ri ght si de tensi oner arm fastener.
REMOVAL) and ti mi ng chai n cover (Refer to 9 -
(10) Col l apse and pi n pri mary chai n tensi oner
(Fi g. 129).
CAUTION: Plate behind left secondary chain ten-
sioner could fall into oil pan. Therefore, cover pan
opening.
(11) Remove secondary chai n tensi oners.
(12) Remove camshaft posi ti on sensor from ri ght
cyl i nder head (Fi g. 130).
CAUTION: Care should be taken not to damage
camshaft target wheel. Do not hold target wheel
while loosening or tightening camshaft sprocket.
Do not place the target wheel near a magnetic
source of any kind. A damaged or magnetized tar-
get wheel could cause a vehicle no start condition.
CAUTION: Do not forcefully rotate the camshafts or
crankshaft independently of each other. Damaging
intake valve to piston contact will occur. Ensure
negative battery cable is disconnected to guard
against accidental starter engagement.
Fig. 128 Cylinder Head Access Plug Location
Fig. 129 Collapsing And Pinning Primary Chain
Tensioner
Fig. 130 Camshaft Position SensorRemoval
DR ENGINE - 4. 7L 9 - 173
(13) Remove l eft and ri ght camshaft sprocket bol ts.
(14) Whi l e hol di ng the l eft camshaft steel tube
wi th adjustabl e pl i ers, (Fi g. 131) remove the l eft
camshaft sprocket. Sl owl y rotate the camshaft
approxi matel y 15 degrees cl ockwi se to a neutral posi -
ti on.
(15) Whi l e hol di ng the ri ght camshaft steel tube
wi th adjustabl e pl i ers, (Fi g. 132) remove the ri ght
camshaft sprocket. Sl owl y rotate the camshaft
approxi matel y 45 degrees countercl ockwi se to a neu-
tral posi ti on.
(16) Remove i dl er sprocket assembl y bol t.
(17) Sl i de the i dl er sprocket assembl y and crank
sprocket forward si mul taneousl y to remove the pri -
mary and secondary chai ns.
(18) Remove both pi voti ng tensi oner arms and
chai n gui des.
(19) Remove chai n tensi oner.
INSPECTION
I nspect the fol l owi ng components:
Sprockets for excessi ve tooth wear. Some tooth
marki ngs are normal and not a cause for sprocket
repl acement.
I dl er sprocket assembl y bushi ng and shaft for
excessi ve wear.
I dl er sprocket assembl y spl i ne joi nt. The joi nt
shoul d be ti ght wi th no backl ash or axi al movement.
Chai n gui des and tensi oner arms. Repl ace these
parts i f groovi ng i n pl asti c face i s more than 1 mm
(0.039 i n.) deep. I f pl asti c face i s severel y grooved or
mel ted, the tensi oner l ube jet may be cl ogged. The
tensi oner shoul d be repl aced.
Secondary chai n tensi oner pi ston and ratcheti ng
devi ce. I nspect for evi dence of heavy contact between
tensi oner pi ston and tensi oner arm. I f thi s condi ti on
exi st the tensi oner and tensi oner arm shoul d be
repl aced.
Pri mary chai n tensi oner pl asti c faces. Repl ace as
requi red (Fi g. 133).
Fig. 131 Camshaft RotationLeft Side
3 - CAMSHAFT
Fig. 132 Camshaft RotationRight Side
2 - CAMSHAFT DOWEL
9 - 174 ENGINE - 4. 7L DR
Fig. 133 Timing Chain System
SIDE NOT COMMON)
5 - CHAIN GUIDE
6 - TWO PLATED LINKS ON RIGHT CAMSHAFT CHAIN
7 - PRIMARY CHAIN
8 - IDLER SPROCKET
11 - TWO PLATED LINKS ON LEFT CAMSHAFT CHAIN
DR ENGINE - 4. 7L 9 - 175
INSTALLATION
(1) Usi ng a vi se, l i ghtl y compress the secondary
chai n tensi oner pi ston unti l the pi ston step i s fl ush
wi th the tensi oner body. Usi ng a pi n or sui tabl e tool ,
rel ease ratchet pawl by pul l i ng pawl back agai nst
spri ng force through access hol e on si de of tensi oner.
Whi l e conti nui ng to hol d pawl back, Push ratchet
devi ce to approxi matel y 2 mm from the tensi oner
body. I nstal l Speci al Tool 8514 l ock pi n i nto hol e on
front of tensi oner. Sl owl y open vi se to transfer pi ston
spri ng force to l ock pi n (Fi g. 134).
(2) Posi ti on pri mary chai n tensi oner over oi l pump
and i nsert bol ts i nto l ower two hol es on tensi oner
bracket. Ti ghten bol ts to 28 Nm (250 i n. l bs.).
CAUTION: Overtightening the tensioner arm torx
bolt can cause severe damage to the cylinder head.
Tighten torx bolt to specified torque only.
(3) I nstal l ri ght si de chai n tensi oner arm. Appl y
Mopar Lock N, Seal to torx bol t, ti ghten bol t to 17
Nm (150 i n. l bs.).
NOTE: The silver bolts retain the guides to the cyl-
inder heads and the black bolts retain the guides to
the engine block.
(4) I nstal l the l eft si de chai n gui de. Ti ghten the
CAUTION: Overtightening the tensioner arm torx
bolt can cause severe damage to the cylinder head.
Tighten torx bolt to specified torque only.
(5) I nstal l l eft si de chai n tensi oner arm. Appl y
Mopar Lock N, Seal to torx bol t, ti ghten bol t to 17
Nm (150 i n. l bs.).
(6) I nstal l the ri ght si de chai n gui de. Ti ghten the
(7) I nstal l both secondary chai ns onto the i dl er
sprocket. Al i gn two pl ated l i nks on the secondary
chai ns to be vi si bl e through the two l ower openi ngs
on the i dl er sprocket (4 ocl ock and 8 ocl ock). Once
the secondary ti mi ng chai ns are i nstal l ed, posi ti on
speci al tool 8515 to hol d chai ns i n pl ace for i nstal l a-
ti on (Fi g. 135).
(8) Al i gn pri mary chai n doubl e pl ated l i nks wi th
the ti mi ng mark at 12 ocl ock on the i dl er sprocket.
Al i gn the pri mary chai n si ngl e pl ated l i nk wi th the
ti mi ng mark at 6 ocl ock on the crankshaft sprocket
(Fi g. 133).
Fig. 134 Resetting Secondary Chain Tensioners
1 - VISE
2 - INSERT LOCK PIN
3 - RATCHET PAWL
4 - RATCHET
5 - PISTON
Fig. 135 Installing Secondary Timing Chains on
Idler Sprocket
1 - LOCK ARM
4 - IDLER SPROCKET
9 - 176 ENGINE - 4. 7L DR
(9) Lubri cate i dl er shaft and bushi ngs wi th cl ean
engi ne oi l .
(10) I nstal l al l chai ns, crankshaft sprocket, and
i dl er sprocket as an assembl y (Fi g. 136). After gui d-
i ng both secondary chai ns through the bl ock and cyl -
i nder head openi ngs, affi x chai ns wi th a el asti c strap
or the equi val ent, Thi s wi l l mai ntai n tensi on on
chai ns to ai d i n i nstal l ati on.
NOTE: It will be necessary to slightly rotate cam-
shafts for sprocket installation.
(11) Al i gn l eft camshaft sprocket L dot to pl ated
l i nk on chai n.
(12) Al i gn ri ght camshaft sprocket R dot to
pl ated l i nk on chai n.
CAUTION: Remove excess oil from the camshaft
sprocket bolt. Failure to do so can result in over-
torque of bolt resulting in bolt failure.
(13) Remove Speci al Tool 8515, then attach both
sprockets to camshafts. Remove excess oi l from bol ts,
then I nstal l sprocket bol ts, but do not ti ghten at thi s
ti me.
(14) Veri fy that al l pl ated l i nks are al i gned wi th
the marks on al l sprockets and the V8 marks on
camshaft sprockets are at the 12 ocl ock posi ti on (Fi g.
133).
CAUTION: Ensure the plate between the left sec-
ondary chain tensioner and block is correctly
installed.
(15) I nstal l both secondary chai n tensi oners.
NOTE: Left and right secondary chain tensioners
are not common.
(16) Before i nstal l i ng i dl er sprocket bol t, l ubri cate
washer wi th oi l , and ti ghten i dl er sprocket assembl y
(17) Remove al l l ocki ng pi ns (3) from tensi oners.
CAUTION: After pulling locking pins out of each
tensioner, DO NOT manually extend the tensioner(s)
ratchet. Doing so will over tension the chains,
resulting in noise and/or high timing chain loads.
(18) Usi ng Speci al Tool 6958, Spanner wi th Adap-
tor Pi ns 8346, ti ghten l eft (Fi g. 137) and ri ght (Fi g.
138). camshaft sprocket bol ts to 122 Nm (90 ft. l bs.).
Fig. 136 Installing Idler Gear, Primary and
Secondary Timing Chains
2 - PRIMARY CHAIN IDLER SPROCKET
Fig. 137 Tightening Left Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
DR ENGINE - 4. 7L 9 - 177
(19) Rotate engi ne two ful l revol uti ons. Veri fy ti m-
i ng marks are at the fol l ow l ocati ons:
pri mary chai n i dl er sprocket dot i s at 12 ocl ock
(Fi g. 133)
pri mary chai n crankshaft sprocket dot i s at 6
ocl ock (Fi g. 133)
secondary chai n camshaft sprockets V8 marks
are at 12 ocl ock (Fi g. 133)
(20) Lubri cate al l three chai ns wi th engi ne oi l .
(21) After i nstal l i ng al l chai ns, i t i s recommended
that the i dl er gear end pl ay be checked (Fi g. 139).
The end pl ay must be wi thi n 0.100.25 mm (0.004
0.010 i n.). I f not wi thi n speci fi cati on, the i dl er gear
must be repl aced.
(22) I nstal l ti mi ng chai n cover (Refer to 9 -
COVER(S) - I NSTALLATI ON) and crankshaft
damper (Refer to 9 - ENGI NE/ENGI NE BLOCK/VI -
BRATI ON DAMPER - I NSTALLATI ON).
(23) I nstal l cyl i nder head covers (Refer to 9 -
NOTE: Before installing threaded plug in right cylin-
der head, the plug must be coated with sealant to
prevent leaks.
(24) Coat the l arge threaded access pl ug wi th
Mopar Thread Sealant with Teflon, then i nstal l
i nto the ri ght cyl i nder head and ti ghten to 81 Nm
(60 ft. l bs.) (Fi g. 128).
(25) I nstal l the oi l fi l l housi ng.
(26) I nstal l access pl ug i n l eft cyl i nder head (Fi g.
128).
(27) I nstal l power steeri ng pump (Refer to 19 -
(28) I nstal l radi ator fan shroud.
Fig. 138 Tightening Right Side Camshaft Sprocket
Bolt
1 - TORQUE WRENCH
Fig. 139 Measuring Idler Gear End Play
1 - IDLER SPROCKET ASSEMBLY
2 - DIAL INDICATOR
9 - 178 ENGINE - 4. 7L DR
IDLER SHAFT
REMOVAL
chai ns and sprockets (Refer to 9 - ENGI NE/VALVE
REMOVAL).
NOTE: To remove the idler shaft, it is necessary to
tap threads into the shaft, to install the removal
tool.
(2) Usi ng a 12 mm X 1.75 tap, cut threads i n the
i dl er shaft center bore.
(3) Cover the radi ator core wi th a sui tabl e cover.
CAUTION: Use care when removing the idler shaft,
Do not strike the radiator cooling fins with the slide
hammer.
(4) Usi ng Speci al Tool 8517 Sl i de Hammer, remove
the i dl er shaft.
INSTALLATION
(1) Thoroughl y cl ean the i dl er shaft bore.
(2) Posi ti on the i dl er shaft i n the bore.
NOTE: The two lubrication holes in the idler shaft
do not require any special alignment.
NOTE: Before using the retaining bolt to install the
idler shaft, coat the threads and the pilot on the
idler shaft, with clean engine oil.
(3) Usi ng the pri mary i dl er sprocket retai ni ng bol t
and washer, careful l y draw the i dl er shaft i nto the
bore unti l ful l y seated.
(4) Coat the i dl er shaft wi th cl ean engi ne oi l .
(5) I nstal l the ti mi ng chai ns and sprockets (Refer
to 9 - ENGI NE/VALVE TI MI NG/TI MI NG BELT/
DR ENGINE - 4. 7L 9 - 179
ENGINE - 5.7L
TABLE OF CONTENTS
page page
ENGINE - 5.7L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 182
DIAGNOSIS - INTRODUCTION . . . . . . . . . . 183
DIAGNOSIS - PERFORMANCE . . . . . . . . . . 183
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . 185
COMPRESSION PRESSURE . . . . . . . . . . . . 186
COMBUSTION PRESSURE LEAKAGE . . . . . 186
DIAGNOSIS AND TESTINGENGINE
DIAGNOSIS - LUBRICATION . . . . . . . . . . . . 187
STANDARD PROCEDURE
DAMAGED OR WORN THREADS . . . . . . . . 190
STANDARD PROCEDUREHYDROSTATIC
LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 191
SPECIFICATIONS
5.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 192
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
SPECIAL TOOLS
5.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 196
AIR INTAKE SYSTEM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 199
CYLINDER HEAD
OPERATIONCYLINDER HEAD . . . . . . . . . . . 199
DIAGNOSIS AND TESTINGCYLINDER HEAD
GASKET FAILURE . . . . . . . . . . . . . . . . . . . . 199
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 200
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 200
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 201
DESCRIPTION
DESCRIPTION - VALVE GUIDES . . . . . . . . . 202
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 202
STANDARD PROCEDURE - REFACING . . . . . 202
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 203
ROCKER ARM / ADJUSTER ASSY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 203
VALVE STEM SEALS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 203
VALVE SPRINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 204
ENGINE BLOCK
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 205
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVAL - CAMSHAFT CORE HOLE PLUG . 205
REMOVAL - CAMSHAFT . . . . . . . . . . . . . . . 205
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 206
INSTALLATION
INSTALLATION - CAMSHAFT CORE HOLE
PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
INSTALLATION - CAMSHAFT . . . . . . . . . . . . 206
CRANKSHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 207
STANDARD PROCEDURE - CRANKSHAFT
MAIN BEARING - FITTING . . . . . . . . . . . . . . 207
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 208
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 208
AREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 209
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 209
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 210
FLEX PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 210
HYDRAULIC TAPPETS
TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 211
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 211
9 - 180 ENGINE - 5. 7L DR
STANDARD PROCEDUREPISTON FITTING . 211
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 213
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 213
PISTON RINGS
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 215
STRUCTURAL COVER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 216
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 216
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 216
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 218
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 220
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 220
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . 220
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
OIL
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 223
OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 224
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 224
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 225
INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 225
MANIFOLD LEAKAGE . . . . . . . . . . . . . . . . . 225
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 226
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 226
EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 226
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 226
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 227
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 227
TIMING/CHAIN COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 227
TIMING/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 228
TIMING CHAIN/TENSIONER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 229
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 229
DR ENGINE - 5. 7L 9 - 181
ENGINE - 5.7L
DESCRIPTION
The 5.7L engi ne (Fi g. 1)(345 CI D) ei ght-cyl i nder
engi ne i s a 90 V-Type l i ghtwei ght, deep ski rt cast
i ron bl ock, al umi num heads, si ngl e cam, overhead
val ve engi ne wi th hydraul i c rol l er tappets. The heads
i ncorporate spl ayed val ves wi th a hemi spheri cal styl e
combusti on chamber and dual spark pl ugs. The cyl -
i nders are numbered from front to rear; 1, 3, 5, 7 on
the l eft bank and 2, 4, 6, 8 on the ri ght bank. The
fi ri ng order i s 1-8-4-3-6-5-7-2.
Fig. 1 5.7L ENGINE
9 - 182 ENGINE - 5. 7L DR
I NG).
SI S AND TESTI NG).
connections.
TESTING).
IGNITION CONTROL/IGNITION COIL
- REMOVAL).
IGNITION CONTROL/SPARK PLUG -
CLEANING).
filter.
7. Faulty fuel pump, relay or wiring. 7. Repair or replace as necessary.
DR ENGINE - 5. 7L 9 - 183
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low. 1. (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/IDLE AIR
CONTROL MOTOR - REMOVAL).
2. Idle mixture too lean or too rich. 2. Refer to Powertrain Diagnosis
Information.
3. Vacuum leak. 3. Inspect intake manifold and
necessary.
- REMOVAL).
5. Incorrect engine timing. 5. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD PROCEDURE).
plugs.
CLEANING).
filter.
system.
7. Inspect and replace as necessary.
- REMOVAL).
1. ENGINE MISSES ON
ACCELERATION
gapped.
CLEANING).
- REMOVAL).
1. ENGINE MISSES AT HIGH SPEED 1. Spark plugs dirty or incorrectly
gapped.
CLEANING).
- REMOVAL).
filter.
9 - 184 ENGINE - 5. 7L DR
crankcase.
MAINTENANCE -
SPECIFICATIONS)
wear.
& SEATS - STANDARD
PROCEDURE)
on valve faces.
& SEATS - STANDARD
PROCEDURE)
MAINTENANCE -
SPECIFICATIONS)
wear.
out-of-round.
MAINTENANCE -
SPECIFICATIONS)
wear.
converter.
DR ENGINE - 5. 7L 9 - 185
ti ons.
ai r.
RELAY - REMOVAL).
revol uti ons.
(6) Record the compressi on pressure on the 3rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
i ng).
jacket.
l oss.
OFF.
mended.
AIR ESCAPES THROUGH
THROTTLE BODY
seated properly
Inspect valve and valve seat. Reface
or replace, as necessary. Inspect
valve springs. Replace as necessary.
AIR ESCAPES THROUGH TAILPIPE Exhaust valve bent, burnt, or not
seated properly
Inspect valve and valve seat. Reface
or replace, as necessary. Inspect
valve springs. Replace as necessary.
AIR ESCAPES THROUGH
RADIATOR
MORE THAN 50% LEAKAGE FROM
ADJACENT CYLINDERS
adjacent cylinders
necessary
Stuck or broken piston rings; cracked
piston; worn rings and/or cylinder wall
9 - 186 ENGINE - 5. 7L DR
DIAGNOSIS AND TESTING ENGINE DIAGNOSIS - LUBRICATION
OIL LEAKS 1. Gaskets and O-Rings. 1.
(a) Misaligned or damaged. (a) Replace as necessary.
(b) Loose fasteners, broken or
porous metal parts.
(b) Tighten fasteners, Repair or
replace metal parts.
2. Crankshaft rear seal 2. Replace as necessary.
3. Crankshaft seal flange.
Scratched, nicked or grooved.
3. Polish or replace crankshaft.
4. Oil pan flange cracked. 4. Replace oil pan.
5.Front cover seal, damaged or
misaligned.
5. Replace seal.
6. Scratched or damaged vibration
damper hub.
6. Polish or replace damper.
7. Crankshaft Rear Flange
Microporosity
7. Replace Crankshaft
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct oil level.
2. Faulty oil pressure sending unit. 2. Replace sending unit.
3. Low oil pressure. 3. Check pump and bearing
clearance.
4. Clogged oil filter. 4. Replace oil filter.
5. Worn oil pump. 5. Replace as necessary.
8. Oil pump relief valve stuck. 8. Replace oil pump.
9. Oil pickup tube loose or
damaged.
9. Replace as necessary.
OIL PUMPING AT RINGS; SPARK
PLUGS FOULING
1. Worn or damaged rings. 1. Hone cylinder bores and replace
rings.
2. Carbon in oil ring slots. 2. Replace rings.
3. Incorrect ring size installed. 3. Replace rings.
4. Worn valve guides. 4. Ream guides and replace valves.
5. Leaking intake gasket. 5. Replace intake gaskets.
6. Leaking valve guide seals. 6. Replace valve guide seals.
DR ENGINE - 5. 7L 9 - 187
ENGINE MECHANICAL DIAGNOSIS CHART
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil. (Refer to 9 -
ENGINE/LUBRICATION/OIL -
STANDARD PROCEDURE)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. (Refer to
9 - ENGINE/LUBRICATION -
engine oil pressure test/
specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic
tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
or valve faces
9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level.
DIAGNOSIS AND TESTING) engine
oil pressure test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
(Refer to 9 - ENGINE/
LUBRICATION/OIL - STANDARD
PROCEDURE) for correct
procedure/engine oil specifications
4. Excessive connecting rod
bearing clearance
4. Measure bearings for correct
clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of
round
5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
9 - 188 ENGINE - 5. 7L DR
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level.
DIAGNOSIS AND TESTING)
4. Excessive main bearing
clearance
4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of
round or worn
6. Grind journals or replace
crankshaft
converter
7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if
necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace oil pump assembly.
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pickup tube loose, broken,
bent or clogged
8. Inspect oil pickup tube and pump,
and clean or replace if necessary
9. Oil pump cover warped or
cracked
9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated
gaskets
1. Replace gasket
2. Loose fastener, broken or porous
metal part
2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking
3. Replace seal
4. Leaking oil gallery plug or cup
plug
4. Remove and reseal threaded
plug. Replace cup style plug
DR ENGINE - 5. 7L 9 - 189
EXCESSIVE OIL CONSUMPTION OR
SPARK PLUGS OIL FOULED
1. CCV System malfunction 1. (Refer to 25 - EMISSIONS
CONTROL/EVAPORATIVE
EMISSIONS - DESCRIPTION) for
correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves
7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
STANDARD PROCEDURE
OR WORN THREADS
equi val ent.
STANDARD PROCEDURE HYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engi ne i s suspected of hydrostati c l ock
(regardl ess of what caused the probl em), fol l ow the
steps bel ow.
(1) Perform the Fuel Pressure Rel ease Procedure
(2) Di sconnect the negati ve cabl e(s) from the bat-
tery.
(3) I nspect ai r cl eaner, i nducti on system, and
i ntake mani fol d to ensure system i s dry and cl ear of
forei gn materi al .
(4) Pl ace a shop towel around the spark pl ugs to
catch any fl ui d that may possi bl y be under pressure
i n the cyl i nder head. Remove the spark pl ugs.
(5) Wi th al l spark pl ugs removed, rotate the crank-
shaft usi ng a breaker bar and socket.
(6) I denti fy the fl ui d i n the cyl i nders (cool ant, fuel ,
oi l , etc.).
(7) Be sure al l fl ui d has been removed from the
cyl i nders.
(8) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
(9) Squi rt a smal l amount of engi ne oi l i nto the
cyl i nders to l ubri cate the wal l s. Thi s wi l l prevent
damage on restart.
(10) I nstal l new spark pl ugs. Ti ghten the spark
pl ugs to 41 Nm (30 ft. l bs.) torque.
(11) Drai n engi ne oi l . Remove and di scard the oi l
fi l ter.
(12) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
Nm (25 ft. l bs.) torque.
(13) I nstal l a new oi l fi l ter.
(14) Fi l l engi ne crankcase wi th the speci fi ed
amount and grade of oi l . (Refer to LUBRI CATI ON &
MAI NTENANCE - SPECI FI CATI ONS).
(15) Connect the negati ve cabl e(s) to the battery.
(16) Start the engi ne and check for any l eaks.
REMOVAL
(1) Perform the Fuel System Pressure Rel ease pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELI V-
ERY - STANDARD PROCEDURE).
(3) Remove the ai r cl eaner resonator and duct
work as an assembl y.
REMOVAL).
9 - 190 ENGINE - 5. 7L DR
(6) Remove the vi scous fan/dri ve (Refer to 7 -
COOLI NG/ENGI NE/RADI ATOR FAN - REMOVAL).
(7) Remove radi ator (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR - REMOVAL).
(8) Remove the upper crossmember and top core
support.
NOTE: It is not necessary to drain A/C system for
engine removal.
(9) Remove the A/C compressor wi th the l i nes
attached. Secure compressor out of the way.
(10) Remove generator assembl y (Refer to 8 -
ELECTRI CAL/CHARGI NG/GENERATOR -
REMOVAL).
(11) Remove the i ntake mani fol d and I AFM as an
assembl y(Refer to 9 - ENGI NE/MANI FOLDS/I N-
TAKE MANI FOLD - REMOVAL).
(12) Di sconnect the heater hoses.
NOTE: It is not necessary to disconnect P/S hoses
from pump, for P/S pump removal.
asi de.
(14) Di sconnect the fuel suppl y l i ne (Refer to 14 -
FUEL SYSTEM/FUEL DELI VERY/QUI CK CON-
NECT FI TTI NG - STANDARD PROCEDURE).
(15) Rai se and support the vehi cl e on a hoi st and
drai n the engi ne oi l .
(16) Remove engi ne front mount thru-bol t nuts.
(17) Remove ri ght si de axl e retai ni ng bol ts.
(18) Di sconnect the transmi ssi on oi l cool er l i nes
from thei r retai ners at the oi l pan bol ts.
(19) Di sconnect exhaust pi pe at mani fol ds.
(20) Di sconnect the starter wi res. Remove starter
motor (Refer to 8 - ELECTRI CAL/STARTI NG/
STARTER MOTOR - REMOVAL).
(21) Remove the structural dust cover and trans-
mi ssi on i nspecti on cover,(Refer to 9 - ENGI NE/EN-
GI NE BLOCK/STRUCTURAL COVER - REMOVAL).
(22) Remove dri ve pl ate to converter bol ts (Auto-
mati c transmi ssi on equi pped vehi cl es).
(23) Remove transmi ssi on bel l housi ng to engi ne
bl ock bol ts.
(25) I nstal l engi ne l i ft fi xture, speci al tool #8984.
(26) Separate engi ne from transmi ssi on, remove
engi ne from vehi cl e, and i nstal l engi ne assembl y on a
repai r stand.
INSTALLATION
(1) I nstal l engi ne l i ft fi xture Speci al tool #8984.
(2) Posi ti on the engi ne i n the engi ne compartment.
(3) Lower engi ne i nto compartment and al i gn
engi ne wi th transmi ssi on:
Manual Transmi ssi on: Al i gn cl utch di sc assem-
bl y (i f di sturbed). I nstal l transmi ssi on i nput shaft
i nto cl utch di sc whi l e mati ng engi ne and transmi s-
si on surfaces. I nstal l two transmi ssi on to engi ne
bl ock mounti ng bol ts fi nger ti ght.
Automati c Transmi ssi on: Mate engi ne and trans-
mi ssi on and i nstal l two transmi ssi on to engi ne bl ock
mounti ng bol ts fi nger ti ght.
(4) Posi ti on the thru-bol t i nto the support cushi on
brackets.
(5) Lower engi ne assembl y unti l engi ne mount
through bol ts rest i n mount perches.
(6) I nstal l remai ni ng transmi ssi on to engi ne bl ock
mounti ng bol ts and ti ghten.
(7) Ti ghten engi ne mount through bol ts.
(8) I nstal l dri ve pl ate to torque converter bol ts.
(Automati c transmi ssi on model s)
(9) I nstal l the structural dust cover and transmi s-
si on dust cover,(Refer to 9 - ENGI NE/ENGI NE
BLOCK/STRUCTURAL COVER - I NSTALLATI ON).
(10) I nstal l the starter and connect the starter
wi res (Refer to 8 - ELECTRI CAL/STARTI NG/
STARTER MOTOR - I NSTALLATI ON).
(11) I nstal l exhaust pi pe to mani fol d.
(13) Remove engi ne l i ft fi xture, speci al tool #8984.
(14) Connect the fuel suppl y l i ne (Refer to 14 -
FUEL SYSTEM/FUEL DELI VERY/QUI CK CON-
NECT FI TTI NG - STANDARD PROCEDURE).
(15) Rei nstal l the power steeri ng pump.
(16) Connect the heater hoses.
(17) I nstal l the i ntake mani fol d.
(18) Usi ng a new gasket, i nstal l throttl e body
(Refer to 14 - FUEL SYSTEM/FUEL I NJECTI ON/
THROTTLE BODY - I NSTALLATI ON).
(19) I nstal l the generator and wi re connecti ons
(Refer to 8 - ELECTRI CAL/CHARGI NG/GENERA-
TOR - I NSTALLATI ON).
(20) I nstal l a/c compressor and l i nes (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG/PLUMBI NG/A/C
COMPRESSOR - I NSTALLATI ON).
(21) I nstal l the accessory dri ve bel t (Refer to 7 -
I NSTALLATI ON).
(22) I nstal l upper radi ator support crossmember.
(23) I nstal l radi ator (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR - I NSTALLATI ON).
(24) Connect the radi ator l ower hose.
(25) Connect the transmi ssi on oi l cool er l i nes to
the radi ator.
(27) I nstal l the fan (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR FAN - I NSTALLATI ON).
(28) Connect the radi ator upper hose.
(29) I nstal l the washer bottl e.
(30) Connect the transmi ssi on cool er l i nes.
DR ENGINE - 5. 7L 9 - 191
(31) I nstal l the ai r cl eaner resonator and duct work..
(32) Add engi ne oi l to crankcase (Refer to LUBRI -
CATI ON & MAI NTENANCE/FLUI D TYPES - SPEC-
I FI CATI ONS).
(36) Road test vehi cl e.
SPECIFICATIONS
5. 7L ENGINE
GENERAL DESCRIPTION
Engine Type 90V-8 OHV
Displacement 5.7 Liters
345 ( Cubic Inches)
Bore 99.5 mm (3.91 in.)
Stroke 90.9 mm (3.58 in.)
Firing Order 1-8-4-3-6-5-7-2
Lubrication Pressure Feed - Full
Flow
Filtration
Cooling System Liquid Cooled - Forced
Circulation
Cylinder Block Cast Iron
Cylinder Head Aluminum
Crankshaft Nodular Iron
Camshaft Hollow Assembled
Camshaft
Pistons Aluminum Alloy
Connecting Rods Powdered Metal
CYLINDER BLOCK
Metric Standard
Cylinder Bore
Diameter
99.50 mm 3.917 in.
Out of Round
(MAX)
0.0076 mm 0003 in.
Taper (MAX) 0.0127 mm 0.0005 in.
Lifter Bore
Diameter
21.45 - 21.425
mm
0.8444 - 0.8435
in.
PISTONS
Metric Standard
Clearance at
Top of Skirt
0.0215 - 0.0485
mm
0.0008 - 0.0019
in.
Measured at
45.0 mm ( 1.77
in.) Below Deck
Land Clearance
Diameter
Groove #1 0.6715 - 0.7105
mm
0.0264 - 0.0279
in.
Groove #2 0.5455 - 0.6245
mm
0.0214 - 0.0245
in.
Weight 413 grams 14.56 oz
Piston Length 54.70 - 55.30 2.153 - 2.177 in.
Ring Groove
Width
No. 1 1.51 - 1.54 mm 0.0594 - 0.0606
in
No. 2 1.51 - 1.53 mm 0.0594 - 0.0602
in.
No. 3 3.030 - 3.055
mm
0.1192 - 0.1202
in.
PISTON PINS
Metric Standard
Clearance In
Piston
0.009 - 0.018
mm
0.00035 -
0.0007 in.
Diameter 24.0 - 24.003
mm
0.9448 - 0.9449
in.
Length 70.53 - 71.03
mm
2.78 - 2.80 in.
9 - 192 ENGINE - 5. 7L DR
PISTON RINGS
Metric Standard
Ring Gap
Top
Compression
Ring
0.23 - 0.38 mm 0.0090 - 0.0149
in.
Second
Compression
Ring
0.35 - 0.60 mm 0.0137 - 0.0236
in.
Oil Control
(Steel Rails)
0.15 - 0.66 mm 0.0059 - 0.0259
in.
Side Clearance
Top
Compression
Ring
.02 - .068 mm 0.0007 - 0.0026
in.
Second
Compression
Ring
0.02 - 0.058
mm
0.0007 - 0.0022
in.
Oil Ring (Steel
Ring)
.019 - .229 mm .0007 - .0091 in.
Ring Width
Top
Compression
Ring
1.472 - 1.490
mm
0.0579 - 0.0586
in.
Second
Compression
Ring
1.472 - 1.490
mm
0.0579 - 0.0586
in.
Oil Ring (Steel
Rails)
0.447 - 0.473
mm
0.0175 - 0.0186
in.
CONNECTING RODS
Metric Standard
Piston Pin Bore
Diameter
23.955 - 23.975
mm
0.9431 - 0.9438
in.
in.
CRANKSHAFT
Metric Standard
Main Bearing
Journal Diameter
64.988 -
65.012 mm
2.5585 -
2.5595 in.
Bearing Clearance 0.023 - 0.051
mm
0.0009 - 0.002
in.
Out of Round
(MAX)
0.005 mm 0.0002 in.
Taper (MAX) 0.003 mm 0.0001 in.
End Play 0.052 - 0.282
mm
0.002 - 0.011
in.
Connecting Rod
Journal Diameter
53.992 -
54.008 mm
2.125 - 2.126
in.
Bearing Clearance 0.020 - 0.060
mm
0.0007 -
0.0023 in.
Out of Round
(MAX)
0.005 mm 0.0002 in.
Taper (MAX) 0.003 mm 0.0001 in.
CAMSHAFT
Metric Standard
Bearing Journal
Diameter
No. 1 58.2 mm 2.29 in.
No. 2 57.8 mm 2.27 in.
No. 3 57.4 mm 2.26 in.
No. 4 57.0 mm 2.24 in.
No. 5 43.633 mm 1.72 in.
Bearing To Journal
Clearance
Standard
No. 1 0.040 - 0.080
mm
.0015 - .003
in.
No. 2 0.050 -0.090
mm
0.0019 - .0035
in.
No. 3 0.040 - 0.080
mm
.0015 - .003
in.
No. 4 0.050 - 0.090
mm
0.0019 - .0035
in.
No. 5 0.040 - 0.080
mm
.0015 - .003
in.
Camshaft End Play .080 -
0.290mm
0.0031 -
0.0114 in.
DR ENGINE - 5. 7L 9 - 193
VALVE TIMING
Intake
Opens (BTDC) 7.0
Closes (ATDC) 253.0
Exhaust
Opens (BTDC) 233
Closes (ATDC) 27
Duration 253.70
Valve Overlap 34
CYLINDER HEAD
Valve Seat Angle 44.5- 45.0
Valve Seat Runout (MAX) 0.05 mm (0.0019 in.)
Valve Seat Width (Finish)
Intake 1.018 - 1.62 mm
(0.0464 - 0.0637 in.)
Exhaust 1.48 - 1.92 mm
(0.0582 - 0.0755 in.)
Guide Bore Diameter
(Std.)
7.975 - 8.00 mm
(0.313 - 0.314 in.)
HYDRAULIC TAPPETS
Metric Standard
Body Diameter 21.387 - 21.405
mm
0.8420 - 0.8427
in.
Clearance (To
Bore)
0.020 - 0.063
mm
0.0007 - 0.0024
in.
Dry Lash 3.0 mm (at the
valve)
0.1181 in.
VALVES
Face Angle 45.0- 45.5
Head Diameter
Intake 50.67 - 50.93 mm
(1.99 - 2.00 in.)
Exhaust 39.27 - 39.53 mm
(1.54 - 1.55 in.)
Length (Overall)
Intake 123.38 - 123.76 mm
(4.857 - 4.872 in.)
Exhaust 120.475 - 120.855 mm
(4.743 - 4.758 in.)
Stem Diameter
Intake 7.935 - 7.953 mm
(0.312 - 0.313 in.)
Exhaust 7.905 - 7.925 mm
(0.311 - 0.312 in.)
Stem - to - Guide
Clearance
Intake 0.022 - 0.065 mm
(0.0008 - 0.0025 in.)
Exhaust 0.050 - 0.095 mm
(0.0019 - 0.0037 in.)
Valve Lift ( @ Zero Lash)
Intake 12.0 mm (0.472 in.)
Exhaust 11.70 mm (0.460 in.)
9 - 194 ENGINE - 5. 7L DR
VALVE SPRING
Spring Force (Valve
Closed)
Intake and Exhaust 422.0 N @ 46.0 mm
(95lbs. @ 1.81 in.)
Spring Force (Valve
Open)
Intake and Exhaust @ 33.5 mm
Number of Coils
Intake and Exhaust 7.4
Wire Diameter
Intake and Exhaust 5.39 4.52 mm
(0.212 - 0.177 in.)
Installed Height (Spring
Seat to Bottom of
Retainer)
Intake and Exhaust 46.0 mm (1.81 in.)
OIL PUMP
Clearance Over Rotors
(MAX)
0.095 mm (0.0038 in.)
Outer Rotor to Pump
Body Clearance (MAX)
.235 mm (.009 in.)
Tip Clearance Between
Rotors (MAX)
0.150 mm (0.006 in.)
OIL PRESSURE
At Curb Idle Speed
(MIN)*
25 kPa (4 psi)
@ 3000 rpm 170 - 758 kPa (25 - 110
psi)
NOT run engine
TORQUE
TORQUE CHART 5.7L ENGINE
Lbs. Lbs.
Block Pipe Plugs
(1/4 NPT)
20 177
(3/8 NPT) 27 240
Camshaft SprocketBolt 122 90
Camshaft Tensioner
PlateBolts
28 250
Timing Chain Case Cover
Bolts
28 250
Lifting Stud 55 40
Connecting Rod CapBolts 21
plus
90
Turn
15
plus
90
Turn
Main Bearing CapBolts

M-12
27
plus
90
Turn

Crossbolts
M-8
28
Cylinder HeadBolts
M-12 Bolts
Step 1 34 25
Step 2 54 40
Step 3 Turn
90
Turn
90
M-8 Bolts
Step 1 20 15
Step 2 34 25
Cylinder Head CoverBolts 8 70
Exhaust Manifold to Cylinder
Head
25 220
Flexplate to crankshaftBolts 95 70
Flywheel to crankshaftBolts 75 55
Front InsulatorThrough
bolt/nut
95 70
Front Insulator to Support
Bracket
Stud Nut (4WD) 41 30
Through Bolt/Nut (4WD) 102 75
Front Insulator to Block
Bolts (2WD)
95 70
DR ENGINE - 5. 7L 9 - 195
Lbs. Lbs.
GeneratorMounting Bolt 55 40
Intake ManifoldBolts Refer to Procedure
Lifter Guide Holder 12 106
Oil Pan Bolts 12 - 105
Oil Dipstick Tube 12 105
Oil PumpAttaching Bolts 28 250
Oil Pump Pickup Tube Bolt
and Nut
28 250
Rear Seal Retainer Attaching
Bolts
15 132
Rear Insulator to Bracket 68 50
Through-Bolt (2WD)
Rear Insulator to
Crossmember
41 30
Support BracketNut (2WD)
Rear Insulator to
Crossmember
68 50
Nuts (4WD)
Rear Insulator to
Transmission
68 50
Bolts (4WD)
Rear Insulator BracketBolts 68 50
(4WD Automatic)
Rear Support Bracket to 41 30
Crossmember FlangeNuts
Rear Support Plate to
Transfer
41 30
CaseBolts
Rocker ArmBolts 22 195
Spark Plugs
Thermostat HousingBolts 28 250
Throttle BodyBolts 12 105
Transfer Case to Insulator 204 105
Mounting PlateNuts
Transmission Support
Bracket
68 50
Bolts (2WD)
Vibration DamperBolt 176 129
Water Pump to Timing Chain 28 250
Case CoverBolts
SPECIAL TOOLS
5. 7L ENGINE
CRANKSHAFT DAMPER REMOVER INSERT - 8513-A
BlocChekKit C-3685A
Puller 8454
9 - 196 ENGINE - 5. 7L DR
Handle C-4171
DR ENGINE - 5. 7L 9 - 197
Adapter, Valve Spring Compressor Off-vehicle 8464
ENGINE LIFT FIXTURE 8984
REAR CAM PLUG INSTALLER 9048
VALVE SPRING COMPRESSOR - 9065
PUSHROD RETAINING PLATE - 9070
FRONT CRANK SEAL REMOVER - 9071
FRONT CRANK SEAL INSTALLER 9072
9 - 198 ENGINE - 5. 7L DR
AIR INTAKE SYSTEM
REMOVAL
Filter Element Only
ter) repl acement.
i ng.
ment.
Housing Assembly
pi ns (Fi g. 3).
INSTALLATION
tabs (Fi g. 2).
housi ng.
l bs.) torque.
CYLINDER HEAD
OPERATION CYLINDER HEAD
The cyl i nder head cl oses the combusti on chamber
al l owi ng the pi stons to compress the ai r fuel mi xture
to the correct rati o for i gni ti on. The val ves l ocated i n
the cyl i nder head open and cl ose to ei ther al l ow cl ean
ai r i nto the combusti on chamber or to al l ow the
exhaust gases out, dependi ng on the stroke of the
engi ne.
DIAGNOSIS AND TESTING CYLINDER HEAD
GASKET FAILURE
A cyl i nder head gasket l eak can be l ocated between
adjacent cyl i nders or between a cyl i nder and the
adjacent water jacket.
l eaki ng between adjacent cyl i nders are:
1 - CLAMP
2 - AIR DUCT
4 - LOCATING TABS
5 - CLIPS (4)
DR ENGINE - 5. 7L 9 - 199
Loss of engi ne power
Engi ne mi sfi ri ng
Poor fuel economy
l eaki ng between a cyl i nder and an adjacent water
jacket are:
Engi ne overheati ng
Loss of cool ant
Excessi ve steam (whi te smoke) emi tti ng from
exhaust
Cool ant foami ng
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders, fol l ow the proce-
dures i n Cyl i nder Compressi on Pressure Test i n thi s
secti on. An engi ne cyl i nder head gasket l eaki ng
between adjacent cyl i nders wi l l resul t i n approxi -
matel y a 5070% reducti on i n compressi on pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
Wi th the engi ne cool , remove the cool ant pressure
cap. Start the engi ne and al l ow i t to warm up unti l
thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
I nstal l Cool i ng System Tester 7700 or equi val ent to
pressure cap neck. Start the engi ne and observe the
testers pressure gauge. I f gauge pul sates wi th every
power stroke of a cyl i nder a combusti on pressure
l eak i s evi dent.
CHEMICAL TEST METHOD
Combusti on l eaks i nto the cool i ng system can al so
be checked by usi ng Bl oc-Chek Ki t C-3685-A or
equi val ent. Perform test fol l owi ng the procedures
suppl i ed wi th the tool ki t.
REMOVAL
(3) Remove the ai r cl eaner resonator and duct
work.
(4) Remove the generator.
(5) Remove cl osed crankcase venti l ati on system.
(6) Di sconnect the evaporati on control system.
(7) Perform the Fuel System Pressure Rel ease pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELI V-
ERY - STANDARD PROCEDURE). Di sconnect the
fuel suppl y l i ne (Refer to 14 - FUEL SYSTEM/FUEL
DELI VERY/QUI CK CONNECT FI TTI NG - STAN-
DARD PROCEDURE).
(8) Di sconnect heater hoses.
(9) Remove cyl i nder head covers and gaskets.
(10) Remove i ntake mani fol d and throttl e body as
an assembl y.
(11) Remove rocker arm assembl i es and push rods.
I denti fy to ensure i nstal l ati on i n ori gi nal l ocati ons.
(12) Remove the head bol ts from each cyl i nder
head and remove cyl i nder heads. Di scard the cyl i n-
der head gasket.
CLEANING
Cl ean al l surfaces of cyl i nder bl ock and cyl i nder
heads.
Cl ean cyl i nder bl ock front and rear gasket surfaces
usi ng a sui tabl e sol vent.
INSPECTION
(1) I nspect the cyl i nder head for out-of-fl atness,
usi ng a strai ghtedge and a feel er gauge. I f tol erances
exceed 0.0508 mm (0.002 i n.) repl ace the cyl i nder
head.
(2) I nspect the val ve seats for damage. Servi ce the
val ve seats as necessary.
(3) I nspect the val ve gui des for wear, cracks or
l ooseness. I f ei ther condi ti on exi st, repl ace the cyl i n-
der head.
(4) I nspect pushrods. Repl ace worn or bent push-
rods.
INSTALLATION
(1) Cl ean al l surfaces of cyl i nder bl ock and cyl i n-
der heads.
(2) Cl ean cyl i nder bl ock front and rear gasket sur-
faces usi ng a sui tabl e sol vent.
CAUTION: The head gaskets are not interchange-
able between left and right sides. They are marked
L and R to indicate left and right sides.
(3) Posi ti on new cyl i nder head gaskets onto the
cyl i nder bl ock.
9 - 200 ENGINE - 5. 7L DR
CAUTION: The head gaskets are marked TOP to
indicate which side goes up.
(4) Posi ti on cyl i nder heads onto head gaskets and
cyl i nder bl ock.
(5) Ti ghten the cyl i nder head bol ts i n three steps
(Fi g. 4):
Step 1 Snug ti ghten M12 cyl i nder head bol ts,
i n sequence, to 34 Nm (25 ft. l bs.) and M8 bol ts to
Step 2 Ti ghten M12 cyl i nder head bol ts, i n
sequence, to 54 Nm (40 ft. l bs.) and veri fy M8 bol ts
to 20 Nm (15 ft. l bs.) torque..
Step 3 Turn M12 cyl i nder head bol ts, i n
sequence, 90 degrees and ti ghten M8 bol ts to 34 Nm
(25 ft. l bs.) torque.
(6) I nstal l push rods and rocker arm assembl i es i n
thei r ori gi nal posi ti on.
(7) I nstal l the i ntake mani fol d and throttl e body
assembl y.
(8) I f requi red, adjust spark pl ugs to speci fi cati ons.
I nstal l the pl ugs.
(9) Connect the heater hoses.
(10) I nstal l the fuel suppl y l i ne.
(11) I nstal l the generator and dri ve bel t.
(13) Connect the evaporati on control system.
(14) I nstal l the ai r cl eaner.
(15) Fi l l cool i ng system.
(17) Start engi ne check for l eaks.
REMOVAL
(2) Di sconnect coi l on pl ug connectors.
CAUTION: The ground straps must be installed in
the same location as removed. The covers are
machined to accept the ground straps in those
locations only.
(3) Remove cyl i nder head cover retai ni ng bol ts,
and ground straps.
INSTALLATION
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the
engine cylinder head cover. Prolonged contact with
other objects may wear a hole in the cylinder head
cover.
(2) I nstal l cyl i nder head cover and hand start al l fas-
teners. Veri fy that al l doubl e ended studs are i n the cor-
rect l ocati on and i nstal l l eft and ri ght ground straps.
CAUTION: The ground straps must be installed in
the same location as removed. The covers are
machined to accept the ground straps in those
locations only.
NOTE: The right hand ground strap is located on
the front inboard stud. The left hand ground strap
is located on the rear inboard stud.
ended studs to 8 Nm (70 i n. l bs). Begi n torque
sequence i n the mi ddl e of head cover and torque
bol ts movi ng outward i n a cri sscross pattern from top
to bottom.
(4) I nstal l i gni ti on coi l on pl ug, and torque fasten-
ers to 12 Nm (105 i n. l bs)
(5) Connect, i gni ti on coi l el ectri cal connectors.
Fig. 4 CYLINDER HEAD TIGHTENING SEQUENCE
DR ENGINE - 5. 7L 9 - 201
SEATS
DESCRIPTION
DESCRIPTION - VALVE GUIDES
The val ve gui des are made of powered metal and
are pressed i nto the cyl i nder head. The gui des are
not repl aceabl e or servi ceabl e, and val ve gui de ream-
i ng i s not recommended. I f the gui des are worn
beyond acceptabl e l i mi ts, repl ace the cyl i nder heads.
DESCRIPTION
Both the i ntake and exhaust val ves are made of
steel . The i ntake val ve i s 50.93 mm (2.00 i nches) i n
di ameter and the exhaust val ve i s 39.53 mm (1.55
i nches) i n di ameter. Al l val ves use three bead l ock
keepers to retai n the spri ngs and promote val ve rota-
ti on.
STANDARD PROCEDURE - REFACING
NOTE: Valve seats that are worn or burned can be
reworked, provided that correct angle and seat
width are maintained. Otherwise the cylinder head
must be replaced.
NOTE: When refacing valves and valve seats, it is
important that the correct size valve guide pilot be
used for reseating stones. A true and complete sur-
face must be obtained.
(1) Usi ng a sui tabl e di al i ndi cator measure the
center of the val ve seat Total run out must not
exceed 0.051 mm (0.002 i n).
(2) Appl y a smal l amount of Prussi an bl ue to the
val ve seat, i nsert the val ve i nto the cyl i nder head,
whi l e appl yi ng l i ght pressure on the val ve rotate the
val ve. Remove the val ve and exami ne the val ve face.
I f the bl ue i s transferred bel ow the top edge of the
val ve face, l ower the val ve seat usi ng a 15 degree
stone. I f the bl ue i s transferred to the bottom edge of
the val ve face, rai se the val ve seat usi ng a 65 degree
stone.
(3) When the seat i s properl y posi ti oned the wi dth
of the i ntake seat must be 1.018 - 1.62 mm (0.0464 -
0.0637 i n.) and the exhaust seat must be 1.48 - 1.92
mm (0.058 - 0.075 i n.).
(4) Check the val ve spri ng i nstal l ed hei ght after
refaci ng the val ve and seat. The i nstal l ed hei ght for
both i ntake and exhaust val ve spri ngs must not
exceed 46.0 mm (1.81 i n.).
VALVE FACE AND VALVE SEAT ANGLE CHART
SEAT WIDTH
INTAKE 1.018 - 1.62 mm
(0.0464 - 0.0637 in.)
EXHAUST 1.48 - 1.92 mm
(0.058 - 0.075 in.)
FACE ANGLE
(INT. AND EXT.) 45- 45
1
2
SEAT ANGLE
(INT. AND EXT.) 44
1
2- 45
(5) The val ve seat must mai ntai n an angl e of 44.5
45.0 degrees angl e.
(6) The val ve face must mai ntai n a face angl e of
45.0 45.5 degrees angl e (Fi g. 5).
2 - RETAINER
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
9 - 202 ENGINE - 5. 7L DR
REMOVAL
(1) Remove the cyl i nder head (Refer to 9 -
(2) Compress val ve spri ngs usi ng Val ve Spri ng
Compressor Tool speci al tool # C-3422and adapter
8464.
(3) Remove val ve retai ni ng l ocks, val ve spri ng
retai ners, val ve stem seal s and val ve spri ngs.
(4) Before removi ng val ves, remove any burrs from
val ve stem l ock grooves to prevent damage to the
val ve gui des. I denti fy val ves to ensure i nstal l ati on i n
ori gi nal l ocati on.
INSTALLATION
(1) Cl ean val ves thoroughl y. Di scard burned,
warped and cracked val ves.
(2) Remove carbon and varni sh deposi ts from
i nsi de of val ve gui des wi th a rel i abl e gui de cl eaner.
(3) Measure val ve stems for wear. I f wear exceeds
0.051 mm (0.002 i nch), repl ace the val ve.
(4) Coat val ve stems wi th l ubri cati on oi l and i nsert
them i n cyl i nder head.
(5) I f val ves or seats are reground, check val ve
stem hei ght. I f val ve i s too l ong, repl ace cyl i nder
head.
(6) I nstal l new seal s on al l val ve gui des. I nstal l
val ve spri ngs and val ve retai ners.
(7) Compress val ve spri ngs wi th Val ve Spri ng
Compressor Tool speci al tool # C- 3422and adapter
8464, i nstal l l ocks and rel ease tool . I f val ves and/or
seats are ground, measure the i nstal l ed hei ght of
spri ngs. Make sure the measurement i s taken from
bottom of spri ng seat i n cyl i nder head to the bottom
surface of spri ng retai ner.
(8) I nstal l cyl i nder head (Refer to 9 - ENGI NE/
CYLI NDER HEAD - I NSTALLATI ON).
ASSY
REMOVAL
(1) Remove cyl i nder head cover.(Refer to 9 -
COVER(S) - REMOVAL)
(2) Loosen the rocker shafts usi ng the fol l owi ng
sequence: Center, center-left, center-right, left,
right,.
CAUTION: The rocker shaft assemblies are not
interchangeable between intake and exhaust. The
intake rocker arms are marked with an I.
(3) Remove the rocker shafts. Note l ocati on for
reassembl y.
CAUTION: The longer push rods are for the exhaust
side, and the shorter push rods are for intake side.
(4) Remove the pushrods. Note pushrod l ocati on
for reassembl y.
INSTALLATION
CAUTION: The longer push rods are for the exhaust
side, and the shorter push rods are for intake side.
(1) I nstal l the push rods i n the same order as
removed.
CAUTION: Verify that pushrod is installed into
rocker arm and lifter correctly while installing
rocker shaft assembly. Recheck after rocker shaft
has been torqued to specification.
CAUTION: The rocker shaft assemblies are not
interchangeable between intake and exhaust. The
intake rocker arms are marked with the letter I.
(2) I nstal l rocker shaft assembl i es i n the same
order as removed.
CAUTION: Ensure that hold downs and rocker arms
are not overlapped when torquing bolts.
(3) Ti ghten the rocker shaft bol ts to 22 Nm (195
i n. l bs.) torque,usi ng the fol l owi ng sequence: Center,
center-right, center-left, right, left .
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(4) I nstal l cyl i nder head cover (Refer to 9 -
VALVE STEM SEALS
DESCRIPTION
DR ENGINE - 5. 7L 9 - 203
VALVE SPRINGS
REMOVAL
(3) Remove ai r i ntake resonator.
(4) Remove spark pl ug cabl es.
(5) Remove i gni ti on coi l connectors (Fi g. 6).
(6) Remove i gni ti on coi l s.
(7) Remove one spark pl ug.
(8) Remove val ve cover.
CAUTION: The piston must be at TDC, and both
valves closed on the cylinder to be serviced.
NOTE: If removing intake valve spring, install spe-
cial tool# 9070, pushrod retaining plate, to retain
the intake pushrods.
(9) Remove exhaust/i ntake rocker arm shafts.
(10) I nstal l spri ng compressor, speci al tool #9065.
NOTE: All valve springs and seals are removed in
the same manner.
(11) Charge cyl i nder wi th ai r.
NOTE: Tap the top of the valve spring retainer to
loosen the spring retainers locks.
(12) Compress val ve spri ng and remove val ve
retai ner l ocks.
(13) Rel ease spri ng compressor and remove val ve
spri ng.
NOTE: The valve springs are interchangeable
between intake and exhaust.
(14) Remove val ve seal .
INSTALLATION
(1) I nstal l val ve seal .
(2) I nstal l val ve spri ng.
(3) Usi ng speci al tool #9065, compress val ve spri ng
and i nstal l val ve spri ng retai ner and l ocks.
(4) Rel ease ai r charge i n cyl i nder.
(5) Remove spri ng compressor tool #9065.
CAUTION: Verify that the pushrods are fully seated
into lifter and rocker arm. Recheck after rocker arm
shaft has been torqued to specification.
(6) I nstal l rocker arm shaft and pushrods(Refer to
9 - ENGI NE/CYLI NDER HEAD/ROCKER ARM /
ADJUSTER ASSY - I NSTALLATI ON).
(7) Ti ghten the rocker shaft bol ts to 22 Nm (195
i n. l bs.) torque,usi ng the fol l owi ng sequence: Center,
center-right, center-left, right, left .
(8) Remove speci al tool # 9070, pushrod retai ni ng
pl ate, i f used.
(9) I nstal l cyl i nder head cover.
ended studs(Refer to 9 - ENGI NE/CYLI NDER
HEAD/CYLI NDER HEAD COVER(S) - I NSTALLA-
TI ON).
(11) I nstal l spark pl ugs.
(12) I nstal l i gni ti on coi l on pl ug, and torque fas-
teners to 12 Nm (105 i n. l bs)
(13) I nstal l i gni ti on coi l connectors.
(14) I nstal l spark pl ug cabl es.
(15) I nstal l ai r i ntake resonator.
(16) I nstal l ai r cl eaner assembl y.
Fig. 6 IGNITION COIL R/I 5.7L V-8
1 - SLIDE LOCK (SLIDE OUTWARD TO UNLOCK)
SPARK PLUG)
3 - RELEASE LOCK / TAB (PUSH HERE)
4 - ELEC. CONNECTOR
5 - IGNITION COIL
6 - COIL MOUNTING BOLTS (2)
IGNITION COIL)
9 - 204 ENGINE - 5. 7L DR
ENGINE BLOCK
CLEANING
ket surfaces.
INSPECTION
above.
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVAL
REMOVAL - CAMSHAFT CORE HOLE PLUG
CAUTION: Do not damage the rear surface of the
camshaft or the core plug sealing surface, when
removing the core plug.
(1) Remove the rear cam beari ng core pl ug.
REMOVAL - CAMSHAFT
(1) Remove the battery negati ve cabl e.
(2) Remove the ai r cl eaner assembl y.
(3) Drai n cool ant.
(4) Remove the accessory dri ve bel t.
(6) Remove the A/C compressor, and set asi de
(7) Remove the radi ator (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR - REMOVAL).
(8) Remove i ntake mani fol d(Refer to 9 - ENGI NE/
MANI FOLDS/I NTAKE MANI FOLD - REMOVAL).
(9) Remove cyl i nder head covers(Refer to 9 -
(10) Remove both l eft and ri ght cyl i nder heads(Re-
fer to 9 - ENGI NE/CYLI NDER HEAD - REMOVAL) .
(11) Remove the oi l pan(Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - REMOVAL).
(12) Remove ti mi ng case cover(Refer to 9 -
(13) Remove the oi l pi ck up tube.
(14) Remove the oi l pump(Refer to 9 - ENGI NE/
LUBRI CATI ON/OI L PUMP - REMOVAL).
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM (1.5 in)
DR ENGINE - 5. 7L 9 - 205
(15) Remove ti mi ng chai n(Refer to 9 - ENGI NE/
VALVE TI MI NG/TI MI NG BELT/CHAI N AND
SPROCKETS - REMOVAL).
(16) Remove camshaft tensi oner/thrust pl ate
assembl y.
NOTE: Identify tappets to ensure installation in orig-
inal location.
(17) Remove the retai ner assembl y and tappets.
(18) I nstal l a l ong bol t i nto front of camshaft to ai d
i n removal of the camshaft. Remove camshaft, bei ng
careful not to damage cam beari ngs wi th the cam
l obes.
INSPECTION
(1) The cam beari ngs are not servi ceabl e. Do not
attempt to repl ace cam beari ngs for any reason.
INSTALLATION
INSTALLATION - CAMSHAFT CORE HOLE PLUG
CAUTION: The new core hole plug must be installed
to the proper depth or camshaft damage could
develope. The plug must be installed squarely in
the bore.
(1) I nstal l a new core hol e pl ug at the rear of cam-
shaft, usi ng speci al tool #9048. Cl ean pl ug and appl y
mopar l ock and seal adhesi ve to the edge of the
pl ug, before i nstal l i ng. The pl ug must be i nstal l ed to
a depth of + /- 0.25mm from the end of the machi ned
bevel , that i s the end of the bevel that i s cl osest to
the cam beari ng.
INSTALLATION - CAMSHAFT
(1) Lubri cate camshaft l obes and camshaft beari ng
journal s and i nsert the camshaft
(2) I nstal l camshaft Tensi oner pl ate assembl y.
Ti ghten bol ts to 28 Nm (250 i n. l bs.) torque.
(3) I nstal l ti mi ng chai n and sprockets(Refer to 9 -
ENGI NE/VALVE TI MI NG/TI MI NG BELT/CHAI N
AND SPROCKETS - I NSTALLATI ON) .
(4) Measure camshaft end pl ay(Refer to 9 -
ENGI NE - SPECI FI CATI ONS). I f not wi thi n l i mi ts
i nstal l a new thrust pl ate.
(5) I nstal l the oi l pump(Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PUMP - I NSTALLATI ON).
(6) I nstal l the oi l pi ck up tube.
(7) Each tappet reused must be i nstal l ed i n the
same posi ti on from whi ch i t was removed. When
camshaft is replaced, all of the tappets must be
replaced.
(8) I nstal l the tappets and retai ner assembl y(Refer
to 9 - ENGI NE/ENGI NE BLOCK/HYDRAULI C LI FT-
ERS (CAM I N BLOCK) - I NSTALLATI ON).
(9) I nstal l both l eft and ri ght cyl i nder heads(Refer
to 9 - ENGI NE/CYLI NDER HEAD - I NSTALLA-
TI ON) .
(10) I nstal l pushrods
(11) I nstal l rocker arms(Refer to 9 - ENGI NE/CYL-
I NDER HEAD/ROCKER ARM / ADJUSTER ASSY -
I NSTALLATI ON).
(12) I nstal l ti mi ng case cover(Refer to 9 -
(13) I nstal l the oi l pan(Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PAN - I NSTALLATI ON).
(15) I nstal l i ntake mani fol d(Refer to 9 - ENGI NE/
MANI FOLDS/I NTAKE MANI FOLD - I NSTALLA-
TI ON).
(16) I nstal l the A/C compressor, and set asi de
(18) I nstal l the accessory dri ve bel t.
(19) I nstal l the radi ator (Refer to 7 - COOLI NG/
ENGI NE/RADI ATOR - I NSTALLATI ON).
(21) I nstal l the battery negati ve cabl e.
(22) Refi l l cool ant.
(23) Refi l l engi ne oi l .
CRANKSHAFT
REMOVAL
(1) Remove the vi brati on damper (Refer to 9 -
REMOVAL).
(2) Remove the oi l pan(Refer to 9 - ENGI NE/LU-
(3) Remove the oi l pump pi ckup.
(4) Remove the wi ndage tray/oi l pan gasket.
(6) Remove the oi l pump(Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L PUMP - REMOVAL).
(7) Remove the ti mi ng dri ve(Refer to 9 - ENGI NE/
SPROCKETS - REMOVAL).
(8) I denti fy rod beari ng caps before removal .
Remove rod beari ng caps wi th beari ngs.
(9) I denti fy mai n beari ng caps before removal .
Remove mai n beari ng caps and beari ngs one at a
ti me.
9 - 206 ENGINE - 5. 7L DR
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
(10) Remove the thrust washers.
(11) Remove the rear oi l seal retai ner(Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT REAR
OI L SEAL RETAI NE - REMOVAL).
(12) Remove the crankshaft out of the bl ock.
(13) Remove and di scard the crankshaft rear oi l
seal .
(14) Remove and di scard the front crankshaft oi l
seal .
INSTALLATION
(1) Sel ect the proper mai n beari ngs(Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT MAI N
BEARI NGS - STANDARD PROCEDURE) .
(2) I nstal l mai n beari ngs i n bl ock and caps, and
l ubri cate beari ngs.
(3) Posi ti on the crankshaft i nto the cyl i nder bl ock.
(4) I nstal l the thrust washers.
NOTE: The main cap crossbolts are torqued after
final torque of the main cap bolts. Always use a
new washer/seal on crossbolts.
(5) Cl ean and oi l al l cap bol ts. I nstal l al l mai n
beari ng caps. I nstal l al l cap bol ts and al ternatel y
ti ghten i n two steps usi ng the fol l owi ng sequence
(Fi g. 8).
Step 1 27 Nm ( 20ft. l bs.) torque.
Step 2 Turn mai n cap bol ts an addi ti onal 90.
(6) I nstal l the crossbol ts wi th new washer/gasket.
Starti ng wi th crossbol t A (Fi g. 8) torque each cross-
bol t to 28 Nm torque.
(7) Repeat crossbol t torque procedure.
(8) Measure crankshaft end pl ay(Refer to 9 -
ENGI NE/ENGI NE BLOCK/CRANKSHAFT MAI N
BEARI NGS - STANDARD PROCEDURE) .
(9) Posi ti on the connecti ng rods onto the crank-
shaft and i nstal l the rod beari ng caps(Refer to 9 -
I NG ROD - I NSTALLATI ON).
(10) I nstal l ti mi ng dri ve(Refer to 9 - ENGI NE/
SPROCKETS - I NSTALLATI ON) .
(11) I nstal l oi l pump (Refer to 9 - ENGI NE/LU-
(13) I nstal l the rear mai n seal and retai ner(Refer
to 9 - ENGI NE/ENGI NE BLOCK/CRANKSHAFT
REAR OI L SEAL RETAI NE - I NSTALLATI ON).
(14) I nstal l the wi ndage tray/oi l pan gasket.
(15) I nstal l the oi l pi ck up tube.
(16) I nstal l the oi l pan(Refer to 9 - ENGI NE/LU-
(17) I nstal l the vi brati on damper(Refer to 9 -
I NSTALLATI ON).
(18) I nstal l the engi ne(Refer to 9 - ENGI NE -
I NSTALLATI ON).
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - CRANKSHAFT MAIN
BEARING - FITTING
Crankshaft removed from the cyl i nder bl ock.
Fig. 8 MAINCAP TIGHTENING SEQUENCE
1 - Stud Location
DR ENGINE - 5. 7L 9 - 207
shaft counterwei ght has grade i denti fi cati on marks
stamped i nto i t. These marks are read from l eft to
ri ght, correspondi ng wi th journal number 1, 2, 3, 4
and 5.
NOTE: Service main bearings are coded. These
codes identify what size (grade) the bearing is.
MAIN BEARING SELECTION CHART - 5.7L
GRADE SIZE mm
(in.)
FOR USE WITH
MARKING JOURNAL SIZE
A 0.008 mm
U/S
64.98864.995 mm
(0.0004 in.)
U/S
(2.5585 2.5588in.)
B NOMINAL 64.99665.004 mm
(2.55882.5592 in.)
C 0.008 mm
O/S
65.00565.012 mm
(0.0004 in.)
O/S
(2.55922.5595 in.)
INSPECTION
wear patterns are i l l ustrated (Fi g. 9).
NOTE: If any of the crankshaft journals are scored,
the crankshaft must be repaired or replaced.
FRONT
REMOVAL
REMOVAL).
(6) Remove radi ator cool i ng fan and shroud (Refer
REMOVAL).
(8) Remove damper usi ng Speci al Tool s 8513A
I nsert and 8454 Three Jaw Pul l er.
front seal .
INSTALLATION
CAUTION: The front crankshaft seal must be
installed dry. Do not apply lubricant to sealing lip or
to outer edge.
(1) Usi ng Speci al Tool 8348 and 8512A, i nstal l
crankshaft front seal .
shaft or Damper, thoroughly clean the damper bore
and the crankshaft nose before installing Damper.
LATI ON).
I NSTALLATI ON).
I NSTALLATI ON).
Fig. 9 Main Bearing Wear Patterns
1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
9 - 208 ENGINE - 5. 7L DR
REAR
LEAKS
area:
these i tems.
Leaks i n general )
seal.
REMOVAL
transmi ssi on.
after removal.
(3) Usi ng Speci al Tool 8506, remove the crankshaft
rear oi l seal .
INSTALLATION
CAUTION: The rear seal must be installed dry for
proper operation. Do not lubricate the seal lip or
outer edge.
(1) Posi ti on the pl asti c seal gui de onto the crank-
shaft rear face. Then posi ti on the crankshaft rear oi l
seal onto the gui de.
Seal I nstal l er and C-4171 Dri ver Handl e, wi th a
hammer, tap the seal i nto pl ace. Conti nue to tap on
the dri ver handl e unti l the seal i nstal l er seats
CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(3) Remove the dri ve pl ate / fl ywheel .
(4) Remove the oi l pan (Refer to 9 - ENGI NE/LU-
(5) Remove the rear oi l seal retai ner mounti ng
bol ts.
(6) Careful l y remove the retai ner from the engi ne
bl ock.
DR ENGINE - 5. 7L 9 - 209
INSTALLATION
(1) Throughl y cl ean al l gasket resdue from the
engi ne bl ock.
(2) Use extream care and cl ean al l gasket resdue
from the retai ner.
(3) Posi ti on the gasket onto the retai ner.
(4) Posi ti on the retai ner onto the engi ne bl ock.
(5) I nstal l the retai ner mounti ng bol ts. Ti ghten the
bol ts to 15 Nm (132 i n. l bs.) usi ng a cri sscross pat-
tern, starti ng wi th the bol t on the l ower ri ght.
(6) I nstal l a new rear seal (Refer to 9 - ENGI NE/
ENGI NE BLOCK/CRANKSHAFT OI L SEAL - REAR
- I NSTALLATI ON).
(7) I nstal l the oi l pan (Refer to 9 - ENGI NE/LU-
(8) I nstal l the dri ve pl ate / fl ywheel .
(10) Check and veri fy engi ne oi l l evel .
FLEX PLATE
REMOVAL
INSTALLATION
(1) Posi ti on the fl expl ate or fl ywheel onto the
crankshaft and i nstal l the bol ts hand ti ght.
(2) For automatic transmissions: Ti ghten the
fl expl ate retai ni ng bol ts to 95 Nm (70 ft. l bs.).
(3) For manual transmissions: Ti ghten the fl y-
wheel retai ni ng bol ts to 75 Nm (55 ft. l bs.).
HYDRAULIC TAPPETS
TAPPETS
Before di sassembl i ng any part of the engi ne to cor-
rect tappet noi se, check the oi l pressure. I f vehi cl e
has no oi l pressure gauge, i nstal l a rel i abl e gauge at
the pressure sendi ng-uni t. The pressure shoul d be
between 207-552 kPa (30-70 psi ) at 3,000 RPM.
Check the oi l l evel after the engi ne reaches normal
operati ng temperature. Al l ow 5 mi nutes to stabi l i ze
oi l l evel , check di psti ck. The oi l l evel i n the pan
shoul d never be above the FULL mark or bel ow the
ADD OI L mark on di psti ck. Ei ther of these two con-
di ti ons coul d be responsi bl e for noi sy tappets.
OIL LEVEL
HIGH
I f oi l l evel i s above the FULL mark, i t i s possi bl e
for the connecti ng rods to di p i nto the oi l . Wi th the
engi ne runni ng, thi s condi ti on coul d create foam i n
the oi l pan. Foam i n oi l pan woul d be fed to the
hydraul i c tappets by the oi l pump causi ng them to
l ose l ength and al l ow val ves to seat noi si l y.
LOW
Low oi l l evel may al l ow oi l pump to take i n ai r. When
ai r i s fed to the tappets, they l ose l ength, whi ch al l ows
val ves to seat noi si l y. Any l eaks on i ntake si de of oi l
pump through whi ch ai r can be drawn wi l l create the
same tappet acti on. Check the l ubri cati on system from
the i ntake strai ner to the pump cover, i ncl udi ng the
rel i ef val ve retai ner cap. When tappet noi se i s due to
aerati on, i t may be i ntermi ttent or constant, and usu-
al l y more than one tappet wi l l be noi sy. When oi l l evel
and l eaks have been corrected, operate the engi ne at
fast i dl e. Run engi ne for a suffi ci ent ti me to al l ow al l of
the ai r i nsi de the tappets to be bl ed out.
TAPPET NOISE DIAGNOSIS
(1) To determi ne source of tappet noi se, operate
engi ne at i dl e wi th cyl i nder head covers removed.
(2) Feel each val ve spri ng or rocker arm to detect
noi sy tappet. The noi sy tappet wi l l cause the affected
spri ng and/or rocker arm to vi brate or feel rough i n
operati on.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
(3) Val ve tappet noi se ranges from l i ght noi se to a
heavy cl i ck. A l i ght noi se i s usual l y caused by excessi ve
l eak-down around the uni t pl unger, or by the pl unger
parti al l y sti cki ng i n the tappet body cyl i nder. The tap-
pet shoul d be repl aced. A heavy cl i ck i s caused by a tap-
pet check val ve not seati ng, or by forei gn parti cl es
wedged between the pl unger and the tappet body. Thi s
wi l l cause the pl unger to sti ck i n the down posi ti on.
Thi s heavy cl i ck wi l l be accompani ed by excessi ve cl ear-
ance between the val ve stem and rocker arm as val ve
cl oses. I n ei ther case, tappet assembl y shoul d be
removed for i nspecti on and cl eani ng.
(4) The val ve trai n generates a noi se very much
l i ke a l i ght tappet noi se duri ng normal operati on.
Care must be taken to ensure that tappets are mak-
i ng the noi se. I f more than one tappet seems to be
noi sy, i ts probabl y not the tappets.
9 - 210 ENGINE - 5. 7L DR
CRANKSHAFT REAR OIL SEAL RETAINER (Continued)
REMOVAL
(2) Remove the ai r cl eaner(Refer to 9 - ENGI NE/
AI R I NTAKE SYSTEM - REMOVAL).
(3) Remove i ntake mani fol d(Refer to 9 - ENGI NE/
MANI FOLDS/I NTAKE MANI FOLD - REMOVAL).
(4) Remove cyl i nder head cover(Refer to 9 -
(5) Remove rocker arm assembl y and push rod-
s(Refer to 9 - ENGI NE/CYLI NDER HEAD/ROCKER
ARM / ADJUSTER ASSY - REMOVAL). I denti fy
push rods to ensure i nstal l ati on i n ori gi nal l ocati on.
(6) Remove the cyl i nder head(Refer to 9 -
(7) Remove bol t from tappet gui de hol der.
(8) Remove tappet gui de hol der.
(9) Pul l tappet out of bore wi th a twi sti ng moti on.
I f al l tappets are to be removed and reused, i denti fy
tappets to ensure i nstal l ati on i n ori gi nal l ocati on.
(10) Check camshaft l obes for abnormal wear.
INSTALLATION
(1) Lubri cate tappets.
(2) I nstal l tappets i n thei r ori gi nal posi ti ons.
(3) I nstal l tappet gui de hol der. I nstal l the tappet
gui de hol der bol t and ti ghten to 12 Nm (106 i n. l bs.)
torque.
(4) I nstal l cyl i nder head(Refer to 9 - ENGI NE/
CYLI NDER HEAD - I NSTALLATI ON).
(5) I nstal l pushrods and rocker arm assembl y(Re-
fer to 9 - ENGI NE/CYLI NDER HEAD/ROCKER
ARM /ADJUSTER ASSY - I NSTALLATI ON).
(6) I nstal l cyl i nder head cover(Refer to 9 -
(7) I nstal l i ntake mani fol d(Refer to 9 - ENGI NE/
MANI FOLDS/I NTAKE MANI FOLD - I NSTALLATI ON).
(8) I nstal l the ai r cl eaner(Refer to 9 - ENGI NE/
AI R I NTAKE SYSTEM - I NSTALLATI ON).
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
(10) Road test vehi cl e and check for l eaks.
DESCRIPTION
or a scratch awl.
al l oy. Pi ston ski rts are coated wi th a sol i d l ubri cant
(Mol ykote) to reduce fri cti on and provi de scuff resi s-
tance. The pi ston top ri ng groove and l and i s anod-
i zed. The connecti ng rods are made of forged
powdered metal , wi th a fractured cap desi gn. A
pressed fi t pi ston pi n i s used to attach the pi ston and
connecti ng rod.
STANDARD PROCEDURE PISTON FITTING
B (Fi g. 11).
pi ston pi n and connecti ng rod pre-assembl ed. The
pi ston-rod assembl y i s speci fi c for the l eft cyl i nder
bank ( odd numbered) and the ri ght cyl i nder bank (
even numbered) and must not be i nterchanged.
requi red.
Fig. 10 MOLY COATED PISTON
1 - MOLY COATED
2 - MOLY COATED
DR ENGINE - 5. 7L 9 - 211
HYDRAULIC TAPPETS (Continued)
REMOVAL
- REMOVAL).
usi ng a permanent i nk marker or scri be tool (Fi g. 12).
damage may occur.
rod surfaces.
(7) Careful l y remove pi ston ri ngs from pi ston(s),
starti ng from the top ri ng down.
CLEANING
l and grooves.
1 - FRONT
2 - BORE GAUGE
3 - CYLINDER BORE
4 - 38 MM
(1.5 in)
Fig. 12 IDENTIFY CONN ROD TO CYLINDER
9 - 212 ENGINE - 5. 7L DR
INSPECTION
i ng.
INSTALLATION
assembl i es i nto the bore, i nstal l the pi ston ri ngs(Re-
fer to 9 - ENGI NE/ENGI NE BLOCK/PI STON RI NGS
tion.
(3) Posi ti on beari ng onto connecti ng rod. Lubri cate
beari ng surface wi th cl ean engi ne oi l .
Gui des i nto connecti ng rod bol t threads.
surface wi th an rai sed F or arrow on top of pi ston
i ndi cati ng i nstal l ati on posi ti on. Thi s mark must be
poi nti ng toward the front of engi ne on both cyl i nder
banks.
engi ne oi l .
or removed.
Ti ghten bol ts to 21 Nm (15 ft. l bs.) pl us a 90 turn.
I NSTALLATI ON).
I nstal l the i ntake mani fol d.
TI ON).
rect l evel .
PISTON RINGS
FITTING
Fig. 13 Ring
1 - FEELER GAUGE
DR ENGINE - 5. 7L 9 - 213
14)make sure the feel er gauge fi ts snugl y between
Ring Position Groove Maximum
Clearance Clearance
Upper Ring 0.6715-
.0.7105mm
0.11mm
(0.0264- 0.0279
in.)
(0.004 in.)
Intermediate Ring 0.5455-
0.6245mm
0.10mm
(0.0214-0.0245
in.)
(0.004 in.)
Upper Ring 0.23-0.38mm 0.43mm
(0.0090-0.0149
in.)
(0.017 in.)
Intermediate Ring 0.35-0.60mm 0.74mm
(0.0137-0.0236
in.)
(0.029 in.)
Oil Control Ring 0.015-0.66mm 1.55mm
(Steel Rail) (0.0059- 0.0259
in.)
(0.061 in.)
of the pi ston.
order:
Oil ring expander.
Fig. 15 SIDE RAIL - INSTALLATION
1 - SIDE RAIL END
1 - FEELER GAUGE
9 - 214 ENGINE - 5. 7L DR
VIBRATION DAMPER
REMOVAL
REMOVAL).
water pump.
(9) Remove damper usi ng Speci al Tool s 8513A
I nsert and 8454 Three Jaw Pul l er.
INSTALLATION
(1) Sl i de damper onto crankshaft sl i ghtl y.
ened beari ng surface of the beari ng MUST face the
Sei ze or (Locti te No. 771).
Fig. 16 UPPER AND INTERMEDIATE RINGS
Fig. 17 PISTON RING END GAP POSITION
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
Fig. 18 Proper Assembly Method for Special Tool
8512
1 - BEARING
2 - NUT
3 - THREADED ROD
5 - HARDENED WASHER
DR ENGINE - 5. 7L 9 - 215
crankshaft.
176 Nm (129 ft. l bs.).
I NSTALLATI ON).
LATI ON).
STRUCTURAL COVER
DESCRIPTION
bel l housi ng to the engi ne.
OPERATION
REMOVAL
CAUTION: On manual transmission vehicles, the
7/16 inch engine block to clutch housing bolts must
be loosened before removal of the structural dust
cover. Clutch housing distortion will occur if this
procedure is not followed.
(2) Remove the bol ts retai ni ng structural cover.
(3) Remove the structural cover.
INSTALLATION
AUTOMATIC TRANSMISSION
(4) Torque the (4)structural dust cover bol ts that
go i nto the transmi ssi on to 6-11 Nm (50-100 i n.l bs.).
(5) Torque the (4) structural dust cover bol ts that
go i nto the engi ne bl ock to 6-11 Nm (50-100 i n.l bs.).
mani fol d.
MANUAL TRANSMISSION
CAUTION: The 7/16 inch engine block to clutch
housing bolts must be loosened before removal/in-
stallation of the structural dust cover. Clutch hous-
ing distortion will occur if this procedure is not
followed.
will cause severe damage to the cover, and engine
noise.
(2) I nstal l al l bol ts retai ni ng the cover-to-engi ne.
DO NOT ti ghten the bol ts at thi s ti me (Fi g. 20).
(3) I nstal l the cover-to-transmi ssi on bol ts. Do NOT
ti ghten at thi s ti me.
1 - BOLT
2 - BOLT
3 - BOLT
9 - 216 ENGINE - 5. 7L DR
against the corner formed by the engine and the
transmission clutch housing during tightening
sequence. Failure to do so may cause damage to
the cover and engine noise.
(4) Torque the (2)structural dust cover bol ts that
go i nto the cl utch housi ng to 6-11 Nm (50-100
i n.l bs.).
(5) Torque the (4) structural dust cover bol ts that
go i nto the engi ne bl ock to 6-11 Nm (50-100 i n.l bs.).
(6) Torque the structural cover bol t that i s cl osest
to the rear face of bl ock on the passenger si de of
bl ock to 54 Nm (40 ft. l bs.).
(7) Torque the structural cover bol t that i s cl osest
to the front face of bl ock on the dri vers si de to 54
Nm (40 ft. l bs.).
(8) Torque the remai ni ng (2) structural cover bol ts
that go i nto the block i n an X pattern to 54 Nm
(40 ft. l bs.).
(9) Torque the structural cover bol ts that go i nto
the clutch housing to 54 Nm (40 ft. l bs.).
(10) Torque the 7/16 i nch engi ne bl ock to cl utch
housi ng bol ts to 68 Nm (50 ft. l bs.).
FRONT MOUNT
REMOVAL
2WD
(3) Remove engi ne mount through bol ts.
(4) Rai se engi ne usi ng engi ne support fi xture spe-
ci al tool #8534.
(5) Remove engi ne mount to i nsul ator bol ts (Fi g.
21), (Fi g. 22).
(6) Remove i nsul ator from engi ne.
4WD
MEMBER - REMOVAL).
Fig. 20 Structural Cover - Manual Transmission
1 - STRUCTURAL COVER
2 - BOLT
3 - BOLT
4 - BOLT
5 - BOLT
6 - BOLT
7 - BOLT
Fig. 21 RH INSULATOR
1 - BOLT
2 - INSULATOR
DR ENGINE - 5. 7L 9 - 217
STRUCTURAL COVER (Continued)
(6) Support the engi ne usi ng engi ne support fi x-
ture, speci al tool #8534.
INSTALLATION
2WD
(1) I nstal l i nsul ator on the engi ne (Fi g. 24).
(2) I nstal l upper and l ower mount mounti ng bol ts.
Ti ghten bol ts to 61 Nm (45 ft. l bs.).
(3) Lower the engi ne usi ng engi ne support fi xture
speci al tool #8534.
Fig. 22 LH INSULATOR
1 - BOLT
2 - INSULATOR
2 - NUT
6 - FRONT AXLE
7 - NUT
9 - 218 ENGINE - 5. 7L DR
(4) I nstal l mount through bol ts.
(5) Ti ghten through bol ts on both si des to 61 Nm
(45 ft. l bs.).
4WD
94 Nm (70 ft. l bs.).
(4) Lower the engi ne usi ng engi ne support fi xture
speci al tool # 8534, unti l the l eft and ri ght si de
Nm (75 ft. l bs.).
Fig. 24 RH INSULATOR
1 - BOLT
2 - INSULATOR
2 - NUT
6 - FRONT AXLE
7 - NUT
DR ENGINE - 5. 7L 9 - 219
(9) I nstal l the engi ne oi l fi l ter, i f removed.
REAR MOUNT
REMOVAL
(Fi g. 26).
INSTALLATION
the crossmember.
LUBRICATION
DESCRIPTION
The l ubri cati on system (Fi g. 27) i s a ful l fl ow fi l -
trati on pressure feed type.
ENGINE OIL PRESSURE
(1) Remove oi l pressure sendi ng uni t and i nstal l
gauge assembl y C-3292.
(3) Oi l Pressure:
Curb I dl e25 kPa (4 psi ) mi ni mum
3000 rpm170 - 758 kPa (25 - 110 psi )
repeat i nspecti on. If the oil leak source is not pos-
itively identified at this time, proceed wi th the ai r
1 - MOUNT
2 - CROSSMEMBER
3 - NUT
4 - BOLT
9 - 220 ENGINE - 5. 7L DR
(1) Remove the PCV val ve from the I AFM. Cap or
pl ug the PCV val ve grommet.
procedures.
Leak.
I nstal l the PCV val ve.
Fig. 27 Engine Oil Lubrication System
DR ENGINE - 5. 7L 9 - 221
area:
i n general )
seal.
assembl ed.
OIL
SERVICE
PROPERLY.
SAE VISCOSITY
pl e vi scosi ti es such as 5W-30 i n the 5.7L engi nes.
These are speci fi ed wi th a dual SAE vi scosi ty grade
whi ch i ndi cates the col d-to-hot temperature vi scosi ty
range. Sel ect an engi ne oi l that i s best sui ted to your
parti cul ar temperature range and vari ati on.
tai ner.
cans (Fi g. 28).
The engi ne oi l l evel i ndi cator i s l ocated at the l eft
hand of the engi ne on the 5.7L engi nes.
i ted l oss of oi l pressure, run the engi ne for about ten
Fig. 28 API SYMBOL
9 - 222 ENGINE - 5. 7L DR
(2) Wi th engi ne OFF, al l ow approxi matel y fi ve
mi nutes for oi l to settl e to bottom of crankcase,
remove engi ne oi l di psti ck.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
di psti ck.
ENGINE OIL CHANGE
descri bed i n Mai ntenance Schedul es(Refer to LUBRI -
CATI ON & MAI NTENANCE/MAI NTENANCE
SCHEDULES - DESCRI PTI ON).
perature.
engi ne off.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase. Torque to 34
Nm ( 25 ft. l bs.).
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
secti on.
OIL FILTER
REMOVAL
Al l engi nes are equi pped wi th a hi gh qual i ty ful l -
fl ow, di sposabl e type oi l fi l ter. Dai ml erChrysl er Cor-
porati on recommends a Mopar or equi val ent oi l
fi l ter be used.
(3) Rotate the oi l fi l ter countercl ockwi se to remove
i t from the cyl i nder bl ock oi l fi l ter boss.
ter.
INSTALLATION
oi l .
ti ghten fi l ter one hal f turn, or 180,do not over
ti ghten.
Fig. 29 Oil Filter Sealing Surface - Typical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
DR ENGINE - 5. 7L 9 - 223
OIL (Continued)
OIL PAN
REMOVAL
MEMBER - REMOVAL).
manifold.
(7) Rai se engi ne usi ng speci al tool #8534 to pro-
vi de cl earance to remove oi l pan.
NOTE: The double ended oil pan studs must be
installed in the same location that they were
removed from.
(9) Unbol t oi l pump pi ckup tube and remove tube.
INSTALLATION
bl ock and oi l pan.
(3) Rei nstal l the oi l pump pi ckup tube wi th new
o-ri ng. Ti ghten tube to pump fasteners to 28 Nm
(250 i n. l bs.).
NOTE: The double ended oil pan studs must be
installed in the same location that they were
removed from.
bol ts and studs.. Ti ghten the mounti ng bol ts to 12
Nm (105 i n.l bs.).
tool #8534.
ft. l bs.).
(7) Remove speci al tool #8534.
OIL PUMP
REMOVAL
(1) Remove the oi l pan and pi ck-up tube(Refer to 9
- ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
(3) Remove the four bol ts, and the oi l pump.
CLEANING
(1) Wash al l parts i n a sui tabl e sol vent.
INSPECTION
CAUTION: Oil pump pressure relief valve and
spring should not be removed from the oil pump. If
these components are disassembled and or
removed from the pump the entire oil pump assem-
bly must be replaced.
(1) Remove the pump cover.
repl aced.
(6) Rei nstal l the pump cover. Torque fasteners to
15 Nm (132 i n. l bs.).
9 - 224 ENGINE - 5. 7L DR
INSTALLATION
i nstal l the 4 oi l pump retai ni ng bol ts.
(2) Ti ghten the oi l pump retai ni ng bol ts to 28 Nm
(250 i n. l bs.).
(4) I nstal l the pi ck-up tube and oi l pan(Refer to 9 -
TI ON).
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d i s made of a composi te mate-
ri al and features l ong runners whi ch maxi mi zes l ow
end torque. The i ntake mani fol d uses si ngl e pl ane
seal i ng whi ch consi st of ei ght i ndi vi dual press i n
pl ace port gaskets to prevent l eaks.
MANIFOLD LEAKAGE
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 31 Measuring Clearance Between Rotors -
Typical
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
Fig. 32 Measuring Clearance Over Rotors - Typical
1 - STRAIGHT EDGE
2 - FEELER GAUGE
DR ENGINE - 5. 7L 9 - 225
REMOVAL
i ng components:
(4) Di sconnect brake booster hose and posi ti ve
(5) Remove generator and set asi de.
NOTE: It is not necessary to remove lines or
remove freon from A/C compressor.
(6) Remove ai r condi ti oni ng compressor and set
asi de..
DURE).
a cri sscross pattern starti ng from the outsi de bol ts
and endi ng at the mi ddl e bol ts.
(9) Remove i ntake mani fol d and I AFM as an
assembl y.
CLEANING
NOTE: There is NO approved repair procedure for
the intake manifold. If severe damage is found dur-
ing inspection, the intake manifold must be
replaced.
Before i nstal l i ng the i ntake mani fol d thoroughl y
cl ean the mati ng surfaces. Use a sui tabl e cl eani ng
sol vent, then ai r dry.
INSPECTION
(1) I nspect the i ntake seal i ng surface for cracks,
ni cks and di storti on.
(2) I nspect the i ntake mani fol d vacuum hose fi t-
ti ngs for l ooseness or bl ockage.
(3) I nspect the mani fol d to throttl e body mati ng
surface for cracks, ni cks and di storti on.
INSTALLATION
(1) I nstal l i ntake mani fol d seal s.
(2) Posi ti on i ntake mani fol d and I AFM.
(3) I nstal l i ntake mani fol d retai ni ng bol ts, and
ti ghten i n sequence from the mi ddl e bol ts towards
the outsi de i n a cri sscross pattern. Torque fasteners
to 12 Nm (105 i n. l bs.).
components:
(5) I nstal l generator.
(6) I nstal l A/C compressor.
(7) Connect Brake booster hose and Posi ti ve crank-
case venti l ati on (PCV) hose.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust mani fol ds are l og styl e wi th a pat-
ented fl ow enhanci ng desi gn to maxi mi ze perfor-
mance. The exhaust mani fol ds are made of hi gh
si l i con mol ybdenum cast i ron. A perforated core
graphi te exhaust mani fol d gasket i s used to i mprove
seal i ng to the cyl i nder head. The exhaust mani fol ds
are covered by a three l ayer l ami nated heat shi el d
for thermal protecti on and noi se reducti on. The heat
shi el ds are fastened wi th a torque prevai l i ng nut
OPERATION
The exhaust mani fol ds col l ect the engi ne exhaust
exi ti ng the combusti on chambers, then channel s the
exhaust gases to the exhaust pi pes attached to the
mani fol ds.
REMOVAL
EXHAUST MANIFOLD
(3) Remove exhaust pi pe to mani fol d bol ts.
(5) I nstal l engi ne support fi xture speci al tool
#8534.
(6) Rai se engi ne enough to remove mani fol ds.
CAUTION: Do not damage engine harness while
raising the engine.
(8) Remove mani fol d bol ts.
(9) Remove mani fol d and gasket.
CLEANING
Cl ean mati ng surfaces on cyl i nder head and mani -
fol d. Wash wi th sol vent and bl ow dry wi th com-
pressed ai r.
9 - 226 ENGINE - 5. 7L DR
INSPECTION
I nspect mani fol d for cracks.
I nspect mati ng surfaces of mani fol d for fl atness
wi th a strai ght edge. Gasket surfaces must be fl at
wi thi n 0.2 mm per 300 mm (0.008 i nch per foot).
INSTALLATION
EXHAUST MANIFOLD
(1) I nstal l mani fol d gasket and mani fol d.
(2) I nstal l mani fol d bol ts and ti ghten to 25 Nm
(18 ft. l bs.).
(3) I nstal l heat shi el d and ti ghten nuts to 15 Nm
(11 ft. l bs.).
(4) Lower engi ne.
CAUTION: Do not damage engine harness while
lowering the engine.
(5) Remove engi ne support fi xture from engi ne.
(7) Ti ghten ri ght and l eft si de engi ne mount
through bol ts.
(8) I nstal l exhaust fl ange to pi pe bol ts.
TIMING/CHAIN COVER
REMOVAL
(4) Remove accessory dri ve bel t.
(5) Remove fan and fan dri ve assembl y (Refer to 7
- COOLI NG/ENGI NE/FAN DRI VE VI SCOUS
CLUTCH - REMOVAL).
(6) Remove cool ant bottl e and washer bottl e.
(7) Remove fan shroud.
NOTE: It is not necessary to disconnect A/C lines or
discharge freon.
(8) Remove A/C compressor and set asi de.
(13) Remove accessory dri ve bel t tensi oner and
both i dl er pul l eys.
(14) Remove crankshaft damper(Refer to 9 -
REMOVAL).
NOTE: Do not remove the hoses from the power
steering pump.
(15) Remove power steeri ng pump and set asi de.
(16) Remove the di psti ck support bol t.
(17) Drai n the engi ne oi l .
(18) Remove the oi l pan and pi ck up tube(Refer to
NOTE: It is not necessary to remove water pump for
timing cover removal.
(19) Remove ti mi ng cover bol ts and remove cover.
INSTALLATION
(1) Cl ean ti mi ng chai n cover and bl ock surface.
NOTE: Always install a new gasket on timing cover.
(2) I nstal l cover and new gasket. Ti ghten fasteners
to 28 Nm (250 i n. l bs.).
NOTE: The large lifting stud is torqued to 55 Nm
(40 ft. lbs.).
(3) I nstal l the oi l pan and pi ck up tube(Refer to 9 -
TI ON).
(4) I nstal l the A/C compressor.
(7) I nstal l the di psti ck support bol t.
(8) I nstal l the thermostat housi ng.
(9) I nstal l crankshaft damper(Refer to 9 -
I NSTALLATI ON).
(10) I nstal l accessory dri ve bel t tensi oner assembl y
and both i dl er pul l eys.
(11) I nstal l radi ator l ower hose.
(13) I nstal l radi ator fan shroud.
(14) I nstal l the fan and fan dri ve assembl y
(15) I nstal l the accessory dri ve bel t.
(16) I nstal l the cool ant bottl e and washer bottl e.
(17) I nstal l the upper radi ator hose.
(19) Fi l l cool i ng system.
(20) Refi l l engi ne oi l .
DR ENGINE - 5. 7L 9 - 227
TIMING/CHAIN AND
SPROCKETS
REMOVAL
(3) Remove Ti mi ng Chai n Cover.
CAUTION: The camshaft pin and the slot in the cam
sprocket must be clocked at 12:00. The crankshaft
keyway must be clocked at 2:00. The crankshaft
sprocket must be installed so that the dots and or
paint marking is at 6:00.
(4) Re-i nstal l the vi brati on damper bol t fi nger
ti ght. Usi ng a sui tabl e socket and breaker bar, rotate
the crankshaft to al i gn ti mi ng chai n sprockets and
keyways as shown (Fi g. 33).
(5) Retract tensi oner shoe unti l hol e i n shoe l i nes
up wi th hol e i n bracket. Sl i de a sui tabl e pi n i nto the
hol es.
(6) Remove camshaft sprocket attachi ng bol t and
remove ti mi ng chai n wi th crankshaft and camshaft
sprockets.
(7) I f tensi oner assembl y i s to be repl aced, remove
the tensi oner to bl ock bol ts and remove tensi oner
assembl y.
INSTALLATION
(1) I f tensi oner assembl y i s bei ng repl aced, i nstal l
tensi oner and mounti ng bol ts. Torque bol ts to 28 Nm
(250 i n. l bs.).
(2) Retract tensi oner i f requi red.
CAUTION: The camshaft pin and the slot in the cam
sprocket must be clocked at 12:00. The crankshaft
keyway must be clocked at 2:00. The crankshaft
sprocket must be installed so that the dots and or
paint marking is at 6:00.
(3) Pl ace both camshaft sprocket and crankshaft
sprocket on the bench wi th ti mi ng marks on exact
i magi nary center l i ne through both camshaft and
crankshaft bores (Fi g. 34).
CAUTION: The timing chain must be installed with
the single plated link aligned with the dot and or
paint marking on the camshaft sprocket. The crank-
shaft sprocket is aligned with the dot and or paint
marking on the sprocket between two plated timing
chain links.
(4) Pl ace ti mi ng chai n around both sprockets (Fi g.
34).
(5) Li ft sprockets and chai n (keep sprockets ti ght
agai nst the chai n i n posi ti on as shown).
(6) Sl i de both sprockets evenl y over thei r respec-
ti ve shafts and check al i gnment of ti mi ng marks.
Fig. 33 5.7L TIMING MARK ALIGNMENT
1 - Chain Tensioner
2 - Camshaft Sprocket
3 - Crankshaft Sprocket
Fig. 34 5.7L TIMING MARK ALIGNMENT
1 - Chain Tensioner
2 - Camshaft Sprocket
3 - Crankshaft Sprocket
9 - 228 ENGINE - 5. 7L DR
(7) I nstal l the camshaft bol t. Ti ghten the bol t to
(8) Remove tensioner pin. Agai n, veri fy al i gn-
ment of ti mi ng marks.
(9) I nstal l the oi l pump(Refer to 9 - ENGI NE/LU-
(10) I nstal l the oi l pan and pi ck up(Refer to 9 -
TI ON).
(12) Fi l l cool i ng system(Refer to 7 - COOLI NG -
(14) Start engi ne and check for oi l and cool ant
l eaks.
TIMING CHAIN/TENSIONER
DESCRIPTION
The ti mi ng chai n tensi oner i s a stamped steel con-
stant tensi on mechani cal desi gn. I t i s mounted to the
front of the engi ne, behi nd the ti mi ng chai n dri ve.
OPERATION
The ti mi ng chai n tensi on i s mai ntai ned by routi ng
the ti mi ng chai n through the tensi oner assembl y. A
nyl on covered spri ng steel arm presses on the ti mi ng
chai n mai ntai ni ng the correct chai n tensi on.
DR ENGINE - 5. 7L 9 - 229
TIMING/CHAIN AND SPROCKETS (Continued)
ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page page
ENGINE 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 232
DIAGNOSIS AND TESTINGENGINE
DIAGNOSIS AND TESTINGSMOKE
DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . 236
COMPRESSION/LEAKAGE TESTS . . . . . . . 239
STANDARD PROCEDURE
PLACE GASKETS AND SEALERS . . . . . . . . 239
DAMAGED OR WORN THREADS . . . . . . . . 240
STANDARD PROCEDUREHYDROSTATIC
LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
REMOVAL
REMOVAL - ENGINE . . . . . . . . . . . . . . . . . . 241
REMOVALCRANKCASE BREATHER . . . . 242
INSTALLATION
INSTALLATION - ENGINE . . . . . . . . . . . . . . 242
INSTALLATIONCRANKCASE BREATHER . 243
SPECIFICATIONS
SPECIFICATIONS - 5.9L DIESEL . . . . . . . . . 244
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
SPECIAL TOOLS
5.9L DIESEL ENGINE . . . . . . . . . . . . . . . . . 246
ENGINE DATA PLATE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 248
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 249
CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 249
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
CLEANING
CLEANINGCYLINDER HEAD . . . . . . . . . . 251
CLEANINGCROSSHEADS . . . . . . . . . . . . 251
CLEANINGPUSHRODS . . . . . . . . . . . . . . 252
INSPECTION
INSPECTION - CYLINDER HEAD . . . . . . . . . 252
INSPECTIONCROSSHEADS . . . . . . . . . . 252
INSPECTIONPUSHRODS . . . . . . . . . . . . . 253
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 253
REMOVAL
REMOVALCYLINDER HEAD COVER . . . . 255
REMOVALROCKER HOUSING . . . . . . . . . 255
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 255
INSTALLATION
INSTALLATIONCYLINDER HEAD COVER . 255
INSTALLATION - ROCKER HOUSING . . . . . 255
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 256
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES,
GUIDES AND SPRINGS . . . . . . . . . . . . . . . . 256
STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION . . . . . . . 259
REMOVAL - VALVE SPRINGS AND SEALS . . . 260
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 261
ROCKER ARM / ADJUSTER ASSY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 261
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 262
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 263
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
BLOCK REFACING . . . . . . . . . . . . . . . . . . . 264
STANDARD PROCEDURE - CYLINDER
BORE - DE-GLAZE . . . . . . . . . . . . . . . . . . . 264
STANDARD PROCEDURECYLINDER
BORE REPAIR . . . . . . . . . . . . . . . . . . . . . . . 265
STANDARD PROCEDURECAM BORE
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 267
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALCAMSHAFT BEARINGS . . . . . . 268
REMOVAL - CAMSHAFT . . . . . . . . . . . . . . . 268
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 270
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS . . 271
INSTALLATION - CAMSHAFT . . . . . . . . . . . . 271
STANDARD PROCEDURE - CONNECTING
ROD BEARING AND CRANKSHAFT
JOURNAL CLEARANCE . . . . . . . . . . . . . . . . 272
CRANKSHAFT AND GEAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 273
REMOVAL - GEAR . . . . . . . . . . . . . . . . . . . . . 273
INSTALLATION - GEAR . . . . . . . . . . . . . . . . . . 273
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . 274
9 - 230 ENGINE 5. 9L DIESEL DR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 275
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 276
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 277
SOLID LIFTERS/TAPPETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 279
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 280
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 281
STANDARD PROCEDURE - HEAD GASKET
SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . 281
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
CLEANINGPISTON AND CONNECTING
ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
INSPECTION
INSPECTION - PISTONS . . . . . . . . . . . . . . . 282
INSPECTIONCONNECTING ROD . . . . . . . 283
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 283
PISTON RINGS
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 285
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 286
FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 287
REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 288
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 289
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 289
DIAGNOSIS AND TESTINGENGINE OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 289
OIL
STANDARD PROCEDURE
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION . . . . . . . . . . . 293
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 293
OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 293
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 293
OIL PRESSURE RELIEF VALVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 294
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 294
OIL PRESSURE SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 294
OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 295
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 296
INTAKE MANIFOLD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 297
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 298
EXHAUST MANIFOLD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 298
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 298
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . 299
GEAR HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 300
GEAR HOUSING COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 301
DR ENGINE 5. 9L DIESEL 9 - 231
ENGINE 5.9L DIESEL
DESCRIPTION
The cyl i nder bl ock i s constructed of cast i ron. The
casti ng i s a ski rted desi gn whi ch i ncorporates l ongi -
tudal ri bs for superi or strength and noi se reducti on.
The bl ock i ncorporates metri c strai ght thread o-ri ng
fi tti ngs at l ubri cati on oi l access poi nts. The engi ne
(Fi g. 1) i s manufactured wi th the cyl i nders bei ng a
non-sl eeved type cyl i nder. However, one approved
servi ce method i s to bore out the cyl i nders and add
cyl i nder sl eeves to the cyl i nder bl ock.
The cyl i nders are numbered front to rear (Fi g. 2); 1
to 6. The fi ri ng order i s 153624.
Fig. 1 Cummins 24-Valve Turbo-Diesel Engine
Fig. 2 Cylinder Numbering
DIAGNOSIS AND TESTING ENGINE DIAGNOSIS - MECHANICAL
LUBRICATING OIL
PRESSURE LOW
1. Low oil level. 1. (a) Check and fill with clean engine oil.
(b) Check for a severe external oil leak that
could reduce the pressure.
2. Oil viscosity thin, diluted or wrong
specification.
2. (a) Verify the correct engine oil is being
used. (Refer to LUBRICATION &
DESCRIPTION).
2. (b) Look for reduced viscosity from fuel
dilution.
3. Improperly operating pressure
switch/gauge.
3. Verify the pressure switch is functioning
correctly. If not, replace switch/gauge.
4. Relief valve stuck open. 4. Check/replace valve.
6. If cooler was replaced, shipping
plugs may have been left in cooler
6. Check/remove shipping plugs.
7. Worn oil pump. 7. Check and replace oil pump.
8. Suction tube loose or seal leaking. 8. Check and replace seal.
9. Loose main bearing cap. 9. Check and install new bearing. Tighten
cap to proper torque.
10. Worn bearings or wrong bearings
installed.
10. Inspect and replace connecting rod or
main bearings. Check and replace directed
piston cooling nozzles.
11. Directed piston cooling nozzles
under piston, bad fit into main
carrier.
11. Check directed piston cooling nozzles
position.
12. Loose oil rifle plug with saddle-jet
style nozzles
12.Tighten oil rifle plug.
13. Loose directed piston cooling
nozzle.
13. Tighten directed piston cooling nozzle.
14. Both J-jet and saddle jet style
cooling nozzle installed.
14. Install correct style jet.
LUBRICATING OIL
PRESSURE TOO HIGH
1. Pressure switch/gauge not
operating properly.
1. Verify pressure switch is functioning
correctly. If not, replace switch/gauge.
ENGINE 5.9L DIESEL (Continued)
2. Engine running too cold. 2. Refer to Coolant Temperature Below
Normal (Refer to 7 - COOLING -
3. Oil viscosity too thick. 3. Make sure the correct oil is being used.
(Refer to LUBRICATION &
DESCRIPTION).
4. Oil pressure relief valve stuck
closed or binding
4. Check and replace valve.
LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as
required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is being
used.
3. Incorrect oil specification or
viscosity.
3. (a) Make sure the correct oil is being
used (Refer to LUBRICATION &
DESCRIPTION).
(b) Look for reduced viscosity from dilution
with fuel.
(c) Review/reduce oil change intervals.
4. Oil cooler leak 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the
breather.
5. Check the breather tube area for signs of
oil loss. Perform the required repairs.
6. Turbocharger leaking oil to the air
intake.
6. Inspect the air ducts for evidence of oil
transfer. Repair as required.
COMPRESSION KNOCKS 1. Air in the fuel system. 1. Identify location of air leak and repair. Do
not bleed high pressure fuel system.
2. Poor quality fuel or water/gasoline
contaminated fuel.
2. Verify by operating from a temporary
tank with good fuel. Clean and flush the
fuel tank. Replace fuel/water separator filter.
3. Engine overloaded. 3. Verify the engine load rating is not being
exceeded.
4. Improperly operating injectors. 5. Check and replace misfiring/inoperative
injectors.
EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts.
2. Damaged fan or improperly
operating accessories.
2. Check and replace the vibrating
components.
3. Improperly operating vibration
damper
3. Inspect/replace vibration damper.
4. Improperly operating electronically
controlled viscous fan drive.
4. Inspect/replace fan drive.
5. Worn or damaged generator
bearing.
5. Check/replace generator.
6. Flywheel housing misaligned. 6. Check/correct flywheel alignment.
7. Loose or broken power
component.
7. Inspect the crankshaft and rods for
damage that causes an unbalance
condition. Repair/replace as required.
8. Worn or unbalanced driveline
components.
8. Check/repair driveline components.
EXCESSIVE ENGINE
NOISES
1. Drive belt squeal, insufficient
tension or abnormally high loading.
1. Check the automatic tensioner and
inspect the drive belt. Make sure water
pump, tensioner pulley, fan hub, generator
and power steering pump turn freely.
2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust Smoke
(Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
3. Excessive valve lash. 3. Adjust valves. Make sure the push rods
are not bent and rocker arms, adjusting
screws, crossheads, are not severely worn.
Replace bent or severely worn components.
4. Turbocharger noise. 4. Check turbocharger impeller and turbine
wheel for housing contact. Repair/replace
as required.
5. Gear train noise. 5. Visually inspect and measure gear
backlash. Replace gears as required.
6. Power function knock. 6. Check/replace rod and main bearings.
DIAGNOSIS AND TESTING SMOKE DIAGNOSIS CHARTS
The fol l owi ng charts i ncl ude possi bl e causes and cor-
recti ons for excess or abnormal exhaust smoke. Smal l
amounts of exhaust smoke (at certai n ti mes) are to be
consi dered normal for a di esel powered engi ne.
EXCESSIVE BLACK SMOKE
POSSIBLE CAUSE CORRECTION
Air filter dirty or plugged. Check Filter Minder at air filter (Refer to 9 - ENGINE/
AIR INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
Air intake system restricted. Check entire air intake system including all hoses and
tubes for restrictions, collapsed parts or damage.
Repair/replace as necessary.
Air Leak in Intake System. Check entire air intake system including all hoses and
tubes for cracks, loose clamps and/or holes in rubber
ducts. Also check intake manifold for loose mounting
hardware.
Diagnostic Trouble Codes (DTCs) active or multiple,
intermittent DTCs.
Refer to Powertrain Diagnostic Procedures Information.
Engine Control Module (ECM) not calibrated or ECM
has incorrect calibration.
Exhaust system restriction is above specifications. Check exhaust pipes for damage/restrictions. Repair as
necessary.
Fuel grade is not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary.
Fuel injection pump malfunctioning. A DTC may have been set. If so, refer to Powertrain
Diagnostic Procedures Information.
Fuel injector malfunctioning. A DTC may have been set. Perform Cylinder Cutout
Test using DRB scan tool to isolate individual
cylinders. Also refer to Powertrain Diagnostic
Procedures Information and, to (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
Fuel return system restricted. Check fuel return lines for restriction (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Intake manifold restricted. Remove restriction.
Manifold Air Pressure (Boost) Sensor or sensor circuit
malfunctioning.
A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Raw fuel in intake manifold. Fuel injectors leaking on engine shutdown. Do Fuel
Injector Test (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - DIAGNOSIS AND
TESTING).
Turbocharger air intake restriction. Remove restriction.
Turbocharger damaged. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
Turbocharger has excess build up on compressor
wheel and/or diffuser vanes.
(Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - CLEANING).
Turbocharger wheel clearance out of specification. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
EXCESSIVE WHITE SMOKE
Air in fuel supply: Possible leak in fuel supply side (between
transfer pump and fuel tank module).
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL
TRANSFER PUMP - DIAGNOSIS AND TESTING).
Coolant leaking into combustion chamber. Do pressure test of cooling system (Refer to 7 - COOLING -
Diagnostic Trouble Codes (DTCs) active or multiple,
intermittent DTCs.
In very cold ambient temperatures, engine block heater is
malfunctioning (if equipped).
(Refer to 7 - COOLING/ENGINE/ENGINE BLOCK HEATER -
REMOVAL).
Engine coolant temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain Diagnostic
Procedures Information. Also check thermostat operation
(Refer to 7 - COOLING/ENGINE/ENGINE COOLANT
THERMOSTAT - DIAGNOSIS AND TESTING).
Engine Control Module (ECM) not calibrated or has incorrect
calibration.
A DTC should have been set. Refer to Powertrain Diagnostic
Procedures Information.
Fuel filter plugged. Refer to Powertrain Diagnostic Manual for fuel system testing.
Fuel grade not correct or fuel quality is poor. Temporarily change fuel brands and note condition. Change
brand if necessary.
Fuel heater element or fuel heater temperature sensor
malfunctioning. This will cause wax type build-up in fuel filter.
Refer to Fuel Heater Testing (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL HEATER - DIAGNOSIS AND
TESTING).
Fuel injector malfunctioning. A DTC should have been set. Perform Cylinder cutout Test
using DRB scan tool to isolate individual cylinders. Also refer
to Powertrain Diagnostic Procedures Information and, (Refer
to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR -
Fuel injector hold-downs loose. Torque to specifications.
Fuel injector protrusion not correct. Check washer (shim) at bottom of fuel injector for correct
thickness. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - INSTALLATION)
Fuel injection pump malfunctioning. A DTC should have been set. Refer to Powertrain Diagnostic
Fuel supply side restriction to transfer pump. Refer to Powertrain Diagnostic Manual for fuel system testing.
Fuel transfer (lift) pump malfunctioning. A DTC may have been set. Refer to Powertrain Diagnostic
Intake/Exhaust valve adjustments not correct (too tight). (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
Intake manifold air temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain Diagnostic
Intake manifold heater circuit not functioning correctly in cold
weather.
A DTC should have been set. Refer to Powertrain Diagnostic
Procedures Information. Also check heater elements for
correct operation.
Intake manifold heater elements not functioning correctly in
cold weather.
A DTC should have been set if heater elements are
malfunctioning. Refer to Powertrain Diagnostic Procedures
Information.
Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of
probable damage.
Restriction in fuel supply side of fuel system. Refer to Powertrain Diagnostic Manual for fuel system testing.
EXCESSIVE BLUE SMOKE
Dirty air cleaner or restricted turbocharger intake duct. Check Filter Minder at air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ELEMENT - REMOVAL).
Air leak in boost system between turbocharger
compressor outlet and intake manifold.
Service air charge system..
Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - REMOVAL).
Restricted turbocharger drain tube. Remove turbocharger drain tube and remove
obstruction.
Crankcase ventilation system plugged. Inspect crankcase ventilation system for function
Valve seals are worn, brittle, or improperly installed. Replace valve stem oil seals (Refer to 9 - ENGINE/
CYLINDER HEAD/INTAKE/EXHAUST VALVES &
SEATS - REMOVAL).
Valve stems and/or guides are worn. Remove valves and inspect valves and guides. (Refer
to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
Broken or Improperly installed piston rings. Tear down engine and inspect piston rings.
Excessive piston ring end gap. Remove pistons and measure piston ring end gap
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS
Excessive cylinder bore wear and taper. Remove pistons and measure cylinder bore wear and
taper (Refer to 9 - ENGINE/ENGINE BLOCK -
Cylinder damage. Remove pistons and inspect cylinder bore for cracks or
porosity. Repair with cylinder liner if necessary. (Refer
to 9 - ENGINE/ENGINE BLOCK - STANDARD
PROCEDURE).
Piston damage. Remove pistons and inspect for cracks, holes. Measure
piston for out-of-round and taper (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECTING
ROD - INSPECTION).
Turbocharger failure. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
COMPRESSION/LEAKAGE TESTS
CYLINDER COMPRESSION PRESSURE
ti ons.
Ensure batteri es are compl etel y charged and the
Otherwi se, the i ndi cated compressi on pressures may
not be val i d for di agnosti c purposes.
(1) Di sconnect the fuel i nl et l i ne to the fuel trans-
fer pump. Pl ug the fuel l i ne from the fuel tank.
(2) Start the engi ne and i dl e unti l the engi ne stal l s
(runs out of fuel ).
(3) Di sconnect al l three i njector wi re harness con-
nectors at the rocker housi ng.
(4) Remove the breather cover and cyl i nder head
cover.
(5) Remove the hi gh pressure fuel l i ne between the
cyl i nder head and fuel rai l for the cyl i nder to be
tested. Use tool #9011 to cap thi s fuel rai l on the cyl -
i nder bei ng tested.
(6) Remove the exhaust rocker l ever.
(7) Use Tool 9010 to remove the i njector and cop-
per seal i ng washer.
(8) I nstal l the exhaust rocker l ever and torque to
36 Nm (27 ft. l bs.).
(9) Cover the remai ni ng rocker l evers wi th cl ean
shop towel s to prevent any oi l spl atter under the
hood.
(10) Pl ace a rag over the compressi on test tool fi t-
ti ng. Crank the engi ne for 23 seconds to purge any
fuel that may have drai ned i nto the cyl i nder when
the i njector was removed.
(11) Connect the compressi on test gauge.
(12) Crank the engi ne for 5 seconds and record the
pressure readi ng. Repeat thi s step three ti mes and
cal cul ate the average of the three readi ngs.
NOTE: The minimum cylinder pressure is 350 psi.
Cylinder pressure should be within 20% from cylin-
der to cylinder.
(13) Combusti on pressure l eakage can be checked
i f cyl i nder pressure i s bel ow the speci fi cati on. Per-
form the l eakage test procedure on each cyl i nder
accordi ng to the tester manufacturer i nstructi ons.
(14) Upon compl eti on of the test check an erase
any engi ne rel ated faul t codes.
CYLINDER COMBUSTION PRESSURE LEAKAGE
i ng).
jacket.
l oss
normal operati ng temperature.
(2) Remove the breather cover and cyl i nder head
cover.
(3) Di sconnect al l three i njector wi re harness con-
nectors at the rocker housi ng.
(4) Bri ng the cyl i nder to be tested to TDC.
(5) Remove the hi gh pressure fuel l i ne between the
cyl i nder head and the fuel rai l for the cyl i nder to be
tested.
(6) I nstal l cappi ng Tool 9011 onto the rai l .
(7) Remove the hi gh pressure connector nut and
hi gh pressure connector wi th Tool 9015.
(8) Remove the exhaust and i ntake rocker l ever.
(9) Use Tool 9010 to remove the i njector and cop-
per seal i ng washer.
(10) I nstal l compressi on test Tool 9007 i nto the
i njector bore.
(11) Connect the l eakage tester and perform the
l eakage test procedure on each cyl i nder accordi ng to
the tester manufacturers i nstructi ons.
(12) Upon compl eti on of the test check and erase
any engi ne rel ated faul t codes.
STANDARD PROCEDURE
GASKETS AND SEALERS
use.
MOPAR ATF RTV
MOPAR GASKET MAKER
APPLICATION
kets.
OR WORN THREADS
equi val ent.
STANDARD PROCEDURE HYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engi ne i s suspected of hydrostati c l ock
(regardl ess of what caused the probl em), fol l ow the
steps bel ow.
(1) Di sconnect the negati ve cabl e(s) from the bat-
tery.
(2) I nspect ai r cl eaner, i nducti on system, and
i ntake mani fol d to ensure system i s dry and cl ear of
forei gn materi al .
(3) Pl ace a shop towel around the fuel i njectors to
catch any fl ui d that may possi bl y be under pressure
i n the cyl i nder head. Remove the fuel i njectors (Refer
to 14 - FUEL SYSTEM/FUEL I NJECTI ON/FUEL
I NJECTOR - REMOVAL).
(4) Wi th al l i njectors removed, rotate the crank-
shaft usi ng the crankshaft barri ng tool (PN 7471B).
(5) I denti fy the fl ui d i n the cyl i nders (cool ant, fuel ,
oi l , etc.).
(6) Be sure al l fl ui d has been removed from the
cyl i nders.
(7) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
(8) Squi rt a smal l amount of engi ne oi l i nto the
cyl i nders to l ubri cate the wal l s. Thi s wi l l prevent
damage on restart.
(9) I nstal l fuel i njectors (Refer to 14 - FUEL SYS-
TEM/FUEL I NJECTI ON/FUEL I NJECTOR -
I NSTALLATI ON).
(10) Drai n engi ne oi l . Remove and di scard the oi l
fi l ter (Refer to 9 - ENGI NE/LUBRI CATI ON/OI L FI L-
TER - REMOVAL).
(12) I nstal l a new oi l fi l ter (Refer to 9 - ENGI NE/
LUBRI CATI ON/OI L FI LTER - I NSTALLATI ON).
(13) Fi l l engi ne crankcase wi th the speci fi ed
amount and grade of oi l (Refer to LUBRI CATI ON &
MAI NTENANCE/FLUI D TYPES - SPECI FI CA-
TI ONS).
(14) Connect the negati ve cabl e(s) to the battery.
(15) Start the engi ne and check for any l eaks.
REMOVAL
REMOVAL - ENGINE
(2) Di sconnect engi ne gri d heater harness at gri d
heater rel ays.
(3) Di sconnect el ectri cal connecti ons from rear of
al ternator.
(4) Recover A/C refri gerant. (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG - STAN-
DARD PROCEDURE).
(5) Rai se vehi cl e on a hoi st.
(6) Drai n engi ne cool ant (Refer to 7 - COOLI NG -
(7) Remove engi ne oi l drai n pl ug and drai n engi ne
oi l .
(8) Rei nstal l drai n pl ug. Ti ghten to 50Nm (37 ft.
l bs.) torque.
(10) Remove fan/dri ve assembl y. Refer to Secti on 7
Fan/Dri ve Removal
(12) Remove upper fan shroud mounti ng bol ts.
(13) Di sconnect the cool ant recovery bottl e hose
from the radi ator fi l l neck and remove bottl e.
(14) Usi ng a 36mm wrench, remove vi scous fan/
dri ve assembl y. (Refer to 7 - COOLI NG/ENGI NE/RA-
DI ATOR FAN - REMOVAL).
(15) Remove cool i ng fan and shroud together.
(16) Di sconnect heater core suppl y and return
hoses from the cyl i nder head fi tti ng and cool ant pi pe.
(17) Rai se vehi cl e on a hoi st.
(18) Remove transmi ssi on and transfer case (i f
equi pped).
(19) Di sconnect exhaust pi pe from turbocharger
extensi on pi pe.
(20) Di sconnect engi ne harness to vehi cl e harness
connectors.
(21) Remove starter motor (Refer to 8 - ELECTRI -
CAL/STARTI NG/STARTER MOTOR - REMOVAL).
(22) Remove fl ywheel /fl expl ate.
(23) Remove transmi ssi on adapter
(24) Di sconnect A/C sucti on/di scharge hose from
the rear of the A/C compressor.
(26) Di sconnect l ower radi ator hose from radi ator
outl et.
(27) Automati c transmi ssi on model s:
(28) Di sconnect transmi ssi on oi l cool er l i nes from
i n front of radi ator usi ng speci al tool #6931
(29) Remove radi ator. (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR - REMOVAL).
(30) I f A/C equi pped, di sconnect A/C condenser
refri gerant l i nes.
(31) Di sconnect charge ai r cool er pi pi ng.
(32) Remove charge ai r cool er mounti ng bol ts.
(33) Remove charge ai r cool er (and A/C condenser
i f equi pped) from vehi cl e.
(34) Remove damper and speed i ndi cator ri ng from
front of engi ne.
(35) Di sconnect engi ne bl ock heater connector.
(36) Di sconnect A/C compressor and pressure sen-
sor el ectri cal connectors.
(37) Remove the passenger battery ground cabl e
from the engi ne bl ock. Remove the dri ver si de bat-
tery ground cabl e from the engi ne bl ock.
(38) Remove power steeri ng pump from engi ne by
removi ng 3 bol ts.
(39) Remove accel erator l i nkage cover.
(40) Di sconnect cabl es from on-engi ne APPS.
(41) Di sconnect the ECM power connector.
(42) Di sconnect the ECM ground wi re from the
hydroform screw.
(43) Di sconnect the fuel suppl y and return hoses.
(44) Remove the cyl i nder head cover. (Refer to 9 -
(45) Di sconnect the 3 i njector harness connectors
at the rocker housi ng. Di sconnect the wi re harnesses
from the i njectors.
(46) Remove the rear engi ne l i ft bracket.
(47) Remove cyl i nder #4, #5, and #6 i ntake and
exhaust rocker arms, pedestal s, and push tubes. Note
the ori gi nal l ocati on for re-assembl y.
(48) Loosen #6 fuel l i ne shi el d bol ts and rotate
shi el d out of the way.
(49) Remove cyl i nder #5 and #6 hi gh pressure fuel
l i nes. Remove the fuel connector tube nut and fuel
connector tube. Remove cyl i nder #5 and #6 fuel i njec-
tor.
(50) Remove rocker housi ng.
(51) Remove two cyl i nder head bol ts accordi ng to
the di agram bel ow and i nstal l Tool # 9009. Torque
bol ts to 105Nm (77ft. l bs.) (Fi g. 3).
(52) Loosen but do not remove engi ne mount
through bol ts and nuts.
(53) Di sconnect hood support struts and posi ti on
hood out of the way.
(54) Attach a chai n wi th two hooks to the engi ne
l i ft brackets.
(55) Whi l e keepi ng engi ne l evel , l i ft strai ght up
out of the mounts.
(56) Rotate nose of engi ne upward and pul l out of
chassi s.
REMOVAL CRANKCASE BREATHER
(1) Remove the oi l fi l l cap.
(2) Remove the breather cover bol ts (Fi g. 4).
(3) Remove breather cover.
(4) Di sconnect breather tube and l ube oi l drai n
tube from breather.
(5) Remove breather mounti ng bol ts.
(6) Remove breather from cyl i nder head cover.
INSTALLATION
INSTALLATION - ENGINE
(1) Remove cyl i nder head bol ts accordi ng to the
di agram bel ow. I nstal l speci al Tool 9009. Torque bol ts
to 105Nm (77ft. l bs.)
(2) Lower engi ne i nto the engi ne compartment and
i nstal l the engi ne the engi ne mount through bol ts
and nuts.
(3) Ti ghten the mount through bol ts and nuts to
88 N-m (65 ft-l bs) torque.
(4) Remove the engi ne l i fti ng devi ce (Tool 9009).
(5) Check cyl i nder head capscrew l ength and
i nstal l i nto cyl i nder head.
(6) Torque i n 4 steps to:
Step 1Ti ghten to 70 Nm (52 ft. l bs.) torque.
Step 2Back off 360.
Step 4Rotate 90.
(7) I nstal l rocker housi ng. Torque to 24 N-m (18 ft-
l bs). Refer to (Refer to 9 - ENGI NE/CYLI NDER
HEAD/CYLI NDER HEAD COVER(S) - I NSTALLA-
TI ON).
Fig. 3 ENGINE LIFT BRACKET
1 - Head bolt
2 - Engine Lift Bracket
3 - Head Bolt
Fig. 4 Crankcase Breather Vapor Canister
1 - BREATHER COVER BOLT
2 - BREATHER COVER
3 - BREATHER TUBE
4 - ROCKER COVER
5 - BREATHER TUBE MOUNTING BRACKET
6 - LUBE OIL DRAIN TUBE
7 - O-RING
8 - BREATHER
9- BREATHER MOUNTING BOLT
(8) Repl ace i njector o-ri ng and seal i ng washer on
i njectors #5 and #6. I nstal l i njectors and torque usi ng
the fol l owi ng steps:
Step 1I nstal l i njector hol d-down capscrews
and torque to 5 Nm (44 i n. l bs.) torque.
Step 2Loosen i njector hol d-down capscrews.
Step 3I nstal l HPC connector tube and nut.
Torque nut to 15 Nm (11 ft. l bs.) torque.
Step 4Torque i njector hol d-down capscrews to
Step 5Torque HPC connector tube nut to 50
(9) I nstal l #5 and #6 hi gh pressure fuel l i nes. Fol -
l ow correct torque sequence per secti on 14. Torque
fuel l i ne fi tti ngs to 30 N-m (22 ft-l b). Torque brace
capscrew to 24 N-m (18 ft-l b).
(10) I nstal l rear engi ne l i ft bracket. Torque to 77
N-m (57 ft-l b).
(11) I nstal l push tubes, rocker arms, and pedestal s
for cyl i nders #4, #5, and #6. Torque the mounti ng
bol ts to 36 N-m (27 ft-l bs).
(12) Reset val ve l ash on cyl i nders #4, #5, and #6.
Torque adjusti ng nuts to 24 N-m (18 ft-l bs).
(13) I nstal l cyl i nder head cover. Torque to 24 N-m
(18 ft-l bs).(Refer to 9 - ENGI NE/CYLI NDER HEAD -
I NSTALLATI ON).
(14) Connect breather tube and l ube oi l drai n tube
to breather housi ng cover. I nstal l breather housi ng.
Torque capscrews to 24 N-m (18 ft-l bs)
(15) Connect fuel suppl y and return hoses.
(16) Connect ECM ground to hydroform screw.
Connect ECM power connector.
(17) I nstal l the APPS cabl e(s) to the APPS. I nstal l
the throttl e l i nkage cover.
(19) I nstal l the damper and speed i ndi cator ri ng.
Torque to 40 N-m (30 ft-l b) pl us 60 degrees.
(20) Connect the engi ne bl ock heater connecti on.
(21) Connect the A/C compressor and pressure sen-
sor connectors
(22) I nstal l the charge ai r cool er and a/c condenser
(i f equi pped). I nstal l and ti ghten the charge ai r
cool er mounti ng bol ts to 2 N-m (17 i n-l bs).
(23) Connect the charge ai r cool er pi pi ng. Torque
al l cl amps to 8 N-m (72 i n-l bs).
(24) Connect the a/c refri gerant l i nes to the a/c
condenser (i f equi pped).
(25) I nstal l the radi ator upper support panel .
(26) I nstal l radi ator.
(27) Connect the transmi ssi on qui ck-connect oi l
cool er l i nes.
(29) Connect a/c compressor sucti on/di scharge hose
(i f equi pped).
(30) I nstal l the radi ator l ower hose and cl amps.
(31) I nstal l the battery negati ve cabl es to the
engi ne bl ock on the dri ver and passenger si de.
(32) I nstal l the transmi ssi on adapter wi th a new
camshaft rectangul ar ri ng seal . Torque to 77 N-m (57
ft-l b).
(33) I nstal l the fl ywheel /fl expl ate. Torque to 137
N-m (101 ft-l b).
(34) I nstal l the starter motor. Torque to 43 N-m
(32 ft-l b). (Refer to 8 - ELECTRI CAL/STARTI NG/
STARTER MOTOR - I NSTALLATI ON).
(35) Connect engi ne to vehi cl e harness connectors.
(36) I nstal l transmi ssi on and transfer case (i f
equi pped).
(37) Connect the exhaust pi pe to the turbocharger
el bow.
(38) Connect the transmi ssi on auxi l i ary oi l cool er
l i nes (i f equi pped).
(40) Connect the heater core suppl y and return
hoses.
(41) I nstal l the cool i ng fan and upper fan shroud
at the same ti me. (Refer to 7 - COOLI NG/ENGI NE/
RADI ATOR FAN - I NSTALLATI ON).
(42) I nstal l the cool ant recovery bottl e.
(43) I nstal l the wi ndshi el d washer bottl e.
(44) I nstal l the upper radi ator hose and cl amps.
(46) Connect el ectroni cal l y control l ed fan dri ve
wi re harness. I nstal l l ower radi ator fan shroud.
(47) Change oi l fi l ter and i nstal l new engi ne oi l .
(48) Fi l l the cool i ng system wi th cool ant. (Refer to
7 - COOLI NG - STANDARD PROCEDURE).
(49) Connect gri d heater harness at gri d heater
rel ays.
(50) Connect el ectri cal connecti ons to rear of al ter-
nator.
(51) Start the engi ne and i nspect for engi ne oi l ,
cool ant, and fuel l eaks.
INSTALLATION CRANKCASE BREATHER
(1) I nstal l a new o-ri ng onto the breather el ement.
(2) Lubri cate o-ri ng and i nstal l i nto cyl i nder head
cover. Torque capscrews to 10 Nm (89 i n. l bs.).
(3) Connect breather tube and l ube oi l drai n tube.
(4) I nstal l breather cover (Fi g. 4). Torque to 24
Nm (18 ft. l bs.)
SPECIFICATIONS
SPECIFICATIONS - 5. 9L DIESEL
GENERAL DESCRIPTION
Engine Type In-Line 6 Cyl. Turbo
Diesel
Displacement 5.9 Liters
359 ( Cubic Inches)
Bore 102.0 mm (4.02 in.)
Stroke 120.0 mm (4.72 in.)
305/250/235 H.P Version
Cylinder Pressure
(Minimum)
350 psi.
Horsepower High Output
48 RE A/T and NV 5600
M/T
305 HP @ 2900 RPM
Horsepower Standard
Output 48 RE A/T and
NV 4500 M/T
235 HP @ 2700 RPM
(CARB)
250 HP @ 2900 RPM
(49 State)
Torque Rating High
Output ( 48RE A/T and
NV 5600 M/T)
555 LB-FT @ 1400 RPM
Torque Rating Standard
Output ( 48RE A/T and
NV 4500 M/T)
460 LB-FT @ 1400 RPM
Lubrication System Pressure Feed-Full Flow
With Bypass Valve
Firing Order 1-5-3-6-2-4
Cylinder Block Cast Iron
Crankshaft Induction Hardened
Forged Steel
Cylinder Head Cast Iron With Valve Seat
Inserts
Combustion Chambers High Swirl Bowl
Camshaft Chilled Ductile Iron
Pistons Cast Aluminum
Connnecting Rods Cross Rolled Micro Alloy
PISTONS
Metric Standard
Skirt Diameter 101.775 -
101.793 mm
4.007 - 4.008 in.
Ring Groove
Clearance
Intermediate
(Min)
0.045 mm .0018 in
(Max) 0.095 mm 0.0037 in.
Oil Control (Min) 0.040 mm .0016 in.
(Max) 0.085 mm .0033 in.
PISTON PINS
Metric Standard
Pin Diameter
(Min)
39.990 mm 1.5744 in.
(Max) 40.003 mm 1.5749 in.
Bore Diameter
(Min)
40.006 mm 1.5750 in.
(Max) 40.012 1.5753 in.
PISTON RINGS
Metric Standard
Ring Gap
Top Ring 0.26 - 0.36mm 0.010 - 0.014 in.
Intermediate 0.85 - 1.15 mm 0.033 - 0.045in.
Oil Control 0.25 - 0.55 mm 0.010 - 0.21 in.
CONNECTING RODS
Metric Standard
Pin Bore
Diameter (Min.
w/ bushing
installed)
40.019 mm 1.5764 in.
Pin Bore
Diameter (Max.
w/ bushing
installed)
40.042 mm 1.5765 in.
Side Clearance
(Min)
0.100 mm 0.004 in.
Side Clearance
(Max)
0.330 mm 0.013 in.
CYLINDER HEAD
Overall Flatness End To
End (max)
0.305 mm (0.012 in.)
Overall Flatness Side To
Side (Max)
0.076 mm (0.003 in.)
Intake Valve Seat Angle 30
Exhaust Valve Seat Angle 45
Valve Stem Diameter
(Min) 6.96 mm (0.2740 in.)
(Max) 7.01 mm (0.2760 in.)
Valve Rim Thickness
(Min.)
0.79 mm (0.031 in.)
OIL PRESSURE
At Idle 69 kPa (10 psi)
@ 2500 rpm 207 kPa (30 psi)
Regulating Valve
Opening Pressure
517 kPa (75 psi)
Oil Filter Bypass
Pressure Setting
344.75 kPa (50 psi)
TORQUE
TORQUE CHART 5.9L DIESEL ENGINE
DESCRIPTION Nm
In.
Lbs.
Ft.
Lbs.
Connecting RodBolts
Step 1 30 22
Step 2 60 44
Step 3 Rotate 60 degrees
Crankshaft Main CapBolts
Step 1 50 37
Step 2 80 59
Step 3 Rotate 90
Cylinder HeadBolts
Step 1 70 52
Step 2 Back off 360 degrees
Step 3 105 77
Step 4 Verify 105 77
Step 5 Rotate All Bolts 1/4
Turn
Cylinder Head Cover Bolts 24 18
Breather Cover Bolts 24 18
HPC Nut 50 37
Fuel Delivery LinesBanjo 24 18
Fuel Drain LineBanjo 24 18
Fuel linerail to cylinder
head
30 22
Fuel linepump to fuel rail 36 27
Injector fuel line brace 24 18
Fuel rail holddown bolt 24 18
Oil PanBolts 28 21
Oil Pressure RegulatorPlug 80 59
Oil Pressure Switch 18 13
Oil PumpBolts
Step1 8 6
Step2 24 18
Oil Suction Tube (Flange)
Bolts
24 18
Oil Suction Tube (Brace)
Bolt
43 32
Rocker Arm/PedestalBolts 36 27
SPECIAL TOOLS
5. 9L DIESEL ENGINE
Universal Driver Handle - C4171
Crankshaft Barring Tool - 7471 - B
Crankshaft Front Oil Seal Installer - 8281
Valve Spring Compressor - 8319A
Test Plug - 8442
Adapter - 8462
Engine Support Fixture - 8534
TAPPET INSTALLATION TOOL - 8502
STEEL BRACKET - 8534-A
Compression Test Adapter - 9007
Engine Lift Bracket - 9009
Fuel Injector Remover - 9010
FUEL BLOCKOFF PLUG - 9011
FUEL TEST FITTING - 9013
Fuel Injector Tube (Connector) Remover - 9015
TURBO TEST ADAPTER - 9022
ENGINE DATA PLATE
DESCRIPTION
The engi ne data pl ate contai ns speci fi c i nformati on
that i s hel pful to servi ci ng and obtai ni ng parts for
the engi ne. The data pl ate can be found affi xed to the
breather cover on the l eft si de of the engi ne. I nforma-
ti on that can be found on the data pl ate i ncl udes:
Date of Engi ne Manufacture
Engi ne Seri al Number
Control Parts Li st (CPL)
Engi ne Rated Horsepower
Engi ne Fi ri ng Order
Engi ne Di spl acement
Val ve Lash Reset Speci fi cati ons
I f the engi ne data pl ate i s mi ssi ng or not l egi bl e,
the engi ne seri al number i s used for engi ne i denti fi -
cati on. The engi ne seri al number i s stamped on the
ri ght si de of the bl ock, on top of the oi l cool er cavi ty
(Fi g. 5).
AIR CLEANER ELEMENT
REMOVAL
Testing Air Cleaner Element using Filter Minder
Do not attempt to unnecessarily remove top
of air cleaner housing for air cleaner element
inspection on diesel engines.
The ai r cl eaner (fi l ter) housi ng i s equi pped wi th an
ai r Fi l ter Mi nder gauge (Fi g. 6). Thi s ai r fl ow
restri cti on gauge wi l l determi ne when ai r cl eaner el e-
ment i s restri cted and shoul d be repl aced.
The Fi l ter Mi nder consi sts of a di aphragm and
cal i brated spri ng seal ed i nsi de of a pl asti c housi ng
(Fi g. 7). A yel l ow col ored di sc attached to di aphragm
moves al ong a graduated scal e on si de of Fi l ter
Mi nder. After the engi ne has been shut off, a ratch-
eti ng devi ce l ocated wi thi n Fi l ter Mi nder wi l l hol d
yel l ow di sc at hi ghest restri cti on that ai r cl eaner el e-
ment has experi enced. A drop i n ai r pressure due to
an ai r cl eaner el ement restri cti on moves di aphragm
and yel l ow di sc wi l l i ndi cate si ze of ai r drop.
CAUTION: Certain engine degreasers or cleaners
may discolor or damage plastic housing of Filter
Minder. Cover and tape Filter Minder if any engine
degreasers or cleaners are to be used.
To test, turn engi ne off. I f yel l ow di sc (Fi g. 7) has
reached red col ored zone on graduated scal e, ai r
cl eaner el ement shoul d be repl aced. Refer to Removal
/ I nstal l ati on.
Resetting Filter Minder: After ai r cl eaner (fi l ter)
el ement has been repl aced, press rubber button on
top of Fi l ter Mi nder (Fi g. 7). Thi s wi l l al l ow yel l ow
col ored di sc to reset. After button has been pressed,
yel l ow di sc shoul d spri ng back to UP posi ti on.
I f Fi l ter Mi nder gauge has reached red col ored
zone, and after an exami nati on of ai r cl eaner (fi l ter)
el ement, el ement appears to be cl ean, hi gh readi ng
may be due to a temporary condi ti on such as snow
bui l d-up at ai r i ntake. Temporary hi gh restri cti ons
may al so occur i f ai r cl eaner (fi l ter) el ement has got-
ten wet such as duri ng a heavy rai n or snow. I f thi s
occurs, al l ow el ement to dry out duri ng normal
engi ne operati on. Reset rubber button on top of Fi l ter
Mi nder and retest after el ement has dri ed.
Fig. 5 Engine Serial Number Location
Fig. 6 5.9L DIESEL AIR CLEANER - FILTER
MINDER
1 - CLIPS
2 - FILTER COVER
3 - FILTER MINDER
4 - INLET AIR TEMPERATURE/ PRESSURE SENSOR
5 - FILTER HOUSING
Filter Removal
(1) The housi ng cover i s equi pped wi th spri ng cl i ps
(Fi g. 6) and i s hi nged wi th pl asti c tabs. Unl atch cl i ps
from top of ai r cl eaner housi ng and ti l t housi ng cover
up for cover removal .
(2) Remove ai r cl eaner el ement from ai r cl eaner
housi ng.
INSTALLATION
(1) Before i nstal l i ng new ai r cl eaner el ement (fi l -
ter), cl ean i nsi de of ai r cl eaner housi ng.
(2) Posi ti on ai r cl eaner cover to tabs on front of ai r
cl eaner housi ng. Latch spri ng cl i ps to seal cover to
housi ng.
CYLINDER HEAD
DESCRIPTION
The cyl i nder head i s constructed of cast i ron and i s
a one pi ece cross fl ow desi gn wi th four val ves per cyl -
i nder. The arrangement of two i ntake and two
exhaust val ves per cyl i nder al l ows for a central l y
l ocated i njector. The cyl i nder head al so i ncl udes an
i ntegral i ntake mani fol d, an i ntegral thermostat
housi ng, and a l ongi tudal fuel return ri fl e, whi ch
exi ts at the rear of the head. The 24 val ve desi gn
al so i ncl udes i ntegral l y cast val ve gui des and hard-
ened i ntake and exhaust val ve seat i nserts.
REMOVAL
(3) Drai n engi ne cool ant.
(4) Di sconnect exhaust pi pe from turbocharger
el bow.
(5) Di sconnect turbocharger oi l drai n tube at rub-
ber hose connecti on. Cap off open ports to prevent
i ntrusi on of di rt or forei gn materi al .
(7) Di sconnect ai r i nl et temperature/pressure sen-
sor.
(8) Remove ai r cl eaner housi ng and snorkel from
the vehi cl e. Cap off turbocharger ai r i nl et to prevent
(9) Di sconnect cab heater core suppl y and return
hoses from the cyl i nder head and heater pi pe.
(10) Di sconnect turbocharger oi l suppl y l i ne at the
turbocharger end. Cap off open ports to prevent
(11) Remove exhaust mani fol d-to-cyl i nder head
bol ts, spacers, heat shi el d, retenti on straps, and cab
heater pl umbi ng. Remove exhaust mani fol d and tur-
bocharger from the vehi cl e as an assembl y.
(12) Remove cool i ng fan assembl y.
REMOVAL).
(14) Remove cool i ng fan support from cyl i nder
bl ock.
(15) Remove upper generator bol t, l oosen l ower
generator bol t, and rotate generator away from cyl i n-
der head.
(16) Di sconnect radi ator upper hose from the ther-
mostat housi ng.
(17) Di sconnect the I ntake Ai r Temperature/Mani -
fol d Ai r Pressure, and Cool ant Temperature sensor
connectors.
(18) Remove the engi ne harness to cyl i nder head
attachi ng bol ts and P-cl i ps at front of head.
(19) Remove the throttl e l i nkage cover (Fi g. 8).
(20) For automati c equi pped vehi cl es onl y, remove
the si x (6) accel erator pedal posi ti on sensor assem-
bl y-to-cyl i nder head bracket bol ts (Fi g. 9) and secure
the enti re assembl y out of the way. Di sconnect the
APPS connector (Fi g. 10). It is not necessary to
disconnect the cables from the throttle control
assembly.
(21) Remove the i ntake ai r gri d heater wi res from
the gri d heater.
(22) Remove engi ne oi l l evel i ndi cator tube attach-
i ng bol t at fuel fi l ter housi ng bracket and i nl et ai r
connecti on..
(23) Remove the charge ai r cool er-to-ai r i nl et hous-
i ng pi pe.
Fig. 7 FILTER MINDER - 5.9L DIESEL
1 - PRESS BUTTON TO RESET
2 - YELLOW DISC
3 - RED ZONE
4 - TO AIR FILTER HOUSING
5 - FILTER MINDER
AIR CLEANER ELEMENT (Continued)
(24) Remove the engi ne wi re harness attachi ng
bol t and wi re harness push-i n fastener from ai r i nl et
housi ng.
(25) Remove the ai r i nl et housi ng and i ntake gri d
heater from the i ntake mani fol d cover.
(26) Remove the two gri d heater harness-to-cyl i n-
der head attachi ng bol ts at front of cyl i nder head.
(27) Remove the engi ne l i ft bracket from the rear
of the cyl i nder head.
(28) Remove the high pressure pump to fuel
rail fuel line as follows:
(a) Loosen fuel l i ne nuts at fuel pump and at
fuel rai l .
(b) Use a back-up wrench on the fi tti ng at the
fuel pump to keep i t from l ooseni ng.
(29) Remove the fuel rai l to cyl i nder head fuel
l i nes as fol l ows:
(a) Loosen No. 6 hi gh pressure fuel l i ne shi el d
and posi ti on out of way.
(b) Loosen the fuel l i ne nuts at the fuel rai l and
at the cyl i nder head.
(c) Remove the fuel l i ne bracket bol ts at the
i ntake mani fol d cover.
(30) Remove the fuel rai l as fol l ows:
(a) Remove fuel rai l pressure sensor connector.
(b) Remove banjo fi tti ng at pressure l i mi ti ng
val ve.
(c) Remove fuel rai l bol ts and fuel rai l .
(31) Remove the l ow pressure l i nes as fol l ows:
(a) Remove the fuel drai n banjo fi tti ng on the
front si de of fuel fi l ter housi ng.
(b) Remove the fuel drai n banjo fi tti ng on rear
si de of fuel fi l ter housi ng.
(c) Remove the fuel drai n l i ne support bracket
on rear si de of fi l ter housi ng.
(d) Di sconnect fuel drai n hose.
(e) Remove banjo fi tti ng at bottom of fuel fi l ter
housi ng.
(f) Di sconnect fuel suppl y hose at l i ft pump.
Fig. 8 Throttle Linkage Cover Auto Trans Only
1 - CABLE/LEVER/LINKAGE COVER
2 - PUSH UP LOWER TAB
3 - SCREWS/CLIPS (2)
4 - TAB PUSH HERE
Fig. 9 APPS Assembly Auto Trans Only
1 - LEVER
3 - WIRE HARNESS CLIP
4 - CALIBRATION SCREWS (NO ADJUSTMENT)
5 - APPS ASSEMBLY
Fig. 10 APPS Connector Auto Trans Only
1 - APPS
2 - TAB
3 - PUSH FOR REMOVAL
4 - APPS CONNECTOR
(32) Di sconnect fuel heater, water i n fuel sensor,
and fuel l i ft pump connectors.
(33) Remove the fuel fi l ter assembl y-to-cyl i nder
head bol ts and remove fi l ter assembl y from vehi cl e.
(34) Remove wi re harness P-cl i p from cyl i nder
head (l ocated behi nd fi l ter housi ng).
(36) Di sconnect rocker housi ng i njector harness
connectors.
(37) Remove i njector harness nuts from i njectors.
(38) Remove the rocker l evers (Fi g. 11), cross
heads and push rods (Fi g. 12). Mark each component
so they can be i nstal l ed i n thei r ori gi nal posi ti ons.
NOTE: The #5 cylinder exhaust and the #6 cylinder
intake and exhaust push rods are removed by lift-
ing them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
(39) Remove the fuel return l i ne and banjo bol t at
the rear of the cyl i nder head. Be careful not to drop
the two (2) seal i ng washers.
(40) Remove the fuel i njectors (Refer to 14 - FUEL
SYSTEM/FUEL I NJECTI ON/FUEL I NJECTOR -
REMOVAL).
(41) Remove rocker housi ng bol ts and rocker hous-
i ng and gasket.
(42) Rei nstal l the engi ne l i ft bracket at the rear of
cyl i nder head. Torque to 77 Nm (57 ft. l bs.).
(43) Remove twenty si x (26) cyl i nder head-to-bl ock
bol ts.
(44) Attach an engi ne l i ft crane to engi ne l i ft
brackets and l i ft cyl i nder head off engi ne and out of
vehi cl e.
(45) Remove the head gasket and i nspect for fai l -
ure.
CLEANING
CLEANING CYLINDER HEAD
CAUTION: Do not wire brush head surface while
fuel injectors are still installed. Fuel injector dam-
age can result.
Remove fuel i njector before cl eani ng (i f not al ready
removed duri ng cyl i nder head removal ).
Cl ean the carbon from the i njector nozzl e seat wi th
a nyl on or brass brush.
Scrape the gasket resi due from al l gasket surfaces.
Wash the cyl i nder head i n hot soapy water sol uti on
(88C or 140F).
After ri nsi ng, use compressed ai r to dry the cyl i n-
der head.
Pol i sh the gasket surface wi th 400 gri t paper. Use
an orbi tal sander or sandi ng bl ock to mai ntai n a fl at
surface.
CLEANING CROSSHEADS
Cl ean al l crossheads i n a sui tabl e sol vent. I f neces-
sary, use a wi re brush or wheel to remove stubborn
deposi ts. Ri nse i n hot water and bl ow dry wi th com-
pressed ai r.
Fig. 11 Rocker Arm and Pedestal Removal
1 - ROCKER ARM
2 - PEDESTAL
Fig. 12 Push Rod Removal
CLEANING PUSHRODS
Cl ean the pushrods i n a sui tabl e sol vent. Ri nse i n
hot water and bl ow dry wi th compressed ai r. I f nec-
essary, use a wi re brush or wheel to remove stubborn
deposi ts.
INSPECTION
INSPECTION - CYLINDER HEAD
I nspect the cyl i nder head for cracks i n the combus-
ti on surface. Pressure test any cyl i nder head that i s
vi si bl y cracked. A cyl i nder head that i s cracked
between the i njector bore and val ve seat can be pres-
sure tested and reused i f OK; however, i f the crack
extends into the val ve seat i nsert bore, the cyl i nder
head must be repl aced.
Vi sual l y i nspect the cyl i nder bl ock and head com-
busti on surfaces for l ocal i zed di ps or i mperfecti ons.
Check the cyl i nder head and bl ock combusti on sur-
faces for overal l out-of-fl atness. I f ei ther the vi sual or
manual i nspecti on exceeds the l i mi ts, then the head
or bl ock must be surfaced.
Check the top surface for damage caused by the
cyl i nder head gasket l eaki ng between cyl i nders.
I nspect the bl ock and head surface for ni cks, ero-
si on, etc.
Check the head di storti on. Maxi mum overal l vari -
ati on end to end i s 0.305 mm (0.012 i nch) (Fi g. 13),
and maxi mum overal l vari ati on si de to si de 0.076
mm ( .003 i n.).
DO NOT proceed wi th the i n-chassi s overhaul i f
the cyl i nder head or bl ock surface i s damaged or not
fl at (wi thi n speci fi cati ons).
Check bl ock surface for di storti on. Maxi mum vari -
ati on end-to-end i s 0.076 mm ( .003 i n.), si de-to-si de
0.051 mm (.002).
Vi sual l y i nspect the cyl i nder head bol ts for dam-
aged threads, corroded/pi tted surfaces, or a reduced
di ameter due to bol t stretchi ng.
I f the bol ts are not damaged, thei r free l ength
shoul d be measured usi ng the cap screw stretch
gauge provi ded wi th the repl acement head gasket.
Pl ace the head of the bol t agai nst the base of the sl ot
and al i gn the bol t wi th the strai ght edge of gauge
(Fi g. 14). I f the end of the bol t touches the foot of the
gauge, the bol t must be di scarded. The maximum
bolt free length is 132.1 mm (5.200 in.).
INSPECTION CROSSHEADS
I nspect the crossheads for cracks and/or excessi ve
wear on rocker l ever and val ve ti p mati ng surfaces
(Fi g. 15). Repl ace any crossheads that exhi bi t abnor-
mal wear or cracks.
Fig. 13 Cylinder Head Combustion Deck Face
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 14 Head Bolt Stretch Gauge
Fig. 15 Inspecting Crosshead for Cracks
INSPECTION PUSHRODS
I nspect the push rod bal l and socket for si gns of
scori ng. Check for cracks where the bal l and the
socket are pressed i nto the tube (Fi g. 16).
Rol l the push rod on a fl at work surface wi th the
socket end hangi ng off the edge (Fi g. 17). Repl ace
any push rod that appears to be bent.
INSTALLATION
WARNING: THE OUTSIDE EDGE OF THE HEAD
GASKET IS VERY SHARP. WHEN HANDLING THE
NEW HEAD GASKET, USE CARE NOT TO INJURE
YOURSELF.
(1) I nstal l a new gasket wi th the part number si de
up, and l ocate the gasket over the dowel sl eeves.
(2) Usi ng an engi ne l i fti ng crane, l ower the cyl i n-
der head onto the engi ne.
(3) Li ghtl y l ubri cate head bol ts wi th engi ne oi l and
i nstal l . Usi ng the sequence shown i n (Fi g. 18),
ti ghten bol ts i n the fol l owi ng steps:
(a) Torque bol ts to 70 Nm (52 ft. l bs.)
(b) Back off 360 degrees i n sequence
(c) Torque bol ts to 105 Nm (77 ft. l bs.)
(d) Re-check al l bol ts to 105 Nm (77 ft. l bs.)
(e) Ti ghten al l bol ts an addi ti onal
1
4 turn (90)
(4) I nstal l push rods i nto thei r ori gi nal l ocati ons
(Fi g. 19). Verify that they are seated in the tap-
pets.
(5) Lubri cate val ve stem ti ps and i nstal l the cross-
heads i n thei r ori gi nal l ocati ons.
(6) Lubri cate the rocker arms and pedestal s and
i nstal l them i n thei r ori gi nal l ocati ons (Fi g. 20).
I nstal l the bol ts and torque them to 36 Nm (27 ft.
l bs.).
(7) Veri fy that the val ve l ash setti ngs are mai n-
tai ned (Refer to 9 - ENGI NE/CYLI NDER HEAD/I N-
TAKE/EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
(8) I nspect rocker housi ng gasket for cuts and
proper i nstal l ati on i nto groove. Repl ace i f damaged.
Fig. 16 Inspecting Push Rod for Cracks
Fig. 17 Inspecting Push Rod for Flatness
Fig. 18 Cylinder Head Bolt Torque Sequence
Fig. 19 Push Rod Installation
(9) I nstal l rocker housi ng and bol ts. Ti ghten to 24
Nm (18 l b. ft.).
(10) I nstal l fuel i njector(Refer to 14 - FUEL SYS-
TEM/FUEL I NJECTI ON/FUEL I NJECTOR -
I NSTALLATI ON).
(11) I nstal l i njector harness nuts. Ti ghten to 1.25
Nm (11 l b. i n.).
(12) I nstal l cyl i nder head cover (Refer to 9 -
(13) I nstal l wi re harness P-cl i p to cyl i nder head
behi nd fi l ter housi ng 24 Nm (18 ft. l bs.).
(14) Connect the I AT/MAP sensor connector.
(15) I nstal l the fuel fi l ter cani ster assembl y and
torque mounti ng bol ts to 24 Nm (18 ft. l bs.).
(16) Connect fuel l i ft pump, WI F sensor, and fuel
heater.
(17) Remove the engi ne l i ft bracket at rear of cyl -
i nder head.
CAUTION: Failure to follow procedure will result in
fuel leaks and/or fuel system failure.
(18) Install the fuel rail and high pressure
fuel lines as follows:
(a) Hand ti ghten fuel rai l bol ts.
(b) Hand ti ghten fuel drai n l i ne to pressure l i m-
i ti ng val ve. Hand ti ghten banjo bol t at fuel fi l ter
housi ng.
(c) Hand ti ghten fuel rai l -to-cyl i nder head hi gh
pressure fuel l i nes.
(d) I nstal l fuel l i ne brace bol ts-to-i ntake mani -
fol d fi nger ti ght.
(e) Hand ti ghten fuel pump to fuel rai l l i ne.
(f) Torque fuel l i ne nuts at cyl i nder head to 30
Nm ( 22 ft. l bs.).
(g) Torque fuel l i ne nuts at fuel rai l to 30 Nm
(22 ft. l bs.)
(h) Usi ng a back up wrench, torque fuel pump to
fuel rai l l i ne to 37 Nm (27 ft. l bs.). At i njecti on
pump.
(i ) Torque fuel pump to fuel rai l l i ne to 37 Nm
(27 ft. l bs.) at fuel rai l .
(j) Torque fuel drai n banjo bol t at pressure l i m-
i ti ng val ve and front of fuel fi l ter housi ng to 24 Nm
(18 ft. l bs.).
(k) Torque fuel l i ne brace bol ts to 24 Nm (18 ft.
l bs.).
(l ) Torque rai l bol ts to 24 Nm (18 ft. l bs.).
(m) Connect fuel pressure sensor.
(19) I nstal l the engi ne l i ft bracket at the rear of
cyl i nder head. Torque to 77 Nm (57 ft. l bs.).
(20) Reposi ti on number 6 fuel l i ne shi el d and
torque to 43 Nm (32 ft. l bs.).
(21) I nstal l the fuel fi l ter to i njecti on pump l ow
pressure l i ne. I nspect and repl ace seal i ng washers i f
necessary. Torque banjo bol ts to 24 Nm (18 ft. l bs.).
(22) Connect fuel return l i ne at back of cyl i nder
head hand ti ght.
(23) Connect fuel return l i ne at fi l ter housi ng hand
ti ght.
(24) Torque banjo connecti ons at cyl i nder head and
fuel fi l ter housi ng to 24 Nm (18 ft. l bs.)
(25) I nstal l bracket to rear of fi l ter housi ng.
Torque to 24 Nm (18 ft. l bs.).
(26) Usi ng new gaskets, i nstal l the i ntake gri d
heater and ai r i nl et housi ng. Torque bol ts to 24 Nm
(18 ft. l bs.).
(27) I nstal l wi re harness P-cl i p and push on cl i p to
ai r i nl et housi ng.
(28) Connect engi ne oi l l evel i ndi cator tube at fuel
fi l ter housi ng and at ai r i nl et housi ng.
(29) Connect the APPS connector.
(30) I nstal l the APPS assembl y to the cyl i nder
head bracket and torque bol ts to 24 Nm (18 ft. l bs.).
(31) I nstal l the throttl e l i nkage cover.
(32) I nstal l the charge ai r cool er-to-ai r i nl et hous-
i ng duct assembl y. Torque al l cl amps to 11 Nm (100
i n. l bs.).
(33) Connect i ntake gri d heater wi res.
(34) Secure engi ne harness to front of cyl i nder
head wi th bol t at four l ocati ons.
(35) Connect engi ne cool ant temperature sensor
connector.
(36) Connect radi ator upper hose to thermostat
housi ng.
1 - ROCKER ARM
2 - PEDESTAL
(37) Rotate generator i nto posi ti on. I nstal l upper
bol t and torque upper and l ower bol ts.
(38) I nstal l wi re harness push-on cl i p bel ow bracket.
(39) I nstal l wi re harness P-cl i p to top of bracket.
(40) I nstal l fan support and torque to 32 Nm (24
ft. l bs.).
(41) I nstal l cool i ng fan/dri ve refer to (Refer to 7 -
COOLI NG/ENGI NE/RADI ATOR FAN - I NSTALLA-
TI ON).
I NSTALLATI ON).
(43) I nstal l exhaust mani fol d/turbocharger assem-
bl y, usi ng new gaskets. Start al l bol ts/spacers by
hand. Torque bol ts to 43 Nm (32 ft. l bs.).
(44) I nstal l exhaust mani fol d heat shi el d to
exhaust mani fol d studs. I nstal l retai ni ng nuts.Torque
to 15 Nm (11 ft. l bs.).
(45) I nstal l exhaust bol t retenti on straps across
cyl i nders 5 & 6.
(46) Connect turbocharger oi l drai n tube. Torque
cl amp to 8 Nm (71 i n. l bs.).
(47) Perform the turbocharger pre-l ube procedure.
Refer to Group 11, Exhaust System and Turbo-
charger for the correct procedure.
(48) Connect the turbocharger oi l suppl y l i ne.
(49) I nstal l ai r cl eaner housi ng and duct.
(50) Connect ai r i nl et temperature/pressure sensor.
(52) I nstal l exhaust pi pe to turbocharger el bow.
Torque bol ts to 11 Nm (100 i n. l bs.).
(54) Fi l l engi ne cool ant (Refer to 7 - COOLI NG -
REMOVAL
REMOVAL CYLINDER HEAD COVER
(3) Remove the breather cover.
(4) Di sconnect the breather hose and breather
drai n tube from the breather housi ng.
(5) Remove cyl i nder head cover bol ts.
(6) Remove the cyl i nder head cover.
REMOVAL ROCKER HOUSING
(1) Remove cyl i nder head cover as outl i ned i n thi s
secti on.
(2) Di sconnect rocker housi ng i njector harness con-
nectors.
(3) Remove i njector harness nuts from i njectors.
(4) Remove rocker housi ng bol ts.
(5) Remove rocker housi ng and gasket.
CLEANING
Usi ng a sui tabl e sol vent, Cl ean and dry gasket
mati ng surfaces on cyl i nder head and rocker housi ng.
Wi pe gasket dry and i nspect for re-use.
INSPECTION
The cylinder head cover gasket and rocker hous-
ing gasket, are reusable. However, shoul d cracks,
ni cks, or tears be present i n the rubber/si l i cone construc-
ti on, the defecti ve components shoul d be repl aced. Al so
repl ace gasket i f i t i s no l onger fl exi bl e. I nspect o-ri ngs
on cyl i nder head cover bol ts. Do not reuse gasket if it
has been removed from the groove in the rocker
housing or cylinder head cover.
INSTALLATION
INSTALLATION CYLINDER HEAD COVER
(1) I nspect cyl i nder head cover gasket for cuts and
proper i nstal l ati on i n groove. Repl ace i f damaged.
(2) Posi ti on cyl i nder cover on top of rocker housi ng.
(3) I nstal l bol ts.
(4) Starti ng wi th the center bol t, torque to 24 Nm
(18 ft. l bs.).
(5) I nstal l breather hose to breather.
(6) I nstal l breather drai n hose to breather.
(7) I nstal l breather cover and wi re harness cl i p.
INSTALLATION - ROCKER HOUSING
(1) I nspect rocker housi ng gasket for cuts, ni cks,
or tears. Repl ace i f damaged or i f gasket has come
out of groove.
(2) I nspect rocker housi ng gasket for proper i nstal -
l ati on i n groove. Gasket bead must be centered i n
groove. A gasket bead that i s ti l ted to the si de wi l l
cause an oi l l eak.
CAUTION: When installing rocker housing onto cyl-
inder head, do not slide housing from side to side,
The gasket could fall out or be damaged.
(3) I nstal l the rocker housi ng. Careful l y gui de the
rocker housi ng evenl y down onto the cyl i nder head.
(4) I nstal l rocker housi ng bol ts and ti ghten fi nger
ti ght.
(5) Torque bol ts, worki ng from center out, to 24
Nm (18ft. l bs.).
(6) I nstal l i njector harness nuts to i njector sol e-
noi d. Torque to 1.25 Nm (11 i n. l bs.).
(7) Connect rocker housi ng i njector harness con-
necti ons.
SEATS
DESCRIPTION
The val ves are made of heat resi stant steel , and
have chrome pl ated stems to prevent scuffi ng. The
i ntake and exhaust val ves are both si mi l ar i n head
di ameter and overal l l ength, but they have uni que
face angl es whi ch makes them non-i nterchangeabl e.
The val ves are di sti ngui shed by uni que di mpl es on
the exhaust val ve head (Fi g. 21).
The exhaust val ve spri ngs are made from hi gh
strength, chrome si l i con steel . The exhaust val ve
spri ngs are al so exhaust brake compati bl e.
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES, GUIDES
AND SPRINGS
REMOVAL
(1) Remove cyl i nder head (Refer to 9 - ENGI NE/
(2) Support cyl i nder head on stands, or i nstal l
head bol ts upsi de down (through combusti on surface
si de) to protect i njector ti ps from damage from work
bench.
(3) I nstal l the val ve spri ng compressor mounti ng
base as shown i n (Fi g. 22).
(4) I nstal l the compressor top pl ate, washer, and
nut. Usi ng a sui tabl e wrench, ti ghten the nut (cl ock-
wi se) to compress the val ve spri ngs (Fi g. 23) and
remove the l ocks.
Fig. 22 Spring Compressor Mounting BasePart of
Tool 8319A
1 - COMPRESSOR MOUNTING BASE
Fig. 23 Compressing Valve Springs with Tool
8319A
Fig. 21 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
(5) Rotate the compressor nut counter-cl ockwi se to
rel i eve tensi on on the spri ngs. Remove the spri ng
compressor.
(6) Remove the retai ners, spri ngs, val ve seal s (i f
necessary), and val ves (Fi g. 24). Arrange or number
al l components so they can be i nstal l ed i n thei r ori g-
i nal l ocati ons.
(7) Repeat the procedure on al l cyl i nders to be ser-
vi ced.
CLEANING
Cl ean the val ve stems wi th crocus cl oth or a
Scotch-Bri te pad. Remove carbon wi th a soft wi re
brush. Cl ean val ves, spri ngs, retai ners, and val ve
retai ni ng l ocks i n a sui tabl e sol vent. Ri nse i n hot
water and bl ow dry wi th compressed ai r.
INSPECTION
Vi sual l y i nspect the val ves for abnormal wear on
the heads, stems, and ti ps. Repl ace any val ve that i s
worn out or bent (Fi g. 25).
Measure the val ve stem di ameter i n three pl aces
as shown i n (Fi g. 26).
Measure the cyl i nder head val ve gui de bore (Fi g.
27).
VALVE GUIDE BORE SPECIFICATIONS
VALVE GUIDE BORE SPECIFICATIONS
Valve guide bore
diameter
Min. 7.027 mm (0.2767 in.)
Max. 7.077 mm (0.2786 in.)
Installed valve guide
depth
Intake
Min. 0.584 mm ( 0.023 in.)
Max. 1.092 mm ( 0.043 in.)
Exhaust
Min. 0.965 mm ( 0.028 in.)
Max. 1.473 mm (0.058 in.)
Fig. 24 Valve Spring, Seal, and Retainers
1 - VALVE RETAINING LOCKS
2 - VALVE
3 - SEAL
4 - SPRING
5 - RETAINER
Fig. 25 Visually Inspect Valves for Abnormal Wear
Fig. 26 Measure Valve Stem Diameter
VALVE STEM DIAMETER
6.96 mm (0.2740 in.) MIN
7.010 mm (0.2760 in.) MAX
Measure val ve margi n (ri m thi ckness) (Fi g. 28).
Measure the val ve spri ng free l ength and maxi -
mum i ncl i nati on (Fi g. 29).
Test val ve spri ng force wi th tool C-647 (Fi g. 30).
Speci fi cati on 72.0 80.7 l bs. when compressed to
35.33 mm (1.39 i n.).
Fig. 27 Measure Valve Guide Bore
Fig. 28 Measure Valve Margin (Rim Thickness)
VALVE MARGIN (RIM THICKNESS)
0.79 mm (0.031 in.) MIN.
Fig. 29 Measure Valve Spring Free Length and Max.
Inclination
APPROXIMATE VALVE SPRING FREE LENGTH
47.75 mm (1.88 in.)
MAX INCLINATION
1.5 mm (.059 in.)
Fig. 30 Testing Valve Spring with Tool C-647
INSTALLATION
(1) I nstal l new val ve seal s. The yel l ow seal s are for
the i ntake val ves and the green seal s are for the
exhaust val ves.
(2) I nstal l the val ves i n thei r ori gi nal posti on. The
exhaust val ves are i denti fi ed by a di mpl e on the
val ve head (Fi g. 31).
(3) I nstal l the val ve spri ngs and retai ner.
(4) I nstal l the val ve spri ng compressor tool 8319A
as shown i n (Fi g. 22) and (Fi g. 23).
(5) Compress the val ve spri ngs and i nstal l the
val ve retai ni ng l ocks (Fi g. 24).
(6) Remove the compressor and repeat the proce-
dure on the remai ni ng cyl i nders.
(7) I nstal l new o-ri ng and seal i ng washer on i njec-
tor.
(8) Lubri cate o-ri ng and i njector bore.
(9) Veri fy seal i ng washer (shi m) was removed wi th
ol d i njector.
(10) I nstal l i njector Refer to (Refer to 14 - FUEL
SYSTEM/FUEL I NJECTI ON/FUEL I NJECTOR -
I NSTALLATI ON).
(11) I nstal l the cyl i nder head (Refer to 9 -
ENGI NE/CYLI NDER HEAD - I NSTALLATI ON).
STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION
NOTE: To obtain accurate readings, valve lash mea-
surements AND adjustments should only be per-
formed when the engine coolant temperature is less
than 60 C (140 F).
The 24val ve overhead system i s a l ow-mai nte-
nance desi gn. Routi ne adjustments are no l onger
necessary, however, measurement shoul d sti l l take
pl ace when troubl e-shooti ng performance probl ems,
or upon compl eti on of a repai r that i ncl udes removal
and i nstal l ati on of the val ve trai n components or
i njectors.
(3) Usi ng the crankshaft barri ng tool #7471B,
rotate crankshaft to al i gn damper TDC mark to
12:00 ocl ock posi ti on.
(a) I f both number one cyl i nder rocker l evers are
l oose, conti nue to next step.
(b) I f both number one cl yl i nder rocker l evers
are not l oose, rotate crankshaft 360 degrees.
(4) Wi th the engi ne i n thi s posi ti on, val ve l ash can
be measured at the fol l owi ng rocker arms: INTAKE
124 / EXHAUST 135. Measure the val ve l ash by
i nserti ng a feel er gauge between the rocker arm
socket and crosshead (Fi g. 32). Refer to VALVE
LASH LI MI T CHART for the correct speci fi cati ons. I f
the measurement fal l s within the l i mi ts, adjust-
ment/resetti ng is not necessary. I f measurement
fi nds the l ash outside of the l i mi ts, adjustment/re-
setti ng is requi red.
VALVE LASH LIMIT CHART
INTAKE EXHAUST
0.152 mm ( 0.006 in.)
MIN.
0.381 mm (0.015 in.)
MIN.
0.381 mm (0.015 in.)
MAX.
0.762 mm (0.030 in.)
MAX.
note:
If measured valve lash falls within these
specifications, no adjustment/reset is necessary.
Engine operation within these ranges has no adverse
affect on performance, emissions, fuel economy or
level of engine noise.
(5) I f adjustment/resetti ng i s requi red, l oosen the
l ock nut on rocker arms and turn the adjusti ng screw
unti l the desi red l ash i s obtai ned:
INTAKE 0.254 mm (0.010 i n.)
EXHAUST 0.508 mm (0.020 i n.) Ti ghten the
l ock nut to 24 Nm (18 ft. l bs.) and re-check the val ve
l ash.
(6) Usi ng the crankshaft barri ng tool , rotate the
crankshaft one revol uti on (360) to al i gn the
damper TDC mark to the 12 ocl ock posi ti on.
Fig. 31 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
(7) Wi th the engi ne i n thi s posi ti on, val ve l ash can
be measured at the remai ni ng rocker arms: INTAKE
356 / EXHAUST 246 . Use the same method as
above for determi ni ng whether adjustment i s neces-
sary, and adjust those that are found to be outsi de of
the l i mi ts.
REMOVAL - VALVE SPRINGS AND SEALS
(3) Di sconnect rocker housi ng i njector harness con-
nector. Remove al l i njector harness sol enoi d nuts.
(4) Remove i njector(s) for cyl i nder(s) to be servi ced.
Refer to Group 14 for i njector removal .
(5) Remove the rocker housi ng.
(6) Remove the rocker arms and crossheads from
the cyl i nder(s) to be servi ced. Mark each component
so they can be i nstal l ed i n thei r ori gi nal posi ti on.
(7) Usi ng the crankshaft barri ng tool #7471B
(Fi g. 33), rotate the engi ne to posi ti on the damper
mark i n the 12 ocl ock posi ti on. At this engine posi-
tion, cylinders #1 and #6 can be serviced.
REMOVAL).
(9) Wi th the damper TDC mark i n the 12 ocl ock
posi ti on, add a pai nt mark anywhere on the gear
housi ng cover next to the crankshaft damper. Pl ace
another mark on the vi brati on damper i n al i gnment
wi th the mark you just made on the cover.
(10) Di vi de the crankshaft damper i nto three
equal l y si zed segments as fol l ows:
(a) Usi ng a tape measure, measure the ci rcum-
ference of the crankshaft damper and di vi de the
measurement by three (3).
(b) Measure that di stance i n a counter-cl ockwi se
di recti on from the fi rst bal ancer mark and pl ace
another mark on the bal ancer.
(c) From the second damper mark, agai n mea-
sure i n a counter-cl ockwi se di recti on and pl ace a
mark on the damper at the same di stance you
measured when pl aci ng the second damper mark.
The damper shoul d now be marked i n three
equal l y spaced l ocati ons and the damper TDC
mark shoul d be i n the 12 ocl ock posi ti on.
(d) Remove i njectors, fuel l i nes, and hi gh pres-
sure connectors for every cyl i nder that requi res
repai r.
(11) Compress the val ve spri ngs at cyl s. #1 and #6
as fol l ows:
(a) I nstal l the val ve spri ng compressor mounti ng
base as shown i n (Fi g. 34).
(b) I nstal l the top pl ate, washer, and nut. Usi ng
a sui tabl e wrench ti ghten the nut (cl ock-wi se) (Fi g.
35) to compress the val ve spri ngs and remove the
col l ets.
(c) Rotate the compressor nut counter-cl ockwi se
to rel i eve tensi on on spri ngs. Remove spri ng com-
pressor.
(d) Remove and repl ace retai ners, spri ngs, and
seal s as necessary.
(e) Do not rotate the engine until the
springs and retainers are re-installed.
(f) I nstal l seal s, spri ngs and retai ners. I nstal l
spri ng compressor, compress val ve spri ngs and
i nstal l the col l ets.
Fig. 32 Measuring Valve Lash - Typical
1 - INTAKE
2 - FEELER GAUGE
3 - EXHAUST
Fig. 33 Rotating Engine with Barring Tool - Typical
1 - REAR FLANGE
2 - BARRING TOOL
(g) Rel ease the spri ng tensi on and remove the
compressor. Veri fy that the col l ets are seated by
tappi ng on the val ve stem wi th a pl asti c hammer.
engi ne unti l the next crankshaft damper pai nt mark
al i gns wi th the mark you pl aced on the cover. In this
position, cylinders #2 and #5 can be serviced.
(13) Repeat the val ve spri ng compressi ng proce-
dure previ ousl y performed and servi ce the retai ners,
spri ngs, and seal s as necessary.
engi ne unti l the next crankshaft damper pai nt mark
al i gns wi th the mark you pl aced on the cover. In this
position, cylinders #3 and #4 can be serviced.
(15) Repeat the spri ng compressi ng procedure pre-
vi ousl y performed and servi ce the retai ners, spri ngs,
and seal s as necessary.
INSTALLATION
(1) I nstal l rocker housi ng.
(2) I nstal l fuel i njectors and hi gh pressure fuel
l i nes.
(3) Lubri cate the val ve ti ps and i nstal l the cross-
(4) Lubri cate the crossheads and push rod sockets
and i nstal l the rocker arms and pedestal s i n thei r
ori gi nal l ocati ons. Ti ghten bol ts to 36 Nm (27 ft. l bs.)
torque.
(5) Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
(6) I nstal l cyl i nder head cover and reusabl e gasket
DER HEAD COVER(S) - I NSTALLATI ON).
ASSY
DESCRIPTION
The uni que i ntake and exhaust rocker arms have
thei r own rocker shafts and are l ubri cated by pas-
sages i ntersecti ng the cyl i nder bl ock mai n oi l ri fl e.
Crossheads are used, whi ch al l ow each rocker arm to
operate two val ves.
The sol i d push rods are hardened at the rocker
arm and tappet contact areas for superi or strength
and durabi l i ty.
REMOVAL
(3) Remove the rocker arm/pedestal fasteners (Fi g.
36) and remove rocker arm and pedestal from cyl i n-
der head. Mark the arms and pedestal s so they can
be i nstal l ed i n thei r ori gi nal posi ti on.
CAUTION: When removing the rocker arms, the
sockets (Fig. 37) may come loose and fall into the
engine. Make sure they stay with the arm upon
removal/installation.
(4) Li ft the push rod(s) up and out of the engi ne
(Fi g. 38). Mark them so they can be i nstal l ed i n thei r
ori gi nal posi ti on.
Fig. 34 Spring Compressor Mounting BasePart of
Tool 8319A
1 - COMPRESSOR MOUNTING BASE
Fig. 35 Compressing Valve Springs with Tool
8319A
NOTE: The #5 cyl. intake and exhaust and #6 cyl.
intake and exhaust push rods must be raised
through the provided cowl panel access holes.
(5) Li ft the crosshead(s) off of the val ve stems.
Mark them so they can be i nstal l ed i n thei r ori gi nal
posi ti on.
CLEANING
Cl ean al l components i n a sui tabl e sol vent. I f nec-
essary, use a wi re brush or wheel to remove stubborn
deposi ts. Ri nse i n hot water and bl ow dry wi th com-
pressed ai r. I nspect oi l passages i n rocker arms and
pedestal s. Appl y compressed ai r to l ubri cati on ori fi ces
to purge contami nants.
INSPECTION
Rocker Arms
(1) Remove rocker shaft and i nspect for cracks and
excessi ve wear i n the bore or shaft. Remove socket
and i nspect bal l i nsert and socket for si gns of wear.
Repl ace retai ner i f necessary.
Measure the rocker arm bore and shaft (Fi g. 39)
(Fi g. 40).
1 - ROCKER ARM
2 - PEDESTAL
Fig. 37 Rocker Arm Assembly Identification
1 - NUT
2 - ADJUSTING SCREW
3 - ROCKER SHAFT
4 - RETAINER
5 - SOCKET
Fig. 38 Push Rod Removal/Installation
Fig. 39 Measuring Rocker Arm Bore
ROCKER ARM BORE (MAX.)
22.027 mm (.867 in.)
ROCKER ARM / ADJ USTER ASSY (Continued)
Push Rods
I nspect the push rod bal l and socket for si gns of
scori ng. Check for cracks where the bal l and the
socket are pressed i nto the tube (Fi g. 41).
Rol l the push rod on a fl at work surface wi th the
socket end hangi ng off the edge (Fi g. 42). Repl ace
any push rod that appears to be bent.
Crossheads
I nspect the crossheads for cracks and/or excessi ve
wear on rocker l ever and val ve ti p mati ng surfaces
(Fi g. 43).
INSTALLATION
(1) I f previ ousl y removed, i nstal l the push rods i n
thei r ori gi nal l ocati on. Verify that they are seated
in the tappets.
(2) Lubri cate the val ve ti ps and i nstal l the cross-
and i nstal l the rocker arms and pedestal s i n thei r
ori gi nal l ocati ons. Ti ghten bol ts to 36 Nm (27 ft. l bs.)
torque.
(5) I nstal l cyl i nder head cover and reusabl e gasket
DER HEAD COVER(S) - I NSTALLATI ON).
Fig. 40 Measuring Rocker Arm Shaft
ROCKER ARM SHAFT (MIN.)
21.965 mm (.865 in.)
Fig. 41 Inspecting Push Rod for Cracks
Fig. 42 Inspecting Push Rod for Flatness
Fig. 43 Inspecting Crosshead for Cracks
ROCKER ARM / ADJ USTER ASSY (Continued)
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER BLOCK
REFACING
(1) The combusti on deck can be refaced twi ce. The
fi rst reface shoul d be 0.25 mm (0.0098 i nch). I f addi -
ti onal refaci ng i s requi red, an addi ti onal 0.25 mm
(0.0098 i nch) can be removed. Total al l owed refaci ng
i s 0.50 mm (0.0197 i nch) - (Fi g. 44).
(2) The upper ri ght corner of the rear face of the
bl ock must be stamped wi th a X when the bl ock i s
refaced to 0.25 mm (0.0098 i nch). A second X must be
stamped besi de the fi rst when the bl ock i s refaced to
0.50 mm (0.0197 i nch) - (Fi g. 45).
(3) Consul t the parts catal og for the proper head
gaskets whi ch must be used wi th refaced bl ocks to
ensure proper pi ston-to-val ve cl earance.
STANDARD PROCEDURE - CYLINDER BORE -
DE-GLAZE
(1) New pi ston ri ngs may not seat i n gl azed cyl i n-
der bores.
(2) De-gl azi ng gi ves the bore the correct surface
fi ni sh requi red to seat the ri ngs. The si ze of the bore
i s not changed by proper de-gl azi ng.
(3) Cover the l ube and tappet hol es i n the top of
the bl ock wi th waterproof tape.
(4) I t crankshaft i s i nstal l ed, wrap connecti ng rod
journal s wi th cl ean cl oth. Cover cl oth wi th water-
proof tape.
(5) A correctl y honed surface wi l l have a cross-
hatch appearance wi th the l i nes at 15 to 25 angl es
(Fi g. 46). For the rough hone, use 80 gri t honi ng
stones. To fi ni sh hone, use 280 gri t honi ng stones.
Fig. 44 Refacing Dimensions of the Cylinder Block
CYLINDER BLOCK REFACING DIMENSIONS
DIMENSION A
1st Reface 0.25mm (0.0098 in.)
2nd Reface 0.25mm (0.0098 in.)
Dim (A) Total 0.50 mm (0.0197 in.)
DIMENSION B
Dim. B (STD.)
323.00 mm 0.10
mm
(12.7165 in.
0.0039 in.)
1st Reface
322.75 mm 0.10
mm
(12.7067 in.
0.0039 in.)
2nd Reface
322.50 mm 0.10
mm
(12.6968 in.
0.0039 in.)
Fig. 45 Stamp Block after Reface
Fig. 46 Cylinder Bore Crosshatch Pattern
(6) Use a dri l l , a fi ne gri t Fl ex-hone and a mi xture
of equal parts of mi neral spi ri ts and SAE 30W engi ne
oi l to de-gl aze the bores.
(7) The crosshatch angl e i s a functi on of dri l l
speed and how fast the hone i s moved verti cal l y (Fi g.
47).
(8) Verti cal strokes MUST be smooth conti nuous
passes al ong the ful l l ength of the bore (Fi g. 47).
(9) I nspect the bore after 10 strokes.
(10) Use a strong sol uti on of hot water and l aun-
dry detergent to cl ean the bores. Cl ean the cyl i nder
bores i mmedi atel y after de-gl azi ng.
(11) Ri nse the bores unti l the detergent i s removed
and bl ow the bl ock dry wi th compressed ai r.
(12) Check the bore cl eanl i ness by wi pi ng wi th a
whi te, l i nt free, l i ghtl y oi l ed cl oth. I f gri t resi due i s
sti l l present, repeat the cl eani ng process unti l al l res-
i due i s removed. Wash the bores and the compl ete
bl ock assembl y wi th sol vent and dry wi th compressed
ai r. Pl ace a cl ean shop towel around the top mai n
beari ng saddl e to defl ect water and resi due from pi s-
ton cool i ng nozzel s. Remove di rected pi ston cool i ng
nozzl es i f i nstal l ed.
(13) Be sure to remove the tape coveri ng the l ube
hol es, rod journal s, and pi ston cool i ng nozzl es after
the cl eani ng process i s compl ete.
STANDARD PROCEDURE CYLINDER BORE
REPAIR
Cyl i nder bore(s) can be repai red by one of two
methods:
Method 1:Over bori ng and usi ng oversi ze pi s-
tons and ri ngs.
Method 2:Bori ng and i nstal l i ng a repai r sl eeve
to return the bore to standard di mensi ons.
METHOD 1 OVERSIZE BORE
Cyl i nder bore(s) can be repai red by one of two
methods:
Oversi ze pi stons and ri ngs are avai l abl e i n two
si zes - 0.50 mm (0.0197 i nch) and 1.00 mm (0.0393
i nch).
Any combi nati on of standard, 0.50 mm (0.0197
i nch) or 1.00 mm (0.0393 i nch) overbore may be used
i n the same engi ne.
I f more than 1.00 mm (0.0393 i nch) overbore i s
needed, a repai r sl eeve can be i nstal l ed (refer to
Method 2Repai r Sl eeve).
Cyl i nder bl ock bores may be bored twi ce before use
of a repai r sl eeve i s requi red. The fi rst bore i s 0.50
mm (0.0197 i nch) oversi ze. The second bore i s 1.00
mm (0.0393 i nch) oversi ze.
After bori ng to si ze, use a honi ng stone to chamfer
the edge of the bore.
CYLINDER BORE DIMENSION CHART
DESCRIPTION MEASUREMENT
BORING DIAMETER
DIMENSION
1st. REBORE - 102.469
mm (4.0342 in.)
2nd. REBORE - 102.969
mm (4.0539 in.)
HONING DIAMETER
DIMENSIONS
STANDARD - 102.020
0.020 mm (4.0165
0.0008 in.)
1st. REBORE - 102.520
0.020 mm (4.0362
0.0008 in.)
2nd. REBORE - 103.020
0.020 mm 4.0559
0.0008 in.)
CHAMFER
DIMENSIONS
Approx. 1.25 mm (0.049
in.) by 30
A correctl y honed surface wi l l have a crosshatch
appearance wi th the l i nes at 15 to 25 angl es wi th
the top of the cyl i nder bl ock (Fi g. 48). For the rough
hone, use 80 gri t honi ng stones. To fi ni sh hone, use
280 gri t honi ng stones.
A maxi mum of 1.2 mi crometer (48 mi croi nch) sur-
face fi ni sh must be obtai ned.
Fig. 47 De-Glazing Drill Speed and Vertical Speed
Fig. 48 Crosshatch Pattern of Repaired Sleeve(s)
After fi ni sh honi ng i s compl ete, i mmedi atel y cl ean
the cyl i nder bores wi th a strong sol uti on of l aundry
detergent and hot water.
After ri nsi ng, bl ow the bl ock dry.
Check the bore cl eanl i ness by wi pi ng wi th a whi te,
l i nt-free, l i ghtl y- oi l ed cl oth. There shoul d be no gri t
resi due present.
I f the bl ock i s not to be used ri ght away, coat i t
wi th a rust- preventi ng compound.
METHOD 2 REPAIR SLEEVE
I f more than a 1.00 mm (0.03937 i nch) di ameter
oversi ze bore i s requi red, the bl ock must be bored
and a repai r sl eeve i nstal l ed.
Bore the bl ock cyl i nder bore to 104.500-104.515
mm (4.1142-4.1148 i nch) - (Fi g. 49).
Repai r sl eeves can be repl aced by usi ng a bori ng
bar to bore out the ol d sl eeve. DO NOT cut the cyl -
i nder bore beyond the oversi ze l i mi t.
REPAIR SLEEVE BLOCK REBORE
DIMENSIONS CHART
BORE DIAMETER STEP DIMENSION
104.500 + 0.015 mm
(4.1142 + 0.0006 in.)
6.35 mm (0.25 in.)
After machi ni ng the bl ock for the new repai r
sl eeve, thoroughl y cl ean the bore of al l metal chi ps,
debri s and oi l resi due before i nstal l i ng the sl eeve.
Cool the repai r sl eeve(s) to a temperature of -12C
(10F) or bel ow for a mi ni mum of one hour. Be ready
to i nstal l the sl eeve i mmedi atel y after removi ng i t
from the freezer.
Appl y a coat of Locti te 620, or equi val ent to the
bore that i s to be sl eeved.
Wear protecti ve gl oves to push the col d sl eeve i nto
the bore as far as possi bl e.
Usi ng a sl eeve dri ver, dri ve the sl eeve downward
unti l i t contacts the step at the bottom of the bore
(Fi g. 50).
A sl eeve dri ver can be constructed as fol l ows (Fi g.
51).
SLEEVE DRIVER CONSTRUCTION
SPECIFICATION CHART
ITEM MEASUREMENT
A 127 mm (5 in.)
B 38 mm (1.5 in.)
C 6.35 mm (0.25 in.)
D 25.4 mm (1 in.)
E 101 mm (3.976 in.)
F 107.343 mm (4.226 in.)
Set up a bori ng bar and machi ne the sl eeve to
101.956 mm (4.014 i nch).
Fig. 49 Block Bore for Repair Sleeve Dimensions
1 - BORE DIAMETER
2 - STEP DIMENSION
Fig. 50 Sleeve Installation
1 - SLEEVE DRIVER
2 - SLEEVE
3 - CONTACT
Fig. 51 Sleeve Driver Construction
1 - DRIVE
2 - HANDLE
After removi ng the bori ng bar, use a honi ng stone
to chamfer the corner of the repai r sl eeve(s).
SLEEVE MACHINING DIMENSIONS CHART
ITEM MEASUREMENT
SLEEVE PROTRUSION MIN. - FLUSH WITH
BLOCK
MAX. - 0.050 mm
(0.0019 in.)
SLEEVE DIAMETER 101.956 mm (4.014 in.)
SLEEVE CHAMFER APPROX. 1.25 mm
(0.049 in.) by 15
A correctl y honed surface wi l l have a crosshatch
appearance wi th the l i nes at 15 to 25 angl es wi th
the top of the cyl i nder bl ock. For the rough hone, use
80 gri t honi ng stones. To fi ni sh hone, use 280 gri t
honi ng stones.
Fi ni shed bore i nsi de di mensi on i s 102.020 0.020
mm (4.0165 0.0008 i nch).
A maxi mum of 1.2 mi crometer (48 mi croi nch) sur-
face fi ni sh must be obtai ned.
After fi ni sh honi ng i s compl ete, i mmedi atel y cl ean
the cyl i nder bores wi th a strong sol uti on of l aundry
detergent and hot water.
After ri nsi ng, bl ow the bl ock dry wi th compressed
ai r.
Wi pe the bore wi th a whi te, l i nt-free, l i ghtl y oi l ed
cl oth. Make sure there i s no gri t resi due present.
Appl y a rust-preventi ng compound i f the bl ock wi l l
not be used i mmedi atel y.
A standard di ameter pi ston and a pi ston ri ng set
must be used wi th a sl eeved cyl i nder bore.
STANDARD PROCEDURE CAM BORE REPAIR
For standard bushi ngs, not oversi zed, maxi mum
front and rear cam bushi ng bore di ameter i s 59.248
mm. (2.3326 i n.). DO NOT bore the i ntermedi ate cam
bore to the front cam bore oversi ze di mensi ons. Max-
i mum front and rear camshaft bushi ng i nstal l ed
di ameter i s 54.147 mm. (2.1318 i n.). Mi ni mum
i nstal l ed di ameter i s 54.083 mm. (2.1293 i n.). Maxi -
mum i ntermedi ate camshaft bore di ameter i s 54.164
mm. (2.1324 i n.).
A surface fi ni sh of 2.3 mi crometers (92 mi croi nch)
must be mai ntai ned. Not more than 20% of an area
of any one bore may be 3.2 mi crometers (126 mi cro-
i nch).
Camshaft bores can be repai red i ndi vi dual l y. I t i s
not necessary to repai r undamaged cam bores i n
order to repai r i ndi vi dual l y damaged cam bores. The
standard front bushi ng cannot be used to repai r
i ntermedi ate bores.
I nstal l al l cam bushi ngs fl ush or bel ow the front
and rear cam bore surface. The front camshaft bush-
i ng shoul d be i nstal l ed fl ush wi th front face of bl ock.
The rear camshaft bushi ng shoul d be i nstal l ed fl ush
wi th rear face of bl ock. The oi l hol e must al i gn to
al l ow a 3.2 mm (0.125 i nch) rod to pass through
freel y (Fi g. 52).
INSPECTION
Measure the combusti on deck face usi ng a strai ght
edge and a feel er gauge (Fi g. 53). Cyl i nder bl ock fl at-
ness: End-to-end 0.076 mm ( .003 i n.). Maxi mum
vari ati on si de-to-si de 0.051 mm (.002 i n.).
I nspect for any l ocal i zed di ps or i mperfecti ons.
I f the surface exceeds the l i mi t, (Refer to 9 -
ENGI NE/ENGI NE BLOCK - STANDARD PROCE-
DURE).
Fig. 52 Oil Hole Alignment
1 - CAMSHAFT BUSHING
Fig. 53 Combustion Deck Face Measurement
1 - STRAIGHT EDGE
2 - FEELER GAUGE
I nspect the cyl i nder bores for damage or excessi ve
wear.
Measure the cyl i nder bores (Fi g. 54). I f the cyl i n-
der bores exceed the l i mi t, (Refer to 9 - ENGI NE/EN-
GI NE BLOCK - STANDARD PROCEDURE).
BORE SPECIFICATIONS
BORE DIAMETER
Min. 102.000 mm (4.0157 in.)
Max. 102.116 mm (4.0203 in.)
OUT OF ROUNDNESS
Max. 0.038 mm (0.0015 in.)
TAPER
Max. 0.076 mm (.003 in.)
I nspect the camshaft bores for scori ng or excessi ve
wear.
Measure the camshaft bores (Refer to 9 - ENGI NE
- SPECI FI CATI ONS).
I f a bore exceeds the l i mi t, (Refer to 9 - ENGI NE/
ENGI NE BLOCK/CAMSHAFT & BEARI NGS (I N
BLOCK) - STANDARD PROCEDURE).
I nspect the tappet bores for scori ng or excessi ve
wear.
Measure tappet bore from bottom of bl ock. Mi ni -
mum tappet bore di ameter 16.000 mm (0.0630 i n.).
Maxi mum tappet bore 16.055 mm. (0.632 i n.).
I f out of l i mi ts, repl ace the cyl i nder bl ock.
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVAL
REMOVAL CAMSHAFT BEARINGS
NOTE: Measure the diameter of each bore. If the
camshaft bore for the first or rear cam bushing is
worn beyond the limit, install a new service bush-
ing. Inspect the rest of the camshaft bores for dam-
age or excessive wear.If the bores without a
bushing are worn beyond the limit, the engine must
be removed for machining and installation of ser-
vice bushings. If badly worn, replace the cylinder
block.
BLOCK) - REMOVAL).
(2) Remove the bushi ng from the No.1 bore and
No.7 usi ng a uni versal cam bushi ng tool .
(3) Mark the cyl i nder bl ock so you can al i gn the oi l
hol e i n the cyl i nder bl ock wi th the oi l hol e i n the
bushi ng.
REMOVAL - CAMSHAFT
(2) Recover A/C refri gerant (i f A/C equi pped) (Refer
to 24 - HEATI NG & AI R CONDI TI ONI NG/PLUMB-
(4) Drai n engi ne cool ant i nto contai ner sui tabl e for
re-use (Refer to 7 - COOLI NG - STANDARD PROCE-
DURE).
(7) Remove vi scous fan/dri ve assembl y and fan
shroud (Refer to 7 - COOLI NG/ENGI NE/RADI ATOR
FAN - REMOVAL).
(8) Di sconnect the cool ant recovery bottl e hose
from the radi ator fi l l er neck.
(9) Di sconnect l ower radi ator hose from radi ator
outl et.
(10) Automatic Transmission models: Di scon-
nect transmi ssi on oi l cool er l i nes from front of radi a-
tor usi ng Speci al Tool 6931 (unl ess equi pped wi th
fi nger-rel ease di sconnect).
(11) Remove radi ator mounti ng screws and l i ft
radi ator out of engi ne compartment.
(12) Remove upper radi ator support panel .
(13) I f A/C equi pped, di sconnect A/C condenser
refri gerant l i nes.
(14) Di sconnect charge ai r cool er pi pi ng from the
cool er i nl et and outl et.
Fig. 54 Cylinder Bore Diameter
(15) Remove the two charge ai r cool er mounti ng
bol ts.
(16) Remove charge ai r cool er (and A/C condenser
i f equi pped) from vehi cl e.
REMOVAL).
(18) Remove accessory dri ve bel t tensi oner.
(19) Remove the fan support/hub assembl y.
(20) Remove crankshaft damper and speed i ndi ca-
tor ri ng (Refer to 9 - ENGI NE/ENGI NE BLOCK/VI -
BRATI ON DAMPER - REMOVAL).
(21) Remove the gear cover-to-housi ng bol ts and
gentl y pry the cover away from the housi ng, taki ng
care not to mar the seal i ng surfaces. Remove dust
seal wi th cover.
(22) Usi ng Speci al Tool 7471B Crankshaft Bar-
ri ng Tool , rotate the crankshaft to al i gn the ti mi ng
marks on the crankshaft and the camshaft gears.
(24) Remove the rocker arms, cross heads, and
push rods (Fi g. 55). Mark each component so they
can be i nstal l ed i n thei r ori gi nal posi ti ons.
NOTE: The #5 cylinder intake and the #6 cylinder
intake and exhaust pushrods are removed by lifting
them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
(25) Rai se the tappets as fol l ows, usi ng the wooden
dowel rods (Fi g. 57)provi ded wi th the Mi l l er Tool Ki t
8502.
(a) I nsert the sl otted end of the dowel rod i nto
the tappet. The dowel rods for the rear two
cylinders will have to be cut for cowl panel
clearance. Press fi rml y to ensure that i t i s seated
i n the tappet.
(b) Rai se the dowel rod to bri ng the tappet to
the top of i ts travel , and wrap a rubber band
around the dowel rods (Fi g. 57) to prevent the tap-
pets from droppi ng i nto the crankcase.
(c) Repeat thi s procedure for the remai ni ng cyl -
i nders.
(26) Veri fy that the camshaft ti mi ng marks are
al i gned wi th the crankshaft mark (Fi g. 56).
(27) Remove the bol ts from the thrust pl ate.
(28) Remove engi ne mount through bol ts.
8534, and steel bracket/wing nut special tool #
8534A.
(30) Rai se engi ne enough to al l ow camshaft
removal .
(31) Remove the camshaft, gear and thrust pl ate.
Fig. 55 Push Rod Removal/Installation
Fig. 56 Timing Mark Alignment
Fig. 57 Use Wooden Dowel Rods to Secure Tappets
in Place - Typical
INSPECTION
Camshaft
(1) I nspect the val ve l obes and beari ng journal s for
cracks, pi tti ng, scori ng, or general l y excessi ve wear.
Repl ace any camshaft that exceeds the al l owabl e l i m-
i ts.
(2) Measure the beari ng journal s and l obes (Fi g.
58).
CAUTION: If Camshaft lobes are worn, requiring
camshaft replacement, it is necessary to replace the
tappets also. (Refer to 9 - ENGINE/ENGINE BLOCK/
SOLID LIFTERS - REMOVAL).
CAMSHAFT DIMENSIONS
CAMSHAFT DIMENSIONS
Journal diameter (No.1 and No.7)
Min. 54.028 mm.
(2.127 in.)
Max. 54.048 mm.
(2.128 in.)
Journal diameter (No.2 through
No.6)
Min. 53.962 mm.
(2.1245 in.)
Max. 54.013 mm.
(2.1265 in.)
Diameter of peak of lobe
Intake
Min. 47.175 mm
(1.857 in.)
Max 47.855 mm.
Exhaust
Min. 45.632 mm.
(1.797 in.)
Max. 46.312 mm.
(1.823 in.)
Camshaft Bushing/Bores
Camshaft bores No. 26 do not use a bushi ng.
(1) I nspect the camshaft bushi ng and bores for
si gns of excessi ve wear.
(2) Measure the camshaft bushi ng and bores (Fi g.
59) wi th a tel escopi ng bore gauge and mi crometer. I f
out of speci fi cati on, (Refer to 9 - ENGI NE/ENGI NE
BLOCK/CAMSHAFT & BEARI NGS (I N BLOCK) -
REMOVAL).
Fig. 59 Measuring Camshaft Bushing and Bores
Fig. 58 Measuring
1 - VALVE LOBE
2 - CAMSHAFT JOURNAL
(3) I nspect the camshaft bushi ng oi l hol es for
al i gnment wi th cyl i nder bl ock (Fi g. 60).
Camshaft Gear
I nspect the camshaft gear for cracks (gear and hub),
and chi pped/broken/fretted teeth. I f repl acement i s nec-
essary, camshaft and gear are repl aced as an assembl y.
(Refer to 9 - ENGI NE/ENGI NE BLOCK/CAMSHAFT &
BEARI NGS (I N BLOCK) - REMOVAL).
Thrust Plate
I nspect the camshaft thrust pl ate for excessi ve
wear i n the camshaft contact area. Measure thrust
pl ate thi ckness usi ng the CAMSHAFT THRUST
PLATE THI CKNESS CHART. Repl ace any thrust
pl ate that fal l s outsi de of these speci fi cati ons:
CAMSHAFT THRUST PLATE THICKNESS CHART
MIN. 9.34 mm (0.368 in.)
MAX. 9.60 mm (0.378 in.)
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS
(1) Appl y a coati ng of Locti te 640 Adhesi ve to the
backsi de of the new bushi ng. Avoi d getti ng adhesi ve
i n the oi l hol e.
(2) Use a uni versal cam bushi ng i nstal l ati on tool
and i nstal l the front bushi ng so that i t i s even wi th
the front face of the cyl i nder bl ock. The oi l hol e must
be al i gned. A 3.2 mm (0.128 i nch) di ameter rod must
be abl e to pass through the hol e. (Fi g. 61).
(3) I nstal l the rear camshaft bushi ng i s fl ush wi th
the rear face of the bl ock. The oi l hol e must be
al i gned. A 3.2 mm (0.128 i nch) di ameter rod must be
abl e to pass through the hol e.
(4) Measure the i nstal l ed bushi ngs at the front
and rear bores. The mi ni mum i nsi de di ameter i s
54.083 mm (2.1293 i nch), and the maxi mum i nsi de
di ameter i s i s 54.147 mm. (2.1318 i n.).
INSTALLATION - CAMSHAFT
(1) Lubri cate the camshaft bushi ng and bores wi th
fresh engi ne oi l or sui tabl e equi val ent.
(2) Li beral l y coat the camshaft l obes, journal s, and
thrust washer wi th fresh engi ne oi l or sui tabl e equi v-
al ent.
CAUTION: When installing the camshaft, DO NOT
push it in farther than it will go with the thrust
washer in place.
(3) I nstal l the camshaft and thrust pl ate. Al i gn the
ti mi ng marks as shown (Fi g. 62).
(4) I nstal l the thrust pl ate bol ts and ti ghten to 24
(5) Measure camshaft back l ash and end cl earance.
BACKLASH 0.0750.250 mm
(0.0030.010 inch)
CLEARANCE 0.0250.500 mm
(0.0010.020 inch)
Fig. 60 Inspecting Oil Hole Alignment
Fig. 61 Oil Hole Alignment
(6) Remove the wooden dowel rods and rubber
bands from the tappets.
(7) Lubri cate the push rods wi th engi ne oi l and
i nstal l i n thei r ori gi nal l ocati on. Verify that they
are seated in the tappets.
(8) Lubri cate the val ve ti ps wi th engi ne oi l and
i nstal l the crossheads i n thei r ori gi nal l ocati ons.
wi th engi ne oi l and i nstal l the rocker arms and ped-
estal s i n thei r ori gi nal l ocati ons. Ti ghten bol ts to 36
(11) I nstal l the cyl i nder head cover and reusabl e
gasket (Refer to 9 - ENGI NE/CYLI NDER HEAD/
CYLI NDER HEAD COVER(S) - I NSTALLATI ON).
(12) I nstal l gear housi ng cover (Refer to 9 -
ENGI NE/VALVE TI MI NG/GEAR HOUSI NG COVER
- I NSTALLATI ON). I nstal l front crankshaft dust
seal .
(13) I nstal l the crankshaft damper wi th the speed
i ndi cator ri ng (Refer to 9 - ENGI NE/ENGI NE
BLOCK/VI BRATI ON DAMPER - I NSTALLATI ON).
(14) I nstal l the fan support/hub assembl y Refer to
(Refer to 7 - COOLI NG/ENGI NE/RADI ATOR FAN -
I NSTALLATI ON).
(16) I nstal l accessory dri ve bel t tensi oner. Torque
bol t to 43 Nm (32 ft. l bs.).
I NSTALLATI ON).
(18) I nstal l the charge ai r cool er (wi th a/c con-
denser and auxi l i ary transmi ssi on oi l cool er, i f
equi pped) and ti ghten the mounti ng bol ts to 2 Nm
(19) Connect charge ai r cool er i nl et and outl et
pi pes. Ti ghten cl amps to 11 Nm (95 i n. l bs.) torque.
(20) I nstal l the radi ator upper support panel .
(21) Cl ose radi ator petcock and l ower the radi ator
i nto the engi ne compartment. Ti ghten the mounti ng
bol ts to 11 Nm (95 i n. l bs.) torque.
(23) Connect radi ator l ower hose and i nstal l
cl amp.
(24) Connect transmi ssi on auxi l i ary oi l cool er l i nes
(i f equi pped).
(26) I nstal l the fan shroud and ti ghten the mount-
i ng screws to 6 Nm (50 i n. l bs.) torque.
(27) I nstal l the el ectroni cal l y control l ed vi scous
fan/dri ve assembl y. Connect harness connector.(Refer
I NSTALLATI ON).
(28) I nstal l the cool ant recovery and wi ndshi el d
washer fl ui d reservoi rs to the fan shroud.
(29) Connect the cool ant recovery hose to the radi -
ator fi l l er neck.
(30) Add engi ne cool ant (Refer to 7 - COOLI NG -
(31) Charge A/C system wi th refri gerant (i f A/C
equi pped) (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG - STANDARD PROCEDURE).
(33) Start engi ne and check for engi ne oi l and cool -
ant l eaks.
STANDARD PROCEDURE - CONNECTING ROD
BEARING AND CRANKSHAFT JOURNAL
CLEARANCE
(1) Measure the connecti ng rod bore wi th beari ngs
removed and the bol ts ti ghtened to 100 Nm (73 ft.
l bs.) torque..
(2) Measure the connecti ng rod bore wi th the bear-
i ngs installed and the bol ts ti ghtened to 100 Nm
Measure wi thi n 20 arc from each si de of the part-
i ng l i ne. Al so measure 90 from parti ng l i ne.
Record the smal l est and l argest di ameter.
Measure the di ameter of the rod journal at the
l ocati on shown (Fi g. 63). Cal cul ate the average di am-
eter for each si de of the journal .
Determi ne mi ni mum beari ng cl earance by cal cul at-
i ng the di fferance between the smal l est connecti ng
rod bore di ameter wi th the beari ng i nstal l ed and the
average di ameter for each si de of the crankshaft jour-
nal .
Determi ne the maxi mum beari ng cl earance by cal -
cul ati ng the di fference between the l argest connect-
i ng rod bore di ameter and the average di ameter wi th
the beari ng i nstal l ed for each si de of the crankshaft
journal .
CONNECTING ROD
BORE, BEARINGS
REMOVED
MIN. 72.99 mm (2.874
in.)
MAX. 73.01 mm (2.875
in.)
CONNECTING ROD
BORE, BEARINGS
INSTALLED
MIN. 69.05 mm (2.719
in.)
MAX. 69.10 mm (2.720
in.)
I f the crankshaft i s wi thi n l i mi ts, repl ace the bear-
i ng. I f the crankshaft i s out of l i mi ts, gri nd the
crankshaft to the next smal l er si ze and use oversi ze
rod beari ngs.
CRANKSHAFT AND GEAR
DESCRIPTION
The crankshaft (Fi g. 64) i s a forged steel , i ntegral l y
bal anced uni t. I t i s supported by seven mai n bear-
i ngs, wi th posi ti on number si x desi gnated as the
thrust journal . The crankshaft i s hel d i n pl ace by
mai n caps and 12 mm capscrews. The crankshaft
al so has i nternal cross dri l l i ngs to suppl y the con-
necti ng rods wi th engi ne oi l .
REMOVAL - GEAR
(1) Remove the gear housi ng cover. (Refer to 9 -
- REMOVAL)
(2) Spl i t the gear and remove i t from the crank-
shaft.
INSTALLATION - GEAR
(1) Remove al l burrs and make sure the gear sur-
face on the end of the crankshaft i s smooth.
(2) I f removed, i nstal l a new al i gnment pi n. Dri ve
the pi n i n usi ng a bal l - peen hammer, l eavi ng i t pro-
trudi ng 1.0 mm (0.039 i nch) to 1.5 mm (0.059 i nch)
above the crankshaft (Fi g. 65).
WARNING: WEAR PROTECTIVE GLOVES TO PRE-
VENT INJURY.
CAUTION: DO NOT heat the gear longer than 45
minutes.
(3) Heat the crankshaft gear for 45 mi nutes at a
temperature of 149C (300F). Do not use torch,
gear failure will occur.
(4) Appl y a thi n coat of l ubri cant to the nose of the
crankshaft.
(5) Posi ti on the gear wi th the ti mi ng mark out and
i nstal l i t on the crankshaft usi ng the al i gnment pi n.
Make sure the gear contacts the shoul der.
Fig. 63 Connecting Rod Journal Diameter Limits
CONNECTING ROD J OURNAL DIAMETER
LIMITS CHART
CRANKSHAFT ROD JOURNAL
DIAMETER
Min. 68.96 mm (2.715 in.)
Max. 69.01 mm (2.717 in.)
BEARING CLEARANCE Min. 0.04 mm (.002 in.)
Max. 0.12 mm (0.005 in.)
Fig. 64 Crankshaft
Fig. 65 Installing Alignment Pin
1 - ALIGNMENT PIN
CONNECTING ROD BEARINGS (Continued)
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE
I nspect the mai n beari ng bores for damage or
abnormal wear.
(1) Remove beari ngs and measure mai n beari ng
bore di ameter after torqui ng mai n beari ng cap bol ts
to 176 Nm (130 ft. l bs.).
(2) I nstal l the crankshaft mai n beari ngs and mea-
sure mai n beari ng bore di ameter wi th the mai n bol ts
ti ghtened to 176 Nm (130 ft. l bs.) torque (Fi g. 66).
(3) Measure the di ameter of the mai n journal at
the l ocati ons shown (Fi g. 67). Cal cul ate the average
di ameter for each si de of the journal .
MAIN BEARING BORE DIAMETER CHART
ITEM MAIN BEARING BORE
DIAMETER (MAXIMUM)
BEARINGS INSTALLED 83.106 mm (3.2719 in.)
BEARINGS REMOVED Min 87.983 mm (3.4639
in.)
Max. 88.019 mm (3.4653
in.)
CRANKSHAFT MAIN J OURNAL DIAMETER
CHART
ITEM SPECIFICATION
Minimum diameter 82.962 mm (3.2662 in.)
Maximum diameter 83.013 mm (3.2682 in.)
Maximum out of
roundness
0.050 mm (.002 in.)
Maximum taper 0.013 mm (.0005 in.)
Thrust distance (at No.6
position)
Min. 0.065 mm (.003 in.)
Max. 0.432 mm (.017 in.)
(4) Cal cul ate the mai n beari ng journal to beari ng
cl earance. Maxi mum cl earance i s 0.119 mm (0.00475
i nch). I f the crankshaft journal i s wi thi n l i mi ts,
repl ace the mai n beari ngs. I f not wi thi n speci fi ca-
ti ons, gri nd the crankshaft to next si ze and use over-
si ze beari ngs.
(5) Measure thrust di stance at the No.6 posi ti on.
Fig. 66 Crankshaft Main Bearing Bore Diameter
1 - MAIN BEARING CAPS
Fig. 67 Crankshaft Main Journal Diameter
REMOVAL
(3) Parti al l y drai n engi ne cool ant i nto contai ner
sui tabl e for re-use (Refer to 7 - COOLI NG - STAN-
DARD PROCEDURE).
(6) Di sconnect cool ant recovery bottl e from radi a-
tor fi l l er neck and l i ft bottl e off of fan shroud.
(7) Di sconnect wi ndshi el d washer pump suppl y
hose and el ectri cal connecti ons and l i ft washer bottl e
off of fan shroud.
(8) Remove the fan shroud-to-radi ator mounti ng bol ts.
(9) Remove vi scous fan/dri ve assembl y. (Refer to 7 -
(10) Remove cool i ng fan shroud and fan assembl y
from the vehi cl e.
REMOVAL).
(12) Remove the cool i ng fan support/hub from the
front of the engi ne.
(13) Rai se the vehi cl e on hoi st.
(14) Remove the crankshaft damper and speed
i ndi cator ri ng.
(15) Remove power steeri ng pump.
care not to mar the gasket surfaces. Remove crank
seal dust shi el d wi th cover.
(18) Support the cover on a fl at work surface wi th
wooden bl ocks (Fi g. 68), and usi ng a sui tabl e punch
and hammer, dri ve the ol d seal out of the cover from
the back si de of the cover to the front si de (Fi g. 68).
INSTALLATION
(1) Cl ean cover and housi ng gasket mati ng sur-
faces. Use a sui tabl e scraper and be careful not to
damage the gear housi ng surface. Remove any ol d
seal er from the oi l seal bore. Thoroughl y cl ean the
front seal area of the crankshaft. The seal l i p and the
seal i ng surface on the crankshaft must be free from
al l oi l resi due to prevent seal l eaks.
(2) I nspect the gear housi ng and cover for cracks
and repl ace i f necessary. Careful l y strai ghten any
bends or i mperfecti ons i n the gear cover wi th a bal l -
peen hammer on a fl at surface. I nspect the crank-
shaft front journal for any grooves or ni cks that
woul d affect the i ntegri ty of the new seal .
(3) Appl y a bead of Mopar Stud & Beari ng Mount
to the outsi de di ameter of the seal . Do not l ubri cate
the i nsi de di ameter of the new seal .
(4) Wi th the cover supported by wood bl ocks, i nstal l
the seal i nto the rear of the cover usi ng crankshaft seal
i nstal l er Speci al Tool 8281 and dri ver handl e C-4171
(Fi g. 69). Stri ke the dri ver handl e unti l the i nstal l ati on
tool bottoms out on the i nsi de of the cover.
CAUTION: Do not distort or damage seal.
(5) I nstal l the pl asti c seal pi l ot (provi ded wi th seal
ki t) i nto the crankshaft seal .
Fig. 68 Removing Seal from Cover
1 - PUNCH
Fig. 69 Installing Seal Into Cover With Tool 8281
1 - SEAL INSTALLER 8281
2 - DRIVER HANDLE C4171
3 - SEAL
(6) Appl y a bead of Mopar Si l i cone Rubber Adhe-
si ve Seal ant or equi val ent to the gear housi ng cover
seal i ng surface.
(7) I nstal l the cover to the gear housi ng, al i gni ng
the seal pi l ot wi th the nose of the crankshaft (Fi g.
70).
(8) I nstal l the cover bol ts and ti ghten to 24 Nm
(18 ft. l bs.) torque. Remove pi l ot tool .
(9) I nstal l dust shi el d over nose of crankshaft.
(10) I nstal l the crankshaft damper and speed i ndi -
cator ri ng. Torque the bol ts to 40 Nm (30 ft. l bs.).
Then rotate an addi ti onal 60. Use the engi ne bar-
ri ng tool to keep the engi ne from rotati ng duri ng
ti ghteni ng operati on.
(11) I nstal l the fan support/hub assembl y and
torque bol ts to 32 Nm (24 ft. l bs.).
bol t to 43 Nm (32 ft.l bs.).
(14) I nstal l cool i ng fan (Refer to 7 - COOLI NG/EN-
GI NE/RADI ATOR FAN - I NSTALLATI ON).
I NSTALLATI ON).
(18) Start engi ne and check for oi l l eaks.
REAR
REMOVAL
(2) Remove the transmi ssi on and transfer case (i f
equi pped).
(3) Remove the cl utch cover and di sc (i f manual
transmi ssi on equi pped) (Refer to 6 - CLUTCH/
CLUTCH DI SC - REMOVAL).
(4) Remove the fl ywheel or converter dri ve pl ate.
(5) Dri l l hol es 180 apart i nto the seal . Be careful
not to contact the dri l l agai nst the crankshaft.
(6) I nstal l #10 sheet metal screws i n the dri l l ed
hol es and remove the rear seal wi th a sl i de hammer
(Fi g. 71).
INSTALLATION
CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks. The crankshaft and seal sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
(1) Cl ean the crankshaft journal wi th a sui tabl e
sol vent and dry wi th a cl ean shop towel or com-
pressed ai r. Wi pe the i nsi de bore of the crankshaft
seal retai ner wi th a cl ean shop towel .
(2) I nspect the crankshaft journal for gouges,
ni cks, or other i mperfecti ons. I f the seal groove i n the
crankshaft i s excessi vel y deep, i nstal l the new seal
1/8 deeper i nto the retai ner bore, or obtai n a crank-
shaft wear sl eeve that i s avai l abl e i n the aftermar-
ket.
(3) I nstal l the seal pi l ot and new seal , provi ded i n
the repl acement ki t, onto the crankshaft.
(4) Remove the seal pi l ot.
(5) I nstal l the i nstal l ati on tool over crankshaft.
(6) Usi ng a bal l peen hammer, stri ke the tool at
the 12, 3, 6, and 9 ocl ock posi ti ons unti l the al i gn-
ment tool bottoms out on the retai ner (Fi g. 72).
Fig. 70 Installing Front Cover with Seal Pilot
1 - SEAL PILOT
Fig. 71 Crankshaft Rear Seal Removal
1 - NO. 10 SCREW
2 - REAR SEAL
3 - CRANKSHAFT
4 - SLIDE HAMMER
(7) I nstal l the fl ywheel or converter dri ve pl ate.
Ti ghten the bol ts to 137 Nm (101 ft. l bs.) torque.
(8) I nstal l the cl utch cover and di sc (i f equi pped)
(Refer to 6 - CLUTCH/CLUTCH DI SC - I NSTALLA-
TI ON).
(9) I nstal l the transmi ssi on and transfer case (i f
equi pped).
(12) Check engi ne oi l l evel and adjust, i f necessary.
CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l . Re-i nstal l pl ug and torque to 50 Nm (44
ft. l bs.) torque.
equi pped) from vehi cl e.
(5) Remove fl ywheel or torque converter dri ve pl ate.
(6) Di sconnect starter cabl es from starter motor.
CAL/STARTI NG/STARTER MOTOR - REMOVAL)
and transmi ssi on adapter pl ate assembl y.
(8) Remove four (4) oi l pan rear bol ts. Sl i de a
feel er gauge between the seal retai ner and oi l pan
gasket to break the seal .
(9) Remove the si x (6) retai ner-to-bl ock bol ts (Fi g.
73).
(10) Remove the rear seal retai ner and gasket
(Fi g. 73).
(11) Support the seal retai ner and dri ve out the
crankshaft seal wi th a hammer and sui tabl e punch.
INSTALLATION
(1) I f usi ng the ol d seal retai ner, the crankshaft
seal must be repl aced.
(2) I nspect oi l pan gasket for ni ckes or cuts. I f gas-
ket i s damaged, the oi l pan must be removed and
gasket must be repl aced. Wi pe oi l pan gasket dry and
appl y l i ght coati ng of RTV.
(3) Usi ng the retai ner al i gnment/seal i nstal l ati on
tool provi ded i n the seal servi ce ki t, i nstal l the al i gn-
ment tool i nto the retai ner and i nstal l to the cyl i nder
bl ock (Fi g. 74), usi ng a new gasket. Ti ghten the si x
(6) mounti ng bol ts by hand.
(4) The seal al i gnment tool i s used to al i gn rear
cover properl y. Starti ng wi th the center two bol ts,
ti ghten the retai ner i n a ci rcul ar pattern to 10 Nm
(89 i n. l bs.). Remove the al i gnment tool .
CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks. The crankshaft and seal sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
Fig. 72 Seal Installation Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
Fig. 73 Crankshaft Rear Seal Retainer and Gasket
1 - RETAINER
2 - GASKET
3 - BOLT
(5) Make sure the provi ded seal pi l ot i s i nstal l ed
i nto the new crankshaft seal . Use the al i gnment/i n-
stal l ati on tool and press the seal onto the crankshaft
(Fi g. 75). Al ternatel y dri ve the seal at the 12, 3, 6
and 9 ocl ock posi ti ons.
(6) Remove the al i gnment tool and tri m the
retai ner gasket even wi th the oi l pan mounti ng sur-
face (Fi g. 76).
(7) Remove the seal pi l ot.
(8) Appl y a smal l amount of Mopar Si l i cone Rub-
ber Adhesi ve Seal ant to the oi l pan rai l T-joi nts.
(9) I nstal l the four (4) oi l pan rear mounti ng bol ts
and torque to 28 Nm (21 ft. l bs.).
(10) I nstal l new rectangul ar ri ng seal for cam bore.
(11) I nstal l the fl ywheel housi ng and bol ts. Torque
(12) I nstal l the fl ywheel or converter dri ve pl ate.
Ti ghten bol ts to 137 Nm (101 ft. l bs.).
(13) I nstal l the starter motor Refer to (Refer to 8 -
ELECTRI CAL/STARTI NG/STARTER MOTOR -
I NSTALLATI ON).
(14) I nstal l the transmi ssi on and transfer case (i f
equi pped).
(16) Fi l l the crankcase wi th new engi ne oi l .
Fig. 74 Aligning Seal Retainer with Alignment/
Installation Tool
1 - ALIGNMENT / INSTALLATION TOOL
2 - SEAL RETAINER
Fig. 75 Installing Seal Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
Fig. 76 Trimming Excess Gasket Material
1 - GASKET
CRANKSHAFT REAR OIL SEAL RETAINER (Continued)
SOLID LIFTERS/TAPPETS
REMOVAL
NOTE: This procedure requires use of Miller Tool
8502 Tappet Replacement Kit.
(1) Remove camshaft (Refer to 9 - ENGI NE/EN-
GI NE BLOCK/CAMSHAFT & BEARI NGS (I N
BLOCK) - REMOVAL).
(2) I nsert the trough (provi ded wi th tool ki t) the
ful l l ength of the camshaft bore (Fi g. 77). Make sure
the cap end goes i n fi rst and the open si de faces up
(towards tappets).
(3) Remove only one tappet at a time. Remove
rubber band from one cyl i nder pai r and attach tappet
dowel not bei ng removed to the next cyl i nder pai r
(Fi g. 78).
(4) Rai se dowel rod (di sengage from tappet) and
al l ow tappet to fal l i nto trough (Fi g. 79).
(5) Careful l y remove trough (do not rotate) and
tappet. I f the tappet i s not bei ng repl aced, mark i t so
i t can be i nstal l ed i n i ts ori gi nal l ocati on.
(6) Re-i nstal l trough and repeat procedure on
remai ni ng tappets.
CLEANING
Cl ean tappet wi th a sui tabl e sol vent. Ri nse i n hot
water and bl ow dry wi th a cl ean shop rag or com-
pressed ai r.
INSPECTION
(1) Vi sual l y i nspect the tappet the tappet socket,
stem, and face for excessi ve wear, cracks, or obvi ous
damage (Fi g. 80).
(2) Measure the tappet stem di ameter. Repl ace the
tappet i f i t fal l s bel ow the mi ni mum si ze (Fi g. 80).
Fig. 77 Inserting the Trough - Typical
1 - TROUGH
Fig. 78 Secure Dowel/Tappet to Adjacent Cylinder -
typical
Fig. 79 Lift Dowel Rod to Disengage from Tappet -
typical
Fig. 80 Tappet Inspection
TAPPET STEM DIAMETER
15.936 mm (0.627 in.) MIN.
15.977 mm (0.629 in.) MAX.
INSTALLATION
(1) I nsert the trough the ful l l ength of the cam-
shaft bore. Agai n, make sure the cap end goes i n fi rst
and the open si de faces up (towards tappets).
(2) Lower the tappet i nstal l ati on tool through the
push rod hol e (Fi g. 81) and i nto the trough.
(3) Retri eve the tappet i nstal l ati on tool usi ng the
hooked rod provi ded wi th the tool ki t (Fi g. 82).
(4) Lubri cate the tappet wi th cl ean engi ne oi l or
sui tabl e equi val ent and i nstal l the tappet to the
i nstal l ati on tool (Fi g. 83).
(5) Pul l the tappet up and i nto posi ti on (Fi g. 83). I f
di ffi cul ty i s experi enced getti ng the tappet to make
the turn i nto the tappet bore, wi ggl e the trough
whi l e gently pul l i ng up on the tappet.
(6) Wi th the tappet i n pl ace, rotate the trough one
hal f turn so the open si de i s down (toward crank-
shaft) (Fi g. 84).
(7) Remove the tappet i nstal l ati on tool from the
tappet.
(8) Re-i nstal l a dowel rod and secure the rod wi th
a rubber band.
(9) Rotate the trough one hal f turn and repeat the
procedure for the remai ni ng tappets.
(10) I nstal l the camshaft (Refer to 9 - ENGI NE/
BLOCK) - I NSTALLATI ON).
Fig. 81 Insert Installation Tool through Push Rod
Hole - Typical
Fig. 82 Retrieve Tappet Installation Tool through
Cam Bore - Typical
Fig. 83 Insert Tool and Pull Tappet Into Place -
Typical
Fig. 84 Rotate Trough One Half Turn (180) - Typical
SOLID LIFTERS/TAPPETS (Continued)
DESCRIPTION
PISTONS
The pi ston (Fi g. 85) i s constructed of al umi num
and i s gravi ty cast, free fl oati ng desi gn. The pi ston
i ncorporates a central l y l ocated hi gh swi rl combus-
ti on bowl , and uti l i zes a keystone styl e top com-
pressi on ri ng (Fi g. 86), and a Tapered Face
i ntermedi ate ri ng (Fi g. 86), for superi or cyl i nder wal l
scrapi ng. Pi ston cool i ng nozzl es cool the pi ston and
pi n wi th engi ne oi l suppl i ed by the crankshaft mai n
journal s. Hi gh horsepower pi stons are gal l ery cool ed
and uti l i ze J-jet pi ston cool i ng nozzl es. Pi stons are
di recti onal i n order to provi de cl earance to pi ston
cool i ng nozzl es.
CONNECTING RODS
The connecti ng rods are a spl i t angl e desi gn. They
have a pressed-i n-pl ace wri st pi n bushi ng that i s
l ubri cated by pi ston cool i ng nozzl e oi l spray.
Machined connecting rods are no longer used
in the diesel engine. Do not install machined
connecting rods into an engine that has frac-
tured split connecting rods.
Fractured spl i t connecti ng rods are fi rst manufac-
tured as a si ngl e pi ece and then fractured i nto two
pi eces. Fractured spl i t connecti ng rods can be i denti -
fi ed by a rough and i rregul ar surface at the connect-
i ng rod spl i t face. To properl y assembl e the rod cap to
the connecti ng rod, the beari ng tangs on the connect-
i ng rod and cap must be l ocated on the same si de of
the rod. The l ong end of the connecti ng rod must be
assembl ed on the i ntake or camshaft si de of the
engi ne.
Each matched fractured spl i t connecti ng rod and
cap i s an assembl y and are not i nterchangeabl e. I f a
connecti ng rod or cap i s damaged, the enti re assem-
bl y must be repl aced.
STANDARD PROCEDURE - HEAD GASKET
SELECTION
(1) Measure pi ston protrusi on for al l si x pi stons.
(2) Cal cul ate the average pi ston protrusi on. Maxi -
mum al l owabl e protrusi on i s 0.516 mm (0.020 i nch).
NOTE: There are two different head gaskets avail-
able. One gasket is for Average piston protrusion
less than 0.30 mm (0.011 inch). The other gasket is
for Average piston protrusion greater than 0.30 mm
(0.011 inch)
REMOVAL
(1) Di sconnect the battery cabl es.
(2) Remove the cyl i nder head (Refer to 9 -
(3) Remove the oi l pan and sucti on tube (Refer to 9
- ENGI NE/LUBRI CATI ON/OI L PAN - REMOVAL).
(4) Remove bol ts and the bl ock sti ffener.
(5) Usi ng Mi l l er Tool 7471-B crankshaft barri ng
tool , rotate the crankshaft so al l of the pi stons are
bel ow TDC.
(6) Before removi ng the pi ston(s) from the bore(s):
(a) Remove any carbon ri dge formati ons or
deposi ts at the top of the bore wi th a dul l scraper
or soft wi re brush.
(b) I f cyl i nder bore wear ri dges are found, use a
ri dge reamer to cut the ri dge from the bore. DO
NOT remove more metal than necessary to remove
the ri dge.
(7) Remove the J-jet cool i ng nozzl es, i f equi pped.
Fig. 85 Piston - Typical
Fig. 86 Piston Ring Identification
NOTE: If cylinders have ridges, the cylinders are
oversize and will more than likely need boring.
(8) Usi ng a hammer and steel stamp, stamp the
cyl i nder number i n the top of each pi ston. The front
of the pi ston i s i denti fi ed by a stampi ng on the top of
the pi ston. DO NOT stamp i n the outsi de 5 mm (.197
i n.) of the pi ston di ameter. DO NOT stamp over the
pi ston pi n.
(9) Mark the connecti ng rod and cap wi th the cor-
respondi ng cyl i nder numbers.
(10) Remove the connecti ng rod bol ts and rod caps.
Use care so the cyl i nder bores and connecti ng rods
are not damaged.
(11) Use a hammer handl e or si mi l ar object to
push the pi ston and connecti ng rod through the cyl -
i nder bore.
(12) Store the pi ston/rod assembl i es i n a rack.
CLEANING PISTON AND CONNECTING ROD
CAUTION: DO NOT use bead blast to clean the pis-
tons. DO NOT clean the pistons and rods in an acid
tank.
PISTON
Cl ean the pi stons and pi ns i n a sui tabl e sol vent,
ri nse i n hot water and bl ow dry wi th compressed ai r.
Soaki ng the pi stons over ni ght wi l l l oosen most of the
carbon bui l d up. De-carbon the ri ng grooves wi th a
broken pi ston ri ng and agai n cl ean the pi stons i n sol -
vent. Ri nse i n hot water and bl ow dry wi th com-
pressed ai r.
CONNECTING ROD
Cl ean the connecti ng rods i n a sui tabl e sol vent,
ri nse i n hot water and bl ow dry wi th compressed ai r.
INSPECTION
INSPECTION - PISTONS
I nspect the pi stons for damage and excessi ve wear.
Check top of the pi ston, ri ng grooves, ski rt and pi n
bore. Measure the pi ston ski rt di ameter. I f the pi ston
i s out of l i mi ts, repl ace the pi ston.
PISTON SKIRT DIAMETER (MIN.)
101.775 mm (4.006 in. )
The upper groove onl y needs to be i nspected for
damage. Use a new pi ston ri ng to measure the cl ear-
ance i n the i ntermedi ate ri ng groove (Fi g. 87). Mi ni -
mum cl earance i s 0.045 mm (0.0018 i nch), maxi mum
cl earance i s 0.095 mm (.0037 i nch). I f the cl earance
of the i ntermedi ate ri ng exceeds speci fi cati ons,
repl ace the pi ston.
Use a new oi l ri ng to measure the cl earance i n the
oi l groove (Fi g. 87). Mi ni mum cl earance i s 0.040 mm
(0.0016 i nch), maxi mum cl earance i s 0.085 mm
(.0033 i nch). I f the cl earance exceeds speci fi cati ons,
Measure the pi n bore (Fi g. 88). The maxi mum
di ameter i s 40.012 mm (1.5753 i nch), Mi ni mum i s
40.006 mm (1.575 i nch). I f the bore i s over l i mi ts,
Fig. 87 Intermediate and Oil Ring Clearances
1 - FEELER GAUGE
2 - RING
3 - PISTON
Fig. 88 Piston Pin Bore
1 - PISTON
2 - PIN BORE
I nspect the pi ston pi n for ni cks, gouges and exces-
si ve wear. Measure the pi n di ameter (Fi g. 89). The
mi ni mum di ameter i s 39.990 mm (1.5744 i nch), max-
i mum 40.003 mm (1.5749 i nch). I f the di ameter i s out
of l i mi ts, repl ace the pi n.
INSPECTION CONNECTING ROD
I nspect the connecti ng rod for damage and wear.
The I -Beam secti on of the connecti ng rod cannot have
dents or other damage. Damage to thi s part can
cause stress ri sers whi ch wi l l progress to breakage.
Measure the connecti ng rod pi n bore (Fi g. 90). The
maxi mum di ameter i s 40.042 mm (1.5765 i nch), mi n-
i mum di ameter i s 40.019 mm (1.5756 i nch). I f out of
l i mi ts, repl ace the connecti ng rod.
INSTALLATION
(1) Lubri cate the cyl i nder bores wi th cl ean engi ne
oi l .
(2) Generousl y l ubri cate the ri ngs and pi ston
ski rts wi th cl ean engi ne oi l .
(3) Ori entate the ri ngs on the pi ston (Refer to 9 -
ENGI NE/ENGI NE BLOCK/PI STON RI NGS - STAN-
DARD PROCEDURE).
(4) Compress the ri ngs usi ng a pi ston ri ng com-
pressor tool (Fi g. 91). I f usi ng a strap-type ri ng com-
pressor, make sure the i nsi de end of the strap does
not hook on a ri ng gap and break the ri ng.
(5) Bar the crankshaft so the rod journal for the
pi ston to be i nstal l ed i s at BDC (Bottom Dead Cen-
ter) - (Fi g. 92).
(6) Make sure the front of the pi ston i s ori ented
properl y accordi ng to the marki ng on the top of the
pi ston and the connecti ng rod i s ori ented properl y.
(7) Posi ti on the pi ston and rod assembl y i nto the
cyl i nder bore wi th the front of the pi ston ori ented
properl y accordi ng to the stampi ng i n the top of the
pi ston. Use care when you i nstal l the pi ston and con-
necti ng rod so the cyl i nder bore i s not damaged. The
l ong si de of the connecti ng rod must be i nstal l ed on
the i ntake si de of the engi ne.
(8) Push the pi ston i nto the bore unti l the top of
the pi ston i s approxi matel y 50 mm (2 i nch) bel ow the
top of the bl ock. Careful l y pul l the connecti ng rod
onto the crankshaft journal .
(9) Use cl ean engi ne oi l to l ubri cate the threads
and under the heads of the connecti ng rod bol ts.
Fig. 89 Piston Pin Diameter
1 - PISTON PIN
Fig. 90 Connecting Rod Pin Bore
1 - CONNECTING ROD
Fig. 91 Piston Ring Compressor Tool
1 - PISTON RING COMPRESSOR TOOL
Fig. 92 Piston/Rod Assembly at BDC
(10) For fractured/split type connecting rods,
the l ong end of the rod must be i nstal l ed towards the
i ntake si de of the engi ne.
(a) The connecti ng rod spl i t/face must face
toward the same si de as the pi ston notch feature
on the ski rt. The spl i t face wi l l face toward the
exhaust si de of the engi ne i f properl y i nstal l ed.
(11) I nstal l the rod cap and bol ts to the connecti ng
rod. Ti ghten the connecti ng rod bol ts evenl y i n 3
steps.
Rotate 60 cl ockwi se.
(12) The crankshaft must rotate freel y. Check for
freedom of rotati on as the caps are i nstal l ed. I f the
crankshaft does not rotate freel y, check the i nstal l a-
ti on of the rod beari ng and the beari ng si ze.
(13) Measure the si de cl earance between the con-
necti ng rod and the crankshaft. DO NOT measure
the cl earance between the cap and crankshaft.
(14) I nstal l J-jet pi ston cool i ng nozzl es i f equi pped.
(15) I nstal l bl ock sti ffener. Torque to 43 Nm (32 ft.
l bs.).
(16) I nstal l the sucti on tube and oi l pan (Refer to 9
TI ON).
(17) I nstal l the cyl i nder head onto the engi ne
(Refer to 9 - ENGI NE/CYLI NDER HEAD - I NSTAL-
LATI ON).
(18) I nstal l a new fi l ter and fi l l the crankcase wi th
new engi ne oi l . Prefill the filter with clean oil.
(19) Connect the battery negati ve cabl es and start
engi ne.
PISTON RINGS
FITTING
(1) Determi ne the pi ston di ameter and obtai n the
appropri ate ri ng set. The pi ston ri ngs can be i denti -
fi ed as shown i n (Fi g. 93).
(2) Posi ti on each ri ng i n the cyl i nder and use a
pi ston to square i t wi th the bore at a depth of 89.0
mm (3.5 i nch) - (Fi g. 94).
(3) Use a feel er gauge to measure the pi ston ri ng
gap.
PISTON RING GAP CHART
TOP RING 0.26 - 0.36 mm
(0.010 - 0.014
in.)
INTERMEDIATE
RING
0.85-1.15 mm
(0.033 - 0.045
in.)
OIL CONTROL
RING
0.25-0.55 mm
(0.010 - 0.022
in.)
Fig. 93 Piston Ring Identification
Fig. 94 Position of Ring in Cylinder Bore
1 - PISTON
2 - CYLINDER BORE
3 - DEPTH
(4) The top surface of al l of the ri ngs are i denti fi ed
wi th the word TOP or the suppl i ers MARK. Assem-
bl e the ri ngs wi th the word TOP or the suppl i ers
MARK up.
(5) Posi ti on the oi l ri ng expander i n the oi l control
ri ng groove (bottom groove).
(6) I nstal l the oi l control ri ng wi th the end gap
OPPOSI TE the ends on the expander (Fi g. 95).
(7) I nstal l the i ntermedi ate pi ston ri ng i n the sec-
ond groove.
(8) I nstal l the top pi ston ri ng i n the top groove
(Fi g. 96).
(9) Posi ti on the ri ngs as shown i n (Fi g. 97).
VIBRATION DAMPER
REMOVAL
REMOVAL).
(2) Remove the four (4) damper to crankshaft bol ts
and remove damper and speed i ndi cator ri ng.
INSPECTION
(1) I nspect the damper hub for cracks and repl ace
i f any are found.
(2) I nspect the i ndex l i nes on the damper hub and
the i nerti a member (Fi g. 98). I f the l i nes are more
than 1.59 mm (1/16 i n.) out of al i gnment, repl ace the
damper.
(3) I nspect the rubber member for deteri orati on or
mi ssi ng segments (Fi g. 99).
Fig. 95 Oil Control Ring/Expander Location in
Groove
1 - OIL CONTROL RING
2 - EXPANDER
3 - PISTON
Fig. 96 Piston Ring Installation Tool
1 - PISTON RING INSTALLATION TOOL
Fig. 97 Piston Ring Orientation
1 - TOP RING
2 - INTERMEDIATE RING
3 - OIL CONTROL RING
Fig. 98 Inspect Index Lines for Alignment
1 - INDEX LINES
2 - HUB
3 - INERTIA MEMBER
INSTALLATION
(1) I nstal l speed i ndi cator ri ng.
NOTE: The speed indicator ring is located over a
dowel pin.
(2) I nstal l the crankshaft damper and bol ts.
Ti ghten bol ts to 40 Nm (30 ft. l bs.) torque, pl us an
addi ti onal 60.
NOTE: The damper must be installed so the hole is
located over the dowel pin.
I NSTALLATI ON).
FRONT MOUNT
REMOVAL
(2) Remove the vi scous fan/dri ve assembl y (Refer
REMOVAL).
(4) I nstal l engi ne support fi xture tool # 8534 and
steel bracket tool #8534A
(5) Loosen the thru-bol t and nut.
(6) Li ft the engi ne SLI GHTLY and remove the
i nsul ator to bl ock bol ts (Fi g. 101) (Fi g. 100).
(7) Remove the i nsul ator from the vehi cl e.
Fig. 99 Inspect Damper Rubber Member
Fig. 100 RH Insulator
1 - Mount
2 - Insulator
3 - Bolt
Fig. 101 LH Insulator
1 - Bolt
2 - Insulator
3 - Mount
INSTALLATION
(1) Wi th engi ne rai sed SLI GHTLY, posi ti on the
i nsul ator to the mount (Fi g. 102) (Fi g. 103). I nstal l
the bol ts and torque to speci fi cati on.
(2) Lower the engi ne usi ng tool #8534, whi l e gui d-
i ng the mount and thru-bol t i nto the frame mounted
support cushi on brackets.
(3) I nstal l the thru-bol t nut and ti ghten the nut to
(4) Remove the engi ne support fi xture tool #8534.
(6) I nstal l the vi scous fan/dri ve assembl y (Refer to
7 - COOLI NG/ENGI NE/RADI ATOR FAN - I NSTAL-
LATI ON).
Fig. 102 LH Insulator
1 - Bolt
2 - Insulator
3 - Mount
Fig. 103 RH Insulator
1 - Mount
2 - Insulator
3 - Bolt
REAR MOUNT
REMOVAL
(2) Posi ti on a transmi ssi on jack i n pl ace.
(3) Remove support cushi on stud nuts (Fi g. 104).
(4) Rai se rear of transmi ssi on and engi ne
SLI GHTLY.
(5) Remove the bol ts hol di ng the support cushi on
to the transmi ssi on support bracket. Remove the sup-
port cushi on.
(6) I f necessary, remove the bol ts hol di ng the
transmi ssi on support bracket to the transmi ssi on.
INSTALLATION
(1) I f removed, posi ti on the transmi ssi on support
bracket to the transmi ssi on. I nstal l new attachi ng
bol ts and ti ghten to 102 Nm (75 ft. l bs.) torque.
(2) Posi ti on support cushi on to transmi ssi on sup-
port bracket. I nstal l stud nuts and ti ghten to 47 Nm
(3) Usi ng the transmi ssi on jack, l ower the trans-
mi ssi on and support cushi on onto the crossmember
(Fi g. 104).
(4) I nstal l the support cushi on bol ts and ti ghten to
(5) Remove the transmi ssi on jack.
Fig. 104 Engine Rear Support Cushion Assembly
LUBRICATION
DESCRIPTION
NOTE: Refer to (Fig. 105) and (Fig. 106) for circuit
illustrations.
A gear dri ven gerotor type oi l pump i s mounted
behi nd the front gear cover i n the l ower ri ght porti on
on the engi ne.
OPERATION
A gerotor styl e oi l pump draws oi l from the crank-
case through the sucti on tube and del i vers i t through
the bl ock where i t enters the oi l cool er cover and
pressure regul ator val ve. When oi l pressure exceeds
517 kPa (75 PSI ), the val ve opens exposi ng the dump
port, whi ch routes excess oi l back to the oi l pump.
At the same ti me, oi l i s di rected to a cast i n pas-
sage i n the oi l cool er cover, l eadi ng to the oi l cool er
el ement. As the oi l travel s through the el ement
pl ates, i t i s cool ed by engi ne cool ant travel i ng past
the outsi de of the pl ates. I t i s then routed to the oi l
fi l ter head and through a ful l fl ow oi l fi l ter. I f a
pl ugged fi l ter i s encountered, the fi l ter by-pass val ve
opens, al l owi ng unfi l tered oi l to l ubri cate the engi ne.
Thi s condi ti on can be avoi ded by frequent oi l and fi l -
ter changes, per the mai ntenance schedul es found i n
the owners manual . The by-pass val ve i s cal i brated
to open when i t sees a pressure drop of more than
345 kPa (50 psi ) across the oi l fi l ter.
The oi l fi l ter head then di vi des the oi l between the
engi ne and the turbocharger. The turbocharger
recei ves fi l tered, cool ed and pressuri zed oi l through a
suppl y l i ne from the fi l ter head. The oi l l ubri cates
the turbocharger and returns to the pan by way of a
drai n tube connecti ng the bottom of the turbocharger
to a pressed i n tube i n the cyl i nder bl ock.
Oi l i s then carri ed across the bl ock to an angl e
dri l l i ng whi ch i ntersects the mai n oi l ri fl e. The mai n
oi l ri fl e runs the l ength of the bl ock and del i vers oi l
to the crankshaft mai n journal s and val ve trai n. Oi l
travel s to the crankshaft through a seri es of transfer
dri l l i ngs (one for each mai n beari ng) and l ubri cates a
groove i n the mai n beari ng upper shel l . From there
another dri l l i ng feeds the camshaft mai n journal s.
The saddl e jet pi ston cool i ng nozzl es are al so sup-
pl i ed by the mai n beari ng upper shel l . J-jet pi ston
cool i ng nozzl es are suppl i ed by a separate oi l ri fl e.
Pl ugs are used i n pl ace of saddl e jets when J-jets are
used. J-jet hol e l ocati ons are pl ugged when saddl e jet
cool i ng nozzl es are used. Crankshaft i nternal cross-
dri l l i ngs suppl y oi l to the connecti ng rod journal s.
Another seri es of transfer dri l l i ngs i ntersecti ng the
mai n oi l ri fl e suppl y the val ve trai n components. Oi l
travel s up the dri l l i ng, through a hol e i n the head
gasket, and through a dri l l i ng i n the cyl i nder head
(one per cyl i nder), where i t enters the rocker arm
pedestal and i s di vi ded between the i ntake and
exhaust rocker arm. Oi l travel s up and around the
rocker arm mounti ng bol t, and l ubri cates the rocker
shaft by cross dri l l i ngs that i ntersect the mounti ng
bol t hol e. Grooves at both ends of the rocker shaft
suppl y oi l through the rocker arm where the oi l trav-
el s to the push rod and socket bal l s (Fi g. 105) and
(Fi g. 106).
DIAGNOSIS AND TESTING ENGINE OIL
PRESSURE
(1) Remove the 1/8 npt pl ug from the top of the oi l
fi l ter housi ng.
(2) I nstal l Oi l Pressure Li ne and Gauge Tool
C-3292 wi th a sui tabl e adapter.
(3) Start engi ne and warm to operati ng tempera-
ture.
(4) Record engi ne oi l pressure and compare wi th
engi ne oi l pressure chart.
CAUTION: If engine oil pressure is zero at idle, DO
NOT RUN THE ENGINE.
Engine Oil Pressure (MIN)
At Idle 68.9 kPa (10 psi)
At 2500 rpm 206.9 kPa (30 psi)
I f mi ni mum engi ne oi l pressure i s bel ow these
ranges, (Refer to 9 - ENGI NE - DI AGNOSI S AND
TESTI NG).
(5) Remove oi l pressure gauge and i nstal l the 1/8
npt pl ug.
Fig. 105 Lubrication System Circulation
1 - TO FILTER
2 - FROM FILTER
3 - TO MAIN OIL RIFLE
4 - CLOSED
5 - OPEN
6 - TO COOLER
7 - FROM PUMP
8 - CLOSED
9 - OPEN
10 - OIL DRAINS BACK TO THE PUMP
11 - OIL DRAIN
12 - OIL SUPPLY
Fig. 106 Lubrication System CirculationContd
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL LEVEL
oil foaming and oil pressure loss can result.
The acceptabl e oi l l evel i s i n the SAFE RANGE on
the engi ne oi l di psti ck (Fi g. 107).
(2) Wi th engi ne OFF, al l ow approxi matel y 15 mi n-
(4) Repl ace di psti ck and veri fy i t i s seated i n the
tube.
(6) Add oi l onl y i f l evel i s bel ow the SAFE RANGE
area on the di psti ck.
(7) Repl ace di psti ck
SERVICE
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
NOTE: Change engine oil and filter at intervals
specified in the owners manual.
(1) Operate the engi ne unti l the water tempera-
ture reaches 60C (140F). Shut the engi ne off.
(2) Use a contai ner that can hol d at l east 14 l i ters
(15 quarts) to hol d the used oi l . Remove the oi l drai n
pl ug and drai n the used engi ne oi l i nto the contai ner.
(3) Al ways check the condi ti on of the used oi l . Thi s
can gi ve you an i ndi cati on of engi ne probl ems that
mi ght exi st.
Thi n, bl ack oi l i ndi cates fuel di l uti on.
Mi l ky di scol orati on i ndi cates cool ant di l uti on.
(4) Cl ean the area around the oi l fi l ter head.
Remove the fi l ter (Refer to 9 - ENGI NE/LUBRI CA-
TI ON/OI L FI LTER - REMOVAL).
(5) I nstal l new oi l fi l ter (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L FI LTER - I NSTALLATI ON).
(6) Cl ean the drai n pl ug and the seal i ng surface of
the pan. Check the condi ti on of the threads and seal -
i ng surface on the oi l pan and drai n pl ug.
(8) Use onl y Hi gh-Qual i ty Mul ti -Vi scosi ty l ubri cat-
i ng oi l i n the Cummi ns Turbo Di esel engi ne. Choose
the correct oi l for the operati ng condi ti ons (Refer to
LUBRI CATI ON & MAI NTENANCE/FLUI D TYPES -
DESCRI PTI ON).
(9) Fi l l the engi ne wi th the correct grade of new oi l
(Refer to LUBRI CATI ON & MAI NTENANCE/FLUI D
CAPACI TI ES - SPECI FI CATI ONS).
(10) Start the engi ne and operate i t at i dl e for sev-
eral mi nutes. Check for l eaks at the fi l ter and drai n
pl ug.
(11) Stop engi ne. Wai t 15 mi nutes to al l ow the oi l
to drai n back to the pan and check the l evel agai n.
Care shoul d be exerci sed when di sposi ng of used
engi ne oi l after i t has been drai ned from a vehi cl es
engi ne.
1 - ROCKER ARM
2 - ROCKER SHAFT
3 - PEDESTAL
4 - FROM MAIN OIL RIFLE
5 - TO VALVE TRAIN
6 - MAIN OIL RIFLE
7 - FROM MAIN OIL RIFLE
8 - TO CAMSHAFT
9 - TO PISTON COOLING NOZZLE
10 - FROM OIL COOLER
11 - CRANKSHAFT MAIN JOURNAL
12 - ROD JOURNAL
13 - TO ROD BEARING
14 - MAIN OIL RIFLE
Fig. 107 Oil Level Indicator (Dipstick)
1 - ADD OIL MARK
2 - O-RING
3 - SAFE RANGE
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION
Cl ean the seal i ng surfaces.
Appl y 483 kPa (70 psi ) ai r pressure to the el ement
to check for l eaks. I f the el ement l eaks, repl ace the
el ement.
OIL FILTER
REMOVAL
(1) Cl ean the area around the oi l fi l ter head.
Remove the fi l ter from bel ow usi ng a cap-styl e fi l ter
wrench.
(2) Cl ean the gasket surface of the fi l ter head. The
fi l ter cani ster O-Ri ng seal can sti ck on the fi l ter
head. Make sure i t i s removed.
INSTALLATION
(1) Fi l l the oi l fi l ter el ement wi th cl ean oi l before
i nstal l ati on. Use the same type oi l that wi l l be used
i n the engi ne.
(2) Appl y a l i ght fi l m of l ubri cati ng oi l to the seal -
i ng surface before i nstal l i ng the fi l ter.
CAUTION: Mechanical over-tightening may distort
the threads or damage the filter element seal.
(3) I nstal l the fi l ter unti l i t contacts the seal i ng
surface of the oi l fi l ter adapter. Ti ghten fi l ter an
addi ti onal
1
2 turn.
OIL PAN
REMOVAL
(2) I nstal l engi ne support fi xture #8534.
(4) Di sconnect starter cabl es from starter motor.
equi pped).
(6) Remove fl ywheel or fl expl ate.
and transmi ssi on adapter pl ate assembl y.
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
(8) Drai n the engi ne oi l (Refer to 9 - ENGI NE/LU-
BRI CATI ON/OI L - STANDARD PROCEDURE).
(9) I nstal l the oi l pan drai n pl ug i f seal i ng surface
i s not damaged and ti ghten to 50 Nm (37 ft. l bs.)
torque.
(10) Remove oi l pan bol ts, break the pan to bl ock
seal , and l ower pan sl i ghtl y and remove oi l sucti on
tube fasteners.
(11) Remove oi l pan and sucti on tube.
CLEANING
Remove al l gasket materi al from the oi l pan and
cyl i nder bl ock seal i ng surfaces. Extra effort may be
requi red around T-joi nt areas. Cl ean oi l pan and
fl ush sucti on tube wi th a sui tabl e sol vent.
INSPECTION
I nspect the oi l pan, sucti on tube, and tube braces
for cracks and damage. Repl ace any defecti ve compo-
nent. I nspect the oi l drai n pl ug and drai n hol e
threads. I nspect the oi l pan seal i ng surface for
strai ghtness. Repai r any mi nor i mperfecti ons wi th a
bal l -peen hammer. Do not attempt to repai r an oi l
pan by wel di ng.
INSTALLATION
(1) Fi l l the T-joi nt between the pan rai l /gear hous-
i ng and pan rai l /rear seal retai ner wi th seal ant. Use
Mopar Si l i cone Rubber Adhesi ve Seal ant or equi va-
l ent.
(2) Pl ace sucti on tube i n oi l pan and gui de them
i nto pl ace. Usi ng a new tube to bl ock gasket, i nstal l
and ti ghten the sucti on tube bol ts by hand. Starti ng
wi th the oi l pump i nl et bol ts, ti ghten the bol ts to 24
Nm (18 ft. l bs.) torque. Ti ghten the remai ni ng tube
brace bol ts to 43 Nm (32 ft. l bs.) torque.
(3) Starti ng i n the center and worki ng outward,
ti ghten the oi l pan bol ts to 28 Nm (21 ft. l bs.)
torque.
(4) I nstal l the fl ywheel housi ng assembl y wi th the
starter motor attached and ti ghten bol ts to 77 Nm
(5) Connect starter motor cabl es.
(6) I nstal l the fl ywheel or fl expl ate. Torque to 137
Nm (101 ft. l bs.).
(7) I nstal l transmi ssi on and transfer case (i f
equi pped).
(9) Remove the engi ne support fi xture #8534.
(10) I nstal l battery negati ve cabl es.
(11) Fi l l the crankcase wi th new engi ne oi l .
(12) Start engi ne and check for l eaks. Stop engi ne,
check oi l l evel , and adjust, i f necessary.
OIL PRESSURE RELIEF VALVE
REMOVAL
(2) Remove the threaded pl ug, spri ng and pl unger
(Fi g. 108). I nsert a fi nger or a seal pi ck to l i ft the
pl unger from the bore.
NOTE: If the plunger is stuck in the bore, it will be
necessary to remove the filter head.
CLEANING
(1) Cl ean the regul ator spri ng and pl unger wi th a
sui tabl e sol vent and bl ow dry wi th compressed ai r. I f
the pl unger bore requi res cl eani ng, i t i s necessary to
remove the oi l fi l ter head to avoi d getti ng debri s i nto
the engi ne.
INSPECTION
I nspect the pl unger and pl unger bore for cracks
and excessi ve wear. Pol i shed surfaces are acceptabl e.
Veri fy that the pl unger moves freel y i n the bore.
Check the spri ng for hei ght and l oad l i mi tati ons
(Fi g. 109). Repl ace the spri ng i f out of l i mi ts shown
i n the fi gure.
INSTALLATION
(1) I nstal l the pl unger, spri ng, and pl ug as shown
i n (Fi g. 108). Ti ghten the pl ug to 80 Nm (59 ft. l bs.)
torque.
(3) Start the engi ne and veri fy that i t has oi l pres-
sure.
OIL PRESSURE SWITCH
REMOVAL
(2) Di sconnect the oi l pressure swi tch connector.
(3) Usi ng a sui tabl e socket, remove the oi l pres-
sure swi tch from the bl ock (counter-cl ockwi se).
INSTALLATION
(1) I f the swi tch i s not bei ng repl aced, repl ace and
l ubri cate the o-ri ng.
(2) I nstal l the oi l pressure swi tch and ti ghten to
(3) Connect oi l pressure swi tch connector.
(5) Start engi ne and check for oi l l eaks at the
swi tch.
OIL PUMP
REMOVAL
(2) Remove fan/dri ve assembl y (Refer to 7 - COOL-
REMOVAL).
(4) Remove the fan support/hub assembl y.
REMOVAL) and speed i ndi cator ri ng.
(8) Remove the gear housi ng cover (Refer to 9 -
- REMOVAL).
Fig. 108 Oil Pressure Regulator
1 - OIL FILTER
2 - PLUG
3 - GASKET
4 - SPRING
5 - VALVE
Fig. 109 Oil Pressure Regulator Spring Check
(9) Remove the four mounti ng bol ts and pul l the
oi l pump from the bore i n the cyl i nder bl ock (Fi g.
110).
CLEANING
Cl ean al l parts i n sol vent and dry wi th compressed
ai r. Cl ean the ol d seal er resi due from the back of the
gear housi ng cover and front of the gear housi ng.
INSPECTION
Disassemble and inspect the oil pump as fol-
lows:
(1) Vi sual l y i nspect the l ube pump gears for chi ps,
cracks or excessi ve wear.
(2) Remove the back pl ate (Fi g. 111).
(3) Mark TOP on the gerotor pl anetary usi ng a fel t
ti p pen (Fi g. 111).
(4) Remove the gerotor pl anetary (Fi g. 111).
I nspect for excessi ve wear or damage. I nspect the
pump housi ng and gerotor dri ve for damaged and
excessi ve wear.
(5) I nstal l the gerotor pl anetary i n the ori gi nal
posi ti on.
(6) Measure the ti p cl earance (Fi g. 112). Maxi mum
cl earance i s 0.1778 mm (0.007 i nch). I f the oi l pump
i s out of l i mi ts, repl ace the pump.
(7) Measure the cl earance of the gerotor dri ve/
gerotor pl anetary to port pl ate (Fi g. 113). Maxi mum
cl earance i s 0.127 mm (0.005 i nch). I f the oi l pump i s
out of l i mi ts, repl ace the pump.
Fig. 110 Oil Pump Removal/Installation
1 - OIL PUMP
2 - BOLT (4)
Fig. 111 Gerotor Planetary and Gerotor
1 - OIL PUMP BACK PLATE
2 - GEROTOR
3 - GEROTOR PLANETARY
Fig. 112 Measuring Tip Clearance
1 - FEELER GAUGE
Fig. 113 Measuring Gerotor to Port Plate Clearance
1 - PORT PLATE
2 - GEROTOR
(8) Measure the cl earance of the gerotor pl anetary
to the body bore (Fi g. 114). Maxi mum cl earance i s
0.381 mm (0.015 i nch). I f the oi l pump i s out of l i m-
i ts, repl ace the pump.
(9) Measure the gears backl ash (Fi g. 115). The l i m-
i ts of a used pump i s 0.15- 0.25 mm (0.006-0.010
i nch). I f the backl ash i s out of l i mi ts, repl ace the oi l
pump.
(10) I nstal l the back pl ate.
INSTALLATION
(1) Lubri cate the pump wi th cl ean engi ne oi l . Fi l l -
i ng the pump wi th cl ean engi ne oi l duri ng i nstal l a-
ti on wi l l hel p to pri me the pump at engi ne start up.
(2) I nstal l the pump (Fi g. 110). Veri fy the i dl er
gear pi n i s i nstal l ed i n the l ocati ng bore i n the cyl i n-
der bl ock. Ti ghten the oi l pump mounti ng bol ts i n
two steps, i n the sequence shown i n (Fi g. 116).
Step 1Ti ghten to 8 Nm (71 i n. l bs.) torque.
(3) The back pl ate on the pump seats agai nst the
bottom of the bore i n the cyl i nder bl ock. When the
pump i s correctl y i nstal l ed, the fl ange on the pump
wi l l not touch the cyl i nder bl ock.
(4) Measure the i dl er gear to pump dri ve gear
backl ash and the i dl er gear to crankshaft gear back-
l ash (Fi g. 117). The backl ash shoul d be 0.15- 0.25
mm (0.006-0.010 i nch). I f the backl ash i s out of l i m-
i ts, repl ace the oi l pump.
(5) I f the adjoi ni ng gear moves when you measure
the backl ash, the readi ng wi l l be i ncorrect.
si ve Seal ant or equi val ent to the gear housi ng cover
seal i ng surface.
(7) I nstal l the gear housi ng cover (Refer to 9 -
- I NSTALLATI ON).
(8) I nstal l the vi brati on damper (Refer to 9 -
I NSTALLATI ON) and speed i ndi cator ri ng.
(9) I nstal l the fan support/hub assembl y Refer to
I NSTALLATI ON)
I NSTALLATI ON).
Fig. 114 Measuring Gerotor Planetary to Body Bore
Clearance
1 - BODY BORE
2 - GEROTOR PLANETARY
Fig. 115 Measure Gear Backlash
1 - OIL PUMP DRIVE GEAR
2 - IDLER GEAR
3 - BACKLASH
4 - BACKLASH
Fig. 116 Oil Pump Mounting Bolt Torque Sequence
Fig. 117 Idler Gear to Pump Drive Gear and
Crankshaft Gear Backlash
(13) I nstal l the cool i ng fan (Refer to 7 - COOLI NG/
INTAKE MANIFOLD
REMOVAL
(2) Remove the charge ai r cool er outl et tube from
the ai r i nl et housi ng (Fi g. 118).
(3) Remove the engi ne oi l di psti ck tube mounti ng
bol t (Fi g. 118).
(4) Remove di psti ck support at fuel fi l ter housi ng.
Posi ti on di psti ck tube to the si de.
(5) Di sconnect the ai r gri d heater power cabl es at
the cabl e mounti ng studs.
(6) Di sconnect the ground strap at the i ntake
cover.
(7) Remove the engi ne wi ri ng harness connecti ons
at the ai r i nl et housi ng el bow.
(8) Remove the four (4) ai r i nl et housi ng mounti ng
bol ts and remove the housi ng from top of the heater
el ements.
(9) Remove the i ntake ai r gri d heater from the
mani fol d (Fi g. 119).
(10) Remove the hi gh pressure fuel l i nes and fuel
rai l (Refer to 14 - FUEL SYSTEM/FUEL DELI VERY/
FUEL LI NES - REMOVAL).
(11) Remove APPS bracket from cyl i nder head to
gai n access to front i ntake mani fol d cover bol ts.
(12) Di sconnect mani fol d ai r temperature/pressure
sensor connector.
(13) Remove the remai ni ng i ntake mani fol d cover-
to-cyl i nder head bol ts.
(14) Remove the i ntake mani fol d cover and gasket.
Keep the gasket materi al and any other materi al out
of the ai r i ntake.
(15) Cl ean the i ntake mani fol d cover and cyl i nder
head seal i ng surface.
CLEANING
Cl ean mani fol d i n sol vent and bl ow dry wi th com-
pressed ai r.
Cl ean cyl i nder bl ock gasket surfaces usi ng a sui t-
abl e sol vent.
The pl enum pan rai l must be cl ean and dry (free of
al l forei gn materi al ).
INSPECTION
I nspect mani fol d for cracks.
I nspect mati ng surfaces of mani fol d for fl atness
wi th a strai ghtedge.
Fig. 118 Charge Air Cooler Air Tube
1 - FRONT WIRING CLIP
2 - GROUND CABLE
3 - TUBE BOLT
4 - ENGINE OIL DIPSTICK TUBE
5 - CLAMPS
6 - AIR TUBE (INT. MAN.-TO-INTERCOOLER)
7 - RUBBER HOSE
8 - AIR INTAKE HOUSING
9 - CABLE BRACKET HOUSING
Fig. 119 Intake Air Grid Heater
1 - INTAKE AIR GRID HEATER
2 - GASKET
INSTALLATION
(1) Usi ng a new gasket, i nstal l the i ntake mani fol d
cover.
(2) I nstal l the cover-to-cyl i nder head bol ts that do
not hol d down the fuel rai l . Ti ghten the bol ts to 24
(3) I nstal l the hi gh pressure rai l and fuel l i nes
FUEL LI NES - I NSTALLATI ON).
(4) Usi ng two (2) new gaskets, i nstal l the i ntake
ai r gri d heater and ai r i nl et housi ng. Posi ti on the
ground cabl e and i nstal l and ti ghten the bol ts to 24
(5) Connect the mani fol d ai r temperature/pressure
sensor connector.
(6) I nstal l and ti ghten the ai r i ntake heater power
suppl y nuts to 14 Nm (120 i n. l bs.) torque.
(7) I nstal l the APPS bracket. Torque fasteners to
43 Nm (32ft l bs.) torque.
(8) I nstal l oi l di psti ck tube support at fuel fi l ter
housi ng.
(9) I nstal l the engi ne oi l di psti ck tube and mount-
i ng bol t.
(10) Posi ti on the charge ai r cool er outl et tube onto
the ai r i nl et housi ng. Ti ghten the cl amps to 11 Nm
(11) Attach the engi ne wi re harness to the ai r i nl et
housi ng at two l ocati ons.
(12) Pri me the fuel system. Refer to the fuel pri m-
i ng procedure i n Group 14, Fuel System.
EXHAUST MANIFOLD
REMOVAL
(3) Di sconnect the exhaust pi pe from the turbo-
charger el bow.
(4) Di sconnect oi l drai n tube from turbocharger.
(6) Di sconnect the turbocharger ai r i nl et hose.
(8) Di sconnect the turbocharger oi l suppl y l i ne.
(9) Di sconnect the charge ai r cool er i nl et pi pe from
the turbocharger.
(10) Remove the turbocharger and gasket from the
exhaust mani fol d.
(11) Remove the cab heater return pi pe nuts from
the exhaust mani fol d stud. Posi ti on the tube out of
the way.
(13) Remove exhaust mani fol d bol t l ockpl ates.
(14) Remove the exhaust mani fol d-to-cyl i nder head
bol ts and spacers (Fi g. 120).
(15) Remove the exhaust mani fol d and gaskets
(Fi g. 120).
CLEANING
Cl ean the cyl i nder head and exhaust mani fol d seal -
i ng surfaces wi th a sui tabl e scraper. Use a Scotch-
Bri te pad or equi val ent.
INSPECTION
I nspect the exhaust mani fol d for cracks. Measure
the exhaust mani fol d for fl atness. Pl ace a rul er over
al l of the exhaust ports and i nsert a feel er gauge
between the port fl ange and the rul er. Maxi mum
devi ati on from fl at i s 0.20 mm (.008 i nch).
INSTALLATION
(1) Usi ng new gaskets, i nstal l the exhaust mani -
fol d and gaskets. I nstal l the bol ts and spacers and
ti ghten the bol ts i n the sequence shown i n to 43 Nm
(2) Retorque the four center bol ts.
Fig. 120 Exhaust Manifold and Gaskets
1 - RETAINING STRAP
2 - BOLT (7)
3 - SPACER
4 - MANIFOLD, EXHAUST
5 - GASKET
6 - BOLT (5)
(3) I nstal l heat shi el d and torque nuts to 15 Nm
(11 ft. l bs.).
(4) I nstal l cab heater tube.
(5) I nstal l exhaust mani fol d bol t retenti on straps.
(6) I nstal l the cab heater return hose to the man-
i fol d bol t stud. Ti ghten the nut to 24 Nm (18 ft. l bs.)
torque.
(7) I nstal l the turbocharger and a new gasket.
Appl y anti -sei ze to the studs and then ti ghten the
turbocharger mounti ng nuts to 43 Nm (32 ft. l bs.)
torque.
(8) Pre-lube the turbocharger. Pour 50 to 60 cc
(2 to 3 oz.) cl ean engi ne oi l i n the oi l suppl y l i ne fi t-
ti ng on the turbo. Rotate the turbocharger i mpel l er
by hand to di strubute the oi l thoroughl y.
(9) I nstal l and ti ghten the oi l suppl y l i ne fi tti ng
nut to 24 Nm (18 ft. l bs.) torque.
(10) Posi ti on the charge ai r cool er i nl et pi pe to the
turbocharger. Wi th the cl amp i n posi ti on, ti ghten the
cl amp nut to 11 Nm (100 i n. l bs.) torque.
(11) Posi ti on the ai r i nl et hose to the turbocharger.
Ti ghten the cl amp to 11 Nm (100 i n. l bs.) torque.
(13) I nstal l the oi l drai n tube and a new gasket to
the turbocharger. Ti ghten the drai n tube bol ts to 24
and ti ghten the bol ts to 11 Nm (100 ft. l bs.) torque.
(17) Start the engi ne to check for l eaks.
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION
(2) Remove fuel i njector from cyl i nder number
1(Refer to 14 - FUEL SYSTEM/FUEL I NJECTI ON/
FUEL I NJECTOR - REMOVAL).
(3) Usi ng Speci al Tool 7471B rotate the engi ne
unti l the TDC mark on the damper i s at 12 ocl ock.
(4) Usi ng a 8 i n.x 1/4 i n. dowel rod i nserted i nto
cyl i nder number 1, rock the crankshaft back and
forth to veri fy pi ston number 1 i s at TDC.
(5) Wi th cyl i nder number sti l l at TDC, i nspect the
keyway on the crankshaft gear for proper al i gnment
(12 ocl ock posi ti on).
(6) I f the keyway i s not at 12 ocl ock posi ti on
repl ace the crankshaft gear assembl y.
(7) I f the keyway i s at 12 ocl ock posi ti on, remove
front gear cover and veri fy ti mi ng mark al i gnment
between the camshaft gear and crankshaft gear, i f
not al i gned i nspect keyway on camshaft gear.
(8) I nspect keyway on camshaft gear for proper
al i gnment wi th the key i n the camshaft, i f al i gnment
i s off repl ace the camshaft/gear assembl y.
(9) I f ti mi ng marks al i gnment i s off and no dam-
age i s found at ei ther the crankshaft or camshaft
gear keyways, real i gn ti mi ng marks as necessary.
GEAR HOUSING
REMOVAL
DARD PROCEDURE).
(6) Di sconnect cool ant recovery bottl e hose from
radi ator fi l l er neck and l i ft bottl e off of fan shroud.
off of fan shroud.
(8) Remove l ower fan shroud fasteners. Di sconnect
fan dri ve wi re harness.
(9) Remove the upper fan shroud-to-radi ator
mounti ng bol ts.
(10) Remove vi scous fan/dri ve assembl y (Refer to 7
- COOLI NG/ENGI NE/RADI ATOR FAN - REMOVAL).
REMOVAL).
REMOVAL) and speed i ndi cator ri ng.
(16) Remove the power steeri ng pump.
(17) Remove the accessory dri ve bel t tensi oner.
care not to mar the gasket surfaces.
(19) Remove the fuel i njecti on pump (Refer to 14 -
FUEL SYSTEM/FUEL DELI VERY/FUEL I NJEC-
TI ON PUMP - REMOVAL).
(20) Di sconnect the camshaft posi ti on sensor con-
nector.
(21) Di sconnect and remove engi ne speed sensor.
BLOCK) - REMOVAL).
(23) Remove the si x front oi l pan fasteners.
(24) Remove the gear housi ng fasteners.
NOTE: Use care when removing the gear housing,
to avoid damage to the oil pan gasket, as the gas-
ket will be reused if it is not damaged.
(25) Sl i de a feel er gauge between the gear housi ng
and oi l pan gasket, to break the gasket seal .
(26) Remove the gear housi ng and gasket.
(27) Cl ean the gasket materi al from the cyl i nder
bl ock and gear housi ng.
INSTALLATION
(1) I nspect oi l pan gasket. I f torn, gasket must be
repl aced.
(2) I nstal l a new gear housi ng gasket onto cyl i nder
bl ock and tri m any excesss gasket materi al fl ush to
oi l pan rai l .
(3) I nstal l the gear housi ng. Torque bol ts to 24
Nm (18 ft. l bs.) (Fi g. 121).
(4) I f a new housi ng i s i nstal l ed, the camshaft
posi ti on sensor, and engi ne speed sensor must be
transferred to the new housi ng.
(5) Connect the camshaft posi ti on sensor connec-
tor.
(6) I nstal l and connect engi ne speed sensor.
(7) I nstal l the i njecti on pump (Refer to 14 - FUEL
SYSTEM/FUEL DELI VERY/FUEL I NJECTI ON
PUMP - I NSTALLATI ON).
(8) I nstal l the camshaft (Refer to 9 - ENGI NE/EN-
GI NE BLOCK/CAMSHAFT & BEARI NGS (I N
BLOCK) - I NSTALLATI ON). Al i gn the crankshaft
and camshaft gear marks as shown i n (Fi g. 122).
(9) I nstal l a new front crankshaft seal i nto the
gear cover.
(10) Appl y a bead of Mopar Si l i cone Rubber
Adhesi ve Seal ant or equi val ent to the gear housi ng
cover. Be sure to surround al l through hol es.
(11) Usi ng the seal pi l ot to al i gn the cover, i nstal l
the cover to the housi ng and i nstal l the bol ts.
(12) Remove the seal pi l ot. I nstal l front seal dust
shi el d.
(14) Tri m any excess gear housi ng gasket to make
i t fl ush wi th the oi l pan rai l .
(15) I nstal l the crankshaft damper and speed i ndi -
cator ri ng (Refer to 9 - ENGI NE/ENGI NE BLOCK/
VI BRATI ON DAMPER - I NSTALLATI ON). Torque
bol ts to 40 Nm (30 ft. l bs.), pl us an addi ti onal 60.
(17) I nstal l the fan support/hub assembl y and
ti ghten bol ts to 32 Nm (24 ft. l bs.) torque.
(19) I nstal l the accessory dri ve bel t tensi oner.
Torque bol t to 43 Nm (32 ft. l bs.) torque.
I NSTALLATI ON).
(21) I nstal l the upper cool i ng fan and shroud
together (Refer to 7 - COOLI NG/ENGI NE/RADI A-
TOR FAN - I NSTALLATI ON).
(22) I nstal l l ower shroud and connect fan dri ve
harness connector.
Fig. 121 GEAR HOUSING CAPSCREW TORQUE
SEQUENCE
GEAR HOUSING (Continued)
(23) I nstal l the wi ndshi el d washer reservoi r to the
fan shroud and connect the washer pump suppl y
hose and el ectri cal connecti on.
(24) I nstal l the cool ant recovery bottl e to the fan
shroud and connect the hose to the radi ator fi l l er
neck.
(25) I nstal l the radi ator upper hose and cl amps.
(26) Add engi ne oi l .
(27) Add cool ant (Refer to 7 - COOLI NG - STAN-
DARD PROCEDURE).
(28) Connect the battery cabl es.
GEAR HOUSING COVER
REMOVAL
DARD PROCEDURE).
(6) Di sconnect cool ant recovery bottl e hose from
radi ator fi l l er neck and l i ft bottl e off of fan shroud.
off of fan shroud.
(8) Remove vi scous fan/dri ve assembl y (Refer to 7 -
REMOVAL).
(14) Remove the crankshaft damper and speed
i ndi cator ri ng (Refer to 9 - ENGI NE/ENGI NE
BLOCK/VI BRATI ON DAMPER - REMOVAL).
care not to mar the gasket surfaces.
INSTALLATION
(1) I nstal l a new front crankshaft oi l seal .
(2) Obtai n a seal pi l ot/i nstal l ati on tool from a
crankshaft front seal servi ce ki t and i nstal l the pi l ot
i nto the seal .
si ve Seal ant or equi val ent to the gear housi ng cover.
Be sure to surround al l through hol es.
(4) Usi ng the seal pi l ot to al i gn the cover (Fi g.
123), i nstal l the cover to the housi ng and i nstal l the
bol ts. Ti ghten the bol ts to 24 Nm (18 ft. l bs.) torque.
(5) Remove the seal pi l ot. I nstal l front seal dust
shi el d.
(7) I nstal l the speed i ndi cator ri ng and the crank-
shaft damper (Refer to 9 - ENGI NE/ENGI NE
BLOCK/VI BRATI ON DAMPER - I NSTALLATI ON).
(9) I nstal l the fan support/hub assy, and ti ghten
bol ts to 32 Nm (24 ft. l bs.) torque.
bol t to 43 Nm (32 ft. l bs.) torque.
I NSTALLATI ON).
(13) I nstal l the cool i ng fan and shroud together
I NSTALLATI ON).
(14) I nstal l the wi ndshi el d washer reservoi r to the
fan shroud and connect the washer pump suppl y
hose and el ectri cal connecti on.
(15) I nstal l the cool ant recovery bottl e to the fan
shroud and connect the hose to the radi ator fi l l er
neck.
(16) I nstal l the radi ator upper hose and cl amps.
(17) Add cool ant (Refer to 7 - COOLI NG - STAN-
DARD PROCEDURE).
(18) Connect the battery cabl es.
Fig. 123 Installing Cover with Seal Pilot
1 - SEAL PILOT
GEAR HOUSING (Continued)
EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - 5.9L DIESEL . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - GAS ENGINE . . . 4
DIAGNOSIS AND TESTING - DIESEL
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS - TORQUE . . . . . . . . . . . . . . . 5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 6
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 7
EXHAUST PIPE
REMOVAL - 3.7L/4.7L/5.7L . . . . . . . . . . . . . . . . . 7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION - 3.7L/4.7L/5.7L . . . . . . . . . . . . . . 7
EXHAUST PIPE
REMOVAL - DIESEL . . . . . . . . . . . . . . . . . . . . . . 7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION - DIESEL . . . . . . . . . . . . . . . . . . 8
HEAT SHIELDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MUFFLER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MUFFLER - 5.9L DIESEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
TAILPIPE - 5.9L DIESEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
TAILPIPE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
TURBOCHARGER SYSTEM
TURBOCHARGER BOOST PRESSURE . . . . . 11
TURBOCHARGER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
CHARGE AIR COOLER AND PLUMBING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
EXHAUST SYSTEM
DESCRIPTION
DESCRIPTION
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
The federal gasol i ne engi ne exhaust system con-
si sts of engi ne exhaust mani fol ds, exhaust pi pes, cat-
al yti c converter(s), extensi on pi pe (i f needed),
exhaust heat shi el ds, muffl er and exhaust tai l pi pe
(Fi g. 1), (Fi g. 2), (Fi g. 3)
The Cal i forni a emi ssi on vehi cl es exhaust system
al so contai ns the above components as wel l as mi ni
catal yti c converters added to the exhaust pi pe.
The exhaust system must be properl y al i gned to
prevent stress, l eakage and body contact. Mi ni mum
cl earance between any exhaust component and the
body or frame i s 25.4 mm (1.0 i n.). I f the system con-
tacts any body panel , i t may ampl i fy objecti onabl e
noi ses from the engi ne or body.
DR EXHAUST SYSTEM 11 - 1
Fig. 1 Exhaust System - 3.7L Engine - Typical
1 - CATALYTIC CONVERTER
2 - TORCA CLAMP
3 - INSULATOR
4 - MUFFLER
5 - TAILPIPE
Fig. 2 Exhaust System 4.7L Engine - Typical
2 - TORCA CLAMP
3 - EXTENSION PIPE
4 - INSULATOR
5 - MUFFLER
6 - TAILPIPE/RESONATOR
11 - 2 EXHAUST SYSTEM DR
EXHAUST SYSTEM (Continued)
DESCRIPTION - 5. 9L DIESEL
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
The di esel engi ne exhaust system consi sts of an
engi ne exhaust mani fol d, turbocharger, exhaust pi pe,
resonator, extensi on pi pe, muffl er and exhaust
tai l pi pe.
Cal i forni a emi ssi on vehi cl es i ncl ude a catal yti c con-
verter.
The exhaust system must be properl y al i gned to
prevent stress, l eakage and body contact. The
exhaust components shoul d be kept a mi ni mum of
25.4 mm (1.0 i n.) away from the body and frame. I f
the system contacts any body panel , i t may ampl i fy
objecti onabl e noi ses from the engi ne or body.
Fig. 3 Exhaust System 5.7L Engine - Typical
2 - TORCA CLAMP
3 - EXTENSION PIPE
4 - INSULATOR
5 - MUFFLER
6 - TAILPIPE/RESONATOR
DIAGNOSIS AND TESTING - GAS ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.
3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.
7. Replace catalytic converter assy.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
CAUTION:
When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing
the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
DIAGNOSIS AND TESTING - DIESEL ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.
3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head bolts. Replace gasket
if necessary.
7. Turbocharger mounting flange
cracked.
7. Remove turbocharger and
inspect. (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER -
REMOVAL).
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
SPECIFICATIONS - TORQUE
DESCRIPTION Nm Ft.
Lbs.
In.
Lbs.
Bolt-Adjusting Strap 23 - 200
Nuts-Air Heater Power
Supply
14 - 124
Bolts-Air Inlet Housing 24 18 -
Nuts-Cab Heater Supply/
Return Line
24 18 -
Nuts-Exhaust Clamp 54.3 40 -
Bolts-Exhaust Manifold to
Cylinder Head-(Diesel
Engine)
43 32 -
Cylinder Head-(5.9L)
31 23 -
Cylinder Head-(8.0L)
22 - 195
Bolts-Exhaust Pipe to
Manifold
31 23 -
Bolts-Generator Mounting 41 30 -
DESCRIPTION Nm Ft.
Lbs.
In.
Lbs.
Bolts-Charge Air Cooler
Mounting
2 - 17
Nuts-Charge Air Cooler Duct 11 - 95
Bolt-Generator to Block-
Diesel
24 18 -
Nuts and Bolts-Heat Shield 11 - 95
Turbocharger flange studs 24 18 -
Nuts-Turbocharger Mounting 43 32 -
Bolts-Turbocharger Oil Drain
Tube
24 18 -
Fitting-Turbocharger Oil
Supply Line
24 18 -
Nut-Turbocharger V-Band
Clamp
5.6 - 70
Turbocharger Oil Supply
fitting (at Turbocharger)
36 27 -
Turbocharger Oil Supply
fitting (at lube filter head)
24 18 -
Turbocharger Drain Hose
Clamps
8 - 71
SPECIAL TOOLS
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
The stai nl ess steel catal yti c converter body i s
desi gned to l ast the l i fe of the vehi cl e. Excessi ve heat
can resul t i n bul gi ng or other di storti on, but exces-
si ve heat wi l l not be the faul t of the converter. I f
unburned fuel enters the converter, overheati ng may
occur. I f a converter i s heat-damaged, correct the
cause of the damage at the same ti me the converter
i s repl aced. Al so, i nspect al l other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
50 State emi ssi on vehi cl es i ncorporate two mi ni
catal yti c converters l ocated after the exhaust mani -
fol ds and before the i nl i ne catal yti c converter.
OPERATION
The catal yti c converter captures and burns any
unburned fuel mi xture exi ti ng the combusti on cham-
bers duri ng the exhaust stroke of the engi ne. Thi s
process ai ds i n reduci ng emi ssi ons output.
REMOVAL
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(2) Saturate the bol ts and nuts wi th heat val ve
l ubri cant. Al l ow 5 mi nutes for penetrati on.
(3) Remove the bol ts from the crossover pi pe to the
catal yti c converter connecti on.
(4) Di sconnect oxygen sensor wi ri ng.
(5) Loosen the nuts from the cl amp that hol d the
catal yti c converter to the exhaust pi pe fl ange connec-
ti on.
NOTE: Do not remove nut from T-Bolt. Only remove
nut far enough, so that the T end can be removed
from the clamp.
(6) Remove the T bol t end of the fastener, from the
cl amp.
(7) Spread the cl amp, and remove the catal yti c
converter from the vehi cl e.
(8) Di scard the cl amp.
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.
REMOVAL
(3) Remove cl amps and nuts.
(4) Remove the catal yti c converter.
INSPECTION
Look at the stai nl ess steel body of the converter,
i nspect for bul gi ng or other di storti on that coul d be a
resul t of overheati ng. I f the converter has a heat
shi el d attached make sure i t i s not bent or l oose.
I f you suspect i nternal damage to the catal yst, tap-
pi ng the bottom of the catal yst wi th a rubber mal l et
may i ndi cate a damaged core.
INSTALLATION
INSTALLATION
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.
TURBOCHARGER TESTER 9022
(1) Posi ti on the catal yti c converter onto the
exhaust pi pe fl ange connecti on. Ti ghten the nuts to
(2) I nstal l the muffl er onto the catal yti c converter
unti l the al i gnment tab i s i nserted i nto the al i gn-
ment sl ot.
(3) I nstal l the exhaust cl amp at the muffl er and
catal yti c converter connecti on. Ti ghten the cl amp
nuts to 54.2 Nm (40 ft. l bs.) torque.
(4) Connect oxygen sensor wi ri ng.
(6) Start the engi ne and i nspect for exhaust l eaks.
Reai r exhaust l eaks as necessary.
(7) Check the exhaust system for contact wi th the
body panel s. A mi ni mum of 25.4 mm (1.0 i n.) i s
requi red between the exhaust system components
and body/frame parts. Make the necessary adjust-
ments, i f needed..
INSTALLATION
(1) Assembl e converter and cl amps l oosel y i n
pl ace.
(2) I nstal l the exhaust pi pe onto exhaust mani -
fol ds, ti ghten 31 Nm (23 ft. l bs.).
(3) Ti ghten al l cl amp nuts to 52.2 Nm (40 ft. l bs.)
torque.
ments, i f needed..
EXHAUST PIPE
REMOVAL - 3. 7L/4. 7L/5. 7L
(3) Remove exhaust pi pe to mani fol d bol ts, retai n-
ers and nuts.
(4) Remove the cl amp nuts.
(5) Remove the exhaust pi pe (Fi g. 4).
INSPECTION
Di scard rusted cl amps, broken or worn supports
and attachi ng parts. Repl ace a component wi th ori g-
i nal equi pment parts, or equi val ent. Thi s wi l l assure
proper al i gnment wi th other parts i n the system and
provi de acceptabl e exhaust noi se l evel s.
INSTALLATION - 3. 7L/4. 7L/5. 7L
(1) Posi ti on the exhaust pi pe for proper cl earance
wi th the frame and underbody parts. A mi ni mum
cl earance of 25.4 mm (1.0 i n.) i s requi red.
(2) Posi ti on the exhaust pi pe to mani fol d. I nstal l
the bol ts, retai ners and nuts. Ti ghten the nuts to 31
(3) Ti ghten the cl amp nuts to 54.2 Nm (40 ft. l bs.)
torque.
(5) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
EXHAUST PIPE
REMOVAL - DIESEL
(2) Rai se and support the vehi cl e on a hoi st.
(4) Remove the exhaust pi pe-to-extensi on pi pe
cl amp. Separate the exhaust pi pe and extensi on pi pe.
(5) Remove the exhaust pi pe-to-turbocharger el bow
cl amp (Fi g. 5).
(6) Remove the exhaust pi pe from the transmi s-
si on support (Fi g. 5).
Fig. 4 Exhaust Pipe to Manifold Connection -
Typical
1 - BOLT
2 - RETAINER
3 - EXHAUST MANIFOLD
4 - NUT
5 - EXHAUST PIPE
CATALYTIC CONVERTER (Continued)
INSPECTION
INSTALLATION - DIESEL
(1) I nstal l the exhaust pi pe i nto the transmi ssi on
support and onto the turbocharger fl ange.
(2) I nstal l the exhaust pi pe-to-turbocharger el bow
cl amp and ti ghten to 11 Nm (100 i n. l bs.) torque.
(3) I nstal l the extensi on pi pe and cl amp to the
exhaust pi pe usi ng a new cl amp and ti ghten the
cl amp nuts to 54.2 Nm (40 ft. l bs.) torque.
ments, i f needed..
HEAT SHIELDS
DESCRIPTION
There are two types of heat shi el ds used. One i s
stamped steel the other i s mol ded foi l sheets. The
shi el ds attach to the vehi cl e around the exhaust sys-
tem to prevent heat from the exhaust system from
enteri ng the passenger area and other areas where
the heat can cause damage to other components.
REMOVAL
(2) Remove the nuts or bol ts hol di ng the exhaust
heat shi el d to the fl oor pan (Fi g. 6) (Fi g. 7) (Fi g. 8),
crossmember or bracket.
(3) Sl i de the shi el d out around the exhaust system.
INSTALLATION
(1) Posi ti on the exhaust heat shi el d to the fl oor
pan, crossmember or bracket and i nstal l the nuts or
bol ts.
(2) Ti ghten the nuts and bol ts 11 Nm (100 i n.
l bs.).
Fig. 5 Exhaust Pipe
1 - Clamp
2 - Support
3 - EXHAUST PIPE
Fig. 6 HEAT SHIELDS - RH - REG CAB
1 - HEAT SHIELD
2 - FASTENER
3 - NUT
4 - HEAT SHIELD
EXHAUST PIPE (Continued)
MUFFLER
REMOVAL
(2) Saturate the cl amp nuts wi th heat val ve l ubri -
cant. Al l ow 5 mi nutes for penetrati on.
(3) Di sconnect the muffl er hangers (Fi g. 9).
(5) Remove the muffl er.
INSTALLATION
(1) Assembl e muffl er and cl amps l oosel y to permi t
proper al i gnment of al l parts.
(2) Connect the muffl er hangers.
(3) Ti ghten the cl amp nuts to 54.2 Nm (40 ft. l bs.)
torque.
ments, i f needed..
Fig. 7 HEAT SHIELDS - RH - QUAD CAB
1 - HEAT SHIELD
2 - FASTENER
3 - NUT
4 - HEAT SHIELD
Fig. 8 HEAT SHIELD LH
1 - HEAT SHIELD
2 - NUT
Fig. 9 MUFFLER
1 - INSULATOR
2 - INSULATOR
3 - MUFFLER
4 - INSULATOR
HEAT SHIELDS (Continued)
MUFFLER - 5.9L DIESEL
REMOVAL
(3) Remove the muffl er to tai l pi pe and extensi on
pi pe cl amps (Fi g. 10).
(4) Di sconnect the muffl er from the hanger i sol a-
tors (Fi g. 10).
(5) Di sconnect the muffl er from the tai l pi pe.
(6) Di sconnect the muffl er from the extensi on pi pe
and remove from the vehi cl e.
INSTALLATION
(1) I nstal l the muffl er hanger rods i nto the i sol a-
tors (Fi g. 10).
(2) I nstal l the muffl er i nto the extensi on pi pe.
(3) I nstal l the muffl er i nto the tai l pi pe.
(4) I nstal l the exhaust cl amps, al i gn the exhaust
system, and ti ghten the exhaust cl amps to 54.2 Nm
ments, i f needed..
TAILPIPE - 5.9L DIESEL
REMOVAL
(4) Di sconnect the exhaust tai l pi pe support hanger
i sol ators (Fi g. 11).
(5) Remove the muffl er-to-tai l pi pe cl amps (Fi g. 11).
(6) Remove the tai l pi pe from the vehi cl e.
INSPECTION
Fig. 10 Muffler Removal/Installation
1 - INSULATOR
2 - ISOLATOR
3 - TAILPIPE
4 - CLAMP
5 - MUFFLER
6 - CLAMP
7 - EXTENSION PIPE
Fig. 11 Tailpipe Removal/Installation
1 - ISOLATOR
2 - TAILPIPRE
3 - CLAMP
4 - MUFFLER
INSTALLATION
(1) I nstal l the tai l pi pe i nto the muffl er.
(2) I nstal l the tai l pi pe hanger rods i nto the i sol a-
tors (Fi g. 11)
(3) I nstal l the exhaust cl amp, al i gn the exhaust
system, and ti ghten the cl amp 48 Nm (35 ft. l bs.)
torque.
ments, i f needed..
TAILPIPE
REMOVAL
(3) Di sconnect the exhaust tai l pi pe support hanger
(Fi g. 12).
(5) Remove the exhaust tai l pi pe.
INSPECTION
INSTALLATION
(1) Loosel y assembl e exhaust tai l pi pe to permi t
proper al i gnment of al l parts.
(2) Connect the support hangers.
(3) Posi ti on the exhaust tai l pi pe for proper cl ear-
ance wi th the underbody parts.
(4) Ti ghten al l cl amp nuts to 54.2 Nm (40 ft. l bs.)
torque.
ments, i f needed..
TURBOCHARGER SYSTEM
DIAGNOSIS AND TESTING - TURBOCHARGER
BOOST PRESSURE
NOTE: This diagnostic procedure is to be used with
the DRB III while test driving the vehicle under
normal load and driving conditions.
Low turbocharger boost pressure can cause poor
engi ne performance and dri veabi l i ty concerns. The
fol l owi ng procedure wi l l test the turbocharger boost
pressure.
(1) Loosen cl amps hol di ng ai r i nl et duct rubber
sl eeve to the i ntake mani fol d and ai r i nl et duct.
Remove rubber sl eeve (Fi g. 13).
(2) Posi ti on Speci al Tool 8462 onto ai r i nl et duct
and i ntake mani fol d. Usi ng the exi sti ng cl amps
ti ghten to 8 Nm (72 i n. l bs.).
(3) I nstal l the 3447.5 kPa 500 psi (gray) Pressure
Transducer (part of OT-CH8520 Transducer Ki t) i nto
Speci al Tool 8462.
(4) Connect the DRB I I I to the pressure trans-
ducer fol l owi ng the i nstructi ons suppl i ed wi th the
DRB I I I .
(5) Enter DRB I I I i nto pressure readi ng mode
and test dri ve vehi cl e.
Fig. 12 TAILPIPE
1 - INSULATOR
2 - TAILPIPE
3 - CLAMP
4 - MUFFLER
5 - CLAMP
6 - INSULATOR
7 - INSULATOR
8 - INSULATOR
TAILPIPE - 5.9L DIESEL (Continued)
(6) Ful l l oad boost pressure at rated speed wi l l be
158 - 186 kPa (23 - 27 psi .) dependi ng on engi ne hp
rati ng.. I f pressure readi ngs are are not wi thi n thi s
range i nspect for the fol l owi ng:
Restri cted ai r i nl et system
Leak i n the charge ai r cool er system (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM/
CHARGE AI R COOLER AND PLUMBI NG - DI AG-
NOSI S AND TESTI NG)
Turbocharger wastegate broken or mi sadjusted
Restri cted/hi gh pressure drop across charge ai r
cool er
Turbocharger damaged (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER SYSTEM/TURBO-
CHARGER - I NSPECTI ON)
TURBOCHARGER
DESCRIPTION
The turbocharger i s an exhaust-dri ven super-
charger whi ch i ncreases the pressure and densi ty of
the ai r enteri ng the engi ne. Wi th the i ncrease of ai r
enteri ng the engi ne, more fuel can be i njected i nto
the cyl i nders, whi ch creates more power duri ng com-
busti on.
The turbocharger assembl y consi sts of four (4)
major component systems (Fi g. 14) (Fi g. 15) :
Turbi ne secti on
Compressor secti on
Beari ng housi ng
Wastegate
Fig. 13 INTAKE MANIFOLD TO AIR INLET DUCT
RUBBER SLEEVE
1 - INTAKE MANIFOLD AIR INLET
2 - CLAMPS
3 - AIR INLET DUCT
4 - AIR INLET DUCT RUBBER SLEEVE
Fig. 14 Turbocharger Operation
1 - TURBINE SECTION
2 - EXHAUST GAS
3 - BEARING HOUSING
4 - COMPRESSOR SECTION
5 - INLET AIR
6 - COMPRESSED AIR TO ENGINE
7 - EXHAUST GAS
8 - EXHAUST GAS TO EXHAUST PIPE
Fig. 15 Turbocharger Wastegate Actuator
1 - TURBOCHARGER
2 - DIAPHRAGM
3 - WASTE GATE ACTUATOR
TURBOCHARGER SYSTEM (Continued)
OPERATION
Exhaust gas pressure and energy dri ve the tur-
bi ne, whi ch i n turn dri ves a centri fugal compressor
that compresses the i nl et ai r, and forces the ai r i nto
the engi ne through the charge ai r cool er and pl umb-
i ng. Si nce heat i s a by-product of thi s compressi on,
the ai r must pass through a charge ai r cool er to cool
the i ncomi ng ai r and mai ntai n power and effi ci ency.
Increasing air flow to the engine provides:
I mproved engi ne performance
Lower exhaust smoke densi ty
I mproved operati ng economy
Al ti tude compensati on
Noi se reducti on.
The turbocharger al so uses a wastegate (Fi g. 16),
whi ch regul ates i ntake mani fol d ai r pressure and
prevents over boosti ng at hi gh engi ne speeds. When
the wastegate val ve i s cl osed, al l of the exhaust gases
fl ow through the turbi ne wheel . As the i ntake mani -
fol d pressure i ncreases, the wastegate actuator opens
the val ve, di verti ng some of the exhaust gases away
from the turbi ne wheel . Thi s l i mi ts turbi ne shaft
speed and ai r output from the i mpel l er.
The turbocharger i s l ubri cated by engi ne oi l that i s
pressuri zed, cool ed, and fi l tered. The oi l i s del i vered
to the turbocharger by a suppl y l i ne that i s tapped
i nto the oi l fi l ter head. The oi l travel s i nto the bear-
i ng housi ng, where i t l ubri cates the shaft and bear-
i ngs (Fi g. 17). A return pi pe at the bottom of the
beari ng housi ng, routes the engi ne oi l back to the
crankcase.
The most common turbocharger fai l ure i s beari ng
fai l ure rel ated to repeated hot shutdowns wi th i nad-
equate cool -down peri ods. A sudden engi ne shut
down after prol onged operati on wi l l resul t i n the
transfer of heat from the turbi ne secti on of the tur-
bocharger to the beari ng housi ng. Thi s causes the oi l
to overheat and break down, whi ch causes beari ng
and shaft damage the next ti me the vehi cl e i s
started.
Letti ng the engi ne i dl e after extended operati on
al l ows the turbi ne housi ng to cool to normal operat-
i ng temperature. The fol l owi ng chart shoul d be used
as a gui de i n determi ni ng the amount of engi ne i dl e
ti me requi red to suffi ci entl y cool down the turbo-
charger before shut down, dependi ng upon the type
of dri vi ng and the amount of cargo.
Fig. 16 Wastegate Operation
1 - SIGNAL LINE
2 - EXHAUST BYPASS VALVE
3 - WASTEGATE
4 - EXHAUST
5 - TURBINE
TURBOCHARGER (Continued)
TURBOCHARGER COOL DOWN CHART
Driving
Condition
Load Turbo-
charger
Temper-
ature
Idle Time (in
minutes)
Before Shut
Down
Stop & Go Empty Cool Less than 1
Stop & Go Medium Warm 1
Highway
Speeds
Medium Warm 2
City Traffic Max.
GCWR
Warm 3
Highway
Speeds
Max.
GCWR
Warm 4
Uphill Grade Max.
GCWR
Hot 5
REMOVAL
(3) Di sconnect the exhaust pi pe from the turbo-
charger el bow(Refer to 11 - EXHAUST SYSTEM/EX-
HAUST PI PE - REMOVAL).
(4) Remove the bol ts from the turbocharger oi l
drai n tube.
(6) Di sconnect the turbocharger ai r i nl et hose (Fi g.
18).
(7) Di sconnect the turbocharger oi l suppl y l i ne
from the turbocharger (Fi g. 19).
(8) Di sconnect the charge ai r cool er i nl et pi pe from
the turbocharger compressor outl et (Fi g. 19).
Fig. 17 Turbocharger Oil Supply and Drain
1 - BEARINGS
2 - OIL SUPPLY (FROM FILTER HEAD)
3 - OIL RETURN (TO SUMP)
Fig. 18 Turbocharger Air Inlet Hose
1 - AIR INLET TUBE
2 - AIR FILTER HOUSING
3 - TURBOCHARGER
Fig. 19 Oil Supply Line and Charge Air Cooler Inlet
Duct
1 - TURBOCHARGERR EXHAUST ELBOW
2 - TURBOCHARGER
3 - OIL SUPPLY LINE
4 - AIR INLET TUBE
5 - TURBOCHARGER COMPRESSOR OUTLET
6 - OIL DRAIN LINE
(9) Remove the turbocharger and gasket from the
exhaust mani fol d.
(10) I f the turbocharger i s not to be i nstal l ed
i mmedi atel y, cover the openi ng to prevent materi al
from enteri ng i nto the mani fol d.
(11) I f repl aci ng the turbocharger, transfer the tur-
bocharger oi l suppl y fi tti ng to the new assembl y.
Ti ghten fi tti ng to 36 Nm (27 ft. l bs.).
(12) Cl ean and i nspect the seal i ng surface.
CAUTION: The turbocharger is only serviced as an
assembly. Do not attempt to repair the turbocharger
as turbocharger and/or engine damage can result.
CLEANING
WARNING: To prevent damage or personal injury,
do not use a combustable cleaner to clean the tur-
bocharger.
Cl ean the turbocharger and exhaust mani fol d
mounti ng surfaces wi th a sui tabl e scraper.
INSPECTION
Vi sual l y i nspect the turbocharger and exhaust
mani fol d gasket surfaces. Repl ace stri pped or eroded
mounti ng studs.
(1) Vi sual l y i nspect the turbocharger for cracks.
The fol l owi ng cracks are NOT acceptabl e:
Cracks i n the turbi ne and compressor housi ng
that go compl etel y through.
Cracks i n the mounti ng fl ange that are l onger
than 15 mm (0.6 i n.).
Cracks i n the mounti ng fl ange that i ntersect
bol t through-hol es.
Two (2) Cracks i n the mounti ng fl ange that are
cl oser than 6.4 mm (0.25 i n.) together.
(2) Vi sual l y i nspect the i mpel l er and compressor
wheel fi ns for ni cks, cracks, or chi ps. Note: Some
i mpel l ers may have a factory pl aced pai nt mark
whi ch, after normal operati on, appears to be a crack.
Remove thi s mark wi th a sui tabl e sol vent to veri fy
that i t i s not a crack.
(3) Vi sual l y i nspect the turbocharger compressor
housi ng for an i mpel l er rubbi ng condi ti on (Fi g. 20).
Repl ace the turbocharger i f the condi ti on exi sts.
(4) Measure the turbocharger axi al end pl ay:
(a) I nstal l a di al i ndi cator as shown i n (Fi g. 21).
Zero the i ndi cator at one end of travel .
(b) Move the i mpel l er shaft fore and aft and
record the measurement. Al l owabl e end pl ay i s
0.026 mm (0.0001 i n.) MI N. and 0.127 mm (0.005
i n.) MAX. I f the recorded measurement fal l s out-
si de these parameters, repl ace the turbocharger
assembl y.
(5) Measure the turbocharger beari ng radi al cl ear-
ance:
(a) I nsert a narrow bl ade or wi re styl e feel er
gauge between the compressor wheel and the hous-
i ng (Fi g. 22).
(b) Gentl y push the compressor wheel toward
the housi ng and record the cl earance.
(c) Wi th the feel er gauge i n the same l ocati on,
gentl y push the compressor wheel away from the
housi ng and agai n record the cl earance.
(d) Subtract the smal l er cl earance from the
l arger cl earance. Thi s i s the radi al beari ng cl ear-
ance.
(e) Al l owabl e radi al beari ng cl earance i s 0.33
mm (0.013 i n.) MI N. and 0.50 mm (0.020 i n.) MAX.
I f the recorded measurement fal l s outsi de these
speci fi cati ons, repl ace the turbocharger assembl y.
INSTALLATION
(1) I nstal l the turbocharger. Appl y anti -sei ze to the
studs and then ti ghten the turbocharger mounti ng
Fig. 20 Inspect Compressor Housing for Impeller
Rubbing Condition
Fig. 21 Measure Turbocharger Axial End Play
(2) Pre-lube the turbocharger. Pour 50 to 60 cc
(2 to 3 oz.) cl ean engi ne oi l i n the oi l suppl y l i ne fi t-
ti ng. Careful l y rotate the turbocharger i mpel l er by
hand to di stri bute the oi l thoroughl y.
(3) I nstal l and ti ghten the oi l suppl y l i ne to 24
(4) Posi ti on the charge ai r cool er i nl et pi pe to the
turbocharger. Wi th the cl amp i n posi ti on, ti ghten the
cl amp nut to 11 Nm (95 i n. l bs.) torque.
(5) Posi ti on the ai r i nl et hose to the turbocharger
(Fi g. 18). Ti ghten the cl amp to 11 Nm (95 i n. l bs.)
torque.
(7) Usi ng a new gasket, i nstal l the oi l drai n tube
to the turbocharger (Fi g. 19). Ti ghten the drai n tube
(8) Ti ghten the oi l drai n tube cl amps to 8 Nm (71
i n. l bs.).
and ti ghten the bol ts to 11.3 Nm (100 i n. l bs.)
torque.
(12) Start the engi ne to check for l eaks.
CHARGE AIR COOLER AND
PLUMBING
DESCRIPTION
The charge ai r system (Fi g. 23) consi sts of the
charge ai r cool er pi pi ng, charge ai r cool er and i ntake
ai r gri d heater.
The charge ai r cool er i s a heat exchanger that uses
ai r fl ow from vehi cl e moti on to di ssi pate heat from
the i ntake ai r. As the turbocharger i ncreases ai r
pressure, the ai r temperature i ncreases. Loweri ng
the i ntake ai r temperature i ncreases engi ne effi -
ci ency and power.
OPERATION
I ntake ai r i s drawn through the ai r cl eaner and
i nto the turbocharger compressor housi ng. Pressur-
i zed ai r from the turbocharger then fl ows forward
through the charge ai r cool er l ocated i n front of the
radi ator. From the charge ai r cool er the ai r fl ows
back i nto the i ntake mani fol d.
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS
Low turbocharger boost pressure and l ow engi ne
performance can be caused by l eaks i n the charge ai r
cool er or pl umbi ng. Fuel stai ni ng on the exhaust
mani fol d can al so be an i ndi cati on that there are
l eaks i n the ai r system.The fol l owi ng procedure out-
l i nes how to check for l eaks i n the charge ai r cool er
system.
(1) Loosen cl amp and remove ai r i nl et hose from
turbocharger.
(2) I nsert Speci al Tool 9022 Adapter i nto the tur-
bocharger i nl et. Ti ghten tool cl amp to 8 Nm (72 i n.
l bs.).
Fig. 22 Measure Turbocharger Bearing Radial
Clearance
1 - FEELER GAUGE
Fig. 23 Intake Air Circulation
1 - CHARGE AIR COOLER
2 - AIRFILTER
3 - TURBOCHARGER
CAUTION: Do not apply more than 138 kPa (20 psi)
air pressure to the charge air cooler system, sever
damage to the charge air cooler system may occur.
(3) Connect a regul ated ai r suppl y to ai r fi tti ng on
Tool 9022 Adapter. Set ai r pressure to a Maxi mum of
138 kPa (20 psi ).
(4) Usi ng soapy water check the rubber sl eeves,
charge ai r cool er and i ntake mani fol d for l eaks.
REMOVAL
WARNING: IF THE ENGINE WAS JUST TURNED
OFF, THE AIR INTAKE SYSTEM TUBES MAY BE
HOT.
(2) Di scharge the A/C system (Refer to 24 - HEAT-
I NG & AI R CONDI TI ONI NG/PLUMBI NG - STAN-
DARD PROCEDURE) and remove the A/C condenser
PLUMBI NG/A/C CONDENSER - REMOVAL) (i f A/C
equi pped).
(3) Remove the transmi ssi on auxi l i ary cool er
(Refer to 7 - COOLI NG/TRANSMI SSI ON/TRANS
COOLER - REMOVAL).
(4) Remove the boost tubes from the charge ai r
cool er (Fi g. 24).
(5) Remove the charge ai r cool er bol ts. Pi vot the
charge ai r cool er forward and up to remove.
CLEANING
CAUTION: Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air cooler
will result.
NOTE: If internal debris cannot be removed from
the cooler, the charge air cooler MUST be replaced.
(1) I f the engi ne experi ences a turbocharger fai l ure
or any other si tuati on where oi l or debri s get i nto the
charge ai r cool er, the charge ai r cool er must be
cl eaned i nternal l y.
(2) Posi ti on the charge ai r cool er so the i nl et and
outl et tubes are verti cal .
(3) Fl ush the cool er i nternal l y wi th sol vent i n the
di recti on opposi te of normal ai r fl ow.
(4) Shake the cool er and l i ghtl y tap on the end
tanks wi th a rubber mal l et to di sl odge trapped
debri s.
(5) Conti nue fl ushi ng unti l al l debri s or oi l are
removed.
(6) Ri nse the cool er wi th hot soapy water to
remove any remai ni ng sol vent.
(7) Ri nse thoroughl y wi th cl ean water and bl ow
dry wi th compressed ai r.
INSPECTION
Vi sual l y i nspect the charge ai r cool er for cracks,
hol es, or damage. I nspect the tubes, fi ns, and wel ds
for tears, breaks, or other damage. Repl ace the
charge ai r cool er i f damage i s found.
Pressure test the charge ai r cool er, usi ng Charge
Ai r Cool er Tester Ki t #3824556. Thi s ki t i s avai l abl e
through Cummi ns Servi ce Products. I nstructi ons
are provi ded wi th the ki t.
INSTALLATION
(1) Posi ti on the charge ai r cool er. I nstal l the bol ts
and ti ghten to 2 Nm (17 i n. l bs.) torque.
(2) I nstal l the ai r i ntake system tubes to the
charge ai r cool er. Wi th the cl amps i n posi ti on, ti ghten
the cl amps to 11 Nm (95 i n. l bs.) torque.
(3) I nstal l the transmi ssi on auxi l i ary cool er (i f
equi pped) (Refer to 7 - COOLI NG/TRANSMI SSI ON/
TRANS COOLER - I NSTALLATI ON).
(4) I nstal l the A/C condenser (i f A/C equi pped)
PLUMBI NG/A/C CONDENSER - I NSTALLATI ON).
Recharge A/C system (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG/PLUMBI NG - STANDARD PRO-
CEDURE).
(6) Start engi ne and check for boost system l eaks.
Fig. 24 Air Intake System Tubes
1 - BOLT
2 - CHARGE AIR COOLER
3 - CLAMP
4 - BOOST TUBE
CHARGE AIR COOLER AND PLUMBING (Continued)
FRAMES & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE . . . . . . . . . . . . . . . 1
FRONT AIR DAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FRONT BUMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FRONT FASCIA
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REAR BUMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FRAME
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 4
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY
FRONT FRAME RAIL TIP REPLACEMENT. . . . 4
STANDARD PROCEDURE - HYDROFORM
FENDER RAIL REPAIR . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - REAR FRAME
H-SECTION REPLACEMENT . . . . . . . . . . . . . 13
SPECIFICATIONS
SPECIFICATIONS - WELD PROCESS . . . . . . 15
SPECIFICATIONS - FRAME DIMENSIONS . . . 16
SPECIFICATIONS - TORQUE . . . . . . . . . . . . 22
FRONT CROSSMEMBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
FRONT SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
FRONT TOW HOOK ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
TRANSMISSION CROSSMEMBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
TRAILER HITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
TRANSFER CASE SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
BUMPERS
Front bumper center bracket nuts 95 70
Front bumper stud plate nuts 95 70
License plate hitch reinforcement bolts 54 40
Rear bumper support bracket stud plate nuts 54 40
Rear bumper support bracket to hitch bolts 54 40
Rear bumper to hitch bolts 54 40
DR FRAMES & BUMPERS 13 - 1
FRONT AIR DAM
REMOVAL
(1) Remove the two outboard screws.
(2) Remove the three mi ddl e screws and remove
the ai r dam.
INSTALLATION
(1) Posi ti on the ai r dam onto the bumper and seat
the carrot type fasteners ful l y.
(2) Starti ng at the center screw i nstal l the three
mi ddl e screws.
(3) I nstal l the two outboard screws.
FRONT BUMPER
REMOVAL
(1) Usi ng a grease penci l or equi val ent, mark the
posi ti on of the bumper on the frame rai l ti p to ai d
i nstal l ati on.
(2) Di sconnect the fog l amp el ectri cal connector at
the l eft frame rai l .
(3) Support the bumper wi th a sui tabl e l i fti ng
devi ce.
(4) Remove the center bracket nuts and bol ts and
remove bumper. (Fi g. 1)
INSTALLATION
(1) I nstal l the bumper onto the frame rai l s and
posi ti on the wheel house spl ash shi el d i nto the sup-
port brackets.
(2) I nstal l the bol ts and nuts.
(3) Li ne up the bumper wi th the marks made pre-
vi ousl y and ti ghten the bol ts and nuts to 95 Nm (70
ft. l bs.).
(4) Check and adjust the bumper al i gnment as
necessary. (Refer to 23 - BODY/BODY STRUCTURE/
GAP AND FLUSH - SPECI FI CATI ONS)
FRONT FASCIA
REMOVAL
ST/SLT/SLT+ - FASCIA REMOVAL
(1) Remove the two screws at each trai l i ng edge of
the fasci a. (Fi g. 2)
(2) Remove the four push pi n fasteners from the
upper edge of the cl ose out panel .
(3) Usi ng a tri m sti ck C-4755 or equi val ent, care-
ful l y rel ease the si x l ower cl i ps and remove the cl ose
out panel .
ful l y remove the step pad.
(5) Remove and di scard the four push pi n fasten-
ers and remove the fasci a.
Fig. 1 BUMPER SUPPORT BRACKET - TYPICAL
1 - FASCIA - SPORT MODEL
2 - SUPPORT BRACKET
3 - FASCIA SUPPORT BRACKET
4 - WHEELHOUSE SPLASH SHIELD SUPPORT BRACKET
5 - BUMPER CENTER BRACKET
6 - NUTS (4 PER SIDE)
7 - FRAME RAIL TIP
8 - CENTER BRACKET NUTS (2 PER SIDE)
9 - CENTER BRACKET BOLTS ASSEMBLY (1 PER SIDE)
10 - FOG LAMP
Fig. 2 UPPER FASCIA - ST/SLT/SLT+
1 - STEP PAD
2 - UPPER FASCIA (ST/SLT/SLT+ MODEL ONLY)
3 - INBOARD BUMPER BRACKET ATTACHMENTS
4 - SCREWS (4)
5 - PUSH PIN FASTENERS (4)
13 - 2 FRAMES & BUMPERS DR
SPORT FASCIA REMOVAL
(1) Rai se and support the vehi cl e. (Refer to
LUBRI CATI ON & MAI NTENANCE/HOI STI NG -
STANDARD PROCEDURE)
(2) Remove the three screws at each trai l i ng edge
of the fasci a. (Fi g. 3)
(3) Remove the fi ve l ower screws.
(4) Remove and di scard the four upper push pi ns.
ful l y rel ease the si x l ower cl i ps and remove the cl ose
out panel .
ful l y remove the step pad.
(7) Spread the fasci a out at the wheel s and remove
from the vehi cl e.
INSTALLATION
NOTE: The left and right inboard bumper to bracket
attachments must be secured before installing the
fascia and step pad.
ST/SLT/SLT+ FASCIA INSTALLATION
(1) I nstal l the fasci a.
(2) Posi ti on the cl ose out panel and seat the 6
l ower cl i ps ful l y.
(3) I nstal l four new upper push pi n fasteners.
(4) Posi ti on the step pad onto the fasci a and ful l y
seat the attachment cl i ps.
(5) Al i gn the fasci a to the fender wi th a 19 mm
(0.75 i nch) gap and i nstal l the two screws at each
trai l i ng edge of the fasci a.
SPORT FASCIA INSTALLATION
(1) Posi ti on the fasci a onto the bumper.
(2) Posi ti on the step pad onto the fasci a and ful l y
seat the attachment cl i ps.
(3) I nstal l four new upper push pi n fasteners.
(4) I nstal l the fi ve l ower screws.
(5) I nstal l the three screws at each trai l i ng edge of
the fasci a.
REAR BUMPER
REMOVAL
STANDARD PROCEDURE)
(2) Remove the l i cense pl ate.
(3) Remove the bol ts behi nd the pl ate.
(4) Di sconnect the l i cense pl ate l i ght el ectri cal con-
nectors.
(5) Di sconnect the trai l er l i ght connector el ectri cal
connecti on, i f equi pped.
(6) Remove the two bol ts al ong the front upper
edge of the bumper near the frame ti ps.
(7) Support the bumper wi th a sui tabl e l i fti ng
devi ce.
(8) Remove the bol ts attachi ng the bumper support
brackets to the trai l er hi tch. (Fi g. 4)
Fig. 3 SPORT FASCIA
1 - STEP PAD
2 - FASCIA (SPORT MODEL ONLY)
3 - SCREWS (3 PER SIDE)
4 - UPPER FASCIA SUPPORT BRACKET
5 - WHEELHOUSE SPLASH SHIELD BRACKET
6 - INBOARD BUMPER BRACKET ATTACHMENTS
8 - LOWER SCREWS (5)
Fig. 4 TRAILER HITCH
1 - HITCH
2 - LD HITCH BOLTS (4)/HD (6)
3 - BUMPER BRACKET BOLTS (4)
4 - BUMPER SUPPORT BRACKETS
FRONT FASCIA (Continued)
INSTALLATION
(1) Al i gn the hol es i n the bumpers to the trai l er
hi tch pi ns and i nstal l the bumper.
(2) I nstal l the support bracket to the hi tch bol ts,
l oosel y.
(3) I nstal l the front upper edge to the trai l er hi tch
bol ts and ti ghten to 54 Nm (40 ft. l bs.).
(4) I nstal l the l i cense pl ate rei nforcement to hi tch
(5) Ti ghten the l eft bumper bracket bol ts to 54
Nm (40 ft. l bs.).
(6) Ti ghten the ri ght bumper bracket bol ts to 54
Nm (40 ft. l bs.).
(7) Connect the trai l er l i ght connector el ectri cal
connecti on, i f equi pped.
(8) Connect the l i cense pl ate l i ght el ectri cal con-
nectors.
(9) I nstal l the l i cense pl ate.
FRAME
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
BEFORE PROCEEDING WITH FRAME REPAIR
INVOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR AREA, PERSONAL INJURY
CAN RESULT.
DO NOT ALLOW OPEN FLAME OR HEAT AND
METAL SPATTER FROM ARC WELDING, TO CON-
TACT PLASTIC BODY PANELS. FIRE OR EXPLO-
SION CAN RESULT.
WHEN WELDED FRAME COMPONENTS ARE
REPLACED, ENSURE COMPLETE PENETRATION
WELD IS ACHIEVED DURING INSTALLATION. IF
NOT, DANGEROUS OPERATING CONDITIONS CAN
RESULT.
STAND CLEAR OF CABLES OR CHAINS ON
PULLING EQUIPMENT DURING FRAME STRAIGHT-
ENING OPERATIONS, PERSONAL INJURY CAN
RESULT.
DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT SUPPORTED ON SAFETY
STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: 1500 series Dodge Ram Trucks (2002 and
later) are not designed for snow plow equipment.
The front collision repair tips must not be installed
on any truck equipped with a snow plow, or even
intended to be equipped with a snow plow.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Failure to use only pro-
duction fasteners or fasteners of equivalent hard-
ness can result in loosening or failure. Do not drill
any holes in the frame that are not specifically out-
lined in this or other, DaimlerChrysler procedure as
frame rail failure can result. When using heat to
straighten frame components do not exceed 566C
(1050F), metal fatigue can result.
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY FRONT
FRAME RAIL TIP REPLACEMENT
CAUTION: This procedure is designed to replace
the front frame rail tips that have been damaged in
the crush initiator zones. Prior to any cutting, the
vehicle must be mounted on the appropriate frame
repair equipment (frame rack), checked with three
dimensional measuring equipment, and the neces-
sary pull corrections made. If damage remains in
the frame beyond the area covered by this service
part after the pull, the frame must be replaced in its
entirety.
NOTE: Procedures for 4X2 and 4X4 are common
except as noted in this procedure.
(1) Before procedi ng wi th thi s repai r procedure
revi ew the requi red servi ce warni ngs and precau-
ti ons. (Refer to 13 - FRAME & BUMPERS/FRAME -
WARNI NG)
cabl e.
(3) Remove the front wheel house spl ash shi el d.
(Refer to 23 - BODY/EXTERI OR/FRONT WHEEL-
HOUSE SPLASH SHI ELD - REMOVAL)
(4) Remove the bol ts and posi ti on asi de the wi re
harness and grounds, i f requi red.
(5) Remove the front bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- REMOVAL)
(6) Loosen and l ower the stabi l i zer bar mount and
bar. (Refer to 2 - SUSPENSI ON/FRONT/STABI -
LI ZER BAR - REMOVAL)
REAR BUMPER (Continued)
(7) Remove the front cab mount bol t to the Front
End Sheet Metal (FESM) bracket. (Fi g. 5)
(8) Make a verti cal mark on the i nsi de and outsi de
face of the frame rai l 112 mm (4.5 i n.) from the for-
ward edge of the PLP hol e i n the si des of the rai l .
(Fi g. 7)
(9) Usi ng a strai ghtedge, connect the two l i nes on
the top and bottom of the rai l .
(10) Usi ng the servi ce ti p as a gui de, re-check your
cut l i nes to ensure the servi ce ti p wi l l fi t when the
cut i s made.
CAUTION: Do not use any flame or plasma cutting
equipment to cut the frame in this procedure. This
is due to the inaccurate nature of the cut-line and
the fact that the high temperatures achieved during
flame or plasma cutting will change the metal char-
acteristics and may weaken the frame and/or repair
location.
(11) Usi ng a reci procati ng saw or equi val ent, care-
ful l y cut and remove the damaged frame rai l ti p.
(Fi g. 6)
(12) Assembl e the servi ce sl eeve. Refer to SER-
VI CE SLEEVE ASSEMBLY at the end of thi s proce-
dure.
NOTE: Any burned surface coatings will need to be
removed from the sleeve prior to installation and
application of corrosion preventative coatings.
(13) Smooth and square the cut edges of the ori gi -
nal frame. (Fi g. 6)
Fig. 5 REPLACEMENT FRAME TIP
1 - FRONT END SHEET METAL (FESM) BRACKET
2 - CAB INSULATOR
3 - RING-FILLET WELD/HOLE
4 - PRINCIPLE LOCATING POINT (PLP)
5 - WELD ROOT GAP 4 mm - 6 mm (0.16 in. - 0.24 in.)
6 - FRONT CAB MOUNT BOLT
7 - REPLACEMENT FRAME TIP
Fig. 6 FRAME CUT LOCATION
1 - REPAIR ROOT OPENING
2 - SERVICE SLEEVE
3 - PRINCIPLE LOCATING POINT (PLP)
4 - SUSPENSION BRACKETS
5 - FRAME
6 - FRAME CUTOFF LOCATION - 112 mm (4.5 in.)
7 - FRAME SERVICE TIP
FRAME (Continued)
(14) Dress the cut edge of the exi sti ng frame i n
preparati on for the new rai l ti p.
(a) Dri l l four 13 mm (0.5 i n.) di ameter hol es i n
the new ti p and four more i n the exi sti ng frame to
accommodate ri ng-fi l l et wel ds. Center these hol es
19 mm (0.75 i n.) from the cut face of the rai l and
38 mm (1.5 i n.) from the top and bottom of the rai l .
(Fi g. 7)
(b) Bevel the edges of the new ti p, exi sti ng
frame, and ri ng-fi l l et hol es 25 - 30. Scri bi ng a
l i ne 2 mm from the cut edge and then gri ndi ng
back to the mark wi l l si mpl i fy the bevel creati on
process and accuracy. (Fi g. 8)
(c) Remove any burrs at the hol es and bevel ed
edges.
(15) Dry fi t the new rai l to ensure al i gnment and
fi t and make any adjustments as necessary.
(16) Remove al l i nternal and external OEM e-coat
wi thi n 51 mm (2.0 i n.) of the wel d joi nt on the
repl acement ti p and the exi sti ng frame rai l .
removed prior to application of corrosion preventa-
tive coatings.
CAUTION: Shield the surrounding area and compo-
nents from exposure to the welding spatter and
heat.
Fig. 7 REPAIR SLEEVE INSTALLATION (TYPICAL)
2 - FRAME RAIL
3 - SERVICE SLEEVE
4 - CENTER LINE
5 - LOCATOR LINES (2)
6 - HORIZONTAL WELD HOLE LOCATION - 38 mm (1.5 in.)(BOTH
FRAME SECTIONS)
7 - LOCATOR LINE DIMENSION - 2 mm (0.08 in.)
8 - VERTICAL WELD HOLE LOCATION - 19 mm (0.75 in.)(BOTH
FRAME SECTIONS)
9 - RING FILLET WELD HOLES
Fig. 8 WELD DIMENSIONS
1 - FRAME REPLACEMENT TIP
2 - FRAME RAIL
3 - FRAME DRESS ANGLE 25-30
4 - ROOT PASS
5 - COVER PASS
6 - SERVICE SLEEVE
7 - WELD ROOT GAP 4 mm - 6 mm (0.16 in. - 0.24 in.)
8 - SERVICE SLEEVE
FRAME (Continued)
(17) On 4X4 model s use the servi ce sl eeve as a
templ ate to dri l l a hol e i n the frame ti p to accommo-
date the sway bar mounti ng bol t. (Fi g. 11)
(18) Sl i de the servi ce sl eeve i nto the repl acement
frame ti p and al i gn to the 2 mm (0.08 i n.) off center
l i ne made previ ousl y duri ng the sl eeve assembl y and
tack the ri ng fi l l et wel ds to hol d them i n pl ace. (Fi g.
9) (Fi g. 10) (Fi g. 11) (Fi g. 12)
(19) On 4X4 model s, i nstal l the sway bar tappi ng
pl ate and secure wi th tack wel ds. (Fi g. 11) (Fi g. 12)
Fig. 9 4X2 SLEEVE INSTALLATION
2 - FRAME RAIL
3 - SERVICE SLEEVE
4 - PLP
5 - SWAY BAR MOUNTING BRACKET
6 - TAPPING PLATE
7 - ROOT WELD GAP
Fig. 10 4X2 SLEEVE INSTALLATION
2 - ROOT WELD GAP
3 - SERVICE SLEEVE
5 - TAPPING PLATE
FRAME (Continued)
(20) Appl y ri ng-fi l l et wel ds i nto the ri ng-fi l l et wel d
hol es on the repl acement frame ti p (Fi g. 13). (Refer
to 13 - FRAME & BUMPERS/FRAME - SPECI FI CA-
TI ONS - WELDI NG)
(21) I nstal l the upper FESM i nsul ator onto the
repl acement ti p and posi ti on the servi ce sl eeve/re-
pl acement ti p i nto the exi sti ng frame rai l .
(22) Loosel y i nstal l the l ower FESM i nsul ator and
cab mounti ng bol t.
(23) Usi ng the appropri ate measuri ng equi pment,
veri fy the front end sheet metal brackets l ocati on i n
al l three (X,Y, and Z) pl anes of space, and adjust i f
requi red. (Fi g. 14)
heat.
(24) When correctl y fi tted and a wel d root gap of 4
mm mi ni mum to 6 mm maxi mum (0.16 i n - 0.24 i n)
i s establ i shed, tack the ri ng fi l l et wel ds to hol d the
ti p i n posi ti on, then compl ete the ri ng fi l l et wel ds.
NOTE: Ring-fillet welds may be filled in with weld
material if an improved cosmetic appearance is
desired.
Fig. 11 4X4 TAPPING PLATE/SLEEVE
INSTALLATION
2 - FRAME RAIL
3 - SERVICE SLEEVE
4 - PLP
6 - TAPPING PLATE
7 - ROOT WELD GAP
8 - SLEEVE TAB
Fig. 12 4X4 TAPPING PLATE/SLEEVE
INSTALLATION
2 - ROOT WELD GAP
3 - SERVICE SLEEVE
5 - TAPPING PLATE
6 - SLEEVE TAB
FRAME (Continued)
(25) Confi rm al i gnment of the repl acement frame
rai l ti p. (Fi g. 14)
(26) Fi nal wel di ng shoul d be performed i n a ski p
(sti tch) type method to mi ni mi ze the heat bui l dup
and frame di storti on, uti l i zi ng the Wel d Process
Speci fi cati ons at the end of thi s secti on. The pre-
ferred method i s GMAW (MI G). (Refer to 13 -
FRAME & BUMPERS/FRAME - SPECI FI CATI ONS -
WELDI NG)
(a) Appl y root pass wel ds to the root joi nt one
quadrant at a ti me, swi tchi ng to the opposi te si de
of the frame for each quadrant. (Fi g. 8)
(b) Cl ean the wel ds of any fl ux and other i mpu-
ri ti es before proceedi ng wi th the cover pass wel ds.
(c) Appl y the cover pass wel ds i n the same man-
ner as descri bed above.
(27) Confi rm al i gnment of the repl acement frame
rai l ti p. (Fi g. 14)
removed prior to application of corrosion preventa-
tive coatings.
(28) Dress the wel ded area and appl y corrosi on
resi stant coati ngs i nsi de and out.
(a) Appl y etch-pri mer to the i nsi de of the frame
rai l repai r area.
(b) I nsi de the rai l , i nject a creepi ng wax based
rust i nhi bi tor compound through the exi sti ng hol es
i n the frame ensuri ng 100% coverage i ncl udi ng the
space between the ori gi nal frame rai l and the rei n-
forci ng sl eeve.
(c) Appl y a durabl e top coat to the outsi de of the
repai r area.
(29) Ti ghten the front cab mounti ng bol t to the
FESM bracket to 81 Nm (60 ft. l bs.).
(30) I nstal l the stabi l i zer bar. (Refer to 2 - SUS-
PENSI ON/FRONT/STABI LI ZER BAR - I NSTALLA-
TI ON)
(31) I nstal l the front bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- I NSTALLATI ON)
(32) I nstal l the wi re harness and ground strap i f
previ ousl y removed and i nstal l the bol t.
(a) I f necessary, re-dri l l and tap the ground
strap mounti ng hol e
(33) I nstal l the front wheel house spl ash shi el d.
HOUSE SPLASH SHI ELD - I NSTALLATI ON)
Fig. 13 RING FILLET WELD
1 - WELD START LOCATION
2 - WELD END LOCATION
3 - RING-FILLET WELD
Fig. 14 FRAME TIP DIMENSIONS
1 - PLP POINT
2 - FRAME
3 - PLP POINT
FRAME (Continued)
SERVICE SLEEVE ASSEMBLY
NOTE: Two sleeve halves are included with each
kit. Modifications as follow, are necessary to create
the correct sleeve assembly for each application.
(1) On 4X2 model s, the l ower sl eeve i s made by
cutti ng off the tab and cutti ng out a notch i n the bot-
tom sl eeve porti on. Round the corners of the cut out
to keep stress cracks from formi ng. On 4X4 model s
the l ower sl eeve i s used as provi ded. (Fi g. 15)
(2) On both 4X2 and 4X4 model s cut off the front
tab on the upper sl eeve porti on. (Fi g. 16)
(3) The sl eeve hal ves are shi pped sl i ghtl y over-
si zed to al l ow custom fi tti ng to each repl acement
frame rai l ti p. I t i s necessary to gri nd the mati ng
surfaces to achi eve the desi red snug fi t i nto the
repl acement ti p (rai l tube has i ncreasi ng hei ght rear-
ward of the cut l i ne). Once the two sl eeve hal ves are
fi tted, bevel the edges 25 - 30.
NOTE: Scribing a line 2 mm from the cut edge and
then grinding back to the mark will simplify the
bevel creation process and accuracy.
(4) Remove any burrs at the bevel ed edges.
(5) Usi ng the Wel d Process Speci fi cati ons tabl e
(Refer to 13 - FRAME & BUMPERS/FRAME - SPEC-
I FI CATI ONS - WELDI NG), wel d the two hal ves of
the repai r sl eeve together. (Fi g. 17)
(6) Cl ean the wel ds of any fl ux and other i mpuri -
ti es and gri nd smooth before proceedi ng wi th the
i nstal l ati on of the sl eeve.
(7) Fi nd the centerl i ne of the sl eeve and scri be a
centerl i ne mark. Mark two addi ti onal l i nes 2 mm
(0.08 i n.) on ei ther si de of the centerl i ne mark to hel p
ensure the requi red 4 mm - 6 mm (0.16 i n. - 0.24 i n.)
wel d root gap. (Fi g. 17)
Fig. 15 4X2 LOWER SLEEVE CUT LOCATION
1 - SERVICE SLEEVE LOWER HALF
2 - CUT DIMENSION 27 mm (1.06 in.)
3 - CUT DIMENSION 36.1 mm (1.42 in)
4 - 4X2 CUTOUT
5 - FRONT TAB CUT LINE (4X2 ONLY)
Fig. 16 UPPER SLEEVE CUT LOCATION
1 - SERVICE SLEEVE UPPER HALF
2 - CUT LOCATION
Fig. 17 SERVICE SLEEVE ASSEMBLY
1 - CENTERLINE SCRIBE MARK
2 - WELD SEAM
3 - REAR TAB (4X4 ONLY)
4 - SCRIBE LINE LOCATION 2 mm (0.08 in.)
5 - FRONT TAB (4X4 ONLY)
FRAME (Continued)
STANDARD PROCEDURE - HYDROFORM
FENDER RAIL REPAIR
CAUTION: This repair procedure assumes damage
to the right or left hydroform fender rail (Fig. 18).
Prior to any repairs, the vehicle must be mounted
on the appropriate frame repair equipment (frame
rack), checked with three dimensional measuring
equipment, and necessary pull corrections made. If
damage exists in the hydroform fender rail, or cab
beyond the area covered by this service procedure
after dimensional corrections are made, the hydro-
form must be replaced in its entirety. Refer to 23 -
BODY/BODY STRUCTURE/WELD LOCATIONS -
SPECIFICATIONS, when replacing the entire hydro-
form.
WARNI NG)
cabl e.
(3) Remove the front wheel house spl ash shi el d.
HOUSE SPLASH SHI ELD - REMOVAL)
(4) Remove the fender. (Refer to 23 - BODY/EXTE-
RI OR/FRONT FENDER - REMOVAL)
(5) Remove the A/C condenser, i f requi red. (Refer
to 24 - HEATI NG & AI R CONDI TI ONI NG/PLUMB-
I NG/A/C CONDENSER - REMOVAL)
(6) Remove the A/C l i nes, i f requi red. Refer to the
Heati ng and Ai r Condi ti oni ng secti on of the manual
for recommended procedures.
(7) Remove the radi ator assembl y. (Refer to 7 -
COOLI NG/ENGI NE/RADI ATOR - REMOVAL)
(8) Remove the ai r cl eaner and support bracket, i f
requi red. (Refer to 9 - ENGI NE/AI R I NTAKE SYS-
TEM/AI R CLEANER ELEMENT - REMOVAL)
(9) Remove the i ntegrated power modul e. (Refer to
8 - ELECTRI CAL/POWER DI STRI BUTI ON/I NTE-
GRATED POWER MODULE - REMOVAL)
(10) Remove the bol ts and posi ti on asi de the wi re
harness and grounds, i f requi red.
(11) Remove the upper radi ator crossmember.
(Refer to 23 - BODY/EXTERI OR/UPPER RADI ATOR
CROSSMEMBER - REMOVAL)
(12) Remove the headl amp uni t. (Refer to 8 -
HEADLAMP UNI T - REMOVAL)
(13) Remove the front cab mount to the Front End
Sheet Metal bracket (FESM) bol t.
Fig. 18 HYDROFORM FENDER RAILS
1 - HYDROFORM FENDER RAIL
2 - FRONT END SHEET METAL BRACKET
3 - UPPER RADIATOR CROSSMEMBER BOLTS (4)
4 - UPPER RADIATOR CROSSMEMBER
5 - LOWER RADIATOR CROSSMEMBER BOLTS (8)
6 - LOWER RADIATOR CROSSMEMBER
FRAME (Continued)
(14) Remove the bol ts attachi ng the l ower radi ator
crossmember to the hydroform fender rai l . (Fi g. 18)
equipment to cut the frame in this procedure. The
inaccurate and high temperatures achieved during
location.
(15) Usi ng a reci procati ng saw or equi val ent, cut
the fender rai l and shotgun at a strai ght and square
secti on of the hydroform and remove.
(16) Smooth and square the cut edges.
(17) Usi ng the damaged structure as a reference
cut the servi ce part at the same l ocati on as the fi rst
cut. Smooth and square the cut edges.
NOTE: The repair structure should butt up to the
remaining structure and provide the same overall
vehicle geometry.
(18) Fabri cate 51 mm (2.0 i n.) l ong repai r i nserts
usi ng scrap from the ol d structure or the repl acement
part. I t wi l l be necessary to spl i t the i nserts on each
of thei r four si des to fi t i nto the hydroform.
(19) Remove any pai nt or e-coat from the i nserts
and al so to the i nteri or and exteri or of the hydro-
forms.
(20) Cut pl ug wel d hol es as descri bed bel ow.
On the upper rai l , cut one 13 mm (0.5 i n.) hol e
on each si de of the rai l , 25 mm (1.0 i n.) from the butt
joi nt of the tubes.
On the l ower rai l , cut one 13 mm (0.5 i n.) hol e
on the top and bottom si des of the rai l 25 mm (1.0
i n.) from the butt joi nt of the tube.
On the l ower rai l , cut two 13 mm (0.5 i n.) hol es
on the i nner and outer si des of the rai l 25 mm (1.0
i n.) from the butt joi nt of the tube.
heat.
(21) I nstal l the i nsert 1 i nto the repl acement part
and tack i nto pl ace wi th a wel d. (Refer to 13 -
FRAME & BUMPERS/FRAME - SPECI FI CATI ONS -
WELDI NG)
(22) I nsert the servi ce part i nto pl ace and usi ng
the appropri ate measuri ng equi pment, veri fy the
front end sheet metal brackets l ocati on i n al l three
(X,Y, and Z) pl anes of space. (Fi g. 19)
(23) Compl ete al l 360 pl ug wel ds.
NOTE: Before the final welding, use three dimen-
sional measuring equipment to ensure the part is in
the correct location. Verify that tap plate extrusion
at the bottom of the vertical post lines up with the
isolator and hole in the frame perch mount. Also
ensure the lower radiator closure tube is bolted into
the forward shotgun ends.
(24) Compl ete wel di ng by maki ng a 360 butt wel d
around the fender rai l s.
(25) Metal fi ni sh the exposed wel ds on the hydro-
forms.
(a) I nsi de the rai l , i nject a creepi ng wax based
rust i nhi bi tor compound to the i nsi de of the hydro-
forms ensuri ng 100% coverage i ncl udi ng the mat-
i ng face between the fender rai l secti ons and i nsert
such that corrosi on protecti on i s restored i n the
i nternal cavi ty.
(b) Appl y a durabl e top coat to the outsi de of the
repai r area.
(27) I nstal l the front cab mount bol t i f previ ousl y
removed and ti ghten to 81 Nm (60 ft. l bs.).
(28) I nstal l the l ower radi ator crossmember bol ts
(29) I nstal l the headl amp uni t. (Refer to 8 - ELEC-
LAMP UNI T - I NSTALLATI ON)
(30) I nstal l the upper radi ator crossmember. (Refer
to 23 - BODY/EXTERI OR/UPPER RADI ATOR
CROSSMEMBER - I NSTALLATI ON)
(31) I nstal l the wi re harness and ground i f previ -
ousl y removed and i nstal l the bol ts.
(32) I nstal l the i ntegrated power modul e, i f previ -
ousl y removed. (Refer to 8 - ELECTRI CAL/POWER
DI STRI BUTI ON/I NTEGRATED POWER MODULE -
I NSTALLATI ON)
(33) I nstal l the ai r cl eaner bracket and ai r cl eaner,
i f previ ousl y removed. (Refer to 9 - ENGI NE/AI R
I NTAKE SYSTEM/AI R CLEANER ELEMENT -
I NSTALLATI ON)
(34) I nstal l the radi ator assembl y. (Refer to 7 -
COOLI NG/ENGI NE/RADI ATOR - I NSTALLATI ON)
(35) I nstal l the A/C l i nes, i f previ ousl y removed.
Refer to the Heati ng and Ai r Condi ti oni ng secti on of
the manual for the recommended procedures.
(36) I nstal l the A/C condenser, i f previ ousl y
removed. (Refer to 24 - HEATI NG & AI R CONDI -
TI ONI NG/PLUMBI NG/A/C CONDENSER - I NSTAL-
LATI ON)
(37) I nstal l the fender. (Refer to 23 - BODY/EXTE-
RI OR/FRONT FENDER - I NSTALLATI ON)
(38) I nstal l the front wheel house spl ash shi el d.
HOUSE SPLASH SHI ELD - I NSTALLATI ON)
(39) Reconnect the battery ground.
FRAME (Continued)
STANDARD PROCEDURE - REAR FRAME
H-SECTION REPLACEMENT
CAUTION: This procedure is designed to replace
the H-section/spare tire support located at the rear
of the frame assembly. Prior to any cutting, the
vehicle must be mounted on the appropriate frame
repair equipment (frame rack), checked with three
dimensional measuring equipment, and the neces-
sary pull corrections made. If damage remains in
the frame beyond the area covered by this service
part after the pull, the frame must be replaced in its
entirety.
WARNI NG)
cabl e.
(3) Remove the cargo box. (Refer to 23 - BODY/EX-
TERI OR/CARGO BOX - REMOVAL)
(4) Remove the trai l er hi tch. (Refer to 13 - FRAME
& BUMPERS/FRAME/TRAI LER HI TCH -
REMOVAL)
(5) Rai se and support the frame so the ti res are off
fl oor.
(6) Remove the shock absorbers. (Refer to 2 - SUS-
PENSI ON/REAR/SHOCK - REMOVAL)
(7) Remove the rear l eaf spri ng shackl e bol ts and
l et the axl e rest on the ground. (Fi g. 20)
(8) Remove the spare wheel .
Fig. 19 ENGINE COMPARTMENT/FRONT STRUCTURE
Fig. 20 REAR SPRING
1 - SPRING SHACKLE
2 - LEAF SPRING EYE BOLT/NUT
3 - REAR LEAF SPRING
FRAME (Continued)
(9) Remove the cl i p and remove the spare ti re
wi nch tube. (Fi g. 21)
(10) Remove the bol ts and remove the spare ti re
wi nch. (Fi g. 22)
(11) Posi ti on the wi re harness forward of the work
area.
equipment to cut the frame in this procedure. The
inaccurate and high temperatures achieved during
location.
(12) Careful l y remove the H-secti on wel ds usi ng a
gri nder or equi val ent tool .
(13) Remove the H-secti on and cl ean any remai n-
i ng wel ds from the frame.
(14) Tri al fi t the repl acement part.
(15) Remove al l e-coat from wi thi n 25 mm (1.0 i n.)
of the wel d area.
(16) Usi ng the appropri ate measuri ng equi pment,
posi ti on the repl acement part and veri fy correct posi -
ti oni ng i n al l three (X,Y, and Z) pl anes of space.
(Refer to 13 - FRAME & BUMPERS/FRAME - SPEC-
I FI CATI ONS - FRAME DI MENSI ONS)
heat.
(17) Wel d the repl acement H-secti on i nto posi ti on.
The wel di ng shoul d be performed i n a ski p (sti tch)
type method to mi ni mi ze the heat bui l dup fol l owi ng
I -CAR or the Ameri can Wel di ng Soci ety wel di ng pro-
cedures and uti l i zi ng the process speci fi cati ons at the
end of thi s secti on. (Refer to 13 - FRAME &
BUMPERS/FRAME - SPECI FI CATI ONS - WELD-
I NG)
(a) I nsi de the rai l , i nject a creepi ng wax based
rust i nhi bi tor compound through the exi sti ng hol es
i n the frame ensuri ng 100% coverage i ncl udi ng the
mati ng face between the frame and repl acement
H-secti on.
(b) Appl y a durabl e top coat to the outsi de of the
repai r area.
(19) Posi ti on the wi ri ng harness back.
CAUTION: Inspect the tire winch assembly for dam-
age. If any one or more of the following are evident,
replace the winch assembly.
Indications of cracked or bulging plastic.
Housing flanges are bent or cracked.
If winch was loose before repair.
(20) I nstal l the spare ti re wi nch and i nstal l the
bol ts. (Fi g. 22)
(21) Ti ghten the bol ts to 41 Nm (30 ft. l bs.).
(22) I nstal l the spare ti re wi nch tube and i nstal l
the cl i p. (Fi g. 21)
(23) I nstal l the spare ti re.
CAUTION: Check operation of the spare tire winch
by manipulating it up and down. If the winch binds
or jambs, replace the winch assembly.
(24) Li ft the axl e i nto posi ti on and i nstal l the rear
shackl e bol ts. (Fi g. 20)
Fig. 21 SPARE TIRE WINCH TUBE
1 - SPARE TIRE WINCH ASSEMBLY
2 - HAIR PIN CLIP
3 - WINCH TUBE
4 - H-SECTION/SPARE WHEEL SUPPORT
Fig. 22 SPARE TIRE WINCH ASSEMBLY
1 - SPARE TIRE WINCH ASSEMBLY
2 - BOLTS
3 - RETAINER BRACKET
4 - H-SECTION/SPARE WHEEL SUPPORT
FRAME (Continued)
(26) I nstal l the l ower shock absorber bol ts. (Refer
to 2 - SUSPENSI ON/REAR/SHOCK - I NSTALLA-
TI ON)
(27) I nstal l the trai l er hi tch. (Refer to 13 - FRAME
& BUMPERS/FRAME/TRAI LER HI TCH - I NSTAL-
LATI ON)
(28) I nstal l the cargo box. (Refer to 23 - BODY/EX-
TERI OR/CARGO BOX - I NSTALLATI ON)
(29) Reconnect the battery ground.
SPECIFICATIONS
SPECIFICATIONS - WELD PROCESS
CAUTION: All welds should conform to
DaimlerChrysler vehicle engineering process stan-
dard ps 9472.
WELDING PROCESS FLUX CORED ARC GAS METAL ARC (MIG)* SHIELDED METAL ARC
(STICK)
Material Thickness 3.7 mm to 4.2 mm 3.7 mm to 4.2 mm 3.7 mm to 4.2 mm
Electrode Type Lincoln Electrical Co.
Product #: NR-211 MP
(Do Not Substitute)
AWS ER70S-3
(Do Not Substitute)
** AWS E 7018
Electrodes Size Inches .045 Tubular .035 Solid 3/32
Electrode Stick Out 3/8 - 1/2 1/2 - 5/8 N/A
Polarity Electrode -
Work Piece +
Electrode +
Work Piece -
Electrode +
Work Piece -
Shielding Gas Self Shielded 75% Ar
25% CO2
Self Shielded
Gas Flow Rate N/A 25 - 35 CFM N/A
Wire Feed Speed
(inches per minute)
110 - 130 Vertical Down
70 - 90 Flat & Overhead
245 - 250 Vertical Down
210 - 225 Flat &
Overhead
N/A
Approximate Amperage
Vertical 110 - 130 175 85 (3/32 Diameter)
Flat & Overhead 70 - 90 155 90 (3/32 Diameter)
Voltage 15 - 18 19 - 20 N/A
Direction of Welding
Vertical Vertical Down Hill (only) Vertical Down Hill (only) Vertical - Up Hill (only)
Flat & Overhead Flat - Push or Drag Flat - Push or Drag Flat - Drag
*First choice - Gas Metal Arc Welding Process: Butt joints - apply two layers (passes) of weld metal. First pass
should only fill approximately
1
2 the thickness. Vertical position welds - maintain electrode wire at leading edge of
weld puddle while traveling down hill to produce maximum penetration into the sleeve. These techniques work for
FCAW as well.
**E7018 new electrodes may be exposed to the atmosphere for up to ten hours with no harmful effect.
Reconditioning schedules should come from the manufacturer.
FRAME (Continued)
SPECIFICATIONS - FRAME DIMENSIONS
NOTE: Frame dimensions are listed in metric scale.
All dimensions are from center to center of Princi-
pal Locating Point (PLP), or from center to center of
PLP and fastener location.
VEHICLE PREPARATION
Posi ti on the vehi cl e on a l evel work surface. Usi ng
screw or bottl e jacks, adjust the vehi cl e PLP hei ghts
to the speci fi ed di mensi on above a l evel work surface.
Verti cal di mensi ons can be taken from the work sur-
face to the l ocati ons i ndi cated were appl i cabl e.
INDEX
DESCRIPTION FIGURE
Frame Dimensional Graphics, Side
And Top View
23
140.5 In Wheelbase - Heavy Duty -
2 Wheel Drive
24
4 Wheel Drive
25
2 Wheel Drive
26
4 Wheel Drive
27
FRAME (Continued)
F
i
g
.
2
3
F
R
A
M
E
D
I
M
E
N
S
I
O
N
S
FRAME (Continued)
F
i
g
.
2
4
1
4
0
.
5
I
N
W
H
E
E
L
B
A
S
E
-
H
E
A
V
Y
D
U
T
Y
-
2
W
H
E
E
L
D
R
I
V
E
FRAME (Continued)
F
i
g
.
2
5
1
4
0
.
5
I
N
W
H
E
E
L
B
A
S
E
-
H
E
A
V
Y
D
U
T
Y
-
4
W
H
E
E
L
D
R
I
V
E
FRAME (Continued)
F
i
g
.
2
6
1
6
0
.
5
I
N
W
H
E
E
L
B
A
S
E
-
H
E
A
V
Y
D
U
T
Y
-
2
W
H
E
E
L
D
R
I
V
E
FRAME (Continued)
F
i
g
.
2
7
1
6
0
.
5
I
N
W
H
E
E
L
B
A
S
E
-
H
E
A
V
Y
D
U
T
Y
-
4
W
H
E
E
L
D
R
I
V
E
FRAME (Continued)
Cab mount bolts 81 60
Cargo box bolts 108 80
Front crossmember bolts - 2WD (light duty only) 61 45
Front crossmember bolts - 2WD (heavy duty only) 75 55
Front crossmember bolts - 4WD (light duty only) 102 75
Front skid plate bolts 34 25
Lower bumper support bracket bolt 54 40
Radiator crossmember bolts - lower 28 21
Radiator crossmember bolts - upper 28 21
Rear crossmember (light duty only) 102 75
Rear crossmember (heavy duty only) 115 85
Rear spring shackle bolts 163 120
Spare tire winch bolts 41 30
Trailer hitch reinforcement bracket bolt 170 125
Transfercase skid plate bolts 34 25
Transercase skid plate crossmember bolts 34 25
Transmission mount to crossmember nuts 54 40
FRONT CROSSMEMBER
REMOVAL
STANDARD PROCEDURE)
(2) Remove the front ski d pl ate, i f equi pped. (Refer
to 13 - FRAME & BUMPERS/FRAME/FRONT SKI D
PLATE - REMOVAL)
(3) Remove the bol ts and remove the crossmember.
(Fi g. 28) or (Fi g. 29)
INSTALLATION
(1) I nstal l the crossmember.
(2) I nstal l the bol ts;
On l i ght duty 2WD vehi cl es, ti ghten the bol ts to
61 Nm (45 ft. l bs.).
On l i ght duty 4WD vehi cl es, ti ghten the bol ts to
102 Nm (75 ft. l bs.).
On heavy duty 2WD vehi cl es, ti ghten the bol ts
to 75 Nm (55 ft. l bs.).
(3) I nstal l the front ski d pl ate, i f equi pped. (Refer
to 13 - FRAME & BUMPERS/FRAME/FRONT SKI D
PLATE - I NSTALLATI ON)
Fig. 28 FRONT CROSSMEMBER - 2WD
1 - CROSSMEMBER
2 - BOLTS (2 PER SIDE)
FRAME (Continued)
FRONT SKID PLATE
REMOVAL
STANDARD PROCEDURE)
(2) Remove the bol ts. (Fi g. 30)
(3) Sl i de ski d pl ate back off of the crossmember
and remove.
INSTALLATION
(1) Snap the rear tabs over the front crossmember
and i nstal l the ski d pl ate.
(2) I nstal l the bol ts and ti ghten to 34 Nm (25 ft.
l bs.).
FRONT TOW HOOK ASSEMBLY
REMOVAL
(1) Remove front bumper. (Refer to 13 - FRAME &
BUMPERS/BUMPERS/FRONT BUMPER -
REMOVAL)
(2) Remove the bol ts and remove the tow hook
assembl y. (Fi g. 31) and (Fi g. 32)
INSTALLATION
(1) I nstal l the tow hook assembl y and bol ts hand
ti ght.
(2) I nstal l the front bumper. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/FRONT BUMPER -
I NSTALLATI ON)
(3) Ti ghten the tow hook bol ts to 68 Nm (50 ft.
l bs.).
Fig. 29 FRONT CROSSMEMBER - 4WD
2 - CROSSMEMBER
Fig. 30 FRONT SKID PLATE
1 - FRONT CROSSMEMBER
2 - FRONT SKID PLATE
3 - BOLTS (2)
Fig. 31 FRONT TOW HOOK ASSEMBLY
1 - BUMPER CENTER SUPPORT BRACKET
2 - BOLTS (6)
3 - TOW HOOK ASSEMBLY
FRONT CROSSMEMBER (Continued)
TRANSMISSION
CROSSMEMBER
REMOVAL
STANDARD PROCEDURE)
(2) Remove the transfercase ski d pl ate, i f
equi pped. (Refer to 13 - FRAME & BUMPERS/
FRAME/TRANSFER CASE SKI D PLATE -
REMOVAL)
(3) Support the transmi ssi on wi th a sui tabl e l i fti ng
devi ce.
(4) Remove the transmi ssi on mount nuts. (Fi g. 33)
or (Fi g. 34)
INSTALLATION
(1) I nstal l the crossmember and i nstal l the bol ts.
On l i ght duty vehi cl es, ti ghten the bol ts to 102
Nm (75 ft. l bs.).
On heavy duty vehi cl es, ti ghten the bol ts to 115
Nm (85 ft. l bs.).
(2) I nstal l the transmi ssi on mount nuts and
(3) Remove the transmi ssi on support.
(4) I nstal l the transfercase ski d pl ate. (Refer to 13
- FRAME & BUMPERS/FRAME/TRANSFER CASE
SKI D PLATE - I NSTALLATI ON)
Fig. 32 FRONT TOW HOOK ASSEMBLY HEAVY
DUTY
1 - BOLTS (4 PER HOOK)
2 - HEAVY DUTY TOW HOOKS (2)
3 - BUMPER CENTER SUPPORT BRACKETS
Fig. 33 REAR CROSSMEMBER - 2WD
1 - TRANSMISSION MOUNT
2 - REAR CROSSMEMBER
3 - TRANSMISSION MOUNT NUTS (2)
4 - CROSSMEMBER BOLTS (2 PER SIDE)
Fig. 34 REAR CROSSMEMBER - 4WD
2 - TORSION BAR
3 - CROSSMEMBER BOLTS (3 PER SIDE)
4 - REAR CROSSMEMBER
5 - TRANSMISSION MOUNT NUTS (2)
FRONT TOW HOOK ASSEMBLY (Continued)
TRAILER HITCH
REMOVAL
(1) Remove the rear bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/REAR BUMPER -
REMOVAL)
(2) Remove the hi tch bol ts. (Fi g. 35) and (Fi g. 36)
(3) Di sconnect al l wi re harness support push pi ns.
(4) Remove the rear two cargo box bol ts and l oosen
the remai ni ng bol ts. (Refer to 23 - BODY/EXTERI -
OR/CARGO BOX - REMOVAL)
(5) Usi ng a sui tabl e l i fti ng devi ce, l i ft and support
the rear of the cargo box and remove the hi tch.
INSTALLATION
(1) I nstal l the hi tch onto the frame rai l s and make
sure the l ocators on the i nsi de of the hi tch brackets
are engaged wi th the hol es i n the top of the frame
rai l s properl y.
(2) Lower the cargo box and i nstal l the rear bol ts.
(Refer to 23 - BODY/EXTERI OR/CARGO BOX -
I NSTALLATI ON)
(3) I nstal l the hi tch bol ts and ti ghten to 170 Nm
(125 ft. l bs.).
(4) Connect al l wi re harness support push pi ns.
(5) I nstal l the rear bumper. (Refer to 13 - FRAME
& BUMPERS/BUMPERS/REAR BUMPER - I NSTAL-
LATI ON)
Fig. 35 TRAILER HITCH LIGHT DUTY
1 - LOCATING TAB HOLE
2 - LOCATING PIN HOLE
3 - U-NUTS (2)
5 - HITCH
7 - HITCH BOLTS (4)
TRANSFER CASE SKID PLATE
REMOVAL
STANDARD PROCEDURE)
(2) Support the ski d pl ate and remove the bol ts.
(Fi g. 37)
(4) Support the ski d pl ate crossmember and
remove the bol ts.
(5) Remove the ski d pl ate crossmember.
INSTALLATION
(1) I nstal l the ski d pl ate crossmember and i nstal l
the bol ts.
(3) I nstal l the ski d pl ate and i nstal l the bol ts.
Fig. 37 TRANSFER CASE SKID PLATE
1 - CROSSMEMBER BOLTS (4)
2 - SKID PLATE CROSSMEMBER
3 - SKID PLATE
4 - SKID PLATE BOLTS (4)
Fig. 36 TRAILER HITCH HEAVY DUTY
1 - LOCATING TAB HOLE
2 - LOCATING PIN HOLE
3 - U-NUTS (2)
5 - HITCH
6 - HITCH TO FRAME NUTS (2)
8 - HITCH BOLTS (6)
TRAILER HITCH (Continued)
FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY - GAS . . . . . . . . . . . . . . . . . . . . 1
FUEL INJECTION - GAS . . . . . . . . . . . . . . . . . . . 21
FUEL DELIVERY - DIESEL . . . . . . . . . . . . . . . . . 44
FUEL INJECTION - DIESEL . . . . . . . . . . . . . . . . 68
FUEL DELIVERY - GAS
TABLE OF CONTENTS
page page
FUEL DELIVERY - GAS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . 3
TORQUE - FUEL SYSTEM - EXCEPT
DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL FILTER/PRESSURE REGULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL LINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
QUICK CONNECT FITTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FUEL PUMP MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL RAIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUEL TANK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL- EXCEPT DIESEL . . . . . . . . . . . . . . 17
INSTALLATION - EXCEPT DIESEL . . . . . . . . . . 19
INLET FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL DELIVERY - GAS
DESCRIPTION
The fuel del i very system consi sts of:
a fuel pump modul e contai ni ng the el ectri c fuel
pump, fuel fi l ter/fuel pressure regul ator, fuel gauge
sendi ng uni t (fuel l evel sensor) and a secondary fuel
fi l ter l ocated at the bottom of the pump modul e
fuel tubes/l i nes/hoses
a combi nati on fuel fi l ter/fuel pressure regul ator
qui ck-connect fi tti ngs
fuel i njector rai l
fuel tank
fuel tank fi l l er/vent tube assembl y
fuel tank fi l l er tube cap
accel erator pedal
throttl e cabl e
Certai n fuel del i very components can be found i n
(Fi g. 1).
DR FUEL SYSTEM 14 - 1
OPERATION
Fuel i s returned through the fuel pump modul e
and back i nto the fuel tank through the fuel fi l ter/
fuel pressure regul ator. A separate fuel return l i ne
from the engi ne to the tank i s not used.
The fuel tank assembl y consi sts of: the fuel tank,
fuel pump modul e assembl y, fuel pump modul e l ock-
nut/gasket, and fuel tank check val ve (refer to Fuel
Tank Check Val ve for i nformati on).
A fuel fi l l er/vent tube assembl y usi ng a pressure/
vacuum, 1/4 turn fuel fi l l er cap i s used. The fuel
fi l l er tube contai ns a fl ap door l ocated bel ow the fuel
fi l l cap.
Al so to be consi dered part of the fuel system i s the
evaporati on control system. Thi s i s desi gned to
reduce the emi ssi on of fuel vapors i nto the atmo-
sphere. The descri pti on and functi on of the Evapora-
ti ve Control System i s found i n Emi ssi on Control
Systems.
Both fuel fi l ters (at bottom of fuel pump modul e
and wi thi n fuel pressure regul ator) are desi gned for
extended servi ce. They do not requi re normal sched-
ul ed mai ntenance. Fi l ters shoul d onl y be repl aced i f
a di agnosti c procedure i ndi cates to do so.
PRESSURE RELEASE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fi l l cap.
Fig. 1 FUEL DELIVERY COMPONENTS
1 - FUEL TANK 8 - LDP FRESH AIR FILTER
2 - CHECK VALVE 9 - LEAK DETECTION PUMP
3 - LIQUID EXPANSION CHAMBER 10 - EVAP CANISTERS (2)
4 - FUEL FILTER / FUEL PRESSURE REGULATOR 11 - FUEL TANK STRAPS (2)
5 - QUICK-CONNECT FITTING AND FUEL LINE (TO ENGINE) 12 - CHECK VALVE
6 - EVAP LINE CONNECTION 13 - FUEL PUMP MODULE LOCK RING
7 - LEAK DETECTION PUMP FRESH AIR LINE 14 - FUEL PUMP MODULE
14 - 2 FUEL DELIVERY - GAS DR
FUEL DELIVERY - GAS (Continued)
(2) Remove fuel pump rel ay from Power Di stri bu-
ti on Center (PDC). For l ocati on of rel ay, refer to l abel
on undersi de of PDC cover.
(3) Start and run engi ne unti l i t stal l s.
(4) Attempt restarti ng engi ne unti l i t wi l l no
l onger run.
(5) Turn i gni ti on key to OFF posi ti on.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unpl ug connector from any fuel i njector.
(7) Attach one end of a jumper wi re wi th al l i gator
cl i ps (18 gauge or smal l er) to ei ther i njector termi nal .
(8) Connect other end of jumper wi re to posi ti ve
si de of battery.
(9) Connect one end of a second jumper wi re to
remai ni ng i njector termi nal .
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentari l y touch other end of jumper wi re
to negati ve termi nal of battery for no more than a
few seconds.
(11) Pl ace a rag or towel bel ow fuel l i ne qui ck-con-
nect fi tti ng at fuel rai l .
(12) Di sconnect qui ck-connect fi tti ng at fuel rai l .
Refer to Qui ck-Connect Fi tti ngs.
(13) Return fuel pump rel ay to PDC.
(14) One or more Di agnosti c Troubl e Codes (DTCs)
may have been stored i n PCM memory due to fuel
pump rel ay removal . The DRB scan tool must be
used to erase a DTC.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
58 psi +/- 2 psi
TORQUE - FUEL SYSTEM - EXCEPT DIESEL
Accelerator Pedal Bracket
Mounting
12 - 105
Accelerator Pedal Position
Sensor Bracket-to-Battery
Tray Bolts
3 - 30
Crankshaft Position
Sensor - 3.7L
28 21 -
Crankshaft Position
Sensor - 4.7L
28 21 -
Crankshaft Position
Sensor - 5.7L
12 - 105 (+/-20)
- 3.7L
12 - 106
- 4.7L
12 - 106
- 5.7L
12 9 105 (+/-) 20
Engine Coolant
Temperature Sensor -
3.7L
11 - 96
Engine Coolant
4.7L
11 - 96
DR FUEL DELIVERY - GAS 14 - 3
Engine Coolant
5.7L
11 - 96
EVAP Canister- to-Bracket
Nuts
8.5 - 75
EVAP Canister-to-frame
bolts
34 25
Fuel Filler Hose Clamp at
Tank
3 - 30
Fuel Filler Housing-to-
Body Screws
2 - 17
Fuel Pump Module Lock
Ring
54 40 -
Fuel Rail Mounting Bolts -
3.7L
11 -
100
4.7L
11 - 100
5.7L
11 - 100
Fuel Tank Mounting Straps 41 30 -
IAC Motor Mounting
Screws - 3.7L
7 - 60
IAC Motor Mounting
Screws - 4.7L
7 - 60
Leak Detection Pump
Mounting Bolt
8.5 - 75
Map Sensor Mounting
Screws - 3.7L
3 - 25
Map Sensor Mounting
Screws - 4.7L
3 - 25
PCM-to-Mounting Bracket
Mounting Screws
4 - 35
Power Steering Pressure
Switch - 3.7L
14-22 - 124-195
Switch - 4.7L
14-22 - 124-195
TPS Mounting Screws -
3.7L
7 - 60
TPS Mounting Screws -
4.7L
7 - 60
Throttle Body Mounting
Bolts - 3.7L
11 - 100
Bolts - 4.7L
12 - 105
Bolts - 5.7L
12 - 105
Oxygen Sensors 30 22 -
SPECIAL TOOLS
FUEL SYSTEM
FUEL FILTER/PRESSURE
REGULATOR
DESCRIPTION
A combi nati on fuel fi l ter and fuel pressure regul a-
tor (Fi g. 2) i s used on al l engi nes. I t i s l ocated on the
top of the fuel pump modul e. A separate frame
mounted fuel fi l ter i s not used wi th any engi ne.
FUEL PRESSURE TESTER - #8978
TEST KIT, FUEL PRESSURE, 8.0L ENGINE - #5069
ADAPTERS, FUEL PRESSURE TEST, 8.0L - #6539
AND/OR #6631
SPANNER WRENCH - #6856
FITTING, AIR METERING - #6714
O2S (OXYGEN SENSOR) REMOVER/INSTALLER -
#C-4907
OPERATION
Fuel Pressure Regulator Operation: The pres-
sure regul ator i s a mechani cal devi ce that i s not con-
trol l ed by engi ne vacuum or the Powertrai n Control
Modul e (PCM).
The regul ator i s cal i brated to mai ntai n fuel system
operati ng pressure of approxi matel y 58 2 psi at the
fuel i njectors. I t contai ns a di aphragm, cal i brated
spri ngs and a fuel return val ve. The i nternal fuel fi l -
ter (Fi g. 2) i s al so part of the assembl y.
Fuel i s suppl i ed to the fi l ter/regul ator by the el ec-
tri c fuel pump through an openi ng tube at the bot-
tom of fi l ter/regul ator (Fi g. 2).
The regul ator acts as a check val ve to mai ntai n
some fuel pressure when the engi ne i s not operati ng.
Thi s wi l l hel p to start the engi ne. A second check
val ve i s l ocated at the outl et end of the el ectri c fuel
pump. Refer to Fuel Pump - Description and
Operation for more information.
I f fuel pressure at the pressure regul ator exceeds
approxi matel y 60 psi , an i nternal di aphragm opens
and excess fuel pressure i s routed back i nto the tank
through the bottom of pressure regul ator.
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sendi ng uni t (fuel l evel sensor) i s
attached to the si de of the fuel pump modul e. The
sendi ng uni t consi sts of a fl oat, an arm, and a vari -
abl e resi stor track (card).
OPERATION
The fuel pump modul e has 4 di fferent ci rcui ts
(wi res). Two of these ci rcui ts are used for the fuel
gauge sendi ng uni t for fuel gauge operati on, and for
certai n OBD I I emi ssi on requi rements. The other 2
wi res are used for el ectri c fuel pump operati on.
For Fuel Gauge Operation: A constant current
source i s suppl i ed to the resi stor track on the fuel
gauge sendi ng uni t. Thi s i s fed di rectl y from the
Powertrai n Control Modul e (PCM). NOTE: For
diagnostic purposes, this 12V power source can
only be verified with the circuit opened (fuel
pump module electrical connector unplugged).
With the connectors plugged, output voltages
will vary fromabout 0.6 volts at FULL, to about
8.6 volts at EMPTY (about 8.6 volts at EMPTY
for J eep models, and about 7.0 volts at EMPTY
for Dodge Truck models). The resi stor track i s
used to vary the vol tage (resi stance) dependi ng on
fuel tank fl oat l evel . As fuel l evel i ncreases, the fl oat
and arm move up, whi ch decreases vol tage. As fuel
l evel decreases, the fl oat and arm move down, whi ch
i ncreases vol tage. The vari ed vol tage si gnal i s
returned back to the PCM through the sensor return
ci rcui t.
Both of the el ectri cal ci rcui ts between the fuel
gauge sendi ng uni t and the PCM are hard-wi red (not
mul ti -pl exed). After the vol tage si gnal i s sent from
the resi stor track, and back to the PCM, the PCM
wi l l i nterpret the resi stance (vol tage) data and send
a message across the mul ti -pl ex bus ci rcui ts to the
i nstrument panel cl uster. Here i t i s transl ated i nto
the appropri ate fuel gauge l evel readi ng. Refer to
I nstrument Panel for addi ti onal i nformati on.
For OBD II Emission Monitor Requirements:
The PCM wi l l moni tor the vol tage output sent from
the resi stor track on the sendi ng uni t to i ndi cate fuel
l evel . The purpose of thi s feature i s to prevent the
OBD I I system from recordi ng/setti ng fal se mi sfi re
and fuel system moni tor di agnosti c troubl e codes.
The feature i s acti vated i f the fuel l evel i n the tank
i s l ess than approxi matel y 15 percent of i ts rated
capaci ty. I f equi pped wi th a Leak Detecti on Pump
(EVAP system moni tor), thi s feature wi l l al so be acti -
vated i f the fuel l evel i n the tank i s more than
approxi matel y 85 percent of i ts rated capaci ty.
Fig. 2 SIDE VIEW - FILTER/REGULATOR
1 - INTERNAL FUEL FILTER
2 - FUEL FLOW TO FUEL INJECTORS
3 - FUEL FILTER/FUEL PRESSURE REGULATOR
4 - EXCESS FUEL BACK TO TANK
5 - FUEL INLET
6 - RUBBER GROMMET
7 - TOP OF PUMP MODULE
FUEL FILTER/PRESSURE REGULATOR (Continued)
REMOVAL
The fuel l evel sendi ng uni t (fuel l evel sensor) and
fl oat assembl y i s l ocated on the si de of the fuel pump
modul e (Fi g. 3).
(1) Remove fuel pump modul e from fuel tank.
Refer to Fuel Pump Modul e Removal /I nstal l ati on.
(2) To remove sendi ng uni t from pump modul e, l i ft
on pl asti c l ocki ng tab (Fi g. 4) whi l e sl i di ng sendi ng
uni t tracks.
(3) Di sconnect 4wi re el ectri cal connector (Fi g. 3)
from fuel pump modul e. Separate necessary sendi ng
uni t wi ri ng from connector usi ng termi nal pi ck /
removal tool . Refer to Speci al Tool s i n 8W Wi ri ng for
tool part numbers.
INSTALLATION
(1) Connect necessary wi ri ng i nto el ectri cal con-
nectors. Connect 4wi re el ectri cal connector to pump
modul e.
(2) Posi ti on sendi ng uni t to pump modul e. Sl i de
and snap i nto pl ace.
(3) I nstal l fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
FUEL LINES
DESCRIPTION
Al so refer to Qui ck-Connect Fi tti ngs.
WARNING: THE FUEL SYSTEM MAY BE UNDER A
CONSTANT PRESSURE (EVEN WITH THE ENGINE
OFF). BEFORE SERVICING ANY FUEL SYSTEM
HOSES, FITTINGS, LINES, OR MOST COMPO-
NENTS, FUEL SYSTEM PRESSURE MUST BE
RELEASED. REFER TO THE FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
The l i nes/tubes/hoses used on fuel i njected vehi cl es
are of a speci al constructi on. Thi s i s due to the
hi gher fuel pressures and the possi bi l i ty of contami -
nated fuel i n thi s system. I f i t i s necessary to repl ace
these l i nes/tubes/hoses, onl y those marked EFM/EFI
may be used.
If equipped: The hose cl amps used to secure rub-
ber hoses on fuel i njected vehi cl es are of a speci al
rol l ed edge constructi on. Thi s constructi on i s used to
prevent the edge of the cl amp from cutti ng i nto the
hose. Onl y these rol l ed edge type cl amps may be
used i n thi s system. Al l other types of cl amps may
cut i nto the hoses and cause hi gh-pressure fuel l eaks.
Use new ori gi nal equi pment type hose cl amps.
Fig. 3 LOCATION - FUEL GAUGE SENDING UNIT
1 - FUEL FILTER / FUEL PRESSURE REGULATOR
2 - FUEL PUMP MODULE ASSEMBLY
3 - 4-WAY ELEC. CONNECT.
4 - FLOAT ARM
5 - ELEC. FUEL PUMP
6 - INLET FILTER
7 - FUEL GAUGE SENDING UNIT
8 - GASKET (SEAL)
Fig. 4 FUEL GAUGE SENDING UNIT - R/I
1 - SENDING UNIT
2 - LOCK TAB
3 - TRACKS
4 - NOTCH
FUEL LEVEL SENDING UNIT / SENSOR (Continued)
QUICK CONNECT FITTING
DESCRIPTION
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Some are equi pped wi th
safety l atch cl i ps. Some may requi re the use of a spe-
ci al tool for di sconnecti on and removal . Refer to
Qui ck-Connect Fi tti ngs Removal /I nstal l ati on for more
i nformati on.
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
Al so refer to Fuel Tubes/Li nes/Hoses and Cl amps.
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Safety l atch cl i ps are
used on certai n components/l i nes. Certai n fi tti ngs
may requi re use of a speci al tool for di sconnecti on.
DISCONNECTING
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure rel ease procedure. Refer
to Fuel Pressure Rel ease Procedure.
(3) Cl ean fi tti ng of any forei gn materi al before di s-
assembl y.
(4) 2Button Type Fitting: Thi s type of fi tti ng i s
equi pped wi th a push-button l ocated on each si de of
qui ck-connect fi tti ng (Fi g. 5). Press on both buttons
si mul taneousl y for removal . Speci al tool s are not
requi red for di sconnecti on.
(5) Pinch-Type Fitting: Thi s fi tti ng i s equi pped
wi th two fi nger tabs. Pi nch both tabs together whi l e
removi ng fi tti ng (Fi g. 6). Speci al tool s are not
requi red for di sconnecti on.
Fig. 5 2-BUTTON TYPE FITTING
1 - QUICK-CONNECT FITTING
2 - PUSH-BUTTONS (2)
Fig. 6 PINCH TYPE QUICK-CONNECT FITTING
2 - PINCH TABS
(6) Single-Tab Type Fitting: Thi s type of fi tti ng
i s equi pped wi th a si ngl e pul l tab (Fi g. 7). The tab i s
removabl e. After tab i s removed, qui ck-connect fi tti ng
can be separated from fuel system component. Spe-
ci al tool s are not requi red for di sconnecti on.
(a) Press rel ease tab on si de of fi tti ng to rel ease
pul l tab (Fi g. 8). If release tab is not pressed
prior to releasing pull tab, pull tab will be
damaged.
(b) Whi l e pressi ng rel ease tab on si de of fi tti ng,
use screwdri ver to pry up pul l tab (Fi g. 8).
(c) Rai se pul l tab unti l i t separates from qui ck-
connect fi tti ng (Fi g. 9).
(7) Two-Tab Type Fitting: Thi s type of fi tti ng i s
equi pped wi th tabs l ocated on both si des of fi tti ng
(Fi g. 10). The tabs are suppl i ed for di sconnecti ng
qui ck-connect fi tti ng from component bei ng servi ced.
(a) To di sconnect qui ck-connect fi tti ng, squeeze
pl asti c retai ner tabs (Fi g. 10) agai nst si des of
qui ck-connect fi tti ng wi th your fi ngers. Tool use i s
not requi red for removal and may damage pl asti c
retai ner.
(b) Pul l fi tti ng from fuel system component
bei ng servi ced.
(c) The pl asti c retai ner wi l l remai n on compo-
nent bei ng servi ced after fi tti ng i s di sconnected.
The o-ri ngs and spacer wi l l remai n i n qui ck-con-
nect fi tti ng connector body.
(8) Plastic Retainer Ring Type Fitting: Thi s
type of fi tti ng can be i denti fi ed by the use of a ful l -
round pl asti c retai ner ri ng (Fi g. 11) usual l y bl ack i n
col or.
(a) To rel ease fuel system component from qui ck-
connect fi tti ng, fi rml y push fi tti ng towards compo-
nent bei ng servi ced whi l e fi rml y pushi ng pl asti c
retai ner ri ng i nto fi tti ng (Fi g. 11). Wi th pl asti c ri ng
depressed, pul l fi tti ng from component. The plas-
tic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked
during removal, it may be difficult to discon-
nect fitting. Use an open-end wrench on
shoulder of plastic retainer ring to aid in dis-
connection.
(b) After di sconnecti on, pl asti c retai ner ri ng wi l l
remai n wi th qui ck-connect fi tti ng connector body.
Fig. 7 SINGLE-TAB TYPE FITTING
1 - PULL TAB
3 - PRESS HERE TO REMOVE PULL TAB
4 - INSERTED TUBE END
Fig. 8 DISCONNECTING SINGLE-TAB TYPE FITTING
1 - PULL TAB
2 - SCREWDRIVER
Fig. 9 REMOVING PULL TAB
1 - FUEL TUBE OR FUEL SYSTEM COMPONENT
2 - PULL TAB
4 - FUEL TUBE STOP
QUICK CONNECT FITTING (Continued)
(c) I nspect fi tti ng connector body, pl asti c retai ner
ri ng and fuel system component for damage.
Repl ace as necessary.
(9) Latch Clips: Dependi ng on vehi cl e model and
engi ne, 2 di fferent types of safety l atch cl i ps are used
(Fi g. 12) or (Fi g. 13). Type-1 i s tethered to fuel l i ne
and type-2 i s not. A speci al tool wi l l be necessary to
di sconnect fuel l i ne after l atch cl i p i s removed. The
l atch cl i p may be used on certai n fuel l i ne/fuel rai l
connecti on, or to joi n fuel l i nes together.
(a) Type 1: Pry up on l atch cl i p wi th a screw-
dri ver (Fi g. 12).
(b) Type 2: Separate and unl atch 2 smal l arms
on end of cl i p (Fi g. 13) and swi ng away from fuel
l i ne.
(c) Sl i de l atch cl i p toward fuel rai l whi l e l i fti ng
wi th screwdri ver.
Fig. 10 TYPICAL 2TAB TYPE FITTING
1 - TAB(S)
Fig. 11 PLASTIC RETAINER RING TYPE FITTING
1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
4 - PLASTIC RETAINER
5 - PUSH
6 - PUSH
7 - PUSH
8 - PUSH
Fig. 12 LATCH CLIP-TYPE 1
1 - TETHER STRAP
2 - FUEL LINE
3 - SCREWDRIVER
4 - LATCH CLIP
5 - FUEL RAIL
Fig. 13 LATCH CLIP-TYPE 2
1 - LATCH CLIP
(d) I nsert speci al fuel l i ne removal tool (Snap-On
number FI H 9055-1 or equi val ent) i nto fuel l i ne
(Fi g. 14). Use tool to rel ease l ocki ng fi ngers i n end
of l i ne.
(e) Wi th speci al tool sti l l i nserted, pul l fuel l i ne
from fuel rai l .
(f) After di sconnecti on, l ocki ng fi ngers wi l l
remai n wi thi n qui ck-connect fi tti ng at end of fuel
l i ne.
(10) Di sconnect qui ck-connect fi tti ng from fuel sys-
tem component bei ng servi ced.
CONNECTING
(1) I nspect qui ck-connect fi tti ng body and fuel sys-
tem component for damage. Repl ace as necessary.
(2) Pri or to connecti ng qui ck-connect fi tti ng to
component bei ng servi ced, check condi ti on of fi tti ng
and component. Cl ean parts wi th a l i nt-free cl oth.
Lubri cate wi th cl ean engi ne oi l .
(3) I nsert qui ck-connect fi tti ng i nto fuel tube or
fuel system component unti l bui l t-on stop on fuel
tube or component rests agai nst back of fi tti ng.
(4) Conti nue pushi ng unti l a cl i ck i s fel t.
(5) Si ngl e-tab type fi tti ng: Push new tab down
unti l i t l ocks i nto pl ace i n qui ck-connect fi tti ng.
(6) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel tube and fi tti ng (15-30 l bs.).
(7) Latch Cl i p Equi pped: I nstal l l atch cl i p (snaps
i nto posi ti on). If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
FUEL PUMP
DESCRIPTION
The el ectri c fuel pump i s l ocated i nsi de of the fuel
pump modul e. A 12 vol t, permanent magnet, el ectri c
motor powers the fuel pump. The el ectri c fuel pump
i s not a separate, servi ceabl e component.
OPERATION
Vol tage to operate the el ectri c pump i s suppl i ed
through the fuel pump rel ay.
Fuel i s drawn i n through a fi l ter at the bottom of
the modul e and pushed through the el ectri c motor
gearset to the pump outl et.
Check Valve Operation: The bottom secti on of
the fuel pump modul e contai ns a one-way check
val ve to prevent fuel fl ow back i nto the tank and to
mai ntai n fuel suppl y l i ne pressure (engi ne warm)
when pump i s not operati onal . I t i s al so used to keep
the fuel suppl y l i ne ful l of gasol i ne when pump i s not
operati onal . After the vehi cl e has cool ed down, fuel
pressure may drop to 0 psi (col d fl ui d contracts), but
l i qui d gasol i ne wi l l remai n i n fuel suppl y l i ne
between the check val ve and fuel i njectors. Fuel
pressure that has dropped to 0 psi on a cooled
down vehicle (engine off) is a normal condition.
The el ectri c fuel pump i s not a separate, servi ce-
abl e component.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump modul e assembl y i s l ocated on the
top of the fuel tank (Fi g. 1). The compl ete assembl y
contai ns the fol l owi ng components:
A combi nati on fuel fi l ter/fuel pressure regul ator
A separate fuel pi ck-up, or i nl et fi l ter
An el ectri c fuel pump
A l ockri ng to retai n pump modul e to tank
A soft gasket between tank fl ange and modul e
A fuel gauge sendi ng uni t (fuel l evel sensor)
Fuel l i ne connecti on
The fuel gauge sendi ng uni t may be servi ced sepa-
ratel y. I f the el ectri cal fuel pump, pri mary i nl et fi l ter,
fuel fi l ter or fuel pressure regul ator requi re servi ce,
the fuel pump modul e must be repl aced.
OPERATION
Refer to Fuel Pump, I nl et Fi l ter, Fuel Fi l ter /Fuel
Pressure Regul ator and Fuel Gauge Sendi ng Uni t.
Fig. 14 FUEL LINE DISCONNECTION USING
SPECIAL TOOL
1 - SPECIAL FUEL LINE TOOL
2 - FUEL LINE
3 - FUEL RAIL
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL PUMP MODULE,
THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(1) Drai n and remove fuel tank. Refer to Fuel
Tank Removal /I nstal l ati on.
(2) The pl asti c fuel pump modul e l ocknut (Fi g. 15)
i s threaded onto fuel tank. I nstal l Speci al Tool 6856
to l ocknut and remove l ocknut (Fi g. 16). The fuel
pump modul e wi l l spri ng up sl i ghtl y when l ocknut i s
removed.
(3) Remove modul e from fuel tank.
INSTALLATION
CAUTION: Whenever the fuel pump module is ser-
viced, the rubber gasket must be replaced.
(1) Usi ng a new gasket, posi ti on fuel pump modul e
i nto openi ng i n fuel tank.
(2) Posi ti on l ocknut over top of fuel pump modul e.
I nstal l l ocknut fi nger ti ght.
(3) Rotate modul e unti l embossed al i gnment arrow
(Fi g. 15) poi nts to center al i gnment mark. Thi s step
must be performed to prevent fl oat from contacti ng
si de of fuel tank. Al so be sure fi tti ng on fuel fi l ter/
fuel pressure regul ator i s poi nted to dri vers si de of
vehi cl e.
(4) I nstal l Speci al Tool 6856 (Fi g. 16) to l ocknut.
(5) Ti ghten l ocknut. Refer to Torque Speci fi cati ons.
(6) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL RAIL
DESCRIPTION
The fuel i njector rai l i s used to mount the fuel
i njectors to the engi ne.
OPERATION
Hi gh pressure from the fuel pump i s routed to the
fuel rai l . The fuel rai l then suppl i es the necessary
fuel to each i ndi vi dual fuel i njector.
A qui ck-connect fi tti ng wi th a safety l atch cl i p i s
used to attach the fuel l i ne to the fuel rai l .
The fuel rai l i s not repai rabl e.
CAUTION: The left and right sections of the fuel rail
are connected with either a flexible connecting
hose, or joints. Do not attempt to separate the rail
halves at these connecting hose or joints. Due to
the design of the connecting hose or joint, it does
not use any clamps. Never attempt to install a
clamping device of any kind to the hose or joint.
When removing the fuel rail assembly for any rea-
son, be careful not to bend or kink the connecting
hose or joint.
Fig. 15 FUEL PUMP MODULE (TOP)
2 - ALIGNMENT ARROW
3 - TOP OF PUMP MODULE
4 - LOCKNUT
5 - ALIGNMENT MARKS
Fig. 16 LOCKNUT REMOVAL/INSTALLATION -
TYPICAL
2 - LOCKNUT
FUEL PUMP MODULE (Continued)
REMOVAL
3. 7L V-6
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate rail
halves at connector tubes (Fig. 18). Due to design
of tubes, it does not use any clamps. Never attempt
to install a clamping device of any kind to tubes.
When removing fuel rail assembly for any reason,
be careful not to bend or kink tubes.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure.
(3) Remove negati ve battery cabl e at battery.
(4) Remove ai r duct at throttl e body ai r box.
(5) Remove ai r box at throttl e body.
(6) Remove ai r resonator mounti ng bracket at
front of throttl e body (2 bol ts).
(7) Di sconnect fuel l i ne l atch cl i p and fuel l i ne at
fuel rai l . A speci al tool wi l l be necessary for fuel l i ne
di sconnecti on. Refer to Qui ck-Connect Fi tti ngs.
(8) Remove necessary vacuum l i nes at throttl e
body.
(9) Di sconnect el ectri cal connectors at al l 6 fuel
i njectors. To remove connector refer to (Fi g. 17). Push
red col ored sl i der away from i njector (1). Whi l e push-
i ng sl i der, depress tab (2) and remove connector (3)
from i njector. The factory fuel i njecti on wi ri ng har-
ness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on. I f harness i s not
tagged, note wi ri ng l ocati on before removal .
(10) Di sconnect el ectri cal connectors at al l throttl e
body sensors.
(11) Remove 6 i gni ti on coi l s. Refer to I gni ti on Coi l
(12) Remove 4 fuel rai l mounti ng bol ts (Fi g. 18).
(13) Gentl y rock and pul l left si de of fuel rai l unti l
fuel i njectors just start to cl ear machi ned hol es i n
cyl i nder head. Gentl y rock and pul l right si de of rai l
unti l i njectors just start to cl ear cyl i nder head hol es.
Repeat thi s procedure (l eft/ri ght) unti l al l i njectors
have cl eared cyl i nder head hol es.
(14) Remove fuel rai l (wi th i njectors attached)
from engi ne.
(15) I f fuel i njectors are to be removed, refer to
Fuel I njector Removal /I nstal l ati on.
Fig. 17 REMOVE/INSTALL INJECTOR CONNECTOR
Fig. 18 FUEL RAIL REMOVE/INSTALL - 3.7L V-6
3 - FUEL RAIL
4 - INJ. #1
5 - INJ. #3
6 - INJ. #5
7 - INJ. #2
8 - INJ. #4
9 - INJ. #6
10 - CONNECTOR TUBE
FUEL RAIL (Continued)
4. 7L V-8
halves at connector tubes (Fig. 19). Due to design
of tubes, it does not use any clamps. Never attempt
to install a clamping device of any kind to tubes.
When removing fuel rail assembly for any reason,
be careful not to bend or kink tubes.
dure.
(4) Remove ai r duct at throttl e body ai r box.
(6) Remove ai r resonator mounti ng bracket at
(8) Remove necessary vacuum l i nes at throttl e
body.
body sensors.
(11) Remove 8 i gni ti on coi l s. Refer to I gni ti on Coi l
(12) Remove 4 fuel rai l mounti ng bol ts (Fi g. 19).
cyl i nder head. Gentl y rock and pul l right si de of rai l
unti l i njectors just start to cl ear cyl i nder head hol es.
Repeat thi s procedure (l eft/ri ght) unti l al l i njectors
have cl eared cyl i nder head hol es.
from engi ne.
5. 7L V-8
halves at connector tube (Fig. 20). Due to design of
tube, it does not use any clamps. Never attempt to
install a clamping device of any kind to tube. When
removing fuel rail assembly for any reason, be care-
ful not to bend or kink tube.
Fig. 19 FUEL RAIL REMOVE/INSTALL - 4.7L V-8
2 - INJ.#7
3 - INJ.#5
5 - INJ.#3
6 - FUEL INJECTOR RAIL
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
13 - PRESSURE TEST PORT CAP
dure.
(4) Remove fl ex tube (ai r cl eaner housi ng to
engi ne).
(5) Remove ai r resonator box at throttl e body.
(6) Di sconnect al l spark pl ug cabl es from al l spark
pl ugs and i gni ti on coi l s. Do not remove cabl es from
cabl e routi ng tray. Note ori gi nal cabl e posi ti ons whi l e
removi ng (Fi g. 22).
(7) Remove spark pl ug cabl e tray from engi ne by
rel easi ng 4 retai ni ng cl i ps (Fi g. 21). Remove tray and
cabl es from engi ne as an assembl y.
(8) Di sconnect el ectri cal connectors at al l 8 i gni -
ti on coi l s. Refer to I gni ti on Coi l Removal /I nstal l ati on.
body sensors.
(12) Remove 4 fuel rai l mounti ng bol ts and hol d-
own cl amps (Fi g. 20).
i ntake mani fol d. Gentl y rock and pul l right si de of
rai l unti l i njectors just start to cl ear i ntake mani fol d
head hol es. Repeat thi s procedure (l eft/ri ght) unti l al l
i njectors have cl eared machi ned hol es.
from engi ne.
INSTALLATION
3. 7L V-6
(1) I f fuel i njectors are to be i nstal l ed, refer to Fuel
I njector Removal /I nstal l ati on.
(2) Cl ean out fuel i njector machi ned bores i n
i ntake mani fol d.
(3) Appl y a smal l amount of engi ne oi l to each fuel
i njector o-ri ng. Thi s wi l l hel p i n fuel rai l i nstal l ati on.
(4) Posi ti on fuel rai l /fuel i njector assembl y to
machi ned i njector openi ngs i n cyl i nder head.
(5) Gui de each i njector i nto cyl i nder head. Be care-
ful not to tear i njector o-ri ngs.
(6) Push right si de of fuel rai l down unti l fuel
i njectors have bottomed on cyl i nder head shoul der.
Push left fuel rai l down unti l i njectors have bot-
tomed on cyl i nder head shoul der.
Fig. 20 5.7L FUEL RAIL
1 - FUEL RAIL
2 - MOUNTING BOLT
3 - HOLDOWN CLAMPS
4 - CONNECTOR TUBE
Fig. 21 5.7L SPARK PLUG CABLE ROUTING TRAY
1 - SPARK PLUG CABLES
2 - RETAINING CLIP
3 - SPARK PLUG CABLE ROUTING TRAY
(7) I nstal l 4 fuel rai l mounti ng bol ts and ti ghten.
(8) I nstal l 6 i gni ti on coi l s. Refer to I gni ti on Coi l
(9) Connect el ectri cal connectors to throttl e body.
(10) Connect el ectri cal connectors at al l fuel i njec-
tors. To i nstal l connector, refer to (Fi g. 17). Push con-
nector onto i njector (1) and then push and l ock red
col ored sl i der (2). Veri fy connector i s l ocked to i njec-
tor by l i ghtl y tuggi ng on connector.
(11) Connect necessary vacuum l i nes to throttl e
body.
(12) I nstal l ai r resonator mounti ng bracket near
(13) Connect fuel l i ne l atch cl i p and fuel l i ne to
fuel rai l . Refer to Qui ck-Connect Fi tti ngs.
(14) I nstal l ai r box to throttl e body.
(15) I nstal l ai r duct to ai r box.
(16) Connect battery cabl e to battery.
4. 7L V-8
i ntake mani fol d.
machi ned i njector openi ngs i n cyl i nder head.
(5) Gui de each i njector i nto cyl i nder head. Be care-
ful not to tear i njector o-ri ngs.
i njectors have bottomed on cyl i nder head shoul der.
Push left fuel rai l down unti l i njectors have bot-
tomed on cyl i nder head shoul der.
(7) I nstal l 4 fuel rai l mounti ng bol ts and ti ghten.
(8) I nstal l 8 i gni ti on coi l s. Refer to I gni ti on Coi l
(9) Connect el ectri cal connectors to throttl e body.
(11) Connect necessary vacuum l i nes to throttl e
body.
(12) I nstal l ai r resonator mounti ng bracket near
(14) I nstal l ai r box to throttl e body.
Fig. 22 5.7L SPARK PLUG CABLE ROUTING
1 - #8 COIL-TO- #5 SPARK PLUG (MARKED 5/8) 7 - CABLE TRAY
2 - #5 COIL-TO- #8 SPARK PLUG (MARKED 5/8) 8 - CLIPS (SPARK PLUG CABLE-TO-TRAY- RETENTION)
6 - CLIPS (TRAY-TO-MANIFOLD RETENTION)
(15) I nstal l ai r duct to ai r box.
5. 7L V-8
i ntake mani fol d.
machi ned i njector openi ngs i n i ntake mani fol d.
(5) Gui de each i njector i nto i ntake mani fol d. Be
careful not to tear i njector o-ri ngs.
i njectors have bottomed on shoul ders. Push left fuel
rai l down unti l i njectors have bottomed on shoul ders.
(7) I nstal l 4 fuel rai l hol down cl amps and 4 mount-
i ng bol ts. Refer to Torque Speci fi cati ons.
(8) Posi ti on spark pl ug cabl e tray and cabl e assem-
bl y to i ntake mani fol d. Snap 4 cabl e tray retai ni ng
cl i ps i nto i ntake mani fol d.
(9) I nstal l al l cabl es to spark pl ugs and i gni ti on
coi l s.
(10) Connect el ectri cal connector to throttl e body.
(11) I nstal l el ectri cal connectors to al l 8 i gni ti on
coi l s. Refer to I gni ti on Coi l Removal /I nstal l ati on.
(12) Connect el ectri cal connector to throttl e body.
(15) I nstal l ai r resonator to throttl e body (2 bol ts).
(16) I nstal l fl exi bl e ai r duct to ai r box.
FUEL TANK
DESCRIPTION
The fuel tank i s constructed of a pl asti c materi al .
I ts mai n functi ons are for fuel storage and for pl ace-
ment of the fuel pump modul e, and (i f equi pped) cer-
tai n ORVR components.
OPERATION
Al l model s pass a ful l 360 degree rol l over test
wi thout fuel l eakage. To accompl i sh thi s, fuel and
vapor fl ow control s are requi red for al l fuel tank con-
necti ons.
Two check (control ) val ves are mounted i nto the
top of the fuel tank. Refer to Fuel Tank Check Val ve
for addi ti onal i nformati on.
An evaporati on control system i s connected to the
fuel tank to reduce emi ssi ons of fuel vapors i nto the
atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal cani ster where they are temporari l y hel d.
When the engi ne i s runni ng, the vapors are drawn
i nto the i ntake mani fol d. Certai n model s are al so
equi pped wi th a sel f-di agnosi ng system usi ng a Leak
Detecti on Pump (LDP) and/or an On-Board Refuel i ng
Vapor Recovery (ORVR) system. Refer to Emi ssi on
Control System for addi ti onal i nformati on.
REMOVAL- EXCEPT DIESEL
Fuel Tank Draining
WARNING: THE FUEL SYSTEM MAY BE UNDER
CONSTANT FUEL PRESSURE EVEN WITH THE
ENGINE OFF. THIS PRESSURE MUST BE
RELEASED BEFORE SERVICING FUEL TANK.
Two di fferent procedures may be used to drai n fuel
tank: through the fuel fi l l fi tti ng on tank, or usi ng
the DRB scan tool . Due to a one-way check val ve
i nstal l ed i nto the fuel fi l l openi ng fi tti ng at the tank,
the tank cannot be drai ned conventi onal l y at the fi l l
cap.
The qui ckest drai ni ng procedure i nvol ves removi ng
the rubber fuel fi l l hose.
As an al ternati ve procedure, the el ectri c fuel pump
may be acti vated al l owi ng tank to be drai ned at fuel
rai l connecti on. Refer to DRB scan tool for fuel pump
acti vati on procedures. Before di sconnecti ng fuel l i ne
at fuel rai l , rel ease fuel pressure. Refer to the Fuel
System Pressure Rel ease Procedure for procedures.
Attach end of speci al test hose tool number 6541,
6539, 6631 or 6923 at fuel rai l di sconnecti on (tool
number wi l l depend on model and/or engi ne appl i ca-
ti on). Posi ti on opposi te end of thi s hose tool to an
approved gasol i ne drai ni ng stati on. Acti vate fuel
pump and drai n tank unti l empty.
I f el ectri c fuel pump i s not operati ng, fuel must be
drai ned through fuel fi l l fi tti ng at tank. Refer to fol -
l owi ng procedures.
(1) Rel ease fuel system pressure.
(3) Thoroughl y cl ean area around fuel fi l l fi tti ng
and rubber fuel fi l l hose at tank.
(4) I f vehi cl e i s equi pped wi th 4 doors and a 6 foot
(short) box, remove l eft-rear ti re/wheel .
(5) Loosen cl amp (Fi g. 23) and di sconnect rubber
fuel fi l l hose at tank fi tti ng. Usi ng an approved gas
hol di ng tank, drai n fuel tank through thi s fi tti ng.
Tank Removal
(1) Loosen cl amp and di sconnect rubber fuel vent
hose (Fi g. 23) at tank fi tti ng.
(2) Support tank wi th a hydraul i c jack.
(3) Remove 2 fuel tank strap nuts (Fi g. 24) and
remove both tank support straps.
(4) Careful l y l ower tank a few i nches and di scon-
nect fuel pump modul e el ectri cal connector (Fi g. 25)
at top of tank. To di sconnect el ectri cal connector:
Push upward on red col ored tab to unl ock. Push on
bl ack col ored tab whi l e removi ng connector.
(5) Di sconnect fuel l i ne at fuel fi l ter /fuel pressure
regul ator (Fi g. 25) by pressi ng on tabs at si de of
qui ck-connect fi tti ng.
(6) Di sconnect EVAP l i ne at top of tank (Fi g. 1).
(7) Conti nue to l ower tank for removal .
(8) I f fuel tank i s to be repl aced, remove fuel pump
modul e from tank. Refer to Fuel Pump Modul e
Removal /I nstal l ati on procedures.
Fig. 23 FUEL TANK FILL / VENT HOSES
1 - BEZEL SCREWS
2 - FUEL FILL BEZEL
3 - HOSE CLAMPS
4 - VENT HOSE
5 - FUEL TANK
6 - FILL HOSE
FUEL TANK (Continued)
INSTALLATION - EXCEPT DIESEL
(1) I f fuel tank i s to be repl aced, i nstal l fuel pump
modul e i nto tank. Refer to Fuel Pump Modul e
(2) Di sconnect cl amps and remove rubber fuel fi l l
hose and fuel vent hose at fuel fi l l tube. I nstal l these
2 hoses to 2 fuel tank fi tti ngs. Rotate hoses unti l
pai nt marks on hoses l i ne up wi th al i gnment marks
(Fi g. 26). Ti ghten both cl amps.
(3) Posi ti on fuel tank to hydraul i c jack.
(4) Rai se tank unti l posi ti oned near body.
(5) Connect EVAP l i ne at tank (Fi g. 1).
(6) Connect fuel pump modul e el ectri cal connector
(Fi g. 25) at top of tank.
(7) Connect fuel l i ne qui ck-connect fi tti ng to fuel
fi l ter / fuel pressure regul ator (Fi g. 1) or (Fi g. 25).
(8) Conti nue rai si ng tank unti l posi ti oned snug to
body.
(9) I nstal l and posi ti on both tank support straps.
I nstal l 2 fuel tank strap nuts (Fi g. 24) and ti ghten.
Tighten rear strap nut first. Refer to Torque Spec-
i fi cati ons.
(10) Connect rubber fi l l and vent hoses to fuel fi l l
tube and ti ghten cl amps.
(12) Fi l l fuel tank wi th fuel .
(13) Start engi ne and check for fuel l eaks near top
of modul e.
Fig. 24 FUEL TANK MOUNTING
1 - FUEL TANK
2 - STRAP MOUNTING STUDS
3 - VEHICLE FRAME
4 - MOUNTING STRAPS
5 - STRAP NUTS
INLET FILTER
REMOVAL
The fuel pump i nl et fi l ter (strai ner) i s l ocated on
the bottom of the fuel pump modul e (Fi g. 27). The
fuel pump modul e i s l ocated i nsi de of fuel tank.
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
(3) Remove fi l ter by careful l y pryi ng 2 l ock tabs at
bottom of modul e wi th 2 screwdri vers. Fi l ter i s
snapped to modul e.
(4) Cl ean bottom of pump modul e.
INSTALLATION
The fuel pump i nl et fi l ter (strai ner) i s l ocated on
the bottom of the fuel pump modul e (Fi g. 27). The
fuel pump modul e i s l ocated i nsi de of fuel tank.
(1) Snap new fi l ter to bottom of modul e. Be sure
o-ri ng i s i n correct posi ti on.
(2) I nstal l fuel pump modul e. Refer to Fuel Pump
I nstal l ati on.
Fig. 25 FUEL PUMP MODULE CONNECTIONS
1 - TOP OF FUEL TANK
2 - FUEL PUMP MODULE
4 - ELEC. CONNECT.
Fig. 26 HOSE ALIGNMENT MARKS
1 - ALIGNMENT MARKS (MARK FOR FILL HOSE IS LOCATED
ON FUEL TANK - MARK FOR VENT HOSE IS LOCATED ON
FITTING)
2 - PAINT MARKS ON RUBBER HOSES
Fig. 27 FUEL PUMP INLET FILTER
1 - FUEL PUMP INLET FILTER
2 - LOCK TABS (2)
3 - FUEL PUMP MODULE (BOTTOM)
FUEL INJ ECTION - GAS
TABLE OF CONTENTS
page page
ACCELERATOR PEDAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
CRANKSHAFT POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUEL INJECTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION
OPERATION - FUEL INJECTOR . . . . . . . . . . 26
OPERATION - PCM OUTPUT . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
FUEL PUMP RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
IDLE AIR CONTROL MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
INTAKE AIR TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
MAP SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OXYGEN SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
PTO SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
THROTTLE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
THROTTLE CONTROL CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
THROTTLE POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
ACCELERATOR PEDAL
REMOVAL
The fol l owi ng procedure appl i es onl y to vehi cl es
wi thout the Adjustabl e Pedal Package (code XAP).
The accel erator pedal i s servi ced as a compl ete
assembl y i ncl udi ng the bracket.
The accel erator cabl e i s connected to the upper
part of the accel erator pedal arm by a pl asti c
retai ner (cl i p) (Fi g. 1). Thi s pl asti c retai ner snaps
i nto the top of the accel erator pedal arm.
(1) From i nsi de the vehi cl e, hol d up accel erator
pedal . Remove pl asti c cabl e retai ner (cl i p) and throt-
tl e cabl e core wi re from upper end of accel erator
pedal arm (Fi g. 1). Pl asti c cabl e retai ner (cl i p) snaps
i nto pedal arm.
(2) Remove 2 accel erator pedal mounti ng bracket
nuts. Remove accel erator pedal assembl y.
INSTALLATION
(1) Pl ace accel erator pedal assembl y over 2 studs.
(2) I nstal l and ti ghten 2 mounti ng nuts. Refer to
(3) Sl i de throttl e cabl e i nto openi ng sl ot i n top of
pedal arm.
(4) Push pl asti c cabl e retai ner (cl i p) i nto accel era-
tor pedal arm openi ng unti l i t snaps i nto pl ace.
DR FUEL INJECTION - GAS 14 - 21
ACCELERATOR PEDAL
POSITION SENSOR
DESCRIPTION
The Accel erator Pedal Posi ti on Sensor (APPS)
assembl y i s l ocated under the vehi cl e battery tray. A
cabl e connects the assembl y to the accel erator pedal .
A pl asti c cover wi th a movabl e door i s used to cover
the assembl y.
The APPS i s used onl y wi th the 5.7L V-8 engi ne.
OPERATION
The Accel erator Pedal Posi ti on Sensor (APPS) i s a
l i near potenti ometer. I t provi des the Powertrai n Con-
trol Modul e (PCM) wi th a DC vol tage si gnal propor-
ti onal to the angl e, or posi ti on of the accel erator
pedal . The APPS si gnal i s transl ated (al ong wi th
other sensors) to pl ace the throttl e pl ate (wi thi n the
throttl e body) to a pre-determi ned posi ti on.
A mechani cal cabl e i s used between the accel erator
pedal and the APPS assembl y. Al though a cabl e i s
used between the pedal and APPS, a mechani cal
cabl e i s not used at the throttl e body. Throttl e pl ate
posi ti on i s el ectri cal l y determi ned.
REMOVAL
The APPS i s servi ced (repl aced) as one assembl y
i ncl udi ng the sensor, pl asti c housi ng and cabl e. The
APPS assembl y i s l ocated under the vehi cl e battery
tray (Fi g. 2). Access to APPS i s gai ned from over top
of l eft / front ti re.
(2) Di sconnect APPS cabl e at accel erator pedal .
Refer to Accel erator Pedal Removal / I nstal l ati on.
(3) Remove wheel house l i ner at l eft /front wheel .
Refer to Body.
(4) Gai n access to APPS el ectri cal connector by
openi ng swi ng-down door (Fi g. 3). Di sconnect el ectri -
cal connector.
(6) Remove APPS assembl y from battery tray.
(7) I f cabl e i s to be separated at APPS, unsnap
cabl e cl i p from bal l socket (Fi g. 4). Rel ease cabl e from
pl asti c housi ng by pressi ng on smal l cabl e rel ease tab
(Fi g. 3).
INSTALLATION
(1) I nstal l Accel erator Pedal Posi ti on Sensor
(APPS) cabl e to accel erator pedal . Refer to Accel era-
tor Pedal Removal / I nstal l ati on.
(2) Connect el ectri cal connector to APPS.
(3) I f necessary, connect cabl e to APPS l ever bal l
socket (snaps on).
(4) Snap APPS cabl e cover cl osed.
Fig. 1 ACCELERATOR PEDAL MOUNTING
1 - ACCELERATOR CABLE
2 - PLASTIC RETAINER (CLIP)
3 - THROTTLE PEDAL ARM
4 - PEDAL / BRACKET ASSEMBLY
5 - CABLE CLIP
Fig. 2 APPS LOCATION
1 - BATTERY TRAY
2 - APPS LOCATION
3 - APPS MOUNTING BOLTS
14 - 22 FUEL INJECTION - GAS DR
ACCELERATOR PEDAL (Continued)
(5) Posi ti on APPS assembl y to bottom of battery
tray and i nstal l 3 bol ts. Refer to Torque Speci fi ca-
ti ons.
(6) I nstal l wheel house l i ner. Refer to Body.
(7) The 5.7L V-8 engine is equipped with a
fully electronic accelerator pedal position sen-
sor. If equipped with a 5.7L, also perform the
following 3 steps:
(a) Connect negati ve battery cabl e to battery.
(b) Turn i gni ti on swi tch ON, but do not crank
engi ne.
(c) Leave i gni ti on swi tch ON for a mi ni mum of
10 seconds. Thi s wi l l al l ow PCM to l earn el ectri cal
parameters.
(d) The DRB I I I Scan Tool may al so be used to
l earn el ectri cal parameters. Go to the Mi scel l a-
neous menu, and then sel ect ETC Learn.
(8) I f the previ ous step i s not performed, a Di ag-
nosti c Troubl e Code (DTC) wi l l be set.
any Di agnosti c Troubl e Codes (DTCs) from PCM.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
3. 7L V-6
The Crankshaft Posi ti on (CKP) sensor i s mounted
i nto the ri ght rear si de of the cyl i nder bl ock. I t i s
posi ti oned and bol ted i nto a machi ned hol e.
4. 7L V-8
5. 7L V-8
OPERATION
3. 7L V-6
Engi ne speed and crankshaft posi ti on are provi ded
through the CKP (Crankshaft Posi ti on) sensor. The
sensor generates pul ses that are the i nput sent to the
Powertrai n Control Modul e (PCM). The PCM i nter-
prets the sensor i nput to determi ne the crankshaft
posi ti on. The PCM then uses thi s posi ti on, al ong wi th
other i nputs, to determi ne i njector sequence and i gni -
ti on ti mi ng.
Fig. 3 APPS REMOVE / INSTALL
1 - BOTTOM OF BATTERY TRAY
3 - APPS
4 - SWING-DOWN DOOR
5 - CABLE (TO PEDAL)
6 - CABLE RELEASE TAB
Fig. 4 APPS CABLE
1 - APPS LEVER
2 - BALL SOCKET
3 - SWING-DOWN DOOR
4 - CABLE CLIP
5 - CABLE
ACCELERATOR PEDAL POSITION SENSOR (Continued)
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
A tonewheel (targetwheel ) i s bol ted to the engi ne
crankshaft (Fi g. 5). Thi s tonewheel has sets of
notches at i ts outer edge (Fi g. 5).
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM.
4. 7L V-8
through the crankshaft posi ti on sensor. The sensor
generates pul ses that are the i nput sent to the pow-
ertrai n control modul e (PCM). The PCM i nterprets
the sensor i nput to determi ne the crankshaft posi -
ti on. The PCM then uses thi s posi ti on, al ong wi th
ti on ti mi ng.
On the 4.7L V8 engi ne, a tonewheel i s bol ted to
the engi ne crankshaft (Fi g. 6). Thi s tonewheel has
sets of notches at i ts outer edge (Fi g. 6).
to the PCM.
5. 7L V-8
through the crankshaft posi ti on sensor. The sensor
generates pul ses that are the i nput sent to the pow-
ertrai n control modul e (PCM). The PCM i nterprets
the sensor i nput to determi ne the crankshaft posi -
ti on. The PCM then uses thi s posi ti on, al ong wi th
ti on ti mi ng.
On the 5.7L V8 engi ne, a tonewheel i s bol ted to
the engi ne crankshaft. Thi s tonewheel has sets of
notches at i ts outer edge (Fi g. 7).
to the PCM.
REMOVAL
3. 7L V-6
i nto the ri ght rear si de of the cyl i nder bl ock (Fi g. 8).
I t i s posi ti oned and bol ted i nto a machi ned hol e.
(2) Di sconnect sensor el ectri cal connector.
Fig. 5 CKP OPERATION - 3.7L V-6
1 - TONEWHEEL
2 - NOTCHES
4 - CRANKSHAFT
Fig. 6 CKP SENSOR OPERATION AND TONEWHEEL
- 4.7L V-8
1 - TONEWHEEL
2 - NOTCHES
4 - CRANKSHAFT
CRANKSHAFT POSITION SENSOR (Continued)
(4) Careful l y twi st sensor from cyl i nder bl ock.
4. 7L V-8
The Crankshaft Posi ti on (CKP) sensor i s l ocated at
the ri ght-rear si de of the engi ne cyl i nder bl ock (Fi g.
9). I t i s posi ti oned and bol ted i nto a machi ned hol e i n
the engi ne bl ock.
(2) Di sconnect CKP el ectri cal connector at sensor.
(3) Remove CKP mounti ng bol t (Fi g. 9).
(5) Remove sensor from vehi cl e.
5. 7L V-8
The Crankshaft Posi ti on (CKP) sensor i s l ocated at
the ri ght-rear si de of the engi ne cyl i nder bl ock (Fi g.
10). I t i s posi ti oned and bol ted i nto a machi ned hol e
i n the engi ne bl ock.
(2) Di sconnect CKP el ectri cal connector at sensor
(Fi g. 10).
(3) Remove CKP mounti ng bol t (Fi g. 10).
(5) Remove sensor from vehi cl e.
INSTALLATION
3. 7L V-6
(1) Cl ean out machi ned hol e i n engi ne bl ock.
Fig. 7 CKP SENSOR OPERATION AND NOTCHES -
5.7L V-8
1 - RIGHT / REAR SIDE OF CYLINDER BLOCK
2 - MACHINED HOLE
3 - NOTCHES
Fig. 8 CKP REMOVAL / INSTALLATION - 3.7L
1 - MOUNTING BOLT
2 - CKP SENSOR
3 - O-RING
Fig. 9 CKP REMOVAL / INSTALLATION - 4.7L
2 - MOUNTING BOLT
o-ri ng.
(3) I nstal l sensor i nto engi ne bl ock wi th a sl i ght
be sure sensor is completely flush to cylinder
block. If sensor is not flush, damage to sensor
(4) I nstal l mounti ng bol t and ti ghten to 28 Nm
4. 7L V-8
o-ri ng.
5. 7L V-8
o-ri ng.
FUEL INJ ECTOR
DESCRIPTION
An i ndi vi dual fuel i njector (Fi g. 11) i s used for each
i ndi vi dual cyl i nder.
OPERATION
OPERATION - FUEL INJECTOR
The top (fuel entry) end of the i njector (Fi g. 11) i s
attached i nto an openi ng on the fuel rai l .
The fuel i njectors are el ectri cal sol enoi ds. The
i njector contai ns a pi ntl e that cl oses off an ori fi ce at
the nozzl e end. When el ectri c current i s suppl i ed to
the i njector, the armature and needl e move a short
di stance agai nst a spri ng, al l owi ng fuel to fl ow out
the ori fi ce. Because the fuel i s under hi gh pressure, a
fi ne spray i s devel oped i n the shape of a penci l
Fig. 10 CKP REMOVAL / INSTALLATION - 5.7L V-8
1 - CYLINDER BLOCK - RIGHT / REAR
2 - ELEC. CONNECTOR
3 - MOUNTING BOLT
4 - CKP SENSOR
Fig. 11 FUEL INJECTOR
1 - FUEL INJECTOR
2 - NOZZLE
3 - TOP (FUEL ENTRY)
stream. The sprayi ng acti on atomi zes the fuel , add-
i ng i t to the ai r enteri ng the combusti on chamber.
The nozzl e (outl et) ends of the i njectors are posi -
ti oned i nto openi ngs i n the i ntake mani fol d just
above the i ntake val ve ports of the cyl i nder head.
The engi ne wi ri ng harness connector for each fuel
i njector i s equi pped wi th an attached numeri cal tag
(I NJ 1, I NJ 2 etc.). Thi s i s used to i denti fy each fuel
i njector.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the Powertrai n Control Modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Battery vol tage i s suppl i ed to the i njectors through
the ASD rel ay.
The PCM determi nes i njector pul se wi dth based on
vari ous i nputs.
OPERATION - PCM OUTPUT
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector wi th i ts
respecti ve cyl i nder number.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the Powertrai n Control Modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Battery vol tage (12 vol ts +) i s suppl i ed to the i njec-
tors through the ASD rel ay. The ASD rel ay wi l l shut-
down the 12 vol t power source to the fuel i njectors i f
the PCM senses the i gni ti on i s on, but the engi ne i s
not runni ng. Thi s occurs after the engi ne has not
been runni ng for approxi matel y 1.8 seconds.
The PCM determi nes i njector on-ti me (pul se wi dth)
based on vari ous i nputs.
REMOVAL
(1) Remove fuel rai l . Refer to Fuel I njector Rai l
Removal .
(2) Di sconnect cl i p(s) that retai n fuel i njector(s) to
fuel rai l (Fi g. 12).
INSTALLATION
(1) I nstal l fuel i njector(s) i nto fuel rai l assembl y
and i nstal l retai ni ng cl i p(s).
(2) I f same i njector(s) i s bei ng rei nstal l ed, i nstal l
new o-ri ng(s).
(3) Appl y a smal l amount of cl ean engi ne oi l to
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(4) I nstal l fuel rai l . Refer to Fuel Rai l I nstal l ati on.
(5) Start engi ne and check for fuel l eaks.
FUEL PUMP RELAY
DESCRIPTION
The 5pi n, 12vol t, fuel pump rel ay i s l ocated i n
the Power Di stri buti on Center (PDC). Refer to the
l abel on the PDC cover for rel ay l ocati on.
OPERATION
The Powertrai n Control Modul e (PCM) energi zes
the el ectri c fuel pump through the fuel pump rel ay.
The fuel pump rel ay i s energi zed by fi rst appl yi ng
battery vol tage to i t when the i gni ti on key i s turned
ON, and then appl yi ng a ground si gnal to the rel ay
from the PCM.
Whenever the i gni ti on key i s turned ON, the el ec-
tri c fuel pump wi l l operate. But, the PCM wi l l shut-
down the ground ci rcui t to the fuel pump rel ay i n
approxi matel y 13 seconds unl ess the engi ne i s oper-
ati ng or the starter motor i s engaged.
Fig. 12 INJECTOR RETAINING CLIP
1 - PLIERS
2 - INJECTOR CLIP
3 - FUEL INJECTOR - TYPICAL
4 - FUEL RAIL - TYPICAL
FUEL INJ ECTOR (Continued)
REMOVAL
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) (Fi g. 13). Refer to l abel on PDC
cover for rel ay l ocati on.
INSTALLATION
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC). Refer to l abel on PDC cover for
rel ay l ocati on.
IDLE AIR CONTROL MOTOR
DESCRIPTION
A separate I AC motor i s not used wi th the 5.7L V-8
engi ne.
The I AC stepper motor i s mounted to the throttl e
body, and regul ates the amount of ai r bypassi ng the
control of the throttl e pl ate. As engi ne l oads and
ambi ent temperatures change, engi ne rpm changes.
A pi ntl e on the I AC stepper motor protrudes i nto a
passage i n the throttl e body, control l i ng ai r fl ow
through the passage. The I AC i s control l ed by the
Powertrai n Control Modul e (PCM) to mai ntai n the
target engi ne i dl e speed.
OPERATION
A separate I AC motor i s not used wi th the 5.7L V-8
engi ne.
At i dl e, engi ne speed can be i ncreased by retract-
i ng the I AC motor pi ntl e and al l owi ng more ai r to
pass through the port, or i t can be decreased by
restri cti ng the passage wi th the pi ntl e and di mi ni sh-
i ng the amount of ai r bypassi ng the throttl e pl ate.
The I AC i s cal l ed a stepper motor because i t i s
moved (rotated) i n steps, or i ncrements. Openi ng the
I AC opens an ai r passage around the throttl e bl ade
whi ch i ncreases RPM.
The PCM uses the I AC motor to control i dl e speed
(al ong wi th ti mi ng) and to reach a desi red MAP dur-
i ng decel (keep engi ne from stal l i ng).
The I AC motor has 4 wi res wi th 4 ci rcui ts. Two of
the wi res are for 12 vol ts and ground to suppl y el ec-
tri cal current to the motor wi ndi ngs to operate the
stepper motor i n one di recti on. The other 2 wi res are
al so for 12 vol ts and ground to suppl y el ectri cal cur-
rent to operate the stepper motor i n the opposi te
di recti on.
To make the I AC go i n the opposi te di recti on, the
PCM just reverses pol ari ty on both wi ndi ngs. I f onl y
1 wi re i s open, the I AC can onl y be moved 1 step
(i ncrement) i n ei ther di recti on. To keep the I AC
motor i n posi ti on when no movement i s needed, the
PCM wi l l energi ze both wi ndi ngs at the same ti me.
Thi s l ocks the I AC motor i n pl ace.
I n the I AC motor system, the PCM wi l l count
every step that the motor i s moved. Thi s al l ows the
PCM to determi ne the motor pi ntl e posi ti on. I f the
memory i s cl eared, the PCM no l onger knows the
posi ti on of the pi ntl e. So at the fi rst key ON, the
PCM dri ves the I AC motor cl osed, regardl ess of
where i t was before. Thi s zeros the counter. From
thi s poi nt the PCM wi l l back out the I AC motor and
keep track of i ts posi ti on agai n.
When engi ne rpm i s above i dl e speed, the I AC i s
used for the fol l owi ng:
Off-i dl e dashpot (throttl e bl ade wi l l cl ose qui ckl y
but i dl e speed wi l l not stop qui ckl y)
Decel erati on ai r fl ow control
A/C compressor l oad control (al so opens the pas-
sage sl i ghtl y before the compressor i s engaged so
that the engi ne rpm does not di p down when the
compressor engages)
Power steeri ng l oad control
The PCM can control pol ari ty of the ci rcui t to con-
trol di recti on of the stepper motor.
Fig. 13 PDC LOCATION
1 - BATTERY
FUEL PUMP RELAY (Continued)
IAC Stepper Motor Program: The PCM i s al so
equi pped wi th a memory program that records the
number of steps the I AC stepper motor most recentl y
advanced to duri ng a certai n set of parameters. For
exampl e: The PCM was attempti ng to mai ntai n a
1000 rpm target duri ng a col d start-up cycl e. The l ast
recorded number of steps for that may have been
125. That val ue woul d be recorded i n the memory
cel l so that the next ti me the PCM recogni zes the
i denti cal condi ti ons, the PCM recal l s that 125 steps
were requi red to mai ntai n the target. Thi s program
al l ows for greater customer sati sfacti on due to
greater control of engi ne i dl e.
Another functi on of the memory program, whi ch
occurs when the power steeri ng swi tch (i f equi pped),
or the A/C request ci rcui t, requi res that the I AC step-
per motor control engi ne rpm, i s the recordi ng of the
l ast targeted steps i nto the memory cel l . The PCM
can anti ci pate A/C compressor l oads. Thi s i s accom-
pl i shed by del ayi ng compressor operati on for approx-
i matel y 0.5 seconds unti l the PCM moves the I AC
stepper motor to the recorded steps that were l oaded
i nto the memory cel l . Usi ng thi s program hel ps el i m-
i nate i dl e-qual i ty changes as l oads change. Fi nal l y,
the PCM i ncorporates a No-Load engi ne speed l i m-
i ter of approxi matel y 1800 - 2000 rpm, when i t rec-
ogni zes that the TPS i s i ndi cati ng an i dl e si gnal and
I AC motor cannot mai ntai n engi ne i dl e.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the I AC motor through the PCM.
REMOVAL
3. 7L V-6
The I dl e Ai r Control (I AC) motor i s l ocated on the
si de of the throttl e body (Fi g. 14).
(2) Di sconnect el ectri cal connector from I AC motor.
(3) Remove two mounti ng bol ts (screws).
(4) Remove I AC motor from throttl e body.
4. 7L V-8
(2) Di sconnect el ectri cal connector from I AC motor.
(3) Remove two mounti ng bol ts (screws).
(4) Remove I AC motor from throttl e body.
5. 7L V-8
The I AC motor i s not servi ceabl e on the 5.7L V-8
engi ne.
INSTALLATION
3. 7L V-6
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
to 7 Nm (60 i n. l bs.) torque.
(3) I nstal l el ectri cal connector.
(4) I nstal l ai r resonator to throttl e body.
4. 7L V-8
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
(4) I nstal l ai r resonator to throttl e body.
5. 7L V-8
The I AC motor i s not servi ceabl e on the 5.7L V-8
engi ne.
Fig. 14 IDLE AIR CONTROL MOTOR - 3.7L V-6
1 - THROTTLE POSITION SENSOR (TPS)
2 - MOUNTING SCREWS
3 - IDLE AIR CONTROL MOTOR (IAC)
4 - MOUNTING SCREWS
IDLE AIR CONTROL MOTOR (Continued)
INTAKE AIR TEMPERATURE
SENSOR
DESCRIPTION
The 2wi re I ntake Mani fol d Ai r Temperature (I AT)
sensor i s i nstal l ed i n the i ntake mani fol d wi th the
sensor el ement extendi ng i nto the ai r stream.
The I AT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as i ntake mani -
fol d temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
The I AT sensor provi des an i nput vol tage to the
Powertrai n Control Modul e (PCM) i ndi cati ng the
densi ty of the ai r enteri ng the i ntake mani fol d based
upon i ntake mani fol d temperature. At key-on, a
5vol t power ci rcui t i s suppl i ed to the sensor from
the PCM. The sensor i s grounded at the PCM
through a l ow-noi se, sensor-return ci rcui t.
The PCM uses thi s i nput to cal cul ate the fol l owi ng:
Adjustment of spark ti mi ng (to hel p prevent
spark knock wi th hi gh i ntake mani fol d ai r-charge
temperatures)
The resi stance val ues of the I AT sensor i s the same
as for the Engi ne Cool ant Temperature (ECT) sensor.
REMOVAL
3. 7L V-6
The i ntake mani fol d ai r temperature (I AT) sensor
i s i nstal l ed i nto the l eft si de of i ntake mani fol d pl e-
num (Fi g. 16).
(1) Di sconnect el ectri cal connector from I AT sen-
sor.
(2) Cl ean di rt from i ntake mani fol d at sensor base.
(3) Gentl y l i ft on smal l pl asti c rel ease tab (Fi g. 16)
or (Fi g. 17) and rotate sensor about 1/4 turn counter-
cl ockwi se for removal .
4. 7L V-8
num (Fi g. 18).
(1) Di sconnect el ectri cal connector from I AT sen-
sor.
Fig. 15 IDLE AIR CONTROL MOTOR - 4.7L V-8
1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR
4 - IAT SENSOR
5 - MOUNTING SCREWS
Fig. 16 IAT SENSOR LOCATION - 3.7L V-6
1 - IAT SENSOR
2 - RELEASE TAB
IDLE AIR CONTROL MOTOR (Continued)
5. 7L V-8
i s i nstal l ed i nto the front of the i ntake mani fol d ai r
box pl enum (Fi g. 19).
(1) Di sconnect el ectri cal connector from I AT sensor
(Fi g. 19).
INSTALLATION
3. 7L V-6
num (Fi g. 16).
(2) Cl ean sensor mounti ng hol e i n i ntake mani fol d.
(3) Posi ti on sensor i nto i ntake mani fol d and rotate
cl ockwi se unti l past rel ease tab (Fi g. 16).
4. 7L V-8
num (Fi g. 18).
Fig. 17 IAT SENSOR TAB / O-RING - 3.7L V-6/4.7L
V-8/5.7L V-8
1 - IAT SENSOR
2 - SENSOR O-RING
3 - RELEASE TAB
Fig. 18 IAT SENSOR - 4.7L V-8
1 - LEFT SIDE OF THROTTLE BODY
2 - ELEC. CONNECT.
3 - IAT SENSOR
4 - RELEASE TAB
Fig. 19 5.7L IAT SENSOR LOCATION
1 - FRONT OF INTAKE MANIFOLD PLENUM
2 - IAT ELECTRICAL CONNECTOR
INTAKE AIR TEMPERATURE SENSOR (Continued)
cl ockwi se unti l past rel ease tab.
5. 7L V-8
i s i nstal l ed i nto the front of the i ntake mani fol d ai r
box pl enum (Fi g. 19).
cl ockwi se unti l past rel ease tab.
MAP SENSOR
DESCRIPTION
3. 7L V-6
The Mani fol d Absol ute Pressure (MAP) sensor i s
mounted i nto the front of the i ntake mani fol d wi th 2
screws.
4. 7L V-8
mounted i nto the front of the i ntake mani fol d wi th 2
screws.
5. 7L V-8
mounted to the front of the i ntake mani fol d ai r pl e-
num box.
OPERATION
The MAP sensor i s used as an i nput to the Power-
trai n Control Modul e (PCM). I t contai ns a si l i con
based sensi ng uni t to provi de data on the mani fol d
vacuum that draws the ai r/fuel mi xture i nto the com-
busti on chamber. The PCM requi res thi s i nformati on
to determi ne i njector pul se wi dth and spark advance.
When mani fol d absol ute pressure (MAP) equal s
Barometri c pressure, the pul se wi dth wi l l be at max-
i mum.
A 5 vol t reference i s suppl i ed from the PCM and
returns a vol tage si gnal to the PCM that refl ects
mani fol d pressure. The zero pressure readi ng i s 0.5V
and ful l scal e i s 4.5V. For a pressure swi ng of 015
psi , the vol tage changes 4.0V. To operate the sensor,
i t i s suppl i ed a regul ated 4.8 to 5.1 vol ts. Ground i s
provi ded through the l ow-noi se, sensor return ci rcui t
at the PCM.
The MAP sensor i nput i s the number one contri b-
utor to fuel i njector pul se wi dth. The most i mportant
functi on of the MAP sensor i s to determi ne baromet-
ri c pressure. The PCM needs to know i f the vehi cl e i s
at sea l evel or at a hi gher al ti tude, because the ai r
densi ty changes wi th al ti tude. I t wi l l al so hel p to cor-
rect for varyi ng barometri c pressure. Barometri c
pressure and al ti tude have a di rect i nverse correl a-
ti on; as al ti tude goes up, barometri c goes down. At
key-on, the PCM powers up and l ooks at MAP vol t-
age, and based upon the vol tage i t sees, i t knows the
current barometri c pressure (rel ati ve to al ti tude).
Once the engi ne starts, the PCM l ooks at the vol tage
agai n, conti nuousl y every 12 mi l l i seconds, and com-
pares the current vol tage to what i t was at key-on.
The di fference between current vol tage and what i t
was at key-on, i s mani fol d vacuum.
Duri ng key-on (engi ne not runni ng) the sensor
reads (updates) barometri c pressure. A normal range
can be obtai ned by moni tori ng a known good sensor.
As the al ti tude i ncreases, the ai r becomes thi nner
(l ess oxygen). I f a vehi cl e i s started and dri ven to a
very di fferent al ti tude than where i t was at key-on,
the barometri c pressure needs to be updated. Any
ti me the PCM sees Wi de Open Throttl e (WOT), based
upon Throttl e Posi ti on Sensor (TPS) angl e and RPM,
i t wi l l update barometri c pressure i n the MAP mem-
ory cel l . Wi th peri odi c updates, the PCM can make
i ts cal cul ati ons more effecti vel y.
The PCM uses the MAP sensor i nput to ai d i n cal -
cul ati ng the fol l owi ng:
Mani fol d pressure
Barometri c pressure
Fig. 20 5.7L IAT SENSOR R/I
1 - FRONT OF INTAKE MANIFOLD PLENUM
2 - IAT SENSOR
3 - RELEASE TAB
INTAKE AIR TEMPERATURE SENSOR (Continued)
Engi ne l oad
Spark-advance programs
Shi ft-poi nt strategi es (certai n automati c trans-
mi ssi ons onl y)
I dl e speed
Decel fuel shutoff
The MAP sensor si gnal i s provi ded from a si ngl e
pi ezoresi sti ve el ement l ocated i n the center of a di a-
phragm. The el ement and di aphragm are both made
of si l i cone. As mani fol d pressure changes, the di a-
phragm moves causi ng the el ement to defl ect, whi ch
stresses the si l i cone. When si l i cone i s exposed to
stress, i ts resi stance changes. As mani fol d vacuum
i ncreases, the MAP sensor i nput vol tage decreases
proporti onal l y. The sensor al so contai ns el ectroni cs
that condi ti on the si gnal and provi de temperature
compensati on.
The PCM recogni zes a decrease i n mani fol d pres-
sure by moni tori ng a decrease i n vol tage from the
readi ng stored i n the barometri c pressure memory
cel l . The MAP sensor i s a l i near sensor; meani ng as
pressure changes, vol tage changes proporti onatel y.
The range of vol tage output from the sensor i s usu-
al l y between 4.6 vol ts at sea l evel to as l ow as 0.3
vol ts at 26 i n. of Hg. Barometri c pressure i s the pres-
sure exerted by the atmosphere upon an object. At
sea l evel on a standard day, no storm, barometri c
pressure i s approxi matel y 29.92 i n Hg. For every 100
feet of al ti tude, barometri c pressure drops 0.10 i n.
Hg. I f a storm goes through, i t can change baromet-
ri c pressure from what shoul d be present for that
al ti tude. You shoul d know what the average pressure
and correspondi ng barometri c pressure i s for your
area.
REMOVAL
3. 7L V-6
mounted i nto the front of the i ntake mani fol d (Fi g.
21). An o-ri ng i s used to seal the sensor to the i ntake
(1) Di sconnect el ectri cal connector at sensor.
(2) Cl ean area around MAP sensor.
(3) Remove 2 sensor mounti ng screws.
(4) Remove MAP sensor from i ntake mani fol d.
(5) Check condi ti on of sensor o-ri ng (Fi g. 22).
4. 7L V-8
The MAP sensor i s l ocated on the front of the
i ntake mani fol d (Fi g. 23). An o-ri ng seal s the sensor
to the i ntake mani fol d.
(2) Cl ean area around MAP sensor.
(3) Remove 2 sensor mounti ng bol ts (Fi g. 23).
(4) Remove MAP sensor from i ntake mani fol d.
Fig. 21 MAP SENSOR - 3.7L V-6
1 - MOUNTING SCREWS
2 - MAP SENSOR
3 - ECT SENSOR
Fig. 22 MAP SENSOR O-RING 3.7L / 4.7L
1 - MAP SENSOR
2 - O-RING
MAP SENSOR (Continued)
5. 7L V-8
num box (Fi g. 24).
(1) Di sconnect el ectri cal connector at sensor by
sl i di ng rel ease l ock out (Fi g. 25). Press down on l ock
tab for removal .
(2) Rotate sensor 1/4 turn counter-cl ockwi se for
removal .
INSTALLATION
3. 7L V-6
mounted i nto the front of the i ntake mani fol d (Fi g.
21). An o-ri ng i s used to seal the sensor to the i ntake
(1) Cl ean MAP sensor mounti ng hol e at i ntake
mani fol d.
(2) Check MAP sensor o-ri ng seal for cuts or tears.
(3) Posi ti on sensor i nto mani fol d.
(4) I nstal l MAP sensor mounti ng bol ts (screws).
(5) Connect el ectri cal connector.
4. 7L V-8
The MAP sensor i s l ocated on the front of the
i ntake mani fol d (Fi g. 23). An o-ri ng seal s the sensor
to the i ntake mani fol d (Fi g. 22).
mani fol d.
Fig. 23 MAP SENSOR - 4.7L V-8
1 - ECT SENSOR
3 - MAP SENSOR
4 - INTAKE MANIFOLD
Fig. 24 5.7L MAP SENSOR LOCATION
1 - MAP SENSOR
Fig. 25 5.7L MAP SENSOR R/I
1 - PRESS DOWN
2 - SLIDE RELEASE LOCK
3 - MAP SENSOR
(4) I nstal l MAP sensor mounti ng bol ts (screws).
5. 7L V-8
num box (Fi g. 24).
mani fol d.
(4) Rotate sensor 1/4 turn cl ockwi se for i nstal l a-
ti on.
OXYGEN SENSOR
DESCRIPTION
The Oxygen Sensors (O2S) are attached to, and
protrude i nto the vehi cl e exhaust system. Dependi ng
on the engi ne or emi ssi on package, the vehi cl e may
use a total of ei ther 2 or 4 sensors.
Federal Emission Packages : Two sensors are
used: upstream (referred to as 1/1) and downstream
(referred to as 1/2). Wi th thi s emi ssi on package, the
upstream sensor (1/1) i s l ocated just before the mai n
catal yti c convertor. The downstream sensor (1/2) i s
l ocated just after the mai n catal yti c convertor.
California Emission Packages: On thi s emi s-
si ons package, 4 sensors are used: 2 upstream
(referred to as 1/1 and 2/1) and 2 downstream
(referred to as 1/2 and 2/2). Wi th thi s emi ssi on pack-
age, the ri ght upstream sensor (2/1) i s l ocated i n the
ri ght exhaust downpi pe just before the mi ni -catal yti c
convertor. The l eft upstream sensor (1/1) i s l ocated i n
the l eft exhaust downpi pe just before the mi ni -cata-
l yti c convertor. The ri ght downstream sensor (2/2) i s
l ocated i n the ri ght exhaust downpi pe just after the
mi ni -catal yti c convertor, and before the mai n cata-
l yti c convertor. The l eft downstream sensor (1/2) i s
l ocated i n the l eft exhaust downpi pe just after the
mi ni -catal yti c convertor, and before the mai n cata-
l yti c convertor.
REMOVAL
CAUTION: Never apply any type of grease to the
oxygen sensor electrical connector, or attempt any
soldering of the sensor wiring harness.
Refer to (Fi g. 26) or (Fi g. 27) for typi cal O2S (oxy-
gen sensor) l ocati ons.
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(2) Di sconnect wi re connector from O2S sensor.
CAUTION: When disconnecting sensor electrical
connector, do not pull directly on wire going into
sensor.
(3) Remove O2S sensor wi th an oxygen sensor
removal and i nstal l ati on tool .
(4) Cl ean threads i n exhaust pi pe usi ng appropri -
ate tap.
Fig. 26 O2 SENSOR SYSTEM - WITH 4 SENSORS
Fig. 27 O2 SENSOR SYSTEM - WITH 2 SENSORS
1 - POST CATALYST OXYGEN SENSOR (1/3)
2 - PRE-CATALYST OXYGEN SENSOR (1/2)
INSTALLATION
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
threads of a new oxygen sensor.
(1) I nstal l O2S sensor. Ti ghten to 30 Nm (22 ft.
l bs.) torque.
(2) Connect O2S sensor wi re connector.
PTO SWITCH
DESCRIPTION
Thi s Powertrai n Control Modul e (PCM) i nput i s
used onl y on model s equi pped wi th aftermarket
Power Take Off (PTO) uni ts.
OPERATION
The i nput i s used onl y to tel l the PCM (or ECM-
Di esel ) that the PTO has been engaged. The PCM (or
ECM) wi l l di sabl e (temporari l y shut down) certai n
OBD I I di agnosti c troubl e codes when the PTO i s
engaged.
J TEC and NGC Engine Controllers: When the
aftermarket PTO swi tch has been engaged, a 12V +
si gnal i s sent through ci rcui t G113 to PCM pi n A13.
The PCM wi l l then sense and determi ne that the
PTO has been acti vated.
CM 845 or CM 848 Diesel Engine Controllers:
When the aftermarket PTO swi tch has been engaged,
a 12V + si gnal i s sent through ci rcui t G113 to ECM
pi n B38. The ECM wi l l then sense and determi ne
that the PTO has been acti vated.
THROTTLE BODY
DESCRIPTION
The throttl e body i s l ocated on the i ntake mani fol d.
Fuel does not enter the i ntake mani fol d through the
throttl e body. Fuel i s sprayed i nto the mani fol d by
the fuel i njectors.
OPERATION
Fi l tered ai r from the ai r cl eaner enters the i ntake
mani fol d through the throttl e body. The throttl e body
contai ns an ai r control passage control l ed by an I dl e
Ai r Control (I AC) motor. The ai r control passage i s
used to suppl y ai r for i dl e condi ti ons. A throttl e val ve
(pl ate) i s used to suppl y ai r for above i dl e condi ti ons.
5.7L V-8 Engine:
The throttl e body on the 5.7L engi ne i s an el ectri -
cal l y control l ed uni t. A mechani cal cabl e i s not used
to connect the throttl e body to the accel erator pedal .
The Accel erator Pedal Posi ti on Sensor (APPS) al ong
wi th i nputs from other sensors sets the throttl e bl ade
to pre-determi ned posi ti ons.
Except 5.7L V-8 Engine:
Certai n sensors are attached to the throttl e body.
The accel erator pedal cabl e, speed control cabl e and
transmi ssi on control cabl e (when equi pped) are con-
nected to the throttl e body l i nkage arm.
control l ed by the PCM.
REMOVAL
3. 7L V-6
control l ed by the Powertrai n Control Modul e (PCM).
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at I AC motor and TPS.
(3) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on for removal /i nstal l ati on procedures.
(4) Di sconnect necessary vacuum l i nes at throttl e
body.
(5) Remove 3 throttl e body mounti ng bol ts (Fi g.
28).
(6) Remove throttl e body from i ntake mani fol d.
(7) Check condi ti on of ol d throttl e body-to-i ntake
mani fol d o-ri ng (Fi g. 29).
4. 7L V-8
(1) Remove ai r duct and ai r resonator box at throt-
tl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at I AC motor and TPS (Fi g. 30).
(3) Remove vacuum l i ne at throttl e body.
(4) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to Accel erator Pedal and Throttl e
Cabl e.
(5) Remove three throttl e body mounti ng bol ts
(Fi g. 30).
5. 7L V-8
CAUTION: Do not use spray (carb) cleaners on any
part of the throttle body. Do not apply silicone lubri-
cants to any part of the throttle body.
(1) Remove ai r duct and ai r resonator box at throt-
tl e body.
OXYGEN SENSOR (Continued)
(2) Di sconnect el ectri cal connector at throttl e body
(Fi g. 31).
(3) Remove 4 throttl e body mounti ng bol ts (Fi g.
31).
(5) Check condi ti on of throttl e body o-ri ng (Fi g.
32).
(6) I f the throttl e body has been changed, the fol -
l owi ng procedure must be performed:
(a) Di sconnect negati ve battery cabl e from bat-
tery. Leave cabl e di sconnected for approxi matel y 90
seconds.
(b) Reconnect cabl e to battery.
(c) Turn i gni ti on swi tch ON, but do not crank
engi ne.
(d) Leave i gni ti on swi tch ON for a mi ni mum of
10 seconds. Thi s wi l l al l ow PCM to l earn throttl e
body el ectri cal parameters.
INSTALLATION
3. 7L V-6
(1) Check condi ti on of throttl e body-to-i ntake man-
i fol d o-ri ng. Repl ace as necessary.
(2) Cl ean mati ng surfaces of throttl e body and
i ntake mani fol d.
(3) I nstal l throttl e body-to-i ntake mani fol d o-ri ng.
(4) I nstal l throttl e body to i ntake mani fol d.
(5) I nstal l 3 mounti ng bol ts. Ti ghten bol ts to 12
(6) I nstal l control cabl es.
(7) I nstal l el ectri cal connectors.
(8) I nstal l necessary vacuum l i nes.
(9) I nstal l ai r pl enum.
Fig. 28 THROTTLE BODY MOUNTING BOLTS - 3.7L
V-6
1 - THROTTLE BODY
Fig. 29 THROTTLE BODY O-RING - 3.7L V-6
1 - INTAKE MANIFOLD
2 - THROTTLE BODY O-RING
Fig. 30 THROTTLE BODY MOUNTING BOLTS - 4.7L
V-8
2 - THROTTLE BODY
3 - IAT SENSOR CONNECTOR
4 - IAC MOTOR CONNECTOR
5 - TPS CONNECTOR
THROTTLE BODY (Continued)
4. 7L V-8
(1) Cl ean throttl e body-to-i ntake mani fol d o-ri ng.
i ntake mani fol d.
(3) I nstal l throttl e body to i ntake mani fol d by posi -
ti oni ng throttl e body to mani fol d al i gnment pi ns.
(4) I nstal l three mounti ng bol ts. Ti ghten bol ts to
(5) I nstal l control cabl es.
(6) I nstal l vacuum l i ne to throttl e body.
(7) I nstal l el ectri cal connectors.
5. 7L V-8
CAUTION: Do not use spray (carb) cleaners on any
part of the throttle body. Do not apply silicone lubri-
cants to any part of the throttle body.
(1) Cl ean and check condi ti on of throttl e body-to-
i ntake mani fol d o-ri ng.
i ntake mani fol d.
(3) I nstal l throttl e body to i ntake mani fol d by posi -
ti oni ng throttl e body to mani fol d al i gnment pi ns.
(4) I nstal l 4 mounti ng bol ts. Refer to Torque Spec-
i fi cati ons.
(7) If the throttle body has been changed, the
following procedure must be performed:
(a) Di sconnect negati ve battery cabl e from bat-
tery. Leave cabl e di sconnected for approxi matel y 90
seconds.
(b) Reconnect cabl e to battery.
(c) Turn i gni ti on swi tch ON, but do not crank
engi ne.
(d) Leave i gni ti on swi tch ON for a mi ni mum of
10 seconds. Thi s wi l l al l ow PCM to l earn throttl e
body el ectri cal parameters.
REMOVAL
3. 7L V-6
CAUTION: Be careful not to damage or kink cable
core wire (within cable sheathing) while servicing
accelerator pedal or throttle cable.
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of pedal arm (Fi g. 1). Pl as-
ti c cabl e retai ner snaps i nto top of pedal arm.
(2) Remove cabl e core wi re at pedal arm.
(3) From i nsi de vehi cl e, remove metal cl i p hol di ng
cabl e to dashpanel (Fi g. 1).
Fig. 31 5.7L V-8 THROTTLE BODY
1 - THROTTLE BODY
3 - SILICONE SEAL
Fig. 32 5.7L V-8 THROTTLE BODY O-RING
1 - INTAKE MANIFOLD
2 - THROTTLE BODY O-RING
THROTTLE BODY (Continued)
(5) Unsnap cabl e from dashpanel routi ng cl i p.
(6) Remove cabl e housi ng from dash panel and
pul l i nto engi ne compartment.
i n thi s posi ti on, sl i de throttl e cabl e pi n (Fi g. 33) from
(8) Usi ng a pi ck or smal l screwdri ver, press rel ease
tab (Fi g. 34) to rel ease pl asti c cabl e mount from
bracket. Press on tab only enough to release
cable from bracket. If tab is pressed too much,
it will be broken. Sl i de pl asti c mount (Fi g. 34)
towards ri ght si de of vehi cl e to remove throttl e cabl e
from throttl e body bracket.
(9) Remove throttl e cabl e from vehi cl e.
4. 7L V-8
accelerator pedal or throttle cable.
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of pedal arm (Fi g. 1). Pl as-
ti c cabl e retai ner (cl i p) snaps i nto pedal arm.
(3) From i nsi de vehi cl e, remove cabl e cl i p hol di ng
(5) Unsnap cabl e from dashpanel routi ng cl i p.
pul l i nto engi ne compartment.
(7) Usi ng fi nger pressure onl y, di sconnect accel era-
tor cabl e connector at throttl e body bel l crank pi n by
pushi ng connector off bel l crank pi n towards front of
vehi cl e (Fi g. 35). DO NOT try to pull connector
off perpendicular to bellcrank pin. Connector
will be broken.
(8) Li ft accel erator cabl e from top of cabl e cam
(Fi g. 35).
(9) Press tab (Fi g. 36) to rel ease pl asti c cabl e
mount from bracket. Press on tab only enough to
release cable from bracket. If tab is pressed too
much, it will be broken. Sl i de pl asti c mount (Fi g.
36) towards passenger si de of vehi cl e to remove cabl e
from bracket.
(10) Remove throttl e cabl e from vehi cl e.
5. 7L V-8
The Throttl e Control Cabl e on the 5.7L V-8 engi ne
connects the accel erator pedal to the Accel erator
Pedal Posi ti on Sensor (APPS). A separate mechani cal
cabl e i s not routed to the throttl e body.
accelerator pedal, cables or APPS.
Remove pl asti c cabl e retai ner and throttl e cabl e core
wi re from upper end of pedal arm (Fi g. 1). The pl as-
ti c cabl e retai ner snaps i nto pedal arm.
Fig. 33 THROTTLE CABLE PIN - 3.7L V-6
1 - THROTTLE CABLE PIN
3 - PUSH UP HERE
Fig. 34 THROTTLE CABLE RELEASE TAB - 3.7L V-6
1 - THROTTLE CABLE
2 - RELEASE TAB
3 - PICK OR SCREWDRIVER
THROTTLE CONTROL CABLE (Continued)
(3) Remove APPS. Refer to Accel erator Pedal Posi -
ti on Sensor (APPS) Removal / I nstal l ati on.
(4) From i nsi de vehi cl e, remove cabl e cl i p (Fi g. 1).
pul l cabl e i nto engi ne compartment.
(6) Remove cabl e housi ng at APPS bracket by
pressi ng on rel ease tab wi th a smal l screwdri ver. To
prevent cable housing breakage, press on tab
only enough to release cable from APPS
bracket.
INSTALLATION
3. 7L V-6
(1) Sl i de accel erator cabl e pl asti c mount i nto throt-
tl e body mounti ng bracket. Conti nue sl i di ng unti l
rel ease tab (Fi g. 34) i s al i gned to hol e i n mounti ng
bracket.
i n thi s posi ti on, sl i de throttl e cabl e pi n (Fi g. 33) i nto
(3) Push cabl e housi ng i nto rubber grommet and
through openi ng i n dash panel .
(4) From i nsi de vehi cl e, i nstal l metal cl i p hol di ng
(5) From i nsi de vehi cl e, sl i de throttl e cabl e core
wi re i nto openi ng (sl ot) i n top of pedal arm.
(6) Push pl asti c cabl e retai ner (cl i p) i nto pedal arm
openi ng unti l i t snaps i n pl ace.
(7) I nstal l ai r resonator tube to throttl e body.
4. 7L V-8
(1) Sl i de accel erator cabl e pl asti c mount i nto
bracket. Conti nue sl i di ng unti l tab (Fi g. 36) i s
al i gned to hol e i n mounti ng bracket.
(2) Route accel erator cabl e over top of cabl e cam.
(3) Connect cabl e end to throttl e body bel l crank
pi n (snaps on rearward).
(4) Sl i de rubber grommet away from pl asti c cabl e
housi ng.
(5) I nstal l rubber grommet i nto dash panel unti l
seated.
(7) From i nsi de vehi cl e, i nstal l cl i p hol di ng cabl e
to dashpanel (Fi g. 1).
wi re i nto openi ng i n top of pedal arm.
(9) Push cabl e retai ner (cl i p) i nto pedal arm open-
i ng unti l i t snaps i n pl ace.
(10) Snap cabl e i nto dashpanel routi ng cl i p.
Fig. 35 ACCELERATOR CABLE AT BELL CRANK -
4.7L V-8
1 - THROTTLE BODY
2 - SPEED CONTROL CABLE CONNECTOR
3 - OFF
4 - OFF
5 - ACCELERATOR CABLE CONNECTOR
6 - CABLE CAM
7 - BELLCRANK
Fig. 36 ACCELERATOR CABLE RELEASE TAB -
4.7L V-8
3 - PRESS TAB FOR REMOVAL
4 - CABLE BRACKET
5 - SLIDE FOR REMOVAL
(11) I nstal l ai r resonator tube to throttl e body.
5. 7L V-8
(1) Attach cabl e to Accel erator Pedal Posi ti on Sen-
sor (APPS). Refer to APPS Removal / I nstal l ati on.
any APPS Di agnosti c Troubl e Codes (DTCs) from
PCM.
THROTTLE POSITION SENSOR
DESCRIPTION
The 3-wi re Throttl e Posi ti on Sensor (TPS) i s
mounted on the throttl e body and i s connected to the
throttl e bl ade shaft.
The 5.7L V-8 engi ne does not use a separate TPS
on the throttl e body.
OPERATION
The 5.7L V-8 engi ne does not use a separate Throt-
tl e Posi ti on Sensor (TPS) on the throttl e body.
The 3wi re TPS provi des the Powertrai n Control
Modul e (PCM) wi th an i nput si gnal (vol tage) that
represents the throttl e bl ade posi ti on of the throttl e
body. The sensor i s connected to the throttl e bl ade
shaft. As the posi ti on of the throttl e bl ade changes,
the output vol tage of the TPS changes.
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The
PCM recei ves an i nput si gnal vol tage from the TPS.
Thi s wi l l vary i n an approxi mate range of from .26
vol ts at mi ni mum throttl e openi ng (i dl e), to 4.49 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons. I n response to
engi ne operati ng condi ti ons, the PCM wi l l adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
The PCM needs to i denti fy the acti ons and posi ti on
of the throttl e bl ade at al l ti mes. Thi s i nformati on i s
needed to assi st i n performi ng the fol l owi ng cal cul a-
ti ons:
I gni ti on ti mi ng advance
Fuel i njecti on pul se-wi dth
I dl e (l earned val ue or mi ni mum TPS)
Off-i dl e (0.06 vol t)
Wi de Open Throttl e (WOT) open l oop (2.608
vol ts above l earned i dl e vol tage)
Decel erati on fuel l ean out
Fuel cutoff duri ng cranki ng at WOT (2.608 vol ts
above l earned i dl e vol tage)
A/C WOT cutoff (certai n automati c transmi s-
si ons onl y)
REMOVAL
3. 7L V6
The Throttl e Posi ti on Sensor (TPS) i s mounted to
the throttl e body (Fi g. 37), or (Fi g. 38).
(1) Remove ai r resonator tube at throttl e body.
(2) Di sconnect TPS el ectri cal connector.
(3) Remove 2 TPS mounti ng screws.
(4) Remove TPS.
Fig. 37 TPS LOCATION - 3.7L V-6
1 - THROTTLE POSITION SENSOR (TPS)
2 - MOUNTING SCREWS
3 - IDLE AIR CONTROL MOTOR (IAC)
4 - MOUNTING SCREWS
4. 7L V-8
The TPS i s l ocated on the throttl e body (Fi g. 39).
(1) Remove ai r duct and tube at throttl e body.
(2) Di sconnect TPS el ectri cal connector.
(3) Remove two TPS mounti ng bol ts (screws) (Fi g.
39).
(4) Remove TPS from throttl e body.
5. 7L V-8
The 5.7L V-8 engi ne does not use a separate Throt-
tl e Posi ti on Sensor (TPS) on the throttl e body.
Fig. 38 TPS INSTALLATION - 3.7 V-6
1 - THROTTLE BODY
2 - TPS
3 - THROTTLE BODY SHAFT
4 - SOCKET LOCATING TANGS
Fig. 39 TPS LOCATION - 4.7L
1 - THROTTLE BODY
2 - TPS
3 - IAC MOTOR
4 - IAT SENSOR
5 - MOUNTING SCREWS
THROTTLE POSITION SENSOR (Continued)
INSTALLATION
3. 7L V-6
The Throttl e Posi ti on Sensor (TPS) i s mounted to
the throttl e body (Fi g. 37).
The throttl e shaft end of throttl e body sl i des i nto a
socket i n TPS (Fi g. 40). The TPS must be i nstal l ed so
that i t can be rotated a few degrees. (I f sensor wi l l
not rotate, i nstal l sensor wi th throttl e shaft on other
si de of socket tangs). The TPS wi l l be under sl i ght
tensi on when rotated.
(1) I nstal l TPS and retai ni ng screws.
(2) Ti ghten screws to 7 Nm (60 i n. l bs.) torque.
(3) Connect TPS el ectri cal connector to TPS.
(4) Manual l y operate throttl e (by hand) to check
for any TPS bi ndi ng before starti ng engi ne.
(5) I nstal l ai r cl eaner tube to throttl e body.
4. 7L V-8
The throttl e shaft end of throttl e body sl i des i nto a
socket i n TPS (Fi g. 41). The TPS must be i nstal l ed so
that i t can be rotated a few degrees. I f sensor wi l l
not rotate, i nstal l sensor wi th throttl e shaft on other
si de of socket tangs. The TPS wi l l be under sl i ght
tensi on when rotated.
(1) I nstal l TPS and two retai ni ng bol ts.
(2) Ti ghten bol ts to 7 Nm (60 i n. l bs.) torque.
(3) Manual l y operate throttl e control l ever by hand
to check for any bi ndi ng of TPS.
(4) Connect TPS el ectri cal connector to TPS.
(5) I nstal l ai r duct/ai r box to throttl e body.
Fig. 40 TPS INSTALLATION - 3.7L
1 - THROTTLE BODY
2 - TPS
3 - THROTTLE BODY SHAFT
4 - SOCKET LOCATING TANGS
Fig. 41 TPS INSTALLATION - 4.7L
1 - THROTTLE BODY
2 - LOCATING TANGS
3 - THROTTLE POSITION SENSOR
4 - SOCKET
5 - THROTTLE SHAFT
THROTTLE POSITION SENSOR (Continued)
FUEL DELIVERY - DIESEL
TABLE OF CONTENTS
page page
DESCRIPTION - DIESEL FUEL SYSTEM . . . . . 45
STANDARD PROCEDURE
STANDARD PROCEDURES - WATER
DRAINING AT FUEL FILTER. . . . . . . . . . . . . . 47
STANDARD PROCEDURES - CLEANING
FUEL SYSTEM PARTS . . . . . . . . . . . . . . . . . 47
PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SPECIFICATIONS
FUEL INJECTOR FIRING ORDER - DIESEL . 48
TORQUE - FUEL SYSTEM - DIESEL
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SPECIAL TOOLS
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . 49
FUEL FILTER / WATER SEPARATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50
FUEL HEATER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 51
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DIAGNOSIS AND TESTING - FUEL HEATER . . . 52
REMOVAL
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . 52
FUEL HEATER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53
FUEL INJECTION PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 53
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DIAGNOSIS AND TESTING - FUEL INJECTION
PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . 53
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 57
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
REMOVAL
FUEL LINES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 57
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DIAGNOSIS AND TESTING - HIGH-
PRESSURE FUEL LINE LEAKS . . . . . . . . . . . 58
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60
FUEL PRESSURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 60
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
FUEL PRESSURE LIMITING VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 61
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
FUEL TANK
DESCRIPTION - DIESEL . . . . . . . . . . . . . . . . . . 62
REMOVAL - DIESEL . . . . . . . . . . . . . . . . . . . . . 62
INSTALLATION - DIESEL . . . . . . . . . . . . . . . . . 62
FUEL TANK MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 63
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64
FUEL TRANSFER PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 64
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 65
CASCADE OVERFLOW VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 66
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
REMOVAL
WATER IN FUEL SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 66
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
FUEL DRAIN CIRCUIT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
14 - 44 FUEL DELIVERY - DIESEL DR
DESCRIPTION - DIESEL FUEL SYSTEM
The fuel system used on the Cummi ns engi ne i s an
el ectroni cal l y control l ed, Bosch HPCR (Hi gh-Pressure
Common Rai l ) system. The HPCR system consi sts of
fi ve mai n components:
El ectri c Fuel Transfer (l i ft) Pump
Fuel Pump/Gear Pump (attached to fuel i njec-
ti on pump)
Hi gh-Pressure Fuel I njecti on Pump
Fuel I njecti on Rai l
Fuel I njectors
Al so to be consi dered as part of the overal l fuel
system are:
Accel erator Pedal
Ai r Cl eaner Housi ng/El ement
Fuel Drai n Mani fol d (passage)
Fuel Drai n Val ve (at fi l ter)
Fuel Fi l ter/Water Separator
Fuel Heater
Fuel Heater Rel ay
Fuel Level (gauge) Sendi ng Uni t
Fuel Pressure Li mi ti ng Val ve
Fuel Tank
Fuel Tank Modul e (contai ni ng fuel gauge send-
i ng uni t and separate fuel fi l ter l ocated at bottom of
tank modul e)
Fuel Tank Fi l l er/Vent Tube Assembl y
Fuel Tank Fi l l er Tube Cap
Fuel Tubes/Li nes/Hoses
Hi gh-Pressure Fuel I njector Li nes
I n-Tank Fuel Fi l ter (at bottom of fuel tank mod-
ul e)
Low-Pressure Fuel Suppl y Li nes
Low-Pressure Fuel Return Li ne
Overfl ow Val ve
Qui ck-Connect Fuel Li ne Fi tti ngs
Throttl e Cabl e
Water Drai ni ng (mai ntenance)
Water-I n-Fuel (WI F) Sensor
The fuel i njecti on pump suppl i es hi gh pressure to
the fuel rai l i ndependent of engi ne speed. Thi s hi gh
pressure fuel i s then accumul ated i n the fuel rai l .
Hi gh pressure fuel i s constantl y suppl i ed to the i njec-
tors by the fuel rai l . The Engi ne Control Modul e
(ECM) control s the fuel i ng and ti mi ng of the engi ne
by actuati ng the i njectors.
Fuel enters the system from the el ectri c fuel trans-
fer (l i ft) pump, whi ch i s attached to the fuel fi l ter
assembl y. Fuel i s forced through the fuel fi l ter el e-
ment and then enters the Fuel Pump/Gear Pump,
whi ch i s attached to the rear of the fuel i njecti on
pump. The Fuel Pump/Gear Pump i s a l ow-pressure
pump and produce pressures rangi ng from 551.5 kpa
(80 psi ) to 1241 kpa (180) psi . Fuel then enters the
fuel i njecti on pump. Low pressure fuel i s then sup-
pl i ed to the FCA (Fuel Control Actuator).
The FCA i s an el ectroni cal l y control l ed sol enoi d
val ve. The ECM control s the amount of fuel that
enters the hi gh-pressure pumpi ng chambers by open-
i ng and cl osi ng the FCA based on a demanded fuel
pressure. The FPS (Fuel Pressure Sensor) on the fuel
rai l moni tors the actual fuel pressure and provi des i t
as an i nput to the ECM. When the actuator i s
opened, the maxi mum amount of fuel i s bei ng sup-
pl i ed to the fuel i njecti on pump. Any fuel that does
not enter the i njecti on pump i s di rected to the over-
fl ow val ve. The overfl ow val ve regul ates how much
excess fuel i s used for l ubri cati on of the pump and
how much i s returned to the tank through the drai n
mani fol d.
Fuel enteri ng the i njecti on pump i s pressuri zed to
between 300-1600 bar (4351-23,206 psi ) by three
radi al pumpi ng chambers. The pressuri zed fuel i s
then suppl i ed to the fuel rai l .
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 160,000 KPA (23,206
PSI). USE EXTREME CAUTION WHEN INSPECTING
FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
Certai n fuel system components can be found i n
(Fi g. 1), or (Fi g. 2).
DR FUEL DELIVERY - DIESEL 14 - 45
Fig. 1 DIESEL FUEL SYSTEM COMPONENTS
1 - ENGINE COOLANT TEMPERATURE (ECT) SENSOR 14 - FUEL SUPPLY LINE (LOW-PRESSURE, TO ENGINE)
2 - THROTTLE LEVER BELLCRANK AND APPS (ACCELERATOR
PEDAL POSITION SENSOR)
15 - FUEL RETURN LINE CONNECTION (TO FUEL TANK)
3 - INTAKE MANIFOLD AIR HEATER/ELEMENTS 16 - FUEL DRAIN TUBE
4 - FUEL PRESSURE SENSOR 17 - OIL PRESSURE SWITCH
5 - FUEL PRESSURE LIMITING VALVE 18 - ENGINE CONTROL MODULE (ECM)
6 - HIGH-PRESSURE FUEL LINES 19 - FUEL INJECTION PUMP
7 - FUEL HEATER 20 - CRANKSHAFT POSITION (ENGINE SPEED) SENSOR
8 - HIGH-PRESSURE FUEL RAIL 21 - CAMSHAFT POSITION SENSOR (CMP)
9 - FUEL HEATER TEMPERATURE SENSOR (THERMOSTAT) 22 - FUEL CONTROL ACTUATOR (FCA)
10 - FUEL FILTER/WATER SEPARATOR 23 - CASCADE OVERFLOW VALVE
11 - FUEL TRANSFER (LIFT) PUMP
12 - FUEL DRAIN MANIFOLD (CYLINDER HEAD FUEL RETURN
LINE)
13 - DRAIN VALVE
FUEL DELIVERY - DIESEL (Continued)
STANDARD PROCEDURE
STANDARD PROCEDURES - WATER DRAINING
AT FUEL FILTER
Refer to Fuel Fi l ter/Water Separator removal /i n-
stal l ati on for procedures.
STANDARD PROCEDURES - CLEANING FUEL
SYSTEM PARTS
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
PRIMING
A certai n amount of ai r becomes trapped i n the
fuel system when fuel system components on the
suppl y and/or hi gh-pressure si de are servi ced or
repl aced. Fuel system pri mi ng i s accompl i shed usi ng
the el ectri c fuel transfer (l i ft) pump.
Servi ci ng or repl aci ng fuel system components wi l l
not requi re fuel system pri mi ng.
The fuel transfer (l i ft) pump i s sel f-pri mi ng: When
the key i s fi rst turned on (wi thout cranki ng engi ne),
the pump operates for approxi matel y 1 to 2 second
and then shuts off. The pump wi l l al so operate for up
to 25 seconds after the starter i s qui ckl y engaged,
and then di sengaged wi thout al l owi ng the engi ne to
start. The pump shuts off i mmedi atel y i f the key i s
on and the engi ne stops runni ng.
(1) Turn key to CRANK posi ti on and qui ckl y
rel ease key to ON posi ti on before engi ne starts. Thi s
wi l l operate fuel transfer pump for approxi matel y 25
seconds.
(2) Crank engi ne. I f the engi ne does not start after
25 seconds, turn key OFF. Repeat previ ous step unti l
engi ne starts.
(3) Fuel system pri mi ng i s now compl eted.
(4) Attempt to start engi ne. I f engi ne wi l l not
start, proceed to fol l owi ng steps. When engine does
start, it may run erratically and be noisy for a
few minutes. This is a normal condition.
CAUTION: Do not engage the starter motor for more
than 30 seconds at a time. Allow two minutes
between cranking intervals.
(5) Perform previ ous fuel pri mi ng procedure steps
usi ng fuel transfer pump. Be sure fuel i s present at
fuel tank.
(6) Crank the engi ne for 30 seconds at a ti me to
al l ow fuel system to pri me.
WARNING: THE FUEL INJECTION PUMP SUPPLIES
EXTREMELY HIGH FUEL PRESSURE TO EACH INDI-
VIDUAL INJECTOR THROUGH THE HIGH-PRES-
SURE LINES. FUEL UNDER THIS AMOUNT OF
PRESSURE CAN PENETRATE THE SKIN AND
CAUSE PERSONAL INJURY. WEAR SAFETY GOG-
GLES AND ADEQUATE PROTECTIVE CLOTHING.
DO NOT LOOSEN FUEL FITTINGS WHILE ENGINE
IS RUNNING.
WARNING: ENGINE MAY START WHILE CRANKING
STARTER MOTOR.
Fig. 2 FUEL INJECTORS
1 - SOLENOID CONNECTIONS
2 - ROCKER HOUSING
3 - FUEL INJECTOR
4 - PASSTHROUGH CONNECTOR
SPECIFICATIONS
FUEL INJECTOR FIRING ORDER - DIESEL
153624
TORQUE - FUEL SYSTEM - DIESEL ENGINE
Accelerator Pedal Bracket Mounting 12 - 105
Accelerator Pedal Position Sensor
Bracket-to-Battery Tray Bolts
3 - 30
Crankshaft Position Sensor 9 80
Camshaft Position Sensor 9 - 80
Engine Coolant Temperature Sensor 18 15 160
Rear Engine Lift Bracket Bolts 77 56 -
Fuel Connector Nut at Cylinder Head 50 37 -
Fuel Filler Hose Clamp at Tank 3 - 30
Fuel Filler Housing-to-Body Screws 2 - 17
Fuel Filter Lid 34 25 -
Fuel Filter Drain Valve Screws 1.5 - 14
Fuel Heater Element Screws 1.5 - 14
Fuel Pump Module Lock Ring 54 40 -
Fuel Line Banjo Fitting Bolts 24 18 -
Fuel Line Fittings (High-Pressure - Pump
to Rail)
37 27 -
Fuel Line Fittings (High-Pressure -
Cylinder head to Rail)
30 22 -
Bracket Over #6 Fuel Line (Bolts) 43 32 -
Fuel Injector Solenoid Nuts 1.25 - 11
Fuel Injection Pump-to-Gear Shaft Nut 105 77 -
Fuel Injection Pump Mounting Nuts 24 18 -
Fuel Line Support Clamps (High-
Pressure)
24 18 -
Fuel Pressure Sensor 70 52 -
Fuel Pressure Limiting Valve (Banjo Bolt) 24 17 -
Fuel Pressure Limiting Valve (In Fuel
Rail)
70 52 -
Fuel Rail Mounting Bolts 24 18 200
Fuel Tank Mounting Straps 41 30 -
Map Sensor Mounting Screws 1 - 9
ECM-to-Engine Bracket Mounting Bolts 24 18 -
ECM Electrical Harness Connector 3 - 27
Water-In-Fuel Sensor 4.5 - 39
SPECIAL TOOLS
DIESEL FUEL SYSTEM
FUEL PRESSURE TEST ADAPTER - # 9012
FUEL PRESSURE TEST ADAPTER - #9014
FUEL INJECTOR REMOVER - #9010
PRESSURE CAP - #9011
FUEL PRESSURE TEST ADAPTER - #9013
FUEL INJECTOR TUBE (CONNECTOR) REMOVER -
#9015
SPANNER WRENCH (FUEL TANK MODULE
REMOVAL/INSTALLATION) - #6856
FUEL FILTER / WATER
SEPARATOR
DESCRIPTION
The fuel fi l ter/water separator assembl y i s l ocated
on l eft si de of engi ne above the starter motor. The
assembl y al so i ncl udes the fuel heater, Water-I n-Fuel
(WI F) sensor, and fuel transfer pump.
OPERATION
The fuel fi l ter/water separator protects the fuel
i njecti on pump by removi ng water and contami nants
from the fuel . The constructi on of the fi l ter/separator
al l ows fuel to pass through i t, but hel ps prevent
moi sture (water) from doi ng so. Moi sture col l ects at
the bottom of the cani ster.
Refer to the mai ntenance schedul es i n the owners
manual for the recommended fuel fi l ter repl acement
i nterval s.
For drai ni ng of water from cani ster, refer to Fuel
Fi l ter/Water Separator Removal /I nstal l ati on secti on.
A Water-I n-Fuel (WI F) sensor i s attached to the
si de of fuel fi l ter housi ng. Refer to Water-I n-Fuel
Sensor Descri pti on/Operati on.
The fuel heater i s i nstal l ed i nto the top of the fi l -
ter/separator housi ng. Refer to Fuel Heater Descri p-
ti on/Operati on.
REMOVAL
Refer to mai ntenance schedul es i n thi s manual , or
the owners manual for recommended fuel fi l ter
repl acement i nterval s.
Draining water from fuel filter/water separa-
tor housing:
The housi ng drai n val ve (Fi g. 3) serves two pur-
poses. One i s to partially the drai n fi l ter housi ng of
excess water. The other i s to completely the drai n
housi ng for fuel fi l ter, drai n val ve, heater el ement, ,
water-i n-fuel sensor repl acement or transfer pump
repl acement.
The fi l ter housi ng shoul d be parti al l y drai ned
whenever the water-i n-fuel warni ng l amp remai ns
i l l umi nated. (Note that l amp wi l l be i l l umi nated for
approxi matel y two seconds when i gni ti on key i s i ni -
ti al l y pl aced i n ON posi ti on for a bul b check).
(1) A drai n hose (Fi g. 3) i s l ocated at the bottom of
drai n val ve. Pl ace drai n pan under drai n hose.
(2) With engine not running, rotate drai n val ve
handl e counter-cl ockwi se (rearward) to OPEN
(DRAI N) posi ti on. Hol d drai n val ve open unti l al l
water and contami nants have been removed and
cl ean fuel exi ts.
(3) I f drai n val ve, fuel heater el ement or Water-I n-
Fuel (WI F) sensor i s bei ng repl aced, drai n housi ng
compl etel y. Di spose of mi xture i n drai n pan accordi ng
to appl i cabl e regul ati ons.
(4) After drai ni ng operati on, rotate val ve handl e
cl ockwi se (forward) to the CLOSE posi ti on.
(5) Fuel Filter Replacement: The fuel fi l ter i s
l ocated i nsi de of the fuel fi l ter housi ng.
(a) Cl ean al l debri s from around cani ster.
(b) Remove fi l ter l i d (Fi g. 4) usi ng a socket.
Attach socket to l arge hex on top of l i d (Fi g. 4).
Rotate counter-cl ockwi se for removal . Remove
o-ri ng. Di scard o-ri ng.
(c) Remove fi l ter el ement by twi sti ng el ement
si deways from fi l ter l i d.
(6) Water-In-Fuel (WIF) Sensor Replacement:
The WI F sensor i s l ocated on the si de of the fuel fi l -
ter housi ng (Fi g. 3).
(a) Di sconnect el ectri cal connector at sensor.
(b) Cl ean area around sensor.
(c) Remove sensor by rotati ng counter-cl ockwi se.
(d) Check condi ti on of sensor o-ri ng. Repl ace i f
damaged.
(7) Fuel Heater Element Replacement: The
heater el ement i s l ocated i n the fuel fi l ter housi ng
(Fi g. 3).
(a) Remove fuel fi l ter. See previ ous steps.
(b) Di sconnect el ectri cal connector.
(c) Remove two T-15 Torx head mounti ng screws
from fuel heater el ement.
(d) Remove fuel heater.
(8) Drain Valve Replacement: The drai n val ve
assembl y i s l ocated on the si de of the fuel fi l ter hous-
i ng (Fi g. 3).
(a) Di sconnect drai n hose from the fuel drai n
val ve.
(b) Remove 4 drai n val ve mounti ng screws (T-15
Torx head).
(c) Remove drai n val ve from fi l ter housi ng.
INSTALLATION
Refer to mai ntenance schedul es for recommended
fuel fi l ter repl acement i nterval s.
(1) Thoroughl y cl ean i nsi de of fi l ter housi ng, fi l ter
cap and al l rel ated components.
(2) Fuel Filter:
(a) The engine has a self-priming low-pres-
sure fuel system. Refer to Standard Proce-
dures-Fuel System Priming.
ENGINE ROTATING (BARRING) TOOL - #7471B
(ALSO PART OF KIT #6860)
(b) I nstal l new o-ri ng to cani ster l i d and l ubri -
cate o-ri ng wi th cl ean engi ne oi l .
(c) Posi ti on new el ement to cani ster l i d. Pl ace
thi s assembl y i nto cani ster by rotati ng cl ockwi se.
(d) Ti ghten cap to 34 Nm (25 ft. l bs.) torque. Do
not overti ghten cap.
(3) Water-In-Fuel (WIF) Sensor:
(a) I nstal l new o-ri ng seal to WI F sensor.
(b) Appl y a l i ght fi l m of cl ean oi l to o-ri ng seal .
(c) I nstal l sensor i nto housi ng.
(d) Ti ghten sensor to 2.5 Nm (25 i n. l bs.) torque.
(e) Connect el ectri cal connector to WI F sensor.
(4) Fuel Heater Element:
(a) I nstal l fuel heater i nto fuel fi l ter housi ng.
(b) I nstal l fuel heater thermostat i nto fuel fi l ter
housi ng.
(c) I nstal l fuel heater mounti ng screws and
ti ghten to 1-1.5 Nm (13 i n. l bs.) torque.
(d) Connect el ectri cal connector to fuel heater
thermostat.
(e) I nstal l new fi l ter cover O-ri ng onto fuel fi l ter
housi ng cover and l ubri cate wi th cl ean engi ne oi l .
(f) Ti ghten fuel fi l ter housi ng cover (l i d) to 34
Nm (25 ft. l bs.).
(5) Drain Valve:
(a) I nstal l 2 new o-ri ngs to val ve and fi l ter hous-
i ng.
(b) Lubri cate wi th si l i con grease.
(c) I nstal l fuel drai n val ve.
(d) I nstal l 4 mounti ng screws and ti ghten to
11.5 Nm (813 i n. l bs.) torque.
(e) Connect drai n hose to drai n val ve.
FUEL HEATER
DESCRIPTION
The fuel heater assembl y i s l ocated on the si de of
the fuel fi l ter housi ng (Fi g. 3).
The heater/el ement assembl y i s equi pped wi th a
temperature sensor (thermostat) that senses fuel
temperature. Thi s sensor i s attached to the fuel heat-
er/el ement assembl y.
OPERATION
The fuel heater i s used to prevent di esel fuel from
waxi ng duri ng col d weather operati on.
When the temperature i s bel ow 45 8 degrees F,
the temperature sensor al l ows current to fl ow to the
heater el ement warmi ng the fuel . When the temper-
ature i s above 75 8 degrees F, the sensor stops cur-
rent fl ow to the heater el ement.
Battery vol tage to operate the fuel heater el ement
i s suppl i ed from the i gni ti on swi tch and through the
fuel heater rel ay. Al so refer to Fuel Heater Rel ay.
Fig. 3 FILTER HOUSING
1 - FILTER HOUSING
2 - FUEL HEATER AND THERMOSTAT
3 - FUEL HEATER MOUNTING SCREWS
4 - FUEL HEATER ELEC. CONNECTOR
5 - WIF SENSOR
6 - WIF SENSOR ELEC. CONNECTOR
7 - DRAIN HOSE
8 - DRAIN VALVE MOUNTING SCREWS
9 - DRAIN VALVE
Fig. 4 FILTER COVER (LID)
1 - FILTER COVER
2 - ATTACH SOCKET HERE
FUEL FILTER / WATER SEPARATOR (Continued)
The fuel heater element and fuel heater relay
are not computer controlled.
The heater el ement operates on 12 vol ts, 300 watts
at 0 degrees F.
DIAGNOSIS AND TESTING - FUEL HEATER
The fuel heater i s used to prevent di esel fuel from
waxi ng duri ng col d weather operati on.
NOTE: The fuel heater element, fuel heater relay
and fuel heater temperature sensor are not con-
trolled by the Engine Control Module (ECM).
A mal functi oni ng fuel heater can cause a wax
bui l d-up i n the fuel fi l ter/water separator. Wax
bui l d-up i n the fi l ter/separator can cause engi ne
starti ng probl ems and prevent the engi ne from rev-
vi ng up. I t can al so cause bl ue or whi te fog-l i ke
exhaust. I f the heater i s not operati ng i n col d tem-
peratures, the engi ne may not operate due to fuel
waxi ng.
The fuel heater assembl y i s l ocated on the si de of
fuel fi l ter housi ng.
The heater assembl y i s equi pped wi th a bui l t-i n
fuel temperature sensor (thermostat) that senses fuel
temperature. When fuel temperature drops bel ow 45
degrees 8 degrees F, the sensor al l ows current to
fl ow to bui l t-i n heater el ement to warm fuel . When
fuel temperature ri ses above 75 degrees 8 degrees
F, the sensor stops current fl ow to heater el ement
(ci rcui t i s open).
Vol tage to operate fuel heater el ement i s suppl i ed
from i gni ti on swi tch, through fuel heater rel ay (al so
refer to Fuel Heater Rel ay), to fuel temperature sen-
sor and on to fuel heater el ement.
The heater el ement operates on 12 vol ts, 300 watts
at 0 degrees F. As temperature i ncreases, power
requi rements decrease.
A mi ni mum of 7 vol ts i s requi red to operate the
fuel heater. The resi stance val ue of the heater el e-
ment i s l ess than 1 ohm (col d) and up to 1000 ohms
warm.
TESTING
(1) Di sconnect el ectri cal connector from thermostat
(Fi g. 3).
Ambi ent temperature must be bel ow the ci rcui t
cl ose temperature. I f necessary, i nduce thi s ambi ent
temperature by pl aci ng i ce packs on thermostat to
produce an effecti ve ambi ent temperature bel ow ci r-
cui t cl ose temperature.
Measure resi stance across two pi ns. Operati ng
range i s 0.3 0.45 Ohms.
(2) I f resi stance i s out of range, remove thermostat
and check resi stance across termi nal connecti ons of
heater. The heater can be checked at room tempera-
ture. Operati ng range i s 0.3 - 0.45 Ohms.
(3) Repl ace heater i f resi stance i s not wi thi n oper-
ati ng range.
(4) I f heater i s wi thi n operati ng range, repl ace
heater thermostat.
REMOVAL
REMOVAL/INSTALLATION
The fuel heater/el ement/sensor assembl y i s l ocated
i nsi de of the fuel fi l ter housi ng. Refer to Fuel Fi l ter/
Water Separator Removal /I nstal l ati on for procedures.
FUEL HEATER RELAY
DESCRIPTION
The fuel heater rel ay i s l ocated i n Power Di stri bu-
ti on Center (PDC) (Fi g. 5). Refer to l abel on i nsi de of
PDC cover for rel ay l ocati on.
OPERATION
Battery vol tage to operate the fuel heater el ement
i s suppl i ed from the i gni ti on swi tch through the fuel
heater rel ay. The fuel heater element and fuel
heater relay are not computer controlled.
REMOVAL
The fuel heater rel ay i s l ocated i n the Power Di s-
tri buti on Center (PDC) (Fi g. 6). Refer to l abel under
Fig. 5 POWER DISTRIBUTION CENTER LOCATION
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
7 - FENDER INNER SHIELD
8 - POWER DISTRIBUTION CENTER
FUEL HEATER (Continued)
INSTALLATION
The fuel heater rel ay i s l ocated i n the Power Di s-
tri buti on Center (PDC) (Fi g. 6). Refer to l abel under
FUEL INJ ECTION PUMP
DESCRIPTION
A Robert Bosch hi gh-pressure fuel i njecti on pump
i s used. The pump i s attached to the back of the ti m-
i ng gear cover at the l eft / rear si de of the engi ne.
OPERATION
The fuel i njecti on pump suppl i es hi gh pressure to
the fuel rai l i ndependent of engi ne speed. Thi s hi gh
pressure i s then accumul ated i n the fuel rai l . Hi gh
pressure fuel i s constantl y suppl i ed to the i njectors
by the fuel rai l . The Engi ne Control Modul e (ECM)
control s the fuel i ng and ti mi ng of the engi ne by actu-
ati ng the i njectors.
Fuel enters the system from the el ectri c fuel trans-
fer (l i ft) pump, whi ch i s attached to the fuel fi l ter
assembl y. Fuel i s forced through the fuel fi l ter el e-
ment and then enters the Fuel Pump/Gear Pump,
whi ch i s attached to the rear of the fuel i njecti on
pump. The Fuel Pump/Gear Pump i s a l ow-pressure
pump and produce pressures rangi ng from 551.5 kpa
(80 psi ) to 1241 kpa (180) psi . Fuel then enters the
fuel i njecti on pump. Low pressure fuel i s then sup-
pl i ed to the FCA (Fuel Control Actuator).
The FCA i s an el ectroni cal l y control l ed sol enoi d
val ve. The ECM control s the amount of fuel that
enters the hi gh-pressure pumpi ng chambers by open-
i ng and cl osi ng the FCA based on a demanded fuel
pressure. The FPS (Fuel Pressure Sensor) on the fuel
rai l provi des the actual fuel pressure. When the
actuator i s opened, the maxi mum amount of fuel i s
bei ng suppl i ed to the fuel i njecti on pump. Any fuel
that does not enter the i njecti on pump i s di rected to
the cascade overfl ow val ve. The cascade overfl ow
val ve regul ates how much excess fuel i s used for
l ubri cati on of the pump and how much i s returned to
the tank through the drai n mani fol d.
Fuel enteri ng the i njecti on pump i s pressuri zed to
between 300-1600 bar (4351-23206 psi ) by three
radi al pumpi ng chambers. The pressuri zed fuel i s
then suppl i ed to the fuel rai l .
DIAGNOSIS AND TESTING - FUEL INJECTION
PUMP TIMING
Wi th the Bosch i njecti on pump, there are no
mechani cal adjustments needed or necessary to
accompl i sh fuel i njecti on ti mi ng. Al l ti mi ng and fuel
adjustments are el ectri cal l y made by the engi ne
mounted Engi ne Control Modul e (ECM).
Fig. 6 POWER DISTRIBUTION CENTER LOCATION
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
7 - FENDER INNER SHIELD
8 - POWER DISTRIBUTION CENTER
FUEL HEATER RELAY (Continued)
REMOVAL
batteri es. Cover and i sol ate ends of both cabl es.
(2) Remove i ntake mani fol d ai r i ntake tube (above
i njecti on pump) and i ts rubber connector hose (Fi g.
7).
(3) Remove accessory dri ve bel t.
(4) Thoroughl y cl ean the rear of i njecti on pump,
and attachment poi nts for i ts 3 fuel l i nes (Fi g. 8).
Al so cl ean the opposi te ends of these same 3 l i nes at
thei r attachment poi nts.
(5) Di sconnect Fuel Control Actuator (FCA) el ectri -
cal connector at rear of i njecti on pump (Fi g. 9).
CAUTION: Whenever a fuel line fitting is connected
to a secondary fitting, always use a back-up wrench
on the secondary fitting. Do not allow the second-
ary fitting to rotate.
(6) Remove fuel l i ne (i njecti on pump-to-fuel pres-
sure l i mi ti ng val ve).
(7) Remove fuel l i ne (i njecti on pump-to-fuel rai l ).
Use back-up wrench on fi tti ng at fuel pump.
(8) Remove fuel l i ne (i njecti on pump-to-fuel fi l ter
housi ng).
(9) Remove fuel pump dri ve gear access cover
(pl ate) wi th a 3/8 dri ve ratchet. Pl ate i s threaded to
ti mi ng gear cover (Fi g. 10).
(10) Remove fuel pump dri ve gear mounti ng nut
and washer.
(11) Attach C3428B, or L4407A (or equi val ent)
gear pul l er (Fi g. 11) to pump dri ve gear wi th 2 bol ts,
and separate gear from pump (a keyway i s not used
on thi s parti cul ar i njecti on pump). Leave dri ve gear
hangi ng l oose wi thi n ti mi ng gear cover.
(12) Remove 3 i njecti on pump mounti ng nuts (Fi g.
12), and remove pump from engi ne.
Fig. 7 INTAKE TUBE AND CONNECTING HOSE
1 - MANIFOLD ABOVE HEATERS
2 - RUBBER CONNECTING HOSE
3 - METAL INTAKE TUBE
4 - CLAMPS (2)
Fig. 8 OVERFLOW VALVE
1 - BANJO BOLTS
2 - PUMP MOUNTING NUTS (3)
3 - FUEL INJECTION PUMP
4 - CASCADE OVERFLOW VALVE
FUEL INJ ECTION PUMP (Continued)
INSTALLATION
(1) I nspect pump mounti ng surfaces at pump and
mounti ng fl ange for ni cks, cuts or damage. I nspect
o-ri ng surfaces for ni cks, cuts or damage.
(2) Cl ean i njecti on pump mounti ng fl ange at gear
housi ng. Al so cl ean front of i njecti on pump.
(3) I nstal l new rubber o-ri ng i nto machi ned groove
(Fi g. 12) at pump mounti ng area.
(4) Appl y cl ean engi ne oi l to injection pump
o-ring only.
The machined tapers on both injection pump
shaft and injection pump gear must be abso-
lutely dry, clean and free of any dirt or oil film.
Fig. 9 FUEL CONTROL ACTUATOR
1 - ACTUATOR MOUNTING BOLTS
2 - FCA (FUEL CONTROL ACTUATOR)
3 - ACTUATOR ELECTRICAL CONNECTOR
Fig. 10 PUMP DRIVE GEAR ACCESS COVER
1 - FRONT TIMING GEAR COVER
2 - GEAR ACCESS PLATE (COVER)
3 - SQUARE DRIVE (FOR COVER REMOVAL/INSTALLATION)
Fig. 11 DRIVE GEAR REMOVAL
1 - FRONT TIMING GEAR COVER
2 - GEAR PULLER TOOL
This will ensure proper gear-to-shaft tighten-
ing.
(5) Cl ean pump gear and pump shaft at machi ned
tapers wi th an evaporati ve type cl eaner such as
brake cl eaner.
(6) Posi ti on i njecti on pump to mounti ng fl ange on
gear housi ng whi l e al i gni ng i njecti on pump shaft
through back of i njecti on pump gear.
(7) After pump i s posi ti oned fl at to mounti ng
fl ange, i nstal l 3 pump mounti ng nuts and ti ghten
finger tight only. Do not attempt a fi nal ti ghteni ng
at thi s ti me. Do not attempt to tighten (pull)
pump to gear housing using mounting nuts.
Damage to pump or gear cover may occur. The
pump must be positioned flat to its mounting
flange before attempting to tighten 3 mounting
nuts.
(8) To prevent damage or cracki ng of components,
i nstal l and ti ghten nuts i n the fol l owi ng sequence:
(a) I nstal l i njecti on pump shaft washer and nut
to pump shaft. Ti ghten nut finger tight only.
(b) Do prel i mi nary (l i ght) ti ghteni ng of i njecti on
pump shaft nut.
(c) Ti ghten 3 i njecti on pump mounti ng nuts to
24 Nm (18 ft. l bs.).
(d) Do a fi nal ti ghteni ng of pump shaft nut to
105 Nm (77 ft. l bs.).
(9) I nstal l dri ve gear access cover (pl ate) usi ng a
3/8 dri ve ratchet. Pl ate i s threaded to ti mi ng gear
cover. Ti ghten to 8 Nm (71 i n. l bs.) torque.
(10) I nstal l fuel l i ne (i njecti on pump-to-pressure
l i mi ti ng val ve). Ti ghten bol ts to 24 Nm (18 ft. l bs.)
torque.
(11) I nstal l fuel l i ne (i njecti on pump-to-fuel rai l ).
(a) Ti ghten fi tti ng at fuel pump to 37 Nm (27 ft.
l bs.) torque. Use a back-up wrench.
(b) Ti ghten fi tti ng at fuel rai l to 37 Nm (27 ft.
l bs.) torque.
(12) I nstal l fuel l i ne (i njecti on pump-to-fuel fi l ter
housi ng). Ti ghten to 24 Nm (18 ft. l bs.) torque.
(13) Connect Fuel Control Actuator (FCA) el ectri -
cal connector to rear of i njecti on pump.
(14) I nstal l i ntake mani fol d ai r i ntake tube (above
i njecti on pump). Ti ghten cl amps.
(15) I nstal l accessory dri ve bel t.
(16) I nstal l cool i ng fan shroud.
(17) I nstal l cool i ng fan assembl y.
batteri es.
(19) Check system for fuel or engi ne oi l l eaks.
Fig. 12 FUEL INJECTION PUMP REMOVAL/INSTALLATION
1 - PUMP DRIVE GEAR NUT
2 - WASHER
3 - PUMP DRIVE GEAR
4 - RUBBER O-RING
7 - PUMP MOUNTING STUDS (3)
8 - O-RING MACHINED GROOVE
9 - FRONT TIMING GEAR HOUSING
FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sendi ng uni t (fuel l evel sensor) i s
attached to the si de of the fuel tank modul e. The
sendi ng uni t consi sts of a fl oat, an arm, and a vari -
abl e resi stor track (card).
OPERATION
The fuel tank modul e on di esel powered model s
has 2 di fferent ci rcui ts (wi res). Two of these ci rcui ts
are used at the fuel gauge sendi ng uni t for fuel
gauge operati on. The di esel engi ne does not have a
fuel tank modul e mounted el ectri c fuel pump. The
el ectri c fuel pump (fuel transfer pump) i s mounted to
the engi ne.
For Fuel Gauge Operation: A constant i nput
vol tage source of about 12 vol ts (battery vol tage) i s
suppl i ed to the resi stor track on the fuel gauge send-
i ng uni t. Thi s i s fed di rectl y from the Engi ne Control
Modul e (ECM). NOTE: For diagnostic purposes,
this 12V power source can only be verified with
the circuit opened (fuel tank module electrical
connector unplugged). With the connectors
plugged, output voltages will vary fromabout .6
volts at FULL, to about 7.0 volts at EMPTY. The
resi stor track i s used to vary the vol tage (resi stance)
dependi ng on fuel tank fl oat l evel . As fuel l evel
i ncreases, the fl oat and arm move up, whi ch
decreases vol tage. As fuel l evel decreases, the fl oat
and arm move down, whi ch i ncreases vol tage. The
vari ed vol tage si gnal i s returned back to the ECM
through the sensor return ci rcui t.
Both of the el ectri cal ci rcui ts between the fuel
gauge sendi ng uni t and the ECM are hard-wi red (not
mul ti -pl exed). After the vol tage si gnal i s sent from
the resi stor track, and back to the ECM, the ECM
wi l l i nterpret the resi stance (vol tage) data and send
a message across the mul ti -pl ex bus ci rcui ts to the
i nstrument panel cl uster. Here i t i s transl ated i nto
the appropri ate fuel gauge l evel readi ng. Refer to
I nstrument Panel for addi ti onal i nformati on.
REMOVAL
For di esel removal and i nstal l ati on procedures,
refer to the gas secti on of Fuel System/Fuel Del i very.
See Fuel Level Sendi ng Uni t/Sensor Removal /I nstal -
l ati on.
FUEL LINES
DESCRIPTION
Low-Pressure Lines Are:
the fuel suppl y l i ne from fuel tank to fuel trans-
fer (l i ft) pump.
the fuel return l i ne back to fuel tank.
the fuel drai n (mani fol d) l i ne at rear of cyl i nder
head.
the fuel suppl y l i ne from fuel fi l ter to fuel i njec-
ti on pump.
the fuel i njecti on pump return l i ne.
High-Pressure Lines Are:
the fuel l i ne from fuel i njecti on pump to fuel
rai l .
the 6 fuel l i nes from fuel rai l up to i njector con-
nector tubes
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 160,000 KPA (23,206
PSI). USE EXTREME CAUTION WHEN INSPECTING
FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
OPERATION
High-Pressure Lines
CAUTION: The high-pressure fuel lines must be
held securely in place in their holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. If lines are ever
kinked or bent, they must be replaced. Use only the
recommended lines when replacement of high-pres-
sure fuel line is necessary.
Hi gh-pressure fuel l i nes del i ver fuel (under pres-
sure) of up to approxi matel y 160,000 kPa (23,206
PSI ) from the i njecti on pump to the fuel i njectors.
The l i nes expand and contract from the hi gh-pres-
sure fuel pul ses generated duri ng the i njecti on pro-
cess. Al l hi gh-pressure fuel l i nes are of the same
l ength and i nsi de di ameter. Correct hi gh-pressure
fuel l i ne usage and i nstal l ati on i s cri ti cal to smooth
engi ne operati on.
WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGH-PRESSURE FUEL LEAKS.
INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
DIAGNOSIS AND TESTING - HIGH-PRESSURE
FUEL LINE LEAKS
Hi gh-pressure fuel l i ne l eaks can cause starti ng
probl ems and poor engi ne performance.
WARNING: DUE TO EXTREME FUEL PRESSURES
OF UP TO 160,000 kPa (23,206 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGH-PRES-
SURE FUEL LEAKS. DO NOT GET YOUR HAND OR
A FINGER NEAR A SUSPECTED LEAK. INSPECT
FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET
OF CARDBOARD. HIGH FUEL INJECTION PRES-
SURE CAN CAUSE PERSONAL INJURY IF CON-
TACT IS MADE WITH THE SKIN.
Start the engi ne. Move the cardboard (Fi g. 13) over
the suspected hi gh-pressure fuel l i ne l eak, and check
for fuel spray onto the cardboard. I f l i ne i s l eaki ng,
retorque l i ne. Repl ace damaged, restri cted or l eaki ng
hi gh-pressure fuel l i nes wi th the correct repl acement
l i ne.
CAUTION: The high-pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high-pressure
fuel line is necessary.
REMOVAL
(1) Di sconnect both negati ve battery cabl es from
both batteri es. Cover and i sol ate ends of cabl es.
(2) Thoroughl y cl ean fuel l i nes at both ends.
(3) I f removi ng fuel l i ne at ei ther #1 or #2 cyl i nder,
the i ntake mani fol d ai r heater el ements must fi rst be
removed from top of i ntake mani fol d. Refer to I ntake
Ai r Heater Removal / I nstal l ati on for procedures.
(4) I f removi ng fuel l i ne at #6 cyl i nder, a bracket
(Fi g. 14) i s l ocated above fuel l i ne connecti on at cyl -
i nder head. Two bol ts secure thi s bracket to rear of
cyl i nder head. The upper bol t hol e i s sl otted. Loosen
(but do not remove) these 2 bracket bol ts. Ti l t
bracket down to gai n access to #6 fuel l i ne connec-
ti on.
(5) Remove engi ne l i ft bracket (i f necessary).
(6) Remove necessary i nsul ated fuel l i ne support
cl amps (Fi g. 15) and bracket bol ts at i ntake mani fol d.
DO NOT remove i nsul ators from fuel l i nes.
(7) Pl ace shop towel s around fuel l i nes at fuel rai l
and i njectors. I f possi bl e, do not al l ow fuel to dri p
down si de of engi ne.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING (Fig. 16) , USE A BACK-UP WRENCH
ON FITTING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
(8) Careful l y remove each fuel l i ne from engi ne.
Note posi ti on of each whi l e removi ng. Do not bend
lines while removing.
Fig. 13 TYPICAL TEST FOR LEAKS USING
CARDBOARD
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - TYPICAL HIGH-PRESSURE FITTING
FUEL LINES (Continued)
Fig. 16 HIGH PRESSURE FUEL LINES
1 - FUEL INJECTOR
2 - HIGH-PRESSURE LINE
3 - INJECTOR MOUNTING BOLTS
5 - SEPARATE FITTING (TYPICAL)
6 - CONNECTOR TUBE RETAINER (FITTING)
7 - CONNECTOR TUBE
Fig. 14 BRACKET - #6 INJECTOR
1 - BRACKET
2 - REAR OF CYLINDER HEAD
3 - FUEL DRAIN MANIFOLD LINE (TO FUEL TANK)
4 - BANJO BOLT/CHECK VALVE
5 - SLOTTED HOLE
6 - BRACKET BOLTS (2)
Fig. 15 FUEL INJECTOR RAIL
1 - FUEL RAIL MOUNTING BOLTS (3)
2 - INSULATED CLAMPS
INSTALLATION
Al l hi gh-pressure fuel l i nes are of the same l ength
and i nsi de di ameter. Correct hi gh-pressure fuel l i ne
usage and i nstal l ati on i s cri ti cal to smooth engi ne
operati on.
CAUTION: Anytime a high-pressure line is removed
from the engine, its fuel connector nut at the cylin-
der head must first be retorqued. Refer to Torque
Specifications.
(1) Ti ghten fuel l i nes at hi gh pressure i njector con-
nector. Refer to Torque Speci fi cati ons.
(2) Posi ti on fuel l i ne support cl amp(s) to fuel
l i ne(s). I nstal l cl amp nuts/bol ts and ti ghten fi nger
ti ght.
(3) Posi ti on proper fuel l i ne to proper i njector on
engi ne. Ti ghten fi tti ngs hand ti ght at both ends of
l i ne.
(4) Ti ghten fuel l i nes at fuel rai l . Refer to Torque
Speci fi cati ons.
(5) Ti ghten cl amp/support nuts and bol ts. Refer to
(6) I nstal l engi ne l i fti ng bracket and bol t. Refer to
(7) I f fuel l i ne at ei ther #1 or #2 cyl i nder has been
repl aced, i nstal l i ntake mani fol d ai r heater el ements
to top of i ntake mani fol d. Refer to I ntake Ai r Heater
Removal / I nstal l ati on for procedures.
(8) I f fuel l i ne at #6 cyl i nder has been repl aced, ti l t
metal bracket upward and ti ghten 2 bol ts at rear of
cyl i nder head. Refer to Torque Speci fi cati ons.
(9) I nstal l remai ni ng fuel l i ne support cl amps and
bracket bol ts at i ntake mani fol d. Refer to Torque
Speci fi cati ons.
batteri es.
(11) Pri me fuel system. Refer to Fuel System
Pri mi ng.
(12) Check l i nes/fi tti ngs for l eaks.
FUEL PRESSURE SENSOR
DESCRIPTION
The fuel pressure sensor i s mounted verti cal l y near
the top/center of the fuel rai l .
OPERATION
The fuel pressure sensor moni tors actual hi gh-
pressure wi thi n the fuel rai l . An output si gnal from
thi s sensor (rel ati ng to fuel pressure) i s sent to the
Engi ne Control Modul e (ECM).
REMOVAL
The fuel pressure sensor i s mounted verti cal l y near
the top/center of the fuel rai l (Fi g. 17).
(2) Remove sensor from fuel rai l .
(3) I nspect sensor seal i ng ri ng and i ts seal i ng sur-
face.
Fig. 17 FUEL PRESSURE SENSOR/FUEL PRES.
LIMIT. VALVE
1 - ELEC. CONNECTOR
2 - BANJO BOLT
3 - FUEL PRESSURE LIMITING VALVE
4 - FUEL PRESSURE SENSOR
5 - TOP OF INTAKE HEATER MANIFOLD
INSTALLATION
(1) I nspect fuel pressure sensor seal i ng surface.
(2) Lubri cate sensor threads wi th cl ean di esel fuel .
(3) I nstal l sensor i nto fuel rai l .
(4) To prevent l eaks, sensor must be ti ghtened to
prescri bed torque. Refer to Torque Speci fi cati ons.
(6) Start engi ne and check for fuel l eaks.
FUEL PRESSURE LIMITING
VALVE
DESCRIPTION
The fuel pressure l i mi ti ng val ve i s l ocated on the
top of the fuel rai l .
OPERATION
Fuel pressure at the fuel rai l i s moni tored by the
fuel rai l pressure sensor. I f fuel pressure becomes
excessi ve, the pressure l i mi ti ng val ve opens and
vents excess pressure i nto the fuel drai n ci rcui t.
REMOVAL
The fuel pressure l i mi ti ng val ve i s l ocated on the
top of the fuel rai l (Fi g. 18).
(1) Thoroughl y cl ean area at pressure l i mi ti ng
val ve.
(2) Remove banjo bol t (Fi g. 18) at banjo fi tti ng.
(3) Remove pressure l i mi ti ng val ve from fuel rai l .
INSTALLATION
(1) Be sure both top of mani fol d and l i mi ti ng val ve
are cl ean.
(2) I nstal l val ve. Refer to Torque Speci fi cati ons.
(3) Assembl e banjo bol t and new seal i ng washers
to l i mi ti ng val ve.
(4) Ti ghten banjo bol t. Refer to Torque Speci fi ca-
ti ons.
Fig. 18 FUEL PRESSURE SENSOR/FUEL
PRESSURE LIMITING VALVE
1 - ELEC. CONNECTOR
2 - BANJO BOLT
3 - FUEL PRESSURE LIMITING VALVE
4 - FUEL PRESSURE SENSOR
5 - TOP OF INTAKE HEATER MANIFOLD
FUEL PRESSURE SENSOR (Continued)
FUEL TANK
DESCRIPTION - DIESEL
The fuel tank i s si mi l ar to the tank used wi th gas-
ol i ne powered model s. The tank i s equi pped wi th a
separate fuel return l i ne and a di fferent fuel tank
modul e for di esel powered model s. A fuel tank
mounted, el ectri c fuel pump i s not used wi th di esel
powered model s. Refer to Fuel Tank Modul e for addi -
REMOVAL - DIESEL
Fuel Tank Draining
Due to a one-way check val ve i nstal l ed i nto the
fuel fi l l openi ng fi tti ng at the tank, the tank cannot
be drai ned conventi onal l y at the fi l l cap.
(2) I f vehi cl e i s equi pped wi th 4 doors and a 6 foot
(short) box, remove l eft-rear ti re/wheel .
(3) Thoroughl y cl ean area at top of fuel tank
around fuel tank modul e.
(4) Remove rubber cap from auxi l i ary fi tti ng on
top of tank modul e (Fi g. 19).
(5) Drai n fuel tank by attachi ng drai n hose from
an approved drai ni ng stati on to auxi l i ary fi tti ng on
top of tank modul e (Fi g. 19).
Tank Removal
(1) Loosen cl amp and di sconnect rubber fuel fi l l
hose at tank.
(2) Support tank wi th a hydraul i c jack.
(3) Remove 2 fuel tank strap nuts (Fi g. 20) and
remove both tank support straps.
(4) Careful l y l ower tank a few i nches and di scon-
nect fuel pump modul e el ectri cal connector (Fi g. 19)
at top of tank. To di sconnect el ectri cal connector:
Push upward on red col ored tab to unl ock. Push on
bl ack col ored tab whi l e removi ng connector.
(5) Di sconnect fuel suppl y and return l i nes at fuel
tank modul e (Fi g. 19). Refer to Qui ck-Connect Fi t-
ti ngs for procedures.
(6) Conti nue to l ower tank for removal .
(7) I f fuel tank i s to be repl aced, remove fuel tank
modul e from tank. Refer to Fuel Tank Modul e
(1) I f fuel tank i s to be repl aced, i nstal l fuel tank
modul e i nto tank. Refer to Fuel Tank Modul e Remov-
al /I nstal l ati on procedures.
(2) Posi ti on fuel tank to hydraul i c jack.
(3) Rai se tank unti l posi ti oned near body.
(4) Connect fuel tank modul e el ectri cal connector
at top of tank.
(5) Connect fuel suppl y and return l i nes to tank
modul e.
(6) Conti nue rai si ng tank unti l posi ti oned snug to
body.
(7) I nstal l and posi ti on both tank support straps.
I nstal l 2 fuel tank strap nuts and ti ghten. Tighten
rear strap nut first. Refer to Torque Speci fi cati ons.
(8) Remove hydraul i c jack.
(9) Connect rubber fi l l hose to fuel fi l l tube and
ti ghten cl amp.
(10) I nstal l ti re / wheel (i f necessary).
(12) Fi l l fuel tank wi th fuel .
(13) Start engi ne and check for fuel l eaks near top
of modul e.
Fig. 19 FUEL TANK MODULE - DIESEL
2 - AUX. FITTING
3 - ELEC. CONNECTOR
4 - FUEL TANK MODULE (TOP)
5 - LOCKNUT
6 - FUEL SUPPLY LINE
7 - FUEL RETURN LINE
FUEL TANK MODULE
DESCRIPTION
An el ectri c fuel pump i s not used i n the fuel tank
modul e for di esel powered engi nes. Fuel i s suppl i ed
by the engi ne mounted fuel transfer (l i ft) pump.
The fuel tank modul e i s i nstal l ed i n the top of the
fuel tank (Fi g. 21). The fuel tank modul e contai ns
Fuel reservoi r
A separate i n-tank fuel fi l ter
Fuel gauge sendi ng uni t (fuel l evel sensor)
Fuel suppl y l i ne connecti on
Fuel return l i ne connecti on
Auxi l i ary non-pressuri zed fi tti ng
OPERATION
Refer to Fuel Gauge Sendi ng Uni t.
REMOVAL
(1) Drai n and remove fuel tank. Refer to Fuel
Tank Removal /I nstal l ati on.
(2) Thoroughl y cl ean area around tank modul e at
top of tank.
(3) The pl asti c fuel tank modul e l ocknut i s
threaded onto fuel tank. I nstal l Speci al Tool 6856 to
l ocknut and remove l ocknut (Fi g. 22). The fuel tank
modul e wi l l spri ng up when l ocknut i s removed.
(4) Remove modul e from fuel tank.
Fig. 20 FUEL TANK MOUNTING
1 - FUEL TANK
2 - STRAP MOUNTING STUDS
3 - VEHICLE FRAME
4 - MOUNTING STRAPS
5 - STRAP NUTS
INSTALLATION
CAUTION: Whenever the fuel tank module is ser-
viced, the rubber gasket must be replaced.
(1) Thoroughl y cl ean l ocknut and l ocknut threads
at top of tank.
(2) Usi ng new gasket, careful l y posi ti on fuel tank
modul e i nto openi ng i n fuel tank.
(3) Posi ti on l ocknut over top of fuel tank modul e.
I nstal l l ocknut fi nger ti ght.
(4) When l ooki ng down at tank from dri vers si de of
tank, the fuel l i ne connectors and fuel gauge el ectri -
cal connector shoul d al l be poi nted to dri vers si de of
vehi cl e. Rotate and al i gn i f necessary before ti ghten-
i ng l ocknut. This step must be performed to pre-
vent the modules float from contacting side of
fuel tank.
(5) Ti ghten l ocknut to 24 - 44 Nm (18 - 32 ft. l bs.)
torque.
I nstal l ati on.
FUEL TRANSFER PUMP
DESCRIPTION
The fuel transfer pump (fuel l i ft pump) i s attached
to the rear of the fuel fi l ter/water separator housi ng.
The 12vol t el ectri c pump i s operated and control l ed
by the Engi ne Control Modul e (ECM).
OPERATION
The purpose of the fuel transfer pump i s to suppl y
(transfer) a l ow-pressure fuel source: from the fuel
tank, through the fuel fi l ter/water separator and to
the fuel i njecti on pump. Here, the l ow-pressure i s
rai sed to a hi gh-pressure by the fuel i njecti on pump
for operati on of the hi gh-pressure fuel i njectors.
Check val ves wi thi n the pump, control di recti on of
fuel fl ow and prevent fuel bl eed-back duri ng engi ne
shut down.
Maxi mum current fl ow to the pump i s 5 amperes.
Wi th the engi ne runni ng, the pump has a 100 per-
cent duty-cycl e.
The transfer pump i s sel f-pri mi ng: When the key i s
fi rst turned on (wi thout cranki ng engi ne), the pump
wi l l operate for approxi matel y 2 seconds and then
shut off. The pump wi l l al so operate for up to 25 sec-
onds after the starter i s engaged, and then di sen-
gaged and the engi ne i s not runni ng. The pump
shuts off i mmedi atel y i f the key i s on and the engi ne
stops runni ng.
The fuel vol ume of the transfer pump wi l l al ways
provi de more fuel than the fuel i njecti on pump
requi res. Excess fuel i s returned from the i njecti on
pump through an overfl ow val ve, and then back to
the fuel tank.
REMOVAL
The fuel transfer pump (fuel l i ft pump) i s attached
to the rear of the fuel fi l ter/water separator housi ng
(Fi g. 23).
Fig. 21 FUEL TANK MODULE - DIESEL
2 - AUX. FITTING
3 - ELEC. CONNECTOR
4 - FUEL TANK MODULE (TOP)
5 - LOCKNUT
Fig. 22 LOCKNUT REMOVAL/INSTALLATION -
TYPICAL MODULE
2 - LOCKNUT
FUEL TANK MODULE (Continued)
(1) Drai n fuel from fuel fi l ter housi ng. Refer to
Fuel Fi l ter/Water Separator - Removal . See Drai ni ng.
(2) Di sconnect el ectri cal connector (Fi g. 23) from
fuel transfer pump.
(3) Di sconnect fuel tank suppl y l i ne from fuel
transfer pump extensi on l i ne. Thi s i s done at di scon-
necti on poi nt at i nsi de of l eft i nner frame rai l (Fi g.
24). Refer to qui ck-connect fi tti ngs for procedures.
(4) Remove 4 pump mounti ng bol ts (hex-al l en),
and remove pump from fuel fi l ter housi ng.
(5) Confi rm that transfer pump o-ri ng i s al so
removed from fuel fi l ter housi ng.
INSTALLATION
(1) I nstal l a new o-ri ng to fuel transfer pump.
(2) Lubri cate o-ri ng and OD of transfer pump i nl et
connector.
(3) Posi ti on fuel transfer pump onto fuel fi l ter
housi ng. Do not use mounting bolts to draw
transfer pump to filter housing.
(4) Be sure pump i s posi ti oned fl at to fuel fi l ter
housi ng. I nstal l mounti ng bol ts and evenl y ti ghten to
7 Nm (61 i n. l bs.).
(5) Connect fuel l i ne extensi on at fuel suppl y l i ne.
(6) Connect el ectri cal connector to pump.
(7) Prime System: Cycl e key to actuate transfer
pump, or use DRB Scan Tool to actuate transfer
pump. Check for l eaks.
(8) Operate engi ne and check for fuel l eaks.
Fig. 23 FUEL TRANSFER (LIFT) PUMP
1 - FILTER HOUSING
2 - ELEC. CONNECTOR
3 - FUEL TRANSFER (LIFT) PUMP
4 - FUEL LINE EXTENTION
Fig. 24 TRANSFER PUMP FUEL LINE CONNECT
1 - LEFT INNER FRAME RAIL
FUEL TRANSFER PUMP (Continued)
CASCADE OVERFLOW VALVE
DESCRIPTION
The cascade overfl ow val ve i s l ocated on the top/
rear si de of the fuel i njecti on pump (Fi g. 25).
OPERATION
When the fuel control actuator (FCA) i s opened,
the maxi mum amount of fuel i s bei ng del i vered to
the fuel i njecti on pump. The cascade val ve regul ates
how much excess fuel i s used for l ubri cati on of the
i njecti on pump, and i s al so used to route excess fuel
through the drai n ci rcui t and back i nto the fuel tank.
REMOVAL
The cascade overfl ow val ve i s not servi ced sepa-
ratel y.
WATER IN FUEL SENSOR
DESCRIPTION
The Water-I n-Fuel (WI F) sensor i s l ocated on the
si de of the fuel fi l ter/water separator cani ster (Fi g.
26).
OPERATION
The sensor sends an i nput to the Engi ne Control
Modul e (ECM) when i t senses water i n the fuel fi l ter/
water separator. As the water l evel i n the fi l ter/sep-
arator i ncreases, the resi stance across the WI F
sensor decreases. Thi s decrease i n resi stance i s sent
as a si gnal to the ECM and compared to a hi gh
water standard val ue. Once the val ue reaches 30 to
40 ki l ohms, the ECM wi l l acti vate the water-i n-fuel
warni ng l amp through CCD bus ci rcui ts. Thi s al l
takes pl ace when the i gni ti on key i s i ni ti al l y put i n
the ON posi ti on. The ECM conti nues to moni tor the
i nput whi l e the engi ne i s runni ng.
REMOVAL
The Water-I n-Fuel (WI F) sensor i s l ocated at the
si de of fuel fi l ter/water separator cani ster. Refer to
Fuel Fi l ter/Water Separator Removal /I nstal l ati on for
WI F sensor removal /i nstal l ati on procedures.
Fig. 25 OVERFLOW VALVE
1 - BANJO BOLTS
4 - CASCADE OVERFLOW VALVE
Fig. 26 FILTER HOUSING
1 - FILTER HOUSING
2 - FUEL HEATER AND THERMOSTAT
3 - FUEL HEATER MOUNTING SCREWS
4 - FUEL HEATER ELEC. CONNECTOR
5 - WIF SENSOR
6 - WIF SENSOR ELEC. CONNECTOR
7 - DRAIN HOSE
8 - DRAIN VALVE MOUNTING SCREWS
9 - DRAIN VALVE
FUEL DRAIN CIRCUIT
OPERATION
The Fuel Drai n Ci rcui t i ncorporates several
sources of fuel return. Fuel travel s from the fuel tank
to the fuel transfer pump and i s forced through the
fuel fi l ter. Thi s fuel then travel s i nto the fuel i njec-
ti on pump. I t then goes to a fuel drai n l i ne and
returns back to the fuel tank.
The fuel that fl ows to the fuel pump i s pressuri zed
by a gear pump and i nternal l y transferred to the fuel
i njecti on pump. At thi s poi nt the fuel i s channel ed
i nto two passages. One passage sends fuel to the
FCA (Fuel Control Actuator). The other passage
sends fuel to the cascade overfl ow val ve. The over-
fl ow val ve sends some fuel to a l ubri cati on passage.
The rest of the fuel i s sent to a drai n passage whi ch
connects to an external fuel l i ne.
Fuel that travel s through the FCA i s pressuri zed
by the fuel i njecti on pump and sent through an
external hi gh pressure fuel l i ne to the fuel rai l . At
the fuel rai l , fuel i s sent to the fuel i njectors. I f fuel
pressure i n the fuel rai l becomes excessi ve, the pres-
sure l i mi ti ng val ve opens and sends fuel through an
external fuel l i ne.
At the fuel i njector, fuel that i s not i njected i s used
for l ubri cati on of the fuel i njectors. Thi s fuel then
travel s through an i nternal passage that i s connected
to the rear of the cyl i nder head, an then i nto an
external fuel l i ne. Thi s l i ne i s connected to the vehi -
cl es fuel return l i ne, and returns excess fuel to the
fuel tank.
FUEL INJ ECTION - DIESEL
TABLE OF CONTENTS
page page
ACCELERATOR PEDAL POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 68
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 71
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 72
CRANKSHAFT POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 72
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
FUEL CONTROL ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 74
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FUEL INJECTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 74
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77
FUEL INJECTOR RAIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 78
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 78
INLET AIR TEMPERATURE SENSOR/
PRESSURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 79
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
INTAKE AIR HEATER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 80
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
INTAKE AIR HEATER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 82
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 82
INTAKE AIR TEMPERATURE SENSOR/MAP
SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 82
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 82
MAP SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 83
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
PTO SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 85
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
ACCELERATOR PEDAL
POSITION SENSOR
DESCRIPTION
Engine Mounted Sensor: The APPS assembl y i s
l ocated at the top-l eft-front of the engi ne. A pl asti c
cover i s used to cover the assembl y. The actual sen-
sor i s l ocated behi nd i ts mounti ng bracket.
Battery Tray Mounted Sensor: The Accel erator
Pedal Posi ti on Sensor (APPS) assembl y i s l ocated
under the vehi cl e battery tray. A cabl e connects the
assembl y to the accel erator pedal . A pl asti c cover
wi th a movabl e door i s used to cover the assembl y.
OPERATION
Engine Mounted Sensor: The Accel erator Pedal
Posi ti on Sensor (APPS) i s a l i near potenti ometer. I t
provi des the Engi ne Control Modul e (ECM) wi th a
DC vol tage si gnal proporti onal to the angl e, or posi -
ti on of the accel erator pedal .
Battery Tray Mounted Sensor: The APPS pro-
vi des the ECM wi th two DC vol tage si gnal s whi ch
change as the posi ti on of the accel erator changes.
One of the DC vol tage si gnal s wi l l be hal f the vol tage
of the other si gnal .
REMOVAL
Engine Mounted Sensor :
i ncl udi ng the l ever, brackets and sensor. The APPS i s
cal i brated to i ts mounti ng bracket. The APPS assem-
bl y i s l ocated at l eft-front of engi ne bel ow pl asti c
cabl e/l ever/l i nkage cover (Fi g. 1).
14 - 68 FUEL INJECTION - DIESEL DR
CAUTION: Do not attempt to remove sensor from
its mounting bracket as electronic calibration will
be destroyed (sensor-to-bracket mounting screws
are permanently attached). Two accelerator lever
set screws (Fig. 3) are used to position lever. Do
not attempt to alter positions of these set screws as
electronic calibration will be destroyed.
batteri es.
(2) Remove cabl e cover (Fi g. 1). Cabl e cover i s
attached wi th 2 Phi l l i ps screws, 2 pl asti c retenti on
cl i ps and 2 push tabs (Fi g. 1). Remove 2 Phi l l i ps
screws and careful l y pry out 2 retenti on cl i ps. After
cl i p removal , push rearward on front tab, and
upward on l ower tab for cover removal .
(3) Usi ng fi nger pressure onl y, di sconnect end of
speed control servo cabl e from throttl e l ever pi n by
pul l i ng forward on connector whi l e hol di ng l ever
rearward (Fi g. 2). DO NOT try to pull connector
off perpendicular to lever pin. Connector will
be broken.
(4) Usi ng two smal l screwdri vers, pry throttl e
cabl e connector socket from throttl e l ever bal l (Fi g.
2). Be very careful not to bend throttle lever
arm.
(5) Di sconnect transmi ssi on control cabl e at l ever
arm (i f equi pped). Refer to 21, Transmi ssi on.
(6) Squeeze pi nch tabs on speed control cabl e (Fi g.
2) and pul l cabl e rearward to remove from cabl e
mounti ng bracket.
(7) Squeeze pi nch tabs on throttl e cabl e (Fi g. 2)
and pul l cabl e rearward to remove from cabl e mount-
i ng bracket.
(8) Refer to 21, Transmi ssi on for transmi ssi on con-
trol cabl e removal procedures.
(9) Di sconnect wi ri ng harness cl i p (Fi g. 3) at bot-
tom of bracket.
(10) Remove 6 mounti ng bol ts (Fi g. 3) and par-
ti al l y remove APPS assembl y from engi ne. After
assembl y i s parti al l y removed, di sconnect el ectri cal
connector from bottom of sensor by pushi ng on con-
nector tab (Fi g. 4).
(11) Remove APPS assembl y from engi ne.
Battery Tray Mounted Sensor :
i ncl udi ng the sensor, pl asti c housi ng and cabl e. The
APPS assembl y i s l ocated under the l eft (dri vers
si de) vehi cl e battery tray (Fi g. 5). Access to APPS i s
gai ned from over top of l eft / front ti re.
(2) Di sconnect APPS cabl e at accel erator pedal .
Refer to Accel erator Pedal Removal / I nstal l ati on.
(3) Remove wheel house l i ner at l eft /front wheel .
Refer to Body.
(4) Gai n access to APPS el ectri cal connector by
openi ng swi ng-down door (Fi g. 6). Di sconnect el ectri -
cal connector.
(6) Remove APPS assembl y from battery tray.
Fig. 1 CABLE/LEVER/THROTTLE LINKAGE COVER
4 - TAB PUSH HERE
Fig. 2 SERVO CABLE AT THROTTLE LEVER
1 - PINCH (2) TABS
3 - PINCH TABS (2)
4 - OFF
5 - THROTTLE CABLE
6 - THROTTLE LEVER
8 - OFF
9 - CONNECTOR
DR FUEL INJECTION - DIESEL 14 - 69
(7) I f cabl e i s to be separated at APPS, unsnap
cabl e cl i p from bal l socket (Fi g. 7). Rel ease cabl e from
pl asti c housi ng by pressi ng on smal l cabl e rel ease tab
(Fi g. 6).
Fig. 3 APPS ASSEMBLY (ON ENGINE MOUNTING)
1 - LEVER
3 - WIRE HARNESS CLIP
4 - CALIBRATION SCREWS (NO ADJUSTMENT)
5 - APPS ASSEMBLY
Fig. 4 APPS CONNECTOR (ON ENGINE MOUNTING)
1 - APPS
2 - TAB
3 - PUSH FOR REMOVAL
4 - APPS CONNECTOR
Fig. 5 APPS LOCATION (OFF ENGINE MOUNTING)
1 - BATTERY TRAY
2 - APPS LOCATION
3 - APPS MOUNTING BOLTS
Fig. 6 APPS REMOVE / INSTALL (OFF ENGINE
MOUNTING)
1 - BOTTOM OF BATTERY TRAY
3 - APPS
4 - SWING-DOWN DOOR
5 - CABLE (TO PEDAL)
6 - CABLE RELEASE TAB
INSTALLATION
Engine Mounted Sensor :
i ncl udi ng the l ever, brackets and sensor. The APPS i s
cal i brated to i ts mounti ng bracket.
(1) Snap el ectri cal connector i nto bottom of sensor.
(2) Posi ti on APPS assembl y to engi ne and i nstal l 6
bol ts. Ti ghten bol ts to 24 Nm (18 ft. l bs.) torque.
(3) Connect wi ri ng harness cl i p at bottom of
bracket.
(4) Refer to Group 21, Transmi ssi on for transmi s-
si on control cabl e i nstal l ati on procedures.
(5) I nstal l speed control cabl e i nto mounti ng
bracket. Be sure pi nch tabs have secured cabl e.
(6) I nstal l throttl e cabl e i nto mounti ng bracket. Be
sure pi nch tabs have secured cabl e.
(7) Connect throttl e cabl e at l ever (snaps on).
(8) Connect speed control cabl e to l ever by pushi ng
cabl e connector rearward onto l ever pi n whi l e hol d-
i ng l ever forward.
(9) I nstal l cabl e cover.
batteri es.
any Di agnosti c Troubl e Codes (DTCs) from ECM.
Battery Tray Mounted Sensor :
(1) I nstal l Accel erator Pedal Posi ti on Sensor
(APPS) cabl e to accel erator pedal . Refer to Accel era-
tor Pedal Removal / I nstal l ati on.
(2) Connect el ectri cal connector to APPS.
(3) I f necessary, connect cabl e to APPS l ever bal l
socket (snaps on).
(4) Snap APPS cabl e cover cl osed.
(5) Posi ti on APPS assembl y to bottom of battery
tray and i nstal l 3 bol ts. Refer to Torque Speci fi ca-
ti ons.
(6) I nstal l wheel house l i ner. Refer to Body.
(7) Perform the fol l owi ng procedure:
(a) Connect negati ve battery cabl es to both bat-
teri es.
(b) Turn key swi tch ON, but do not crank
engi ne.
(c) Leave key swi tch ON for a mi ni mum of 10
seconds. Thi s wi l l al l ow ECM to l earn el ectri cal
parameters.
any Di agnosti c Troubl e Codes (DTCs) from ECM.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
housi ng.
OPERATION
The di esel Camshaft Posi ti on Sensor (CMP) con-
tai ns a hal l effect devi ce. A rotati ng target wheel
(tonewheel ) for the CMP i s l ocated on the camshaft
gear. Thi s hal l effect devi ce detects notches l ocated
on the back si de of the camshaft gear. As the cam-
shaft gear rotates, the notches pass the ti p of the
CMP.
When the l eadi ng edge of the notch passes the ti p
of the CMP, the fol l owi ng occurs: The i nterrupti on of
magneti c fi el d causes the vol tage to swi tch hi gh
resul ti ng i n a si gnal of approxi matel y 5 vol ts.
When the trai l i ng edge of the notch passes the ti p
of the CMP, the fol l owi ng occurs: The change of the
magneti c fi el d causes the si gnal vol tage to swi tch l ow
to 0 vol ts.
The CMP (Fi g. 8) provi des a si gnal to the Engi ne
Control Modul e (ECM) at al l ti mes when the engi ne
i s runni ng. The ECM uses the CMP i nformati on pri -
mari l y on engi ne start-up. Once the engi ne i s run-
ni ng, the ECM uses the CMP as a backup sensor for
engi ne speed. The Crankshaft Posi ti on Sensor (CKP)
Fig. 7 APPS CABLE (OFF ENGINE MOUNTING)
1 - APPS LEVER
2 - BALL SOCKET
3 - SWING-DOWN DOOR
4 - CABLE CLIP
5 - CABLE
i s the pri mary engi ne speed i ndi cator for the engi ne
after the engi ne i s runni ng.
REMOVAL
housi ng (Fi g. 9).
(Fi g. 9).
(2) Remove sensor mounti ng bol t.
(3) Careful l y twi st sensor from ti mi ng gear hous-
i ng.
INSTALLATION
(1) Cl ean out machi ned hol e i n back of ti mi ng gear
housi ng (cover).
o-ri ng.
(3) I nstal l sensor i nto ti mi ng gear housi ng (cover)
wi th a sl i ght rocki ng acti on. Do not twi st sensor i nto
posi ti on as damage to o-ri ng may resul t.
be sure sensor is completely flush to back of timing
chain housing (cover). If sensor is not flush, dam-
age to sensor mounting tang may result.
CRANKSHAFT POSITION
SENSOR
DESCRIPTION
The Crankshaft Posi ti on Sensor (CKP) on the di e-
sel engi ne i s attached at the front / l eft si de of the
engi ne next to the engi ne harmoni c bal ancer (crank-
shaft damper).
OPERATION
The Crankshaft Posi ti on Sensor (CKP) i s the pri -
mary engi ne speed i ndi cator for the engi ne after the
engi ne i s runni ng (Fi g. 10). The CKP contai ns a hal l
effect devi ce. A rotati ng, notched target wheel (tone-
wheel ) for the CKP i s l ocated on the engi ne harmoni c
bal ancer (Fi g. 11). Thi s hal l effect devi ce detects
notches l ocated on the tonewheel . As the tonewheel
rotates, the notches pass the ti p of the CKP.
1 - CMP
7 - BACK OF TIMING GEAR HOUSING
1 - CMP
7 - BACK OF TIMING GEAR HOUSING
passes the ti p of the CKP, the fol l owi ng occurs: The
i nterrupti on of magneti c fi el d causes the vol tage to
swi tch hi gh resul ti ng i n a si gnal of approxi matel y 5
vol ts.
passes the ti p of the CKP, the fol l owi ng occurs: The
change of the magneti c fi el d causes the si gnal vol tage
to swi tch l ow to 0 vol ts.
The Camshaft Posi ti on Sensor (CMP) al so provi des
a si gnal to the Engi ne Control Modul e (ECM) at al l
ti mes when the engi ne i s runni ng. The ECM uses
thi s CMP i nformati on pri mari l y on engi ne start-up.
Once the engi ne i s runni ng, the ECM uses the CMP
as a backup sensor for engi ne speed.
REMOVAL
(1) Rai se and support vehi cl e
(2) Di sconnect el ectri cal connector at CKP sensor
(Fi g. 12).
(3) Remove 1 sensor mounti ng bol t.
(4) Remove CKP sensor.
INSTALLATION
(1) Posi ti on and i nstal l CKP sensor to engi ne.
(2) I nstal l 1 sensor mounti ng bol t and ti ghten to 9
(3) I nstal l el ectri cal connector to CKP sensor (Fi g.
12).
Fig. 10 5.9L DIESEL CKP
1 - ENGINE HARMONIC BALANCER
2 - FRONT OF TIMING GEAR COVER
3 - CKP MOUNTING BOLT
4 - ELEC. CONNECTOR
5 - CKP SENSOR
6 - NOTCHES
Fig. 11 CKP NOTCHED TONEWHEEL
2 - NOTCHED TONEWHEEL
3 - FRONT OF CRANKSHAFT
Fig. 12 5.9L DIESEL CKP
2 - FRONT OF TIMING GEAR COVER
3 - CKP MOUNTING BOLT
4 - ELEC. CONNECTOR
5 - CKP SENSOR
6 - NOTCHES
FUEL CONTROL ACTUATOR
DESCRIPTION
The Fuel Control Actuator (FCA) i s l ocated at the
rear of the hi gh-pressure, fuel i njecti on pump (Fi g.
13).
OPERATION
The Fuel Control Actuator (FCA) i s an el ectroni -
cal l y control l ed sol enoi d val ve. The ECM control s the
amount of fuel that enters the hi gh-pressure pump-
i ng chambers by openi ng and cl osi ng the FCA based
on a demanded fuel pressure. When the FCA i s
opened, the maxi mum amount of fuel i s bei ng sup-
pl i ed to the fuel i njecti on pump. Any fuel that does
not enter the i njecti on pump i s di rected to the cas-
cade overfl ow val ve. The cascade overfl ow val ve reg-
ul ates how much excess fuel i s used for l ubri cati on of
the pump and how much i s returned to the fuel tank
through the drai n mani fol d.
An audi bl e cl i ck from the FCA i s normal when
operati ng the key from the ON to the OFF posi ti on.
REMOVAL
The Fuel Control Actuator (FCA) i s a non-servi -
cabl e part.
FUEL INJ ECTOR
DESCRIPTION
Si x i ndi vi dual , sol enoi d actuated hi gh-pressure fuel
i njectors are used (Fi g. 14). The i njectors are verti -
cal l y mounted i nto a bored hol e i n the top of the cyl -
i nder head. Thi s bored hol e i s l ocated between the
i ntake/exhaust val ves. Hi gh-pressure connectors (Fi g.
15), mounted i nto the si de of the cyl i nder head, con-
nect each fuel i njector to each hi gh-pressure fuel l i ne.
OPERATION
Hi gh-pressure fuel i s suppl i ed from the i njecti on
pump, through a hi gh-pressure fuel l i ne, i nto a fuel
rai l , through hi gh-pressure l i nes, through steel con-
nectors and i nto the sol enoi d actuated fuel i njector.
The ECM actuates the sol enoi d causi ng the needl e
val ve to ri se and fuel fl ows through the spray hol es
i n the nozzl e ti p i nto the combusti on chamber.
Each fuel i njector i s connected to the fuel rai l by a
hi gh-pressure fuel l i ne and a steel connector. Thi s
steel connector i s posi ti oned i nto the cyl i nder head
and seal ed wi th an o-ri ng. The connector i s retai ned
i n the cyl i nder head by a nut (fi tti ng) that i s
threaded i nto the cyl i nder head.
Fig. 13 FUEL CONTROL ACTUATOR
1 - ACTUATOR MOUNTING BOLTS
2 - FCA (FUEL CONTROL ACTUATOR)
3 - ACTUATOR ELECTRICAL CONNECTOR
Fig. 14 FUEL INJECTOR - DIESEL
1 - SOLENOID ELECTRICAL CONNECTOR STUDS
2 - MOUNTING BOLTS
3 - MOUNTING PLATES
4- COPPER SEALING WASHER
5 - INJECTOR TIP
6 - INJECTOR O-RING
7 - INJECTOR ELECTRICAL SOLENOID
The torqui ng force of thi s threaded nut (fi tti ng)
provi des a seal i ng pressure between the fuel l i ne con-
nector and the fuel i njector. Retaining nut torque
is very critical. I f the nut (fi tti ng) i s under torqued,
the mati ng surfaces wi l l not seal and a hi gh-pressure
fuel l eak wi l l resul t. I f the fi tti ng i s over torqued, the
connector and i njector wi l l deform and al so cause a
hi gh-pressure fuel l eak. Thi s l eak wi l l be i nsi de the
cyl i nder head and wi l l not be vi si bl e. The resul t wi l l
be a possi bl e fuel i njector mi ss-fi re and l ow power, or
a no-start condi ti on.
The fuel i njectors use hol e type nozzl es. Hi gh-pres-
sure fl ows i nto the si de of the i njector, the ECM acti -
vates the sol enoi d causi ng the i njector needl e to l i ft
and fuel to be i njected. The cl earances i n the nozzl e
bore are extremel y smal l and any di rt or contami -
nants wi l l cause the i njector to sti ck. Because of thi s,
i t i s very i mportant to do a thorough cl eani ng of any
l i nes before openi ng up any fuel system component.
Al ways cover or cap any open fuel connecti ons before
a fuel system repai r i s performed.
Each fuel i njector connector tube contai ns an edge
fi l ter that i s desi gned to beak up smal l contami nants
before enteri ng the fuel i njector. The edge filters
are not a substitute for proper cleaning and
covering of all fuel system components during
repair.
The bottom of each fuel i njector i s seal ed to the
cyl i nder head wi th a 1.5mm thi ck copper shi m (gas-
ket). The correct thi ckness shi m must al ways be re-
i nstal l ed after removi ng an i njector.
Fuel pressure i n the i njector ci rcui t decreases after
i njecti on. The i njector needl e val ve i s i mmedi atel y
cl osed and fuel fl ow i nto the combusti on chamber i s
stopped. Exhaust gases are prevented from enteri ng
the i njector nozzl e by the needl e val ve.
REMOVAL
CAUTION: Refer to Cleaning Fuel System Parts.
Si x i ndi vi dual , sol enoi d actuated hi gh-pressure fuel
i njectors are used (Fi g. 14). The i njectors are verti -
cal l y mounted i nto a bored hol e i n the top of the cyl -
i nder head. Thi s bored hol e i s l ocated between the
i ntake/exhaust val ves. Hi gh-pressure connectors (Fi g.
15), mounted i nto the si de of the cyl i nder head, con-
nect each fuel i njector to each hi gh-pressure fuel l i ne.
(1) Di sconnect both negati ve battery cabl es from
both batteri es. Cover and i sol ate ends of cabl es.
(2) Remove breather assembl y.
Fig. 15 HIGH-PRESSURE CONNECTOR
1 - HIGH-PRESSURE CONNECTOR (TO FUEL INJECTOR)
2 - O-RING
3 - CONNECTOR RETAINER
4 - FUEL RAIL
5 - HIGH-PRESSURE FUEL LINES
6 - LOCATING PINS
(3) Remove val ve cover. Refer to Engi nes for proce-
dures.
(4) Remove necessary hi gh pressure fuel l i ne con-
necti ng necessary fuel i njector rai l to hi gh pressure
connector. Refer to Fuel Li ne Removal for procedures.
(5) A connector retai ner (nut) (Fi g. 15) i s used on
each connector tube. Remove thi s nut(s) by unthread-
i ng from cyl i nder head.
(6) Usi ng speci al hi gh-pressure connector removal
tool #9015 (Fi g. 16), or (Fi g. 17) remove necessary
hi gh-pressure connector(s) from cyl i nder head. Tool
#9015 threads onto connector tube. Use tool to pry
connector tube(s) from cyl i nder head.
(7) Remove necessary exhaust rocker arm assem-
bl y(s).
(8) Di sconnect i njector sol enoi d wi re nuts at top of
i njectors (Fi g. 18).
(9) Remove 2 fuel i njector hol d-down cl amp bol ts
at each i njector bei ng removed.
(10) USING TOOL #9010:
(a) Speci al Tool #9010 (Fi g. 19) i s equi pped wi th
2 cl amshel l cl amps, a sl i di ng retai ner sl eeve to
retai n the cl amshel l cl amps, a 2pi ece mounti ng
stud, and a pi voti ng handl e. Do not attempt to
remove the fuel injector with any other
device. Damage to injector will occur.
(b) The rocker housi ng (Fi g. 18) i s bol ted to the
top of cyl i nder head. The mounti ng stud from tool
#9010 was meant to temporari l y repl ace a rocker
housi ng mounti ng bol t. Remove the necessary
rocker housi ng mounti ng bol t. These mounti ng
bol ts are l ocated at the center of each of the 3
rocker housi ng support bri dges.
(c) I nstal l and ti ghten 2pi ece mounti ng stud to
rocker housi ng. I f removi ng the #6 fuel i njector,
separate the 2pi ece mounti ng stud. I nstal l l ower
hal f of mounti ng stud to center of rocker housi ng
bri dge. I nstal l upper hal f of mounti ng stud to l ower
hal f.
(d) Posi ti on tool handl e to mounti ng stud and
i nstal l handl e nut. Leave handl e nut l oose to al l ow
a pi voti ng acti on.
(e) Posi ti on l ower part of cl amshel l hal ves to
si des of fuel i njector (wi der shoul der to bottom).
The upper part of cl amshel l hal ves shoul d al so be
posi ti oned i nto machi ned shoul der on the handl es
pi voti ng head.
(f) Sl i de the retai ner sl eeve over pi voti ng handl e
head to l ock cl amshel l hal ves together.
(g) Be sure handl e pi vot nut i s l oose.
(h) Depress handl e downward to remove fuel
i njector strai ght up from cyl i nder head bore.
(11) Remove and di scard i njector seal i ng washer.
Thi s shoul d be l ocated on ti p of i njector (Fi g. 20) or
(Fi g. 21).
Fig. 16 CONNECTOR TUBE REMOVAL
1 - CONNECTOR TUBE
2 - TOOL #9015
3 - CYLINDER HEAD (LEFT SIDE)
Fig. 17 TOOL #9015 AND CONNECTOR TUBE
1 - CONNECTOR TUBE
2 - LOCATING PINS
3 - RUBBER O-RING
4 - TOOL #9015
INSTALLATION
(1) Inspect fuel injector:
(a) Look for burrs on i njector i nl et.
(b) Check nozzl e hol es for hol e erosi on or pl ug-
gi ng.
(c) I nspect end of nozzl e for burrs or rough
machi ne marks.
(d) Look for cracks at nozzl e end.
(e) I f any of these condi ti ons occur, repl ace i njec-
tor.
(2) Thoroughl y cl ean fuel i njector cyl i nder head
bore. Bl ow out bore hol e wi th compressed ai r.
(3) The bottom of fuel i njector i s seal ed to cyl i nder
head bore wi th a copper seal i ng washer (shi m) of a
certai n thi ckness (Fi g. 20). A new shi m wi th correct
thi ckness must al ways be re-i nstal l ed after removi ng
i njector. Measure thi ckness of i njector shi m (Fi g. 21).
Shim Thickness: 1.5 mm (.060)
(4) I nstal l new shi m (washer) to bottom of i njector.
Appl y l i ght coati ng of cl ean engi ne oi l to washer. Thi s
wi l l keep washer i n pl ace duri ng i nstal l ati on.
(5) I nstal l new o-ri ng to fuel i njector. Appl y smal l
amount of cl ean engi ne oi l to o-ri ng.
Fig. 18 FUEL INJECTORS
1 - SOLENOID CONNECTIONS
2 - ROCKER HOUSING
3 - FUEL INJECTOR
4 - PASSTHROUGH CONNECTOR
Fig. 19 FUEL INJECTOR REMOVER - #9010
Fig. 20 FUEL INJECTOR SEALING WASHER (SHIM)
LOCATION
1 - FUEL INJECTOR
2 - COPPER SEALING WASHER (SHIM)
Fig. 21 MEASURING INJECTOR SEALING WASHER
(SHIM)
1 - SHIM
(6) I nstal l i njector i nto cyl i nder head wi th mal e
connector port faci ng the i ntake mani fol d. Push down
on fuel i njector mounti ng fl ange to engage o-ri ng and
seat i njector.
(7) Ti ghteni ng Sequence:
(a) I nstal l fuel i njector hol down cl amp (mount-
i ng fl ange) bol ts. Do a preliminary tightening
of these bolts to 5 Nm (44 in. lbs.) torque.
This preliminary tightening insures the fuel
injector is seated and centered.
(b) After ti ghteni ng, rel i eve bol t torque, but
l eave both bol ts threaded i n pl ace.
(c) I nstal l hi gh-pressure connector and retai ni ng
nut. Do a prel i mi nary ti ghteni ng to 15 Nm (11 ft.
l bs.) torque.
(d) Al ternatel y ti ghten i njector hol down bol ts to
(e) Do a fi nal ti ghteni ng of the hi gh-pressure
connector and retai ni ng nut. Ti ghten to 50 Nm (37
ft. l bs.) torque.
(8) Connect i njector sol enoi d wi res and nuts to top
of i njectors (Fi g. 18). Ti ghten connector nuts to 1.25
Nm (11 i n. l bs.) torque. Be very careful not to
overtighten these nuts as damage to fuel injec-
tor will occur.
(9) I nstal l exhaust rocker arm assembl y. Refer to
Engi ne.
(10) Set exhaust val ve l ash. Refer to Engi ne.
(11) I nstal l hi gh pressure fuel l i ne. Refer to Torque
Speci fi cati ons. Be sure to use a secondary
back-up wrench on the connector nut (fitting)
while torquing fuel line fitting. Refer to Fuel Li ne
I nstal l ati on for addi ti onal i nformati on.
(12) I nstal l val ve cover. Refer to Engi ne.
(13) I nstal l breather assembl y.
(14) Connect negati ve battery cabl es to both bat-
teri es.
FUEL INJ ECTOR RAIL
DESCRIPTION
The fuel i njector rai l i s bol ted to the top of the
i ntake mani fol d.
OPERATION
The fuel rai l i s used as a di stri buti on devi ce to
suppl y hi gh-pressure fuel to the hi gh-pressure fuel
l i nes.
REMOVAL
batteri es. I sol ate ends of both cabl es.
(2) Di sconnect el ectri cal connector at fuel pressure
sensor.
(3) Remove banjo bol t at fuel l i mi ti ng val ve.
(4) Di sconnect necessary wi ri ng harness retenti on
cl i ps from i ntake mani fol d.
(5) Li ft 2 rubber covers to gai n access to posi ti ve
(+), i ntake heater cabl e nuts. Remove 2 nuts and
remove 2 cabl es from studs.
(6) Careful l y remove 4 hi gh-pressure fuel l i nes
from top of i njector rai l engi ne. Note posi ti on of each
l i ne whi l e removi ng. Do not bend lines while
removing.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING, USE A BACK-UP WRENCH ON FIT-
TING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
(7) Careful l y remove 2 hi gh-pressure fuel l i nes at
each end of i njector rai l . Note posi ti on of each l i ne
whi l e removi ng. Do not bend lines while remov-
ing.
(8) Remove fuel l i ne connecti ng i njector pump to
fuel rai l .
(9) Remove 3 i njector rai l mounti ng bol ts (Fi g. 22).
(10) Remove rai l from top of i ntake mani fol d.
INSTALLATION
(1) Cl ean any di rt/debri s from top of i ntake mani -
fol d and bottom of fuel rai l .
(2) Posi ti on fuel rai l to top of mani fol d and i nstal l
3 mounti ng bol ts. Refer to Torque Speci fi cati ons.
(3) I nstal l al l hi gh-pressure l i nes to rai l . Refer to
Fuel Li nes for procedures.
(4) Reposi ti on wi ri ng harness to i ntake mani fol d
and i nstal l new ti e wraps.
(5) I nstal l and ti ghten fuel l i mi ti ng val ve banjo
bol t. Refer to Torque Speci fi cati ons.
(6) Connect el ectri cal connector to fuel pressure
sensor.
(7) Posi ti on 2 posi ti ve (+) cabl es to i ntake heater
studs. I nstal l 2 nuts.
(8) Connect battery cabl es to both batteri es.
INLET AIR TEMPERATURE
SENSOR/PRESSURE SENSOR
DESCRIPTION
The combi nati on, dual functi on I nl et Ai r Tempera-
ture/Pressure Sensor i s l ocated on the ai r cl eaner (fi l -
ter) cover.
OPERATION
The I nl et Ai r Temperature/Pressure Sensor i s a
combi nati on dual -functi on sensor. The sensor el ement
extends i nto the i ntake ai r stream at the top of the
ai r fi l ter housi ng. Ambi ent ai r temperature as wel l as
barometri c pressure i s moni tored by thi s sensor. The
Engi ne Control Modul e (ECM) moni tors si gnal s from
thi s sensor.
REMOVAL
The I nl et Ai r Temperature/Pressure Sensor i s
l ocated on the ai r cl eaner cover (Fi g. 23).
(1) Di sconnect el ectri cal connector at sensor (Fi g.
24).
(2) Remove two Torx-type mounti ng screws.
(3) Remove sensor from ai r cl eaner cover.
INSTALLATION
(2) Posi ti on sensor i nto top of ai r cl eaner cover
wi th a sl i ght twi sti ng acti on.
(3) I nstal l 2 mounti ng screws.
Fig. 22 FUEL INJECTOR RAIL
1 - FUEL RAIL MOUNTING BOLTS (3)
2 - INSULATED CLAMPS
Fig. 23 IAT/PRESSURE SENSOR LOCATION - 5.9L
DIESEL
1 - CLIPS
2 - FILTER COVER
3 - FILTER MINDER
4 - INLET AIR TEMPERATURE/ PRESSURE SENSOR
5 - FILTER HOUSING
FUEL INJ ECTOR RAIL (Continued)
INTAKE AIR HEATER
DESCRIPTION
The i ntake mani fol d ai r heater el ement assembl y
i s l ocated i n the top of the i ntake mani fol d.
OPERATION
The ai r heater el ements are used to heat i ncomi ng
ai r to the i ntake mani fol d. Thi s i s done to hel p
engi ne starti ng and i mprove dri veabi l i ty wi th cool or
col d outsi de temperatures.
El ectri cal suppl y for the 2 ai r heater el ements i s
control l ed by the Engi ne Control Modul e (ECM)
through the 2 ai r heater rel ays. Refer to I ntake Man-
i fol d Ai r Heater Rel ays for more i nformati on.
Two heavy-duty cabl es connect the 2 ai r heater el e-
ments to the 2 ai r heater rel ays. Each of these cabl es
wi l l suppl y approxi matel y 95 amps at 12 vol ts to an
i ndi vi dual heati ng el ement wi thi n the heater bl ock
assembl y.
Refer to the Powertrai n Di agnosti c Procedures
manual for el ectri cal operati on and compl ete descri p-
ti on of the i ntake heaters, i ncl udi ng pre-heat and
post-heat cycl es.
REMOVAL
I f servi ci ng ei ther of the heater el ements, the
enti re bl ock/el ement assembl y must be repl aced.
batteri es. Cover and i sol ate ends of both cabl es.
(2) Remove both the i ntake mani fol d ai r i ntake
tube (above i njecti on pump), and i ts rubber connector
hose (Fi g. 26).
(3) Li ft 2 rubber covers (Fi g. 27) to gai n access to 2
posi ti ve (+) cabl e nuts. Remove these 2 nuts (Fi g. 28)
and remove 2 cabl es from studs.
(4) Di sconnect ground strap (Fi g. 27) at heater el e-
ment stud.
(5) Remove wi ri ng harness cl i ps.
(6) Remove engi ne oi l di psti ck tube bracket from
ai r i nl et connecti on and fuel fi l ter housi ng.
(7) Remove 4 housi ng mounti ng bol ts (Fi g. 27) and
remove heater el ement assembl y.
INSTALLATION
I f servi ci ng ei ther of the heater el ements, the
enti re bl ock/el ement assembl y must be repl aced.
(1) Usi ng 2 new gaskets, posi ti on el ement assem-
bl y and ai r housi ng to i ntake mani fol d.
(2) I nstal l ground cabl e to ai r housi ng.
(3) I nstal l 4 housi ng bol ts and ti ghten to 24 Nm
(4) Connect 2 posi ti ve (+) heater cabl es at cabl e
mounti ng studs. Do not allow either of the cable
eyelets to contact any other metal source other
than the cable nuts/studs.
Fig. 24 INLET/PRESSURE SENSOR REMOVAL/
INSTALLATION
1 - INLET/PRESSURE SENSOR
2 - ELEC. CONNECTOR
3 - SENSOR MOUNTING SCREWS (2)
4 - TOP OF AIR FILTER COVER
Fig. 25 SENSOR O-RING
1 - IAT/PRESSURE SENSOR
2 - O-RING
INLET AIR TEMPERATURE SENSOR/PRESSURE SENSOR (Continued)
(5) I nstal l engi ne oi l di psti ck tube and mounti ng
bol t.
(6) Connect rubber connector hose and i ntake tube
to ai r i ntake housi ng. Ti ghten cl amp bol ts to 11 Nm
(7) Connect both negati ve battery cabl es at both
batteri es.
Fig. 26 INTAKE TUBE AND CONNECTING HOSE
1 - MANIFOLD ABOVE HEATERS
2 - RUBBER CONNECTING HOSE
3 - METAL INTAKE TUBE
4 - CLAMPS (2)
Fig. 27 AIR HEATER MANIFOLD
1 - GROUND CABLE
3 - RUBBER COVERS
4 - OIL DIPSTICK TUBE
5 - DIPSTICK MOUNTING BOLT
6 - NUT (GROUND CABLE)
Fig. 28 AIR HEATER ELEMENTS
2 - AIR HEATER MANIFOLD
3 - INTAKE MANIFOLD
4 - HEATER ELEMENTS
5 - LOWER GASKET
6 - NUTS (2) POSITIVE CABLES
7 - UPER GASKET
INTAKE AIR HEATER (Continued)
INTAKE AIR HEATER RELAY
DESCRIPTION
The 2 i ntake mani fol d ai r heater rel ays are l ocated
i n the engi ne compartment. They are attached to a
common bracket. Thi s bracket i s attached to the
ri ght battery tray (Fi g. 29).
OPERATION
The Engi ne Control Modul e (ECM) operates the 2
heati ng el ements through the 2 i ntake mani fol d ai r
heater rel ays.
Refer to Powertrai n Di agnosti c Procedures for an
el ectri cal operati on and compl ete descri pti on of the
i ntake heaters, i ncl udi ng pre-heat and post-heat
cycl es.
REMOVAL
The 2 i ntake mani fol d ai r heater rel ays are l ocated
i n the engi ne compartment. They are attached to a
common bracket. Thi s bracket i s attached to the
ri ght battery tray (Fi g. 29).
The mounti ng bracket and both rel ays are repl aced
as an assembl y.
batteri es.
(2) Di sconnect four rel ay tri gger wi res at both
rel ays. Note posi ti on of wi ri ng before removi ng.
(3) Li ft four rubber shi el ds from al l 4 cabl es.
(4) Remove four nuts at cabl e connectors. Note
posi ti on of wi ri ng before removi ng.
(5) Remove rel ay mounti ng bracket bol ts and
remove rel ay assembl y.
INSTALLATION
(1) I nstal l rel ay assembl y to battery tray. Ti ghten
mounti ng bol ts to 4.5 Nm (40 i n. l bs.) torque.
(2) Connect ei ght el ectri cal connectors to rel ays.
(3) Connect battery cabl es to both batteri es.
INTAKE AIR TEMPERATURE
SENSOR/MAP SENSOR
DESCRIPTION
The combi nati on, dual functi on I ntake Mani fol d
Ai r Temperature Sensor/MAP Sensor i s i nstal l ed i nto
the top of the i ntake mani fol d.
OPERATION
Ai r Temperature Sensor/MAP Sensor i s i nstal l ed i nto
the top of the i ntake mani fol d wi th the sensor el e-
ment extendi ng i nto the ai r stream.
The I AT porti on of the sensor provi des an i nput
vol tage to the Engi ne Control Modul e (ECM) i ndi cat-
i ng i ntake mani fol d ai r temperature. The MAP por-
ti on of the sensor provi des an i nput vol tage to the
ECM i ndi cati ng turbocharger boost pressure.
REMOVAL
Ai r Temperature Sensor/MAP (I AT/MAP) sensor i s
i nstal l ed i nto the top of the i ntake mani fol d (Fi g. 30).
(1) Cl ean area around sensor.
(2) Di sconnect el ectri cal connector from I AT/MAP
sensor.
(3) Remove two T-15 Torx headed screws.
(4) Remove sensor from i ntake mani fol d.
INSTALLATION
(2) Lubri cate sensor o-ri ng wi th cl ean engi ne oi l .
(3) Cl ean sensor mounti ng area at i ntake mani -
fol d.
(4) Posi ti on sensor i nto i ntake mani fol d.
(5) I nstal l and ti ghten 2 sensor mounti ng screws
Fig. 29 INTAKE MANIFOLD AIR HEATER RELAYS
1 - BATTERY
2 - CABLES TO INTAKE HEATERS
3 - RELAY TRIGGER WIRES
4 - INTAKE AIR HEATER RELAYS (2)
MAP SENSOR
DESCRIPTION
A combi nati on, dual functi on I ntake Mani fol d Ai r
Temperature Sensor/MAP Sensor i s used. Refer to
I ntake Ai r Temperature Sensor/MAP Sensor for i nfor-
mati on.
REMOVAL
If Equipped With Engine Mounted Accelerator Pedal
Position Sensor
batteri es.
(6) Remove cabl e cover (Fi g. 33). Cabl e cover i s
attached wi th 2 Phi l l i ps screws, 2 pl asti c retenti on
cl i ps and 2 push tabs (Fi g. 33). Remove 2 Phi l l i ps
screws and careful l y pry out 2 retenti on cl i ps. After
cl i p removal , push rearward on front tab, and
upward on l ower tab for cover removal .
(7) Usi ng 2 screwdri vers, pry cabl e connector
socket from throttl e l ever bal l (Fi g. 34). Be very
careful not to bend throttle lever arm.
If Equipped With Battery Tray Mounted Accelerator Pedal
Position Sensor
The Throttl e Control Cabl e connects the accel era-
tor pedal to the Accel erator Pedal Posi ti on Sensor
(APPS). A separate mechani cal cabl e i s not routed to
the throttl e body.
accelerator pedal, cables or APPS.
batteri es.
(4) Remove APPS. Refer to (Di esel ) Accel erator
Pedal Posi ti on Sensor (APPS) Removal /I nstal l ati on.
Fig. 30 INTAKE/MAP SENSOR
2 - IAT/MAP SENSOR
3 - ELEC. CONNECTOR
Fig. 31 SENSOR O-RING
1 - IAT/MAP SENSOR
2 - O-RING
INTAKE AIR TEMPERATURE SENSOR/MAP SENSOR (Continued)
(7) Remove cabl e housi ng at APPS bracket by
pressi ng on rel ease tab wi th a smal l screwdri ver. To
prevent cable housing breakage, press on tab
only enough to release cable from APPS
bracket.
INSTALLATION
Accelerator Pedal Position Sensor Mounted To Engine
(1) I nstal l cabl e through mounti ng hol e on cabl e
mounti ng bracket (Fi g. 34). Cabl e snaps i nto bracket.
Be sure 2 pi nch tabs are secure.
(2) Usi ng l arge pl i ers, connect cabl e end socket to
throttl e l ever bal l (snaps on).
(3) I nstal l remai ni ng cabl e housi ng end i nto and
through dash panel openi ng (snaps i nto posi ti on).
The two pl asti c pi nch tabs shoul d l ock cabl e to dash
panel .
I nstal l throttl e cabl e core wi re and pl asti c cabl e
retai ner i nto and through upper end of pedal arm
(the pl asti c retai ner i s snapped i nto pedal arm).
When i nstal l i ng pl asti c retai ner to accel erator pedal
arm, note i ndex tab on pedal arm (Fi g. 32). Al i gn
i ndex sl ot on pl asti c cabl e retai ner to thi s i ndex tab.
(5) Connect negati ve battery cabl es to both batter-
i es.
(7) I nstal l cabl e/l ever cover.
5 - CABLE CLIP
Fig. 33 CABLE/LEVER/THROTTLE LINKAGE COVER
4 - TAB PUSH HERE
Fig. 34 SERVO CABLE AT THROTTLE LEVER
1 - PINCH (2) TABS
3 - PINCH TABS (2)
4 - OFF
5 - THROTTLE CABLE
6 - THROTTLE LEVER
8 - OFF
9 - CONNECTOR
Accelerator Pedal Position Sensor Not Mounted To Engine
(1) Attach cabl e to Accel erator Pedal Posi ti on Sen-
sor (APPS). Refer to APPS (Di esel ) Removal / I nstal -
l ati on.
any APPS Di agnosti c Troubl e Codes (DTCs) from
Engi ne Control Modul e (ECM).
PTO SWITCH
DESCRIPTION
Thi s Engi ne Control Modul e (ECM) i nput i s used
onl y on model s equi pped wi th aftermarket Power
Take Off (PTO) uni ts.
OPERATION
Thi s i nput i s used onl y to tel l the PCM (non-di e-
sel ), or ECM (di esel ) that the aftermarket PTO
(Power Take Off) uni t has been engaged. The PCM
(or ECM) wi l l di sabl e (temporari l y shut down) cer-
tai n OBD I I di agnosti c troubl e codes when the PTO
uni t i s engaged.
5 - CABLE CLIP
STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . 2
STEERING FLOW AND PRESSURE . . . . . . . . 4
SPECIAL TOOLS
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GEAR - INDEPENDENT FRONT SUSPENSION . . 17
GEAR - LINK/COIL . . . . . . . . . . . . . . . . . . . . . . . 20
LINKAGE - INDEPENDENT FRONT
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
LINKAGE - LINK/COIL . . . . . . . . . . . . . . . . . . . . 34
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
STEERING
DESCRIPTION
CAUTION: MOPAR ATF+4 is to be used in the
power steering system. No other power steering or
automatic transmission fluid is to be used in the
not overfill.
Power steeri ng systems consi st of:
Steeri ng col umn
Rack and pi ni on steeri ng gear
Bel t dri ven hydraul i c steeri ng pump
Pump pressure and return hoses
Oi l Cool er
OPERATION
The steeri ng col umn shaft i s attached to the gear
pi ni on. The rotati on of the pi ni on moves the gear
rack from si de-to-si de. Thi s l ateral acti on of the rack
pushes and pul l s the ti e rods to change the di recti on
of the front wheel s (Fi g. 1).
Power assi st i s provi ded by an engi ne mounted
hydraul i c pump whi ch suppl i es hydraul i c fl ui d pres-
sure to the steeri ng gear.
Fig. 1 STEERING COMPONENTS
1 - POWER STEERING PUMP ASSEMBLY
2 - RESERVOIR
3 - HOSES
4 - TIE ROD ENDS
5 - MOUNTING BOLTS
6 - RACK & PINION
DR STEERING 19 - 1
DIAGNOSIS AND TESTING - POWER STEERING
SYSTEM
There i s some noi se i n al l power steeri ng systems. One of the most common i s a hi ssi ng sound evi dent at a
standsti l l parki ng. Or when the steeri ng wheel i s at the end of i ts travel . Hi ss i s a hi gh frequency noi se si mi l ar
to that of a water tap bei ng cl osed sl owl y. The noi se i s present i n al l val ves that have a hi gh vel oci ty fl ui d passi ng
through an ori fi ce. There i s no rel ati onshi p between thi s noi se and steeri ng performance.
STEERING NOISE
OBJECTIONAL HISS OR
WHISTLE
1. Steering intermediate shaft to dash panel
seal.
1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components.
2. Inspect and repair suspension.
3. Internal gear noise. 3. Replace steering gear.
4. Pressure hose in contact with other
components.
4. Reposition hose.
5. Loose or damaged intermediate shaft or
column.
5. Inspect and repair or replace.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.
2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
4. Air in fluid 4. Check for lekas, Evacuate air
from P/S system.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose
fitting.
2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
5. Reservoir cap not installed correctly. 5. Install reservoir cap correctly.
SCRUBBING OR
KNOCKING
1. Wrong tire size. 1. Verify tire size.
19 - 2 STEERING DR
STEERING (Continued)
BINDING AND STICKING
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
3. Steering components (ball
joints/tie rod ends).
3 Inspect and repair as necessary.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn. 7. Replace gear.
8. Pump seized / Stuck valve 8. Replace pump.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT
3. Loose belt. 3. Adjust or replace.
4. Low pump pressure. 4. Pressure test and repair as
necessary.
5. Internal gear leak. 5. Replace gear.
STEERING WHEEL DOES NOT
WANT TO RETURN TO CENTER
POSITION
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate suspension
compnents.
4. High friction in steering gear. 4. Replace gear.
LOOSE STEERING AND VEHICLE LEAD
EXCESSIVE PLAY IN STEERING
WHEEL
1. Worn or loose suspension or
steering components.
1. Inspect and repair as necessary.
2. Worn or loose wheel bearings. 2. Inspect and repair or adjust
bearings.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Replace gear.
5. Worn or loose steering coupler. 5. Inspect and replace as
necessary.
VEHICLE PULLS OR LEADS TO
ONE SIDE.
1. Tire Pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Rotate tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align front end.
DR STEERING 19 - 3
DIAGNOSIS AND TESTING - POWER STEERING
FLOW AND PRESSURE
The fol l owi ng procedure i s used to test the opera-
ti on of the power steeri ng system on the vehi cl e. Thi s
test wi l l provi de the gal l ons per mi nute (GPM) or
fl ow rate of the power steeri ng pump al ong wi th the
maxi mum rel i ef pressure. Perform test any ti me a
power steeri ng system probl em i s present. Thi s test
wi l l determi ne i f the power steeri ng pump or power
steeri ng gear i s not functi oni ng properl y. The fol l ow-
i ng pressure and fl ow test i s performed usi ng Power
Steeri ng Anal yzer Tool ki t 6815 and (Fi g. 2) Adapter
Ki t 6893.
FLOW AND PRESSURE TEST
(1) Check the power steeri ng bel t to ensure i t i s i n
good condi ti on and adjusted properl y.
(2) Connect pressure gauge hose from the Power
Steeri ng Anal yzer to adapter 6826.
(3) Connect tube 6825A to Power Steeri ng Ana-
l yzer test val ve end.
(4) Di sconnect the hi gh pressure hose from the
power steeri ng pump.
(5) Connect the tube 6825A to the pump fi tti ng.
(6) Connect the power steeri ng hose from the
steeri ng gear to the adapter 6826.
(7) Open the test val ve compl etel y.
(8) Start engi ne and l et i dl e l ong enough to ci rcu-
l ate power steeri ng fl ui d through fl ow/pressure test
gauge and to get ai r out of the fl ui d. Then shut off
engi ne.
(9) Check fl ui d l evel , add fl ui d as necessary. Start
engi ne agai n and l et i dl e.
(10) Gauge shoul d read bel ow 862 kPa (125 psi ), i f
above, i nspect the hoses for restri cti ons and repai r as
necessary. The i ni ti al pressure readi ng shoul d be i n
the range of 345-552 kPa (50-80 psi ).
(11) I ncrease the engi ne speed to 1500 RPM and
read the fl ow meter. I f the fl ow rate (GPM) i s bel ow
speci fi cati on, (refer to pump speci fi cati on chart for
GPM) the pump shoul d be repl aced.
CAUTION: The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than three seconds as the pump could be
damaged.
(12) Cl ose val ve ful l y three ti mes and record hi gh-
est pressure i ndi cated each ti me. All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
Pressures above speci fi cati ons but not wi thi n
345 kPa (50 psi ) of each other, repl ace pump.
Pressures wi thi n 345 kPa (50 psi ) of each other
but bel ow speci fi cati ons, repl ace pump.
(13) Open the test val ve and turn the steeri ng
wheel to the extreme l eft and ri ght posi ti ons three
ti mes agai nst the stops. Record the hi ghest pressure
readi ng at each posi ti on. Compare readi ngs to the
pump speci fi cati ons chart. I f pressures readi ngs are
not wi thi n 50 psi of each other, the gear i s l eaki ng
i nternal l y and must be repl aced.
CAUTION: Do not force the pump to operate against
the stops for more than 2 to 3 seconds at a time
because, pump damage will result.
PUMP SPECIFICATION
ENGINE
RELIEF PRESSURE
65
FLOW RATE
(GPM) AT 1500
RPM
1500
series
11032 kPa
(1615 65 psi)
3.1 - 3.5
2500 &
3500
series
12400 kPa
(1800 50 psi)
3.5 - 4.0
Fig. 2 Analyzer With Tube and Adapter
1 - TUBE
2 - ADAPTER FITTINGS
3 - ANALYZER
4 - GAUGE HOSE
19 - 4 STEERING DR
SPECIAL TOOLS
STEERING
PULLER - 8677
ADAPTERS, POWER STEERING FLOW/PRESSURE
TESTER - 6893
ANALYZER SET, POWER STEERING FLOW/
PRESSURE 6815
ADAPTER, POWER STEERING FLOW/PRESSURE -
6825A
DR STEERING 19 - 5
COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - STEERING
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IGNITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - IGNITION
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
KEY-IN IGNITION SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - IGNITION
SWITCH AND KEY LOCK CYLINDER . . . . . . . 11
KEY CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
GEAR SHIFT LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
UPPER STEERING COUPLING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD . 14
REMOVAL - 4X4 HD . . . . . . . . . . . . . . . . . . . 14
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION - 4X4 HD . . . . . . . . . . . . . . . . 15
STEERING WHEEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
TILT LEVER KNOB RELEASE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
COLUMN
DESCRIPTION
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
The ti l t and standard col umn (Fi g. 1) has been
desi gned to be servi ced as an assembl y; l ess wi ri ng,
swi tches, shrouds, steeri ng wheel , etc. Most steeri ng
col umn components can be servi ced wi thout remov-
i ng the steeri ng col umn from the vehi cl e.
To servi ce the steeri ng wheel , swi tches or ai rbag,
refer to Restrai nts and fol l ow al l WARNI NGS and
CAUTI ONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear-
ing.
CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism. Do not
remove shaft lock plate or plate retainer. This will
damage the column.
CAUTION: Do not attempt to remove or modify the
park lock slider or link.
19 - 6 COLUMN DR
NOTE: When servicing the steering wheel after
removing the old bolt a new bolt must be used
when installing.
NOTE: When servicing the coupler a new bolt must
be used when installing.
DIAGNOSIS AND TESTING - STEERING
COLUMN
I f the vehi cl e i s i nvol ved i n a front end col l i si on/the
ai r bag has depl oyed the col umn must be i nspected.
Thi s i nspecti on wi l l determi ne i f the Col umn has col -
l apsed. I nspect the col umn mounti ng capsul es vi su-
al l y and manual l y push and pul l them to check for
separati on or fractures. I f capsul es are fractured or
have moved the col umn MUST be repl aced.
REMOVAL
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.
(1) Posi ti on the front wheel s straight ahead.
(2) Di sconnect the negati ve (ground) cabl e from
the battery.
(3) Remove the two swi tches from the steeri ng
wheel .
(4) Remove the ai rbag, (Refer to 8 - ELECTRI CAL/
RESTRAI NTS/DRI VER AI RBAG - REMOVAL).
(5) Remove the steeri ng wheel wi th speci al tool
CJ981 or an appropri ate steeri ng wheel pul l er.
CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel/
clockspring.
I NG COLUMN OPENI NG COVER - REMOVAL).
(7) Remove the ti l t l ever.
(8) Remove the col umn shrouds (Fi g. 2).
(9) Remove the cl ock spri ng, (Refer to 8 - ELEC-
TRI CAL/RESTRAI NTS/CLOCKSPRI NG -
REMOVAL).
(10) Di sconnect the wi ri ng harness to the col umn.
1 - LOCK CYLINDER
2 - GEAR SHIFT LEVER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - TILT LEVER
Fig. 2 UPPER & LOWER SHROUDS
1 - UPPER SHROUD
2 - LOWER SHROUD
DR COLUMN 19 - 7
COLUMN (Continued)
(11) Remove the shi ft cabl e from the col umn shi ft
l ever actuator (Refer to 21 - TRANSMI SSI ON/
TRANSAXLE/AUTOMATI C - 32RH/GEAR SHI FT
CABLE - REMOVAL). (Fi g. 3).
(12) Rel ease the shi ft cabl e from the col umn
bracket and remove i t from the bracket.
(13) Remove the SKI M modul e i n order to di scon-
nect the el ectri cal connector.
(14) Remove the upper steeri ng shaft coupl er bol t
and sl i de the shaft down (Fi g. 4) & (Fi g. 5)
(15) Remove the brake l i ght swi tch and di scard
(Refer to 8 - ELECTRI CAL/LAMPS/LI GHTI NG -
EXTERI OR/BRAKE LAMP SWI TCH - REMOVAL).
(16) Remove the four steeri ng col umn mounti ng
nuts (Fi g. 6).
Fig. 3 SHIFT CABLE CONNECTOR
1 - Shift lever
2 - Cable Connection
3 - Overdrive Electrical Wiring
4 - Mounting Screws
Fig. 4 COUPLER SHAFT
1 - MOUNTING HOLES
2 - COUPLER BOLT HOLE
Fig. 5 UPPER STEERING COUPLER
1 - STEERING COUPLER
2 - PINCH BOLT HOLE
Fig. 6 MOUNTING HOLES
1 - MOUNTING HOLES
19 - 8 COLUMN DR
COLUMN (Continued)
(17) Remove the steeri ng col umn assembl y from
the vehi cl e. (Fi g. 7)
INSTALLATION
ARMED. REFER TO ELECTRICAL RESTRAINT SYS-
TEM FOR SERVICE PROCEDURES. FAILURE TO DO
SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIRBAG AND POSSIBLE PERSONAL INJURY.
CAUTION: All fasteners must be torqued to specifi-
cation to ensure proper operation of the steering
column.
(1) Posi ti on the steeri ng col umn on the dash panel
support and l oosel y i nstal l the mounti ng nuts.
(2) Fi rml y sl i de the steeri ng col umn upward
agai nst the studs i n dash panel and hand ti ghten the
nuts.
(3) I nstal l the steeri ng shaft coupl er on the steer-
i ng shaft and l oosel y i nstal l a new bol t.
(4) Center steeri ng col umn i n dash openi ng and
ti ghten mounti ng nuts to 28 Nm (250 i n. l bs.).
NOTE: Torque the upper left nut first then the lower
right nut. Then torque the lower left nut then the
upper right nut.
NOTE: A new bolt must be used for reinstallation.
(5) Ti ghten the coupl er bol t to 57 Nm (42 ft. l bs.).
(6) I nstal l a new brake l i ght swi tch (Refer to 8 -
(7) I nstal l the shi fter cabl e. (Refer to 21 - TRANS-
MI SSI ON/TRANSAXLE/AUTOMATI C - 32RH/GEAR
SHI FT CABLE - I NSTALLATI ON)
(8) Connect the wi ri ng harness to the col umn.
(9) I nstal l the SKI M modul e.
(10) I nstal l the cl ockspri ng(Refer to 8 - ELECTRI -
CAL/RESTRAI NTS/CLOCKSPRI NG - REMOVAL).
(11) I nstal l the shrouds.
TI ON).
(13) Al i gn the spl i ne on the wheel hub to shaft.
(14) Then i nstal l the steeri ng wheel and i nstal l a
new bol t. Ti ghten the bol t to 61 Nm (45 ft. l bs.).
(15) I nstal l the ai rbag (Refer to 8 - ELECTRI CAL/
RESTRAI NTS/DRI VER AI RBAG - I NSTALLATI ON).
(16) I nstal l the two steeri ng wheel swi tches.
(17) I nstal l the ti l t l ever handl e.
(18) I nstal l the negati ve battery termi nal .
(19) Test the operati on of the horn, El ectroni c
PRNDL I ndi cator, l i ghts and any other functi ons that
are steeri ng col umn operated.
IGNITION SWITCH
DESCRIPTION
The i gni ti on swi tch i s l ocated on the steeri ng col -
umn. I t i s used as the mai n on/off swi tchi ng devi ce
for most el ectri cal components. The mechani cal key
cyl i nder i s used to engage/di sengage the el ectri cal
i gni ti on swi tch.
OPERATION
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an i nterl ock devi ce i s l ocated wi thi n the shi ft cabl e.
Thi s i nterl ock devi ce i s used to l ock the transmi ssi on
shi fter i n the PARK posi ti on when the key cyl i nder i s
i n any posi ti on and the brake pedal i s not depressed.
DIAGNOSIS AND TESTING - IGNITION SWITCH
TEST AND REPAIR
I f the key removal effort i s excessi ve on a vehi cl e
wi th a automati c transmi ssi on fi rst adjust the shi ft
l i nkage, (Refer to 21 - TRANSMI SSI ON/TRANS-
AXLE/AUTOMATI C - 46RE/GEAR SHI FT CABLE -
ADJUSTMENTS).
I f the i gni ti on swi tch effort i s excessi ve remove the
i gni ti on key cyl i nder from the steeri ng col umn. (Refer
to 19 - STEERI NG/COLUMN/LOCK CYLI NDER
1 - Steering Wheel
2 - Key Cylinder
3 - Gear Shift Lever
4 - Steering Column
5 - Tilt Lever Cable
DR COLUMN 19 - 9
COLUMN (Continued)
HOUSI NG - REMOVAL). Check the turni ng effort of
the key cyl i nder. I f the i gni ti on key cyl i nder effort i s
excessi ve repl ace the key cyl i nder.
REMOVAL
SERVICE PRECAUTIONS
NOTE: The steering column on vehicles equipped
with an automatic transmission is not equipped
with an internal locking shaft with the ignition cyl-
inder. Alternative methods of locking the steering
wheel for service will have to be used.
The ti l t and standard col umn (Fi g. 8) have been
desi gned to be servi ced as an assembl y; wi thout wi r-
i ng, swi tches, shrouds, steeri ng wheel , etc. Most
steeri ng col umn components can be servi ced wi thout
removi ng the steeri ng col umn from the vehi cl e.
Safety goggl es shoul d be worn at al l ti mes when
worki ng on steeri ng col umns.
To servi ce the steeri ng wheel , swi tches or ai rbag,
Refer to El ectri cal Restrai nts and fol l ow al l WARN-
I NGS and CAUTI ONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
CAUTION: Do not hammer on steering column
shaft. This may cause damage to the shaft or bear-
ing.
CAUTION: Do not attempt to remove the pivot bolts
to disassemble the tilting mechanism.
The i gni ti on key must be i n the key cyl i nder for
cyl i nder removal . The key cyl i nder must be removed
fi rst before removi ng i gni ti on swi tch.
(1) Remove the negati ve (ground) cabl e from the
battery.
(2) Di sabl e the ai rbag, (Refer to 8 - ELECTRI CAL/
RESTRAI NTS/DRI VER AI RBAG - REMOVAL).
(3) Remove the l ower and upper shrouds.
(4) Remove key cyl i nder. (Refer to 19 - STEER-
I NG/COLUMN/LOCK CYLI NDER HOUSI NG -
REMOVAL).
(5) Di sconnect the l ower cl ockspri ng connectors.
(6) Remove the wi re retai ner from the ti l t l ever
bracket.
(7) Remove the ti l t l ever mounti ng screws to gai n
access to the i gni ti on swi tch mounti ng screws. (Fi g.
9)
1 - KEY CYLINDER
3 - MOUNTING HOLES
4 - STEERING COLUMN
5 - IGNITION SWITCH
Fig. 9 IGNITION SWITCH WITH TILT
1 - IGNITION SWITCH
2 - TILT LEVER MECHANISM
19 - 10 COLUMN DR
IGNITION SWITCH (Continued)
(8) For col umns wi thout ti l t remove the bracket to
gai n access to the i gni ti on swi tch mounti ng screws.
(Fi g. 10)
(9) Di sconnect the el ectri cal connector at rear of
i gni ti on swi tch (Fi g. 11).
(10) Remove i gni ti on swi tch mounti ng screw.
(11) Usi ng a smal l screwdri ver, push on l ocki ng
tab and remove swi tch from steeri ng col umn.
INSTALLATION
cyl i nder removal . The key cyl i nder must be removed
fi rst before i nstal l i ng i gni ti on swi tch.
(1) Before i nstal l i ng i gni ti on swi tch, rotate the sl ot
i n the swi tch to the ON posi ti on.
(2) Connect the el ectri cal connector to rear of the
i gni ti on swi tch. Make sure that l ocki ng tabs are ful l y
seated i nto wi ri ng connector.
(3) Posi ti on swi tch to col umn and i nstal l the
mounti ng screw. Ti ghten screw to 3 Nm (26 i n. l bs.).
(4) I nstal l the ti l t l ever bracket mounti ng screws.
Ti ghten screws to 4.5 Nm (40 i n. l bs.).
(5) I f the col umn i s non-ti l t i nstal l the bracket.
Ti ghten screws to 4.5 Nm (40 i n. l bs.) (Fi g. 10)
(6) Posi ti on the wi re retai ner i nto the ti l t l ever
bracket.
(7) Reconnect the l ower cl ockspri ng connectors.
(8) I nstal l the key cyl i nder.
(9) I nstal l steeri ng col umn upper and l ower
shrouds.
(10) Enabl e the ai rbag system. (Refer to 8 - ELEC-
TRI CAL/RESTRAI NTS/DRI VER AI RBAG - I NSTAL-
LATI ON).
KEY-IN IGNITION SWITCH
DESCRIPTION
The key-i n i gni ti on swi tch i s i ntegral to the i gni -
ti on swi tch, whi ch i s mounted on the l eft si de of the
steeri ng col umn. I t cl oses a path to ground for the
Central Ti mer Modul e (CTM) when the i gni ti on key
i s i nserted i n the i gni ti on key cyl i nder and the dri ver
door ajar swi tch i s cl osed (dri ver door i s open). The
key-i n i gni ti on swi tch opens the ground path when
the key i s removed from the i gni ti on key cyl i nder.
The ground path i s al so opened when the dri ver door
ajar swi tch i s open (dri ver door i s cl osed).
The key-i n i gni ti on swi tch cannot be repai red and,
i f faul ty or damaged, the enti re i gni ti on swi tch must
be repl aced, (Refer to 19 - STEERI NG/COLUMN/I G-
NI TI ON SWI TCH - REMOVAL).
DIAGNOSIS AND TESTING - IGNITION SWITCH
AND KEY LOCK CYLINDER
ELECTRICAL DIAGNOSIS
For i gni ti on swi tch el ectri cal schemati cs, refer to
I gni ti on Swi tch i n the appropri ate secti on of El ectri -
cal Wi ri ng Di agrams.
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO
ROTATE)
(Refer to 19 - STEERI NG/COLUMN/I GNI TI ON
SWI TCH - DI AGNOSI S AND TESTI NG).
Fig. 10 IGNITION SWITCH WITHOUT TILT
1 - Ignition Switch Mounting Screws
2 - Non-Tilt Mounitng Bracket Screws
Fig. 11 IGNITION SWITCH
1 - Ignition Switch
2 - Ignition Switch Mounting Screws
DR COLUMN 19 - 11
IGNITION SWITCH (Continued)
KEY CYLINDER
REMOVAL
cyl i nder removal .
(2) Remove upper and l ower covers (shrouds) from
steeri ng col umn.
(3) Pl ace shi fter i n PARK posi ti on.
(4) A retai ni ng pi n (Fi g. 12) i s l ocated at si de of
key cyl i nder assembl y.
(a) Rotate key to RUN posi ti on.
(b) Press i n on retai ni ng pi n whi l e pul l i ng key
cyl i nder from i gni ti on swi tch (Fi g. 13).
INSTALLATION
cyl i nder i nstal l ati on.
(1) I nstal l the key cyl i nder i nto the housi ng usi ng
care to al i gn the end of the key cyl i nder wi th the
i gni ti on swi tch.
(2) Push the key cyl i nder i n unti l i t cl i cks.
(3) Repl ace the upper and l ower shrouds.
(4) Reconnect the battery.
GEAR SHIFT LEVER
REMOVAL
(1) Remove the kneebl ocker. (Refer to 23 - BODY/
I NSTRUMENT PANEL/KNEE BLOCKER -
REMOVAL).
(2) Remove the upper and l ower col umn shroud.
(3) Remove and di scard the brake l i ght swi tch.
(4) Loosen the col umn bol ts and l ower the col umn
enough to al l ow cl earance for the gear shi ft l ever
removal .
(5) Di sconnect the overdri ve swi tch harness (i f
equi pped).
(6) Di sconnect the shi ft cabl e from the shi ft l ever.
(7) Remove the SKI M.
(8) Remove the gear shi ft l ever mounti ng screws
and remove the l ever. (Fi g. 14)
(9) Remove the bl ocker pi n from the i nhi bi t l i nk
sl ot (Fi g. 14).
INSTALLATION
(1) I nstal l the l ever assembl y usi ng care to i nstal l
the pi n i n the bl ocker to sl i der sl ot (Fi g. 15) and
i nstal l the mounti ng screws and ti ghten to 12 Nm
(105 i n. l bs.).
Fig. 12 KEY CYLINDER
1 - KEY
2 - KEY CYLINDER
3 - RETAINING PIN HOLE
Fig. 13 KEY CYLINDER
1 - KEY CYLINDER
2 - PUNCH
Fig. 14 GEAR SHIFT LEVER
1 - PARK INHIBIT BLOCKER SPRING
19 - 12 COLUMN DR
(2) Cycl e the key from ACC to RUN and ensure
that the bl ocker does not sti ck or bi nd.
(3) Turn the key to the OFF posi ti on and ensure
that the shi fter wi l l not pul l from the PARK posi ti on.
(4) Connect the over dri ve swi tch harness (i f
equi pped).
NOTE: Route and tie off harness to original loca-
tion.
(5) Connect the shi ft cabl e to the l ever.
(6) Ensure the gear shi ft l ever and transmi ssi on
are i n the PARK posi ti on and snap the cabl e adjust
cl i p i n pl ace.
(7) I nstal l a new brake l i ght swi tch (Refer to 8 -
BRAKE LAMP SWI TCH - I NSTALLATI ON).
(8) I nstal l the SKI M and hal o.
(9) I nstal l the upper and l ower col umn shroud.
(10) I nstal l the col umn back i nto pl ace and
ti ghten.
(11) I nstal l the kneebl ocker. (Refer to 23 - BODY/
I NSTRUMENT PANEL/KNEE BLOCKER - I NSTAL-
LATI ON).
UPPER STEERING COUPLING
REMOVAL
have to be used.
(2) Lock the steeri ng wheel wi th the ti re i n the
strai ght posi ti on.
(3) Remove and di scard the l ower pi nch bol t.
(4) Lower the steeri ng coupl er shaft from the col -
umn.
(5) Remove the upper steeri ng coupl i ng shaft seal
by pushi ng i n the four tags securi ng i t to the panel
(Fi g. 16).
(6) Remove and di scard the l ower coupl er pi nch
bol t from the l ower steeri ng coupl i ng shaft (Fi g. 17).
(7) Remove the upper steeri ng coupl i ng shaft from
the vehi cl e (Fi g. 17).
INSTALLATION
(1) I nstal l the upper steeri ng coupl i ng shaft to the
Fig. 15 GEAR SHIFT LEVER SPRING
1 - BLOCKER TO INHIBIT LINK SLOT
Fig. 16 RELEASE TANGS
1 - RELEASE TANGS (4)
2 - UPPER STEERING COUPLER SHAFT
Fig. 17 UPPER STEERING COUPLER SHAFT
1 - LOWER STEERING COUPLER
2 - RELEASE TANGS (4)
3 - UPPER STEERING COUPLER SHAFT
DR COLUMN 19 - 13
GEAR SHIFT LEVER (Continued)
(2) I nstal l the upper steeri ng coupl i ng shaft seal
by pushi ng i t i n securi ng the four tangs to the panel
(Fi g. 16).
NOTE: Note: A new steering coupling shaft pinch
bolt for the upper and lower shafts must be used.
(3) I nstal l the steeri ng coupl er shaft to the col umn
(Fi g. 17).
(4) I nstal l the upper pi nch bol t use new bol t and
ti ghten to 57 N.m (42 ft.l bs).
(5) I nstal l the shaft to the l ower coupl er (Fi g. 17).
(6) I nstal l the l ower pi nch bol t use new bol t and
ti ghten to 57 N.m (42 ft.l bs).
(7) Unl ock the steeri ng wheel .
LOWER STEERING COUPLING
REMOVAL
REMOVAL - ALL LD & HD EXCEPT 4X4 HD
have to be used.
(4) Remove the l eft front ti re and wheel assembl y.
(5) Mark both coupl er connecti ons for proper
i nstal l ati on.
(6) Remove and di scard the upper coupl er pi nch
bol t.
bol t.
(8) Remove the l ower steeri ng shaft coupl er (Fi g.
18).
REMOVAL - 4X4 HD
have to be used.
(4) Remove the l eft front ti re and wheel assembl y.
(5) Remove and di scard the upper coupl er pi nch
bol t (Fi g. 20).
bol t (Fi g. 19).
(7) Remove the l ower steeri ng shaft coupl er (Fi g.
20).
INSTALLATION
INSTALLATION - ALL LD & HD EXCEPT 4X4
HD
(1) I nstal l the coupl er to the steeri ng rack & pi n-
i on usi ng the marks made i n the removal process.
Fig. 18 LOWER STEERING COUPLER
Fig. 19 LOWER COUPLER PINCH BOLT
1 - INTERMEDIATE STEERING SHAFT
2 - LOWER COUPLING BOLT
3 - STEERING GEAR
19 - 14 COLUMN DR
UPPER STEERING COUPLING (Continued)
(2) I nstal l the coupl er to the i ntermedi ate shaft
usi ng the marks made i n the removal process.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) I nstal l the l ower pi nch bol t and ti ghten to 57
Nm (42 ft. l bs.).
(4) I nstal l the upper pi nch bol t and ti ghten to 57
Nm (42 ft. l bs.).
(5) I nstal l the l eft front ti re and wheel assembl y
(Refer to 22 - TI RES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
INSTALLATION - 4X4 HD
(1) I nstal l the coupl er to the steeri ng gear.
(2) I nstal l the coupl er to the i ntermedi ate shaft.
NOTE: New pinch bolts must be used for reinstalla-
tion.
(3) I nstal l the l ower pi nch bol t and ti ghten to 28
Nm (250 i n. l bs.).
(4) I nstal l the upper pi nch bol t and ti ghten to 57
Nm (42 ft. l bs.).
(5) I nstal l the l eft front ti re and wheel assembl y
(Refer to 22 - TI RES/WHEELS/WHEELS - STAN-
DARD PROCEDURE).
STEERING WHEEL
REMOVAL
(1) Di sabl e and remove the dri vers si de ai r-
bag.(Refer to 8 - ELECTRI CAL/RESTRAI NTS/
(2) Parti al l y remove the steeri ng wheel bol t and
l eave the bol t i n the col umn.
(3) I nstal l pul l er CJ98-1 or equi val ent usi ng the
top of the bol t to push on. (Fi g. 21)
(4) Remove and di scard the steeri ng wheel bol t.
(5) Remove the steeri ng wheel .
INSTALLATION
NOTE: Do not reuse the old steering wheel bolt (a
new bolt must be used)
(1) I nstal l steeri ng wheel to the col umn
NOTE: Be certain that the steering wheel mounting
bolt is tightened to the proper torque specification
to ensure proper clockspring operation.
(2) I nstal l the new steeri ng wheel bol t. Ti ghten the
(3) I nstal l the dri vers si de ai r bag. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/DRI VER AI RBAG -
I NSTALLATI ON).
Fig. 20 INTERMEDIATE STEERING SHAFT
1 - UPPER COUPLING BOOT AND BOLT
2 - INTERMEDIATE STEERING SHAFT
4 - STEERING GEAR
Fig. 21 STEERING WHEEL PULLER
1 - STEERING WHEEL
2 - SPECIAL TOOL CJ98-1
DR COLUMN 19 - 15
LOWER STEERING COUPLING (Continued)
TILT LEVER KNOB RELEASE
REMOVAL
(1) Remove the ti l t l ever handl e.
I NG COLUMN OPENI NG COVER - REMOVAL).
(3) Remove the l ower shroud.
NOTE: Use special care not to pry on the clock-
spring electrical connector when removing or
installing the mounting screw located next to the
clockspring.
(4) Remove the two mounti ng screws from the ti l t
l ever knob rel ease bracket (Fi g. 22).
(5) Di sconnect the el ectri cal harness pl asti c
mounti ng tab from the the bracket (Fi g. 22).
(6) Unsnap the cabl e from the bracket (Fi g. 23).
(7) Remove the end of the cabl e from the ti l t l ever
knob rel ease bracket (Fi g. 24).
INSTALLATION
(1) Route the cabl e i nto the ti l t l ever rel ease knob
bracket (Fi g. 24).
(2) Snap the cabl e end i nto the bracket (Fi g. 23).
NOTE: Use special care not to pry on the clock-
spring electrical connector when removing or
installing the mounting screw located next to the
clockspring.
NOTE: New screws should be used when installing
the tilt lever release knob bracket to the column.
(3) I nstal l the ti l t l ever rel ease knob bracket to the
col umn and i nstal l the two new mounti ng screws
(Fi g. 22) Ti ghten the two new screws to 4.5 Nm (40
i n. l bs.).
(4) I nstal l the el ectri cal harness pl asti c mounti ng
tab to the bracket (Fi g. 22).
(5) I nstal l the l ower shroud.
TI ON).
(7) I nstal l the ti l t l ever handl e.
Fig. 22 TILT LEVER KNOB RELEASE BRACKET
1 - TILT LEVER RELEASE KNOB BRACKET
2 - ELECTRICAL HARNESS TAB
3 - MOUNTING SCREWS (2)
Fig. 23 CABLE UNSNAPPED
1 - TILT LEVER RLEASE KNOB BRACKET
2 - TILT LEVER CABLE REMOVAL/INSTALL
Fig. 24 END OF CABLE TO THE TILT LEVER
RELEASE KNOB
1 - TILT LEVER RELEASE KNOB BRACKET
2 - END OF CABLE REMOVAL/INSTALL
19 - 16 COLUMN DR
GEAR - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page page
GEAR - INDEPENDENT FRONT SUSPENSION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 19
BUSHING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
GEAR - INDEPENDENT FRONT
SUSPENSION
DESCRIPTION
A rack and pi ni on steeri ng gears (Fi g. 1) i s made
up of two mai n components, the pi non shaft and the
rack. The gear cannot be adjusted or i nternal l y ser-
vi ced. I f a mal functi on or a fl ui d l eak occurs, the gear
must be repl aced as an assembl y.
REMOVAL
have to be used.
(1) Lock the steeri ng wheel .
(2) Drai n and si phon the power steeri ng fl ui d from
the reservoi r.
(4) Remove and di scard the steeri ng coupl er pi nch
bol t.
(5) Remove the power steeri ng hoses from the rack
& pi ni on.
(7) Remove the ti e rod end nuts and separate ti e
rod ends from the knuckl es wi th Speci al tool 8677
(Refer to 19 - STEERI NG/LI NKAGE/TI E ROD END -
REMOVAL).
(8) Remove the ski d pl ate (Refer to 13 - FRAME &
BUMPERS/FRAME/FRONT SKI D PLATE -
REMOVAL).
(9) Remove the rack & pi ni on mounti ng bol ts. (Fi g.
2) & (Fi g. 3)
(10) Remove the rack & pi ni on from the vehi cl e.
Fig. 1 STEERING GEAR
1 - OUTER TIE ROD ENDS
2 - MOUNTING BUSHINGS
3 - BELLOWS
Fig. 2 STEERING GEAR MOUNTING BOLTS
1 - STEERING GEAR MOUNTING BOLTS 4X4
DR GEAR - INDEPENDENT FRONT SUSPENSION 19 - 17
INSTALLATION
NOTE: Before installing gear inspect bushings and
replace if worn or damaged.
NOTE: In the frame there is two holes for the
mounting of the steering gear one is slotted and
one is round, When tightening the gear to specifi-
cations make sure to tighten the mounting bolt with
the hole first to avoided movement of the steering
gear.
(1) I nstal l the gear on the front crossmember and
ti ghten the mounti ng bol ts to 319 Nm (235 ft. l bs.).
(Fi g. 4) & (Fi g. 3).
(2) Sl i de the shaft coupl er onto the gear. I nstal l
new pi nch bol t and ti ghten to 49 Nm (36 ft. l bs.).
(3) Cl ean and dry the ti e rod end studs and the
knuckl e tapers.
(4) I nstal l the ti e rod ends i nto the steeri ng knuck-
l es and ti ghten the nuts to 61 Nm (45 ft. l bs.) then
an addi ti onal 90. (Refer to 19 - STEERI NG/LI NK-
AGE/TI E ROD END - I NSTALLATI ON).
(5) I nstal l the pressure power steeri ng hose to the
steeri ng gear and ti ghten to 32 Nm (23 ft. l bs.).
(Refer to 19 - STEERI NG/PUMP/HOSES - I NSTAL-
LATI ON).
(6) I nstal l the return power steeri ng hose to the
steeri ng gear and ti ghten to 71 Nm (52 ft. l bs.).
(Refer to 19 - STEERI NG/PUMP/HOSES - I NSTAL-
LATI ON).
(7) I nstal l the front ski d pl ate (Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT SKI D PLATE
- I NSTALLATI ON).
DURE).
(10) Fi l l the system wi th fl ui d, (Refer to 19 -
STEERI NG/PUMP - STANDARD PROCEDURE).
(11) Adjust the toe posi ti on. (Refer to 2 - SUSPEN-
SI ON/WHEEL ALI GNMENT - STANDARD PROCE-
DURE).
Fig. 3 STEERING GEAR 4X2
1 - SWAY BAR
2 - STEERING GEAR
3 - LEFT OUTER TIE ROD END
4 - LOWER CONTROL ARMS
5 - LEFT INNER & RIGHT OUTER (TIE ROD ENDS)
Fig. 4 STEERING GEAR 4X4
1 - FRONT AXLE
2 - STEERING GEAR MOUNTING NUTS & BUSHINGS
19 - 18 GEAR - INDEPENDENT FRONT SUSPENSION DR
GEAR - INDEPENDENT FRONT SUSPENSION (Continued)
SPECIFICATIONS
TORQUE CHART
Rack and Pinion Steering
Gear
Gear to Frame Bolts
319 235
Rack and Pinion Steering
Gear
Coupler Bolt
49 36
Tie Rod End
Knuckle Nut
61
Then tighten an additional
90
45
Then tighten an additional
90
Tie Rod End

Jam Nut
75 55
Power Steering Line
Pressure Line
32 23
Power Steering Line
Return Line
71 52
Power Steering Line
Pressure Line To Pump
37 27
BUSHING
REMOVAL
(1) Remove the steeri ng gear (Refer to 19 -
STEERI NG/GEAR - REMOVAL).
CAUTION: Do not overtighten the vise on the gear
case.
(2) Mount the steeri ng gear i n a soft jawed vi se.
NOTE: If the bushings are seized a brass punch can
be used to remove the bushings from the gear
using care not to strike the gear.
(3) Remove the front mounti ng bushi ngs.
(4) Remove the rear mounti ng bushi ngs.
(5) Remove the steeri ng gear from the vi se and
pl ace i t on the bench.
INSTALLATION
NOTE: Coat all bushings with a thin rubber lubri-
cate oil prior to installation.
NOTE: A rubber mallet can be used to assist in the
installation of the bushings once lubricated.
(1) Coat the rear bushi ngs wi th a thi n rubber
l ubri cate oi l then i nstal l the rear bushi ngs usi ng a
rubber mal l et to seat the bushi ngs i n the gear.
(2) Coat the front bushi ngs wi th a thi n rubber
l ubri cate oi l then i nstal l the front bushi ngs usi ng a
rubber mal l et to seat the bushi ngs i n the gear.
(3) I nstal l the steeri ng gear (Refer to 19 - STEER-
I NG/GEAR - I NSTALLATI ON).
(4) Adjust the toe posi ti on (i f necessary) (Refer to 2
- SUSPENSI ON/WHEEL ALI GNMENT - STAN-
DARD PROCEDURE).
DR GEAR - INDEPENDENT FRONT SUSPENSION 19 - 19
GEAR - INDEPENDENT FRONT SUSPENSION (Continued)
GEAR - LINK/COIL
TABLE OF CONTENTS
page page
GEAR - LINK/COIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS
POWER STEERING GEAR . . . . . . . . . . . . . . 22
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 23
SPECIAL TOOLS
POWER STEERING GEAR . . . . . . . . . . . . . . 23
PITMAN SHAFT SEAL
REMOVAL
REMOVAL - GAS ENGINE . . . . . . . . . . . . . . . 25
REMOVAL - DIESEL . . . . . . . . . . . . . . . . . . . 25
INSTALLATION
INSTALLATION - GAS ENGINE . . . . . . . . . . . 26
INSTALLATION - DIESEL . . . . . . . . . . . . . . . . 26
STEERING GEAR INPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
PITMAN SHAFT
REMOVAL
REMOVAL - GAS . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL - DIESEL . . . . . . . . . . . . . . . . . . . 30
INSTALLATION
INSTALLATION - GAS . . . . . . . . . . . . . . . . . . 31
GEAR - LINK/COIL
DESCRIPTION
The power steeri ng gear i s a reci rcul ati ng bal l type
gear (Fi g. 1). The gear rati os used are 12.5:1.
OPERATION
The gear acts as a rol l i ng thread between the
worm shaft and rack pi ston. The worm shaft i s sup-
ported by a thrust beari ng at the l ower end and a
beari ng assembl y at the upper end. When the worm
shaft i s turned from i nput from the steeri ng col umn
the rack pi ston moves. The rack pi ston teeth mesh
wi th the pi tman shaft. Turni ng the worm shaft, turns
the pi tman shaft, whi ch turns the steeri ng l i nkage.
REMOVAL
(1) Pl ace the front wheel s i n a strai ght-ahead posi -
ti on.
have to be used.
(2) Lock the steeri ng wheel .
(3) Si phon out as much power steeri ng fl ui d as
possi bl e.
Fig. 1 STEERING GEAR
1 - INPUT SHAFT
2 - OUTLET
3 - INLET
4 - VALVE ASSEMBLY HOUSING
5 - PITMAN SHAFT COVER BOLTS
6 - STEERING GEAR
7 - MESHLOAD ADJUSTER NUT
8 - PITMAN SHAFT
19 - 20 GEAR - LINK/COIL DR
(4) Di sconnect and cap the fl ui d hoses from steer-
i ng gear (Refer to 19 - STEERI NG/PUMP/HOSES -
REMOVAL).
(5) Remove coupl er pi nch bol t at the steeri ng gear
and sl i de shaft off gear (Fi g. 2).
(6) Mark the pi tman shaft and pi tman arm for
i nstal l ati on reference. Remove the pi tman arm from
the shaft wi th Pul l er C-4150A (Refer to 19 - STEER-
I NG/LI NKAGE/PI TMAN ARM - REMOVAL), (Fi g. 3).
(7) Remove steeri ng gear three mounti ng bol ts
(Fi g. 4). Remove the steeri ng gear from the vehi cl e.
INSTALLATION
(1) Posi ti on the steeri ng gear on the frame rai l and
i nstal l the three mounti ng bol ts (Fi g. 4). Ti ghten the
mounti ng bol ts to 196 Nm (145 ft. l bs.).
(2) Al i gn steeri ng coupl er on gear shaft. I nstal l
pi nch bol t and ti ghten to 49 Nm (36 ft. l bs.) torque.
(3) Al i gn and i nstal l the pi tman arm (Refer to 19 -
STEERI NG/LI NKAGE/PI TMAN ARM - I NSTALLA-
TI ON).
(4) I nstal l the washer and retai ni ng nut on the pi t-
man shaft. Ti ghten the nut to 305 Nm (225 ft. l bs.).
(5) Connect fl ui d hoses to steeri ng gear (Refer to
19 - STEERI NG/PUMP/HOSES - I NSTALLATI ON),
(6) Add fl ui d, (Refer to 19 - STEERI NG/PUMP -
(7) Reset the toe and center the steeri ng wheel
(Refer to 2 - SUSPENSI ON/WHEEL ALI GNMENT -
ADJ USTMENTS
ADJUSTMENT
CAUTION: Steering gear must be adjusted in the
proper order. If adjustments are not performed in
order, gear damage and improper steering response
may result.
NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.
(1) Remove the steeri ng gear from the vehi cl e
(Refer to 19 - STEERI NG/GEAR - REMOVAL).
(2) Mount the gear careful l y i nto a soft-jawed vi se.
Fig. 2 COLUMN SHAFT
1 - STEERING COUPLER
2 - STEERING GEAR INPUT SHAFT
Fig. 3 PITMAN ARM REMOVAL
1 - PITMAN ARM
2 - C-4150A PULLER
Fig. 4 STEERING GEAR REMOVAL/INSTALLATION
1 - STEERING GEAR
DR GEAR - LINK/COIL 19 - 21
GEAR - LINK/COIL (Continued)
case. This may affect the adjustment
(3) Hol d the steeri ng gear upsi de down over a
drai n pan and rotate the i nput shaft back and forth
several ti mes l ock-to-l ock to di scharge the fl ui d from
the steeri ng gear
(4) Rotate the i nput shaft to the l eft stop and then
back-off approxi matel y 45 degrees. Usi ng an i nch-
pound torque wrench on the i nput shaft, record the
peak torque requi red to sl owl y and evenl y rotate the
i nput shaft cl ockwi se
1
2 turn (180 degrees) starti ng
from the 45 degree posi ti on. Thi s peak torque read-
i ng i s the prel oad torque. The prel oad torque must be
wi thi n 2 - 10 i n-l bs.
(5) Rotate the i nput shaft to i ts center of travel
(approxi matel y 1.5 turns from ei ther stop). Pl ace the
torque wrench on the i nput shaft wi th the handl e i n
the verti cal posi ti on. Rotate the torque wrench sl owl y
and evenl y
1
4 turn (90 degrees) each si de of center
and record the peak torque measure on or near cen-
ter. Thi s total on-center torque readi ng must be 5 - 9
i n-l bs hi gher than the previ ousl y measured prel oad
torque wi thout exceedi ng a total of 17 i n-l bs. The
val ue of the total on-center mi nus the prel oad torque
i s defi ned as the meshl oad torque
(6) I f requi red, adjust the on-center torque by l oos-
eni ng the adjuster screw l ock nut and turni ng the
adjuster screw unti l the total on-center and meshl oad
torque readi ngs fal l wi thi n the speci fi ed val ues. Turn
the adjuster screw cl ockwi se to i ncrease and counter-
cl ockwi se to decrease the torque readi ng. Whi l e hol d-
i ng the adjuster screw i n pl ace, ti ghten the l ock nut
to 31 Nm (23 ft. l bs.).
(7) Re-check the prel oad and on-center torque
readi ngs.
(8) I nstal l pi tman arm on the steeri ng gear (Refer
to 19 - STEERI NG/LI NKAGE/PI TMAN ARM -
I NSTALLATI ON).
(9) Rei nstal l steeri ng gear to the vehi cl e (Refer to
19 - STEERI NG/GEAR - I NSTALLATI ON).
SPECIFICATIONS
POWER STEERING GEAR
SPECIFICATIONS
Steering Gear
Type
Recirculating Ball
Gear Code & Ratio 12.5:1
Preload
Torque
0.23-1.13 2-10
Meshload Torque 0.56-1.02 5-9
+ Preload (17 Max)
TORQUE CHART
Steering Gear Mounting
Frame Bolts
196 145
Power Steering Line
Pressure
32 23
Power Steering Line
Return
71 52
Power Steering Line
37 27
Steering Gear
Adjustment Screw Locknut
31 23
Steering Gear
Pitman Shaft Nut
305 225
Steering Gear
Pitman Shaft Cover Bolts
68 50
Steering Gear
Valve Housing to Gear
Bolts
54 40
Steering Gear
Retainer Ring Screw
2.26 20
Steering Gear
Retainer Ring
97 72
SPECIAL TOOLS
POWER STEERING GEAR
HANDLE C-4171
INPUT SHAFT SEAL INSTALLER - 8987
PULLER, SLIDE HAMMER - C-3752
SEAL REMOVER ADAPTER - 8990
PITMAN SHAFT SEAL INSTALLER - 8989
RETAINER RING WRENCH - 8988
PITMAN SHAFT SEAL PROTECTOR - 8993
INPUT SHAFT SEAL PROTECTOR - 8986
PITMAN SHAFT SEAL
REMOVAL
REMOVAL - GAS ENGINE
(1) Seperate the pi tman arm from the gear box
(Refer to 19 - STEERI NG/LI NKAGE/PI TMAN ARM -
REMOVAL).
(2) Cl ean exposed end of pi tman shaft and housi ng
wi th a wi re brush.
(3) Rotate the steeri ng wheel from stop to stop and
count the number of turns.
(4) Center the steeri ng wheel by rotati ng i t from
the stop back 1 1/2 turns to achi eve center posi ti on.
(5) Remove the pi tman shaft cover bol ts.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(6) Remove the pi tman shaft from the gear.
(7) Remove dust seal from the housi ng wi th a spe-
ci al tool (Fi g. 5).
CAUTION: Use care not to score the housing bore
when prying out seals and washer.
(8) Remove retai ni ng ri ng wi th snap ri ng pl i ers.
(9) Remove washer from the housi ng.
NOTE: Tighten the slide hammer adapter 8990 into
the seal using wrenches, in order to make a tight fit
to pull the seal out. If this is not performed the seal
may tear on the removal making it difficult to
remove.
(10) Remove oi l seal from the housi ng wi th a spe-
ci al tool 8990 wi th sl i de hammer C-3752.
REMOVAL - DIESEL
(1) Seperate the pi tman arm from the gear box
REMOVAL).
(2) Remove the steeri ng gear box (Refer to 19 -
(3) I nstal l the steeri ng gear i n a soft jawed bench
vi se.
(5) Rotate the i nput shaft wi th a 12 poi nt socket
from stop to stop and count the number of turns (Fi g.
6).
(6) Center the i nput shaft by rotati ng i t from the
stop 1/2 of the total amount of turns (Fi g. 6).
it is not centered.
(8) Remove the pi tman shaft from the gear.
(9) Remove dust seal from the housi ng wi th a spe-
ci al tool 8990 (Fi g. 5).
when prying out seals.
(10) Remove retai ni ng ri ng wi th snap ri ng pl i ers.
(11) Remove washer from the housi ng.
Fig. 5 SLIDE HAMMER
1 - STEERING GEAR
2 - SLIDE HAMMER C-3752 USED WITH SPECIAL TOOL
ADAPTER
8990
Fig. 6 CENTERING STEERING GEAR
1 - STEERING GEAR
2 - 12 POINT SOCKET
3 - RATCHET
4 - INPUT SHAFT
NOTE: Tighten the slide hammer adapter 8990 into
the seal using wrenches, in order to make a tight fit
to pull the seal out. If this is not performed the seal
may tear on the removal making it difficult to
remove.
(12) Remove oi l seal from the housi ng wi th a spe-
ci al tool 8990 wi th sl i de hammer C-3752. (Fi g. 5).
INSTALLATION
INSTALLATION - GAS ENGINE
NOTE: Generous amounts of the high temperature
grease from the seal kit should be applied to areas
between the pitman shaft bearing and oil seals and
also between the dust seals and snap ring.
(1) Coat the oi l seal and washer wi th high temp
grease.
NOTE: Install the oil seal with the lip facing inward.
Flat side of the oil seal should be against the
washer.
(2) I nstal l the oi l seal wi th speci al tool 8989 dri ver
and C-4171 handl e (Fi g. 7).
(3) I nstal l backup washer.
(4) I nstal l the retai ner ri ng wi th snap ri ng pl i ers.
(5) Coat the dust seal wi th high temp grease.
(6) I nstal l the dust seal wi th a dri ver and handl e
(Fi g. 7).
(7) I nstal l protecti ve seal protector 8993 over the
shaft (Fi g. 8).
(8) I nstal l the pi tman shaft i nto the steeri ng gear
unti l i t ful l y seats i nto the beari ng.
(9) I nstal l the new cover bol ts and ti ghten to 68
Nm (50 ft. l bs.).
(10) I nstal l the pi tman arm (Refer to 19 - STEER-
I NG/LI NKAGE/PI TMAN ARM - I NSTALLATI ON).
(1) Coat the oi l seal and washer wi th high temp
grease.
NOTE: Install the oil seal with the lip facing inward.
Flat side of the oil seal should be against the
washer.
(2) I nstal l the oi l seal wi th speci al tool 8989 dri ver
(3) I nstal l backup washer.
(4) I nstal l the retai ner ri ng wi th snap ri ng pl i ers.
(5) Coat the dust seal wi th high temp grease.
(6) I nstal l the dust seal wi th speci al tool 8989
dri ver and C-4171 handl e (Fi g. 7).
(7) I nstal l protecti ve seal protector 8993 over the
shaft (Fi g. 8).
Nm (50 ft. l bs.).
(10) I nstal l the steeri ng gear (Refer to 19 -
STEERI NG/GEAR - I NSTALLATI ON).
Fig. 7 SEAL INSTALLATION
3 - STEERING GEAR
Fig. 8 PITMAN SHAFT SEAL PROTECTOR
1 - STEERING GEAR
PITMAN SHAFT SEAL (Continued)
PROCEDURE).
STEERING GEAR INPUT
SHAFT SEAL
REMOVAL
(1) Remove the steeri ng gear from the vehi cl e
(Refer to 19 - STEERI NG/GEAR - REMOVAL).
case. This may affect the adjustment
(2) Mount the steeri ng gear upsi de down over a
drai n pan i n a soft jawed vi se.
(3) Pl ace a drai n pan under the gear and rotate
the i nput shaft back and forth several ti mes l ock-to-
l ock to di scharge the fl ui d from the steeri ng gear
(4) Drai n al l the remai ni ng fl ui d from the gear.
(5) Rotate the i nput shaft from stop to stop and
count the number of turns usi ng a 12 poi nt socket
(Fi g. 9).
it is not centered.
(6) Center the i nput shaft by rotati ng i t from the
stop back 1 1/2 turns to achi eve center posi ti on (Fi g.
9).
(7) Remove the pi tman shaft (Refer to 19 -
STEERI NG/GEAR/PI TMAN SHAFT - REMOVAL).
(8) Remove the four bol ts securi ng the val ve hous-
i ng.
(9) Remove the val ve housi ng from the steeri ng
gear (Fi g. 10).
(10) Remove the val ve housi ng and wormshaft
assembl y from the steeri ng gear housi ng and pl ace
the val ve housi ng i n a soft jawed vi se (Fi g. 11).
1 - STEERING GEAR
2 - 12 POINT SOCKET
3 - RATCHET
4 - INPUT SHAFT
Fig. 10 VALVE ASSEMBLY
1 - VALVE HOUSING
2 - WORMSHAFT BALLS
3 - STEERING GEAR HOUSING
Fig. 11 VALVE HOUSING AND WORMSHAFT
1 - VALVE HOUSING
2 - SET SCREW
3 - RETAINER RING
PITMAN SHAFT SEAL (Continued)
(11) Remove the retai ner ri ng set screw from the
val ve housi ng (Fi g. 12).
(12) Usi ng speci al tool reatai ner ri ng wrench to
remove the steeri ng gear worm thrust beari ng
reatai ner ri ng (Fi g. 13).
(13) Separate the wormshaft assembl y from the
val ve housi ng, Then remove the wormshaft assembl y
from the vi se (Fi g. 14).
(14) Remove the dust seal wi th a pi ck (Fi g. 15).
Fig. 12 SET SCREW FOR THE RETAINER RING
1 - SET SCREW
2 - 3/32 ALLEN HEAD SOCKET
3 - RETAINER RING
Fig. 13 REATINER RING REMOVAL
1 - SPECIAL TOOL
8988
2 - RATCHET
Fig. 14 WORMSHAFT AND VALVE ASSEMBLY
1 - PISTON TEFLON SEALS
2 - RETAINER RING
Fig. 15 DUST SEAL REMOVAL
1 - PICK
2 - VALVE HOUSING
3 - SEAL
STEERING GEAR INPUT SHAFT SEAL (Continued)
when removing seals.
(15) Remove the snap ri ng wi th snap ri ng pl i ers
(Fi g. 16).
(16) Usi ng speci al tool sl i de hammer C-3752 wi th
adapter 8990 remove the oi l seal (Fi g. 17).
INSTALLATION
(1) I nspect the pi ston tefl on seal s for damage.
Repl ace i f needed.
NOTE: To replace the teflon seals, use a pick to
remove the teflon o-ring and the rubber o-ring
underneath. Install a new rubber o-ring in the piston
seal grove and a new teflon o-ring over the top of it.
(2) I nstal l the val ve i nto the val ve housi ng.
(3) Thread the retai ner ri ng i nto the val ve housi ng
(Fi g. 18). Ti ghten to 97 Nm (72 ft. l bs.)
NOTE: It is very important to make sure to compen-
sate for the added length of the torque wrench
when torquing to proper specifications.
(4) I nstal l the retai ner ri ng set screw. Ti ghten to
2.26 Nm (20 i n. l bs.)
(5) Cl ean the steeri ng gear housi ng.
CAUTION: Valve assembly must be centered to the
housing (Fig. 19).
(6) I nstal l the val ve assembl y i nto the steeri ng
gear (Fi g. 19). Ti ghten the new bol ts to 54 Nm (40 ft.
l bs.)
Fig. 16 SNAP RING REMOVAL
2 - SNAP RING
3 - VALVE HOUSING
Fig. 17 OIL SEAL REMOVAL
1 - SPECIAL TOOL
8990
WITH SLIDE HAMMER C-3752
2 - VALVE HOUSING
Fig. 18 RETAINER RING INSTALLATION
1 - VALVE HOUSING
2 - SPECIAL TOOL
3 - TORQUE WRENCH
Fig. 19 CENTERED GEAR TEETH
1 - GEAR INSTALLED WITH THE CENTER TOOTH CENTERED IN
HOLE
2 - VALVE HOUSING
(7) I nstal l the i nput shaft seal protector 8986 (Fi g.
20).
(8) Coat the new seal i n high temp grease and
I nstal l the new oi l seal usi ng speci al tool 8987 dri ver
NOTE: Drive the oil seal into the housing until the
outer edge does not quite clear the snap ring
groove.
(9) I nsert the snap ri ng i nto the housi ng. Usi ng
speci al tool 8987 dri ver and C-4171 handl e push the
snap ri ng and oi l seal together unti l the snap ri ng
seats i n the groove.
(10) I nstal l the new dust seal usi ng high temp
grease, speci al tool C-4171 (dri ver) and 8987 (han-
dl e).
(11) Check to make sure the gear i s centered i n
the mi ddl e tooth before i nstal l i ng the pi tman shaft
(Fi g. 19).
(Refer to 19 - STEERI NG/GEAR/PI TMAN SHAFT -
I NSTALLATI ON).
(13) Perform over-center meshl oad adjustment
(Refer to 19 - STEERI NG/GEAR - ADJUSTMENTS).
(14) I nstal l the steeri ng gear to the vehi cl e (Refer
to 19 - STEERI NG/GEAR - I NSTALLATI ON).
PROCEDURE).
PITMAN SHAFT
REMOVAL
REMOVAL - GAS
(1) Separate the pi tman arm from the gear box
REMOVAL).
(3) Rotate the steeri ng wheel from stop to stop and
count the number of turns.
(4) Center the steeri ng wheel by rotati ng i t from
the stop back 1 1/2 turns to achi eve center posi ti on.
it is not centered.
(6) Remove the pi tman shaft from the gear (Fi g.
22).
(7) Remove the cover i f needed by l oosi ng the
adjuster nut, Then removi ng the cover from the pi t-
man shaft.
REMOVAL - DIESEL
(1) Separate the pi tman arm from the gear box
REMOVAL).
(2) Remove the steeri ng gear box (Refer to 19 -
(3) I nstal l the steeri ng gear i n a soft jawed bench
vi se.
Fig. 20 INPUT SHAFT SEAL PROTECTOR
1 - INPUT SHAFT
Fig. 21 INPUT SHAFT SEAL INSTALLATION
1 - VALVE HOUSING
(5) Rotate the stub shaft wi th a 12 poi nt socket
from stop to stop and count the number of turns (Fi g.
23).
(6) Center the stub shaft by rotati ng i t from the
stop 1/2 of the total amount of turns (Fi g. 23).
it is not centered.
(8) Remove the pi tman shaft from the gear (Fi g. 24).
(9) Remove the cover i f needed by l oosi ng the
adjuster nut, Then removi ng the cover from the pi t-
man shaft.
INSTALLATION
INSTALLATION - GAS
(1) Coat the seal wi th power steering fluid.
(2) I nstal l pi tman shaft i nto the steeri ng gear unti l
i t ful l y seats i nto the beari ng.
Nm (50 ft. l bs.).
(4) Perform over-center meshl oad adjustment,
PROCEDURE).
(1) Coat the seal wi th power steering fluid.
Nm (50 ft. l bs.).
(4) Perform over-center meshl oad adjustment
(5) I nstal l the steeri ng gear (Refer to 19 - STEER-
I NG/GEAR - I NSTALLATI ON).
PROCEDURE).
Fig. 22 PITMAN SHAFT
1 - PITMAN SHAFT
2 - O-RING SEAL
3 - COVER
4 - ADJUSTING NUT
1 - STEERING GEAR
2 - 12 POINT SOCKET
3 - RATCHET
4 - INPUT SHAFT
Fig. 24 PITMAN SHAFT
1 - PITMAN SHAFT
2 - O-RING SEAL
3 - COVER
4 - ADJUSTING NUT
PITMAN SHAFT (Continued)
LINKAGE - INDEPENDENT FRONT SUSPENSION
TABLE OF CONTENTS
page page
LINKAGE - INDEPENDENT FRONT
SUSPENSION
DIAGNOSIS AND TESTING - OUTER TIE ROD
END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TIE ROD END
REMOVAL - OUTER TIE ROD END . . . . . . . . . . 32
INSTALLATION - OUTER TIE ROD END . . . . . . 33
LINKAGE - INDEPENDENT
FRONT SUSPENSION
DIAGNOSIS AND TESTING - OUTER TIE ROD
END
NOTE: If the outer tie rod end is equipped with a
lubrication fitting, grease the joint then road test
the vehicle before performing test.
(2) Remove the front ti res.
(3) Mount a di al i ndi cator sol i dl y to the vehi cl e
steeri ng knuckl e and then zero the di al i ndi cator.
(4) Posi ti on i ndi cator pl unger on the topsi de of the
outer ti e rod end.
dicular to the machined surface of the outer tie rod
end.
(5) Posi ti on a pry bar i n order to pry downwards
on the outer ti e rod end.
the outer ti e rod end (Refer to 19 - STEERI NG/
LI NKAGE/TI E ROD END - REMOVAL).
(7) I f the outer ti e rod end i s wi thi n specs rei nstal l
the front ti res (Refer to 22 - TI RES/WHEELS/
WHEELS - STANDARD PROCEDURE).
TIE ROD END
REMOVAL - OUTER TIE ROD END
NOTE: Do not twist the boot anytime during
removal or installation.
(1) Loosen the jam nut.
(2) Remove the outer ti e rod end nut from the bal l
stud.
(3) Separate the ti e rod bal l stud from the knuckl e
wi th Remover 8677 (Fi g. 1).
(4) Unthread the outer ti e rod end from the i nner
ti e rod.
Fig. 1 TIE ROD SEPARATION
1 - TIE ROD END
19 - 32 LINKAGE - INDEPENDENT FRONT SUSPENSION DR
INSTALLATION - OUTER TIE ROD END
NOTE: Do not twist the boot at anytime during
removal or installation.
(1) Thread the outer ti e rod end onto the i nner ti e
rod, to i ts ori gi nal posi ti on (Fi g. 2).
(2) I nstal l the outer ti e rod end i nto the steeri ng
knuckl e (Fi g. 2).
(3) Ti ghten the bal l stud nut on the bal l stud to 61
Nm (45 ft. l bs.) then an addi ti onal 90.
(4) Set wheel toe pattern, (Refer to 2 - SUSPEN-
SI ON/WHEEL ALI GNMENT - STANDARD PROCE-
DURE).
(5) Ti ghten jam nut to 75 Nm (55 ft. l bs.) (Fi g. 2).
Fig. 2 TIE ROD END
1 - JAM NUT
2 - TIE ROD - INNER
3 - TIE ROD END - OUTER
DR LINKAGE - INDEPENDENT FRONT SUSPENSION 19 - 33
TIE ROD END (Continued)
LINKAGE - LINK/COIL
TABLE OF CONTENTS
page page
LINKAGE - LINK/COIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
STANDARD PROCEDURE - LUBRICATION . . . . 34
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 35
SPECIAL TOOLS
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . 35
DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
DRAG LINK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
PITMAN ARM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
TIE ROD END
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
TRACK BAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
LINKAGE - LINK/COIL
DESCRIPTION
The steeri ng l i nkage i s compri sed of a ti e rod end, ti e
rod, drag l i nk, steeri ng damper and pi tman arm (Fi g. 1).
CAUTION: If any steering components are replaced
or serviced an alignment must be performed.
NOTE: To avoid damaging ball stud seals, use
Puller C-3894A or an appropriate puller to remove
tie rod ends (Fig. 2).
STANDARD PROCEDURE - LUBRICATION
Peri odi c l ubri cati on of the steeri ng system compo-
nents i s requi red. Refer to Lubri cati on And Mai nte-
nance for the recommended mai ntenance schedul e.
The fol l owi ng components must be l ubri cated:
Ti e rod
Ti e rod end
Drag l i nk
Fig. 1 LINK/COIL FRONT SUSPENSION
1 - STABILIZER BAR
2 - PITMAN ARM
3 - STEERING GEAR
4 - STABILIZER LINK
5 - TIE ROD ENDS
6 - LOWER SUSPENSION ARMS
7 - DRAG LINK
8 - TRACK BAR
9 - DAMPER
Fig. 2 Ball Stud Puller
1 - CLAMP
2 - ADJUSTMENT SLEEVE
3 - PULLER TOOL C-3894A
4 - SEAL
5 - TIE-ROD END
19 - 34 LINKAGE - LINK/COIL DR
SPECIFICATIONS
TORQUE CHART
Pitman Arm
Gear Shaft Nut
300 225
Drag Link
Pitman Arm
88 65
Drag Link
Tie Rod
108 80
Drag Link
Adjuster Clamp
61 45
Tie Rod End
Knuckle
108 80
Tie Rod End
Adjuster Clamp
61 45
Stabilizer Bar Link to Axle 68 50
Steering Damper
Axle
95 70
Steering Damper
Tie Rod
81 60
SPECIAL TOOLS
STEERING LINKAGE
Remover Ball Stud MB-991113
Puller Tie Rod C-3894-A
Remover Ball Joint C-4150A
DR LINKAGE - LINK/COIL 19 - 35
LINKAGE - LINK/COIL (Continued)
DAMPER
REMOVAL
(1) Remove the steeri ng damper mounti ng nuts
and bol ts.
(2) Sl i de the damper from the i sol ati on bushi ng.
(3) Remove the damper.
INSTALLATION
(1) I nstal l the steeri ng damper on the axl e and i so-
l ati on bushi ng. Ti ghten nut to 95 Nm (75 ft. l bs.).
(2) I nstal l the steeri ng damper on the ti e rod.
Ti ghten nut to 81 Nm (60 ft. l bs.).
DRAG LINK
REMOVAL
(1) Remove the dragl i nk nut from the pi tman arm
si de.
(2) Remove the drag l i nk nut from the knuckl e si de.
(3) Remove the drag l i nk from the ri ght knuckl e
and pi tman arm wi th Pul l er C-3894A (Fi g. 3).
INSTALLATION
(1) I nstal l the drag l i nk to the pi tman arm. I nstal l
the nut and ti ghten to 88 Nm (65 ft. l bs.).
(2) I nstal l the drag l i nk to the ri ght steeri ng
knuckl e. I nstal l the nut and ti ghten to 108 Nm (80
ft. l bs.).
(3) I nstal l ti e rod to the l eft steeri ng knuckl e and
drag l i nk. I nstal l the nuts and ti ghten to 108 Nm
(80 ft. l bs.).
(4) Remove the supports and l ower the vehi cl e to
the surface. Center steeri ng wheel and adjust toe,
(5) After adjustment ti ghten ti e rod adjustment
sl eeve cl amp bol ts to 61 Nm (45 ft. l bs.).
NOTE: Position the clamp on the sleeve so retain-
ing bolt is located on the bottom side of the sleeve.
PITMAN ARM
REMOVAL
(1) Remove the drag l i nk from the ri ght knuckl e
and pi tman arm wi th Pul l er C-4150A (Fi g. 4).
Fig. 3 DRAGLINK REMOVAL
1 - PITMAN ARM
2 - DRAGLINK
3 - C -3894-A PULLER
Fig. 4 PITMAN ARM REMOVAL
1 - PITMAN ARM
2 - C-4150A PULLER
(2) Mark the pi tman arm and shaft posi ti ons for
i nstal l ati on reference. Remove the nut and washer
from the pi tman arm (Fi g. 5). Remove the pi tman
arm wi th Pul l er C-4150A.
INSTALLATION
(1) Al i gn reference marks and i nstal l pi tman arm.
(2) I nstal l the l ock washer and retai ni ng nut on
the pi tman shaft and ti ghten nut to 251 Nm (185 ft.
l bs.).
(3) I nstal l the drag l i nk to the pi tman arm (Fi g. 6).
I nstal l the nut and ti ghten to 108 Nm (80 ft. l bs.).
TIE ROD END
REMOVAL
(1) Remove ti e rod nuts (Fi g. 7).
(2) Remove ti e rod from drag l i nk and l eft knuckl e
wi th Pul l er C-4150A.
INSTALLATION
(1) I nstal l ti e rod to the l eft steeri ng knuckl e and
drag l i nk. I nstal l the nuts and ti ghten to 108 Nm
(80 ft. l bs.).
Fig. 5 PITMAN ARM REMOVAL/INSTALLATION
1 - STEERING GEAR
2 - PITMAN ARM
3 - NUT
4 - WASHER
Fig. 6 PITMAN ARM INSTALLED
1 - DRAGLINK
2 - STEERING GEAR
3 - SWAYBAR
4 - NUT/WASHER
5 - PITMAN ARM
Fig. 7 TIE ROD ENDS
1 - NUT
2 - TIE ROD ENDS
DR LINKAGE - LINK/COIL 19 - 37
PITMAN ARM (Continued)
TRACK BAR
REMOVAL
(1) Rai se and support the axl e.
(2) Remove the track bar bol ts and nuts (Fi g. 8).
(3) Remove the track bar (Fi g. 8).
INSTALLATION
(1) I nstal l the track bar.
(2) I nstal l the new bol ts and nuts. Ti ghten to 203
Nm (150 ft l bs.).
(3) Remove the supports under the axl e and l ower
the vehi cl e to the ground.
Fig. 8 TRACK BAR REMOVAL/INSTALLATION
1 - TRACK BAR
2 - BOLT
3 - NUT
PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 40
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION. . . . 40
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM . . . . . . . . . . . . 40
REMOVAL
REMOVAL - GAS . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL - DIESEL . . . . . . . . . . . . . . . . . . . 41
INSTALLATION
INSTALLATION - GAS . . . . . . . . . . . . . . . . . . 42
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 42
FLUID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
STANDARD PROCEDURE - POWER
STEERING FLUID LEVEL CHECKING . . . . . . 43
FLUID COOLER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
HOSES - I.F.S.
REMOVAL
REMOVAL - RETURN HOSE - GEAR TO
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
REMOVAL - PRESSURE HOSE . . . . . . . . . . . 44
REMOVAL - RETURN HOSE - RESERVOIR
TO COOLER . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION
INSTALLATION - RETURN HOSE - GEAR TO
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION - PRESSURE HOSE . . . . . . . 44
INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER . . . . . . . . . . . . . . . 44
HOSES - LINK/COIL
REMOVAL
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL - PRESSURE HOSE . . . . . . . . . . . 45
REMOVAL - RETURN HOSE - RESERVOIR
TO COOLER . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION - PRESSURE HOSE . . . . . . . 45
INSTALLATION - RETURN HOSE -
RESERVOIR TO COOLER . . . . . . . . . . . . . . . 45
POWER STEERING PRESSURE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
REMOVAL - 3.7L & 5.7L . . . . . . . . . . . . . . . . . . 46
INSTALLATION - 3.7L & 5.7L . . . . . . . . . . . . . . . 46
PULLEY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
RESERVOIR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
PUMP
DESCRIPTION
not overfill.
The pump i s connected to the steeri ng gear vi a the
pressure hose and the return hose. The pump shaft
has a pressed-on pul l ey that i s bel t dri ven by the
crankshaft pul l ey.
Al l vehi cl es are equi pped wi th a power steeri ng
fl ui d cool er.
NOTE: Power steering pumps are not interchange-
able with pumps installed on other vehicles.
DR PUMP 19 - 39
OPERATION
Hydraul i c pressure i s provi ded for the power steer-
i ng gear by the bel t dri ven power steeri ng pump (Fi g.
1). The power steeri ng pumps are constant fl ow rate
and di spl acement, vane-type pumps.
DIAGNOSIS AND TESTING - PUMP LEAKAGE
The pump i s servi ced as an assembl y and shoul d
not be di sassembl ed. The pl asti c pump reservoi r and
the reservoi r o-ri ngs can be repl aced.
Check for l eaks i n the fol l owi ng areas:
Pump shaft seal behi nd the pul l ey
Pump to reservoi r O-ri ng
Reservoi r cap
Pressure and return l i nes
Fl ow control val ve fi tti ng
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER STEERING
PUMP - INITIAL OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal temperature.
(1) Turn steeri ng wheel al l the way to the l eft
(2) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two (2) mi nutes.
(3) Rai se the front wheel s off the ground.
(4) Sl owl y turn the steeri ng wheel l ock-to-l ock 20
ti mes wi th the engi ne off whi l e checki ng the fl ui d
l evel .
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times.
(5) Start the engi ne. Wi th the engi ne i dl i ng mai n-
tai n the fl ui d l evel .
(6) Lower the front wheel s and l et the engi ne i dl e
for two mi nutes.
(7) Turn the steeri ng wheel i n both di recti on and
veri fy power assi st and qui et operati on of the pump.
I f the fl ui d i s extremel y foamy or mi l ky l ooki ng,
al l ow the vehi cl e to stand a few mi nutes and repeat
the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
STANDARD PROCEDURE - FLUSHING POWER
STEERING SYSTEM
Fl ushi ng i s requi red when the power steeri ng/hy-
draul i c booster system fl ui d has become contami -
nated. Contami nated fl ui d i n the steeri ng/booster
system can cause seal deteri orati on and affect steer-
i ng gear/booster spool val ve operati on.
(1) Rai se the front end of the vehi cl e off the
ground unti l the wheel s are free to turn.
(2) Remove the return l i ne from the pump.
NOTE: If vehicle is equipped with a hydraulic
booster remove both return lines from the pump.
(3) Pl ug the return l i ne port/ports at the pump.
(4) Posi ti on the return l i ne/l i nes i nto a l arge con-
tai ner to catch the fl ui d.
(5) Whi l e an assi stant i s fi l l i ng the pump reservoi r
start the engi ne.
(6) Wi th the engi ne runni ng at i dl e turn the wheel
back and forth.
NOTE: Do not contact or hold the wheel against the
steering stops.
(7) Run a quart of fl ui d through the system then
stop the engi ne and i nstal l the return l i ne/l i nes.
Fig. 1 POWER STEERING PUMP
1 - 3.7L & 4.7L (6 GROOVE)
PHENOLIC (PLASTIC TYPE) PULLEY
1 - 5.7L,5.9L & 8.0L (7 GROOVE)
PHENOLIC (PLASTIC TYPE) PULLEY
1 - 5.9L DIESEL (8 GROOVE)
STEEL PULLEY
2 - PUMP ASSEMBLY
3 - RESERVOIR
4 - CAP
19 - 40 PUMP DR
PUMP (Continued)
(8) Fi l l the system wi th fl ui d and perform Steeri ng
Pump I ni ti al Operati on, (Refer to 19 - STEERI NG/
PUMP - STANDARD PROCEDURE).
(9) Start the engi ne and run i t for fi fteen mi nutes
then stop the engi ne.
(10) Remove the return l i ne/l i nes from the pump
and pl ug the pump port/ports.
(11) Pour fresh fl ui d i nto the reservoi r and check
the drai ni ng fl ui d for contami nati on. I f the fl ui d i s
sti l l contami nated, then fl ush the system agai n.
(12) I nstal l the return l i ne/l i nes and perform
Steeri ng Pump I ni ti al Operati on, (Refer to 19 -
REMOVAL
REMOVAL - GAS
the reservoi r.
(2) Remove the serpenti ne bel t.
CAUTION: Do not remove the fitting on the pump
that the high pressure hose screws into. The fitting
may come loose unless it is backed up using
another wrench. If the fitting does come loose, it
must be retightened before continuing. (57 - 67Nm,
40 - 50 lbft) If this fitting comes out of the pump
body, the internal spring and valve parts will fall out
of the pump and they cannot be reinstalled prop-
erly. If this occurs the pump needs to be replaced
with a new pump.
(3) Di sconnect the return hose. (Fi g. 2)
(4) Di sconnect the pressure hose. (Fi g. 2)
(5) Access to remove the three bol ts securi ng the
pump to the cyl i nder head can be gai ned thru the
pul l ey hol es. (Fi g. 2)
REMOVAL - DIESEL
the reservoi r.
CAUTION: Do not remove the fitting on the pump
that the high pressure hose screws into. The fitting
may come loose unless it is backed up using
another wrench. If the fitting does come loose, it
must be retightened before continuing. (57 - 67Nm,
40 - 50 lbft) If this fitting comes out of the pump
body, the internal spring and valve parts will fall out
of the pump and they cannot be reinstalled prop-
erly. If this occurs the pump needs to be replaced
with a new pump.
(3) Di sconnect the return hose.
(4) Di sconnect the pressure hose.
(5) Access to remove the three bol ts securi ng the
pump to the cyl i nder head can be gai ned thru the
pul l ey hol es.
(6) Loosen the pump bracket to the bl ock.
(7) Remove the 6 i ntake pl enum bol ts (Fi g. 3).
(8) l oosen the i nner cool er tube cl amp at the
i ntake pl enum and remove the i ntake pl enum.
(9) Loosen the i nner cool er tube cl amp at the radi -
ator support si de and remove the tube from the vehi -
cl e.
(10) Remove the power steeri ng pump from the top
of the engi ne compartment where the i ntake pl enum
was (Fi g. 3).
Fig. 2 POWER STEERING PUMP
1 - POWER STEERING PULLEY
2 - POWER STEERING RESERVOIR
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
Fig. 3 POWER STEERING PUMP ACCESS
1 - INTAKE PLENUM MOUNTING
DR PUMP 19 - 41
PUMP (Continued)
INSTALLATION
INSTALLATION - GAS
(1) Al i gn the pump wi th the mounti ng hol es i n the
l eft cyl i nder head.
(2) I nstal l 3 pump mounti ng bol ts through the pul -
l ey access hol es. Ti ghten the bol ts to 28 Nm (21 ft.
l bs.).
(3) Reconnect the pressure l i ne and return hose to
the pump and reservoi r. Ti ghten the pressure l i ne to
37 Nm (27 ft. l bs.).
(4) I nstal l the serpenti ne dri ve bel t, (Refer to 7 -
I NSTALLATI ON).
(5) Fi l l the power steeri ng pump, (Refer to 19 -
(1) Set the power steeri ng pump i n pl ace i n the
engi ne compartment from the top (Fi g. 3).
(2) I nstal l the i nner cool er tube.
(3) Ti ghten the i nner cool er tube cl amp at the
radi ator support si de.
(4) I nstal l the 6 i ntake pl enum bol ts (Fi g. 3).
(5) Ti ghten the i nner cool er tube cl amp at the
i ntake pl enum.
(6) I nstal l 3 pump mounti ng bol ts through the pul -
l ey access hol es. Ti ghten the bol ts to 28 Nm (21 ft.
l bs.).
(7) Ti ghten the pump bracket to the bl ock.
(8) Reconnect the pressure l i ne and return hose to
the pump and reservoi r. Ti ghten the pressure l i ne to
37 Nm (27 ft. l bs.).
I NSTALLATI ON).
SPECIFICATIONS
TORQUE CHART
Switch
10 80
Power Steering Line
Pressure Line
32 23
Power Steering Line
Return Line
HD
51 38
Power Steering Line
Return Line
LD
70 52
Power Steering Line
37 27
Power Steering Pump
Mounting Bolts
28 27
Power Steering Pump
Reservoir Bolts
13 10 120
Power Steering Pump
Bracket Bolts
5 5 62
19 - 42 PUMP DR
PUMP (Continued)
FLUID
DESCRIPTION
The recommended fl ui d for the power steeri ng sys-
tem i s Mopar ATF +4.
Mopar ATF+4, when new i s red i n col or. The
ATF+4 i s dyed red so i t can be i denti fi ed from other
fl ui ds used i n the vehi cl e such as engi ne oi l or anti -
freeze. The red col or i s not permanent and i s not an
i ndi cator of fl ui d condi ti on, As the vehi cl e i s dri ven,
the ATF+4 wi l l begi n to l ook darker i n col or and may
eventual l y become brown. THIS IS NORMAL.
ATF+4 al so has a uni que odor that may change wi th
age. Consequentl y, odor and col or cannot be used to
i ndi cate the fl ui d condi ti on or the need for a fl ui d
change.
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
not overfill.
The power steeri ng fl ui d l evel can be vi ewed on the
di psti ck attached to the fi l l er cap. There are two
ranges l i sted on the di psti ck, COLD and HOT. Before
openi ng power steeri ng system, wi pe the reservoi r
fi l l er cap free of di rt and debri s. Remove the cap and
check the fl ui d l evel on i ts di psti ck. When the fl ui d i s
at normal ambi ent temperature, approxi matel y 21C
to 27C (70F to 80F), the fl ui d l evel shoul d read
between the mi ni mum and maxi mum area of the col d
range. When the fl ui d i s hot, fl ui d l evel i s al l owed to
read up to the hi ghest end of the HOT range. Onl y
add fl ui d when the vehi cl e i s col d.
Use only Mopar ATF+4 Do not overfi l l the
power steeri ng system.
FLUID COOLER
REMOVAL
(1) Drai n and si phon the power steeri ng fl ui d.
(2) Di sconnect the return and suppl y hoses con-
nected to the power steeri ng fl ui d cool er.
(3) Remove the mounti ng bracket bol ts securi ng
the fl ui d cool er to the brace. (Fi g. 4)& (Fi g. 5)
(4) Remove the fl ui d cool er from the vehi cl e.
INSTALLATION
(1) I nstal l the fl ui d cool er to the vehi cl e.
(2) I nstal l the mounti ng bracket bol ts securi ng the
fl ui d cool er to the brace (Fi g. 4)& (Fi g. 5).
(3) Recl amp the return and suppl y hoses to the
power steeri ng fl ui d cool er.
(4) Refi l l the power steeri ng fl ui d (Refer to 19 -
Fig. 4 V6 & V8 P/S FLUID COOLER
1 - POWER STEERING FLUID COOLER
2 - MOUNTING BOLTS
Fig. 5 V10 & DIESEL P/S FLUID COOLER
1 - RADIATOR
2 - POWER STEERING HOSES
3 - MOUNTING BOLTS
4 - P/S FLUID COOLER
DR PUMP 19 - 43
HOSES - I.F.S.
REMOVAL
COOLER
(1) Drai n and si phon the power steeri ng system.
(3) Di sconnect the return hose at the cool er.
(4) Di sconnect the return hose at the gear (Fi g. 6).
(5) Remove the return hose from the routi ng cl amp
at the fan shroud and then remove from the vehi cl e.
REMOVAL - PRESSURE HOSE
(3) Di sconnect the pressure hose at the pump.
(4) Di sconnect the pressure hose at the gear (Fi g. 6).
(5) Remove the pressure hose from the vehi cl e.
REMOVAL - RETURN HOSE - RESERVOIR TO
COOLER
(2) Di sconnect the return hose at the reservoi r.
at the fan shroud.
(6) Remove the hose from the vehi cl e.
INSTALLATION
COOLER
(1) I nstal l the return hose to the vehi cl e.
(2) Reconnect the return hose at the cool er.
(3) Reconnect the return hose at the gear. Ti ghten
the hose to 71 Nm (52 ft. l bs.) (Fi g. 6).
(4) Reattach the hose to the routi ng cl i p at the fan
shroud.
(6) Refi l l the power steeri ng system,(Refer to 19 -
INSTALLATION - PRESSURE HOSE
NOTE: Be sure to align the pressure hose so it
does not contact the fan shroud or the frame rail.
(1) I nstal l the pressure hose to the vehi cl e.
(2) Reconnect the pressure hose at the gear.
Ti ghten the hose to 32 Nm (23 ft. l bs.) (Fi g. 6).
(3) Reconnect the pressure hose at the pump.
Ti ghten the hose to 36 Nm (27 ft. l bs.).
INSTALLATION - RETURN HOSE - RESERVOIR
TO COOLER
shroud.
(5) Reconnect the return hose at the reservoi r.
Fig. 6 HOSE CONNECTIONS
1 - RETURN HOSE
2 - PRESSURE HOSE
19 - 44 PUMP DR
HOSES - LINK/COIL
REMOVAL
COOLER
(4) Di sconnect the return hose at the gear (Fi g. 7).
at the fan shroud and then remove from the vehi cl e.
REMOVAL - PRESSURE HOSE
(3) Di sconnect the pressure hose at the pump.
(4) Di sconnect the pressure hose at the gear (Fi g. 8).
(5) Remove the pressure hose from the vehi cl e.
REMOVAL - RETURN HOSE - RESERVOIR TO
COOLER
(2) Di sconnect the return hose at the reservoi r.
at the fan shroud.
(6) Remove the hose from the vehi cl e.
INSTALLATION
COOLER
(3) Reconnect the return hose at the gear. Ti ghten
the hose to 51 Nm (38 ft. l bs.) (Fi g. 7).
shroud.
INSTALLATION - PRESSURE HOSE
NOTE: Be sure to align the pressure hose so it
does not contact the fan shroud or the frame rail.
(1) I nstal l the pressure hose to the vehi cl e.
(2) Reconnect the pressure hose at the gear.
Ti ghten the hose to 32 Nm (23 ft. l bs.) (Fi g. 8).
(3) Reconnect the pressure hose at the pump.
Ti ghten the hose to 36 Nm (27 ft. l bs.).
INSTALLATION - RETURN HOSE - RESERVOIR
TO COOLER
shroud.
Fig. 7 POWER STEERING HOSES TO STEERING GEAR
2 - RETURN HOSE
3 - STEERING GEAR
Fig. 8 HOSES INSTALLED
3 - RETURN HOSE
4 - STEERING GEAR
5 - PITMAN ARM
DR PUMP 19 - 45
(5) Reconnect the return hose at the reservoi r.
POWER STEERING PRESSURE
SWITCH
DESCRIPTION
A pressure sensi ng swi tch i s used i n the power
steeri ng system. I t i s mounted on the hi gh-pressure
steeri ng hose (Fi g. 9). Thi s swi tch wi l l be used wi th
both 3.7L and 5.7L engi nes. There i s no pressure
swi tch used for the 4.7L or the 5.9L pump.
OPERATION
The swi tch i s used on the 3.7L V-6 & 5.7L V-8
engi nes.
The power steeri ng pressure swi tch provi des an
i nput to the Powertrai n Control Modul e (PCM). Thi s
i nput i s provi ded duri ng peri ods of hi gh steeri ng
pump l oad and l ow engi ne rpm; such as duri ng park-
i ng maneuvers. The PCM i ncreases the i dl e speed
through the I dl e Ai r Control (I AC) motor. Thi s i s
done to prevent the engi ne from stal l i ng under the
i ncreased l oad.
When steeri ng pump pressure exceeds 3275 kPa
690 kPa (475 psi 100 psi ), the Normal l y Cl osed
(NC) swi tch wi l l open and the PCM wi l l i ncrease the
engi ne i dl e speed. Thi s wi l l prevent the engi ne from
stal l i ng.
When pump pressure drops to approxi matel y 1379
kPa (200 psi ), the swi tch ci rcui t wi l l re-cl ose and
engi ne i dl e speed wi l l return to i ts previ ous setti ng.
REMOVAL - 3. 7L & 5. 7L
The power steeri ng pressure swi tch i s i nstal l ed i n
the power steeri ng hi gh-pressure hose (Fi g. 9).
(1) Di sconnect el ectri cal connector from power
steeri ng pressure swi tch.
(2) Pl ace a smal l contai ner or shop towel beneath
swi tch to col l ect any excess fl ui d.
(3) Remove swi tch. Use back-up wrench on power
steeri ng l i ne to prevent l i ne bendi ng.
INSTALLATION - 3. 7L & 5. 7L
Thi s swi tch i s used onl y wi th the 3.7L V6 and the
5.7L V-8 engi nes.
(1) I nstal l power steeri ng swi tch i nto power steer-
i ng l i ne.
(2) Ti ghten to 811 Nm (70100 i n. l bs.) torque.
(3) Connect el ectri cal connector to swi tch.
(4) Check power steeri ng fl ui d and add as neces-
sary.
(5) Start engi ne and agai n check power steeri ng
fl ui d. Add fl ui d i f necessary.
Fig. 9 PRESSURE SWITCH
1 - POWER STEERING PULLEY
2 - POWER STEERING PUMP HOUSING
3 - POWER STEERING FLUID RESERVOIR
4 - RETURN HOSE
5 - HIGH PRESSURE HOSE WITH PRESSURE SWITCH
19 - 46 PUMP DR
HOSES - LINK/COIL (Continued)
PULLEY
REMOVAL
CAUTION: Do not reuse the old power steering
pump pulley it is not intended for reuse. A new pul-
ley must be installed if removed.
(1) Remove the power steeri ng pump assembl y,
(Refer to 19 - STEERI NG/PUMP - REMOVAL).
(2) Remove the pul l ey from the pump usi ng (OTC
7185) power steeri ng pul l ey removal tool or equi va-
l ent (Fi g. 10).
INSTALLATION
CAUTION: Do not reuse the old power steering
pump pulley it is not intended for reuse. A new pul-
ley must be installed if removed.
(1) Repl ace the pul l ey i f i ts bent, cracked, or l oose.
(2) I nstal l the pul l ey on the pump usi ng (OTC
7771) power steeri ng pul l ey i nstal l ati on tool or equi v-
al ent (Fi g. 11) maki ng sure i t i s fl ush wi th the end of
the shaft. Ensure the tool and pul l ey remai n al i gned
wi th the pump shaft.
(3) I nstal l the power steeri ng pump assembl y,
(Refer to 19 - STEERI NG/PUMP - I NSTALLATI ON).
(4) Run engi ne unti l warm (5 mi n.) and note any
bel t chi rp. I f chi rp exi sts, move pul l ey outward
approxi matel y 0.5 mm (0.020 i n.). I f noi se i ncreases,
press on 1.0 mm (0.040 i n.). Be careful that pulley
does not contact mounting bolts.
RESERVOIR
REMOVAL
the reservoi r.
(3) Remove the power steeri ng pump (Refer to 19 -
(4) Remove the reservoi r mounti ng bol ts.
(5) Remove the reservoi r.
(6) Remove the rear bracket to the pump mounti ng
bol ts.
INSTALLATION
(1) I nstal l the reservoi r bracket to the pump hous-
i ng. Do not reuse the o-rings (install new
o-rings). Ti ghten bol ts to 7 Nm (62 i n. l bs.).
NOTE: Ensure the reservoir is fully seated onto the
pump.
(2) I nstal l the reservoi r to the bracket/pump body.
(3) I nstal l the reservoi r mounti ng bol ts. Ti ghten
(4) I nstal l the power steeri ng pump (Refer to 19 -
I NSTALLATI ON).
Fig. 10 PULLEY REMOVAL
2 - PULLEY
3 - POWER STEERING PULLEY REMOVAL TOOL
Fig. 11 PULLEY INSTALLATION
2 - PULLEY
3 - POWER STEERING PUMP PULLEY INSTALLATION TOOL
DR PUMP 19 - 47
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
MANUAL TRANSMISSION - NV3500 . . . . . . . . . . 1
AUTOMATIC TRANSMISSION - 48RE . . . . . . . . 130
AUTOMATIC TRANSMISSION - 45RFE/545RFE . 311
TRANSFER CASE - NV241 GENII . . . . . . . . . . . 415
TRANSFER CASE - NV271 . . . . . . . . . . . . . . . . 447
TRANSFER CASE - NV243 . . . . . . . . . . . . . . . . 482
TRANSFER CASE - NV244 GENII . . . . . . . . . . . 512
TRANSFER CASE - NV273 . . . . . . . . . . . . . . . . 542
MANUAL TRANSMISSION - NV3500
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 40
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 40
MANUAL TRANSMISSION -
NV3500
DESCRIPTION
The transmi ssi on i s a medi um-duty 5-speed, con-
stant mesh ful l y synchroni zed manual transmi ssi on
wi th fi fth gear overdri ve range. The transmi ssi on i s
avai l abl e i n two and four-wheel dri ve confi gurati ons.
The transmi ssi on gear case consi sts of two al umi num
housi ngs (Fi g. 1). The cl utch housi ng i s an i ntegral
part of the transmi ssi on front housi ng.
A combi nati on of rol l er and bal l beari ngs are used
to support the transmi ssi on shafts i n the two hous-
i ngs. The transmi ssi on gears al l rotate on caged type
needl e beari ngs. A rol l er beari ng i s used between the
i nput and output shaft.
The transmi ssi on has a si ngl e shaft shi ft mecha-
ni sm wi th three shi ft forks al l mounted on the shaft.
The shaft i s supported i n the front and rear housi ngs
by bushi ngs and one l i near bal l beari ng. I nternal
shi ft components consi st of the forks, shaft, shi ft
l ever socket and detent components
OPERATION
The manual transmi ssi on recei ves power through the
cl utch assembl y from the engi ne. The cl utch di sc i s
spl i ned to the transmi ssi on i nput shaft and i s turned at
engi ne speed at al l ti mes that the cl utch i s engaged.
The i nput shaft i s connected to the transmi ssi on coun-
tershaft through the mesh of fourth speed gear on the
i nput shaft and the fourth countershaft gear. At thi s
poi nt, al l the transmi ssi on gears are spi nni ng.
The dri ver sel ects a parti cul ar gear by movi ng the
shi ft l ever to the desi red gear posi ti on. Thi s movement
moves the i nternal transmi ssi on shi ft components to
begi n the shi ft sequence. As the shi ft l ever moves the
sel ected shi ft rai l , the shi ft fork attached to that rai l
begi ns to move. The fork i s posi ti oned i n a groove i n the
outer ci rcumference of the synchroni zer sl eeve. As the
shi ft fork moves the synchroni zer sl eeve, the synchro-
ni zer begi ns to speed-up or sl ow down the sel ected gear
(dependi ng on whether we are up-shi fti ng or down-shi ft-
i ng). The synchroni zer does thi s by havi ng the synchro-
ni zer hub spl i ned to the mai nshaft and movi ng the
bl ocker ri ng i nto contact wi th the gears fri cti on cone. As
the bl ocker ri ng and fri cti on cone come together, the
gear speed i s brought up or down to the speed of the
synchroni zer. As the two speeds match, the spl i nes on
the i nsi de of the synchroni zer sl eeve become al i gned
wi th the teeth on the bl ocker ri ng and the fri cti on cone
and eventual l y wi l l sl i de over the teeth, l ocki ng the gear
to the mai nshaft, or countershaft, through the synchro-
ni zer.
DR TRANSMISSION AND TRANSFER CASE 21 - 1
Fig. 1 NV3500 TRANSMISSION
21 - 2 MANUAL TRANSMISSION - NV3500 DR
MANUAL TRANSMISSION - NV3500 (Continued)
LOW LUBRICANT LEVEL
A l ow transmi ssi on l ubri cant l evel i s general l y the
resul t of a l eak, i nadequate l ubri cant fi l l or an i ncor-
rect l ubri cant l evel check. Leaks can occur at the
mati ng surfaces of the gear case, adaptor or exten-
si on housi ng, or from the front/rear seal s. A sus-
pected l eak coul d al so be the resul t of an overfi l l
condi ti on.
Leaks at the rear of the extensi on or adapter hous-
i ng wi l l be from the housi ng oi l seal s. Leaks at com-
ponent mati ng surfaces wi l l probabl y be the resul t of
i nadequate seal er, gaps i n the seal er, i ncorrect bol t
ti ghteni ng or use of a non-recommended seal er.
A l eak at the front of the transmi ssi on wi l l be from
ei ther the front beari ng retai ner or retai ner seal .
Lubri cant may be seen dri ppi ng from the cl utch
housi ng after extended operati on. I f the l eak i s
severe, i t may al so contami nate the cl utch di sc caus-
i ng the di sc to sl i p, grab and or chatter.
A correct l ubri cant l evel check can onl y be made
when the vehi cl e i s l evel . Al so al l ow the l ubri cant to
settl e for a mi nute or so before checki ng. These rec-
ommendati ons wi l l ensure an accurate check and
avoi d an underfi l l or overfi l l condi ti on. Al ways check
the l ubri cant l evel after any addi ti on of fl ui d to avoi d
an i ncorrect l ubri cant l evel condi ti on.
HARD SHIFTING
Hard shi fti ng i s usual l y caused by a l ow l ubri cant
l evel , i mproper or contami nated l ubri cants. The con-
sequence of usi ng non-recommended l ubri cants i s
noi se, excessi ve wear, i nternal bi nd and hard shi ft-
i ng. Substanti al l ubri cant l eaks can resul t i n gear,
shi ft rai l , synchro, and beari ng damage. I f a l eak
goes undetected for an extended peri od, the fi rst i ndi -
cati ons of component damage are usual l y hard shi ft-
i ng and noi se.
Shi ft component damage or damaged cl utch pres-
sure pl ate or di sc are addi ti onal probabl e causes of
i ncreased shi ft effort. Worn/damaged pressure pl ate
or di sc can cause i ncorrect rel ease. I f cl utch probl em
i s advanced, gear cl ash duri ng shi fts can resul t.
Worn or damaged synchro ri ngs can cause gear cl ash
when shi fti ng i nto any forward gear. I n some new or
rebui l t transmi ssi ons, new synchro ri ngs may tend to
sti ck sl i ghtl y causi ng hard or noi sy shi fts. I n most
cases thi s condi ti on wi l l decl i ne as the ri ngs wear-i n.
TRANSMISSION NOISE
Most manual transmi ssi ons make some noi se dur-
i ng normal operati on. Rotati ng gears generate a mi l d
whi ne that i s audi bl e, but general l y onl y at extreme
speeds.
Severe hi ghl y audi bl e transmi ssi on noi se i s gener-
al l y the i ni ti al i ndi cator of a l ubri cant probl em.
I nsuffi ci ent, i mproper or contami nated l ubri cant wi l l
promote rapi d wear of gears, synchros, shi ft rai l s,
forks and beari ngs. The overheati ng caused by a
l ubri cant probl em, can al so l ead to gear and beari ng
damage.
REMOVAL
(2) Shi ft transmi ssi on i nto Neutral .
(3) Remove shi ft boot bezel screws and sl i de boot
upward on shi ft l ever extensi on.
(4) Remove shi ft l ever extensi on from the shi ft
tower and l ever assembl y.
(7) Drai n l ubri cant i f transmi ssi on wi l l be di sas-
sembl ed for servi ce.
(8) Mark propel l er shaft/shafts and compani on
fl ange yoke/yokes for i nstal l ati on reference and
remove propel l er shaft/shafts.
(9) Di sconnect harness from cl i ps on transmi ssi on
housi ng.
(10) Remove transfer case l i nkage i f equi pped.
(11) Remove transfer case mounti ng nuts and
remove transfer case i f equi pped.
(12) Remove sl ave cyl i nder mounti ng nut and
remove cyl i nder (Fi g. 2).
Fig. 2 SLAVE CYLINDER
1 - MOUNTING NUTS
2 - SLAVE CYLINDER
DR MANUAL TRANSMISSION - NV3500 21 - 3
(13) Remove starter motor, structural dust cover
bol ts to cl utch housi ng, dust shi el d bol t and suspen-
si on crossmember (Fi g. 3).
CAUTION: Do not remove structural dust cover
from enigne block. If cover is removed clutch hous-
ing and cover must be aligned with the engine.
(14) Remove exhaust pi pe from the exhaust mani -
fol ds.
(15) Support engi ne wi th adjustabl e jack stand
and wood bl ock.
(16) Support and secure transmi ssi on to a trans-
mi ssi on jack wi th safety chai ns.
(17) Remove bol ts from the rear transmi ssi on
mount.
(18) Remove the rear crossmember and transmi s-
si on mount (Fi g. 4).
(19) Remove bol ts attachi ng transmi ssi on to the
engi ne.
(20) Move transmi ssi on rearward unti l i nput shaft
i s cl ear of cl utch di sc and pressure pl ate. Then l ower
jack and remove transmi ssi on from under vehi cl e.
DISASSEMBLY
FRONT HOUSING
(2) I f l ubri cant was not drai ned out of transmi s-
si on duri ng removal , remove drai n pl ug and drai n
l ubri cant.
(3) I nspect drai n pl ug magnet for debri s.
(4) Remove backup l i ght swi tch l ocated on passen-
ger si de of rear housi ng (Fi g. 5).
(5) Remove shi ft tower bol ts and remove tower and
l ever assembl y (Fi g. 6).
Fig. 3 DUST COVER
1 - DUST SHIELD
2 - STARTER MOTOR
3 - DUST COVER
4 - CROSSMEMBER
Fig. 4 CROSSMEMBER
2 - CROSSMEMBER
Fig. 5 BACKUP LIGHT SWITCH
1 - BACKUP LIGHT SWITCH
Fig. 6 SHIFT TOWER
1 - SHIFT TOWER
2 - SHIFT SOCKET
3 - SEAL
(6) Remove shi ft shaft l ock bol t (Fi g. 7) from the
top of front housi ng. The bol t secures the shi ft shaft
bushi ng and l ever.
NOTE: This is a special bolt and can not be substi-
tuted with any other bolt.
(7) Remove i nput shaft beari ng retai ner bol ts from
the front housi ng, then careful l y pry on the retai ner
to break seal er bead l oose (Fi g. 8).
(8) Remove beari ng retai ner from i nput shaft (Fi g.
9).
(9) Remove i nput shaft snap ri ng (Fi g. 10).
(10) Remove shi ft shaft detent pl ug from the si de
of the transmi ssi on wi th Remover 8117A. Attach fi n-
gers of the remover to the detent pl ug and push the
cup down ti l l i t contacts the trans. Then ti ghten the
nut ti l l i t pul l s the pl ug from the case.
(11) Remove shi ft shaft detent pl unger and spri ng
wi th a penci l magnet.
Fig. 7 SHAFT LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 8 BEARING RETAINER SEAL
1 - PRY TOOL
2 - INPUT SHAFT BEARING RETAINER
Fig. 9 INPUT SHAFT BEARING RETAINER
1 - SHAFT BEARING
3 - INPUT SHAFT
Fig. 10 INPUT SHAFT SNAP RING
1 - INPUT SHAFT SNAP RING
2 - OIL FEED
(12) Remove bol ts that attach front housi ng to the
rear housi ng (Fi g. 11). Three bol ts at extreme rear of
housi ng are for the output shaft beari ng retai ner.
Leave one bol t i n pl ace unti l geartrai n i s ready to be
removed from case.
(13) Separate the housi ngs (Fi g. 12) by tappi ng the
front housi ng off al i gnment dowel s wi th a pl asti c
hammer.
(14) Remove i nput shaft beari ng and countershaft
front beari ng race (Fi g. 13).
Fig. 11 HOUSING & BEARING RETAINER BOLT
1 - RETAINER BOLTS
2 - HOUSING BOLTS
3 - RETAINER BOLT
4 - HOUSING BOLT LOCATIONS
Fig. 12 FRONT HOUSING
1 - FRONT HOUSING
2 - REAR HOUSING
3 - DOWELS (2)
4 - PLASTIC MALLET
Fig. 13 Input Shaft Bearing and Countershaft Front
Bearing Race
1 - INPUT SHAFT BEARING
2 - FRONT HOUSING
3 - COUNTERSHAFT FRONT BEARING
(15) Note posi ti on of i nput shaft, shi ft shaft, forks
and geartrai n components i n housi ng (Fi g. 14).
SHIFT/FORK SHAFTS AND REVERSE IDLER
SEGMENT
(1) Pl ace a shop towel over the shaft l ever to con-
tai n the l ever detent bal l and spri ng.
(2) Rotate l ever and bushi ng upward out of the
shi ft forks and catch bal l and spri ng (Fi g. 15).
(3) Unseat shi ft socket rol l pi n wi th Remover 6858.
Posi ti on remover on shi ft shaft and center tool over
the rol l pi n. Veri fy tool l egs are fi rml y seated on the
shi ft socket (Fi g. 16).
(4) Ti l t socket toward the si de of the case to avoi d
trappi ng the pi n between the gear teeth.
(5) Ti ghten remover to press the rol l pi n down-
ward and out of the shi ft socket (Fi g. 16).
NOTE: Roll pin must only clear the shift shaft. Do
not push the pin into the geartrain.
Fig. 14 GEARTRAIN AND SHIFT COMPONENT
1 - SHIFT SHAFT
2 - BUSHING
3 - REAR HOUSING
4 - REVERSE IDLER AND SUPPORT
5 - OUTPUT SHAFT AND GEARS
6 - COUNTERSHAFT
7 - 1-2 FORK
8 - INPUT SHAFT
9 - 3-4 FORK
Fig. 15 DETENT SPRING AND BALL
1 - SHAFT LEVER
2 - SPRING AND BALL
3 - MAGNET
Fig. 16 SHIFT SOCKET
1 - REMOVER
2 - SHIFT SOCKET
(6) Dri ve out shi ft bushi ng and l ever rol l pi n wi th
a hammer and punch (Fi g. 17).
NOTE: Use proper size punch to avoid bending the
shift shaft.
(7) Pul l shi ft shaft strai ght out of rear housi ng,
shi ft socket, fi fth-reverse fork and 1-2 fork (Fi g. 18).
(8) Remove shi ft socket from rear housi ng (Fi g.
19).
(9) Remove shaft l ever and bushi ng (Fi g. 20).
(10) Rotate 3-4 fork around synchro sl eeve unti l
fork cl ears shi ft arms on 1-2 and fi fth-reverse forks,
then remove 3-4 fork (Fi g. 21).
Fig. 17 SHIFT SHAFT LEVER & BUSHING ROLL PIN
1 - PIN PUNCH
2 - BUSHING AND LEVER
3 - SHIFT SHAFT
Fig. 18 SHIFT SHAFT
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
Fig. 19 SHIFT SOCKET & ROLL PIN
1 - SHAFT BORE
2 - ROLL PIN
3 - SHIFT SOCKET
Fig. 20 SHIFT SHAFT LEVER & BUSHING
1 - SHAFT LEVER AND BUSHING
2 - 3-4 FORK
Fig. 21 3-4 SHIFT FORK
1 - 3-4 FORK
2 - 1-2 AND 5TH-REVERSE FORK ARMS
3 - 3-4 SYNCHRO SLEEVE
(11) Remove reverse i dl er shaft support bol t and
l oosen rear reverse i dl er shaft bol t (Fi g. 22).
(12) Remove reverse i dl er shaft support segment
by sl i di ng i t strai ght out of housi ng.
(13) Support geartrai n and rear housi ng on Fi x-
ture 6747 as fol l ows:
(a) Adjust hei ght of reverse i dl er pedestal rod
unti l the reverse i dl e shaft bottoms i n Cup 8115.
(b) Posi ti on Adapters 6747-1A and 6747-2A on
Fi xture 6747.
(c) Sl i de fi xture tool onto i nput shaft, counter-
shaft and i dl er gear (Fi g. 23).
(d) Stand geartrai n and rear housi ng upri ght on
fi xture (Fi g. 24). Have hel per hol d fi xture tool i n
pl ace whi l e housi ng and geartrai n i s bei ng rotated
i nto upri ght posi ti on.
(14) Remove rear bol t hol di ng reverse i dl er shaft
i n housi ng.
Fig. 22 REVERSE IDLER SHAFT & SUPPORT
1 - SUPPORT BOLT
2 - SHAFT BOLT
Fig. 23 FIXTURE ASSEMBLY
1 - FIXTURE 6747
2 - ADAPTER 6747-1A
3 - CUP ADAPTER 8115
4 - REVERSE IDLER PEDESTAL
5 - ADAPTER 6747-2A
Fig. 24 GEARTRAIN & HOUSING ON FIXTURE
1 - INPUT SHAFT
2 - COUNTERSHAFT
3 - FIXTURE 6747
REAR HOUSING - 2WD
(1) On 2-wheel dri ve transmi ssi on, remove three
bol ts that attach output shaft beari ng retai ner to
rear case (Fi g. 25). Bol ts are rear of shi ft tower open-
i ng.
(2) Tap rear housi ng upward and off output shaft
beari ng wi th a pl asti c/rawhi de hammer (Fi g. 26).
(3) Li ft rear housi ng up and off geartrai n (Fi g. 27).
Fig. 26 SEPARATE REAR HOUSING & OUTPUT
SHAFT BEARING
1 - REAR HOUSING
2 - MALLET
3 - FIXTURE
Fig. 27 REAR HOUSING - 2WD
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
Fig. 25 OUTPUT SHAFT
1 - OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT
IS AT OPPOSITE SIDE OF CASE)
(4) Remove countershaft rear beari ng from coun-
tershaft (Fi g. 28).
REAR ADAPTER HOUSING - 4WD
(1) I nserti ng screw from sl i de hammer (Fi g. 29)
i nto one of the di mpl es i n face of rear seal (Fi g. 30)
and remove seal .
(2) Remove rear beari ng snap ri ng from output
shaft (Fi g. 31).
(3) Li ft rear adapter housi ng upward and off
geartrai n (Fi g. 32).
(4) Remove beari ng retai ner bol ts and remove rear
beari ng retai ner and rear beari ng (Fi g. 33). Push or
tap beari ng out of housi ng wi th a hammer handl e i f
needed.
Fig. 28 COUNTERSHAFT REAR BEARING
1 - COUNTERSHAFT REAR BEARING
2 - OUTPUT SHAFT
3 - COUNTER SHAFT
Fig. 29 REAR SEAL
1 - SLIDE HAMMER
2 - REMOVER TOOL
3 - REAR SEAL
Fig. 30 REAR SEAL FACE
1 - DIMPLES
2 - SEAL FACE
Fig. 31 REAR BEARING SNAP RING
1 - HEAVY DUTY SNAP RING PLIERS
2 - REAR BEARING SNAP RING
3 - OUTPUT SHAFT
Fig. 32 REAR ADAPTER HOUSING
1 - REAR ADAPTER HOUSING
2 - OUTPUT SHAFT
NOTE: Housing must be replaced if race, bearing
bore or idler shaft notch are worn or damaged.
GEARTRAIN FROM FIXTURE
(1) Remove reverse i dl er gear assembl y from
assembl y fi xture cup.
(2) Remove 1-2 and fi fth-reverse forks from syn-
chro sl eeves.
(3) Sl i de countershaft out of fi xture tool .
(4) Remove output shaft beari ng retai ner from
rear surface of fi fth gear (retai ner wi l l drop onto gear
after bol ts are removed).
(5) Li ft and remove output shaft and gears off
i nput shaft.
(6) Li ft and remove i nput shaft, pi l ot beari ng and
fourth gear synchro ri ng from the fi xture.
OUTPUT SHAFT
NOTE: Synchronizer hubs and sleeves are different
and must not be mixed. Remove each synchronizer
unit as an assembly to avoid mixing parts. Mark
each synchro hub and sleeve with a scriber or paint
for correct assembly reference.
(1) Remove snap ri ng that secures 3-4 synchro hub
on output shaft.
(2) Posi ti on Beari ng Spl i tter 1130 between second
and thi rd gears and press off 3-4 synchro assembl y,
thi rd gear synchro ri ng and thi rd gear wi th a shop
press.
(3) Remove thi rd gear needl e beari ng (Fi g. 34).
(4) Remove retai ni ng ri ng that secures two-pi ece
thrust washer on shaft wi th a smal l pry tool (Fi g.
35).
Fig. 33 REAR ADAPTER HOUSING COMPONENTS
2 - RETAINER BOLTS (3)
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT REAR BEARING RACE
5 - REAR BEARING
Fig. 34 THIRD GEAR NEEDLE BEARING
1 - THIRD GEAR NEEDLE BEARING
Fig. 35 THRUST WASHER
1 - PRY TOOL
2 - THRUST WASHER RETAINING RING
(5) Remove two-pi ece thrust washer (Fi g. 36) and
note posi ti on of washer l ocati ng l ugs i n shaft notches
(6) Remove second gear and needl e beari ng (Fi g.
37).
(7) Remove second gear synchro ri ng, synchro fri c-
ti on cone, synchro cone and i nterm ri ng (Fi g. 38).
(8) Remove 1-2 synchro hub snap ri ng.
(9) Posi ti on Beari ng Spl i tter 1130 between fi rst
and reverse gear. Press off 1-2 synchro hub, sl eeve
and fi rst gear from output shaft wi th shop press (Fi g.
39).
(10) Remove fi rst gear needl e beari ng (Fi g. 40).
Fig. 36 TWO-PIECE THRUST WASHER
1 - SECOND GEAR
2 - THRUST WASHER (2-PIECE)
3 - WASHER LOCATING LUG
Fig. 37 SECOND GEAR
1 - SECOND GEAR
2 - SECOND GEAR NEEDLE BEARING
Fig. 38 SECOND GEAR SYNCHRO RING & CONES
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - INTERM RING
3 - SYNCHRO FRICTION CONE
4 - SYNCHRO CONE
5 - SYNCHRO RING
Fig. 39 HUB SLEEVE & 1-2 SYNCHRO
1 - 1-2 SYNCHRO HUB AND SLEEVE
2 - BEARING SPLITTER 1130
Fig. 40 FIRST GEAR NEEDLE BEARING
1 - FIRST GEAR NEEDLE BEARING
(11) Remove output shaft beari ng snap ri ng (Fi g.
41).
(12) On 2-wheel dri ve model s, remove output shaft
beari ng.
(13) Remove fi fth gear (Fi g. 42).
(14) Remove fi fth gear needl e beari ng. Spread
beari ng just enough to cl ear shoul der on output shaft
(Fi g. 43).
(15) Remove fi fth-reverse synchro hub snap ri ng
(Fi g. 44).
Fig. 41 OUTPUT SHAFT BEARING SNAP RING
1 - OUTPUT SHAFT BEARING
2 - BEARING SNAP RING
Fig. 42 FIFTH GEAR
1 - FIFTH GEAR AND SYNCHRO RING
Fig. 43 FIFTH GEAR NEEDLE BEARING
1 - FIFTH GEAR NEEDLE BEARING
Fig. 44 FIFTH-REVERSE SYNCHRO HUB SNAP
RING
1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
2 - SYNCHRO HUB SNAP RING
(16) Remove fi fth-reverse synchro hub and sl eeve
wi th shop press (Fi g. 45).
(17) Remove reverse gear and needl e beari ng (Fi g.
46).
REVERSE IDLER
(1) Remove i dl er gear snap ri ngs (Fi g. 47).
(2) Remove thrust washer, wave washer, thrust
pl ate and i dl er gear from shaft.
(3) Remove i dl er gear needl e beari ng from shaft.
CLEANING
Cl ean the gears, shafts, shi ft components and
transmi ssi on housi ngs wi th a standard parts cl ean-
i ng sol vent. Do not use aci d or corrosi ve base sol -
vents. Dry al l parts except beari ngs wi th compressed
ai r.
Cl ean the shaft beari ngs wi th a mi l d sol vent such
as Mopar degreasi ng sol vent, Gunk or si mi l ar sol -
vents. Do not dry the beari ngs wi th compressed ai r.
Al l ow the beari ngs to ei ther ai r dry or wi pe them dry
wi th cl ean shop towel s.
Fig. 45 FIFTH-REVERSE SYNCHRO
1 - PRESS
2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 - REVERSE GEAR
4 - OUTPUT SHAFT
Fig. 46 REVERSE GEAR & NEEDLE BEARING
1 - REVERSE GEAR AND NEEDLE BEARING
Fig. 47 Reverse Idler Components
1 - SNAP RING
2 - FLAT WASHER
3 - WAVE WASHER
4 - THRUST WASHER
5 - REVERSE IDLER GEAR
6 - IDLER GEAR BEARING
7 - IDLER SHAFT
8 - THRUST WASHER
9 - SNAP RING
10 - THRUST WASHER LOCKBALLS
INSPECTION
SHIFT LEVER ASSEMBLY
The shi ft l ever assembl y i s not servi ceabl e. Repl ace
the l ever and shi ft tower as an assembl y i f the tower,
l ever, l ever bal l or i nternal components are worn or
damaged.
SHIFT SHAFT AND FORKS
I nspect the shi ft fork i nterl ock arms and synchro
sl eeve contact surfaces (Fi g. 48). Repl ace any fork
exhi bi ti ng wear or damage i n these areas. Do not
attempt to sal vage shi ft forks.
Check condi ti on of the shi ft shaft detent pl unger
and spri ng. The pl unger shoul d be smooth and free of
ni cks or scores. The pl unger spri ng shoul d be
strai ght and not col l apsed, or di storted. Mi nor
scratches or ni cks on the pl unger can be smoothed
wi th 320/400 gri t emery soaked i n oi l . Repl ace the
pl unger and spri ng i f i n doubt about condi ti on. Check
condi ti on of detent pl unger bushi ngs. Repl ace i f dam-
aged.
I nspect shi ft shaft, shi ft shaft bushi ng, beari ng,
shaft l ever and l ever bushi ng that fi ts over the l ever.
Repl ace shaft i f bent, cracked or severel y scored.
Mi nor burrs, ni cks or scratches can be smoothed off
wi th 320/400 gri t emery cl oth fol l owed by pol i shi ng
wi th crocus cl oth. Repl ace the shi ft shaft bushi ng or
beari ng i f damaged.
Repl ace the shaft l ever and bushi ng i f ei ther part
i s deformed, or worn. Do not attempt to sal vage these
parts as shi ft fork bi ndi ng wi l l occur. Repl ace the rol l
pi n that secures the l ever to the shaft.
FRONT/REAR HOUSINGS AND BEARING
RETAINERS
I nspect the housi ngs careful l y. Look for cracks,
stri pped threads, scored mati ng surfaces, damaged
beari ng bores or worn dowel pi n hol es. Mi nor ni cks
on mati ng surfaces can be dressed off wi th a fi ne fi l e
or emery cl oth. Damaged threads can be renewed by
ei ther re-tappi ng or i nstal l i ng Hel i coi l i nserts.
NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. These components
are NOT serviceable items. The front housing will
have to be replaced if the countershaft bearing race
is loose, worn or damaged. The rear housing will
have to be replaced if the countershaft rear bearing
race is loose, worn or damaged.
I nspect the i nput shaft beari ng retai ner. Be sure
the rel ease beari ng sl i de surface of the retai ner i s i n
good condi ti on. Mi nor ni cks on the surface can be
smoothed off wi th 320/420 gri t emery cl oth and fi nal
pol i shed wi th oi l coated crocus cl oth. Repl ace the
retai ner seal i f necessary.
Fig. 48 Shift Forks And Shaft
1 - SHIFT SHAFT
2 - SHAFT LEVER
3 - SHAFT LEVER BUSHING
4 - 3-4 SHIFT FORK
5 - 1-2 SHIFT FORK
6 - FIFTH-REVERSE SHIFT FORK
I nspect output shaft beari ng retai ner, the
U-shaped retai ner must be fl at and free of di storti on.
Repl ace the retai ner i f the threads are damaged or i f
the retai ner i s bent or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft beari ngs and races are machi ne
l apped duri ng manufacture to form matched sets.
The beari ngs and races shoul d not be i nterchanged.
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear-
ing race becomes damaged, the front or rear hous-
ing must be replaced. A new countershaft bearing
will be supplied with each new housing for service
use.
REVERSE IDLER COMPONENTS
I nspect the i dl er gear, beari ng, shaft, thrust
washer, wave washer and thrust pl ate. Repl ace the
beari ng i f any of the needl e beari ng rol l ers are worn,
chi pped, cracked, fl at-spotted or bri nnel l ed. Al so
repl ace the beari ng i f the pl asti c beari ng cage i s
damaged or di storted.
Repl ace thrust washer, wave washer or thrust
pl ate i f cracked, chi pped or worn. Repl ace i dl er gear
i f the teeth are chi pped, cracked or worn thi n.
Repl ace shaft i f worn, scored or the bol t threads are
damaged beyond repai r. Repl ace support segment i f
cracked or chi pped and repl ace the i dl er attachi ng
bol ts i f the threads are damaged.
Shift Socket
I nspect the shi ft socket for wear or damage.
Repl ace the socket i f the rol l pi n or shi ft shaft bores
are damaged. Mi nor ni cks i n the shi ft l ever bal l seat
i n the socket can be smoothed down wi th 400 gri t
emery or wet/dry paper. Repl ace the socket i f the bal l
seat i s worn or cracked. Do not reuse the ori gi nal
shi ft socket rol l pi n. I nstal l a new pi n duri ng assem-
bl y. The socket rol l pi n i s approxi matel y 33 mm
(1-1/4 i n.) l ong.
Output Shaft And Geartrain
I nspect al l gears for worn, cracked, chi pped or bro-
ken teeth. Al so check condi ti on of the beari ng bore i n
each gear. The bores shoul d be smooth and free of
surface damage. Di scol orati on of the gear bores i s a
normal occurrence and i s not a reason for repl ace-
ment. Repl ace gears onl y when tooth damage has
occurred or i f the bores are bri nnel l ed or severel y
scored.
I nspect the shaft spl i nes and beari ngs surfaces.
Mi nor ni cks on the beari ng surfaces can be smoothed
wi th 320/420 gri t emery and fi nal pol i shed wi th cro-
cus cl oth. Repl ace the shaft i f the spl i nes are dam-
aged or beari ng surfaces are deepl y scored, worn or
bri nnel l ed.
ASSEMBLY
NOTE: Sealers are used at all case joints. Use
Mopar Gasket Maker or equivalent for all case joints
and Mopar silicone sealer or equivalent for the
input shaft bearing retainer.
SYNCHRONIZER
(1) Sl i de sl eeve onto the hub, l eavi ng enough room
to i nstal l the spri ng i n the hub and strut i n the hub
groove.
(2) I nstal l fi rst spri ng i n the hub, then i nstal l a
strut over the spri ng. Veri fy spri ng i s seated i n the
spri ng bore i n the strut.
(3) Sl i de sl eeve onto the hub far enough to hol d
the fi rst strut and spri ng i n pl ace.
(4) Pl ace detent bal l i n the top of the strut, then
press the bal l i nto pl ace wi th a smal l screwdri ver.
Work the sl eeve over the bal l to hol d i t i n pl ace.
(5) Repeat procedure for the remai ni ng spri ngs,
struts and bal l s. Use tape or rubber bands to tempo-
rari l y secure each strut and bal l as they are
i nstal l ed.
(6) Veri fy the synchro three spri ngs, struts and
detent bal l s are al l i n pl ace (Fi g. 49).
Fig. 49 SYNCHRONIZER COMPONENTS
1 - SLEEVE
2 - HUB SHOULDER
3 - SPRING (3)
4 - STRUT (3)
5 - DETENT BALL (3)
6 - HUB
OUTPUT SHAFT
NOTE: Lubricate shaft, gears, bearings and
immerse each synchro ring with recommended
lubricant during assembly. Petroleum jelly can be
used to hold parts in place.
(1) I nstal l reverse gear needl e beari ng up agai nst
shoul der on output shaft (Fi g. 50).
(2) I nstal l reverse gear over needl e beari ng (Fi g.
51).
(3) I nstal l brass synchro ri ng on reverse gear (Fi g.
52).
(4) Start fi fth-reverse synchro assembl y on output
shaft spl i nes by hand. Then seat synchro onto shaft
wi th shop press and Remover 6310-1 (Fi g. 53).
CAUTION: One side of the hub has shoulders
around the hub bore, this side faces the front of the
shaft. One side of the sleeve is tapered the tapered
side faces the front of the shaft.
Fig. 50 REVERSE GEAR BEARING
1 - REVERSE GEAR BEARING
2 - SHOULDER
Fig. 51 REVERSE GEAR
1 - REVERSE GEAR
Fig. 52 REVERSE GEAR SYNCHRO
1 - REVERSE GEAR
2 - SYNCHRO RING
Fig. 53 FIFTH/REVERSE SYNCHRO ASSEMBLY
1 - SPACER
2 - PRESS RAM
3 - REVERSE GEAR
4 - FIFTH-REVERSE SYNCHRO ASSEMBLY
5 - REMOVER 6310-1
6 - PRESS BLOCKS
7 - OUTPUT SHAFT
(5) I nstal l new fi fth-reverse hub snap ri ng (Fi g.
54). Veri fy snap ri ng i s seated i n the groove.
(6) I nstal l fi fth gear synchro ri ng i n synchro hub
and sl eeve (Fi g. 55).
(7) I nstal l fi fth gear beari ng. Spread beari ng onl y
enough to cl ear shoul der on output shaft (Fi g. 56).
Veri fy beari ng i s properl y seated.
(8) I nstal l fi fth gear on shaft and onto beari ng
(Fi g. 57).
Fig. 54 FIFTH/REVERSE SYNCHRO HUB SNAP RING
2 - SNAP RING
3 - PRESS BED
4 - PRESS BLOCKS
Fig. 55 FIFTH GEAR SYNCHRO RING
1 - FIFTH-SPEED SYNCHRO RING
Fig. 56 FIFTH GEAR BEARING
1 - SHAFT SHOULDER
2 - FIFTH GEAR BEARING
Fig. 57 FIFTH GEAR
1 - FIFTH GEAR
2 - BEARING
(9) I nvert output shaft and set the shaft i n Col l ar
6310-1 so fi fth gear i s seated on the tool (Fi g. 58).
(10) I nstal l fi rst gear beari ng on output shaft (Fi g.
58). Veri fy beari ng i s seated on shaft shoul der and i s
properl y joi ned.
(11) I nstal l fi rst gear on shaft and over beari ng
(Fi g. 59) wi th beari ng synchro cone faci ng up.
(12) I nstal l fi rst gear synchro ri ng (Fi g. 60).
(13) Start 1-2 synchro assembl y on shaft by hand
(Fi g. 61).
CAUTION: One side of the synchro sleeve is
marked First Gear Side, this side must face first
gear.
Fig. 58 FIRST GEAR
1 - FIRST GEAR BEARING
2 - SHAFT SHOULDER
3 - COLLAR
4 - PRESS BLOCKS
Fig. 59 FIRST GEAR
1 - FIRST GEAR
2 - COLLAR
3 - BEARING
Fig. 60 FIRST GEAR SYNCHRO RING
1 - FIRST GEAR SYNCHRO RING
2 - COLLAR
3 - FIRST GEAR
Fig. 61 STARTING 1-2 SYNCHRO
1 - 1-2 SYNCHRO ASSEMBLY
2 - COLLAR
3 - FIRST GEAR SIDE
(14) Press 1-2 synchro onto output shaft usi ng
sui tabl e si ze pi pe and shop press (Fi g. 62).
CAUTION: Keep synchro ring and sleeve aligned as
the hub is being pressed onto the shaft. The syn-
chro ring can be cracked if it becomes misaligned.
(15) I nstal l i nterm ri ng.
(16) I nstal l new 1-2 synchro hub snap ri ng (Fi g.
63). Veri fy snap ri ng i s seated i n shaft groove.
(17) I nstal l second gear synchro ri ng i n 1-2 syn-
chro hub and sl eeve (Fi g. 64). Veri fy synchro ri ng i s
seated i n sl eeve.
(18) I nstal l synchro fri cti on cone and synchro cone
i n synchro ri ng.
Fig. 62 1-2 SYNCHRO ON OUTPUT SHAFT
1 - PIPE TOOL
2 - SYNCHRO RING
3 - COLLAR
5 - PRESS RAM
Fig. 63 1-2 SYNCHRO HUB SNAP RING
1 - 1-2 SYNCHRO
2 - COLLAR
3 - SYNCHRO SNAP RING
Fig. 64 SECOND GEAR SYNCHRO RING
1 - SECOND GEAR SYNCHRO RING
2 - 1-2 SYNCHRO
3 - COLLAR
(19) I nstal l second gear needl e beari ng on shaft
(Fi g. 65).
(20) I nstal l second gear onto shaft and beari ng
(Fi g. 66). Veri fy second gear i s seated on synchro
components.
(21) I nstal l two-pi ece thrust washer wi th hal ves
seated i n the shaft groove and washer l ugs seated i n
shaft l ug bores (Fi g. 67). Veri fy i .d. grooves and
marki ngs noted duri ng removal are faci ng the correct
di recti on.
(22) Start retai ni ng ri ng around two-pi ece thrust
washer (Fi g. 68). Veri fy l ocati ng di mpl e i s between
thrust washer hal ves.
Fig. 65 SECOND GEAR BEARING
1 - SECOND GEAR BEARING
2 - COLLAR
Fig. 66 SECOND GEAR
1 - COLLAR
3 - BEARING
4 - SECOND GEAR
Fig. 67 TWO-PIECE THRUST WASHER
1 - WASHER GROOVE IN SHAFT
2 - LUG BORE
3 - THRUST WASHER LUGS
4 - LUG BORE
5 - LUG
6 - WASHER HALF
Fig. 68 RETAINING RING
2 - THRUST WASHER HALVES
3 - SECOND GEAR
4 - LOCATING DIMPLE
(23) Seat thrust washer retai ni ng ri ng wi th pl asti c
mal l et (Fi g. 69).
(24) I nstal l thi rd gear needl e beari ng on shaft (Fi g.
70).
(25) I nstal l thi rd gear on shaft and beari ng (Fi g.
71).
(26) I nstal l thi rd speed synchro ri ng on thi rd gear
(Fi g. 72).
(27) Start 3-4 synchro hub on output shaft spl i nes
by hand (Fi g. 73).
CAUTION: The 3-4 synchro hub and sleeve can be
installed backwards if care is not exercised. One
side of the sleeve has grooves in it, this side must
faces the front of the shaft.
Fig. 69 THRUST RETAINER
1 - PLASTIC MALLET
Fig. 70 THIRD GEAR BEARING
1 - THIRD GEAR BEARING
Fig. 71 THIRD GEAR
1 - THIRD GEAR
2 - BEARING
Fig. 72 THIRD GEAR SYNCHRO RING
1 - THIRD SPEED SYNCHRO RING
2 - THIRD GEAR
Fig. 73 3-4 SYNCHRO HUB ON OUTPUT SHAFT
1 - GROOVED SIDE OF SLEEVE
(28) Press 3-4 synchro assembl y onto output shaft
wi th shop press and sui tabl e si ze pi pe (Fi g. 74).
NOTE: Tool presses on hub must be as close to
output shaft as possible but not contacting the
shaft splines.
(29) I nstal l new 3-4 synchro hub snap ri ng (Fi g.
75). Veri fy snap ri ng i s seated i n groove.
(30) I nstal l output shaft beari ng.
(31) I nstal l output shaft beari ng snap ri ng wi th
heavy duty snap ri ng pl i ers (Fi g. 76). Veri fy snap
ri ng i s seated i n shaft groove.
NOTE: Spread snap ring only enough to install it.
(32) Veri fy posi ti on of synchro sl eeves before pro-
ceedi ng (Fi g. 77). Grooved si de of 3-4 sl eeve must
face forward. Fi rst gear si de of 1-2 sl eeve must face
fi rst gear. Tapered si de of fi fth-reverse sl eeve must
face forward.
REVERSE IDLER ASSEMBLY
(1) Lubri cate i dl er components wi th gear l ube.
(2) Sl i de i dl er gear beari ng on shaft (Fi g. 78).
Beari ng fi ts ei ther way on shaft.
(3) Sl i de gear onto shaft. Si de of gear wi th recess
goes to rear (Fi g. 78).
(4) Pl ace fi rst l ock bal l i n di mpl e at rear end of
i dl er shaft (Fi g. 78). Petrol eum jel l y can be used to
hol d bal l i n pl ace i f desi red.
(5) Sl i de thrust rear thrust washer onto shaft and
over l ock bal l (Fi g. 79).
(6) I nstal l snap ri ng i n groove at rear of shaft (Fi g.
79).
(7) I nstal l l ock bal l i n di mpl e at front of shaft.
Hol d bal l i n pl ace wi th petrol eum jel l y i f desi red.
Fig. 74 3-4 SYNCHRO ON OUTPUT SHAFT
1 - PRESS RAM
2 - PIPE TOOL
3 - 3-4 SYNCHRO
4 - THIRD SPEED SYNCHRO RING
Fig. 75 3-4 SYNCHRO HUB SNAP RING
1 - 3-4 SYNCHRO HUB SNAP RING
Fig. 76 OUTPUT SHAFT BEARING SNAP
1 - BEARING SNAP RING
Fig. 77 SYNCHRO SLEEVE LOCATIONS
1 - DOUBLE GROOVE FORWARD
2 - GROOVE FORWARD
3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR
4 - TAPER FORWARD
5 - GROOVE FORWARD
6 - 5TH-REV SYNCHRO SLEEVE
Fig. 78 IDLER GEAR & BEARING
1 - IDLER GEAR
2 - BEARING
3 - LOCK BALL
4 - REAR OF SHAFT
Fig. 79 IDLER GEAR REAR THRUST WASHER
1 - LOCK BALL
2 - SNAP RING GROOVE
3 - THRUST WASHER
(8) I nstal l front thrust washer on shaft and sl i de
washer up agai nst gear and over l ock bal l (Fi g. 80).
(9) I nstal l wave washer, fl at washer and remai n-
i ng snap ri ng on i dl er shaft (Fi g. 80). Veri fy snap
ri ng i s seated.
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/
BEARINGS
(1) I nspect shi ft shaft bushi ng and beari ng for
damage.
(2) I f necessary, the shi ft shaft bushi ng can be
repl aced as fol l ows:
(a) Locate a bol t that wi l l thread i nto the bush-
i ng wi thout great effort.
(b) Thread the bol t i nto the bushi ng, al l owi ng
the bol t to make i ts own threads i n the bushi ng.
(c) Attach a sl i de hammer or sui tabl e pul l er to
the bol t and remove bushi ng.
(d) Use the short end of I nstal l er 8119 to i nstal l
the new bushi ng.
(e) Bushi ng i s correctl y i nstal l ed i f fl ush wi th
the transmi ssi on case.
(3) I f necessary, the shi ft shaft beari ng can be
repl aced as fol l ows:
(a) Locate a bol t that wi l l thread i nto the bear-
i ng wi thout great effort.
(b) Thread the bol t i nto the beari ng as much as
possi bl e.
(c) Attach a sl i de hammer or sui tabl e pul l er to
the bol t and remove the beari ng.
(d) Use the short end of I nstal l er 8119 to i nstal l
the new beari ng.
(e) Beari ng i s correctl y i nstal l ed i f fl ush wi th the
transmi ssi on case.
(4) I nspect detent pl unger bushi ngs for damage.
NOTE: The detent plunger bushings are installed to
a specific depth. The space between the two bush-
ings when correctly installed contain an oil feed
hole. Do not attempt to install the bushings with
anything other than the specified tool or this oil
hole may become restricted.
(5) I f necessary, the detent pl unger bushi ngs can
be repl aced as fol l ows:
(a) Usi ng the l ong end of I nstal l er 8119, dri ve
the detent bushi ngs through the outer case and
i nto the shi ft shaft bore.
(b) Remove the bushi ngs from the shi ft shaft
bore.
(c) I nstal l a new detent pl unger bushi ng on the
l ong end of I nstal l er 8118.
(d) Start bushi ng i n the detent pl unger bore i n
the case.
(e) Dri ve bushi ng i nto the bore unti l the tool
contacts the transmi ssi on case.
(f) I nstal l a new detent pl unger bushi ng on the
short end of I nstal l er 8118.
(g) Start the bushi ng i n the detent pl unger bore
i n the case.
(h) Dri ve bushi ng i nto the bore unti l the tool
contacts the transmi ssi on case.
Fig. 80 IDLER GEAR & SHAFT ASSEMBLY
1 - REAR OF SHAFT
2 - GEAR
3 - THRUST WASHER AND BALL
4 - WAVE WASHER
5 - FLAT WASHER
6 - FRONT OF SHAFT
7 - SNAP RING
8 - SNAP RING
GEARTRAIN ASSEMBLY
(1) I nstal l Adapter 6747-1A on i nput shaft hub of
Fi xture 6747 (Fi g. 81). Then i nstal l Adapter 6747-2A
on front beari ng hub of countershaft. Be sure the
shoul der i s seated agai nst the countershaft.
(2) I nstal l i nput shaft i n fi xture tool wi th Adapter Tool
6747-1A posi ti oned under the shaft as shown (Fi g. 82).
(3) I nstal l pi l ot beari ng i n i nput shaft (Fi g. 82).
NOTE: The side of the pilot bearing with the small
diameter goes toward the input shaft.
(4) I nstal l fourth gear synchro ri ng on i nput shaft
(Fi g. 83).
(5) Adjust hei ght of i dl er gear pedestal on fi xture
(Fi g. 84). Start wi th a basi c hei ght of 18.4 cm (7-1/4
i n.). Fi nal adjustment can be made after gear i s posi -
ti oned on pedestal .
Fig. 81 FIXTURE FOR GEARTRAIN BUILD-UP
1 - ADAPTER 6747-2A
2 - CUP 8115
3 - ADAPTER 6747-1A
4 - FIXTURE 6747
Fig. 82 PILOT BEARING & INPUT SHAFT
1 - PILOT BEARING
2 - INPUT SHAFT
Fig. 83 FOURTH GEAR SYNCHRO
1 - FOURTH GEAR SYNCHRO RING
2 - INPUT SHAFT
Fig. 84 IDLER PEDESTAL BASE HEIGHT
1 - REVERSE IDLER PEDESTAL
(6) I nstal l assembl ed output shaft and geartrai n i n
i nput shaft (Fi g. 85). Careful l y rotate output shaft
unti l the 3-4 synchro ri ng seats i n synchro hub and
sl eeve.
(7) I nstal l Adapter 6747-2A on front beari ng hub of
countershaft, i f not previ ousl y done. The shoul der
goes toward the countershaft.
(8) Sl i de countershaft (and adapter) i nto fi xture
sl ot. Veri fy countershaft and output shaft gears are
ful l y meshed wi th the mai nshaft gears before pro-
ceedi ng (Fi g. 86).
(9) Check al i gnment of countershaft and output
shaft gear teeth. Gears may not al i gn perfectl y a di f-
ference i n hei ght of 1.57 to 3.18 mm (1/16 to 1/8 i n.)
wi l l probabl y exi st. Thi s wi l l not i nterfere wi th
assembl y. I f di fference i s greater than thi s, the coun-
tershaft adapter tool i s probabl y upsi de down.
(10) Posi ti on reverse i dl er i n support cup of fi xture
(Fi g. 87). Veri fy i dl er gear i s properl y meshed and
al i gned wi th shaft gear teeth and that bol t hol es are
faci ng out from the geartrai n. Adjust pedestal up or
down i f necessary and veri fy short end of i dl er shaft
i s faci ng up as shown.
Fig. 85 OUTPUT SHAFT, GEARTRAIN & INPUT
SHAFT
1 - OUTPUT SHAFT AND GEARTRAIN
2 - INPUT SHAFT
3 - FIXTURE 6747
Fig. 86 COUNTERSHAFT ON FIXTURE
2 - COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
Fig. 87 REVERSE IDLER ASSEMBLY ON FIXTURE
2 - COUNTERSHAFT
3 - REVERSE IDLER ASSEMBLY
4 - PEDESTAL
(11) On 2-wheel dri ve transmi ssi on, thread one
Al i gnment Pi n 8120 i n center or passenger si de hol e
of output shaft beari ng retai ner. Then posi ti on
retai ner on fi fth gear as shown (Fi g. 88).
(12) Assembl e 1-2 and fi fth reverse-shi ft forks (Fi g.
89). Arm of fi fth-reverse fork goes through sl ot i n 1-2
fork.
(13) I nstal l assembl ed shi ft forks i n synchro
sl eeves and veri fy forks are seated i n sl eeves (Fi g.
90).
REAR HOUSING - 2WD
NOTE: Transmission shift components must be in
Neutral position to prevent damaging the synchro
and shift components when installing the housings.
(1) Dri ve adapter housi ng al i gnment dowel s back
i nto housi ng unti l dowel s are fl ush wi th mounti ng
surface (Fi g. 91).
Fig. 88 ALIGN OUTPUT SHAFT BEARING RETAINER
1 - ALIGNMENT PIN
2 - OUTPUT SHAFT BEARING RETAINER
Fig. 89 1-2 & FIFTH-REVERSE SHIFT FORKS
1 - 1-2 FORK
2 - 1-2 FORK ARM
3 - FIFTH-REVERSE FORK
Fig. 90 SHIFT FORKS IN SYNCHRO
1 - SYNCHRO SLEEVES
2 - FORK ARMS
3 - SHIFT FORKS
Fig. 91 REAR HOUSING DOWELS
1 - HOUSING ALIGNMENT DOWELS
2 - REAR HOUSING
3 - DOWEL FLUSH WITH SURFACE
(2) Appl y l i beral quanti ty of petrol eum jel l y to
countershaft rear beari ng and beari ng race.
(3) I nstal l countershaft rear beari ng i n beari ng
race (Fi g. 92).
NOTE: Large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 93).
(4) Appl y extra petrol eum jel l y to hol d counter-
shaft rear beari ng i n pl ace when housi ng i s i nstal l ed.
(5) Appl y l i ght coat of petrol eum jel l y to shi ft shaft
bushi ng/beari ng i n rear housi ng (Fi g. 93).
(6) Reach i nto countershaft rear beari ng wi th fi n-
ger and push each beari ng rol l er outward agai nst the
race. Then appl y extra petrol eum jel l y to hol d rol l ers
i n pl ace duri ng housi ng i nstal l ati on.
(7) I nstal l rear housi ng onto geartrai n (Fi g. 94)
and veri fy beari ng retai ner pi l ot stud i s i n correct
bol t hol e i n housi ng. Veri fy countershaft and output
shaft beari ngs are al i gned i n housi ng and on counter-
shaft.
NOTE: It may be necessary to lift upward on coun-
tershaft slightly to ensure that the countershaft rear
bearing engages to the countershaft before the rear
output shaft bearing engages the housing.
(8) Seat rear housi ng on output shaft rear beari ng
and countershaft by tappi ng the housi ng wi th a pl as-
ti c mal l et.
2 - REAR BEARING RACE
3 - REAR HOUSING
4 - PETROLEUM JELLY
Fig. 93 COUNTERSHAFT BEARING
1 - SHIFT SHAFT BUSHING/BEARING
Fig. 94 REAR HOUSING
1 - REAR HOUSING
2 - SHIFT FORKS AND GEARTRAIN
(9) Appl y Mopar Gasket Maker or equi val ent to
housi ng bol t threads, bol t shanks and under bol t
heads (Fi g. 95).
(10) Start fi rst two bol ts i n retai ner (Fi g. 96). I t
may be necessary to move retai ner rearward (wi th
pi l ot stud) i n order to start bol ts i n retai ner.
(11) Remove Al i gnment Pi n 8120 and i nstal l l ast
retai ner bol t (Fi g. 96).
(12) Ti ghten retai ner bol ts to 30-35 Nm (22-26 ft.
l bs.).
ADAPTER HOUSING - 4WD
NOTE: Transmission shift components must be in
Neutral to prevents damaging to the synchro and
shift components when installing the housings.
(1) I nstal l rear beari ng i n adapter housi ng. Use
wood hammer handl e or wood dowel to tap beari ng
i nto pl ace.
(2) Posi ti on rear beari ng retai ner i n adapter hous-
i ng (Fi g. 97).
threads, bol t shanks and under hex heads of beari ng
retai ner bol ts (Fi g. 95).
countershaft rear beari ng and beari ng race.
(5) I nstal l countershaft rear beari ng i n beari ng
race (Fi g. 93).
NOTE: Large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 93).
(6) Appl y extra petrol eum jel l y to hol d counter-
shaft rear beari ng i n pl ace when housi ng i s i nstal l ed.
(7) Appl y l i ght coat of petrol eum jel l y to shi ft shaft
bushi ng/beari ng i n adapter housi ng (Fi g. 93).
(8) I nstal l adapter housi ng on geartrai n.
Fig. 95 HOUSING BOLTS
1 - GASKET MAKER
2 - RETAINER AND HOUSING BOLTS
3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
Fig. 96 Alitgnment Pin And Retainer Bolts
1 - BEARING RETAINER BOLT
2 - ALIGNMENT PIN
Fig. 97 ADAPTER HOUSING
2 - RETAINER BOLT
3 - IDLER SHAFT NOTCH
4 - COUNTERSHAFT BEARING RACE
5 - REAR BEARING
(9) I nstal l rear beari ng snap ri ng on output shaft
(Fi g. 98).
(10) Lubri cate l i p of new rear seal (Fi g. 99) wi th
Mopar Door Ease, or transmi ssi on fl ui d.
(11) I nstal l new rear seal i n adapter housi ng bore
wi th I nstal l er C-3860-A. Veri fy seal i s seated i n hous-
i ng bore (Fi g. 99).
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND
SHIFT SOCKET
(1) Veri fy al l synchro sl eeves are i n Neutral posi -
ti on (centered on hub).
CAUTION: Transmission synchros must all be in
Neutral position to prevent damaging the housings,
shift forks and gears while installing the housings.
(2) I nstal l 3-4 shi ft fork i n synchro sl eeve (Fi g.
100). Veri fy groove i n fork arm i s al i gned wi th
grooves i n 1-2 and fi fth-reverse fork arms as shown.
(3) Sl i de shi ft shaft through 3-4 shi ft fork (Fi g.
101).
Fig. 98 REAR BEARING SNAP RING
2 - SNAP RING
3 - OUTPUT SHAFT
Fig. 99 ADAPTER HOUSING REAR SEAL
1 - REAR SEAL
2 - SEAL LIP
3 - OUTPUT SHAFT
Fig. 100 3-4 SHIFT FORK
1 - 3-4 FORK
2 - ALIGN GROOVES IN FORK ARMS
Fig. 101 SHIFT SHAFT
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
(4) Assembl e shi ft shaft shi ft l ever and bushi ng
(Fi g. 102). Veri fy sl ot i n bushi ng i s faci ng up and rol l
pi n hol e for l ever i s al i gned wi th hol e i n shaft.
(5) I nstal l assembl ed l ever and bushi ng on shi ft
shaft (Fi g. 103).
(6) Sl i de shi ft shaft through 1-2 and fi fth-reverse
fork and i nto shi ft l ever openi ng i n rear housi ng (Fi g.
104).
(7) Al i gn shi ft socket wi th shaft and sl i de shaft
through socket and i nto shi ft shaft beari ng i n rear
(8) Rotate shi ft shaft so detent notches i n shaft are
faci ng the TOP of the transmi ssi on housi ng.
CAUTION: Both shaft roll pins can be installed
when the shaft is 180 off. If this occurs, the trans-
mission will have to be disassembled again to cor-
rect shaft alignment.
Fig. 102 SHIFT SHAFT LEVER AND BUSHING
1 - SHAFT LEVER
2 - LEVER BUSHING
3 - BUSHING LOCK PIN SLOT
Fig. 103 SHIFT SHAFT LEVER AND BUSHING
1 - SHIFT SHAFT
2 - SHAFT LEVER AND BUSHING
3 - 3-4 FORK
Fig. 104 SHAFT LEVER OPENING
1 - SHIFT SHAFT
Fig. 105 SHIFT SOCKET
1 - SHIFT SOCKET
2 - SHIFT SHAFT
(9) Sel ect correct new rol l pi n for shi ft shaft l ever
(Fi g. 106). Shaft l ever rol l pi n i s approxi matel y 22
mm (7/8 i n.) l ong. Shi ft socket rol l pi n i s approxi -
matel y 33 mm (1-1/4 i n.) l ong.
(10) Al i gn rol l pi n hol es i n shi ft shaft, l ever and
bushi ng. Then start rol l pi n i nto shaft l ever by hand
(Fi g. 107).
(11) Seat shaft l ever rol l pi n wi th pi n punch (Fi g.
108).
CAUTION: Shaft lever roll pin must be flush with
the surface of the lever. The lever bushing will bind
on the roll pin if the pin is not seated flush.
(12) Veri fy that l ock pi n sl ot i n l ever bushi ng i s
posi ti oned as shown (Fi g. 108).
(13) Al i gn rol l pi n hol es i n shi ft socket and shi ft
shaft. Then start rol l pi n i nto shi ft shaft by hand
(Fi g. 109).
Fig. 106 ROLL PIN IDENTIFICATION
1 - SHAFT LEVER ROLL PIN
2 - SHIFT SOCKET ROLL PIN
Fig. 107 SHIFT SHAFT ROLL PIN
1 - SHAFT LEVER ROLL PIN
2 - LEVER AND BUSHING
Fig. 108 SHIFT SHAFT/LEVER ROLL PIN
1 - BUSHING LOCK PIN SLOT
2 - SEAT ROLL PIN FLUSH WITH LEVER
Fig. 109 SHIFT SOCKET ROLL PIN
1 - ROLL PIN
2 - SHIFT SOCKET
3 - SHIFT SHAFT
(14) Seat rol l pi n i n shi ft socket wi th pi n punch.
Rol l pi n must be fl ush wi th socket after i nstal l ati on
(Fi g. 110).
(15) Veri fy that notches i n shi ft fork arms are
al i gned (Fi g. 111). Real i gn arms i f necessary.
(16) Rotate shi ft l ever and bushi ng downward to
expose detent bore i n the l ever.
(17) I nstal l detent spri ng then the bal l i nto the
detent bore (Fi g. 112) and hol d the bal l i n the l ever.
Then rotate the l ever upward i nto the fork arm
notches.
NOTE: Verify detent ball is seated in the fork arms
before proceeding.
FRONT HOUSING AND INPUT SHAFT BEARING
RETAINER
(1) I f previ ousl y removed, i nstal l i nput shaft bear-
i ng i n front housi ng bore (Fi g. 113). I nstal l snap ri ng
and use pl asti c mal l et to seat beari ng. Beari ng goes
i n from front si de of housi ng onl y.
Fig. 110 SEAT SHIFT SOCKET
1 - PIN PUNCH
2 - SHIFT SOCKET
3 - SEAT ROLL PIN FLUSH
4 - SHIFT SOCKET
Fig. 111 SHIFT LEVER POSITION
1 - SHIFT FORK ARMS
2 - DETENT BORE
Fig. 112 DETENT SPRING AND BALL
1 - SHAFT LEVER
2 - SPRING AND BALL
3 - MAGNET
Fig. 113 INPUT SHAFT & COUNTERSHAFT
BEARING
3 - SHIFT SHAFT BUSHING
countershaft front beari ng. Then i nsert beari ng i n
front housi ng race (Fi g. 113). Large di ameter si de of
beari ng cage goes toward countershaft (Fi g. 114).
Smal l di ameter si de goes toward beari ng race i n
housi ng.
(3) Reach i nto countershaft front beari ng wi th fi n-
ger and push each beari ng rol l er outward agai nst
race. Then appl y extra petrol eum jel l y to hol d rol l ers
i n pl ace duri ng housi ng i nstal l ati on.
(4) Appl y smal l amount of petrol eum jel l y to shi ft
shaft bushi ng i n front housi ng.
(5) Appl y 1/8 i n. wi de bead of Mopar Gasket
Maker or equi val ent to mati ng surfaces of front and
rear housi ngs (Fi g. 115).
(6) Have hel per hol d rear housi ng and geartrai n i n
upri ght posi ti on. Then i nstal l front housi ng on rear
housi ng and geartrai n.
(7) Work front housi ng downward onto geartrai n
unti l seated on rear housi ng.
CAUTION: Front housings will not seat if shift com-
ponents are not in Neutral or one or more compo-
nents are misaligned. Do not force the front
housing into place.
(8) Tap rear housi ng al i gnment dowel s back i nto
pl ace wi th hammer and pi n punch. Both dowel s
shoul d be fl ush fi t i n each housi ng. Have hel per hol d
transmi ssi on upri ght whi l e dowel s are tapped back
i nto pl ace.
(9) Pl ace transmi ssi on i n hori zontal posi ti on.
housi ng attachi ng bol ts. Appl y seal er materi al seal er
to undersi de of bol t heads and to bol t shanks and
threads (Fi g. 116).
(11) I nstal l and start housi ng attachi ng bol ts by
hand (Fi g. 116). Then ti ghten bol ts to 34 Nm (25 ft.
l bs.).
Fig. 114 COUNTERSHAFT FRONT BEARING
1 - BEARING RACE
2 - PETROLEUM JELLY
Fig. 115 SEAL HOUSINGS
1 - HOUSING FLANGE SURFACE
2 -GASKET MAKER
Fig. 116 HOUSING BOLTS
1 - HOUSING BOLTS
(12) I nstal l shi ft shaft bushi ng l ock bol t (Fi g. 117).
Appl y Mopar Gasket Maker or equi val ent to bol t
threads, shank and undersi de of bol t head before
i nstal l ati on.
CAUTION: If lock bolt cannot be fully installed the
shift shaft is not in Neutral, or the shaft bushing (or
lever) is misaligned.
(13) Lubri cate then i nstal l shi ft shaft detent
pl unger i n housi ng bore. Lubri cate pl unger wi th
semi -syntheti c/syntheti c grease. Veri fy pl unger i s
ful l y seated i n detent notch i n shi ft shaft.
(14) I nstal l detent spri ng i nsi de pl unger.
(15) I nstal l detent pl ug i n end of I nstal l er 8123.
Posi ti on pl ug on detent spri ng and compress spri ng
unti l detent pl ug pi l ots i n detent pl unger bore. Dri ve
detent pl ug i nto transmi ssi on case unti l pl ug seats.
(16) I nstal l backup l i ght swi tch (Fi g. 118).
(17) I nstal l i nput shaft snap ri ng (Fi g. 119).
(18) I nstal l new oi l seal i n front beari ng retai ner
wi th I nstal l er 6448 (Fi g. 120).
(19) Appl y bead of Mopar si l i cone seal er or equi v-
al ent to fl ange surface of front beari ng retai ner (Fi g.
121).
Fig. 117 SHAFT LOCK BOLT
1 - SHIFT SHAFT LOCK BOLT
2 - SHAFT SOCKET
Fig. 118 BACKUP LIGHT SWITCH
1 - BACKUP LIGHT SWITCH
Fig. 119 SHAFT SNAP RING - TYPICAL
1 - INPUT SHAFT SNAP RING
Fig. 120 BEARING RETAINER OIL SEAL
1 - INSTALLER
2 - FRONT BEARING RETAINER
Fig. 121 SEAL BEARING RETAINER - TYPICAL
1 - APPLY SEALER BEAD
2 - INPUT SHAFT BEARING RETAINER
(20) Al i gn and i nstal l front beari ng retai ner over
i nput shaft and onto housi ng mounti ng surface (Fi g.
122). Veri fy bol t hol es are al i gned before seati ng
retai ner.
CAUTION: Be sure sealer does not get into the oil
feed hole in the transmission case or bearing
retainer.
(21) I nstal l and ti ghten beari ng retai ner bol ts to
7-10 Nm (5-7 ft. l bs.) (Fi g. 123).
SHIFT TOWER AND LEVER
(1) Appl y petrol eum jel l y to bal l end of shi ft l ever
and i nteri or of shi ft socket.
(2) Shi ft the transmi ssi on i nto thi rd gear.
(3) Al i gn and i nstal l shi ft tower and l ever assem-
bl y (Fi g. 124). Be sure shi ft bal l i s seated i n socket
and the offset i n the tower i s toward the passenger
si de of the vehi cl e before i nstal l i ng tower bol ts.
(4) I nstal l shi ft tower bol ts (Fi g. 125) and ti ghten
bol ts to 8.5 Nm (75.2 i n. l bs.).
(5) Fi l l transmi ssi on to bottom edge of fi l l pl ug
hol e wi th l ubri cant.
(6) I nstal l and ti ghten fi l l pl ug to 34 Nm (25 ft.
l bs.).
(7) Check transmi ssi on vent. Be sure vent i s open
and not restri cted.
Fig. 122 INPUT SHAFT BEARING RETAINER
1 - INPUT SHAFT
2 - OIL FEED
Fig. 123 BEARING RETAINER BOLTS - TYPICAL
1 - RETAINER BOLTS
2 - RETAINER
Fig. 124 SHIFT TOWER
1 - SHIFT TOWER
2 - SHAFT SOCKET
3 - SHIFT BALL
Fig. 125 SHIFT TOWER BOLTS
1 - SHIFT TOWER AND LEVER ASSEMBLY
INSTALLATION
NOTE: If a new transmission is being installed, use
all components supplied with the new transmission.
For example, if a new shift tower is supplied, do not
re-use the original shift tower.
(1) Cl ean transmi ssi on front housi ng mounti ng
surface.
beari ng grease or equi val ent to contact surfaces (Fi g.
126) of fol l owi ng components:
rel ease fork bal l stud.
rel ease beari ng sl i de surface.
i nput shaft spl i nes.
rel ease beari ng bore.
propel l er shaft sl i p yoke.
(3) Support and secure transmi ssi on to jack.
(4) Rai se and al i gn transmi ssi on i nput shaft wi th
cl utch di sc, then sl i de transmi ssi on i nto pl ace.
(5) Veri fy front housi ng i s ful l y seated. I nstal l
transmi ssi on bol ts wi thout washers and ti ghten bol ts
i nto the engi ne to 41 Nm (30 ft. l bs.). Ti ghten the
bol ts wi th washers i nto the transmi ssi on to 68 Nm
(50 ft. l bs.) (Fi g. 127).
(6) I nstal l rear crossmember and ti ghten nuts to
102 Nm (75 ft. l bs.).
(7) I nstal l transmi ssi on rear mounti ng bol ts and
(8) I nstal l front dust shi el d ti ghten bol t to 4.5 Nm
(40 i n. l bs.). I f cover was removed, i nstal l onto the
transmi ssi on and engi ne(Refer to 9 - ENGI NE/EN-
GI NE BLOCK/STRUCTURAL COVER - I NSTALLA-
TI ON).
(9) I nstal l structural dust cover and ti ghten the
(10) I nstal l starter motor.
(11) I nstal l suspensi on crossmember and ti ghten
nuts to 102 Nm (75 ft. l bs.).
(12) Connect transmi ssi on harnesses to cl i ps on
case and connect swi tches.
(13) I nstal l sl ave cyl i nder and ti ghten cyl i nder
nuts to 23 Nm (200 i n. l bs.).
(14) I nstal l transfer case and transfer case l i nkage
i f equi pped.
(15) Remove transmi ssi on jack.
(16) I nstal l propel l er shaft/shafts wi th reference
marks al i gned.
(17) I nstal l exhaust on the exhaust mani fol ds.
(18) Fi l l transmi ssi on wi th l ubri cant. Correct fi l l
l evel i s to bottom edge of fi l l pl ug hol e.
Fig. 126 LUBRICATION POINTS
1 - RELEASE FORK
2 - FORK BALL STUD
3 - BEARING SLIDE SURFACE
4 - SPLINE
5 - RELEASE BEAING
Fig. 127 TRANSMISSION
1 - BOLT WITHOUT WASHER
2 - BOLT WITH WASHER
SPECIFICATIONS
Crossmember Nuts 102 75 -
Transmission Mount Bolts 4WD 68 50 -
Transmission Mount Bolts 2WD 68 50 -
Structural Dust Cover Bolts 54 40 -
Drain/Fill Plug 9-27 14-20 -
Front To Rear Housing Bolts 30-35 22-26 -
Front Bearing Retainer Bolts 7-10 5-7 62-88
Idler Shaft Bolts 19-25 14-18 -
Rear Bearing Retainer Bolts 30-35 22-26 -
Shift Tower Bolts 7-10 5-7 62-88
Slave Cylinder Nuts 23 17 -
Transfer Case Nuts 47 35 -
SPECIAL TOOLS
REMOVER C-3985-B
INSTALLER C-3972-A
REMOVER 6957
INSTALLER 6951
HANDLE C-4171
REMOVER/INSTALLER 6858
FIXTURE 6747
ADAPTER 6747-1A
ADAPTER 6747-2A
CUP 8115
BEARING SPLITTER 1130
TUBE 6310-1
INSTALLER 8118
REMOVER/INSTALLER 8119
ALIGNMENT STUD 8120
INSTALLER C-3860-A
INSTALLER 8123
INSTALLER 6448
REMOVER 8117A
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 46
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 62
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 81
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 81
ADAPTER HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
EXTENSION HOUSING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
SHIFT MECHANISM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 87
SHIFT COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 87
NV4500
DESCRIPTION
The NV4500 i s a fi ve speed constant mesh manual
transmi ssi on. Al l gear ranges i ncl udi ng reverse are
synchroni zed. Fi fth gear i s an overdri ve range. The
transmi ssi on has a cast i ron gear case and al umi num
shi ft cover.
Two versi ons are used, a standard duty for 5.7L
appl i cati ons and a heavy duty for V10 and Cummi ns
di esel appl i cati ons. Mai n di fference i s a l arger di am-
eter i nput shaft, for the heavy duty model .
Tapered rol l er beari ngs support the dri ve gear,
mai nshaft and countershaft i n the gear case. Rol l er
beari ngs i n the dri ve gear support the forward end of
the mai nshaft. The mai nshaft gears are al l supported
on caged type rol l er beari ngs. Dri ve gear thrust reac-
ti on i s control l ed by a needl e type thrust beari ng.
The beari ng i s l ocated at the forward end of the
mai nshaft.
The transmi ssi on i s a top l oader styl e. The shi ft
l ever i s l ocated i n a shi fter tower whi ch i s bol ted to
the shi ft cover and operates the shi ft forks and rai l s
di rectl y. The shi ft forks and rai l s are al l l ocated
wi thi n the al umi num cover whi ch i s bol ted to the top
of the gear case.
IDENTIFICATION
The transmi ssi on i denti fi cati on tag i s attached to
the dri ver si de PTO cover (Fi g. 1).
The tag provi des the transmi ssi on model number,
bui l d date and part number. Be sure to rei nstal l the
I .D. tag i f removed duri ng servi ce. The i nformati on
on the tag i s essenti al to correct parts orderi ng.
OPERATION
The manual transmi ssi on recei ves power through
the cl utch assembl y from the engi ne. The cl utch di sc
i s spl i ned to the transmi ssi on i nput shaft and i s
turned at engi ne speed at al l ti mes that the cl utch i s
engaged. The i nput shaft i s connected to the trans-
mi ssi on countershaft through the mesh of fourth
speed gear on the i nput shaft and the fourth counter-
shaft gear. At thi s poi nt al l the transmi ssi on gears
are spi nni ng.
Fig. 1 IDENTIFICATION TAG LOCATION
1 - PTO COVER
2 - I.D. TAG
shi ft l ever to the desi red gear posi ti on. Thi s move-
ment moves the i nternal transmi ssi on shi ft compo-
nents to begi n the shi ft sequence. As the shi ft l ever
moves the sel ected shi ft rai l , the shi ft fork attached
to that rai l begi ns to move. The fork i s posi ti oned i n
a groove i n the outer ci rcumference of the synchro-
ni zer sl eeve. As the shi ft fork moves the synchroni zer
sl eeve, the synchroni zer begi ns to speed-up or sl ow
down the sel ected gear (dependi ng on whether the
dri ver i s up-shi fti ng or down-shi fti ng). The synchro-
ni zer does thi s by havi ng the synchroni zer hub
spl i ned to the mai nshaft, or the countershaft i n some
cases, and movi ng the bl ocker ri ng i nto contact wi th
the gears fri cti on cone. As the bl ocker ri ng and fri c-
ti on cone come together, the gear speed i s brought up
or down to the speed of the synchroni zer. As the two
speeds match, the spl i nes on the i nsi de of the syn-
chroni zer sl eeve become al i gned wi th the teeth on
the bl ocker ri ng and the fri cti on cone and eventual l y
wi l l sl i de over the teeth, l ocki ng the gear to the
mai nshaft, or countershaft, through the synchroni zer.
LOW LUBRICANT LEVEL
rect l ubri cant l evel check. A correct l ubri cant l evel
check can onl y be made when the vehi cl e i s l evel .
Al so al l ow the l ubri cant to settl e for a mi nute or so
before checki ng. These recommendati ons wi l l ensure
an accurate check and avoi d an underfi l l or overfi l l
condi ti on. Al ways check the l ubri cant l evel after any
addi ti on of fl ui d to avoi d an i ncorrect l ubri cant l evel
condi ti on.
Leaks can occur at the mati ng surfaces of the gear
case, adaptor or extensi on housi ng, or from the front/
rear seal s. A suspected l eak coul d al so be the resul t
of an overfi l l condi ti on. Leaks at the rear of the
extensi on or adapter housi ng wi l l be from the hous-
i ng oi l seal s. Leaks at component mati ng surfaces
wi l l probabl y be the resul t of i nadequate seal er, gaps
i n the seal er, i ncorrect bol t ti ghteni ng or use of a
non-recommended seal er. A l eak at the front of the
transmi ssi on wi l l be from ei ther the front beari ng
retai ner or retai ner seal . Lubri cant may be seen dri p-
pi ng from the cl utch housi ng after extended opera-
ti on. I f the l eak i s severe, i t may al so contami nate
the cl utch di sc causi ng the di sc to sl i p, grab and or
chatter.
HARD SHIFTING
i ng and noi se.
Component damage, i ncorrect cl utch adjustment or
damaged cl utch pressure pl ate or di sc are addi ti onal
probabl e causes of i ncreased shi ft effort. I ncorrect
adjustment or a worn/damaged pressure pl ate or di sc
can cause i ncorrect rel ease. I f cl utch probl em i s
advanced, gear cl ash duri ng shi fts can resul t. Worn
or damaged synchro ri ngs can cause gear cl ash when
shi fti ng i nto any forward gear. I n some new or
TRANSMISSION NOISE
speeds. Severe hi ghl y audi bl e transmi ssi on noi se i s
general l y the i ni ti al i ndi cator of a l ubri cant probl em.
I nsuffi ci ent, i mproper or contami nated l ubri cant
wi l l promote rapi d wear of gears, synchros, shi ft
rai l s, forks and beari ngs. The overheati ng caused by
a l ubri cant probl em, can al so l ead to gear breakage.
REMOVAL
(2) Remove shi ft boot screws from fl oorpan and
sl i de boot upward on the shi ft l ever.
(3) Remove shi ft l ever extensi on from shi ft tower
and l ever assembl y.
(4) Remove shi ft tower bol ts (Fi g. 2).
Fig. 2 SHIFT TOWER
1 - SHIFT TOWER
2 - SHIFTER
3 - BOLTS
(5) Remove shi ft tower and i sol ator pl ate from
transmi ssi on shi ft cover.
(8) Mark propel l er shaft and axl e yokes for i nstal -
l ati on reference and remove shaft/shafts.
(9) Remove exhaust system Y-pi pe.
(10) Di sconnect speed sensor and backup l i ght
swi tch connectors.
(11) Support engi ne wi th safety stand and a wood
bl ock.
(12) I f transmi ssi on i s to be di sassembl ed, remove
drai n bol t at bottom of PTO cover and drai n l ubri -
cant (Fi g. 3).
TWO WHEEL DRIVE
(1) Remove bol ts attachi ng transmi ssi on to rear
crossmember mount.
(2) Support and secure transmi ssi on wi th safety
chai ns to a transmi ssi on jack.
(3) Remove rear crossmember bol ts and pry out
crossmenber.
(4) Remove cl utch sl ave cyl i nder bol ts and move
cyl i nder asi de for cl earance.
NOTE: The hydraulic linkage has a quick connect at
the slave cylinder. This fitting should not be discon-
nected.
(5) Remove transmi ssi on harness wi res from cl i ps
on transmi ssi on shi ft cover.
(6) Remove transmi ssi on to cl utch housi ng bol ts.
(7) Sl i de transmi ssi on and jack rearward unti l
i nput shaft cl ears cl utch housi ng.
(8) Lower transmi ssi on jack and remove transmi s-
si on from under vehi cl e.
FOUR WHEEL DRIVE
(1) Di sconnect transfer case shi ft l i nkage at trans-
fer case range l ever. Then remove transfer case shi ft
mechani sm from transmi ssi on (Fi g. 4).
(2) Support and secure transfer case to transmi s-
si on jack wi th safety chai ns.
(3) Remove transfer case mounti ng nuts.
(4) Move transfer case rearward unti l i nput gear
cl ears transmi ssi on mai nshaft.
(5) Lower transfer case assembl y and move i t from
under vehi cl e.
(7) Remove transmi ssi on harness from retai ni ng
cl i ps on transmi ssi on shi ft cover.
(8) Remove bol ts/nuts attachi ng transmi ssi on
mount to rear crossmember.
crossmenber.
(10) Remove cl utch sl ave cyl i nder spl ash shi el d, i f
equi pped.
NOTE: The hydraulic linkage has a quick connect at
the slave cylinder. This fitting should not be discon-
nected.
(12) Remove transmi ssi on to cl utch housi ng bol ts.
i nput shaft cl ears cl utch housi ng.
(14) Lower transmi ssi on jack and remove trans-
mi ssi on from under vehi cl e.
Fig. 3 FILL AND DRAIN PLUGS
1 - PTO COVER
2 - DRAIN BOLT
3 - FILL PLUG
Fig. 4 TRANSFER CASE SHIFTER-TYPICAL
1 - TRANSMISSION
2 - TRANSFER CASE SHIFT MECHANISM
DISASSEMBLY
SHIFT MECHANISM
(1) Remove bol ts hol di ng shi ft tower to shi ft mech-
ani sm cover and remove tower.
(2) Remove bol ts hol di ng shi ft mechani sm cover to
transmi ssi on.
(3) Pry up shi ft mechani sm cover at sl ot (Fi g. 5) i n
cover.
(4) Rai se mechani sm up enough to di sengage i t
from the dowl pi ns (Fi g. 6).
(5) Rai se front of the mechani sm and l i ft up and
off the transmi ssi on.
EXTENSION/ADAPTER HOUSING
(1) Remove bol ts attachi ng extensi on/adapter hous-
i ng to gear case (Fi g. 7).
(2) Remove extensi on/adapter housi ng (Fi g. 8).
There i s one al i gnment dowel i n the gear case and
one i n the extensi on/adapter housi ng.
Fig. 5 LOOSEN SHIFT MECHANISM
1 - SHIFT MECHANISM COVER SLOT
2 - PRY TOOL
Fig. 6 SHIFT MECHANISM COVER
1 - SHIFT MECHANISM COVER
2 - ALIGNMENT DOWELS
Fig. 7 EXTENSION/ADAPTER HOUSING BOLTS
1 - EXTENSION HOUSING
2 - BOLTS (8)
Fig. 8 EXTENSION/ADAPTER HOUSING
1 - GEAR CASE
(3) Remove rubber spl i ne seal from end of mai n-
shaft (Fi g. 9). The seal i s used to prevent l ubri cant
l oss duri ng shi ppi ng and does not have to be repl aced
i f damaged.
FIFTH GEAR NUT
(1) Remove extensi on/adapter housi ng.
(2) Loosen fi fth gear cl amp nut cl ampi ng screw
approxi matel y 1 1/2 turns.
(3) I nstal l Wrench 6743 on fi fth gear nut (Fi g. 10).
NOTE: Wrench only fits one way on nut. Make sure
wrench is fully engaged in nut slots and is not cocked.
(4) I nstal l Socket 6993 4X2 or Socket 6984 4X4 wi th
breaker bar to hol d mai nshaft and remove fi fth gear nut.
NOTE: Wedge breaker bar handle against workbench.
Purpose of socket wrench and breaker bar is to pre-
vent mainshaft from turning while nut is loosened.
(5) Remove fi fth gear nut, then remove bel l evi l l e
washer from mai nshaft.
FIFTH GEAR
(1) Remove fi fth gear shi ft fork rol l pi ns (Fi g. 11).
Dri ve rol l pi ns out from the bottom of fork.
(2) Remove fi fth gear cl utch hub and gear snap
ri ng from countershaft (Fi g. 12).
(3) Remove countershaft fi fth gear cl utch gear and
stop ri ng.
(4) Tap off fi fth gear shi ft fork and gear assembl y
off rai l wi th pl asti c mal l et.
(5) Remove fi fth gear shi ft fork from sl eeve.
(6) Remove sl eeve, struts and strut spri ngs from
countershaft fi fth gear hub, i f necessary.
Fig. 10 FIFTH GEAR NUT
1 - WRENCH
2 - FIFTH GEAR NUT
3 - SPLINE SOCKET
Fig. 9 MAINSHAFT SPLINE SEAL
1 - MAINSHAFT
2 - RUBBER SPLINE SEAL
Fig. 11 FIFTH GEAR SHIFT FORK ROLL PINS
1 - ROLL PINS
2 - FIFTH GEAR SHIFT FORK
Fig. 12 FIFTH GEAR CLUTCH GEAR SNAP RING
1 - CLUTCH GEAR RING
2 - FIFTH SYNCHRO CLUTCH GEAR
(7) Remove countershaft fi fth gear needl e beari ng
assembl y (Fi g. 13).
(8) Remove coned shape rear beari ng thrust
washer from countershaft (Fi g. 14).
NOTE: Note washer bore locating notch for assem-
bly reference.
(9) Remove thrust washer l ocati ng pi n from coun-
tershaft.
(10) Remove mai nshaft fi fth gear wi th Pul l er Set
6444 and Jaw 6459 or 6820. Posi ti on fi rst Jaw on
gear (Fi g. 15).
(11) Assembl e Pul l er Fl ange 6444-1and Pul l er
Rods 6444-3 4X2 or 6444-4 4X4 (Fi g. 16). Sl i de
assembl y onto output shaft and seat fl ange i n notch
of jaw.
Fig. 13 COUNTERSHAFT FIFTH GEAR NEEDLE
BEARING
1 - NEEDLE BEARING
2 - COUNTERSHAFT
Fig. 14 COUNTERSHAFT REAR BEARING THRUST
WASHER
1 - THRUST WASHER
2 - THRUST WASHER PIN
Fig. 15 JAW ON MAINSHAFT FIFTH GEAR
1 - MAINSHAFT FIFTH GEAR
2 - JAW
3 - MAINSHAFT
Fig. 16 PULLER FLANGE
1 - JAW
2 - PULLER FLANGE
(12) Posi ti on second pul l er jaw on gear and i n
notch of pul l er fl ange (Fi g. 17). Sl i de Col l ar 6444-8
over pul l er jaws to hol d them i n pl ace.
(13) I nstal l Pul l er and Bol t 6444 on pul l er rods
and secure pul l er to rods wi th retai ni ng nuts (Fi g.
18). Ti ghten pul l er bol t to remove gear from shaft
spl i nes.
(14) Remove mai nshaft rear beari ng pl ate bol ts
and remove fi fth gear pl ate end pl ay shi ms and bear-
i ng cup (Fi g. 19).
FRONT RETAINER
(1) Remove and di scard front beari ng retai ner
bol ts (Fi g. 20).
CAUTION: Do not reuse retainer bolts.
(2) Li ghtl y tap retai ner back and forth wi th pl asti c
mal l et to work i t out of gear case.
NOTE: Retainer flange extends into transmission
case and is a snug fit.
Fig. 17 PULLER COLLAR
1 - JAWS
2 - COLLAR
Fig. 18 PULLER ASSEMBLY
1 - COLLAR
2 - JAWS
3 - BOLT
4 - WRENCH
5 - MAINSHAFT
6 - PULLER FLANGE
Fig. 19 FIFTH GEAR BEARING PLATE, SHIMS AND
BEARING CUP
1 - MAINSHAFT REAR BEARING CUP
2 - BEARING SHIMS
3 - BEARING PLATE
4 - FIFTH GEAR
Fig. 20 FRONT BEARING RETAINER
1 - DRIVE GEAR
(3) Remove front retai ner seal by (Fi g. 21) col l aps-
i ng one si de of seal then pryi ng i t out.
(4) Remove front retai ner beari ng cup wi th Pul l er
6444. Assembl e Pul l er Fl ange 6444-1 and Pul l er Rods
6444-4 (Fi g. 22). I nsert Jaws 6453-1 i n pul l er fl ange.
Narrow l i p of pul l er jaws wi l l go under beari ng cup.
(5) I nstal l Di sc C-4487-1 i nto beari ng retai ner for
I nsert 6453-2 to rest upon.
(6) I nstal l assembl ed tool s i n front retai ner (Fi g.
23) wi th pul l er jaws seated under beari ng cup. Pl ace
I nsert 6453-2 i n center of pul l er jaws, to hol d pul l er
jaws i n pl ace.
(7) I nstal l Pul l er 6444 on pul l er rods (Fi g. 24) and
i nstal l retai ni ng nuts on pul l er rods. Ti ghten pul l er
bol t to draw beari ng cup out of retai ner.
Fig. 21 BEARING RETAINER SEAL
1 - SEAL
Fig. 22 PULLER RODS, FLANGE AND JAWS
1 - RODS
2 - FLANGE
3 - JAWS
Fig. 23 INSERT AND RETAINER
1 - INSERT
2 - FRONT RETAINER
3 - JAWS
Fig. 24 BEARING CUP PULLER ASSEMBLY
1 - WRENCH
2 - INSERT
3 - FRONT RETAINER
4 - PULLER
5 - WRENCH
DRIVE GEAR
(1) Remove dri ve gear (Fi g. 25).
(2) Remove pi l ot beari ng from dri ve gear (Fi g. 26).
(3) Remove tapered beari ng from dri ve gear wi th
Pul l er Fl ange 6444-1 and Pul l er Rods 6444-6 (Fi g.
27).
(4) Posi ti on fi rst Jaw 6447 on beari ng. Sl i de
assembl ed pul l er fl ange and rod tool s onto i nput
shaft. Then seat fl ange i n notch of pul l er jaw.
(5) Posi ti on second Jaw 6447 on gear and i n notch
of pul l er fl ange. Sl i de Col l ar 6444-8 over pul l er jaws
to hol d them i n pl ace.
(6) I nstal l Pul l er 6444 on pul l er rods then i nstal l
retai ni ng nuts. Ti ghten pul l er bol t to remove beari ng
cone from dri ve gear.
Fig. 25 DRIVE GEAR
1 - MAINSHAFT
2 - DRIVE GEAR
Fig. 26 PILOT BEARING
1 - DRIVE GEAR
2 - MAINSHAFT PILOT BEARING
Fig. 27 FRONT BEARING PULLER
1 - PULLER
2 - RODS
3 - JAWS
4 - COLLAR
5 - FLANGE
6 - DRIVE GEAR
MAINSHAFT AND GEARTRAIN
(1) Move 1-2 and 3-4 synchro sl eeves i nto neutral .
(2) Remove dri ve gear thrust beari ng from forward
end of mai nshaft (Fi g. 28).
(3) Remove fourth gear cl utch gear and synchro
stop ri ng from mai nshaft (Fi g. 29).
(4) Rol l gear case onto l eft si de.
(5) Remove mai nshaft assembl y (Fi g. 30) by l i fti ng
front end of mai nshaft sl i ghtl y. Then grasp mai nshaft
rear spl i nes and turn spl i ne end of mai nshaft coun-
tercl ockwi se to rotate shaft and geartrai n out of case.
Ti l t mai nshaft outward and removed from case.
NOTE: Handling mainshaft carefully because gears
are lose on the mainshaft.
REVERSE IDLER AND COUNTERSHAFT
(1) Remove countershaft rear beari ng pl ate (Fi g.
31).
(2) Remove countershaft end pl ay shi m and rear
beari ng cup (Fi g. 32).
Fig. 28 DRIVE GEAR THRUST BEARING
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 29 FOURTH GEAR CLUTCH GEAR STOP RING
1 - FOURTH GEAR SYNCHRO STOP RING
2 - FOURTH SPEED CLUTCH GEAR
Fig. 30 MAINSHAFT AND GEARTRAIN
1 - MAINSHAFT AND CASE
Fig. 31 COUNTERSHAFT REAR BEARING PLATE
1 - REAR BEARING PLATE
2 - COUNTERSHAFT
Fig. 32 END PLAY SHIM AND REAR BEARING CUP
1 - COUNTERSHAFT REAR BEARING CUP
2 - END PLAY SHIM
(3) Remove reverse i dl er shaft (Fi g. 33).
(4) Rotate countershaft outward and push reverse
i dl er gear away from countershaft and toward front
of case (Fi g. 34).
(5) Remove i dl er gear (Fi g. 35).
(6) Keep reverse i dl er gear beari ngs and spacer
together (Fi g. 36). I nsert i dl er shaft through gear and
beari ngs to keep them i n pl ace.
(7) Remove i dl er gear thrust washers from gear
case. I nstal l washers on i dl er shaft to keep them
together for cl eani ng and i nspecti on.
Fig. 33 REVERSE IDLER SHAFT
1 - REVERSE IDLER SHAFT
Fig. 34 IDLER GEAR AND COUNTERSHAFT
2 - COUNTERSHAFT
Fig. 35 REVERSE IDLER GEAR
2 - DRIVE GEAR BORE
Fig. 36 IDLER GEAR COMPONENTS
1 - BEARINGS
(8) Remove countershaft rear beari ng wi th Pul l er
Fl ange 6444-1 and Pul l er Rods 6444-4 (Fi g. 37).
NOTE: Shaft cannot be removed from case until
rear bearing has been removed.
(9) Posi ti on fi rst Jaw 6449 on beari ng cone and
seat pul l er fl ange i n notch of pul l er.
(10) I nstal l second Jaw 6449 on beari ng and i n
notch of pul l er fl ange. Sl i de Col l ar 6444-8 over pul l er
jaws to hol d them i n pl ace.
NOTE: Retaining collar has small lip on one end
and only fits one way over jaws.
(11) I nstal l Pul l er 6444 on pul l er rods, then secure
pul l er to rods wi th retai ni ng nuts.Ti ghten pul l er bol t
to remove beari ng from shaft.
NOTE: If bearing is exceptionally tight, tap end of
puller bolt with copper mallet to help loosen bear-
ing.
(12) Remove beari ng pul l er tool s then rotate coun-
tershaft out of gear case (Fi g. 38).
(13) Remove countershaft front beari ng, wi th
Pul l er Fl ange 6444-1 and Pul l er Bol ts 6444-4 (Fi g.
39).
(14) Posi ti on fi rst Jaw 6451 on beari ng and seat
pul l er fl ange i n notch of pul l er jaw.
(15) I nstal l second Jaw 6451 on beari ng and i n
notch of pul l er fl ange. Sl i de Col l ar 6444-8 over pul l er
jaws to hol d them i n pl ace.
NOTE: Retaining collar has small lip on one end
and only fits one way over jaws.
(16) I nstal l pul l er bri dge and bol t assembl y 6444
on pul l er bol ts and i nstal l retai ni ng nuts. Ti ghten
pul l er bol t to remove beari ng from shaft.
NOTE: If bearing is exceptionally tight, tap end of
puller bolt with mallet to help loosen bearing.
(17) Remove beari ng pul l er tool s.
1 - COLLAR
2 - JAWS
3 - PULLER
4 - WRENCH
Fig. 38 COUNTERSHAFT AND CASE
1 - COUNTERSHAFT
Fig. 39 Countershaft Front Bearing
1 - JAWS
2 - COLLAR
3 - PULLER
4 - FLANGE
GEAR CASE
(1) Remove countershaft front beari ng cap wi th
hammer (Fi g. 40).
(2) Remove countershaft front beari ng cup wi th
Remover 6454 and Handl e C-4171 (Fi g. 41).
(3) Remove rol l pi n that secures shi ft l ug on shi ft
rai l i n case (Fi g. 42). A smal l pi n punch can be mod-
i fi ed by putti ng a sl i ght bend i n i t to dri ve pi n com-
pl etel y out of shi ft rai l (Fi g. 42).
(4) Remove shi ft l ug rai l .
Fig. 40 COUNTERSHAFT FRONT BEARING CAP
1 - HAMMER
2 - BEARING CAP
Fig. 41 COUNTERSHAFT FRONT BEARING CUP
1 - REMOVER
2 - HANDLE
Fig. 42 SHIFT LUG ROLL PIN
1 - PUNCH
2 - 30BEND
3 - PIN PUNCH MODIFICATION
4 - SHIFT LUG
5 - SHIFT RAIL
MAINSHAFT
NOTE: Gear and synchro components can be
installed backwards. Paint or scribe gear and syn-
chro components for installation reference. Then
stack geartrain parts in order of removal.
(1) Remove dri ve gear thrust beari ng from end of
mai nshaft, i f not previ ousl y removed.
(2) Pl ace 3-4 gear i n a press wi th support under
3rd gear and Remove 3-4 synchro hub, thi rd gear
stop ri ng and thi rd gear as an assembl y (Fi g. 43).
(3) Remove thi rd gear beari ng from mai nshaft
(Fi g. 44).
(4) Remove thi rd gear beari ng spacer (Fi g. 45).
(5) Remove second gear thrust washer snap ri ng
from mai nshaft (Fi g. 45).
Fig. 43 THIRD GEAR, STOP RING, AND 3-4 HUB
1 - THIRD GEAR
2 - THIRD GEAR STOP RING
3 - 3-4 SYNCHRO HUB
1 - THIRD GEAR NEEDLE BEARING
Fig. 45 SNAP RING AND THIRD GEAR BEARING
SPACER
1 - SECOND GEAR THRUST WASHER
2 - THRUST WASHER SNAP RING
3 - THIRD GEAR BEARING SPACER
(6) Remove second gear thrust washer (Fi g. 46).
Note washer notch for l ocati ng pi n.
(7) Remove thrust washer l ocati ng pi n (Fi g. 47)
wi th needl e nose pl i ers.
(8) Remove second gear (Fi g. 48).
(9) Remove second gear beari ng (Fi g. 49).
Fig. 46 SECOND GEAR THRUST WASHER
1 - SECOND GEAR
2 - THRUST WASHER
Fig. 47 THRUST WASHER LOCATING PIN
1 - THRUST WASHER LOCATING PIN
Fig. 48 SECOND GEAR
1 - SECOND GEAR
1 - SECOND GEAR NEEDLE BEARING
(10) Remove second gear cl utch cone snap ri ng
from mai nshaft synchro hub groove (Fi g. 50).
(11) Remove second gear cl utch cone, synchro
cl utch ri ng and synchro stop ri ng (Fi g. 51).
(12) Remove 1-2 synchro hub snap ri ng (Fi g. 52).
(13) Remove 1-2 synchro sl eeve, hub, struts and
spri ngs as an assembl y (Fi g. 53).
NOTE: Tapered side of sleeve also goes toward
front. Do not disassemble synchro components
unless worn or damaged.
Fig. 50 SECOND GEAR CLUTCH CONE SNAP RING
1 - 1-2 SLEEVE
2 - SNAP RING
3 - SECOND GEAR CLUTCH CONE
Fig. 51 SECOND GEAR CLUTCH CONE AND RING
1 - 1-2 SLEEVE AND HUB
2 - SYNCHRO STOP RING
3 - CLUTCH RING
Fig. 52 1-2 SLEEVE AND HUB SNAP RING
1 - 1-2 HUB SNAP RING
Fig. 53 1-2 SYNCHRO SLEEVE AND HUB
(14) Remove fi rst gear synchro stop ri ng and
cl utch ri ng (Fi g. 54).
(15) Remove fi rst gear cl utch cone front snap ri ng
from mai nshaft hub (Fi g. 55).
(16) Remove fi rst gear cl utch cone (Fi g. 56).
(17) Remove fi rst gear cl utch gear rear snap ri ng
from mai nshaft hub (Fi g. 56).
NOTE: Do not remove this snap ring unless main-
shaft is being replaced.
Fig. 54 FIRST GEAR STOP AND CLUTCH RING
1 - FIRST GEAR CLUTCH RING
2 - FIRST GEAR STOP RING
Fig. 55 FIRST GEAR CLUTCH GEAR FRONT SNAP
RING
1 - FIRST SPEED CLUTCH GEAR
2 - CLUTCH GEAR SNAP RING (FRONT)
Fig. 56 FIRST GEAR CLUTCH GEAR
1 - CLUTCH GEAR SNAP RING (REAR)
2 - FIRST SPEED CLUTCH GEAR
(18) Remove mai nshaft rear beari ng, wi th Pul l er
Fl ange 6444-1 and Pul l er Rods 6444-3 for 4X2 or
6444-4 for 4X4.
(19) Posi ti on the fi rst Jaw 6445 on the beari ng
cone and seat Pul l er Fl ange 6444-1 i n notch of jaw
(Fi g. 57).
(20) I nstal l second Jaw 6445 on the beari ng cone
and pul l er fl ange. Sl i de Col l ar 6444-8 over jaws to
hol d them i n pl ace.
(21) I nstal l Pul l er 6444 on the pul l er rods and
secure wi th nuts (Fi g. 58). Ti ghten pul l er bol t to the
remove beari ng.
Fig. 57 MAINSHAFT REAR BEARING PULLER
1 - REAR BEARING
2 - FLANGE
3 - JAW
4 - COLLAR
5 - MAINSHAFT
6 - PULLER
7 - RODS
8 - JAW
(22) Remove beari ng pul l er tool s and rear mai n-
shaft beari ng from output shaft.
(23) Remove reverse gear thrust washer (Fi g. 59).
(24) Remove reverse gear and synchro components
as assembl y (Fi g. 60).
CAUTION: Do not disassemble synchro compo-
nents unless they are damaged. If synchro sleeve
or struts require service, mark position of sleeve on
hub before removal. Correct sleeve position is
important as sleeve can be installed backwards
causing shift problems.
(25) Remove reverse gear beari ng assembl y from
mai nshaft (Fi g. 60).
(26) Remove reverse gear beari ng spacer from
mai nshaft (Fi g. 61).
(27) Remove reverse cl utch gear snap ri ng (Fi g.
61). Heavy duty snap ri ng pl i ers wi l l be requi red to
spread the ri ng far enough to remove i t.
Fig. 58 MAINSHAFT REAR BEARING
1 - JAWS
2 - COLLAR
3 - FLANGE
4 - MAINSHAFT
5 - PULLER
6 - TIGHTENING WRENCH
7 - HOLDING WRENCH
8 - RODS
Fig. 59 REVERSE GEAR THRUST WASHER
1 - REVERSE GEAR
2 - THRUST WASHER
Fig. 60 REVERSE GEAR, BEARING, AND STOP
RING
1 - FIRST GEAR
2 - REVERSE GEAR ASSEMBLY
3 - BEARING ASSEMBLY
4 - STOP RING
Fig. 61 REVERSE GEAR BEARING SPACER AND
FIRST GEAR SNAP RING
1 - CLUTCH GEAR SNAP RING
2 - REVERSE GEAR BEARING SPACER
(28) Remove reverse cl utch gear (Fi g. 62).
(29) Remove fi rst gear from beari ng and mai nshaft
(Fi g. 63).
(30) Remove fi rst gear beari ng from mai nshaft
(Fi g. 64).
CLEANING
Cl ean the gears, shafts, shi ft components and
transmi ssi on housi ngs wi th a standard parts cl ean-
i ng sol vent. Do not use aci d or corrosi ve base sol -
vents. Dry al l parts except beari ngs wi th compressed
ai r.
Cl ean the shaft beari ngs wi th a mi l d sol vent such
as Mopar degreasi ng sol vent, Gunk or si mi l ar sol -
vents. Do not dry the beari ngs wi th compressed ai r.
Al l ow the beari ngs to ei ther ai r dry or wi pe them dry
wi th cl ean shop towel s.
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be
smoothed with 400 grit emery and polished out with
crocus cloth.
I nspect the reverse i dl er gear, beari ngs, shaft and
thrust washers. Repl ace the beari ngs i f the rol l ers
are worn, chi pped, cracked, fl at-spotted or bri nnel l ed.
Repl ace the gear i f the teeth are chi pped, cracked or
worn thi n.
I nspect the front beari ng retai ner and beari ng cup.
Repl ace the beari ng cup i f scored, cracked, bri nnel l ed
or rough. Check the rel ease beari ng sl i de surface of
the retai ner careful l y. Repl ace the retai ner i f worn or
damaged i n any way.
I nspect mai nshaft beari ng surfaces, spl i nes, snap
ri ng grooves and threads. Repl ace the shaft i f any
surfaces exhi bi t consi derabl e wear or damage.
I nspect the countershaft and beari ngs. Repl ace the
shaft i f any surfaces exhi bi t consi derabl e wear or
damage.
I nspect shi ft forks for wear and di storti on. Check
fi t of the sl eeve i n the fork to be sure the two parts
fi t and work smoothl y. Repl ace the fork i f the rol l pi n
hol es are worn oversi ze or damaged. Do not attempt
to sal vage a worn fork. Repl ace shi ft fork rol l pi ns i f
necessary or i f doubt exi sts about thei r condi ti on.
The al l beari ngs for wear, roughness, fl at spots,
pi tti ng or other damage. Repl ace the beari ngs i f nec-
essary.
I nspect the bl ocker ri ngs and fi cti on cones. repl ace
ei ther part i f worn or damaged i n any way. Repl ace i f
the fri cti on materi al i s burned, fl aki ng off or worn.
I nspect synchro components wear or damage.
Repl ace parts i f worn, cracked or di storted.
I nspect al l of the thrust washers and l ocati ng pi ns.
Repl ace the pi ns i f bent or worn. Repl ace the wash-
ers i f worn or the l ocati ng pi n notches are di storted.
I nspect the case and housi ng/adapter seal i ng and
mati ng surfaces are free of burrs and ni cks. I nspcet
Fig. 62 Reverse Clutch Gear
1 - REVERSE CLUTCH GEAR
Fig. 63 FIRST GEAR
1 - FIRST GEAR
Fig. 64 FIRST GEAR BEARING
1 - MAINSHAFT
the al i gnment dowel s i n the case top surface and i n
the housi ng/adapter are ti ght and i n good condi ti on.
Repl ace the gear case or housi ng/adapter i f cracked
or broken.
ASSEMBLY
NOTE: Gaskets are not used in the transmission.
Use Mopar Silicone Sealer or equivalent on all gear
case and extension housing sealing surfaces.
COUNTERSHAFT AND REVERSE IDLER GEAR
(1) I nstal l countershaft front beari ng cup i n case
wi th Handl e C-4171 and I nstal l er 6061-1.
(2) I nstal l front beari ng on countershaft wi th
I nstal l er C-4340 (Fi g. 65).
(3) Lubri cate countershaft front beari ng cup and
cone wi th petrol eum jel l y.
(4) Posi ti on gear case on end wi th rear of case fac-
i ng up (Fi g. 66).
(5) I nstal l countershaft i n gear case (Fi g. 66).
NOTE: Do not install rear countershaft bearing on
countershaft at this time.
(6) Lubri cate reverse i dl er gear beari ngs wi th
petrol eum jel l y and i nstal l fi rst beari ng and second
beari ng (Fi g. 67).
(7) I nstal l i dl er gear front thrust washer on boss
i n gear case (Fi g. 67). Coat thrust washer wi th l i b-
eral quanti ty of petrol eum jel l y to hol d i t i n pl ace.
Fig. 65 COUNTERSHAFT FRONT BEARING
1 - FRONT BEARING
2 - INSTALLER
3 - COUNTERSHAFT
Fig. 66 COUNTERSHAFT IN GEAR CASE
1 - GEAR CASE
2 - COUNTERSHAFT
Fig. 67 IDLER GEAR FRONT THRUST WASHER
1 - IDLER GEAR FRONT THRUST WASHER ON BOSS
(8) I nstal l reverse i dl er gear i n case (Fi g. 68).
(9) I nstal l i dl er gear rear thrust washer between
i dl er gear and case boss (Fi g. 68).
(10) Al i gn i dl er gear beari ngs and thrust washers
wi th a dri ft.
(11) I nstal l reverse i dl er shaft wi th notched end of
shaft faci ng countershaft (Fi g. 69).
(12) Li ft countershaft upward and posi ti on wood
bl ock between front of shaft and case (Fi g. 70).
(13) I nstal l rear beari ng cone on countershaft wi th
I nstal l er C-4040 (Fi g. 71).
Fig. 68 IDLER GEAR
1 - REAR THRUST WASHER
3 - FRONT THRUST WASHER
Fig. 69 REVERSE IDLER SHAFT
1 - COUNTERSHAFT
2 - SHAFT NOTCH
3 - REVERSE IDLER SHAFT
Fig. 70 SUPPORTING COUNTERSHAFT
1 - COUNTERSHAFT
2 - WOOD BLOCK
1 - INSTALLER
2 - REAR BEARING
3 - COUNTERSHAFT
(14) Remove wood bl ock from under countershaft
and l ower countershaft front beari ng i nto front bear-
i ng cup.
(15) Lubri cate countershaft rear beari ng cup and
cone wi th petrol eum jel l y.
(16) I nstal l countershaft rear beari ng cup i n gear
case and over rear beari ng (Fi g. 72). Tap cup i nto
pl ace wi th pl asti c mal l et i f necessary.
(17) I nstal l countershaft rear beari ng pl ate (Fi g.
73).
NOTE: Verify plate is seated in notch in reverse
idler shaft before tightening bearing plate bolts.
(18) Appl y Mopar si l i cone adhesi ve/seal er or equi v-
al ent to fl ange and l i p of new cap. I nstal l new front
beari ng cap i n gear case (Fi g. 74) wi th Handl e
C-4171 and I nstal l er C-3972-A.
COUNTERSHAFT END PLAY
(1) Rotate countershaft 4-5 ti mes to seat beari ngs.
(2) Mount di al i ndi cator on case. Then posi ti on
i ndi cator pl unger on end of countershaft and zero
di al i ndi cator (Fi g. 75).
(3) Rai se countershaft wi th screwdri ver and note
end pl ay readi ng on di al i ndi cator. End pl ay shoul d
be 0.051 - 0.15 mm (0.002 - 0.006 i n.).
Fig. 72 COUNTERSHAFT REAR BEARING CUP
1 - COUNTERSHAFT REAR BEARING CUP
Fig. 73 COUNTERSHAFT REAR BEARING PLATE
1 - COUNTERSHAFT
2 - REAR BEARING PLATE
3 - IDLER SHAFT
Fig. 74 COUNTERSHAFT FRONT BEARING CAP
1 - FRONT BEARING CAP
Fig. 75 MEASURING COUNTERSHAFT END PLAY
1 - DIAL INDICATOR
2 - COUNTER SHAFT
3 - INDICATOR MOUNTING ARM AND BASE
(4) Remove countershaft rear beari ng pl ate.
(5) I nstal l a end pl ay shi m that wi l l provi de mi ni -
mum countershaft end pl ay. Posi ti on shi m on rear
beari ng cup (Fi g. 76).
(6) I nstal l countershaft rear beari ng pl ate (Fi g.
73).
NOTE: Verify plate is seated in reverse idler shaft
notch and end play shims are still in position
before installing bolts.
(7) Appl y 1-2 drops Mopar Loc N Seal or equi va-
l ent to threads of rear beari ng pl ate bol ts. Then
i nstal l and ti ghten beari ng pl ate bol ts to 23 Nm (200
i n. l bs.).
SHIFT LUG AND RAIL
(1) Lubri cate shi ft l ug and rai l wi th Castrol Syn-
torq or equi val ent.
(2) I nsert shi ft l ug rai l part way i nto case.
(3) I nstal l shi ft l ug on rai l .
(4) Posi ti on shi ft rai l so rol l pi n notches are
toward outsi de of case (Fi g. 77).
(5) I nstal l rol l pi n that secures l ug to rai l (Fi g. 77).
MAINSHAFT AND GEARTRAIN
CAUTION: The reverse, 1-2 and 3-4 synchro compo-
nents can be assembled and installed incorrectly.
Follow assembly procedures for component identi-
fication and location.
Lubri cate mai nshaft beari ng surfaces and al l bear-
i ng assembl i es wi th Castrol Syntorq or wi th petro-
l eum jel l y.
(1) I nstal l fi rst snap ri ng i n rear most groove of
mai nshaft hub (Fi g. 78). Thi s snap ri ng l ocates fi rst
gear cl utch gear on shaft.
NOTE: Four of these snap rings are used to secure
various components on the mainshaft 1-2 synchro
hub. The snap rings are all the same size and are
interchangeable.
Fig. 76 COUNTERSHAFT END PLAY SHIM
1 - REAR BEARING CUP
2 - END PLAY SHIM (SELECTIVE)
Fig. 77 SHIFT LUG AND RAIL
1 - NOTCHES (FOR 5TH GEAR SHIFT FORK ROLL PINS)
2 - LUG RAIL
3 - ROLL PIN HOLE
4 - SHIFT LUG
Fig. 78 FIRST GEAR BEARING AND SNAP RING
1 - SNAP RING
3 - MAINSHAFT SYNCHRO HUB
(2) I nstal l fi rst gear cl utch cone on mai nshaft 1-2
synchro hub wi th recessed si de of cone faci ng front
(Fi g. 79). Veri fy cone i s seated agai nst snap ri ng on
hub.
(3) I nstal l snap ri ng on mai nshaft 1-2 synchro hub
to secure cl utch cone (Fi g. 80). Veri fy snap ri ng i s
seated i n hub groove and agai nst cl utch cone.
(4) Support mai nshaft i n upri ght posi ti on to i nstal l
remai ni ng gears, snap ri ngs and synchro compo-
nents. Shaft can be supported i n gear case or hol e
can be cut i n workbench to support shaft.
(5) I f 1-2 synchro hub and sl eeve were di sassem-
bl ed for servi ce, reassembl e hub, sl eeve, struts and
spri ngs as fol l ows:
(a) Al i gn and i nstal l sl eeve on hub. Rotate sl eeve
unti l i t sl i des onto hub. Sl eeve onl y fi ts one way
and wi l l easi l y sl i de onto hub when l ong sl ot i n
sl eeve, al i gns wi th l ong shoul der on hub (Fi g. 81).
(b) Pl ace wood bl ocks under hub that wi l l rai se hub
about 3.5 cm (1.375 i n.) above surface of workbench.
Then al l ow sl eeve to drop down on hub (Fi g. 82).
(c) I nstal l spri ngs and struts i n hub (Fi g. 82). Use
l ots of petrol eum jel l y to hol d them i n pl ace. Then
compress struts wi th your fi ngers and move sl eeve
upward unti l struts are started i n sl eeve. Veri fy that
struts are engaged i n sl eeve before proceedi ng.
(d) Turn synchro assembl y upri ght. Then move
sl eeve i nto neutral posi ti on on hub and work struts
i nto sl eeve at same ti me. Be sure struts are seated
and spri ngs are not di spl aced duri ng assembl y.
Fig. 79 FIRST GEAR CLUTCH CONE
1 - MAINSHAFT 1-2 SYNCHRO HUB
2 - FIRST GEAR CLUTCH CONE
Fig. 80 FIRST GEAR CLUTCH CONE SNAP RING
1 - FIRST GEAR CLUTCH CONE
2 - MAINSHAFT 1-2 SYNCHRO HUB
3 - CLUTCH CONE SNAP RING
Fig. 81 1-2 SYNCHRO SLEEVE ON HUB
1 - ALIGN WIDE SLOT IN SLEEVE WITH WIDE SPLINE OF HUB
Fig. 82 1-2 SYNCHRO STRUTS AND SPRINGS
1 - WOOD BLOCKS
2 - HUB
3 - SLEEVE
4 - STRUTS AND SPRINGS (4 EACH)
(6) I nstal l fi rst gear stop ri ng i n 1-2 synchro hub
and sl eeve (Fi g. 83). Veri fy stop ri ng i s seated and
engaged i n hub and sl eeve.
(7) I nstal l 1-2 synchro assembl y and stop ri ng on
mai nshaft wi th the taper on the sl eeve faci ng for-
ward. (Fi g. 84).
(8) I nstal l snap ri ng that secures 1-2 synchro on
mai nshaft hub (Fi g. 85). Veri fy snap ri ng i s seated i n
groove i n mai nshaft hub.
(9) Assembl e second gear cl utch cone, cl utch ri ng
and stop ri ng (Fi g. 86).
Fig. 83 FIRST GEAR STOP RING IN SYNCHRO HUB
Fig. 84 1-2 SYNCHRO
1 - MAINSHAFT HUB
3 - TAPERED SIDE OF SLEEVE
Fig. 85 1-2 SYNCHRO SNAP RING
1 - SYNCHRO SNAP RING
3 - MAINSHAFT HUB
Fig. 86 SECOND GEAR CLUTCH CONE, CLUTCH
RING AND STOP RING
1 - STOP RING
2 - CLUTCH RING
3 - CLUTCH CONE
(10) I nstal l assembl ed second gear cl utch cone and
ri ngs on mai nshaft and i n 1-2 synchro hub (Fi g. 87).
(11) I nstal l snap ri ng that secures second gear
cl utch cone on mai nshaft (Fi g. 88). Use narrow bl ade
screwdri ver to work snap ri ng i nto hub groove as
shown. Veri fy snap ri ng i s seated i n mai nshaft
groove.
NOTE: If snap ring will not fit in groove, clutch cone
is slightly misaligned.
(12) I nstal l second gear beari ng on mai nshaft (Fi g.
89).
(13) I nstal l second gear on mai nshaft and beari ng.
Rotate gear unti l tabs of second gear cl utch ri ng are
seated i n tab sl ots i n gear (Fi g. 90).
Fig. 87 SECOND GEAR CLUTCH CONE, CLUTCH
RING AND STOP RING
1 - CLUTCH CONE
2 - STOP RING
3 - CLUTCH RING
Fig. 88 SECOND GEAR CLUTCH CONE SNAP RING
1 - SCREWDRIVER
2 - MAINSHAFT HUB
3 - SNAP RING
Fig. 90 SECOND GEAR
1 - SECOND GEAR
2 - CLUTCH RING TABS
3 - TAB SLOTS (IN GEAR)
(14) I nstal l thrust washer pi n i n shaft (Fi g. 91).
(15) I nstal l second gear thrust washer. Veri fy
washer i s seated on gear and pi n (Fi g. 92).
(16) I nstal l second gear thrust washer snap ri ng
(Fi g. 93). Veri fy snap ri ng i s seated i n mai nshaft
groove.
(17) I nstal l thi rd gear beari ng spacer on shaft and
seat i t agai nst thrust washer snap ri ng (Fi g. 93).
(18) I nstal l thi rd gear beari ng on mai nshaft (Fi g.
94). Beari ng shoul d be fl ush wi th mai nshaft hub.
NOTE: If bearing is not flush with hub, the bearing
spacer or snap ring was not installed.
(19) I nstal l thi rd gear over beari ng and onto mai n-
shaft (Fi g. 95).
Fig. 91 THRUST WASHER PIN
2 - SECOND GEAR
Fig. 92 SECOND GEAR THRUST WASHER
1 - SECOND GEAR
3 - LOCATING PIN IN WASHER NOTCH
Fig. 93 SNAP RING AND THIRD
2 - THRUST WASHER SNAP RING
3 - THIRD GEAR BEARING SPACER
1 - THIRD GEAR BEARING
Fig. 95 THIRD GEAR
1 - THIRD GEAR
(20) I nstal l synchro stop ri ng on thi rd gear (Fi g.
96). Veri fy stop ri ng i s seated on cone taper.
(21) I f 3-4 synchro was di sassembl ed for servi ce,
reassembl e synchro components as fol l ows:
(a) Al i gn and i nstal l synchro sl eeve on hub (Fi g.
97). Front side of hub has a narrow groove
machined in it.
(b) I nsert al l three synchro struts i n sl ots
machi ned i n sl eeve and hub (Fi g. 97).
(c) I nstal l and seat synchro spri ngs (Fi g. 97).
Use screwdri ver to compress spri ngs and seat them
i n struts and hub as shown.
(22) Start 3-4 synchro assembl y on mai nshaft wi th
the hub groove and sl eeve groove both faci ng for-
ward. Tap assembl y onto shaft spl i nes unti l hub i s
about 3 mm (0.125 i n.) away from thi rd gear stop
ri ng. Then al i gn stop ri ng wi th synchro sl eeve and
hub and seat synchro assembl y wi th I nstal l er C-4040
(Fi g. 98).
(23) Veri fy 3-4 synchro hub i s seated on shaft wi th
approxi matel y 3 mm (0.125 i n.) of shaft spl i ne vi si -
bl e.
NOTE: If hub is not seated, stop ring lugs are mis-
aligned. Rotate ring until lugs are engaged in 3-4
hub slots.
(24) Veri fy that second and thi rd gear rotate freel y
at thi s poi nt. I f not, determi ne the cause and correct.
(25) I nvert mai nshaft i n case or bench.
(26) I nstal l fi rst gear beari ng on mai nshaft.
(27) I nstal l fi rst gear on shaft wi th cl utch hub si de
of gear faci ng the front of shaft (Fi g. 99). Veri fy tabs
on cl utch ri ng are al i gned and seated i n fi rst gear
hub.
NOTE: 1-2 synchro hub will not seat properly if
clutch ring tabs are misaligned.
Fig. 96 THIRD GEAR STOP RING
1 - SYNCHRO STOP RING
2 - THIRD GEAR
Fig. 97 SYNCHRO ASSEMBLY (3-4)
1 - STRUT (3)
2 - SPRING (3)
3 - 3-4 SLEEVE
4 - 3-4 HUB
Fig. 98 SEATING 3-4 SYNCHRO ASSEMBLY ON
MAINSHAFT
1 - 3-4 SYNCHRO HUB
2 - HUB GROOVE
3 - INSTALLER C-4040
(28) I nstal l reverse cl utch gear on fi rst gear (Fi g.
99). Veri fy cl utch gear i s seated on shaft spl i nes.
(29) I nstal l reverse cl utch gear snap ri ng wi th
heavy duty snap ri ng pl i ers (Fi g. 99). Veri fy snap
ri ng i s seated i n groove.
NOTE: Reverse gear will not fit properly if snap ring
is not seated.
(30) I nstal l stop ri ng on cl utch cone (Fi g. 100). Ver-
i fy stop ri ng i s seated on cone taper.
(31) I nstal l reverse gear beari ng spacer on mai n-
shaft and seat agai nst reverse cl utch gear snap ri ng
(Fi g. 101).
(32) I nstal l reverse gear beari ng on mai nshaft
(Fi g. 101).
(33) I f reverse gear sl eeve and struts were di sas-
sembl ed for servi ce, reassembl e sl eeve, struts and
spri ngs as fol l ows:
CAUTION: The reverse sleeve will fit either way on
the hub. Verify tapered side of the sleeve faces
rearward.
(a) Posi ti on sl eeve on hub so tapered si de of
sl eeve faces rearward. (Fi g. 102).
(b) Rotate sl eeve to al i gn teeth on sl eeve and
hub. Sl eeve wi l l sl i de easi l y i nto pl ace on hub when
properl y al i gned.
(c) I nstal l spri ngs i n gear hub (Fi g. 102). Use
petrol eum jel l y to hol d spri ngs i n pl ace i f desi red.
Fig. 102 REVERSE GEAR SYNCHRO ASSEMBLY
1 - REVERSE GEAR
2 - SLEEVE
3 - SPRING (3)
4 - STRUT (3)
5 - HUB
Fig. 99 FIRST GEAR AND CLUTCH GEAR
1 - FIRST GEAR
2 - REVERSE CLUTCH GEAR SNAP RING
3 - REVERSE CLUTCH GEAR
Fig. 100 CLUTCH GEAR STOP RING
1 - REVERSE GEAR STOP RING
2 - CLUTCH GEAR
3 - FIRST GEAR
Fig. 101 REVERSE GEAR BEARING AND SPACER
1 - REVERSE GEAR BEARING
2 - BEARING SPACER
3 - FIRST GEAR
(d) Compress fi rst spri ng wi th fl at bl ade screw-
dri ver and sl i de strut i nto posi ti on i n hub sl ot.
Then work spri ng i nto seat i n strut wi th smal l
hooked tool or screwdri ver.
(e) I nstal l second and thi rd struts i n same man-
ner as descri bed i n step (d).
(f) Work sl eeve upward on hub unti l struts are
centered and seated i n sl eeve. Sl eeve shoul d be i n
neutral posi ti on after seati ng struts.
(34) I nstal l reverse gear and synchro assembl y on
mai nshaft (Fi g. 103). Rotate assembl y unti l stop ri ng
l ugs engage i n hub sl ots and gear drops i nto seated
posi ti on.
(35) I nstal l reverse gear thrust washer (Fi g. 104).
(36) I nstal l rear beari ng on mai nshaft wi th
I nstal l er 6446. Seat beari ng on output shaft and
agai nst thrust washer (Fi g. 105).
(37) I nstal l fourth gear stop ri ng i n 3-4 synchro
sl eeve (Fi g. 106).
(38) I nstal l fourth gear cl utch gear i n stop ri ng
(Fi g. 107).
Fig. 103 REVERSE GEAR
1 - REVERSE GEAR AND SYNCHRO ASSEMBLY
Fig. 104 REVERSE GEAR THRUST WASHER
1 - THRUST WASHER
2 - REVERSE GEAR
Fig. 105 MAINSHAFT REAR BEARING
1 - INSTALLER
2 - MAINSHAFT REAR BEARING
Fig. 106 FOURTH GEAR STOP RING
2 - FOURTH SPEED STOP RING
Fig. 107 FOURTH GEAR CLUTCH GEAR
(39) Rol l gear case onto i ts l eft si de.
(40) Gri p mai nshaft at pi l ot beari ng hub and just
behi nd reverse gear. Then l i ft assembl y and gui de
rear of shaft through beari ng bore at rear of case.
(41) Conti nue hol di ng front of shaft but swi tch
gri p at rear to shaft output spl i nes. Li ft mai nshaft
assembl y sl i ghtl y, al i gn gears and seat assembl y i n
case.
(42) Set transmi ssi on case upri ght (Fi g. 108).
(43) I nstal l dri ve gear thrust beari ng on mai nshaft
(Fi g. 109). Use pl enty of petrol eum jel l y to hol d bear-
i ng i n pl ace.
(44) Check al i gnment and mesh of mai nshaft
gears. I f gears are not al i gned, rol l case on si de and
real i gn shaft and gears i n case.
DRIVE GEAR AND RETAINER
(1) I nstal l beari ng on dri ve gear wi th I nstal l er
6448 (Fi g. 110).
(2) Lubri cate pi l ot beari ng wi th petrol eum jel l y
and i nstal l i t i n dri ve gear bore.
(3) I nstal l dri ve gear on mai nshaft. Work gear
rearward unti l mai nshaft hub i s seated i n pi l ot bear-
i ng.
(4) I nstal l beari ng cup i n front retai ner wi th Han-
dl e C-4171 and I nstal l er C-4308 (Fi g. 111).
Fig. 108 MAINSHAFT AND GEARTRAIN IN CASE
1 - MAINSHAFT AND GEARTRAIN
Fig. 109 DRIVE GEAR THRUST BEARING
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 110 FRONT BEARING ON DRIVE GEAR
1 - INSTALLER
2 - BEARING
3 - DRIVE GEAR
Fig. 111 FRONT BEARING CUP IN RETAINER
1 - INSTALLER
2 - HANDLE
3 - WOOD BLOCKS
4 - RETAINER
(5) I nstal l new oi l seal i n front beari ng retai ner
wi th I nstal l er 6052 (Fi g. 112). Use one or two wood
bl ocks to support retai ner as shown. Lubri cate seal
l i p wi th petrol eum jel l y after i nstal l ati on.
(6) Cl ean contact surfaces of gear case and front
beari ng retai ner wi th a wax and grease remover.
(7) Appl y Mopar Si l i cone Seal er or equi val ent to
fl ange surface of front beari ng retai ner (Fi g. 113).
(8) I nstal l front beari ng retai ner over dri ve gear
and start i t i nto case.
(9) Start front beari ng retai ner i n gear case. Veri fy
retai ner l ube channel i s at the top-center (12
Oclock) posi ti on (Fi g. 113).
(10) Al i gn front beari ng retai ner bol t hol es and tap
retai ner i nto pl ace wi th pl asti c mal l et. I nstal l new
retai ner bol ts and ti ghten to 30 Nm (22 ft. l bs.) (Fi g.
114).
NOTE: Never reuse the old bolts.
MAINSHAFT END PLAY
(1) I nstal l mai nshaft rear beari ng cup i n case and
over beari ng. Tap beari ng cup i nto pl ace wi th pl asti c
mal l et.
(2) I nstal l rear beari ng pl ate to hol d mai nshaft
and rear beari ng i n posi ti on (Fi g. 115).
NOTE: Do not install any end play shims at this
time.
(3) Ti ghten rear beari ng pl ate bol ts securel y.
(4) Pl ace gear case i n upri ght posi ti on on bench.
Ei ther cut hol e i n bench to accept dri ve gear and
front retai ner or use C-cl amps to secure transmi ssi on
on bench.
NOTE: Do not leave transmission unsupported.
(5) I nstal l Extensi on Rod 8161 i nto a sui tabl e
threaded hol e i n rear of case.
(6) Mount di al i ndi cator on extensi on rod and posi -
ti on i ndi cator pl unger agai nst end of mai nshaft.
(7) Move mai nshaft forward to remove al l pl ay
then zero di al i ndi cator.
(8) Move mai nshaft upward and record di al i ndi ca-
tor readi ng. Move mai nshaft wi th pry tool posi ti oned
between dri ve gear and case.
(9) End pl ay shoul d be 0.051-0.15 mm (0.002-0.006
i n.). Sel ect fi t shi ms are avai l abl e to adjust end pl ay.
I f end pl ay adjustment i s requi red, remove beari ng
pl ate and i nstal l necessary shi m.
(10) Rei nstal l rear beari ng pl ate wi th oi l hol e i n
beari ng pl ate at the top (Fi g. 115).
(11) Appl y Mopar Lock N Seal or equi val ent to
beari ng pl ate bol t threads. I nstal l and ti ghten bol ts
to 23 Nm (200 i n. l bs.).
Fig. 112 BEARING RETAINER OIL SEAL
1 - INSTALLER
2 - RETAINER
3 - WOOD BLOCK
Fig. 113 LOCATION OF FRONT RETAINER LUBE
CHANNEL
1 - LUBE CHANNEL
2 - FRONT RETAINER
3 - APPLY GASKET MAKER HERE
Fig. 114 FRONT BEARING RETAINER
1 - DRIVE GEAR
(12) I nstal l mai nshaft fi fth gear wi th I nstal l er
6446 (Fi g. 116). Gear i s seated when i t contacts rear
beari ng.
COUNTERSHAFT FIFTH GEAR SYNCHRO
(1) I nstal l thrust washer pi n i n countershaft (Fi g.
117).
(2) I nstal l thrust washer on countershaft. Turn
washer unti l pi n engages i n washer notch (Fi g. 118).
NOTE: The flat side of washer faces the rear and
cone side faces the front.
(3) Lubri cate and i nstal l fi fth gear beari ng on
countershaft (Fi g. 119).
Fig. 115 REAR BEARING PLATE
1 - BEARING PLATE OIL HOLE (AT TOP)
2 - MAINSHAFT REAR BEARING PLATE
Fig. 116 MAINSHAFT FIFTH GEAR
1 - MAINSHAFT FIFTH GEAR
2 - INSTALLER
Fig. 117 FIFTH GEAR THRUST WASHER PIN
2 - COUNTERSHAFT
Fig. 118 FIFTH GEAR THRUST WASHER
1 - PIN
2 - THRUST WASHER
Fig. 119 COUNTERSHAFT FIFTH GEAR BEARING
1 - COUNTERSHAFT
2 - FIFTH GEAR NEEDLE BEARING
(4) I nstal l synchro sl eeve on hub of countershaft
fi fth gear wi th tapered si de of sl eeve faci ng front and
the fl at si de faci ng rear (Fi g. 120).
(5) I nstal l shi ft fork i n synchro sl eeve (Fi g. 121).
(6) I nstal l assembl ed fi fth gear, synchro sl eeve and
shi ft fork (Fi g. 122). Al i gn fork wi th shi ft l ug rai l and
al i gn gear wi th beari ngs and countershaft. Start
components onto shaft and rai l , then tap gear and
fork i nto pl ace wi th pl asti c or rawhi de mal l et.
(7) I nstal l fi fth gear synchro struts and spri ngs
(Fi g. 123).
Fig. 120 SYNCHRO SLEEVE ON COUNTERSHAFT
FIFTH
1 - GEAR HUB
2 - SYNCHRO SLEEVE
3 - COUNTERSHAFT FIFTH GEAR
Fig. 121 FIFTH GEAR SHIFT FORK IN SYNCHRO
SLEEVE
1 - SYNCHRO SLEEVE
2 - SHIFT FORK
Fig. 122 COUNTERSHAFT FIFTH GEAR, SHIFT
FORK AND SYNCHRO SLEEVE
1 - SHIFT FORK AND SLEEVE
2 - FIFTH GEAR HUB
3 - SHIFT FORK ROLL PINS
Fig. 123 FIFTH GEAR SYNCHRO STRUTS AND
SPRINGS
1 - FIFTH GEAR HUB
2 - SYNCHRO SPRING (3)
3 - SYNCHRO STRUT (3)
(8) Assembl e and i nstal l fi fth synchro cl utch gear
and stop ri ng i n fi fth gear hub (Fi g. 124). Veri fy
parts are seated i n fi fth gear hub.
(9) I nstal l cl utch gear snap ri ng (Fi g. 125).
(10) Al i gn rol l pi n hol es i n shi ft fork wi th notches
i n shi ft l ug rai l . Then i nstal l rol l pi ns from top si de
of fork (Fi g. 122).
NOTE: Roll pins only fit one way due to small
shoulder at one end of each pin.
FIFTH GEAR NUT
(1) I nstal l bel l evi l l e washer onto the mai nshaft.
(2) I nstal l fi fth gear nut over the mai nshaft.
(3) Ti ghten the cl amp bol t unti l the gap i n the
cl amp nut assembl y i s cl osed.
(4) Back the cl amp bol t off one ful l turn.
(5) Pl ace 10-15 drops of Locti te 272 onto the mai n-
shaft threads where the fi fth gear nut wi l l be
engaged.
(6) I nstal l fi fth gear nut on mai nshaft (Fi g. 126).
(7) Hol d mai nshaft Socket 6993 4X2 or Socket
6984 4X4 whi l e i nstal l i ng the fi fth gear nut.
(8) Ti ghten fi fth gear nut as much as possi bl e wi th
Wrench 6743, l ong handl e ratchet, breaker bar and
appl i cabl e socket wrench (Fi g. 127).
(9) Lock mai nshaft gears by shi fti ng al l synchro
sl eeves i nto engaged posi ti on.
Fig. 124 FIFTH SYNCHRO CLUTCH GEAR AND
STOP RING
1 - STOP RING
2 - CLUTCH GEAR
Fig. 125 FIFTH SYNCHRO CLUTCH SNAP RING
1 - CLUTCH GEAR RING
2 - FIFTH SYNCHRO CLUTCH GEAR
1 - FIFTH GEAR
2 - FIFTH GEAR NUT
1 - WRENCH
2 - FIFTH GEAR NUT
3 - SOCKET
(10) Ti ghten fi fth gear nut wi th Nut Wrench 6743
and hi gh capaci ty torque wrench. Ti ghten nut to 366-
380 Nm (270-280 ft. l bs.). Have hel per hol d trans-
mi ssi on steady i f necessary.
(11) Torque the fi fth gear cl amp nut cl ampi ng bol t
to 13.5 Nm (10 ft. l bs.).
(12) Unl ock the mai nshaft gears by shi fti ng al l
synchro sl eeves out of the engaged posi ti on.
(1) Cl ean mati ng surfaces of extensi on/adapter
housi ng and gear case wi th a wax and grease
remover.
(2) Check al i gnment dowel s i n gear case and hous-
i ng or adapter. Be sure dowel s are i n posi ti on and
seated.
(3) Appl y Mopar Si l i cone Seal er or equi val ent to
gear case and housi ng mati ng surfaces.
(4) Al i gn and i nstal l extensi on/adapter housi ng on
gear case (Fi g. 128).
threads of extensi on/adapter housi ng bol ts.
(6) I nstal l and ti ghten housi ng bol ts to 54 Nm (40
ft. l bs.).
SHIFT MECHANISM
(1) Cl ean mati ng surfaces of shi ft cover and gear
case wi th wax and grease remover.
(2) Appl y a smal l amount of Mopar si l i cone seal er
or equi val ent to seal i ng surface of shi ft cover.
CAUTION: Do not over-apply an excesive amount
sealer. Excess can squeezed into gear case and
could block lubricant feed holes in time.
(3) Lubri cate synchro sl eeves wi th Castrol Syn-
torq gear l ubri cant or equi val ent. Then appl y l i ght
coat of petrol eum jel l y to shi ft fork contact surfaces.
(4) Veri fy shi ft fork pads (Fi g. 129) are secure.
(5) Veri fy 1-2 and 3-4 synchro sl eeves and forks i n
shi ft cover are i n neutral posi ti on.
(6) Al i gn and seat shi ft cover on transmi ssi on.
NOTE: If cover will not seat, it may not be aligned
on gear case dowels or shift forks are not aligned
with sleeves and shift lug.
threads of shi ft cover bol ts.
(8) I nstal l shi ft cover bol ts and ti ghten to 27-31
Nm (216-276 i n. l bs.).
(9) Appl y seal er to backup l amp swi tch. I nstal l
swi tch i nto cover and ti ghten to 22-34 Nm (193-265
i n. l bs.).
(10) I nstal l vent assembl y i f removed. Appl y an
adhesi ve/seal er to vent tube to hel p secure i t i n cover.
Fig. 128 INSTALLING EXTENSION/ADAPTER
HOUSING
1 - GEAR CASE
Fig. 129 SHIFT FORK PAD
1 - SHIFT FORK PADS
INSTALLATION
NOTE: If a new transmission is being installed, use all
components supplied with the new transmission. For
example, if a new shift tower is supplied with the new
transmission, do not re-use the original shift tower.
beari ng grease or equi val ent to contact surfaces of
rel ease beari ng sl i de surface of front retai ner.
rel ease fork.
(2) Appl y seal er to threads of bottom PTO cover
bol t and i nstal l bol t i n case.
(3) Mount transmi ssi on on jack and posi ti on trans-
mi ssi on under vehi cl e.
(4) Rai se transmi ssi on unti l i nput shaft i s centered
i n rel ease beari ng and cl utch di sc hub.
(5) Move transmi ssi on forward and start i nput shaft
i n rel ease beari ng, cl utch di sc and pi l ot bushi ng.
(6) Work transmi ssi on forward unti l seated agai nst
cl utch housi ng. Do not al l ow transmi ssi on to remai n
unsupported after i nput shaft has entered cl utch di sc.
(7) I nstal l transmi ssi on bol ts and ti ghten to 108
Nm (80 ft. l bs.).
(8) I nstal l transmi ssi on mount on transmi ssi on or
rear crossmember.
(9) I nstal l rear crossmember.
(10) Remove transmi ssi on jack and engi ne support
fi xture.
(11) Posi ti on transmi ssi on harness wi res i n cl i ps
on shi ft cover.
(12) I nstal l cl utch sl ave cyl i nder and i nstal l sl ave
cyl i nder shi el d, i f equi pped.
(13) Connect speed sensor and backup l i ght swi tch
wi res.
TWO WHEEL DRIVE
(1) Fi l l transmi ssi on wi th recommended l ubri cant.
Correct fi l l l evel i s bottom edge of fi l l pl ug hol e.
(2) Al i gn and i nstal l propel l er shaft.
(4) Cl ean the mati ng surfaces of shi ft tower, i sol a-
tor pl ate and shi ft cover wi th sui tabl e wax and
grease remover.
the seal i ng surface of the shi ft cover. Do not over
appl y seal ant.
(6) I nstal l the i sol ator pl ate onto the shi ft cover,
metal si de down.
(7) I nstal l the shi ft tower onto the i sol ator pl ate.
No seal ant i s necessary between the shi ft tower and
the i sol ator pl ate.
(8) Veri fy that the shi ft tower, i sol ator pl ate and
the shi ft tower bushi ngs are properl y al i gned.
(9) I nstal l the bol ts to hol d the shi ft tower to the
i sol ator pl ate and the shi ft cover. Ti ghten the shi ft
tower bol ts to 10.2-11.25 Nm (7.5-8.3 ft. l bs.).
(10) I nstal l the shi ft l ever extensi on onto the shi ft
(11) I nstal l shi ft boot and bezel .
FOUR WHEEL DRIVE
(1) I nstal l transfer case shi ft mechani sm on trans-
mi ssi on.
(2) I nstal l transfer case on transmi ssi on jack.
Secure transfer case to jack wi th safety chai ns.
(3) Rai se jack and al i gn transfer case i nput gear
wi th transmi ssi on mai nshaft.
(4) Move transfer case forward and seat i t on
adapter.
(5) I nstal l transfer case nuts and ti ghten to:
I f 3/8 studs 41-47 Nm (30-35 ft. l bs.).
I f 5/16 studs 30-41 Nm (22-30 ft. l bs.).
(6) I nstal l transfer case shi ft mechani sm to si de of
transfer case.
(7) Connect transfer case shi ft l ever to range l ever
on transfer case.
(8) Al i gn and connect propel l er shafts.
(9) Fi l l transmi ssi on wi th requi red l ubri cant.
Check l ubri cant l evel i n transfer case and add l ubri -
cant i f necessary.
(10) I nstal l transfer case ski d pl ate, i f equi pped
and crossmember. Ti ghten attachi ng bol ts/nuts to 41
Nm (30 ft. l bs.).
(11) I nstal l exhaust system components.
(13) Cl ean the mati ng surfaces of shi ft tower, i so-
l ator pl ate and shi ft cover wi th sui tabl e wax and
grease remover.
appl y seal ant.
metal si de down.
i sol ator pl ate and the shi ft cover. Ti ghten the shi ft
(19) I nstal l the shi ft l ever extensi on onto the shi ft
(20) I nstal l shi ft l ever boot and bezel .
SPECIFICATIONS
Switch, Back-up Lamp 22-34 16-25 -
Countershaft Bearing Plate Bolts 19-26 14-19 170-230
Fifth Gear Nut 366-380 270-280 -
Fifth Gear Nut Clamp Bolt 13.5 10 -
Drain and Fill Plug 34-47 25-35 -
Front Bearing Retainer Bolts 27-34 20-25 235-305
Mainshaft Bearing Plate Bolts 19-26 14-19 170-230
PTO Cover Bolts 27-54 20-40 -
Extension/Adapter Housing Bolts 41-68 30-50 -
Shift Mechanism Cover Bolts 27-31 20-23 -
Transmission Bolts 108 80 -
SPECIAL TOOLS
REMOVER C-3985-B
BUSHING REMOVER 6957
REMOVER BUSHING 8155
INSTALLER BUSHING 6951
INSTALLER BUSHING 8156
HANDLE C-4171
INSTALLER SEAL C-3972-A
INSTALLER SEAL 8154
INSTALLER SEAL C-3860-A
WRENCH 6443
WRENCH 6743
SOCKET 6441
SOCKET 6442
SOCKET 6993
SOCKET 6984
PULLER 6444
JAWS 6459
JAWS 6820
JAWS & INSERT 6453
JAWS 6447
JAWS 6449
JAWS 6451
REMOVER 6454
INSTALLER 6061
INSTALLER C-4340
INSTALLER C-4040
INSTALLER 6448
INSTALLER C-4308
INSTALLER 6052
ROD EXTENSION 8161
INSTALLER 6446
JAWS 6445
REMOVAL
(2) Mark the propel l er shafts and yokes for i nstal -
l ati on reference and remove the shafts.
(3) Support transmi ssi on wi th a transmi ssi on jack.
(4) Remove engi ne rear support.
(5) Remove transfer case.
(6) Remove adapter housi ng seal wi th a pry tool or
sl i de hammer mounted screw (Fi g. 130).
INSTALLATION
(1) I nstal l adapter housi ng seal wi th I nstal l er
C-3860-A and Handl e C-4171.
(2) I nstal l transfer case.
(3) I nstal l propel l er shafts wi th reference marks
al i gned.
(4) Fi l l transfer case and transmi ssi on to proper
l evel .
REMOVAL
(1) Mark the propel l er shaft and yoke for i nstal l a-
ti on reference.
(2) Remove the propel l er shaft.
(3) Remove extensi on housi ng seal (Fi g. 131) usi ng
Remover C-3985-B.
(4) On heavy duty 4X2 vehi cl es, remove extensi on
housi ng seal wi th a pry tool or a sl i de hammer
mounted screw.
(5) On l i ght duty transmi ssi ons, remove the exten-
si on housi ng bushi ng wi th Remover 6957.
(6) On heavy duty transmi ssi ons, remove the
extensi on housi ng bushi ng wi th Remover 8155.
INSTALLATION
(1) I nstal l housi ng bushi ng wi th Handl e C-4171
(Fi g. 132) and I nstal l er.
Li ght Duty - I nstal l er 6951
Heavy Duty - I nstal l er 8161
Fig. 130 Adapter Housing (4Wheel Drive Models)
1 - ADAPTER HOUSING
2 - SEAL
Fig. 131 EXTENSION HOUSING AND SEAL (4X2)
2 - SEAL
Fig. 132 Extension Housing Bushing
1 - HANDLE
2 - INSTALLER
(2) I nstal l housi ng seal wi th Handl e C-4171 (Fi g.
133) and I nstal l er.
Li ght Duty - I nstal l er C-3972-A
Heavy Duty - I nstal l er 8154
al i gned.
(4) Check and fi l l transmi ssi on.
SHIFT MECHANISM
REMOVAL
(1) Remove transmi ssi on from vehi cl e.
(2) Remove shi ft mechani sm cover bol ts.
(3) Pry up shi ft mechani sm cover at sl ots provi ded
i n cover (Fi g. 134).
(4) Rai se cover enough to di sengage i t from al i gn-
ment dowel s i n gear case (Fi g. 135).
(5) Rai se front of shi ft mechani sm cover and l i ft
cover up and off gear case (Fi g. 135).
FIFTH-REVERSE SHIFT FORK PADS
Three shi ft pads on the forks are hel d i n pl ace by
tensi on and a smal l l ocati ng tang (Fi g. 136).
To remove the pads, grasp a pad wi th hand and ti l t
i t out and off the fork. I f pad i s di ffi cul t to remove by
hand, i nsert a screwdri ver bl ade between the pad
and fork and pry the pad off.
EXPANSION PLUG
The expansi on pl ugs at the rear of the shi ft rai l
bores (Fi g. 137) can be repl aced i f l oose/l eaki ng.
(1) Dri l l 6 mm (1/4 i n.) di ameter hol e i n center of
the pl ug to be removed.
(2) Pry pl ug out of cover wi th tapered punch.
Fig. 133 Pinion Seal
1 - HANDLE
2 - INSTALLER
Fig. 134 LOOSEN SHIFT MECHANISM
1 - SHIFT MECHANISM COVER SLOT
2 - PRY TOOL
Fig. 135 SHIFT MECHANISM COVER
1 - SHIFT MECHANISM COVER
2 - ALIGNMENT DOWELS
Fig. 136 SHIFT FORK PAD LOCATIONS
1 - SHIFT FORK PADS
EXTENSION HOUSING SEAL (Continued)
(3) Cl ean al l chi ps from shi ft cover and pl ug bores.
Then cl ean pl ug bores wi th sol vent and dry wi th
cl ean shop towel .
INSTALLATION
EXPANSION PLUG
(1) Appl y smal l bead of Mopar si l i cone seal er or
equi val ent to outer edge of each new pl ug.
(2) Posi ti on each pl ug i n bore and tap i nto pl ace
wi th hammer and punch or socket.
FIFTH-REVERSE SHIFT FORK PADS
(1) Al i gn pad l ocati ng tab.
(2) Snap pads i nto pl ace and veri fy l ocati ng tabs
are l ocked-i n.
SHIFT COVER
(1) Cl ean mati ng surfaces of shi ft mechani sm
cover and gear case wi th wax and grease remover.
(2) Appl y a smal l amount of Mopar si l i cone seal er or
equi val ent to seal i ng surface of shi ft mechani sm cover.
CAUTION: Do not use an excessive amount sealer.
Excess can squeezed into gear case and could
block lubricant feed holes in time.
(3) Lubri cate synchro sl eeves wi th Castrol Syn-
torq gear l ubri cant or equi val ent. Then appl y l i ght
coat of petrol eum jel l y to shi ft fork contact surfaces.
(4) Veri fy shi ft fork pads (Fi g. 138) are secure.
(5) Veri fy 1-2 and 3-4 synchro sl eeves and forks i n
shi ft cover are i n neutral posi ti on.
(6) Al i gn and seat shi ft mechani sm cover on trans-
mi ssi on.
NOTE: If cover will not seat, it may not be aligned
on gear case dowels or shift forks are not aligned
with sleeves and shift lug.
threads of shi ft cover bol ts.
(8) I nstal l shi ft cover mechani sm bol ts and ti ghten
to 27-31 Nm (216-276 i n. l bs.).
(9) Appl y seal er to backup l amp swi tch. I nstal l swi tch
i nto cover and ti ghten to 22-34 Nm (193-265 i n. l bs.).
(10) I nstal l vent assembl y i f removed. Appl y an
adhesi ve/seal er to vent tube to hel p secure i t i n cover.
(11) I nstal l transmi ssi on.
SHIFT COVER
REMOVAL
(2) Unscrew and remove the shi ft l ever extensi on
from the shi ft
(3) Remove screws attachi ng shi ft boot to fl oorpan.
Then sl i de boot upward on the shi ft l ever.
(4) Remove the bol ts hol di ng the shi ft tower to the
i sol ator pl ate and transmi ssi on shi ft cover.
(5) Remove the shi ft tower and i sol ator pl ate from
the transmi ssi on shi ft cover.
INSTALLATION
tor pl ate and shi ft cover wi th sui tabl e wax and
grease remover.
appl y seal ant.
metal si de down.
(5) Veri fy shi ft tower, i sol ator pl ate and shi ft tower
bushi ngs are properl y al i gned.
(6) I nstal l bol ts to hol d the shi ft tower to the i so-
l ator pl ate and the shi ft cover. Ti ghten the shi ft
(7) I nstal l shi ft l ever extensi on, shi ft boot and bezel .
Fig. 137 EXPANSION PLUG LOCATION
1 - EXPANSION PLUGS
Fig. 138 SHIFT FORK PAD
1 - SHIFT FORK PADS
SHIFT MECHANISM (Continued)
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 88
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 91
CLEANING - TRANSMISSION . . . . . . . . . . . . . 106
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 106
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 121
SPECIFICATIONS - NV5600 . . . . . . . . . . . . . . 123
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 123
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 128
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 128
SHIFT COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 129
NV5600
DESCRIPTION
The NV5600 i s a si x speed constant mesh manual
transmi ssi on (Fi g. 1). Al l gear ranges i ncl udi ng
reverse are synchroni zed. Fi rst and second gears uti -
l i ze dual cone synchroni zers i n order to ai d shi fti ng.
Si xth gear i s an overdri ve range. The transmi ssi on
uses cast i ron for the gear case and extensi on/
adapter housi ng and al umi num for the cl utch hous-
i ng.
To drai n the trans remove the bottom PTO cover
bol t. Fi l l the trans through the pl ug to the rear of the
PTO cover (Fi g. 1). Dry fi l l i s approxi matel y 4.5 l i ters
(9.5 pi nts) or to the bottom edge of the fi l l pl ug hol e.
The gear rati os are:
GEAR RATIOS
GEAR RATIO
FIRST 5.63:1
SECOND 3.38:1
THIRD 2.04:1
FOURTH 1.39:1
FIFTH 1.00:1
SIXTH 0.73:1
REVERSE 5.63:1
Fig. 1 NV5600 MANUAL TRANSMISSION
IDENTIFICATION
The transmi ssi on has two i denti fi cati on tags
attached to the dri ver si de upper cl utch housi ng (Fi g.
2). One tag provi des the transmi ssi on part number.
The second tag provi des sequenci ng and bui l d date
i nformati on. The i nformati on on the tags are essen-
ti al to correct parts orderi ng.
OPERATION
shi ft l ever to the desi red gear posi ti on. As the shi ft
l ever moves the sel ected shi ft rai l , the shi ft fork
attached to that rai l begi ns to move. The fork i s posi -
ti oned i n a groove i n the outer ci rcumference of the
synchroni zer sl eeve. As the shi ft fork moves the syn-
chroni zer sl eeve, the synchroni zer begi ns to speed-up
or sl ow down the sel ected gear (dependi ng on
whether we are up-shi fti ng or down-shi fti ng). The
synchroni zer does thi s by havi ng the synchroni zer
hub spl i ned to the mai nshaft or the countershaft i n
some cases, and movi ng the bl ocker ri ng i nto contact
wi th the gears fri cti on cone. As the bl ocker ri ng and
fri cti on cone come together, the gear speed i s brought
up or down to the speed of the synchroni zer. As the
two speeds match, the spl i nes on the i nsi de of the
synchroni zer sl eeve become al i gned wi th the teeth on
the bl ocker ri ng and fri cti on cone and eventual l y wi l l
sl i de over the teeth, l ocki ng the gear to the mai n-
shaft or countershaft through the synchroni zer.
LOW LUBRICANT LEVEL
rect l ubri cant l evel check. A correct l ubri cant l evel
check can onl y be made when the vehi cl e i s l evel .
Al so al l ow the l ubri cant to settl e for a mi nute or so
before checki ng. These recommendati ons wi l l ensure
an accurate check and avoi d an underfi l l or overfi l l
condi ti on. Al ways check the l ubri cant l evel after any
addi ti on of fl ui d to avoi d an i ncorrect l ubri cant l evel
condi ti on.
Leaks can occur at the mati ng surfaces of the gear
case, adaptor or extensi on housi ng, or from the front/
rear seal s. A suspected l eak coul d al so be the resul t
of an overfi l l condi ti on. Leaks at the rear of the
extensi on or adapter housi ng wi l l be from the hous-
i ng oi l seal s. Leaks at component mati ng surfaces
wi l l probabl y be the resul t of i nadequate seal er, gaps
i n the seal er, i ncorrect bol t ti ghteni ng or use of a
non-recommended seal er. A l eak at the front of the
transmi ssi on wi l l be from ei ther the front beari ng
retai ner or retai ner seal . Lubri cant may be seen dri p-
pi ng from the cl utch housi ng after extended opera-
ti on. I f the l eak i s severe, i t may al so contami nate
the cl utch di sc causi ng the di sc to sl i p, grab and or
chatter.
HARD SHIFTING
i ng and noi se.
Component damage, i ncorrect cl utch adjustment or
damaged cl utch pressure pl ate or di sc are addi ti onal
probabl e causes of i ncreased shi ft effort. I ncorrect
adjustment or a worn/damaged pressure pl ate or di sc
can cause i ncorrect rel ease. I f cl utch probl em i s
advanced, gear cl ash duri ng shi fts can resul t. Worn
or damaged synchro ri ngs can cause gear cl ash when
shi fti ng i nto any forward gear. I n some new or
TRANSMISSION NOISE
speeds. Severe hi ghl y audi bl e transmi ssi on noi se i s
general l y the i ni ti al i ndi cator of a l ubri cant probl em.
I nsuffi ci ent, i mproper or contami nated l ubri cant
wi l l promote rapi d wear of gears, synchros, shi ft
rai l s, forks and beari ngs. The overheati ng caused by
a l ubri cant probl em, can al so l ead to gear breakage.
REMOVAL
Fig. 2 IDENTIFICATION TAG LOCATION
1 - IDENTIFICATION TAGS
i sol ator pl ate and transmi ssi on gear case.
(4) Remove the shi ft tower and i sol ator pl ate from
the transmi ssi on gear case.
(7) Mark propel l er shaft/shafts and axl e yokes for
(9) Di sconnect and remove exhaust system as nec-
essary.
(10) Di sconnect wi res at backup l i ght swi tch.
(11) Support engi ne wi th adjustabl e safety stand
and wood bl ock.
(12) I f transmi ssi on i s to be di sassembl ed for
repai r, remove drai n bol t at bottom of PTO cover and
drai n l ubri cant from transmi ssi on (Fi g. 3).
(13) Remove cl utch sl ave cyl i nder spl ash shi el d, i f
equi pped.
(15) Remove wi re harness from cl i ps on transmi ssi on.
TWO WHEEL DRIVE
(1) Remove bol ts/nuts mounti ng transmi ssi on to
the rear mount.
crossmember.
(4) Remove transmi ssi on cl utch housi ng bol ts at
the engi ne bl ock.
i nput shaft cl ears cl utch di sc and pressure pl ate.
(6) Lower transmi ssi on jack and remove transmi s-
si on from under vehi cl e.
FOUR WHEEL DRIVE
(1) Di sconnect transfer case shi ft l i nkage at trans-
fer case range l ever.
(2) Support and secure transfer case wi th safety
(3) Remove transfer case mounti ng nuts.
(4) Move transfer case rearward unti l i nput gear
cl ears transmi ssi on mai nshaft.
(5) Lower transfer case assembl y and move i t from
under vehi cl e.
(7) Remove bol ts/nuts attachi ng transmi ssi on
mount to rear crossmember.
crossmember.
(9) Remove transmi ssi on cl utch housi ng bol ts at
the engi ne bl ock.
(10) Move transmi ssi on rearward unti l i nput shaft
cl ears cl utch di sc.
(11) Lower transmi ssi on and remove i t from under
vehi cl e.
DISASSEMBLY
NOTE: Use Fixture 8241 for moving and handling
the transmission. The fixture supports the transmis-
sion at the center of gravity in order to ease mount-
ing the transmission into the build fixture.
(1) Mount the transmi ssi on i nto Fi xture 8230 (Fi g. 4).
Fig. 3 NV5600 DRAIN BOLT
1 - PTO COVER
2 - DRAIN BOLT
Fig. 4 TRANSMISSION FIXTURE
1 - FIXTURE
2 - TRANSMISSION
(2) Rotate the transmi ssi on to the hori zontal posi -
ti on, i f necessary.
(3) Remove the shi ft tower (Fi g. 5) and i sol ator
pl ate (Fi g. 6).
(4) Remove pri mary shi ft rai l detent pl ug (Fi g. 7).
(5) Remove pri mary shi ft rai l detent spri ng (Fi g.
8).
Fig. 5 REMOVE SHIFT TOWER
1 - SHIFT TOWER
2 - TRANSMISSION
Fig. 6 SHIFT TOWER ISOLATOR PLATE
1 - ISOLATOR PLATE
2 - TRANSMISSION
Fig. 7 PRIMARY SHIFT RAIL DETENT PLUG
1 - DETENT PLUG
Fig. 8 PRIMARY SHIFT RAIL DETENT SPRING
1 - DETENT SPRING
(6) Remove pri mary shi ft rai l detent pl unger (Fi g.
9).
(7) Remove cl utch housi ng bol ts (10) (Fi g. 10) from
i nsi de the housi ng.
(8) Remove shi ft rai l bl ocker bol t (Fi g. 11) from the
si de of the transmi ssi on gear case.
(1) Remove bol ts hol di ng the extensi on/adapter
housi ng onto the transmi ssi on gear case.
(2) Remove extensi on/adapter housi ng from the
transmi ssi on gear case wi th Pul l er 8244 (Fi g. 12).
NOTE: It may be necessary to straighten the housing
during removal due to the tendency for the reverse
idler shaft to bind into one side of the housing.
Fig. 9 PRIMARY SHIFT RAIL DETENT PLUNGER
1 - DETENT PLUNGER
Fig. 10 CLUTCH HOUSING BOLTS
1 - BOLTS (10)
Fig. 11 SHIFT RAIL BLOCKER BOLT
1 - BLOCKER BOLT
Fig. 12 TRANSMISSION CASE PULLER
1 - PULLER
2 - EXTENSION/ADAPTER HOUSING
(3) Remove crossover detent pl ug, spri ng and
pl unger from the extensi on/adapter housi ng (Fi g. 13).
(4) Remove bol t and washer hol di ng the crossover
cam to the extensi on/adapter housi ng (Fi g. 14).
(5) Remove crossover cam from the extensi on/
adapter housi ng.
(6) Remove back-up l amp swi tch from the exten-
si on/adapter housi ng.
(7) Remove countershaft rear beari ng race from
the extensi on/adapter housi ng wi th Remover L-4518
(Fi g. 15).
NOTE: Tag all countershaft pre-load shims from
between the bearing race and the housing (Fig. 16).
(8) Remove crossover cam bushi ng from the exten-
si on/adapter housi ng wi th Remover 8240.
(9) On 4X2 vehi cl es, remove extensi on housi ng
seal wi th a pry tool or a sl i de hammer and screw.
(10) On 4X4 vehi cl es, remove adapter housi ng seal
wi th a pry tool or a sl i de hammer and screw.
Fig. 13 CROSSOVER CAM DETENT PLUG
1 - DETENT PLUG
Fig. 14 CROSSOVER CAM BOLT
1 - CROSSOVER CAM
2 - BOLT
Fig. 15 COUNTERSHAFT REAR BEARING RACE
1 - REMOVER
Fig. 16 COUNTERSHAFT REAR BEARING RACE
AND SHIM
1 - PRE-LOAD SHIM
2 - BEARING RACE
REVERSE GEAR
(1) Remove crossover cam rol l ers and pi n (Fi g. 17).
(2) Remove reverse i dl er thrust washer from the
reverse i dl er.
(3) Remove reverse i dl er and reverse countershaft
gears together (Fi g. 18).
(4) Remove reverse i dl er gear rear beari ng, bear-
i ng spacer, front beari ng and front thrust washer
from the i dl er gear shaft.
(5) Remove reverse countershaft rear beari ng from
the countershaft reverse gear assembl y wi th Pul l er
C-293-PA and Adapters C-293-52 (Fi g. 19).
(6) Seperate countershaft reverse gear and sl eeve.
(7) Remove output shaft nut wi th Wrench 8226 on
the shaft nut and Socket 6993 or 6984 to hol d the
shaft (Fi g. 20). Di scard output shaft nut from the
output shaft.
NOTE: If necessary strike the flat side area of
Wrench 8226 with a hammer to break the nut loose.
Fig. 17 CROSSOVER CAM ROLLERS AND PIN
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
Fig. 18 REVERSE IDLER AND COUNTERSHAFT
GEARS
2 - COUNTERSHAFT REVERSE GEAR
Fig. 19 COUNTERSHAFT REAR BEARING PULLER
1 - PULLER
2 - ADAPTERS
Fig. 20 LOOSEN OUTPUT SHAFT NUT
1 - WRENCH
2 - SOCKET
(8) Remove output shaft bal l beari ng assembl y and
reverse thrust washer from the output shaft (Fi g.
21).
(9) Remove reverse gear, reverse gear synchroni zer
cone, reverse gear outer bl ocker ri ng and reverse
gear beari ng (Fi g. 22).
(10) Remove reverse gear beari ng sl eeve from the
output shaft (Fi g. 23).
NOTE: If necessary heat the sleeve slightly with a
heat gun. Do not use a torch to heat the sleeve or
damage to the output shaft may occur.
(11) Remove rol l -pi n securi ng the reverse shi ft fork
to the reverse shi ft rai l wi th a 6 mm (7/32 i n.) punch
and hammer.
Fig. 21 OUTPUT SHAFT BEARING AND THRUST
WASHER
1 - OUTPUT SHAFT BALL BEARING
2 - THRUST WASHER
Fig. 22 REVERSE GEAR COMPONENTS
1 - REVERSE GEAR
2 - REVERSE BEARING
3 - BLOCKER RING
4 - FRICTION CONE
Fig. 23 REVERSE BEARING SLEEVE
1 - REVERSE GEAR BEARING SLEEVE
(12) Remove reverse shi ft fork and synchroni zer as
an assembl y from the reverse shi ft rai l and the out-
put shaft (Fi g. 24).
TRANSMISSION GEAR CASE
(1) Remove remai ni ng bol ts hol di ng the transmi s-
si on gear case to the cl utch housi ng.
(2) Remove the shi ft socket rol l pi n wi th a 6 mm
(7/32 i n.) punch and hammer.
(3) Turn shi ft socket so i t wont catch the case
when l i fti ng i t up.
(4) I nstal l Fi xture 8232 to the transmi ssi on gear
case.
(5) Attach an engi ne crane or equi val ent to Fi xture
8232 and remove the transmi ssi on gear case from the
cl utch housi ng (Fi g. 25).
(6) Remove rear output shaft and countershaft
beari ng races from the transmi ssi on gear case wi th a
brass dri ft and hammer.
GEARTRAIN
(1) Remove bol ts hol di ng the 5-6 crossover bracket
to the cl utch housi ng (Fi g. 26).
Fig. 24 REVERSE SHIFT FORK AND SYNCHRO
1 - REVERSE SYNCHRO
2 - REVERSE SHIFT FORK
Fig. 25 TRANSMISSION CASE LIFT FIXTURE
1 - FIXTURE
2 - TRANSMISSION CASE
Fig. 26 5-6 CROSSOVER BRACKET BOLTS
1 - 5-6 CROSSOVER BRACKET
(2) Attach Fi xture 8232 to the output shaft and
countershaft (Fi g. 27).
8232 and rai se the geartrai n approxi matel y 1/4 i n.
from the cl utch housi ng.
(4) Remove 5-6 crossover bracket from the cl utch
housi ng.
(5) Lower the geartrai n back i nto the cl utch hous-
i ng.
(6) I nstal l Hol di ng Tool 8242 (Fi g. 28) onto the 5-6
synchro and ti ghten the screw to hol d the 5-6 syn-
chro together duri ng the removal operati on.
NOTE: Note the order of the shift fork arms at the
primary shift rail, while in the Neutral position.
(7) Rai se geartrai n and shi ft rai l s unti l al l the
shi ft rai l s cl ear the cl utch housi ng.
(8) Remove shi ft rai l s from the rest of the
geartrai n (Fi g. 29).
(9) Rai se the geartrai n unti l the i nput shaft i s
cl ear of the cl utch housi ng.
Fig. 27 FIXTURE/OUTPUT SHAFT
1 - OUTPUT SHAFT
2 - FIXTURE
Fig. 28 Remove Holding Tool
1 - HOLDING TOOL
2 - 5-6 SYNCHRO
Fig. 29 SHIFT RAILS
1 - 5-6 SHIFT RAIL
(10) Remove geartrai n from the cl utch housi ng and
i nstal l the geartrai n i nto Support Stand 8246 (Fi g.
30).
(11) Remove Fi xture 8232 from the output shaft
and the countershaft.
(12) Separate the countershaft from the output
shaft.
(13) Separate the output shaft from the i nput
shaft. Hol d the 5-6 synchro together whi l e removi ng
the output shaft to prevent the synchro sl eeve from
bei ng di sl odged from the synchro hub.
COUNTERSHAFT BEARINGS
(1) Remove snap-ri ng hol di ng the front counter-
shaft beari ng onto the countershaft.
(2) Remove front countershaft beari ng wi th Col l ar
6444-8, Jaws 6451, Pul l er Rods 6444-4 and Pul l er
6444 (Fi g. 31).
(3) Remove rear countershaft beari ng wi th Col l ar
6444-8, Jaws 6447, Pul l er Rods 6444-4, Pul l er 6444
and sui tabl e press button (Fi g. 32).
Fig. 30 GEARTRAIN FIXTURE
1 - FIXTURE
2 - SUPPORT STAND
Fig. 31 FRONT COUNTERSHAFT BEARING
1 - PULLER
2 - JAWS
Fig. 32 REAR COUNTERSHAFT BEARING
1 - PULLER
2 - JAWS
OUTPUT SHAFT BEARINGS
(1) Remove snap-ri ng hol di ng the pocket beari ng
onto the output shaft.
(2) Remove pocket beari ng from the output shaft
wi th Sl eeve 6444-8, Jaws 8234, Pul l er Rods 6444-4
and the remai nder of Pul l er 6444 (Fi g. 33).
(3) Remove snap-ri ng hol di ng the rear output shaft
beari ng onto the output shaft.
(4) Use Col l ar 6444-8, Jaws 8271 and Pul l er Rods
6444-3 for 4X2 vehi cl es or Pul l er Rods 6444-4 for 4X4
vehi cl es wi th the remai nder of Pul l er 6444 to remove
the rear output shaft beari ng from the output shaft.
(5) Remove rear output shaft thrust washer from
the output shaft.
INPUT SHAFT
(1) Remove fi fth gear bl ocker ri ng from the i nput
shaft (Fi g. 34).
(2) Remove fi fth gear fri cti on cone from the i nput
shaft (Fi g. 35).
Fig. 33 OUTPUT SHAFT POCKET BEARING
1 - PULLER
2 - JAWS
Fig. 34 FIFTH GEAR BLOCKER RING
1 - FIFTH GEAR BLOCKER RING
2 - INPUT SHAFT
Fig. 35 FIFTH GEAR FRICTION CONE
1 - FRICTION CONE
2 - INPUT SHAFT
(3) Remove output shaft pocket beari ng race from
the i nput shaft wi th Pul l er L-4518 (Fi g. 36).
(4) Remove i nput shaft beari ng and oi l gui de from
the i nput shaft wi th Col l ar 6444-8, Jaws 8243, Pul l er
Rods 6444-6 and the remai nder of Pul l er 6444 (Fi g.
37).
OUTPUT SHAFT
NOTE: Some gear and synchro components can be
installed backwards. Mark the gears, clutch gears,
synchro hubs, and sleeves for installation reference
during disassembly. Use paint or a scribe for mark-
ing purposes. Then stack the geartrain parts in
order of removal.
(1) Remove fi rst gear from the output shaft.
(2) Remove fi rst gear beari ng from the output
shaft (Fi g. 38).
Fig. 36 OUTPUT SHAFT POCKET BEARING RACE
1 - PULLER
2 - INPUT SHAFT
Fig. 37 INPUT SHAFT BEARING
1 - PULLER
2 - JAWS
Fig. 38 FIRST GEAR BEARING
1 - OUTPUT SHAFT
(3) Remove fi rst gear bl ocker ri ngs (2) and cones
from the 1-2 synchro assembl y (Fi g. 39).
(4) I nstal l the remai nder of the output shaft i nto
Fi xture 8227 wi th press bl ocks under second gear.
(5) I nstal l shaft and Fi xture assembl y i nto a shop
press (Fi g. 40).
(6) Press second gear, 1-2 synchro assembl y and
fi rst gear beari ng sl eeve from the output shaft.
(7) Remove second gear beari ng from the output
shaft.
(8) Reverse output shaft i n the Fi xture 8227 wi th
press bl ocks posi ti oned under the 5-6 synchro assem-
bl y.
(9) Press the 5-6 synchro assembl y from the out-
put shaft.
Fig. 39 FIRST GEAR BLOCKER RINGS AND
FRICTION CONE
1 - OUTPUT SHAFT
2 - FIRST GEAR BLOCKER RINGS
3 - FIRST GEAR FRICTION CONE
Fig. 40 SECOND GEAR, 1-2 SYNCHRO & FIRST
GEAR BEARING SLEEVE
1 - OUTPUT SHAFT
2 - FIRST GEAR BEARING SLEEVE
3 - SECOND GEAR
4 - FIXTURE
5 - 1-2 SYNCHRO
(10) Remove si xth gear and the si xth gear beari ng
from the output shaft (Fi g. 41).
COUNTERSHAFT
(1) I nstal l the countershaft i nto Fi xture 8227 wi th
press bl ocks l ocated under the fi fth countershaft
gear.
(2) Pl ace the assembl y i nto a shop press.
(3) Use Gui de 8235 on end of countershaft and
press the countershaft fi fth gear from the counter-
shaft (Fi g. 42).
(4) Pl ace countershaft i n Fi xture 8227 wi th press
bl ocks pl aced under the si xth countershaft gear.
(5) Use Gui de 8235 on end of countershaft and
press the countershaft si xth gear from the counter-
shaft (Fi g. 43).
Fig. 41 SIXTH GEAR COMPONENTS
1 - SIXTH GEAR FRICTION CONE
2 - SIXTH GEAR
3 - OUTPUT SHAFT
4 - SIXTH GEAR BLOCKER RING
5 - 5-6 SYNCHRO
Fig. 42 FIFTH COUNTERSHAFT GEAR
1 - GUIDE
2 - FIFTH COUNTER SHAFT GEAR
3 - FIXTURE
Fig. 43 SIXTH COUNTERSHAFT GEAR
1 - GUIDE
2 - SIXTH COUNTER SHAFT GEAR
3 - FIXTURE
(6) Remove countershaft from the press and Fi x-
ture 8227.
(7) Remove fourth countershaft gear, fri cti on cone,
bl ocker ri ng and beari ng from the countershaft (Fi g.
44).
(8) I nstal l countershaft i nto Fi xture 8227 wi th
press bl ocks l ocated under the thi rd countershaft
gear.
(9) Pl ace assembl y i nto a shop press and press
thi rd countershaft gear, 3-4 synchro and fourth coun-
tershaft gear beari ng sl eeve from the countershaft
(Fi g. 45).
(10) Remove countershaft from the press and Fi x-
ture 8227.
(11) Remove thi rd countershaft gear beari ng from
the countershaft (Fi g. 46).
(12) The 2-3 thrust washer shoul d not normal l y
need to be removed from the countershaft. I f neces-
sary sl i de 2-3 thrust washer off countershaft.
Fig. 44 FOURTH COUNTERSHAFT GEAR
COMPONENTS
1 - FOURTH GEAR BLOCKER RING
2 - FOURTH GEAR BEARING
3 - COUNTERSHAFT
4 - FOURTH GEAR FRICTION CONE
5 - FOURTH COUNTERSHAFT GEAR
Fig. 45 THIRD COUNTERSHAFT GEAR
COMPONENTS
1 - THIRD COUNTERSHAFT GEAR
2 - FIXTURE
3 - 3-4 SYNCHRO
4 - BEARING SLEEVE
5 - COUNTERSHAFT
1 - COUNTERSHAFT
2 - 2-3 THRUST WASHER
3 - THIRD COUNTERSHAFT GEAR BEARING
CLUTCH HOUSING
(1) Remove i nput shaft retai ner bol ts from the
cl utch housi ng and remove retai ner (Fi g. 47).
(2) Remove countershaft oi l gui de from the coun-
tershaft front beari ng bore i n the cl utch housi ng (Fi g.
48).
(3) Remove countershaft front beari ng race, end-
pl ay shi ms and spacer from the cl utch housi ng wi th
Remover 6061-1 and Handl e C-4171 (Fi g. 49).
(4) Remove i nput shaft beari ng race wi th Remover/
I nstal l er 8237 and Handl e C-4171.
Fig. 47 INPUT SHAFT RETAINER
1 - INPUT SHAFT RETAINER
2 - CLUTCH HOUSING
Fig. 48 COUNTERSHAFT OIL GUIDE
1 - CLUTCH HOUSING
2 - COUNTERSHAFT OIL GUIDE
Fig. 49 FRONT COUNTERSHAFT BEARING RACE
1 - CLUTCH HOUSING
2 - HANDLE
3 - REMOVER
(5) Remove i nput shaft oi l gui de and retai ner seal
(Fi g. 50).
CLEANING - TRANSMISSION
Cl ean the gears, beari ngs shafts, extensi on/adapter
housi ng and gear case wi th sol vent. Dry al l parts
except the beari ngs wi th compressed ai r. Al l ow the
beari ngs to ei ther ai r dry or wi pe them dry wi th
cl ean shop towel s.
INSPECTION
NOTE: Minor corrosion, nicks, or pitting can be
smoothed with 400 grit emery and polished out with
crocus cloth.
I nspect the reverse i dl er gear, beari ngs, shaft and
thrust washers. Repl ace the beari ngs i f the rol l ers
are worn, chi pped, cracked, fl at-spotted or bri nnel l ed.
Repl ace the gear i f the teeth are chi pped, cracked or
worn thi n.
I nspect the front beari ng retai ner and beari ng cup.
Repl ace the beari ng cup i f scored, cracked, bri nnel l ed
or rough. Check the rel ease beari ng sl i de surface of
the retai ner careful l y. Repl ace the retai ner i f worn or
I nspect mai nshaft beari ng surfaces, spl i nes, snap
ri ng grooves and threads. Repl ace the shaft i f any
surfaces exhi bi t consi derabl e wear or damage.
I nspect the countershaft and beari ngs. Repl ace the
shaft i f any surfaces exhi bi t consi derabl e wear or
damage.
I nspect shi ft forks for wear and di storti on. Check
fi t of the sl eeve i n the fork to be sure the two parts
fi t and work smoothl y. Repl ace the fork i f the rol l pi n
hol es are worn oversi ze or damaged. Do not attempt
to sal vage a worn fork. Repl ace shi ft fork rol l pi ns i f
necessary or i f doubt exi sts about thei r condi ti on.
The al l beari ngs for wear, roughness, fl at spots,
pi tti ng or other damage. Repl ace the beari ngs i f nec-
essary.
I nspect the bl ocker ri ngs and fi cti on cones. repl ace
ei ther part i f worn or damaged i n any way. Repl ace i f
the fri cti on materi al i s burned, fl aki ng off or worn.
I nspect synchro components wear or damage.
Repl ace parts i f worn, cracked or di storted.
I nspect al l of the thrust washers and l ocati ng pi ns.
Repl ace the pi ns i f bent or worn. Repl ace the wash-
ers i f worn or the l ocati ng pi n notches are di storted.
I nspect the case and housi ng/adapter seal i ng and
mati ng surfaces are free of burrs and ni cks. I nspcet
the al i gnment dowel s i n the case top surface and i n
the housi ng/adapter are ti ght and i n good condi ti on.
Repl ace the gear case or housi ng/adapter i f cracked
or broken.
ASSEMBLY
NOTE: Gaskets are not used in the transmission.
Use Mopar Gasket Maker or equivalent on all gear
case and extension housing sealing surfaces.
OUTPUT SHAFT
(1) Pl ace second gear on bench wi th the synchro
cl utch ri ng up.
(2) I nstal l second gear synchro i nner bl ocker ri ng
onto second gear (Fi g. 51).
Fig. 50 OIL GUIDE AND SEAL
1 - INPUT SHAFT OIL GUIDE
2 - INPUT SHAFT OIL SEAL
Fig. 51 INNER BLOCKER RING
1 - INNER BLOCKER RING
2 - GEAR
(3) I nstal l second gear synchro fri cti on cone over
the bl ocker ri ng and onto second gear (Fi g. 52).
(4) I nstal l second gear synchro outer bl ocker ri ng
over the second gear synchro fri cti on cone. Al i gn one
of the l ugs on the outer ri ng wi th a l ug on the i nner
ri ng (Fi g. 53).
(5) I nstal l 1-2 synchro assembl y onto the second
gear assembl y (Fi g. 54).
(6) Reverse assembl y on the bench.
(7) Lubri cate and i nstal l second gear beari ng i nto
second gear (Fi g. 55).
Fig. 52 FRICTION CONE
1 - GEAR
2 - FRICTION CONE
Fig. 53 OUTER BLOCKER RING
1 - OUTER BLOCKER RING
2 - LUG
3 - GEAR
Fig. 54 3-4 SYNCHRO ASSEMBLY
1 - SYNCHRO
2 - GEAR
Fig. 55 SECOND GEAR AND BEARING
1 - BEARING
2 - GEAR
(8) Pl ace 1-2 synchro, second gear and second gear
beari ng assembl y on shop press wi th second gear fac-
i ng upward.
(9) I nstal l output shaft i nto the second gear 1-2
synchro assembl y wi th the front of the output shaft
faci ng upward (Fi g. 56).
(10) Press the output shaft i nto posi ti on.
(11) Pl ace fi rst gear on bench wi th the synchro
cl utch ri ng up.
(12) I nstal l fi rst gear synchro i nner bl ocker ri ng
onto fi rst gear (Fi g. 51).
(13) I nstal l fi rst gear synchro fri cti on cone over the
bl ocker ri ng and onto fi rst gear (Fi g. 52).
(14) I nstal l fi rst gear synchro outer bl ocker ri ng
over the fi rst gear synchro fri cti on cone. Al i gn one of
the l ugs on the outer ri ng wi th a l ug on the i nner
ri ng (Fi g. 53).
(15) Reverse the output shaft i n the press.
(16) I nstal l fi rst gear beari ng sl eeve onto the out-
put shaft.
(17) I nstal l fi rst gear beari ng sl eeve the remai nder
of the way onto the output shaft usi ng I nstal l er 8228
and a shop press (Fi g. 57).
(18) I nstal l fi rst gear and bl ocker assembl y onto
the output shaft (Fi g. 58).
(19) I nstal l fi rst gear beari ng over the output shaft
and i nto fi rst gear.
Fig. 56 OUTPUT SHAFT INTO 1-2 SYNCHRO
1 - OUTPUT SHAFT
2 - 1-2 SYNCHRO
3 - SECOND GEAR
Fig. 57 FIRST GEAR BEARING SLEEVE
1 - INSTALLER
2 - FIRST GEAR BEARING SLEEVE
Fig. 58 FIRST GEAR AND BLOCKER ASSEMBLY
1 - OUTPUT SHAFT
2 - FIRST GEAR ASSEMBLY
(20) I nstal l output shaft thrust washer onto the
output shaft (Fi g. 59).
(21) I nstal l rear output shaft beari ng onto the out-
put shaft wi th I nstal l er 8228 and a shop press (Fi g.
60).
(22) I nstal l a new snap-ri ng to hol d the rear out-
put beari ng onto the output shaft. I nstal l the thi ck-
est snap-ri ng whi ch wi l l fi t i nto the groove.
(23) Reverse output shaft i n the Fi xture 8227 and
support the shaft wi th press bl ocks under fi rst gear.
(24) I nstal l si xth gear beari ng onto the output
shaft.
(25) I nstal l si xth gear onto the output shaft and
over the si xth gear beari ng (Fi g. 61).
(26) I nstal l the si xth gear fri cti on cone onto si xth
gear.
Fig. 59 OUTPUT SHAFT THRUST WASHER
1 - OUTPUT SHAFT
2 - OUTPUT SHAFT THRUST WASHER
Fig. 60 REAR OUTPUT SHAFT BEARING
1 - INSTALLER
2 - REAR OUTPUT SHAFT BEARING
Fig. 61 SIXTH GEAR
1 - SIXTH GEAR
2 - SIXTH GEAR BEARING
(27) I nstal l si xth gear bl ocker ri ng over the si xth
gear fri cti on cone (Fi g. 62).
(28) I nstal l Gui de 8235 onto the end of the output
shaft (Fi g. 63).
(29) I nstal l 5-6 synchro over Gui de 8235 and onto
the output shaft.
(30) Press 5-6 synchro (Fi g. 64) onto the output
shaft wi th I nstal l er 8156 and a shop press.
Fig. 62 SIXTH GEAR BLOCKER RING
1 - SIXTH GEAR BLOCKER RING
2 - SIXTH GEAR FRICTION CONE
Fig. 63 OUTPUT SHAFT GUIDE
1 - GUIDE
2 - OUTPUT SHAFT
Fig. 64 5-6 SYNCHRO
1 - INSTALLER
2 - 5-6 SYNCHRO
(31) I nstal l output shaft pocket beari ng onto the
output shaft.
(32) Press pocket beari ng the remai nder of the
way onto the output shaft usi ng Gui de 8235 and a
shop press (Fi g. 65).
(33) I nstal l a new snap-ri ng to hol d the output
shaft pocket beari ng onto the output shaft.
COUNTERSHAFT
(1) Pl ace thi rd countershaft gear on the bench
wi th the synchro cl utch ri ng up.
(2) I nstal l thi rd countershaft gear fri cti on cone
onto thi rd gear (Fi g. 66).
(3) I nstal l thi rd countershaft gear bl ocker ri ng
onto the fri cti on cone (Fi g. 67).
Fig. 65 OUTPUT SHAFT POCKET BEARING
1 - GUIDE
2 - POCKET BEARING
Fig. 66 FRICTION CONE AND THIRD GEAR
1 - FRICTION CONE
2 - GEAR
3 - CLUTCH RING
Fig. 67 BLOCKER RING ONTO FRICTION CONE
1 - BLOCKER RING
2 - GEAR
3 - FRICTION CONE
(4) I nstal l 3-4 synchro assembl y onto the bl ocker
ri ng/gear assembl y (Fi g. 68).
(5) Reverse the assembl y on the bench.
(6) I nstal l thi rd countershaft gear beari ng i nto the
thi rd countershaft gear.
(7) I nstal l 2-3 thrust washer onto the countershaft.
(8) Pl ace thi rd gear/3-4 synchro assembl y i n a shop
press.
(9) I nstal l countershaft through the thi rd gear/3-4
synchro assembl y.
(10) Press countershaft i nto the 3-4 synchro
assembl y (Fi g. 69).
(11) I nstal l fourth countershaft gear beari ng sl eeve
(12) Press fourth countershaft beari ng sl eeve onto
the countershaft wi th I nstal l er 8228 and a shop
press.
(13) Pl ace fourth countershaft gear on the bench
wi th the synchro cl utch ri ng up.
(14) I nstal l fourth countershaft gear fri cti on cone
onto fourth countershaft gear (Fi g. 66).
(15) I nstal l fourth countershaft gear bl ocker ri ng
onto the fri cti on cone (Fi g. 67).
(16) I nstal l fourth countershaft gear beari ng i nto
the fourth countershaft gear.
(17) Pl ace si xth countershaft gear i n the shop
press.
(18) Posi ti on fourth countershaft gear assembl y
onto the si xth countershaft gear (Fi g. 70).
Fig. 68 3-4 SYNCHRO ASSEMBLY
1 - SYNCHRO
2 - GEAR
Fig. 69 COUNTERSHAFT INTO 3-4 SYNCHRO
1 - COUNTERSHAFT
2 - 2-3 THRUST WASHER
3 - THIRD COUNTERSHAFT GEAR
Fig. 70 FOURTH COUNTERSHAFT ONTO SIXTH
COUNTERSHAFT GEAR
1 - FOURTH BEARING
2 - FOURTH COUNTERSHAFT GEAR
3 - SIXTH COUNTERSHAFT GEAR
(19) I nstal l countershaft i nto the fourth/si xth coun-
tershaft gear assembl y i n the shop press.
(20) Press countershaft i nto si xth gear (Fi g. 71).
CAUTION: Gear and shaft must be aligned while
pressing or the gear will bind on the shaft.
(21) Pl ace fi fth countershaft gear i nto the shop
press.
(22) I nstal l countershaft i nto the fi fth countershaft
gear and press countershaft i nto fi fth gear (Fi g. 72).
CAUTION: Gear and shaft must be aligned while
pressing or the gear will bind on the shaft.
(23) Pl ace front countershaft beari ng onto the
countershaft.
(24) I nstal l front countershaft beari ng onto the
countershaft wi th I nstal l er 8236 and Handl e C-4171.
(25) I nstal l a new snap-ri ng to hol d the front
countershaft beari ng onto the countershaft.
(26) Pl ace rear countershaft beari ng onto the coun-
tershaft.
Fig. 71 COUNTERSHAFT INTO SIXTH GEAR
1 - COUNTERSHAFT
2 - SIXTH COUNTERSHAFT GEAR
3 - 3-4 SYNCHRO
Fig. 72 COUNTERSHAFT TO FIFTH
COUNTERSHAFT GEAR
1 - COUNTERSHAFT
2 - FIFTH COUNTERSHAFT GEAR
INPUT SHAFT
(1) Pl ace the i nput shaft beari ng onto the i nput
shaft.
(2) I nstal l i nput shaft beari ng wi th I nstal l er
MD998805 (Fi g. 73).
(3) Posi ti on the i nput shaft beari ng oi l gui de on
the i nput shaft (Fi g. 74).
(4) I nstal l i nput shaft beari ng oi l gui de wi th
I nstal l er MD998805.
(5) Pl ace the output shaft pocket beari ng race i n
the i nput shaft.
(6) I nstal l output shaft pocket beari ng race i nto
the i nput shaft wi th I nstal l er C-4628 and Handl e
C-4171 (Fi g. 75).
Fig. 73 INPUT SHAFT BEARING
1 - INSTALLER
Fig. 74 INPUT SHAFT OIL GUIDE
1 - INPUT SHAFT
2 - INPUT SHAFT OIL GUIDE
Fig. 75 OUTPUT SHAFT POCKET BEARING RACE
1 - HANDLE
2 - INPUT SHAFT
3 - INSTALLER
CLUTCH HOUSING
(1) I nstal l i nput shaft beari ng race so that the
beari ng race protrudes 0.3 i n. above the front surface
of the cl utch housi ng. I nstal l beari ng race wi th
Remover/I nstal l er 8237 and Handl e C-4171.
(2) I nstal l countershaft front beari ng race i nto the
cl utch housi ng so that the beari ng race protrudes 0.4
i n. above the front surface of the cl utch housi ng.
I nstal l beari ng race wi th Remover 6061-1 and Han-
dl e C-4171.
(3) I nstal l countershaft oi l gui de and spacer i nto
the countershaft front beari ng bore i n the cl utch
(4) Cl ean al l ol d seal er from the i nput shaft
retai ner and the cl utch housi ng but DO NOT appl y
new seal er at thi s ti me. New seal er wi l l be appl i ed
after al l the prel oad measurements are made and
end-pl ay shi ms are i nstal l ed.
NOTE: Do not replace the input shaft seal at this
time. A new seal will be installed after all the pre-
load measurements are made and endplay shims
are installed.
(5) I nstal l i nput shaft retai ner onto the cl utch
housi ng and i nstal l bol ts to hol d the i nput shaft
retai ner.
GEARTRAIN
(1) I nstal l i nput shaft i nto Support Stand 8246.
(2) I nstal l fi fth gear fri cti on cone onto the i nput
shaft.
(3) I nstal l fi fth gear bl ocker ri ng onto the fi fth
gear fri cti on cone.
(4) I nstal l output shaft i nto the i nput shaft (Fi g.
77).
Fig. 76 OIL GUIDE AND SPACER
1 - 0.3 IN. BEYOND FLUSH
2 - 0.4 IN. BEYOND FLUSH
Fig. 77 OUTPUT SHAFT AND INPUT SHAFT
1 - OUTPUT SHAFT
2 - INPUT SHAFT
3 - SUPPORT STAND
(5) I nstal l countershaft i nto the Support Stand
8246 and veri fy that al l gears are meshed wi th thei r
mates on the output shaft (Fi g. 78).
(6) I nstal l Fi xture 8232 to the output shaft and
countershaft.
(7) I nstal l Hol di ng Tool 8242 onto the 5-6 synchro
and ti ghten the screw to hol d the 5-6 synchro
together duri ng the remai nder of the i nstal l ati on pro-
cedure.
(8) Attach a engi ne crane or equi val ent to Fi xture
8232 and move the geartrai n from the Support Stand
8246 to the cl utch housi ng (Fi g. 79).
(9) I nstal l shi ft forks and rai l s onto the geartrai n
(Fi g. 80).
NOTE: The closest shift arm to the geartrain is for
Reverse. The next is 5-6, then 3-4 and then 1-2
when moving out from the geartrain.
(10) I nstal l geartrai n and shi ft rai l s i nto the cl utch
housi ng. Lower the geartrai n and rai l s i nto the hous-
i ng sl owl y whi l e gui di ng i nput shaft through i nput
shaft seal . Avoi d any bi nds on the shi ft rai l s, forks
and synchros as the rai l s enter thei r bushi ngs.
Fig. 78 COUNTERSHAFT WITH OUTPUT SHAFT
1 - COUNTERSHAFT
2 - OUTPUT SHAFT
3 - SUPPORT STAND
Fig. 79 GEARTRAIN FIXTURE
1 - FIXTURE
2 - SUPPORT STAND
Fig. 80 SHIFT RAILS INSTALLED
1 - SHIFT RAILS
CAUTION: Do not damage input shaft seal with the
input shaft splines.
(11) Wi th the geartrai n approxi matel y 1/4 i n. from
the cl utch housi ng, remove Hol di ng Tool 8242 from
the 5-6 synchro (Fi g. 81).
(12) I nstal l 5-6 crossover bracket and arm to the
shi ft rai l s and the cl utch housi ng.
(13) Lower geartrai n the remai nder of the way
i nto the cl utch housi ng.
(14) I nstal l the 5-6 crossover bracket bol ts and
(15) Remove engi ne crane and Fi xture 8232 from
the output shaft and the countershaft.
TRANSMISSION GEAR CASE
(1) I nstal l rear output shaft beari ng race i nto the
transmi ssi on gear case wi th I nstal l er C-4308 and
Handl e C-4171.
(2) I nstal l rear countershaft beari ng race i nto the
transmi ssi on gear case wi th I nstal l er 8153 and Han-
dl e C-4171.
(3) I nstal l Fi xture 8232 to the transmi ssi on gear
case.
NOTE: Shift socket must be loose on the shift shaft
and is rotated a minimum of 90 from its normal
position. This will ensure enough clearance to
install the transmission gear case.
(4) Appl y seal ant to the cl utch housi ng.
8232 and i nstal l the transmi ssi on gear case onto the
cl utch housi ng (Fi g. 83).
(6) I nstal l cl utch housi ng bol ts and ti ghten to 48
Nm (35 ft.l bs.).
(7) I nstal l shi ft socket rol l pi n wi th a sui tabl e 6
mm (7/32 i n.) punch and hammer.
MAINSHAFT AND COUNTERSHAFT ENDPLAY
(1) Wi th transmi ssi on i n verti cal posi ti on, use
Socket 6993 to rotate the shafts and seat the bear-
i ngs.
Fig. 81 HOLDING TOOL
1 - HOLDING TOOL
2 - 5-6 SYNCHRO
Fig. 82 5-6 CROSSOVER BRACKET BOLTS
1 - 5-6 CROSSOVER BRACKET
Fig. 83 LIFT FIXTURE
1 - FIXTURE
2 - TRANSMISSION CASE
(2) Measure mai nshaft endpl ay wi th Di al I ndi cator
Set C-3339 and Extensi on Rod 8161 i nstal l ed onto
the rear of the transmi ssi on gear case (Fi g. 84).
(3) Measure countershaft end-pl ay wi th Di al I ndi -
cator Set C-3339 and Extensi on Rod 8161 i nstal l ed
onto the rear of the transmi ssi on gear case (Fi g. 85).
(4) Rotate transmi ssi on i nto a hori zontal posi ti on
and remove the i nput shaft retai ner.
(5) I nstal l shi ms necessary to achi eve an end-pl ay
of 0-0.10 mm (0-0.004 i n.) for the mai nshaft and
countershaft.
NOTE: Countershaft shims go between the bearing
race and spacer. Mainshaft shims go into the input
shaft retainer.
(6) I nstal l a new i nput shaft seal i nto the i nput
shaft retai ner wi th I nstal l er C-4965.
(7) I nstal l i nput shaft oi l gui de wi th C-3972-A and
Handl e C-4171.
(8) Appl y seal er to the i nput shaft retai ner and
i nstal l retai ner onto the cl utch housi ng. I nstal l bol ts
and ti ghten to 28 Nm (20 ft.l bs.).
REVERSE GEAR
(1) I nstal l reverse shi ft fork and synchroni zer as
an assembl y onto the reverse shi ft rai l and output
shaft (Fi g. 86).
NOTE: Raised square shoulder and snap-ring on
the synchro face the case.
Fig. 84 MEASURE MAINSHAFT ENDPLAY
1 - DIAL INDICATOR
2 - EXTENSION ROD
3 - MAIN SHAFT
Fig. 85 MEASURE COUNTERSHAFT END-PLAY
1 - EXTENSION ROD
2 - DIAL INDICATOR
3 - COUNTERSHAFT
Fig. 86 REVERSE SHIFT FORK AND SYNCHRO
1 - REVERSE SYNCHRO
2 - REVERSE SHIFT FORK
(2) I nstal l rol l -pi n securi ng the reverse shi ft fork
to the reverse shi ft rai l wi th 6 mm (7/32 i n.) punch
and a hammer.
(3) I nstal l reverse gear beari ng sl eeve onto the
output shaft wi th I nstal l er 6446 i f necessary (Fi g.
87).
(4) I nstal l reverse gear, reverse gear synchroni zer
cone, reverse gear outer bl ocker ri ng and reverse
gear beari ng (Fi g. 88).
(5) I nstal l output shaft bal l beari ng assembl y and
reverse thrust washer onto the output shaft (Fi g. 89).
NOTE: Raised shoulder on thrust washer faces
away from the reverse gear.
(6) I nstal l a new output shaft nut onto the output
shaft.
(7) Wi th Wrench 8226 on the output shaft nut and
Socket 6993 or 6984 hol di ng the output shaft, ti ghten
the nut to 339 Nm (250 ft.l bs.).
(8) Stake nut i nto the sl ot i n the output shaft wi th
a 9 mm (5/16 i n.) punch.
(9) Press countershaft reverse gear i nto the sl eeve
wi th a shop press.
Fig. 87 REVERSE BEARING SLEEVE
1 - REVERSE GEAR BEARING SLEEVE
Fig. 88 REVERSE GEAR COMPONENTS
1 - REVERSE GEAR
2 - REVERSE BEARING
3 - BLOCKER RING
4 - FRICTION CONE
Fig. 89 OUTPUT SHAFT BEARING AND THRUST
WASHER
1 - OUTPUT SHAFT BALL BEARING
2 - THRUST WASHER
(10) I nstal l reverse countershaft rear beari ng onto
the countershaft reverse gear assembl y wi th I nstal l er
C-4652 and Handl e C-4171.
(11) I nstal l reverse i dl er gear rear beari ng, beari ng
spacer, front beari ng, and front thrust washer onto
the i dl er gear shaft.
(12) I nstal l i dl er and reverse countershaft gears
together (Fi g. 90).
(13) I nstal l reverse i dl er thrust washer from the
reverse i dl er.
(14) I nstal l crossover cam rol l ers and pi n (Fi g. 91).
(1) I nstal l extensi on housi ng bushi ng wi th
I nstal l er 8156 and Handl e C-4171, i f necessary. The
oi l feed hol e must be at the 12 ocl ock posi ti on when
i nstal l ed.
(2) On 4X2 vehi cl es, i nstal l extensi on housi ng seal
wi th I nstal l er 8154 and Handl e C-4171, wi th the
weep hol e at the bottom.
NOTE: Drain hole located in the dust boot portion
of the seal must face downward ( toward the
ground) when installed.
(3) On 4X4 vehi cl es, i nstal l adapter housi ng seal
wi th I nstal l er C-3860-A and Handl e C-4171.
(4) I nstal l the crossover cam bushi ng i nto the
extensi on/adapter housi ng wi th I nstal l er 8239 and
Handl e C-4171.
(5) Cl ean the rear of the transmi ssi on case of al l
seal er.
(6) I nstal l reverse countershaft gear beari ng race
onto the reverse countershaft gear beari ng.
(7) Measure the di stance from the back of the
beari ng race to Gauge Bar 6311 (Fi g. 92).
(8) Measure thi ckness of the gauge bar and record
the total of the two measurements.
(9) Cl ean al l the seal er from the extensi on/adapter
housi ng.
Fig. 90 REVERSE IDLER AND COUNTERSHAFT
GEARS
2 - COUNTERSHAFT REVERSE GEAR
Fig. 91 CROSSOVER CAM ROLLERS AND PIN
1 - CROSSOVER CAM PIN
2 - CROSSOVER CAM ROLLERS
Fig. 92 Measure Height of Reverse Countershaft
1 - MEASURE DISTANCE FROM RACE TO GAUGE BAR
(10) Pl ace Gauge Bar 6311 across the housi ng face.
Measure the di stance from the top of the bar to the
bottom of the reverse countershaft beari ng race bore
(Fi g. 93).
(11) Subtract thi ckness of the gauge bar from the
measurement and record the resul t.
(12) The di fference between the two measurements
i s the end-pl ay for the reverse countershaft gear
assembl y.
(13) I nstal l shi ms to achi eve 0.15-0.25 mm (0.006-
0.010 i n.) end-pl ay for the reverse countershaft gear
assembl y i nto the reverse countershaft beari ng race
bore.
(14) Use I nstal l er to i nstal l the reverse counter-
shaft beari ng race i nto the extensi on/adapter hous-
i ng.
(15) I nstal l back-up l amp swi tch i nto the exten-
si on/adapter housi ng and ti ghten to 28 Nm (20
ft.l bs.).
(16) I nstal l crossover cam i nto the extensi on/
adapter housi ng.
(17) I nstal l bol t to hol d the crossover cam to the
extensi on/adapter housi ng (Fi g. 94).
(18) I nstal l crossover detent pl unger, spri ng and
pl ug i nto the extensi on/adapter housi ng. Ti ghten the
pl ug to 47.5 Nm (35 ft.l bs.) (Fi g. 95).
(19) Appl y seal er to the surface of the transmi s-
si on case.
(20) I nstal l extensi on/adapter housi ng onto the
(21) I nstal l bol ts to hol d the extensi on/adapter
housi ng onto the transmi ssi on gear case. Ti ghten
bol ts to 48 Nm (35 ft.l bs.).
(22) I nstal l shi ft rai l bl ocker bol t and ti ghten bol t
to 55 Nm (41 ft.l bs.).
(23) I nstal l pri mary shi ft rai l detent pl unger,
spri ng and pl ug i nto the transmi ssi on case. Ti ghten
detent pl ug to 47.5 Nm (35 ft.l bs.).
(24) I nstal l shi ft tower onto the transmi ssi on case
and ti ghten bol ts to 9 Nm (7 ft.l bs.).
INSTALLATION
NOTE: If installing a new transmission, use all com-
ponents supplied with the transmission. If a new
shift tower is supplied with the new transmission,
do not re-use the original shift tower.
Fig. 93 MEASURE DEPTH OF REVERSE
COUNTERSHAFT GEAR BEARING RACE BORE
1 - GAUGE BAR TO BEARING RACE BORE MEASUREMENT
Fig. 94 CROSSOVER CAM BOLT
1 - CROSSOVER CAM
2 - BOLT
Fig. 95 CROSSOVER CAM DETENT PLUG
1 - DETENT PLUG
(1) Appl y a l i ght coat of Mopar hi gh temperature
beari ng grease or equi val ent to contact surfaces of
fol l owi ng components:
rel ease beari ng sl i de surface of front retai ner.
rel ease fork.
(2) Appl y seal er to threads of bottom PTO cover
bol t and i nstal l bol t i n case.
(3) Mount transmi ssi on on jack and posi ti on trans-
mi ssi on under vehi cl e.
(4) Rai se transmi ssi on unti l i nput shaft i s centered
i n cl utch di sc hub.
(5) Move transmi ssi on forward and start i nput
shaft i n cl utch di sc and pi l ot bushi ng/beari ng.
(6) Work transmi ssi on forward unti l seated agai nst
engi ne bl ock. Do not al l ow transmi ssi on to remai n
unsupported after i nput shaft has entered cl utch di sc.
(7) I nstal l and ti ghten transmi ssi on-to-engi ne
bl ock bol ts.
(8) I nstal l cl utch sl ave cyl i nder.
(9) Connect backup l i ght swi tch wi res.
(10) Posi ti on transmi ssi on harness wi res i n cl i ps
on transmi ssi on.
(11) I nstal l transmi ssi on mount on transmi ssi on or
rear crossmember.
(12) I nstal l rear crossmember.
(13) Remove transmi ssi on jack and engi ne support
fi xture.
(14) Fi l l transmi ssi on wi th requi red l ubri cant (Fi g.
96). Check l ubri cant l evel i n transfer case i f equi pped.
TWO WHEEL DRIVE
(1) I nstal l propel l er shaft wi th referece marks
al i gned.
(4) Shi ft transmi ssi on i nto thi rd gear.
(5) Cl ean the mati ng surfaces of shi ft tower and
i sol ator pl ate wi th sui tabl e wax and grease remover.
seal i ng surface of the transmi ssi on case. Do not over
appl y seal ant.
(7) I nstal l i sol ator pl ate onto the transmi ssi on case
metal si de down.
(8) I nstal l shi ft tower onto the i sol ator pl ate. No
seal ant i s necessary between the shi ft tower and top
of i sol ator pl ate.
(9) Veri fy shi ft tower, i sol ator pl ate and the shi ft
socket are properl y al i gned.
(10) I nstal l bol ts to hol d the shi ft tower to the i so-
l ator pl ate and the transmi ssi on case. Ti ghten bol ts
to 10.211.25 Nm (7.58.3 ft. l bs.).
(11) I nstal l shi ft boot and bezel .
FOUR WHEEL DRIVE
(1) I nstal l and secure transfer case on the trans-
mi ssi on jack.
(2) Rai se and al i gn transfer case i nput gear wi th
transmi ssi on mai nshaft.
(3) Move transfer case forward and seat i t on
adapter.
(4) I nstal l and ti ghten transfer case mounti ng nuts to
41-47 Nm (30-35 ft. l bs.) i f case has 3/8 studs. I f case
has 5/16 studs ti ghten to 30-41 Nm (22-30 ft. l bs.).
(5) Connect transfer case shi ft l ever to range l ever
on transfer case.
(6) I nstal l propel l er shafts wi th reference marks
al i gned.
(7) I nstal l transfer case ski d pl ate, i f equi pped,
and crossmember. Ti ghten attachi ng bol ts/nuts to 41
Nm (30 ft. l bs.).
(11) Cl ean the mati ng surfaces of shi ft tower, i so-
l ator pl ate and transmi ssi on case wi th sui tabl e wax
and grease remover.
the seal i ng surface of the transmi ssi on case. Do not
over appl y seal ant.
(13) I nstal l i sol ator pl ate onto the transmi ssi on
case, metal si de down.
seal ant i s necessary between the shi ft tower and top
of i sol ator pl ate.
i sol ator pl ate and the transmi ssi on case. Ti ghten the
shi ft tower bol ts to 10.2-11.25 Nm (7.5-8.3 ft. l bs.).
(17) I nstal l shi ft l ever boot and bezel .
Fig. 96 FILL PLUG
1 - FILL PLUG
SPECIFICATIONS - NV5600
Plug, Crossover Cam and Detent 48 35 -
Bolt, Input Retainer 28 20 -
Bolt, 5-6 Crossover Bracket 28 20 -
Bolt, Clutch Housing 48 35 -
Bolt, Extension/Adapter Housing 48 35 -
Bolt, Shift Tower 9 7 80
Switch, Back-up Lamp 28 20 -
Bolt, Shift Blocker 55 41 -
Bolt, PTO Cover 40 30 -
Pivot, Clutch Release Lever 22 16 -
Plug, Fill 30 22 -
Nut, Output Shaft 339 250 -
SPECIAL TOOLS
REMOVER 8155
INSTALLER 8156
HANDLE C-4171
INSTALLER C-3972-A
INSTALLER 8154
WRENCH 8226
SOCKET 6984
SOCKET 6984
PULLER 6444
JAWS 6447
JAWS 6451
INSTALLER 6061
INSTALLER 6448
INSTALLER C-4308
ROD EXTENSION 8161
FIXTURE 8227
INSTALLER 8228
FIXTURE 8230
FIXTURE 8232
REMOVER 8233
REMOVER 8234
GUIDE 8235
INSTALLER 8236
INSTALLER/REMOVER 8237
INSTALLER/REMOVE 8238
INSTALLER 8239
REMOVER 8240
FIXTURE 8241
HOLDING 8242
REMOVER 8243
PULLER 8244
REMOVER 8245
SUPPORT STAND 8246
REMOVER 8262
REMOVER 8271
DIAL INDICATOR C-3339
INSTALLER C-4965
REMOVER L-4418
PULLER C-293-PA
ADAPTERS C-293-52
INSTALLER MD998805
REMOVAL
(2) Mark propel l er shaft and yokes for i nstal l ati on
reference and remove shaft.
(3) Remove the transfer case.
(4) Remove the adapter housi ng seal wi th a pry
tool or sl i de hammer wi th a screw.
INSTALLATION
(1) I nstal l adapter housi ng seal wi th I nstal l er and
Handl e C-4171.
(2) I nstal l transfer case.
al i gned.
(4) Check fl ui d l evel .
REMOVAL
(1) Mark propel l er shaft and pi ni on yoke for
i nstal l ati on reference and remove the propel l er shaft.
(2) Remove extensi on housi ng seal wi th a pry tool
or a sl i de hammer and screw.
(3) Remove extensi on housi ng bushi ng wi th
Remover 8155 (Fi g. 97).
INSTALLATION
(1) I nstal l extensi on housi ng bushi ng wi th
I nstal l er 8156 and Handl e C-4171 (Fi g. 98).
(2) I nstal l extensi on housi ng seal wi th I nstal l er
8154 and Handl e C-4171 (Fi g. 99).
al i gned.
(4) Check and fi l l transmi ssi on.
Fig. 97 EXTENSION HOUSING BUSHING REMOVAL
1 - REMOVER
Fig. 98 Install Extension Housing Bushing
1 - HANDLE
2 - INSTALLER
3 - BUSHING
Fig. 99 EXTENSION HOUSING SEAL INSTALLER
1 - INSTALLER
2 - HANDLE
SHIFT COVER
REMOVAL
(2) Unscrew and remove the shi ft l ever extensi on
from the shi ft
i sol ator pl ate and transmi ssi on gear case.
(5) Remove the shi ft tower (Fi g. 100) and i sol ator
pl ate (Fi g. 101) from the transmi ssi on.
INSTALLATION
tor pl ate and transmi ssi on gear case wi th sui tabl e
wax and grease remover.
the seal i ng surface of the transmi ssi on. Do not over
appl y seal ant.
(4) I nstal l i sol ator pl ate onto the transmi ssi on,
metal si de down.
seal ant i s necessary between the shi ft tower and i so-
l ator pl ate.
(6) Veri fy shi ft tower, i sol ator pl ate and shi ft tower
bushi ngs are properl y al i gned.
(7) I nstal l shi ft tower bol ts and ti ghten the shi ft
tower bol ts to 8-10 Nm (7-9 ft. l bs.).
(8) I nstal l shi ft l ever extensi on, shi ft boot and
bezel .
Fig. 100 SHIFT TOWER
1 - SHIFT TOWER
2 - TRANSMISSION
Fig. 101 SHIFT TOWER ISOLATOR PLATE
1 - ISOLATOR PLATE
2 - TRANSMISSION
AUTOMATIC TRANSMISSION - 48RE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 48RE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 132
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 134
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 140
DIAGNOSIS AND TESTING - PRELIMINARY . 140
DIAGNOSIS AND TESTING - ROAD
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . 141
DIAGNOSIS AND TESTING - AIR TESTING
TRANSMISSION CLUTCH AND BAND
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 144
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK . . . . . . . . . . . . . . . . 144
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR . . . . . . . . . . . . . . . . . . . . . 158
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 160
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 166
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 174
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . 176
SPECIFICATIONS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 189
SPECIAL TOOLS
RE TRANSMISSION . . . . . . . . . . . . . . . . . . 191
ACCUMULATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 193
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 193
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 194
BANDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 194
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 194
ADJUSTMENTS
ADJUSTMENT - BANDS . . . . . . . . . . . . . . . 195
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 196
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 196
TRANSMISSION SHIFT INTERLOCK . . . . . . 196
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK . . . . . . . . . . . . . . . . . . . 196
ELECTRONIC GOVERNOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 197
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 198
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 200
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 201
FLUID AND FILTER
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL . . . . . . . . . . . . . 201
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID . . . . . . . . . . . . . . . . . . . . . . . 201
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION . . . . . . . . . . . . . . . . . . . . 202
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT . . . . . . . . . . . . . . . 203
STANDARD PROCEDURE - TRANSMISSION
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
FRONT CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 205
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 205
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 205
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 206
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
FRONT SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 208
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 208
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 209
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 209
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 211
ADJUSTMENTS
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . 212
OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 213
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 213
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 214
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 214
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
21 - 130 AUTOMATIC TRANSMISSION - 48RE DR
OUTPUT SHAFT FRONT BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 216
OUTPUT SHAFT REAR BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 217
OVERDRIVE CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 217
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 217
OVERDRIVE UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 218
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 225
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 235
OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 236
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 236
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 236
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 237
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
PISTONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 239
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 239
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 241
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 241
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 242
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 243
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
REAR CLUTCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 247
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 248
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 248
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 248
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
REAR SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 251
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 251
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 251
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
SHIFT MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 252
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 252
SOLENOID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 252
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 252
SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 253
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 253
THROTTLE VALVE CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 253
ADJUSTMENTS - THROTTLE VALVE CABLE . 254
TORQUE CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 255
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 259
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 260
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 261
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 261
STANDARD PROCEDURE - TORQUE
CONVERTER DRAINBACK VALVE . . . . . . . . 261
TOW/HAUL OVERDRIVE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 261
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 262
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS . . . . . . . . . . . . . . 262
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 262
TRANSMISSION RANGE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 263
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 263
DIAGNOSIS AND TESTING - TRANSMISSION
RANGE SENSOR (TRS) . . . . . . . . . . . . . . . . 264
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 266
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 267
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 267
VALVE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 267
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 272
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 287
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 298
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 309
ADJUSTMENTS - VALVE BODY . . . . . . . . . . . 310
DR AUTOMATIC TRANSMISSION - 48RE 21 - 131
AUTOMATIC TRANSMISSION -
48RE
DESCRIPTION
The 48RE (Fi g. 1) i s a four speed ful l y automati c
transmi ssi ons wi th an el ectroni c governor. The 48RE
i s equi pped wi th a l ock-up cl utch i n the torque con-
verter. Fi rst through thi rd gear ranges are provi ded
by the cl utches, bands, overrunni ng cl utch, and pl an-
etary gear sets i n the transmi ssi on. Fourth gear
range i s provi ded by the overdri ve uni t that contai ns
an overdri ve cl utch, di rect cl utch, pl anetary gear set,
and overrunni ng cl utch.
The transmi ssi on contai ns a front, rear, and di rect
cl utch whi ch functi on as the i nput dri vi ng compo-
nents. I t al so contai ns the ki ckdown (front) and the
l ow/reverse (rear) bands whi ch, al ong wi th the over-
runni ng cl utch and overdri ve cl utch, serve as the
hol di ng components. The dri vi ng and hol di ng compo-
nents combi ne to sel ect the necessary pl anetary gear
components, i n the front, rear, or overdri ve pl anetary
gear set, transfer the engi ne power from the i nput
shaft through to the output shaft.
The val ve body i s mounted to the l ower si de of the
transmi ssi on and contai ns the val ves to control pres-
sure regul ati on, fl ui d fl ow control , and cl utch/band
appl i cati on. The oi l pump i s mounted at the front of
the transmi ssi on and i s dri ven by the torque con-
verter hub. The pump suppl i es the oi l pressure nec-
essary for cl utch/band actuati on and transmi ssi on
l ubri cati on.
F
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8
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AUTOMATIC TRANSMISSION - 48RE (Continued)
IDENTIFICATION
Transmi ssi on i denti fi cati on numbers are stamped
on the l eft si de of the case just above the oi l pan gas-
ket surface (Fi g. 2). Refer to thi s i nformati on when
orderi ng repl acement parts.
GEAR RATIOS
The 48RE gear rati os are:
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.45:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.69:1
Rev. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20:1
OPERATION
The appl i cati on of each dri vi ng or hol di ng compo-
nent i s control l ed by the val ve body based upon the
manual l ever posi ti on, throttl e pressure, and gover-
nor pressure. The governor pressure i s a vari abl e
pressure i nput to the val ve body and i s one of the
si gnal s that a shi ft i s necessary. Fi rst through fourth
gear are obtai ned by sel ecti vel y appl yi ng and rel eas-
i ng the di fferent cl utches and bands. Engi ne power i s
thereby routed to the vari ous pl anetary gear assem-
bl i es whi ch combi ne wi th the overrunni ng cl utch
assembl i es to generate the di fferent gear rati os. The
torque converter cl utch i s hydraul i cal l y appl i ed and
i s rel eased when fl ui d i s vented from the hydraul i c
ci rcui t by the torque converter control (TCC) sol enoi d
on the val ve body. The torque converter cl utch i s con-
trol l ed by the Powertrai n Control Modul e (PCM). The
torque converter cl utch engages i n fourth gear, and
i n thi rd gear under vari ous condi ti ons, such as when
the O/D swi tch i s OFF, when the vehi cl e i s crui si ng
on a l evel surface after the vehi cl e has warmed up.
The torque converter cl utch can al so be engaged i n
the MANUAL SECOND gear posi ti on i f hi gh trans-
mi ssi on temperatures are sensed by the PCM. The
torque converter cl utch wi l l di sengage momentari l y
when an i ncrease i n engi ne l oad i s sensed by the
PCM, such as when the vehi cl e begi ns to go uphi l l or
the throttl e pressure i s i ncreased. The torque con-
verter cl utch feature i ncreases fuel economy and
reduces the transmi ssi on fl ui d temperature.
Si nce the overdri ve cl utch i s appl i ed i n fourth gear
onl y and the di rect cl utch i s appl i ed i n al l ranges
except fourth gear, the transmi ssi on operati on for
park, neutral , and fi rst through thi rd gear wi l l be
descri bed fi rst. Once these powerfl ows are descri bed,
the thi rd to fourth shi ft sequence wi l l be descri bed.
1 - TORQUE CONVERTER 10 - OVERDRIVE CLUTCH
2 - INPUT SHAFT 11 - DIRECT CLUTCH
3 - OIL PUMP 12 - PLANETARY GEAR
4 - FRONT BAND 13 - INTERMEDIATE SHAFT
5 - FRONT CLUTCH 14 - OVERDRIVE OVERRUNNING CLUTCH
6 - REAR CLUTCH 15 - DIRECT CLUTCH SPRING
7 - PLANETARIES 16 - OVERDRIVE PISTON RETAINER
8 - REAR BAND 17 - OIL PAN
9 - OVERRUNNING CLUTCH 18 - VALVE BODY
Fig. 2 Transmission Part Number And Serial
Number Location
1 - PART NUMBER
2 - BUILD DATE
3 - SERIAL NUMBER
PARK POWERFLOW
As the engi ne i s runni ng and the crankshaft i s
rotati ng, the fl expl ate and torque converter, whi ch
are al so bol ted to i t, are al l rotati ng i n a cl ockwi se
di recti on as vi ewed from the front of the engi ne. The
notched hub of the torque converter i s connected to
the oi l pumps i nternal gear, suppl yi ng the transmi s-
si on wi th oi l pressure. As the converter turns, i t
turns the i nput shaft i n a cl ockwi se di recti on. As the
i nput shaft i s rotati ng, the front cl utch hub-rear
cl utch retai ner and al l thei r associ ated parts are al so
rotati ng, al l bei ng di rectl y connected to the i nput
shaft. The power fl ow from the engi ne through the
front cl utch hub and rear cl utch retai ner stops at the
rear cl utch retai ner. Therefore, no power fl ow to the
output shaft occurs because no cl utches are appl i ed.
The onl y mechani sm i n use at thi s ti me i s the park-
i ng sprag (Fi g. 3), whi ch l ocks the parki ng gear on
the output shaft to the transmi ssi on case.
NEUTRAL POWERFLOW
Wi th the gear sel ector i n the NEUTRAL posi ti on
(Fi g. 4), the power fl ow of the transmi ssi on i s essen-
ti al l y the same as i n the park posi ti on. The onl y
operati onal di fference i s that the parki ng sprag has
been di sengaged, unl ocki ng the output shaft from the
transmi ssi on case and al l owi ng i t to move freel y.
Fig. 3 Park Powerflow
1 - PAWL ENGAGED FOR PARK
2 - PARK SPRAG
3 - OUTPUT SHAFT
Fig. 4 Neutral Powerflow
1 - PAWL DISENGAGED FOR NEUTRAL
2 - PARK SPRAG
3 - OUTPUT SHAFT
4 - CAM
5 - PAWL
REVERSE POWERFLOW
When the gear sel ector i s moved i nto the
REVERSE posi ti on (Fi g. 5), the front cl utch and the
rear band are appl i ed. Wi th the appl i cati on of the
front cl utch, engi ne torque i s appl i ed to the sun gear,
turni ng i t i n a cl ockwi se di recti on. The cl ockwi se
rotati on of the sun gear causes the rear pl anet pi n-
i ons to rotate agai nst engi ne rotati on i n a counter-
cl ockwi se di recti on. The rear band i s hol di ng the l ow
reverse drum, whi ch i s spl i ned to the rear carri er.
Si nce the rear carri er i s bei ng hel d, the torque from
the pl anet pi ni ons i s transferred to the rear annul us
gear, whi ch i s spl i ned to the output shaft. The output
shaft i n turn rotates wi th the annul us gear i n a
countercl ockwi se di recti on gi vi ng a reverse gear out-
put. The enti re transmi ssi on of torque i s appl i ed to
the rear pl anetary gearset onl y. Al though there i s
torque i nput to the front gearset through the sun
gear, no other member of the gearset i s bei ng hel d.
Duri ng the enti re reverse stage of operati on, the
front pl anetary gears are i n an i dl i ng condi ti on.
Fig. 5 Reverse Powerflow
1 - FRONT CLUTCH ENGAGED 5 - OUTPUT SHAFT
2 - OUTPUT SHAFT 6 - INPUT SHAFT
3 - LOW/REVERSE BAND APPLIED 7 - FRONT CLUTCH ENGAGED
4 - INPUT SHAFT 8 - LOW/REVERSE BAND APPLIED
FIRST GEAR POWERFLOW
When the gearshi ft l ever i s moved i nto the DRI VE
posi ti on the transmi ssi on goes i nto fi rst gear (Fi g. 6).
As soon as the transmi ssi on i s shi fted from PARK or
NEUTRAL to DRI VE, the rear cl utch appl i es, appl y-
i ng the rear cl utch pack to the front annul us gear.
Engi ne torque i s now appl i ed to the front annul us
gear turni ng i t i n a cl ockwi se di recti on. Wi th the
front annul us gear turni ng i n a cl ockwi se di recti on, i t
causes the front pl anets to turn i n a cl ockwi se di rec-
ti on. The rotati on of the front pl anets cause the sun
to revol ve i n a countercl ockwi se di recti on. The sun
gear now transfers i ts countercl ockwi se rotati on to
the rear pl anets whi ch rotate back i n a cl ockwi se
di recti on. Wi th the rear annul us gear stati onary, the
rear pl anet rotati on on the annul us gear causes the
rear pl anet carri er to revol ve i n a countercl ockwi se
di recti on. The rear pl anet carri er i s spl i ned i nto the
l ow-reverse drum, and the l ow reverse drum i s
spl i ned to the i nner race of the over-runni ng cl utch.
Wi th the over-runni ng cl utch l ocked, the pl anet car-
ri er i s hel d, and the resul ti ng torque provi ded by the
pl anet pi ni ons i s transferred to the rear annul us
gear. The rear annul us gear i s spl i ned to the output
shaft and rotated al ong wi th i t (cl ockwi se) i n an
underdri ve gear reducti on mode.
Fig. 6 First Gear Powerflow
1 - OUTPUT SHAFT 5 - OVER-RUNNING CLUTCH HOLDING
2 - OVER-RUNNING CLUTCH HOLDING 6 - INPUT SHAFT
3 - REAR CLUTCH APPLIED 7 - REAR CLUTCH APPLIED
SECOND GEAR POWERFLOW
I n DRI VE-SECOND (Fi g. 7), the same el ements
are appl i ed as i n MANUAL-SECOND. Therefore, the
power fl ow wi l l be the same, and both gears wi l l be
di scussed as one i n the same. I n DRI VE-SECOND,
the transmi ssi on has proceeded from fi rst gear to i ts
shi ft poi nt, and i s shi fti ng from fi rst gear to second.
The second gear shi ft i s obtai ned by keepi ng the rear
cl utch appl i ed and appl yi ng the front (ki ckdown)
band. The front band hol ds the front cl utch retai ner
that i s l ocked to the sun gear dri vi ng shel l . Wi th the
rear cl utch sti l l appl i ed, the i nput i s sti l l on the front
annul us gear turni ng i t cl ockwi se at engi ne speed.
Now that the front band i s hol di ng the sun gear sta-
ti onary, the annul us rotati on causes the front pl anets
to rotate i n a cl ockwi se di recti on. The front carri er i s
then al so made to rotate i n a cl ockwi se di recti on but
at a reduced speed. Thi s wi l l transmi t the torque to
the output shaft, whi ch i s di rectl y connected to the
front pl anet carri er. The rear pl anetary annul us gear
wi l l al so be turni ng because i t i s di rectl y spl i ned to
the output shaft. Al l power fl ow has occurred i n the
front pl anetary gear set duri ng the dri ve-second
stage of operati on, and now the over-runni ng cl utch,
i n the rear of the transmi ssi on, i s di sengaged and
freewheel i ng on i ts hub.
Fig. 7 Second Gear Powerflow
1 - KICKDOWN BAND APPLIED 6 - INPUT SHAFT
2 - OUTPUT SHAFT 7 - REAR CLUTCH APPLIED
3 - REAR CLUTCH ENGAGED 8 - KICKDOWN BAND APPLIED
5 - OVER-RUNNING CLUTCH FREE-WHEELING
DIRECT DRIVE POWERFLOW
The vehi cl e has accel erated and reached the shi ft
poi nt for the 2-3 upshi ft i nto di rect dri ve (Fi g. 8).
When the shi ft takes pl ace, the front band i s
rel eased, and the front cl utch i s appl i ed. The rear
cl utch stays appl i ed as i t has been i n al l the forward
gears. Wi th the front cl utch now appl i ed, engi ne
torque i s now on the front cl utch retai ner, whi ch i s
l ocked to the sun gear dri vi ng shel l . Thi s means that
the sun gear i s now turni ng i n engi ne rotati on (cl ock-
wi se) and at engi ne speed. The rear cl utch i s sti l l
appl i ed so engi ne torque i s al so sti l l on the front
annul us gear. I f two members of the same pl anetary
set are dri ven, di rect dri ve resul ts. Therefore, when
two members are rotati ng at the same speed and i n
the same di recti on, i t i s the same as bei ng l ocked up.
The rear pl anetary set i s al so l ocked up, gi ven the
sun gear i s sti l l the i nput, and the rear annul us gear
must turn wi th the output shaft. Both gears are
turni ng i n the same di recti on and at the same speed.
The front and rear pl anet pi ni ons do not turn at al l
i n di rect dri ve. The onl y rotati on i s the i nput from
the engi ne to the connected parts, whi ch are acti ng
as one common uni t, to the output shaft.
FOURTH GEAR POWERFLOW
Fourth gear overdri ve range i s el ectroni cal l y con-
trol l ed and hydraul i cal l y acti vated. Vari ous sensor
i nputs are suppl i ed to the powertrai n control modul e
to operate the overdri ve sol enoi d on the val ve body.
The sol enoi d contai ns a check bal l that opens and
cl oses a vent port i n the 3-4 shi ft val ve feed passage.
The overdri ve sol enoi d (and check bal l ) are not ener-
gi zed i n fi rst, second, thi rd, or reverse gear. The vent
port remai ns open, di verti ng l i ne pressure from the
2-3 shi ft val ve away from the 3-4 shi ft val ve. The
Tow/Haul control swi tch must be i n the ON posi ti on
to transmi t overdri ve status to the PCM. A 3-4
upshi ft occurs onl y when the overdri ve sol enoi d i s
energi zed by the PCM. The PCM energi zes the over-
dri ve sol enoi d duri ng the 3-4 upshi ft. Thi s causes the
sol enoi d check bal l to cl ose the vent port al l owi ng
l i ne pressure from the 2-3 shi ft val ve to act di rectl y
on the 3-4 upshi ft val ve. Li ne pressure on the 3-4
shi ft val ve overcomes val ve spri ng pressure movi ng
the val ve to the upshi ft posi ti on. Thi s acti on exposes
the feed passages to the 3-4 ti mi ng val ve, 3-4 qui ck
fi l l val ve, 3-4 accumul ator, and ul ti matel y to the
overdri ve pi ston. Li ne pressure through the ti mi ng
Fig. 8 Direct Drive Powerflow
1 - FRONT CLUTCH APPLIED 6 - INPUT SHAFT
2 - OVER-RUNNING CLUTCH FREE-WHEELING 7 - OVER-RUNNING CLUTCH FREE-WHEELING
3 - OUTPUT SHAFT 8 - REAR CLUTCH APPLIED
4 - REAR CLUTCH APPLIED 9 - FRONT CLUTCH APPLIED
val ve moves the overdri ve pi ston i nto contact wi th
the overdri ve cl utch. The di rect cl utch i s di sengaged
before the overdri ve cl utch i s engaged. The boost
val ve provi des i ncreased fl ui d appl y pressure to the
overdri ve cl utch duri ng 3-4 upshi fts, and when accel -
erati ng i n fourth gear. The 3-4 accumul ator cushi ons
overdri ve cl utch engagement to smooth 3-4 upshi fts.
The accumul ator i s charged at the same ti me as
appl y pressure acts agai nst the overdri ve pi ston.
TRANSMISSION
Automati c transmi ssi on probl ems can be a resul t of
poor engi ne performance, i ncorrect fl ui d l evel , i ncor-
rect l i nkage or cabl e adjustment, band or hydraul i c
control pressure adjustments, hydraul i c system mal -
functi ons or el ectri cal /mechani cal component mal -
functi ons. Begi n di agnosi s by checki ng the easi l y
accessi bl e i tems such as: fl ui d l evel and condi ti on,
l i nkage adjustments and el ectri cal connecti ons. A
road test wi l l determi ne i f further di agnosi s i s neces-
sary.
Two basi c procedures are requi red. One procedure
for vehi cl es that are dri vabl e and an al ternate proce-
dure for di sabl ed vehi cl es (wi l l not back up or move
forward).
VEHICLE IS DRIVEABLE
(1) Check for transmi ssi on faul t codes usi ng DRB
scan tool .
(2) Check fl ui d l evel and condi ti on.
(3) Adjust throttl e and gearshi ft l i nkage i f com-
pl ai nt was based on del ayed, errati c, or harsh shi fts.
(4) Road test and note how transmi ssi on upshi fts,
downshi fts, and engages.
(5) Perform hydraul i c pressure test i f shi ft prob-
l ems were noted duri ng road test.
(6) Perform ai r-pressure test to check cl utch-band
operati on.
VEHICLE IS DISABLED
(2) Check for broken or di sconnected gearshi ft or
throttl e l i nkage.
(3) Check for cracked, l eaki ng cool er l i nes, or l oose
or mi ssi ng pressure-port pl ugs.
(4) Rai se and support vehi cl e on safety stands,
start engi ne, shi ft transmi ssi on i nto gear, and note
fol l owi ng:
(a) I f propel l er shaft turns but wheel s do not,
probl em i s wi th di fferenti al or axl e shafts.
(b) I f propel l er shaft does not turn and transmi s-
si on i s noi sy, stop engi ne. Remove oi l pan, and
check for debri s. I f pan i s cl ear, remove transmi s-
si on and check for damaged dri ve pl ate, converter,
oi l pump, or i nput shaft.
(c) I f propel l er shaft does not turn and transmi s-
si on i s not noi sy, perform hydraul i c-pressure test to
determi ne i f probl em i s hydraul i c or mechani cal .
DIAGNOSIS AND TESTING - ROAD TESTING
Before road testi ng, be sure the fl ui d l evel and con-
trol cabl e adjustments have been checked and
adjusted i f necessary. Veri fy that di agnosti c troubl e
codes have been resol ved.
Observe engi ne performance duri ng the road test.
A poorl y tuned engi ne wi l l not al l ow accurate anal y-
si s of transmi ssi on operati on.
Operate the transmi ssi on i n al l gear ranges. Check
for shi ft vari ati ons and engi ne fl are whi ch i ndi cates
sl i ppage. Note i f shi fts are harsh, spongy, del ayed,
earl y, or i f part throttl e downshi fts are sensi ti ve.
Sl i ppage i ndi cated by engi ne fl are, usual l y means
cl utch, band or overrunni ng cl utch probl ems. I f the
condi ti on i s advanced, an overhaul wi l l be necessary
to restore normal operati on.
A sl i ppi ng cl utch or band can often be determi ned
by compari ng whi ch i nternal uni ts are appl i ed i n the
vari ous gear ranges. The Cl utch and Band Appl i ca-
ti on chart provi des a basi s for anal yzi ng road test
resul ts.
CLUTCH AND BAND APPLICATION CHART
SHIFT
LEVER
POSITION
TRANSMISSION CLUTCHES AND BANDS OVERDRIVE CLUTCHES
FRONT
CLUTCH
FRONT
BAND
REAR
CLUTCH
REAR
BAND
OVER-
RUNNING
CLUTCH
OVER-
DRIVE
CLUTCH
DIRECT
CLUTCH
OVER-
RUNNING
CLUTCH
Reverse X X X
Drive -
First
X X X X
Drive -
Second
X X X X
Drive -
Third
X X X X
Drive -
Fourth
X X X
Manual
Second
X X X X
Manual
First
X X X X X
Note that the rear cl utch i s appl i ed i n al l forward
ranges (D, 2, 1). The transmi ssi on overrunni ng cl utch
i s appl i ed i n fi rst gear (D, 2 and 1 ranges) onl y. The
rear band i s appl i ed i n 1 and R range onl y.
Note that the overdri ve cl utch i s appl i ed onl y i n
fourth gear and the overdri ve di rect cl utch and over-
runni ng cl utch are appl i ed i n al l ranges except fourth
gear.
For exampl e: I f sl i ppage occurs i n fi rst gear i n D
and 2 range but not i n 1 range, the transmi ssi on
overrunni ng cl utch i s faul ty. Si mi l arl y, i f sl i ppage
occurs i n any two forward gears, the rear cl utch i s
sl i ppi ng.
Appl yi ng the same method of anal ysi s, note that
the front and rear cl utches are appl i ed si mul ta-
neousl y onl y i n D range thi rd and fourth gear. I f the
transmi ssi on sl i ps i n thi rd gear, ei ther the front
cl utch or the rear cl utch i s sl i ppi ng.
I f the transmi ssi on sl i ps i n fourth gear but not i n
thi rd gear, the overdri ve cl utch i s sl i ppi ng. By sel ect-
i ng another gear whi ch does not use these cl utches,
the sl i ppi ng uni t can be determi ned. For exampl e, i f
the transmi ssi on al so sl i ps i n Reverse, the front
cl utch i s sl i ppi ng. I f the transmi ssi on does not sl i p i n
Reverse, the rear cl utch i s sl i ppi ng.
I f sl i ppage occurs duri ng the 3-4 shi ft or onl y i n
fourth gear, the overdri ve cl utch i s sl i ppi ng. Si mi -
l arl y, i f the di rect cl utch were to fai l , the transmi s-
si on woul d l ose both reverse gear and overrun
braki ng i n 2 posi ti on (manual second gear).
I f the transmi ssi on wi l l not shi ft to fourth gear, the
control swi tch, overdri ve sol enoi d or rel ated wi ri ng
may al so be the probl em cause.
Thi s process of el i mi nati on can be used to i denti fy
a sl i ppi ng uni t and check operati on. Proper use of
the Cl utch and Band Appl i cati on Chart i s the key.
Al though road test anal ysi s wi l l hel p determi ne the
sl i ppi ng uni t, the actual cause of a mal functi on usu-
al l y cannot be determi ned unti l hydraul i c and ai r
pressure tests are performed. Practi cal l y any condi -
ti on can be caused by l eaki ng hydraul i c ci rcui ts or
sti cki ng val ves.
Unl ess a mal functi on i s obvi ous, such as no dri ve
i n D range fi rst gear, do not di sassembl e the trans-
mi ssi on. Perform the hydraul i c and ai r pressure tests
to hel p determi ne the probabl e cause.
PRESSURE TEST
Hydraul i c test pressures range from a l ow of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at the rear servo pressure port i n reverse.
An accurate tachometer and pressure test gauges
are requi red. Test Gauge C-3292 has a 100 psi range
and i s used at the accumul ator, governor, and front
servo ports. Test Gauge C-3293-SP has a 300 psi
range and i s used at the rear servo and overdri ve
ports where pressures exceed 100 psi .
Pressure Test Port Locations
Test ports are l ocated at both si des of the transmi s-
si on case (Fi g. 9).
Li ne pressure i s checked at the accumul ator port
on the ri ght si de of the case. The front servo pressure
port i s at the ri ght si de of the case just behi nd the
fi l l er tube openi ng.
The rear servo and governor pressure ports are at
the ri ght rear of the transmi ssi on case. The overdri ve
cl utch pressure port i s at the l eft rear of the case.
Test One - Transmission In Manual Low
Thi s test checks pump output, pressure regul ati on,
and condi ti on of the rear cl utch and servo ci rcui t.
Both test gauges are requi red for thi s test.
(1) Connect tachometer to engi ne. Posi ti on tachom-
eter so i t can be observed from dri ver seat i f hel per
wi l l be operati ng engi ne. Rai se vehi cl e on hoi st that
wi l l al l ow rear wheel s to rotate freel y.
(2) Connect 100 psi Gauge C-3292 to accumul ator
port. Then connect 300 psi Gauge C-3293-SP to rear
servo port.
(3) Di sconnect throttl e and gearshi ft cabl es from
l evers on transmi ssi on val ve body manual shaft.
(4) Have hel per start and run engi ne at 1000 rpm.
(5) Move transmi ssi on shi ft l ever ful l y forward
i nto 1 range.
(6) Gradual l y move transmi ssi on throttl e l ever
from ful l forward to ful l rearward posi ti on and note
pressures on both gauges:
Li ne pressure at accumul ator port shoul d be
54-60 psi (372-414 kPa) wi th throttl e l ever forward
and gradual l y i ncrease to 90-96 psi (621-662 kPa) as
throttl e l ever i s moved rearward.
Rear servo pressure shoul d be same as l i ne pres-
sure wi thi n 3 psi (20.68 kPa).
Test Two - Transmission In 2 Range
Thi s test checks pump output, l i ne pressure and
pressure regul ati on. Use 100 psi Test Gauge C-3292
for thi s test.
(1) Leave vehi cl e i n pl ace on hoi st and l eave Test
Gauge C-3292 connected to accumul ator port.
(2) Have hel per start and run engi ne at 1000 rpm.
(3) Move transmi ssi on shi ft l ever one detent rear-
ward from ful l forward posi ti on. Thi s i s 2 range.
(4) Move transmi ssi on throttl e l ever from ful l for-
ward to ful l rearward posi ti on and read pressure on
gauge.
(5) Li ne pressure shoul d be 54-60 psi (372-414
kPa) wi th throttl e l ever forward and gradual l y
i ncrease to 90-96 psi (621-662 kPa) as l ever i s moved
rearward.
Test Three - Transmission In D Range Third Gear
Thi s test checks pressure regul ati on and condi ti on
of the cl utch ci rcui ts. Both test gauges are requi red
for thi s test.
(1) Turn OD swi tch off.
(2) Leave vehi cl e on hoi st and l eave Gauge C-3292
i n pl ace at accumul ator port.
(3) Move Gauge C-3293-SP over to front servo port
for thi s test.
(4) Have hel per start and run engi ne at 1600 rpm
for thi s test.
(5) Move transmi ssi on shi ft l ever two detents rear-
ward from ful l forward posi ti on. Thi s i s D range.
(6) Read pressures on both gauges as transmi ssi on
throttl e l ever i s gradual l y moved from ful l forward to
ful l rearward posi ti on:
Li ne pressure at accumul ator i n D range thi rd
gear, shoul d be 54-60 psi (372-414 kPa) wi th throttl e
l ever forward and i ncrease as l ever i s moved rear-
ward.
Front servo pressure i n D range thi rd gear,
shoul d be wi thi n 3 psi (21 kPa) of l i ne pressure up to
ki ckdown poi nt.
Test Four - Transmission In Reverse
Thi s test checks pump output, pressure regul ati on
and the front cl utch and rear servo ci rcui ts. Use 300
psi Test Gauge C-3293-SP for thi s test.
(1) Leave vehi cl e on hoi st and l eave gauge C-3292
i n pl ace at accumul ator port.
(2) Move 300 psi Gauge C-3293-SP back to rear
servo port.
Fig. 9 Pressure Test Port Locations
1 - REAR SERVO TEST PORT
2 - GOVERNOR TEST PORT
3 - ACCUMULATOR TEST PORT
4 - FRONT SERVO TEST PORT
5 - OVERDRIVE CLUTCH TEST PORT
(3) Have hel per start and run engi ne at 1600 rpm
for test.
(4) Move transmi ssi on shi ft l ever four detents rear-
ward from ful l forward posi ti on. Thi s i s Reverse range.
(5) Move transmi ssi on throttl e l ever ful l y forward
then ful l y rearward and note readi ng at Gauge
C-3293-SP.
(6) Pressure shoul d be 145 - 175 psi (1000-1207
kPa) wi th throttl e l ever forward and i ncrease to 230 -
280 psi (1586-1931 kPa) as l ever i s gradual l y moved
rearward.
Test Five - Governor Pressure
Thi s test checks governor operati on by measuri ng
governor pressure response to changes i n vehi cl e
speed. I t i s usual l y not necessary to check governor
operati on unl ess shi ft speeds are i ncorrect or i f the
transmi ssi on wi l l not downshi ft. The test shoul d be
performed on the road or on a hoi st that wi l l al l ow
the rear wheel s to rotate freel y.
(1) Move 100 psi Test Gauge C-3292 to governor
pressure port.
(2) Move transmi ssi on shi ft l ever two detents rear-
ward from ful l forward posi ti on. Thi s i s D range.
(3) Have hel per start and run engi ne at curb i dl e
speed. Then fi rml y appl y servi ce brakes so wheel s
wi l l not rotate.
(4) Note governor pressure:
Governor pressure shoul d be no more than 20.6
kPa (3 psi ) at curb i dl e speed and wheel s not rotati ng.
I f pressure exceeds 20.6 kPa (3 psi ), a faul t
exi sts i n governor pressure control system.
(5) Rel ease brakes, sl owl y i ncrease engi ne speed,
and observe speedometer and pressure test gauge (do
not exceed 30 mph on speedometer). Governor pres-
sure shoul d i ncrease i n proporti on to vehi cl e speed.
Or approxi matel y 6.89 kPa (1 psi ) for every 1 mph.
(6) Governor pressure ri se shoul d be smooth and
drop back to no more than 20.6 kPa (3 psi ), after
engi ne returns to curb i dl e and brakes are appl i ed to
prevent wheel s from rotati ng.
(7) Compare resul ts of pressure test wi th anal ysi s
chart.
Test Six - Transmission In Overdrive Fourth Gear
Thi s test checks l i ne pressure at the overdri ve
cl utch i n fourth gear range. Use 300 psi Test Gauge
C-3293-SP for thi s test. The test shoul d be performed
on the road or on a chassi s dyno.
(1) Remove tachometer; i t i s not needed for thi s test.
(2) Move 300 psi Gauge to overdri ve cl utch pres-
sure test port. Then remove other gauge and rei nstal l
test port pl ug.
(4) Turn OD swi tch on.
(5) Secure test gauge so i t can be vi ewed from
dri vers seat.
(6) Start engi ne and shi ft i nto D range.
(7) I ncrease vehi cl e speed gradual l y unti l 3-4 shi ft
occurs and note gauge pressure.
(8) Pressure shoul d be 524-565 kPa (76-82 psi )
wi th cl osed throttl e and i ncrease to 690-896 kPa
(100-130 psi ) at 1/2 to 3/4 throttl e. Note that pres-
sure can i ncrease to around 965 kPa (140 psi ) at ful l
throttl e.
(9) Return to shop or move vehi cl e off chassi s
dyno.
PRESSURE TEST ANALYSIS CHART
TEST CONDITION INDICATION
Line pressure OK during
any one test
Pump and regulator
valve OK
Line pressure OK in R
but low in D, 2, 1
Leakage in rear clutch
area (seal rings, clutch
seals)
Pressure low in D Fourth
Gear Range
Overdrive clutch piston
seal, or check ball
problem
Pressure OK in 1, 2 but
low in D3 and R
Leakage in front clutch
area
Pressure OK 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
Clogged filter, stuck
regulator valve, worn or
faulty pump, low oil level
Governor pressure too
high at idle speed
Governor pressure
solenoid valve system
fault. Refer to diagnostic
book.
Governor pressure low at
all mph figures
Faulty governor pressure
solenoid, transmission
control module, or
governor pressure
sensor
Lubrication pressure low
at all throttle positions
Clogged fluid cooler or
lines, seal rings leaking,
worn pump bushings,
pump, clutch retainer, or
clogged filter.
Line pressure high Output shaft plugged,
sticky regulator valve
Line pressure low Sticky regulator valve,
clogged filter, worn pump
DIAGNOSIS AND TESTING - AIR TESTING
TRANSMISSION CLUTCH AND BAND
OPERATION
Ai r-pressure testi ng can be used to check transmi s-
si on front/rear cl utch and band operati on. The test
can be conducted wi th the transmi ssi on ei ther i n the
vehi cl e or on the work bench, as a fi nal check, after
overhaul .
Ai r-pressure testi ng requi res that the oi l pan and
val ve body be removed from the transmi ssi on. The
servo and cl utch appl y passages are shown (Fi g. 10).
Front Clutch Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through front cl utch appl y pas-
sage. Pi ston movement can be fel t and a soft thump
heard as the cl utch appl i es.
Rear Clutch Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through rear cl utch appl y passage.
Pi ston movement can be fel t and a soft thump heard
as the cl utch appl i es.
Front Servo Air Test
Appl y ai r pressure to the front servo appl y pas-
sage. The servo rod shoul d extend and cause the
band to ti ghten around the drum. Spri ng pressure
shoul d rel ease the servo when ai r pressure i s
removed.
Rear Servo Air Test
Appl y ai r pressure to the rear servo appl y passage.
The servo rod shoul d extend and cause the band to
ti ghten around the drum. Spri ng pressure shoul d
rel ease the servo when ai r pressure i s removed.
HOUSING FLUID LEAK
When di agnosi ng converter housi ng fl ui d l eaks,
two i tems must be establ i shed before repai r.
(1) Veri fy that a l eak condi ti on actual l y exi sts.
(2) Determi ned the true source of the l eak.
Some suspected converter housi ng fl ui d l eaks may
not be l eaks at al l . They may onl y be the resul t of
resi dual fl ui d i n the converter housi ng, or excess
fl ui d spi l l ed duri ng factory fi l l or fi l l after repai r.
Converter housi ng l eaks have several potenti al
sources. Through careful observati on, a l eak source
can be i denti fi ed before removi ng the transmi ssi on
for repai r. Pump seal l eaks tend to move al ong the
dri ve hub and onto the rear of the converter. Pump
body l eaks fol l ow the same path as a seal l eak (Fi g.
11). Pump vent or pump attachi ng bol t l eaks are gen-
eral l y deposi ted on the i nsi de of the converter hous-
i ng and not on the converter i tsel f (Fi g. 11). Pump
o-ri ng or gasket l eaks usual l y travel down the i nsi de
of the converter housi ng. Front band l ever pi n pl ug
l eaks are general l y deposi ted on the housi ng and not
on the converter.
Fig. 10 Air Pressure Test Passages
1 - LINE PRESSURE TO ACCUMULATOR
2 - REAR SERVO APPLY
3 - FRONT SERVO APPLY
4 - FRONT SERVO RELEASE
5 - PUMP SUCTION
6 - PUMP PRESSURE
7 - FRONT CLUTCH APPLY
8 - REAR CLUTCH APPLY
9 - TO TORQUE CONVERTOR
10 - TO COOLER
11 - FROM TORQUE CONVERTER
TORQUE CONVERTER LEAK POINTS
Possi bl e sources of converter l eaks are:
Leaks at the wel d joi nt around the outsi de di am-
eter wel d.
Leaks at the converter hub wel d.
CONVERTER HOUSING AREA LEAK CORRECTION
(1) Remove converter.
(2) Ti ghten front band adjusti ng screw unti l band
i s ti ght around front cl utch retai ner. Thi s prevents
front/rear cl utches from comi ng out when oi l pump i s
removed.
(3) Remove oi l pump and remove pump seal .
I nspect pump housi ng drai nback and vent hol es for
obstructi ons. Cl ear hol es wi th sol vent and wi re.
(4) I nspect pump bushi ng and converter hub. I f
bushi ng i s scored, repl ace i t. I f converter hub i s
scored, ei ther pol i sh i t wi th crocus cl oth or repl ace
converter.
(5) I nstal l new pump seal , O-ri ng, and gasket.
Repl ace oi l pump i f cracked, porous or damaged i n
any way. Be sure to l oosen the front band before
i nstal l i ng the oi l pump, damage to the oi l pump seal
may occur i f the band i s sti l l ti ghtened to the front
cl utch retai ner.
(6) Loosen ki ckdown l ever pi n access pl ug three
turns. Appl y Locti te 592, or Permatex No. 2 to
pl ug threads and ti ghten pl ug to 17 Nm (150 i n. l bs.)
torque.
(7) Adjust front band.
(8) Lubri cate pump seal and converter hub wi th
transmi ssi on fl ui d or petrol eum jel l y and i nstal l con-
verter.
(9) I nstal l transmi ssi on and converter housi ng
dust shi el d.
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS
The di agnosi s charts provi de addi ti onal reference
when di agnosi ng a transmi ssi on faul t. The charts
provi de general i nformati on on a vari ety of transmi s-
si on, overdri ve uni t and converter cl utch faul t condi -
ti ons.
The hydraul i c fl ow charts i n the Schemati cs and
Di agrams secti on of thi s group, outl i ne fl ui d fl ow and
hydraul i c ci rcui try. Ci rcui t operati on i s provi ded for
PARK, NEUTRAL, FI RST, SECOND, THI RD,
FOURTH, MANUAL FI RST, MANUAL SECOND,
and REVERSE gear ranges. Normal worki ng pres-
sures are al so suppl i ed for each of the gear ranges.
Fig. 11 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
DIAGNOSIS CHARTS
HARSH ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)
1. Fluid Level Low. 1. Add Fluid
2. Throttle Linkage Mis-adjusted. 2. Adjust linkage - setting may be too long.
3. Mount and Driveline Bolts Loose. 3. Check engine mount, transmission
mount, propeller shaft, rear spring to body
bolts, rear control arms, crossmember and
axle bolt torque. Tighten loose bolts and
replace missing bolts.
4. U-Joint Worn/Broken. 4. Remove propeller shaft and replace
U-Joint.
5. Axle Backlash Incorrect. 5. Check per Service Manual. Correct as
needed.
6. Hydraulic Pressure Incorrect. 6. Check pressure. Remove, overhaul or
adjust valve body as needed.
7. Band Mis-adjusted. 7. Adjust rear band.
8. Valve Body Check Balls Missing. 8. Inspect valve body for proper check ball
installation.
9. Axle Pinion Flange Loose. 9. Replace nut and check pinion threads
before installing new nut. Replace pinion
gear if threads are damaged.
10. Clutch, band or planetary
component damaged.
10. Remove, disassemble and repair
transmission as necessary.
11. Converter Clutch Faulty. 11. Replace converter and flush cooler and
line before installing new converter.
DELAYED ENGAGEMENT
(FROM NEUTRAL TO
DRIVE OR REVERSE)
1. Fluid Level Low. 1. Correct level and check for leaks.
2. Filter Clogged. 2. Change filter.
3. Gearshift Linkage Mis-adjusted. 3. Adjust linkage and repair linkage if worn
or damaged.
4. Torque Converter Drain Back (Oil
drains from torque converter into
transmission sump).
4. If vehicle moves normally after 5
seconds after shifting into gear, no repair is
necessary. If longer, inspect pump bushing
for wear. Replace pump house.
5. Rear Band Mis-adjusted. 5. Adjust band.
6. Valve Body Filter Plugged. 6. Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary.
7. Oil Pump Gears Worn/Damaged. 7. Remove transmission and replace oil
pump.
8. Governor Circuit and Solenoid
Valve Electrical Fault.
8. Test with DRB scan tool and repair as
required.
9. Hydraulic Pressure Incorrect. 9. Perform pressure test, remove
transmission and repair as needed.
10. Reaction Shaft Seal Rings
Worn/Broken.
10. Remove transmission, remove oil pump
and replace seal rings.
11. Rear Clutch/Input Shaft, Rear
Clutch Seal Rings Damaged.
11. Remove and disassemble transmission
12. Regulator Valve Stuck. 12. Clean.
13. Cooler Plugged. 13. Transfer case failure can plug cooler.
NO DRIVE RANGE
(REVERSE OK)
1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.
2. Repair or replace linkage components.
3. Rear Clutch Burnt. 3. Remove and disassemble transmission
and rear clutch and seals. Repair/replace
worn or damaged parts as needed.
4. Valve Body Malfunction. 4. Remove and disassemble valve body.
Replace assembly if any valves or bores
are damaged.
5. Transmission Overrunning Clutch
Broken.
5. Remove and disassemble transmission.
Replace overrunning clutch.
6. Input Shaft Seal Rings Worn/
Damaged.
Replace seal rings and any other worn or
damaged parts.
7. Front Planetary Failed Broken. 7. Remove and repair.
NO DRIVE OR REVERSE
(VEHICLE WILL NOT
MOVE)
1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
Loose/Misadjusted.
2. Inspect, adjust and reassemble linkage
as needed. Replace worn/damaged parts.
3. U-Joint/Axle/Transfer Case
Broken.
3. Perform preliminary inspection procedure
for vehicle that will not move. Refer to
procedure in diagnosis section.
4. Filter Plugged. 4. Remove and disassemble transmission.
Repair or replace failed components as
needed. Replace filter. If filter and fluid
contained clutch material or metal particles,
an overhaul may be necessary. Perform
lube flow test. Flush oil. Replace cooler as
necessary.
5. Oil Pump Damaged. 5. Perform pressure test to confirm low
pressure. Replace pump body assembly if
necessary.
6. Valve Body Malfunctioned. 6. Check 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.
7. Transmission Internal Component
Damaged.
Repair or replace failed components as
needed.
8. Park Sprag not Releasing - Check
Stall Speed, Worn/Damaged/Stuck.
8. Remove, disassemble, repair.
9. Torque Converter Damage. 9. Inspect and replace as required.
SHIFTS DELAYED OR
ERRATIC (SHIFTS ALSO
HARSH AT TIMES)
1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if
low.
2. Fluid Filter Clogged. 2. Replace filter. If filter and fluid contained
clutch material or metal particles, an
overhaul may be necessary. Perform lube
flow test.
3. Throttle Linkage Mis-adjusted. 3. Adjust linkage as described in service
section.
4. Throttle Linkage Binding. 4. Check cable for binding. Check for return
to closed throttle at transmission.
Mis-adjusted.
5. Adjust linkage/cable as described in
service section.
6. Clutch or Servo Failure. 6. Remove valve body and air test clutch,
and band servo operation. Disassemble
and repair transmission as needed.
7. Governor Circuit Electrical Fault. 7. Test using DRB scan tool and repair as
required.
8. Front Band Mis-adjusted. 8. Adjust band.
9. Pump Suction Passage Leak. 9. Check for excessive foam on dipstick
after normal driving. Check for loose pump
bolts, defective gasket. Replace pump
assembly if needed.
NO REVERSE (D RANGES
OK)
Mis-adjusted/Damaged.
1. Repair or replace linkage parts as
needed.
2. Park Sprag Sticking. 2. Replace overdrive annulus gear.
3. Rear Band Mis-adjusted/Worn. 3. Adjust band; replace.
4. Valve Body Malfunction. 4. Remove and service valve body. Replace
valve body if any valves or valve bores are
worn or damaged.
5. Rear Servo Malfunction. 5. Remove and disassemble transmission.
Replace worn/damaged servo parts as
necessary.
6. Direct Clutch in Overdrive Worn. 6. Disassemble overdrive. Replace worn or
damaged parts.
7. Front Clutch Burnt. 7. Remove and disassemble transmission.
Replace worn, damaged clutch parts as
required.
HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)
1. Governor Circuit Electrical Fault. 1. Test using DRB scan tool and repair as
required.
2. Valve Body Malfunction. 2. Repair stuck 1-2 shift valve or governor
plug.
3. Front Servo/Kickdown Band
Damaged/Burned.
3. Repair/replace.
MOVES IN 2ND OR 3RD
GEAR, ABRUPTLY
DOWNSHIFTS TO LOW
1. Valve Body Malfunction. 1. Remove, clean and inspect. Look for
stuck 1-2 valve or governor plug.
NO LOW GEAR (MOVES
IN 2ND OR 3RD GEAR
ONLY)
1. Governor Circuit Electrical Fault. 1. Test with DRB scan tool and repair as
required.
2. Valve Body Malfunction. 2. Remove, clean and inspect. Look for
sticking 1-2 shift valve, 2-3 shift valve,
governor plug or broken springs.
3. Front Servo Piston Cocked in
Bore.
3. Inspect servo and repair as required.
4. Front Band Linkage Malfunction 4. Inspect linkage and look for bind in
linkage.
NO KICKDOWN OR
NORMAL DOWNSHIFT
1. Throttle Linkage Mis-adjusted. 1. Adjust linkage.
2. Accelerator Pedal Travel
Restricted.
2. Verify floor mat is not under pedal, repair
worn accelerator cable or bent brackets.
3. Valve Body Hydraulic Pressures
Too High or Too Low Due to Valve
Body Malfunction or Incorrect
Hydraulic Control Pressure
Adjustments.
3. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.
4. Governor Circuit Electrical Fault. 4. Test with DRB scan tool and repair as
required.
5. Valve Body Malfunction. 5. Perform hydraulic pressure tests to
Correct valve body pressure adjustments as
required.
6. TPS Malfunction. 6. Replace sensor, check with DRB scan
tool.
7. PCM Malfunction. 7. Check with DRB scan tool and replace
if required.
8. Valve Body Malfunction. 8. Repair sticking 1-2, 2-3 shift valves,
governor plugs, 3-4 solenoid, 3-4 shift
valve, 3-4 timing valve.
STUCK IN LOW GEAR
(WILL NOT UPSHIFT)
1. Throttle Linkage Mis-adjusted/
Stuck.
1. Adjust linkage and repair linkage if worn
or damaged. Check for binding cable or
missing return spring.
2. Gearshift Linkage Mis-adjusted. 2. Adjust linkage and repair linkage if worn
or damaged.
3. Governor Component Electrical
Fault.
3. Check operating pressures and test with
DRB scan tool, repair faulty component.
4. Front Band Out of Adjustment. 4. Adjust Band.
5. Clutch or Servo Malfunction. 5. Air pressure check operation of clutches
and bands. Repair faulty component.
CREEPS IN NEUTRAL 1. Gearshift Linkage Mis-adjusted. 1. Adjust linkage.
2. Rear Clutch Dragging/Warped. 2. Disassemble and repair.
3. Valve Body Malfunction. 3. Perform hydraulic pressure test to
BUZZING NOISE 1. Fluid Level Low 1. Add fluid and check for leaks.
2. Shift Cable Mis-assembled. 2. Route cable away from engine and bell
housing.
3. Valve Body Mis-assembled. 3. Remove, disassemble, inspect valve
body. Reassemble correctly if necessary.
Replace assembly if valves or springs are
damaged. Check for loose bolts or screws.
4. Pump Passages Leaking. 4. Check pump for porous casting, scores
on mating surfaces and excess rotor
clearance. Repair as required. Loose pump
bolts.
5. Cooling System Cooler Plugged. 5. Flow check cooler circuit. Repair as
needed.
6. Overrunning Clutch Damaged. 6. Replace clutch.
SLIPS IN REVERSE ONLY 1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Gearshift Linkage Mis-adjusted. 2. Adjust linkage.
4. Rear Band Worn. 4. Replace as required.
5. Overdrive Direct Clutch Worn. 5. Disassemble overdrive. Repair as
needed.
6. Hydraulic Pressure Too Low. 6. Perform hydraulic pressure tests to
determine cause.
7. Rear Servo Leaking. 7. Air pressure check clutch-servo operation
and repair as required.
8. Band Linkage Binding. 8. Inspect and repair as required.
SLIPS IN FORWARD
DRIVE RANGES
1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Fluid Foaming. 2. Check for high oil level, bad pump
gasket or seals, dirt between pump halves
and loose pump bolts. Replace pump if
necessary.
3. Throttle Linkage Mis-adjusted. 3. Adjust linkage.
4. Gearshift Linkage Mis-adjusted. 4. Adjust linkage.
5. Rear Clutch Worn. 5. Inspect and replace as needed.
6. Low Hydraulic Pressure Due to
Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking,
Leaking Seal Rings, Clutch Seals
Leaking, Servo Leaks, Clogged Filter
or Cooler Lines.
6. Perform hydraulic and air pressure tests
to determine cause.
7. Rear Clutch Malfunction, Leaking
Seals or Worn Plates.
7. Air pressure check clutch-servo operation
and repair as required.
8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).
8. Replace Clutch.
SLIPS IN LOW GEAR D
ONLY, BUT NOT IN
MANUAL 1 POSITION
Overrunning Clutch Faulty. Replace overrunning clutch.
GROWLING, GRATING OR
SCRAPING NOISES
1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.
2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.
3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components Scored/
Binding.
5. Remove, inspect and repair as required.
6. Output Shaft Bearing or Bushing
Damaged.
6. Remove, inspect and repair as required.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands Mis-
adjusted.
8. Adjust bands.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band Mis-adjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in
case.
5. Servo Band or Linkage
Malfunction.
5. Air pressure check servo operation and
repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required
(look for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Perform flow
check. Inspect pump for excessive side
clearance. Replace pump as required.
NO 4-3 DOWNSHIFT 1. Circuit Wiring and/or Connectors
Shorted.
1. Test wiring and connectors with test lamp
and volt/ohmmeter. Repair wiring as
necessary. Replace connectors and/or
harnesses as required.
2. PCM Malfunction. 2. Check PCM operation with DRB scan
tool. Replace PCM only if faulty.
3. TPS Malfunction 3. Check TPS with DRB scan tool at PCM.
4. Lockup Solenoid Not Venting. 4. Remove valve body and replace solenoid
assembly if plugged or shorted.
5. Overdrive Solenoid Not Venting. 5. Remove valve body and replace solenoid
if plugged or shorted.
6. Valve Body Valve Sticking. 6. Repair stuck 3-4 shift valve or lockup
timing valve.
NO 4-3 DOWNSHIFT
WHEN CONTROL SWITCH
IS TURNED OFF
1. Control Switch Open/Shorted. 1. Test and replace switch if faulty.
2. Overdrive Solenoid Connector
Shorted.
2. Test solenoids and replace if seized or
shorted.
3. PCM Malfunction. 3. Test with DRB scan tool. Replace PCM
if faulty.
4. Valve Body Stuck Valves. 4. Repair stuck 3-4, lockup or lockup timing
valve.
CLUNK NOISE FROM
DRIVELINE ON CLOSED
THROTTLE 4-3
DOWNSHIFT
1. Transmission Fluid Low. 1. Add Fluid.
2. Throttle Cable Mis-adjusted. 2. Adjust cable.
3. Overdrive Clutch Select Spacer
Wrong Spacer.
3. Replace overdrive piston thrust plate
spacer.
3-4 UPSHIFT OCCURS
IMMEDIATELY AFTER 2-3
SHIFT
1. Overdrive Solenoid Connector or
Wiring Shorted.
1. Test connector and wiring for loose
connections, shorts or ground and repair as
needed.
2. TPS Malfunction. 2. Test TPS and replace as necessary.
Check with DRB scan tool.
3. PCM Malfunction. 3. Test PCM with DRB scan tool and
replace controller if faulty.
4. Overdrive Solenoid Malfunction. 4. Replace solenoid.
5. Valve Body Malfunction. 5. Remove, disassemble, clean and inspect
valve body components. Make sure all
valves and plugs slide freely in bores.
Polish valves with crocus cloth if needed.
WHINE/NOISE RELATED
TO ENGINE SPEED
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
NO 3-4 UPSHIFT 1. O/D Switch In OFF Position. 1. Turn control switch to ON position.
2. Overdrive Circuit Fuse Blown. 2. Replace fuse. Determine why fuse failed
and repair as necessary (i.e., shorts or
grounds in circuit).
3. O/D Switch Wire Shorted/Open
Cut.
3. Check wires/connections with 12V test
lamp and voltmeter. Repair damaged or
loose wire/connection as necessary.
4. Distance or Coolant Sensor
Malfunction.
4. Check with DRB scan tool and repair or
replace as necessary.
5. TPS Malfunction. 5. Check with DRB scan tool and replace
if necessary.
6. Neutral Sense to PCM Wire
Shorted/Cut.
6. Test switch/sensor as described in
service section and replace if necessary.
Engine no start.
7. PCM Malfunction. 7. Check with DRB scan tool and replace
if necessary.
8. Overdrive Solenoid Shorted/Open. 8. Replace solenoid if shorted or open and
repair loose or damaged wires (DRB scan
tool).
9. Solenoid Feed Orifice in Valve
Body Blocked.
9. Remove, disassemble, and clean valve
body thoroughly. Check feed orifice.
10. Overdrive Clutch Failed. 10. Disassemble overdrive and repair as
needed.
11. Hydraulic Pressure Low. 11. Pressure test transmission to determine
cause.
12. Valve Body Valve Stuck. 12. Repair stuck 3-4 shift valve, 3-4 timing
valve.
13. O/D Piston Incorrect Spacer. 13. Remove unit, check end play and install
correct spacer.
14. Overdrive Piston Seal Failure. 14. Replace both seals.
15. O/D Check Valve/Orifice Failed. 15. Check for free movement and secure
assembly (in piston retainer). Check ball
bleed orifice.
SLIPS IN OVERDRIVE
FOURTH GEAR
2. Overdrive Clutch Pack Worn. 2. Remove overdrive unit and rebuild clutch
pack.
3. Overdrive Piston Retainer Bleed
Orifice Blown Out.
3. Disassemble transmission, remove
retainer and replace orifice.
4. Overdrive Piston or Seal
Malfunction.
4. Remove overdrive unit. Replace seals if
worn. Replace piston if damaged. If piston
retainer is damaged, remove and
disassemble the transmission.
5. 3-4 Shift Valve, Timing Valve or
Accumulator Malfunction.
5. Remove and overhaul valve body.
Replace accumulator seals. Make sure all
valves operate freely in bores and do not
bind or stick. Make sure valve body screws
are correctly tightened and separator plates
are properly positioned.
6. Overdrive Unit Thrust Bearing
Failure.
6. Disassemble overdrive unit and replace
thrust bearing (NO. 1 thrust bearing is
between overdrive piston and clutch hub;
NO. 2 thrust bearing is between the
planetary gear and the direct clutch spring
plate; NO. 3 thrust bearing is between
overrunning clutch hub and output shaft).
7. O/D Check Valve/Bleed Orifice
Failure.
7. Check for function/secure orifice insert in
O/D piston retainer.
DELAYED 3-4 UPSHIFT
(SLOW TO ENGAGE)
2. Throttle Valve Cable Mis-adjusted. 2. Adjust throttle valve cable.
3. Overdrive Clutch Pack Worn/
Burnt.
3. Remove unit and rebuild clutch pack.
4. TPS Faulty. 4. Test with DRB scan tool and replace as
necessary
5. Overdrive Clutch Bleed Orifice
Plugged.
5. Disassemble transmission and replace
orifice.
6. Overdrive Solenoid or Wiring
Shorted/Open.
6. Test solenoid and check wiring for
loose/corroded connections or shorts/
grounds. Replace solenoid if faulty and
repair wiring if necessary.
7. Overdrive Excess Clearance. 7. Remove unit. Measure end play and
select proper spacer.
8. O/D Check Valve Missing or
Stuck.
8. Check for presence of check valve.
Repair or replace as required.
TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEAR
Lockup Solenoid, Relay or Wiring
Shorted/Open.
Test solenoid, relay and wiring for
continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.
HARSH 1-2, 2-3, 3-4 OR
3-2 SHIFTS
Lockup Solenoid Malfunction. Remove valve body and replace solenoid
assembly.
NO START IN PARK OR
NEUTRAL
Mis-adjusted.
1. Adjust linkage/cable.
2. Neutral Sense Wire Open/Cut. 2. Check continuity with test lamp. Repair
as required.
3. Park/Neutral Switch, or
Transmission Range Sensor Faulty.
3. Refer to service section for test and
replacement procedure.
Transmission Range Sensor
Connection Faulty.
4. Connectors spread open. Repair.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.
5. Inspect lever assembly and replace if
damaged.
NO REVERSE (OR SLIPS
IN REVERSE)
1. Direct Clutch Pack (front clutch)
Worn.
1. Disassemble unit and rebuild clutch
pack.
3. Front Clutch Malfunctioned/
Burned.
3. Air-pressure test clutch operation.
Remove and rebuild if necessary.
4. Overdrive Thrust Bearing Failure. 4. Disassemble geartrain and replace
bearings.
5. Direct Clutch Spring Collapsed/
Broken.
5. Remove and disassemble unit. Check
clutch position and replace spring.
OIL LEAKS. 1. Fluid Lines and Fittings Loose/
Leaks/Damaged.
1. Tighten fittings. If leaks persist, replace
fittings and lines if necessary.
2. Fill Tube (where tube enters case)
Leaks/Damaged.
2. Replace tube seal. Inspect tube for
cracks in fill tube.
3. Pressure Port Plug Loose
Loose/Damaged.
3. Tighten to correct torque. Replace plug
or reseal if leak persists.
4. Pan Gasket Leaks. 4. Tighten pan screws (150 in. lbs.). If leaks
persist, replace gasket.
5. Valve Body Manual Lever Shaft
Seal Leaks/Worn.
5. Replace shaft seal.
6. Rear Bearing Access Plate Leaks. 6. Replace gasket. Tighten screws.
7. Gasket Damaged or Bolts are
Loose.
7. Replace bolts or gasket or tighten both.
8. Adapter/Extension Gasket
Damaged Leaks/Damaged.
8. Replace gasket.
Transmission Range Sensor
Leaks/Damaged.
9. Replace switch and gasket.
10. Converter Housing Area Leaks. 10. 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.
11. Pump Seal Leaks/Worn/
Damaged.
11. Replace seal.
12. Torque Converter Weld
Leak/Cracked Hub.
12. Replace converter.
13. Case Porosity Leaks. 13. Replace case.
NOISY OPERATION IN
FOURTH GEAR ONLY
1. Overdrive Clutch Discs, Plates or
Snap Rings Damaged.
1. Remove unit and rebuild clutch pack.
2. Overdrive Piston or Planetary
Thrust Bearing Damaged.
2. Remove and disassemble unit. Replace
either thrust bearing if damaged.
3. Output Shaft Bearings Scored/
Damaged.
3. Remove and disassemble unit. Replace
either bearing if damaged.
4. Planetary Gears Worn/Chipped. 4. Remove and overhaul overdrive unit.
5. Overdrive Unit Overrunning Clutch
Rollers Worn/Scored.
5. Remove and overhaul overdrive unit.
THREAD REPAIR
Damaged or worn threads i n the al umi num trans-
mi ssi on case and val ve body can be repai red by the
use of Hel i -Coi l s , or equi val ent. Thi s repai r con-
si sts of dri l l i ng out the worn-out damaged threads.
Then tap the hol e wi th a speci al Hel i -Coi l tap, or
equi val ent, and i nstal l i ng a Hel i -Coi l i nsert, or
equi val ent, i nto the hol e. Thi s bri ngs the hol e back to
i ts ori gi nal thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
REMOVAL
NOTE: The overdrive unit can be removed and ser-
viced separately. It is not necessary to remove the
entire transmission assembly to perform overdrive
unit repairs.
(3) Remove the transfer case ski d pl ate (Fi g. 12), i f
equi pped.
(4) Di sconnect and l ower or remove necessary
exhaust components.
(5) Remove engi ne-to-transmi ssi on struts.
(6) Remove starter motor. (Refer to 8 - ELECTRI -
(7) Di sconnect and remove the crankshaft posi ti on
sensor. (Refer to 14 - FUEL SYSTEM/FUEL I NJEC-
TI ON/CRANKSHAFT POSI TI ON SENSOR -
REMOVAL) Retai n the sensor attachi ng bol ts.
(8) I f transmi ssi on i s bei ng removed for overhaul ,
remove transmi ssi on oi l pan, drai n fl ui d and rei nstal l
pan.
(9) Remove torque converter access cover.
(10) Rotate crankshaft i n cl ockwi se di recti on unti l
converter bol ts are accessi bl e. Then remove bol ts one
at a ti me. Rotate crankshaft wi th socket wrench on
dampener bol t.
(11) Mark propel l er shaft and axl e yokes for
assembl y al i gnment. Then di sconnect and remove
propel l er shaft. On 4 x 4 model s, remove both propel -
l er shafts. (Refer to 3 - DI FFERENTI AL & DRI V-
ELI NE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(12) Di sconnect wi res from the transmi ssi on range
sensor and transmi ssi on sol enoi d connector.
(13) Di sconnect gearshi ft cabl e (Fi g. 13) from the
transmi ssi on.
Fig. 12 Transfer Case Skid Plate
1 - FRAME RAIL
2 - SKID PLATE
3 - BOLTS (6)
Fig. 13 Gearshift Cable At Transmission
1 - GEARSHIFT CABLE
2 - TRANSMISSION MANUAL LEVER
3 - CABLE SUPPORT BRACKET
(14) Di sconnect throttl e val ve cabl e from transmi s-
si on bracket and throttl e val ve l ever.
(15) On 4X4 model s, di sconnect shi ft rod from
transfer case shi ft l ever.
(16) Support rear of engi ne wi th safety stand or
jack.
(17) Rai se transmi ssi on sl i ghtl y wi th servi ce jack
to rel i eve l oad on crossmember and supports.
(18) Remove bol ts securi ng rear support and cush-
i on (Fi g. 14) and (Fi g. 15) to transmi ssi on and cross-
member and remove rear support.
(19) Remove bol ts attachi ng crossmember to frame
and remove crossmember.
(20) On 4X4 model s, remove transfer case wi th
transmi ssi on jack or ai d of hel per.
(21) Di sconnect fl ui d cool er l i nes at transmi ssi on.
(22) Remove fi l l tube bracket bol ts and pul l tube
out of transmi ssi on. Retai n fi l l tube seal . On 4X4
model s, i t wi l l al so be necessary to remove bol t
attachi ng transfer case vent tube to converter hous-
i ng (Fi g. 16).
(23) Remove al l converter housi ng bol ts.
(24) Careful l y work transmi ssi on and torque con-
verter assembl y rearward off engi ne bl ock dowel s.
(25) Lower transmi ssi on and remove assembl y
from under the vehi cl e.
(26) To remove torque converter, remove C-cl amp
from edge of bel l housi ng and careful l y sl i de torque
converter out of the transmi ssi on.
Fig. 14 Engine Rear Mount - 4X2 Automatic
Transmission
1 - ENGINE REAR MOUNT
2 - BOLT
3 - NUT
4 - THROUGH BOLT NUT
5 - TRANSMISSION
Fig. 15 Engine Rear Mount - 4X4 Automatic
Transmission
1 - TRANSMISSION
2 - ENGINE REAR MOUNT
3 - BOLT
Fig. 16 Fill Tube Attachment
1 - TRANSFER CASE VENT TUBE
2 - FILL TUBE (V8)
3 - TUBE SEAL
4 - FILL TUBE (V6)
DISASSEMBLY
(1) Cl ean exteri or of transmi ssi on wi th sui tabl e
sol vent or pressure washer.
(2) Pl ace transmi ssi on i n verti cal posi ti on.
(3) Measure the i nput shaft end pl ay as fol l ows
(Fi g. 17).
(a) Attach Adapter 8266-5 to Handl e 8266-8.
(b) Attach di al i ndi cator C-3339 to Handl e
8266-8.
(c) I nstal l the assembl ed tool onto the i nput
shaft of the transmi ssi on and ti ghten the retai ni ng
screw on Adapter 8266-5 to secure i t to the i nput
shaft.
(d) Posi ti on the di al i ndi cator pl unger agai nst a
fl at spot on the oi l pump and zero the di al i ndi ca-
tor.
(e) Move i nput shaft i n and out and record read-
i ng. Record the maxi mum travel for assembl y ref-
erence
(4) Remove the overdri ve uni t from the mai n
transmi ssi on case. I f overdri ve uni t i s not to be ser-
vi ced, i nstal l Al i gnment Shaft 6227-2 i nto the over-
dri ve uni t to prevent mi sal i gnment of the overdri ve
cl utches duri ng servi ce of mai n transmi ssi on compo-
nents.
(5) Remove throttl e and shi ft l evers from val ve
body manual shaft and throttl e l ever shaft.
(6) Remove transmi ssi on oi l pan and gasket.
(7) Remove fi l ter from val ve body (Fi g. 18). Keep
fi l ter screws separate from other val ve body screws.
Fi l ter screws are l onger and shoul d be kept wi th fi l -
ter.
(8) Remove the transmi ssi on range sensor.
(9) Remove hex head bol ts attachi ng val ve body to
transmi ssi on case (Fi g. 19). A total of 10 bol ts are
used. Note di fferent bol t l engths for assembl y refer-
ence.
Fig. 19 Valve Body Bolt Locations
1 - VALVE BODY BOLTS
2 - VALVE BODY BOLTS
Fig. 17 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-5
3 - TOOL C-3339
Fig. 18 Oil Filter Removal
1 - OIL FILTER
2 - VALVE BODY
3 - FILTER SCREWS (2)
(10) Remove val ve body assembl y. Push val ve body
harness connector out of case. Then work park rod
and val ve body out of case (Fi g. 20).
(11) Remove accumul ator outer spri ng, pi ston and
i nner spri ng (Fi g. 21). Note posi ti on of pi ston and
spri ngs for assembl y reference. Remove and di scard
pi ston seal s i f worn or cut.
(12) Remove pump oi l seal wi th sui tabl e pry tool
or sl i de-hammer mounted screw.
(13) Remove front band l ever pi n access pl ug (Fi g.
22). Use square end of 1/4 i n. dri ve extensi on to
remove pl ug as shown.
(14) Remove oi l pump and reacti on shaft support
assembl y as fol l ows:
(a) Ti ghten front band adjusti ng screw unti l
band i s ti ght around front cl utch retai ner (Fi g. 23).
Thi s wi l l prevent retai ner from comi ng out wi th
pump and possi bl y damagi ng cl utch or pump com-
ponents.
Fig. 23 Tightening Front Band To Hold Front Clutch
In Place
1 - LOCK-NUT
2 - FRONT BAND ADJUSTER
Fig. 20 Valve Body Removal
1 - GOVERNOR PRESSURE SENSOR
2 - VALVE BODY
3 - PARK ROD
4 - ACCUMULATOR PISTON
5 - GOVERNOR PRESSURE SOLENOID
Fig. 21 Accumulator Component Removal
2 - OUTER SPRING
3 - INNER SPRING
Fig. 22 Front Band Lever Pin Access Plug
1 - FRONT BAND REACTION PIN ACCESS PLUG
2 - 1/4 DRIVE EXTENSION AND RATCHET
(b) Remove oi l pump bol ts.
(c) Thread Sl i de Hammer Tool s C-3752 i nto
threaded hol es i n fl ange of oi l pump housi ng (Fi g.
24).
(d) Remove oi l pump and reacti on shaft support
by bumpi ng sl i de hammers outward al ternatel y to
pul l pump from case (Fi g. 25).
(15) Remove oi l pump gasket (Fi g. 26). Note gas-
ket posi ti on i n case for assembl y reference.
(16) Loosen front band adjusti ng screw unti l band
i s compl etel y l oose.
(17) Remove front band strut and anchor (Fi g. 27).
Fig. 24 Oil Pump Removal Tools
1 - PUMP HOUSING
2 - SLIDE HAMMER TOOLS (THREAD INTO PUMP HOUSING)
Fig. 25 Oil Pump Removal
1 - OIL PUMP AND REACTION SHAFT SUPPORT
Fig. 26 Oil Pump Gasket
1 - OIL PUMP GASKET
Fig. 27 Front Band Linkage
1 - LEVER
2 - STRUT
3 - ANCHOR
4 - FRONT BAND
(18) Squeeze front band together sl i ghtl y and sl i de
band over front cl utch retai ner and out of case (Fi g.
28).
(19) Remove front and rear cl utch assembl i es as a
uni t (Fi g. 29).
(20) Remove front band reacti on pi n and l ever.
Start pi n through l ever and out of case bore wi th
dri ft or punch. Then use penci l magnet to wi thdraw
pi n compl etel y (Fi g. 30).
(21) Remove i ntermedi ate shaft thrust washer. Tri -
angul ar shaped washer wi l l ei ther be on shaft pi l ot
hub or i n rear cl utch retai ner (Fi g. 31).
Fig. 29 Removing Front/Rear Clutch Assemblies
1 - FRONT AND REAR CLUTCH ASSEMBLIES
Fig. 30 Front Band Lever And Pin
1 - BAND LEVER
2 - USE PENCIL MAGNET TO REMOVE REACTION PIN
Fig. 31 Intermediate Shaft Thrust Washer
1 - THRUST WASHER
2 - INTERMEDIATE SHAFT PILOT HUB
Fig. 28 Front Band Removal
1 - FRONT BAND
2 - FRONT CLUTCH RETAINER
(22) Remove thrust pl ate from i ntermedi ate shaft
hub (Fi g. 32).
(23) Remove i ntermedi ate shaft-pl anetary
geartrai n assembl y (Fi g. 33).
(24) Loosen rear band l ocknut and l oosen adjust-
i ng screw 3-4 turns.
(25) Remove snap-ri ng that retai ns l ow-reverse
drum on overdri ve pi ston retai ner hub (Fi g. 34).
(26) Sl i de l ow-reverse drum and thrust washer off
pi ston retai ner hub and out of rear band (Fi g. 35).
Fig. 35 Low-Reverse Drum And Thrust Washer
1 - LOW-REVERSE DRUM
2 - SPOTFACE FOR WASHER
3 - THRUST WASHER
Fig. 32 Intermediate Shaft Thrust Plate
1 - SHAFT THRUST PLATE
Fig. 33 Intermediate Shaft And Planetary Geartrain
1 - INTERMEDIATE SHAFT AND PLANETARY GEAR TRAIN
ASSEMBLY
Fig. 34 Low-Reverse Drum Snap-Ring
2 - TABBED WASHER
3 - SNAP-RING
(27) Note that overrunni ng cl utch race wi l l remai n
on spl i nes of l ow-reverse drum after removal (Fi g.
36). The race is a permanent press fit on the
hub splines. Do not attempt to remove the race.
(28) Remove overrunni ng cl utch assembl y (Fi g.
37). Assembl y can be removed wi thout di spl aci ng
rol l ers and spri ngs i f care i s exerci sed. Note posi ti on
of rol l ers and spri ngs for assembl y reference.
(29) Remove rear band adjusti ng l ever and reac-
ti on pi n.
(30) Remove rear band.
(31) Compress front servo rod gui de wi th l arge
C-cl amp and Tool C-4470, or Compressor Tool
C-3422-B (Fi g. 38). Compress gui de onl y enough to
permi t snap-ri ng removal (about 1/8 i n.).
(32) Remove servo pi ston snap-ri ng (Fi g. 38).
Unseat one end of ri ng. Then careful l y work removal
tool around back of ri ng unti l free of ri ng groove.
Exercise caution when removing snap-ring.
Servo bore can be scratched or nicked if care is
not exercised.
Fig. 38 Front Servo Retaining Snap-Ring
1 - C-CLAMP
2 - FRONT SERVO ROD GUIDE
3 - SNAP-RING
4 - TOOL C-4470
Fig. 36 Overrunning Clutch Race Position On
Low-Reverse Drum
1 - OVERRUNNING CLUTCH RACE
Fig. 37 Overrunning Clutch
1 - CLUTCH CAM
2 - OVERRUNNING CLUTCH ASSEMBLY
(33) Remove tool s and remove servo pi ston and
spri ng.
(34) Compress rear servo pi ston wi th C-cl amp and
Tool C-4470, or Val ve Spri ng Compressor C-3422-B
(Fi g. 39). Compress servo spri ng retai ner onl y
enough to permi t snap-ri ng removal .
(35) Remove servo pi ston snap-ri ng (Fi g. 39). Start
one end of ri ng out of bore. Then careful l y work
removal tool around back of snap-ri ng unti l free of
ri ng groove. Exercise caution when removing
snap-ring. Servo bore can be scratched or
nicked if care is not exercised.
(36) Remove tool s and remove rear servo retai ner,
spri ng and pi ston assembl y.
CLEANING
Cl ean the case i n a sol vent tank. Fl ush the case
bores and fl ui d passages thoroughl y wi th sol vent.
Dry the case and al l fl ui d passages wi th compressed
ai r. Be sure al l sol vent i s removed from the case and
that al l fl ui d passages are cl ear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
Lubri cate transmi ssi on parts wi th Mopar ATF +4,
Automati c Transmi ssi on fl ui d, duri ng overhaul and
assembl y. Use petrol eum jel l y to prel ubri cate seal s,
O-ri ngs, and thrust washers. Petrol eum jel l y can al so
be used to hol d parts i n pl ace duri ng reassembl y.
INSPECTION
I nspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repai red wi th Hel i coi l thread i nserts. However, the
case wi l l have to be repl aced i f i t exhi bi ts any type of
damage or wear.
Lubri cate the front band adjusti ng screw threads
wi th petrol eum jel l y and thread the screw part-way
i nto the case. Be sure the screw turns freel y.
I nspect the transmi ssi on bushi ngs duri ng overhaul .
Bushi ng condi ti on i s i mportant as worn, scored bush-
i ngs contri bute to l ow pressures, cl utch sl i p and
accel erated wear of other components. However, do
not repl ace bushi ngs as a matter of course. Repl ace
bushi ngs onl y when they are actual l y worn, or
scored.
The use of crocus cl oth i s permi ssi bl e where neces-
sary, provi di ng i t i s used careful l y. When used on
shafts, or val ves, use extreme care to avoi d roundi ng
off sharp edges. Sharp edges are vi tal as they pre-
vent forei gn matter from getti ng between the val ve
and val ve bore.
Do not reuse oi l seal s, gaskets, seal ri ngs, or
O-ri ngs duri ng overhaul . Repl ace these parts as a
matter of course. Al so do not reuse snap ri ngs or
E-cl i ps that are bent or di storted. Repl ace these parts
as wel l .
ASSEMBLY
Do not al l ow di rt, grease, or forei gn materi al to
enter the case or transmi ssi on components duri ng
assembl y. Keep the transmi ssi on case and compo-
nents cl ean. Al so make sure the tool s and workbench
area used for reassembl y operati ons are equal l y
cl ean.
Shop towel s used for wi pi ng off tool s and your
hands must be made from lint free materi al s. Li nt
wi l l sti ck to transmi ssi on parts and coul d i nterfere
wi th val ve operati on or even restri ct fl ui d passages.
Lubri cate transmi ssi on cl utch and gear compo-
nents wi th Mopar ATF +4 duri ng reassembl y. Soak
cl utch di scs i n transmi ssi on fl ui d before i nstal l ati on.
Use petrol eum jel l y on pi ston seal s and o-ri ngs to
ease i nstal l ati on. Petrol eum jel l y can al so be used to
l ubri cate and hol d thrust washers and pl ates i n posi -
ti on duri ng assembl y.
Do not use chassis grease, bearing grease,
white grease, or similar lubricants on any part.
These types of l ubri cants can eventual l y bl ock or
restri ct fl ui d passages and val ve operati on. Use
petrol eum jel l y onl y.
Do not force parts i nto pl ace. The transmi ssi on
components and sub-assembl i es are easi l y i nstal l ed
by hand when properl y al i gned. I f a part seems di f-
fi cul t to i nstal l , i t i s ei ther mi sal i gned or i ncorrectl y
Fig. 39 Rear Servo Retaining Snap-Ring
1 - TOOL C-4470
2 - C-CLAMP
3 - REAR SERVO SPRING RETAINER
4 - RETAINER SNAP-RING
assembl ed. Veri fy that thrust washers, thrust pl ates
and seal ri ngs are correctl y posi ti oned.
The pl anetary geartrai n, front/rear cl utch assem-
bl i es and oi l pump are al l much easi er to i nstal l
when the transmi ssi on case i s upri ght. Ei ther ti l t the
case upward wi th wood bl ocks, or cut a hol e i n the
bench l arge enough for the i ntermedi ate shaft and
rear support. Then l ower the shaft and support i nto
the hol e and support the rear of the case di rectl y on
the bench.
FRONT/REAR SERVO
(1) Lubri cate rear servo pi ston seal wi th ATF +4.
Lubri cate servo bore i n case wi th ATF +4.
(2) I nstal l rear servo pi ston i n case. Posi ti on pi ston
at sl i ght angl e to bore and i nsert pi ston wi th twi sti ng
moti on (Fi g. 40).
(3) I nstal l rear servo spri ng and retai ner i n case
bore (Fi g. 41). Be sure spri ng i s seated on pi ston.
(4) Compress rear servo pi ston wi th C-cl amp or
Val ve Spri ng Compressor C-3422-B and i nstal l servo
pi ston snap-ri ng (Fi g. 42).
(5) Lubri cate front servo pi ston components and
servo bore i n case wi th transmi ssi on fl ui d.
(6) I nstal l front servo pi ston i n bore. Careful l y
run smal l , sui tabl e tool around pi ston ri ng to press
i t back i nto groove and ease i nstal l ati on (Fi g. 43).
Rotate pi ston i nto bore at same ti me. Rock pi ston
sl i ghtl y to ease pi ston ri ng past snap-ri ng groove and
i nto bore.
Fig. 40 Rear Servo Piston
1 - REAR SERVO PISTON
Fig. 41 Rear Servo Piston Spring And Retainer
1 - PISTON SPRING
2 - REAR SERVO PISTON
3 - SPRING RETAINER
Fig. 42 Rear Servo Snap Ring
1 - TOOL C-4470
2 - C-CLAMP
3 - REAR SERVO SPRING RETAINER
4 - RETAINER SNAP-RING
(7) Bottom front servo pi ston i n bore and i nstal l
servo spri ng.
(8) I nstal l front servo pi ston rod gui de as fol l ows:
(a) Pl ace Tool SP-5560 (or si mi l ar si ze tool ) on
gui de and posi ti on C-cl amp on tool and case (Fi g.
44).
(b) Sl owl y compress rod gui de whi l e si mul ta-
neousl y easi ng seal ri ng i nto bore wi th sui tabl e
tool .
(9) I nstal l rod gui de snap-ri ng (Fi g. 44).
OVERRUNNING CLUTCH, REAR BAND, AND
LOW-REVERSE DRUM
(1) I nstal l overrunni ng cl utch components i f not
yet i nstal l ed.
(2) Posi ti on rear band reacti on pi n and band i n
case. Be sure that the twi n l ugs on the band are
seated agai nst the reacti on pi n.
(3) I nstal l l ow-reverse drum. Sl i de drum through
rear band, onto pi ston retai ner hub and i nto engage-
ment wi th overrunni ng cl utch and race.
(4) I nstal l thrust washer i n l ow-reverse drum spot-
face (Fi g. 45). Use petrol eum jel l y to hol d washer i n
pl ace.
(5) I nstal l snap-ri ng that secures l ow-reverse drum
to pi ston retai ner hub (Fi g. 45).
(6) I nsert the rear band pi vot pi n part way i nto
the case.
(7) I nstal l rear band adjusti ng l ever and pi vot pi n.
Be sure l ever and the si ngl e l ug on the band are
al i gned and engaged before seati ng band pi vot pi n i n
case.
Fig. 43 Front Servo Piston
1 - USE SUITABLE TOOL TO HELP SEAT PISTON RING
2 - FRONT SERVO PISTON
Fig. 44 Front Servo Rod Guide And Snap Ring
1 - C-CLAMP
2 - ROD GUIDE
3 - SMALL SCREWDRIVER
4 - ROD GUIDE SNAP-RING
5 - TOOL SP-5560
Fig. 45 Low-Reverse Drum Snap Ring
2 - TABBED WASHER
3 - SNAP-RING
PLANETARY GEARTRAIN, FRONT/REAR CLUTCH,
AND FRONT BAND
(1) Remove Al i gnment Shaft 6227-2, i f i nstal l ed
previ ousl y.
(2) I nstal l assembl ed i ntermedi ate shaft and pl an-
etary geartrai n (Fi g. 46). Support shaft carefully
during installation. Do not allow shaft bearing/
bushing surfaces to become nicked or
scratched.
(3) Lubri cate i ntermedi ate shaft thrust pl ate wi th
petrol eum jel l y and i nstal l pl ate on shaft pi l ot hub
(Fi g. 47).
(4) Check i nput shaft front seal ri ngs, fi ber thrust
washer and rear seal ri ng (Fi g. 48). Be sure the ends
of rear seal ri ng are hooked together and di agonal
cut ends of front seal ri ngs are fi rml y seated agai nst
each other as shown. Lubri cate seal ri ngs wi th petro-
l eum jel l y after checki ng them.
(5) Assembl e front and rear cl utches (Fi g. 49).
Al i gn l ugs on front cl utch di scs. Mount front cl utch
on rear cl utch. Turn front cl utch retai ner back and
forth unti l front cl utch di scs are ful l y seated on rear
cl utch spl i ned hub.
Fig. 46 Intermediate Shaft And Planetary Geartrain
1 - INTERMEDIATE SHAFT AND PLANETARY GEAR TRAIN
ASSEMBLY
Fig. 47 Intermediate Shaft Thrust Plate
1 - SHAFT THRUST PLATE
Fig. 48 Input Shaft Seal Ring And Thrust Washer
1 - TORLON FRONT SEAL RINGS
2 - INPUT SHAFT
3 - REAR SEAL RING
4 - THRUST WASHER
(6) I nstal l i ntermedi ate shaft thrust washer i n hub
of rear cl utch retai ner (Fi g. 50). Use petrol eum jel l y
to hol d washer i n pl ace. Posi ti on washer so grooves
are faci ng outward. Washer only fits one way in
clutch retainer hub.
(7) Pl ace transmi ssi on case i n upri ght posi ti on, or
pl ace bl ocks under front end of transmi ssi on repai r
stand to ti l t case rearward. Thi s makes i t easi er to
i nstal l front/rear cl utch assembl y.
(8) Al i gn di scs i n rear cl utch. Then i nstal l and
engage assembl y i n front pl anetary and dri vi ng shel l
(Fi g. 51). Turn cl utch retai ners back and forth unti l
both cl utches are seated.
(9) Posi ti on front band l ever i n case and over servo
rod gui de. Then i nstal l front band l ever pi n i n case
and sl i de i t through l ever.
(10) Coat threads of front band pi n access pl ug
wi th seal er and i nstal l i t i n case. Ti ghten pl ug to 17
Fig. 50 Intermediate Shaft Thrust Washer
1 - BE SURE WASHER GROOVES FACE OUT AS SHOWN
2 - REAR CLUTCH RETAINER HUB
3 - SHAFT THRUST WASHER
Fig. 51 Front/Rear Clutch Assemblies
1 - FRONT AND REAR CLUTCH ASSEMBLIES
Fig. 49 Assembling Front And Rear Clutches
1 - FRONT CLUTCH ASSEMBLY
2 - REAR CLUTCH ASSEMBLY
3 - REAR CLUTCH SPLINED HUB
(11) Sl i de front band over front cl utch retai ner and
i nstal l front band strut and anchor (Fi g. 52).
(12) Ti ghten front band adjusti ng screw unti l band
i s ti ght on cl utch retai ner. Thi s wi l l hol d cl utches i n
pl ace whi l e oi l pump i s bei ng i nstal l ed. Verify that
front/rear clutch assembly is still properly
seated before tightening band.
OIL PUMP
(1) I nstal l oi l pump Pi l ot Studs C-3288-B i n case
(Fi g. 53).
(2) I nstal l new oi l pump gasket on pi l ot studs and
seat i t i n case. Be sure gasket i s properl y al i gned
wi th fl ui d passages i n case (Fi g. 53).
(3) Coat the reacti on shaft thrust washer wi th
petrol eum jel l y to hol d i t i n pl ace. Then i nstal l
washer over reacti on shaft hub and seat i t on pump
(Fi g. 54).
CAUTION: The thrust washer bore (I.D.), is cham-
fered on one side. Make sure the chamfered side is
installed so it faces the pump.
Fig. 53 Oil Pump Gasket And Pilot Studs
1 - OIL PUMP GASKET
2 - PILOT STUDS C-3288-B
Fig. 54 Front Clutch Thrust Washer Installation
1 - THRUST WASHER
2 - CHAMFERED SIDE OF WASHER BORE GOES TOWARD
PUMP
Fig. 55 Reaction Shaft Seal Ring And Thrust Washer
1 - SEAL RINGS
2 - REACTION SHAFT SUPPORT
3 - THRUST WASHER (FIBER)
Fig. 52 Front Band And Linkage
1 - LEVER
2 - STRUT
3 - ANCHOR
4 - FRONT BAND
(4) Check seal ri ngs on reacti on shaft support. Be
sure ri ngs are hooked together correctl y. Al so be sure
fi ber thrust washer i s i n posi ti on (Fi g. 55). Use extra
petrol eum jel l y to hol d washer i n pl ace i f necessary.
(5) Check the torque converter hub seal ri ng on
the reacti on shaft for damage. Al so check that the
seal ri ng rotates freel y i n the reacti on shaft groove.
Repl ace the seal i f necessary.
(6) Lubri cate oi l pump seal s wi th petrol eum
Mopar ATF +4.
(7) Mount oi l pump on pi l ot studs and sl i de pump
i nto case openi ng (Fi g. 56). Work pump into case
by hand. Do not use a mallet or similar tools to
seat pump.
(8) Remove pi l ot studs and i nstal l oi l pump bol ts.
Ti ghten pump bol ts al ternatel y and evenl y to ful l y
seat pump i n case. Then fi nal -ti ghten pump bol ts to
(9) Veri fy correct i nstal l ati on. Rotate i nput and
i ntermedi ate shafts and check for bi nd. I f bi nd exi sts,
components are ei ther mi s-assembl ed, or not seated.
Di sassembl e and correct as necessary before proceed-
i ng.
INPUT SHAFT END PLAY CHECK
NOTE: Overdrive unit must be installed in order to
correctly measure the input shaft end-play.
(1) Measure i nput shaft end pl ay (Fi g. 57).
NOTE: If end play is incorrect, transmission is
incorrectly assembled, or reaction shaft thrust
washer is incorrect. The reaction shaft thrust
washer is selective.
(a) Attach Adapter 8266-5 to Handl e 8266-8.
(b) Attach di al i ndi cator C-3339 to Handl e
8266-8.
(c) I nstal l the assembl ed tool onto the i nput
shaft of the transmi ssi on and ti ghten the retai ni ng
screw on Adapter 8266-5 to secure i t to the i nput
shaft.
(d) Posi ti on the di al i ndi cator pl unger agai nst a
fl at spot on the oi l pump and zero the di al i ndi ca-
tor.
(e) Move i nput shaft i n and out and record read-
i ng. End pl ay shoul d be 0.86 - 2.13 mm (0.034 -
0.084 i n.). Adjust as necessary.
ACCUMULATOR, VALVE BODY, OIL PAN, AND
TORQUE CONVERTER
(1) I nstal l accumul ator i nner spri ng, pi ston and
outer spri ng (Fi g. 58).
(2) Veri fy that the transmi ssi on range sensor has
not been i nstal l ed i n case. Val ve body can not be
i nstal l ed i f sensor i s i n posi ti on.
(3) I nstal l new val ve body manual shaft seal i n
case (Fi g. 59). Lubri cate seal l i p and manual shaft
wi th petrol eum jel l y. Start seal over shaft and i nto
case. Seat seal wi th 15/16 i nch, deep wel l socket.
(4) I nstal l val ve body as fol l ows:
Fig. 56 Oil Pump
1 - SEAT OIL PUMP IN CASE BY HAND
2 - REMOVE PILOT STUDS WHEN PUMP IS SEATED
Fig. 57 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-5
3 - TOOL C-3339
(a) Start park rod i nto park pawl . I f rod wi l l not
sl i de past park pawl , pawl i s engaged i n park gear.
Rotate overdri ve output shaft wi th sui tabl e si ze 12
poi nt socket; thi s wi l l free pawl and al l ow rod to
engage.
(b) Al i gn and seat val ve body on case. Be sure
manual l ever shaft and overdri ve connector are
ful l y seated i n case.
(c) I nstal l and start al l val ve body attachi ng
bol ts by hand. Then ti ghten bol ts evenl y, i n a di ag-
onal pattern to 12 Nm (105 i n. l bs.) torque. Do
not overtighten valve body bolts. This could
result in distortion and cross leakage after
installation..
(5) I nstal l new fi l ter on val ve body. Ti ghten fi l ter
screws to 4 Nm (35 i n. l bs.).
CAUTION: If the condition of the transmission
before the overhaul procedure caused excessive
metallic or fiber contamination in the fluid, replace
the torque converter and reverse flush the cooler(s)
and cooler lines. Fluid contamination and transmis-
sion failure can result if not done.
(6) Move the transmi ssi on manual shaft l ever to
the manual LOW posi ti on.
(7) I nstal l the TRS mounti ng bracket i nto the
transmi ssi on case. Usi ng Adapter 8581 (Fi g. 60),
ti ghten the mounti ng bracket to 34 Nm (300 i n.l bs.).
(8) I nstal l the TRS (Fi g. 61) i nto the mounti ng
bracket wi th the wi ri ng connector faci ng the front of
the transmi ssi on.
Fig. 58 Accumulator Piston And Springs
2 - OUTER SPRING
3 - INNER SPRING
Fig. 59 Manual Lever Shaft Seal
1 - 15/16 SOCKET
2 - SEAL
Fig. 60 Tighten the TRS Mounting Bracket
1 - SOLENOID CASE CONNECTOR
2 - TRS MOUNTING BRACKET
3 - ADAPTER 8581
Fig. 61 Remove Transmission Range Sensor
3 - TRANSMISSION RANGE SENSOR
(9) I nstal l the two screws to hol d the TRS to the
mounti ng bracket. Ti ghten the screws to 5 Nm (45
i n.l bs.).
(10) Veri fy proper sensor operati on (Fi g. 62).
the PARK posi ti on.
(12) I nstal l torque converter. Use C-cl amp or metal
strap to hol d converter i n pl ace for i nstal l ati on.
BAND ADJUSTMENT AND FINAL
(1) Adjust front and rear bands as fol l ows:
(a) Loosen l ocknut on each band adjusti ng screw
4-5 turns.
(b) Ti ghten both adjusti ng screws to 8 Nm (72
i n. l bs.).
(c) Back off front band adjusti ng screw 1-3/4
turns.
(d) Back off rear band adjusti ng screw 3 turns.
(e) Hol d each adjusti ng screw i n posi ti on and
ti ghten l ocknut to 34 Nm (25 ft. l bs.) torque.
(2) I nstal l magnet i n oi l pan. Magnet seats on
smal l protrusi on at corner of pan.
(3) Posi ti on new oi l pan gasket on case and i nstal l
oi l pan. Ti ghten pan bol ts to 13.6 Nm (125 i n. l bs.).
(4) I nstal l throttl e val ve and shi ft sel ector l evers
on val ve body manual l ever shaft.
(5) Appl y smal l quanti ty of di el ectri c grease to ter-
mi nal pi ns of sol enoi d case connector and neutral
swi tch.
(6) Fi l l transmi ssi on wi th recommended fl ui d.
INSTALLATION
(1) Check torque converter hub i nner and outer
di ameters and hub dri ve notches for sharp edges
burrs, scratches, or ni cks. Pol i sh the hub and notches
wi th 320/400 gri t paper and crocus cl oth i f necessary.
The hub must be smooth to avoi d damagi ng pump
seal at i nstal l ati on.
(2) Lubri cate pocket i n the rear oi l pump seal l i p
wi th transmi ssi on fl ui d.
(3) Lubri cate converter pi l ot hub of the crankshaft
wi th a l i ght coati ng of Mopar Hi gh Temp Grease.
(4) Al i gn and i nstal l converter i n oi l pump.
(5) Careful l y i nsert converter i n oi l pump. Then
rotate converter back and forth unti l ful l y seated i n
pump gears.
(6) Check converter seati ng wi th steel scal e and
strai ghtedge (Fi g. 63). Surface of converter l ugs
shoul d be 19mm (0.75 i n.) to rear of strai ghtedge
when converter i s ful l y seated.
(7) Temporari l y secure converter wi th C-cl amp.
(8) Posi ti on transmi ssi on on jack and secure i t
wi th chai ns.
(9) Check condi ti on of converter dri vepl ate.
Repl ace the pl ate i f cracked, di storted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Rai se transmi ssi on and al i gn converter wi th
dri ve pl ate and converter housi ng wi th engi ne bl ock.
(11) Move transmi ssi on forward. Then rai se, l ower
or ti l t transmi ssi on to al i gn converter housi ng wi th
engi ne bl ock dowel s.
(12) Careful l y work transmi ssi on forward and over
engi ne bl ock dowel s unti l converter hub i s seated i n
crankshaft.
Fig. 62 Transmission Range Sensor Operation
1 - NEUTRAL CONTACT
2 - MANUAL LEVER AND SENSOR PLUNGER IN REVERSE
POSITION
3 - PARK CONTACT
Fig. 63 Checking Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
(13) I nstal l bol ts attachi ng converter housi ng to
engi ne.
(14) I nstal l rear support.
(15) I nstal l the rear transmi ssi on crossmember.
(16) Lower transmi ssi on onto crossmember and
i nstal l bol ts attachi ng transmi ssi on mount to cross-
member.
(17) Remove engi ne support fi xture.
(18) I nstal l the transfer case, i f equi pped.
(19) I nstal l crankshaft posi ti on sensor. (Refer to 14
- FUEL SYSTEM/FUEL I NJECTI ON/CRANKSHAFT
POSI TI ON SENSOR - I NSTALLATI ON)
(20) Connect gearshi ft cabl e (Fi g. 64) and throttl e
cabl e to transmi ssi on.
(21) Connect wi res to the transmi ssi on range sen-
sor and transmi ssi on sol enoi d connector. Be sure the
transmi ssi on harnesses are properl y routed.
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.
(22) I nstal l torque converter-to-dri vepl ate bol ts.
(23) I nstal l converter housi ng access cover.
(24) I nstal l starter motor and cool er l i ne bracket.
(Refer to 8 - ELECTRI CAL/STARTI NG/STARTER
MOTOR - I NSTALLATI ON)
(25) Connect cool er l i nes (Fi g. 65) to transmi ssi on.
(26) I nstal l transmi ssi on fi l l tube. I nstal l new seal
on tube before i nstal l ati on.
(27) I nstal l any exhaust components previ ousl y
removed.
(28) Al i gn and connect propel l er shaft. (Refer to 3 -
DI FFERENTI AL & DRI VELI NE/PROPELLER
SHAFT/PROPELLER SHAFT - I NSTALLATI ON)
(29) Adjust gearshi ft cabl e and throttl e val ve
cabl e, i f necessary.
(30) I nstal l the transfer case ski d pl ate, i f
equi pped.
(32) Fi l l transmi ssi on wi th Mopar ATF +4, Auto-
mati c Transmi ssi on fl ui d.
Fig. 64 Gearshift Cable At Transmission
1 - GEARSHIFT CABLE
2 - TRANSMISSION MANUAL LEVER
3 - CABLE SUPPORT BRACKET
Fig. 65 Transmission Cooler Lines
1 - TRANSMISSION
2 - RADIATOR
3 - COOLER LINES
HYDRAULIC SCHEMATICS
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SPECIFICATIONS
TRANSMISSION
GENERAL
Component Metric Inch
Planetary end play 0.150-1.22
mm
0.006-0.048
in.
Input shaft end play 0.86-2.13
mm
0.034-0.084
in.
Clutch pack clearance/
Front.
2.5-4.09
mm
0.098-0.161
in.
Clutch pack clearance/
Rear.
0.635-0.914
mm
0.025-0.036
in.
Front clutch 5 discs
Rear clutch 4 discs
Overdrive clutch 5(STD) OR 6(Diesel HO)
discs
Direct clutch 23 Single Sided discs
Band adjustment from
72 in. lbs.
Front band Back off 1 3/4 turns
Rear band Back off 3 turns
Recommended fluid Mopar ATF +4
GEAR RATIOS
1ST GEAR 2.45:1
2ND GEAR 1.45:1
3RD GEAR 1.0:1
4TH GEAR 0.69:1
REVERSE 2.20:1
THRUST WASHER/SPACER/SNAP-RING DIMENSIONS
Front clutch thrust washer (reaction shaft support hub) 1.55 mm 0.061 in.
2.15 mm 0.084 in.
2.59 mm 0.102 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Intermediate shaft thrust plate (shaft hub pilot) 1.5-1.6 mm 0.060-0.063 in.
Output shaft thrust washer (rear clutch hub) 1.3-1.4 mm 0.052-0.054 in.
1.75-1.8 mm 0.068-0.070 in.
2.1-2.2 mm 0.083-0.085 in.
Rear clutch pack snap-ring 1.5-1.6 mm 0.060-0.062 in.
1.9-1.95 mm 0.074-0.076 in.
Planetary geartrain snap-ring (at front of output shaft) 1.4-1.5 mm 0.055-0.059 in.
1.6-1.7 mm 0.062-0.066 in.
Overdrive piston thrust plate Thrust plate and
spacer are select fit.
Refer to size charts
and selection
procedures in
Overdrive Unit D&A
procedures
Intermediate shaft spacer
PRESSURE TEST
Overdrive clutch Fourth gear only Pressure should be 524-565 kPa (76-82 psi) with
closed throttle and increase to 965 kPa (140 psi) at 1/2
to 3/4 throttle.
Line pressure (at
accumulator)
Closed throttle 372-414 kPa (54-60 psi).
Front servo Third or Fourth gear only No more than 21 kPa (3 psi) lower than line pressure.
Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
R range 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 (0-1.5 psi) when stopped with
transmission in D, 1, 2. Pressure above 7 kPa (1.5 psi)
at stand still will prevent transmission from
downshifting.
Fitting, cooler line at trans 18 13 -
Bolt, torque convertor 47 35 -
Bolt, clevis bracket to crossmember 47 35 -
Bolt, clevis bracket to rear support 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Plug, front band reaction 17 13 -
Locknut, front band adj. 34 25 -
Bolt, fluid pan 13.6 - 120
Screws, fluid filter 4 - 35
Bolt, oil pump 20 15 -
Bolt, overrunning clutch cam 17 13 -
Bolt, O/D to trans. 34 25 -
Bolt, O/D piston retainer 17 13 -
Plug, pressure test port 14 10 -
Bolt, reaction shaft support 20 15 -
Locknut, rear band 41 30 -
Bolt, valve body to case 12 - 100
Sensor, trans speed 27 20 -
Screw, solenoid wiring connector 4 - 35
Screw, solenoid to transfer plate 4 - 35
Bracket, transmission range sensor mounting 34 25 -
Screw, transmision range sensor to mounting
bracket
5 - 45
SPECIAL TOOLS
RE TRANSMISSION
Pilot Studs C-3288-B
Oil Pressure Gauge - C-3292
Pressure Gauge - C-3293SP
Adapter, Band Adjuster - C-3705
Puller/Slide Hammer, C-3752
Gauge, Throttle Setting - C-3763
Installer C-3860-A
Spring Compressor - C-3863-A
Handle C-4171
Dial Caliper - C-4962
Spring Compressor and Alignment Shaft - 6227
Gauge Bar - 6311
Gauge - 6312
Retainer - 6583
Installer - 8114
Socket, TRS Mounting Bracket - 8581
Installer, Seal - 9037
ACCUMULATOR
DESCRIPTION
The accumul ator (Fi g. 66) i s a hydraul i c devi ce
that has the sol e purpose of cushi oni ng the appl i ca-
ti on of a band or cl utch. The accumul ator consi sts of
a dual -l and pi ston and a spri ng l ocated i n a bore i n
the transmi ssi on case. The 3-4 accumul ator i s l ocated
i n a housi ng attached to the si de of the val ve body
(Fi g. 67).
OPERATION
Both the accumul ator and the 3-4 accumul ator
functi on the same. Li ne pressure i s di rected to the
smal l end of the pi ston when the transmi ssi on i s
pl aced i nto a DRI VE posi ti on (Fi g. 68), bottomi ng i t
agai nst the accumul ator pl ate. When the 1-2 upshi ft
occurs (Fi g. 69), l i ne pressure i s di rected to the l arge
end of the pi ston and then to the ki ckdown servo. As
the l i ne pressure reaches the accumul ator, the com-
bi nati on of spri ng pressure and l i ne pressure forces
the pi ston away from the accumul ator pl ate. Thi s
causes a bal anced pressure si tuati on, whi ch resul ts
i n a cushi oned band appl i cati on. After the ki ckdown
servo has become i mmovabl e, l i ne pressure wi l l fi n-
i sh pushi ng the accumul ator up i nto i ts bore. When
the l arge end of the accumul ator pi ston i s seated i n
i ts bore, the band or cl utch i s ful l y appl i ed.
NOTE: The accumulator is shown in the inverted
position for illustrative purposes.
Fig. 66 Accumulator
2 - PISTON SPRING
Fig. 67 3-4 Accumulator and Housing
2 - 3-4 ACCUMULATOR HOUSING
3 - TEFLON SEALS
4 - PISTON SPRING
5 - COVER PLATE AND SCREWS
Fig. 68 Accumulator in DRIVE - FIRST Gear Position
1 - LINE PRESSURE
INSPECTION
I nspect the accumul ator pi ston and seal ri ngs.
Repl ace the seal ri ngs i f worn or cut. Repl ace the pi s-
ton i f chi pped or cracked.
Check condi ti on of the accumul ator i nner and
outer spri ngs. Repl ace the spri ngs i f the coi l s are
cracked, di storted or col l apsed.
BANDS
DESCRIPTION
KICKDOWN (FRONT) BAND
The ki ckdown, or front, band (Fi g. 70) hol ds the
common sun gear of the pl anetary gear sets. The
front (ki ckdown) band i s made of steel , and faced on
i ts i nner ci rcumference wi th a fri cti on-type l i ni ng.
One end of the band i s anchored to the transmi ssi on
case, and the other i s acted on wi th a pushi ng force
by a servo pi ston. The front band i s a si ngl e-wrap
desi gn (the band does not compl etel y encompass/
wrap the drum that i t hol ds).
LOW/REVERSE (REAR) BAND
The l ow/reverse band, or rear, band (Fi g. 71) i s
si mi l ar i n appearance and operati on to the front
band. The rear band i s sl i ghtl y di fferent i n that i t
does not use a l i nk bar, but i s acted di rectl y on by
the appl y l ever. Thi s i s referred to as a doubl e-wrap
band desi gn (the drum i s compl etel y encompassed/
wrapped by the band). The doubl e-wrap band pro-
vi des a greater hol di ng power i n compari son to the
si ngl e-wrap desi gn.
OPERATION
KICKDOWN (FRONT) BAND
The ki ckdown band hol ds the common sun gear of
the pl anetary gear sets by appl yi ng and hol di ng the
front cl utch retai ner, whi ch i s spl i ned to the sun gear
dri vi ng shel l , and i n turn spl i ned di rectl y to the sun
gear. The appl i cati on of the band by the servo i s typ-
i cal l y done by an appl y l ever and l i nk bar.
Fig. 69 Accumulator in SECOND Gear Position
1 - BOTTOM OF BORE
2 - LINE PRESSURE
3 - SHUTTLE VALVE
Fig. 70 Front Band
1 - FRONT BAND
2 - TRANSMISSION HOUSING
Fig. 71 Rear Band
1 - ADJUSTING SCREW
2 - LOCKNUT
3 - LEVER
4 - REAR BAND
5 - REACTION PIN
6 - O-RINGS
7 - PIVOT PIN
ACCUMULATOR (Continued)
LOW/REVERSE (REAR) BAND
The rear band hol ds the rear pl anet carri er sta-
ti onary by bei ng mounted around and appl i ed to the
l ow/reverse drum.
ADJ USTMENTS
ADJUSTMENT - BANDS
FRONT BAND
The front (ki ckdown) band adjusti ng screw i s
l ocated on the l eft si de of the transmi ssi on case
above the manual val ve and throttl e val ve l evers.
(2) Loosen band adjusti ng screw l ocknut (Fi g. 72).
Then back l ocknut off 3-5 turns. Be sure adjusti ng
screw turns freel y i n case. Appl y l ubri cant to screw
threads i f necessary.
(3) Ti ghten band adjusti ng screw to 8 Nm (72 i n.
l bs.) torque wi th an appropri ate Torx socket.
CAUTION: If Adapter C-3705 is needed to reach the
adjusting screw, tighten the screw to only 5 Nm
(47-50 in. lbs.) torque.
(4) Back off front band adjusti ng screw 1-3/4
turns.
(5) Hol d adjuster screw i n posi ti on and ti ghten
l ocknut to 41 Nm (30 ft. l bs.) torque.
REAR BAND
The transmi ssi on oi l pan must be removed for
access to the rear band adjusti ng screw.
(2) Remove transmi ssi on oi l pan and drai n fl ui d.
(3) Loosen band adjusti ng screw l ocknut 5-6 turns.
Be sure adjusti ng screw turns freel y i n l ever.
(4) Ti ghten adjusti ng screw to 8 Nm (72 i n. l bs.)
torque (Fi g. 73).
(5) Back off adjusti ng screw 3 turns.
(6) Hol d adjusti ng screw i n pl ace and ti ghten l ock-
nut to 34 Nm (25 ft. l bs.) torque.
(7) Posi ti on new gasket on oi l pan and i nstal l pan
on transmi ssi on. Ti ghten pan bol ts to 17 Nm (13 ft.
l bs.) torque.
(8) Lower vehi cl e and refi l l transmi ssi on wi th
Mopar ATF +4, Automati c Transmi ssi on fl ui d.
Fig. 72 Front Band Adjustment Screw Location
1 - LOCK-NUT
2 - FRONT BAND ADJUSTER
Fig. 73 Rear Band Adjustment Screw Location
1 - LOW-REVERSE BAND ADJUSTMENT
BANDS (Continued)
BRAKE TRANSMISSION SHIFT
INTERLOCK SYSTEM
DESCRIPTION
The Brake Transmi ssi on Shi fter I nterl ock (BTSI )
(Fi g. 74), i s a sol enoi d operated system. I t consi sts of
a sol enoi d permanentl y mounted on the gearshi ft
cabl e.
OPERATION
The system l ocks the shi fter i nto the PARK posi -
ti on. The i nterl ock system i s engaged whenever the
i gni ti on swi tch i s i n the LOCK or ACCESSORY posi -
ti on. An addi ti onal el ectri cal l y acti vated feature wi l l
prevent shi fti ng out of the PARK posi ti on unl ess the
brake pedal i s depressed approxi matel y one-hal f an
i nch. A magneti c hol di ng devi ce i n l i ne wi th the park
l ock cabl e i s energi zed when the i gni ti on i s i n the
RUN posi ti on. When the key i s i n the RUN posi ti on
and the brake pedal i s depressed, the shi fter i s
unl ocked and wi l l move i nto any posi ti on. The i nter-
l ock system al so prevents the i gni ti on swi tch from
bei ng turned to the LOCK or ACCESSORY posi ti on,
unl ess the shi fter i s ful l y l ocked i nto the PARK posi -
ti on.
TRANSMISSION SHIFT INTERLOCK
(1) Veri fy that the key can onl y be removed i n the
PARK posi ti on
(2) When the shi ft l ever i s i n PARK And the shi ft
handl e pushbutton i s i n the OUT posi ti on, the i gni -
ti on key cyl i nder shoul d rotate freel y from OFF to
LOCK. When the shi fter i s i n any other gear or neu-
tral posi ti on, the i gni ti on key cyl i nder shoul d not
rotate to the LOCK posi ti on.
(3) Shi fti ng out of PARK shoul d not be possi bl e
when the i gni ti on key cyl i nder i s i n the OFF posi -
ti on.
whi l e appl yi ng normal pushbutton force and i gni ti on
key cyl i nder i s i n the RUN or START posi ti ons
unl ess the foot brake pedal i s depressed approxi -
matel y 1/2 i nch (12mm).
when the i gni ti on key cyl i nder i s i n the ACCESSORY
or LOCK posi ti ons.
(6) Shi fti ng between any gears, NEUTRAL or i nto
PARK may be done wi thout depressi ng foot brake
pedal wi th i gni ti on swi tch i n RUN or START posi -
ti ons.
SHIFT INTERLOCK
Correct cabl e adjustment i s i mportant to proper
i nterl ock operati on. The gearshi ft cabl e must be cor-
rectl y adjusted i n order to shi ft out of PARK.
ADJUSTMENT PROCEDURE
(1) Remove the steeri ng col umn tri m as necessary
for access to the brake transmi ssi on shi ft i nterl ock.
(2) Shi ft the transmi ssi on i nto the PARK posi ti on.
(3) Pul l upward on both the BTSI l ock tab and the
gearshi ft cabl e l ock tab (Fi g. 75).
(4) Veri fy that the shi ft l ever i s i n the PARK posi -
ti on.
(5) Veri fy posi ti ve engagement of the transmi ssi on
park l ock by attempti ng to rotate the propel l er shaft.
The shaft wi l l not rotate when the park l ock i s
engaged.
(6) Turn i gni ti on swi tch to LOCK posi ti on. Be
sure ignition key cylinder is in the LOCK posi-
tion. Cable will not adjust correctly in any
other position.
(7) Ensure that the cabl e i s free to sel f-adjust by
pushi ng cabl e rearward and rel easi ng.
(8) Push the gearshi ft cabl e l ock tab down unti l i t
snaps i n pl ace.
(9) Locate the BTSI al i gnment hol e i n the bottom
of the BTSI mechani sm between the BTSI l ock tab
and the BTSI connector.
(10) Move the BTSI assembl y up or down on the
gearshi ft cabl e unti l an appropri ate si ze dri l l bi t can
be i nserted i nto the al i gnment hol e and through the
assembl y.
(11) Push the BTSI l ock tab down unti l i t snaps
i nto pl ace and remove the dri l l bi t.
(12) I nstal l any steeri ng col umn tri m previ ousl y
removed.
Fig. 74 Brake Transmission Interlock Mechanism
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
3 - GEARSHIFT CABLE LOCK TAB
4 - BTSI SOLENOID LOCK TAB
5 - BTSI CONNECTOR
BTSI FUNCTION CHECK
(1) Veri fy removal of i gni ti on key al l owed i n PARK
posi ti on onl y.
(2) When the shi ft l ever i s i n PARK, the i gni ti on
key cyl i nder shoul d rotate freel y from off to l ock.
When the shi fter i s i n any other posi ti on, the i gni ti on
key shoul d not rotate from off to l ock.
(3) Shi fti ng out of PARK shoul d be possi bl e when
the i gni ti on key cyl i nder i s i n the off posi ti on.
whi l e appl yi ng normal force, and i gni ti on key cyl i n-
der i s i n the run or start posi ti ons, unl ess the foot
brake pedal i s depressed approxi matel y 1/2 i nch
(12mm).
when the i gni ti on key cyl i nder i s i n the accessory or
l ock posi ti on.
(6) Shi fti ng between any gear and NEUTRAL, or
PARK, may be done wi thout depressi ng foot brake
wi th i gni ti on swi tch i n run or start posi ti ons.
(7) Engi ne starts must be possi bl e wi th shi fter
l ever i n PARK or NEUTRAL posi ti ons onl y. Engi ne
starts must not be possi bl e i n any posi ti on other than
PARK or NEUTRAL.
(8) Wi th shi fter l ever i n the:
PARK posi ti on - Appl y upward force on the shi ft
arm and remove pressure. Engi ne starts must be
possi bl e.
PARK posi ti on - Appl y downward force on the
shi ft arm and remove pressure. Engi ne starts must
be possi bl e.
NEUTRAL posi ti on - Normal posi ti on. Engi ne
starts must be possi bl e.
NEUTRAL posi ti on - Engi ne runni ng and brakes
appl i ed, appl y upward force on the shi ft arm. Trans-
mi ssi on shal l not be abl e to shi ft from neutral to
reverse.
ELECTRONIC GOVERNOR
DESCRIPTION
Governor pressure i s control l ed el ectroni cal l y. Com-
ponents used for governor pressure control i ncl ude:
Governor body
Val ve body transfer pl ate
Governor pressure sol enoi d val ve
Governor pressure sensor
Fl ui d temperature thermi stor
Transmi ssi on speed sensor
Powertrai n control modul e (PCM)
GOVERNOR PRESSURE SOLENOID VALVE
The sol enoi d val ve i s a duty-cycl e sol enoi d whi ch
regul ates the governor pressure needed for upshi fts
and downshi fts. I t i s an el ectro-hydraul i c devi ce
l ocated i n the governor body on the val ve body trans-
fer pl ate (Fi g. 76).
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
5 - BTSI CONNECTOR
Fig. 76 Governor Pressure Solenoid Valve
1 - SOLENOID FILTER
BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM (Continued)
GOVERNOR PRESSURE SENSOR
The governor pressure sensor measures output
pressure of the governor pressure sol enoi d val ve (Fi g.
77).
GOVERNOR BODY AND TRANSFER PLATE
The transfer pl ate i s desi gned to suppl y transmi s-
si on l i ne pressure to the governor pressure sol enoi d
val ve and to return governor pressure.
The governor pressure sol enoi d val ve i s mounted i n
the governor body. The body i s bol ted to the l ower
si de of the transfer pl ate (Fi g. 77).
GOVERNOR PRESSURE CURVES
There are four governor pressure curves pro-
grammed i nto the transmi ssi on control modul e. The
di fferent curves al l ow the control modul e to adjust
governor pressure for varyi ng condi ti ons. One curve
i s used for operati on when fl ui d temperature i s at, or
bel ow, 1C (30F). A second curve i s used when fl ui d
temperature i s at, or above, 10C (50F) duri ng nor-
mal ci ty or hi ghway dri vi ng. A thi rd curve i s used
duri ng wi de-open throttl e operati on. The fourth curve
i s used when dri vi ng wi th the transfer case i n l ow
range.
OPERATION
Compensati on i s requi red for performance vari a-
ti ons of two of the i nput devi ces. Though the sl ope of
the transfer functi ons i s ti ghtl y control l ed, offset may
vary due to vari ous envi ronmental factors or manu-
facturi ng tol erances.
The pressure transducer i s affected by barometri c
pressure as wel l as temperature. Cal i brati on of the
zero pressure offset i s requi red to compensate for
shi fti ng output due to these factors.
Normal cal i brati on wi l l be performed when sump
temperature i s above 50 degrees F, or i n the absence
of sump temperature data, after the fi rst 10 mi nutes
of vehi cl e operati on. Cal i brati on of the pressure
transducer offset occurs each ti me the output shaft
speed fal l s bel ow 200 RPM. Cal i brati on shal l be
repeated each 3 seconds the output shaft speed i s
bel ow 200 RPM. A 0.5 second pul se of 95% duty cycl e
i s appl i ed to the governor pressure sol enoi d val ve
and the transducer output i s read duri ng thi s pul se.
Averagi ng of the transducer si gnal i s necessary to
reject el ectri cal noi se.
Under col d condi ti ons (bel ow 50 degrees F sump),
the governor pressure sol enoi d val ve response may
be too sl ow to guarantee 0 psi duri ng the 0.5 second
cal i brati on pul se. Cal i brati on pul ses are conti nued
duri ng thi s peri od, however the transducer output
val ves are di scarded. Transducer offset must be read
at key-on, under condi ti ons whi ch promote a stabl e
readi ng. Thi s val ue i s retai ned and becomes the off-
set duri ng the col d peri od of operati on.
GOVERNOR PRESSURE SOLENOID VALVE
The i nl et si de of the sol enoi d val ve i s exposed to
normal transmi ssi on l i ne pressure. The outl et si de of
the val ve l eads to the val ve body governor ci rcui t.
The sol enoi d val ve regul ates l i ne pressure to pro-
duce governor pressure. The average current sup-
pl i ed to the sol enoi d control s governor pressure. One
amp current produces zero kPa/psi governor pres-
sure. Zero amps sets the maxi mum governor pres-
sure.
The powertrai n control modul e (PCM) turns on the
trans control rel ay whi ch suppl i es el ectri cal power to
the sol enoi d val ve. Operati ng vol tage i s 12 vol ts
(DC). The PCM control s the ground si de of the sol e-
noi d usi ng the governor pressure sol enoi d control ci r-
cui t.
GOVERNOR PRESSURE SENSOR
The sensor output si gnal provi des the necessary
feedback to the PCM. Thi s feedback i s needed to ade-
quatel y control governor pressure.
GOVERNOR BODY AND TRANSFER PLATE
The transfer pl ate channel s l i ne pressure to the
sol enoi d val ve through the governor body. I t al so
channel s governor pressure from the sol enoi d val ve
to the governor ci rcui t. I t i s the sol enoi d val ve that
devel ops the necessary governor pressure.
GOVERNOR PRESSURE CURVES
LOW TRANSMISSION FLUID TEMPERATURE
When the transmi ssi on fl ui d i s col d the conven-
ti onal governor can del ay shi fts, resul ti ng i n hi gher
than normal shi ft speeds and harsh shi fts. The el ec-
troni cal l y control l ed l ow temperature governor pres-
Fig. 77 Governor Pressure Sensor
1 - GOVERNOR BODY
2 - GOVERNOR PRESSURE SENSOR/TRANSMISSION FLUID
TEMPERATURE THERMISTOR
ELECTRONIC GOVERNOR (Continued)
sure curve i s hi gher than normal to make the
transmi ssi on shi ft at normal speeds and sooner. The
PCM uses a temperature sensor i n the transmi ssi on
oi l sump to determi ne when l ow temperature gover-
nor pressure i s needed.
NORMAL OPERATION
Normal operati on i s refi ned through the i ncreased
computi ng power of the PCM and through access to
data on engi ne operati ng condi ti ons provi ded by the
PCM that were not avai l abl e wi th the previ ous
stand-al one el ectroni c modul e. Thi s faci l i tated the
devel opment of a l oad adapti ve shi ft strategy - the
abi l i ty to al ter the shi ft schedul e i n response to vehi -
cl e l oad condi ti on. One mani festati on of thi s capabi l -
i ty i s grade hunti ng preventi on - the abi l i ty of the
transmi ssi on l ogi c to del ay an upshi ft on a grade i f
the engi ne does not have suffi ci ent power to mai n-
tai n speed i n the hi gher gear. The 3-2 downshi ft and
the potenti al for hunti ng between gears occurs wi th a
heavi l y l oaded vehi cl e or on steep grades. When
hunti ng occurs, i t i s very objecti onabl e because shi fts
are frequent and accompani ed by l arge changes i n
noi se and accel erati on.
WIDE OPEN THROTTLE OPERATION
I n wi de-open throttl e (WOT) mode, adapti ve mem-
ory i n the PCM assures that up-shi fts occur at the
preprogrammed opti mum speed. WOT operati on i s
determi ned from the throttl e posi ti on sensor, whi ch
i s al so a part of the emi ssi on control system. The i ni -
ti al setti ng for the WOT upshi ft i s bel ow the opti -
mum engi ne speed. As WOT shi fts are repeated, the
PCM l earns the ti me requi red to compl ete the shi fts
by compari ng the engi ne speed when the shi fts occur
to the opti mum speed. After each shi ft, the PCM
adjusts the shi ft poi nt unti l the opti mum speed i s
reached. The PCM al so consi ders vehi cl e l oadi ng,
grade and engi ne performance changes due to hi gh
al ti tude i n determi ni ng when to make WOT shi fts. I t
does thi s by measuri ng vehi cl e and engi ne accel era-
ti on and then factori ng i n the shi ft ti me.
TRANSFER CASE LOW RANGE OPERATION
On four-wheel dri ve vehi cl es operati ng i n l ow
range, the engi ne can accel erate to i ts peak more
rapi dl y than i n Normal range, resul ti ng i n del ayed
shi fts and undesi rabl e engi ne fl are. The l ow range
governor pressure curve i s al so hi gher than normal
to i ni ti ate upshi fts sooner. The PCM compares el ec-
troni c vehi cl e speed si gnal used by the speedometer
to the transmi ssi on output shaft speed si gnal to
determi ne when the transfer case i s i n l ow range.
REMOVAL
(2) Remove transmi ssi on fl ui d pan and fi l ter.
(3) Di sengage wi re connectors from pressure sen-
sor and sol enoi d (Fi g. 78).
(4) Remove screws hol di ng pressure sol enoi d
retai ner to governor body.
(5) Separate sol enoi d retai ner from governor (Fi g.
79).
Fig. 78 Governor Solenoid And Pressure Sensor
1 - PRESSURE SENSOR
2 - PRESSURE SOLENOID
3 - GOVERNOR
Fig. 79 Pressure Solenoid Retainer
1 - PRESSURE SOLENOID RETAINER
2 - GOVERNOR
(6) Pul l sol enoi d from governor body (Fi g. 80).
(7) Pul l pressure sensor from governor body.
(8) Remove bol ts hol di ng governor body to val ve
body.
(9) Separate governor body from val ve body (Fi g.
81).
(10) Remove governor body gasket.
INSTALLATION
Before i nstal l i ng the pressure sensor and sol enoi d
i n the governor body, repl ace o-ri ng seal s, cl ean the
gasket surfaces and repl ace gasket.
(1) Pl ace gasket i n posi ti on on back of governor
body (Fi g. 82).
(2) Pl ace governor body i n posi ti on on val ve body.
(3) I nstal l bol ts to hol d governor body to val ve
body.
(4) Lubri cate o-ri ng on pressure sensor wi th trans-
mi ssi on fl ui d.
(5) Al i gn pressure sensor to bore i n governor body.
(6) Push pressure sensor i nto governor body.
(7) Lubri cate o-ri ng, on pressure sol enoi d, wi th
transmi ssi on fl ui d.
(8) Al i gn pressure sol enoi d to bore i n governor
body (Fi g. 83).
(9) Push sol enoi d i nto governor body.
Fig. 80 Pressure Solenoid and O-ring
2 - O-RING
3 - GOVERNOR
Fig. 81 Governor Body and Gasket
1 - GOVERNOR BODY
2 - GASKET
Fig. 82 Governor Body and Gasket
1 - GOVERNOR BODY
2 - GASKET
Fig. 83 Pressure Solenoid and O-ring
2 - O-RING
3 - GOVERNOR
(10) Pl ace sol enoi d retai ner i n posi ti on on governor
(Fi g. 84).
(11) I nstal l screws to hol d pressure sol enoi d
retai ner to governor body.
(12) Engage wi re connectors i nto pressure sensor
and sol enoi d (Fi g. 85).
(13) I nstal l transmi ssi on fl ui d pan and (new) fi l ter.
(14) Lower vehi cl e and road test to veri fy repai r.
REMOVAL
(2) Mark propel l er shaft and axl e yoke for al i gn-
ment reference.
(3) Di sconnect and remove propel l er shaft.
(4) Remove ol d seal wi th a screw mounted i n a
sl i de hammer.
INSTALLATION
(1) Pl ace seal i n posi ti on on overdri ve housi ng.
(2) Dri ve seal i nto overdri ve housi ng wi th Seal
I nstal l er 9037 (Fi g. 86).
(3) Careful l y gui de propel l er shaft sl i p yoke i nto
housi ng and onto output shaft spl i nes. Al i gn marks
made at removal and connect propel l er shaft to rear
axl e pi ni on yoke.
FLUID AND FILTER
INCORRECT FLUID LEVEL
A l ow fl ui d l evel al l ows the pump to take i n ai r
al ong wi th the fl ui d. Ai r i n the fl ui d wi l l cause fl ui d
pressures to be l ow and devel op sl ower than normal .
I f the transmi ssi on i s overfi l l ed, the gears churn the
fl ui d i nto foam. Thi s aerates the fl ui d and causi ng
the same condi ti ons occurri ng wi th a l ow l evel . I n
ei ther case, ai r bubbl es cause fl ui d overheati ng, oxi -
dati on and varni sh bui l dup whi ch i nterferes wi th
val ve and cl utch operati on. Foami ng al so causes fl ui d
expansi on whi ch can resul t i n fl ui d overfl ow from the
transmi ssi on vent or fi l l tube. Fl ui d overfl ow can eas-
i l y be mi staken for a l eak i f i nspecti on i s not careful .
BURNT FLUID
Burnt, di scol ored fl ui d i s a resul t of overheati ng
whi ch has two pri mary causes.
(1) A resul t of restri cted fl ui d fl ow through the
mai n and/or auxi l i ary cool er. Thi s condi ti on i s usu-
al l y the resul t of a faul ty or i mproperl y i nstal l ed
drai nback val ve, a damaged mai n cool er, or severe
restri cti ons i n the cool ers and l i nes caused by debri s
or ki nked l i nes.
Fig. 84 Pressure Solenoid Retainer
1 - PRESSURE SOLENOID RETAINER
2 - GOVERNOR
Fig. 85 Governor Solenoid And Pressure Sensor
1 - PRESSURE SENSOR
3 - GOVERNOR
Fig. 86 Installing Overdrive Housing Yoke Seal
(2) Heavy duty operati on wi th a vehi cl e not prop-
erl y equi pped for thi s type of operati on. Trai l er tow-
i ng or si mi l ar hi gh l oad operati on wi l l overheat the
transmi ssi on fl ui d i f the vehi cl e i s i mproperl y
equi pped. Such vehi cl es shoul d have an auxi l i ary
transmi ssi on fl ui d cool er, a heavy duty cool i ng sys-
tem, and the engi ne/axl e rati o combi nati on needed to
handl e heavy l oads.
CONTAMINATION
Transmi ssi on fl ui d contami nati on i s general l y a
resul t of:
addi ng i ncorrect fl ui d
fai l ure to cl ean di psti ck and fi l l tube when
checki ng l evel
engi ne cool ant enteri ng the fl ui d
i nternal fai l ure that generates debri s
overheat that generates sl udge (fl ui d break-
down)
fai l ure to repl ace contami nated converter after
repai r
The use of non-recommended fl ui ds can resul t i n
transmi ssi on fai l ure. The usual resul ts are errati c
shi fts, sl i ppage, abnormal wear and eventual fai l ure
due to fl ui d breakdown and sl udge formati on. Avoi d
thi s condi ti on by usi ng recommended fl ui ds onl y.
The di psti ck cap and fi l l tube shoul d be wi ped
cl ean before checki ng fl ui d l evel . Di rt, grease and
other forei gn materi al on the cap and tube coul d fal l
i nto the tube i f not removed beforehand. Take the
ti me to wi pe the cap and tube cl ean before wi thdraw-
i ng the di psti ck.
Engi ne cool ant i n the transmi ssi on fl ui d i s gener-
al l y caused by a cool er mal functi on. The onl y remedy
i s to repl ace the radi ator as the cool er i n the radi ator
i s not a servi ceabl e part. I f cool ant has ci rcul ated
through the transmi ssi on, an overhaul i s necessary.
The torque converter shoul d al so be repl aced when-
ever a fai l ure generates sl udge and debri s. Thi s i s
necessary because normal converter fl ushi ng proce-
dures wi l l not remove al l contami nants.
STANDARD PROCEDURE
CHECK
Low fl ui d l evel can cause a vari ety of condi ti ons
because i t al l ows the pump to take i n ai r al ong wi th
the fl ui d. As i n any hydraul i c system, ai r bubbl es
make the fl ui d spongy, therefore, pressures wi l l be
l ow and bui l d up sl owl y.
I mproper fi l l i ng can al so rai se the fl ui d l evel too
hi gh. When the transmssi on has too much fl ui d, the
geartrai n churns up foam and cause the same condi -
ti ons whi ch occur wi th a l ow fl ui d l evel .
I n ei ther case, ai r bubbl es can cause overheati ng
and/or fl ui d oxi dati on, and varni shi ng. Thi s can
i nterfere wi th normal val ve, cl utch, and accumul ator
operati on. Foami ng can al so resul t i n fl ui d escapi ng
from the transmi ssi on vent where i t may be mi s-
taken for a l eak.
After the fl ui d has been checked, seat the di psti ck
ful l y to seal out water and di rt.
The transmi ssi on has a di psti ck to check oi l l evel .
I t i s l ocated on the ri ght si de of the engi ne. Be sure
to wi pe al l di rt from di psti ck handl e before removi ng.
Fl ui d l evel i s checked wi th the engi ne runni ng at
curb i dl e speed, the transmi ssi on i n NEUTRAL and
the transmi ssi on fl ui d at normal operati ng tempera-
ture. The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground.
The transmi ssi on fl ui d l evel can be checked two
ways.
PROCEDURE ONE
(1) Transmi ssi on fl ui d must be at normal operat-
i ng temperature for accurate fl ui d l evel check. Dri ve
vehi cl e i f necessary to bri ng fl ui d temperature up to
normal hot operati ng temperature of 82C (180F).
(3) Start and run engi ne at curb i dl e speed.
(4) Appl y parki ng brakes.
(5) Shi ft transmi ssi on momentari l y i nto al l gear
ranges. Then shi ft transmi ssi on back to NEUTRAL.
(6) Cl ean top of fi l l er tube and di psti ck to keep
di rt from enteri ng tube.
(7) Remove di psti ck (Fi g. 87) and check fl ui d l evel
as fol l ows:
(a) Correct acceptabl e l evel i s i n crosshatch area.
(b) Correct maxi mum l evel i s to MAX arrow
mark.
(c) I ncorrect l evel i s at or bel ow MI N l i ne.
(d) I f fl ui d i s l ow, add onl y enough Mopar ATF
+4 to restore correct l evel . Do not overfi l l .
Fig. 87 Dipstick Fluid Level Marks - Typical
1 - DIPSTICK
2 - MAXIMUM CORRECT FLUID LEVEL
3 - ACCEPTABLE FLUID LEVEL
FLUID AND FILTER (Continued)
PROCEDURE TWO
(1) Start engi ne and appl y parki ng brake.
(2) Shi ft the transmi ssi on i nto DRI VE for approxi -
matel y 2 seconds.
(3) Shi ft the transmi ssi on i nto REVERSE for
approxi matel y 2 seconds.
(4) Shi ft the transmi ssi on i nto PARK.
(5) Hook up DRB scan tool and sel ect engi ne.
(6) Sel ect sensors.
(7) Read the transmi ssi on temperature val ue.
(8) Compare the fl ui d temperature val ue wi th the
chart.
(9) Adjust transmi ssi on fl ui d l evel shown on the
di psti ck accordi ng to the chart (Fi g. 88).
NOTE: After adding any fluid to the transmission,
wait a minimum of 2 minutes for the oil to fully
drain from the fill tube into the transmission before
rechecking the fluid level.
(10) Check transmi ssi on for l eaks.
STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT
For proper servi ce i nterval s (Refer to LUBRI CA-
TI ON & MAI NTENANCE/MAI NTENANCE SCHED-
ULES - DESCRI PTI ON). The servi ce fl ui d fi l l after a
fi l ter change i s approxi matel y 3.8 l i ters (4.0 quarts).
REMOVAL
(2) Pl ace a l arge di ameter shal l ow drai n pan
beneath the transmi ssi on pan.
(3) Remove bol ts hol di ng front and si des of pan to
transmi ssi on (Fi g. 89).
(4) Loosen bol ts hol di ng rear of pan to transmi s-
si on.
Fig. 88 48RE Fluid Fill Graph
Fig. 89 Transmission Pan
1 - TRANSMISSION
2 - REUSABLE GASKET
3 - PAN
(5) Sl owl y separate front of pan and reusabl e gas-
ket away from transmi ssi on al l owi ng the fl ui d to
drai n i nto drai n pan.
(6) Hol d up pan and remove remai ni ng bol t hol d-
i ng pan to transmi ssi on.
(7) Whi l e hol di ng pan l evel , l ower pan and gasket
away from transmi ssi on.
(8) Pour remai ni ng fl ui d i n pan i nto drai n pan.
(9) Remove screws hol di ng fi l ter to val ve body
(Fi g. 90).
(10) Separate fi l ter from val ve body and pour fl ui d
i n fi l ter i nto drai n pan.
(11) Di spose of used trans fl ui d and fi l ter properl y.
INSTALLATION
(1) Posi ti on a new transmi ssi on oi l fi l ter onto the
val ve body.
(2) I nstal l the screws to hol d the fi l ter to the val ve
body. Ti ghten the screws to 4 Nm (35 i n.l bs.).
(3) Cl ean the gasket surfaces of the transmi ssi on
oi l pan and transmi ssi on pan rai l .
NOTE: The transmission pan oil gasket is reusable.
Inspect the sealing surfaces of the gasket. If the
sealing ribs on both surfaces appear to be in good
condition, clean the gasket of any foreign material
and reinstall.
(4) Posi ti on the oi l pan gasket onto the oi l pan.
(5) Posi ti on the oi l pan and gasket onto the trans-
mi ssi on and i nstal l several bol ts to hol d the pan and
gasket to the transmi ssi on.
(6) I nstal l the remai nder of the oi l pan bol ts.
Ti ghten the bol ts to 13.6 Nm (125 i n.l bs.).
(7) Lower vehi cl e and fi l l transmi ssi on. (Refer to
21 - TRANSMI SSI ON/AUTOMATI C/FLUI D - STAN-
DARD PROCEDURE)
FILL
To avoi d overfi l l i ng transmi ssi on after a fl ui d
change or overhaul , perform the fol l owi ng procedure:
(1) Remove di psti ck and i nsert cl ean funnel i n
transmi ssi on fi l l tube.
(2) Add fol l owi ng i ni ti al quanti ty of Mopar ATF
+4 to transmi ssi on:
(a) I f onl y fl ui d and fi l ter were changed, add 3
pints (1-1/2 quarts) of ATF +4 to transmi ssi on.
(b) I f transmi ssi on was compl etel y overhaul ed,
torque converter was repl aced or drai ned, and
cool er was fl ushed, add 12 pints (6 quarts) of ATF
+4 to transmi ssi on.
(3) Appl y parki ng brakes.
(4) Start and run engi ne at normal curb i dl e
speed.
(5) Appl y servi ce brakes, shi ft transmi ssi on
through al l gear ranges then back to NEUTRAL, set
parki ng brake, and l eave engi ne runni ng at curb i dl e
speed.
(6) Remove funnel , i nsert di psti ck and check fl ui d
l evel . I f l evel i s l ow, add fluid to bring level to
MIN mark on dipstick. Check to see i f the oi l l evel
i s equal on both si des of the di psti ck. I f one si de i s
noti cabl y hi gher than the other, the di psti ck has
pi cked up some oi l from the di psti ck tube. Al l ow the
oi l to drai n down the di psti ck tube and re-check.
(7) Dri ve vehi cl e unti l transmi ssi on fl ui d i s at nor-
mal operati ng temperature.
(8) Wi th the engi ne runni ng at curb i dl e speed, the
gear sel ector i n NEUTRAL, and the parki ng brake
appl i ed, check the transmi ssi on fl ui d l evel .
CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.
(9) Add fl ui d to bri ng l evel up to MAX arrow
mark.
When fl ui d l evel i s correct, shut engi ne off, rel ease
park brake, remove funnel , and i nstal l di psti ck i n fi l l
tube.
Fig. 90 Transmission Filter
1 - TRANSMISSION
2 - FILTER
FRONT CLUTCH
DESCRIPTION
The front cl utch assembl y (Fi g. 91) i s composed of
the front cl utch retai ner, pressure pl ate, cl utch
pl ates, dri vi ng di scs, pi ston, pi ston return spri ng,
return spri ng retai ner, and snap-ri ngs. The front
cl utch i s the forward-most component i n the trans-
mi ssi on geartrai n and i s di rectl y behi nd the oi l pump
and i s consi dered a dri vi ng component.
OPERATION
To appl y the cl utch, pressure i s appl i ed between
the cl utch retai ner and pi ston. The fl ui d pressure i s
provi ded by the oi l pump, transferred through the
control val ves and passageways, and enters the
cl utch through the hub of the reacti on shaft support.
Wi th pressure appl i ed between the cl utch retai ner
and pi ston, the pi ston moves away from the cl utch
retai ner and compresses the cl utch pack. Thi s acti on
appl i es the cl utch pack, al l owi ng torque to fl ow
through the i nput shaft i nto the dri vi ng di scs, and
i nto the cl utch pl ates and pressure pl ate that are
l ugged to the cl utch retai ner. The waved snap-ri ng i s
used to cushi on the appl i cati on of the cl utch pack.
When pressure i s rel eased from the pi ston, the
spri ng returns the pi ston to i ts ful l y rel eased posi ti on
and di sengages the cl utch. The rel ease spri ng al so
hel ps to cushi on the appl i cati on of the cl utch assem-
bl y. When the cl utch i s i n the process of bei ng
rel eased by the rel ease spri ng, fl ui d fl ows through a
vent and one-way bal l -check-val ve l ocated i n the
cl utch retai ner. The check-val ve i s needed to el i mi -
nate the possi bi l i ty of pl ate drag caused by centri fu-
gal force acti ng on the resi dual fl ui d trapped i n the
cl utch pi ston retai ner.
DISASSEMBLY
(1) Remove the waved snap-ri ng, reacti on pl ate,
cl utch pl ates, and cl utch di scs.
Fig. 91 48RE Front Clutch Components
1 - INNER PISTON SEAL 7 - CLUTCH DISCS
2 - CLUTCH PISTON 8 - RETAINER SNAP-RING
3 - CLUTCH PISTON SPRING RETAINER 9 - CLUTCH PISTON SPRINGS
4 - CLUTCH PLATES 10 - OUTER PISTON SEAL
5 - CLUTCH PACK SNAP-RING (WAVED) 11 - FRONT CLUTCH RETAINER
6 - REACTION PLATE
(2) Compress cl utch pi ston retai ner and pi ston
spri ngs wi th Compressor Tool C-3863-A (Fi g. 92).
(3) Remove retai ner snap-ri ng and remove com-
pressor tool .
(4) Remove cl utch pi ston spri ngs (Fi g. 93). Note
posi ti on and number of pi ston spri ngs for assembl y
reference.
(5) Remove cl utch pi ston from retai ner wi th a
twi sti ng moti on.
(6) Remove and di scard cl utch pi ston i nner and
outer seal s.
INSPECTION
I nspect the front cl utch components. Repl ace the
cl utch di scs i f warped, worn, scored, burned or
charred, the l ugs are damaged, or i f the faci ng i s
fl aki ng off. Repl ace the steel pl ates and reacti on
pl ate i f heavi l y scored, warped, or broken. Be sure
the dri vi ng l ugs on the di scs and pl ate are al so i n
good condi ti on. The l ugs must not be bent, cracked or
Repl ace the pi ston spri ngs and spri ng retai ner i f
ei ther are di storted, warped or broken.
Check the l ug grooves i n the cl utch pi ston retai ner.
The steel pl ates shoul d sl i de freel y i n the sl ots. Repl ace
the pi ston retai ner i f the grooves are worn or damaged.
Al so check acti on of the check bal l i n the pi ston
retai ner. The bal l must move freel y and not sti ck.
Repl ace the retai ner bushi ng i f worn, scored, or
there i s any doubt about bushi ng condi ti on.
6 - REACTION PLATE
Fig. 92 Removing Front Clutch Spring Retainer
Snap-Ring
1 - SPECIAL TOOL C-3863-A
2 - SNAP-RING
FRONT CLUTCH (Continued)
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y scored.
Check the cl utch pi ston check bal l . The bal l shoul d
be securel y i n pl ace. Repl ace the pi ston i f the bal l i s
mi ssi ng, or sei zed i n pl ace.
ASSEMBLY
NOTE: The 48RE transmission uses five plates and
discs for the front clutch.
(1) Soak cl utch di scs i n transmi ssi on fl ui d.
(2) I nstal l new i nner pi ston seal onto the outer
di ameter of the cl utch retai ner i nner hub.
(3) I nstal l new outer seal onto the cl utch pi ston. Be
sure seal l i ps of both seal s face the i nteri or of the
retai ner.
(4) Lubri cate new i nner and outer pi ston seal s
wi th petrol eum jel l y.
(5) I nstal l cl utch pi ston i n retai ner. Use twi sti ng
moti on to seat pi ston i n bottom of retai ner. A thi n
stri p of pl asti c (about 0.015 - 0.020 i n. thi ck), can be
used to gui de seal s i nto pl ace i f necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(6) I nstal l and posi ti on ni ne cl utch pi ston spri ngs
(Fi g. 94).
(7) I nstal l spri ng retai ner on top of pi ston spri ngs.
(8) Compress spri ng retai ner and pi ston spri ngs
wi th Tool C-3863-A.
(9) I nstal l spri ng retai ner snap-ri ng and remove
compressor tool .
(10) I nstal l cl utch pl ates and di scs (Fi g. 95). Fi ve
cl utch di scs, fi ve steel pl ates and one reacti on pl ate
are requi red.
Fig. 94 Front Clutch Spring Position
1 - 9 SPRING CLUTCH
6 - REACTION PLATE
(11) I nstal l reacti on pl ate fol l owed by waved snap-
ri ng.
(12) Check cl utch pack cl earance wi th feel er gauge
(Fi g. 96). Cl earance between waved spri ng and pres-
sure pl ate shoul d 2.5-4.09 mm (0.098-0.161 i n.). I f
cl earance i s i ncorrect, cl utch pl ates, cl utch di scs,
snap-ri ng, or pressure pl ate may have to be changed.
FRONT SERVO
DESCRIPTION
The ki ckdown servo (Fi g. 97) consi sts of a two-l and
pi ston wi th an i nner pi ston, a pi ston rod and gui de,
and a return spri ng. The dual -l and pi ston uses seal
ri ngs on i ts outer di ameters and an O-ri ng for the
i nner pi ston.
OPERATION
The appl i cati on of the pi ston i s accompl i shed by
appl yi ng pressure between the two l ands of the pi s-
ton. The pressure acts agai nst the l arger l ower l and
to push the pi ston downward, al l owi ng the pi ston rod
to extend though i ts gui de agai nst the appl y l ever.
Rel ease of the servo at the 2-3 upshi ft i s accom-
pl i shed by a combi nati on of spri ng and l i ne pressure,
acti ng on the bottom of the l arger l and of the pi ston.
The smal l pi ston i s used to cushi on the appl i cati on of
the band by bl eedi ng oi l through a smal l ori fi ce i n
the l arger pi ston. The rel ease ti mi ng of the ki ckdown
servo i s very i mportant to obtai n a smooth but fi rm
shi ft. The rel ease has to be very qui ck, just as the
front cl utch appl i cati on i s taki ng pl ace. Otherwi se,
engi ne runaway or a shi ft hesi tati on wi l l occur. To
accompl i sh thi s, the band retai ns i ts hol di ng capaci ty
unti l the front cl utch i s appl i ed, gi vi ng a smal l
amount of overl ap between them.
Fig. 96 Typical Method Of Measuring Front Clutch
Pack Clearance
1 - FEELER GAUGE
2 - WAVED SNAP-RING
3 - FEELER GAUGE
Fig. 97 Front Servo
1 - VENT
2 - INNER PISTON
3 - PISTON
4 - SPRING
5 - RELEASE PRESSURE
6 - APPLY PRESSURE
7 - PISTON ROD
DISASSEMBLY
(1) Remove seal ri ng from rod gui de (Fi g. 98).
(2) Remove smal l snap-ri ng from servo pi ston rod.
Then remove pi ston rod, spri ng and washer from pi s-
ton.
(3) Remove and di scard servo component O-ri ng
and seal ri ngs.
CLEANING
Cl ean the servo pi ston components (Fi g. 99) wi th
sol vent and dry them wi th compressed ai r.
INSPECTION
I nspect the servo components (Fi g. 100). Repl ace
the spri ngs i f col l apsed, di storted or broken. Repl ace
the gui de, rod and pi ston i f cracked, bent, or worn.
Di scard the servo snap-ri ng i f di storted or warped.
Check the servo pi ston bore for wear. I f the bore i s
severel y scored, or damaged, i t wi l l be necessary to
repl ace the case.
Repl ace any servo component i f doubt exi sts about
condi ti on. Do not reuse suspect parts.
ASSEMBLY
Cl ean and i nspect front servo components.
(1) Lubri cate new o-ri ng and seal ri ngs wi th petro-
l eum jel l y and i nstal l them on pi ston, gui de and rod.
Fig. 98 Front Servo
1 - PISTON RINGS
2 - SERVO PISTON
3 - O-RING
4 - SNAP-RING
5 - PISTON ROD GUIDE
6 - SEAL RING
7 - SNAP-RING
8 - SERVO SPRING
9 - WASHER
10 - SPRING
11 - PISTON ROD
Fig. 99 Front Servo
1 - VENT
2 - INNER PISTON
3 - PISTON
4 - SPRING
5 - RELEASE PRESSURE
6 - APPLY PRESSURE
7 - PISTON ROD
Fig. 100 Front Servo
1 - PISTON RINGS
2 - SERVO PISTON
3 - O-RING
4 - SNAP-RING
6 - SEAL RING
7 - SNAP-RING
8 - SERVO SPRING
9 - WASHER
10 - SPRING
11 - PISTON ROD
FRONT SERVO (Continued)
(2) I nstal l rod i n pi ston. I nstal l spri ng and washer
on rod. Compress spri ng and i nstal l snap-ri ng (Fi g.
101).
GEARSHIFT CABLE
CABLE
(1) Engi ne starts must be possi bl e wi th shi ft l ever
i n PARK or NEUTRAL posi ti ons onl y. Engi ne starts
must not be possi bl e i n any other gear posi ti on.
(2) Wi th the shi ft l ever i n the:
(a) PARK posi ti on - Appl y upward force on the
be possi bl e.
(b) PARK posi ti on - Appl y downward force on
the shi ft arm and remove pressure. Engi ne starts
must be possi bl e.
(c) NEUTRAL posi ti on - Normal posi ti on. Engi ne
(d) NEUTRAL posi ti on - Engi ne runni ng and
brakes appl i ed, appl y upward force on the shi ft
arm. Transmi ssi on shal l not be abl e to shi ft from
neutral to reverse.
REMOVAL
(1) Shi ft transmi ssi on i nto PARK.
(3) Di sengage cabl e eyel et at transmi ssi on shi ft
l ever and pul l cabl e adjuster out of mounti ng bracket
(Fi g. 102) or (Fi g. 103).
Fig. 101 Front Servo
1 - PISTON RINGS
2 - SERVO PISTON
3 - O-RING
4 - SNAP-RING
6 - SEAL RING
7 - SNAP-RING
8 - SERVO SPRING
9 - WASHER
10 - SPRING
11 - PISTON ROD
Fig. 102 Gearshift Cable at Transmission - RFE
1 - GEARSHIFT CABLE
2 - RFE TRANSMISSION
3 - MANUAL LEVER
Fig. 103 Gearshift Cable at Transmission - RE
1 - GEARSHIFT CABLE
2 - RE TRANSMISSION
3 - MANUAL LEVER
FRONT SERVO (Continued)
(5) Remove the dash panel i nsul ati on pad as nec-
essary to access the gearshi ft cabl e grommet (Fi g.
104).
(6) Remove grommet from the dash panel .
(7) Remove any steeri ng col umn tri m necessary to
access the gearshi ft cabl e and BTSI mechani sm.
(8) Di sconnect the BTSI wi ri ng connector.
(9) Di sconnect cabl e at l ower col umn bracket and
shi ft l ever pi n and pul l the cabl e through the dash
panel openi ng i nto the vehi cl e (Fi g. 105).
(10) Remove gearshi ft cabl e from vehi cl e.
INSTALLATION
(1) Route the transmi ssi on end of the gearshi ft
cabl e through the openi ng i n the dash panel (Fi g.
106).
(2) Seat the cabl e grommet i nto the dash panel
openi ng.
(3) Snap the cabl e i nto the steeri ng col umn
bracket so the retai ni ng ears (Fi g. 107) are engaged
and snap the cabl e eyel et onto the shi ft l ever bal l
stud.
(5) Pl ace the transmi ssi on manual shi ft l ever i n
the PARK detent (rearmost) posi ti on and rotate
prop shaft to ensure transmi ssi on i s i n PARK.
Fig. 104 Gearshift Cable at the Dash Panel
1 - GEARSHIFT CABLE
2 - GROMMET
Fig. 105 Gearshift Cable at Steering Column
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
5 - BTSI CONNECTOR
1 - GEARSHIFT CABLE
2 - GROMMET
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
5 - BTSI CONNECTOR
GEARSHIFT CABLE (Continued)
(6) Route the gearshi ft cabl e through the transmi s-
si on mounti ng bracket and secure the cabl e by snap-
pi ng the cabl e retai ni ng ears i nto the transmi ssi on
bracket and snappi ng the cabl e eyel et on the manual
shi ft l ever bal l stud.
(8) Lock the shi ft cabl e adjustment by pressi ng the
cabl e adjuster l ock tab downward unti l i t snaps i nto
pl ace.
(9) Check for proper operati on of the transmi ssi on
range sensor.
(10) Adjust the gearshi ft cabl e (Refer to 21 -
TRANSMI SSI ON/AUTOMATI C/GEAR SHI FT
CABLE - ADJUSTMENTS) and BTSI mechani sm
(Refer to 21 - TRANSMI SSI ON/AUTOMATI C/
BRAKE TRANSMI SSI ON SHI FT I NTERLOCK SYS-
TEM - ADJUSTMENTS) as necessary.
ADJ USTMENTS
GEARSHIFT CABLE
Check adjustment by starti ng the engi ne i n PARK
and NEUTRAL. Adjustment i s CORRECT i f the
engi ne starts onl y i n these posi ti ons. Adjustment i s
I NCORRECT i f the engi ne starts i n one but not both
posi ti ons. I f the engi ne starts i n any posi ti on other
than PARK or NEUTRAL, or i f the engi ne wi l l not
start at al l , the transmi ssi on range sensor may be
faul ty.
Gearshift Adjustment Procedure
(2) Rel ease cabl e adjuster l ock tab (underneath the
steeri ng col umn) (Fi g. 108) to unl ock cabl e.
(4) Di sengage the cabl e eyel et from the transmi s-
si on manual shi ft l ever.
(5) Veri fy transmi ssi on shi ft l ever i s i n PARK
detent by movi ng l ever ful l y rearward. Last rearward
detent i s PARK posi ti on.
(6) Veri fy posi ti ve engagement of transmi ssi on
park l ock by attempti ng to rotate propel l er shaft.
Shaft wi l l not rotate when park l ock i s engaged.
(7) Snap the cabl e eyel et onto the transmi ssi on
manual shi ft l ever.
(9) Lock shi ft cabl e by pressi ng cabl e adjuster l ock
tab downward unti l i t snaps i nto pl ace.
(10) Check engi ne starti ng. Engi ne shoul d start
onl y i n PARK and NEUTRAL
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
5 - BTSI CONNECTOR
OIL PUMP
DESCRIPTION
The oi l pump (Fi g. 109) i s l ocated i n the pump
housi ng i nsi de the bel l housi ng of the transmi ssi on
case. The oi l pump consi sts of an i nner and outer
gear, a housi ng, and a reacti on shaft support.
OPERATION
As the torque converter rotates, the converter hub
rotates the i nner and outer gears. As the gears
rotate, the cl earance between the gear teeth
i ncreases i n the crescent area, and creates a sucti on
at the i nl et si de of the pump. Thi s sucti on draws
fl ui d through the pump i nl et from the oi l pan. As the
cl earance between the gear teeth i n the crescent area
decreases, i t forces pressuri zed fl ui d i nto the pump
outl et and to the val ve body.
Fig. 109 Oil Pump Assembly
1 - OIL SEAL 7 - BOLTS (6)
2 - VENT BAFFLE 8 - #1 THRUST WASHER (SELECTIVE)
3 - OIL PUMP BODY 9 - INNER GEAR
4 - GASKET 10 - OUTER GEAR
5 - REACTION SHAFT SUPPORT 11 - O RING
6 - SEAL RINGS 12 - TORQUE CONVERTER SEAL RING
DISASSEMBLY
(1) Mark posi ti on of support i n oi l pump body for
assembl y al i gnment reference. Use scri ber or pai nt to
make al i gnment marks.
(2) Pl ace pump body on two wood bl ocks.
(3) Remove reacti on shaft support bol ts and sepa-
rate support from pump body (Fi g. 110).
(4) Remove pump i nner and outer gears (Fi g. 111).
(5) Remove o-ri ng seal from pump body (Fi g. 112).
Di scard seal after removal .
(6) Remove oi l pump seal wi th Remover Tool
C-3981. Di scard seal after removal .
CLEANING
Cl ean pump and support components wi th sol vent
and dry them wi th compressed ai r.
INSPECTION
Check condi ti on of the seal ri ngs and thrust
washer on the reacti on shaft support. The seal ri ngs
do not need to be repl aced unl ess cracked, broken, or
severel y worn.
I nspect the pump and support components. Repl ace
the pump or support i f the seal ri ng grooves or
machi ned surfaces are worn, scored, pi tted, or dam-
aged. Repl ace the pump gears i f pi tted, worn
chi pped, or damaged.
I nspect the pump bushi ng. Then check the reacti on
shaft support bushi ng. Repl ace ei ther bushi ng onl y i f
heavi l y worn, scored or damaged. I t i s not necessary
to repl ace the bushi ngs unl ess they are actual l y dam-
aged.
Cl earance between outer gear and reacti on shaft
housi ng shoul d be 0.010 to 0.063 mm (0.0004 to
0.0025 i n.). Cl earance between i nner gear and reac-
ti on shaft housi ng shoul d be 0.010 to 0.063 mm
(0.0004 to 0.0025 i n.). Both cl earances can be mea-
sured at the same ti me by i nstal l i ng the gears i n the
pump body and measure pump component cl earances
as fol l ows:
(1) Posi ti on an appropri ate pi ece of Pl asti gage
across both gears.
(2) Al i gn the pl asti gage to a fl at area on the reac-
ti on shaft housi ng.
(3) I nstal l the reacti on shaft to the pump housi ng.
(4) Separate the reacti on shaft housi ng from the
pump housi ng and measure the Pl asti gage fol l ow-
i ng the i nstructi ons suppl i ed wi th i t.
Cl earance between i nner gear tooth and outer gear
shoul d be 0.051 to 0.19 mm (0.002 to 0.0075 i n.).
Measure cl earance wi th an appropri ate feel er gauge
(Fi g. 113).
Cl earance between outer gear and pump housi ng
shoul d be 0.10 to 0.229 mm (0.004 to 0.009 i n.). Mea-
sure cl earance wi th an appropri ate feel er gauge.
ASSEMBLY
(1) Lubri cate pump gears wi th transmi ssi on fl ui d
and i nstal l them i n pump body.
(2) I nstal l thrust washer on reacti on shaft support
hub. Lubri cate washer wi th petrol eum jel l y or trans-
mi ssi on fl ui d before i nstal l ati on.
(3) I f reacti on shaft seal ri ngs are bei ng repl aced,
i nstal l new seal ri ngs on support hub. Lubri cate seal
ri ngs wi th transmi ssi on fl ui d or petrol eum jel l y after
i nstal l ati on. Squeeze each ri ng unti l ri ng ends are
securel y hooked together.
Fig. 110 Reaction Shaft Support
1 - OIL PUMP
2 - REACTION SHAFT SUPPORT
Fig. 111 Pump Gears
1 - GEAR BORE
2 - PUMP BODY
3 - INNER GEAR
4 - OUTER GEAR
CAUTION: The reaction shaft support seal rings will
break if overspread, or twisted. If new rings are
being installed, spread them only enough for instal-
lation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
during installation.
1 - OIL SEAL 7 - BOLTS (6)
2 - VENT BAFFLE 8 - #1 THRUST WASHER (SELECTIVE)
3 - OIL PUMP BODY 9 - INNER GEAR
4 - GASKET 10 - OUTER GEAR
5 - REACTION SHAFT SUPPORT 11 - O RING
6 - SEAL RINGS 12 - TORQUE CONVERTER SEAL RING
Fig. 113 Checking Pump Gear Tip Clearance
1 - FEELER GAUGE
2 - INNER GEAR
3 - OUTER GEAR
(4) Al i gn and i nstal l reacti on shaft support on
pump body.
(5) I nstal l bol ts attachi ng reacti on shaft support to
pump. Ti ghten bol ts to 20 Nm (175 i n. l bs.) torque.
(6) I nstal l new pump seal wi th I nstal l er Tool
C-3860-A (Fi g. 114). Use hammer or mal l et to tap
seal i nto pl ace.
(7) I nstal l new o-ri ng on pump body. Lubri cate oi l
seal and o-ri ng wi th petrol eum jel l y.
(8) Cover pump assembl y to prevent dust entry
and set asi de for assembl y i nstal l ati on.
OUTPUT SHAFT FRONT
BEARING
REMOVAL
(1) Remove overdri ve uni t from the vehi cl e.
(2) Remove overdri ve geartrai n from housi ng.
(3) Remove snap-ri ng hol di ng output shaft front
beari ng to overdri ve geartrai n. (Fi g. 115).
(4) Pul l beari ng from output shaft.
INSTALLATION
(1) Pl ace repl acement beari ng i n posi ti on on
geartrai n wi th l ocati ng retai ner groove toward the
rear.
(2) Push beari ng onto shaft unti l the snap-ri ng
groove i s vi si bl e.
(3) I nstal l snap-ri ng to hol d beari ng onto output
shaft.
(4) I nstal l overdri ve geartrai n i nto housi ng.
(5) I nstal l overdri ve uni t i n vehi cl e.
OUTPUT SHAFT REAR
BEARING
REMOVAL
(1) Remove overdri ve uni t from the vehi cl e. (Refer
to 21 - TRANSMI SSI ON/AUTOMATI C/OVERDRI VE
- REMOVAL)
(2) Remove overdri ve geartrai n from housi ng.
(3) Remove snap-ri ng hol di ng output shaft rear
beari ng i nto overdri ve housi ng (Fi g. 116).
(4) Usi ng a sui tabl e dri ver i nserted through the
rear end of housi ng, dri ve beari ng from housi ng.
Fig. 114 Oil Pump Seal
1 - SPECIAL TOOL C-3860-A
2 - PUMP BODY
3 - PUMP SEAL
Fig. 115 Output Shaft Front Bearing
1 - OUTPUT SHAFT FRONT BEARING
2 - SNAP-RING
3 - OUTPUT SHAFT
4 - GROOVE TO REAR
5 - OVERDRIVE GEARTRAIN
Fig. 116 Output Shaft Rear Bearing
1 - OUTPUT SHAFT REAR BEARING
2 - OVERDRIVE HOUSING
3 - SNAP-RING
INSTALLATION
(1) Pl ace repl acement beari ng i n posi ti on i n hous-
i ng.
(2) Usi ng a sui tabl e dri ver, dri ve beari ng i nto
housi ng unti l the snap-ri ng groove i s vi si bl e.
(3) I nstal l snap-ri ng to hol d beari ng i nto housi ng
(Fi g. 116).
(4) I nstal l overdri ve geartrai n i nto housi ng.
(5) I nstal l overdri ve uni t i n vehi cl e.
OVERDRIVE CLUTCH
DESCRIPTION
The overdri ve cl utch (Fi g. 117) i s composed of the
pressure pl ate, cl utch pl ates, hol di ng di scs, overdri ve
pi ston retai ner, pi ston, pi ston spacer, and snap-ri ngs.
The overdri ve cl utch i s the forwardmost component
i n the transmi ssi on overdri ve uni t and i s consi dered
a hol di ng component. The overdri ve pi ston retai ner,
pi ston, and pi ston spacer are l ocated on the rear of
the mai n transmi ssi on case.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
the pi ston retai ner and pi ston. The fl ui d pressure i s
cl utch through passages at the l ower rear porti on of
the val ve body area. Wi th pressure appl i ed between
the pi ston retai ner and pi ston, the pi ston moves
away from the pi ston retai ner and compresses the
cl utch pack. Thi s acti on appl i es the cl utch pack,
al l owi ng torque to fl ow through the i ntermedi ate
shaft i nto the overdri ve pl anetary gear set. The over-
dri ve cl utch di scs are attached to the overdri ve cl utch
hub whi l e the overdri ve cl utch pl ates, reacti on pl ate,
and pressure pl ate are l ugged to the overdri ve hous-
i ng. Thi s al l ows the i ntermedi ate shaft to transfer
the engi ne torque to the pl anetary gear and overrun-
ni ng cl utch. Thi s dri ves the pl anetary gear i nsi de the
annul us, whi ch i s attached to the overdri ve cl utch
drum and output shaft, creati ng the desi red gear
rati o. The waved snap-ri ng i s used to cushi on the
appl i cati on of the cl utch pack for the 5 di sc versi on of
the overdri ve cl utch. The 6 di sc overdri ve cl utch does
not use a waved snap-ri ng.
Fig. 117 Overdrive Clutch
1 - REACTION PLATE 2 - PRESSURE PLATE
OUTPUT SHAFT REAR BEARING (Continued)
OVERDRIVE UNIT
REMOVAL
(3) Remove transfer case, i f equi pped.
(4) Mark propel l er shaft uni versal joi nt(s) and axl e
pi ni on yoke, or the compani on fl ange and fl ange
yoke, for al i gnment reference at i nstal l ati on, i f neces-
sary.
(5) Di sconnect and remove the rear propel l er shaft,
i f necessary. (Refer to 3 - DI FFERENTI AL & DRI V-
ELI NE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(6) Remove transmi ssi on oi l pan, remove gasket,
drai n oi l and rei nstal l pan.
(7) I f overdri ve uni t had mal functi oned, or i f fl ui d
i s contami nated, remove enti re transmi ssi on. I f di ag-
nosi s i ndi cated overdri ve probl ems onl y, remove just
the overdri ve uni t.
(8) Support transmi ssi on wi th transmi ssi on jack.
(9) Remove bol ts attachi ng overdri ve uni t to trans-
mi ssi on (Fi g. 118).
CAUTION: Support the overdrive unit with a jack
before moving it rearward. This is necessary to pre-
vent damaging the intermediate shaft. Do not allow
the shaft to support the entire weight of the over-
drive unit.
(10) Careful l y work overdri ve uni t off i ntermedi ate
shaft. Do not ti l t uni t duri ng removal . Keep i t as
l evel as possi bl e.
(11) I f overdri ve uni t does not requi re servi ce,
i mmedi atel y i nsert Al i gnment Tool 6227-2 i n spl i nes
of pl anetary gear and overrunni ng cl utch to prevent
spl i nes from rotati ng out of al i gnment. I f mi sal i gn-
ment occurs, overdri ve uni t wi l l have to be di sassem-
bl ed i n order to real i gn spl i nes.
(12) Remove and retai n overdri ve pi ston thrust
beari ng. Beari ng may remai n on pi ston or i n cl utch
hub duri ng removal .
(13) Posi ti on drai n pan on workbench.
(14) Pl ace overdri ve uni t over drai n pan. Ti l t uni t
to drai n resi dual fl ui d from case.
(15) Exami ne fl ui d for cl utch materi al or metal
fragments. I f fl ui d contai ns these i tems, overhaul wi l l
be necessary.
(16) I f overdri ve uni t does not requi re any servi ce,
l eave al i gnment tool i n posi ti on. Tool wi l l prevent
acci dental mi sal i gnment of pl anetary gear and over-
runni ng cl utch spl i nes.
DISASSEMBLY
(1) Remove transmi ssi on speed sensor and o-ri ng
seal from overdri ve case (Fi g. 119).
(2) Remove overdri ve pi ston thrust beari ng (Fi g.
120).
Fig. 118 Overdrive Unit Bolts
1 - OVERDRIVE UNIT
2 - ATTACHING BOLTS (7)
Fig. 119 Transmission Speed Sensor
1 - SOCKET AND WRENCH
2 - SPEED SENSOR
3 - O-RING
OVERDRIVE PISTON
(1) Remove overdri ve pi ston thrust pl ate (Fi g.
121). Retai n thrust pl ate. I t i s a sel ect fi t part and
may possi bl y be reused.
(2) Remove i ntermedi ate shaft spacer (Fi g. 122).
Retai n spacer. I t i s a sel ect fi t part and may possi bl y
be reused.
(3) Remove overdri ve pi ston from retai ner (Fi g.
123).
Fig. 120 Overdrive Piston Thrust Bearing Removal/
Installation
1 - THRUST BEARING
2 - OVERDRIVE PISTON
3 - THRUST PLATE
Fig. 121 Overdrive Piston Thrust Plate Removal/
Installation
2 - OVERDRIVE PISTON SPACER (SELECT FIT)
Fig. 122 Intermediate Shaft Spacer Location
1 - INTERMEDIATE SHAFT
2 - INTERMEDIATE SHAFT SPACER (SELECT FIT)
Fig. 123 Overdrive Piston Removal
1 - PISTON RETAINER
OVERDRIVE UNIT (Continued)
OVERDRIVE CLUTCH PACK
(1) Remove overdri ve cl utch pack wi re retai ni ng
ri ng (Fi g. 124).
(2) Remove overdri ve cl utch pack (Fi g. 125).
(3) Note posi ti on of cl utch pack components for
assembl y reference (Fi g. 126).
OVERDRIVE GEARTRAIN
(1) Remove overdri ve cl utch wave spri ng (Fi g.
127), 5 di sc cl utch onl y.
(2) Remove overdri ve cl utch reacti on snap-ri ng
(Fi g. 128). Note that snap-ri ng i s l ocated i n same
groove as wave spri ng.
Fig. 124 Removing Overdrive Clutch Pack Retaining
Ring
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig. 125 Overdrive Clutch Pack Removal
1 - OVERDRIVE CLUTCH PACK
Fig. 126 Overdrive Clutch Component Position -
Typical
1 - REACTION PLATE
2 - CLUTCH PLATES
3 - PRESSURE PLATE
4 - CLUTCH DISCS
Fig. 127 Overdrive Clutch Wave Spring Removal - 5
Disc Clutch Only
1 - WAVE SPRING
Fig. 128 Overdrive Clutch Reaction Snap-Ring
Removal
1 - REACTION RING
2 - CLUTCH HUB
(3) Remove Torx head screws that attach access
cover and gasket to overdri ve case (Fi g. 129).
(4) Remove access cover and gasket (Fi g. 130).
(5) Expand output shaft beari ng snap-ri ng wi th
expandi ng-type snap-ri ng pl i ers. Then push output
shaft forward to rel ease shaft beari ng from l ocati ng
ri ng (Fi g. 131).
(6) Li ft gear case up and off geartrai n assembl y
(Fi g. 132).
(7) Remove snap-ri ng that retai ns rear beari ng on
output shaft.
(8) Remove rear beari ng from output shaft (Fi g.
133).
Fig. 129 Access Cover Screw Removal
1 - TORX SCREWDRIVER (T25)
2 - ACCESS COVER SCREWS
Fig. 130 Access Cover And Gasket Removal
1 - ACCESS COVER AND GASKET
Fig. 131 Releasing Bearing From Locating Ring
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING
PLIERS
2 - ACCESS HOLE
Fig. 132 Removing Geartrain
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
Fig. 133 Rear Bearing Removal
1 - OUTPUT SHAFT
2 - REAR BEARING
3 - SNAP-RING
DIRECT CLUTCH, HUB AND SPRING
WARNING: THE NEXT STEP IN DISASSEMBLY
INVOLVES COMPRESSING THE DIRECT CLUTCH
SPRING. IT IS EXTREMELY IMPORTANT THAT PROPER
EQUIPMENT BE USED TO COMPRESS THE SPRING AS
SPRING FORCE IS APPROXIMATELY 830 POUNDS. USE
SPRING COMPRESSOR TOOL 6227-1 AND A HYDRAU-
LIC SHOP PRESS WITH A MINIMUM RAM TRAVEL OF
5-6 INCHES. THE PRESS MUST ALSO HAVE A BED
THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED.
RELEASE CLUTCH SPRING TENSION SLOWLY AND
COMPLETELY TO AVOID PERSONAL INJURY.
(1) Mount geartrai n assembl y i n shop press (Fi g. 134).
(2) Posi ti on Compressor Tool 6227-1 on cl utch hub
(Fi g. 134). Support output shaft fl ange wi th steel
press pl ates as shown and center assembl y under
press ram.
(3) Appl y press pressure sl owl y. Compress hub and
spri ng far enough to expose cl utch hub retai ni ng ri ng
and rel i eve spri ng pressure on cl utch pack snap-ri ng
(Fi g. 134).
(4) Remove di rect cl utch pack snap-ri ng (Fi g. 135).
(5) Remove di rect cl utch hub retai ni ng ri ng (Fi g.
136).
Fig. 134 Geartrain Mounted In Shop Press
1 - PRESS RAM
2 - SPECIAL TOOL C-3995-A (OR SIMILAR TOOL)
3 - CLUTCH HUB
4 - PLATES
5 - PRESS BED
6 - SPECIAL TOOL 6227-1
Fig. 135 Direct Clutch Pack Snap-Ring Removal
1 - CLUTCH HUB
3 - DIRECT CLUTCH PACK SNAP-RING
4 - PRESS PLATES
5 - CLUTCH DRUM
Fig. 136 Direct Clutch Hub Retaining Ring Removal
2 - CLUTCH HUB RETAINING RING
3 - PRESS BED
4 - PRESS PLATES
(6) Rel ease press l oad sl owl y and compl etel y (Fi g.
137).
(7) Remove Speci al Tool 6227-1. Then remove
cl utch pack from hub (Fi g. 137). Note the ori entati on
of the cl utch di scs. The cl utch pack consi sts of 23 si n-
gl e-si ded di scs and they must be i nstal l ed i n the
same ori entati on as they were removed.
GEARTRAIN
(1) Remove di rect cl utch hub and spri ng (Fi g. 138).
(2) Remove sun gear and spri ng pl ate. Then
remove pl anetary thrust beari ng and pl anetary gear
(Fi g. 139).
Fig. 137 Direct Clutch Pack Removal
2 - DIRECT CLUTCH HUB
3 - DIRECT CLUTCH PACK
Fig. 138 Direct Clutch Hub And Spring Removal
1 - DIRECT CLUTCH SPRING
2 - DIRECT CLUTCH HUB
Fig. 139 Removing Sun Gear, Thrust Bearing And
Planetary Gear
1 - PLANETARY GEAR
2 - PLANETARY THRUST BEARING
3 - CLUTCH SPRING PLATE
4 - SPRING PLATE SNAP-RING
5 - SUN GEAR
(3) Remove overrunni ng cl utch assembl y wi th
expandi ng type snap-ri ng pl i ers (Fi g. 140). I nsert pl i -
ers i nto cl utch hub. Expand pl i ers to gri p hub spl i nes
and remove cl utch wi th countercl ockwi se, twi sti ng
moti on.
(4) Remove thrust beari ng from overrunni ng
cl utch hub.
(5) Remove overrunni ng cl utch from hub.
(6) Mark posi ti on of annul us gear and di rect cl utch
drum for assembl y al i gnment reference (Fi g. 141).
Use smal l center punch or scri ber to make al i gnment
marks.
(7) Remove di rect cl utch drum rear retai ni ng ri ng
(Fi g. 142).
(8) Remove di rect cl utch drum outer retai ni ng ri ng
(Fi g. 143).
Fig. 142 Clutch Drum Inner Retaining Ring Removal
1 - INNER RETAINING RING
2 - DIRECT CLUTCH DRUM
3 - ANNULUS GEAR
Fig. 143 Clutch Drum Outer Retaining Ring Removal
1 - OUTER RETAINING RING
Fig. 140 Overrunning Clutch Assembly Removal/
Installation
1 - OVERRUNNING CLUTCH
2 - NEEDLE BEARING
Fig. 141 Marking Direct Clutch Drum And Annulus
Gear For Assembly Alignment
1 - DIRECT CLUTCH DRUM
2 - HAMMER
3 - PUNCH
(9) Mark annul us gear and output shaft for assem-
bl y al i gnment reference (Fi g. 144). Use punch or
scri ber to mark gear and shaft.
(10) Remove snap-ri ng that secures annul us gear
on output shaft (Fi g. 145). Use two screwdri vers to
unseat and work snap-ri ng out of groove as shown.
(11) Remove annul us gear from output shaft (Fi g.
146). Use rawhi de or pl asti c mal l et to tap gear off
shaft.
GEAR CASE AND PARK LOCK
(1) Remove l ocati ng ri ng from gear case.
(2) Remove park pawl shaft retai ni ng bol t and
remove shaft, pawl and spri ng.
(3) Remove reacti on pl ug snap-ri ng and remove
reacti on pl ug.
(4) Remove output shaft seal .
CLEANING
Cl ean the geartrai n and case components wi th sol -
vent. Dry al l parts except the beari ngs wi th com-
pressed ai r. Al l ow beari ngs to ai r dry.
Do not use shop towel s for wi pi ng parts dry unl ess
the towel s are made from a l i nt-free materi al . A suf-
fi ci ent quanti ty of l i nt (from shop towel s, cl oths, rags,
etc.) coul d pl ug the transmi ssi on fi l ter and fl ui d pas-
sages.
Di scard the ol d case gasket and seal s. Do not
attempt to sal vage these parts. They are not reus-
abl e. Repl ace any of the overdri ve uni t snap-ri ngs i f
di storted or damaged.
Mi nor ni cks or scratches on components can be
smoothed wi th crocus cl oth. However, do not attempt
to reduce severe scori ng on any components wi th
abrasi ve materi al s. Repl ace severel y scored compo-
nents; do not try to sal vage them.
INSPECTION
Check condi ti on of the park l ock components and
the overdri ve case.
Check the bushi ngs i n the overdri ve case. Repl ace
the bushi ngs i f severel y scored or worn. Al so repl ace
the case seal i f l oose, di storted, or damaged.
Exami ne the overdri ve and di rect cl utch di scs and
pl ates. Repl ace the di scs i f the faci ng i s worn,
severel y scored, or burned and fl aki ng off. Repl ace
the cl utch pl ates i f worn, heavi l y scored, or cracked.
Fig. 144 Marking Annulus Gear And Output Shaft
For Assembly Alignment
1 - OUTPUT SHAFT
2 - HAMMER
3 - PUNCH
Fig. 145 Annulus Gear Snap-Ring Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
3 - SNAP-RING
Fig. 146 Annulus Gear Removal
1 - OUTPUT SHAFT
2 - ANNULUS GEAR
Check the l ugs on the cl utch pl ates for wear. The
pl ates shoul d sl i de freel y i n the drum. Repl ace the
pl ates or drum i f bi ndi ng occurs.
Check condi ti on of the annul us gear, di rect cl utch
hub, cl utch drum and cl utch spri ng. Repl ace the gear,
hub and drum i f worn or damaged. Repl ace the
spri ng i f col l apsed, di storted, or cracked.
Be sure the spl i nes and l ugs on the gear, drum and
hub are i n good condi ti on. The cl utch pl ates and
di scs shoul d sl i de freel y i n these components.
I nspect the thrust beari ngs and spri ng pl ate.
Repl ace the pl ate i f worn or scored. Repl ace the bear-
i ngs i f rough, noi sy, bri nnel l ed, or worn.
I nspect the pl anetary gear assembl y and the sun
gear and bushi ngs. I f ei ther the sun gear or the
bushi ngs are damaged, repl ace the gear and bush-
i ngs as an assembl y. The gear and bushi ngs are not
servi ced separatel y.
The pl anetary carri er and pi ni ons must be i n good
condi ti on. Al so be sure the pi ni on pi ns are secure and i n
good condi ti on. Repl ace the carri er i f worn or damaged.
I nspect the overrunni ng cl utch and race. The race
surface shoul d be smooth and free of scores. Repl ace
the overrunni ng cl utch assembl y or the race i f ei ther
assembl y i s worn or damaged i n any way.
Repl ace the shaft pi l ot bushi ng and i nner bushi ng
i f damaged. Repl ace ei ther shaft beari ng i f rough or
noi sy. Repl ace the beari ng snap-ri ngs i f di storted or
cracked.
Check the machi ned surfaces on the output shaft.
These surfaces shoul d cl ean and smooth. Very mi nor
ni cks or scratches can be smoothed wi th crocus cl oth.
Repl ace the shaft i f worn, scored or damaged i n any
way.
I nspect the output shaft bushi ngs. The smal l bush-
i ng i s the i ntermedi ate shaft pi l ot bushi ng. The l arge
bushi ng i s the overrunni ng cl utch hub bushi ng.
Repl ace ei ther bushi ng i f scored, pi tted, cracked, or
worn.
ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH
(1) Soak di rect cl utch and overdri ve cl utch di scs i n
Mopar ATF +4, Automati c Transmi ssi on fl ui d. Al l ow
di scs to soak for 10-20 mi nutes.
(2) I nstal l annul us gear on output shaft, i f
removed. Then i nstal l annul us gear retai ni ng snap-
ri ng (Fi g. 147).
(3) Al i gn and i nstal l cl utch drum on annul us gear
(Fi g. 148). Be sure drum i s engaged i n annul us gear
l ugs.
(4) I nstal l cl utch drum outer retai ni ng ri ng (Fi g.
148).
Fig. 147 Annulus Gear Installation
1 - SNAP-RING
2 - OUTPUT SHAFT FRONT BEARING
3 - ANNULUS GEAR
Fig. 148 Clutch Drum And Outer Retaining Ring
Installation
1 - ANNULUS GEAR
2 - OUTER SNAP-RING
3 - CLUTCH DRUM
(5) Sl i de cl utch drum forward and i nstal l i nner
retai ni ng ri ng (Fi g. 149).
(6) I nstal l rear beari ng and snap-ri ng on output
shaft (Fi g. 150). Be sure l ocati ng ri ng groove i n bear-
i ng i s toward rear.
(7) I nstal l overrunni ng cl utch on hub (Fi g. 151).
Note that cl utch onl y fi ts one way. Shoul der on cl utch
shoul d seat i n smal l recess at edge of hub.
(8) I nstal l thrust beari ng on overrunni ng cl utch
hub. Use generous amount of petrol eum jel l y to hol d
beari ng i n pl ace for i nstal l ati on. Beari ng fi ts one way
onl y. Be sure beari ng i s seated squarel y agai nst hub.
Rei nstal l beari ng i f i t does not seat squarel y.
(9) I nstal l overrunni ng cl utch i n output shaft (Fi g.
152). I nsert snap-ri ng pl i ers i n hub spl i nes. Expand
pl i ers to gri p hub. Then i nstal l assembl y wi th coun-
tercl ockwi se, twi sti ng moti on.
Fig. 152 Overrunning Clutch Installation
1 - CLUTCH DRUM
2 - OVERRUNNING CLUTCH ASSEMBLY
3 - EXPANDING-TYPE SNAP-RING PLIERS
4 - CLUTCH DRUM
5 - ANNULUS GEAR
6 - OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT
SHAFT
Fig. 149 Clutch Drum Inner Retaining Ring
Installation
1 - ANNULUS GEAR
2 - INNER SNAP-RING
3 - CLUTCH DRUM
Fig. 150 Rear Bearing And Snap-Ring Installation
1 - REAR BEARING
2 - SNAP-RING
Fig. 151 Assembling Overrunning Clutch And Hub
1 - CLUTCH HUB
(10) I nstal l pl anetary gear i n annul us gear (Fi g.
153). Be sure pl anetary pi ni ons are ful l y seated i n
annul us gear before proceedi ng.
(11) Coat pl anetary thrust beari ng and beari ng
contact surface of spri ng pl ate wi th generous amount
of petrol eum jel l y. Thi s wi l l hel p hol d beari ng i n
pl ace duri ng i nstal l ati on.
(12) I nstal l pl anetary thrust beari ng on sun gear
(Fi g. 154). Sl i de beari ng onto gear and seat i t agai nst
spri ng pl ate as shown. Beari ng fi ts one way onl y. I f i t
does not seat squarel y agai nst spri ng pl ate, remove
and reposi ti on beari ng.
(13) I nstal l assembl ed sun gear, spri ng pl ate and
thrust beari ng (Fi g. 155). Be sure sun gear and
thrust beari ng are ful l y seated before proceedi ng.
(14) Mount assembl ed output shaft, annul us gear,
and cl utch drum i n shop press. Di rect cl utch spri ng,
hub and cl utch pack are easi er to i nstal l wi th assem-
bl y mounted i n press.
(15) Al i gn spl i nes i n hubs of pl anetary gear and
overrunni ng cl utch wi th Al i gnment tool 6227-2 (Fi g.
156). I nsert tool through sun gear and i nto spl i nes of
both hubs. Be sure al i gnment tool i s ful l y seated
before proceedi ng.
Fig. 156 Alignment Tool Installation
2 - PRESS PLATES
3 - ASSEMBLED DRUM AND ANNULUS GEAR
4 - SUN GEAR
Fig. 153 Planetary Gear Installation
1 - PLANETARY GEAR
2 - ANNULUS GEAR
Fig. 154 Planetary Thrust Bearing Installation
1 - SPRING PLATE
2 - PLANETARY THRUST BEARING
3 - SUN GEAR
Fig. 155 Sun Gear Installation
1 - SUN GEAR AND SPRING PLATE ASSEMBLY
(16) I nstal l di rect cl utch spri ng (Fi g. 157). Be sure
spri ng i s properl y seated on spri ng pl ate.
NOTE: The direct clutch in a 48RE transmission
uses 23 single-sided clutch discs.
(17) Assembl e and i nstal l di rect cl utch pack on
hub as fol l ows:
(a) I nstal l di rect cl utch reacti on pl ate on cl utch
hub fi rst. Note that one si de of reacti on pl ate i s
counterbored. Be sure thi s si de faces rearward.
Spl i nes at rear of hub are rai sed sl i ghtl y. Counter-
bore i n pl ate fi ts over rai sed spl i nes. Pl ate shoul d
be fl ush wi th thi s end of hub (Fi g. 158).
(b) I nstal l fi rst cl utch di sc wi th i nternal spl i nes
fri cti on si de up, fol l owed by a di sc wi th external
l ugs fri cti on si de up. Conti nue al ternati ng i nternal
and external di scs unti l al l di scs have been
i nstal l ed.
Fig. 158 Correct Position Of Direct Clutch Reaction
Plate
1 - REACTION PLATE COUNTERBORE
2 - DIRECT CLUTCH REACTION PLATE (FLUSH WITH END OF HUB)
3 - CLUTCH HUB
Fig. 157 Direct Clutch Spring Installation
2 - DIRECT CLUTCH SPRING
3 - CLUTCH HUB
4 - PRESS PLATES
(c) I nstal l pressure pl ate. Thi s i s l ast cl utch pack
i tem to be i nstal l ed. Be sure pl ate i s i nstal l ed wi th
shoul der si de faci ng upward (Fi g. 159).
(18) I nstal l cl utch hub and cl utch pack on di rect
cl utch spri ng (Fi g. 160). Be sure hub i s started on
sun gear spl i nes before proceedi ng.
WARNING: THE NEXT STEP IN GEARTRAIN
ASSEMBLY INVOLVES COMPRESSING THE DIRECT
CLUTCH HUB AND SPRING. IT IS EXTREMELY
IMPORTANT THAT PROPER EQUIPMENT BE USED
TO COMPRESS THE SPRING AS SPRING FORCE IS
APPROXIMATELY 830 POUNDS. USE COMPRES-
SOR TOOL C-6227-1 AND A HYDRAULIC-TYPE
SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 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.
(19) Posi ti on Compressor Tool 6227-1 on cl utch
hub.
(20) Compress cl utch hub and spri ng just enough
to pl ace tensi on on hub and hol d i t i n pl ace.
(21) Sl owl y compress cl utch hub and spri ng. Com-
press spri ng and hub onl y enough to expose ri ng
grooves for cl utch pack snap-ri ng and cl utch hub
retai ni ng ri ng.
(22) Real i gn cl utch pack on hub and seat cl utch
di scs and pl ates i n cl utch drum.
(23) I nstal l di rect cl utch pack snap-ri ng (Fi g. 161).
Be very sure snap-ri ng i s ful l y seated i n cl utch drum
ri ng groove.
Fig. 161 Direct Clutch Pack Snap-Ring Installation
2 - DIRECT CLUTCH PACK SNAP-RING
Fig. 159 Correct Position Of Direct Clutch
1 - DIRECT CLUTCH PRESSURE PLATE
2 - CLUTCH PACK
3 - BE SURE SHOULDER SIDE OF PLATE FACES UPWARD
Fig. 160 Direct Clutch Pack And Clutch Hub
Installation
1 - CLUTCH HUB
2 - DIRECT CLUTCH PACK
3 - CLUTCH DRUM
(24) I nstal l cl utch hub retai ni ng ri ng (Fi g. 162). Be
very sure retai ni ng ri ng i s ful l y seated i n sun gear
ri ng groove.
(25) Sl owl y rel ease press ram, remove compressor
tool s and remove geartrai n assembl y.
GEAR CASE
(1) Posi ti on park pawl and spri ng i n case and
i nstal l park pawl shaft. Veri fy that end of spri ng
wi th 90 bend i s hooked to pawl and strai ght end of
spri ng i s seated agai nst case.
(2) I nstal l pawl shaft retai ni ng bol t. Ti ghten bol t
to 27 Nm (20 ft. l bs.) torque.
(3) I nstal l park l ock reacti on pl ug. Note that pl ug
has l ocati ng pi n at rear (Fi g. 163). Be sure pi n i s
seated i n hol e i n case before i nstal l i ng snap-ri ng.
(4) I nstal l reacti on pl ug snap-ri ng (Fi g. 164). Com-
press snap-ri ng onl y enough for i nstal l ati on; do not
di stort i t.
(5) Veri fy that tab ends of rear beari ng l ocati ng
ri ng extend i nto access hol e i n gear case (Fi g. 165).
(6) Support geartrai n on Tool 6227-1 (Fi g. 166). Be
sure tool i s securel y seated i n cl utch hub.
Fig. 165 Correct Rear Bearing Locating Ring
Position
1 - CASE ACCESS HOLE
2 - TAB ENDS OF LOCATING RING
Fig. 162 Clutch Hub Retaining Ring Installation
2 - CLUTCH HUB RETAINING RING
Fig. 163 Reaction Plug Locating Pin And Snap-Ring
1 - REACTION PLUG SNAP-RING (DO NOT OVERCOMPRESS
TO INSTALL)
2 - LOCATING PIN
3 - PARK LOCK REACTION PLUG
Fig. 164 Reaction Plug And Snap-Ring Installation
1 - REACTION PLUG SNAP-RING
2 - SNAP-RING PLIERS
(7) I nstal l overdri ve gear case on geartrai n (Fi g.
166).
(8) Expand front beari ng l ocati ng ri ng wi th snap-
ri ng pl i ers (Fi g. 167). Then sl i de case downward unti l
l ocati ng ri ng l ocks i n beari ng groove and rel ease
snap-ri ng.
(9) I nstal l l ocati ng ri ng access cover and gasket i n
overdri ve uni t case (Fi g. 168).
OVERDRIVE CLUTCH
NOTE: The overdrive clutch in a 48RE transmission
uses 5 or 6 clutch discs depending on the applica-
tion.
(1) I nstal l overdri ve cl utch reacti on ri ng fi rst.
Reacti on ri ng i s fl at wi th notched ends (Fi g. 169).
(2) For 5 di sc overdri ve cl utch versi ons, i nstal l
wave spri ng on top of reacti on ri ng (Fi g. 170). Reac-
ti on ri ng and wave ri ng both fi t i n same ri ng groove.
Use screwdri ver to seat each ri ng securel y i n groove.
Al so ensure that the ends of the two ri ngs are offset
from each other.
(3) Assembl e overdri ve cl utch pack.
(4) I nstal l overdri ve cl utch reacti on pl ate fi rst.
Fig. 166 Overdrive Gear Case Installation
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
Fig. 167 Seating Locating Ring In Rear Bearing
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING
PLIERS
2 - ACCESS HOLE
Fig. 168 Locating Ring Access Cover And Gasket
Installation
1 - TORX SCREWDRIVER (T25)
2 - ACCESS COVER SCREWS
Fig. 169 Overdrive Clutch Reaction Ring Installation
1 - REACTION RING
2 - CLUTCH HUB
Fig. 170 Overdrive Clutch Wave Spring Installation -
5 Disc Clutch Only
1 - WAVE SPRING
(5) I nstal l fi rst cl utch di sc fol l owed by fi rst cl utch
pl ate. Then i nstal l remai ni ng cl utch di scs and pl ates
i n same order.
(6) I nstal l cl utch pack pressure pl ate.
(7) I nstal l cl utch pack wi re-type retai ni ng ri ng
(Fi g. 171).
INTERMEDIATE SHAFT SPACER SELECTION
(1) Pl ace overdri ve uni t i n verti cal posi ti on. Mount
i t on bl ocks, or i n workbench wi th appropri ate si ze
mounti ng hol e cut i nto i t. Be sure uni t i s faci ng
upward for access to di rect cl utch hub. Al so be sure
output shaft i s not l oaded and i nternal components
are moved rearward for accurate measurement.
(2) Determi ne correct thi ckness i ntermedi ate shaft
spacer as fol l ows:
(a) I nsert Speci al Tool 6312 through sun gear,
pl anetary gear and i nto pi l ot bushi ng i n output
shaft. Be sure tool bottoms agai nst pl anetary
shoul der.
(b) Posi ti on Gauge Tool 6311 across face of over-
dri ve case (Fi g. 172). Then posi ti on Di al Cal i per
C-4962 over gauge tool .
(c) Extend sl i di ng scal e of di al cal i per downward
through gauge tool sl ot unti l scal e contacts end of
Gauge Al i gnment Tool 6312. Lock scal e i n pl ace.
Remove di al cal i per tool and note di stance mea-
sured (Fi g. 172).
(d) Sel ect proper thi ckness end pl ay spacer from
spacer chart based on di stance measured (Fi g.
173).
(e) Remove Gauge Al i gnment Tool 6312.
Fig. 171 Overdrive Clutch Pack Retaining Ring
Installation
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig. 172 Shaft End Play Measurement
Fig. 173 Intermediate Shaft End Play Spacer
Selection
OD THRUST PLATE SELECTION
(1) Pl ace overdri ve uni t i n verti cal posi ti on. Mount
i t on bl ocks, or i n workbench wi th appropri ate si ze
mounti ng hol e cut i nto i t. Be sure uni t i s faci ng
upward for access to di rect cl utch hub. Al so be sure
output shaft i s not l oaded and i nternal components
are moved rearward for accurate measurement.
(2) Determi ne correct thi ckness overdri ve pi ston
thrust pl ate as fol l ows:
(a) Posi ti on Gauge Tool 6311 across face of over-
dri ve case. Then posi ti on Di al Cal i per C-4962 over
gauge tool (Fi g. 174).
(b) Measure di stance to cl utch hub thrust bear-
i ng seat at four poi nts 90 apart. Then average
measurements by addi ng them and di vi di ng by 4.
(c) Sel ect and i nstal l requi red thrust pl ate from
i nformati on i n thrust pl ate chart (Fi g. 175).
(3) Leave Al i gnment Tool 6227-2 i n pl ace. Tool wi l l
keep pl anetary and cl utch hub spl i nes i n al i gnment
unti l overdri ve uni t i s ready for i nstal l ati on on trans-
mi ssi on.
(4) Transmi ssi on speed sensor can be i nstal l ed at
thi s ti me i f desi red. However, i t i s recommended that
sensor not be i nstal l ed unti l after overdri ve uni t i s
secured to transmi ssi on.
OVERDRIVE PISTON
(1) I nstal l new seal s on overdri ve pi ston.
(2) Stand transmi ssi on case upri ght on bel l hous-
i ng.
(3) Posi ti on Gui de Ri ng 8114-1 on outer edge of
overdri ve pi ston retai ner.
(4) Posi ti on Seal Gui de 8114-3 on i nner edge of
(5) I nstal l overdri ve pi ston i n overdri ve pi ston
retai ner by:
(a) Al i gni ng l ocati ng l ugs on overdri ve pi ston to
the two mati ng hol es i n retai ner.
(b) Lubri cate overdri ve pi ston seal s wi th Mopar
ATF+4.
(c) I nstal l pi ston over Seal Gui de 8114-3 and
i nsi de Gui de Ri ng 8114-1.
(d) Push overdri ve pi ston i nto posi ti on i n
retai ner.
(e) Veri fy that the l ocati ng l ugs entered the l ug
bores i n the retai ner.
(6) I nstal l i ntermedi ate shaft spacer on i ntermedi -
ate shaft.
(7) I nstal l overdri ve pi ston thrust pl ate on over-
dri ve pi ston.
(8) I nstal l overdri ve pi ston thrust beari ng on over-
dri ve pi ston.
(9) I nstal l transmi ssi on speed sensor and o-ri ng
seal i n overdri ve case.
Fig. 174 Overdrive Piston Thrust Plate Measurement
2 - DIRECT CLUTCH HUB THRUST BEARING SEAT
Fig. 175 Overdrive Piston Thrust Plate Selection
INSTALLATION
(1) Be sure overdri ve uni t Al i gnment Tool 6227-2
i s ful l y seated before movi ng uni t. I f tool i s not
seated and gear spl i nes rotate out of al i gnment, over-
dri ve uni t wi l l have to be di sassembl ed i n order to
real i gn spl i nes.
(2) I f overdri ve pi ston retai ner was not removed
duri ng servi ce and ori gi nal case gasket i s no l onger
reusabl e, prepare new gasket by tri mmi ng i t.
(3) Cut out ol d case gasket around pi ston retai ner
wi th razor kni fe (Fi g. 176).
(4) Use ol d gasket as templ ate and tri m new gas-
ket to fi t.
(5) Posi ti on new gasket over pi ston retai ner and
on transmi ssi on case. Use petrol eum jel l y to hol d
gasket i n pl ace i f necessary. Do not use any type of
seal er to secure gasket. Use petrol eum jel l y onl y.
(6) I nstal l sel ecti ve spacer on i ntermedi ate shaft, i f
removed. Spacer goes i n groove just rearward of
shaft rear spl i nes (Fi g. 177).
(7) I nstal l thrust beari ng i n overdri ve uni t sl i di ng
hub. Use petrol eum jel l y to hol d beari ng i n posi ti on.
CAUTION: Be sure the shoulder on the inside diam-
eter of the bearing is facing forward.
(8) Veri fy that spl i nes i n overdri ve pl anetary gear
and overrunni ng cl utch hub are al i gned wi th Al i gn-
ment Tool 6227-2. Overdri ve uni t cannot be i nstal l ed
i f spl i nes are not al i gned. I f spl i nes have rotated out
of al i gnment, uni t wi l l have to be di sassembl ed to
(9) Careful l y sl i de Al i gnment Tool 6227-2 out of
overdri ve pl anetary gear and overrunni ng cl utch
spl i nes.
(10) Rai se overdri ve uni t and careful l y sl i de i t
strai ght onto i ntermedi ate shaft. I nsert park rod i nto
park l ock reacti on pl ug at same ti me. Avoi d ti l ti ng
overdri ve duri ng i nstal l ati on as thi s coul d cause
pl anetary gear and overrunni ng cl utch spl i nes to
rotate out of al i gnment. I f thi s occurs, i t wi l l be nec-
essary to remove and di sassembl e overdri ve uni t to
(11) Work overdri ve uni t forward on i ntermedi ate
shaft unti l seated agai nst transmi ssi on case.
(12) I nstal l bol ts attachi ng overdri ve uni t to trans-
mi ssi on uni t. Ti ghten bol ts i n di agonal pattern to 34
Nm (25 ft-l bs).
(13) Connect the transmi ssi on speed sensor and
overdri ve wi ri ng connectors.
(14) I nstal l the transfer case, i f equi pped.
(15) Al i gn and i nstal l rear propel l er shaft, i f nec-
essary. (Refer to 3 - DI FFERENTI AL & DRI VELI NE/
PROPELLER SHAFT/PROPELLER SHAFT -
I NSTALLATI ON)
Fig. 176 Trimming Overdrive Case Gasket
1 - GASKET
2 - SHARP KNIFE
Fig. 177 Intermediate Shaft Selective Spacer
Location
1 - SELECTIVE SPACER
2 - SPACER GROOVE
OVERRUNNING CLUTCH
CAM/OVERDRIVE PISTON
RETAINER
DESCRIPTION
The overrunni ng cl utch (Fi g. 178) consi sts of an
i nner race, an outer race (or cam), rol l ers and
spri ngs, and the spri ng retai ner. The number of rol l -
ers and spri ngs depends on what transmi ssi on and
whi ch overrunni ng cl utch i s bei ng deal t wi th.
OPERATION
As the i nner race i s rotated i n a cl ockwi se di recti on
(as vi ewed from the front of the transmi ssi on), the
race causes the rol l ers to rol l toward the spri ngs,
causi ng them to compress agai nst thei r retai ner. The
compressi on of the spri ngs i ncreases the cl earance
between the rol l ers and cam. Thi s i ncreased cl ear-
ance between the rol l ers and cam resul ts i n a free-
wheel i ng condi ti on. When the i nner race attempts to
rotate countercl ockwi se, the acti on causes the rol l ers
to rol l i n the same di recti on as the race, ai ded by the
pushi ng of the spri ngs. As the rol l ers try to move i n
the same di recti on as the i nner race, they are
wedged between the i nner and outer races due to the
desi gn of the cam. I n thi s condi ti on, the cl utch i s
l ocked and acts as one uni t.
DISASSEMBLY
(1) Remove the overdri ve pi ston (Fi g. 179).
(2) Remove the overdri ve pi ston retai ner bol ts.
(3) Remove overdri ve pi ston retai ner.
(4) Remove case gasket.
(5) Tap ol d cam out of case wi th pi n punch. I nsert
punch through bol t hol es at rear of case (Fi g. 180).
Al ternate posi ti on of punch to avoi d cocki ng cam dur-
i ng removal .
(6) Cl ean cl utch cam bore and case. Be sure to
remove al l chi ps/shavi ngs generated duri ng cam
removal .
CLEANING
Cl ean the overrunni ng cl utch assembl y, cl utch cam,
l ow-reverse drum, and overdri ve pi ston retai ner i n
sol vent. Dry them wi th compressed ai r after cl ean-
i ng.
1 - OUTER RACE (CAM)
2 - ROLLER
3 - SPRING
4 - SPRING RETAINER
5 - INNER RACE (HUB)
Fig. 179 Overdrive Piston Removal
1 - OVERDRIVE CLUTCH PISTON
3 - SELECTIVE SPACER
4 - PISTON RETAINER
Fig. 180 Overrunning Clutch Cam
1 - PIN PUNCH
2 - REAR SUPPORT BOLT HOLES
INSPECTION
I nspect condi ti on of each cl utch part after cl eani ng.
Repl ace the overrunni ng cl utch rol l er and spri ng
assembl y i f any rol l ers or spri ngs are worn or dam-
aged, or i f the rol l er cage i s di storted, or damaged.
Repl ace the cam i f worn, cracked or damaged.
Repl ace the l ow-reverse drum i f the cl utch race,
rol l er surface or i nsi de di ameter i s scored, worn or
damaged. Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Exami ne the overdri ve pi ston retai ner careful l y for
wear, cracks, scori ng or other damage. Be sure the
retai ner hub i s a snug fi t i n the case and drum.
Repl ace the retai ner i f worn or damaged.
ASSEMBLY
(1) Temporari l y i nstal l overdri ve pi ston retai ner i n
case. Use 3-4 bol ts to secure retai ner.
(2) Al i gn and start new cl utch cam i n the trans-
mi ssi on case. Be sure serrati ons on cam and i n case
are al i gned (Fi g. 181). Then tap cam i nto case just
enough to hol d i t i n pl ace.
(3) Veri fy that cam i s correctl y posi ti oned before
proceedi ng any further. Narrow ends of cam ramps
shoul d be to l eft when cam i s vi ewed from front end
of case (Fi g. 181).
(4) I nsert Adapter Tool SP-5124 from I nstal l er/Re-
mover C-3863-A i nto pi ston retai ner (Fi g. 182).
(5) Assembl e Pul l er Bol t SP-3701 and Press Pl ate
SP-3583-A (Fi g. 183).
Fig. 181 Positioning Replacement Clutch Cam In
Case
1 - ALIGN SERRATIONS ON CAM AND IN CASE
2 - CLUTCH CAM
Fig. 182 Positioning Adapter Tool In Overdrive
Piston Retainer
1 - PISTON RETAINER
2 - SPECIAL TOOL SP-5124
Fig. 183 Assembling Clutch Cam Puller Bolt And
Press Plate
1 - PULLER BOLT SP-3701
2 - PRESS PLATE SP-3583-A
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)
(6) I nstal l assembl ed pul l er pl ate and bol t (Fi g.
184). I nsert bol t through cam, case and adapter tool .
Be sure pl ate i s seated squarel y on cam.
(7) Hol d pul l er pl ate and bol t i n pl ace and i nstal l
pul l er nut SP-3701 on pul l er bol t (Fi g. 185).
(8) Ti ghten pul l er nut to press cl utch cam i nto
case (Fi g. 185). Be sure cam i s pressed i nto case
evenl y and does not become cocked.
(9) Remove cl utch cam i nstal l er tool s.
(10) Stake case i n 14 pl aces around cl utch cam to
hel p secure cam i n case. Use bl unt punch or chi sel to
stake case.
(11) Remove pi ston retai ner from case. Cover
retai ner wi th pl asti c sheeti ng, or paper to keep i t
dust free.
(12) Cl ean case and cam thoroughl y. Be sure any
chi ps/shavi ngs generated duri ng cam i nstal l ati on are
removed from case.
(13) I nstal l new gasket at rear of transmi ssi on
case. Use petrol eum jel l y to hol d gasket i n pl ace. Be
sure to al i gn governor feed hol es i n gasket wi th feed
passages i n case (Fi g. 186). Al so i nstal l gasket before
overdri ve pi ston retai ner. Center hol e i n gasket i s
smal l er than retai ner and cannot be i nstal l ed over
retai ner.
Fig. 186 Installing/Aligning Case Gasket
1 - CASE GASKET
2 - BE SURE GOVERNOR TUBE FEED HOLES IN CASE AND
GASKET ARE ALIGNED
Fig. 184 Positioning Puller Plate On Clutch Cam
2 - BE SURE PLATE SP-3583-A IS SEATED SQUARELY ON CAM
Fig. 185 Pressing Overrunning Clutch Cam Into
Case
1 - SPECIAL TOOL SP-3583-A
2 - TIGHTEN NUT TO DRAW CAM INTO CASE (NUT IS PART OF
BOLT SP-3701)
(14) Posi ti on overdri ve pi ston retai ner on trans-
mi ssi on case and al i gn bol t hol es i n retai ner, gasket
and case (Fi g. 187). Then i nstal l and ti ghten retai ner
(15) I nstal l new seal s on overdri ve pi ston.
(16) Stand transmi ssi on case upri ght on bel l hous-
i ng.
(17) Posi ti on Gui de Ri ng 8114-1 on outer edge of
(18) Posi ti on Seal Gui de 8114-3 on i nner edge of
(19) I nstal l overdri ve pi ston i n overdri ve pi ston
retai ner by: al i gni ng l ocati ng l ugs on overdri ve pi ston
to the two mati ng hol es i n retai ner.
(a) Al i gni ng l ocati ng l ugs on overdri ve pi ston to
the two mati ng hol es i n retai ner.
(b) Lubri cate overdri ve pi ston seal s wi th Mopar
Door Ease, or equi val ent.
(c) I nstal l pi ston over Seal Gui de 8114-3 and
i nsi de Gui de Ri ng 8114-1.
(d) Push overdri ve pi ston i nto posi ti on i n
retai ner.
(e) Veri fy that the l ocati ng l ugs entered the l ug
bores i n the retai ner.
PISTONS
DESCRIPTION
There are several si zes and types of pi stons used i n
an automati c transmi ssi on. Some pi stons are used to
appl y cl utches, whi l e others are used to appl y bands.
They al l have i n common the fact that they are
round or ci rcul ar i n shape, l ocated wi thi n a smooth
wal l ed cyl i nder, whi ch i s cl osed at one end and con-
verts fl ui d pressure i nto mechani cal movement. The
fl ui d pressure exerted on the pi ston i s contai ned
wi thi n the system through the use of pi ston ri ngs or
seal s.
OPERATION
The pri nci pal whi ch makes thi s operati on possi bl e
i s known as Pascal s Law. Pascal s Law can be stated
as: Pressure on a confi ned fl ui d i s transmi tted
equal l y i n al l di recti ons and acts wi th equal force on
equal areas.
PRESSURE
Pressure (Fi g. 188) i s nothi ng more than force
(l bs.) di vi ded by area (i n or ft.), or force per uni t
area. Gi ven a 100 l b. bl ock and an area of 100 sq. i n.
on the fl oor, the pressure exerted by the bl ock i s: 100
l bs. 100 i n or 1 pound per square i nch, or PSI as i t i s
commonl y referred to.
Fig. 187 Aligning Overdrive Piston Retainer
1 - PISTON RETAINER
2 - GASKET
3 - RETAINER BOLTS
Fig. 188 Force and Pressure Relationship
PRESSURE ON A CONFINED FLUID
Pressure i s exerted on a confi ned fl ui d (Fi g. 189)
by appl yi ng a force to some gi ven area i n contact
wi th the fl ui d. A good exampl e of thi s i s a cyl i nder
fi l l ed wi th fl ui d and equi pped wi th a pi ston that i s
cl osel y fi tted to the cyl i nder wal l . I f a force i s appl i ed
to the pi ston, pressure wi l l be devel oped i n the fl ui d.
Of course, no pressure wi l l be created i f the fl ui d i s
not confi ned. I t wi l l si mpl y l eak past the pi ston.
There must be a resi stance to fl ow i n order to create
pressure. Pi ston seal i ng i s extremel y i mportant i n
hydraul i c operati on. Several ki nds of seal s are used
to accompl i sh thi s wi thi n a transmi ssi on. These
i ncl ude but are not l i mi ted to O-ri ngs, D-ri ngs, l i p
seal s, seal i ng ri ngs, or extremel y cl ose tol erances
between the pi ston and the cyl i nder wal l . The force
exerted i s downward (gravi ty), however, the pri nci pl e
remai ns the same no matter whi ch di recti on i s taken.
The pressure created i n the fl ui d i s equal to the force
appl i ed, di vi ded by the pi ston area. I f the force i s 100
l bs., and the pi ston area i s 10 sq. i n., then the pres-
sure created equal s 10 PSI . Another i nterpretati on of
Pascal s Law i s that regardl ess of contai ner shape or
si ze, the pressure wi l l be mai ntai ned throughout, as
l ong as the fl ui d i s confi ned. I n other words, the
pressure i n the fl ui d i s the same everywhere wi thi n
the contai ner.
FORCE MULTIPLICATION
Usi ng the 10 PSI exampl e used i n the i l l ustrati on
(Fi g. 190), a force of 1000 l bs. can be moved wi th a
force of onl y 100 l bs. The secret of force mul ti pl i ca-
ti on i n hydraul i c systems i s the total fl ui d contact
area empl oyed. The i l l ustrati on, (Fi g. 190), shows an
area that i s ten ti mes l arger than the ori gi nal area.
The pressure created wi th the smal l er 100 l b. i nput
i s 10 PSI . The concept pressure i s the same every-
where means that the pressure underneath the
l arger pi ston i s al so 10 PSI . Pressure i s equal to the
force appl i ed di vi ded by the contact area. Therefore,
by means of si mpl e al gebra, the output force may be
found. Thi s concept i s extremel y i mportant, as i t i s
al so used i n the desi gn and operati on of al l shi ft
val ves and l i mi ti ng val ves i n the val ve body, as wel l
as the pi stons, of the transmi ssi on, whi ch acti vate
the cl utches and bands. I t i s nothi ng more than
usi ng a di fference of area to create a di fference i n
pressure to move an object.
Fig. 189 Pressure on a Confined Fluid
Fig. 190 Force Multiplication
PISTONS (Continued)
PISTON TRAVEL
The rel ati onshi p between hydraul i c l ever and a
mechani cal l ever i s the same. Wi th a mechani cal
l ever i ts a wei ght-to-di stance output rather than a
pressure-to-area output. Usi ng the same forces and
areas as i n the previ ous exampl e, the smal l er pi ston
(Fi g. 191) has to move ten ti mes the di stance
requi red to move the l arger pi ston one i nch. There-
fore, for every i nch the l arger pi ston moves, the
smal l er pi ston moves ten i nches. Thi s pri nci pl e i s
true i n other i nstances al so. A common garage fl oor
jack i s a good exampl e. To rai se a car wei ghi ng 2000
l bs., an effort of onl y 100 l bs. may be requi red. For
every i nch the car moves upward, the i nput pi ston at
the jack handl e must move 20 i nches downward.
PLANETARY GEARTRAIN/
OUTPUT SHAFT
DESCRIPTION
The pl anetary gearsets (Fi g. 192) are desi gnated as
the front, rear, and overdri ve pl anetary gear assem-
bl i es and l ocated i n such order. A si mpl e pl anetary
gearset consi sts of three mai n members:
The sun gear whi ch i s at the center of the sys-
tem.
The pl anet carri er wi th pl anet pi ni on gears
whi ch are free to rotate on thei r own shafts and are
i n mesh wi th the sun gear.
The annul us gear, whi ch rotates around and i s
i n mesh wi th the pl anet pi ni on gears.
NOTE: The number of pinion gears does not affect
the gear ratio, only the duty rating.
OPERATION
Wi th any gi ven pl anetary gearset, several condi -
ti ons must be met for power to be abl e to fl ow:
One member must be hel d.
Another member must be dri ven or used as an
i nput.
The thi rd member may be used as an output for
power fl ow.
For di rect dri ve to occur, two gear members i n
the front pl anetary gearset must be dri ven.
NOTE: Gear ratios are dependent on the number of
teeth on the annulus and sun gears.
Fig. 191 Piston Travel
Fig. 192 Planetary Gearset
1 - ANNULUS GEAR
2 - SUN GEAR
3 - PLANET CARRIER
4 - PLANET PINIONS (4)
PISTONS (Continued)
DISASSEMBLY
(1) Remove pl anetary snap-ri ng from i ntermedi ate
shaft (Fi g. 193). Di scard snap-ri ng as i t i s not reus-
abl e.
(2) Remove front pl anetary gear and front annul us
gear as assembl y (Fi g. 194).
(3) Remove front pl anetary gear and thrust
washer from front annul us gear (Fi g. 195). Note
thrust washer posi ti on for assembl y reference.
(4) Remove tabbed thrust washer from dri vi ng
shel l (Fi g. 196). Note washer posi ti on for assembl y
reference.
Fig. 193 Removing Planetary Snap-Ring
1 - PLANETARY SNAP-RING
Fig. 194 Removing Front Planetary And Annulus
Gears
1 - DRIVING SHELL
2 - FRONT ANNULUS GEAR
3 - FRONT PLANETARY GEAR
Fig. 195 Disassembling Front Planetary And
Annulus Gears
2 - TABBED THRUST WASHER
4 - TORLON BUSHING
Fig. 196 Driving Shell Thrust Washer Removal
1 - DRIVING SHELL
3 - SUN GEAR
PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)
(5) Remove sun gear and dri vi ng shel l as assembl y
(Fi g. 197).
(6) Remove tabbed thrust washer from rear pl ane-
tary gear (Fi g. 198). Note washer posi ti on on gear for
assembl y reference.
(7) Remove rear pl anetary gear and rear annul us
gear from i ntermedi ate shaft (Fi g. 199).
(8) Remove thrust washer from rear pl anetary
gear (Fi g. 200).
INSPECTION
I nspect the pl anetary gear sets and annul us gears.
The pl anetary pi ni ons, shafts, washers, and retai ni ng
pi ns are servi ceabl e. However, i f a pi ni on carri er i s
damaged, the enti re pl anetary gear set must be
repl aced as an assembl y.
Repl ace the annul us gears i f the teeth are chi pped,
broken, or worn, or the gear i s cracked. Repl ace the
pl anetary thrust pl ates and the tabbed thrust wash-
ers i f cracked, scored or worn.
I nspect the machi ned surfaces of the i ntermedi ate
shaft. Be sure the oi l passages are open and cl ear.
Repl ace the shaft i f scored, pi tted, or damaged.
I nspect the sun gear and dri vi ng shel l . I f ei ther
component i s worn or damaged, remove the sun gear
rear retai ni ng ri ng and separate the sun gear and
thrust pl ate from the dri vi ng shel l . Then repl ace the
necessary component.
Repl ace the sun gear as an assembl y i f the gear
teeth are chi pped or worn. Al so repl ace the gear as
an assembl y i f the bushi ngs are scored or worn. The
sun gear bushi ngs are not servi ceabl e. Repl ace the
Fig. 197 Sun Gear And Driving Shell Removal
2 - DRIVING SHELL
3 - SUN GEAR
Fig. 198 Rear Planetary Thrust Washer Removal
1 - SUN GEAR
2 - REAR PLANETARY THRUST WASHER
3 - DRIVING SHELL
Fig. 199 Rear Planetary And Annulus Gear Removal
2 - REAR ANNULUS GEAR
3 - REAR PLANETARY GEAR
Fig. 200 Rear Annulus Thrust Washer Removal
2 - THRUST WASHER
thrust pl ate i f worn, or severel y scored. Repl ace the
dri vi ng shel l i f di storted, cracked, or damaged i n any
way.
Repl ace al l snap-ri ngs duri ng geartrai n assembl y.
Reusi ng snap-ri ngs i s not recommended.
ASSEMBLY
(1) Lubri cate sun gear and pl anetary gears wi th
transmi ssi on fl ui d duri ng assembl y. Use petrol eum
jel l y to l ubri cate i ntermedi ate shaft bushi ng surfaces,
thrust washers and thrust pl ates and to hol d these
parts i n pl ace duri ng assembl y.
(2) I nstal l front snap-ri ng on sun gear and i nstal l
gear i n dri vi ng shel l . Then i nstal l thrust pl ate over
sun gear and agai nst rear si de of dri vi ng shel l (Fi g.
201). I nstal l rear snap-ri ng to secure sun gear and
thrust pl ate i n dri vi ng shel l . Note that the l arge I D
chamfer on the sun gear goes forward.
(3) I nstal l rear annul us gear on i ntermedi ate shaft
(Fi g. 202).
(4) I nstal l thrust washer to rear pl anetary gear
(Fi g. 203) usi ng petrol eum jel l y. Be sure washer i s
seated agai nst corner wi tht teh tabs compl etel y i n
the l ocati ng hol es.
(5) I nstal l rear pl anetary gear i n rear annul us
gear (Fi g. 204). Be sure pl anetary carri er i s seated
agai nst annul us gear.
Fig. 202 Installing Rear Annulus Gear On
Intermediate Shaft
2 - OUTPUT SHAFT
Fig. 203 Installing Rear Annulus Thrust Washer
2 - THRUST WASHER
Fig. 204 Installing Rear Planetary Gear
Fig. 201 Sun Gear Installation
1 - DRIVING SHELL
2 - SUN GEAR
3 - THRUST PLATE
4 - SUN GEAR REAR RETAINING RING
(6) I nstal l tabbed thrust washer on front face of
rear pl anetary gear (Fi g. 205). Seat washer tabs i n
matchi ng sl ots i n face of gear carri er. Use extra
petrol eum jel l y to hol d washer i n pl ace i f desi red.
(7) Lubri cate sun gear bushi ngs wi th petrol eum
jel l y or transmi ssi on fl ui d.
(8) I nstal l sun gear and dri vi ng shel l on i nterme-
di ate shaft (Fi g. 206). Seat shel l agai nst rear pl ane-
tary gear. Veri fy that thrust washer on pl anetary
gear was not di spl aced duri ng i nstal l ati on.
(9) I nstal l tabbed thrust washer i n dri vi ng shel l
(Fi g. 207), be sure washer tabs are seated i n tab sl ots
of dri vi ng shel l . Use extra petrol eum jel l y to hol d
washer i n pl ace i f desi red.
(10) I nstal l tabbed thrust washer on front pl ane-
tary gear (Fi g. 208). Seat washer tabs i n matchi ng
sl ots i n face of gear carri er. Use extra petrol eum jel l y
to hol d washer i n pl ace i f desi red.
(11) I nstal l the torl on bushi ng onto the front pl an-
etary carri er hub.
Fig. 205 Installing Rear Planetary Thrust Washer
Fig. 206 Installing Sun Gear And Driving Shell
1 - OUTPUT SHAFT
2 - DRIVING SHELL
4 - OUTPUT SHAFT
5 - SUN GEAR
Fig. 207 Installing Driving Shell Thrust Washer
1 - TAB SLOTS (3)
2 - DRIVING SHELL
Fig. 208 Installing Thrust Washer On Front
Planetary Gear
(12) I nstal l front annul us gear over and onto front
pl anetary gear (Fi g. 209). Be sure gears are ful l y
meshed and seated.
(13) I nstal l front pl anetary and annul us gear
assembl y (Fi g. 210). Hol d gears together and sl i de
them onto shaft. Be sure pl anetary pi ni ons are
seated on sun gear and that pl anetary carri er i s
seated on i ntermedi ate shaft.
(14) Pl ace geartrai n i n upri ght posi ti on. Rotate
gears to be sure al l components are seated and prop-
erl y assembl ed. Snap-ri ng groove at forward end of
i ntermedi ate shaft wi l l be compl etel y exposed when
components are assembl ed correctl y.
(15) I nstal l new pl anetary snap-ri ng i n groove at
end of i ntermedi ate shaft (Fi g. 211).
(16) Turn pl anetary geartrai n over. Posi ti on wood
bl ock under front end of i ntermedi ate shaft and sup-
port geartrai n on shaft. Be sure al l geartrai n parts
have moved forward agai nst pl anetary snap-ri ng.
Thi s i s i mportant for accurate end pl ay check.
Fig. 209 Assembling Front Planetary And
Annulus Gears
Fig. 210 Installing Front Planetary And Annulus
Gear Assembly
1 - DRIVING SHELL
2 - ASSEMBLED FRONT PLANETARY AND ANNULUS GEARS
Fig. 211 Installing Planetary Snap
1 - SNAP-RING PLIERS
2 - PLANETARY SNAP-RING
(17) Check pl anetary geartrai n end pl ay wi th
feel er gauge (Fi g. 212). I nsert gauge between rear
annul us gear and shoul der on i ntermedi ate shaft as
shown. End pl ay shoul d be 0.15 to 1.22 mm (0.006 to
0.048 i n.).
(18) I f end pl ay i s i ncorrect, i nstal l thi nner/thi cker
pl anetary snap-ri ng as needed.
REAR CLUTCH
DESCRIPTION
The rear cl utch assembl y (Fi g. 213) i s composed of
the rear cl utch retai ner, pressure pl ate, cl utch pl ates,
dri vi ng di scs, pi ston, Bel l evi l l e spri ng, and snap-
ri ngs. The Bel l evi l l e spri ng acts as a l ever to mul ti -
pl y the force appl i ed on to i t by the appl y pi ston. The
i ncreased appl y force on the rear cl utch pack, i n com-
pari son to the front cl utch pack, i s needed to hol d
agai nst the greater torque l oad i mposed onto the rear
pack. The rear cl utch i s di rectl y behi nd the front
cl utch and i s consi dered a dri vi ng component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
Fig. 212 Checking Planetary Geartrain End Play
1 - OUTPUT SHAFT
3 - FEELER GAUGE
Fig. 213 Rear Clutch Components
1 - REAR CLUTCH RETAINER 11 - REACTION PLATE
2 - TORLON SEAL RINGS 12 - CLUTCH PLATES
3 - INPUT SHAFT 13 - WAVE SPRING
4 - PISTON RETAINER 14 - SPACER RING
5 - OUTPUT SHAFT THRUST WASHER 15 - PISTON
6 - INNER PISTON SEAL 16 - OUTER PISTON SEAL
7 - PISTON SPRING 17 - REAR SEAL RING
8 - PRESSURE PLATE 18 - FIBER THRUST WASHER
9 - CLUTCH DISCS 19 - RETAINING RING
10 - SNAP-RING (SELECTIVE)
OPERATION
the cl utch retai ner and pi ston. The fl ui d pressure i s
cl utch through the hub of the reacti on shaft support.
Wi th pressure appl i ed between the cl utch retai ner
and pi ston, the pi ston moves away from the cl utch
retai ner and compresses the cl utch pack. Thi s acti on
appl i es the cl utch pack, al l owi ng torque to fl ow
through the i nput shaft i nto the dri vi ng di scs, and
i nto the cl utch pl ates and pressure pl ate that are
l ugged to the cl utch retai ner. The waved spri ng i s
used to cushi on the appl i cati on of the cl utch pack.
The snap-ri ng i s sel ecti ve and used to adjust cl utch
pack cl earance.
When pressure i s rel eased from the pi ston, the
spri ng returns the pi ston to i ts ful l y rel eased posi ti on
and di sengages the cl utch. The rel ease spri ng al so
hel ps to cushi on the appl i cati on of the cl utch assem-
bl y. When the cl utch i s i n the process of bei ng
rel eased by the rel ease spri ng, fl ui d fl ows through a
vent and one-way bal l -check-val ve l ocated i n the pi s-
ton. The check-val ve i s needed to el i mi nate the pos-
si bi l i ty of pl ate drag caused by centri fugal force
acti ng on the resi dual fl ui d trapped i n the cl utch pi s-
ton retai ner.
DISASSEMBLY
(1) Remove fi ber thrust washer from forward si de
of cl utch retai ner.
(2) Remove i nput shaft front and rear seal ri ngs.
(3) Remove sel ecti ve cl utch pack snap-ri ng (Fi g.
214).
(4) Remove the reacti on pl ate, cl utch di scs, steel
pl ates, pressure pl ate, wave spri ng, spacer ri ng, and
pi ston spri ng (Fi g. 214).
(5) Remove cl utch pi ston wi th rotati ng moti on.
(6) Remove and di scard pi ston seal s.
(7) Remove i nput shaft retai ni ng ri ng. I t may be
necessary to press the i nput shaft i n sl i ghtl y to
rel i eve tensi on on the retai ni ng ri ng
(8) Press i nput shaft out of retai ner wi th shop
press and sui tabl e si ze press tool . Use a sui tabl y
si zed press tool to support the retai ner as cl ose to the
i nput shaft as possi bl e.
CLEANING
Cl ean the cl utch components wi th sol vent and dry
them wi th compressed ai r. Do not use rags or shop
towel s to dry any of the cl utch parts. Li nt from such
materi al s wi l l adhere to component surfaces and
coul d restri ct or bl ock fl ui d passages after assembl y.
INSPECTION
Repl ace the cl utch di scs i f warped, worn, scored,
burned/charred, the l ugs are damaged, or i f the fac-
i ng i s fl aki ng off. Repl ace the top and bottom pres-
sure pl ates i f scored, warped, or cracked. Be sure the
dri vi ng l ugs on the pressure and cl utch pl ates are
al so i n good condi ti on. The l ugs must not be bent,
cracked or damaged i n any way.
Repl ace the pi ston spri ng and wave spri ng i f ei ther
part i s di storted, warped or broken.
Check the l ug grooves i n the cl utch retai ner. The
cl utch and pressure pl ates shoul d sl i de freel y i n the
sl ots. Repl ace the retai ner i f the grooves are worn or
damaged. Al so check acti on of the check bal l s i n the
retai ner and pi ston. Each check bal l must move
freel y and not sti ck.
Repl ace the retai ner bushi ng i f worn, scored, or
doubt exi sts about bushi ng condi ti on.
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y scored.
Check condi ti on of the fi ber thrust washer and
metal output shaft thrust washer. Repl ace ei ther
washer i f worn or damaged.
Check condi ti on of the seal ri ngs on the i nput shaft
and cl utch retai ner hub. Repl ace the seal ri ngs onl y
i f worn, di storted, or damaged. The i nput shaft front
seal ri ng i s tefl on wi th chamfered ends. The rear ri ng
i s metal wi th i nterl ocki ng ends.
Check the i nput shaft for wear, or damage. Repl ace
the shaft i f worn, scored or damaged i n any way.
REAR CLUTCH (Continued)
ASSEMBLY
(1) Soak cl utch di scs i n transmi ssi on fl ui d whi l e
assembl i ng other cl utch parts.
(2) I nstal l new seal ri ngs on cl utch retai ner hub
and i nput shaft i f necessary.
(a) Be sure cl utch hub seal ri ng i s ful l y seated i n
groove and i s not twi sted.
(3) Lubri cate spl i ned end of i nput shaft and cl utch
retai ner wi th transmi ssi on fl ui d. Then parti al l y press
i nput shaft i nto retai ner (Fi g. 215). Use a sui tabl y
si zed press tool to support retai ner as cl ose to i nput
shaft as possi bl e.
(4) I nstal l i nput shaft retai ni ng ri ng.
(5) Press the i nput shaft the remai nder of the way
i nto the cl utch retai ner.
(6) I nstal l new seal s on cl utch pi ston. Be sure l i p
of each seal faces i nteri or of cl utch retai ner.
(7) Lubri cate l i p of pi ston seal s wi th generous
quanti ty of Mopar Door Ease. Then l ubri cate
retai ner hub and bore wi th l i ght coat of transmi ssi on
fl ui d.
(8) I nstal l cl utch pi ston i n retai ner. Use twi sti ng
moti on to seat pi ston i n bottom of retai ner. A thi n
stri p of pl asti c (about 0.020 thi ck), can be used to
gui de seal s i nto pl ace i f necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(9) I nstal l pi ston spri ng i n retai ner and on top of
pi ston. Concave si de of spri ng faces downward
(toward pi ston).
Fig. 214 Rear Clutch Components
1 - REAR CLUTCH RETAINER 11 - REACTION PLATE
2 - TORLON SEAL RINGS 12 - CLUTCH PLATES
3 - INPUT SHAFT 13 - WAVE SPRING
4 - PISTON RETAINER 14 - SPACER RING
5 - OUTPUT SHAFT THRUST WASHER 15 - PISTON
6 - INNER PISTON SEAL 16 - OUTER PISTON SEAL
7 - PISTON SPRING 17 - REAR SEAL RING
8 - PRESSURE PLATE 18 - FIBER THRUST WASHER
9 - CLUTCH DISCS 19 - RETAINING RING
10 - SNAP-RING (SELECTIVE)
(10) I nstal l the spacer ri ng and wave spri ng i nto
the retai ner. Be sure spri ng i s compl etel y seated i n
retai ner groove.
(11) I nstal l pressure pl ate (Fi g. 214). Ri dged si de
of pl ate faces downward (toward pi ston) and fl at si de
toward cl utch pack.
(12) I nstal l fi rst cl utch di sc i n retai ner on top of
pressure pl ate. Then i nstal l a cl utch pl ate fol l owed
by a cl utch di sc unti l enti re cl utch pack i s i nstal l ed
(4 di scs and 3 pl ates are requi red) (Fi g. 214).
(13) I nstal l the reacti on pl ate.
(14) I nstal l sel ecti ve snap-ri ng. Be sure snap-ri ng
i s ful l y seated i n retai ner groove.
(15) Usi ng a sui tabl e gauge bar and di al i ndi cator,
measure cl utch pack cl earance (Fi g. 216).
(a) Posi ti on gauge bar across the cl utch drum
wi th the di al i ndi cator poi nter on the pressure
pl ate (Fi g. 216).
(b) Usi ng two smal l screw dri vers, l i ft the pres-
sure pl ate and rel ease i t.
(c) Zero the di al i ndi cator.
(d) Li ft the pressure pl ate unti l i t contacts the
snap-ri ng and record the di al i ndi cator readi ng.
Cl earance shoul d be 0.635 - 0.914 mm (0.025 -
0.036 i n.). I f cl earance i s i ncorrect, steel pl ates, di scs,
sel ecti ve snap ri ng and pressure pl ates may have to
be changed.
The sel ecti ve snap ri ng thi cknesses are:
0.107 - 0.109 i n.
0.098 - 0.100 i n.
0.095 - 0.097 i n.
0.083 - 0.085 i n.
0.076 - 0.078 i n.
0.071 - 0.073 i n.
0.060 - 0.062 i n.
(16) Coat rear cl utch thrust washer wi th petro-
l eum jel l y and i nstal l washer over i nput shaft and
i nto cl utch retai ner (Fi g. 217). Use enough petrol eum
jel l y to hol d washer i n pl ace.
(17) Set rear cl utch asi de for i nstal l ati on duri ng
fi nal assembl y.
Fig. 215 Pressing Input Shaft Into Rear Clutch
Retainer
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - PRESS RAM Fig. 216 Checking Rear Clutch Pack Clearance
1 - DIAL INDICATOR
2 - PRESSURE PLATE
3 - SNAP-RING
4 - STAND
5 - REAR CLUTCH
6 - GAUGE BAR
Fig. 217 Installing Rear Clutch Thrust Washer
1 - REAR CLUTCH RETAINER
2 - REAR CLUTCH THRUST WASHER
REAR SERVO
DESCRIPTION
The rear (l ow/reverse) servo consi sts of a si ngl e
stage or di ameter pi ston and a spri ng l oaded pl ug.
The spri ng i s used to cushi on the appl i cati on of the
rear (l ow/reverse) band.
OPERATION
Whi l e i n the de-energi zed state (no pressure
appl i ed), the pi ston i s hel d up i n i ts bore by the pi s-
ton spri ng. The pl ug i s hel d down i n i ts bore, i n the
pi ston, by the pl ug spri ng. When pressure i s appl i ed
to the top of the pi ston, the pl ug i s forced down i n i ts
bore, taki ng up any cl earance. As the pi ston moves, i t
causes the pl ug spri ng to compress, and the pi ston
moves down over the pl ug. The pi ston conti nues to
move down unti l i t hi ts the shoul der of the pl ug and
ful l y appl i es the band. The peri od of ti me from the
i ni ti al appl i cati on, unti l the pi ston i s agai nst the
shoul der of the pl ug, represents a reduced shocki ng
of the band that cushi ons the shi ft.
DISASSEMBLY
(1) Remove smal l snap-ri ng and remove pl ug and
spri ng from servo pi ston (Fi g. 218).
(2) Remove and di scard servo pi ston seal ri ng.
CLEANING
Remove and di scard the servo pi ston seal ri ng (Fi g.
219). Then cl ean the servo components wi th sol vent
and dry wi th compressed ai r. Repl ace ei ther spri ng i f
col l apsed, di storted or broken. Repl ace the pl ug and
pi ston i f cracked, bent, or worn. Di scard the servo
snap-ri ngs and use new ones at assembl y.
ASSEMBLY
(1) Lubri cate pi ston and gui de seal s (Fi g. 220)
wi th petrol eum jel l y. Lubri cate other servo parts wi th
(2) I nstal l new seal ri ng on servo pi ston.
(3) Assembl e pi ston, pl ug, spri ng and new snap-
ri ng.
(4) Lubri cate pi ston seal l i p wi th petrol eum jel l y.
Fig. 218 Rear Servo Components
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
SHIFT MECHANISM
DESCRIPTION
The gear shi ft mechani sm provi des si x shi ft posi -
ti ons whi ch are:
PARK (P)
REVERSE (R)
NEUTRAL (N)
DRI VE (D)
Manual SECOND (2)
Manual LOW (1)
OPERATION
Manual LOW (1) range provi des fi rst gear onl y.
Overrun braki ng i s al so provi ded i n thi s range. Man-
ual SECOND (2) range provi des fi rst and second gear
onl y.
DRI VE range provi des fi rst, second, thi rd, and
overdri ve fourth gear ranges. The shi ft i nto overdri ve
fourth gear range occurs onl y after the transmi ssi on
has compl eted the shi ft i nto D thi rd gear range. No
further movement of the shi ft mechani sm i s requi red
to compl ete the 3-4 shi ft.
The fourth gear upshi ft occurs automati cal l y when
the overdri ve sel ector swi tch i s i n the ON posi ti on.
No upshi ft to fourth gear wi l l occur i f any of the fol -
l owi ng are true:
The transmi ssi on fl ui d temperature i s bel ow 10
C (50 F) or above 121 C (250 F).
The shi ft to thi rd i s not yet compl ete.
Vehi cl e speed i s too l ow for the 3-4 shi ft to occur.
Battery temperature i s bel ow -5 C (23 F).
SOLENOID
DESCRIPTION
The typi cal el ectri cal sol enoi d used i n automoti ve
appl i cati ons i s a l i near actuator. I t i s a devi ce that
produces moti on i n a strai ght l i ne. Thi s strai ght l i ne
moti on can be ei ther forward or backward i n di rec-
ti on, and short or l ong di stance.
A sol enoi d i s an el ectromechani cal devi ce that uses
a magneti c force to perform work. I t consi sts of a coi l
of wi re, wrapped around a magneti c core made from
steel or i ron, and a spri ng l oaded, movabl e pl unger,
whi ch performs the work, or strai ght l i ne moti on.
The sol enoi ds used i n transmi ssi on appl i cati ons
are attached to val ves whi ch can be cl assi fi ed as nor-
mally open or normally closed. The normally
open sol enoi d val ve i s defi ned as a val ve whi ch
al l ows hydraul i c fl ow when no current or vol tage i s
appl i ed to the sol enoi d. The normally closed sol e-
noi d val ve i s defi ned as a val ve whi ch does not al l ow
hydraul i c fl ow when no current or vol tage i s appl i ed
to the sol enoi d. These val ves perform hydraul i c con-
trol functi ons for the transmi ssi on and must there-
fore be durabl e and tol erant of di rt parti cl es. For
these reasons, the val ves have hardened steel pop-
pets and bal l val ves. The sol enoi ds operate the val ves
di rectl y, whi ch means that the sol enoi ds must have
very hi gh outputs to cl ose the val ves agai nst the si z-
abl e fl ow areas and l i ne pressures found i n current
transmi ssi ons. Fast response ti me i s al so necessary
to ensure accurate control of the transmi ssi on.
The strength of the magneti c fi el d i s the pri mary
force that determi nes the speed of operati on i n a par-
ti cul ar sol enoi d desi gn. A stronger magneti c fi el d wi l l
cause the pl unger to move at a greater speed than a
weaker one. There are basi cal l y two ways to i ncrease
the force of the magneti c fi el d:
1. I ncrease the amount of current appl i ed to the
coi l or
2. I ncrease the number of turns of wi re i n the coi l .
The most common practi ce i s to i ncrease the num-
ber of turns by usi ng thi n wi re that can compl etel y
fi l l the avai l abl e space wi thi n the sol enoi d housi ng.
The strength of the spri ng and the l ength of the
pl unger al so contri bute to the response speed possi -
bl e by a parti cul ar sol enoi d desi gn.
A sol enoi d can al so be descri bed by the method by
whi ch i t i s control l ed. Some of the possi bi l i ti es
i ncl ude vari abl e force, pul se-wi dth modul ated, con-
stant ON, or duty cycl e. The vari abl e force and pul se-
wi dth modul ated versi ons uti l i ze si mi l ar methods to
control the current fl ow through the sol enoi d to posi -
ti on the sol enoi d pl unger at a desi red posi ti on some-
where between ful l ON and ful l OFF. The constant
ON and duty cycl ed versi ons control the vol tage
across the sol enoi d to al l ow ei ther ful l fl ow or no fl ow
through the sol enoi ds val ve.
OPERATION
When an el ectri cal current i s appl i ed to the sol e-
noi d coi l , a magneti c fi el d i s created whi ch produces
an attracti on to the pl unger, causi ng the pl unger to
move and work agai nst the spri ng pressure and the
l oad appl i ed by the fl ui d the val ve i s control l i ng. The
pl unger i s normal l y di rectl y attached to the val ve
whi ch i t i s to operate. When the current i s removed
from the coi l , the attracti on i s removed and the
pl unger wi l l return to i ts ori gi nal posi ti on due to
spri ng pressure.
The pl unger i s made of a conducti ve materi al and
accompl i shes thi s movement by provi di ng a path for
the magneti c fi el d to fl ow. By keepi ng the ai r gap
between the pl unger and the coi l to the mi ni mum
necessary to al l ow free movement of the pl unger, the
magneti c fi el d i s maxi mi zed.
SPEED SENSOR
DESCRIPTION
The speed sensor (Fi g. 221) i s l ocated i n the over-
dri ve gear case. The sensor i s posi ti oned over the
park gear and moni tors transmi ssi on output shaft
rotati ng speed.
OPERATION
Speed sensor si gnal s are tri ggered by the park
gear l ugs as they rotate past the sensor pi ckup face.
I nput si gnal s from the sensor are sent to the trans-
mi ssi on control modul e for processi ng. Si gnal s from
thi s sensor are shared wi th the powertrai n control
modul e.
THROTTLE VALVE CABLE
DESCRIPTION
Transmi ssi on throttl e val ve cabl e (Fi g. 222) adjust-
ment i s extremel y i mportant to proper operati on.
Thi s adjustment posi ti ons the throttl e val ve, whi ch
control s shi ft speed, qual i ty, and part-throttl e down-
shi ft sensi ti vi ty.
I f cabl e setti ng i s too l oose, earl y shi fts and sl i p-
page between shi fts may occur. I f the setti ng i s too
ti ght, shi fts may be del ayed and part throttl e down-
shi fts may be very sensi ti ve.
The transmi ssi on throttl e val ve i s operated by a
cam on the throttl e l ever. The throttl e l ever i s oper-
ated by an adjustabl e cabl e (Fi g. 223). The cabl e i s
attached to an arm mounted on the throttl e l ever
shaft. A retai ni ng cl i p at the engi ne-end of the cabl e
i s removed to provi de for cabl e adjustment. The
retai ni ng cl i p i s then i nstal l ed back onto the throttl e
val ve cabl e to l ock i n the adjustment.
Fig. 222 Throttle Valve Cable Attachment - At Engine
1 - THROTTLE VALVE CABLE
2 - CABLE BRACKET
3 - THROTTLE BODY LEVER
Fig. 223 Throttle Valve Cable at Throttle Linkage
1 - THROTTLE LINKAGE
2 - THROTTLE VALVE CABLE LOCKING CLIP
Fig. 221 Transmission Output Speed Sensor
1 - TRANSMISSION OUTPUT SHAFT SPEED SENSOR
2 - SEAL
ADJUSTMENTS - THROTTLE VALVE CABLE
A correctl y adjusted throttl e val ve cabl e wi l l cause
the throttl e l ever on the transmi ssi on to move si mul -
taneousl y wi th the throttl e body l ever from the i dl e
posi ti on. Proper adjustment wi l l al l ow si mul taneous
movement wi thout causi ng the transmi ssi on throttl e
l ever to ei ther move ahead of, or l ag behi nd the l ever
on the throttl e body.
ADJUSTMENT VERIFICATION
(1) Turn i gni ti on key to OFF posi ti on.
(2) Remove ai r cl eaner.
(3) Veri fy that l ever on throttl e body i s at curb i dl e
posi ti on (Fi g. 224). Then veri fy that the transmi ssi on
throttl e l ever (Fi g. 225) i s al so at i dl e (ful l y forward)
posi ti on.
(4) Sl i de cabl e off attachment stud on throttl e body
l ever.
(5) Compare posi ti on of cabl e end to attachment
stud on throttl e body l ever:
Cabl e end and attachment stud shoul d be
al i gned (or centered on one another) to wi thi n 1 mm
(0.039 i n.) i n ei ther di recti on (Fi g. 226).
I f cabl e end and attachment stud are mi sal i gned
(off center), cabl e wi l l have to be adjusted as
descri bed i n Throttl e Val ve Cabl e Adjustment proce-
dure.
Fig. 225 Throttle Valve Cable at Transmission
1 - TRANSMISSION SHIFTER CABLE
3 - TRANSFER CASE SHIFTER CABLE
4 - TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT (1 OR 2)
5 - THROTTLE VALVE CABLE BRACKET RETAINING BOLT
7 - TRANSMISSION FLUID LINES
Fig. 226 Throttle Valve Cable at Throttle Linkage
1 - THROTTLE LINKAGE
2 - THROTTLE VALVE CABLE LOCKING CLIP
Fig. 224 Throttle Valve Cable Attachment - At
Engine
2 - CABLE BRACKET
3 - THROTTLE BODY LEVER
THROTTLE VALVE CABLE (Continued)
(6) Reconnect cabl e end to attachment stud. Then
wi th ai d of a hel per, observe movement of transmi s-
si on throttl e l ever and l ever on throttl e body.
I f both l evers move si mul taneousl y from i dl e to
hal f-throttl e and back to i dl e posi ti on, adjustment i s
correct.
I f transmi ssi on throttl e l ever moves ahead of, or
l ags behi nd throttl e body l ever, cabl e adjustment wi l l
be necessary. Or, i f throttl e body l ever prevents
transmi ssi on l ever from returni ng to cl osed posi ti on,
cabl e adjustment wi l l be necessary.
(1) Turn i gni ti on swi tch to OFF posi ti on.
(2) Remove ai r cl eaner i f necessary.
(3) Di sconnect cabl e end from attachment stud.
Carefully slide cable off stud. Do not pry or pull
cable off.
(4) Veri fy that transmi ssi on throttl e l ever i s i n
ful l y cl osed posi ti on. Then be sure l ever on throttl e
body i s at curb i dl e posi ti on.
(5) Pry the T.V. cabl e l ock (A) i nto the UP posi ti on
(Fi g. 226). Thi s wi l l unl ock the cabl e and al l ow for
readjustment.
(6) Appl y just enough tensi on on the T.V. cabl e (B)
to remove any sl ack i n the cabl e.Pulling too tight
will cause the T.V. lever on the transmission to
move out of its idle position, which will result
in an incorrect T.V. cable adjustment. Sl i de the
sheath of the T.V. cabl e (D) back and forth unti l the
centerl i nes of the T.V. cabl e end (B) and the throttl e
bel l crank l ever (C) are al i gned wi thi n one mi l l i meter
(1mm) (Fi g. 226).
(7) Whi l e hol di ng the T.V. cabl e i n the set posi ti on
push the T.V. cabl e l ock (A) i nto the down posi ti on
(Fi g. 226). Thi s wi l l l ock the present T.V. cabl e
adjustment.
NOTE: Be sure that as the cable is pulled forward
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.
(8) Reconnect the T.V. cabl e (B) to the throttl e
bel l crank l ever (C).
(9) Check cabl e adjustment. Veri fy transmi ssi on
throttl e l ever and l ever on throttl e body move si mul -
taneousl y.
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fi g. 227) i s a hydraul i c
devi ce that coupl es the engi ne crankshaft to the
transmi ssi on. The torque converter consi sts of an
outer shel l wi th an i nternal turbi ne, a stator, an
overrunni ng cl utch, an i mpel l er and an el ectroni cal l y
appl i ed converter cl utch. The converter cl utch pro-
vi des reduced engi ne speed and greater fuel economy
when engaged. Cl utch engagement al so provi des
reduced transmi ssi on fl ui d temperatures. The torque
converter hub dri ves the transmi ssi on oi l (fl ui d)
pump.
The torque converter i s a seal ed, wel ded uni t that
i s not repai rabl e and i s servi ced as an assembl y.
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid. If the fluid
is contaminated, flush the all transmission fluid
cooler(s) and lines.
Fig. 227 Torque Converter Assembly
1 - TURBINE
2 - IMPELLER
3 - HUB
4 - STATOR
5 - FRONT COVER
6 - CONVERTER CLUTCH DISC
7 - DRIVE PLATE
THROTTLE VALVE CABLE (Continued)
IMPELLER
The i mpel l er (Fi g. 228) i s an i ntegral part of the
converter housi ng. The i mpel l er consi sts of curved
bl ades pl aced radi al l y al ong the i nsi de of the housi ng
on the transmi ssi on si de of the converter. As the con-
verter housi ng i s rotated by the engi ne, so i s the
i mpel l er, because they are one and the same and are
the dri vi ng members of the system.
Fig. 228 Impeller
1 - ENGINE FLEXPLATE 4 - ENGINE ROTATION
2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE
SECTION
5 - ENGINE ROTATION
3 - IMPELLER VANES AND COVER ARE INTEGRAL
TORQUE CONVERTER (Continued)
TURBINE
The turbi ne (Fi g. 229) i s the output, or dri ven,
member of the converter. The turbi ne i s mounted
wi thi n the housi ng opposi te the i mpel l er, but i s not
attached to the housi ng. The i nput shaft i s i nserted
through the center of the i mpel l er and spl i ned i nto
the turbi ne. The desi gn of the turbi ne i s si mi l ar to
the i mpel l er, except the bl ades of the turbi ne are
curved i n the opposi te di recti on.
Fig. 229 Turbine
1 - TURBINE VANE 4 - PORTION OF TORQUE CONVERTER COVER
2 - ENGINE ROTATION 5 - ENGINE ROTATION
3 - INPUT SHAFT 6 - OIL FLOW WITHIN TURBINE SECTION
STATOR
The stator assembl y (Fi g. 230) i s mounted on a sta-
ti onary shaft whi ch i s an i ntegral part of the oi l
pump. The stator i s l ocated between the i mpel l er and
turbi ne wi thi n the torque converter case (Fi g. 231).
The stator contai ns an over-runni ng cl utch, whi ch
al l ows the stator to rotate onl y i n a cl ockwi se di rec-
ti on. When the stator i s l ocked agai nst the over-run-
ni ng cl utch, the torque mul ti pl i cati on feature of the
torque converter i s operati onal .
TORQUE CONVERTER CLUTCH (TCC)
The TCC (Fi g. 232) was i nstal l ed to i mprove the
effi ci ency of the torque converter that i s l ost to the
sl i ppage of the fl ui d coupl i ng. Al though the fl ui d cou-
pl i ng provi des smooth, shock-free power transfer, i t i s
natural for al l fl ui d coupl i ngs to sl i p. I f the i mpel l er
and turbi ne were mechani cal l y l ocked together, a
zero sl i ppage condi ti on coul d be obtai ned. A hydraul i c
pi ston was added to the turbi ne, and a fri cti on mate-
ri al was added to the i nsi de of the front cover to pro-
vi de thi s mechani cal l ock-up.
Fig. 230 Stator Components
1 - CAM (OUTER RACE)
2 - ROLLER
3 - SPRING
4 - INNER RACE
Fig. 231 Stator Location
1 - STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
Fig. 232 Torque Converter Clutch (TCC)
1 - IMPELLER FRONT COVER
2 - THRUST WASHER ASSEMBLY
3 - IMPELLER
4 - STATOR
5 - TURBINE
6 - PISTON
7 - FRICTION DISC
OPERATION
The converter i mpel l er (Fi g. 233) (dri vi ng member),
whi ch i s i ntegral to the converter housi ng and bol ted
to the engi ne dri ve pl ate, rotates at engi ne speed.
The converter turbi ne (dri ven member), whi ch reacts
from fl ui d pressure generated by the i mpel l er, rotates
and turns the transmi ssi on i nput shaft.
TURBINE
As the fl ui d that was put i nto moti on by the i mpel -
l er bl ades stri kes the bl ades of the turbi ne, some of
the energy and rotati onal force i s transferred i nto the
turbi ne and the i nput shaft. Thi s causes both of them
(turbi ne and i nput shaft) to rotate i n a cl ockwi se
di recti on fol l owi ng the i mpel l er. As the fl ui d i s l eav-
i ng the trai l i ng edges of the turbi nes bl ades i t con-
ti nues i n a hi nderi ng di recti on back toward the
i mpel l er. I f the fl ui d i s not redi rected before i t stri kes
the i mpel l er, i t wi l l stri ke the i mpel l er i n a di recti on
that woul d tend to sl ow i t down.
Fig. 233 Torque Converter Fluid Operation
1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
STATOR
Torque mul ti pl i cati on i s achi eved by l ocki ng the
stators over-runni ng cl utch to i ts shaft (Fi g. 234).
Under stal l condi ti ons the turbi ne i s stati onary and
the oi l l eavi ng the turbi ne bl ades stri kes the face of
the stator bl ades and tri es to rotate them i n a coun-
tercl ockwi se di recti on. When thi s happens the over-
runni ng cl utch of the stator l ocks and hol ds the
stator from rotati ng. Wi th the stator l ocked, the oi l
stri kes the stator bl ades and i s redi rected i nto a
hel pi ng di recti on before i t enters the i mpel l er. Thi s
ci rcul ati on of oi l from i mpel l er to turbi ne, turbi ne to
stator, and stator to i mpel l er, can produce a maxi -
mum torque mul ti pl i cati on of about 1.75:1. As the
turbi ne begi ns to match the speed of the i mpel l er, the
fl ui d that was hi tti ng the stator i n such as way as to
cause i t to l ock-up i s no l onger doi ng so. I n thi s con-
di ti on of operati on, the stator begi ns to free wheel
and the converter acts as a fl ui d coupl i ng.
The torque converter cl utch i s hydraul i cal l y
appl i ed or rel eased when fl ui d i s feed or vented from
the hydraul i c ci rcui t by the torque converter control
(TCC) sol enoi d on the val ve body. The torque con-
verter cl utch i s control l ed by the Powertrai n Control
Modul e (PCM). The torque converter cl utch engages
i n FOURTH gear, and i n THI RD gear under vari ous
condi ti ons, such as when the O/D swi tch i s OFF, or
when the vehi cl e i s crui si ng on a l evel surface after
the vehi cl e has warmed up. The torque converter
cl utch can al so be engaged i n the MANUAL SEC-
OND gear posi ti on i f hi gh transmi ssi on temperatures
are sensed by the PCM. The torque converter cl utch
may di sengage momentari l y when an i ncrease i n
engi ne l oad i s sensed by the PCM, such as when the
vehi cl e begi ns to go uphi l l or the throttl e pressure i s
i ncreased.
REMOVAL
(1) Remove transmi ssi on and torque converter
from vehi cl e.
(2) Pl ace a sui tabl e drai n pan under the converter
housi ng end of the transmi ssi on.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pul l the torque converter forward unti l the cen-
ter hub cl ears the oi l pump seal .
(4) Separate the torque converter from the trans-
mi ssi on.
INSTALLATION
Check converter hub and dri ve notches for sharp
edges, burrs, scratches, or ni cks. Pol i sh the hub and
notches wi th 320/400 gri t paper or crocus cl oth i f nec-
essary. The hub must be smooth to avoi d damagi ng
the pump seal at i nstal l ati on.
(1) Lubri cate oi l pump seal l i p wi th transmi ssi on
fl ui d.
(2) Pl ace torque converter i n posi ti on on transmi s-
si on.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Al i gn torque converter to oi l pump seal open-
i ng.
(4) I nsert torque converter hub i nto oi l pump.
(5) Whi l e pushi ng torque converter i nward, rotate
converter unti l converter i s ful l y seated i n the oi l
pump gears.
Fig. 234 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
(6) Check converter seati ng wi th a scal e and
shoul d be 19mm (0.75 i n.) to the rear of the strai ght-
edge when converter i s ful l y seated.
(7) I f necessary, temporari l y secure converter wi th
C-cl amp attached to the converter housi ng.
(8) I nstal l the transmi ssi on i n the vehi cl e.
(9) Fi l l the transmi ssi on wi th the recommended
fl ui d.
TORQUE CONVERTER
DRAINBACK VALVE
DESCRIPTION
The drai nback val ve i s l ocated i n the transmi ssi on
cool er outl et (pressure) l i ne.
OPERATION
The val ve prevents fl ui d from drai ni ng from the
converter i nto the cool er and l i nes when the vehi cl e
i s shut down for l engthy peri ods. Producti on val ves
have a hose ni ppl e at one end, whi l e the opposi te end
i s threaded for a fl are fi tti ng. Al l val ves have an
arrow (or si mi l ar mark) to i ndi cate di recti on of fl ow
through the val ve.
STANDARD PROCEDURE - TORQUE
CONVERTER DRAINBACK VALVE
The converter drai nback check val ve i s l ocated i n
the cool er outl et (pressure) l i ne near the radi ator
tank. The val ve prevents fl ui d drai nback when the
vehi cl e i s parked for l engthy peri ods. The val ve check
bal l i s spri ng l oaded and has an openi ng pressure of
approxi matel y 2 psi .
The val ve i s servi ced as an assembl y; i t i s not
repai rabl e. Do not cl ean the val ve i f restri cted, or
contami nated by sl udge, or debri s. I f the val ve fai l s,
or i f a transmi ssi on mal functi on occurs that gener-
ates si gni fi cant amounts of sl udge and/or cl utch par-
ti cl es and metal shavi ngs, the val ve must be
repl aced.
I f the val ve i s restri cted, i nstal l ed backwards, or i n
the wrong l i ne, i t wi l l cause an overheati ng condi ti on
and possi bl e transmi ssi on fai l ure.
CAUTION: The drainback valve is a one-way flow
device. It must be properly oriented in terms of flow
direction for the cooler to function properly. The
valve must be installed in the pressure line. Other-
wise flow will be blocked and would cause an over-
heating condition and eventual transmission failure.
TOW/HAUL OVERDRIVE
SWITCH
DESCRIPTION
The tow/haul overdri ve OFF (control ) swi tch i s
l ocated i n the shi ft l ever arm (Fi g. 236). The swi tch
i s a momentary contact devi ce that si gnal s the PCM
to toggl e current status of the overdri ve functi on.
Fig. 235 Typical Method Of Checking Converter
Seating
1 - SCALE
2 - STRAIGHTEDGE
Fig. 236 Tow/Haul Overdrive Off Switch
OPERATION
At key-on, overdri ve operati on i s al l owed. Pressi ng
the swi tch once causes the tow/haul overdri ve OFF
mode to be entered and the Tow/Haul l amp to be i l l u-
mi nated. Pressi ng the swi tch a second ti me causes
normal overdri ve operati on to be restored and the
tow/haul l amp to be turned off. The tow/haul over-
dri ve OFF mode defaul ts to ON after the i gni ti on
swi tch i s cycl ed OFF and ON. The normal posi ti on
for the control swi tch i s the ON posi ti on. The swi tch
must be i n thi s posi ti on to energi ze the sol enoi d and
al l ow a 3-4 upshi ft. The control swi tch i ndi cator l i ght
i l l umi nates onl y when the tow/haul overdri ve swi tch
i s turned to the OFF posi ti on, or when i l l umi nated
by the transmi ssi on control modul e.
DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS
The tow/haul overdri ve off swi tch, val ve body sol e-
noi d, case connectors and rel ated wi ri ng can al l be
tested wi th a 12 vol t test l amp or a vol t/ohmmeter.
Check conti nui ty of each component when di agnosi s
i ndi cates thi s i s necessary.
Swi tch and sol enoi d conti nui ty shoul d be checked
whenever the transmi ssi on fai l s to shi ft i nto fourth
gear range.
REMOVAL
(1) Usi ng a pl asti c tri m tool , remove the tow/haul
overdri ve off swi tch retai ner from the shi ft l ever (Fi g.
237).
(2) Pul l the swi tch outwards to rel ease i t from the
connector i n the l ever (Fi g. 238)
INSTALLATION
NOTE: There is enough slack in the wire to pull out
the connector from the lever.
(1) Pul l the connector out of the l ever just enough
to grasp i t.
CAUTION: Be careful not to bend the pins on the
tow/haul overdrive off switch. Use care when
installing the switch, as it is not indexed, and can
be accidentally installed incorrectly.
(2) I nstal l the tow/haul overdri ve off swi tch i nto
the connector (Fi g. 239)
(3) Push the tow/haul overdri ve off swi tch and wi r-
i ng i nto the shi ft l ever.
(4) I nstal l the tow/haul overdri ve off swi tch
retai ner onto the shi ft l ever.
Fig. 237 Tow/Haul Overdrive Off Switch Retainer
Fig. 238 Remove the Tow/Haul Overdrive Off Switch
Fig. 239 Install the Tow/Haul Overdrive Off Switch
TOW/HAUL OVERDRIVE SWITCH (Continued)
TRANSMISSION RANGE
SENSOR
DESCRIPTION
The Transmi ssi on Range Sensor (TRS) (Fi g. 240)
has 3 pri mary functi ons:
Provi de a PARK/NEUTRAL start si gnal to the
engi ne control l er and the starter rel ay.
Turn the Back-up l amps on when the transmi s-
si on i s i n REVERSE and the engi ne (i gni ti on) i s on.
Provi de a transmi ssi on range si gnal to the
The sensor i s mounted i n the transmi ssi on housi ng
near the val ve body, just above the pan rai l . I ts i n
the same posi ti on as the Park/Neutral swi tch on
other transmi ssi ons. The TRS contacts a cammed
surface on the manual val ve l ever. The cammed sur-
face transl ates the rotati onal moti on of the manual
l ever i nto the l i near moti on of the sensor. The
cammed surface on the manual l ever i s compri sed of
two parts control l i ng the TRS si gnal : The i nsul ator
porti on contacts the swi tch poppet when the manual
l ever i s not i n PARK or NEUTRAL. The manual
l ever i tsel f contacts the poppet when the l ever i s i n
PARK or NEUTRAL; provi di ng a ground for the si g-
nal from the starter rel ay and the JTEC engi ne con-
trol l er.
OPERATION
As the swi tch moves through i ts l i near moti on (Fi g.
241) contacts sl i de across a ci rcui t board whi ch
changes the resi stance between the range sensi ng
pi ns of the swi tch. A power suppl y on the i nstrument
cl uster provi des a regul ated vol tage si gnal to the
swi tch. The return si gnal i s decoded by the cl uster,
whi ch then control s the PRNDL di spl ay to corre-
spond wi th the correct transmi ssi on range. A bus
message of transmi ssi on range i s al so sent by the
cl uster. I n REVERSE range a second contact set
cl oses the ci rcui t provi di ng power to the reverse
l amps.
Fig. 240 Transmission Range Sensor
Fig. 241 Transmission Range Sensor Linear
Movement
Indicated Gear Position Transmission
Status
Column Shifter
Position
Mechanical State Electronic Display
(Ignition Unlocked)
Electronic Display
(Ignition On)
P P P Vehicle is in PARK
with the pawl
engaged.
In the PARK gate.
R The PARK pawl is
disengaged and the
vehicle is free to
roll, but REVERSE
is not engaged.
Between the PARK
and REVERSE
gates.
R R R The transmission is
hydraulically in
REVERSE.
In the REVERSE
gate.
N The transmission is
transitioning
between REVERSE
and NEUTRAL.
Between the
REVERSE and
NEUTRAL gates.
N N N The vehicle is in
NEUTRAL.
In the NEUTRAL
gate.
N The transmission is
transitioning
between NEUTRAL
and DRIVE, but is
not in DRIVE.
Between the
NEUTRAL and
DRIVE gates.
D D D The transmission is
hydraulically in
DRIVE.
In the DRIVE gate,
2 2 2 The transmission is
hydraulically in
Manual SECOND.
In the SECOND
gate.
1 1 1 The transmission is
hydraulically in
Manual FIRST.
In the FIRST gate.
DIAGNOSIS AND TESTING - TRANSMISSION
RANGE SENSOR (TRS)
NOTE: For all circuit identification in the following
steps, Refer to the appropriate Wiring Information.
(1) Rai se vehi cl e on sui tabl e hoi st.
(2) Di sconnect the vehi cl es shi ft cabl e from the
manual l ever.
(3) Wi th the manual l ever i n the PARK posi ti on
(the PARK posi ti on i s wi th the manual l ever moved
to the ful l rearward posi ti on), measure the resi stance
between the Park/Neutral Posi ti on Sense pi n of the
TRS and the transmi ssi on case. The resi stance
shoul d be l ess than 5 ohms.
(4) Wi th the manual l ever i n the NEUTRAL posi -
ti on (the NEUTRAL posi ti on i s wi th the manual
l ever moved two detents forward of the ful l rearward
posi ti on), measure the resi stance between the Park/
Neutral Posi ti on Sense pi n of the TRS and the trans-
mi ssi on case. The resi stance shoul d be l ess than 5
ohms.
(5) I f the resi stance i s greater than 5 ohms i n
ei ther of the previ ous steps, check for a di rty contact
between the ti p of the TRS rod and the val ve body
manual l ever. I f the contact i s OK, repl ace the TRS.
(6) Wi th the manual l ever i n the REVERSE posi -
ti on (the REVERSE posi ti on i s wi th the manual l ever
moved one detent forward of the ful l rearward posi -
ti on), measure the resi stance between the Fused
I gni ti on Swi tch Output and the Back-up Lamp feed
pi ns of the TRS. The resi stance shoul d be l ess than 5
ohms. I f the resi stance i s greater than 5 ohms,
repl ace the TRS.
TRANSMISSION RANGE SENSOR (Continued)
(7) Wi th the manual l ever i n the PARK posi ti on
(the PARK posi ti on i s wi th the manual l ever moved
to the ful l rearward posi ti on), measure the resi stance
between the Transmi ssi on Range Sensor MUX and
the Transmi ssi on Range Sensor 5V Suppl y pi ns of
the TRS. The resi stance shoul d be 522.2 ohms. I f the
resi stance i s not correct, repl ace the TRS.
(8) Wi th the manual l ever i n the REVERSE posi -
ti on (the REVERSE posi ti on i s wi th the manual l ever
moved one detent forward of the ful l rearward posi -
ti on), measure the resi stance between the Transmi s-
si on Range Sensor MUX and the Transmi ssi on Range
Sensor 5V Suppl y pi ns of the TRS. The resi stance
shoul d be 206.2 ohms. I f the resi stance i s not correct,
repl ace the TRS.
(9) Wi th the manual l ever i n the NEUTRAL posi -
ti on (the NEUTRAL posi ti on i s wi th the manual
l ever moved two detents forward of the ful l rearward
posi ti on), measure the resi stance between the Trans-
mi ssi on Range Sensor MUX and the Transmi ssi on
Range Sensor 5V Suppl y pi ns of the TRS. The resi s-
tance shoul d be 108.6 ohms. I f the resi stance i s not
correct, repl ace the TRS.
(10) Wi th the manual l ever i n the DRI VE posi ti on
(the DRI VE posi ti on i s wi th the manual l ever moved
three detents forward of the ful l rearward posi ti on),
measure the resi stance between the Transmi ssi on
Range Sensor MUX and the Transmi ssi on Range
Sensor 5V Suppl y pi ns of the TRS. The resi stance
shoul d be 59.9 ohms. I f the resi stance i s not correct,
repl ace the TRS.
(11) Wi th the manual l ever i n the SECOND posi -
ti on (the SECOND posi ti on i s wi th the manual l ever
moved one detent rearward of the ful l forward posi -
ti on), measure the resi stance between the Transmi s-
si on Range Sensor MUX and the Back-up Lamp feed
pi ns of the TRS. The resi stance shoul d be 31.9 ohms.
I f the resi stance i s not correct, repl ace the TRS.
(12) Wi th the manual l ever i n the LOW posi ti on
(the LOW posi ti on i s wi th the manual l ever moved to
the ful l forward posi ti on), measure the resi stance
between the Transmi ssi on Range Sensor MUX and
the Back-up Lamp feed pi ns of the TRS. The resi s-
tance shoul d be 13.7 ohms. I f the resi stance i s not
correct, repl ace the TRS.
REMOVAL
(1) Rai se vehi cl e and posi ti on drai n pan under the
transmi ssi on range sensor (TRS).
(2) Move the transmi ssi on manual l ever to the
manual LOW posi ti on. The manual LOW posi ti on i s
wi th the manual l ever i n the forward-most detent.
(3) Di sengage the wi ri ng connector from the TRS.
(4) Remove the two screws hol di ng the TRS to the
TRS mounti ng bracket.
(5) Remove the TRS (Fi g. 242) from the TRS
mounti ng bracket by pul l i ng i t strai ght out of the
bracket.
(6) Loosen the TRS mounti ng bracket i n the trans-
mi ssi on case usi ng Adapter 8581 (Fi g. 243).
Fig. 243 Loosen the TRS Mounting Bracket
3 - ADAPTER 8581
(7) Remove the TRS mounti ng bracket (Fi g. 244)
from the transmi ssi on case.
INSTALLATION
the manual LOW posi ti on.
(2) I nstal l the TRS mounti ng bracket i nto the
transmi ssi on case. Usi ng Adapter 8581 (Fi g. 245),
ti ghten the mounti ng bracket to 34 Nm (300 i n.l bs.).
(3) I nstal l the TRS (Fi g. 246) i nto the mounti ng
bracket wi th the wi ri ng connector faci ng the front of
the transmi ssi on.
(4) I nstal l the two screws to hol d the TRS to the
mounti ng bracket. Ti ghten the screws to 5 Nm (45
i n.l bs.).
(5) Veri fy proper sensor operati on (Fi g. 247).
the PARK posi ti on.
(7) Connect TRS wi ri ng connector to the TRS and
l ower vehi cl e.
(8) Refi l l the transmi ssi on fl ui d to the correct
l evel .
Fig. 244 Remove TRS Mounting Bracket
Fig. 245 Tighten the TRS Mounting Bracket
3 - ADAPTER 8581
Fig. 247 Transmission Range Sensor Operation
1 - NEUTRAL CONTACT
2 - MANUAL LEVER AND SENSOR PLUNGER IN REVERSE
POSITION
3 - PARK CONTACT
TRANSMISSION
TEMPERATURE SENSOR
DESCRIPTION
Transmi ssi on fl ui d temperature readi ngs are sup-
pl i ed to the transmi ssi on control modul e by the ther-
mi stor (Fi g. 248). The temperature readi ngs are used
to control engagement of the fourth gear overdri ve
cl utch, the converter cl utch, and governor pressure.
Normal resi stance val ue for the thermi stor at room
temperature i s approxi matel y 2000 ohms.
The thermi stor i s part of the governor pressure
sensor assembl y and i s i mmersed i n transmi ssi on
fl ui d at al l ti mes.
OPERATION
The PCM prevents engagement of the converter
cl utch and overdri ve cl utch, when fl ui d temperature
i s bel ow approxi matel y 10C (50F).
I f fl ui d temperature exceeds 126C (260F), the
PCM causes a 4-3 downshi ft and engage the con-
verter cl utch. Engagement i s accordi ng to the thi rd
gear converter cl utch engagement schedul e.
The Tow/Haul l amp i n the i nstrument panel i l l umi -
nates when the shi ft back to thi rd occurs. The trans-
mi ssi on wi l l not al l ow fourth gear operati on unti l
fl ui d temperature decreases to approxi matel y 110C
(230F).
VALVE BODY
DESCRIPTION
The val ve body consi sts of a cast al umi num val ve
body, a separator pl ate, and transfer pl ate. The val ve
body contai ns val ves and check bal l s that control
fl ui d del i very to the torque converter cl utch, bands,
and fri cti onal cl utches. The val ve body contai ns the
fol l owi ng components (Fi g. 249), (Fi g. 250), (Fi g.
251), and (Fi g. 252):
Regul ator val ve
Regul ator val ve throttl e pressure pl ug
Li ne pressure sl eeve
Ki ckdown val ve
Ki ckdown l i mi t val ve
1-2 shi ft val ve
1-2 control val ve
2-3 shi ft val ve
2-3 governor pl ug
3-4 shi ft val ve
3-4 ti mi ng val ve
3-4 qui ck fi l l val ve
3-4 accumul ator
Throttl e val ve
Throttl e pressure pl ug
Swi tch val ve
Manual val ve
Converter cl utch l ock-up val ve
Converter cl utch l ock-up ti mi ng Val ve
Shuttl e val ve
Shuttl e val ve throttl e pl ug
Boost Val ve
9 check bal l s
By adjusti ng the spri ng pressure acti ng on the reg-
ul ator val ve, transmi ssi on l i ne pressure can be
adjusted.
Fig. 248 Governor Pressure Sensor
1 - GOVERNOR BODY
2 - GOVERNOR PRESSURE SENSOR/TRANSMISSION FLUID
TEMPERATURE THERMISTOR
Fig. 249 Upper Housing Control Valve Locations
1 - UPPER HOUSING 8 - MANUAL VALVE
2 - REGULATOR VALVE 9 - 1-2 GOVERNOR PLUG
3 - SWITCH VALVE 10 - GOVERNOR PLUG COVER
4 - REGULATOR VALVE SPRING 11 - THROTTLE PLUG
5 - KICKDOWN VALVE 12 - 2-3 GOVERNOR PLUG
6 - KICKDOWN DETENT 13 - SHUTTLE VALVE PRIMARY SPRING
7 - THROTTLE VALVE AND SPRING
VALVE BODY (Continued)
Fig. 250 Shuttle and Boost Valve Locations
1 - SPRING 8 - SHUTTLE VALVE COVER
2 - RETAINER 9 - SHUTTLE VALVE
3 - BOOST VALVE 10 - SHUTTLE VALVE PRIMARY SPRING
4 - BOOST VALVE PLUG 11 - GOVERNOR PLUG COVER
5 - SPRING GUIDES 12 - THROTTLE PLUG
6 - E-CLIP 13 - UPPER HOUSING
7 - SHUTTLE VALVE SECONDARY SPRING 14 - BOOST VALVE COVER
Fig. 251 Upper Housing Shift Valve and Pressure Plug Locations
1 - UPPER HOUSING 7 - LIMIT VALVE AND SPRING
2 - 1-2 SHIFT VALVE AND SPRING 8 - RETAINER
3 - 2-3 SHIFT VALVE AND SPRING 9 - 1-2 SHIFT CONTROL VALVE AND SPRING
4 - 2-3 THROTTLE PLUG 10 - PRESSURE PLUG COVER
5 - LIMIT VALVE HOUSING 11 - PLUG SLEEVE
6 - LIMIT VALVE COVER 12 - THROTTLE PRESSURE SPRING AND PLUG
Fig. 252 Lower Housing Shift Valves and Springs
1 - 3-4 ACCUMULATOR HOUSING 11 - TIMING VALVE COVER
2 - 3-4 SHIFT VALVE AND SPRING 12 - PLUG
3 - PLUG 13 - 3-4 TIMING VALVE AND SPRING
4 - SPRING RETAINER 14 - LOWER HOUSING
5 - CONVERTER CLUTCH VALVE AND SPRING 15 - ACCUMULATOR END PLATE
6 - CONVERTER CLUTCH TIMING VALVE AND SPRING 16 - 3-4 ACCUMULATOR PISTON AND SPRING
7 - OVERDRIVE SEPARATOR PLATE 17 - E-CLIP
8 - CASE CONNECTOR 18 - 3-4 QUICK FILL SPRING AND VALVE
9 - CONVERTER CLUTCH SOLENOID 19 - SOLENOID GASKET
10 - OVERDRIVE SOLENOID 20 - HARNESS
OPERATION
NOTE: Refer to the Hydraulic Schematics for a
visual aid in determining valve location, operation
and design.
CHECK BALLS
CHECK BALL NUMBER DESCRIPTION
1 Allows either the manual valve to put line pressure on the 1-2 governor plug or
the KD Valve to put WOT line pressure on the 1-2 governor plug.
3 Allows either the Reverse circuit or the 3rd gear circuit to pressurize the front
clutch.
4 Allows either the Manual Low circuit from the Manual Valve or the Reverse
from the Manual Valve circuit to pressurize the rear servo.
5 Directs line pressure to the spring end of the 2-3 shift valve in either Manual
Low or Manual 2nd, forcing the downshift to 2nd gear regardless of governor
pressure.
6 Provides a by-pass around the front servo orifice so that the servo can release
quickly.
7 Provides a by-pass around the rear clutch orifice so that the clutch can release
quickly.
8 Directs reverse line pressure through an orifice to the throttle valve eliminating
the extra leakage and insuring that Reverse line pressure pressure will be
sufficient.
9 Provides a by-pass around the rear servo orifice so that the servo can release
quickly.
10 Allows the lockup clutch to used at WOT in 3rd gear by putting line pressure
from the 3-4 Timing Valve on the interlock area of the 2-3 shift valve, thereby
preventing a 3rd gear Lock-up to 2nd gear kickdown.
REGULATOR VALVE
The pressure regul ator val ve i s needed to control
the hydraul i c pressure wi thi n the system and reduce
the amount of heat produced i n the fl ui d. The pres-
sure regul ator val ve i s l ocated i n the val ve body near
the manual val ve. The pressure regul ator val ve trai n
control s the maxi mum pressure i n the l i nes by
meteri ng the dumpi ng of fl ui d back i nto the sump.
Regul ated pressure i s referred to as l i ne pressure.
The regul ator val ve (Fi g. 253) has a spri ng on one
end that pushes the val ve to the l eft. Thi s cl oses a
dump (vent) that i s used to l ower pressure. The cl os-
i ng of the dump wi l l cause the oi l pressure to
i ncrease. Oi l pressure on the opposi te end of the
val ve pushes the val ve to the ri ght, openi ng the
dump and l oweri ng oi l pressure. The resul t i s spri ng
pressure worki ng agai nst oi l pressure to mai ntai n
the oi l at speci fi c pressures. Wi th the engi ne run-
ni ng, fl ui d fl ows from the pump to the pressure reg-
ul ator val ve, manual val ve, and the i nterconnected
ci rcui ts. As fl ui d i s sent through passages to the reg-
ul ator val ve, the pressure pushes the val ve to the
ri ght agai nst the l arge spri ng. I t i s al so sent to the
reacti on areas on the l eft si de of the throttl e pressure
pl ug and the l i ne pressure pl ug. Wi th the gear sel ec-
tor i n the PARK posi ti on, fl ui d reci rcul ates through
the regul ator and manual val ves back to the sump.
Fig. 253 Regulator Valve in Park Position
Meanwhi l e, the torque converter i s fi l l ed sl owl y. I n
al l other gear posi ti ons (Fi g. 254), fl ui d fl ows
between two ri ght si de l ands to the swi tch val ve and
torque converter. At l ow pump speeds, the fl ow i s
control l ed by the pressure val ve groove to reduce
pressure to the torque converter. After the torque
converter and swi tch val ve fi l l wi th fl ui d, the swi tch
val ve becomes the control l i ng meteri ng devi ce for
torque converter pressure. The regul ator val ve then
begi ns to control the l i ne pressure for the other
transmi ssi on ci rcui ts. The bal ance of the fl ui d pres-
sure pushi ng the val ve to the ri ght and the spri ng
pressure pushi ng to the l eft determi nes the si ze of
the meteri ng passage at l and #2 (l and #1 bei ng at
the far ri ght of the val ve i n the di agram). As fl ui d
l eaks past the l and, i t moves i nto a groove connected
to the fi l ter or sump. As the l and meters the fl ui d to
the sump, i t causes the pressure to reduce and the
spri ng decreases the si ze of the meteri ng passage.
When the si ze of the meteri ng passage i s reduced,
the pressure ri ses agai n and the si ze of the l and i s
i ncreased agai n. Pressure i s regul ated by thi s con-
stant bal ance of hydraul i c and spri ng pressure.
The meteri ng at l and #2 establ i shes the l i ne pres-
sure throughout the transmi ssi on. I t i s vari ed accord-
i ng to changes i n throttl e posi ti on and the
transmi ssi ons i nternal condi ti on wi thi n a range of
57-94 psi (except i n REVERSE) (Fi g. 255). The regu-
l ated l i ne pressure i n REVERSE (Fi g. 256) i s hel d at
much hi gher pressures than i n the other gear posi -
ti ons: 145-280 psi . The hi gher pressure for
REVERSE i s achi eved by the manual val ve bl ocki ng
the suppl y of l i ne pressure to the reacti on area l eft of
l and #4. Wi th thi s pressure bl ocked, there i s l ess
area for pressure to act on to bal ance the force of the
spri ng on the ri ght. Thi s al l ows l i ne pressure to push
the val ve trai n to the ri ght, reduci ng the amount of
fl ui d returned to the pumps i nl et, i ncreasi ng l i ne
pressure.
Fig. 254 Regulator Valve in Neutral Position
Fig. 255 Regulator Valve in Drive Position
Fig. 256 Regulator Valve in Reverse Position
KICKDOWN VALVE
When the throttl e val ve i s as far over to the l eft as
i t can go, the maxi mum l i ne pressure possi bl e wi l l
enter the throttl e pressure ci rcui t. I n thi s case, throt-
tl e pressure wi l l equal l i ne pressure. Wi th the ki ck-
down val ve (Fi g. 257) pushed i nto the bore as far as
i t wi l l go, fl ui d i ni ti al l y fl ows through the annul ar
groove of the 2-3 shi ft val ve (whi ch wi l l be i n the
di rect dri ve posi ti on to the ri ght).
After passi ng the annul ar groove, the fl ui d i s
routed to the spri ng end of the 2-3 shi ft val ve. Fl ui d
pressure reacti ng on the area of l and #1 overcomes
governor pressure, downshi fti ng the 2-3 shi ft val ve
i nto the ki ckdown, or second gear stage of operati on.
The val ve i s hel d i n the ki ckdown posi ti on by throttl e
pressure routed from a seated check bal l (#2). Agai n,
i f vehi cl e speed i s l ow enough, throttl e pressure wi l l
al so push the 1-2 shi ft val ve l eft to seat i ts governor
pl ug, and downshi ft to dri ve breakaway.
Fig. 257 Kickdown Valve - Wide Open Throttle
KICKDOWN LIMIT VALVE
The purpose of the l i mi t val ve i s to prevent a 3-2
downshi ft at hi gher speeds when a part-throttl e
downshi ft i s not desi rabl e. At these hi gher speeds
onl y a ful l throttl e 3-2 downshi ft wi l l occur. At l ow
road speeds (Fi g. 258) the l i mi t val ve does not come
i nto pl ay and does not affect the downshi fts. As the
vehi cl es speed i ncreases (Fi g. 259), the governor
pressure al so i ncreases. The i ncreased governor pres-
sure acts on the reacti on area of the bottom l and of
the l i mi t val ve overcomi ng the spri ng force tryi ng to
push the val ve toward the bottom of i ts bore. Thi s
pushes the val ve upward agai nst the spri ng and bot-
toms the val ve agai nst the top of the housi ng. Wi th
the val ve bottomed agai nst the housi ng, the throttl e
pressure suppl i ed to the val ve wi l l be cl osed off by
the bottom l and of the l i mi t val ve. When the suppl y
of throttl e pressure has been shut off, the 3-2 part
throttl e downshi ft pl ug becomes i noperati ve, because
no pressure i s acti ng on i ts reacti on area.
Fig. 258 Kickdown Limit Valve - Low Speeds
Fig. 259 Kickdown Limit Valve - High Speeds
1-2 SHIFT VALVE
The 1-2 shi ft val ve assembl y (Fi g. 260), or mecha-
ni sm, consi sts of: the 1-2 shi ft val ve, governor pl ug,
and a spri ng on the end of the val ve. After the man-
ual val ve has been pl aced i nto a forward gear range,
l i ne pressure i s di rected to the 1-2 shi ft val ve. As the
throttl e i s depressed, throttl e pressure i s appl i ed to
the ri ght si de of the 1-2 shi ft val ve assembl y. Wi th
throttl e pressure appl i ed to the ri ght si de of the
val ve, there i s now both spri ng pressure and throttl e
pressure acti ng on the val ve, hol di ng i t agai nst the
governor pl ug. As the vehi cl e begi ns to move and
bui l d speed, governor pressure i s created and i s
appl i ed to the l eft of the val ve at the governor pl ug.
When governor pressure bui l ds to a poi nt where i t
can overcome the combi ned force of the spri ng and
throttl e pressure on the other si de of the val ve, the
val ve wi l l begi n to move over to the ri ght. As the
val ve moves to the ri ght, the mi ddl e l and of the val ve
wi l l cl ose off the ci rcui t suppl yi ng the throttl e pres-
sure to the ri ght si de of the val ve. When the throttl e
pressure i s cl osed off, the val ve wi l l move even far-
ther to the ri ght, al l owi ng l i ne pressure to enter
another ci rcui t and energi ze the front servo, appl yi ng
the front band (Fi g. 261).
The governor pl ug serves a dual purpose:
I t al l ows the shi ft val ves to move ei ther l eft or
ri ght, al l owi ng both upshi fts and downshi fts.
When i n a manual sel ecti on posi ti on, i t wi l l be
hydraul i cal l y bl ocked i nto posi ti on so no upshi ft can
occur.
The physi cal bl ocki ng of the upshi ft whi l e i n the
manual 1 posi ti on i s accompl i shed by the di recti ng
of l i ne pressure between both l ands of the governor
pl ug. The l i ne pressure reacts agai nst the l arger l and
of the pl ug, pushi ng the pl ug back agai nst the end
pl ate overcomi ng governor pressure. Wi th the combi -
nati on of the l i ne pressure and spri ng pressure, the
val ve cannot move, preventi ng any upshi ft.
Fig. 260 1-2 Shift Valve - Before Shift
Fig. 261 1-2 Shift Valve - After Shift
1-2 SHIFT CONTROL VALVE
I t contai ns a val ve wi th four l ands and a spri ng. I t
i s used as both a rel ay and bal anced val ve.
The val ve has two speci fi c operati ons (Fi g. 262):
Ai d i n qual i ty of the 1-2 upshi ft.
Ai d i n the qual i ty and ti mi ng of the 3-2 ki ck-
down ranges.
When the manual val ve i s set to the DRI VE posi -
ti on and the transmi ssi on i s i n the fi rst or second
gear range, 1-2 shi ft control or modul ated throttl e
pressure i s suppl i ed to the mi ddl e of the accumul a-
tor pi ston by the 1-2 shi ft control val ve. Duri ng the
1-2 upshi ft, thi s pressure i s used to control the ki ck-
down servo appl y pressure that i s needed to appl y
the ki ckdown and accumul ator pi stons. Thus, the 1-2
shi ft poi nt i s cushi oned and the qual i ty i s
i mproved. Duri ng a WOT ki ckdown, ki ckdown pres-
sure i s appl i ed between the ki ckdown val ve and the
1-2 shi ft control val ve. Thi s addi ti onal pressure i s
di rected to the 1-2 shi ft control s spri ng cavi ty, add-
i ng to the spri ng l oad on the val ve. The resul t of thi s
i ncreased modul ated throttl e pressure i s a fi rmer
WOT upshi ft.
Fig. 262 1-2 Shift Control Valve
2-3 SHIFT VALVE
The 2-3 shi ft val ve mechani sm (Fi g. 263) consi sts
of the 2-3 shi ft val ve, governor pl ug and spri ng, and
a throttl e pl ug. After the 1-2 shi ft val ve has com-
pl eted i ts operati on and appl i ed the front band, l i ne
pressure i s di rected to the 2-3 shi ft val ve through the
connecti ng passages from the 1-2 shi ft val ve. The l i ne
pressure wi l l then deadend at l and #2 unti l the 2-3
val ve i s ready to make i ts shi ft. Now that the vehi cl e
i s i n moti on and under accel erati on, there i s throttl e
pressure bei ng appl i ed to the spri ng si de of the val ve
and between l ands #3 and #4.
As vehi cl e speed i ncreases, governor pressure
i ncreases proporti onatel y, unti l i t becomes great
enough to overcome the combi ned throttl e and spri ng
pressure on the ri ght si de of the val ve. Si nce the
throttl e pressure end of the 2-3 shi ft val ve i s l arger
i n di ameter than the 1-2 shi ft val ve, the 2-3 shi ft wi l l
al ways happen at a greater speed than the 1-2 shi ft.
When thi s happens, the governor pl ug i s forced
agai nst the shi ft val ve movi ng i t to the ri ght. The
shi ft val ve causes l and #4 to cl ose the passage sup-
pl yi ng throttl e pressure to the 2-3 shi ft val ve. Wi th-
out throttl e pressure present i n the ci rcui t now, the
governor pl ug wi l l push the val ve over far enough to
bottom the val ve i n i ts bore. Thi s al l ows l and #2 to
di rect l i ne pressure to the front cl utch.
After the shi ft (Fi g. 264), l i ne pressure i s di rected
to the rel ease si de of the ki ckdown servo. Thi s
rel eases the front band and appl i es the front cl utch,
shi fti ng i nto thi rd gear or di rect dri ve. The rear
cl utch remai ns appl i ed, as i t has been i n the other
gears. Duri ng a manual 1 or manual 2 gear sel ec-
ti on, l i ne pressure i s sent between the two l ands of
the 2-3 governor pl ug. Thi s l i ne pressure at the gov-
ernor pl ug l ocks the shi ft val ve i nto the second gear
posi ti on, preventi ng an upshi ft i nto di rect dri ve. The
theory for the bl ocki ng of the val ve i s the same as
that of the 1-2 shi ft val ve.
I f the manual 2 or manual 1 gear posi ti on i s
sel ected from the dri ve posi ti on, the PCM wi l l control
the ti mi ng of the downshi ft by targeti ng for a hi gh
governor pressure. When a safe vehi cl e speed i s
reached, the PCM wi l l swi tch to i ts normal control
governor curve and the downshi ft wi l l occur.
3-4 SHIFT VALVE
The PCM energi zes the overdri ve sol enoi d duri ng
the 3-4 upshi ft (Fi g. 265). Thi s causes the sol enoi d
check bal l to cl ose the vent port al l owi ng l i ne pres-
sure from the 2-3 shi ft val ve to act di rectl y on the 3-4
upshi ft val ve. Li ne pressure on the 3-4 shi ft val ve
overcomes val ve spri ng pressure movi ng the val ve to
the upshi ft posi ti on (Fi g. 266). Thi s acti on exposes
the feed passages to the 3-4 ti mi ng val ve, 3-4 qui ck
fi l l val ve, 3-4 accumul ator, and ul ti matel y to the
overdri ve pi ston.
Fig. 263 2-3 Shift Valve - Before Shift
Fig. 264 2-3 Shift Valve - After Shift
Fig. 265 3-4 Shift Valve Before Shift Fig. 266 3-4 Shift Valve After Shift
3-4 TIMING VALVE
The 3-4 ti mi ng val ve i s moved by l i ne pressure
comi ng through the 3-4 shi ft val ve (Fi g. 266) or the
converter cl utch val ve. After the shi ft, the ti mi ng
val ve hol ds the 2-3 shi ft val ve i n an upshi ft posi ti on.
The purpose i s to prevent the 2-3 val ve from down-
shi fti ng whi l e ei ther the overdri ve cl utch or converter
cl utch i s appl i ed (Fi g. 265).
3-4 QUICK FILL VALVE
The 3-4 qui ck fi l l val ve provi des faster engagement
of the overdri ve cl utch duri ng 3-4 upshi fts. The val ve
temporari l y bypasses the cl utch pi ston feed ori fi ce at
the start of a 3-4 upshi ft (Fi g. 265). Thi s exposes a
l arger passage i nto the pi ston retai ner resul ti ng i n a
much faster cl utch fi l l and appl y sequence. The qui ck
fi l l val ve does not bypass the regul ar cl utch feed ori -
fi ce throughout the 3-4 upshi ft. I nstead, once a pre-
determi ned pressure devel ops wi thi n the cl utch, the
val ve cl oses the bypass (Fi g. 266). Cl utch fi l l i s then
compl eted through the regul ar feed ori fi ce.
THROTTLE VALVE
I n al l gear posi ti ons the throttl e val ve (Fi g. 267) i s
bei ng suppl i ed wi th l i ne pressure. The throttl e val ve
meters and reduces the l i ne pressure that now
becomes throttl e pressure. The throttl e val ve i s
moved by a spri ng and the ki ckdown val ve, whi ch i s
mechani cal l y connected to the throttl e. The l arger
the throttl e openi ng, the hi gher the throttl e pressure
(to a maxi mum of l i ne pressure). The smal l er the
throttl e openi ng, the l ower the throttl e pressure (to a
mi ni mum of zero at i dl e). As engi ne speed i ncreases,
the i ncrease i n pump speed i ncreases pump output.
The i ncrease i n pressure and vol ume must be regu-
l ated to mai ntai n the bal ance wi thi n the transmi s-
si on. To do thi s, throttl e pressure i s routed to the
reacti on area on the ri ght si de of the throttl e pres-
sure pl ug (i n the regul ator val ve).
The hi gher engi ne speed and l i ne pressure woul d
open the vent too far and reduce l i ne pressure too
much. Throttl e pressure, whi ch i ncreases wi th engi ne
speed (throttl e openi ng), i s used to oppose the move-
ment of the pressure val ve to hel p control the meter-
i ng passage at the vent. The throttl e pressure i s
combi ned wi th spri ng pressure to reduce the force of
the throttl e pressure pl ug on the pressure val ve. The
l arger spri ng at the ri ght cl oses the regul ator val ve
passage and mai ntai ns or i ncreases l i ne pressure.
The i ncreased l i ne pressure works agai nst the reac-
ti on area of the l i ne pressure pl ug and the reacti on
area l eft of l and #3 si mul taneousl y moves the regu-
l ator val ve trai n to the ri ght and control s the meter-
i ng passage.
The ki ckdown val ve, al ong wi th the throttl e val ve,
serve to del ay upshi fts unti l the correct vehi cl e speed
has been reached. I t al so control s downshi fts upon
dri ver demand, or i ncreased engi ne l oad. I f these
val ves were not i n pl ace, the shi ft poi nts woul d be at
the same speed for al l throttl e posi ti ons. The ki ck-
down val ve i s actuated by a cam connected to the
throttl e. Thi s i s accompl i shed through ei ther a l i nk-
age or a cabl e. The cam forces the ki ckdown val ve
toward the throttl e val ve compressi ng the spri ng
between them and movi ng the throttl e val ve. As the
throttl e val ve l and starts to uncover i ts port, l i ne
Fig. 267 Throttle Valve
pressure i s metered out i nto the ci rcui ts and vi ewed
as throttl e pressure. Thi s i ncreased throttl e pressure
i s metered out i nto the ci rcui ts i t i s appl i ed to: the
1-2 and 2-3 shi ft val ves. When the throttl e pressure
i s hi gh enough, a 3-2 downshi ft wi l l occur. I f the
vehi cl e speed i s l ow enough, a 2-1 downshi ft wi l l
occur.
SWITCH VALVE
When the transmi ssi on i s i n Dri ve Second before
the TCC appl i cati on occurs (Fi g. 268), the pressure
regul ator val ve i s suppl yi ng torque converter pres-
sure to the swi tch val ve. The swi tch val ve di rects
thi s pressure through the transmi ssi on i nput shaft,
i nto the converter, through the converter, back out
between the i nput shaft and the reacti on shaft, and
back up to the swi tch val ve. From the swi tch val ve,
the fl ui d pressure i s di rected to the transmi ssi on
cool er, and l ubri cati on pressure returns from the
cool er to l ubri cate di fferent porti ons of the transmi s-
si on.
Fig. 268 Switch Valve - Torque Converter Unlocked
Once the TCC control val ve has moved to the ri ght
(Fi g. 269), l i ne pressure i s di rected to the ti p of the
swi tch val ve, forci ng the val ve to the ri ght. The
swi tch val ve now vents oi l from the front of the pi s-
ton i n the torque converter, and suppl i es l i ne pres-
sure to the (rear) appl y si de of the torque converter
pi ston. Thi s pressure di fferenti al causes the pi ston to
appl y agai nst the fri cti on materi al , cutti ng off any
further fl ow of l i ne pressure oi l . After the swi tch
val ve i s shuttl ed ri ght al l owi ng l i ne pressure to
engage the TCC, torque converter pressure i s
di rected past the swi tch val ve i nto the transmi ssi on
cool er and l ubri cati on ci rcui ts.
Fig. 269 Switch Valve - Torque Converter Locked
MANUAL VALVE
The manual val ve (Fi g. 270) i s a rel ay val ve. The
purpose of the manual val ve i s to di rect fl ui d to the
correct ci rcui t needed for a speci fi c gear or dri vi ng
range. The manual val ve, as the name i mpl i es, i s
manual l y operated by the dri ver wi th a l ever l ocated
on the si de of the val ve body. The val ve i s connected
mechani cal l y by ei ther a cabl e or l i nkage to the gear-
shi ft mechani sm. The val ve i s hel d i n each of i ts
posi ti ons by a spri ng-l oaded rol l er or bal l that
engages the roostercomb of the manual val ve l ever.
CONVERTER CLUTCH LOCK-UP VALVE
The torque converter cl utch (TCC) l ock-up val ve
control s the back (ON) si de of the torque converter
cl utch. When the PCM energi zes the TCC sol enoi d to
engage the converter cl utch pi ston, pressure i s
appl i ed to the TCC l ock-up val ve whi ch moves to the
ri ght and appl i es pressure to the torque converter
cl utch.
CONVERTER CLUTCH LOCK-UP TIMING VALVE
The torque converter cl utch (TCC) l ock-up ti mi ng
val ve i s there to bl ock any 4-3 downshi ft unti l the
TCC i s compl etel y unl ocked and the cl utch i s di sen-
gaged.
SHUTTLE VALVE
The assembl y i s contai ned i n a bore i n the val ve
body above the shi ft val ves. When the manual val ve
i s posi ti oned i n the Dri ve range, throttl e pressure
acts on the throttl e pl ug of the shuttl e val ve (Fi g.
262) to move i t agai nst a spri ng, i ncreasi ng the
spri ng force on the shuttl e val ve. Duri ng a part or
ful l throttl e 1-2 upshi ft, the throttl e pl ug i s bottomed
by throttl e pressure, hol di ng the shuttl e val ve to the
ri ght agai nst governor pressure, and openi ng a
bypass ci rcui t. The shuttl e val ve control s the qual -
i ty of the ki ckdown shi ft by restri cti ng the rate of
fl ui d di scharge from the front cl utch and servo
rel ease ci rcui ts. Duri ng a 3-2 ki ckdown, fl ui d di s-
charges through the shuttl e by-pass ci rcui t. When
the shuttl e val ve cl oses the by-pass ci rcui t, fl ui d di s-
charge i s restri cted and control l ed for the appl i cati on
of the front band. Duri ng a 2-3 l i ft foot upshi ft, the
shuttl e val ve by-passes the restri cti on to al l ow ful l
fl ui d fl ow through the by-pass groove for a faster
rel ease of the band.
Fig. 270 Manual Valve
BOOST VALVE
The boost val ve (Fi g. 271) provi des i ncreased fl ui d
appl y pressure to the overdri ve cl utch duri ng 3-4
upshi fts (Fi g. 272), and when accel erati ng i n fourth
gear. The boost val ve al so serves to i ncrease l i ne
pressure duri ng torque converter l ock-up.
REMOVAL
The val ve body can be removed for servi ce wi thout
havi ng to remove the transmi ssi on assembl y.
The val ve body can be di sassembl ed for cl eani ng
and i nspecti on of the i ndi vi dual components.
The onl y repl aceabl e val ve body components are:
Manual l ever.
Manual l ever washer, seal , E-cl i p, and shaft
seal .
Manual l ever detent bal l .
Throttl e l ever.
Fl ui d fi l ter.
Pressure adjusti ng screw bracket.
Governor pressure sol enoi d.
Governor pressure sensor (i ncl udes transmi ssi on
temperature thermi stor).
Converter cl utch/overdri ve sol enoi d assembl y
and harness.
Governor housi ng gasket.
Sol enoi d case connector O-ri ngs.
(1) Shi ft transmi ssi on i nto NEUTRAL.
(3) Remove gearshi ft and throttl e l evers from shaft
of val ve body manual l ever.
(4) Di sconnect wi res at sol enoi d case connector
(Fi g. 273).
(5) Remove the transmi ssi on range sensor (Refer
to 21 - TRANSMI SSI ON/AUTOMATI C/TRANSMI S-
SI ON RANGE SENSOR - REMOVAL).
(6) Posi ti on drai n pan under transmi ssi on oi l pan.
(7) Remove transmi ssi on oi l pan and gasket.
(8) Remove fl ui d fi l ter from val ve body.
(9) Remove bol ts attachi ng val ve body to transmi s-
si on case.
(10) Lower val ve body enough to remove accumu-
l ator pi ston and spri ngs.
Fig. 273 Transmission Case Connector
Fig. 271 Boost Valve Before Lock-up
Fig. 272 Boost Valve After Lock-up
(11) Work manual l ever shaft and el ectri cal con-
nector out of transmi ssi on case.
(12) Lower val ve body, rotate val ve body away
from case, pul l park rod out of sprag, and remove
val ve body (Fi g. 274).
DISASSEMBLY
CAUTION: Do not clamp any valve body component
in a vise. This practice can damage the component
resulting in unsatisfactory operation after assembly
and installation. Do not use pliers to remove any of
the valves, plugs or springs and do not force any of
the components out or into place. The valves and
valve body housings will be damaged if force is
used. Tag or mark the valve body springs for refer-
ence as they are removed. Do not allow them to
become intermixed.
(1) Di sconnect wi res from governor pressure sen-
sor and sol enoi d.
(2) Remove screws attachi ng governor body and
retai ner pl ate to transfer pl ate.
(3) Remove retai ner pl ate, governor body and gas-
ket from transfer pl ate.
(4) Remove governor pressure sensor from gover-
nor body.
(5) Remove governor pressure sol enoi d by pul l i ng
i t strai ght out of bore i n governor body. Remove and
di scard sol enoi d O-ri ngs i f worn, cut, or torn.
(6) Remove smal l shoul der bol t that secures sol e-
noi d harness case connector to 3-4 accumul ator hous-
i ng (Fi g. 275). Retai n shoul der bol t. Ei ther tape i t to
harness or thread i t back i nto accumul ator housi ng
after connector removal .
(7) Unhook overdri ve/converter sol enoi d harness
from 3-4 accumul ator cover pl ate (Fi g. 276).
Fig. 275 Solenoid Harness Case Connector
Shoulder Bolt
1 - SOLENOID HARNESS CASE CONNECTOR
Fig. 276 Solenoid Harness Routing
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
Fig. 274 Valve Body
1 - VALVE BODY
2 - WIRE HARNESS
3 - PARK ROD
5 - GOVERNOR PRESSURE SENSOR
(8) Turn val ve body over and remove screws that
attach overdri ve/converter sol enoi d assembl y to val ve
body (Fi g. 277).
(9) Remove sol enoi d and harness assembl y from
val ve body (Fi g. 278).
(10) Remove boost val ve cover (Fi g. 279).
(11) Remove boost val ve retai ner, val ve spri ng and
boost val ve (Fi g. 280).
Fig. 277 Solenoid Assembly Screws
1 - OVERDRIVE/CONVERTER CLUTCH SOLENOID ASSEMBLY
2 - HARNESS
Fig. 278 Solenoid Assembly
1 - GOVERNOR SOLENOID WIRES
2 - CONVERTER CLUTCH SOLENOID
3 - SOLENOID SCREWS
4 - GOVERNOR SENSOR WIRES
5 - OVERDRIVE SOLENOID
6 - HARNESS
7 - CASE CONNECTOR
Fig. 279 Boost Valve Cover Location
1 - BOOST VALVE HOUSING AND COVER
2 - BOOST VALVE TUBE
Fig. 280 Boost Valve Components
1 - SPRING AND VALVE RETAINER
2 - COVER SCREWS
3 - BOOST VALVE COVER
4 - BOOST VALVE PLUG
5 - BOOST VALVE
6 - BOOST VALVE SPRING
(12) Secure detent bal l and spri ng wi th Retai ner
Tool 6583 (Fi g. 281).
(13) Remove park rod E-cl i p and separate rod from
manual l ever (Fi g. 282).
(14) Remove E-cl i p and washer that retai ns throt-
tl e l ever shaft i n manual l ever (Fi g. 283).
(15) Remove manual l ever and throttl e l ever (Fi g.
284). Rotate and l i ft manual l ever off val ve body and
throttl e l ever shaft. Then sl i de throttl e l ever out of
val ve body.
(16) Posi ti on penci l magnet next to detent housi ng
to catch detent bal l and spri ng. Then careful l y
remove Retai ner Tool 6583 and remove detent bal l
and spri ng (Fi g. 285).
Fig. 281 Detent Ball Spring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 282 Park Rod
1 - MANUAL LEVER
2 - E-CLIP
3 - PARK ROD
Fig. 283 Throttle Lever E-Clip And Washer
1 - THROTTLE LEVER SHAFT
2 - E-CLIP AND WASHER
3 - MANUAL SHAFT
Fig. 284 Manual And Throttle Lever
1 - PARK ROD
2 - MANUAL LEVER ASSEMBLY
3 - THROTTLE LEVER
Fig. 285 Detent Ball And Spring
1 - DETENT HOUSING
2 - DETENT SPRING
3 - DETENT BALL
4 - PENCIL MAGNET
(17) Remove screws attachi ng pressure adjusti ng
screw bracket to val ve body and transfer pl ate (Fi g.
286). Hol d bracket fi rml y agai nst spri ng tensi on
whi l e removi ng l ast screw.
(18) Remove adjusti ng screw bracket, l i ne pressure
adjusti ng screw, pressure regul ator val ve spri ng and
swi tch val ve spri ng (Fi g. 287). Do not remove throttl e
pressure adjusti ng screw from bracket and do not
di sturb setti ng of ei ther adjusti ng screw duri ng
removal .
(19) Turn upper housi ng over and remove swi tch
val ve, regul ator val ve and spri ng, and manual val ve
(Fi g. 288).
(20) Remove ki ckdown detent, ki ckdown val ve, and
throttl e val ve and spri ng (Fi g. 288).
(21) Loosen l eft-si de 3-4 accumul ator housi ng
attachi ng screw about 2-3 threads. Then remove cen-
ter and ri ght-si de housi ng attachi ng screws (Fi g.
289).
(22) Careful l y rotate 3-4 accumul ator housi ng
upward and remove 3-4 shi ft val ve spri ng and con-
verter cl utch val ve pl ug and spri ng (Fi g. 290).
Fig. 287 Adjusting Screw Bracket
1 - SWITCH VALVE SPRING
2 - LINE PRESSURE SCREW
3 - THROTTLE PRESSURE ADJUSTING SCREW
4 - ADJUSTING SCREW BRACKET
5 - PRESSURE REGULATOR VALVE SPRING
Fig. 286 Adjusting Screw Bracket Fastener
1 - T25 TORX BIT
2 - REMOVE THESE SCREWS FIRST
3 - BRACKET
4 - BRACKET
5 - REMOVE THIS SCREW LAST
Fig. 289 Accumulator Housing Screw Locations
1 - LOOSEN THIS SCREW
2 - REMOVE THESE SCREWS
Fig. 290 3-4 Shift And Converter Clutch Valve
Springs and Plug
1 - ACCUMULATOR HOUSING
2 - CONVERTER CLUTCH VALVE SPRING
3 - CLUTCH VALVE PLUG
4 - 3-4 SHIFT VALVE SPRING
(23) Remove l eft-si de screw and remove 3-4 accu-
mul ator housi ng from val ve body (Fi g. 291).
(24) Bend back tabs on boost val ve tube brace (Fi g.
292).
(25) Remove boost val ve connecti ng tube (Fi g.
293). Di sengage tube from upper housi ng port fi rst.
Then rock opposi te end of tube back and forth to
work i t out of l ower housi ng.
CAUTION: Do not use tools to loosen or pry the
connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.
(26) Turn val ve body over so l ower housi ng i s fac-
i ng upward (Fi g. 294). I n thi s posi ti on, the two check
bal l s i n upper housi ng wi l l remai n i n pl ace and not
fal l out when l ower housi ng and separator pl ate are
removed.
(27) Remove screws attachi ng val ve body l ower
housi ng to upper housi ng and transfer pl ate (Fi g.
294). Note posi ti on of boost val ve tube brace for
assembl y reference.
(28) Remove l ower housi ng and overdri ve separa-
tor pl ate from transfer pl ate (Fi g. 294).
Fig. 293 Boost Valve Tube
2 - LOWER HOUSING
3 - DISENGAGE THIS END OF TUBE FIRST
4 - UPPER HOUSING
Fig. 294 Lower Housing
1 - LOWER HOUSING
2 - OVERDRIVE SEPARATOR PLATE
3 - TRANSFER PLATE AND UPPER HOUSING
Fig. 291 Accumulator Housing, Valve Springs, and
Plug
2 - CONVERTER CLUTCH VALVE SPRING AND PLUG
Fig. 292 Boost Valve Tube Brace
2 - TUBE BRACE (DOUBLE TAB)
(29) Remove the Number 10 check bal l from the
transfer pl ate (Fi g. 295). The check bal l i s approxi -
matel y 4.8 mm (3/16 i n.) i n di ameter.
(30) Remove transfer pl ate from upper housi ng
(Fi g. 296).
(31) Turn transfer pl ate over so upper housi ng sep-
arator pl ate i s faci ng upward.
(32) Remove upper housi ng separator pl ate from
transfer pl ate (Fi g. 297). Note posi ti on of fi l ter i n
separator pl ate for assembl y reference.
(33) Remove rear cl utch and rear servo check bal l s
from transfer pl ate. Note check bal l l ocati on for
assembl y reference (Fi g. 298).
Fig. 295 Number 10 Check Ball
1 - NUMBER 10 CHECK BALL (3/16)
Fig. 296 Transfer Plate
1 - UPPER HOUSING
2 - TRANSFER PLATE
Fig. 297 Upper Housing Separator Plate
1 - TRANSFER PLATE
2 - UPPER HOUSING SEPARATOR PLATE
3 - FILTER SCREEN
4 - BRACE
Fig. 298 Rear Clutch and Rear Servo Check Ball
Locations
1 - REAR CLUTCH CHECK BALL
2 - REAR SERVO CHECK BALL
3 - TRANSFER PLATE
VALVE BODY UPPER HOUSING
(1) Note l ocati on of check bal l s i n val ve body upper
housi ng (Fi g. 299). Then remove the one l arge di am-
eter and the fi ve smal l er di ameter check bal l s.
(2) Remove governor pl ug and shuttl e val ve covers
(Fi g. 301).
(3) Remove E-cl i p that secures shuttl e val ve sec-
ondary spri ng on val ve stem (Fi g. 300).
(4) Remove throttl e pl ug, pri mary spri ng, shuttl e
val ve, secondary spri ng, and spri ng gui des (Fi g. 301).
(5) Remove boost val ve retai ner, spri ng and val ve
i f not previ ousl y removed.
(6) Remove throttl e pl ug and 1-2 and 2-3 governor
pl ugs (Fi g. 288).
(7) Turn upper housi ng around and remove l i mi t
val ve and shi ft val ve covers (Fi g. 302).
(8) Remove l i mi t val ve housi ng. Then remove
retai ner, spri ng, l i mi t val ve, and 2-3 throttl e pl ug
from l i mi t val ve housi ng (Fi g. 302).
(9) Remove 1-2 shi ft control val ve and spri ng (Fi g.
302).
(10) Remove 1-2 shi ft val ve and spri ng (Fi g. 302).
(11) Remove 2-3 shi ft val ve and spri ng from val ve
body (Fi g. 302).
(12) Remove pressure pl ug cover (Fi g. 302).
(13) Remove l i ne pressure sl eeve, throttl e pressure
pl ug and spri ng (Fi g. 302).
Fig. 299 Check Ball Locations In Upper Housing
1 - SMALL DIAMETER CHECK BALLS (5)
2 - LARGE DIAMETER CHECK BALL (1)
Fig. 300 Shuttle Valve E-Clip And Secondary Spring
1 - E-CLIP
2 - SECONDARY SPRING AND GUIDES
3 - SHUTTLE VALVE
Fig. 301 Shuttle and Boost Valve Location
VALVE BODY LOWER HOUSING
(1) Remove ti mi ng val ve cover.
(2) Remove 3-4 ti mi ng val ve and spri ng.
(3) Remove 3-4 qui ck fi l l val ve, spri ng and pl ug.
(4) Remove 3-4 shi ft val ve and spri ng.
(5) Remove converter cl utch val ve, spri ng and pl ug
(Fi g. 303).
(6) Remove converter cl utch ti mi ng val ve, retai ner
and val ve spri ng.
3-4 ACCUMULATOR HOUSING
(1) Remove end pl ate from housi ng.
(2) Remove pi ston spri ng.
(3) Remove pi ston. Remove and di scard pi ston
seal s (Fi g. 304).
CLEANING
Cl ean the val ve housi ngs, val ves, pl ugs, spri ngs,
and separator pl ates wi th a standard parts cl eani ng
sol uti on onl y. Do not use gasol i ne, kerosene, or any
type of causti c sol uti on.
Do not i mmerse any of the el ectri cal components i n
cl eani ng sol uti on. Cl ean the governor sol enoi d and
sensor and the dual sol enoi d and harness assembl y
by wi pi ng them off wi th dry shop towel s onl y.
Dry al l except the el ectri cal parts wi th compressed
ai r. Make sure al l passages are cl ean and free from
obstructi ons. Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
Wi pe the governor pressure sensor and sol enoi d
val ve wi th dry, l i nt free shop towel s onl y. The O-ri ngs
on the sensor and sol enoi d val ve are the onl y servi ce-
abl e components. Be sure the vent ports i n the sol e-
noi d val ve are open and not bl ocked by di rt or debri s.
Repl ace the val ve and/or sensor onl y when DRB scan
tool di agnosi s i ndi cates thi s i s necessary. Or, i f ei ther
part has sustai ned physi cal damage (dented,
deformed, broken, etc.).
CAUTION: Do not turn the small screw at the end of
the solenoid valve for any reason. Turning the
screw in either direction will ruin solenoid calibra-
tion and result in solenoid failure. In addition, the
filter on the solenoid valve is NOT serviceable. Do
not try to remove the filter as this will damage the
valve housing.
INSPECTION
I nspect the throttl e and manual val ve l evers and
shafts. Do not attempt to strai ghten a bent shaft or
correct a l oose l ever. Repl ace these components i f
worn, bent, l oose or damaged i n any way.
I nspect al l of the val ve body mati ng surfaces for
scratches, ni cks, burrs, or di storti on. Use a strai ght-
edge to check surface fl atness. Mi nor scratches may
be removed wi th crocus cl oth usi ng onl y very l i ght
pressure.
Mi nor di storti on of a val ve body mati ng surface
may be corrected by smoothi ng the surface wi th a
sheet of crocus cl oth. Posi ti on the crocus cl oth on a
surface pl ate, sheet of pl ate gl ass or equal l y fl at sur-
face. I f di storti on i s severe or any surfaces are
heavi l y scored, the val ve body wi l l have to be
repl aced.
CAUTION: Many of the valves and plugs, such as
the throttle valve, shuttle valve plug, 1-2 shift valve
and 1-2 governor plug, are made of coated alumi-
num. Aluminum components are identified by the
dark color of the special coating applied to the sur-
face (or by testing with a magnet). Do not sand alu-
minum valves or plugs under any circumstances.
This practice could damage the special coating
causing the valves/plugs to stick and bind.
I nspect the val ves and pl ugs for scratches, burrs,
ni cks, or scores. Mi nor surface scratches on steel
val ves and pl ugs can be removed wi th crocus cl oth
but do not round off the edges of the valve or
plug lands.Mai ntai ni ng sharpness of these edges i s
vi tal l y i mportant. The edges prevent forei gn matter
from l odgi ng between the val ves and pl ugs and the
bore.
I nspect al l the val ve and pl ug bores i n the val ve
body. Use a penl i ght to vi ew the bore i nteri ors.
Repl ace the val ve body i f any bores are di storted or
scored. I nspect al l of the val ve body spri ngs. The
spri ngs must be free of di storti on, warpage or broken
coi l s.
3 - TEFLON SEALS
4 - PISTON SPRING
Check the two separator pl ates for di storti on or
damage of any ki nd. I nspect the upper housi ng,
l ower housi ng, 3-4 accumul ator housi ng, and transfer
pl ate careful l y. Be sure al l fl ui d passages are cl ean
and cl ear. Check condi ti on of the upper housi ng and
transfer pl ate check bal l s as wel l . The check bal l s
and bal l seats must not be worn or damaged.
Tri al fi t each val ve and pl ug i n i ts bore to check
freedom of operati on. When cl ean and dry, the val ves
and pl ugs shoul d drop freel y i nto the bores.
Val ve body bores do not change di mensi onal l y wi th
use. I f the val ve body functi oned correctl y when new,
i t wi l l conti nue to operate properl y after cl eani ng and
i nspecti on. I t shoul d not be necessary to repl ace a
val ve body assembl y unl ess i t i s damaged i n han-
dl i ng.
The onl y servi ceabl e val ve body components are
l i sted bel ow. The remai ni ng val ve body components
are servi ced onl y as part of a compl ete val ve body
assembl y. Servi ceabl e parts are:
dual sol enoi d and harness assembl y
sol enoi d gasket
sol enoi d case connector O-ri ngs and shoul der
bol t
swi tch val ve and spri ng
pressure adjusti ng screw and bracket assembl y
throttl e l ever
manual l ever and shaft seal
throttl e l ever shaft seal , washer, and E-cl i p
fl ui d fi l ter and screws
detent bal l and spri ng
val ve body screws
governor pressure sol enoi d
governor pressure sensor and retai ni ng cl i p
park l ock rod and E-cl i p
ASSEMBLY
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the housings resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recom-
mended torque only.
LOWER HOUSING
(1) Lubri cate val ves, spri ngs, and the housi ng
val ve and pl ug bores wi th cl ean transmi ssi on fl ui d
(Fi g. 305).
(2) I nstal l 3-4 ti mi ng val ve spri ng and val ve i n
l ower housi ng.
(3) I nstal l 3-4 qui ck fi l l val ve i n l ower housi ng.
(4) I nstal l 3-4 qui ck fi l l val ve spri ng and pl ug i n
housi ng.
(5) I nstal l ti mi ng val ve end pl ate. Ti ghten end
pl ate screws to 4 Nm (35 i n. l bs.) torque.
3-4 ACCUMULATOR
(1) Lubri cate accumul ator pi ston, seal s and hous-
i ng pi ston bore wi th cl ean transmi ssi on fl ui d (Fi g.
306).
(2) I nstal l new seal ri ngs on accumul ator pi ston.
(3) I nstal l pi ston and spri ng i n housi ng.
(4) I nstal l end pl ate on housi ng.
TRANSFER PLATE
(1) I nstal l rear cl utch and rear servo check bal l s i n
transfer pl ate (Fi g. 307).
(2) I nstal l fi l ter screen i n upper housi ng separator
pl ate (Fi g. 308).
(3) Al i gn and posi ti on upper housi ng separator
pl ate on transfer pl ate (Fi g. 309).
(4) I nstal l brace pl ate (Fi g. 309). Ti ghten brace
attachi ng screws to 4 Nm (35 i n. l bs.) torque.
(5) I nstal l remai ni ng separator pl ate attachi ng
screws. Ti ghten screws to 4 Nm (35 i n. l bs.) torque.
3 - TEFLON SEALS
4 - PISTON SPRING
Fig. 307 Rear Clutch And Rear Servo Check Ball
Locations
1 - REAR CLUTCH CHECK BALL
2 - REAR SERVO CHECK BALL
3 - TRANSFER PLATE
Fig. 308 Separator Plate Filter Screen Installation
1 - UPPER HOUSING SEPARATOR PLATE
2 - FILTER SCREEN
Fig. 309 Brace Plate
1 - BRACE
2 - TRANSFER PLATE
3 - SEPARATOR PLATE
UPPER AND LOWER HOUSING
(1) Posi ti on upper housi ng so i nternal passages
and check bal l seats are faci ng upward. Then i nstal l
check bal l s i n housi ng (Fi g. 310). Seven check bal l s
are used. The si ngl e l arge check bal l i s approxi -
matel y 8.7 mm (11/32 i n.) di ameter. The si ngl e smal l
check bal l i s approxi matel y 4.8 mm (3/16 i n.) i n
di ameter. The remai ni ng 5 check bal l s are approxi -
(2) Posi ti on assembl ed transfer pl ate and upper
housi ng separator pl ate on upper housi ng (Fi g. 311).
Be sure fi l ter screen i s seated i n proper housi ng
recess.
(3) I nstal l the Number 10 check bal l i nto the
transfer pl ate (Fi g. 312). The check bal l i s approxi -
(4) Posi ti on l ower housi ng separator pl ate on
transfer pl ate (Fi g. 313).
Fig. 310 Check Ball Locations In Upper Housing
1 - SMALL DIAMETER CHECK BALLS (5)
2 - LARGE DIAMETER CHECK BALL (1)
Fig. 311 Installing Transfer Plate On Upper Housing
1 - FILTER SCREEN
2 - TRANSFER PLATE/SEPARATOR PLATE ASSEMBLY
3 - UPPER HOUSING
Fig. 312 Number 10 Check Ball
1 - NUMBER 10 CHECK BALL (3/16)
Fig. 313 Lower Housing Separator Plate
1 - BE SURE TO ALIGN BORES
2 - TRANSFER PLATE
3 - LOWER HOUSING (OVERDRIVE) SEPARATOR PLATE
(5) I nstal l l ower housi ng on assembl ed transfer
pl ate and upper housi ng (Fi g. 314).
(6) I nstal l and start al l val ve body screws by hand
except for the screws to hol d the boost val ve tube
brace. Save those screws for l ater i nstal l ati on. Then
ti ghten screws evenl y to 4 Nm (35 i n. l bs.) torque.
Start at center and work out to si des when ti ghten-
i ng screws (Fi g. 314).
UPPER HOUSING VALVE AND PLUG
Refer to (Fi g. 315), (Fi g. 316) and (Fi g. 317) to per-
form the fol l owi ng steps.
(1) Lubri cate val ves, pl ugs, spri ngs wi th cl ean
(2) Assembl e regul ator val ve l i ne pressure sl eeve,
throttl e pl ug and spri ng. I nsert assembl y i n upper
housi ng and i nstal l cover pl ate. Ti ghten cover pl ate
screws to 4 Nm (35 i n. l bs.) torque.
(3) I nstal l 1-2 and 2-3 shi ft val ves and spri ngs.
(4) I nstal l 1-2 shi ft control val ve and spri ng.
Fig. 314 Installing Lower Housing On Transfer Plate
And Upper Housing
1 - VALVE BODY SCREWS (13)
2 - LOWER HOUSING
3 - UPPER HOUSING
4 - TRANSFER PLATE
Fig. 315 Shuttle and Boost Valve Locations
(5) I nstal l retai ner, spri ng, l i mi t val ve, and 2-3
throttl e pl ug from l i mi t val ve housi ng.
(6) I nstal l l i mi t val ve housi ng and cover pl ate.
Ti ghten screws to 4 Nm (35 i n. l bs.).
(7) I nstal l shuttl e val ve as fol l ows:
(a) I nsert pl asti c gui des i n shuttl e val ve second-
ary spri ng and i nstal l spri ng on end of val ve.
(b) I nstal l shuttl e val ve i nto housi ng.
(c) Hol d shuttl e val ve i n pl ace.
(d) Compress secondary spri ng and i nstal l E-cl i p
i n groove at end of shuttl e val ve.
(e) Veri fy that spri ng and E-cl i p are properl y
seated before proceedi ng.
(8) I nstal l shuttl e val ve cover pl ate. Ti ghten cover
pl ate screws to 4 Nm (35 i n. l bs.) torque.
(9) I nstal l 1-2 and 2-3 val ve governor pl ugs i n
val ve body.
(10) I nstal l shuttl e val ve pri mary spri ng and
throttl e pl ug.
(11) Al i gn and i nstal l governor pl ug cover. Ti ghten
cover screws to 4 Nm (35 i n. l bs.) torque.
BOOST VALVE TUBE AND BRACE
(1) Posi ti on val ve body assembl y so l ower housi ng
i s faci ng upward (Fi g. 318).
(2) Lubri cate tube ends and housi ng ports wi th
transmi ssi on fl ui d or petrol eum jel l y.
(3) Start tube i n l ower housi ng port fi rst. Then
swi ng tube downward and work opposi te end of tube
i nto upper housi ng port (Fi g. 318).
(4) I nsert and seat each end of tube i n housi ngs.
(5) Sl i de tube brace under tube and i nto al i gnment
wi th val ve body screw hol es (Fi g. 319).
(6) I nstal l and fi nger ti ghten three screws that
secure tube brace to val ve body housi ngs (Fi g. 319).
(7) Bend tube brace tabs up and agai nst tube to
hol d i t i n posi ti on (Fi g. 320).
(8) Ti ghten al l val ve body housi ng screws to 4 Nm
(35 i n. l bs.) torque after tube and brace are i nstal l ed.
Ti ghten screws i n di agonal pattern starti ng at center
and worki ng outward.
Fig. 318 Boost Valve Tube
2 - LOWER HOUSING
3 - DISENGAGE THIS END OF TUBE FIRST
4 - UPPER HOUSING
Fig. 319 Boost Valve Tube And Brace
2 - TUBE BRACE
Fig. 320 Securing Boost Valve Tube With Brace
Tabs
1 - BEND TABS UP AGAINST TUBE AS SHOWN
3-4 ACCUMULATOR
(1) Posi ti on converter cl utch val ve and 3-4 shi ft
val ve spri ngs i n housi ng (Fi g. 321).
(2) Loosel y attach accumul ator housi ng wi th ri ght-
si de screw (Fi g. 321). I nstal l onl y one screw at thi s
ti me as accumul ator must be free to pi vot upward for
ease of i nstal l ati on.
(3) I nstal l 3-4 shi ft val ve and spri ng.
(4) I nstal l converter cl utch ti mi ng val ve and
spri ng.
(5) Posi ti on pl ug on end of converter cl utch val ve
spri ng. Then compress and hol d spri ngs and pl ug i n
pl ace wi th fi ngers of one hand.
(6) Swi ng accumul ator housi ng upward over val ve
spri ngs and pl ug.
(7) Hol d accumul ator housi ng fi rml y i n pl ace and
i nstal l remai ni ng two attachi ng screws. Be sure
spri ngs and cl utch val ve pl ug are properl y seated
(Fi g. 322). Ti ghten screws to 4 Nm (35 i n. l bs.).
VALVE BODY FINAL
(1) I nstal l boost val ve, val ve spri ng, retai ner and
cover pl ate. Ti ghten cover pl ate screws to 4 Nm (35
i n. l bs.) torque.
(2) I nsert manual l ever detent spri ng i n upper
housi ng.
(3) Posi ti on detent bal l on end of spri ng. Then hol d
detent bal l and spri ng i n detent housi ng wi th
Retai ner Tool 6583 (Fi g. 323).
(4) I nstal l throttl e l ever i n upper housi ng. Then
i nstal l manual l ever over throttl e l ever and start
manual l ever i nto housi ng.
(5) Al i gn manual l ever wi th detent bal l and man-
ual val ve. Hol d throttl e l ever upward. Then press
down on manual l ever unti l ful l y seated. Remove
detent bal l retai ner tool after l ever i s seated.
(6) Then i nstal l manual l ever seal , washer and
E-cl i p.
Fig. 323 Detent Ball Spring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 321 Converter Clutch And 3-4 Shift Valve
Springs
1 - RIGHT-SIDE SCREW
2 - 3-4 ACCUMULATOR
4 - CONVERTER CLUTCH VALVE SPRING
Fig. 322 Seating 3-4 Accumulator On Lower
Housing
1 - ACCUMULATOR BOX
2 - CONVERTER CLUTCH VALVE PLUG
(7) Veri fy that throttl e l ever i s al i gned wi th end of
ki ckdown val ve stem and that manual l ever arm i s
engaged i n manual val ve (Fi g. 324).
(8) Posi ti on l i ne pressure adjusti ng screw i n
adjusti ng screw bracket.
(9) I nstal l spri ng on end of l i ne pressure regul ator
val ve.
(10) I nstal l swi tch val ve spri ng on tang at end of
adjusti ng screw bracket.
(11) I nstal l manual val ve.
(12) I nstal l throttl e val ve and spri ng.
(13) I nstal l ki ckdown val ve and detent.
(14) I nstal l pressure regul ator val ve.
(15) I nstal l swi tch val ve.
(16) Posi ti on adjusti ng screw bracket on val ve
body. Al i gn val ve spri ngs and press bracket i nto
pl ace. I nstal l short, upper bracket screws fi rst and
l ong bottom screw l ast. Veri fy that val ve spri ngs and
bracket are properl y al i gned. Then ti ghten al l three
bracket screws to 4 Nm (35 i n. l bs.) torque.
(17) Perform Li ne Pressure and Throttl e Pressure
adjustments. (Refer to 21 - TRANSMI SSI ON/TRANS-
AXLE/AUTOMATI C/VALVE BODY - ADJUST-
MENTS)
(18) Lubri cate sol enoi d case connector O-ri ngs and
shaft of manual l ever wi th l i ght coat of petrol eum
jel l y.
(19) Attach sol enoi d case connector to 3-4 accumu-
l ator wi th shoul der-type screw. Connector has smal l
l ocati ng tang that fi ts i n di mpl e at top of accumul a-
tor housi ng (Fi g. 325). Seat tang i n di mpl e before
ti ghteni ng connector screw.
(20) I nstal l sol enoi d assembl y and gasket. Ti ghten
sol enoi d attachi ng screws to 8 Nm (72 i n. l bs.)
torque.
(21) Veri fy that sol enoi d wi re harness i s properl y
routed (Fi g. 326). Sol enoi d harness must be cl ear of
manual l ever and park rod and not be pi nched
between accumul ator housi ng and cover.
Fig. 324 Manual And Throttle Lever Alignment
1 - THROTTLE LEVER
2 - MANUAL LEVER VALVE ARM
3 - MANUAL VALVE
4 - KICKDOWN VALVE
Fig. 325 Solenoid Harness Case Connector
Shoulder Bolt
1 - SOLENOID HARNESS CASE CONNECTOR
Fig. 326 Solenoid Harness Routing
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
GOVERNOR BODY, SENSOR AND SOLENOID
(1) Turn val ve body assembl y over so accumul ator
si de of transfer pl ate i s faci ng down.
(2) I nstal l new O-ri ngs on governor pressure sol e-
noi d and sensor.
(3) Lubri cate sol enoi d and sensor O-ri ngs wi th
cl ean transmi ssi on fl ui d.
(4) I nstal l governor pressure sensor i n governor
body.
(5) I nstal l governor pressure sol enoi d i n governor
body. Push sol enoi d i n unti l i t snaps i nto pl ace i n
body.
(6) Posi ti on governor body gasket on transfer
pl ate.
(7) I nstal l retai ner pl ate on governor body and
around sol enoi d. Be sure sol enoi d connector i s posi -
ti oned i n retai ner cutout.
(8) Al i gn screw hol es i n governor body and trans-
fer pl ate. Then i nstal l and ti ghten governor body
screws to 4 Nm (35 i n. l bs.) torque.
(9) Connect harness wi res to governor pressure
sol enoi d and governor pressure sensor.
(10) I nstal l fl ui d fi l ter and pan.
(12) Fi l l transmi ssi on wi th recommended fl ui d and
road test vehi cl e to veri fy repai r.
INSTALLATION
(1) Check condi ti on of O-ri ng seal s on val ve body
harness connector (Fi g. 327). Repl ace seal s on con-
nector body i f cut or worn.
(2) Check condi ti on of manual l ever shaft seal i n
transmi ssi on case. Repl ace seal i f l i p i s cut or worn.
I nstal l new seal wi th 15/16 deep wel l socket (Fi g.
328).
(3) Check condi ti on of seal s on accumul ator pi ston.
I nstal l new pi ston seal s, i f necessary.
(4) Pl ace val ve body manual l ever i n l ow (1 posi -
ti on) so bal l on park l ock rod wi l l be easi er to i nstal l
i n sprag.
(5) Lubri cate shaft of manual l ever wi th petrol eum
jel l y. Thi s wi l l ease i nserti ng shaft through seal i n
case.
(6) Lubri cate seal ri ngs on val ve body harness con-
nector wi th petrol eum jel l y.
(7) Posi ti on val ve body i n case and work end of
park l ock rod i nto and through pawl sprag. Turn pro-
pel l er shaft to al i gn sprag and park l ock teeth i f nec-
essary. The rod wi l l cl i ck as i t enters pawl . Move rod
to check engagement.
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into this cavity.
(8) I nstal l accumul ator spri ng and pi ston i nto case.
Then swi ng val ve body over pi ston and outer spri ng
to hol d i t i n pl ace.
(9) Al i gn accumul ator pi ston and outer spri ng,
manual l ever shaft and el ectri cal connector i n case.
(10) Then seat val ve body i n case and i nstal l one
or two bol ts to hol d val ve body i n pl ace.
(11) Ti ghten val ve body bol ts al ternatel y and
evenl y to 11 Nm (100 i n. l bs.) torque.
(12) I nstal l new fl ui d fi l ter on val ve body. Ti ghten
fi l ter screws to 4 Nm (35 i n. l bs.) torque.
(13) I nstal l throttl e and gearshi ft l evers on val ve
body manual l ever shaft.
(14) Check and adjust front and rear bands i f nec-
essary.
(15) I nstal l the transmi ssi on range sensor (Refer
to 21 - TRANSMI SSI ON/AUTOMATI C/TRANSMI S-
SI ON RANGE SENSOR - I NSTALLATI ON).
(16) Connect sol enoi d case connector wi res.
(17) I nstal l oi l pan and new gasket. Ti ghten pan
bol ts to 13.6 Nm (125 i n. l bs.) torque.
(18) Lower vehi cl e and fi l l transmi ssi on wi th
(19) Check and adjust gearshi ft and throttl e val ve
cabl es, i f necessary.
Fig. 327 Valve Body Harness Connector O-Ring Seal
1 - CONNECTOR O-RINGS
2 - VALVE BODY HARNESS CONNECTOR
3 - HARNESS
ADJUSTMENTS - VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
val ve body;
Li ne Pressure
Throttl e Pressure
Li ne and throttl e pressures are i nterdependent
because each affects shi ft qual i ty and ti mi ng. As a
resul t, both adjustments must be performed properl y
and i n the correct sequence. Adjust l i ne pressure fi rst
and throttl e pressure l ast.
LINE PRESSURE ADJUSTMENT
Measure di stance from the val ve body to the i nner
edge of the adjusti ng screw wi th an accurate steel
scal e (Fi g. 329).
Di stance shoul d be 33.4 mm (1-5/16 i n.).
I f adjustment i s requi red, turn the adjusti ng screw
i n, or out, to obtai n requi red di stance setti ng.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One compl ete turn of the adjusti ng screw changes
l i ne pressure approxi matel y 1-2/3 psi (9 kPa).
Turni ng the adjusti ng screw countercl ockwi se
i ncreases pressure whi l e turni ng the screw cl ockwi se
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
I nsert Gauge Tool C-3763 between the throttl e
l ever cam and the ki ckdown val ve stem (Fi g. 330).
Push the gauge tool i nward to compress the ki ck-
down val ve agai nst the spri ng and bottom the throt-
tl e val ve.
Mai ntai n pressure agai nst ki ckdown val ve spri ng.
Turn throttl e l ever stop screw unti l the screw head
touches throttl e l ever tang and the throttl e l ever cam
touches gauge tool .
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
Fig. 328 Manual Lever Shaft Seal
1 - 15/16 SOCKET
2 - SEAL
Fig. 329 Line Pressure Adjustment
1 - WRENCH
2 - 15/16 INCH
Fig. 330 Throttle Pressure Adjustment
1 - HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW)
2 - SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE
LEVER AND KICKDOWN VALVE)
AUTOMATIC TRANSMISSION - 45RFE/545RFE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 45RFE/545RFE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 312
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 313
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 314
PRELIMINARY . . . . . . . . . . . . . . . . . . . . . . . 314
DIAGNOSIS AND TESTING - ROAD
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . 316
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH OPERATION . . . . 317
HOUSING FLUID LEAK . . . . . . . . . . . . . . . . 318
THREAD REPAIR . . . . . . . . . . . . . . . . . . . . . 318
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 320
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 326
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 333
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . 337
SPECIFICATIONS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 358
SPECIAL TOOLS
RFE TRANSMISSION . . . . . . . . . . . . . . . . . 359
4C RETAINER/BULKHEAD
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 362
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 364
BRAKE TRANSMISSION SHIFT INTERLOCK
SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 364
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 364
TRANSMISSION SHIFT INTERLOCK . . . . . . 364
SHIFT INTERLOCK . . . . . . . . . . . . . . . . . . . 365
FLUID AND FILTER
INCORRECT FLUID LEVEL . . . . . . . . . . . . . 366
BURNT FLUID . . . . . . . . . . . . . . . . . . . . . . . 366
CONTAMINATION . . . . . . . . . . . . . . . . . . . . 366
STANDARD PROCEDURE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT . . . . . . . . . . . . . . . 367
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
GEARSHIFT CABLE
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 370
ADJUSTMENTS
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . 370
HOLDING CLUTCHES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 371
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 372
INPUT CLUTCH ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 373
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 373
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 374
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
INPUT SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 382
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 382
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 382
LINE PRESSURE (LP) SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 382
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 383
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 383
LOW/REVERSE CLUTCH
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 384
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 385
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 386
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 386
STANDARD PROCEDURE - OIL PUMP
VOLUME CHECK . . . . . . . . . . . . . . . . . . . . . 387
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 388
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 390
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
OIL PUMP FRONT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
DR AUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 311
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 391
OUTPUT SPEED SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 391
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 391
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 392
TOW/HAUL OVERDRIVE SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 392
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 392
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 393
PISTONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 393
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 393
PLANETARY GEARTRAIN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 395
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 396
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 396
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 397
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
SHIFT MECHANISM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 398
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 398
SOLENOID SWITCH VALVE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 398
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 398
SOLENOIDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 398
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 399
TORQUE CONVERTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 399
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 403
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 404
TRANSMISSION CONTROL RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 405
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 405
TRANSMISSION RANGE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 405
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 405
TRANSMISSION SOLENOID/TRS ASSEMBLY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 406
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 406
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 408
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 408
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 408
VALVE BODY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 408
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 408
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 410
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 413
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 414
AUTOMATIC TRANSMISSION -
45RFE/545RFE
DESCRIPTION
The 45RFE/545RFE automati c transmi ssi ons i s a
sophi sti cated, mul ti -range, el ectroni cal l y control l ed
transmi ssi on whi ch combi nes opti mi zed gear rati os
for responsi ve performance, state of the art effi ci ency
features and l ow NVH. Other features i ncl ude dri ver
adapti ve shi fti ng and three pl anetary gear sets to
provi de wi de rati o capabi l i ty wi th preci se rati o steps
for opti mum dri veabi l i ty. The three pl anetary gear
sets al so make avai l abl e a uni que al ternate second
gear rati o. The pri mary 2nd gear rati o fi ts between
1st and 3rd gears for normal through-gear accel era-
ti ons. The al ternate second gear rati o (2pri me) al l ows
smoother 4-2 ki ckdowns at hi gh speeds to provi de
2nd gear passi ng performance over a wi der hi ghway
crui si ng range.
The hydraul i c porti on of the transmi ssi on consi sts
of the transmi ssi on fl ui d, fl ui d passages, hydraul i c
val ves, and vari ous l i ne pressure control components.
The pri mary mechani cal components of the trans-
mi ssi on consi st of the fol l owi ng:
Three mul ti pl e di sc i nput cl utches
Three mul ti pl e di sc hol di ng cl utches
Fi ve hydraul i c accumul ators
Three pl anetary gear sets
Dual Stage Hydraul i c oi l pump
Val ve body
Sol enoi d pack
The TCM i s the heart or brai n of the el ectroni c
control system and rel i es on i nformati on from vari -
ous di rect and i ndi rect i nputs (sensors, swi tches, etc.)
to determi ne dri ver demand and vehi cl e operati ng
condi ti ons. Wi th thi s i nformati on, the TCM can cal -
cul ate and perform ti mel y and qual i ty shi fts through
vari ous output or control devi ces (sol enoi d pack,
transmi ssi on control rel ay, etc.).
21 - 312 AUTOMATIC TRANSMISSION - 45RFE/545RFE DR
TRANSMISSION IDENTIFICATION
Transmi ssi on i denti fi cati on numbers are stamped
on the l eft si de of the case just above the oi l pan
seal i ng surface (Fi g. 1). Refer to thi s i nformati on
when orderi ng repl acement parts. A l abel i s attached
to the transmi ssi on case above the stamped numbers.
The l abel gi ves addi ti onal i nformati on whi ch may
al so be necessary for i denti fi cati on purposes.
GEAR RATIOS
The 45RFE gear rati os are:
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67:1
2nd Pri me . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
GEAR RATIOS
The 545RFE gear rati os are:
1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67:1
2nd Pri me . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50:1
3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75:1
5th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.67:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
OPERATION
The 45RFE/545RFE offers ful l el ectroni c control of
al l automati c up and downshi fts, and features real -
ti me adapti ve cl osed-l oop shi ft and pressure control .
El ectroni c shi ft and torque converter cl utch control s
hel p protect the transmi ssi on from damage due to
hi gh temperatures, whi ch can occur under severe
operati ng condi ti ons. By al teri ng shi ft schedul es, l i ne
pressure, and converter cl utch control , these control s
reduce heat generati on and i ncrease transmi ssi on
cool i ng.
To hel p reduce effi ci ency-robbi ng parasi ti c l osses,
the transmi ssi ons i ncl udes a dual -stage transmi ssi on
fl ui d pump wi th el ectroni c output pressure control .
Under most dri vi ng condi ti ons, pump output pres-
sure greatl y exceeds that whi ch i s needed to keep the
cl utches appl i ed. The 45RFE/545RFE pump-pressure
control system moni tors i nput torque and adjusts the
pump pressure accordi ngl y. The pri mary stage of the
pump works conti nuousl y; the second stage i s
bypassed when demand i s l ow. The control system
al so moni tors i nput and output speed and, i f i nci pi -
ent cl utch sl i p i s observed, the pressure control sol e-
noi d duty cycl e i s vari ed, i ncreasi ng pressure i n
proporti on to demand.
A hi gh-travel torque converter damper assembl y
al l ows earl i er torque converter cl utch engagement to
reduce sl i ppage. Needl e-type thrust beari ngs reduce
i nternal fri cti on. The 45RFE/545RFE i s packaged i n
a one-pi ece di e-cast al umi num case. To reduce NVH,
the case has hi gh l ateral , verti cal and torsi onal sti ff-
ness. I t i s al so desi gned to maxi mi ze the benefi t of
the structural dust cover that connects the bottom of
the bel l housi ng to the engi ne bedpl ate, enhanci ng
overal l power trai n sti ffness. Dual fi l ters protect the
pump and other components. A pump return fi l ter i s
added to the customary mai n sump fi l ter. I ndepen-
dent l ubri cati on and cool er ci rcui ts assure ampl e
pressure for normal transmi ssi on operati on even i f
the cool er i s obstructed or the fl ui d cannot fl ow due
to extremel y l ow temperatures.
The hydraul i c control system desi gn (wi thout el ec-
troni c assi st) provi des the transmi ssi on wi th PARK,
REVERSE, NEUTRAL, SECOND, and THI RD gears,
based sol el y on dri ver shi ft l ever sel ecti on. Thi s
desi gn al l ows the vehi cl e to be dri ven (i n l i mp-i n
mode) i n the event of a el ectroni c control system fai l -
ure, or a si tuati on that the Transmi ssi on Control
Modul e (TCM) recogni zes as potenti al l y damagi ng to
the transmi ssi on.
The TCM al so performs certai n sel f-di agnosti c
functi ons and provi des comprehensi ve i nformati on
(sensor data, DTCs, etc.) whi ch i s hel pful i n proper
di agnosi s and repai r. Thi s i nformati on can be vi ewed
wi th the DRB scan tool .
Fig. 1 Transmission Part And Serial Number
Location
1 - IDENTIFICATION NUMBERS (STAMPED)
AUTOMATIC TRANSMISSION - 45RFE/545RFE (Continued)
TRANSMISSION
CAUTION: Before attempting any repair on a RFE
automatic transmission, check for Diagnostic Trou-
ble Codes with the DRB scan tool.
Transmi ssi on mal functi ons may be caused by these
general condi ti ons:
Poor engi ne performance
I mproper adjustments
Hydraul i c mal functi ons
Mechani cal mal functi ons
El ectroni c mal functi ons
Di agnosi s of these probl ems shoul d al ways begi n
by checki ng the easi l y accessi bl e vari abl es: fl ui d l evel
and condi ti on, gearshi ft cabl e adjustment. Then per-
form a road test to determi ne i f the probl em has been
corrected or i f more di agnosi s i s necessary. I f the
probl em persi sts after the prel i mi nary tests and cor-
recti ons are compl eted, hydraul i c pressure checks
shoul d be performed.
Two basi c procedures are requi red. One procedure
for vehi cl es that are dri vabl e and an al ternate proce-
dure for di sabl ed vehi cl es (wi l l not back up or move
forward).
VEHICLE IS DRIVABLE
(1) Check for transmi ssi on faul t codes usi ng DRB
scan tool .
(3) Adjust gearshi ft cabl e i f compl ai nt was based
on del ayed, errati c, or harsh shi fts.
(4) Road test and note how transmi ssi on upshi fts,
downshi fts, and engages.
(5) Perform hydraul i c pressure test i f shi ft prob-
l ems were noted duri ng road test.
(6) Perform ai r-pressure test to check cl utch oper-
ati on.
VEHICLE IS DISABLED
(2) Check for broken or di sconnected gearshi ft
cabl e.
(3) Check for cracked, l eaki ng cool er l i nes, or l oose
or mi ssi ng pressure-port pl ugs.
(4) Rai se and support vehi cl e on safety stands,
start engi ne, shi ft transmi ssi on i nto gear, and note
fol l owi ng:
(a) I f propel l er shaft turns but wheel s do not,
probl em i s wi th di fferenti al or axl e shafts.
(b) I f propel l er shaft does not turn and transmi s-
si on i s noi sy, stop engi ne. Remove oi l pan, and
check for debri s. I f pan i s cl ear, remove transmi s-
si on and check for damaged dri vepl ate, converter,
oi l pump, or i nput shaft.
(c) I f propel l er shaft does not turn and transmi s-
si on i s not noi sy, perform hydraul i c-pressure test to
determi ne i f probl em i s hydraul i c or mechani cal .
DIAGNOSIS AND TESTING - ROAD TESTING
Before road testi ng, be sure the fl ui d l evel and con-
trol cabl e adjustments have been checked and
adjusted i f necessary. Veri fy that al l di agnosti c trou-
bl e codes have been resol ved.
Observe engi ne performance duri ng the road test.
A poorl y tuned engi ne wi l l not al l ow accurate anal y-
si s of transmi ssi on operati on.
Operate the transmi ssi on i n al l gear ranges. Check
for shi ft vari ati ons and engi ne fl are whi ch i ndi cates
sl i ppage. Note i f shi fts are harsh, spongy, del ayed,
earl y, or i f part throttl e downshi fts are sensi ti ve.
Sl i ppage i ndi cated by engi ne fl are, usual l y means
cl utch, overrunni ng cl utch, or l i ne pressure probl ems.
A sl i ppi ng cl utch can often be determi ned by com-
pari ng whi ch i nternal uni ts are appl i ed i n the vari -
ous gear ranges. The Cl utch Appl i cati on charts
provi de a basi s for anal yzi ng road test resul ts.
45RFE CLUTCH APPLICATION CHART
SLP UD OD R 2C 4C L/R OVERRUNNING
PPARK ON
RREVERSE ON ON
N-NEUTRAL ON
DOVERDRIVE
FIRST
ON ON* ON
SECOND ON ON
SECOND PRIME ON ON
THIRD ON ON
FOURTH ON ON
LIMP-IN ON ON
2FIRST ON ON* ON
SECOND ON ON
LIMP-IN ON ON
1LOW ON ON ON
*L/R clutch is on only with the output shaft speed below 150 rpm.
545RFE CLUTCH APPLICATION CHART
SLP UD OD R 2C 4C L/R OVERRUNNING
PPARK ON
RREVERSE ON ON
N-NEUTRAL ON
DOVERDRIVE
FIRST
ON ON* ON
SECOND ON ON
SECOND PRIME ON ON
THIRD ON ON
FOURTH ON ON
FIFTH ON ON
LIMP-IN ON ON
2FIRST ON ON* ON
SECOND ON ON
LIMP-IN ON ON
1LOW ON ON ON
*L/R clutch is on only with the output shaft speed below 150 rpm.
PRESSURE TEST
An accurate tachometer and pressure test gauges
are requi red. Test Gauge C-3293-SP has a 300 psi
range and i s used at al l l ocati ons where pressures
exceed 100 psi .
Pressure Test Port Locations
Onl y two pressure ports are suppl i ed on the trans-
mi ssi on case. The torque converter cl utch appl y and
rel ease ports are l ocated on the ri ght si de of the
transmi ssi on case (Fi g. 2).
To determi ne the l i ne pressure, there are two avai l -
abl e methods. The DRB scan tool can be used to
read l i ne pressure from the l i ne pressure sensor. The
second method i s to i nstal l Li ne Pressure Adapter
8259 (Fi g. 4) i nto the transmi ssi on case and then
i nstal l the pressure gauge and the ori gi nal sensor
i nto the adapter. Thi s wi l l al l ow a compari son of the
DRB readi ngs and the gauge readi ng to determi ne
the accuracy of the l i ne pressure sensor. The DRB
l i ne pressure readi ng shoul d match the gauge read-
i ng wi thi n 10 psi .
I n order to access any other pressure tap l ocati ons,
the transmi ssi on oi l pan must be removed, the pres-
sure port pl ugs removed and Val ve Body Pressure
Tap Adapter 8258-A (Fi g. 5) i nstal l ed. The extensi ons
suppl i ed wi th Adapter 8258-A wi l l al l ow the i nstal l a-
ti on of pressure gauges to the val ve body. Refer to
(Fi g. 3) for correct pressure tap l ocati on i denti fi ca-
ti on.
TEST PROCEDURE
Al l pressure readi ngs shoul d be taken wi th the
transmi ssi on fl ui d l evel ful l , transmi ssi on oi l at the
normal operati ng temperature, and the engi ne at
1500 rpm. Check the transmi ssi on for proper opera-
ti on i n each gear posi ti on that i s i n questi on or i f a
speci fi c el ement i s i n questi on, check the pressure
readi ngs i n at l east two gear posi ti ons that empl oy
that el ement. Refer to the Hydraul i c Schemati cs at
the rear of thi s secti on to determi ne the correct pres-
sures for each el ement i n a gi ven gear posi ti on.
Fig. 2 Torque Converter Pressure Locations
1 - TCC RELEASE
2 - TO COOLER
3 - TCC APPLY
4 - FROM COOLER
5 - LINE PRESSURE SENSOR
Fig. 3 Pressure Tap Locations
Fig. 4 Line Pressure Adapter 8259
1 - LINE PRESSURE SENSOR PORT
3 - TOOL 8259
4 - PRESSURE TAP
NOTE: The 45RFE/545RFE utilizes closed loop con-
trol of pump line pressure. The pressure readings
may therefore vary greatly but should always follow
line pressure.
Some common pressures that can be measured to
eval uate pump and cl utch performance are the
upshi ft/downshi ft pressures, garage shi ft pressures,
and TCC pressure. The upshi ft/downshi ft pressure
for al l shi fts are shown i n UPSHI FT PRESSURES
and DOWNSHI FT PRESSURES. I n-gear maxi mum
pressure for each gear posi ti on i s shown i n I N-GEAR
PRESSURES. The garage shi ft pressure when per-
formi ng a N-R shi ft i s 220 psi for 3.7L/4.7L equi pped
vehi cl es and 250 psi for 5.7L equi pped vehi cl es. The
garage shi ft pressure for the R-N shi ft i s 120 psi . The
garage shi ft pressure for the N-1 shi ft i s 135 psi for
3.7L/4.7L equi pped vehi cl es and 165 psi for 5.7L
equi pped vehi cl es. Torque converter l ock-up pressure
i s 120 psi for 3.7L/4.7L equi pped vehi cl es and 125 psi
for 5.7L equi pped vehi cl es.
UPSHIFT PRESSURES
ENGINE 1-2 2-3 2prime-3 3-4 2prime-4 2-5 3-5 4-5
5.7L
150 125 125 135 135 135 135 135
3.7L/
4.7L
120 120 120 120 120 120 120 130
DOWNSHIFT PRESSURES
ENG-
INE
5-
4
5-3 5-2 4-3
4-2
prime
3-2
3-2
prime
2
prime-
1
2-
1
3-1
5.7L
135 135 135 135 135 135 135 135 135 135
3.7L/
4.7L
120 120 120 120 120 120 120 120 120 120
IN-GEAR PRESSURES
ENGINE 1 2
2
prime
3 4 5
NEUT-
RAL
REV-
ERSE
5.7L
160 135 135 135 135 135 120 250
3.7L/
4.7L
135 120 120 120 120 120 120 220
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH OPERATION
Ai r-pressure testi ng can be used to check transmi s-
si on cl utch operati on. The test can be conducted wi th
the transmi ssi on ei ther i n the vehi cl e or on the work
bench, as a fi nal check.
Ai r-pressure testi ng requi res that the oi l pan and
val ve body be removed from the transmi ssi on. The
cl utch appl y passages are shown (Fi g. 6).
NOTE: The air supply which is used must be free of
moisture and dirt. Use a pressure of 30 psi to test
clutch operation.
Appl y ai r pressure at each port. I f the cl utch i s
functi oni ng, a soft thump wi l l be heard as the cl utch
Fig. 5 Valve Body Pressure Tap Adapter 8258-A
1 - 45RFE TRANSMISSION
2 - TOOL 8258-A
Fig. 6 Air Pressure Test Passages
1 - LOW REVERSE CLUTCH
2 - 4TH CLUTCH
3 - 2ND CLUTCH
4 - OVERDRIVE CLUTCH
5 - UNDERDRIVE CLUTCH
6 - REVERSE CLUTCH
i s appl i ed. The cl utch appl i cati on can al so be fel t by
touchi ng the appropri ate el ement whi l e appl yi ng ai r
pressure. As the ai r pressure i s rel eased, the cl utch
shoul d al so rel ease.
HOUSING FLUID LEAK
When di agnosi ng converter housi ng fl ui d l eaks,
two i tems must be establ i shed before repai r.
(1) Veri fy that a l eak condi ti on actual l y exi sts.
(2) Determi ned the true source of the l eak.
Some suspected converter housi ng fl ui d l eaks may
not be l eaks at al l . They may onl y be the resul t of
resi dual fl ui d i n the converter housi ng, or excess
fl ui d spi l l ed duri ng factory fi l l or fi l l after repai r.
Converter housi ng l eaks have several potenti al
sources. Through careful observati on, a l eak source
can be i denti fi ed before removi ng the transmi ssi on
for repai r. Torque converter seal l eaks tend to move
al ong the dri ve hub and onto the rear of the con-
verter. Pump cover seal tend to run down the cover
and the i nsi de surface of the bel l housi ng.
Some l eaks, or suspected l eaks, may be parti cu-
l arl y di ffi cul t to l ocate. I f necessary, a Mopar
approved dye may be used to l ocate a l eak.
TORQUE CONVERTER LEAK POINTS
Possi bl e sources of converter l eaks are:
(1) Leaks at the wel d joi nt around the outsi de
di ameter wel d (Fi g. 7).
(2) Leaks at the converter hub wel d (Fi g. 7).
THREAD REPAIR
Damaged or worn threads i n the al umi num trans-
mi ssi on case and val ve body can be repai red by the
use of Hel i -Coi l s , or equi val ent. Thi s repai r con-
si sts of dri l l i ng out the worn-out damaged threads.
Then tap the hol e wi th a speci al Hel i -Coi l tap, or
equi val ent, and i nstal l i ng a Hel i -Coi l i nsert, or
equi val ent, i nto the hol e. Thi s bri ngs the hol e back to
i ts ori gi nal thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
REMOVAL
(3) Remove any necessary ski d pl ates. (Refer to 13
- FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKI D PLATE - REMOVAL)
(4) Mark propel l er shaft and axl e compani on
fl anges for assembl y al i gnment.
(5) Remove the rear propel l er shaft
(6) Remove the front propel l er shaft, i f necessary.
(7) Remove the engi ne to transmi ssi on col l ar (Fi g.
8).
(8) Remove the exhaust support bracket from the
rear of the transmi ssi on.
(9) Di sconnect and l ower or remove any necessary
exhaust components.
1 - TURBINE ASSEMBLY
2 - STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
Fig. 8 Transmission Collar
1 - ENGINE
2 - STRUCTURAL DUST COVER
3 - TRANSMISSION
(10) Remove the starter motor.
(11) Rotate crankshaft i n cl ockwi se di recti on unti l
converter bol ts are accessi bl e. Then remove bol ts one
at a ti me. Rotate crankshaft wi th socket wrench on
dampener bol t.
(12) Di sengage the output speed sensor connector
from the output speed sensor (Fi g. 9).
(13) Di sengage the i nput speed sensor connector
from the i nput speed sensor (Fi g. 10).
(14) Di sengage the transmi ssi on sol enoi d/TRS
assembl y connector from the transmi ssi on sol enoi d/
TRS assembl y (Fi g. 11).
(15) Di sengage the l i ne pressure sensor connector
from the l i ne pressure sensor (Fi g. 12).
Fig. 9 Disconnect Output Speed Sensor
1 - TRANSMISSION
Fig. 10 Disconnect Input Speed Sensor
1 - TRANSMISSION
Fig. 11 Disconnect Transmission Solenoid/TRS
Assembly
1 - TRANSMISSION
2 - TRANSMISSION SOLENOID/TRS ASSEMBLY
Fig. 12 Disconnect Line Pressure Sensor
1 - TRANSMISSION
(16) Di sconnect gearshi ft cabl e from transmi ssi on
manual val ve l ever (Fi g. 13).
(17) Di sconnect the transmi ssi on vent hose from
the transmi ssi on.
(18) Support rear of engi ne wi th safety stand or
jack.
(19) Rai se transmi ssi on sl i ghtl y wi th servi ce jack
to rel i eve l oad on crossmember and supports.
(20) Remove bol ts securi ng rear support and cush-
i on to transmi ssi on and crossmember.
(21) Remove transfer case, i f necessary.
(22) Di sconnect transmi ssi on fl ui d cool er l i nes at
transmi ssi on fi tti ngs and cl i ps.
(23) Remove al l remai ni ng converter housi ng bol ts.
(24) Careful l y work transmi ssi on and torque con-
verter assembl y rearward off engi ne bl ock dowel s.
(25) Hol d torque converter i n pl ace duri ng trans-
mi ssi on removal .
(26) Lower transmi ssi on and remove (Fi g. 14)
assembl y from under the vehi cl e.
(27) To remove torque converter, careful l y sl i de
torque converter out of the transmi ssi on.
DISASSEMBLY
(1) Drai n fl ui d from transmi ssi on.
(2) Cl ean exteri or of transmi ssi on wi th sui tabl e
sol vent or pressure washer.
(3) Remove the torque converter from the trans-
mi ssi on.
(4) Remove the manual shi ft l ever from the trans-
mi ssi on.
(5) Remove the i nput, output, and l i ne pressure
sensors from the transmi ssi on case (Fi g. 15).
1 - GEARSHIFT CABLE
3 - MANUAL LEVER
Fig. 14 Remove Transmission
1 - ENGINE
2 - TRANSMISSION
Fig. 15 Remove Input, Output, and Line Pressure
Sensors
(6) I nspect the ends of the sensors for debri s,
whi ch may i ndi cate the nature of the transmi ssi on
fai l ure.
(7) I nstal l Support Stand 8257 onto the transmi s-
(8) Usi ng Adapter 8266-1 from End-Pl ay Tool Set
8266 and Di al I ndi cator C-3339, measure and record
the i nput shaft end-pl ay (Fi g. 17).
NOTE: When measuring the input shaft end-play,
two stops will be felt. When the input shaft is
pushed inward and the dial indicator zeroed, the
first stop felt when the input shaft is pulled out-
ward is the movement of the input shaft in the input
clutch housing hub. This value should not be
included in the end-play measured value and there-
fore must be recorded and subtracted from the dial
indicator reading.
(9) Remove the bol ts hol di ng the transmi ssi on
extensi on/adapter housi ng to the transmi ssi on case.
(10) Remove the extensi on/adapter housi ng from
the transmi ssi on case.
(11) Usi ng Al i gnment Pl ate 8261, Adapter 8266-17
from End-Pl ay Tool Set 8266 and Di al I ndi cator
C-3339, measure and record the output shaft end-
pl ay (Fi g. 18).
Fig. 16 Install Support Stand - Tool 8257
1 - TOOL 8257
Fig. 17 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
Fig. 18 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
(12) Remove the bol ts hol di ng the transmi ssi on oi l
pan to the transmi ssi on case.
(13) Remove the transmi ssi on oi l pan from the
(14) Remove the pri mary oi l fi l ter and the oi l
cool er return fi l ter (Fi g. 19).
(15) Remove the cool er return fi l ter bypass val ve.
(16) Remove the bol ts hol di ng the val ve body to
the transmi ssi on case (Fi g. 20).
(17) Remove the val ve body from the transmi ssi on
case.
(18) Remove the outer snap-ri ng securi ng the
transmi ssi on front cover i nto the transmi ssi on case
(Fi g. 21).
(19) Remove the i nner snap-ri ng securi ng the
transmi ssi on front cover to the oi l pump (Fi g. 21).
Fig. 19 Remove Primary Oil and Cooler Filters
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 20 Remove Valve Body Assembly
1 - VALVE BODY TO CASE BOLT (6)
Fig. 21 Remove Transmission Front Cover
1 - INNER SNAP-RING
2 - TRANSMISSION COVER
3 - OUTER SNAP-RING
(20) Reachi ng through a case openi ng i n the val ve
body area wi th a l ong bl unted tool , remove the trans-
mi ssi on front cover from the transmi ssi on case.
(21) Remove the bol ts hol di ng the oi l pump i nto
(22) Remove the oi l pump. Hol d i nward on the
i nput shaft to prevent pul l i ng the i nput cl utch
assembl y wi th the oi l pump (Fi g. 22).
NOTE: If the input shaft is not held during oil pump
removal, the input clutch assembly will attempt to
move forward with the oil pump and the numbers 2,
3, or 4 bearings inside the input clutch assembly
may become dislodged.
(23) Remove the number 1 beari ng from the i nput
cl utch assembl y (Fi g. 23).
(24) Remove the i nput cl utch assembl y from the
(25) Remove the number 5 beari ng and sel ecti ve
thrust pl ate from the i nput cl utch assembl y (Fi g. 23),
or the 4C cl utch retai ner/bul khead.
(26) Remove the 4C cl utch retai ner/bul khead
tapered snap-ri ng from the transmi ssi on case (Fi g.
24).
(27) Remove the 4C cl utch retai ner/bul khead from
Fig. 22 Remove Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
Fig. 23 Remove Input Clutch Assembly
1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT)
3 - INPUT CLUTCH ASSEMBLY
Fig. 24 Remove 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
(28) Remove the front 2C cl utch pack snap-ri ng
from the transmi ssi on case (Fi g. 25).
(29) Remove the 2C cl utch pack from the transmi s-
(30) Remove the rear sel ecti ve pl ate and number 6
beari ng from the reacti on annul us (Fi g. 26).
(31) Remove the reacti on annul us from the reac-
ti on pl anetary carri er (Fi g. 26).
(32) Remove the number 7 beari ng (Fi g. 26).
(33) Remove the reacti on sun gear (Fi g. 26).
(34) Remove the number 8 beari ng from the reac-
ti on pl anetary carri er (Fi g. 26).
(35) Remove the reacti on pl anetary carri er (Fi g.
26). Note that thi s pl anetary gear set has three pi n-
i on gears.
(36) Remove the number 9 beari ng from the
reverse pl anetary gear set (Fi g. 26).
Fig. 25 Remove 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
Fig. 26 Remove Reaction Annulus and Carrier
1 - BEARING NUMBER 8 5 - BEARING NUMBER 7
2 - BEARING NUMBER 9 6 - THRUST PLATE (SELECT)
3 - REACTION PLANETARY CARRIER 7 - BEARING NUMBER 6
4 - REACTION SUN GEAR 8 - REACTION ANNULUS
(37) Remove the snap-ri ng hol di ng the park sprag
gear onto the output shaft (Fi g. 27).
(38) Remove the park sprag gear from the output
shaft (Fi g. 28).
(39) Remove the i nput/reverse pl anetary assembl y
(Fi g. 29).
(40) Remove the number 12 beari ng from the
i nput/reverse pl anetary assembl y (Fi g. 29).
(41) Remove the snap-ri ng hol di ng the l ow/reverse
cl utch retai ner i nto the transmi ssi on case (Fi g. 30).
(42) Remove the l ow/reverse cl utch retai ner from
Fig. 27 Remove Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 28 Remove Park Sprag Gear
1 - PARK SPRAG GEAR
Fig. 29 Remove Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
Fig. 30 Remove Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
(43) Remove the park pawl rod and e-cl i p (Fi g. 31).
(44) Remove the park pawl rod gui de snap-ri ng
(Fi g. 31).
(45) Remove the park pawl rod gui de (Fi g. 31).
(46) Remove the park pawl pi vot shaft, park pawl ,
and spri ng (Fi g. 31).
(47) Remove the manual sel ector shaft (Fi g. 31).
(48) Remove the manual sel ector shaft seal .
(49) Remove the di psti ck tube seal .
CLEANING
The use of crocus cl oth i s permi ssi bl e where neces-
sary, provi di ng i t i s used careful l y. When used on shafts,
or val ves, use extreme care to avoi d roundi ng off sharp
edges. Sharp edges are vi tal as they prevent forei gn
matter from getti ng between the val ve and val ve bore.
Do not reuse oi l seal s, gaskets, seal ri ngs, or O-ri ngs
duri ng overhaul . Repl ace these parts as a matter of
course. Al so do not reuse snap ri ngs or E-cl i ps that are
bent or di storted. Repl ace these parts as wel l .
Lubri cate transmi ssi on parts wi th Mopar ATF +4,
Automati c Transmi ssi on Fl ui d, duri ng overhaul and
assembl y. Use petrol eum jel l y, Mopar Door Ease, or
Ru-Gl yde to prel ubri cate seal s, O-ri ngs, and thrust
washers. Petrol eum jel l y can al so be used to hol d
parts i n pl ace duri ng reassembl y.
Cl ean the case i n a sol vent tank. Fl ush the case
bores and fl ui d passages thoroughl y wi th sol vent.
Dry the case and al l fl ui d passages wi th compressed
ai r. Be sure al l sol vent i s removed from the case and
that al l fl ui d passages are cl ear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
INSPECTION
I nspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repai red wi th Hel i coi l thread i nserts. However, the
case wi l l have to be repl aced i f i t exhi bi ts any type of
damage or wear.
ASSEMBLY
(1) Cl ean and i nspect al l components. Repl ace any
components whi ch show evi dence of excessi ve wear
or scori ng.
(2) I nstal l the cool er fi l ter bypass val ve.
(3) Torque the bypass val ve to speci fi cati on. The
val ve uses a tapered pi pe thread and excessi ve
torque can damage the transmi ssi on case. Ti ghten
the cool er fi l ter bypass val ve to 4.5 Nm (40 i n.l bs.).
(4) I nstal l a new sel ector shaft seal usi ng Seal
Fig. 31 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 32 Install Selector Shaft
1 - SEAL
2 - TOOL 8253
(5) I nstal l the manual sel ector shaft and retai ni ng
screw. Ti ghten the manual sel ector shaft retai ni ng
screw to 28 Nm (250 i n.l bs.).
(6) I nstal l the park pawl , spri ng, and shaft (Fi g.
33).
(7) I nstal l the park rod and e-cl i p (Fi g. 33).
(8) I nstal l the park rod gui de and snap-ri ng (Fi g.
33).
(9) I nstal l a new di psti ck tube seal usi ng Seal
NOTE: Before final assembly of transmission cen-
terline, the 2C/4C clutch components should be
installed into position and measured as follows:
(10) I nstal l the 2C reacti on pl ate i nto the trans-
mi ssi on case (Fi g. 35).
(11) I nstal l the 2C cl utch pack i nto the transmi s-
(12) I nstal l the fl at 2C cl utch snap-ri ng i nto the
(13) I nstal l the 4C retai ner/bul khead i nto the
transmi ssi on case. Make sure that the oi l feed hol es
are poi nti ng toward the val ve body area.
(14) I nstal l the 4C retai ner/bul khead tapered
snap-ri ng i nto the transmi ssi on case. Make sure that
the open ends of the snap-ri ng are l ocated i n the case
openi ng toward the val ve body area.
(15) Usi ng a feel er gauge through the openi ng i n
the rear of the transmi ssi on case, measure the 2C
cl utch pack cl earance between the 2C reacti on pl ate
and the transmi ssi on case at four di fferent poi nts.
The average of these measurements i s the 2C cl utch
pack cl earance. The correct cl utch cl earance i s 0.455-
1.335 mm (0.018-0.053 i n.). The reacti on pl ate i s not
sel ecti ve. I f the cl utch pack cl earance i s not wi thi n
Fig. 33 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 34 Install Dipstick Tube Seal Using Tool 8254
1 - TOOL 8254
2 - SEAL
Fig. 35 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
speci fi cati on, the reacti on pl ate, al l the fri cti on di scs,
and steel s must be repl aced.
(16) Remove the 4C retai ner/bul khead and al l of
the 2C cl utch components from the transmi ssi on
case.
(17) I nstal l the l ow/reverse cl utch assembl y (Fi g.
36). Make sure that the oi l feed hol e poi nts toward
the val ve body area and that the bl eed ori fi ce i s
al i gned wi th the notch i n the rear of the transmi s-
si on case.
(18) I nstal l the snap-ri ng to hol d the l ow/reverse
cl utch retai ner i nto the transmi ssi on case (Fi g. 36).
The snap-ri ng i s tapered and must be i nstal l ed wi th
the tapered si de forward. Once i nstal l ed, veri fy that
the snap-ri ng i s ful l y seated i n the snap-ri ng groove.
(19) Ai r check the l ow/reverse cl utch and veri fy
correct overrunni ng cl utch operati on.
(20) I nstal l the number 12 beari ng over the output
shaft and agai nst the rear pl anetary gear set. The
fl at si de of the beari ng goes toward the pl anetary
gearset and the rai sed tabs on the i nner race shoul d
face the rear of the transmi ssi on.
(21) I nstal l the reverse/i nput pl anetary assembl y
through the l ow/reverse cl utch assembl y (Fi g. 37).
(22) I nstal l the park sprag onto the output shaft
(Fi g. 38).
Fig. 38 Install Park Sprag Gear
1 - PARK SPRAG GEAR
Fig. 36 Install Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
Fig. 37 Install Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
(23) I nstal l the snap-ri ng to hol d the park sprag
onto the output shaft (Fi g. 39).
(24) I nstal l the 2C reacti on pl ate i nto the trans-
mi ssi on case (Fi g. 40).
(25) I nstal l the 2C cl utch pack i nto the transmi s-
(26) I nstal l the number 8 beari ng i nsi de the reac-
ti on carri er wi th the outer race agai nst the reacti on
pl anetary carri er.
(27) I nstal l the reacti on pl anetary gear set and the
number 9 beari ng, wi th the i nner race agai nst the
reacti on pl anetary carri er, i nto the transmi ssi on case
(Fi g. 41).
(28) I nstal l the fl at 2C cl utch snap-ri ng i nto the
(29) I nstal l the reacti on sun gear i nto the reacti on
pl anetary gear set. Make sure the smal l shoul der i s
faci ng the front of the transmi ssi on (Fi g. 41).
(30) I nstal l the number 7 beari ng onto the reacti on
sun gear wi th the i nner race agai nst the sun gear
(Fi g. 41).
Fig. 39 Install Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 40 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
Fig. 41 Install Reaction Annulus and Carrier
(31) I nstal l the output shaft sel ecti ve thrust pl ate
onto the reacti on annul us wi th the oi l grooves faci ng
the annul us gear and the tabs and notches al i gned as
(32) I nstal l the number 6 beari ng agai nst the out-
put shaft sel ecti ve thrust pl ate wi th the fl at si de
agai nst the thrust pl ate (Fi g. 41) and the rai sed tabs
on the i nner race faci ng the front of the transmi s-
si on.
(33) I nstal l the reacti on annul us i nto the reacti on
pl anetary gear set (Fi g. 41).
(34) I nstal l the 4C retai ner/bul khead i nto the
transmi ssi on case. Make sure that the oi l feed hol es
are poi nti ng toward the val ve body area. Rotate the
reacti on annul us duri ng the i nstal l ati on of the 4C
retai ner/bul khead to ease i nstal l ati on.
(35) I nstal l the 4C retai ner/bul khead tapered
snap-ri ng i nto the transmi ssi on case (Fi g. 43) wi th
the taper toward the front of the case. Make sure
that the open ends of the snap-ri ng are l ocated i n the
case openi ng toward the val ve body area.
(36) Ai r check the 2C and 4C cl utch operati on.
(37) Usi ng Al i gnment Pl ate 8261, Adapter 8266-17
from End-Pl ay Tool Set 8266 and Di al I ndi cator
C-3339, measure and record the output shaft end-
pl ay (Fi g. 44). The correct output shaft end-pl ay i s
0.22-0.55 mm (0.009-0.021 i n.). Adjust as necessary.
I nstal l the chosen output shaft sel ecti ve thrust pl ate
and re-measure end-pl ay to veri fy sel ecti on.
(38) Appl y a bead of RTV si l i cone and i nstal l the
extensi on/adapter housi ng onto the transmi ssi on
case.
(39) I nstal l and torque the bol ts to hol d the exten-
si on/adapter housi ng onto the transmi ssi on case. The
correct torque i s 54 Nm (40 ft.l bs.).
(40) I nstal l the number 5 beari ng and sel ecti ve
thrust pl ate onto the 4C retai ner/bul khead (Fi g. 45).
Be sure that the outer race of the beari ng i s agai nst
the thrust pl ate.
(41) I nstal l the i nput cl utch assembl y i nto the
transmi ssi on case (Fi g. 45). Make sure that the i nput
cl utch assembl y i s ful l y i nstal l ed by performi ng a
Fig. 42 Thrust Plate Alignment
1 - LOCATING LUG (3)
2 - THRUST PLATE
Fig. 43 Install 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
Fig. 44 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
vi sual i nspecti on through the i nput speed sensor
hol e. I f the tone wheel teeth on the i nput cl utch
assembl y are centered i n the hol e, the assembl y i s
ful l y i nstal l ed.
(42) I nstal l the number 1 beari ng wi th the outer
race up i n the pocket of the i nput cl utch assembl y
(Fi g. 45).
(43) I nstal l the oi l pump i nto the transmi ssi on
case (Fi g. 46).
(44) I nstal l the bol ts to hol d the oi l pump i nto the
transmi ssi on case. Ti ghten the oi l pump bol ts to 28
Nm (250 i n.l bs.).
(45) Usi ng Adapter 8266-1 from End-Pl ay Tool Set
8266 and Di al I ndi cator C-3339, measure and record
the i nput shaft end-pl ay (Fi g. 47). The correct end-
pl ay i s 0.46-0.89 mm (0.018-0.035 i n.). Adjust as nec-
essary. I nstal l the chosen thrust pl ate on the number
5 beari ng and re-measure end-pl ay to veri fy sel ec-
ti on.
NOTE: When measuring the input shaft end-play,
two stops will be felt. When the input shaft is
pushed inward and the dial indicator zeroed, the
first stop felt when the input shaft is pulled out-
ward is the movement of the input shaft in the input
clutch housing hub. This value should not be
included in the end-play measured value and there-
fore must be recorded and subtracted from the dial
indicator reading.
Fig. 45 Install Input Clutch Assembly
2 - THRUST PLATE (SELECT)
Fig. 46 Install Oil Pump
2 - OIL PUMP
Fig. 47 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
(46) I nstal l the transmi ssi on front cover i nto the
(47) I nstal l the outer snap-ri ng to hol d the trans-
mi ssi on front cover i nto the transmi ssi on case (Fi g.
48).
(48) Parti al l y i nstal l the i nner transmi ssi on front
cover snap-ri ng onto the oi l pump (Fi g. 48).
(49) Usi ng I nstal l er 8255, i nstal l the i nner trans-
mi ssi on front cover snap-ri ng the remai nder of the
way onto the oi l pump (Fi g. 49).
(50) I nstal l the val ve body (Fi g. 50). Veri fy that
the pi n on the manual l ever has properl y engaged
the TRS sel ector pl ate. Ti ghten the val ve body to
transmi ssi on case bol ts to 12 Nm (105 i n.l bs.).
CAUTION: The primary oil filter seal MUST be fully
installed flush against the oil pump body. DO NOT
install the seal onto the filter neck and attempt to
install the filter and seal as an assembly. Damage to
the transmission will result.
(51) I nstal l a new pri mary oi l fi l ter seal i n the oi l
pump i nl et bore. Seat the seal i n the bore wi th the
butt end of a hammer, or other sui tabl e tool .
(52) I nstal l the pri mary oi l fi l ter and the oi l cool er
return fi l ter (Fi g. 51). Ti ghten the screw to hol d the
pri mary oi l fi l ter to the val ve body to 4.5 Nm (40
i n.l bs.). Usi ng Oi l Fi l ter Wrench 8321, ti ghten the
cool er return oi l fi l ter to the transmi ssi on case to 14
Nm (125 i n.l bs.).
(53) Appl y RTV si l i cone to the oi l pan and i nstal l
the transmi ssi on oi l pan. Ti ghten the bol ts to 12 Nm
(105 i n.l bs.).
(54) I nstal l the i nput, output, and l i ne pressure
sensors (Fi g. 52). Ti ghten the bol ts to 12 Nm (105
i n.l bs.).
(55) I nstal l the manual shi ft l ever from the trans-
mi ssi on. Torque the retai ni ng cross-bol t to 16 Nm
(140 i n.l bs.).
INSTALLATION
(1) Check torque converter hub and hub dri ve fl ats
for sharp edges burrs, scratches, or ni cks. Pol i sh the
hub and fl ats wi th 320/400 gri t paper and crocus
cl oth i f necessary. Veri fy that the converter hub
Fig. 48 Install the Transmission Front Cover
1 - INNER SNAP-RING
2 - TRANSMISSION COVER
3 - OUTER SNAP-RING
Fig. 49 Seat Snap-Ring Using Tool 8255
1 - TOOL 8255
2 - SNAP-RING
Fig. 50 Install Valve Body Assembly
o-ri ng i s properl y i nstal l ed and i s free of any debri s.
The hub must be smooth to avoi d damagi ng pump
seal at i nstal l ati on.
(2) I f a repl acement transmi ssi on i s bei ng
i nstal l ed, transfer any components necessary, such as
the manual shi ft l ever and shi ft cabl e bracket, from
the ori gi nal transmi ssi on onto the repl acement trans-
mi ssi on.
fl ui d.
(4) Al i gn converter and oi l pump.
(5) Careful l y i nsert converter i n oi l pump. Then
rotate converter back and forth unti l ful l y seated i n
pump gears.
(6) Check converter seati ng wi th steel scal e and
shoul d be at l east 13mm (1/2 i n.) to rear of strai ght-
(7) Temporari l y secure converter wi th C-cl amp.
(8) Posi ti on transmi ssi on on jack and secure i t
wi th chai ns.
(9) Check condi ti on of converter dri vepl ate.
Repl ace the pl ate i f cracked, di storted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Appl y a l i ght coati ng of Mopar Hi gh Temp
Grease to the torque converter hub pocket i n the rear
pocket of the engi nes crankshaft.
(11) Rai se transmi ssi on (Fi g. 54) and al i gn the
torque converter wi th the dri ve pl ate and transmi s-
si on converter housi ng wi th the engi ne bl ock.
(12) Move transmi ssi on forward. Then rai se, l ower
or ti l t transmi ssi on to al i gn the converter housi ng
wi th engi ne bl ock dowel s.
(13) Careful l y work transmi ssi on forward and over
engi ne bl ock dowel s unti l converter hub i s seated i n
crankshaft. Veri fy that no wi res, or the transmi ssi on
vent hose, have become trapped between the engi ne
bl ock and the transmi ssi on.
(14) I nstal l two bol ts to attach the transmi ssi on to
the engi ne.
(15) I nstal l remai ni ng torque converter housi ng to
engi ne bol ts. Ti ghten to 68 Nm (50 ft.l bs.).
Fig. 51 Install Primary Oil and Cooler Filters
4 - VALVE BODY
Fig. 52 Install Input, Output, and Line Pressure
Sensors
Fig. 53 Checking Torque Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
(16) I nstal l transfer case, i f equi pped. Ti ghten
transfer case nuts to 35 Nm (26 ft.l bs.).
(17) I nstal l rear support to transmi ssi on. Ti ghten
bol ts to 47 Nm (35 ft.l bs.).
(18) Lower transmi ssi on onto crossmember and
i nstal l bol ts attachi ng transmi ssi on mount to cross-
member. Ti ghten cl evi s bracket to crossmember bol ts
to 47 Nm (35 ft.l bs.). Ti ghten the cl evi s bracket to
rear support bol t to 68 Nm (50 ft.l bs.).
(19) Remove engi ne support fi xture.
(20) Connect gearshi ft cabl e to transmi ssi on.
(21) Connect wi res to sol enoi d and pressure swi tch
assembl y (Fi g. 55) connector, i nput (Fi g. 56) and out-
put (Fi g. 57) speed sensors, and l i ne pressure sensor
(Fi g. 58). Be sure transmi ssi on harnesses are prop-
erl y routed.
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.
Fig. 54 Install Transmission
1 - ENGINE
2 - TRANSMISSION
Fig. 55 Connect Transmission Solenoid
1 - TRANSMISSION
2 - TRANSMISSION SOLENOID/TRS ASSEMBLY
Fig. 56 Connect Input Speed Sensor
1 - TRANSMISSION
Fig. 57 Connect Output Speed Sensor
1 - TRANSMISSION
(22) I nstal l torque converter-to-dri vepl ate bol ts.
(23) I nstal l starter motor and cool er l i ne bracket.
(24) Connect cool er l i nes to transmi ssi on.
(25) I nstal l transmi ssi on fi l l tube.
(26) I nstal l exhaust components, i f necessary.
(27) I nstal l the structural dust cover (Fi g. 59)
(Refer to 9 - ENGI NE/ENGI NE BLOCK/STRUC-
TURAL COVER - I NSTALLATI ON) onto the trans-
mi ssi on and the engi ne.
(28) Al i gn and connect propel l er shaft(s).
(29) Adjust gearshi ft cabl e i f necessary.
(30) I nstal l any ski d pl ates removed previ ousl y.
(Refer to 13 - FRAMES & BUMPERS/FRAME/
TRANSFER CASE SKI D PLATE - I NSTALLATI ON)
(32) Fi l l transmi ssi on wi th Mopar ATF +4, Auto-
mati c Transmi ssi on Fl ui d.
Fig. 58 Connect Line Pressure Sensor
1 - TRANSMISSION
Fig. 59 Transmission Collar
1 - ENGINE
2 - STRUCTURAL DUST COVER
3 - TRANSMISSION
HYDRAULIC SCHEMATICS
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SPECIFICATIONS
TRANSMISSION
GENERAL
Output Shaft End Play 0.22-0.55
mm
0.009-0.021
in.
Input Shaft End Play 0.46-0.89
mm
0.018-0.035
in.
2C Clutch Pack
Clearance
0.455-1.335
mm
0.018-0.053
in.
4C Clutch Pack
Clearance
0.770-1.390
mm
0.030-0.055
in.
L/R Clutch Pack
Clearance
1.00-1.74
mm
0.039-0.069
in.
OD Clutch Pack
Clearance
1.103-1.856
mm
0.043-0.073
in.
UD Clutch Pack
Clearance
0.84-1.54
mm
0.033-0.061
in.
Reverse Clutch Pack
Clearance
0.81-1.24
mm
0.032-0.049
in.
Recommended fluid Mopar ATF +4
GEAR RATIOS
1ST 3.00:1
2ND 1.67:1
2ND Prime 1.50:1
3RD 1.0:1
4TH 0.75:1
5TH 0.67:1
REVERSE 3.00:1
Fitting, cooler line at trans 17.5 - 155
Bolt, torque convertor 31 23 -
Bolt/nut, crossmember 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Bolt, oil pan 11.8 - 105
Screw, primary fluid filter 4.5 - 40
Bolt, oil pump 28.2 - 250
Bolt, oil pump body to cover 4.5 - 40
Screw, plate to oil pump body 4.5 - 40
Bolt, valve body to case 11.8 - 105
Plug, pressure test port 5.1 - 45
Bolt, reaction shaft support 11.8 - 105
Screw, valve body to transfer plate 5.6 - 50
Screw, solenoid module to transfer plate 5.7 - 50
Screw, accumulator cover 8 - 70
Screw, detent spring 4.5 - 40
Bolt, input speed sensor 11.8 - 105
Bolt, output speed sensor 11.8 - 105
Bolt, line pressure sensor 11.8 - 105
Bolt, extension housing 54 40 -
Valve, cooler return filter bypass 4.5 - 40
Screw, manual valve cam retaining 4.5 - 40
Bolt, manual lever 28.2 - 250
SPECIAL TOOLS
RFE TRANSMISSION
Gauge, Oil Pressure - C-3292
Gauge, Oil Pressure - C-3293SP
Dial Indicator - C-3339
Installer, Seal - C-3860-A
Compressor, Spring - 8249
Installer, Piston - 8252
Installer, Snap-ring - 8255
Stand, Support - 8257
Adapter, Pressure Tap - 8258-A
Adapter, Line Pressure - 8259
Fixture, Input Clutch Pressure - 8260
Plate, Alignment - 8261
End Play Set - 8266
Installer, Bearing - 8320
Wrench, Filter - 8321
Installer, Piston - 8504
4C RETAINER/BULKHEAD
DISASSEMBLY
(1) Remove the 2C pi ston bel l evi l l e spri ng snap-
ri ng from the 4C retai ner /bul khead (Fi g. 60).
(2) Remove the 2C pi ston Bel l evi l l e spri ng from
the retai ner/bul khead (Fi g. 60).
(3) Remove the 2C pi ston from the retai ner/bul k-
head. Use 20 psi of ai r pressure to remove the pi ston
i f necessary.
(4) Remove the 4C cl utch snap-ri ng from the
retai ner/bul khead (Fi g. 60).
(5) Remove the 4C cl utch pack from the retai ner/
bul khead (Fi g. 60).
(6) Usi ng Spri ng Compressor 8250 and a sui tabl e
shop press, compress the 4C pi ston return spri ng and
remove the snap-ri ng (Fi g. 60).
(7) Remove the 4C pi ston return spri ng and pi ston
from the retai ner/bul khead (Fi g. 60). Use 20 psi of
ai r pressure to remove the pi ston i f necessary.
Fig. 60 4C Retainer/Bulkhead Components
1 - SEAL 8 - REACTION PLATE
2 - 2C PISTON 9 - SNAP-RING
3 - PLATE 10 - RETURN SPRING
4 - DISC 11 - SEAL
5 - 2C BELLEVILLE SPRING 12 - 4C PISTON
6 - SNAP-RING 13 - 4C RETAINER/BULKHEAD
7 - SNAP-RING (SELECT)
ASSEMBLY
or scori ng.
(2) I nstal l new seal s on the 2C and 4C pi stons
(Fi g. 60).
(3) Lubri cate al l seal s wi th Mopar ATF +4 pri or
to i nstal l ati on.
(4) I nstal l the 4C pi ston i nto the 4C retai ner/bul k-
head (Fi g. 60).
(5) Posi ti on the 4C pi ston return spri ng onto the
4C pi ston.
shop press, compress the 4C pi ston return spri ng and
i nstal l the snap-ri ng (Fi g. 61).
(7) Assembl e and i nstal l the 4C cl utch pack i nto
the retai ner/bul khead (Fi g. 60) wi th the steel separa-
tor pl ate agai nst the pi ston.
(8) I nstal l the 4C reacti on pl ate and snap-ri ng i nto
the retai ner/bul khead (Fi g. 60). The 4C reacti on pl ate
i s non-di recti onal .
(9) Measure the 4C cl utch cl earance. The correct
cl utch cl earance i s 0.77-1.39 mm (0.030-0.055 i n.).
The snap-ri ng i s sel ectabl e. I nstal l the chosen snap-
ri ng and re-measure to veri fy the sel ecti on.
(10) I nstal l the 2C pi ston i nto the retai ner/bul k-
head (Fi g. 60).
(11) Posi ti on the 2C Bel l evi l l e spri ng onto the 2C
pi ston.
(12) Posi ti on the 2C Bel l evi l l e spri ng snap-ri ng
onto the 2C Bel l evi l l e spri ng (Fi g. 60).
shop press (Fi g. 62), compress the bel l evi l l e spri ng
unti l the snap-ri ng i s engaged wi th the snap-ri ng
groove i n the retai ner/bul khead.
Fig. 61 Compress 4C Piston Return Spring Using
Tool 8250
1 - PRESS
2 - TOOL 8250
Fig. 62 Compress 2C Belleville Spring Using Tool
8249
1 - PRESS
2 - TOOL 8249
4C RETAINER/BULKHEAD (Continued)
REMOVAL
(1) Remove the transfer case from the transmi s-
si on.
(2) Usi ng a screw mounted on a sl i de hammer,
remove the adapter housi ng seal .
INSTALLATION
(1) Cl ean the adapter seal bore i n the adapter
housi ng of any resi due or parti cl es remai ni ng from
the ori gi nal seal .
(2) I nstal l new oi l seal i n the adapter housi ng
usi ng Seal I nstal l er C-3860-A (Fi g. 63). A properl y
i nstal l ed seal i s fl ush to the face of the seal bore.
(3) I nstal l the transfer case onto the transmi ssi on.
BRAKE TRANSMISSION SHIFT
INTERLOCK SYSTEM
DESCRIPTION
The Brake Transmi ssi on Shi fter I nterl ock (BTSI )
(Fi g. 64), i s a sol enoi d operated system. I t consi sts of
a sol enoi d permanentl y mounted on the gearshi ft
cabl e.
OPERATION
The system l ocks the shi fter i nto the PARK posi ti on.
The i nterl ock system i s engaged whenever the i gni ti on
swi tch i s i n the LOCK or ACCESSORY posi ti on. An
addi ti onal el ectri cal l y acti vated feature wi l l prevent
shi fti ng out of the PARK posi ti on unl ess the brake pedal
i s depressed approxi matel y one-hal f an i nch. A magneti c
hol di ng devi ce i n l i ne wi th the park l ock cabl e i s ener-
gi zed when the i gni ti on i s i n the RUN posi ti on. When
the key i s i n the RUN posi ti on and the brake pedal i s
depressed, the shi fter i s unl ocked and wi l l move i nto
any posi ti on. The i nterl ock system al so prevents the
i gni ti on swi tch from bei ng turned to the LOCK or
ACCESSORY posi ti on, unl ess the shi fter i s ful l y l ocked
i nto the PARK posi ti on.
TRANSMISSION SHIFT INTERLOCK
(1) Veri fy that the key can onl y be removed i n the
PARK posi ti on
(2) When the shi ft l ever i s i n PARK And the shi ft
handl e pushbutton i s i n the OUT posi ti on, the i gni -
ti on key cyl i nder shoul d rotate freel y from OFF to
LOCK. When the shi fter i s i n any other gear or neu-
tral posi ti on, the i gni ti on key cyl i nder shoul d not
rotate to the LOCK posi ti on.
when the i gni ti on key cyl i nder i s i n the OFF posi -
ti on.
whi l e appl yi ng normal pushbutton force and i gni ti on
key cyl i nder i s i n the RUN or START posi ti ons
unl ess the foot brake pedal i s depressed approxi -
matel y 1/2 i nch (12mm).
when the i gni ti on key cyl i nder i s i n the ACCESSORY
or LOCK posi ti ons.
(6) Shi fti ng between any gears, NEUTRAL or i nto
PARK may be done wi thout depressi ng foot brake pedal
wi th i gni ti on swi tch i n RUN or START posi ti ons.
Fig. 63 Adapter Housing Seal Installation
1 - TOOL C-3860-A
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
5 - BTSI CONNECTOR
SHIFT INTERLOCK
Correct cabl e adjustment i s i mportant to proper
i nterl ock operati on. The gearshi ft cabl e must be cor-
rectl y adjusted i n order to shi ft out of PARK.
(1) Remove the steeri ng col umn tri m as necessary
for access to the brake transmi ssi on shi ft i nterl ock.
(2) Shi ft the transmi ssi on i nto the PARK posi ti on.
(3) Pul l upward on both the BTSI l ock tab and the
gearshi ft cabl e l ock tab (Fi g. 65).
(4) Veri fy that the shi ft l ever i s i n the PARK posi -
ti on.
(5) Veri fy posi ti ve engagement of the transmi ssi on
park l ock by attempti ng to rotate the propel l er shaft.
The shaft wi l l not rotate when the park l ock i s
engaged.
(6) Turn i gni ti on swi tch to LOCK posi ti on. Be
sure ignition key cylinder is in the LOCK posi-
tion. Cable will not adjust correctly in any
other position.
(7) Ensure that the cabl e i s free to sel f-adjust by
pushi ng cabl e rearward and rel easi ng.
(8) Push the gearshi ft cabl e l ock tab down unti l i t
snaps i n pl ace.
(9) Locate the BTSI al i gnment hol e i n the bottom
of the BTSI mechani sm between the BTSI l ock tab
and the BTSI connector.
(10) Move the BTSI assembl y up or down on the
gearshi ft cabl e unti l an appropri ate si ze dri l l bi t can
be i nserted i nto the al i gnment hol e and through the
assembl y.
(11) Push the BTSI l ock tab down unti l i t snaps
i nto pl ace and remove the dri l l bi t.
(12) I nstal l any steeri ng col umn tri m previ ousl y
removed.
BTSI FUNCTION CHECK
(1) Veri fy removal of i gni ti on key al l owed i n PARK
posi ti on onl y.
(2) When the shi ft l ever i s i n PARK, the i gni ti on
key cyl i nder shoul d rotate freel y from off to l ock.
When the shi fter i s i n any other posi ti on, the i gni ti on
key shoul d not rotate from off to l ock.
(3) Shi fti ng out of PARK shoul d be possi bl e when
the i gni ti on key cyl i nder i s i n the off posi ti on.
whi l e appl yi ng normal force, and i gni ti on key cyl i n-
der i s i n the run or start posi ti ons, unl ess the foot
brake pedal i s depressed approxi matel y 1/2 i nch
(12mm).
when the i gni ti on key cyl i nder i s i n the accessory or
l ock posi ti on.
(6) Shi fti ng between any gear and NEUTRAL, or
PARK, may be done wi thout depressi ng foot brake
wi th i gni ti on swi tch i n run or start posi ti ons.
(7) Engi ne starts must be possi bl e wi th shi fter
l ever i n PARK or NEUTRAL posi ti ons onl y. Engi ne
starts must not be possi bl e i n any posi ti on other than
PARK or NEUTRAL.
(8) Wi th shi fter l ever i n the:
PARK posi ti on - Appl y upward force on the shi ft
arm and remove pressure. Engi ne starts must be
possi bl e.
PARK posi ti on - Appl y downward force on the
be possi bl e.
NEUTRAL posi ti on - Normal posi ti on. Engi ne
NEUTRAL posi ti on - Engi ne runni ng and brakes
appl i ed, appl y upward force on the shi ft arm. Trans-
mi ssi on shal l not be abl e to shi ft from neutral to
reverse.
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
5 - BTSI CONNECTOR
BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM (Continued)
FLUID AND FILTER
INCORRECT FLUID LEVEL
A l ow fl ui d l evel al l ows the pump to take i n ai r
al ong wi th the fl ui d. Ai r i n the fl ui d wi l l cause fl ui d
pressures to be l ow and devel op sl ower than normal .
I f the transmi ssi on i s overfi l l ed, the gears churn the
fl ui d i nto foam. Thi s aerates the fl ui d and causi ng
the same condi ti ons occurri ng wi th a l ow l evel . I n
ei ther case, ai r bubbl es cause fl ui d overheati ng, oxi -
dati on and varni sh bui l dup whi ch i nterferes wi th
val ve and cl utch operati on. Foami ng al so causes fl ui d
expansi on whi ch can resul t i n fl ui d overfl ow from the
transmi ssi on vent or fi l l tube. Fl ui d overfl ow can eas-
i l y be mi staken for a l eak i f i nspecti on i s not careful .
BURNT FLUID
Burnt, di scol ored fl ui d i s a resul t of overheati ng
whi ch has three pri mary causes.
(1) I nternal cl utch sl i ppage, usual l y caused by l ow
l i ne pressure, i nadequate cl utch appl y pressure, or
cl utch seal fai l ure.
(2) A resul t of restri cted fl ui d fl ow through the
mai n and/or auxi l i ary cool er. Thi s condi ti on i s usu-
al l y the resul t of a faul ty or i mproperl y i nstal l ed
drai nback val ve, a damaged mai n cool er, or severe
restri cti ons i n the cool ers and l i nes caused by debri s
or ki nked l i nes.
(3) Heavy duty operati on wi th a vehi cl e not prop-
erl y equi pped for thi s type of operati on. Trai l er tow-
i ng or si mi l ar hi gh l oad operati on wi l l overheat the
transmi ssi on fl ui d i f the vehi cl e i s i mproperl y
equi pped. Such vehi cl es shoul d have an auxi l i ary
transmi ssi on fl ui d cool er, a heavy duty cool i ng sys-
tem, and the engi ne/axl e rati o combi nati on needed to
handl e heavy l oads.
CONTAMINATION
Transmi ssi on fl ui d contami nati on i s general l y a
resul t of:
addi ng i ncorrect fl ui d
fai l ure to cl ean di psti ck and fi l l tube when
checki ng l evel
engi ne cool ant enteri ng the fl ui d
i nternal fai l ure that generates debri s
overheat that generates sl udge (fl ui d break-
down)
fai l ure to repl ace contami nated converter after
repai r
The use of non-recommended fl ui ds can resul t i n
transmi ssi on fai l ure. The usual resul ts are errati c
shi fts, sl i ppage, abnormal wear and eventual fai l ure
due to fl ui d breakdown and sl udge formati on. Avoi d
thi s condi ti on by usi ng recommended fl ui ds onl y.
The di psti ck cap and fi l l tube shoul d be wi ped
cl ean before checki ng fl ui d l evel . Di rt, grease and
other forei gn materi al on the cap and tube coul d fal l
i nto the tube i f not removed beforehand. Take the
ti me to wi pe the cap and tube cl ean before wi thdraw-
i ng the di psti ck.
Engi ne cool ant i n the transmi ssi on fl ui d i s gener-
al l y caused by a cool er mal functi on. The onl y remedy
i s to repl ace the radi ator as the cool er i n the radi ator
i s not a servi ceabl e part. I f cool ant has ci rcul ated
through the transmi ssi on, an overhaul i s necessary.
The torque converter shoul d al so be repl aced when-
ever a fai l ure generates sl udge and debri s. Thi s i s
necessary because normal converter fl ushi ng proce-
dures wi l l not remove al l contami nants.
STANDARD PROCEDURE
CHECK
Low fl ui d l evel can cause a vari ety of condi ti ons
because i t al l ows the pump to take i n ai r al ong wi th
the fl ui d. As i n any hydraul i c system, ai r bubbl es
make the fl ui d spongy, therefore, pressures wi l l be
l ow and bui l d up sl owl y.
I mproper fi l l i ng can al so rai se the fl ui d l evel too
hi gh. When the transmssi on has too much fl ui d, the
geartrai n churns up foam and cause the same condi -
ti ons whi ch occur wi th a l ow fl ui d l evel .
I n ei ther case, ai r bubbl es can cause overheati ng
and/or fl ui d oxi dati on, and varni shi ng. Thi s can
i nterfere wi th normal val ve, cl utch, and accumul ator
operati on. Foami ng can al so resul t i n fl ui d escapi ng
from the transmi ssi on vent where i t may be mi s-
taken for a l eak.
After the fl ui d has been checked, seat the di psti ck
ful l y to seal out water and di rt.
The transmi ssi on has a di psti ck to check oi l l evel .
I t i s l ocated on the ri ght si de of the engi ne. Be sure
to wi pe al l di rt from di psti ck handl e before removi ng.
The torque converter fi l l s i n both the P (PARK)
and N (NEUTRAL) posi ti ons. Pl ace the sel ector l ever
i n P (PARK) to be sure that the fl ui d l evel check i s
accurate. The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground. At normal operati ng temperature
(approxi matel y 82 C. or 180 F.), the fl ui d l evel i s cor-
rect i f i t i s i n the HOT regi on (cross-hatched area) on
the oi l l evel i ndi cator. The fl ui d l evel wi l l be approx-
i matel y at the upper COLD hol e of the di psti ck at
70 F fl ui d temperature.
NOTE: Engine and Transmission should be at nor-
mal operating temperature before performing this
procedure.
(1) Start engi ne and appl y parki ng brake.
(2) Shi ft the transmi ssi on i nto DRI VE for approxi -
matel y 2 seconds.
(3) Shi ft the transmi ssi on i nto REVERSE for
approxi matel y 2 seconds.
(4) Shi ft the transmi ssi on i nto PARK.
(5) Hook up DRB scan tool and sel ect transmi s-
si on.
(6) Sel ect sensors.
(7) Read the transmi ssi on temperature val ue.
(8) Compare the fl ui d temperature val ue wi th the
chart. (Fi g. 66)
(9) Adjust transmi ssi on fl ui d l evel shown on the
di psti ck accordi ng to the chart.
NOTE: After adding any fluid to the transmission,
wait a minimum of 2 minutes for the oil to fully
drain from the fill tube into the transmission before
rechecking the fluid level.
(10) Check transmi ssi on for l eaks.
STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT
For proper servi ce i nterval s (Refer to LUBRI CA-
TI ON & MAI NTENANCE/MAI NTENANCE SCHED-
ULES - DESCRI PTI ON).
REMOVAL
(2) Pl ace a l arge di ameter shal l ow drai n pan
beneath the transmi ssi on pan.
(3) Remove bol ts hol di ng front and si des of pan to
transmi ssi on.
(4) Loosen bol ts hol di ng rear of pan to transmi s-
si on.
(5) Sl owl y separate front of pan away from trans-
mi ssi on al l owi ng the fl ui d to drai n i nto drai n pan.
(6) Hol d up pan and remove remai ni ng bol ts hol d-
i ng pan to transmi ssi on.
(7) Whi l e hol di ng pan l evel , l ower pan away from
transmi ssi on.
(8) Pour remai ni ng fl ui d i n pan i nto drai n pan.
(9) Remove screw hol di ng fi l ter to val ve body (Fi g.
67).
(10) Separate fi l ter from val ve body and oi l pump
and pour fl ui d i n fi l ter i nto drai n pan.
Fig. 66 Transmission Fluid Temperature Chart
(11) Remove and di scard the oi l fi l ter seal from the
bottom of the oi l pump.
(12) I f repl aci ng the cool er return fi l ter, use Oi l
Fi l ter Wrench 8321 to remove the fi l ter from the
transmi ssi on.
(13) Di spose of used trans fl ui d and fi l ter(s) prop-
erl y.
INSPECTION
I nspect bottom of pan and magnet for excessi ve
amounts of metal . A l i ght coati ng of cl utch materi al
on the bottom of the pan does not i ndi cate a probl em
unl ess accompani ed by a sl i ppi ng condi ti on or shi ft
l ag. I f fl ui d and pan are contami nated wi th excessi ve
amounts of debri s, refer to the di agnosi s secti on of
thi s group.
CLEANING
(1) Usi ng a sui tabl e sol vent, cl ean pan and mag-
net.
(2) Usi ng a sui tabl e gasket scraper, cl ean ori gi nal
seal i ng materi al from surface of transmi ssi on case
and the transmi ssi on pan.
INSTALLATION
(2) Pl ace repl acement fi l ter i n posi ti on on val ve
body and i nto the oi l pump.
(3) I nstal l screw to hol d fi l ter to val ve body (Fi g.
67). Ti ghten screw to 4.5 Nm (40 i n. l bs.) torque.
(4) I nstal l new cool er return fi l ter onto the trans-
mi ssi on, i f necessary. Torque the fi l ter to 14.12 Nm
(125 i n.l bs.).
(5) Pl ace bead of Mopar RTV seal ant onto the
transmi ssi on case seal i ng surface.
(6) Pl ace pan i n posi ti on on transmi ssi on.
(7) I nstal l bol ts to hol d pan to transmi ssi on.
Ti ghten bol ts to 11.8 Nm (105 i n. l bs.) torque.
Mopar ATF +4.
FILL
To avoi d overfi l l i ng transmi ssi on after a fl ui d
change or overhaul , perform the fol l owi ng procedure:
(1) Remove di psti ck and i nsert cl ean funnel i n
transmi ssi on fi l l tube.
(2) Add fol l owi ng i ni ti al quanti ty of Mopar ATF
+4 to transmi ssi on:
(a) I f onl y fl ui d and fi l ter were changed, add 10
pints (5 quarts) of ATF +4 to transmi ssi on.
(b) I f transmi ssi on was compl etel y overhaul ed
and the torque converter was repl aced or drai ned,
add 24 pints (12 quarts) of ATF +4 to transmi s-
si on.
(3) Check the transmi ssi on fl ui d (Refer to 21 -
TRANSMI SSI ON/AUTOMATI C - RFE/FLUI D -
STANDARD PROCEDURE) and adjust as requi red.
GEARSHIFT CABLE
CABLE
(1) Engi ne starts must be possi bl e wi th shi ft l ever
i n PARK or NEUTRAL posi ti ons onl y. Engi ne starts
must not be possi bl e i n any other gear posi ti on.
(2) Wi th the shi ft l ever i n the:
(a) PARK posi ti on - Appl y upward force on the
be possi bl e.
(b) PARK posi ti on - Appl y downward force on
the shi ft arm and remove pressure. Engi ne starts
must be possi bl e.
(c) NEUTRAL posi ti on - Normal posi ti on. Engi ne
(d) NEUTRAL posi ti on - Engi ne runni ng and
brakes appl i ed, appl y upward force on the shi ft
arm. Transmi ssi on shal l not be abl e to shi ft from
neutral to reverse.
Fig. 67 Transmission Filters - 4X4 Shown
4 - VALVE BODY
REMOVAL
(3) Di sengage cabl e eyel et at transmi ssi on shi ft
l ever and pul l cabl e adjuster out of mounti ng bracket
(Fi g. 68) or (Fi g. 69).
(5) Remove the dash panel i nsul ati on pad as nec-
essary to access the gearshi ft cabl e grommet (Fi g.
70).
(6) Remove grommet from the dash panel .
(7) Remove any steeri ng col umn tri m necessary to
access the gearshi ft cabl e and BTSI mechani sm.
(8) Di sconnect the BTSI wi ri ng connector.
(9) Di sconnect cabl e at l ower col umn bracket and
shi ft l ever pi n and pul l the cabl e through the dash
panel openi ng i nto the vehi cl e (Fi g. 71).
(10) Remove gearshi ft cabl e from vehi cl e.
1 - GEARSHIFT CABLE
3 - MANUAL LEVER
Fig. 69 Gearshift Cable at Transmission - RE
1 - GEARSHIFT CABLE
2 - RE TRANSMISSION
3 - MANUAL LEVER
1 - GEARSHIFT CABLE
2 - GROMMET
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
5 - BTSI CONNECTOR
INSTALLATION
(1) Route the transmi ssi on end of the gearshi ft
cabl e through the openi ng i n the dash panel (Fi g.
72).
(2) Seat the cabl e grommet i nto the dash panel
openi ng.
(3) Snap the cabl e i nto the steeri ng col umn
bracket so the retai ni ng ears (Fi g. 73) are engaged
and snap the cabl e eyel et onto the shi ft l ever bal l
stud.
(5) Pl ace the transmi ssi on manual shi ft l ever i n
the PARK detent (rearmost) posi ti on and rotate
prop shaft to ensure transmi ssi on i s i n PARK.
(6) Route the gearshi ft cabl e through the transmi s-
si on mounti ng bracket and secure the cabl e by snap-
pi ng the cabl e retai ni ng ears i nto the transmi ssi on
bracket and snappi ng the cabl e eyel et on the manual
shi ft l ever bal l stud.
(8) Lock the shi ft cabl e adjustment by pressi ng the
cabl e adjuster l ock tab downward unti l i t snaps i nto
pl ace.
(9) Check for proper operati on of the transmi ssi on
range sensor.
(10) Adjust the gearshi ft cabl e (Refer to 21 -
TRANSMI SSI ON/AUTOMATI C/GEAR SHI FT
CABLE - ADJUSTMENTS) and BTSI mechani sm
(Refer to 21 - TRANSMI SSI ON/AUTOMATI C/
BRAKE TRANSMI SSI ON SHI FT I NTERLOCK SYS-
TEM - ADJUSTMENTS) as necessary.
ADJ USTMENTS
GEARSHIFT CABLE
Check adjustment by starti ng the engi ne i n PARK
and NEUTRAL. Adjustment i s CORRECT i f the
engi ne starts onl y i n these posi ti ons. Adjustment i s
I NCORRECT i f the engi ne starts i n one but not both
posi ti ons. I f the engi ne starts i n any posi ti on other
than PARK or NEUTRAL, or i f the engi ne wi l l not
start at al l , the transmi ssi on range sensor may be
faul ty.
Gearshift Adjustment Procedure
(2) Rel ease cabl e adjuster l ock tab (underneath the
steeri ng col umn) (Fi g. 74) to unl ock cabl e.
(4) Di sengage the cabl e eyel et from the transmi s-
si on manual shi ft l ever.
(5) Veri fy transmi ssi on shi ft l ever i s i n PARK
detent by movi ng l ever ful l y rearward. Last rearward
detent i s PARK posi ti on.
(6) Veri fy posi ti ve engagement of transmi ssi on
park l ock by attempti ng to rotate propel l er shaft.
Shaft wi l l not rotate when park l ock i s engaged.
(7) Snap the cabl e eyel et onto the transmi ssi on
manual shi ft l ever.
1 - GEARSHIFT CABLE
2 - GROMMET
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
5 - BTSI CONNECTOR
(9) Lock shi ft cabl e by pressi ng cabl e adjuster l ock
tab downward unti l i t snaps i nto pl ace.
(10) Check engi ne starti ng. Engi ne shoul d start
onl y i n PARK and NEUTRAL
HOLDING CLUTCHES
DESCRIPTION
Three hydraul i cal l y appl i ed mul ti -di sc cl utches are
used to hol d some pl anetary geartrai n components
stati onary whi l e the i nput cl utches dri ve others. The
2C, 4C, and Low/Reverse cl utches are consi dered
hol di ng cl utches. The 2C and 4C cl utches are l ocated
i n the 4C retai ner/bul khead (Fi g. 75), whi l e the Low/
Reverse cl utch i s l ocated at the rear of the transmi s-
1 - STEERING COLUMN
2 - GEARSHIFT CABLE
5 - BTSI CONNECTOR
Fig. 75 2C and 4C Clutches
1 - SEAL 8 - REACTION PLATE
2 - 2C PISTON 9 - SNAP-RING
3 - PLATE 10 - RETURN SPRING
4 - DISC 11 - SEAL
5 - 2C BELLEVILLE SPRING 12 - 4C PISTON
6 - SNAP-RING 13 - 4C RETAINER/BULKHEAD
7 - SNAP-RING (SELECT)
OPERATION
2C CLUTCH
The 2C cl utch i s hydraul i cal l y appl i ed i n second
and fi fth gear by pressuri zed fl ui d agai nst the 2C
pi ston. When the 2C cl utch i s appl i ed, the reverse
sun gear assembl y i s hel d or grounded to the trans-
mi ssi on case by hol di ng the reacti on pl anetary car-
ri er.
4C CLUTCH
The 4C cl utch i s hydraul i cal l y appl i ed i n second
pri me and fourth gear by pressuri zed fl ui d agai nst
the 4C cl utch pi ston. When the 4C cl utch i s appl i ed,
the reacti on annul us gear i s hel d or grounded to the
LOW/REVERSE CLUTCH
The Low/Reverse cl utch i s hydraul i cal l y appl i ed i n
park, reverse, neutral , and fi rst gear, onl y at l ow
speeds, by pressuri zed fl ui d agai nst the Low/Reverse
cl utch pi ston. When the Low/Reverse cl utch i s
appl i ed, the i nput annul us assembl y i s hel d or
grounded to the transmi ssi on case.
Fig. 76 Low/Reverse Clutch
1 - SNAP-RING (SELECT) 8 - SEAL
2 - REACTION PLATE 9 - BELLEVILLE SPRING
3 - DISC 10 - RETAINER
4 - PLATE 11 - SNAP-RING
5 - L/R CLUTCH RETAINER 12 - OVERRUNNING CLUTCH
6 - SEAL 13 - SNAP-RING
7 - PISTON
HOLDING CLUTCHES (Continued)
INPUT CLUTCH ASSEMBLY
DESCRIPTION
Three hydraul i cal l y appl i ed i nput cl utches are used
to dri ve pl anetary components. The underdri ve, over-
dri ve, and reverse cl utches are consi dered i nput
cl utches and are contai ned wi thi n the i nput cl utch
assembl y (Fi g. 77) and (Fi g. 78). The i nput cl utch
assembl y al so contai ns:
I nput shaft
I nput hub
Cl utch retai ner
Underdri ve pi ston
Overdri ve/reverse pi ston
Overdri ve hub
Underdri ve hub
OPERATION
The three i nput cl utches are responsi bl e for dri vi ng
di fferent components of the pl anetary geartrai n.
UNDERDRIVE CLUTCH
The underdri ve cl utch i s hydraul i cal l y appl i ed i n
fi rst, second, second pri me, and thi rd (di rect) gears
by pressuri zed fl ui d agai nst the underdri ve pi ston.
When the underdri ve cl utch i s appl i ed, the under-
dri ve hub dri ves the i nput sun gear.
Fig. 77 Input Clutch Assembly - Part 1
1 - INPUT CLUTCH HUB 11 - UD CLUTCH
2 - O-RING SEALS 12 - PLATE
3 - SEAL 13 - CLUTCH RETAINER
4 - SNAP-RING 14 - SEAL
5 - SNAP-RING 15 - OD/REV PISTON
6 - UD BALANCE PISTON 16 - BELLEVILLE SPRING
7 - SNAP-RING 17 - SNAP-RING
8 - UD PISTON 18 - SEAL RINGS
9 - SPRING 19 - INPUT SHAFT
10 - DISC 20 - LUBRICATION CHECK VALVE AND SNAP-RING
OVERDRIVE CLUTCH
The overdri ve cl utch i s hydraul i cal l y appl i ed i n
thi rd (di rect), fourth, and fi fth gears by pressuri zed
fl ui d agai nst the overdri ve/reverse pi ston. When the
overdri ve cl utch i s appl i ed, the overdri ve hub dri ves
the reverse carri er/i nput annul us assembl y.
REVERSE CLUTCH
The reverse cl utch i s hydraul i cal l y appl i ed i n
reverse gear by pressuri zed fl ui d agai nst the over-
dri ve/reverse pi ston. When the reverse cl utch i s
appl i ed, the reacti on annul us gear i s dri ven.
DISASSEMBLY
(1) Remove the reverse reacti on pl ate sel ecti ve
snap-ri ng from the i nput cl utch retai ner (Fi g. 79).
(2) Remove the reverse reacti on pl ate from the
i nput cl utch retai ner.
(3) Remove the reverse hub and reverse cl utch
pack from the i nput cl utch retai ner.
(4) Remove the number 4 beari ng from the over-
dri ve hub.
(5) Remove the overdri ve hub from the i nput
cl utch retai ner (Fi g. 79).
1 - BEARING NUMBER 3 10 - SNAP-RING (SELECT)
2 - OD HUB/SHAFT 11 - PLATE
3 - SNAP-RING (WAVE) 12 - DISC
4 - REV/OD REACTION PLATE 13 - OD CLUTCH
5 - BEARING NUMBER 4 14 - SNAP-RING (TAPERED)
6 - SNAP-RING (FLAT) 15 - UD/OD REACTION PLATE
7 - REVERSE HUB/SHAFT 16 - SNAP-RING (FLAT)
8 - REVERSE CLUTCH 17 - UD HUB/SHAFT
9 - REVERSE REACTION PLATE 18 - BEARING NUMBER 2
INPUT CLUTCH ASSEMBLY (Continued)
(6) Remove the number 3 beari ng from the under-
dri ve hub.
(7) Remove the OD/reverse reacti on pl ate snap-
ri ng from the i nput cl utch retai ner.
(8) Remove the underdri ve hub, overdri ve cl utch,
and overdri ve reacti on pl ate from the i nput cl utch
retai ner (Fi g. 79).
NOTE: The overdrive friction discs and steel discs
are thicker than the matching components in the
underdrive and reverse clutches.
cl utch hub.
(10) Remove the overdri ve cl utch wave snap-ri ng
from the i nput cl utch retai ner.
(11) Remove the UD/OD reacti on pl ate tapered
snap-ri ng from the i nput cl utch retai ner.
(12) Remove the UD/OD reacti on pl ate from the
(13) Remove the UD/OD reacti on pl ate fl at snap-
ri ng from the i nput cl utch retai ner (Fi g. 79).
(14) Remove the underdri ve cl utch pack from the
i nput cl utch retai ner (Fi g. 81).
(15) Usi ng Spri ng Compressor 8251, compress the
UD/OD bal ance pi ston and remove the snap-ri ng
from the i nput cl utch hub (Fi g. 80).
(16) Remove the UD/OD bal ance pi ston and pi ston
return spri ng from the i nput cl utch retai ner (Fi g. 81).
(17) Remove the underdri ve pi ston from the i nput
NOTE: Both the UD/OD balance piston and the
underdrive piston have seals molded onto them. If
the seal is damaged, do not attempt to install a new
seal onto the piston. The piston/seal must be
replaced as an assembly.
(18) Remove the i nput cl utch retai ner tapered
snap-ri ng.
(19) Separate i nput cl utch retai ner from i nput
cl utch hub.
(20) Separate OD/reverse pi ston from i nput cl utch
hub retai ner (Fi g. 81).
(21) Remove al l seal s and o-ri ngs from the i nput
shaft and i nput hub. The o-ri ngs on the i nput hub
are col or coded. Be sure to make note of whi ch o-ri ng
bel ongs i n whi ch l ocati on.
Fig. 80 Compressing UD/OD Balance Piston Using
Tool 8251
1 - PRESS
2 - TOOL 8251
3 - BALANCE PISTON
ASSEMBLY
(1) I nstal l al l new seal s and o-ri ngs onto the i nput
shaft and i nput hub. The o-ri ngs on the i nput hub
are col or coded. Be sure to i nstal l the correct o-ri ng
i n the correct l ocati on.
(2) Check the transmi ssi on l ubri cati on check val ve
l ocated i n the i nput shaft usi ng shop ai r. The val ve
shoul d onl y al l ow ai r fl ow i n one di recti on. I f the
val ve al l ows no ai r fl ow, or ai r fl ow i n both di rec-
ti ons, the val ve wi l l need to be repl aced.
(3) Lubri cate al l seal s wi th Mopar ATF +4, Auto-
mati c Transmi ssi on Fl ui d, pri or to i nstal l ati on.
(4) Assembl e the OD/reverse pi ston onto the i nput
cl utch hub (Fi g. 82).
(5) Assembl e the i nput cl utch retai ner onto the
i nput cl utch hub.
(6) I nstal l the i nput cl utch retai ner tapered snap-
ri ng wi th tapered si de up onto the i nput cl utch hub.
Fig. 82 Input Clutch Assembly - Part I
(7) I nstal l Pi ston Gui des 8504 i nto the i nput cl utch
retai ner (Fi g. 83) and onto the i nput cl utch hub to
gui de the i nner and outer underdri ve pi ston seal s
i nto posi ti on.
(8) I nstal l the underdri ve pi ston i nto the i nput
cl utch retai ner and over the i nput cl utch hub (Fi g.
82).
(9) I nstal l the UD/OD bal ance pi ston return spri ng
pack i nto the i nput cl utch retai ner.
(10) I nstal l Pi ston Gui de 8252 i nto the i nput
cl utch retai ner (Fi g. 84) to gui de the UD/OD bal ance
pi ston seal i nto posi ti on i nsi de the underdri ve pi ston.
(11) I nstal l the UD/OD bal ance pi ston i nto the
i nput cl utch retai ner and the underdri ve pi ston.
(12) Usi ng Spri ng Compressor 8251, compress the
UD/OD return spri ng pack and secure the pi ston i n
pl ace wi th the snap-ri ng (Fi g. 85).
(13) I nstal l the underdri ve cl utch pack i nto the
i nput cl utch retai ner (Fi g. 82).
(14) I nstal l the UD/OD reacti on pl ate l ower fl at
snap-ri ng (Fi g. 86). The correct snap-ri ng can be
i denti fi ed by the two tabbed ears.
(15) I nstal l the UD/OD reacti on pl ate i nto the
i nput cl utch retai ner. The reacti on pl ate i s to be
i nstal l ed wi th the bi g step down.
(16) I nstal l the UD/OD reacti on pl ate upper
tapered snap-ri ng wi th tapered si de up.
(17) I nstal l the i nput cl utch assembl y i nto I nput
Cl utch Pressure Fi xture 8260 (Fi g. 87). Mount a di al
i ndi cator to the assembl y, push down on the cl utch
di scs and zero the i ndi cator agai nst the underdri ve
cl utch di scs (Fi g. 88). Appl y 20 psi of ai r pressure to
the underdri ve cl utch and record the di al i ndi cator
readi ng. Measure and record UD cl utch pack mea-
surement i n four (4) pl aces, 90 apart. Take average
of four measurements and compare wi th UD cl utch
pack cl earance speci fi cati on. The correct cl utch cl ear-
ance i s 0.84-1.54 mm (0.033-0.061 i n.). The reacti on
pl ate i s not sel ecti ve. I f the cl utch cl earance i s not
wi thi n speci fi cati on, repl ace the reacti on pl ate al ong
wi th al l the fri cti on and steel di scs.
(18) I nstal l the overdri ve cl utch pack i nto the
i nput cl utch retai ner (Fi g. 86). The overdri ve steel
Fig. 83 Install Underdrive Piston Using Tool 8504
1 - TOOL 8504
Fig. 84 Install Balance Piston Using Tool 8252
1 - TOOL 8252
Fig. 85 Compressing UD/OD Balance Piston Using
Tool 8251
1 - PRESS
2 - TOOL 8251
3 - BALANCE PISTON
separator pl ates can be i denti fi ed by the l ack of the
hal f-moon cuts i n the l ocati ng tabs.
(19) I nstal l the overdri ve cl utch wavy snap-ri ng
wi th the two tabbed ears i nto the i nput cl utch
retai ner.
(20) I nstal l the OD/reverse reacti on pl ate i nto the
i nput cl utch retai ner. The reacti on pl ate i s non-di rec-
ti onal (Fi g. 86).
(21) I nstal l the OD/reverse reacti on pl ate fl at
snap-ri ng i nto the i nput cl utch retai ner.
(22) Mount a di al i ndi cator to the assembl y and
zero the i ndi cator agai nst the OD/reverse reacti on
pl ate (Fi g. 89). Appl y 20 psi of ai r pressure to the
overdri ve cl utch and record the di al i ndi cator read-
i ng. Measure and record OD cl utch pack measure-
ment i n four (4) pl aces, 90 apart. Take average of
four measurements and compare wi th OD cl utch
pack cl earance speci fi cati on.Veri fy that the cl utch
cl earance i s 1.103-1.856 mm (0.043-0.073 i n.). The
reacti on pl ate i s not sel ecti ve. I f the cl utch cl earance
i s not wi thi n speci fi cati on, repl ace the reacti on pl ate
al ong wi th al l the fri cti on and steel di scs.
(23) I nstal l the reverse cl utch pack i nto the i nput
Fig. 86 Input Clutch Assembly - Part II
(24) I nstal l the reverse reacti on pl ate i nto the
(25) I nstal l the reverse reacti on pl ate sel ecti ve
snap-ri ng i nto the i nput cl utch retai ner.
(26) Mount a di al i ndi cator to the assembl y, push
down on the cl utch di scs, pul l up on the reacti on
pl ate to ensure the pl ate i s properl y seated and zero
the i ndi cator agai nst the reverse cl utch di scs (Fi g.
90). Appl y 20 psi of ai r pressure to the reverse cl utch
and record the di al i ndi cator readi ng. Measure and
record Reverse cl utch pack measurement i n four (4)
pl aces, 90 apart. Take average of four measurements
and compare wi th Reverse cl utch pack cl earance
speci fi cati on. The correct cl utch cl earance i s 0.58-1.47
mm (0.023-0.058 i n.). Adjust as necessary. I nstal l the
chosen snap-ri ng and re-measure to veri fy sel ecti on.
(27) Remove the reverse cl utch pack from the
Fig. 87 Input Clutch Assembly Mounted on Tool
8260
2 - TOOL 8260
Fig. 88 Measuring UD Clutch Clearance
1 - TOOL C-3339
2 - UNDERDRIVE CLUTCH PACK
Fig. 89 Measuring OD Clutch Clearance
1 - TOOL C-3339
2 - OD/REV REACTION PLATE
Fig. 90 Measuring Reverse Clutch Clearance
1 - TOOL C-3339
2 - REVERSE CLUTCH PACK
(28) I nstal l the number 2 beari ng onto the under-
dri ve hub wi th outer race agai nst the hub wi th petro-
l eum jel l y.
(29) I nstal l the underdri ve hub i nto the i nput
cl utch retai ner.
(30) I nstal l the number 3 beari ng i nto the over-
dri ve hub wi th the outer race agai nst the hub wi th
petrol eum jel l y.
(31) I nstal l the overdri ve hub i nto the i nput cl utch
retai ner.
(32) I nstal l the number 4 beari ng i nto the reverse
hub wi th outer race agai nst the hub wi th petrol eum
jel l y.
(33) I nstal l the reverse hub i nto the i nput cl utch
retai ner.
(34) I nstal l the compl ete reverse cl utch pack.
(35) I nstal l the reverse reacti on pl ate and snap-
ri ng.
(36) Push up on reacti on pl ate to al l ow reverse
cl utch to move freel y.
INPUT SPEED SENSOR
DESCRIPTION
The I nput and Output Speed Sensors are two-wi re
magneti c pi ckup devi ces that generate AC si gnal s as
rotati on occurs. They are mounted i n the l eft si de of
the transmi ssi on case and are consi dered pri mary
i nputs to the Transmi ssi on Control Modul e (TCM).
OPERATION
The I nput Speed Sensor provi des i nformati on on
how fast the i nput shaft i s rotati ng. As the teeth of
the i nput cl utch hub pass by the sensor coi l , an AC
vol tage i s generated and sent to the TCM. The TCM
i nterprets thi s i nformati on as i nput shaft rpm.
The Output Speed Sensor generates an AC si gnal
i n a si mi l ar fashi on, though i ts coi l i s exci ted by rota-
ti on of the rear pl anetary carri er l ugs. The TCM
i nterprets thi s i nformati on as output shaft rpm.
The TCM compares the i nput and output speed
si gnal s to determi ne the fol l owi ng:
Transmi ssi on gear rati o
Speed rati o error detecti on
CVI cal cul ati on
The TCM al so compares the i nput speed si gnal and
the engi ne speed si gnal to determi ne the fol l owi ng:
Torque converter cl utch sl i ppage
Torque converter el ement speed rati o
REMOVAL
(2) Pl ace a sui tabl e fl ui d catch pan under the
transmi ssi on.
(3) Remove the wi ri ng connector from the i nput
speed sensor (Fi g. 91).
(4) Remove the bol t hol di ng the i nput speed sensor
to the transmi ssi on case.
(5) Remove the i nput speed sensor from the trans-
mi ssi on case.
INSTALLATION
(1) I nstal l the i nput speed sensor i nto the trans-
mi ssi on case.
(2) I nstal l the bol t to hol d the i nput speed sensor
i nto the transmi ssi on case. Ti ghten the bol t to 11.9
Nm (105 i n.l bs.).
(3) I nstal l the wi ri ng connector onto the i nput
speed sensor
(4) Veri fy the transmi ssi on fl ui d l evel . Add fl ui d as
necessary.
LINE PRESSURE (LP) SENSOR
DESCRIPTION
The TCM uti l i zes a cl osed-l oop system to control
transmi ssi on l i ne pressure. The system contai ns a
vari abl e force styl e sol enoi d, the Pressure Control
Sol enoi d, mounted on the si de of the sol enoi d and
pressure swi tch assembl y. The sol enoi d i s duty cycl e
control l ed by the TCM to vent the unnecessary l i ne
pressure suppl i ed by the oi l pump back to the sump.
The system al so contai ns a vari abl e pressure styl e
sensor, the Li ne Pressure Sensor, whi ch i s a di rect
i nput to the TCM. The l i ne pressure sol enoi d moni -
tors the transmi ssi on l i ne pressure and compl etes the
Fig. 91 Input Speed Sensor
feedback l oop to the TCM. The TCM uses thi s i nfor-
mati on to adjust i ts control of the pressure control
sol enoi d to achi eve the desi red l i ne pressure.
OPERATION
The TCM cal cul ates the desi red l i ne pressure
based upon i nputs from the transmi ssi on and engi ne.
The TCM cal cul ates the torque i nput to the trans-
mi ssi on and uses that i nformati on as the pri mary
i nput to the cal cul ati on. The l i ne pressure i s set to a
predetermi ned val ue duri ng shi fts and when the
transmi ssi on i s i n the PARK and NEUTRAL posi -
ti ons. Thi s i s done to ensure consi stent shi ft qual i ty.
Duri ng al l other operati on, the actual l i ne pressure i s
compared to the desi red l i ne pressure and adjust-
ments are made to the pressure control sol enoi d duty
cycl e.
REMOVAL
transmi ssi on.
(3) Remove the wi ri ng connector from the l i ne
pressure sensor (Fi g. 92).
(4) Remove the bol t hol di ng the l i ne pressure sen-
sor to the transmi ssi on case.
(5) Remove the l i ne pressure sensor from the
INSTALLATION
(1) I nstal l the l i ne pressure sensor i nto the trans-
mi ssi on case.
(2) I nstal l the bol t to hol d the l i ne pressure sensor
Nm (105 i n.l bs.).
(3) I nstal l the wi ri ng connector onto the l i ne pres-
sure sensor
necessary.
Fig. 92 Line Pressure Sensor
LINE PRESSURE (LP) SENSOR (Continued)
LOW/REVERSE CLUTCH
DISASSEMBLY
(1) Remove the i nner overrunni ng cl utch snap-ri ng
from the l ow/reverse cl utch retai ner (Fi g. 93).
(2) Remove the outer l ow/reverse reacti on pl ate
fl at snap-ri ng (Fi g. 93).
(3) Remove the l ow/reverse cl utch and the over-
runni ng cl utch from the l ow/reverse cl utch retai ner
as an assembl y (Fi g. 93).
(4) Separate the l ow/reverse cl utch from the over-
runni ng cl utch.
Fig. 93 Low/Reverse Clutch Assembly
1 - SNAP-RING (SELECT) 8 - SEAL
2 - REACTION PLATE 9 - BELLEVILLE SPRING
3 - DISC 10 - RETAINER
4 - PLATE 11 - SNAP-RING
5 - L/R CLUTCH RETAINER 12 - OVERRUNNING CLUTCH
6 - SEAL 13 - SNAP-RING
7 - PISTON
(5) Remove the overrunni ng cl utch snap-ri ng (Fi g.
94).
(6) Remove the spacer from the overrunni ng cl utch
(Fi g. 94).
(7) Separate the i nner and outer races of the over-
runni ng cl utch (Fi g. 94).
(8) Remove the overrunni ng cl utch l ower snap-ri ng
(Fi g. 94).
shop press (Fi g. 95), compress the l ow/reverse pi ston
Bel l evi l l e spri ng and remove the spl i t retai ni ng ri ng
hol di ng the Bel l evi l l e spri ng i nto the l ow/reverse
cl utch retai ner.
(10) Remove the l ow/reverse cl utch Bel l evi l l e
spri ng and pi ston from the l ow/reverse cl utch
retai ner. Use 20 psi of ai r pressure to remove the pi s-
ton i f necessary.
CLEANING
Cl ean the overrunni ng cl utch assembl y, cl utch cam,
and l ow-reverse cl utch retai ner. Dry them wi th com-
pressed ai r after cl eani ng.
INSPECTION
I nspect condi ti on of each cl utch part after cl eani ng.
Repl ace the overrunni ng cl utch rol l er and spri ng
assembl y i f any rol l ers or spri ngs are worn or dam-
aged, or i f the rol l er cage i s di storted, or damaged.
Repl ace the cam i f worn, cracked or damaged.
Repl ace the l ow-reverse cl utch retai ner i f the
cl utch race, rol l er surface or i nsi de di ameter i s
scored, worn or damaged.
ASSEMBLY
(1) Check the bl eed ori fi ce to ensure that i t i s not
pl ugged or restri cted.
(2) I nstal l a new seal on the l ow/reverse pi ston.
Lubri cate the seal wi th Mopar ATF +4, Automati c
Transmi ssi on Fl ui d, pri or to i nstal l ati on.
(3) I nstal l the l ow/reverse pi ston i nto the l ow/re-
verse cl utch retai ner.
(4) Posi ti on the l ow/reverse pi ston Bel l evi l l e spri ng
on the l ow/reverse pi ston.
shop press (Fi g. 95), compress the l ow/reverse pi ston
Bel l evi l l e spri ng and i nstal l the spl i t retai ni ng ri ng
to hol d the Bel l evi l l e spri ng i nto the l ow/reverse
cl utch retai ner.
(6) I nstal l the l ower overrunni ng cl utch snap-ri ng
(Fi g. 94).
(7) Assembl e the i nner and outer races of the over-
runni ng cl utch (Fi g. 94).
(8) Posi ti on the overrunni ng cl utch spacer on the
overrunni ng cl utch.
(9) I nstal l the upper overrunni ng cl utch snap-ri ng
(Fi g. 94).
(10) Assembl e and i nstal l the l ow/reverse cl utch
pack i nto the l ow/reverse cl utch retai ner (Fi g. 93).
(11) I nstal l the l ow/reverse reacti on pl ate i nto the
l ow/reverse cl utch retai ner (Fi g. 93). The reacti on
pl ate i s di recti onal and must be i nstal l ed wi th the
fl at si de down.
(12) I nstal l the l ow/reverse cl utch pack snap-ri ng
(Fi g. 93). The snap-ri ng i s sel ectabl e and shoul d be
chosen to gi ve the correct cl utch pack cl earance.
1 - SNAP-RING
2 - OUTER RACE
4 - SPACER
Fig. 95 Compress Low/Reverse Belleville Spring
Using Tool 8285
1 - PRESS
2 - TOOL 8285
3 - BELLEVILLE SPRING
LOW/REVERSE CLUTCH (Continued)
(13) Measure the l ow/reverse cl utch pack cl earance
and adjust as necessary. The correct cl utch cl earance
i s 1.00-1.74 mm (0.039-0.075 i n.).
(14) I nstal l the overrunni ng cl utch i nto the l ow/re-
verse cl utch retai ner maki ng sure that the i ndex
spl i nes are al i gned wi th the retai ner.
(15) I nstal l the overrunni ng cl utch i nner snap-
ri ng.
OIL PUMP
DESCRIPTION
The oi l pump (Fi g. 96) i s l ocated at the front of the
transmi ssi on i nsi de the bel l housi ng and behi nd the
transmi ssi on front cover. The oi l pump consi sts of
two i ndependent pumps (Fi g. 97), a number of val ves
(Fi g. 98), a front seal (Fi g. 99), and a bol t on reacti on
shaft. The converter cl utch swi tch and regul ator
val ves, pressure regul ator val ve, and converter pres-
sure l i mi t val ve are al l l ocated i n the oi l pump val ve
body.
OPERATION
As the torque converter rotates, the converter hub
rotates the oi l pump dri ve gear. As the dri ve gear
rotates both dri ven gears, a vacuum i s created when
the gear teeth come out of mesh. Thi s sucti on draws
fl ui d through the pump i nl et from the oi l pan. As the
gear teeth come back i nto mesh, pressuri zed fl ui d i s
forced i nto the pump outl et and to the oi l pump
val ves.
At l ow speeds, both si des of the pump suppl y fl ui d
to the transmi ssi on. As the speed of the torque con-
verter i ncreases, the fl ow from both si des i ncreases
unti l the fl ow from the pri mary si de al one i s suffi -
ci ent to meet system demands. At thi s poi nt, the
check val ve l ocated between the two pumps cl oses.
The secondary si de i s shut down and the pri mary
si de suppl i es al l the fl ui d to the transmi ssi on.
CONVERTER CLUTCH SWITCH VALVE
The converter cl utch swi tch val ve i s used to control
the hydraul i c pressure suppl i ed to the front (OFF)
si de of the torque converter cl utch.
Fig. 96 Oil Pump
2 - OIL PUMP
Fig. 97 Oil Pump Gears
1 - PUMP HOUSING
2 - DRIVE GEAR
3 - DRIVEN GEARS
Fig. 98 Oil Pump Valves
1 - TORQUE CONVERTER CLUTCH ACCUMULATOR VALVE
2 - TORQUE CONVERTER CLUTCH CONTROL VALVE
3 - TORQUE CONVERTER CLUTCH SWITCH VALVE
4 - PUMP VALVE BODY
5 - PRESSURE REGULATOR VALVE
6 - TORQUE CONVERTER CLUTCH LIMIT VALVE
LOW/REVERSE CLUTCH (Continued)
CONVERTER CLUTCH REGULATOR VALVE
The converter cl utch regul ator val ve i s used to con-
trol the hydraul i c pressure suppl i ed to the back (ON)
si de of the torque converter cl utch.
TORQUE CONVERTER LIMIT VALVE
The torque converter l i mi t val ve serves to l i mi t the
avai l abl e l i ne pressure to the torque converter cl utch.
STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuri ng the oi l pump output vol ume wi l l deter-
mi ne i f suffi ci ent oi l fl ow to the transmi ssi on oi l
cool er exi sts, and whether or not an i nternal trans-
mi ssi on fai l ure i s present.
Veri fy that the transmi ssi on fl ui d i s at the proper
l evel . Refer to the Fl ui d Level Check procedure i n
thi s secti on. I f necessary, fi l l the transmi ssi on to the
proper l evel wi th Mopar ATF +4, Automati c Trans-
mi ssi on Fl ui d.
(1) Di sconnect the To cooler l i ne at the cool er
i nl et and pl ace a col l ecti ng contai ner under the di s-
connected l i ne.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engi ne at 1800 rpm, wi th the shi ft
sel ector i n neutral . Veri fy that the transmi ssi on fl ui d
temperature i s bel ow 104.5 C (220 F) for thi s test.
Fig. 99 Oil Pump Reaction Shaft
1 - PUMP HOUSING 4 - SEAL RING (5)
2 - SEAL 5 - REACTION SHAFT SUPPORT
3 - OIL FILTER SEAL 6 - PUMP VALVE BODY
(3) I f one quart of transmi ssi on fl ui d i s col l ected i n
the contai ner i n 30 seconds or l ess, oi l pump fl ow vol -
ume i s wi thi n acceptabl e l i mi ts. I f fl ui d fl ow i s i nter-
mi ttent, or i t takes more than 30 seconds to col l ect
one quart of fl ui d, refer to the Hydraul i c Pressure
tests i n thi s secti on for further di agnosi s.
(4) Re-connect the To cooler l i ne to the transmi s-
si on cool er i nl et.
(5) Refi l l the transmi ssi on to proper l evel .
DISASSEMBLY
(1) Remove the bol ts hol di ng the reacti on shaft
support to the oi l pump (Fi g. 100).
(2) Remove the reacti on shaft support from the oi l
pump (Fi g. 100).
(3) Remove al l bol ts hol di ng the oi l pump hal ves
together (Fi g. 100).
(4) Usi ng sui tabl e pryi ng tool s, separate the oi l
pump secti ons by i nserti ng the tool s i n the suppl i ed
areas and pryi ng the hal ves apart.
NOTE: The oil pump halves are aligned to each
other through the use of two dowels. Be sure to pry
upward evenly to prevent damage to the oil pump
components.
(5) Remove the screws hol di ng the separator pl ate
onto the oi l pump body (Fi g. 101).
(6) Remove the separator pl ate from the oi l pump
body (Fi g. 101).
1 - PUMP HOUSING 4 - SEAL RING (5)
2 - SEAL 5 - REACTION SHAFT SUPPORT
3 - OIL FILTER SEAL 6 - PUMP VALVE BODY
(7) Mark al l gears for l ocati on. The gears are
sel ect fi t and i f the oi l pump i s to be reused, the
gears must be returned to thei r ori gi nal l ocati ons.
(8) Remove the oi l pump gears from the oi l pump
case (Fi g. 101).
Fig. 101 Oil Pump Housing and Gears
1 - SEPARATOR PLATE 5 - DOWEL (2)
2 - DRIVEN GEAR (2) 6 - DRIVE GEAR
3 - CHECK VALVE 7 - SCREW
4 - PUMP HOUSING
(9) Remove the oi l pump val ve retai ners and asso-
ci ated val ve and spri ng one at a ti me (Fi g. 102) (Fi g.
103). Mark the combi nati on of components as a
group and tag them as to the l ocati on from whi ch
they were removed.
CLEANING
Cl ean pump and support components wi th sol vent
and dry them wi th compressed ai r.
INSPECTION
Check condi ti on of the seal ri ngs and thrust
washer on the reacti on shaft support. The seal ri ngs
do not need to be repl aced unl ess cracked, broken, or
severel y worn.
I nspect the pump and support components. Repl ace
the pump or support i f the seal ri ng grooves or
machi ned surfaces are worn, scored, pi tted, or dam-
aged. Repl ace the pump gears i f pi tted, worn
chi pped, or damaged.
I nspect the pump reacti on shaft support bushi ngs.
Repl ace ei ther bushi ng onl y i f heavi l y worn, scored or
damaged. I t i s not necessary to repl ace the bushi ngs
unl ess they are actual l y damaged.
I nspect the val ves and pl ugs for scratches, burrs,
ni cks, or scores. Mi nor surface scratches on steel
val ves and pl ugs can be removed wi th crocus cl oth
but do not round off the edges of the valve or
plug lands. Mai ntai ni ng sharpness of these edges i s
vi tal l y i mportant. The edges prevent forei gn matter
from l odgi ng between the val ves and pl ugs and the
bore.
I nspect al l the val ve and pl ug bores i n the oi l
pump cover. Use a penl i ght to vi ew the bore i nteri -
ors. Repl ace the oi l pump i f any bores are di storted
or scored. I nspect al l of the val ve spri ngs. The
coi l s.
ASSEMBLY
(1) Cl ean and i nspect al l components. Make sure
that al l passages are thoroughl y cl eaned and are free
from di rt or debri s. Make sure that al l val ves move
freel y i n thei r proper bore. Make sure that al l gear
pockets and bushi ngs are free from excessi ve wear
and scori ng. Repl ace the oi l pump i f any excessi ve
wear or scori ng i s found.
(2) Coat the gears wi th Mopar ATF +4 and i nstal l
i nto thei r ori gi nal l ocati ons.
(3) Lubri cate the oi l pump val ves wi th Mopar
ATF +4 and i nstal l the val ve, spri ng and retai ner
Fig. 102 Oil Pump Valve Body
1 - T/C REGULATOR VALVE
2 - T/C LIMIT VALVE
3 - REGULATOR VALVE
4 - OIL PUMP VALVE BODY
Fig. 103 T/C Switch Valve
1 - RETAINER
2 - T/C SWITCH VALVE
3 - OIL PUMP VALVE BODY
i nto the appropri ate oi l pump val ve body bore (Fi g.
102) (Fi g. 103).
(4) Pl ace the separator pl ate onto the oi l pump
body (Fi g. 101).
(5) I nstal l the screws to hol d the separator pl ate
onto the oi l pump body (Fi g. 101). Ti ghten the screws
to 4.5 Nm (40 i n.l bs.).
(6) Posi ti on the oi l pump cover onto the l ocati ng
dowel s (Fi g. 100).
(7) Seat the two oi l pump hal ves together and
i nstal l al l bol ts fi nger ti ght.
(8) Torque al l bol ts down sl owl y starti ng i n the
center and worki ng outward. The correct torque i s
4.5 Nm (40 i n.l bs.).
(9) Veri fy that the oi l pump gears rotate freel y and
smoothl y.
(10) Posi ti on the reacti on shaft support i nto the oi l
pump (Fi g. 100).
(11) I nstal l and torque the bol ts to hol d the reac-
ti on shaft support to the oi l pump (Fi g. 100). The cor-
rect torque i s 12 Nm (105 i n.l bs.).
OIL PUMP FRONT SEAL
REMOVAL
(1) Remove transmi ssi on from the vehi cl e.
(2) Remove the torque converter from the trans-
mi ssi on.
(3) Usi ng a screw mounted i n a sl i de hammer,
remove the oi l pump front seal .
INSTALLATION
(1) Cl ean seal bore of the oi l pump of any resi due
or parti cl es from the ori gi nal seal .
(2) I nstal l new oi l seal i n the oi l pump housi ng
usi ng Seal I nstal l er C-3860-A (Fi g. 104).
OUTPUT SPEED SENSOR
DESCRIPTION
The I nput and Output Speed Sensors are two-wi re
magneti c pi ckup devi ces that generate AC si gnal s as
rotati on occurs. They are mounted i n the l eft si de of
the transmi ssi on case and are consi dered pri mary
i nputs to the Transmi ssi on Control Modul e (TCM).
OPERATION
The I nput Speed Sensor provi des i nformati on on
how fast the i nput shaft i s rotati ng. As the teeth of
the i nput cl utch hub pass by the sensor coi l , an AC
vol tage i s generated and sent to the TCM. The TCM
i nterprets thi s i nformati on as i nput shaft rpm.
The Output Speed Sensor generates an AC si gnal
i n a si mi l ar fashi on, though i ts coi l i s exci ted by rota-
ti on of the rear pl anetary carri er l ugs. The TCM
i nterprets thi s i nformati on as output shaft rpm.
The TCM compares the i nput and output speed
si gnal s to determi ne the fol l owi ng:
Transmi ssi on gear rati o
Speed rati o error detecti on
CVI cal cul ati on
The TCM al so compares the i nput speed si gnal and
the engi ne speed si gnal to determi ne the fol l owi ng:
Torque converter cl utch sl i ppage
Torque converter el ement speed rati o
REMOVAL
transmi ssi on.
(3) Remove the wi ri ng connector from the output
speed sensor (Fi g. 105).
(4) Remove the bol t hol di ng the output speed sen-
sor to the transmi ssi on case.
(5) Remove the output speed sensor from the
Fig. 104 Install Oil Pump Front Seal
1 - TOOL C-3860-A
INSTALLATION
(1) I nstal l the output speed sensor i nto the trans-
mi ssi on case.
(2) I nstal l the bol t to hol d the output speed sensor
Nm (105 i n.l bs.).
(3) I nstal l the wi ri ng connector onto the output
speed sensor
necessary.
TOW/HAUL OVERDRIVE
SWITCH
DESCRIPTION
The tow/haul overdri ve OFF (control ) swi tch i s
l ocated i n the shi ft l ever arm (Fi g. 106). The swi tch
i s a momentary contact devi ce that si gnal s the PCM
to toggl e current status of the overdri ve functi on.
OPERATION
At key-on, overdri ve operati on i s al l owed. Pressi ng
the swi tch once causes the tow/haul overdri ve OFF
mode to be entered and the Tow/Haul l amp to be i l l u-
mi nated. Pressi ng the swi tch a second ti me causes
normal overdri ve operati on to be restored and the
tow/haul l amp to be turned off. The tow/haul over-
dri ve OFF mode defaul ts to ON after the i gni ti on
swi tch i s cycl ed OFF and ON. The normal posi ti on
for the control swi tch i s the ON posi ti on. The swi tch
must be i n thi s posi ti on to energi ze the sol enoi d and
al l ow a 3-4 upshi ft. The control swi tch i ndi cator l i ght
i l l umi nates onl y when the tow/haul overdri ve swi tch
i s turned to the OFF posi ti on, or when i l l umi nated
by the transmi ssi on control modul e.
REMOVAL
(1) Usi ng a pl asti c tri m tool , remove the tow/haul
overdri ve off swi tch retai ner from the shi ft l ever (Fi g.
107).
Fig. 105 Output Speed Sensor
Fig. 106 Tow/Haul Overdrive Off Switch
Fig. 107 Tow/Haul Overdrive Off Switch Retainer
OUTPUT SPEED SENSOR (Continued)
(2) Pul l the swi tch outwards to rel ease i t from the
connector i n the l ever (Fi g. 108)
INSTALLATION
NOTE: There is enough slack in the wire to pull out
the connector from the lever.
(1) Pul l the connector out of the l ever just enough
to grasp i t.
CAUTION: Be careful not to bend the pins on the
tow/haul overdrive off switch. Use care when
installing the switch, as it is not indexed, and can
be accidentally installed incorrectly.
(2) I nstal l the tow/haul overdri ve off swi tch i nto
the connector (Fi g. 109)
(3) Push the tow/haul overdri ve off swi tch and wi r-
i ng i nto the shi ft l ever.
(4) I nstal l the tow/haul overdri ve off swi tch
retai ner onto the shi ft l ever.
PISTONS
DESCRIPTION
There are several si zes and types of pi stons used i n
an automati c transmi ssi on. Some pi stons are used to
appl y cl utches, whi l e others are used to appl y bands.
They al l have i n common the fact that they are
round or ci rcul ar i n shape, l ocated wi thi n a smooth
wal l ed cyl i nder, whi ch i s cl osed at one end and con-
verts fl ui d pressure i nto mechani cal movement. The
fl ui d pressure exerted on the pi ston i s contai ned
wi thi n the system through the use of pi ston ri ngs or
seal s.
OPERATION
The pri nci pal whi ch makes thi s operati on possi bl e
i s known as Pascal s Law. Pascal s Law can be stated
as: Pressure on a confi ned fl ui d i s transmi tted
equal l y i n al l di recti ons and acts wi th equal force on
equal areas.
PRESSURE
Pressure (Fi g. 110) i s nothi ng more than force (l bs.)
di vi ded by area (i n or ft.), or force per uni t area.
Gi ven a 100 l b. bl ock and an area of 100 sq. i n. on
the fl oor, the pressure exerted by the bl ock i s: 100
l bs. 100 i n or 1 pound per square i nch, or PSI as i t i s
commonl y referred to.
Fig. 108 Remove the Tow/Haul Overdrive Off Switch
Fig. 109 Install the Tow/Haul Overdrive Off Switch
Fig. 110 Force and Pressure Relationship
TOW/HAUL OVERDRIVE SWITCH (Continued)
PRESSURE ON A CONFINED FLUID
Pressure i s exerted on a confi ned fl ui d (Fi g. 111) by
appl yi ng a force to some gi ven area i n contact wi th
the fl ui d. A good exampl e of thi s i s a cyl i nder fi l l ed
wi th fl ui d and equi pped wi th a pi ston that i s cl osel y
fi tted to the cyl i nder wal l . I f a force i s appl i ed to the
pi ston, pressure wi l l be devel oped i n the fl ui d. Of
course, no pressure wi l l be created i f the fl ui d i s not
confi ned. I t wi l l si mpl y l eak past the pi ston. There
must be a resi stance to fl ow i n order to create pres-
sure. Pi ston seal i ng i s extremel y i mportant i n
hydraul i c operati on. Several ki nds of seal s are used
to accompl i sh thi s wi thi n a transmi ssi on. These
i ncl ude but are not l i mi ted to O-ri ngs, D-ri ngs, l i p
seal s, seal i ng ri ngs, or extremel y cl ose tol erances
between the pi ston and the cyl i nder wal l . The force
exerted i s downward (gravi ty), however, the pri nci pl e
remai ns the same no matter whi ch di recti on i s taken.
The pressure created i n the fl ui d i s equal to the force
appl i ed, di vi ded by the pi ston area. I f the force i s 100
l bs., and the pi ston area i s 10 sq. i n., then the pres-
sure created equal s 10 PSI . Another i nterpretati on of
Pascal s Law i s that regardl ess of contai ner shape or
si ze, the pressure wi l l be mai ntai ned throughout, as
l ong as the fl ui d i s confi ned. I n other words, the
pressure i n the fl ui d i s the same everywhere wi thi n
the contai ner.
FORCE MULTIPLICATION
Usi ng the 10 PSI exampl e used i n the i l l ustrati on
(Fi g. 112), a force of 1000 l bs. can be moved wi th a
force of onl y 100 l bs. The secret of force mul ti pl i ca-
ti on i n hydraul i c systems i s the total fl ui d contact
area empl oyed. The i l l ustrati on, (Fi g. 112), shows an
area that i s ten ti mes l arger than the ori gi nal area.
The pressure created wi th the smal l er 100 l b. i nput
i s 10 PSI . The concept pressure i s the same every-
where means that the pressure underneath the
l arger pi ston i s al so 10 PSI . Pressure i s equal to the
force appl i ed di vi ded by the contact area. Therefore,
by means of si mpl e al gebra, the output force may be
found. Thi s concept i s extremel y i mportant, as i t i s
al so used i n the desi gn and operati on of al l shi ft
val ves and l i mi ti ng val ves i n the val ve body, as wel l
as the pi stons, of the transmi ssi on, whi ch acti vate
the cl utches and bands. I t i s nothi ng more than
usi ng a di fference of area to create a di fference i n
pressure to move an object.
Fig. 111 Pressure on a Confined Fluid
Fig. 112 Force Multiplication
PISTONS (Continued)
PISTON TRAVEL
The rel ati onshi p between hydraul i c l ever and a
mechani cal l ever i s the same. Wi th a mechani cal l ever
i ts a wei ght-to-di stance output rather than a pressure-to-
area output. Usi ng the same forces and areas as i n the
previ ous exampl e, the smal l er pi ston (Fi g. 113) has to
move ten ti mes the di stance requi red to move the l arger
pi ston one i nch. Therefore, for every i nch the l arger pi s-
ton moves, the smal l er pi ston moves ten i nches. Thi s
pri nci pl e i s true i n other i nstances al so. A common
garage fl oor jack i s a good exampl e. To rai se a car wei gh-
i ng 2000 l bs., an effort of onl y 100 l bs. may be requi red.
For every i nch the car moves upward, the i nput pi ston at
the jack handl e must move 20 i nches downward.
PLANETARY GEARTRAIN
DESCRIPTION
The pl anetary geartrai n i s l ocated behi nd the 4C
retai ner/bul khead, toward the rear of the transmi s-
si on. The pl anetary geartrai n consi sts of three pri -
mary assembl i es:
Reacti on (Fi g. 114).
Reverse (Fi g. 115).
I nput (Fi g. 115).
Fig. 113 Piston Travel
Fig. 114 Reaction Planetary Geartrain
PISTONS (Continued)
OPERATION
REACTION PLANETARY GEARTRAIN
The reacti on pl anetary carri er and reverse sun
gear of the reacti on pl anetary geartrai n are a si ngl e
component whi ch i s hel d by the 2C cl utch when
requi red. The reacti on annul us gear i s a stand al one
component that can be dri ven by the reverse cl utch
or hel d by the 4C cl utch. The reacti on sun gear i s
dri ven by the overdri ve cl utch.
REVERSE PLANETARY GEARTRAIN
The reverse pl anetary geartrai n i s the mi ddl e of
the three pl anetary sets. The reverse pl anetary car-
ri er can be dri ven by the overdri ve cl utch as
requi red. The reverse pl anetary carri er i s al so
spl i ned to the i nput annul us gear, whi ch can be hel d
by the l ow/reverse cl utch. The reverse pl anetary
annul us, i nput pl anetary carri er, and output shaft
are al l one pi ece.
INPUT PLANETARY GEARTRAIN
The i nput sun gear of the i nput pl anetary
geartrai n i s dri ven by the underdri ve cl utch.
DISASSEMBLY
(1) Remove the snap-ri ng hol di ng the i nput annu-
l us i nto the i nput carri er (Fi g. 116).
(2) Remove the i nput annul us from the i nput car-
ri er (Fi g. 116).
(3) Remove the number 9 beari ng from the reverse
pl anetary carri er. Note that thi s pl anetary carri er
has four pi ni on gears.
(4) Remove the reverse pl anetary gear carri er (Fi g.
116).
sun gear (Fi g. 116).
(6) Remove the i nput sun gear from the i nput car-
ri er (Fi g. 116).
carri er (Fi g. 116).
CLEANING
Cl ean the pl anetary components i n sol vent and dry
them wi th compressed ai r.
Fig. 115 Reverse/Input Planetary Geartrain
1 - SNAP-RING 5 - INPUT PLANETARY CARRIER
2 - BEARING NUMBER 10 6 - INPUT SUN GEAR
3 - BEARING NUMBER 11 7 - REVERSE PLANETARY CARRIER
4 - INPUT ANNULUS
PLANETARY GEARTRAIN (Continued)
INSPECTION
Check sun gear and dri vi ng shel l condi ti on.
Repl ace the gear i f damaged or i f the bushi ngs are
scored or worn. The bushi ngs are not servi ceabl e.
Repl ace the dri vi ng shel l i f worn, cracked or dam-
aged.
Repl ace pl anetary gear sets i f gears, pi ni on pi ns, or
carri er are damaged i n any way. Repl ace the annul us
gears and supports i f ei ther component i s worn or
damaged.
Repl ace the output shaft i f the machi ned surfaces
are scored, pi tted, or damaged i n any way. Al so
repl ace the shaft i f the spl i nes are damaged, or
exhi bi ts cracks at any l ocati on.
ASSEMBLY
or scori ng.
(2) I nstal l the number 11 beari ng i nto the i nput
pl anetary carri er so that the i nner race wi l l be
toward the front of the transmi ssi on (Fi g. 116).
(3) I nstal l the i nput sun gear i nto the i nput carri er
(Fi g. 116).
(4) I nstal l the number 10 beari ng onto the rear of
the reverse pl anetary carri er wi th the i nner race
toward the carri er (Fi g. 116).
(5) I nstal l the number 9 beari ng onto the front of
the reverse pl anetary carri er wi th the outer race
toward the carri er and the i nner race faci ng upward
(Fi g. 116).
(6) I nstal l the reverse pl anetary gear carri er i nto
the i nput carri er (Fi g. 116).
(7) I nstal l the i nput annul us gear i nto the i nput
carri er (Fi g. 116).
(8) I nstal l the snap-ri ng to hol d the i nput annul us
gear i nto the i nput carri er (Fi g. 116).
Fig. 116 Reverse/Input Planetary Carrier Assembly
1 - SNAP-RING 5 - INPUT PLANETARY CARRIER
2 - BEARING NUMBER 10 6 - INPUT SUN GEAR
3 - BEARING NUMBER 11 7 - REVERSE PLANETARY CARRIER
4 - INPUT ANNULUS
PLANETARY GEARTRAIN (Continued)
SHIFT MECHANISM
DESCRIPTION
The gear shi ft mechani sm provi des si x shi ft posi -
ti ons whi ch are:
Park (P)
Reverse (R)
Neutral (N)
Dri ve (D)
Manual second (2)
Manual l ow (1)
OPERATION
MANUAL LOW (1) range provi des fi rst gear onl y.
Overrun braki ng i s al so provi ded i n thi s range.
MANUAL SECOND (2) range provi des fi rst and sec-
ond gear onl y.
DRI VE range provi des FI RST, SECOND, THI RD,
OVERDRI VE FOURTH, and OVERDRI VE FI FTH (i f
appl i cabl e) gear ranges. The shi ft i nto OVERDRI VE
FOURTH and FI FTH (i f appl i cabl e) gear ranges
occurs onl y after the transmi ssi on has compl eted the
shi ft i nto D THI RD gear range. No further movement
of the shi ft mechani sm i s requi red to compl ete the
3-4 or 4-5 (i f appl i cabl e) shi fts.
The FOURTH and FI FTH (i f appl i cabl e) gear
upshi fts occur automati cal l y when the overdri ve
sel ector swi tch i s i n the ON posi ti on. No upshi ft to
FOURTH or FI FTH (i f appl i cabl e) gears wi l l occur i f
any of the fol l owi ng are true:
The transmi ssi on fl ui d temperature i s bel ow 10
C (50 F) or above 121 C (250 F).
The shi ft to THI RD i s not yet compl ete.
Vehi cl e speed i s too l ow for the 3-4 or 4-5 (i f
appl i cabl e) shi fts to occur.
Upshi fts i nto FOURTH or FI FTH (i f appl i cabl e)
wi l l be del ayed when the transmi ssi on fl ui d temper-
ature i s bel ow 4.5 C (40 F) or above 115.5 C (240
F).
DESCRIPTION
The Sol enoi d Swi tch Val ve (SSV) i s l ocated i n the
val ve body and control s the di recti on of the transmi s-
si on fl ui d when the L/R-TCC sol enoi d i s energi zed.
OPERATION
The Sol enoi d Swi tch Val ve control s l i ne pressure
from the LR-TCC sol enoi d. I n 1st gear, the SSV wi l l
be i n the downshi fted posi ti on, thus di recti ng fl ui d to
the L/R cl utch ci rcui t. I n 2nd, 3rd, 4th, and 5th (i f
appl i cabl e) gears, the sol enoi d swi tch val ve wi l l be i n
the upshi fted posi ti on and di rects the fl ui d i nto the
torque converter cl utch (TCC) ci rcui t.
When shi fti ng i nto 1st gear, a speci al hydraul i c
sequence i s performed to ensure SSV movement i nto
the downshi fted posi ti on. The L/R pressure swi tch i s
moni tored to confi rm SSV movement. I f the move-
ment i s not confi rmed (the L/R pressure swi tch does
not cl ose), 2nd gear i s substi tuted for 1st. A DTC wi l l
be set after three unsuccessful attempts are made to
get i nto 1st gear i n one gi ven key start.
SOLENOIDS
DESCRIPTION
The typi cal el ectri cal sol enoi d used i n automoti ve
appl i cati ons i s a l i near actuator. I t i s a devi ce that
produces moti on i n a strai ght l i ne. Thi s strai ght l i ne
moti on can be ei ther forward or backward i n di rec-
ti on, and short or l ong di stance.
A sol enoi d i s an el ectromechani cal devi ce that uses
a magneti c force to perform work. I t consi sts of a coi l
of wi re, wrapped around a magneti c core made from
steel or i ron, and a spri ng l oaded, movabl e pl unger,
whi ch performs the work, or strai ght l i ne moti on.
The sol enoi ds used i n transmi ssi on appl i cati ons
are attached to val ves whi ch can be cl assi fi ed as nor-
mally open or normally closed. The normally
open sol enoi d val ve i s defi ned as a val ve whi ch
al l ows hydraul i c fl ow when no current or vol tage i s
appl i ed to the sol enoi d. The normally closed sol e-
noi d val ve i s defi ned as a val ve whi ch does not al l ow
hydraul i c fl ow when no current or vol tage i s appl i ed
to the sol enoi d. These val ves perform hydraul i c con-
trol functi ons for the transmi ssi on and must there-
fore be durabl e and tol erant of di rt parti cl es. For
these reasons, the val ves have hardened steel pop-
pets and bal l val ves. The sol enoi ds operate the val ves
di rectl y, whi ch means that the sol enoi ds must have
very hi gh outputs to cl ose the val ves agai nst the si z-
abl e fl ow areas and l i ne pressures found i n current
transmi ssi ons. Fast response ti me i s al so necessary
to ensure accurate control of the transmi ssi on.
The strength of the magneti c fi el d i s the pri mary
force that determi nes the speed of operati on i n a par-
ti cul ar sol enoi d desi gn. A stronger magneti c fi el d wi l l
cause the pl unger to move at a greater speed than a
weaker one. There are basi cal l y two ways to i ncrease
the force of the magneti c fi el d:
1. I ncrease the amount of current appl i ed to the
coi l or
2. I ncrease the number of turns of wi re i n the coi l .
The most common practi ce i s to i ncrease the num-
ber of turns by usi ng thi n wi re that can compl etel y
fi l l the avai l abl e space wi thi n the sol enoi d housi ng.
The strength of the spri ng and the l ength of the
pl unger al so contri bute to the response speed possi -
bl e by a parti cul ar sol enoi d desi gn.
A sol enoi d can al so be descri bed by the method by
whi ch i t i s control l ed. Some of the possi bi l i ti es
i ncl ude vari abl e force, pul se-wi dth modul ated, con-
stant ON, or duty cycl e. The vari abl e force and pul se-
wi dth modul ated versi ons uti l i ze si mi l ar methods to
control the current fl ow through the sol enoi d to posi -
ti on the sol enoi d pl unger at a desi red posi ti on some-
where between ful l ON and ful l OFF. The constant
ON and duty cycl ed versi ons control the vol tage
across the sol enoi d to al l ow ei ther ful l fl ow or no fl ow
through the sol enoi ds val ve.
OPERATION
When an el ectri cal current i s appl i ed to the sol e-
noi d coi l , a magneti c fi el d i s created whi ch produces
an attracti on to the pl unger, causi ng the pl unger to
move and work agai nst the spri ng pressure and the
l oad appl i ed by the fl ui d the val ve i s control l i ng. The
pl unger i s normal l y di rectl y attached to the val ve
whi ch i t i s to operate. When the current i s removed
from the coi l , the attracti on i s removed and the
pl unger wi l l return to i ts ori gi nal posi ti on due to
spri ng pressure.
The pl unger i s made of a conducti ve materi al and
accompl i shes thi s movement by provi di ng a path for
the magneti c fi el d to fl ow. By keepi ng the ai r gap
between the pl unger and the coi l to the mi ni mum
necessary to al l ow free movement of the pl unger, the
magneti c fi el d i s maxi mi zed.
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fi g. 117) i s a hydraul i c
devi ce that coupl es the engi ne crankshaft to the
transmi ssi on. The torque converter consi sts of an
outer shel l wi th an i nternal turbi ne, a stator, an
overrunni ng cl utch, an i mpel l er and an el ectroni cal l y
appl i ed converter cl utch. The converter cl utch pro-
vi des reduced engi ne speed and greater fuel economy
when engaged. Cl utch engagement al so provi des
reduced transmi ssi on fl ui d temperatures. The torque
converter hub dri ves the transmi ssi on oi l (fl ui d)
pump and contai ns an o-ri ng seal to better control oi l
fl ow.
The torque converter i s a seal ed, wel ded uni t that
i s not repai rabl e and i s servi ced as an assembl y.
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid.
1 - TURBINE ASSEMBLY
2 - STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
SOLENOIDS (Continued)
IMPELLER
The i mpel l er (Fi g. 118) i s an i ntegral part of the
converter housi ng. The i mpel l er consi sts of curved
bl ades pl aced radi al l y al ong the i nsi de of the housi ng
on the transmi ssi on si de of the converter. As the con-
verter housi ng i s rotated by the engi ne, so i s the
i mpel l er, because they are one and the same and are
the dri vi ng members of the system.
Fig. 118 Impeller
1 - ENGINE FLEXPLATE 4 - ENGINE ROTATION
2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE
SECTION
5 - ENGINE ROTATION
3 - IMPELLER VANES AND COVER ARE INTEGRAL
TURBINE
The turbi ne (Fi g. 119) i s the output, or dri ven,
member of the converter. The turbi ne i s mounted
wi thi n the housi ng opposi te the i mpel l er, but i s not
attached to the housi ng. The i nput shaft i s i nserted
through the center of the i mpel l er and spl i ned i nto
the turbi ne. The desi gn of the turbi ne i s si mi l ar to
the i mpel l er, except the bl ades of the turbi ne are
curved i n the opposi te di recti on.
Fig. 119 Turbine
1 - TURBINE VANE 4 - PORTION OF TORQUE CONVERTER COVER
2 - ENGINE ROTATION 5 - ENGINE ROTATION
3 - INPUT SHAFT 6 - OIL FLOW WITHIN TURBINE SECTION
STATOR
The stator assembl y (Fi g. 120) i s mounted on a sta-
ti onary shaft whi ch i s an i ntegral part of the oi l
pump. The stator i s l ocated between the i mpel l er and
turbi ne wi thi n the torque converter case (Fi g. 121).
The stator contai ns an over-runni ng cl utch, whi ch
al l ows the stator to rotate onl y i n a cl ockwi se di rec-
ti on. When the stator i s l ocked agai nst the over-run-
ni ng cl utch, the torque mul ti pl i cati on feature of the
torque converter i s operati onal .
The TCC (Fi g. 122) was i nstal l ed to i mprove the
effi ci ency of the torque converter that i s l ost to the
sl i ppage of the fl ui d coupl i ng. Al though the fl ui d cou-
pl i ng provi des smooth, shock-free power transfer, i t i s
natural for al l fl ui d coupl i ngs to sl i p. I f the i mpel l er
and turbi ne were mechani cal l y l ocked together, a
zero sl i ppage condi ti on coul d be obtai ned. A hydraul i c
pi ston wi th fri cti on materi al was added to the tur-
bi ne assembl y to provi de thi s mechani cal l ock-up.
I n order to reduce heat bui l d-up i n the transmi s-
si on and buffer the powertrai n agai nst torsi onal
vi brati ons, the TCM can duty cycl e the L/R-CC Sol e-
noi d to achi eve a smooth appl i cati on of the torque
converter cl utch. Thi s functi on, referred to as El ec-
troni cal l y Modul ated Converter Cl utch (EMCC) can
occur at vari ous ti mes dependi ng on the fol l owi ng
vari abl es:
Shi ft l ever posi ti on
Current gear range
Transmi ssi on fl ui d temperature
Engi ne cool ant temperature
I nput speed
Throttl e angl e
Engi ne speed
Fig. 120 Stator Components
1 - CAM (OUTER RACE)
2 - ROLLER
3 - SPRING
4 - INNER RACE
Fig. 121 Stator Location
1 - STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
Fig. 122 Torque Converter Clutch (TCC)
1 - IMPELLER FRONT COVER
2 - THRUST WASHER ASSEMBLY
3 - IMPELLER
4 - STATOR
5 - TURBINE
6 - PISTON
7 - FRICTION DISC
OPERATION
The converter i mpel l er (Fi g. 123) (dri vi ng member),
whi ch i s i ntegral to the converter housi ng and bol ted
to the engi ne dri ve pl ate, rotates at engi ne speed.
The converter turbi ne (dri ven member), whi ch reacts
from fl ui d pressure generated by the i mpel l er, rotates
and turns the transmi ssi on i nput shaft.
TURBINE
As the fl ui d that was put i nto moti on by the i mpel -
l er bl ades stri kes the bl ades of the turbi ne, some of
the energy and rotati onal force i s transferred i nto the
turbi ne and the i nput shaft. Thi s causes both of them
(turbi ne and i nput shaft) to rotate i n a cl ockwi se
di recti on fol l owi ng the i mpel l er. As the fl ui d i s l eav-
i ng the trai l i ng edges of the turbi nes bl ades i t con-
ti nues i n a hi nderi ng di recti on back toward the
i mpel l er. I f the fl ui d i s not redi rected before i t stri kes
the i mpel l er, i t wi l l stri ke the i mpel l er i n such a
di recti on that i t woul d tend to sl ow i t down.
STATOR
Torque mul ti pl i cati on i s achi eved by l ocki ng the
stators over-runni ng cl utch to i ts shaft (Fi g. 124).
Under stal l condi ti ons (the turbi ne i s stati onary), the
oi l l eavi ng the turbi ne bl ades stri kes the face of the
stator bl ades and tri es to rotate them i n a counter-
cl ockwi se di recti on. When thi s happens the over-run-
ni ng cl utch of the stator l ocks and hol ds the stator
from rotati ng. Wi th the stator l ocked, the oi l stri kes
the stator bl ades and i s redi rected i nto a hel pi ng
di recti on before i t enters the i mpel l er. Thi s ci rcul a-
ti on of oi l from i mpel l er to turbi ne, turbi ne to stator,
and stator to i mpel l er, can produce a maxi mum
torque mul ti pl i cati on of about 2.4:1. As the turbi ne
begi ns to match the speed of the i mpel l er, the fl ui d
that was hi tti ng the stator i n such as way as to
cause i t to l ock-up i s no l onger doi ng so. I n thi s con-
di ti on of operati on, the stator begi ns to free wheel
and the converter acts as a fl ui d coupl i ng.
I n a standard torque converter, the i mpel l er and
turbi ne are rotati ng at about the same speed and the
stator i s freewheel i ng, provi di ng no torque mul ti pl i -
cati on. By appl yi ng the turbi nes pi ston and fri cti on
materi al to the front cover, a total converter engage-
ment can be obtai ned. The resul t of thi s engagement
i s a di rect 1:1 mechani cal l i nk between the engi ne
and the transmi ssi on.
The cl utch can be engaged i n second, thi rd, fourth,
and fi fth (i f appi cabl e) gear ranges dependi ng on
overdri ve control swi tch posi ti on. I f the overdri ve
control swi tch i s i n the normal ON posi ti on, the
cl utch wi l l engage after the shi ft to fourth gear. I f the
Fig. 123 Torque Converter Fluid Operation - Typical
1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
control swi tch i s i n the OFF posi ti on, the cl utch wi l l
engage after the shi ft to thi rd gear.
The TCM control s the torque converter by way of
i nternal l ogi c software. The programmi ng of the soft-
ware provi des the TCM wi th control over the L/R-CC
Sol enoi d. There are four output l ogi c states that can
be appl i ed as fol l ows:
No EMCC
Parti al EMCC
Ful l EMCC
Gradual -to-no EMCC
NO EMCC
Under No EMCC condi ti ons, the L/R Sol enoi d i s
OFF. There are several condi ti ons that can resul t i n
NO EMCC operati ons. No EMCC can be i ni ti ated
due to a faul t i n the transmi ssi on or because the
TCM does not see the need for EMCC under current
dri vi ng condi ti ons.
PARTIAL EMCC
Parti al EMCC operati on modul ates the L/R Sol e-
noi d (duty cycl e) to obtai n parti al torque converter
cl utch appl i cati on. Parti al EMCC operati on i s mai n-
tai ned unti l Ful l EMCC i s cal l ed for and actuated.
Duri ng Parti al EMCC some sl i p does occur. Parti al
EMCC wi l l usual l y occur at l ow speeds, l ow l oad and
l i ght throttl e si tuati ons.
FULL EMCC
Duri ng Ful l EMCC operati on, the TCM i ncreases
the L/R Sol enoi d duty cycl e to ful l ON after Parti al
EMCC control bri ngs the engi ne speed wi thi n the
desi red sl i p range of transmi ssi on i nput speed rel a-
ti ve to engi ne rpm.
GRADUAL-TO-NO EMCC
Thi s operati on i s to soften the change from Ful l or
Parti al EMCC to No EMCC. Thi s i s done at mi d-
throttl e by decreasi ng the L/R Sol enoi d duty cycl e.
REMOVAL
(1) Remove transmi ssi on and torque converter
from vehi cl e.
(2) Pl ace a sui tabl e drai n pan under the converter
housi ng end of the transmi ssi on.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pul l the torque converter forward unti l the cen-
ter hub cl ears the oi l pump seal .
(4) Separate the torque converter from the trans-
mi ssi on.
INSTALLATION
Check converter hub and dri ve fl ats for sharp
edges, burrs, scratches, or ni cks. Pol i sh the hub and
fl ats wi th 320/400 gri t paper or crocus cl oth i f neces-
sary. Veri fy that the converter hub o-ri ng i s properl y
i nstal l ed and i s free from debri s. The hub must be
smooth to avoi d damagi ng the pump seal at i nstal l a-
ti on.
fl ui d.
(2) Pl ace torque converter i n posi ti on on transmi s-
si on.
CAUTION: Do not damage oil pump seal or con-
verter hub o-ring while inserting torque converter
into the front of the transmission.
(3) Al i gn torque converter to oi l pump seal open-
i ng.
(4) I nsert torque converter hub i nto oi l pump.
(5) Whi l e pushi ng torque converter i nward, rotate
converter unti l converter i s ful l y seated i n the oi l
pump gears.
(6) Check converter seati ng wi th a scal e and
shoul d be at l east 13 mm (1/2 i n.) to rear of strai ght-
(7) I f necessary, temporari l y secure converter wi th
C-cl amp attached to the converter housi ng.
(8) I nstal l the transmi ssi on i n the vehi cl e.
Fig. 124 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
(9) Fi l l the transmi ssi on wi th the recommended
fl ui d.
TRANSMISSION CONTROL
RELAY
DESCRIPTION
The rel ay i s suppl i ed fused B+ vol tage, energi zed
by the TCM, and i s used to suppl y power to the sol e-
noi d pack when the transmi ssi on i s i n normal oper-
ati ng mode.
OPERATION
When the rel ay i s off, no power i s suppl i ed to the
sol enoi d pack and the transmi ssi on i s i n l i mp-i n
mode. After a control l er reset, the TCM energi zes the
rel ay. Pri or to thi s, the TCM veri fi es that the con-
tacts are open by checki ng for no vol tage at the
swi tched battery termi nal s. After thi s i s veri fi ed, the
vol tage at the sol enoi d pack pressure swi tches i s
checked. After the rel ay i s energi zed, the TCM mon-
i tors the termi nal s to veri fy that the vol tage i s
greater than 3 vol ts.
TRANSMISSION RANGE
SENSOR
DESCRIPTION
The Transmi ssi on Range Sensor (TRS) i s part of
the sol enoi d modul e, whi ch i s mounted to the top of
the val ve body i nsi de the transmi ssi on.
The Transmi ssi on Range Sensor (TRS) has fi ve
swi tch contact pi ns that:
Determi ne shi ft l ever posi ti on
Suppl y ground to the Starter Rel ay i n Park and
Neutral onl y.
Suppl y +12 V to the backup l amps i n Reverse onl y.
The TRS al so has an i ntegrated temperature sen-
sor (thermi stor) that communi cates transmi ssi on
temperature to the TCM and PCM.
OPERATION
The Transmi ssi on Range Sensor (TRS) communi -
cates shi ft l ever posi ti on to the TCM as a combi na-
ti on of open and cl osed swi tches. Each shi ft l ever
posi ti on has an assi gned combi nati on of swi tch states
(open/cl osed) that the TCM recei ves from four sense
ci rcui ts. The TCM i nterprets thi s i nformati on and
determi nes the appropri ate transmi ssi on gear posi -
ti on and shi ft schedul e.
There are many possi bl e combi nati ons of open and
cl osed swi tches (codes). Seven of these possi bl e codes
are rel ated to gear posi ti on and fi ve are recogni zed
as between gear codes. Thi s resul ts i n many codes
whi ch shoul d never occur. These are cal l ed
i nval i d codes. An i nval i d code wi l l resul t i n a DTC,
and the TCM wi l l then determi ne the shi ft l ever
posi ti on based on pressure swi tch data. Thi s al l ows
reasonabl y normal transmi ssi on operati on wi th a
TRS fai l ure.
GEAR C5 C4 C3 C2 C1
Park CL OP OP CL CL
Temp 1 CL OP OP CL OP
Reverse OP OP OP CL OP
Temp 2 OP OP CL CL OP
Neutral 1 OP OP CL CL CL
Neutral 2 OP CL CL CL CL
Temp 3 OP CL CL CL OP
Drive OP CL CL OP OP
Temp 4 OP CL OP OP OP
Manual 2 CL CL OP OP OP
Temp 5 CL OP OP OP OP
Manual 1 CL OP CL OP OP
Fig. 125 Checking Torque Converter Seating-Typical
1 - SCALE
2 - STRAIGHTEDGE
TRANSMISSION SOLENOID/
TRS ASSEMBLY
DESCRIPTION
The transmi ssi on sol enoi d/TRS assembl y i s i nter-
nal to the transmi ssi on and mounted on the val ve
body assembl y (Fi g. 126). The assembl y consi sts of
si x sol enoi ds that control hydraul i c pressure to the
si x fri cti on el ements (transmi ssi on cl utches), and the
torque converter cl utch. The pressure control sol e-
noi d i s l ocated on the si de of the sol enoi d/TRS assem-
bl y. The sol enoi d/TRS assembl y al so contai ns fi ve
pressure swi tches that feed i nformati on to the TCM.
OPERATION
SOLENOIDS
Sol enoi ds are used to control the L/R, 2C, 4C, OD,
and UD fri cti on el ements. The reverse cl utch i s con-
trol l ed by l i ne pressure and the posi ti on of the man-
ual val ve i n the val ve body. Al l the sol enoi ds are
contai ned wi thi n the Sol enoi d and Pressure Swi tch
Assembl y. The sol enoi d and pressure swi tch assembl y
contai ns one addi ti onal sol enoi d, Mul ti -Sel ect (MS),
whi ch serves pri mari l y to provi de 2nd and 3rd gear
l i mp-i n operati on.
The sol enoi ds recei ve el ectri cal power from the
Transmi ssi on Control Rel ay through a si ngl e wi re.
The TCM energi zes or operates the sol enoi ds i ndi vi d-
ual l y by groundi ng the return wi re of the sol enoi d as
necessary. When a sol enoi d i s energi zed, the sol enoi d
val ve shi fts, and a fl ui d passage i s opened or cl osed
(vented or appl i ed), dependi ng on i ts defaul t operat-
i ng state. The resul t i s an appl y or rel ease of a fri c-
ti onal el ement.
The MS and UD sol enoi ds are normal l y appl i ed to
al l ow transmi ssi on l i mp-i n i n the event of an el ectri -
cal fai l ure.
The conti nui ty of the sol enoi ds and ci rcui ts are
peri odi cal l y tested. Each sol enoi d i s turned on or off
dependi ng on i ts current state. An i nducti ve spi ke
shoul d be detected by the TCM duri ng thi s test. I f no
spi ke i s detected, the ci rcui t i s tested agai n to veri fy
the fai l ure. I n addi ti on to the peri odi c testi ng, the
sol enoi d ci rcui ts are tested i f a speed rati o or pres-
sure swi tch error occurs.
Fig. 126 Transmission Solenoid/TRS Assembly
1 - PRESSURE CONTROL SOLENOID
2 - TRANSMISSION RANGE SELECTOR PLATE
4 - SOLENOID PACK
6 - VALVE BODY
PRESSURE SWITCHES
The TCM rel i es on fi ve pressure swi tches to moni -
tor fl ui d pressure i n the L/R, 2C, 4C, UD, and OD
hydraul i c ci rcui ts. The pri mary purpose of these
swi tches i s to hel p the TCM detect when cl utch ci r-
cui t hydraul i c fai l ures occur. The swi tches cl ose at 23
psi and open at 11 psi , and si mpl y i ndi cate whether
or not pressure exi sts. The swi tches are conti nuousl y
moni tored by the TCM for the correct states (open or
cl osed) i n each gear as shown i n the fol l owi ng charts
45RFE PRESSURE SWI TCH STATES and 545RFE
PRESSURE SWI TCH STATES :
45RFE PRESSURE SWITCH STATES
GEAR L/R 2C 4C UD OD
R OP OP OP OP OP
P/N CL OP OP OP OP
1ST CL* OP OP CL OP
2ND OP CL OP CL OP
2ND
PRIME
OP OP CL CL OP
D OP OP OP CL CL
FOURTH OP OP CL OP CL
*L/R is closed if output speed is below 100 rpm in
Drive and Manual 2. L/R is open in Manual 1.
545RFE PRESSURE SWITCH STATES
GEAR L/R 2C 4C UD OD
R OP OP OP OP OP
P/N CL OP OP OP OP
1ST CL* OP OP CL OP
2ND OP CL OP CL OP
2ND
PRIME
OP OP CL CL OP
D OP OP OP CL CL
4TH OP OP CL OP CL
5TH OP CL OP OP CL
*L/R is closed if output speed is below 100 rpm in
Drive and Manual 2. L/R is open in Manual 1.
A Di agnosti c Troubl e Code (DTC) wi l l set i f the
TCM senses any swi tch open or cl osed at the wrong
ti me i n a gi ven gear.
REMOVAL
(1) Remove the val ve body from the transmi ssi on
(Fi g. 127).
(2) Remove the screws hol di ng the transmi ssi on
sol enoi d/TRS assembl y onto the val ve body (Fi g. 128).
(3) Separate the transmi ssi on sol enoi d/TRS assem-
bl y from the val ve body.
Fig. 127 Valve Body Bolts
Fig. 128 Transmission Solenoid/TRS Assembly
Screws
1 - SOLENOID PACK BOLTS (15)
TRANSMISSION SOLENOID/TRS ASSEMBLY (Continued)
INSTALLATION
(1) Pl ace TRS sel ector pl ate i n the PARK posi ti on.
(2) Posi ti on the transmi ssi on sol enoi d/TRS assem-
bl y onto the val ve body. Be sure that both al i gnment
dowel s are ful l y seated i n the val ve body and that
the TRS swi tch contacts are properl y posi ti oned i n
the sel ector pl ate
(3) I nstal l the screws to hol d the transmi ssi on
sol enoi d/TRS assembl y onto the val ve body.
(4) Ti ghten the sol enoi d assembl y screws adjacent
to the arrows cast i nto the bottom of the val ve body
fi rst. Ti ghten the screws to 5.7 Nm (50 i n.l bs.).
(5) Ti ghten the remai nder of the sol enoi d assembl y
screws to 5.7 Nm (50 i n.l bs.).
(6) I nstal l the val ve body i nto the transmi ssi on.
TRANSMISSION
TEMPERATURE SENSOR
DESCRIPTION
The transmi ssi on temperature sensor i s a ther-
mi stor that i s i ntegral to the Transmi ssi on Range
Sensor (TRS).
OPERATION
The transmi ssi on temperature sensor i s used by
the TCM to sense the temperature of the fl ui d i n the
sump. Si nce fl ui d temperature can affect transmi s-
si on shi ft qual i ty and convertor l ock up, the TCM
requi res thi s i nformati on to determi ne whi ch shi ft
schedul e to operate i n.
Calculated Temperature
A fai l ure i n the temperature sensor or ci rcui t wi l l
resul t i n cal cul ated temperature bei ng substi tuted for
actual temperature. Cal cul ated temperature i s a pre-
di cted fl ui d temperature whi ch i s cal cul ated from a
combi nati on of i nputs:
Battery (ambi ent) temperature
Engi ne cool ant temperature
I n-gear run ti me si nce start-up
VALVE BODY
DESCRIPTION
The val ve body consi sts of a cast al umi num val ve
body, a separator pl ate, and a transfer pl ate. The
val ve body contai ns val ves and check bal l s that con-
trol fl ui d del i very to the torque converter cl utch,
bands, and fri cti onal cl utches. The val ve body con-
tai ns the fol l owi ng components (Fi g. 129) and (Fi g.
130):
Sol enoi d swi tch val ve
Manual val ve
Low/reverse swi tch val ve
5 Accumul ators
7 check bal l s
OPERATION
NOTE: Refer to the Hydraulic Schematics for a
visual aid in determining valve location, operation
and design.
The Sol enoi d Swi tch Val ve (SSV) control s the di rec-
ti on of the transmi ssi on fl ui d when the L/R-TCC sol e-
noi d i s energi zed.
When shi fti ng i nto 1st gear, a speci al hydraul i c
sequence i s performed to ensure SSV movement i nto
the downshi fted posi ti on. The L/R pressure swi tch i s
moni tored to confi rm SSV movement. I f the move-
ment i s not confi rmed (the L/R pressure swi tch does
not cl ose), 2nd gear i s substi tuted for 1st. A DTC wi l l
be set after three unsuccessful attempts are made to
get i nto 1st gear i n one gi ven key start.
MANUAL VALVE
The manual val ve i s a rel ay val ve. The purpose of
the manual val ve i s to di rect fl ui d to the correct ci r-
cui t needed for a speci fi c gear or dri vi ng range. The
manual val ve, as the name i mpl i es, i s manual l y oper-
ated by the dri ver wi th a l ever l ocated on the top of
the val ve body. The val ve i s connected mechani cal l y
by a cabl e to the gearshi ft mechani sm. The val ve i s
hel d i n each of i ts posi ti ons by a rol l er detent spri ng
(Fi g. 131) that engages the roostercomb of the TRS
sel ector pl ate.
TRANSMISSION SOLENOID/TRS ASSEMBLY (Continued)
Fig. 129 Valve Body Components
1 - LOW/REVERSE ACCUMULATOR 6 - OVERDRIVE ACCUMULATOR
2 - LOW/REVERSE SWITCH VALVE 7 - UNDERDRIVE ACCUMULATOR
3 - UPPER VALVE BODY 8 - 4C ACCUMULATOR
4 - MANUAL VALVE 9 - 2C ACCUMULATOR
5 - SOLENOID SWITCH VALVE
Fig. 130 Check Ball Locations
Fig. 131 TRS Selector Plate and Detent Spring
1 - TRS SELECTOR PLATE
2 - DETENT SPRING
3 - CLUTCH PASSAGE SEALS
LOW/REVERSE SWITCH VALVE
The l ow/reverse swi tch val ve al l ows the l ow/reverse
cl utch to be operated by ei ther the LR/CC sol enoi d or
the MS sol enoi d.
REMOVAL
The val ve body can be removed for servi ce wi thout
havi ng to remove the transmi ssi on assembl y.
The val ve body can be di sassembl ed for cl eani ng
and i nspecti on of the i ndi vi dual components. (Refer
to 21 - TRANSMI SSI ON/AUTOMATI C - 45RFE/
VALVE BODY - DI SASSEMBLY)
(3) Di sconnect wi res at the sol enoi d and pressure
swi tch assembl y connector.
(4) Posi ti on drai n pan under transmi ssi on oi l pan.
(5) Remove transmi ssi on oi l pan.
(6) Remove the pri mary oi l fi l ter from val ve body.
(Fi g. 132)
(7) Remove bol ts attachi ng val ve body to transmi s-
(8) Lower the val ve body and work the el ectri cal
connector out of transmi ssi on case.
(9) Separate the val ve body from the transmi ssi on.
DISASSEMBLY
(1) Remove the screws hol di ng the sol enoi d and
pressure swi tch assembl y to the val ve body (Fi g.
134). Do not remove the screws on the top of the sol e-
noi d and pressure swi tch assembl y.
(2) Separate the sol enoi d and pressure swi tch
assembl y from the val ve body.
Fig. 132 Remove Primary Oil Filter
4 - VALVE BODY
Fig. 133 Valve Body Bolts
Fig. 134 Solenoid and Pressure Switch Assembly
Screws
1 - SOLENOID PACK BOLTS (15)
(3) Remove the screw hol di ng the detent spri ng
(Fi g. 135) onto the val ve body.
(4) Remove the detent spri ng from the val ve body.
(5) Remove the TRS sel ector pl ate from the val ve
body and the manual val ve.
(6) Remove the cl utch passage seal s from the val ve
body, i f necessary.
(7) Remove the screws hol di ng the accumul ator
cover onto the val ve body (Fi g. 136).
(8) Remove the accumul ator spri ngs and pi stons
from the val ve body. Note whi ch accumul ator pi ston
and spri ng bel ong i n each l ocati on.
(9) Pl ace the val ve body on the bench wi th the
transfer pl ate upward.
NOTE: The valve body contains seven check balls.
The transfer plate must be placed upward to pre-
vent losing the check balls when the transfer plate
is removed from the valve body.
(10) Remove the screws hol di ng the val ve body to
the val ve body transfer pl ate.
Fig. 135 Valve Body External Components
1 - TRS SELECTOR PLATE
2 - DETENT SPRING
3 - CLUTCH PASSAGE SEALS
1 - LOW/REVERSE ACCUMULATOR 6 - OVERDRIVE ACCUMULATOR
2 - LOW/REVERSE SWITCH VALVE 7 - UNDERDRIVE ACCUMULATOR
3 - UPPER VALVE BODY 8 - 4C ACCUMULATOR
4 - MANUAL VALVE 9 - 2C ACCUMULATOR
(11) Remove the transfer pl ate from the val ve
body. Note the l ocati on of al l check bal l s (Fi g. 137).
(12) Remove the check bal l s from the val ve body.
(13) Remove the retai ners securi ng the sol enoi d
swi tch val ve, manual val ve, and the l ow/reverse
swi tch val ve i nto the val ve body and remove the
associ ated val ve and spri ng. Tag each val ve and
spri ng combi nati on wi th l ocati on i nformati on to ai d
i n assembl y. (Fi g. 138)
CLEANING
Cl ean the val ve housi ngs, val ves, pl ugs, spri ngs,
and separator pl ates wi th a standard parts cl eani ng
sol uti on onl y. Do not use gasol i ne, kerosene, or any
type of causti c sol uti on. (Fi g. 139)
Do not i mmerse any of the el ectri cal components i n
cl eani ng sol uti on. Cl ean the el ectri cal components by
wi pi ng them off wi th dry shop towel s onl y.
Dry al l except the el ectri cal parts wi th compressed
ai r. Make sure al l passages are cl ean and free from
obstructi ons. Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
Fig. 137 Check Ball Locations
2 - MANUAL VALVE
3 - LOW REVERSE SWITCH VALVE
4 - LOW REVERSE ACCUMULATOR
5 - 2ND CLUTCH ACCUMULATOR
6 - UNDERDRIVE ACCUMULATOR
7 - OVERDRIVE ACCUMULATOR
8 - 4TH CLUTCH ACCUMULATOR
9 - CHECK BALLS (7)
INSPECTION
I nspect al l of the val ve body mati ng surfaces for
scratches, ni cks, burrs, or di storti on. Use a strai ght-
edge to check surface fl atness. Mi nor scratches may
be removed wi th crocus cl oth usi ng onl y very l i ght
pressure.
Mi nor di storti on of a val ve body mati ng surface
may be corrected by smoothi ng the surface wi th a
sheet of crocus cl oth. Posi ti on the crocus cl oth on a
surface pl ate, sheet of pl ate gl ass or equal l y fl at sur-
face. I f di storti on i s severe or any surfaces are
heavi l y scored, the val ve body wi l l have to be
repl aced.
I nspect the val ves and pl ugs (Fi g. 140) for
scratches, burrs, ni cks, or scores. Mi nor surface
scratches on steel val ves and pl ugs can be removed
wi th crocus cl oth but do not round off the edges
of the valve or plug lands. Mai ntai ni ng sharpness
of these edges i s vi tal l y i mportant. The edges prevent
forei gn matter from l odgi ng between the val ves and
pl ugs and the bore.
I nspect al l the val ve and pl ug bores i n the val ve
body. Use a penl i ght to vi ew the bore i nteri ors.
Repl ace the val ve body i f any bores are di storted or
scored. I nspect al l of the val ve body spri ngs. The
coi l s.
Val ve body bores do not change di mensi onal l y wi th
use. I f the val ve body functi oned correctl y when new,
i t wi l l conti nue to operate properl y after cl eani ng and
i nspecti on. I t shoul d not be necessary to repl ace a
val ve body assembl y unl ess i t i s damaged i n han-
dl i ng.
I nspect al l the accumul ator bores i n the val ve body.
Use a penl i ght to vi ew the bore i nteri ors. Repl ace the
val ve body i f any bores are di storted or scored.
I nspect al l of the accumul ator spri ngs. The spri ngs
must be free of di storti on, warpage or broken coi l s.
2 - MANUAL VALVE
9 - CHECK BALLS (7)
2 - MANUAL VALVE
9 - CHECK BALLS (7)
I nspect al l the fl ui d seal s on the val ve body (Fi g.
141). Repl ace any seal s that are cracked, di storted, or
damaged i n any way. These seal s pass fl ui d pressure
di rectl y to the cl utches. Any pressure l eak at these
poi nts, may cause transmi ssi on performance prob-
l ems.
ASSEMBLY
(1) Lubri cate val ves, spri ngs, and the housi ng
val ve bores wi th cl ean transmi ssi on fl ui d.
(2) I nstal l sol enoi d swi tch val ve, manual val ve,
and the l ow/reverse swi tch val ve i nto the val ve body.
(3) I nstal l the retai ners to hol d each val ve i nto the
val ve body.
(4) I nstal l the val ve body check bal l s i nto thei r
proper l ocati ons.
(5) Posi ti on the transfer pl ate onto the val ve body.
(6) I nstal l the screws to hol d the transfer pl ate to
the val ve body. Ti ghten the screws to 5.6 Nm (50 i n.
l bs.).
(7) I nstal l the accumul ator pi stons and spri ngs
i nto the val ve body i n the l ocati on from whi ch they
were removed. Note that al l accumul ators except the
overdri ve have two spri ngs. The overdri ve accumul a-
tor pi ston has onl y one spri ng.
(8) Posi ti on the accumul ator cover onto the val ve
body.
(9) I nstal l the screws to hol d the accumul ator
cover onto the val ve body. Ti ghten the screws to 8
Nm (70 i n. l bs.).
(10) I nstal l the TRS sel ector pl ate onto the val ve
body and the manual val ve.
(11) I nstal l the sol enoi d and pressure swi tch
assembl y onto the val ve body.
(12) I nstal l the screws to hol d the sol enoi d and
pressure swi tch assembl y onto the val ve body.
Ti ghten the screws to 5.7 Nm (50 i n. l bs.). Ti ghten
the screws adjacent to the arrows cast i nto the bot-
tom of the transfer pl ate fi rst.
(13) Posi ti on the detent spri ng onto the val ve body.
(14) I nstal l the screw to hol d the detent spri ng
onto the val ve body. Ti ghten the screw to 4.5 Nm (40
i n. l bs.).
(15) I nstal l new cl utch passage seal s onto the
val ve body, i f necessary
INSTALLATION
(1) Check condi ti on of seal s on val ve body and the
sol enoi d and pressure swi tch assembl y. Repl ace seal s
i f cut or worn.
(2) Pl ace TRS sel ector pl ate i n the PARK posi ti on.
(3) Pl ace the transmi ssi on i n the PARK posi ti on.
(4) Lubri cate seal on the sol enoi d and pressure
swi tch assembl y connector wi th petrol eum jel l y.
(5) Posi ti on val ve body i n transmi ssi on and al i gn
the manual l ever on the val ve body to the pi n on the
transmi ssi on manual shi ft l ever.
(6) Seat val ve body i n case and i nstal l one or two
bol ts to hol d val ve body i n pl ace.
(7) Ti ghten val ve body bol ts al ternatel y and evenl y
(9) Pl ace repl acement fi l ter i n posi ti on on val ve
body and i nto the oi l pump.
(10) I nstal l screw to hol d fi l ter to val ve body.
Ti ghten screw to 4.5 Nm (40 i n. l bs.) torque.
(11) Connect the sol enoi d and pressure swi tch
assembl y connector.
(12) I nstal l oi l pan. Ti ghten pan bol ts to 12 Nm
Mopar ATF +4.
(14) Check and adjust gearshi ft cabl e, i f necessary.
Fig. 141 Valve Body Seals
1 - UNDERDRIVE ACCUMULATOR (2 SPRINGS)
2 - 4TH CLUTCH ACCUMULATOR (2 SPRINGS)
3 - 2ND CLUTCH ACCUMULATOR (2 SPRINGS)
4 - LOW REVERSE ACCUMULATOR (2 SPRINGS)
5 - LOW/REVERSE PASSAGE SEAL
6 - 2ND CLUTCH PASSAGE SEAL
7 - 4TH CLUTCH PASSAGE SEAL
8 - OVERDRIVE ACCUMULATOR (1 SPRING)
TRANSFER CASE - NV241 GENII
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 415
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 415
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV241 GENII . . . . . . . . . . . . . . . . . . 416
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 417
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 426
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 438
SPECIFICATIONS
TRANSFER CASE - NV241 GENII . . . . . . . . 438
SPECIAL TOOLS
TRANSFER CASE - NV241/NV243 . . . . . . . . 439
EXTENSION HOUSING BUSHING AND SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 440
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
FRONT OUTPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 442
POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 442
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 442
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 443
SHIFT LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 445
ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER . . . . . . . . . . 446
TRANSFER CASE - NV241
GENII
DESCRIPTION
The NV241 GENI I transfer case i s a part-ti me
transfer case wi th a l ow-range gear system. I t pro-
vi des three operati ng ranges pl us a NEUTRAL posi -
ti on. The l ow range posi ti on provi des a gear
reducti on rati o of 2.72:1 for i ncreased l ow speed
torque capabi l i ty.
The gear cases and extensi on are al l of al umi num
(Fi g. 1). Dri ve sprockets and an i nterconnecti ng dri ve
chai n are used to transmi t engi ne torque to the front/
rear propel l er shafts. The mai nshaft, i nput gear and
front output shaft are supported by bal l and needl e
beari ngs.
IDENTIFICATION
An i denti fi cati on tag (Fi g. 2) i s attached to the rear
case of every transfer case. The tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
OPERATION
OPERATING RANGE
Transfer case operati ng ranges are:
2H (2-wheel dri ve)
4H (4-wheel dri ve)
4LO (4-wheel dri ve l ow range)
The 2H range i s for use on any road surface at any
ti me.
The 4H and 4LO ranges are for off road use onl y.
They are not for use on hard surface roads. The onl y
excepti on bei ng when the road surface i s covered by
i ce and snow.
The l ow range reducti on gear system i s operati ve
i n 4LO range onl y. Thi s range i s for extra pul l i ng
Fig. 1 Transfer Case - Front View
1 - TRANSFER CASE
2 - MANUAL LEVER
3 - POSITION SENSOR
DR TRANSFER CASE - NV241 GENII 21 - 415
power i n off road si tuati ons. Low range reducti on
rati o i s 2.72:1.
SHIFT MECHANISM
The transfer case i s operated by an adjustabl e fl oor
mounted shi ft l i nkage. The transfer case shi ft l ever
i s di rectl y attached to the shi ft sector. The sector
operates the range and mode forks wi thi n the trans-
fer case.
A strai ght l i ne shi ft pattern i s used wi th a NEU-
TRAL detent. Lever range posi ti ons are i mpri nted i n
the shi ft knob.
SHIFTING
The transfer case can be shi fted between the 2H
and 4H operati ng ranges whi l e the vehi cl e i s i n
moti on. The vehi cl e must have the transmi ssi on
pl aced i n NEUTRAL, or the cl utch depressed i n the
case of a manual transmi ssi on, and be movi ng l ess
than 2-3 MPH when shi fti ng i nto and out of the 4L
operati ng range.
DIAGNOSIS AND TESTING - TRANSFER CASE -
NV241 GENII
Before begi nni ng repai r on a suspected transfer
case mal functi on, check al l other dri vel i ne compo-
nents beforehand.
The actual cause of a probl em may be rel ated to
such i tems as: front hubs, axl es, propel l er shafts,
wheel s and ti res, transmi ssi on, or cl utch i nstead. I f
al l other dri vel i ne components are i n good condi ti on
and operati ng properl y, refer to the Di agnosi s Chart
for further i nformati on.
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer Case difficult to shift or will
not shift into desired range.
1) Vehicle speed too great to permit
shifting.
1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3-4 km/h (2-3 mph) before
attempting the shift.
2) If vehicle was operated for an
extended period in 4H on a dry
paved surface, the driveline torque
load may be causing a bind.
2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved
surfaces.
3) Transfer case external shift
linkage binding.
3) Lubricate, repair, or replace
linkage bushings, or tighten loose
4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fill hole
with Mopar ATF +4, Automatic
Transmission fluid.
5) Internal components binding,
worn, or damaged.
5) Disassemble the transfer case
and replace worn or damaged
Transfer Case noisy in all operating
ranges.
Transmission fluid.
Fig. 2 Transfer Case - Rear View
1 - TRANSFER CASE
2 - IDENTIFICATION TAG
21 - 416 TRANSFER CASE - NV241 GENII DR
TRANSFER CASE - NV241 GENII (Continued)
Noisy in, or jumps out of, four wheel
drive low range.
1) Transfer case not completely
engaged in 4L position.
1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.
necessary.
Lubricant leaking from output shaft
seal or vent.
1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.
3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.
1) Operate vehicle in the 2H
position on hard, dry surfaces.
REMOVAL
(2) Remove ski d pl ate, i f equi pped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
(3) Posi ti on drai n oi l contai ner under transfer
case.
(4) Remove transfer case drai n pl ug and drai n
l ubri cant i nto contai ner.
(5) Di sconnect vent hose and transfer case posi ti on
sensor connector.
(6) Di sconnect shi ft rod from grommet i n transfer
case shi ft l ever, or from fl oor shi ft arm whi chever
provi des easy access. Use channel l ock styl e pl i ers to
press rod out of l ever grommet.
(7) Support transmi ssi on wi th jack stand.
(8) Mark front and rear propel l er shafts for assem-
bl y reference.
(9) Remove front and rear propel l er shafts. (Refer
to 3 - DI FFERENTI AL & DRI VELI NE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(10) Support transfer case wi th sui tabl e jack.
(11) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(12) Move transfer case assembl y rearward unti l
free of transmi ssi on output shaft.
(13) Lower jack and move transfer case from
under vehi cl e.
DISASSEMBLY
Posi ti on transfer case i n a shal l ow drai n pan.
Remove drai n pl ug and drai n any remai ni ng l ubri -
cant remai ni ng i n case.
SHIFT LEVER AND FRONT OUTPUT SHAFT SEAL
(1) Shi ft transfer case i nto NEUTRAL.
(2) Remove nut that retai ns the shi ft l ever to sec-
tor shaft. Then remove shi ft l ever from shaft (Fi g. 3).
(3) Remove the front propel l er shaft seal boot
retai ni ng cl amp (Fi g. 4).
(4) Remove the front propel l er shaft seal boot (Fi g.
5).
(5) Remove the front output shaft seal sl i nger by
bendi ng (Fi g. 6) the sl i nger ears away from the
transfer case.
(6) Usi ng a sui tabl e pry tool (Fi g. 7), remove the
sl i nger from the output shaft usi ng care not to dam-
age the shaft.
(7) Usi ng a screw and a sl i de hammer, remove the
front output shaft seal .
Fig. 3 Remove Range Lever Nut
1 - RANGE LEVER
Fig. 4 Remove Boot Clamp
1 - SEAL BOOT
2 - BOOT CLAMP
Fig. 5 Remove Seal Boot
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 6 Bend Slinger Ears
1 - SLINGER
2 - BEND UPWARD
Fig. 7 Remove Slinger From Shaft
1 - SLINGER
2 - PRY TOOL
REAR EXTENSION
(1) Remove rear extensi on bol ts (Fi g. 8).
(2) Remove rear extensi on housi ng (Fi g. 9). Tap
extensi on once or twi ce wi th a pl asti c mal l et to break
seal er bead and l oosen i t.
(3) Remove output beari ng retai ni ng ri ng wi th
heavy duty snap-ri ng pl i ers (Fi g. 10).
OIL PUMP AND REAR CASE
(1) Remove rear case-to-front case bol ts (Fi g. 11).
Fig. 8 Remove Rear Extension Bolts
2 - TRANSFER CASE
Fig. 9 Remove Rear Extension
2 - TRANSFER CASE
3 - PRY SLOT
Fig. 10 Remove Output Shaft Retaining Ring
1 - REAR OUTPUT SHAFT
3 - RETAINING RING
4 - TRANSFER CASE
Fig. 11 Remove Case Bolts
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
(2) Loosen rear case wi th pry tool to break seal er
bead. I nsert tool i n sl ot at each end of case (Fi g. 12).
(3) Unseat rear case from al i gnment dowel s.
(4) Remove rear case and oi l pump assembl y from
front case (Fi g. 13).
CAUTION: Do not remove the bolts holding the oil
pump cover to the rear case half. The oil pump
cover is aligned to the rear output shaft bearing
inner race and will become mis-aligned if the bolts
are loosened. If the transfer case failure has gener-
ated any debris which may have become trapped in
the oil pump, the rear case and oil pump assembly
MUST be replaced.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove shi ft rai l cup and spri ng (Fi g. 14).
(2) Remove front sprocket retai ni ng ri ng (Fi g. 15).
Fig. 12 Loosen Case Halves
1 - REAR CASE
2 - FRONT CASE
3 - PRY SLOTS
Fig. 13 Remove Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 14 Shift Rail Cup And Spring Removal
1 - SHIFT RAIL
2 - SPRING
3 - CUP
Fig. 15 Removing Front Sprocket Retaining Ring
1 - FRONT SPROCKET
2 - RETAINING RING
3 - FRONT OUTPUT SHAFT
(3) Pul l mai nshaft, front sprocket and chai n out-
ward about 25.4 mm (1-i nch) si mul taneousl y (Fi g.
16).
(4) Remove chai n from mai nshaft dri ve sprocket
and remove front sprocket and chai n as assembl y.
SHIFT FORKS AND MAINSHAFT
(1) Remove the transfer case posi ti on sensor (Fi g.
17).
(2) Loosen detent pl ug.
(3) Remove detent pl ug, spri ng, and pl unger (Fi g.
18). Note that the pl ug has an O-ri ng seal . Remove
and di scard thi s seal .
(4) Remove the front output shaft snap-ri ng (Fi g.
19).
Fig. 16 Remove Front Sprocket and Drive Chain
1 - FRONT DRIVE SPROCKET
2 - DRIVE CHAIN
3 - MAINSHAFT
Fig. 17 Remove Position Sensor
1 - FRONT CASE
2 - POSITION SENSOR
Fig. 18 Remove Detent Plug, Spring, and Plunger
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
Fig. 19 Remove Front Output Shaft Snap-ring
2 - SNAP-RING
(5) Remove front output shaft from beari ng i n case
(Fi g. 20).
(6) Pul l mai nshaft assembl y out of i nput gear,
mode sl eeve, and case (Fi g. 21).
(7) Remove mode fork, mode sl eeve, and shi ft rai l
as assembl y (Fi g. 22). Note whi ch way the sl eeve fi ts
i n the fork (l ong si de of sl eeve goes to front).
(8) Remove range fork retai ni ng ri ng.
(9) Remove range fork and hub as an assembl y
(Fi g. 23). Note fork posi ti on for i nstal l ati on reference.
Fig. 23 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 20 Remove Front Output Shaft
1 - FRONT CASE
Fig. 21 Remove Mainshaft
1 - FRONT CASE
2 - MAINSHAFT
Fig. 22 Remove Mode Fork and Shift Rail
1 - MODE FORK
2 - SHIFT RAIL
3 - MODE SLEEVE
(10) Remove the shi ft sector support (Fi g. 24).
(11) Remove shi ft sector (Fi g. 25).
MAINSHAFT
(1) Remove the dri ve sprocket retai ni ng ri ng (Fi g.
26) from the output shaft.
(2) Remove the dri ve sprocket thrust washer (Fi g.
Fig. 24 Remove Sector Support
1 - SECTOR SUPPORT
2 - FRONT CASE
3 - SECTOR SHAFT
Fig. 25 Remove Shift Sector
1 - SHIFT SECTOR
Fig. 26 Remove The Drive Sprocket Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - DRIVE SPROCKET
Fig. 27 Remove Drive Sprocket Thrust Washer
1 - OUTPUT SHAFT
2 - THRUST WASHER
3 - DRIVE SPROCKET
(3) Remove dri ve sprocket (Fi g. 28) from the out-
put shaft.
(4) Remove the cl utch gear (Fi g. 29) and hub (Fi g.
(5) Remove the mode hub retai ni ng ri ng (Fi g. 31)
from the output shaft.
Fig. 31 Remove Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - MODE HUB
Fig. 28 Remove Drive Sprocket
1 - OUTPUT SHAFT
2 - DRIVE SPROCKET
Fig. 29 Remove Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 30 Remove Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
(6) Remove the mode hub (Fi g. 32) from the output
shaft.
INPUT AND PLANETARY GEAR
(1) Remove i nput gear seal wi th sui tabl e screw
and sl i de hammer.
(2) Remove i nput gear retai ni ng ri ng (Fi g. 33) wi th
heavy duty snap-ri ng pl i ers.
(3) Pl ace front case i n hori zontal posi ti on. Then
remove i nput gear and l ow range gear as an assem-
bl y (Fi g. 34). Tap gear out of beari ng wi th pl asti c
mal l et, i f necessary.
(1) Remove snap-ri ng that retai ns i nput gear i n
l ow range gear (Fi g. 35).
Fig. 35 Input Gear Snap-Ring Removal
1 - INPUT GEAR SNAP-RING
Fig. 32 Remove Mode Hub
1 - OUTPUT SHAFT
2 - MODE HUB
Fig. 33 Remove Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 34 Remove Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
(2) Remove retai ner (Fi g. 36).
(3) Remove front tabbed thrust washer (Fi g. 37).
(4) Remove i nput gear (Fi g. 38).
(5) Remove rear tabbed thrust washer from l ow
range gear (Fi g. 39).
CLEANING
Cl ean the transfer case parts wi th a standard
parts cl eani ng sol vent. Remove al l traces of seal er
from the cases and retai ners wi th a scraper and
3M al l purpose cl eaner. Use compressed ai r to
remove sol vent resi due from oi l feed passages i n the
case hal ves, retai ners, gears, and shafts.
INSPECTION
MAINSHAFT/SPROCKET/HUB
I nspect the spl i nes on the hub and shaft and the
teeth on the sprocket. Mi nor ni cks and scratches can
be smoothed wi th an oi l stone, however, repl ace any
part that i s damaged.
Check the contact surfaces i n the sprocket bore
and on the mai nshaft. Mi nor ni cks and scratches can
be smoothed wi th 320-400 gri t emery cl oth but do not
try to sal vage the shaft i f ni cks or wear i s severe.
Fig. 36 Input Gear Retainer Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 37 Front Tabbed Thrust Washer Removal
1 - FRONT TABBED THRUST WASHER
Fig. 38 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 39 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fi g. 40). Mi nor ni cks
can be dressed off wi th an oi l stone but repl ace the
gear i f any teeth are broken, cracked, or chi pped. The
beari ng surface on the gear can be smoothed wi th
300-400 gri t emery cl oth i f necessary.
Exami ne the carri er body and pi ni on gears for
wear or damage. The carri er wi l l have to be repl aced
as an assembl y i f the body, pi ni on pi ns, or pi ni on
gears are damaged.
Check the l ock ri ng and both thrust washers for
wear or cracks. Repl ace them i f necessary. Al so
repl ace the l ock retai ni ng ri ng i f bent, di storted, or
broken.
SHIFT FORKS/HUBS/SLEEVES
Check condi ti on of the shi ft forks and mode fork
shi ft rai l (Fi g. 41). Mi nor ni cks on the shi ft rai l can
be smoothed wi th 320-400 gri t emery cl oth.
I nspect the shi ft fork wear pads (Fi g. 42). The
mode fork pads are servi ceabl e and can be repl aced i f
necessary. The range fork pads are not servi ceabl e.
The fork must be repl aced as an assembl y i f the pads
are worn or damaged.
Check both of the sl eeves for wear or damage,
especi al l y on the i nteri or teeth. Repl ace the sl eeves i f
wear or damage i s evi dent.
REAR RETAINER COMPONENTS
I nspect the retai ner components. Repl ace the bear-
i ng i f rough or noi sy. Check the retai ner for cracks or
wear i n the beari ng bore.
I nspect the retai ni ng ri ngs and washers. Repl ace
any part i f di storted, bent, or broken. Reuse i s not
recommended.
I nspect rear extensi on bushi ng. Repl ace i f worn or
scored.
Fig. 40 Input Gear And Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR
Fig. 41 Shift Forks
1 - RANGE FORK
2 - MODE FORK AND RAIL
3 - MODE SPRING
DRIVE CHAIN
Exami ne the dri ve chai n and shaft beari ngs.
repl ace the chai n i f stretched, di storted, or i f any of
the l i nks bi nd. Repl ace the beari ngs i f rough, or
noi sy.
LOW RANGE ANNULUS GEAR
I nspect annul us gear condi ti on careful l y. The gear
i s onl y servi ced as part of the front case. I f the gear
i s damaged, i t wi l l be necessary to repl ace the gear
and front case as an assembl y. Do not attempt to
remove the gear (Fi g. 43)
FRONT CASE AND REAR CASE
I nspect the cases for wear and damage.
Check case condi ti on. I f l eaks were a probl em, l ook
for gouges and severe scori ng of case seal i ng sur-
faces. Al so make sure the front case mounti ng studs
are i n good condi ti on.
Check the front case mounti ng studs and vent
tube. The tube can be secured wi th Locti te 271 or
680 i f l oose. The stud threads can be cl eaned up wi th
a di e i f necessary. Al so check condi ti on of the fi l l /
drai n pl ug threads i n the rear case. The threads can
be repai red wi th a thread chaser or tap i f necessary.
Or the threads can be repai red wi th Hel i coi l stai n-
l ess steel i nserts i f requi red.
OIL PUMP/OIL PICKUP
Exami ne the oi l pump pi ckup parts. Repl ace the
pump i f any part appears to be worn or damaged. Do
not di sassembl e the pump as i ndi vi dual parts are not
avai l abl e. The pump i s onl y avai l abl e as a compl ete
assembl y. The pi ckup screen, hose, and tube are the
onl y servi ceabl e parts and are avai l abl e separatel y.
ASSEMBLY
BEARINGS AND SEALS
(1) Remove the i nput shaft beari ng (Fi g. 44) from
the front case wi th sui tabl e snap-ri ng pl i ers.
(2) Transfer the retai ni ng ri ng to the new beari ng
i f necessary and i nstal l the beari ng i nto the front
case.
Fig. 42 Shift Fork And Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
3 - WEAR PADS (SERVICEABLE)
Fig. 43 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
Fig. 44 Remove Input Gear Bearing
1 - INPUT GEAR BEARING
2 - FRONT CASE
(3) Usi ng I nstal l er 6436 and Handl e C-4171 (Fi g.
45), remove front output shaft beari ng.
(4) Start front output shaft beari ng i n case. Then
seat beari ng wi th Handl e C-4171 and I nstal l er 6953.
(5) I nstal l front output shaft beari ng retai ni ng
ri ng.
(6) Remove i nput gear pi l ot beari ng by i nserti ng a
sui tabl y si zed dri ft i nto the spl i ned end of the i nput
gear and dri vi ng the beari ng out wi th the dri ft and a
hammer (Fi g. 46).
(7) I nstal l new pi l ot beari ng wi th Remover/I n-
stal l er 8684.
(8) Remove the front output shaft rear beari ng
wi th the screw and jaws from Remover L-4454 and
Cup 8148 (Fi g. 47).
Fig. 47 Front Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
Fig. 45 Remove Front Output Shaft Bearing
1 - FRONT CASE
2 - INSTALLER 6436
3 - HANDLE C-4171
Fig. 46 Remove Input Gear Cup Plug
1 - DRIFT
2 - INPUT GEAR
(9) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 48). The beari ng bore i s
chamfered at the top. I nstal l the beari ng so i t i s
fl ush wi th the l ower edge of thi s chamfer (Fi g. 49).
(10) Remove the rear output shaft beari ng from
the rear case usi ng Remover/I nstal l er 8684 and Han-
dl e C-4171 (Fi g. 50).
(11) I nstal l the rear output shaft beari ng (Fi g. 51)
i nto the rear case usi ng Remover/I nstal l er 6953 and
Handl e C-4171.
Fig. 48 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 49 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
Fig. 50 Remove Rear Output Shaft Bearing
1 - REAR CASE
2 - REMOVER/INSTALLER 8684
3 - HANDLE C-4171
Fig. 51 Install Rear Output Shaft Bearing
1 - REAR CASE
3 - HANDLE C-4171
(1) Lubri cate gears and thrust washers (Fi g. 52)
wi th recommended transmi ssi on fl ui d.
(2) I nstal l fi rst thrust washer i n l ow range gear
(Fi g. 52). Be sure washer tabs are properl y al i gned i n
gear notches.
(3) I nstal l i nput gear i n l ow range gear. Be sure
i nput gear i s ful l y seated.
(4) I nstal l remai ni ng thrust washer i n l ow range
gear and on top of i nput gear. Be sure washer tabs
are properl y al i gned i n gear notches.
(5) I nstal l retai ner on i nput gear and i nstal l snap-
ri ng.
(6) Al i gn and i nstal l l ow range/i nput gear assem-
bl y i n front case (Fi g. 53). Be sure l ow range gear
pi ni ons are engaged i n annul us gear and that i nput
gear shaft i s ful l y seated i n front beari ng.
(7) I nstal l snap-ri ng to hol d i nput/l ow range gear
i nto front beari ng (Fi g. 54).
(8) I nstal l a new i nput gear seal usi ng I nstal l er
Fig. 52 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
Fig. 53 Install Input Planetary Assembly
1 - FRONT CASE
Fig. 54 Install Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
(1) Lubri cate mai nshaft spl i nes wi th recommended
(2) I nstal l the mode hub (Fi g. 55) onto the output
shaft.
(3) I nstal l the mode hub retai ni ng ri ng (Fi g. 56)
(4) I nstal l the sprocket hub (Fi g. 57) onto the out-
put shaft.
(5) I nstal l the cl utch gear (Fi g. 58) onto the output
shaft.
(6) I nstal l the dri ve sprocket (Fi g. 59) onto the out-
put shaft.
Fig. 55 Install Mode Hub
1 - OUTPUT SHAFT
2 - MODE HUB
Fig. 56 Install Mode Hub Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - MODE HUB
Fig. 57 Install Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
Fig. 58 Install Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 59 Install Drive Sprocket
1 - OUTPUT SHAFT
2 - DRIVE SPROCKET
(7) I nstal l the dri ve sprocket thrust washer (Fi g.
60) onto the output shaft.
(8) I nstal l the dri ve sprocket retai ni ng ri ng (Fi g.
(9) Lubri cate sector shaft wi th transmi ssi on fl ui d
and i nstal l shi ft sector i n case (Fi g. 62). Posi ti on sl ot
i n sector so i t wi l l be al i gned wi th shi ft fork pi n
when shi ft forks are i nstal l ed.
(10) I nstal l the shi ft sector support (Fi g. 63).
Ti ghten the sector support to 27-42 Nm (20-30
ft.l bs.).
Fig. 60 Install Drive Sprocket Thrust Washer
1 - OUTPUT SHAFT
2 - THRUST WASHER
3 - DRIVE SPROCKET
Fig. 61 Install The Drive Sprocket Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - DRIVE SPROCKET
Fig. 62 Install Shift Sector
1 - SHIFT SECTOR
Fig. 63 Install Sector Support
1 - SECTOR SUPPORT
2 - FRONT CASE
3 - SECTOR SHAFT
(11) Assembl e and i nstal l range fork and hub (Fi g.
64). Be sure hub i s properl y seated i n l ow range gear
and engaged to the i nput gear.
(12) Al i gn and i nsert range fork pi n i n shi ft sector
sl ot.
(13) I nstal l the range fork retai ni ng ri ng.
(14) I nstal l mode fork and shi ft rai l onto the mode
sl eeve.
(15) I nstal l the mode fork, sl eeve, and shi ft rai l
i nto the transfer case (Fi g. 65).
(16) I nstal l mai nshaft i nto the transfer case (Fi g.
66). Gui de mai nshaft through the mode and range
sl eeves and i nto the i nput gear.
(17) I nstal l the transfer case posi ti on sensor (Fi g.
67). Ti ghten the sensor to 20-34 Nm (16-25 ft. l bs.)
torque.
Fig. 64 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 65 Install Mode Fork and Shift Rail
1 - MODE FORK
2 - SHIFT RAIL
3 - MODE SLEEVE
Fig. 66 Install Mainshaft
1 - FRONT CASE
2 - MAINSHAFT
Fig. 67 Install Position Sensor
1 - FRONT CASE
2 - POSITION SENSOR
(18) I nstal l range l ever on sector shaft (Fi g. 68).
(19) I nstal l washer and nut on sector shaft to
secure shi ft l ever. Appl y 1-2 drops Mopar Lock N
Seal , or equi val ent, to nut threads before i nstal l ati on.
Then ti ghten nut to 27-34 Nm (20-25 ft. l bs.) torque.
(20) I nstal l new o-ri ng on detent pl ug (Fi g. 69).
(21) I nstal l detent pl unger, spri ng, and pl ug (Fi g.
70). Ti ghten the pl ug to 16-25 Nm (12-18 ft. l bs.).
(1) I nstal l the front output shaft (Fi g. 71) i nto the
front output shaft beari ng.
(2) I nstal l the front output shaft retai ni ng ri ng
(Fi g. 72) onto the output shaft.
(3) I nstal l the new front output shaft seal wi th
I nstal l er MB991168A
(4) I nsert front sprocket i n dri ve chai n.
Fig. 68 Install Range Lever Nut
1 - RANGE LEVER
Fig. 69 O-Ring Installation On Detent Plug
1 - O-RING
2 - DETENT PLUG
Fig. 70 Install Detent Plug, Spring, and Plunger
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
Fig. 71 Install Front Output Shaft
1 - FRONT CASE
Fig. 72 Install Front Output Shaft Snap-ring
2 - SNAP-RING
(5) I nstal l dri ve chai n around mai nshaft sprocket
(Fi g. 73). Then posi ti on front sprocket over front
shaft.
(6) Rai se mai nshaft about 2.54 cm (one i nch) and
seat front sprocket on front output shaft.
(7) I f mai nshaft and mode sl eeve were unseated
duri ng chai n i nstal l ati on, al i gn and reseat mai nshaft
i n i nput gear and hub.
(8) I nstal l front sprocket retai ni ng ri ng (Fi g. 74).
(9) I nstal l spri ng and cup on shi ft rai l (Fi g. 75).
(10) I nsert magnet i n front case pocket (Fi g. 76).
cover is aligned to the rear output shaft inner bear-
ing race and will become mis-aligned if the bolts
the oil pump. the rear case and oil pump assembly
MUST be replaced.
(1) Appl y bead of Mopar Gasket Maker, or equi v-
al ent, to mati ng surface of front case. Keep seal er
bead wi dth to maxi mum of 3/16 i nch. Do not use
excessi ve amount of seal er as excess wi l l be di spl aced
i nto case i nteri or.
Fig. 73 Install Front Sprocket and Drive Chain
2 - DRIVE CHAIN
3 - MAINSHAFT
Fig. 74 Front Sprocket Retaining Ring Installation
1 - FRONT SPROCKET
2 - RETAINING RING
Fig. 75 Shift Rail Spring And Cup Installation
1 - CUP
2 - SPRING
Fig. 76 Case Magnet Installation
1 - MAGNET
2 - CASE POCKET
(2) Al i gn oi l pump wi th mai nshaft and al i gn shi ft
rai l wi th bore i n rear case. Then i nstal l rear case and
oi l pump assembl y (Fi g. 77).
(3) I nstal l 4-5 rear case-to front case bol ts (Fi g. 78)
to hol d rear case i n posi ti on. Ti ghten bol ts snug but
not to speci fi ed torque at thi s ti me.
CAUTION: Verify that shift rail, and case alignment
dowels are seated before installing any bolts. Case
could be cracked if shaft rail or dowels are mis-
aligned.
(4) Appl y Locti te 242 to remai nder of rear case-
to-front case bol t threads and i nstal l bol ts. Ti ghten
bol ts to 20-27 Nm (15-24 ft. l bs.),
(5) I nstal l rear output beari ng snap-ri ng (Fi g. 79)
to output shaft.
SEAL BOOT
(1) I nstal l the front output shaft seal sl i nger wi th
I nstal l er 8840. I nstal l the sl i nger onto the shaft unti l
the tool contacts the rear of the output shaft.
(2) I nstal l a new seal boot cl amp onto the seal
boot.
(3) I nstal l the seal boot and cl amp onto the sl i nger
hub and ti ghten the cl amp wi th Cri mp Tool C-4975-A.
Fig. 77 Install Rear Case
1 - REAR CASE
2 - FRONT CASE
Fig. 78 Install Case Bolts
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
Fig. 79 Install Output Shaft Retaining Ring
3 - RETAINING RING
4 - TRANSFER CASE
REAR EXTENSION
(1) I nstal l new seal i n rear extensi on housi ng seal
wi th I nstal l er D-163 and Handl e C-4171..
al ent, to mati ng surface of rear extensi on housi ng.
Keep seal er bead wi dth to maxi mum of 3/16 i nch. Do
not use excessi ve amount of seal er as excess coul d be
di spl aced i nto output beari ng.
(3) Al i gn and i nstal l rear extensi on on retai ner
(Fi g. 80).
(4) Appl y Mopar Si l i cone Seal er to threads of rear
extensi on housi ng bol ts. Then i nstal l and ti ghten
bol ts to 16-24 Nm (12-18 ft. l bs.) torque.
INSTALLATION
(1) Al i gn and seat transfer case on transmi ssi on.
Be sure transfer case i nput gear spl i nes are al i gned
wi th transmi ssi on output shaft. Al i gn spl i nes by
rotati ng transfer case rear output shaft yoke i f nec-
essary. Do not i nstal l any transfer case attachi ng
nuts unti l the transfer case i s compl etel y seated
agai nst the transmi ssi on.
(2) I nstal l and ti ghten transfer case attachi ng
nuts. Ti ghten nuts to 30-41 Nm (20-30 ft.l bs.).
(3) Remove jack stand from under transmi ssi on.
(4) Al i gn and connect propel l er shafts. (Refer to 3 -
(5) Connect vent hose and transfer case posi ti on
sensor connector.
(6) Connect shi ft rod to transfer case l ever or fl oor
shi ft arm. Use channel l ock styl e pl i ers to press rod
back i nto l ever grommet.
(7) Adjust shi ft l i nkage, i f necessary.
(8) Fi l l transfer case wi th recommended transmi s-
si on fl ui d and i nstal l fi l l pl ug.
(9) I nstal l ski d pl ate, i f equi pped. (Refer to 13 -
(10) Lower vehi cl e
SPECIFICATIONS
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 16-24 12-18 -
Bolt, Case Half 20-27 15-24 -
Screw, Oil Pump 12-16 8-12 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-42 20-30 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 16-25 -
Fig. 80 Install Rear Extension Bolts
2 - TRANSFER CASE
SPECIAL TOOLS
TRANSFER CASE - NV241/NV243
Handle, Universal - C-4171
Installer, Seal - C-4210
Remover, Bushing - 6957
Installer, Bushing - 8157
Installer, Seal - D-163
EXTENSION HOUSING
BUSHING AND SEAL
REMOVAL
(2) Remove rear propel l er shaft. (Refer to 3 - DI F-
FERENTI AL & DRI VELI NE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Usi ng a sui tabl e pry tool or sl i de-hammer
mounted screw, remove the extensi on housi ng seal .
INSTALLATION
(1) Cl ean fl ui d resi due from seal i ng surface and
i nspect for defects.
(2) Usi ng I nstal l er D-163, i nstal l seal i n extensi on
(3) I nstal l propel l er shaft. (Refer to 3 - DI FFER-
ENTI AL & DRI VELI NE/PROPELLER SHAFT/PRO-
PELLER SHAFT - I NSTALLATI ON)
(4) Veri fy proper transfer case fl ui d l evel .
Plug, Extension - C-293-3
Remover - L-4454
Cup - 8148
Installer, Pump Housing Seal - 7888
Fig. 81 Install Rear Seal in Extension Housing
2 - SPECIAL TOOL D-163
FLUID
REFILL
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 82).
(2) Posi ti on drai n pan under transfer case.
(3) Remove drai n and fi l l pl ugs and drai n l ubri -
cant compl etel y.
(4) I nstal l drai n pl ug. Ti ghten pl ug to 20-34 Nm
(15-25 ft. l bs.).
(5) Remove drai n pan.
(6) Fi l l transfer case to bottom edge of fi l l pl ug
openi ng wi th Mopar ATF +4, Automati c Transmi s-
si on fl ui d.
(7) I nstal l and ti ghten fi l l pl ug to 20-34 Nm
(15-25 ft. l bs.).
REMOVAL
(1) Remove the front propel l er shaft (Refer to 3 -
SHAFT/PROPELLER SHAFT - REMOVAL).
84).
1 - SEAL BOOT
2 - BOOT CLAMP
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 82 Fill/Drain Plug and I.D. Tag Location
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
transfer case.
age the shaft.
INSTALLATION
boot.
hub and ti ghten the cl amp wi th Cri mp Tool
C-4975-A.
(5) I nstal l front propel l er shaft (Refer to 3 - DI F-
PROPELLER SHAFT - I NSTALLATI ON).
POSITION SENSOR
DESCRIPTION
The transfer case posi ti on sensor i s an el ectroni c
devi ce whose output can be i nterpreted to i ndi cate
the transfer cases current operati ng mode. The sen-
sor consi sts of a fi ve posi ti on, resi sti ve mul ti pl exed
ci rcui t whi ch returns a speci fi c resi stance val ue to
the Powertrai n Control Modul e (PCM) for each trans-
fer case operati ng mode. The sensor i s l ocated on the
top of the transfer case, just l eft of the transfer case
centerl i ne and ri des agai nst the sector pl ate rooster-
comb. The PCM suppl i es 5VDC (+/- 0.5V) to the sen-
sor and moni tors the return vol tage to determi ne the
sector pl ate, and therefore the transfer case, posi ti on.
OPERATION
Duri ng normal vehi cl e operati on, the Powertrai n
Control Modul e (PCM) moni tors the transfer case
posi ti on sensor return vol tage to determi ne the oper-
ati ng mode of the transfer case. Refer to the Operat-
i ng Mode Versus Resi stance tabl e for the correct
resi stance for each posi ti on (Fi g. 87).
1 - SLINGER
2 - BEND UPWARD
1 - SLINGER
2 - PRY TOOL
FRONT OUTPUT SHAFT SEAL (Continued)
OPERATING MODE VERSUS RESISTANCE
SENSOR POSITION OPERATING MODE SENSOR RESISTANCE (ohms)
1 2H 1124-1243
2 4H 650-719
3 NEUTRAL 389-431
4 4L 199-221
5 NOT USED 57-64
REMOVAL
(2) Di sengage the transfer case posi ti on sensor
connector from the posi ti on sensor.
(3) Remove the posi ti on sensor from the transfer
case.
INSTALLATION
(1) I nspect the o-ri ng seal on the transfer case
posi ti on sensor. Repl ace the o-ri ng i f necessary.
(2) I nstal l the transfer case posi ti on sensor i nto
the transfer case. Torque the sensor to 20-34 Nm
(15-25 ft.l bs.).
(3) Engage the transfer case posi ti on sensor con-
nector to the posi ti on sensor.
(5) Veri fy proper sensor operati on.
Fig. 87 Position Sensor Linear Movement
1 - POSITION 1 - 10mm 0.5mm
6 - POSITION 6 - 20mm0.5mm - FULL EXTENSION
POSITION SENSOR (Continued)
SHIFT LEVER
REMOVAL
(1) Shi ft transfer case i nto 2H.
(3) Loosen adjusti ng trunni on l ock bol t and sl i de
shi ft rod out of trunni on. I f rod l acks enough travel
to come out of trunni on, push trunni on out of shi ft
l ever.
(5) Remove transfer case shi fter knob cap.
(6) Remove nut hol di ng shi fter knob to shi ft l ever.
(7) Remove shi fter knob.
(8) Remove the shi ft boot from the shi fter consol e.
(9) Remove the bol ts securi ng the shi fter mecha-
ni sm to the fl oor pan (Fi g. 88).
(10) Separate shi ft l ever mechani sm from the vehi -
cl e.
Fig. 88 Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2 - SHIFTER KNOB 5 - ALIGNMENT PIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
INSTALLATION
(1) I f the shi fter mechani sm does not have a
adjustment l ocati ng pi n i nstal l ed, al i gn the adjust-
ment channel on the shi fter assembl y to the l ocati ng
hol e i n the l ower shi ft l ever and i nstal l an appropri -
atel y si zed pi n to retai n the posi ti on (Fi g. 89).
(2) Posi ti on shi ft l ever i n vehi cl e.
(3) I nstal l the bol ts to hol d the shi fter mechani sm
to the fl oor pan.
(5) Veri fy that the transfer case i s sti l l i n the 2H
posi ti on. The 2H detent posi ti on on the transfer case
shi ft arm i s the second posi ti on from ful l forward.
(6) I nstal l trunni on to shi ft l ever, i f necessary.
(7) I nstal l shi ft rod to trunni on, i f necessary.
(8) Ti ghten the shi ft rod l ock bol t to 10 Nm (90
i n.l bs.).
(9) Remove the shi fter adjustment l ocati ng pi n
from the adjustment channel and the l ocati ng hol e.
(11) I nstal l the transfer case shi fter consol e.
(12) I nstal l the shi fter boot and the shi fter knob
onto the shi fter l ever.
(13) I nstal l nut to hol d shi fter knob to shi ft l ever.
(14) I nstal l shi fter knob cap.
(15) Veri fy transfer case operati on.
SHIFT LEVER (Continued)
ADJ USTMENTS
ADJUSTMENT - SHIFT LEVER
(1) Move shi ft l ever i nto 2H posi ti on.
(3) Loosen shi ft rod l ock bol t at trunni on.
(4) Check shi ft rod fi t i n trunni on. Be sure rod
does not bi nd i n trunni on. Lubri cate the shi ft rod
and trunni on i f necessary.
(5) Veri fy that transfer case shi ft l ever i s i n 2H
detent posi ti on. The 2H detent posi ti on on the trans-
fer case shi ft arm i s the second posi ti on from ful l for-
ward.
(6) Al i gn the adjustment l ocati ng hol e on the l ower
shi fter l ever wi th the adjustment channel on the
shi fter bracket assembl y (Fi g. 90).
(7) I nsert an appropri atel y si zed pi n through i nto
the adjustment channel and through the l ocati ng
hol e to hol d the shi fter i n the correct posi ti on.
(8) Ti ghten shi ft rod l ock bol t to 10 Nm (90 i n.
l bs.) torque.
(9) Remove the l ocati ng pi n from the adjustment
channel and l ocati ng hol e.
(10) Check shi ft l i nkage operati on. Be sure trans-
fer case shi fts i nto and operates properl y i n al l
ranges.
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 447
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 448
CASE - NV271 . . . . . . . . . . . . . . . . . . . . . . . 448
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 450
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 459
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 473
SPECIFICATIONS
TRANSFER CASE - NV271 . . . . . . . . . . . . . 473
SPECIAL TOOLS
TRANSFER CASE NV271/NV273 . . . . . . . . . 474
EXTENSION HOUSING SEAL AND DUST BOOT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 476
FLUID
REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 477
POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 477
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 477
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 478
SHIFT LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 480
ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER . . . . . . . . . . 481
DESCRIPTION
The NV271 transfer case i s a part-ti me transfer
case wi th a l ow-range gear system. I t provi des three
operati ng ranges pl us a NEUTRAL posi ti on. The l ow
range posi ti on provi des a gear reducti on rati o of
2.72:1 for i ncreased l ow speed torque capabi l i ty.
The gear cases and extensi on are al l of al umi num
(Fi g. 1). Dri ve sprockets and an i nterconnecti ng dri ve
chai n are used to transmi t engi ne torque to the front/
rear propel l er shafts. The mai nshaft, i nput gear and
front output shaft are supported by bal l and needl e
beari ngs.
Fig. 1 Transfer Case - Front View
1 - TRANSFER CASE
2 - MANUAL LEVER
3 - POSITION SENSOR
DR TRANSFER CASE - NV271 21 - 447
IDENTIFICATION
An i denti fi cati on tag (Fi g. 2) i s attached to the rear
case of every transfer case. The tag provi des the
OPERATION
OPERATING RANGE
2H (2-wheel dri ve)
4H (4-wheel dri ve)
4LO (4-wheel dri ve l ow range
The 2H range i s for use on any road surface at any
ti me.
The 4H and 4LO ranges are for off road use onl y.
excepti on bei ng when the road surface i s covered by
i ce and snow.
rati o i s 2.72:1.
SHIFT MECHANISM
The transfer case i s operated by an adjustabl e fl oor
mounted shi ft l i nkage. The transfer case shi ft l ever
i s di rectl y attached to the shi ft sector. The sector
operates the range and mode forks wi thi n the trans-
fer case.
A strai ght l i ne shi ft pattern i s used wi th a NEU-
TRAL detent. Lever range posi ti ons are i mpri nted i n
the shi ft knob.
SHIFTING
The transfer case can be shi fted between the 2H
and 4H operati ng ranges whi l e the vehi cl e i s i n
moti on. The vehi cl e must have the transmi ssi on
pl aced i n NEUTRAL, or the cl utch depressed i n the
case of a manual transmi ssi on, and be movi ng l ess
than 2-3 MPH when shi fti ng i nto and out of the 4L
operati ng range.
DIAGNOSIS AND TESTING - TRANSFER CASE -
NV271
Before begi nni ng repai r on a suspected transfer
case mal functi on, check al l other dri vel i ne compo-
nents beforehand.
The actual cause of a probl em may be rel ated to
such i tems as: front hubs, axl es, propel l er shafts,
wheel s and ti res, transmi ssi on, or cl utch i nstead. I f
al l other dri vel i ne components are i n good condi ti on
and operati ng properl y, refer to the Di agnosi s Chart
for further i nformati on.
1 - TRANSFER CASE
21 - 448 TRANSFER CASE - NV271 DR
TRANSFER CASE - NV271 (Continued)
DIAGNOSIS CHART
Transfer Case difficult to shift or will not
shift into desired range.
1) Vehicle speed too great to permit
shifting.
1) Stop vehicle and shift into desired
range. Or, reduce speed to below 3-4
km/h (2-3 mph) before attempting the
shift.
extended period in 4H on a dry paved
surface, the driveline torque load may
be causing a bind.
2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate vehicle
in 2H on dry paved surfaces.
3) Transfer case external shift linkage
binding.
3) Lubricate, repair, or replace linkage
bushings, or tighten loose components
as necessary.
Transmission fluid.
5) Internal components binding, worn,
or damaged.
5) Disassemble the transfer case and
replace worn or damaged components
as necessary.
Transfer Case noisy in all operating
ranges.
Transmission fluid.
Noisy in, or jumps out of, four wheel
drive low range.
engaged in 4L position.
1) With the transmission in NEUTRAL,
or the clutch depressed in the case of a
manual transmission and the vehicle
moving under 3-4 km/h (2-3 mph), shift
the transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment. 2) Adjust linkage.
3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair linkage as
necessary.
4) Range fork damaged, inserts worn,
or fork is binding on the shift rail.
necessary.
5) Low range gear worn or damaged. 5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft seal
or vent.
1) Transfer case overfilled. 1) Drain lubricant to the correct level.
2) Vent closed or restricted. 2) Clear or replace vent as necessary.
3) Output shaft seals damaged or
3) Replace seal as necessary. Check to
ensure that another component, the
propeller shaft slip yoke for example, is
not causing damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.
1) Operate vehicle in the 2H position on
hard, dry surfaces.
REMOVAL
(2) Remove ski d pl ate, i f equi pped. (Refer to 13 -
(3) Posi ti on drai n oi l contai ner under transfer
case.
(4) Remove transfer case drai n pl ug and drai n
l ubri cant i nto contai ner.
(5) Di sconnect vent hose and transfer case posi ti on
sensor connector.
(6) Di sconnect shi ft rod from grommet i n transfer
case shi ft l ever, or from fl oor shi ft arm whi chever
provi des easy access. Use channel l ock styl e pl i ers to
press rod out of l ever grommet.
(8) Mark front and rear propel l er shafts for assem-
bl y reference.
(9) Remove front and rear propel l er shafts. (Refer
to 3 - DI FFERENTI AL & DRI VELI NE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(10) Support transfer case wi th sui tabl e jack.
mi ssi on.
(12) Move transfer case assembl y rearward unti l
free of transmi ssi on output shaft.
(13) Lower jack and move transfer case from
under vehi cl e.
DISASSEMBLY
COMPANION FLANGE AND EXTENSION HOUSING
(1) I nstal l two bol ts 180 apart i nto the front out-
put shaft compani on fl ange.
(2) Pl ace hol der over the bol ts and agai nst the
compani on fl ange (Fi g. 3).
(3) Remove and di scard the front compani on fl ange
nut.
(4) Remove the compani on fl ange from the front
output shaft. I t may be necessary to use Fl ange
pul l er 8992 to remove the compani on fl ange.
(5) Use a sui tabl e chi sel or pry tool to remove the
rear extensi on housi ng dust boot (Fi g. 4).
rear extensi on housi ng seal .
Fig. 3 Remove Companion Flange Nut
1 - HOLDER 6719
2 - BOLTS
Fig. 4 Remove Extension Housing Dust Boot
2 - DUST BOOT
(1) Di sengage the oi l pump pi ck-up tube (Fi g. 7)
from the oi l pump.
NOTE: The oil pump pick-up tube seals to the oil
pump with an o-ring. Verify that the o-ring was
removed with the tube and is in good condition.
Replace the o-ring if necessary.
(2) Remove the oi l pump (Fi g. 8).
Fig. 5 Remove Extension Housing Bolts
2 - BOLTS
Fig. 6 Remove Extension Housing
1 - REAR CASE HALF
Fig. 7 Disengage The Oil Pick-up From Oil Pump
1 - OIL PUMP
2 - OIL PICK-UP TUBE
1 - REAR CASE HALF
3 - OIL PUMP
(4) Remove the rear output shaft beari ng i nner
snap-ri ng (Fi g. 10) from the output shaft usi ng sui t-
abl e snap-ri ng pl i ers.
snap-ri ng (Fi g. 11) from the output shaft.
bead. I nsert tool at each end of case (Fi g. 12).
Fig. 9 Remove Case Half Bolts
1 - FRONT CASE HALF
2 - REAR CASE HALF
3 - BOLTS
Fig. 10 Remove Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
Fig. 12 Separate Front and Rear Case Halves
1 - FRONT CASE HALF
2 - REAR CASE HALF
(8) Remove the rear case from the front case (Fi g.
13).
(1) Remove the oi l pi ck-up tube (Fi g. 14) and
screen from the front case hal f.
(2) Remove the shi ft rai l spri ng (Fi g. 15).
(3) Remove the front output shaft dri ve sprocket
Fig. 16 Remove Front Output Shaft Sprocket
Retaining Ring
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 13 Remove Rear Case Half
1 - FRONT CASE HALF
2 - REAR CASE HALF
Fig. 14 Remove Oil Pick-Up Tube and Screen
1 - FRONT CASE HALF
2 - OIL SCREEN
3 - PICK-UP TUBE
Fig. 15 Remove Shift Rail Spring
1 - SHIFT RAIL
2 - SPRING
(4) Remove the rear output shaft dri ve sprocket
(5) Pul l front sprocket (Fi g. 18), rear sprocket, and
chai n upward unti l cl ear of the front and rear output
shaft sprocket spl i nes.
(6) Remove chai n and sprockets as an assembl y.
(1) Shi ft transfer case i nto NEUTRAL.
(2) Remove nut that retai ns the shi ft l ever to sec-
tor shaft. Then remove shi ft l ever (Fi g. 19) and
spacer from the shaft.
(3) Remove the sector support wi th Socket 9033.
(4) Remove the transfer case posi ti on sensor (Fi g.
20).
Fig. 17 Remove Rear Output Shaft Sprocket
Retaining Ring
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 18 Remove Drive Chain and Sprockets
1 - FRONT CASE HALF
2 - CHAIN
3 - DRIVE SPROCKETS
Fig. 19 Remove Manual Shift Lever
1 - SHIFT SECTOR
2 - SECTOR SUPPORT
3 - MANUAL SHIFT LEVER
Fig. 20 Remove Position Sensor
1 - FRONT CASE
2 - POSITION SENSOR
(5) Loosen detent pl ug (Fi g. 21).
remove the front output shaft seal .
23).
(Fi g. 24).
Fig. 21 Loosen the Detent Plug
1 - FRONT CASE HALF
2 - DETENT PLUG
Fig. 22 Remove Detent plug, Spring, and Plunger
1 - FRONT CASE HALF
2 - DETENT PLUG
3 - SPRING
4 - PLUNGER
Fig. 23 Remove Front Output Shaft Bearing Inner
Snap-Ring
1 - FRONT CASE HALF
2 - SNAP-RING
1 - FRONT CASE
i n the fork (l ong si de of sl eeve goes to front or the
poi nts on the sl eeve teeth go to the rear of case).
Fig. 25 Remove Mainshaft Assembly
1 - FRONT CASE HALF
2 - MAINSHAFT ASSEMBLY
Fig. 26 Remove Mode Fork, Sleeve, and Shift Rail
Assembly
1 - SHIFT RAIL
2 - MODE FORK
3 - MODE SLEEVE
1 - RANGE HUB
2 - RANGE FORK
1 - SHIFT SECTOR
MAINSHAFT
(1) Remove the cl utch gear (Fi g. 29) from the out-
put shaft.
from the mai nshaft.
(3) Remove the mode hub (Fi g. 31) from the mai n-
shaft.
(4) Remove the dri ve sprocket dri ve hub (Fi g. 32)
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 30 Remove Mode Hub Retaining Ring
1 - MAINSHAFT
2 - MODE HUB
3 - RETAINING RING
1 - MAINSHAFT
2 - MODE HUB
Fig. 32 Remove the Drive Sprocket Drive Hub
1 - MAINSHAFT
2 - DRIVE SPROCKET DRIVE HUB
and sl i de hammer.
the l ow range gear (Fi g. 35).
1 - INPUT GEAR
2 - RETAINING RING
Fig. 36 Remove Input Gear Retainer
1 - INPUT GEAR
2 - RETAINER
1 - INPUT GEAR
2 - RETAINING RING
1 - FRONT CASE
(6) Remove front thrust pl ate (Fi g. 37).
(8) Remove bottom tabbed thrust washer from l ow
range pl anetary (Fi g. 39).
CLEANING
INSPECTION
MAINSHAFT/SPROCKET/HUB
be smoothed wi th an oi l stone, however, repl ace any
wear or damage. Check the pi ni on gear thrust wash-
ers on the pi non pi ns for damage. The carri er wi l l
have to be repl aced as an assembl y i f the body, pi n-
i on pi ns, or pi ni on gears are damaged.
broken.
Fig. 37 Remove Input Gear Thrust Plate
1 - INPUT GEAR
2 - THRUST PLATE
Fig. 38 Remove Input Gear From Planetary
1 - INPUT GEAR
2 - LOW RANGE PLANETARY
Fig. 39 Remove Bottom Input Gear Thrust Plate
1 - PLANETARY
2 - THRUST PLATE
mode and range fork pads are servi ceabl e and can be
repl aced i f necessary.
Fig. 41 Shift forks
1 - RANGE FORK
3 - MODE SPRING
1 - RANGE FORK
2 - MODE FORK
DRIVE CHAIN
repl ace the chai n i f stretched, di storted, or i f any of
the l i nks bi nd. Repl ace the beari ngs i f rough, or
noi sy.
FRONT CASE AND REAR CASE
OIL PUMP/OIL PICKUP
ASSEMBLY
BEARINGS AND SEALS
(1) Remove the i nput shaft beari ng snap-ri ng from
the front case hal f wi th sui tabl e snap-ri ng pl i ers.
(2) Remove the i nput shaft beari ng from the front case
hal f wi th I nstal l er 6953 and Handl e C-4171 (Fi g. 44).
(3) I nstal l the i nput shaft beari ng i nto the front
case hal f wi th I nstal l er 8151 i nverted on Handl e
C-4171 (Fi g. 45).
(4) I nstal l the i nput shaft beari ng snap-ri ng i nto
1 - FRONT CASE
1 - FRONT CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 6953
Fig. 45 Install Input Gear Bearing
1 - FRONT CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8151 (INVERTED)
(5) Remove the front output shaft front beari ng
snap-ri ng from the front case hal f.
46), remove the front output shaft front beari ng.
(7) Start front output shaft front beari ng i n case.
Then seat beari ng wi th I nstal l er 8891 (Fi g. 47).
(8) I nstal l front output shaft beari ng retai ni ng ri ng.
hammer (Fi g. 48).
(10) I nstal l new pi l ot beari ng wi th I nstal l er 9035.
Cup 8148 (Fi g. 49).
Fig. 46 Remove Front Output Shaft Front Bearing
1 - FRONT CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 6953
Fig. 47 Install Front Output Shaft Front Bearing
1 - FRONT CASE HALF
2 - INSTALLER 8891
Fig. 48 Remove Input Gear Cup Bearing
1 - DRIFT
2 - INPUT GEAR
1 - REAR CASE
(13) Remove seal from oi l pump wi th sui tabl e pry
tool .
(14) I nstal l new seal i n oi l pump wi th I nstal l er
7888 (Fi g. 52).
(15) Remove the rear output shaft beari ng snap-
ri ng (Fi g. 53) from the rear case hal f.
Fig. 53 Remove Rear Output Bearing Outer
Snap-Ring
1 - REAR CASE HALF
3 - SNAP-RING
Fig. 50 Install Front Output Shaft Rear Bearing
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8128
2 - CHAMFER
Fig. 52 Oil Pump Seal Installation
1 - HOUSING SEAL
3 - OIL PUMP FEED HOUSING
the rear case usi ng I nstal l er 7888 (Fi g. 54).
i nto the rear case usi ng I nstal l er 8152 and Handl e
C-4171.
(18) I nstal l the rear output shaft beari ng snap-
ri ng i nto the rear case hal f.
(1) Lubri cate gears and thrust washers wi th rec-
ommended transmi ssi on fl ui d.
(2) I nstal l bottom thrust washer (Fi g. 56) i n l ow
range gear pl anetary. Be sure washer tabs are prop-
erl y al i gned i n gear notches.
(3) I nstal l i nput gear i n l ow range gear (Fi g. 57).
Be sure i nput gear i s ful l y seated.
1 - REAR CASE HALF
2 - INSTALLER 7888
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8152
Fig. 56 Install Bottom Input Gear Thrust Plate
1 - PLANETARY
2 - THRUST PLATE
Fig. 57 Install Input Gear From Planetary
1 - INPUT GEAR
(4) I nstal l remai ni ng thrust washer (Fi g. 58) i n
l ow range gear and on top of i nput gear.
(5) I nstal l retai ner (Fi g. 59) on i nput gear and
i nstal l snap-ri ng (Fi g. 60).
1 - FRONT CASE
Fig. 58 Install Input Gear Thrust Plate
1 - INPUT GEAR
2 - THRUST PLATE
Fig. 59 Install Input Gear Retainer
1 - INPUT GEAR
2 - RETAINER
1 - INPUT GEAR
2 - RETAINING RING
(9) I nstal l a new i nput gear oi l seal wi th I nstal l er
(2) Coat the i nteri or of the dri ve sprocket hub wi th
ATF+4 and i nstal l the dri ve sprocket dri ve hub (Fi g.
63) onto the mai nshaft.
(3) I nstal l the mode hub (Fi g. 64) onto the mai n-
shaft.
onto the mai nshaft.
1 - INPUT GEAR
2 - RETAINING RING
Fig. 63 Install the Drive Sprocket Drive Hub
1 - MAINSHAFT
1 - MAINSHAFT
2 - MODE HUB
1 - MAINSHAFT
2 - MODE HUB
3 - RETAINING RING
shaft. Veri fy that the poi nted ends of the cl utch gear
teeth are poi nti ng to the front of the mai nshaft.
(7) Appl y Locti te 242, or equi val ent, to the
threads of the sector support to repl enti sh the factory
appl i ed patch. I nstal l the shi ft sector support.
Ti ghten the sector support wi th Socket 9033 to 27-34
Nm (20-25 ft.l bs.).
sl ot.
sl eeve.
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
1 - SHIFT SECTOR
1 - RANGE HUB
2 - RANGE FORK
Fig. 69 Install Mode Fork, Sleeve, and Shift Rail
Assembly
1 - SHIFT RAIL
2 - MODE FORK
3 - MODE SLEEVE
(13) I nstal l the transfer case posi ti on sensor (Fi g.
71). Ti ghten the sensor to 20-34 Nm (15-25 ft. l bs.)
torque.
(14) I nstal l manual shi ft l ever and spacer onto sec-
tor shaft (Fi g. 72).
(15) I nstal l washer and nut on sector shaft to
secure shi ft l ever. Appl y 1-2 drops Mopar Lock N
Seal , or equi val ent, to nut threads before i nstal l ati on.
Then ti ghten nut to 27-34 Nm (20-25 ft. l bs.) torque.
1 - O-RING
2 - DETENT PLUG
Fig. 70 Install Mainshaft Assembly
1 - FRONT CASE HALF
Fig. 71 Install Position Sensor
1 - FRONT CASE
2 - POSITION SENSOR
Fig. 72 Install Manual Shift Lever
1 - SHIFT SECTOR
2 - SECTOR SUPPORT
3 - MANUAL SHIFT LEVER
front output shaft front beari ng.
(2) I nstal l the front output shaft beari ng i nner
snap-ri ng (Fi g. 76) onto the output shaft.
(4) I nsert front dri ve sprocket i n dri ve chai n.
(5) I nstal l dri ve chai n around rear dri ve sprocket.
(6) Posi ti on rear dri ve sprocket (Fi g. 77) over the
output shaft and l ower the sprocket and chai n
assembl y unti l the front sprocket i s posi ti oned over
the front output shaft.
(7) Al i gn the spl i nes i n the sprockets to the spl i nes
on the output shafts and i nstal l the sprockets onto
the output shafts.
Fig. 74 Install Detent plug, Spring, and Plunger
1 - FRONT CASE HALF
2 - DETENT PLUG
3 - SPRING
4 - PLUNGER
1 - FRONT CASE
Fig. 76 Install Front Output Shaft Bearing Inner
Snap-Ring
1 - FRONT CASE HALF
2 - SNAP-RING
Fig. 77 Install Drive Chain and Sprockets
1 - FRONT CASE HALF
2 - CHAIN
3 - DRIVE SPROCKETS
(9) I nstal l rear sprocket retai ni ng ri ng (Fi g. 79).
(10) I nstal l spri ng onto shi ft rai l (Fi g. 80).
REAR CASE
(1) I nstal l the oi l pi ck-up tube and screen i nto the
rear case hal f.
(3) Al i gn mai nshaft wi th he rear output shaft
beari ng and al i gn shi ft rai l wi th bore i n rear case.
Then i nstal l rear case (Fi g. 82). Veri fy that the case
al i gnment dowel s correctl y seat i nto thei r mati ng
recesses.
Fig. 78 Install Front Output Shaft Sprocket
Retaining Ring
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 79 Install Rear Output Shaft Sprocket Retaining
Ring
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 80 Install Shift Rail Spring
1 - SHIFT RAIL
2 - SPRING
1 - MAGNET
2 - CASE POCKET
aligned.
(5) Ti ghten bol ts to 27-34 Nm (20-25 ft. l bs.),
(6) I nstal l rear output beari ng i nner snap-ri ng
(Fi g. 84) to output shaft.
OIL PUMP AND REAR EXTENSION
(1) I nstal l the oi l pump (Fi g. 85) onto the output
shaft.
1 - REAR CASE HALF
3 - OIL PUMP
Fig. 82 Install Rear Case Half
1 - FRONT CASE HALF
2 - REAR CASE HALF
Fig. 83 Install Case Half Bolts
1 - FRONT CASE HALF
2 - REAR CASE HALF
3 - BOLTS
Fig. 84 Install Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
(2) Engage the oi l pump pi ck-up tube (Fi g. 86) i nto
the oi l pump. Veri fy that the pi ck-up tube o-ri ng i s
on the tube and i s correctl y i nstal l ed to the oi l pump.
(4) I nstal l extensi on housi ng (Fi g. 87) onto the
rear case hal f.
(5) I nstal l rear extensi on bol ts (Fi g. 88). Ti ghten
the bol ts to 27-34 Nm (20-25 ft.l bs.).
(6) I nstal l the extensi on housi ng boot and seal
assembl y wi th I nstal l er 9037 and Handl e C-4171
(Fi g. 89).
Fig. 86 Engage The Oil Pick-up To Oil Pump
1 - OIL PUMP
Fig. 87 Install Extension Housing
1 - REAR CASE HALF
Fig. 88 Install Extension Housing Bolts
2 - BOLTS
Fig. 89 Install Extension Housing Seal
2 - HANDLE C-4171
3 - INSTALLER 9037
(7) I nstal l the front compani on fl ange onto the
front output shaft.
(10) I nstal l a new front compani on fl ange nut.
Ti ghten the compani on fl ange nut to 176-271 Nm
(130-200 ft.l bs.).
INSTALLATION
(1) Al i gn and seat transfer case on transmi ssi on.
Be sure transfer case i nput gear spl i nes are al i gned
wi th transmi ssi on output shaft. Al i gn spl i nes by
rotati ng transfer case rear output shaft yoke i f nec-
essary. Do not i nstal l any transfer case attachi ng
nuts unti l the transfer case i s compl etel y seated
agai nst the transmi ssi on.
(2) I nstal l and ti ghten transfer case attachi ng
nuts. Ti ghten nuts to 30-41 Nm (20-30 ft.l bs.).
(3) Remove jack stand from under transmi ssi on.
(4) Al i gn and connect propel l er shafts. (Refer to 3 -
(5) Connect vent hose and transfer case posi ti on
sensor connector.
(6) Connect shi ft rod to transfer case l ever or fl oor
shi ft arm. Use channel l ock styl e pl i ers to press rod
back i nto l ever grommet.
(7) Adjust shi ft l i nkage, i f necessary.
(8) Fi l l transfer case wi th recommended transmi s-
si on fl ui d and i nstal l fi l l pl ug.
(9) I nstal l ski d pl ate, i f equi pped. (Refer to 13 -
(10) Lower vehi cl e
SPECIFICATIONS
Plug, Detent 16-25 12-18 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-34 20-25 -
Position Sensor 20-34 15-25 -
Nut, Companion Flange 176-271 130-200 -
Fig. 90 Install Companion Flange Nut
1 - HOLDER 6719
2 - BOLTS
SPECIAL TOOLS
TRANSFER CASE NV271/NV273
Remover - L-4454
Cup - 8148
Installer - 8151
Installer - 8152
Installer - 8891
Socket - 9033
AND DUST BOOT
REMOVAL
INSTALLATION
(2) I nstal l the extensi on housi ng dust boot and
seal assembl y wi th I nstal l er 9037 and Handl e C-4171
(Fi g. 92).
FLUID
REFILL
(Fi g. 93).
cant compl etel y.
(30-40 ft. l bs.).
2 - DUST BOOT
2 - HANDLE C-4171
3 - INSTALLER 9037
Fig. 93 Drain and Fill Locations
1 - FILL HOLE
2 - DRAIN HOLE
si on fl ui d.
(30-40 ft. l bs.).
REMOVAL
nut.
INSTALLATION
I nstal l er MB991168A.
front output shaft.
(190-230 ft.l bs.).
POSITION SENSOR
DESCRIPTION
The transfer case posi ti on sensor i s an el ectroni c
devi ce whose output can be i nterpreted to i ndi cate
the transfer cases current operati ng mode. The sen-
sor consi sts of a fi ve posi ti on, resi sti ve mul ti pl exed
ci rcui t whi ch returns a speci fi c resi stance val ue to
the Powertrai n Control Modul e (PCM) for each trans-
fer case operati ng mode. The sensor i s l ocated on the
top of the transfer case, just l eft of the transfer case
centerl i ne and ri des agai nst the sector pl ate rooster-
comb. The PCM suppl i es 5VDC (+/- 0.5V) to the sen-
sor and moni tors the return vol tage to determi ne the
sector pl ate, and therefore the transfer case, posi ti on.
OPERATION
Duri ng normal vehi cl e operati on, the Powertrai n
Control Modul e (PCM) moni tors the transfer case
posi ti on sensor return vol tage to determi ne the oper-
ati ng mode of the transfer case. Refer to the Operat-
i ng Mode Versus Resi stance tabl e for the correct
resi stance for each posi ti on (Fi g. 96).
1 - HOLDER 6719
2 - BOLTS
1 - HOLDER 6719
2 - BOLTS
FLUID (Continued)
OPERATING MODE VERSUS RESISTANCE
SENSOR POSITION OPERATING MODE SENSOR RESISTANCE (ohms)
1 2H 1172-1195
2 4H 677-691
3 NEUTRAL 406-415
4 4L 208-213
5 NOT USED 60-61
REMOVAL
(2) Di sengage the transfer case posi ti on sensor
connector from the posi ti on sensor.
(3) Remove the posi ti on sensor from the transfer
case.
INSTALLATION
(1) I nspect the o-ri ng seal on the transfer case
posi ti on sensor. Repl ace the o-ri ng i f necessary.
(2) I nstal l the transfer case posi ti on sensor i nto
the transfer case. Torque the sensor to 20-34 Nm
(15-25 ft.l bs.).
(3) Engage the transfer case posi ti on sensor con-
nector to the posi ti on sensor.
(5) Veri fy proper sensor operati on.
Fig. 96 Position Sensor Linear Movement
6 - POSITION 6 - 20mm 0.5mm - FULL EXTENSION
POSITION SENSOR (Continued)
SHIFT LEVER
REMOVAL
(1) Shi ft transfer case i nto 2H.
(3) Loosen adjusti ng trunni on l ock bol t and sl i de
shi ft rod out of trunni on. I f rod l acks enough travel
to come out of trunni on, push trunni on out of shi ft
l ever.
(5) Remove transfer case shi fter knob cap.
(6) Remove nut hol di ng shi fter knob to shi ft l ever.
(7) Remove shi fter knob.
(8) Remove the shi ft boot from the shi fter consol e.
(9) Remove the bol ts securi ng the shi fter mecha-
ni sm to the fl oor pan (Fi g. 97).
(10) Separate shi ft l ever mechani sm from the vehi -
cl e.
INSTALLATION
(1) I f the shi fter mechani sm does not have a
adjustment l ocati ng pi n i nstal l ed, al i gn the adjust-
ment channel on the shi fter assembl y to the l ocati ng
hol e i n the l ower shi ft l ever and i nstal l an appropri -
atel y si zed pi n to retai n the posi ti on (Fi g. 98).
(2) Posi ti on shi ft l ever i n vehi cl e.
(3) I nstal l the bol ts to hol d the shi fter mechani sm
to the fl oor pan.
(5) Veri fy that the transfer case i s sti l l i n the 2H
posi ti on. The 2H detent posi ti on on the transfer case
shi ft arm i s the second posi ti on from ful l forward.
(6) I nstal l trunni on to shi ft l ever, i f necessary.
(7) I nstal l shi ft rod to trunni on, i f necessary.
(8) Ti ghten the shi ft rod l ock bol t to 10 Nm (90
i n.l bs.).
(9) Remove the shi fter adjustment l ocati ng pi n
from the adjustment channel and the l ocati ng hol e.
(11) I nstal l the transfer case shi fter consol e.
(12) I nstal l the shi fter boot and the shi fter knob
onto the shi fter l ever.
(13) I nstal l nut to hol d shi fter knob to shi ft l ever.
(14) I nstal l shi fter knob cap.
(15) Veri fy transfer case operati on.
ADJ USTMENTS
ADJUSTMENT - SHIFT LEVER
(1) Move shi ft l ever i nto 2H posi ti on.
(3) Loosen shi ft rod l ock bol t at trunni on.
(4) Check shi ft rod fi t i n trunni on. Be sure rod
does not bi nd i n trunni on. Lubri cate the shi ft rod
and trunni on i f necessary.
(5) Veri fy that transfer case shi ft l ever i s i n 2H
detent posi ti on. The 2H detent posi ti on on the trans-
fer case shi ft arm i s the second posi ti on from ful l for-
ward.
(6) Al i gn the adjustment l ocati ng hol e on the l ower
shi fter l ever wi th the adjustment channel on the
shi fter bracket assembl y (Fi g. 99).
(7) I nsert an appropri atel y si zed pi n through i nto
the adjustment channel and through the l ocati ng
hol e to hol d the shi fter i n the correct posi ti on.
(8) Ti ghten shi ft rod l ock bol t to 10 Nm (90 i n.
l bs.) torque.
(9) Remove the l ocati ng pi n from the adjustment
channel and l ocati ng hol e.
(10) Check shi ft l i nkage operati on. Be sure trans-
fer case shi fts i nto and operates properl y i n al l
ranges.
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 482
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 483
CASE - NV243 . . . . . . . . . . . . . . . . . . . . . . . 483
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 484
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 493
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 505
SPECIFICATIONS
TRANSFER CASE - NV243 . . . . . . . . . . . . . 505
SPECIAL TOOLS
TRANSFER CASE - NV243 . . . . . . . . . . . . . 506
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 507
FLUID
REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 508
MODE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 509
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 509
SELECTOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 510
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 510
SHIFT MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 511
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 511
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 511
DESCRIPTION
The NV243 i s an el ectroni cal l y control l ed part-ti me
transfer case wi th a l ow range gear reducti on system.
The NV243 has three operati ng ranges pl us a NEU-
TRAL posi ti on. The l ow range system provi des a gear
reducti on rati o for i ncreased l ow speed torque capa-
bi l i ty.
The geartrai n i s mounted i n two al umi num case
hal ves attached wi th bol ts. The mai nshaft front and
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
OPERATING RANGES
2WD (2-wheel dri ve)
4HI (4-wheel dri ve)
NEUTRAL
The 2WD range i s for use on any road surface at
any ti me.
The 4HI and 4LO ranges are for off road use onl y.
excepti on bei ng when the road surface i s wet or sl i p-
pery or covered by i ce and snow.
rati o i s 2.72:1.
SHIFT MECHANISM
Operati ng ranges are sel ected wi th a dash
mounted shi ft sel ector swi tch. The shi ft sel ector
swi tch provi des a i nput to the Transfer Case Control
Modul e (TCCM) to i ndi cate the dri vers desi re to
change operati ng ranges. The TCCM uses thi s i nput,
al ong wi th i nput from the transfer case mounted
mode sensor and i nformati on from the vehi cl es bus,
to determi ne i f a shi ft i s permi tted. I f the TCCM
deci des the shi ft i s permi tted, the TCCM control s the
shi ft motor, mounted to the exteri or of the transfer
case, to perform the shi ft.
IDENTIFICATION
A ci rcul ar I D tag i s attached to the rear case of
each transfer case (Fi g. 1). The I D tag provi des the
OPERATION
The i nput gear i s spl i ned to the transmi ssi on out-
put shaft. The i nput gear dri ves the mai nshaft
through the pl anetary assembl y and range sl eeve.
The front output shaft i s operated by a dri ve chai n
that connects the shaft to a dri ve sprocket on the
mai nshaft. The dri ve sprocket i s engaged/di sengaged
by the mode fork, whi ch operates the mode sl eeve
and hub. The sl eeve and hub are not equi pped wi th a
synchroni zer mechani sm for shi fti ng.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV243
DIAGNOSIS CHART
Transfer case difficult to shift or will
1) Transfer case electronically
controlled shift system malfunction.
1) Verify proper operation per the
appropriate diagnostic manual.
extended period in 4HI mode on
dry surface, driveline torque load
may cause difficulty.
2) Drive the vehicle in a straight line
and momentarily release the
accelerator. The transfer case can
then be shifted to the desired mode.
3) Insufficient or incorrect lubricant. 3) Drain and refill transfer case with
the correct quantity of Mopar ATF
+4, Automatic Transmission Fluid.
4) Internal transfer case
components binding, worn, or
damaged.
4) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.
+4, type 9602, Automatic
Transmission Fluid.
damaged.
necessary.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
Transfer case noisy while in, or
jumps out of, 4LO mode.
engaged in 4LO position.
1) While rolling 2-3 MPH and the
transmission in NEUTRAL, or clutch
depressed on vehicles equipped
with a manual transmission, shift
transfer case to the 2WD or 4HI
position, and then back into the 4LO
position.
rail.
necessary.
damaged.
necessary.
Lubricant leaking from transfer case
seals or vent.
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
3) Replace suspect seal.
Abnormal tire wear. 1) Extended operation in 4HI mode
on dry surfaces,
1) Operate vehicle in 2WD mode on
dry surfaces.
REMOVAL
(1) Shi ft transfer case i nto 2WD.
(3) Drai n transfer case l ubri cant.
(4) Mark front and rear propel l er shafts for al i gn-
ment reference.
(6) Remove the transfer case ski d pl ate, i f
equi pped.
(7) Di sconnect front and rear propel l er shafts at
transfer case.
(8) Di sconnect transfer case shi ft motor and mode
sensor wi re connectors.
(9) Di sconnect transfer case vent hose.
(10) Support transfer case wi th transmi ssi on jack.
(11) Secure transfer case to jack wi th chai ns.
(13) Pul l transfer case and jack rearward to di sen-
gage transfer case.
(14) Remove transfer case from under vehi cl e.
DISASSEMBLY
Fig. 2 Remove Transfer Case - Typical
1 - TRANSMISSION
2 - TRANSFER CASE
3 - MODE SENSOR CONNECTOR
SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT
SHAFT SEAL
(1) Remove the bol ts (Fi g. 3) whi ch hol d the shi ft
motor and mode sensor assembl y to the transfer
case.
(2) Remove the shi ft motor and mode sensor
assembl y from the transfer case.
5).
transfer case.
Fig. 4 Remove Boot Clamp - Typical
1 - SEAL BOOT
2 - BOOT CLAMP
Fig. 5 Remove Seal Boot - Typical
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 6 Bend Slinger Ears - Typical
1 - SLINGER
2 - BEND UPWARD
Fig. 3 Remove the Shift Motor and Mode Sensor
Assembly Bolts - Typical
1 - TRANSFER CASE
2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
3 - BOLT
age the shaft.
REAR EXTENSION
Fig. 7 Remove Slinger From Shaft - Typical
1 - SLINGER
2 - PRY TOOL
2 - TRANSFER CASE
2 - TRANSFER CASE
3 - PRY SLOT
3 - RETAINING RING
4 - TRANSFER CASE
MUST be replaced.
(5) Remove the oi l pump pi ckup tube.
(1) Remove shi ft rai l cup and spri ng (Fi g. 14).
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
1 - REAR CASE
2 - FRONT CASE
3 - PRY SLOTS
1 - REAR CASE
2 - FRONT CASE
Fig. 14 Shift Rail Cup And Spring Removal
1 - SHIFT RAIL
2 - SPRING
3 - CUP
(3) Pul l mai nshaft, front sprocket and chai n out-
ward about 25.4 mm (1-i nch) si mul taneousl y (Fi g.
16).
(4) Remove chai n from mai nshaft dri ve sprocket
and remove front sprocket and chai n as assembl y.
18).
1 - FRONT SPROCKET
2 - RETAINING RING
Fig. 16 Remove Front Sprocket and Drive Chain
2 - DRIVE CHAIN
3 - MAINSHAFT
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
Fig. 18 Remove Front Output Shaft Snap-ring -
Typical
2 - SNAP-RING
(Fi g. 19).
i n the fork (l ong si de of sl eeve goes to front).
(7) Remove range fork retai ni ng ri ng.
1 - RANGE HUB
2 - RANGE FORK
1 - FRONT CASE
Fig. 20 Remove Mainshaft
1 - FRONT CASE
2 - MAINSHAFT
Fig. 21 Mode Fork And Sleeve Removal
1 - MODE SLEEVE
(10) Remove the shi ft sector o-ri ng (Fi g. 24).
MAINSHAFT
(1) Remove the dri ve sprocket retai ni ng ri ng (Fi g.
(2) Remove the dri ve sprocket thrust washer (Fi g.
Fig. 23 Shift Sector Removal
1 - SHIFT SECTOR
Fig. 24 Remove the Shift Sector O-Ring
1 - TRANSFER CASE FRONT HOUSING
2 - SHIFT SECTOR O-RING
Fig. 25 Remove The Drive Sprocket Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - DRIVE SPROCKET
Fig. 26 Remove Drive Sprocket Thrust Washer
1 - OUTPUT SHAFT
2 - THRUST WASHER
3 - DRIVE SPROCKET
(3) Remove dri ve sprocket (Fi g. 27) from the out-
put shaft.
(4) Remove the cl utch gear (Fi g. 28) and hub (Fi g.
from the output shaft.
Fig. 30 Remove Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - MODE HUB
Fig. 27 Remove Drive Sprocket
1 - OUTPUT SHAFT
2 - DRIVE SPROCKET
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 29 Remove Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
(6) Remove the mode hub (Fi g. 31) from the output
shaft.
and sl i de hammer.
1 - OUTPUT SHAFT
2 - MODE HUB
1 - INPUT GEAR
2 - RETAINING RING
1 - FRONT CASE
CLEANING
INSPECTION
MAINSHAFT/SPROCKET/HUB INSPECTION
be smoothed wi th an oi l stone. However, repl ace any
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
1 - INPUT GEAR
2 - LOW RANGE GEAR
1 - LOW RANGE GEAR
gears are damaged.
broken.
Fig. 39 Input Gear and Carrier Components
Fig. 40 Shift Forks
1 - RANGE FORK
3 - MODE SPRING
REAR EXTENSION HOUSING
I nspect the extensi on housi ng seal and bushi ng.
Repl ace both components i f ei ther show any si gn of
wear or damage.
I nspect the shaft threads, sprocket teeth, and bear-
i ng surfaces. Mi nor ni cks on the teeth can be
smoothed wi th an oi l stone. Use 320-400 gri t emery to
smooth mi nor scratches on the shaft beari ng sur-
faces. Rough threads on the shaft can be chased i f
necessary. Repl ace the shaft i f the threads are dam-
aged, beari ng surfaces are scored, or i f any sprocket
teeth are cracked or broken.
Repl ace the chai n and both sprockets i f the chai n i s
stretched, di storted, or i f any of the l i nks bi nd.
Repl ace the beari ngs i f rough, or noi sy.
FRONT AND REAR CASES
OIL PUMP/OIL PICKUP
1 - RANGE FORK
2 - MODE FORK
4 - WEAR PADS (SERVICEABLE) Fig. 42 Low Range Annulus Gear
1 - FRONT CASE
ASSEMBLY
BEARINGS AND SEALS
case.
44), remove front output shaft beari ng.
seat beari ng wi th Handl e C-4171 and I nstal l er 6953.
ri ng.
hammer (Fi g. 45).
(7) I nstal l new pi l ot beari ng wi th Remover/I n-
stal l er 8684.
2 - FRONT CASE
Fig. 44 Remove Front Output Shaft Bearing
1 - FRONT CASE
2 - INSTALLER 6436
3 - HANDLE C-4171
Fig. 45 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
Cup 8148 (Fi g. 46).
1 - REAR CASE
Fig. 47 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
3 - INSTALLER 5066
2 - CHAMFER
the rear case usi ng Remover/I nstal l er 8684 and Han-
dl e C-4171 (Fi g. 49).
Handl e C-4171.
gear notches.
ri ng.
1 - REAR CASE
3 - HANDLE C-4171
1 - REAR CASE
3 - HANDLE C-4171
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
(2) I nstal l the mode hub (Fi g. 54) onto the output
shaft.
1 - FRONT CASE
1 - INPUT GEAR
2 - RETAINING RING
1 - OUTPUT SHAFT
2 - MODE HUB
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - MODE HUB
(4) I nstal l the sprocket hub (Fi g. 56) onto the out-
put shaft.
shaft.
(6) I nstal l the dri ve sprocket (Fi g. 58) onto the out-
put shaft.
(7) I nstal l the dri ve sprocket thrust washer (Fi g.
Fig. 59 Install Drive Sprocket Thrust Washer
1 - OUTPUT SHAFT
2 - THRUST WASHER
3 - DRIVE SPROCKET
Fig. 56 Install Sprocket Hub
1 - OUTPUT SHAFT
2 - SPROCKET HUB
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
Fig. 58 Install Drive Sprocket
1 - OUTPUT SHAFT
2 - DRIVE SPROCKET
(8) I nstal l the dri ve sprocket retai ni ng ri ng (Fi g.
(10) I nstal l the shi ft sector o-ri ng.
sl ot.
(13) I nstal l the range fork retai ni ng ri ng.
sl eeve.
Fig. 63 Mode Fork And Sleeve Installation
1 - MODE SLEEVE
Fig. 60 Install The Drive Sprocket Retaining Ring
1 - OUTPUT SHAFT
2 - RETAINING RING
3 - DRIVE SPROCKET
1 - SHIFT SECTOR
1 - RANGE HUB
2 - RANGE FORK
front output shaft beari ng.
(2) I nstal l the front output shaft retai ni ng ri ng
(4) I nsert front sprocket i n dri ve chai n.
Fig. 64 Install Mainshaft
1 - FRONT CASE
2 - MAINSHAFT
1 - O-RING
2 - DETENT PLUG
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
1 - FRONT CASE
Fig. 68 Install Front Output Shaft Snap-ring - Typical
2 - SNAP-RING
(5) I nstal l dri ve chai n around mai nshaft sprocket
(Fi g. 69). Then posi ti on front sprocket over front
shaft.
(6) Rai se mai nshaft about 2.54 cm (one i nch) and
seat front sprocket on front output shaft.
(7) I f mai nshaft and mode sl eeve were unseated
duri ng chai n i nstal l ati on, al i gn and reseat mai nshaft
i n i nput gear and hub.
(9) I nstal l spri ng and cup on shi ft rai l (Fi g. 71).
Fig. 69 Install Front Sprocket and Drive Chain
2 - DRIVE CHAIN
3 - MAINSHAFT
Fig. 70 Front Sprocket Retaining Ring Installation
1 - FRONT SPROCKET
2 - RETAINING RING
Fig. 71 Shift Rail Spring And Cup Installation
1 - CUP
2 - SPRING
1 - MAGNET
2 - CASE POCKET
Lubri cate the oi l pump components wi th transmi s-
si on fl ui d before i nstal l ati on. Pri me the oi l pi ckup
tube by pouri ng a l i ttl e oi l i nto the tube before i nstal -
l ati on.
MUST be replaced.
(1) I nstal l new o-ri ng i n pi ckup tube i nl et of oi l
pump.
(2) I nsert oi l pi ckup tube i nto the oi l pump.
aligned.
(6) Appl y Locti te 242 to remai nder of rear case-
to-front case bol t threads and i nstal l bol ts. Ti ghten
bol ts to 20-27 Nm (15-24 ft. l bs.),
to output shaft.
SEAL BOOT AND SHIFT MOTOR ASSEMBLY
boot.
C-4975-A.
1 - REAR CASE
2 - FRONT CASE
Fig. 74 Install Case Bolts - Typical
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
3 - RETAINING RING
4 - TRANSFER CASE
(4) Posi ti on the shi ft motor and mode sensor
assembl y onto the transfer case.
(5) I nstal l the bol ts to hol d the shi ft motor and
mode sensor assembl y to the transfer case. Ti ghten
the bol ts to 16-25 Nm (12-18 ft. l bs.).
REAR EXTENSION
wi th I nstal l er D-163 and Handl e C-4171..
(Fi g. 76).
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case onto the transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 27-34 Nm (20-25 ft. l bs.) torque.
(6) Connect the vent hose.
(7) Connect the shi ft motor and mode sensor wi r-
i ng connectors. Secure wi re harness to cl i ps on trans-
fer case.
(8) Al i gn and connect the propel l er shafts.
(9) Fi l l transfer case wi th correct fl ui d. (Refer to
21 - TRANSMI SSI ON/TRANSFER CASE/FLUI D -
STANDARD PROCEDURE)
(11) Remove transmi ssi on jack and support stand.
(12) Lower vehi cl e and veri fy transfer case shi ft
operati on.
SPECIFICATIONS
Plug, Detent 16-24 12-18 -
Bolts, Shift Motor and
Mode Sensor Assembly
16-24 12-18 -
2 - TRANSFER CASE
SPECIAL TOOLS
Handle - C-4171
Tool Set - L-4518
Installer, Seal - MB991168A
Cup - 8148
Installer - 8840
REMOVAL
INSTALLATION
FLUID
REFILL
(Fi g. 78).
cant compl etel y.
(15-25 ft. l bs.).
(6) Fi l l transfer case to bottom edge of fi l l pl ug open-
i ng wi th Mopar ATF +4, Automati c Transmi ssi on fl ui d.
(15-25 ft. l bs.).
REMOVAL
1 - SEAL BOOT
2 - BOOT CLAMP
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
80).
transfer case.
age the shaft.
INSTALLATION
boot.
C-4975-A.
1 - SEAL BOOT
2 - SEAL SLINGER
1 - SLINGER
2 - BEND UPWARD
1 - SLINGER
2 - PRY TOOL
MODE SENSOR
DESCRIPTION
The transfer case mode sensor (Fi g. 83) i s an el ec-
troni c devi ce whose output can be i nterpreted to i ndi -
cate the shi ft motor shafts rotary posi ti on. The
sensor consi sts of a magneti c ri ng and four Hal l
Effect Transi stors to create a 4 channel di gi tal devi ce
(non-contacti ng) whose output converts the motor
shaft posi ti on i nto a coded si gnal . The TCCM must
suppl y 5VDC (+/- 0.5v) to the sensor and moni tor the
shi ft motor posi ti on. The four channel s are denoted
A, B, C, and D. The sensor i s mechani cal l y l i nked to
the shaft of the cam whi ch causes the transfer case
shi fti ng. The mode sensor draws l ess than 53 mA.
OPERATION
Duri ng normal vehi cl e operati on, the Transfer Case
Control Modul e (TCCM) moni tors the mode sensor
outputs at l east every 250 (+/-50) mi l l i seconds when
the shi ft motor i s stati onary and 400 mi croseconds
when the shi ft motor i s acti ve. A mode sensor si gnal
between 3.8 Vol ts and 0.8 Vol ts i s consi dered to be
undefi ned.
Refer to SECTOR ANGLES vs. TRANSFER CASE
POSI TI ON for the rel ati ve angl es of the transfer case
shi ft sector versus the i nterpreted transfer case gear
operati ng mode. Refer to MODE SENSOR CHAN-
NEL STATES for the sensor codes returned to the
TCCM for each transfer case mode sensor posi ti on.
The vari ous between gears posi ti ons can al so be
referred as the transfer cases coarse posi ti on. These
coarse posi ti ons come i nto pl ay duri ng shi ft attempts.
SECTOR ANGLES VS. TRANSFER CASE POSITION
Shaft Angle (Degrees) Transfer Case Position
+40 4LO
+20 N
0 2WD/AWD
-20 4HI
MODE SENSOR CHANNEL STATES
Transfer Case
Angle (degrees)
Sensor Channel A Sensor Channel B Sensor Channel C Sensor Channel D
Between Gears H H L H
+40 (4LO) H H L L
Between Gears H L L H
+20 (NEUTRAL) H L L L
Between Gears H L H H
0 (2WD/AWD) H L H L
Between Gears L L H H
-20 (4HI) L L H L
Between Gears L H H H
Fig. 83 Mode Sensor
1 - MODE SENSOR
SELECTOR SWITCH
DESCRIPTION
The sel ector swi tch assembl y (Fi g. 84) i s mounted
i n the l eft si de of the vehi cl es I nstrument Panel (I P)
and consi sts of a rotary knob connected to a resi sti ve
network for the mode and range shi ft sel ecti ons. Al so
l ocated i n thi s assembl y i s a recessed, normal l y open
momentary swi tch for maki ng shi fts i nto and out of
transfer case NEUTRAL. A pen, or si mi l ar i nstru-
ment, i s used to make a NEUTRAL shi ft sel ecti on,
thus reduci ng the l i kel i hood of an i nadvertent shi ft
request.
The sel ector swi tch al so contai ns four l i ght emi t-
ti ng di odes (LEDs) to i ndi cate the transfer case posi -
ti on and whether a shi ft i s i n progress.
OPERATION
As the posi ti on of the sel ector swi tch vari es, the
resi stance between the Mode Sensor suppl y vol tage
pi n and the Mode Sensor output wi l l vary. Hardware,
software, and cal i brati ons wi thi n the Transfer Case
Control Modul e (TCCM) are provi ded that i nterpret
the sel ector swi tch resi stance as gi ven i n the tabl e
bel ow: SELECTOR SWI TCH I NTERPRETATI ON
SELECTOR SWITCH INTERPRETATION
Step Resistance
Range (ohms)
Required
Interpretation
A <200 Shorted
B 400-700 NEUTRAL
C 1050-1450 4LO
D 1850-2300 4HI
E 3050-5950 2WD (Default)
F 9.5-12.5K In between
positions
G >15.5K Open
For resi stances between the ranges B-E shown for
each val i d posi ti on (T-Case NEUTRAL, 4LO, 4HI ,
2WD), the TCCM may i nterpret the resi stance as:
ei ther of the nei ghbori ng val i d posi ti ons.
as an i nval i d faul t posi ti on.
For resi stances between the ranges E and F shown
for 2WD and i n-between posi ti ons, the TCCM may
i nterpret the resi stance as:
the 2WD posi ti on.
an i nval i d faul t posi ti on.
a val i d i n-between posi ti on.
For resi stances between the ranges F and G shown
for i n-between posi ti ons and faul t condi ti on (open),
the TCCM may i nterpret the resi stance as:
For resi stances between the ranges A and B shown
for the faul t condi ti on (short) and , T-Case NEU-
TRAL, the TCCM may i nterpret the resi stance as:
the T-Case NEUTRAL posi ti on.
The LEDs i n the sel ector assembl y are i l l umi nat-
ed/fl ashed i n the fol l owi ng manner to i ndi cate a par-
ti cul ar condi ti on or state.
A sol i dl y i l l umi nated LED i ndi cates a success-
ful l y compl eted shi ft and the current operati ng mode
of the transfer case. Whi l e a shi ft has been requested
but not yet compl eted, the LED for the desi red trans-
fer case posi ti on i s fl ashed.
Fig. 84 Transfer Case Selector Switch
1 - SELECTOR SWITCH
A fl ashi ng operati ng mode LED for the desi red
gear i ndi cates that a shi ft to that posi ti on has been
requested, but al l of the dri ver control l abl e condi ti ons
have not been met. Thi s i s i n an attempt to noti fy the
dri ver that the transmi ssi on needs to be put i nto NEU-
TRAL, the vehi cl e speed i s too great, or some other con-
di ti on outl i ned (other than a di agnosti c fai l ure that
woul d prevent thi s shi ft) el sewhere (Refer to 8 - ELEC-
TRI CAL/ELECTRONI C CONTROL MODULES/TRANS-
FER CASE CONTROL MODULE - OPERATI ON) i s not
met. Note that thi s fl ashi ng wi l l conti nue i ndefi ni tel y
unti l the condi ti ons are eventual l y met, or the sel ector
swi tch posi ti on i s changed, or i f di agnosti c routi nes no
l onger al l ow the requested shi ft.
I f the dri ver attempts to make a shi ft i nto transfer
case NEUTRAL, and any of the dri ver control l abl e con-
di ti ons are not met, the request wi l l be i gnored unti l al l
of the condi ti ons are met or unti l the NEUTRAL sel ect
button i s rel eased. Addi ti onal l y the neutral l amp wi l l
fl ash, or begi n to fl ash whi l e the button i s depressed
and operator control l abl e condi ti ons are not bei ng met.
Al l of the LEDs except the Neutral wi l l fl ash i f any of
the operator control l abl e condi ti ons for shi fti ng are not
met whi l e the Neutral button i s depressed. Thi s toggl e
type of feature i s necessary because the TCCM woul d
i nterpret another request i mmedi atel y after the shi ft
i nto transfer case NEUTRAL has compl eted.
No LEDs i l l umi nated i ndi cate a faul t i n the
transfer case control system.
SHIFT MOTOR
DESCRIPTION
The shi ft motor (Fi g. 85) consi sts of a permanent
magnet D.C. motor wi th gear reducti on to convert a
hi gh speed-l ow torque devi ce i nto a l ow speed-hi gh
torque devi ce. The output of the devi ce i s coupl ed to a
shaft whi ch i nternal l y moves the mode and range forks
that change the transfer case operati ng ranges. The
motor i s rated at 25 amps maxi mum at 72 F wi th 10
vol ts at the motor l eads.
OPERATION
The transfer case shi ft motor responds to the Transfer
Case Control Modul e (TCCM) commands to move the
transfer case shi ft sector bi -di recti onal l y, as requi red, to
obtai n the transfer case operati ng mode i ndi cated by
the i nstrument panel mounted sel ector swi tch.
REMOVAL
NOTE: New shift motor assemblies are shipped in the
2WD/AWD position. If a new shift motor assembly will
be installed, it will be necessary to shift the transfer
case to the 2WD/AWD position prior to motor removal.
(1) Rai se the vehi cl e on a sui tabl e hoi st.
(2) Di sengage the wi ri ng connectors from the shi ft
motor and mode sensor.
(3) Remove the bol ts hol di ng the shi ft motor and
mode sensor assembl y onto the transfer case.
(4) Separate the shi ft motor and mode sensor
INSTALLATION
(1) Veri fy that the shi ft sector o-ri ng i s cl ean and
properl y posi ti oned over the shi ft sector and agai nst
the transfer case.
NOTE: Verify that the shift motor position and sec-
tor shaft orientation are aligned. It may be neces-
sary to manually shift the transfer case if the shift
motor and sector shaft are not aligned.
(3) I nstal l the bol ts to hol d the assembl y onto the
transfer case. Ti ghten the bol ts to 16-24 Nm (12-18
ft.l bs.).
CAUTION: If the original shift motor and mode sen-
sor assembly bolts are reused, be sure to use
Mopar Lock & Seal or Loctite 242 to replenish
the lock patch material originally found on the bolts
(4) Engage the wi ri ng connectors to the shi ft motor
and mode sensor.
(5) Refi l l the transfer case as necessary.
(6) Lower vehi cl e and veri fy transfer case opera-
ti on.
Fig. 85 Shift Motor - Shown Inverted - Typical
1 - SHIFT MOTOR
SELECTOR SWITCH (Continued)
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 512
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 513
CASE - NV244 . . . . . . . . . . . . . . . . . . . . . . . 513
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 514
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 523
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 525
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 534
SPECIFICATIONS
SPECIAL TOOLS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 536
FLUID
REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 538
MODE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 538
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 539
SELECTOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 539
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 540
SHIFT MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 541
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 541
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 541
GENII
DESCRIPTION
The NV244 GENI I i s an el ectroni cal l y control l ed
ful l and part-ti me transfer case wi th no two wheel
dri ve operati on.
A di fferenti al i n the transfer case i s used to control
torque transfer to the front and rear axl es. A l ow
range gear reducti on system provi des i ncreased l ow
speed torque capabi l i ty for off road operati on. The
l ow range provi des a 2.72:1 reducti on rati o.
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
OPERATING RANGES
NV244 GENI I operati ng ranges are:
AWD(Al l -Wheel Dri ve)
4HI (Part-ti me)
4LO
NEUTRAL
The AWD mode can be used at any ti me and on
any road surface.
The 4HI (Part-ti me) and 4LO ranges are for off
road use onl y. The onl y ti me these ranges can be
used i s when the road surface i s covered wi th snow,
i ce, or other l oose sl i ppery materi al .
SHIFT MECHANISM
al ong wi th the i nput from the transfer case mounted
IDENTIFICATION
OPERATION
mai nshaft. The dri ve sprocket i s spl i ned to a di ffer-
enti al assembl y. Dependi ng on the posi ti on of the
mode fork and sl eeve, the front output shaft i s dri ven
di rectl y by the mai nshaft or through the di fferenti al .
The mode fork operates the mode sl eeve and hub.
The sl eeve and hub are not equi pped wi th a synchro-
ni zer mechani sm for shi fti ng.
DIAGNOSIS CHART
damaged.
necessary.
modes.
damaged.
necessary.
jumps out of, 4LO.
transmission in NEUTRAL, or the
clutch depressed on vehicles
equipped with a manual
transmission, shift the transfer case
to the AWD or 4HI position, and
then back into the 4LO position.
rail.
necessary.
damaged.
necessary.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
seals or vent.
level.
restricted.
necessary.
Transfer case will not shift through
4HI (Part-time) range.
1) Incomplete shift due to drivetrain
torque load.
1) Drive in a straight line and
momentarily release the accelerator
pedal to complete the shift.
2) Incorrect tire pressure. 2) Correct tire pressure as
necessary.
3) Excessive tire wear. 3) Correct tire condition as
necessary.
4) Excessive vehicle loading. 4) Correct as necessary.
REMOVAL
(1) Shi ft transfer case i nto AWD.
ment reference.
(6) Remove the transfer case ski d pl ate, i f equi pped.
transfer case.
gage transfer case.
DISASSEMBLY
SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT
SHAFT SEAL
(1) Remove the bol ts (Fi g. 3) whi ch hol d the shi ft
case.
1 - TRANSMISSION
2 - TRANSFER CASE
Fig. 3 Remove the Shift Motor and Mode Sensor
1 - TRANSFER CASE
3 - BOLT
(2) Remove the shi ft motor and mode sensor
5).
bendi ng (Fi g. 6) the sl i nger away from the transfer
case.
(6) Usi ng a sui tabl e pry tool , remove the sl i nger
from the output shaft usi ng care not to damage the
shaft.
REAR EXTENSION
2 - TRANSFER CASE
1 - SEAL BOOT
2 - CLAMP
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 6 Bend Slinger Upward
1 - SEAL SLINGER
2 - BEND UPWARD
MUST be replaced.
2 - TRANSFER CASE
3 - PRY SLOT
3 - RETAINING RING
4 - TRANSFER CASE
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
1 - REAR CASE
2 - FRONT CASE
3 - PRY SLOTS
(5) Remove the oi l pump pi ckup tube.
(1) Remove shi ft rai l spri ng (Fi g. 13).
(3) Remove the mode fork (Fi g. 15) and sl eeve
from the shi ft rai l and mai nshaft.
1 - REAR CASE
2 - FRONT CASE
Fig. 13 Remove Shift Rail Spring
1 - SHIFT RAIL
2 - SPRING
1 - FRONT SPROCKET
2 - RETAINING RING
Fig. 15 Remove Mode Fork and Sleeve
1 - SHIFT RAIL
2 - MODE FORK
3 - MODE SLEEVE
(4) Remove the rear output shaft retai ni ng ri ng
(Fi g. 16) from the output shaft.
(5) Pul l front sprocket, rear sprocket, and chai n
outward si mul taneousl y (Fi g. 17).
(6) Remove front sprocket, rear sprocket, and
chai n as an assembl y.
19).
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
Fig. 19 Remove Front Output Shaft Snap-ring
2 - SNAP-RING
Fig. 16 Remove Rear Output Shaft Retaining Ring
2 - RETAINING RING
Fig. 17 Remove Drive Sprockets and Chain
2 - DRIVE CHAIN
3 - REAR DRIVE SPROCKET
(4) Remove front output shaft from beari ng i n
case.
(5) Remove the mai nshaft and di fferenti al assem-
bl y (Fi g. 20) from the i nput gear and transfer case.
(6) Remove the shi ft rai l (Fi g. 21) from the range
fork assembl y and the front case.
Fig. 20 Remove Mainshaft and Differential Assembly
1 - FRONT CASE
2 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
Fig. 21 Remove Shift Rail
1 - SHIFT RAIL
2 - RANGE FORK ASSEMBLY
Fig. 22 Remove Range Fork and Sleeve
1 - RANGE SLEEVE
2 - RANGE FORK
Fig. 23 Shift Sector Removal
1 - SHIFT SECTOR
(9) Remove the shi ft sector o-ri ng (Fi g. 24).
MAINSHAFT
(1) Remove i ntermedi ate cl utch shaft snap-ri ng
(Fi g. 25).
(2) Remove the i ntermedi ate cl utch shaft thrust
ri ng (Fi g. 26).
(3) Remove the i ntermedi ate cl utch shaft (Fi g. 27).
Fig. 24 Remove the Shift Sector O-Ring
1 - TRANSFER CASE FRONT HOUSING
2 - SHIFT SECTOR O-RING
Fig. 25 Remove the Intermediate Clutch Shaft
Snap-ring
1 - SNAP-RING
2 - INTERMEDIATE CLUTCH SHAFT
Thrust Ring
1 - CLUTCH SHAFT THRUST RING
(4) Remove the di fferenti al snap-ri ng (Fi g. 28).
(5) Remove the di fferenti al assembl y (Fi g. 29) from
the mai nshaft.
(6) Remove the mode hub (Fi g. 30) and mode hub
retai ner from the di fferenti al assembl y.
(7) Remove the mode hub retai ner (Fi g. 31) from
the mode hub.
Fig. 28 Remove the Differential Snap-ring
1 - DIFFERENTIAL SNAP-RING
Fig. 29 Remove the Differential
1 - DIFFERENTIAL ASSEMBLY
2 - MAINSHAFT
Fig. 30 Remove the Mode Hub and Retainer
2 - MODE HUB AND RETAINER
Fig. 31 Remove Retainer from Mode Hub
1 - MODE HUB RETAINER
2 - MODE HUB
and sl i de hammer.
1 - INPUT GEAR
2 - RETAINING RING
1 - FRONT CASE
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
CLEANING
INSPECTION
gears are damaged.
broken.
shi ft rai l . Mi nor ni cks on the shi ft rai l can be
smoothed wi th 320-400 gri t emery cl oth.
1 - INPUT GEAR
2 - LOW RANGE GEAR
1 - LOW RANGE GEAR
wear or damage.
I nspect the shaft spl i nes and beari ng surfaces.
Mi nor ni cks on the spl i nes can be smoothed wi th an
oi l stone. Use 320-400 gri t emery to smooth mi nor
scratches on the shaft beari ng surfaces. Repl ace the
shaft i f the beari ng surfaces are scored or i f any of
the spl i nes are cracked or broken.
Fig. 39 Input Gear and Carrier Components
Fig. 40 Shift Fork and Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
1 - FRONT CASE
OIL PUMP/OIL PICKUP
ASSEMBLY
BEARINGS AND SEALS
case.
(3) Remove the front output shaft beari ng retai n-
i ng ri ng from i nsi de the front case hal f.
(4) Usi ng I nstal l er 6436 and Handl e C-4171,
remove front output shaft beari ng.
seat beari ng wi th Handl e C-4171 and I nstal l er 6953
(Fi g. 43).
ri ng.
Cup 8148 (Fi g. 44).
2 - FRONT CASE
Fig. 43 Install Front Output Shaft Bearing
1 - FRONT CASE
2 - INSTALLER 6953
3 - HANDLE C-4171
1 - REAR CASE
and I nstal l er 5066 (Fi g. 45).
(9) Remove the rear output shaft beari ng from the
rear case usi ng I nstal l er 5065 and Handl e C-4171
(Fi g. 46).
Handl e C-4171.
gear notches.
Fig. 45 Front Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
3 - INSTALLER 5066
1 - HANDLE C-4171
2 - INSTALLER 5065
1 - REAR CASE
3 - HANDLE C-4171
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
ri ng.
NOTE: Replace the mode hub retainer if the legs
were distorted during removal.
(2) I nstal l the mode hub retai ner (Fi g. 51) onto the
mode hub.
(3) I nstal l the mode hub (Fi g. 52) and mode hub
retai ner onto the di fferenti al assembl y. Make sure
the retai ner i s ful l y seated onto the di fferenti al .
1 - FRONT CASE
1 - INPUT GEAR
2 - RETAINING RING
Fig. 51 Install Retainer onto Mode Hub
1 - MODE HUB RETAINER
2 - MODE HUB
Fig. 52 Install the Mode Hub and Retainer
2 - MODE HUB AND RETAINER
(4) I nstal l the di fferenti al assembl y (Fi g. 53) onto
the mai nshaft.
(5) I nstal l the di fferenti al snap-ri ng (Fi g. 54).
(6) I nstal l the i ntermedi ate cl utch shaft (Fi g. 55).
(7) I nstal l the cl utch shaft thrust ri ng (Fi g. 56).
Fig. 53 Install the Differential
2 - MAINSHAFT
Fig. 54 Installing Differential Snap-Ring
1 - DIFFERENTIAL SNAP-RING
Fig. 55 Installing Intermediate Clutch Shaft
Fig. 56 Installing Clutch Shaft Thrust Ring
1 - CLUTCH SHAFT THRUST RING
(8) I nstal l cl utch shaft snap-ri ng (Fi g. 57).
(10) I nstal l the shi ft sector o-ri ng.
sl ot.
(13) I nstal l the shi ft rai l (Fi g. 60) i nto the range
fork assembl y and the front case.
Fig. 57 Installing Clutch Shaft Snap-Ring
1 - SNAP-RING
1 - SHIFT SECTOR
1 - RANGE HUB
2 - RANGE FORK
Fig. 60 Install Shift Rail
1 - SHIFT RAIL
2 - RANGE FORK ASSEMBLY
(14) I nstal l the mai nshaft and di fferenti al assem-
bl y (Fi g. 61) i nto the i nput gear and transfer case.
(1) I nstal l the front output shaft i nto the front out-
put shaft beari ng.
(2) I nstal l the front output shaft snap-ri ng (Fi g.
NOTE: Shift the transfer case to the same range/
mode position it was in when the shift motor was
removed prior to installing the shift detent compo-
nents.
Fig. 61 Install Mainshaft and Differential Assembly
1 - FRONT CASE
2 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
Fig. 62 Install Front Output Shaft Snap-ring
2 - SNAP-RING
1 - O-RING
2 - DETENT PLUG
1 - FRONT CASE
2 - DETENT PLUG
3 - DETENT SPRING
4 - DETENT PLUNGER
(6) I nstal l the new front output shaft seal sl i nger
(Fi g. 65) wi th I nstal l er 8840. I nstal l the sl i nger onto
the shaft unti l the tool contacts the front of the out-
put shaft.
(7) I nstal l the front sprocket, rear sprocket, and
chai n as an assembl y.
(8) Lower the front sprocket, rear sprocket, and
chai n over the front and rear output shafts si mul ta-
neousl y (Fi g. 66) unti l ful l y seated on both spl i nes.
(9) I nstal l the rear output shaft retai ni ng ri ng
(10) I nstal l the front sprocket retai ni ng ri ng (Fi g.
68).
Fig. 65 Install Front Output Shaft Seal Slinger
1 - SEAL SLINGER
2 - INSTALLER 8840
Fig. 66 Install Drive Sprockets and Chain
2 - DRIVE CHAIN
3 - REAR DRIVE SPROCKET
Fig. 67 Install Rear Output Shaft Retaining Ring
2 - RETAINING RING
Fig. 68 Installing Front Sprocket Retaining Ring
1 - FRONT SPROCKET
2 - RETAINING RING
(11) I nspect mode fork assembl y (Fi g. 69). Repl ace
pads i f necessary. Al so check spri ngs and sl i der
bracket. Repl ace worn or damaged components.
(12) I nstal l the mode fork (Fi g. 70) and sl eeve over
the shi ft rai l and mai nshaft.
(13) I nstal l spri ng onto the shi ft rai l (Fi g. 71).
Fig. 69 Mode Fork Assembly
1 - MODE FORK
2 - SPRING
Fig. 70 Install Mode Fork and Sleeve
1 - SHIFT RAIL
2 - MODE FORK
3 - MODE SLEEVE
Fig. 71 Install Shift Rail Spring
1 - SHIFT RAIL
2 - SPRING
Fig. 72 Install the Transfer Case Sump Magnet
1 - SUMP MAGNET
2 - CASE POCKET
Lubri cate the oi l pump components wi th transmi s-
si on fl ui d before i nstal l ati on. Pri me the oi l pi ckup
tube by pouri ng a l i ttl e oi l i nto the tube before i nstal -
l ati on.
MUST be replaced.
(1) I nstal l new o-ri ng i n pi ckup tube i nl et of oi l
pump, i f necessary.
(2) I nsert oi l pi ckup tube i nto the oi l pump.
to output shaft.
aligned.
(7) Appl y Mopar Lock n Seal Adhesi ve to remai n-
der of rear case-to-front case bol t threads and i nstal l
bol ts. Ti ghten bol ts to 25-28 Nm (18-21 ft. l bs.),
1 - REAR CASE
2 - FRONT CASE
3 - RETAINING RING
4 - TRANSFER CASE
Fig. 75 Install Case Bolts
1 - REAR CASE
2 - FRONT CASE
3 - BOLT
SEAL BOOT AND SHIFT MOTOR ASSEMBLY
boot.
(2) I nstal l the seal boot (Fi g. 76) and cl amp onto
the sl i nger hub and ti ghten the cl amp wi th Cri mp
Tool C-4975-A.
(4) I nstal l the bol ts (Fi g. 77) to hol d the shi ft
case. Ti ghten the bol ts to 16-25 Nm (12-18 ft. l bs.).
REAR EXTENSION
wi th I nstal l er D-163 and Handl e C-4171. Veri fy that
the weep hol e i n the rubber i s ori ented downward.
(Fi g. 78).
INSTALLATION
fer case.
STANDARD PROCEDURE)
operati on.
Fig. 76 Install Seal Boot
1 - SEAL BOOT
2 - SEAL SLINGER
Fig. 77 Install the Shift Motor and Mode Sensor
1 - TRANSFER CASE
3 - BOLT
2 - TRANSFER CASE
SPECIFICATIONS
Plug, Detent 16-24 12-18 -
16-24 12-18 -
SPECIAL TOOLS
Remover - L-4454
Installer, Seal - MB991168A
REMOVAL
INSTALLATION
Cup - 8148
Installer - 8840
FLUID
REFILL
(Fi g. 80).
cant compl etel y.
(15-25 ft. l bs.).
si on fl ui d.
(15-25 ft. l bs.).
REMOVAL
82).
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
1 - SEAL BOOT
2 - CLAMP
1 - SEAL BOOT
2 - SEAL SLINGER
bendi ng (Fi g. 83) the sl i nger away from the transfer
case.
(5) Usi ng a sui tabl e pry tool , remove the sl i nger
from the output shaft usi ng care not to damage the
shaft.
INSTALLATION
boot.
C-4975-A.
MODE SENSOR
DESCRIPTION
Fig. 83 Bend Slinger Upward
1 - SEAL SLINGER
2 - BEND UPWARD
Fig. 84 Mode Sensor - Typical
1 - MODE SENSOR
OPERATION
undefi ned.
+40 4LO
+20 N
0 2WD/AWD
-20 4HI
Transfer Case
Angle (degrees)
+40 (4LO) H H L L
0 (2WD/AWD) H L H L
-20 (4HI) L L H L
SELECTOR SWITCH
DESCRIPTION
The sel ector swi tch assembl y i s mounted i n the l eft
si de of the vehi cl es I nstrument Panel (I P) and con-
si sts of a rotary knob connected to a resi sti ve net-
work for the mode and range shi ft sel ecti ons. Al so
request.
The sel ector swi tch al so contai ns l i ght emi tti ng
di odes (LEDs) to i ndi cate the transfer case posi ti on
and whether a shi ft i s i n progress.
MODE SENSOR (Continued)
OPERATION
Step Resistance
Range (ohms)
Required
Interpretation
A <200 Shorted
B 400-700 NEUTRAL
C 1050-1450 4LO
D 1850-2300 4H
E 3050-5950 AWD (Default)
positions
G >15.5K Open
AWD), the TCCM may i nterpret the resi stance as:
for AWD and i n-between posi ti ons, the TCCM may
the AWD posi ti on.
have not been met. Thi s i s i n an attempt to noti fy
the dri ver that the transmi ssi on needs to be put i nto
NEUTRAL, the vehi cl e speed i s too great, or some
other condi ti on outl i ned (other than a di agnosti c fai l -
ure that woul d prevent thi s shi ft) el sewhere (Refer to
8 - ELECTRI CAL/ELECTRONI C CONTROL MOD-
ULES/TRANSFER CASE CONTROL MODULE -
OPERATI ON) i s not met. Note that thi s fl ashi ng wi l l
conti nue i ndefi ni tel y unti l the condi ti ons are eventu-
al l y met, or the sel ector swi tch posi ti on i s changed,
or i f di agnosti c routi nes no l onger al l ow the
requested shi ft.
I f the dri ver attempts to make a shi ft i nto trans-
fer case NEUTRAL, and any of the dri ver control l a-
bl e condi ti ons are not met, the request wi l l be
i gnored unti l al l of the condi ti ons are met or unti l
the NEUTRAL sel ect button i s rel eased. Addi ti onal l y
the neutral l amp wi l l fl ash, or begi n to fl ash whi l e
the button i s depressed and operator control l abl e
condi ti ons are not bei ng met. Al l of the LEDs except
the Neutral wi l l fl ash i f any of the operator control -
l abl e condi ti ons for shi fti ng are not met whi l e the
Neutral button i s depressed. Thi s toggl e type of fea-
ture i s necessary because the TCCM woul d i nterpret
another request i mmedi atel y after the shi ft i nto
transfer case NEUTRAL has compl eted.
SHIFT MOTOR
DESCRIPTION
torque devi ce. The output of the devi ce i s coupl ed to
a shaft whi ch i nternal l y moves the mode and range
forks that change the transfer case operati ng ranges.
The motor i s rated at 25 amps maxi mum at 72 F
wi th 10 vol ts at the motor l eads.
OPERATION
The transfer case shi ft motor responds to the
Transfer Case Control Modul e (TCCM) commands to
move the transfer case shi ft sector bi -di recti onal l y, as
requi red, to obtai n the transfer case operati ng mode
i ndi cated by the i nstrument panel mounted sel ector
swi tch.
REMOVAL
NOTE: New shift motor assemblies are shipped in
the 2WD/AWD position. If a new shift motor assem-
bly will be installed, it will be necessary to shift the
transfer case to the 2WD/AWD position prior to
motor removal.
INSTALLATION
the transfer case.
ft.l bs.).
and mode sensor.
(6) Lower vehi cl e and veri fy transfer case opera-
ti on.
1 - SHIFT MOTOR
TABLE OF CONTENTS
page page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 542
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 543
CASE - NV273 . . . . . . . . . . . . . . . . . . . . . . . 543
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 544
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 554
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 568
SPECIFICATIONS
TRANSFER CASE - NV273 . . . . . . . . . . . . . 568
SPECIAL TOOLS
TRANSFER CASE NV271/NV273 . . . . . . . . . 569
EXTENSION HOUSING SEAL AND DUST BOOT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 571
FLUID
REFILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 572
MODE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 573
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 573
SELECTOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 574
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 574
SHIFT MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 575
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 575
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 575
DESCRIPTION
The NV273 i s an el ectroni cal l y control l ed part-ti me
transfer case wi th a l ow range gear reducti on system.
The NV273 has three operati ng ranges pl us a NEU-
TRAL posi ti on. The l ow range system provi des a gear
reducti on rati o for i ncreased l ow speed torque capa-
bi l i ty.
rear beari ngs are mounted i n al umi num case hal ves.
OPERATING RANGES
2WD (2-wheel dri ve)
4HI (4-wheel dri ve)
NEUTRAL
The 2WD range i s for use on any road surface at
any ti me.
The 4HI and 4LO ranges are for off road use onl y.
excepti on bei ng when the road surface i s wet or sl i p-
pery or covered by i ce and snow.
rati o i s 2.72:1.
SHIFT MECHANISM
al ong wi th i nput from the transfer case mounted
IDENTIFICATION
OPERATION
mai nshaft. The dri ve sprocket i s engaged/di sengaged
by the mode fork, whi ch operates the mode sl eeve
and hub. The sl eeve and hub are not equi pped wi th a
synchroni zer mechani sm for shi fti ng.
DIAGNOSIS CHART
extended period in 4HI mode on
dry surface, driveline torque load
may cause difficulty.
2) Drive the vehicle in a straight line
and momentarily release the
accelerator. The transfer case can
then be shifted to the desired mode.
damaged.
necessary.
modes.
+4, type 9602, Automatic
Transmission Fluid.
damaged.
necessary.
1 - TRANSFER CASE
jumps out of, 4LO mode.
transmission in NEUTRAL, or clutch
depressed on vehicles equipped
with a manual transmission, shift
transfer case to the 2WD or 4HI
position, and then back into the 4LO
position.
rail.
necessary.
damaged.
necessary.
seals or vent.
level.
restricted.
necessary.
Abnormal tire wear. 1) Extended operation in 4HI mode
on dry surfaces,
1) Operate vehicle in 2WD mode on
dry surfaces.
REMOVAL
(1) Shi ft transfer case i nto 2WD.
ment reference.
(6) Remove the transfer case ski d pl ate, i f
equi pped.
transfer case.
gage transfer case.
DISASSEMBLY
1 - TRANSMISSION
2 - TRANSFER CASE
COMPANION FLANGE AND EXTENSION HOUSING
nut.
Fig. 3 Remove Companion Flange Nut - Typical
1 - HOLDER 6719
2 - BOLTS
2 - DUST BOOT
Fig. 5 Remove Extension Housing Bolts
2 - BOLTS
(1) Di sengage the oi l pump pi ck-up tube (Fi g. 7)
from the oi l pump.
NOTE: The oil pump pick-up tube seals to the oil
pump with an o-ring. Verify that the o-ring was
removed with the tube and is in good condition.
Replace the o-ring if necessary.
(2) Remove the oi l pump (Fi g. 8).
Fig. 7 Disengage The Oil Pick-up From Oil Pump
1 - OIL PUMP
Fig. 6 Remove Extension Housing
1 - REAR CASE HALF
1 - REAR CASE HALF
3 - OIL PUMP
Fig. 9 Remove Case Half Bolts
1 - FRONT CASE HALF
2 - REAR CASE HALF
3 - BOLTS
snap-ri ng (Fi g. 10) from the output shaft usi ng sui t-
abl e snap-ri ng pl i ers.
snap-ri ng (Fi g. 11) from the output shaft.
bead. I nsert tool at each end of case (Fi g. 12).
(8) Remove the rear case from the front case (Fi g.
13).
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
Fig. 12 Separate Front and Rear Case Halves
1 - FRONT CASE HALF
2 - REAR CASE HALF
Fig. 13 Remove Rear Case Half
1 - FRONT CASE HALF
2 - REAR CASE HALF
(1) Remove the oi l pi ck-up tube (Fi g. 14) and
screen from the front case hal f.
(2) Remove the front output shaft dri ve sprocket
(3) Remove the rear output shaft dri ve sprocket
(4) Pul l front sprocket (Fi g. 17), rear sprocket, and
chai n upward unti l cl ear of the front and rear output
shaft sprocket spl i nes.
(5) Remove chai n and sprockets as an assembl y.
Fig. 14 Remove Oil Pick-Up Tube and Screen
1 - FRONT CASE HALF
2 - OIL SCREEN
3 - PICK-UP TUBE
Fig. 15 Remove Front Output Shaft Sprocket
Retaining Ring
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 16 Remove Rear Output Shaft Sprocket
Retaining Ring
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 17 Remove Drive Chain and Sprockets
1 - FRONT CASE HALF
2 - CHAIN
3 - DRIVE SPROCKETS
(1) Remove the bol ts (Fi g. 18) that hol d the shi ft
motor assembl y to the transfer case.
(2) Remove the shi ft motor assembl y (Fi g. 19) from
the transfer case.
(3) Remove the sector support wi th Socket 9033.
(4) Loosen detent pl ug (Fi g. 20).
Fig. 18 Remove Shift Motor Assembly Bolts
1 - TRANSFER CASE
2 - SHIFT MOTOR ASSEMBLY
3 - BOLTS
Fig. 19 Remove Shift Motor Assembly From
Transfer Case
1 - TRANSFER CASE
Fig. 20 Loosen the Detent Plug
1 - FRONT CASE HALF
2 - DETENT PLUG
Fig. 21 Remove Detent plug, Spring, and Plunger
1 - FRONT CASE HALF
2 - DETENT PLUG
3 - SPRING
4 - PLUNGER
remove the front output shaft seal .
22).
(Fi g. 23).
i n the fork (l ong si de of sl eeve goes to front or the
poi nts on the sl eeve teeth go to the rear of case).
Fig. 22 Remove Front Output Shaft Bearing Inner
Snap-Ring
1 - FRONT CASE HALF
2 - SNAP-RING
1 - FRONT CASE
Fig. 24 Remove Mainshaft Assembly
1 - FRONT CASE HALF
Fig. 25 Mode Fork And Sleeve Removal
1 - MODE SLEEVE
(12) Remove the shi ft sector (Fi g. 27).
MAINSHAFT
(1) Remove the cl utch gear (Fi g. 28) from the out-
put shaft.
Fig. 29 Remove Mode Hub Retaining Ring
1 - MAINSHAFT
2 - MODE HUB
3 - RETAINING RING
1 - RANGE HUB
2 - RANGE FORK
1 - SHIFT SECTOR
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
(3) Remove the mode hub (Fi g. 30) from the mai n-
shaft.
(4) Remove the dri ve sprocket dri ve hub (Fi g. 31)
and sl i de hammer.
1 - MAINSHAFT
2 - MODE HUB
Fig. 31 Remove the Drive Sprocket Drive Hub
1 - MAINSHAFT
1 - INPUT GEAR
2 - RETAINING RING
1 - FRONT CASE
the l ow range gear (Fi g. 34).
(6) Remove front thrust pl ate (Fi g. 36).
Fig. 37 Remove Input Gear From Planetary
1 - INPUT GEAR
1 - INPUT GEAR
2 - RETAINING RING
Fig. 35 Remove Input Gear Retainer
1 - INPUT GEAR
2 - RETAINER
Fig. 36 Remove Input Gear Thrust Plate
1 - INPUT GEAR
2 - THRUST PLATE
(8) Remove bottom tabbed thrust washer from l ow
range pl anetary (Fi g. 38).
CLEANING
INSPECTION
wear or damage. Check the pi ni on gear thrust wash-
ers on the pi non pi ns for damage. The carri er wi l l
have to be repl aced as an assembl y i f the body, pi n-
i on pi ns, or pi ni on gears are damaged.
broken.
Fig. 38 Remove Bottom Input Gear Thrust Plate
1 - PLANETARY
2 - THRUST PLATE
wear or damage.
I nspect the shaft threads, sprocket teeth, and bear-
i ng surfaces. Mi nor ni cks on the teeth can be
smoothed wi th an oi l stone. Use 320-400 gri t emery to
smooth mi nor scratches on the shaft beari ng sur-
faces. Rough threads on the shaft can be chased i f
necessary. Repl ace the shaft i f the threads are dam-
aged, beari ng surfaces are scored, or i f any sprocket
teeth are cracked or broken.
Fig. 40 Shift Forks
1 - RANGE FORK
3 - MODE SPRING
1 - RANGE FORK
2 - MODE FORK
1 - FRONT CASE
OIL PUMP/OIL PICKUP
ASSEMBLY
BEARINGS AND SEALS
(1) Remove the i nput shaft beari ng snap-ri ng from
(2) Remove the i nput shaft beari ng from the front
case hal f wi th I nstal l er 6953 and Handl e C-4171
(Fi g. 43).
(3) I nstal l the i nput shaft beari ng i nto the front
case hal f wi th I nstal l er 8151 i nverted on Handl e
C-4171 (Fi g. 44).
(4) I nstal l the i nput shaft beari ng snap-ri ng i nto
(5) Remove the front output shaft front beari ng
snap-ri ng from the front case hal f.
45), remove the front output shaft front beari ng.
Fig. 45 Remove Front Output Shaft Front Bearing
1 - FRONT CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 6953
1 - FRONT CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 6953
Fig. 44 Install Input Gear Bearing
1 - FRONT CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8151 (INVERTED)
(7) Start front output shaft front beari ng i n case.
Then seat beari ng wi th I nstal l er 8891 (Fi g. 46).
ri ng.
hammer (Fi g. 47).
(10) I nstal l new pi l ot beari ng wi th I nstal l er 9035.
Cup 8148 (Fi g. 48).
Fig. 47 Remove Input Gear Cup Bearing
1 - DRIFT
2 - INPUT GEAR
1 - REAR CASE
Fig. 46 Install Front Output Shaft Front Bearing
1 - FRONT CASE HALF
2 - INSTALLER 8891
(13) Remove seal from oi l pump wi th sui tabl e pry
tool .
(14) I nstal l new seal i n oi l pump wi th I nstal l er
7888 (Fi g. 51).
(15) Remove the rear output shaft beari ng snap-
ri ng (Fi g. 52) from the rear case hal f.
Fig. 52 Remove Rear Output Bearing Outer
Snap-Ring
1 - REAR CASE HALF
3 - SNAP-RING
Fig. 49 Install Front Output Shaft Rear Bearing
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8128
2 - CHAMFER
Fig. 51 Oil Pump Seal Installation
1 - HOUSING SEAL
3 - OIL PUMP FEED HOUSING
the rear case usi ng I nstal l er 7888 (Fi g. 53).
i nto the rear case usi ng I nstal l er 8152 and Handl e
C-4171.
(18) I nstal l the rear output shaft beari ng snap-
ri ng i nto the rear case hal f.
(1) Lubri cate gears and thrust washers wi th rec-
ommended transmi ssi on fl ui d.
(2) I nstal l bottom thrust washer (Fi g. 55) i n l ow
range gear pl anetary. Be sure washer tabs are prop-
erl y al i gned i n gear notches.
(3) I nstal l i nput gear i n l ow range gear (Fi g. 56).
Be sure i nput gear i s ful l y seated.
1 - REAR CASE HALF
2 - INSTALLER 7888
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8152
Fig. 55 Install Bottom Input Gear Thrust Plate
1 - PLANETARY
2 - THRUST PLATE
Fig. 56 Install Input Gear From Planetary
1 - INPUT GEAR
(4) I nstal l remai ni ng thrust washer (Fi g. 57) i n
l ow range gear and on top of i nput gear.
(5) I nstal l retai ner (Fi g. 58) on i nput gear and
i nstal l snap-ri ng (Fi g. 59).
1 - FRONT CASE
Fig. 57 Install Input Gear Thrust Plate
1 - INPUT GEAR
2 - THRUST PLATE
Fig. 58 Install Input Gear Retainer
1 - INPUT GEAR
2 - RETAINER
1 - INPUT GEAR
2 - RETAINING RING
(9) I nstal l a new i nput gear oi l seal wi th I nstal l er
(2) Coat the i nteri or of the dri ve sprocket hub wi th
ATF+4 and i nstal l the dri ve sprocket dri ve hub (Fi g.
62) onto the mai nshaft.
(3) I nstal l the mode hub (Fi g. 63) onto the mai n-
shaft.
onto the mai nshaft.
1 - INPUT GEAR
2 - RETAINING RING
Fig. 62 Install the Drive Sprocket Drive Hub
1 - MAINSHAFT
1 - MAINSHAFT
2 - MODE HUB
1 - MAINSHAFT
2 - MODE HUB
3 - RETAINING RING
shaft. Veri fy that the poi nted ends of the cl utch gear
teeth are poi nti ng to the front of the mai nshaft.
(7) Appl y Locti te 242, or equi val ent, to the
threads of the sector support to repl enti sh the factory
appl i ed patch. I nstal l the shi ft sector support.
Ti ghten the sector support wi th Socket 9033 to 27-34
Nm (20-25 ft.l bs.).
sl ot.
sl eeve.
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
1 - SHIFT SECTOR
1 - RANGE HUB
2 - RANGE FORK
Fig. 68 Mode Fork And Sleeve Installation
1 - MODE SLEEVE
assembl y (Fi g. 71) onto the transfer case.
(2) I nstal l the bol ts (Fi g. 72) to hol d the shi ft
case. Ti ghten the bol ts to 16-25 Nm (12-18 ft. l bs.).
1 - O-RING
2 - DETENT PLUG
Fig. 70 Install Detent plug, Spring, and Plunger
1 - FRONT CASE HALF
2 - DETENT PLUG
3 - SPRING
4 - PLUNGER
Fig. 71 Install Shift Motor Assembly Onto Transfer
Case
1 - TRANSFER CASE
Fig. 72 Install Shift Motor Assembly Bolts
1 - TRANSFER CASE
3 - BOLTS
front output shaft front beari ng.
(2) I nstal l the front output shaft beari ng i nner
snap-ri ng (Fi g. 75) onto the output shaft.
(4) I nsert front dri ve sprocket i n dri ve chai n.
(5) I nstal l dri ve chai n around rear dri ve sprocket.
(6) Posi ti on rear dri ve sprocket (Fi g. 76) over the
output shaft and l ower the sprocket and chai n
assembl y unti l the front sprocket i s posi ti oned over
the front output shaft.
(7) Al i gn the spl i nes i n the sprockets to the spl i nes
on the output shafts and i nstal l the sprockets onto
the output shafts.
Fig. 73 Install Mainshaft Assembly
1 - FRONT CASE HALF
1 - FRONT CASE
Fig. 75 Install Front Output Shaft Bearing Inner
Snap-Ring
1 - FRONT CASE HALF
2 - SNAP-RING
Fig. 76 Install Drive Chain and Sprockets
1 - FRONT CASE HALF
2 - CHAIN
3 - DRIVE SPROCKETS
(9) I nstal l rear sprocket retai ni ng ri ng (Fi g. 78).
REAR CASE
(1) I nstal l the oi l pi ck-up tube and screen i nto the
rear case hal f.
(3) Al i gn mai nshaft wi th the rear output shaft
beari ng and al i gn shi ft rai l wi th bore i n rear case.
Then i nstal l rear case (Fi g. 80). Veri fy that the case
al i gnment dowel s correctl y seat i nto thei r mati ng
recesses.
Fig. 77 Install Front Output Shaft Sprocket
Retaining Ring
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 78 Install Rear Output Shaft Sprocket Retaining
Ring
2 - DRIVE SPROCKET
3 - RETAINING RING
1 - MAGNET
2 - CASE POCKET
Fig. 80 Install Rear Case Half
1 - FRONT CASE HALF
2 - REAR CASE HALF
aligned.
(5) Ti ghten bol ts to 27-34 Nm (20-25 ft. l bs.),
(6) I nstal l rear output beari ng i nner snap-ri ng
(Fi g. 82) to output shaft.
OIL PUMP AND REAR EXTENSION
(1) I nstal l the oi l pump (Fi g. 83) onto the output
shaft.
(2) Engage the oi l pump pi ck-up tube (Fi g. 84) i nto
the oi l pump. Veri fy that the pi ck-up tube o-ri ng i s
on the tube and i s correctl y i nstal l ed to the oi l pump.
Fig. 81 Install Case Half Bolts
1 - FRONT CASE HALF
2 - REAR CASE HALF
3 - BOLTS
Fig. 82 Install Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
1 - REAR CASE HALF
3 - OIL PUMP
Fig. 84 Engage The Oil Pick-up To Oil Pump
1 - OIL PUMP
(4) I nstal l extensi on housi ng (Fi g. 85) onto the
rear case hal f.
(5) I nstal l rear extensi on bol ts (Fi g. 86). Ti ghten
the bol ts to 27-34 Nm (20-25 ft.l bs.).
(Fi g. 87).
Fig. 85 Install Extension Housing
1 - REAR CASE HALF
Fig. 86 Install Extension Housing Bolts
2 - BOLTS
2 - HANDLE C-4171
3 - INSTALLER 9037
front output shaft.
(130-200 ft.l bs.).
INSTALLATION
fer case.
STANDARD PROCEDURE)
operati on.
SPECIFICATIONS
Plug, Detent 16-24 12-18 -
Support, Sector 27-34 20-25 -
16-25 12-18 -
Nut, Companion Flange 176-271 130-200 -
1 - HOLDER 6719
2 - BOLTS
SPECIAL TOOLS
TRANSFER CASE NV271/NV273
Remover - L-4454
Cup - 8148
Installer - 8151
Installer - 8152
Installer - 8891
Socket - 9033
AND DUST BOOT
REMOVAL
INSTALLATION
(Fi g. 90).
FLUID
REFILL
(Fi g. 91).
cant compl etel y.
(30-40 ft. l bs.).
2 - DUST BOOT
2 - HANDLE C-4171
3 - INSTALLER 9037
Fig. 91 Drain and Fill Locations
1 - FILL HOLE
2 - DRAIN HOLE
si on fl ui d.
(30-40 ft. l bs.).
REMOVAL
nut.
INSTALLATION
I nstal l er MB991168A.
front output shaft.
(190-230 ft.l bs.).
1 - HOLDER 6719
2 - BOLTS
1 - HOLDER 6719
2 - BOLTS
FLUID (Continued)
MODE SENSOR
DESCRIPTION
OPERATION
undefi ned.
+40 4LO
+20 N
0 2WD/AWD
-20 4HI
Transfer Case
Angle (degrees)
+40 (4LO) H H L L
0 (2WD/AWD) H L H L
-20 (4HI) L L H L
Fig. 94 Mode Sensor
1 - MODE SENSOR
SELECTOR SWITCH
DESCRIPTION
The sel ector swi tch assembl y (Fi g. 95) i s mounted
i n the l eft si de of the vehi cl es I nstrument Panel (I P)
and consi sts of a rotary knob connected to a resi sti ve
network for the mode and range shi ft sel ecti ons. Al so
request.
The sel ector swi tch al so contai ns four l i ght emi t-
ti ng di odes (LEDs) to i ndi cate the transfer case posi -
ti on and whether a shi ft i s i n progress.
OPERATION
Step Resistance
Range (ohms)
Required
Interpretation
A <200 Shorted
B 400-700 NEUTRAL
C 1050-1450 4LO
D 1850-2300 4HI
E 3050-5950 2WD (Default)
positions
G >15.5K Open
2WD), the TCCM may i nterpret the resi stance as:
for 2WD and i n-between posi ti ons, the TCCM may
the 2WD posi ti on.
Fig. 95 Transfer Case Selector Switch
1 - SELECTOR SWITCH
have not been met. Thi s i s i n an attempt to noti fy
the dri ver that the transmi ssi on needs to be put i nto
NEUTRAL, the vehi cl e speed i s too great, or some
other condi ti on outl i ned (other than a di agnosti c fai l -
ure that woul d prevent thi s shi ft) el sewhere (Refer to
ULES/TRANSFER CASE CONTROL MODULE -
OPERATI ON) i s not met. Note that thi s fl ashi ng wi l l
conti nue i ndefi ni tel y unti l the condi ti ons are eventu-
al l y met, or the sel ector swi tch posi ti on i s changed,
or i f di agnosti c routi nes no l onger al l ow the
requested shi ft.
I f the dri ver attempts to make a shi ft i nto transfer
case NEUTRAL, and any of the dri ver control l abl e con-
di ti ons are not met, the request wi l l be i gnored unti l al l
of the condi ti ons are met or unti l the NEUTRAL sel ect
button i s rel eased. Addi ti onal l y the neutral l amp wi l l
fl ash, or begi n to fl ash whi l e the button i s depressed
and operator control l abl e condi ti ons are not bei ng met.
Al l of the LEDs except the Neutral wi l l fl ash i f any of
the operator control l abl e condi ti ons for shi fti ng are not
met whi l e the Neutral button i s depressed. Thi s toggl e
type of feature i s necessary because the TCCM woul d
i nterpret another request i mmedi atel y after the shi ft
i nto transfer case NEUTRAL has compl eted.
SHIFT MOTOR
DESCRIPTION
torque devi ce. The output of the devi ce i s coupl ed to
a shaft whi ch i nternal l y moves the mode and range
forks that change the transfer case operati ng ranges.
The motor i s rated at 25 amps maxi mum at 72 F
wi th 10 vol ts at the motor l eads.
OPERATION
The transfer case shi ft motor responds to the
Transfer Case Control Modul e (TCCM) commands to
move the transfer case shi ft sector bi -di recti onal l y, as
requi red, to obtai n the transfer case operati ng mode
i ndi cated by the i nstrument panel mounted sel ector
swi tch.
REMOVAL
NOTE: New shift motor assemblies are shipped in
the 2WD/AWD position. If a new shift motor assem-
bly will be installed, it will be necessary to shift the
transfer case to the 2WD/AWD position prior to
motor removal.
INSTALLATION
the transfer case.
ft.l bs.).
and mode sensor.
(6) Lower vehi cl e and veri fy transfer case
operati on.
1 - SHIFT MOTOR
TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND
WHEEL RUNOUT . . . . . . . . . . . . . . . . . . . . . . 1
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE ROTATION . 3
STANDARD PROCEDURE - MATCH
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE - TIRE AND
WHEEL BALANCE . . . . . . . . . . . . . . . . . . . . . . 4
TIRES
DESCRIPTION
DESCRIPTION - SPARE TIRE /
TEMPORARY . . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - TIRES . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - RADIAL PLY TIRES . . . . . . 6
DESCRIPTION - TIRE PRESSURE FOR
HIGH SPEEDS. . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION - REPLACEMENT TIRES . . . . . 7
DESCRIPTION - TIRE INFLATION
PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - PRESSURE
GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - TIRE NOISE
OR VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - REPAIRING
LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
TIRE REVOLUTIONS PER MILE . . . . . . . . . . 10
WHEELS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - DUAL REAR
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 13
STUDS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
WHEEL COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION
SPARE TIRE
DESCRIPTION
DESCRIPTION - SPARE / TEMPORARY
TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION - FULL SIZE, SPARE WHEEL
WITH MATCHING TIRE . . . . . . . . . . . . . . . . . 15
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
RUNOUT
Radi al runout i s the di fference between the hi gh
and l ow poi nts on the ti re or wheel (Fi g. 1).
Lateral runout i s the wobble of the ti re or wheel .
Radi al runout of more than 1.5 mm (.060 i nch)
measured at the center l i ne of the tread may cause
the vehi cl e to shake.
Lateral runout of more than 2.0 mm (.080 i nch)
measured near the shoul der of the ti re may cause the
vehi cl e to shake.
Someti mes radi al runout can be reduced. Rel ocate
the wheel and ti re assembl y on the mounti ng studs
(See Method 1). I f thi s does not reduce runout to an
acceptabl e l evel , the ti re can be rotated on the wheel .
(See Method 2).
DR TIRES/WHEELS 22 - 1
METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Dri ve vehi cl e a short di stance to el i mi nate ti re
fl at spotti ng from a parked posi ti on.
(2) Check wheel beari ngs and adjust i f adjustabl e
or repl ace i f necessary.
(3) Check the wheel mounti ng surface.
(4) Rel ocate wheel on the mounti ng, two studs
over from the ori gi nal posi ti on.
(5) Ti ghten wheel nuts unti l al l are properl y
torqued, to el i mi nate brake di storti on.
(6) Check radi al runout. I f sti l l excessi ve, mark
ti re si dewal l , wheel , and stud at poi nt of maxi mum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
NOTE: Rotating the tire on wheel is particularly
effective when there is runout in both tire and
wheel.
(1) Remove ti re from wheel and mount wheel on
servi ce dynami c bal ance machi ne.
(2) Check wheel radi al runout (Fi g. 2) and l ateral
runout (Fi g. 3).
STEEL WHEELS: Radi al runout 0.031 i n., Lat-
eral runout 0.031 i n. (maxi mum)
ALUMI NUM WHEELS: Radi al runout 0.020 i n.,
Lateral runout 0.025 i n. (maxi mum)
(3) I f poi nt of greatest wheel l ateral runout i s near
ori gi nal chal k mark, remount ti re 180 degrees.
Recheck runout, Refer to match mounti ng procedure.
Fig. 1 Checking Tire/Wheel/Hub Runout
1 - RADIAL RUNOUT
2 - LATERAL RUNOUT
Fig. 2 Radial Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 3 Lateral Runout
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
22 - 2 TIRES/WHEELS DR
TIRES/WHEELS (Continued)
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE ROTATION
Ti res on the front and rear axl es operate at di ffer-
ent l oads and perform di fferent steeri ng, dri vi ng, and
braki ng functi ons. For these reasons, the ti res wear
at unequal rates. They may al so devel op i rregul ar
wear patterns. These effects can be reduced by rotat-
i ng the ti res accordi ng to the mai ntenance schedul e
i n the Owners Manual . Thi s wi l l i mprove tread l i fe,
tracti on and mai ntai n a smooth qui et ri de.
The recommended method of ti re rotati on i s (Fi g.
4) & (Fi g. 5). Other methods can be used, but may
not provi de the same ti re l ongevi ty benefi ts.
CAUTION: 3500 Dual rear tires have a new tire rota-
tion pattern. This is to accommodate the asymmet-
rical design of the ON/OFF road tires and the use of
the outlined white letter (OWL) tires. When replac-
ing a flat, the spare tire may have to be remounted
on the rim or installed at a different location to
maintain the correct placement of the asymmetrical
design or the (OWL).
STANDARD PROCEDURE - MATCH MOUNTING
Wheel s and ti res are match mounted at the factory.
Thi s means that the hi gh spot of the ti re i s matched
to the l ow spot on the wheel ri m. Each are marked
wi th a bri ght col ored temporary l abel on the out-
board surface for al i gnment. The wheel i s al so
marked permanentl y on the i nsi de of the ri m i n the
ti re wel l . Thi s permanent mark may be a pai nt dot
or l i ne, a permanent l abel or a stamped i mpressi on
such as an X. An opti onal l ocati on mark i s a smal l
spheri cal i ndentati on on the verti cal face of the out-
board fl ange on some non styl ed base steel wheel s.
The ti re must be removed to l ocate the permanent
mark on the i nsi de of the wheel .
Before di smounti ng a ti re from i ts wheel , a refer-
ence mark shoul d be pl aced on the ti re at the val ve
stem l ocati on. Thi s reference wi l l ensure that i t i s
remounted i n the ori gi nal posi ti on on the wheel .
(1) Remove the ti re and wheel assembl y from the
vehi cl e and mount on a servi ce dynami c bal ance
machi ne.
(2) Measure the total runout on the center of the
ti re tread ri b wi th a di al i ndi cator. Record the i ndi -
cator readi ng. Mark the ti re to i ndi cate the hi gh spot.
Pl ace a mark on the ti re at the val ve stem l ocati on
(Fi g. 6).
Fig. 4 TIRE ROTATION PATTERN - SINGLE REAR
WHEEL (SRW)
Fig. 5 TIRE ROTATION PATTERN - DUAL REAR
WHEELS (DRW)
Fig. 6 First Measurement On Tire
1 - REFERENCE MARK
2 - 1ST MEASUREMENT HIGH SPOT MARK TIRE AND RIM
3 - WHEEL
4 - VALVE STEM
(3) Break down the ti re and remount i t 180
degrees on the ri m (Fi g. 7).
(4) Measure the total i ndi cator runout agai n. Mark
the ti re to i ndi cate the hi gh spot.
(5) I f runout i s sti l l excessi ve, the fol l owi ng proce-
dures must be done.
I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.) of
the fi rst spot and i s sti l l excessi ve, repl ace the ti re.
I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.) of
the fi rst spot on the wheel , the wheel may be out of
speci fi cati ons. Refer to Wheel and Ti re Runout.
I f the hi gh spot i s NOT wi thi n 101.6 mm (4.0
i n.) of ei ther hi gh spot, draw an arrow on the tread
from second hi gh spot to fi rst. Break down the ti re
and remount i t 90 degrees on ri m i n that di recti on
(Fi g. 8). Thi s procedure wi l l normal l y reduce the
runout to an acceptabl e amount, i f not repl ace the
ri m.
STANDARD PROCEDURE - TIRE AND WHEEL
BALANCE
I t i s recommended that a two pl ane servi ce
dynami c bal ancer be used when a ti re and wheel
assembl y requi re bal anci ng. Refer to bal ancer opera-
ti on i nstructi ons for proper cone mounti ng proce-
dures. Typi cal l y use front cone mounti ng method for
steel wheel s. For al umi num wheel use back cone
mounti ng method wi thout cone spri ng.
NOTE: Static should be used only when a two plane
balancer is not available.
NOTE: Cast aluminum and forged aluminum wheels
require coated balance weights and special align-
ment equipment.
Wheel bal anci ng can be accompl i shed wi th ei ther
on or off vehi cl e equi pment. When usi ng on-vehi cl e
bal anci ng equi pment, remove the opposi te wheel /ti re.
Off-vehi cl e bal anci ng i s recommended.
For stati c bal anci ng, fi nd the l ocati on of the heavy
spot causi ng the i mbal ance. Counter bal ance wheel
di rectl y opposi te the heavy spot. Determi ne wei ght
requi red to counter bal ance the area of i mbal ance.
Pl ace hal f of thi s wei ght on the inner ri m fl ange and
the other hal f on the outer ri m fl ange (Fi g. 9).
For dynami c bal anci ng, the bal anci ng equi pment i s
desi gned to l ocate the amount of wei ght to be appl i ed
to both the i nner and outer ri m fl ange (Fi g. 10).
Fig. 7 Remount Tire 180 Degrees
1 - VALVE STEM
2 - REFERENCE MARK
Fig. 8 Remount Tire 90 Degrees In Direction of
Arrow
1 - 2ND HIGH SPOT ON TIRE
2 - 1ST HIGH SPOT ON TIRE
Fig. 9 Static Unbalance & Balance
1 - HEAVY SPOT
2 - CENTER LINE OF SPINDLE
3 - ADD BALANCE WEIGHTS HERE
4 - CORRECTIVE WEIGHT LOCATION
5 - TIRE OR WHEEL TRAMP, OR WHEEL HOP
Fig. 10 Dynamic Unbalance & Balance
1 - CENTER LINE OF SPINDLE
2 - ADD BALANCE WEIGHTS HERE
3 - CORRECTIVE WEIGHT LOCATION
4 - HEAVY SPOT WHEEL SHIMMY AND VIBRATION
TIRES
DESCRIPTION
DESCRIPTION - SPARE TIRE / TEMPORARY
The temporary spare ti re i s desi gned for emer-
gency use onl y. The ori gi nal ti re shoul d be repai red
or repl aced at the fi rst opportuni ty, then rei nstal l ed.
Do not exceed speeds of 50 M.P.H. when usi ng the
temporary spare ti re. Refer to Owners Manual for
compl ete detai l s.
DESCRIPTION - TIRES
Ti res are desi gned and engi neered for each speci fi c
vehi cl e. They provi de the best overal l performance
for normal operati on. The ri de and handl i ng charac-
teri sti cs match the vehi cl es requi rements. Wi th
proper care they wi l l gi ve excel l ent rel i abi l i ty, trac-
ti on, ski d resi stance, and tread l i fe.
Dri vi ng habi ts have more effect on ti re l i fe than
any other factor. Careful dri vers wi l l obtai n i n most
cases, much greater mi l eage than severe use or care-
l ess dri vers. A few of the dri vi ng habi ts whi ch wi l l
shorten the l i fe of any ti re are:
Rapi d accel erati on
Severe brake appl i cati ons
Hi gh speed dri vi ng
Excessi ve speeds on turns
Stri ki ng curbs and other obstacl es
Radi al -pl y ti res are more prone to i rregul ar tread
wear. I t i s i mportant to fol l ow the ti re rotati on i nter-
val shown i n the secti on on Ti re Rotati on, (Refer to
22 - TI RES/WHEELS - STANDARD PROCEDURE).
Thi s wi l l hel p to achi eve a greater tread l i fe.
TIRE IDENTIFICATION
Ti re type, si ze, aspect rati o and speed rati ng are
encoded i n the l etters and numbers i mpri nted on the
si de wal l of the ti re. Refer to the chart to deci pher
the ti re i denti fi cati on code (Fi g. 11).
Performance ti res have a speed rati ng l etter after
the aspect rati o number. The speed rati ng i s not
al ways pri nted on the ti re si dewal l . These rati ngs
are:
Q up to 100 mph
R up to 106 mph
S up to 112 mph
T up to 118 mph
U up to 124 mph
H up to 130 mph
V up to 149 mph
Z more than 149 mph (consul t the ti re manu-
facturer for the speci fi c speed rati ng)
An Al l Season type ti re wi l l have ei ther M +S, M
& S or MS (i ndi cati ng mud and snow tracti on)
i mpri nted on the si de wal l .
TIRE CHAINS
Ti re snow chai ns may be used on certain model s.
Refer to the Owners Manual for more i nformati on.
DESCRIPTION - RADIAL PLY TIRES
Radi al -pl y ti res i mprove handl i ng, tread l i fe and
ri de qual i ty, and decrease rol l i ng resi stance.
Radi al -pl y ti res must al ways be used i n sets of
four. Under no ci rcumstances shoul d they be used on
the front onl y. They may be mi xed wi th temporary
spare ti res when necessary. A maxi mum speed of 50
MPH i s recommended whi l e a temporary spare i s i n
use.
Radi al -pl y ti res have the same l oad-carryi ng capac-
i ty as other types of ti res of the same si ze. They al so
use the same recommended i nfl ati on pressures.
The use of oversi zed ti res, ei ther i n the front or
rear of the vehi cl e, can cause vehi cl e dri ve trai n fai l -
ure. Thi s coul d al so cause i naccurate wheel speed
si gnal s when the vehi cl e i s equi pped wi th Anti -Lock
Brakes.
The use of ti res from di fferent manufactures on the
same vehi cl e i s NOT recommended. The proper ti re
pressure shoul d be mai ntai ned on al l four ti res.
Fig. 11 Tire Identification
DESCRIPTION - TIRE PRESSURE FOR HIGH
SPEEDS
For proper ti re pressure speci fi cati on refer to the
Owners Manual .
DESCRIPTION - REPLACEMENT TIRES
The ori gi nal equi pment ti res provi de a proper bal -
ance of many characteri sti cs such as:
Ri de
Noi se
Handl i ng
Durabi l i ty
Tread l i fe
Tracti on
Rol l i ng resi stance
Speed capabi l i ty
I t i s recommended that ti res equi val ent to the ori g-
i nal equi pment ti res be used when repl acement i s
needed.
Fai l ure to use equi val ent repl acement ti res may
adversel y affect the safety and handl i ng of the vehi -
cl e.
The use of oversi ze ti res may cause i nterference
wi th vehi cl e components. Under extremes of suspen-
si on and steeri ng travel , i nterference wi th vehi cl e
components may cause ti re damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
DESCRIPTION - TIRE INFLATION PRESSURES
Under i nfl ati on wi l l cause rapi d shoul der wear, ti re
fl exi ng, and possi bl e ti re fai l ure (Fi g. 12).
Over i nfl ati on wi l l cause rapi d center wear and
l oss of the ti res abi l i ty to cushi on shocks (Fi g. 13).
I mproper i nfl ati on can cause:
Uneven wear patterns
Reduced tread l i fe
Reduced fuel economy
Unsati sfactory ri de
Vehi cl e dri ft
For proper ti re pressure speci fi cati on refer to the
vehi cl es Owners Manual .
WARNING: OVER OR UNDER INFLATED TIRES CAN
AFFECT VEHICLE HANDLING AND TREAD WEAR.
THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY,
RESULTING IN LOSS OF VEHICLE CONTROL.
DIAGNOSIS AND TESTING - PRESSURE
GAUGES
A qual i ty ai r pressure gauge i s recommended to
check ti re pressure. After checki ng the ai r pressure,
repl ace val ve cap fi nger ti ght.
DIAGNOSIS AND TESTING - TIRE NOISE OR
VIBRATION
Radi al -pl y ti res are sensi ti ve to force i mpul ses
caused by i mproper mounti ng, vi brati on, wheel
defects, or possi bl y ti re i mbal ance.
To fi nd out i f ti res are causi ng the noi se or vi bra-
ti on, dri ve the vehi cl e over a smooth road at varyi ng
speeds. Note the noi se l evel duri ng accel erati on and
decel erati on. The engi ne, di fferenti al and exhaust
noi ses wi l l change as speed vari es, whi l e the ti re
noi se wi l l usual l y remai n constant.
Fig. 12 Under Inflation Wear
1 - THIN TIRE THREAD AREAS
Fig. 13 Over Inflation Wear
1 - THIN TIRE THREAD AREA
TIRES (Continued)
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS
Tread wear i ndi cators are mol ded i nto the bottom
of the tread grooves. When tread depth i s 1.6 mm
(1/16 i n.), the tread wear i ndi cators wi l l appear as a
13 mm (1/2 i n.) band (Fi g. 14).
Ti re repl acement i s necessary when i ndi cators
appear i n two or more grooves or i f l ocal i zed bal di ng
occurs.
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS
Under i nfl ati on wi l l cause wear on the shoul ders of
ti re. Over i nfl ati on wi l l cause wear at the center of
ti re.
Excessi ve camber causes the ti re to run at an
angl e to the road. One si de of tread i s then worn
more than the other (Fi g. 15).
Excessi ve toe-i n or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fi g. 15).
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD
Use the fol l owi ng Vehi cl e Lead Di agnosi s And Cor-
recti on Chart to di agnose and correct a vehi cl e l ead
or dri ft probl em (Fi g. 16).
Fig. 15 Tire Wear Patterns
Fig. 14 Tread Wear Indicators
1 - TREAD ACCEPTABLE
2 - TREAD UNACCEPTABLE
3 - WEAR INDICATOR
TIRES (Continued)
Fig. 16 VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART
TIRES (Continued)
STANDARD PROCEDURE - REPAIRING LEAKS
For proper repai ri ng, a radi al ti re must be removed
from the wheel . Repai rs shoul d onl y be made i f the
defect, or puncture, i s i n the tread area (Fi g. 17). The
ti re shoul d be repl aced i f the puncture i s l ocated i n
the si dewal l .
Defl ate ti re compl etel y before removi ng the ti re
from the wheel . Use l ubri cati on such as a mi l d soap
sol uti on when di smounti ng or mounti ng ti re. Use
tool s free of burrs or sharp edges whi ch coul d dam-
age the ti re or wheel ri m.
Before mounti ng ti re on wheel , make sure al l rust
i s removed from the ri m bead and repai nt i f neces-
sary.
I nstal l wheel on vehi cl e, and ti ghten to proper
torque speci fi cati on, (Refer to 22 - TI RES/WHEELS/
WHEELS - SPECI FI CATI ONS).
SPECIFICATIONS
TIRE REVOLUTIONS PER MILE
TIRE SIZE SUPPLIER REVOLUTIONS PER MILE
P245/70R17
WRANGLER SRA
GOODYEAR 685
LT245/70R17
LTX A/S
MICHELIN
675
LT265/70R17
LTX A/S
MICHELIN 657
LT245/70R17
RUGGED TRAIL T/A
BF GOODRICH
684
LT265/70R17
RUGGED TRAIL T/A
BF GOODRICH
658
P265/70R17
WRANGLER SR/A
GOODYEAR 657
P265/70R17
WRANGLER GS/A
GOODYEAR 661
LT275/70R17
WRANGLER AT/S
GOODYEAR 649
LT275/70R17
TTL
GOODYEAR 649
P275/55R20
EAGLE LS
GOODYEAR 655
P275/60R20
WRANGLER HP
GOODYEAR 636
LT235/80R17E
WRANGLER SRA
GOODYEAR
649
LT235/80R17E
WRANGLER GSA
GOODYEAR
649
Fig. 17 TIRE REPAIR AREA
1 - TIRE REPAIR AREA
TIRES (Continued)
WHEELS
DESCRIPTION
Ori gi nal equi pment wheel s are desi gned for the
speci fi ed Maxi mum Vehi cl e Capaci ty.
Al l model s use steel or al umi num drop center
wheel s.
Al umi num wheel s requi re speci al bal ance wei ghts
and al i gnment equi pment.
(1) On vehi cl es equi pped wi th dual rear wheel s,
The ri m i s an ei ght stud hol e pattern wheel . The
wheel s have a fl at mounti ng surface (Fi g. 18). The
sl ots i n the wheel must be al i gned to provi de access
to the val ve stem (Fi g. 19).
OPERATION
The wheel (Fi g. 20) has rai sed secti ons between
the ri m fl anges and the ri m wel l . I ni ti al i nfl ati on of
the ti re forces the bead over these rai sed secti ons. I n
case of ti re fai l ure, the rai sed secti ons hol d the ti re
i n posi ti on on the wheel unti l the vehi cl e can be
brought to a safe stop.
WHEEL INSPECTION
I nspect wheel s for:
Excessi ve run out
Dents or cracks
Damaged wheel l ug nut hol es
Ai r Leaks from any area or surface of the ri m
NOTE: Do not attempt to repair a wheel by hammer-
ing, heating or welding.
I f a wheel i s damaged an ori gi nal equi pment
repl acement wheel shoul d be used. When obtai ni ng
repl acement wheel s, they shoul d be equi val ent i n
l oad carryi ng capaci ty. The di ameter, wi dth, offset,
pi l ot hol e and bol t ci rcl e of the wheel shoul d be the
same as the ori gi nal wheel .
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
VEHICLE. USED WHEELS ARE NOT RECOM-
MENDED. THE SERVICE HISTORY OF THE WHEEL
MAY HAVE INCLUDED SEVERE TREATMENT OR
VERY HIGH MILEAGE. THE RIM COULD FAIL WITH-
OUT WARNING.
Fig. 18 FLAT FACE WHEEL
1 - FLAT FACE
2 - VALVE STEM
Fig. 19 DUAL REAR WHEELS
1 - WINDOW OPENINGS (5)
2 - INBOARD VALVE STEM
3 - OUTBOARD VALVE STEM
Fig. 20 Safety Rim
1 - FLANGE
2 - RIDGE
3 - WELL
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL
REPLACEMENT
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. They must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts whi ch feature an
enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the al umi num wheel s.
NOTE: Do not use chrome plated lug nuts with
chrome plated wheels.
Before i nstal l i ng the wheel , be sure to remove any
bui l d up of corrosi on on the wheel mounti ng surfaces.
Ensure wheel s are i nstal l ed wi th good metal -to-metal
contact. I mproper i nstal l ati on coul d cause l ooseni ng
of wheel nuts (Fi g. 21). Thi s coul d affect the safety
and handl i ng of your vehi cl e.
To i nstal l the wheel , fi rst posi ti on i t properl y on
the mounti ng surface (Fi g. 21). Al l wheel nuts shoul d
then be ti ghtened just snug. Gradual l y ti ghten them
i n sequence to the proper torque speci fi cati on, (Fi g.
22) (Fi g. 23). Never use oil or grease on studs or
nuts.
Wheel s must be repl aced i f they have:
Excessi ve runout
Bent or dented
Leak ai r through wel ds
Have damaged bol t hol es
Wheel repai rs empl oyi ng hammeri ng, heati ng, or
wel di ng are not al l owed.
Ori gi nal equi pment wheel s are avai l abl e through
your deal er. Repl acement wheel s from any other
source shoul d be equi val ent i n:
Load carryi ng capaci ty
Di ameter
Wi dth
Offset
Mounti ng confi gurati on
Fai l ure to use equi val ent repl acement wheel s may
affect the safety and handl i ng of your vehi cl e.
Repl acement wi th used wheel s i s not recommended.
Thei r servi ce hi story may have i ncl uded severe treat-
ment.
STANDARD PROCEDURE - DUAL REAR WHEEL
INSTALLATION
Dual rear wheel s use a speci al heavy duty l ug nut
wrench. I t i s recommended to remove and i nstal l
dual rear wheel s onl y when the proper wrench i s
avai l abl e. The wrench i s al so use to remove wheel
Fig. 21 WHEEL INSTALLATION 8-LUG SHOWN
1 - CENTER CAP
2 - LUG NUT
3 - TIRE/WHEEL ASSEMBLY
4 - WHEEL STUDS
Fig. 22 8-LUG TIGHTENING PATTERN
Fig. 23 TYPICAL 6 - LUG NUT TIGHTENING
PATTERN
WHEELS (Continued)
center caps for more i nformati on refer to Owners
Manual .
The ti res on both wheel s must be compl etel y rai sed
off the ground when ti ghteni ng the l ug nuts. Thi s
wi l l ensure correct wheel centeri ng and maxi mum
wheel cl ampi ng.
A two pi ece fl at face l ug nut wi th ri ght-hand
threads i s used for retai ni ng the wheel s on the hubs
(Fi g. 24).
The dual rear wheel l ug nuts shoul d be ti ghtened
accordi ng to the fol l owi ng procedure:
Pl ace two drops of oi l to the i nterface of the nut/
washer (Fi g. 24) before i nstal l i ng on the wheel stud.
NOTE: Do not use more then two drops of oil on
the nut/washer, since the center caps attach in this
area.
Ti ghten the wheel l ug nuts i n the numbered
sequenti al pattern unti l they are snug ti ght. Then
ti ghten l ug nut to speci fi ed torque fol l owi ng same
number sequence, (Refer to 22 - TI RES/WHEELS/
WHEELS - SPECI FI CATI ONS).
Ti ghten l ug nuts i n same numbered sequence a
second ti me to the speci fi ed torque. Thi s wi l l ensure
that the wheel s are thoroughl y mated.
Check l ug nut speci fi ed torque after 100 mi l es
(160 ki l ometers). Al so after 500 mi l es (800 ki l ome-
ters) of vehi cl e operati on.
NOTE: Wheel lug nuts should be tightened to spec-
ified torque at every maintenance interval thereafter.
SPECIFICATIONS
TORQUE CHART
1500 Series
Lug Nut 9/16 X 18 with
60Cone
180 135
2500 Series
60Cone
180 135
3500 Series
Flat Washer
195 145
Fig. 24 Oil Location
1 - PLACE TWO DROPS OF OIL HERE
WHEELS (Continued)
STUDS
REMOVAL
(3) Remove the brake cal i per, cal i per adapter and
rotor, (Refer to 5 - BRAKES/HYDRAULI C/MECHAN-
I CAL/ROTORS - REMOVAL).
(4) Remove the stud from the hub wi th Remover
C-4150A (Fi g. 25).
INSTALLATION
(1) I nstal l the new stud i nto the hub fl ange.
(2) I nstal l the three washers onto the stud, then
i nstal l the l ug nut wi th the fl at si de of the nut
agai nst the washers.
(3) Ti ghten the l ug nut unti l the stud i s pul l ed
i nto the hub fl ange. Veri fy that the stud i s properl y
seated i nto the fl ange.
(4) Remove the l ug nut and washers.
(5) I nstal l the brake rotor, cal i per adapter, and cal -
i per, (Refer to 5 - BRAKES/HYDRAULI C/MECHAN-
I CAL/ROTORS - I NSTALLATI ON).
(6) I nstal l the wheel and ti re assembl y, (Refer to
CEDURE), use new the l ug nut on stud or studs that
were repl aced.
WHEEL COVER
REMOVAL
NOTE: The hub caps must be removed before rais-
ing the vehicle off the ground.
NOTE: You must use the flat end of the hub/cap
remover/installer combination tool to pry off the
wheel skins. Insert the flat tip completely and using
a back and forth motion, loosen the wheel skin.
repeat this procedure around the tire until the wheel
skin pops off.
(1) On 2500/3500 si ngl e rear wheel (SRW) model s,
i nsert a hub/cap remover/i nstal l er combi nati on tool
usi ng the bl ade on the end of the tool to pry the cap
off i n a back and forth moti on.
(2) On 3500 model s wi th dual rear wheel s (DRW),
you must fi rst remove the hub caps. The hub/cap
remover/i nstal l er combi nati on tool must be i nserted
i n the pry off notch of the rear hub caps.
(3) Posi ti on the hub/cap remover/i nstal l er combi na-
ti on tool and pul l out on the tool fi rml y. The cap
shoul d come off.
(4) The wheel ski ns can now be removed from the
wheel .
(5) On 3500 model s front hub caps use the hub/cap
remover/i nstal l er combi nati on tool to pry off the cap
i n a back and forth moti on. The wheel ski ns can now
be removed.
INSTALLATION
INSTALLATION - REAR
(1) I nstal l one 1 1/2 i n. val ve stem extensi on on
each rear i nner wheel .
NOTE: A 3/8 in. drive 10mm deep wheel socket with
a 10 in. or greater extension can be used to remove
the existing valve stem cap and install the exten-
sion.
(2) I nstal l one 1 i n. val ve stem extensi on on each
outer wheel .
(3) Al i gn the cool i ng wi ndows of the wheel ski n
wi th the cool i ng wi ndows of the wheel . Seat one si de
of the wheel ski ns retai ner onto the wheel . Usi ng a
rubber mal l et, stri ke thew wheel ski n on the outer
ci rcumference. Stri ke at several l ocati ons around the
ci rcumference unti l the ski n i s ful l y seated.
NOTE: The wheel skin and the hub cap are fully
seated when there is a consistent gap between the
skin/cap and the wheel.
(4) Tug on the hub/cap wheel ski n to ensure that
they are properl y i nstal l ed.
(1) Al i gn the val ve stem wi th the notch i n the
wheel ski n.
Fig. 25 Wheel Stud Removal
1 - REMOVER
2 - WHEEL STUD
(2) Seat on si de of the wheel ski ns wi re retai ner
on to the wheel .
(3) Usi ng a rubber mal l et, stri ke the opposi te si de
of the wheel ski n unti l the ski n i s properl y seated.
NOTE: The wheel skin and the hub cap are fully
seated when there is a consistant gap between the
skin/ cap and the wheel.
(4) Tug on the hub cap/wheel ski n to ensure that
they are properl y i nstal l ed.
SPARE TIRE
DESCRIPTION
DESCRIPTION - SPARE / TEMPORARY TIRE
The temporary spare ti re i s desi gned for emer-
gency use onl y. The ori gi nal ti re shoul d be repai red
or repl aced at the fi rst opportuni ty, then rei nstal l ed.
Do not exceed speeds of 50 M.P.H. when usi ng the
temporary spare ti re. Refer to Owners Manual for
compl ete detai l s.
DESCRIPTION - FULL SIZE, SPARE WHEEL
WITH MATCHING TIRE
The spare i s a ful l usage wheel wi th a matchi ng
ti re, I t can be used wi thi n the (posted l egal ) speed
l i mi ts or di stance l i mi tati ons as of the rest of the
vehi cl es four ti res. Refer to Owners Manual for com-
pl ete detai l s.
WHEEL COVER (Continued)
BODY
TABLE OF CONTENTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING - WATER LEAKS . 1
DIAGNOSIS AND TESTING - WIND NOISE . . . 2
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE - HEAT STAKING . . 3
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 3
STANDARD PROCEDURE - BUZZ, SQUEAK
& RATTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS - TORQUE . . . . . . . . . . . . . . 12
SPECIAL TOOLS
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DOOR - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . 18
DOORS - REAR . . . . . . . . . . . . . . . . . . . . . . . . . 28
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . 49
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . 86
WEATHERSTRIP/SEALS . . . . . . . . . . . . . . . . . . . 91
BODY STRUCTURE . . . . . . . . . . . . . . . . . . . . . . 95
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use
when welding.
Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.
Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
DIAGNOSIS AND TESTING - WATER LEAKS
Water l eaks can be caused by poor seal i ng,
i mproper body component al i gnment, body seam
porosi ty, mi ssi ng pl ugs, or bl ocked drai n hol es. Cen-
tri fugal and gravi tati onal force can cause water to
dri p from a l ocati on away from the actual l eak poi nt,
maki ng l eak detecti on di ffi cul t. Al l body seal i ng
poi nts shoul d be water ti ght i n normal wet-dri vi ng
condi ti ons. Water fl owi ng downward from the front of
the vehi cl e shoul d not enter the passenger or l uggage
compartment. Movi ng seal i ng surfaces wi l l not
al ways seal water ti ght under al l condi ti ons. At
ti mes, si de gl ass or door seal s wi l l al l ow water to
enter the passenger compartment duri ng hi gh pres-
sure washi ng or hard dri vi ng rai n (severe) condi -
ti ons. Overcompensati ng on door or gl ass
adjustments to stop a water l eak that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After compl eti ng
a repai r, water test vehi cl e to veri fy l eak has stopped
before returni ng vehi cl e to use.
DR BODY 23 - 1
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Veri fy that fl oor and body pl ugs are i n pl ace, body
drai ns are cl ear, and body components are properl y
al i gned and seal ed. I f component al i gnment or seal -
i ng i s necessary, refer to the appropri ate secti on of
thi s group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the condi ti ons causi ng a water l eak have
been determi ned, si mul ate the condi ti ons as cl osel y
as possi bl e.
I f a l eak occurs wi th the vehi cl e parked i n a
steady l i ght rai n, fl ood the l eak area wi th an open-
ended garden hose.
I f a l eak occurs whi l e dri vi ng at hi ghway speeds
i n a steady rai n, test the l eak area wi th a reasonabl e
vel oci ty stream or fan spray of water. Di rect the
spray i n a di recti on comparabl e to actual condi ti ons.
I f a l eak occurs when the vehi cl e i s parked on an
i ncl i ne, hoi st the end or si de of the vehi cl e to si mu-
l ate thi s condi ti on. Thi s method can be used when
the l eak occurs when the vehi cl e accel erates, stops or
turns. I f the l eak occurs on accel erati on, hoi st the
front of the vehi cl e. I f the l eak occurs when braki ng,
hoi st the back of the vehi cl e. I f the l eak occurs on l eft
turns, hoi st the l eft si de of the vehi cl e. I f the l eak
occurs on ri ght turns, hoi st the ri ght si de of the vehi -
cl e. For hoi sti ng recommendati ons (Refer to LUBRI -
CATI ON & MAI NTENANCE/HOI STI NG -
WATER LEAK DETECTION
To detect a water l eak poi nt-of-entry, do a water
test and watch for water tracks or dropl ets formi ng
on the i nsi de of the vehi cl e. I f necessary, remove i nte-
ri or tri m covers or panel s to gai n vi sual access to the
l eak area. I f the hose cannot be posi ti oned wi thout
bei ng hel d, have someone hel p do the water test.
Some water l eaks must be tested for a consi derabl e
l ength of ti me to become apparent. When a l eak
appears, fi nd the hi ghest poi nt of the water track or
drop. The hi ghest poi nt usual l y wi l l show the poi nt of
entry. After l eak poi nt has been found, repai r the
l eak and water test to veri fy that the l eak has
stopped.
Locati ng the entry poi nt of water that i s l eaki ng
i nto a cavi ty between panel s can be di ffi cul t. The
trapped water may spl ash or run from the cavi ty,
often at a di stance from the entry poi nt. Most water
l eaks of thi s type become apparent after accel erati ng,
stoppi ng, turni ng, or when on an i ncl i ne.
MIRROR INSPECTION METHOD
When a l eak poi nt area i s vi sual l y obstructed, use
a sui tabl e mi rror to gai n vi sual access. A mi rror can
al so be used to defl ect l i ght to a l i mi ted-access area
to assi st i n l ocati ng a l eak poi nt.
BRIGHT LIGHT LEAK TEST METHOD
Some water l eaks i n the l uggage compartment can
be detected wi thout water testi ng. Posi ti on the vehi -
cl e i n a bri ghtl y l i t area. From i nsi de the darkened
l uggage compartment i nspect around seal s and body
seams. I f necessary, have a hel per di rect a drop l i ght
over the suspected l eak areas around the l uggage
compartment. I f l i ght i s vi si bl e through a normal l y
seal ed l ocati on, water coul d enter through the open-
i ng.
PRESSURIZED LEAK TEST METHOD
When a water l eak i nto the passenger compart-
ment cannot be detected by water testi ng, pressuri ze
the passenger compartment and soap test exteri or of
the vehi cl e. To pressuri ze the passenger compart-
ment, cl ose al l doors and wi ndows, start engi ne, and
set heater control to hi gh bl ower i n HEAT posi ti on. I f
engi ne can not be started, connect a charger to the
battery to ensure adequate vol tage to the bl ower.
Wi th i nteri or pressuri zed, appl y di sh detergent sol u-
ti on to suspected l eak area on the exteri or of the
vehi cl e. Appl y detergent sol uti on wi th spray devi ce or
soft bri stl e brush. I f soap bubbl es occur at a body
seam, joi nt, seal or gasket, the l eak entry poi nt coul d
be at that l ocati on.
DIAGNOSIS AND TESTING - WIND NOISE
Wi nd noi se i s the resul t of most ai r l eaks. Ai r l eaks
can be caused by poor seal i ng, i mproper body compo-
nent al i gnment, body seam porosi ty, or mi ssi ng pl ugs
i n the engi ne compartment or door hi nge pi l l ar areas.
Al l body seal i ng poi nts shoul d be ai rti ght i n normal
dri vi ng condi ti ons. Movi ng seal i ng surfaces wi l l not
al ways seal ai rti ght under al l condi ti ons. At ti mes,
si de gl ass or door seal s wi l l al l ow wi nd noi se to be
noti ced i n the passenger compartment duri ng hi gh
cross wi nds. Over compensati ng on door or gl ass
adjustments to stop wi nd noi se that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After a repai r pro-
cedure has been performed, test vehi cl e to veri fy
noi se has stopped before returni ng vehi cl e to use.
VISUAL INSPECTION BEFORE TESTS
Veri fy that fl oor and body pl ugs are i n pl ace and
body components are al i gned and seal ed. I f compo-
nent al i gnment or seal i ng i s necessary, refer to the
appropri ate secti on of thi s group for proper proce-
dures.
23 - 2 BODY DR
BODY (Continued)
ROAD TESTING WIND NOISE
(1) Dri ve the vehi cl e to veri fy the general l ocati on
of the wi nd noi se.
(2) Appl y 50 mm (2 i n.) maski ng tape i n 150 mm
(6 i n.) l engths al ong weatherstri ps, wel d seams or
mol di ngs. After each l ength i s appl i ed, dri ve the vehi -
cl e. I f noi se goes away after a pi ece of tape i s appl i ed,
remove tape, l ocate, and repai r defect.
POSSIBLE CAUSE OF WIND NOISE
Mol di ngs standi ng away from body surface can
catch wi nd and whi stl e.
Gaps i n seal ed areas behi nd overhangi ng body
fl anges can cause wi nd-rushi ng sounds.
Mi sal i gned movabl e components.
Mi ssi ng or i mproperl y i nstal l ed pl ugs i n pi l l ars.
Wel d burn through hol es.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
Al l mechani sms and l i nkages shoul d be l ubri cated
when necessary. Thi s wi l l mai ntai n ease of operati on
and provi de protecti on agai nst rust and excessi ve
wear. The weatherstri p seal s shoul d be l ubri cated to
prol ong thei r l i fe as wel l as to i mprove door seal i ng.
Al l appl i cabl e exteri or and i nteri or vehi cl e operat-
i ng mechani sms shoul d be i nspected and cl eaned.
Pi vot/sl i di ng contact areas on the mechani sms shoul d
then be l ubri cated.
(1) When necessary, l ubri cate the operati ng mech-
ani sms wi th the speci fi ed l ubri cants.
(2) Appl y si l i cone l ubri cant to a cl oth and wi pe i t
on door seal s to avoi d over-spray that can soi l pas-
sengers cl othi ng.
(3) Before appl yi ng l ubri cant, the component
shoul d be wi ped cl ean. After l ubri cati on, any excess
l ubri cant shoul d be removed.
(4) The hood l atch, l atch rel ease mechani sm, l atch
stri ker, and safety l atch shoul d be l ubri cated peri od-
i cal l y.
(5) The door l ock cyl i nders shoul d be l ubri cated
twi ce each year (preferabl y autumn and spri ng).
Spray a smal l amount of l ock cyl i nder l ubri cant
di rectl y i nto the l ock cyl i nder.
Appl y a smal l amount to the key and i nsert i t
i nto the l ock cyl i nder.
Rotate i t to the l ocked posi ti on and then back to
the unl ocked posi ti on several ti mes.
Remove the key. Wi pe the l ubri cant from i t wi th
a cl ean cl oth to avoi d soi l i ng of cl othi ng.
STANDARD PROCEDURE - HEAT STAKING
(1) Remove tri m panel .
(2) Bend or move the tri m panel components at
the heat staked joi nts. Observe the heat staked l oca-
ti ons and/or component seams for l ooseness.
(3) Heat stake the components.
(a) I f the heat staked or component seam l oca-
ti on i s l oose, hol d the two components ti ghtl y
together and usi ng a sol deri ng gun wi th a fl at ti p,
mel t the materi al securi ng the components
together. Do not over heat the affected area, dam-
age to the exteri or of the tri m panel may occur.
(b) I f the heat staked materi al i s broken or mi ss-
i ng, use a hot gl ue gun to appl y new materi al to
the area to be repai red. The panel s that are bei ng
heat staked must be hel d together whi l e the appl y-
i ng the gl ue. Once the new materi al i s i n pl ace, i t
may be necessary to use a sol deri ng gun to mel t
the newl y appl i ed materi al . Do not over heat the
affected area, damage to the exteri or of the tri m
panel may occur.
(4) Al l ow the repai red area to cool and veri fy the
repai r.
(5) I nstal l tri m panel .
STANDARD PROCEDURE - PLASTIC BODY
PANEL REPAIR
There are many di fferent types of pl asti cs used i n
todays automoti ve envi ronment. We group pl asti cs i n
three di fferent categori es: Ri gi d, Semi -Ri gi d, and
Fl exi bl e. Any of these pl asti cs may requi re the use of
an adhesi on promoter for repai r. These types of pl as-
ti c are used extensi vel y on Dai ml erChrysl er Motors
vehi cl es. Al ways fol l ow repai r materi al manufactur-
ers pl asti c i denti fi cati on and repai r procedures.
Rigid Plastics:
Exampl es of ri gi d pl asti c use: Fasci as, Hoods,
Doors, and other Body Panel s, whi ch i ncl ude SMC,
ABS, and Pol ycarbonates.
Semi-Rigid Plastics:
Exampl es of semi -ri gi d pl asti c use: I nteri or Panel s,
Under Hood Panel s, and other Body Tri m Panel s.
Flexible Plastics:
Exampl es of fl exi bl e pl asti c use: Fasci as, Body
Mol di ngs, and upper and l ower Fasci a Covers.
Repair Procedure:
The repai r procedure for al l three categori es of
pl asti cs i s basi cal l y the same. The one di fference i s
the materi al used for the repai r. The materi al s must
be speci fi c for each substrate, ri gi d repai r materi al
for ri gi d pl asti c repai r, semi -ri gi d repai r materi al for
semi -ri gi d pl asti c repai r and fl exi bl e repai r materi al
for fl exi bl e pl asti c repai r.
DR BODY 23 - 3
BODY (Continued)
Adhesion Promoter/Surface Modifier:
Adhesi on Promoters/Surface Modi fi ers are requi red
for certai n pl asti cs. Al l three categori es may have
pl asti cs that requi re the use of adhesi on promoter/
surface modi fi ers. Al ways fol l ow repai r materi al man-
ufacturers pl asti c i denti fi cati on and repai r
procedures.
SAFETY PRECAUTION AND WARNINGS
WARNING:
EYE PROTECTION SHOULD BE USED WHEN
SERVICING COMPONENTS. PERSONAL INJURY
CAN RESULT.
USE AN OSHA APPROVED BREATHING MASK
WHEN MIXING EPOXY, GRINDING, AND SPRAYING
PAINT OR SOLVENTS IN A CONFINED AREA. PER-
AVOID PROLONGED SKIN CONTACT WITH
RESIN, PETROLEUM, OR ALCOHOL BASED SOL-
VENTS. PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT PROPERLY SUPPORTED ON
SAFETY STANDS. PERSONAL INJURY CAN
RESULT.
NOTE:
When holes must be drilled or cut in body pan-
els, verify locations of internal body components
and electrical wiring. Damage to vehicle can result.
Do not use abrasive chemicals or compounds
on undamaged painted surfaces around repair
areas. Damage to finish can result.
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
ASA ACRYLONITRILE STYRENE
ACRYLITE
LURAN S CONSOLES, GRILLES
ABS ACRYLONITRILE
BUTADIENE STYRENE
TERLURAN A PILLARS, CONSOLES,
GRILLES
ABS/PC ABS/PC ALLOY PULSE, PROLOY, BAYBLEND DOORS, INSTRUMENT
PANELS
ABS/PVC ABS/PV ALLOY PROLOY, PULSE, LUSTRAN,
CYCLOVIN
DOOR PANELS, GRILLES,
TRIM
BMC BULK MOLDING
COMPOUND
BMC FENDER EXTENSIONS
EMA EHTYLENE METHYL
ACRYLATE/IONOMER
SURLYN, EMA, IONOMER BUMPER GUARDS, PADS
METTON METTON METTON GRILLES, KICK PANELS,
RUNNING BOARDS
MPPO MODIFIED
POLYPHENYLENE OXIDE
MPPO SPOILER ASSEMBLY
PA POLYAMID ZYTEL, VYDYNE, PA,
MINLON
FENDERS, QUARTER
PANELS
PET THERMOPLASTIC
POLYESTER
RYNITE TRIM
PBT/PPO PBT/PPO ALLOY GERMAX CLADDINGS
PBTP POLYBUTYLENE
THEREPTHALATE
PBT, PBTP, POCAN, VALOX WHEEL COVERS, FENDERS,
GRILLES
PBTP/EEBC POLYBUTYLENE
THEREPTHALATE/EEBC
ALLOY
BEXLOY, M, PBTP/EEBC FASCIAS, ROCKER PANEL,
MOLDINGS
PC POLYCARBONATE LEXAN, MERLON, CALIBRE,
MAKROLON PC
TAIL LIGHT LENSES, IP TRIM,
VALANCE PANELS
23 - 4 BODY DR
BODY (Continued)
PC/ABS PC/ABS ALLOY GERMAX, BAY BLENDS,
PULSE
DOORS, INSTRUMENT
PANELS
PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN,
MARLEX, PRFAX, NORYL,
GTX, PPO
INTERIOR TRIM, DOOR
PANELS, SPLASH SHIELDS,
STEERING COLUMN
SHROUD
PPO/PA POLYPHENYLENE/
POLYAMID
PPO/PA, GTX 910 FENDERS, QUARTER
PANELS
PR/FV FIBERGLASS REINFORCED
PLASTIC
FIBERGLASS, FV, PR/FV BODY PANELS
PS POLYSTYRENE LUSTREX, STYRON, PS DOOR PANELS, DASH
PANELS
RTM RESIN TRANSFER
MOLDING COMPOUND
RTM BODY PANELS
SMC SHEET MOLDED
COMPOUND
SMC BODY PANELS
TMC TRANSFER MOLDING
COMPOUND
TMC GRILLES
UP UNSATURATED
POLYESTER
(THERMOSETTING)
SMC, BMC, TMC, ZMC, IMC,
XSMC, UP
GRILLE OPENING PANEL,
LIFTGATES, FLARESIDE
FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED
CO-POLYMER
EEBC BUMPERS
EEBC/PBTP EEBC/POLYBUTYLENE
TEREPTHALATE
EEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS
EMPP ETHYLENE MODIFIED
POLYPROPYLENE
EMPP BUMPER COVERS
EPDM ETHYLENE/
PROPROPYLENE DIENE
MONOMER
EPDM, NORDEL, VISTALON BUMPERS
EPM ETHYLENE/
PROPROPYLENE CO-
POLYMER
EPM FENDERS
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN,
LUPOLEN, MARLEX
-
PP POLYPROPYLENE
(BLENDS)
NORYL, AZDEL, MARLOX,
DYLON, PRAVEX
INNER FENDER, SPOILERS,
KICK PANELS
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM REACTION INJECTED
MOLDED POLYURETHANE
RIM, BAYFLEX FRONT FASCIAS, MODULAR
WINDOWS
DR BODY 23 - 5
BODY (Continued)
RRIM REINFORCED REACTION
INJECTED MOLDED
PUR, RRIM FASCIAS, BODY PANELS,
BODY TRIMS
TPE THERMO POLYETHYLENE TPE, HYTREL, BEXLOY-V FASCIAS, BUMPERS,
CLADDINGS
TPO THERMOPOLYOLEFIN POLYTROPE, RENFLEX,
SANTOPRENE, VISAFLEX,
ETA, APEX, TPO, SHIELDS,
CLADDINGS
BUMPERS, END CAPS,
TELCAR, RUBBER, STRIPS,
SIGHT, INTERIOR B POST
TPP THERMO-POLYPROPYLENE TPP BUMPERS
TPU THERMOPOLYURETHANE,
POLYESTER
TPU, HYTREL, TEXIN,
ESTANE
BUMPERS, BODY SIDE,
MOLDINGS, FENDERS,
FASCIAS
PANEL SECTIONING
I f i t i s requi red to secti on a l arge panel for a pl as-
ti c repai r, i t wi l l be necessary to rei nforce the panel
(Fi g. 1). To bond two pl asti c panel s together, a rei n-
forcement must overl ap both panel s. The panel s
must be Vd at a 20 degree angl e. The area to be
rei nforced shoul d be washed, then sanded. Be sure to
wi pe off any excess soap and water when fi ni shed.
Li ghtl y sand or abrade the pl asti c wi th an abrasi ve
pad or sandpaper. Bl ow off any dust wi th compressed
ai r or wi pe wi th a cl ean dry rag.
When bondi ng pl asti c panel s, Fol l ow repai r mate-
ri al manufacturers recommendati ons. Be sure that
enough adhesi ve has been appl i ed to al l ow squeeze
out and to fi l l the ful l bond l i ne. Once the pi eces
have been brought together, do not move them unti l
the adhesi ve i s cured. The assembl y can be hel d
together wi th cl amps, ri vets, etc. A faster cure can be
obtai ned by heati ng wi th a heat l amp or heat gun.
After the parts have been bonded and have had ti me
to cure, rough sand the seam and appl y the fi nal
adhesi ve fi l l er to the area bei ng repai red. Smooth the
fi l l er wi th a spreader, wooden tongue depressor, or
squeegee. For fi ne texturi ng, a smal l amount of
water can be appl i ed to the fi l l er surface whi l e
smoothi ng. The cured fi l l er can be sanded as neces-
sary and, as a fi nal step, cl eanup can be done wi th
soapy water. Wi pe the surface cl ean wi th a dry cl oth
al l owi ng ti me for the panel to dry before movi ng on
wi th the repai r.
PANEL REINFORCEMENT
Structural repai r procedures for ri gi d panel s wi th
l arge cracks and hol es wi l l requi re a rei nforcement
backi ng. Rei nforcements can be made wi th several
appl i cati ons of gl ass cl oth saturated wi th structural
adhesi ve. Semi -ri gi d or fl exi bl e repai r materi al s
shoul d be used for semi -ri gi d or fl exi bl e backi ng rei n-
forcement (Fi g. 2) and (Fi g. 3). Open meshed fi ber-
gl ass dry wal l tape can be used to form a
rei nforcement. The dry wal l tape al l ows the resi n to
penetrate through and make a good bond between
the panel and the adhesi ve. Structural l y, the more
dry wal l tape used, the stronger the repai r.
Another ki nd of repai r that can be done to repai r
l arge cracks and hol es i s to use a scrap pi ece of si m-
i l ar pl asti c and bond wi th structural adhesi ve. The
rei nforcement shoul d cover the enti re break and
shoul d have a generous amount of overl ap on ei ther
si de of the cracked or broken area.
When repai ri ng pl asti c, the damaged area i s fi rst
Vd out, or bevel ed. Large bondi ng areas are desi r-
abl e when repai ri ng pl asti c because smal l repai rs are
l ess l i kel y to hol d permanentl y. Bevel i ng the area
around a crack at a 20 degree angl e wi l l i ncrease the
bondi ng surface for a repai r (Fi g. 4). I t i s recom-
mended that sharp edges be avoi ded because the
joi nt may show through after the panel i s refi ni shed.
Fig. 1 PANEL SECTIONING
1 - EXISTING PANEL
2 - NEW PANEL
3 - PANEL ADHESIVE
4 - BONDING STRIP
23 - 6 BODY DR
BODY (Continued)
Panel repai r for both fl exi bl e and ri gi d panel s
are basi cal l y the same. The pri mary di fference
between fl exi bl e panel repai r and ri gi d panel repai r
i s i n the adhesi ve materi al s used (Fi g. 5).
The techni ci an shoul d fi rst deci de what needs to
be done when worki ng on any type of body panel .
One shoul d determi ne i f i t i s possi bl e to return the
damage part to i ts ori gi nal strength and appearance
wi thout exceedi ng the val ue of the repl acement part.
When pl asti c repai rs are requi red, i t i s recom-
mended that the part be l eft on the vehi cl e when
every possi bl e. That wi l l save ti me, and the panel
wi l l remai n stati onary duri ng the repai r. Mi sal i gn-
ment can cause stress i n the repai r areas and can
resul t i n future fai l ure.
VISUAL INSPECTION
Composi te materi al s can mask the severi ty of an
acci dent. Adhesi ve bond l i nes, i nteri or structure of
the doors, and steel structures need to be i nspected
careful l y to get a true damage assessment. Cl ose
i nspecti on may requi re parti al removal of i nteri or
tri m or i nner panel s.
I denti fy the type of repai r: Puncture or Crack -
Damage that has penetrated compl etel y through the
panel . Damage i s confi ned to one general area; a
panel secti on i s not requi red. However, a backer
panel , open fi bergl ass tape, or matted materi al must
be bonded from behi nd (Fi g. 7) (Fi g. 6).
PANEL SURFACE PREPARATION
I f a body panel has been punctured, cracked, or
crushed, the damaged area must be removed from
the panel to achi eve a successful repai r. Al l spi der
web cracks l eadi ng away from a damaged area must
be stopped or removed. To stop a runni ng crack i n a
panel , dri l l a 6 mm (0.250 i n.) hol e at the end of the
crack farthest away from the damage. I f spi der web
cracks can not be stopped, the panel woul d requi re
repl acement. The surfaces around the damaged area
Fig. 2 SOFTENED EDGES
1 - SOFTENED EDGES
2 - PANEL ADHESIVE
3 - BONDING STRIP
Fig. 3 PANEL REINFORCEMENT
1 - PANEL ADHESIVE
2 - REINFORCEMENT
Fig. 4 BEVELING ANGLE - 20 DEGREE
Fig. 5 FIBERGLASS TAPE
Fig. 6 DAMAGE COMPONENT
1 - PUNCTURE
DR BODY 23 - 7
BODY (Continued)
shoul d be stri pped of pai nt and freed from wax and
oi l . Scuff surfaces around repai r area wi th 360 gri t
wet/dry sandpaper, or equi val ent, to assure adhesi on
of repai r materi al s.
PATCHING PANELS
An panel that has extensi ve puncture type damage
can be repai red by cutti ng out the damaged materi al
(Fi g. 7). Use a sui tabl e reci procati ng saw or cut off
wheel to remove the secti on of the panel that i s dam-
aged. The pi ece cut out can be used as a templ ate to
shape the new patch. I t i s not necessary to have
access to the back of the panel to i nstal l a patch.
Bevel edges of cutout at 20 degrees to expose a l arger
bondi ng area on the outer si de. Thi s wi l l al l ow for an
i ncreased rei nforcement areas.
PANEL PATCH FABRICATIONS
A patch can be fabri cated from any ri gi d fi bergl ass
panel that has comparabl e contour wi th the repai r
area. Li ft gates and fenders can be used to suppl y
patch materi al . I f exi sti ng materi al i s not avai l abl e
or compati bl e, a patch can be constructed wi th adhe-
si ve and rei nforcement mesh (dry wal l tape). Perform
the fol l owi ng operati on i f requi red:
(1) Cover waxed paper or pl asti c wi th adhesi ve
backed nyl on mesh (dry wal l tape) l arger than the
patch requi red (Fi g. 8).
(2) Tape waxed paper or pl asti c sheet wi th mesh to
a surface that has a compati bl e contour to the repai r
area.
(3) Appl y a l i beral coat of adhesi ve over the rei n-
forcement mesh (Fi g. 8). I f necessary appl y a second
or thi rd coat of adhesi ve and mesh after fi rst coat
has cured. The thi ckness of the patch shoul d be the
same as the repai r area.
(4) After patch has cured, peel waxed paper or
pl asti c from the back of the patch.
(5) I f desi red, a thi n fi l m coat of adhesi ve can be
appl i ed to the back of the patch to cover mesh for
added strength.
PANEL PATCH INSTALLATION
(1) Make a paper or cardboard pattern the si ze
and shape of the cutout hol e i n the panel .
(2) Tri m 3 mm (0.125 i n.) from edges of pattern so
patch wi l l have a gap between connecti ng surfaces.
(3) Usi ng the pattern as a gui de, cut the patch to
si ze.
(4) Cut scrap pi eces of patch materi al i nto 50 mm
(2 i n.) squares to use as patch supports to sustai n
the patch i n the cutout.
(5) Dri l l 4 mm (0.160 i n.) hol es 13 mm (0.5 i n.) i n
from edge of cutout hol e (Fi g. 7).
(6) Dri l l 4 mm (0.160 i n.) hol es 13 mm (0.5 i n.)
away from edge of patch across from hol es dri l l ed
around cutout.
Fig. 7 DAMAGED PANEL CUTOUT AND PATCH
1 - CUTOUT
2 - DAMAGED BODY PANEL
3 - 4 MM (0.160 IN.) HOLES
4 - PATCH CUT TO SIZE
Fig. 8 FABRICATED PANEL
1 - STRUCTURAL ADHESIVE
2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE
3 - WIDTH OF V-GROOVE
4 - WAXED PAPER
23 - 8 BODY DR
BODY (Continued)
(7) Dri l l 3 mm (0.125 i n.) hol es i n the support
squares 13 mm (0.5 i n.) from the edge i n the center
of one si de.
(8) Scuff the backsi de of the body panel around the
cutout hol e wi th a scuff pad or sandpaper.
(9) Mi x enough adhesi ve to cover one si de of al l
support squares.
(10) Appl y adhesi ve to cover one si de of al l support
squares.
(11) Usi ng number 8 sheet metal screws, secure
support squares to back si de of body panel wi th
adhesi ve sandwi ched between the panel and squares
(Fi g. 9).
(12) Posi ti on patch i n cutout agai nst support
squares and adjust patch unti l the gap i s equal al ong
al l si des (Fi g. 10).
(13) Dri l l 3 mm (0.125 i n.) hol es i n the support
squares through the pre-dri l l ed hol es i n the patch.
(14) Appl y a coat of adhesi ve to the exposed ends
of the support squares (Fi g. 11).
(15) I nstal l screws to hol d the patch to support
squares (Fi g. 12). Ti ghten screws unti l patch surface
i s fl ush wi th panel surface.
(16) Al l ow adhesi ve to cure, and remove al l screws.
(17) Usi ng a 125 mm (5 i n.) 24 gri t di sc gri nder,
gri nd a 50 mm (2 i n.) to 75 mm (3 i n.) wi de and 2
mm (0.080 i n.) deep path across the gaps around the
patch (Fi g. 13). Wi th compressed ai r, bl ow dust from
around patch.
(18) Appl y adhesi ve backed nyl on mesh (dry wal l
tape) over gaps around patch (Fi g. 14).
(19) Mi x enough adhesi ve to cover the enti re patch
area.
(20) Appl y adhesi ve over the mesh around patch,
and smooth epoxy wi th a wi de spreader to reduce fi n-
i sh gri ndi ng. Use two to three l ayers of mesh and
adhesi ve to create a stronger repai r (Fi g. 15).
Fig. 9 SECURE SUPPORT SQUARES TO BODY
PANEL
1 - SUPPORT SQUARES
2 - SCREWS
3 - DAMAGED BODY PANEL
Fig. 10 POSITION PATCH IN CUTOUT AND ALIGN
1 - CUTOUT
2 - SUPPORT SQUARES
Fig. 11 APPLY ADHESIVE TO SUPPORT SQUARES
1 - APPLICATOR
2 - SUPPORT SQUARES
3 - ADHESIVE
DR BODY 23 - 9
BODY (Continued)
PATCHED PANEL SURFACING
After patch panel i s i nstal l ed, the patch area can
be fi ni shed usi ng the same methods as fi ni shi ng
other types of body panel s. I f mesh materi al i s
exposed i n the patched area, gri nd surface down, and
appl y a coat of hi gh qual i ty ri gi d pl asti c body fi l l er.
Pri me, bl ock sand, and pai nt as requi red.
Fig. 12 INSTALL SCREWS
1 - PATCH
2 - GAP
Fig. 13 GRIND SURFACE
1 - PATCH
2 - GAP
3 - DISC GRINDER
Fig. 14 COVER GAPS WITH MESH
1 - GROUND DOWN AREA
2 - PATCH
3 - MESH
Fig. 15 COVER MESH WITH ADHESIVE
1 - ADHESIVE
2 - MESH
3 - PATCH
4 - SPREADER
23 - 10 BODY DR
BODY (Continued)
STANDARD PROCEDURE - BUZZ, SQUEAK &
RATTLE
Buzz, Squeak & Rattl es (BSR) may be caused by
any one or more of the fol l owi ng and may be cor-
rected as i ndi cated:
Loose fasteners shoul d be ti ghtened to speci fi ca-
ti ons.
Damaged or mi ssi ng cl i ps shoul d be repl aced.
Damaged tri m panel s shoul d be repl aced.
I ncorrectl y i nstal l ed tri m panel s shoul d be rei n-
stal l ed properl y.
Many BSR compl ai nts such as l oose tri m, can be
servi ced usi ng the Mopar Parts BSR Noi se Reduc-
ti on Ki t. Thi s ki t contai ns vari ous tapes i ncl udi ng
foam, fl ock and anti -squeak used to el i mi nate noi ses
caused by metal , pl asti c and vi nyl components. Long
l i fe l ubri cants and greases can al so be used on a vari -
ety of components. Refer to the Buzz, Squeak & Rat-
tl e Ki t tabl e for materi al contents and usage.
BUZZ, SQUEAK & RATTLE KIT
ITEM FEATURES APPLICATIONS SERVICE TEMP
Itch And Squeak
Tape
An abrasion resistant material
thin enough to conform to most
irregular surfaces. Stops most
itches and squeaks.
Between metal and metal,
metal and plastic, metal and
vinyl, vinyl and plastic. Interior.
Examples: Trim panels and
bezels.
-40to 225
Fahrenheit
(-40to 107
Celsius)
Black Nylon Flock Nylon Flock with an aggressive
acrylic adhesive. Provides for
cushioning and compression fit,
also isolates components.
Water-resistant.
metal and plastic, vinyl and
plastic.
Examples: Pull cups, bezels,
clips, ducts, top cover to glass,
cowl panel.
-40to 180
Fahrenheit
(-40to 82Celsius)
High Density
Urethane Foam
Tear resistant, highly resilient
and durable.
metal and plastic. Water-
resistant.
Examples: I/P, heavy metal
rattles, isolating brackets.
-40to 180
Fahrenheit
(-40to 82Celsius)
Open Cell Foam
Tape
Soft foam conforms to irregular
surfaces.
Wire harness and connector
wrap.
Examples: Seals, gasket,
wiring, heat ducts.
-40to 180
Fahrenheit
(-40to 82Celsius)
Closed Cell Low
Density Foam Tape
Soft, conformable. Water-
resistant.
Wherever bulk is needed.
Prevents closing flutters and
rattles when applied to door
watershield.
Examples: Door, I/P.
-40to 180
Fahrenheit
(-40to 82Celsius)
NYE Grease 880 Long life. Suspensions.
Examples: Strut busings, sway
bars.
-40to 390
Fahrenheit
(-40to 200
Celsius)
Krytox Oil Long life. Will not dry out or
harm plastics or rubber.
When access is not possible, oil
will migrate to condition. Vinyl,
rubber, plastic, metal.
Examples: Convertible top
bushings, pull cups trim panel
inserts.
-30to 400
Fahrenheit
(-34to 205
Celsius)
Krytox Grease Long life. Will not dry out or
harm plastics or rubber.
Vinyl, rubber, plastic, metal,
glass.
Examples: Weather-strips,
backlite and windshield
moldings.
-30to 400
Fahrenheit
(-34to 205
Celsius)
DR BODY 23 - 11
BODY (Continued)
Description Nm Ft. Lbs. In. Lbs.
A-pillar trim/grab handle bolts 6 55
Body Isolator/cab bolts 81 60
Cargo box bolts 108 80
Cargo box tie down/cleat bolts 34 25
Center seat assembly nuts* 25 18
Center seat cushion/hinge bolts* 20 15
Center seat back hinge to storage bin bolts* 25 18
Center seat back free pivot hinge bolt* 25 18
Center seat back inertia hinge pivot bolt* 10 89
Center seat inertia hinge to seat back bolts* 25 18
Fender bolts - front lower 9 80
Fender bolts - lower inside 17 13
Fender to hinge support bolts 11 8
Fender to upper fender rail bolts 9 80
Footmans loop bolts 12 9
Front center seat nuts* 25 18
Front door glass lift plate nuts 10 89
Front door hinge to a-pillar nuts 28 21
Front door hinge to door nuts/bolts 28 21
Front door inside handle bolt 9 80
Front door latch adjustment screw 3 30
Front door latch assembly bolts 10 89
Front door latch striker bolts 28 21
Front door latch striker bolts 28 21
Front door regulator bolts 10 89
Front door regulator stabilizer nuts 10 89
Front door remote handle actuator nuts 10 89
Front door run channel screws 10 89
Front seat assembly front bolts* 28 30
Front seat assembly rear bolts* 40 30
Front seat track nuts* 25 18
Fuel fill door bolts 9 80
Hood hinge to fender rail bolts 20 15
Hood latch bolts 11 8
Hood latch striker/safety catch bolts 11 8
Hood hinge to hood nuts 23 17
Instrument panel center bracket bolts 12 9
Instrument panel column support bolts 14 10
Instrument panel side mounting bolts 12 9
23 - 12 BODY DR
BODY (Continued)
Instrument panel top bolts 12 9
Load floor nuts 25 18
Load floor/rear seat bolts 40 30
Lower seat belt anchor bolt - quad cab 40 30
Overhead/b-pillar grab handle bolts 6 55
Radiator and condenser to radiator crossmember bolts 8 75
Radiator upper crossmember bolts 28 21
Rear door glass lift plate nuts 10 89
Rear door glass run channels 10 89
Rear door hinge to b-pillar bolts 28 21
Rear door hinge to door bolts/nuts 28 21
Rear door inside handle bolt 9 80
Rear door latch adjustment screw 3 30
Rear door latch bolts 10 89
Rear door latch striker bolts 28 21
Rear door regulator bolts 10 89
Rear door regulator stabilizer nuts 10 89
Rear door remote handle actuator nuts 10 89
Rear fender bottom screws 7 60
Rear fender nuts 7 60
Rear fender support bracket bolts 11 8
Rear seat assembly bolts* 40 30
Rear seat back hinge bolts* 25 18
Rear seat cushion hinge bolts* 32 24
Rear shoulder belt anchor bolts 40 30
Rear view mirror set screw 1 15
Shifter knob nut 27 20
Side view mirror nuts 7 60
Tailgate check cable bolt 23 17
Tailgate hinge/pivot screws 34 25
Tailgate latch bolts 23 17
Tailgate latch striker 34 25
Tailgate release handle nuts 7 60
NOTE: *Seat fasteners should be discarded and
replaced with new fasteners during assembly.
DR BODY 23 - 13
BODY (Continued)
SPECIAL TOOLS
BODY
Trim Stick C-4755
Torx Bit Set C-4794-B
REMOVER, MOLDINGS C-4829-A
23 - 14 BODY DR
BODY (Continued)
TAILGATE
TABLE OF CONTENTS
page page
CHECK CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
RELEASE HANDLE/LATCH REMOTE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
TAILGATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHECK CABLE
REMOVAL
(1) Open tai l gate.
(2) Pry l ock tab outward to cl ear stud head on
cargo box (Fi g. 1).
(3) Push cabl e end forward unti l stud head i s i n
cl earance hol e porti on of cabl e end.
(4) Separate cabl e end from stud.
(5) Remove screw attachi ng cabl e to tai l gate. (Fi g.
2)
(6) Separate check cabl e from tai l gate.
INSTALLATION
(1) Posi ti on check cabl e on tai l gate.
(2) I nstal l bol t attachi ng smal l end of cabl e to tai l -
gate.
(3) Ti ghten tai l gate check cabl e bol t to 23 Nm (17
ft. l bs.).
(4) Posi ti on l arge end of cabl e onto stud head and
sl i de downward to secure l ock tab.
Fig. 1 Tailgate Check
1 - TAILGATE STRIKER
2 - SCREW DRIVER
3 - TAILGATE CHECK CABLE
4 - LOCK TAB
Fig. 2 LATCH HANDLE - LATCH
1 - EXTERIOR HANDLE
2 - CONTROL ASSEMBLY
3 - NUTS (2)
4 - TAILGATE
5 - LATCH
6 - CHECK CABLE
7 - CHECK/LATCH BOLT
8 - LATCH BOLT
DR TAILGATE 23 - 15
COVER
REMOVAL
(1) Open the tai l gate.
(2) Remove the ei ght screws and remove tai l gate
l i ner, i f equi pped.
(3) Remove the bol ts and remove the cover. (Fi g. 3)
INSTALLATION
(1) I nstal l the cover and i nstal l the bol ts and
ti ghten by hand.
(2) I nstal l the l i ner and i nstal l the screws, i f
equi pped.
HINGE
REMOVAL
(1) Remove the tai l gate. (Refer to 23 - BODY/
TAI LGATE/TAI LGATE - REMOVAL)
(2) Remove the two screws and remove the hi nge/
pi vot. (Fi g. 4)
INSTALLATION
(1) I nstal l the hi nge/pi vot and i nstal l the screws.
(2) Ti ghten the screws to 34 Nm (25 ft. l bs.).
(3) I nstal l the tai l gate. (Refer to 23 - BODY/TAI L-
GATE/TAI LGATE - I NSTALLATI ON)
LATCH
REMOVAL
(1) Remove the cover. (Refer to 23 - BODY/TAI L-
GATE/COVER - REMOVAL)
actuator rod for i nstal l ati on.
(3) Di sconnect the actuator rod at the control
assembl y. (Fi g. 3)
(4) Remove the l atch bol t and the check cabl e bol t.
(Fi g. 5)
(5) Remove the l atch and actuator rod assembl y.
INSTALLATION
(1) I nstal l the l atch and actuator rod assembl y.
(2) I nstal l the l atch and the check cabl e bol ts and
(3) Connect the actuator rod to the control assem-
bl y l i ne up the marks made duri ng removal .
(4) I nstal l the cover. (Refer to 23 - BODY/TAI L-
GATE/COVER - I NSTALLATI ON)
LATCH STRIKER
REMOVAL
(1) Open tai l gate.
(2) Usi ng a grease penci l or equi val ent, mark out-
l i ne of stri ker on cargo box jamb to ai d i nstal l ati on.
(3) Usi ng a Torx dri ve wrench, remove stri ker and
washer from cargo box.
Fig. 3 TAILGATE ASSEMBLY
1 - LATCH ASSEMBLY
3 - ACTUATOR ROD (2)
4 - COVER
5 - BOLTS (10)
Fig. 4 TAILGATE HINGE
1 - HINGE/PIVOT
2 - TAILGATE PILLAR
3 - CLIP/BUSHING
4 - BOLTS (2)
23 - 16 TAILGATE DR
INSTALLATION
(1) Posi ti on stri ker and washer on jamb usi ng
al i gnment outl i ne as reference and i nstal l wi th Torx
dri ve wrench.
(2) Ti ghten the stri ker to 34 Nm (25 ft. l bs.).
RELEASE HANDLE/LATCH
REMOTE
REMOVAL
(1) Remove the tai l gate cover. (Refer to 23 - BODY/
TAI LGATE/COVER - REMOVAL)
l atch actuator rods for ease of i nstal l ati on.
(3) Di sconnect the l atch actuator rods. (Fi g. 3)
(4) Remove the control assembl y nuts and remove
the control assembl y and the exteri or handl e. (Fi g. 5)
INSTALLATION
(1) I nstal l the handl e and the control assembl y.
(2) I nstal l the nuts and ti ghten to 7 Nm (60 i n.
l bs.).
(3) Connect the actuator rods usi ng the marks
made duri ng removal .
(4) I nstal l the cover. (Refer to 23 - BODY/TAI L-
GATE/COVER - I NSTALLATI ON)
TAILGATE
REMOVAL
(1) Open the tai l gate.
(2) Di sconnect the tai l gate check cabl es (Fi g. 6).
(Refer to 23 - BODY/TAI LGATE/CHECK CABLE -
REMOVAL)
(3) Cl ose tai l gate unti l the notch i n the ri ght hand
col l ar al i gns wi th the pi vot pi n.
(4) Sl i p tai l gate hi nge col l ar from pi vot pi ns.
(5) Sl i de tai l gate to the ri ght and separate l eft
hand col l ar from the pi vot pi n.
(6) Separate tai l gate from vehi cl e.
INSTALLATION
(1) Posi ti on tai l gate col l ar on l eft hand pi vot pi n
and sl i de tai l gate to the l eft.
(2) Rai se tai l gate unti l the notch i n the ri ght hand
col l ar al i gns wi th the pi vot pi n.
(3) Connect the tai l gate check cabl es. (Refer to 23 -
BODY/TAI LGATE/CHECK CABLE - I NSTALLA-
TI ON)
Fig. 5 LATCH HANDLE - LATCH
1 - EXTERIOR HANDLE
3 - NUTS (2)
4 - TAILGATE
5 - LATCH
6 - CHECK CABLE
7 - CHECK/LATCH BOLT
8 - LATCH BOLT
Fig. 6 TAILGATE ASSEMBLY
1 - LATCH STRIKER
2 - CHECK CABLE BOLT
3 - CHECK CABLE
4 - TAILGATE
5 - HINGE BUSHING
DR TAILGATE 23 - 17
LATCH STRIKER (Continued)
DOOR - FRONT
TABLE OF CONTENTS
page page
DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 19
DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
EXTERIOR HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
GLASS RUN CHANNEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSIDE HANDLE ACTUATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 23
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 24
LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
WATERDAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
WINDOW REGULATOR - POWER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
WINDOW REGULATOR - MANUAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
SIDE VIEW MIRROR FLAG
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
DOOR
REMOVAL
(1) Di sconnect the door wi re harness el ectri cal con-
nector at the A-pi l l ar. (Fi g. 1)
outl i ne of the door hi nges on the door to ai d i n i nstal -
l ati on.
(3) Support the door wi th a sui tabl e l i fti ng devi ce.
NOTE: The epoxy bonded washers should not be
seperated from the hinge. If the washers are
removed the door may have to be re-adjusted.
(4) Remove the nuts and bol ts attachi ng the door
hi nges to the door.
INSTALLATION
(1) Support the door wi th a sui tabl e l i fti ng devi ce
and i nstal l the door onto the hi nges.
(2) I nstal l the washers, i f there were removed pre-
vi ousl y, nuts and ti ghten to 28 Nm (21 ft. l bs.).
(3) Connect the el ectri cal connectors.
(4) Adjust the door as necessary. (Refer to 23 -
BODY/DOOR - FRONT/DOOR - ADJUSTMENTS)
23 - 18 DOOR - FRONT DR
ADJ USTMENTS
ADJUSTMENT
NOTE: For vehicles with four doors, it is recom-
mended that you adjust the rear door before adjust-
ing the front door. (Refer to 23 - BODY/DOORS -
REAR/DOOR - ADJUSTMENTS)
Door adjustment measurements should be
taken from stationary or welded body panels like
the roof, rocker or quarter panels.
During adjustment procedures, it is recom-
mended that all the hinge fasteners be loosened
except for the upper most fasteners. Adjustments
can be made using the upper bolts to hold the door
with final torque of the fasteners occurring after
correct door positioning is achieved.
A suitable body sealant should be used when
removing or moving the hinges.
FORE/AFT
NOTE: Fore/aft (lateral) door adjustment is done by
loosening the hinge to the hinge pillar fasteners
one hinge at a time and moving the door to the cor-
rect position.
(2) Loosen the hi nge to hi nge pi l l ar fasteners. (Refer
to 23 - BODY/DOOR - FRONT/HI NGE - REMOVAL)
(3) Adjust the door to the correct posi ti on. (Refer
to 23 - BODY/BODY STRUCTURE/GAP AND
FLUSH - SPECI FI CATI ONS)
(4) Ti ghten the hi nge pi l l ar fasteners to 28 Nm
(21 ft. l bs.).
UP/DOWN
NOTE: Up/down door adjustment is done by loosen-
ing either the hinge to the hinge pillar fasteners or
the hinge to door fasteners and moving the door to
the correct position.
NOTE: When adjustment of the door requires the
loosening of the door to hinge fasteners, it will be
necessary to separate the epoxy bonded washers
with a chisel or other suitable tool.
NOTE: When the up/down adjustments are done
correctly, the top of the door is positioned over
flush to the roof. (Refer to 23 - BODY/BODY STRUC-
TURE/GAP AND FLUSH - SPECIFICATIONS)
(2) Loosen the l atch stri ker bol ts. (Refer to 23 -
BODY/DOOR - FRONT/LATCH STRI KER -
REMOVAL)
(3) Loosen the hi nge to door fasteners (Refer to 23
- BODY/DOOR - FRONT/DOOR - REMOVAL) or
l oosen the hi nge to hi nge pi l l ar fasteners (Refer to 23
- BODY/DOOR - FRONT/HI NGE - REMOVAL).
(5) Ti ghten the hi nge pi l l ar fasteners or the door
to hi nges fasteners to 28 Nm (21 ft. l bs.).
(6) Ti ghten the l atch stri ker bol ts. (Refer to 23 -
BODY/DOOR - FRONT/LATCH STRI KER - I NSTAL-
LATI ON)
IN/OUT
NOTE: In/out door adjustment is done by loosening
the hinge to door fasteners one hinge at a time and
moving the door to the correct position.
(2) Loosen the l atch stri ker bol ts. (Refer to 23 -
BODY/DOOR - FRONT/LATCH STRI KER -
REMOVAL)
(3) Loosen the hi nge to door fasteners. (Refer to 23
- BODY/DOOR - FRONT/DOOR - REMOVAL)
Fig. 1 FRONT DOOR
1 - NUTS (2)
2 - UPPER HINGE
3 - STUDS
4 - FRONT DOOR
5 - WIRE HARNESS
6 - LOWER HINGE
7 - ELECTRICAL CONNECTORS (2)
8 - BOLTS (2)
DR DOOR - FRONT 23 - 19
DOOR (Continued)
(5) Ti ghten the door to hi nges fasteners to 28 Nm
(21 ft. l bs.).
(6) Ti ghten the l atch stri ker bol ts. (Refer to 23 -
BODY/DOOR - FRONT/LATCH STRI KER - I NSTAL-
LATI ON)
DOOR GLASS
REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(2) Rei nstal l the wi ndow handl e, i f equi pped.
(3) Remove the wi ndow swi tch from the door tri m
panel and reconnect i t to the door wi re harness, i f
equi pped.
(4) Rai se the wi ndow to the posi ti on shown and
remove the two nuts attachi ng the gl ass to the wi n-
dow regul ator. (Fi g. 2)
(5) Remove the two front run channel screws.
(Refer to 23 - BODY/DOOR - FRONT/GLASS RUN
CHANNEL - REMOVAL)
(6) Remove the i nner bel t mol di ng. (Refer to 23 -
BODY/WEATHERSTRI P/SEALS/FRONT DOOR
I NNER BELT WEATHERSTRI P - REMOVAL)
(7) Di sengage the gl ass from the regul ator and
l ower i nto the door.
(8) Twi st the gl ass forward i n the door wi ndow
openi ng and remove.
INSTALLATION
(1) Posi ti on the gl ass i nto the wi ndow openi ng.
(2) Engage the gl ass i nto the gl ass run weather-
stri p.
(3) Rai se the gl ass wi thi n the door openi ng and
connect the wi ndow regul ator to the l i ft pl ate.
l bs.).
(5) I nstal l the i nner bel t mol di ng. (Refer to 23 -
I NNER BELT WEATHERSTRI P - I NSTALLATI ON)
(6) Posi ti on the front run channel and i nstal l the
screws. (Refer to 23 - BODY/DOOR - FRONT/GLASS
RUN CHANNEL - I NSTALLATI ON)
(7) Remove the wi ndow swi tch from the wi re har-
ness, i f equi pped.
(8) Remove the wi ndow handl e, i f equi pped.
(9) I nstal l the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - I NSTALLATI ON)
EXTERIOR HANDLE
REMOVAL
(1) Remove the door gl ass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - REMOVAL)
(2) Di sconnect the l ock swi tch el ectri cal connector,
i f equi pped. (Fi g. 3)
(3) Di sconnect the actuator rods at the handl e.
(4) Remove the nuts and remove the handl e.
Fig. 2 DOOR GLASS POSITIONING
1 - SIGHT WINDOW
2 - WIDOW REGULATOR
3 - SIGHT WINDOW
4 - REGULATOR STABILIZER
Fig. 3 EXTERIOR HANDLE
1 - EXTERIOR HANDLE
2 - NUTS (2)
4 - FRONT DOOR
5 - DOOR LATCH ASSEMBLY
6 - LATCH ACTUATOR ROD
7 - LOCK SWITCH WIRE HARNESS
8 - KEY CYLINDER ACTUATOR ROD
DOOR (Continued)
INSTALLATION
(1) I nstal l the exteri or handl e and i nstal l the nuts.
(2) Connect the actuator rods at the handl e
(3) Connect the l ock swi tch el ectri cal connector, i f
equi pped.
(4) I nstal l the door gl ass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - I NSTALLATI ON)
GLASS RUN CHANNEL
REMOVAL
(1) Rai se gl ass i nto the ful l up posi ti on.
FRONT RUN CHANNEL
(1) Remove the wi ndow regul ator. (Refer to 23 -
BODY/DOOR - FRONT/WI NDOW REGULATOR -
REMOVAL)
(2) Loosen the front run channel screws, sl i de up
and di sengage from the door. (Fi g. 4)
(3) Separate the gl ass run weatherstri p from the
channel and remove the front channel .
REAR RUN CHANNEL
(1) On standard cab model s, remove the screws
from the si de of the door. (Fi g. 5)
(2) On quad cab model s, remove the l ower screw
from the si de of the door, l oosen the upper screw and
di sengage from the door. (Fi g. 6)
rear channel and remove the channel .
Fig. 4 FRONT RUN CHANNEL
1 - FRONT GLASS RUN CHANNEL
2 - UPPER SCREW
3 - LOWER SCREW
4 - DOOR PANEL OPENING
5 - RUN CHANNEL MOUNTING SLOTS (2)
Fig. 5 REAR RUN CHANNEL - QUAD CAB
1 - SCREWS
2 - REAR GLASS RUN CHANNEL
Fig. 6 REAR RUN CHANNEL - STANDARD CAB
1 - LOWER SCREW
3 - REAR GLASS RUN CHANNEL
4 - UPPER SCREW
EXTERIOR HANDLE (Continued)
INSTALLATION
FRONT RUN CHANNEL
(1) I nstal l the channel , posi ti on the screws i n the
door panel sl ots and sl i de i nto pl ace.
(2) Ti ghten the screws to 10 Nm (89 i n. l bs.).
(3) I nstal l the wi ndow regul ator. (Refer to 23 -
BODY/DOOR - FRONT/WI NDOW REGULATOR -
I NSTALLATI ON)
REAR RUN CHANNEL
(1) On quad cab model s, i nstal l the channel and
sl i de the upper screw i nto the sl ot.
(2) I nstal l the l ower screw and ti ghten both upper
and l ower screws to 10 Nm (89 i n. l bs.).
(3) On standard cab model s, i nstal l the channel
and i nstal l the screws.
(4) Ti ghten the screws to 10 Nm (89 i n. l bs.).
BOTH CHANNELS
(1) Stuff the gl ass run weatherstri p i nto the chan-
nel s.
(2) Veri fy correct wi ndow operati on.
HINGE
REMOVAL
(1) Remove the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - REMOVAL)
hi nge l ocati on and remove the bol ts.
INSTALLATION
(1) I nstal l the hi nges and bol ts.
(2) Ti ghten bol ts to 28 Nm (21 ft. l bs.).
(3) I nstal l the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - I NSTALLATI ON)
REMOVAL
(1) Remove the screw and remove the i nsi de han-
dl e. (Fi g. 7)
(2) Remove the door tri m panel . (Refer to 23 -
BODY/DOOR - FRONT/TRI M PANEL - REMOVAL)
(3) Di sconnect the l atch actuator rod. (Fi g. 8)
(4) Remove the nuts and remove the remote han-
dl e actuator.
INSTALLATION
(1) I nstal l the remote handl e actuator and i nstal l
the nuts.
(2) Ti ghten the nuts to 10 Nm (89 i n. l bs.).
(3) Connect the l atch actuator rod.
Fig. 7 INSIDE HANDLE ACTUATOR
1 - BOLT
2 - HANDLE
3 - TRIM PANEL OPENING
Fig. 8 REMOTE HANDLE ACTUATOR
1 - DOOR
2 - LATCH ASSEMBLY
4 - NUTS (2)
5 - HANDLE REMOTE
GLASS RUN CHANNEL (Continued)
(4) I nstal l the door tri m panel . (Refer to 23 -
TI ON)
(5) I nstal l the i nsi de handl e and i nstal l the bol t.
(6) Ti ghten the bol t to 9 Nm (80 i n. l bs.).
LATCH
REMOVAL
(1) Rai se the wi ndow to the ful l up posi ti on.
(3) Di sconnect the actuator rods.
(5) Di sconnect the el ectri cal connector and remove
the l atch.
INSTALLATION
(1) Connect the el ectri cal connector and i nstal l the
l atch assembl y.
(2) I nstal l the bol ts and ti ghten to 10 Nm (89 i n.
l bs.).
(3) Connect the actuator rods.
(4) Adjust the l atch as needed. (Refer to 23 -
BODY/DOOR - FRONT/LATCH - ADJUSTMENTS)
DOOR - FRONT/LATCH - I NSTALLATI ON)
ADJ USTMENTS
ADJUSTMENT
(1) Locate access hol e and remove the myl ar tape
coveri ng i t. (Fi g. 10)
(2) I nsert a 5/32-i nch hex-wrench through hol e and
i nto adjustment screw. Loosen screw.
(3) Operate outsi de handl e several ti mes to rel ease
any restri cti on because of mi s-al i gnment.
(4) Ti ghten adjustment screw to 3 Nm (30 i n.
l bs.).
(5) Test handl e for proper operati on.
LATCH STRIKER
REMOVAL
posi ti on of the stri ker.
(2) Remove the bol ts and remove the stri ker.
INSTALLATION
(1) I nstal l the stri ker and i nstal l the bol ts.
(3) Adjust the stri ker i f needed. (Refer to 23 -
BODY/DOOR - FRONT/LATCH STRI KER - ADJUST-
MENTS)
Fig. 9 LATCH ASSEMBLY
1 - DOOR
3 - LATCH ASSEMBLY
4 - BOLTS
Fig. 10 LATCH ADJUSTMENT SCREW - TYPICAL
1 - DOOR LATCH
2 - MYLAR TAPE
3 - ADJUSTMENT SCREW
INSIDE HANDLE ACTUATOR (Continued)
ADJ USTMENTS
ADJUSTMENT
posi ti on of the stri ker to ai d i n adjustment.
(2) Loosen the stri ker bol ts.
(3) Change the stri ker posi ti on to adjust the rear
gap and fl ush measurement. (Refer to 23 - BODY/
BODY STRUCTURE/GAP AND FLUSH - SPECI FI -
CATI ONS)
LOCK CYLINDER
REMOVAL
(1) Remove the exteri or handl e. (Refer to 23 -
BODY/DOOR - FRONT/EXTERI OR HANDLE -
REMOVAL)
(2) Remove the cl i p and remove the l ock cyl i nder
l ever and swi tch, i f equi pped.
(3) Remove the screw and remove the l ock cyl i n-
der. (Fi g. 11)
INSTALLATION
(1) I nstal l the l ock cyl i nder and i nstal l the screw.
(2) I nstal l the l ock cyl i nder swi tch, i f equi pped,
l ever and retai ni ng cl i p.
(3) I nstal l the exteri or handl e. (Refer to 23 -
BODY/DOOR - FRONT/EXTERI OR HANDLE -
I NSTALLATI ON)
TRIM PANEL
REMOVAL
(1) Remove the wi ndow crank, i f equi pped. (Fi g.
13)
(2) Remove the i nteri or handl e. (Refer to 23 -
BODY/DOOR - FRONT/I NSI DE HANDLE ACTUA-
TOR - REMOVAL)
(3) Remove the screws at the mi rror fl ag and near
the i nsi de handl e. (Fi g. 12)
CAUTION: Trim panel is attached to the door using
hooks molded into the panel. Do not pull the trim
panel straight off or damage to the panel and/or
power switch assembly may occur.
(4) Li ft the tri m panel up off the bel t seal and
attachment hooks and separate the panel from the
door sl i ghtl y.
(5) Di sconnect the power wi ndow swi tch el ectri cal
connector, i f equi pped, and remove the tri m panel .
INSTALLATION
(1) I nstal l the wi ndow swi tch i nto the tri m panel ,
i f equi pped.
(2) Posi ti on the tri m panel onto the l ower hooks
and connect the power wi ndow swi tch el ectri cal con-
nector, i f equi pped.
(3) Posi ti on the remai ni ng tri m panel attachment
hooks i nto the door panel and seat the tri m panel
i nto the bel t seal ful l y.
(4) I nstal l the screws near the i nsi de handl e and
at the mi rror fl ag.
Fig. 11 LOCK CYLINDER
1 - LOCK CYLINDER
2 - EXTERIOR HANDLE
3 - SCREW
4 - LOCK SWITCH WIRE HARNESS
Fig. 12 TRIM PANEL ASSEMBLY
1 - SCREW INSERT (2)
2 - SCREWS (2)
3 - DOOR TRIM PANEL
4 - LOWER SCREWS (3)
5 - ATTACHMENT HOOKS
LATCH STRIKER (Continued)
(5) I nstal l the i nteri or handl e. (Refer to 23 -
TOR - I NSTALLATI ON)
(6) I nstal l the wi ndow crank, i f equi pped.
WATERDAM
REMOVAL
CAUTION: Do not allow the waterdam or adhesive
to become contaminated with dirt or other foreign
substances.
Do not damage the waterdam during removal and
installation.
If the waterdam becomes contaminated or dam-
aged, replace the waterdam.
(1) Remove the i nsi de handl e actuator. (Refer to 23
- BODY/DOOR - FRONT/I NSI DE HANDLE ACTUA-
TOR - REMOVAL)
(2) Remove the speaker. (Refer to 8 - ELECTRI -
CAL/AUDI O/SPEAKER - REMOVAL)
(3) Separate the waterdam from the i nner door
panel and off of the l atch l i nkages.
INSTALLATION
CAUTION: Do not allow the waterdam or adhesive
to become contaminated with dirt or other foreign
substances.
Do not damage the waterdam during removal and
installation.
If the waterdam becomes contaminated or dam-
aged, replace the waterdam.
(1) Posi ti on the wi re harness and actuator rods
through the hol es i n the waterdam.
(2) Secure the waterdam to the i nner door panel .
(3) I nstal l the speaker. (Refer to 8 - ELECTRI CAL/
AUDI O/SPEAKER - I NSTALLATI ON)
(4) I nstal l the i nsi de handl e actuator. (Refer to 23 -
WINDOW REGULATOR -
POWER
REMOVAL
panel and reconnect i t to the door harness.
remove the nuts. (Fi g. 14)
(4) Di sengage the door gl ass from the regul ator l i ft
pl ate and posi ti on i nto the ful l up posi ti on.
(5) Secure the gl ass i n the up posi ti on usi ng a
wood wedge or equi val ent.
(6) Lower the regul ator.
(7) Remove the stabi l i zer nuts.
(8) Remove the forward regul ator bol t and l oosen
the other two. (Fi g. 15)
(9) Sl i de the regul ator up and out of the keyhol e
sl ots i n the door panel .
(10) Di sconnect the el ectri cal connector and
remove the regul ator.
Fig. 13 WINDOW CRANK REMOVAL TOOL
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
Fig. 14 DOOR GLASS POSITIONING
1 - SIGHT WINDOW
2 - WIDOW REGULATOR
3 - SIGHT WINDOW
TRIM PANEL (Continued)
INSTALLATION
(1) I nstal l the regul ator through the door panel
openi ng and connect the el ectri cal connector.
(2) Posi ti on the regul ator bol ts i nto the keyhol e
sl ots and sl i de i nto pl ace.
(3) I nstal l the forward bol t and ti ghten al l three to
10 Nm (89 i n. l bs.).
(4) Posi ti on the stabi l i zer, i nstal l the nuts and
(5) Rai se the regul ator to the posi ti on shown i n
(Fi g. 14).
(6) Remove the gl ass support and connect to the
regul ator l i ft pl ate.
(7) I nstal l the gl ass nuts and ti ghten to 10 Nm
(89 i n. l bs.).
(8) Di sconnect the wi ndow swi tch and i nstal l i nto
the door tri m panel .
WINDOW REGULATOR -
MANUAL
REMOVAL
(2) Rei nstal l the wi ndow handl e and rai se the wi n-
dow to the posi ti on shown and remove the nuts. (Fi g.
14)
(6) Remove the stabi l i zer nuts.
(7) Remove the two l ower and l oosen the two
upper bol ts. (Fi g. 16)
sl ot.
(9) Remove the regul ator from the door panel
openi ng.
Fig. 15 WINDOW REGULATOR - POWER
2 - INNER DOOR PANEL
3 - STABILIZER NUTS (2)
4 - REGULATOR
5 - FORWARD BOLT
6 - WIRE HARNESS
7 - BOLTS (2)
Fig. 16 WINDOW REGULATOR - MANUAL
1 - DOOR
2 - REGULATOR BOLTS (4)
3 - REGULATOR
WINDOW REGULATOR - POWER (Continued)
INSTALLATION
(1) I nstal l the regul ator through the hol e i n the
i nner door panel .
(2) Posi ti on the regul ator and sl i de the upper bol ts
i nto the keyhol e sl ots.
(3) I nstal l the l ower two bol ts.
(4) Ti ghten the regul ator bol ts to 10 Nm (89 i n.
l bs.).
(6) Usi ng the wi ndow handl e rai se the regul ator to
the posi ti on shown i n (Fi g. 14).
(89 i n. l bs.).
(9) Remove the wi ndow handl e and i nstal l the
waterdam.
SIDE VIEW MIRROR FLAG
REMOVAL
CAUTION: Do not use a drill to remove the heat
stakes.
(2) Remove the heat stakes usi ng a razor kni fe or
equi val ent.
(3) Rel ease the tabs and remove the mi rror fl ag.
INSTALLATION
NOTE: Clean the excess heat staking off of the
studs to aid installation.
(1) I nstal l the new mi rror fl ag over the tabs and
i nstal l the screws i nto the heat stake studs.
TI ON)
WINDOW REGULATOR - MANUAL (Continued)
DOORS - REAR
TABLE OF CONTENTS
page page
DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 28
DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
EXTERIOR HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
GLASS RUN CHANNEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 33
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
ADJUSTMENTS
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 33
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
WATERDAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
WINDOW REGULATOR - POWER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
WINDOW REGULATOR - MANUAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
DOOR
REMOVAL
(1) Di sconnect the door wi re harness el ectri cal con-
nector at the b-pi l l ar. (Fi g. 1)
outl i ne of the door hi nges on the door to ai d i n i nstal -
l ati on.
NOTE: The epoxy bonded washers should not be
seperated from the hinge. If the washers are
(4) Remove the nuts and bol ts attachi ng the door
hi nges to the door.
INSTALLATION
(1) Support the door wi th a sui tabl e l i fti ng devi ce
and i nstal l the door onto the hi nges.
(2) I nstal l the bol ts, nuts and washers, i f there
were removed previ ousl y, and ti ghten to 28 Nm (21
ft. l bs.).
(4) Adjust the door as necessary. (Refer to 23 -
BODY/DOORS - REAR/DOOR - ADJUSTMENTS)
ADJ USTMENTS
ADJUSTMENT
NOTE: For vehicles equipped with four doors, it is
recommended that you adjust the rear door before
adjusting the front door.
Door adjustment measurements should be
taken from stationary or welded body panels like
the roof, rocker or quarter panels.
During adjustment procedures, it is recom-
mended that all the hinge fasteners be loosened
except for the upper most fasteners. Adjustments
can be made using the upper fasteners to hold the
door with final torque of the fasteners occurring
after correct door positioning is achieved.
23 - 28 DOORS - REAR DR
FORE/AFT
NOTE: Fore/aft (lateral) door adjustment is done by
loosening the hinge to the hinge pillar fasteners
one hinge at a time and moving the door to the cor-
rect position.
(2) Loosen the hi nge to hi nge pi l l ar fasteners.
(Refer to 23 - BODY/DOORS - REAR/HI NGE -
REMOVAL)
(4) Ti ghten to hi nge pi l l ar fasteners to 28 Nm (21
ft. l bs.). (Refer to 23 - BODY/DOORS - REAR/HI NGE
- I NSTALLATI ON)
NOTE: Use a suitable body sealer on the hinge to
body mating surfaces.
UP/DOWN
NOTE: Up/down door adjustment is done by loosen-
ing either the hinge to the hinge pillar fasteners or
the hinge to door fasteners and moving the door to
the correct position.
NOTE: When the up/down adjustments are done
correctly, the top of the door is positioned over
flush to the roof. (Refer to 23 - BODY/BODY STRUC-
TURE/GAP AND FLUSH - SPECIFICATIONS)
(2) Remove the l atch stri ker. (Refer to 23 - BODY/
DOORS - REAR/LATCH STRI KER - REMOVAL)
(3) Loosen the hi nge to hi nge pi l l ar fasteners
REMOVAL) or l oosen the hi nge to door fasteners
(Refer to 23 - BODY/DOORS - REAR/DOOR -
REMOVAL).
(5) Ti ghten to hi nge pi l l ar fasteners or the door to
hi nges fasteners and fasteners to 28 Nm (21 ft. l bs.).
I NSTALLATI ON)
(6) I nstal l the l atch stri ker. (Refer to 23 - BODY/
DOORS - REAR/LATCH STRI KER - I NSTALLA-
TI ON)
IN/OUT
NOTE: In/out door adjustment is done by loosening
the hinge to door fasteners one hinge at a time and
moving the door to the correct position.
(2) Remove the l atch stri ker. (Refer to 23 - BODY/
DOORS - REAR/LATCH STRI KER - REMOVAL)
(3) Loosen the hi nge to door fasteners. (Refer to 23
- BODY/DOORS - REAR/DOOR - REMOVAL)
(4) Adjust the front of the door to the correct posi -
ti on. (Refer to 23 - BODY/BODY STRUCTURE/GAP
AND FLUSH - SPECI FI CATI ONS)
(5) Ti ghten the door to hi nges fasteners to 28 Nm
(21 ft. l bs.).
(6) I nstal l the l atch stri ker. (Refer to 23 - BODY/
DOORS - REAR/LATCH STRI KER - I NSTALLA-
TI ON)
Fig. 1 DOOR ASSEMBLY
1 - NUTS (2)
2 - UPPER HINGE
3 - UPPER STUD
4 - REAR DOOR
5 - WIRE HARNESS
6 - LOWER STUD
7 - LOWER HINGE
9 - BOLTS (2)
DR DOORS - REAR 23 - 29
DOOR (Continued)
DOOR GLASS
REMOVAL
(1) Remove the gl ass run channel s. (Refer to 23 -
BODY/DOORS - REAR/GLASS RUN CHANNEL -
REMOVAL)
(2) Remove the gl ass support and pl ace the gl ass
i nto the bottom of the door.
rear of the wi ndow openi ng.
(4) Remove the i nner bel t mol di ng. (Refer to 23 -
I NNER BELT WEATHERSTRI P - REMOVAL)
(5) Remove the gl ass from the wi ndow openi ng.
INSTALLATION
(1) I nstal l the gl ass through the wi ndow openi ng
and pace the gl ass i nto the bottom of the door.
(2) I nstal l the i nner bel t mol di ng. (Refer to 23 -
I NNER BELT WEATHERSTRI P - I NSTALLATI ON)
(3) Stuff the gl ass run weatherstri p i nto the wi n-
dow frame.
(5) I nstal l the gl ass run channel s. (Refer to 23 -
BODY/DOORS - REAR/GLASS RUN CHANNEL -
I NSTALLATI ON)
EXTERIOR HANDLE
REMOVAL
(1) Remove the front gl ass run channel . (Refer to
23 - BODY/DOORS - REAR/GLASS RUN CHANNEL
- REMOVAL)
(3) Remove the nuts and remove the handl e.
INSTALLATION
(1) I nstal l the l atch and i nstal l the nuts.
(3) I nstal l the front gl ass run channel . (Refer to 23
- BODY/DOORS - REAR/GLASS RUN CHANNEL -
I NSTALLATI ON)
GLASS RUN CHANNEL
REMOVAL
(1) Remove the wi ndow regul ator. (Refer to 23 -
REMOVAL)
(2) Remove the bottom screws and l oosen the top
screws from bol t channel s. (Fi g. 3) and (Fi g. 4)
(3) Sl i de the channel s up to di sengage from the
keyhol e sl ots.
channel and remove the channel s.
Fig. 2 EXTERIOR HANDLE
2 - LATCH
3 - NUTS (2)
Fig. 3 FRONT RUN CHANNEL
1 - BOLTS
2 - FRONT RUN CHANNEL
INSTALLATION
(1) Posi ti on the run channel s i nto the door and
engage the upper screws i nto the keyhol e sl ots.
(2) I nstal l the l ower screws and ti ghten to 10 Nm
(89 i n. l bs.).
(3) Ti ghten the upper screws to 10 Nm (89 i n.
l bs.).
(4) Stuff the gl ass run weatherstri p i nto the chan-
nel s.
(5) Veri fy correct wi ndow operati on.
(6) I nstal l the wi ndow regul ator. (Refer to 23 -
I NSTALLATI ON)
HINGE
REMOVAL
NOTE: It is not necessary to remove the door to
replace the hinges if they are replaced one at a
time.
NOTE: The epoxy coated washers should not be
removed from the hinge. If the washers are
(1) Open the front door
UPPER HINGE
posi ti on of the hi nge on the door and b-pi l l ar.
(2) Remove the nut and bol t attachi ng the hi nge to
the door.
(3) Remove the three bol ts attachi ng the hi nge to
the b-pi l l ar and remove the hi nge.
LOWER HINGE
posi ti on of the hi nge on the door and b-pi l l ar.
(2) Remove the l ower b-pi l l ar tri m. (Refer to 23 -
REMOVAL)
(3) Remove the nut and bol t attachi ng the hi nge to
the door.
(4) Remove the two bol ts attachi ng the hi nge to
the b-pi l l ar.
(5) From the i nsi de of the vehi cl e remove the
remai ni ng bol t attachi ng the hi nge to the b-pi l l ar
and remove the hi nge.
INSTALLATION
UPPER HINGE
(1) I nstal l the hi nge to door washers, i f there were
removed previ ousl y, nut and bol t and ti ghten to 28
Nm (21 ft. l bs.).
(2) I nstal l the three hi nge to b-pi l l ar bol ts and
(3) Adjust the door i f needed. (Refer to 23 - BODY/
DOORS - REAR/DOOR - ADJUSTMENTS)
LOWER HINGE
(1) I nstal l the hi nge and i nstal l the b-pi l l ar bol ts.
(3) I nstal l the hi nge to door washers, i f there were
removed previ ousl y, nut and bol t and ti ghten to 28
Nm (21 ft. l bs.).
(4) Adjust the door i f needed. (Refer to 23 - BODY/
DOORS - REAR/DOOR - ADJUSTMENTS)
(5) I nstal l the l ower b-pi l l ar tri m. (Refer to 23 -
I NSTALLATI ON)
REMOVAL
(1) Remove the screw and remove the i nsi de han-
dl e. (Fi g. 5)
BODY/DOORS - REAR/TRI M PANEL - REMOVAL)
(4) Remove the nuts and remove the remote han-
dl e actuator.
Fig. 4 REAR RUN CHANNEL
1 - REAR RUN CHANNEL
2 - SCREW LOCATIONS
GLASS RUN CHANNEL (Continued)
INSTALLATION
(1) I nstal l the remote handl e actuator and i nstal l
the nuts.
(2) Ti ghten the nuts to 10 Nm (89 i n. l bs.).
TI ON)
(5) I nstal l the i nsi de handl e and i nstal l the bol t.
(6) Ti ghten the bol t to 9 Nm (80 i n. l bs.).
LATCH
REMOVAL
(1) Rai se the wi ndow to the ful l up posi ti on.
(3) Di sconnect the actuator rods.
the l atch.
INSTALLATION
(1) Connect the el ectri cal connector and i nstal l the
l atch assembl y.
l bs.).
(3) Connect the actuator rods.
(4) Adjust the l atch as needed. (Refer to 23 -
BODY/DOORS - REAR/LATCH - ADJUSTMENTS)
DOORS - REAR/WATERDAM - I NSTALLATI ON)
Fig. 5 INSIDE HANDLE ACTUATOR
1 - TRIM PANEL OPENING
2 - INSIDE LATCH HANDLE
3 - BOLT
Fig. 6 REMOTE HANDLE ACTUATOR
1 - NUTS (2)
3 - HANDLE REMOTE
Fig. 7 LATCH ASSEMBLY
1 - DOOR
3 - LATCH ASSEMBLY
4 - BOLTS
INSIDE HANDLE ACTUATOR (Continued)
ADJ USTMENTS
ADJUSTMENT
(1) Locate access hol e and remove the myl ar tape
coveri ng i t. (Fi g. 8)
(2) I nsert a 5/32-i nch hex-wrench through hol e and
i nto adjustment screw. Loosen screw.
(3) Operate outsi de handl e several ti mes to rel ease
any restri cti on because of mi s-al i gnment.
(4) Ti ghten adjustment screw to 3 Nm (30 i n.
l bs.).
(5) Test handl e for proper operati on.
LATCH STRIKER
REMOVAL
posi ti on of the stri ker.
(2) Remove the bol ts and remove the stri ker.
INSTALLATION
(1) I nstal l the stri ker and i nstal l the bol ts.
(3) Adjust the stri ker i f needed. (Refer to 23 -
BODY/DOOR - FRONT/LATCH STRI KER - ADJUST-
MENTS)
ADJ USTMENTS
ADJUSTMENT
posi ti on of the stri ker to ai d i n adjustment.
(2) Loosen the stri ker bol ts.
(3) Change the stri ker posi ti on to adjust the rear
gap and fl ush measurement. (Refer to 23 - BODY/
CATI ONS)
TRIM PANEL
REMOVAL
(1) Remove the wi ndow crank, i f equi pped. (Fi g.
10)
(2) Remove the i nteri or handl e. (Refer to 23 -
BODY/DOORS - REAR/I NSI DE HANDLE ACTUA-
TOR - REMOVAL)
(3) Remove the screw near the i nsi de handl e. (Fi g.
9)
CAUTION: Trim panel is attached to the door using
hooks molded into the panel. Do not pull the trim
panel straight off or damage to the panel and/or
power switch assembly may occur.
(4) Li ft the tri m panel up off the bel t seal and
attachment hooks and separate the panel from the
door sl i ghtl y.
(5) Di sconnect the power wi ndow swi tch el ectri cal
connector, i f equi pped, and remove the tri m panel .
INSTALLATION
(1) Posi ti on the tri m panel onto the l ower hooks
and connect the power wi ndow swi tch el ectri cal con-
(2) Posi ti on the remai ni ng tri m panel attachment
hooks i nto the door panel and seat the tri m panel
i nto the bel t seal ful l y.
(3) I nstal l the screw near the i nsi de handl e.
Fig. 8 LATCH ADJUSTMENT SCREW - TYPICAL
1 - DOOR LATCH
2 - MYLAR TAPE
3 - ADJUSTMENT SCREW
Fig. 9 TRIM PANEL
1 - DOOR
3 - ATTACHMENT HOOKS
4 - SCREW
5 - TRIM PANEL
LATCH (Continued)
(4) I nstal l the i nteri or handl e. (Refer to 23 -
(5) I nstal l the wi ndow crank, i f equi pped.
WATERDAM
REMOVAL
(1) Remove the i nsi de handl e actuator. (Refer to 23
- BODY/DOORS - REAR/I NSI DE HANDLE ACTUA-
TOR - REMOVAL)
(2) Remove the speaker. (Refer to 8 - ELECTRI -
CAL/AUDI O/SPEAKER - REMOVAL)
(3) Separate the waterdam from the i nner door
panel and off of the l atch l i nkages.
INSTALLATION
(1) Posi ti on the wi re harness and actuator rods
through the hol es i n the waterdam.
(2) Secure the waterdam to the i nner door panel .
(3) I nstal l the speaker. (Refer to 8 - ELECTRI CAL/
AUDI O/SPEAKER - I NSTALLATI ON)
(4) I nstal l the i nsi de handl e actuator. (Refer to 23 -
WINDOW REGULATOR -
POWER
REMOVAL
DOORS - REAR/WATERDAM - REMOVAL)
panel and reconnect i t to the door wi re harness.
remove the two nuts attachi ng the gl ass to the wi n-
dow regul ator. (Fi g. 11)
(4) Remove the stabi l i zer nut.
(8) Di sconnect the el ectri cal connector. (Fi g. 12)
(9) Remove the l ower regul ator bol t and l oosen the
upper two. (Fi g. 12)
(11) Remove the regul ator through the hol e i n the
i nner door panel .
INSTALLATION
i nner door panel .
(3) I nstal l the l ower regul ator bol t and ti ghten al l
three to 10 Nm (89 i n. l bs.).
(5) Posi ti on the stabi l i zer, i nstal l the nut and
(6) Rai se the regul ator to the posi ti on shown i n
(Fi g. 11).
(89 i n. l bs.).
Fig. 10 WINDOW CRANK REMOVAL TOOL
1 - WINDOW CRANK REMOVAL TOOL
2 - WINDOW CRANK
Fig. 11 GLASS POSITIONING
1 - SIGHT WINDOW
2 - STABILIZER NUT
3 - GLASS LIFT PLATE
TRIM PANEL (Continued)
DOORS - REAR/WATERDAM - I NSTALLATI ON)
WINDOW REGULATOR -
MANUAL
REMOVAL
DOORS - REAR/WATERDAM - REMOVAL)
(2) Rei nstal l the wi ndow handl e and rai se the wi n-
dow to the posi ti on shown and remove the nuts. (Fi g.
11)
(3) Remove the stabi l i zer nuts. (Fi g. 13)
(7) Remove the two back regul ator bol ts and
l oosen the front two.
(9) Remove the regul ator through the hol e i n the
i nner door panel .
INSTALLATION
i nner door panel .
(3) I nstal l the back regul ator bol ts and ti ghten al l
four to 10 Nm (89 i n. l bs.).
the posi ti on shown i n (Fi g. 11).
(89 i n. l bs.).
the posi ti on shown i n (Refer to 23 - BODY/DOORS -
REAR/WATERDAM - I NSTALLATI ON)
Fig. 12 WINDOW REGULATOR MOTOR
1 - REGULATOR BOLTS
2 - REGULATOR MOTOR
3 - ELECTRICAL CONNECTOR.
Fig. 13 WINDOW REGULATOR - MANUAL
1 - DOOR
2 - REGULATOR BOLTS (4)
4 - REGULATOR
WINDOW REGULATOR - POWER (Continued)
EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
BODY ISOLATORS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
CARGO BOX
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
CARGO BOX - TIE DOWN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
COWL GRILLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
EXTERIOR NAME PLATES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
FRONT FENDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
FUEL FILL DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
GRILLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
GRILLE FRAME
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
REAR WHEELHOUSE SPLASH SHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
SIDE VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
UPPER RADIATOR CROSSMEMBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
SIDE VIEW MIRROR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
REAR FENDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
BODY SIDE MOLDINGS
REMOVAL
NOTE: Body side moldings are attached to the body
panels with adhesive tape.
(1) Appl y a l ength of maski ng tape on the body
panel , paral l el to the top edge of the mol di ng and to
one end to use as a gui de for i nstal l ati on, i f neces-
sary.
(2) I f temperature i s bel ow 21C (70F) warm
mol di ng wi th a heat l amp or gun. Do not exceed 52C
(120F) when heati ng mol di ng.
(3) Usi ng a tri m sti ck C-4755 or equi val ent,
remove and di scard the mol di ng from the outsi de of
the body panel .
INSTALLATION
(1) Thoroughl y cl ean al l resi due from the body si de
mol di ng attachment area of the body panel .
(2) Wi pe area wi th a cl ean l i nt free cl oth moi st-
ened wi th a 50% sol uti on of water and al cohol and
wi pe dry i mmedi atel y wi th a dry l i nt free cl oth.
(3) Appl y new body si de mol di ng usi ng the gui de
tape on the body panel and appl y consi stent and uni -
form pressure of approxi matel y 40 p.s.i . over the
enti re surface of the mol di ng.
BODY ISOLATORS
REMOVAL
(1) Loosen al l cab to frame mounti ng bol ts (si x
standard cab, ei ght quad cab). (Fi g. 1)
(2) Remove the mounti ng bol ts and rebound cush-
i ons
(3) Usi ng a fl oor jack and bl ock of wood under the
cab si l l , l i ft the body to gai n access to the i sol ators.
(4) Remove the i sol ators.
(5) I nstal l new i sol ators and repeat steps one
through 4, for the opposi te si de.
23 - 36 EXTERIOR DR
INSTALLATION
(1) For the rear i sol ators i nstal l the rebound cush-
i ons, washers, rei nforcement pl ates and bol ts. (Fi g. 1)
(2) I nstal l the remai ni ng rebound cushi ons and
bol ts.
CARGO BOX
REMOVAL
(1) Di sconnect the fuel fi l l hose and vent hose.
FUEL TANK - REMOVAL)
(2) Di sconnect the tai l l amp wi re harness.
(3) Remove the cargo box bol ts. (Fi g. 2) or (Fi g. 3)
(4) Remove the cargo box.
INSTALLATION
(1) I nstal l the cargo box and i nstal l the bol ts.
(3) Connect the fuel fi l l and vent hoses. (Refer to
14 - FUEL SYSTEM/FUEL DELI VERY/FUEL TANK
- I NSTALLATI ON)
(4) Connect the tai l l amp wi re harness.
Fig. 1 BODY ISOLATORS - TYPICAL
1 - CAB SILL
2 - ISOLATORS
3 - REBOUND CUSHION
4 - WASHER (REAR ISOLATOR ONLY)
5 - BOLTS
6 - REINFORCEMENT PLATE (REAR ISOLATOR ONLY)
Fig. 2 SHORT CARGO BOX
1 - CARGO BOX
2 - FRAME
Fig. 3 LONG CARGO BOX
1 - CARGO BOX
2 - FRAME
DR EXTERIOR 23 - 37
BODY ISOLATORS (Continued)
CARGO BOX - TIE DOWN
REMOVAL
(1) Remove the bol ts and remove the ti e down
cl eat. (Fi g. 4)
INSTALLATION
(1) I nstal l the ti e down cl eat and i nstal l the bol ts.
COWL GRILLE
REMOVAL
(1) Remove the wi per arms. (Refer to 8 - ELEC-
TRI CAL/WI PERS/WASHERS/WI PER ARMS -
REMOVAL)
(2) Di sconnect the washer hose.
(3) Remove the hood seal .
(4) Remove the si x push pi n fasteners from the
front of the gri l l e. (Fi g. 5)
(5) Remove the two rear corner screws and remove
the gri l l es.
INSTALLATION
(1) I nstal l the gri l l and i nstal l the two rear corner
screws.
(2) I nstal l the si x push pi n fasteners al ong the
front of the gri l l e.
(3) I nstal l the hood seal .
(4) Connect the washer hose.
(5) I nstal l the wi per arms. (Refer to 8 - ELECTRI -
CAL/WI PERS/WASHERS/WI PER ARMS - I NSTAL-
LATI ON)
EXTERIOR NAME PLATES
REMOVAL
NOTE: Exterior name plates are attached to body
panels with adhesive tape.
(1) Appl y a l ength of maski ng tape on the body,
paral l el to the top edge and one end of the name
pl ate to use as a gui de for i nstal l ati on, i f necessary.
embl em wi th a heat l amp or gun. Do not exceed 52C
(120F) when heati ng name pl ate.
remove and di scard the name pl ate.
INSTALLATION
(1) Thoroughl y cl ean al l resi due from the name
pl ate attachment area of the body panel .
(2) Wi pe area wi th a cl ean l i nt free cl oth moi st-
ened wi th a 50% sol uti on of water and al cohol and
wi pe dry i mmedi atel y wi th a dry l i nt free cl oth.
(3) Remove protecti ve cover from adhesi ve tape on
back of name pl ate.
(4) Posi ti on name pl ate properl y on the body panel .
(5) Appl y consi stent and uni form pressure over the
enti re surface of the name pl ate, wi th pal m of hand.
embl em wi th a heat l amp or gun to assure adhesi on.
Do not exceed 52C (120F) when heati ng name
pl ate.
Fig. 4 TIE DOWN CLEAT
1 - BOLTS (2)
2 - CLEAT
Fig. 5 COWL GRILLE
2 - COWL GRILLE
3 - SCREWS (2)
23 - 38 EXTERIOR DR
FRONT FENDER
REMOVAL
(1) Remove the antenna, i f equi pped. (Refer to 8 -
ELECTRI CAL/AUDI O/ANTENNA BODY & CABLE -
REMOVAL)
(2) Remove the battery tray, i f requi red. (Refer to 8
- ELECTRI CAL/BATTERY SYSTEM/TRAY -
REMOVAL)
(3) Remove the cowl gri l l e. (Refer to 23 - BODY/
EXTERI OR/COWL GRI LLE - REMOVAL)
(4) Remove the headl amp uni t. (Refer to 8 - ELEC-
LAMP UNI T - REMOVAL)
(5) Remove the wheel house spl ash shi el d. (Refer to
23 - BODY/EXTERI OR/FRONT WHEELHOUSE
SPLASH SHI ELD - REMOVAL)
(6) Remove the i nsi de and l ower bol ts. (Fi g. 6)
(7) Remove the two bol ts bel ow the headl amp.
(8) Remove the hi nge support bol t at the cowl .
(9) Remove the three bol ts al ong the fender rai l .
INSTALLATION
(1) I nstal l the three bol ts al ong the upper fender
rai l and ti ghten to 9 Nm (80 i n. l bs.).
(2) I nstal l the upper hi nge support bol t at the cowl
(3) I nstal l the two bol ts bel ow the headl amp and
(4) I nstal l the i nsi de and l ower bol ts and ti ghten
to 17 Nm (13 ft. l bs.).
(5) Check the fender posi ti oni ng and adjust as
requi red by addi ng shi ms. (Refer to 23 - BODY/
CATI ONS)
(6) I nstal l the wheel house spl ash shi el d. (Refer to
SPLASH SHI ELD - I NSTALLATI ON)
(7) I nstal l the headl amp uni t. (Refer to 8 - ELEC-
(8) I nstal l the cowl gri l l e. (Refer to 23 - BODY/EX-
TERI OR/COWL GRI LLE - I NSTALLATI ON)
(9) I nstal l the battery tray, i f requi red. (Refer to 8
- ELECTRI CAL/BATTERY SYSTEM/TRAY -
I NSTALLATI ON)
(10) I nstal l the antenna, i f requi red. (Refer to 8 -
ELECTRI CAL/AUDI O/ANTENNA BODY & CABLE -
I NSTALLATI ON)
FUEL FILL DOOR
REMOVAL
(1) Open fi l l door and remove the bol ts. (Fi g. 7)
(2) Remove the door.
INSTALLATION
(1) I nstal l the fuel fi l l door.
l bs.).
Fig. 6 FRONT FENDER
1 - HOOD HINGE SUPPORT BOLT (1)
2 - HOOD HINGE
3 - INNER BOLT (1)
4 - FRONT BOLTS (2)
5 - LOWER BOLT INSERT
6 - FENDER
7 - UPPER BOLTS (3)
Fig. 7 FUEL FILL DOOR
1 - FUEL FILL DOOR
2 - BOLTS (2)
DR EXTERIOR 23 - 39
GRILLE
REMOVAL
(1) Open the hood.
(2) Remove the si x l ower screws. (Fi g. 8)
(3) Remove the si x upper nuts and separate the
gri l l e from the gri l l e frame.
INSTALLATION
(1) Posi ti on the gri l l e onto the gri l l e frame.
(2) I nstal l the si x upper nuts.
(3) I nstal l the si x l ower screws.
GRILLE FRAME
REMOVAL
(1) Remove the gri l l e. (Refer to 23 - BODY/EXTE-
RI OR/GRI LLE - REMOVAL)
(2) Remove the screws and remove the gri l l e
frame. (Fi g. 9)
INSTALLATION
(1) I nstal l the gri l l e frame and i nstal l the si x
screws.
(2) I nstal l the gri l l e. (Refer to 23 - BODY/EXTERI -
OR/GRI LLE - I NSTALLATI ON)
Fig. 8 GRILLE
1 - NUTS (6)
2 - HOOD
3 - GRILLE
4 - GRILLE FRAME
5 - SCREWS (6)
Fig. 9 GRILLE FRAME
1 - HOOD
2 - GRILLE FRAME
3 - SCREWS (6)
23 - 40 EXTERIOR DR
FRONT WHEELHOUSE
SPLASH SHIELD
REMOVAL
(1) Remove the three screws at the fender. (Fi g.
10)
(2) Remove the el ectri cal connector push pi n fas-
tener.
(3) Remove the fi ve i nsi de screws and remove the
spl ash shi el d.
INSTALLATION
(1) I nstal l the spl ash shi el d and posi ti on the front
edge i nto the support bracket on the bumper.
(2) I nstal l the fi ve i nner screws.
(3) I nstal l the three screws at the fender.
(4) I nstal l the el ectri cal connector push pi n fas-
tener.
REAR WHEELHOUSE SPLASH
SHIELD
REMOVAL
(1) Remove the screws and remove the shi el d. (Fi g.
11)
INSTALLATION
(1) I nstal l the spl ash shi el d and i nstal l the screws.
SIDE VIEW MIRROR
REMOVAL
(1) Remove the door tri m panel as necessary to
gai n access to the mi rror. (Refer to 23 - BODY/DOOR
- FRONT/TRI M PANEL - REMOVAL)
the nuts. (Fi g. 12)
(3) Squeeze the el ectri cal connector tabs and
remove the mi rror. (Fi g. 13)
Fig. 10 FRONT SPLASH SHIELD
1 - FENDER RAIL
2 - FENDER
3 - SCREWS (8)
4 - WHEELHOUSE SPLASH SHIELD
Fig. 11 REAR SPLASH SHIELD
1 - CARGO BOX
2 - SCREWS (3)
3 - SPLASH SHIELD
Fig. 12 SIDE VIEW MIRROR
1 - MIRROR
2 - NUTS (3)
DR EXTERIOR 23 - 41
INSTALLATION
(1) I nstal l the mi rror onto the door and engage the
el ectri cal connector tabs. (Fi g. 13)
l bs.).
TI ON)
UPPER RADIATOR
CROSSMEMBER
REMOVAL
(1) Remove the hood l atch. (Refer to 23 - BODY/
HOOD/LATCH - REMOVAL)
(2) Remove the radi ator and condenser bol ts. (Fi g.
14)
(Fi g. 15)
INSTALLATION
(1) I nstal l the crossmember and i nstal l the bol ts.
(3) I nstal l the radi ator and condenser bol ts and
(4) I nstal l the hood l atch. (Refer to 23 - BODY/
HOOD/LATCH - I NSTALLATI ON)
SIDE VIEW MIRROR GLASS
REMOVAL
WARNING: ALWAYS WEAR EYE AND HAND PRO-
TECTION WHEN SERVICING THE MIRROR ASSEM-
BLY. FAILURE TO OBSERVE THESE WARNINGS
MAY RESULT IN PERSONAL INJURY FROM BRO-
KEN GLASS.
Standard Mirror
(1) Posi ti on the mi rror gl ass so that i ts faci ng i n
toward the vehi cl e as far as possi bl e. (Fi g. 16)
Fig. 13 MIRROR ELECTRICAL CONNECTOR
1 - DOOR
2 - MIRROR STUDS
3 - CONNECTOR TABS
Fig. 14 CONDENSER/RADIATOR FASTENERS
1 - CONDENSER BOLT
2 - RADIATOR BOLT
3 - RADIATOR CROSSMEMBER
Fig. 15 RADIATOR CROSSMEMBER
1 - BOLTS (2)
2 - CROSSMEMBER
3 - BOLTS (2)
23 - 42 EXTERIOR DR
SIDE VIEW MIRROR (Continued)
(2) Di sengage the rear housi ng cover retai ni ng
tabs and remove the cover. (Fi g. 17)
(3) Di sengage the l ower gl ass retai ni ng tab to
motor. (Fi g. 18)
(4) Sl i de gl ass up and remove from motor.
(5) Di sconnect the two heated mi rror el ectri cal
connectors, i f equi pped.
Tow Package Mirror
(1) Posi ti on the mi rror i n the out posi ti on. (Fi g. 19)
(2) Rel ease the retai ni ng cl i p and separate the
gl ass.
(3) Di sconnect the four heated gl ass el ectri cal con-
nectors, i f equi pped. (Fi g. 20)
INSTALLATION
Standard Mirror
(1) Connect the two heated mi rror el ectri cal con-
nectors, i f equi pped. (Fi g. 21)
(2) Posi ti on the mi rror gl ass mounti ng hol es over
the four feet of the mi rror motor and sl i de down.
(Fi g. 22)
(3) Engage the l ower gl ass retai ni ng tab to the
motor. (Fi g. 18)
(4) Posi ti on the rear housi ng cover and seat the
retai ni ng tabs ful l y. (Fi g. 17)
Tow Package Mirror
(1) Make sure the retai ni ng cl i p i s seated i n the
cl osed posi ti on on the mi rror gl ass.
Fig. 16 STANDARD MIRROR POSITION
1 - RETAINING TABS (2)
2 - MIRROR HOUSING
3 - MIRROR GLASS
Fig. 17 STANDARD MIRROR HOUSING COVER
1 - MIRROR HOUSING COVER
2 - RETAINING TABS (3)
Fig. 18 STANDARD MIRROR RETAINING TAB
1 - MIRROR ASSEMBLY
2 - MIRROR GLASS LOWER RETAINING TAB
Fig. 19 TOW PACKAGE MIRROR POSITION
1 - MIRROR HOUSING ASSEMBLY
2 - MIRROR GLASS RETAINING CLIP
3 - MIRROR GLASS
DR EXTERIOR 23 - 43
SIDE VIEW MIRROR GLASS (Continued)
(2) Connect the heated mi rror el ectri cal connec-
tors, i f equi pped.
NOTE: Pressure must be applied equally over the
center portion of the mirror to engage the mirror
glass retaining clip fully.
(3) Posi ti on the gl ass over the motor mounti ng and
seat ful l y. Make sure the retai ni ng cl i p seats ful l y.
REAR FENDER
REMOVAL
(1) Remove the wheel house spl ash shi el d. (Refer
to 23 - BODY/EXTERI OR/REAR WHEELHOUSE
(2) Di sconnect the marker l amps el ectri cal connec-
tors.
(3) Remove the tai l l amp uni ts. (Refer to 8 -
TAI L LAMP UNI T - REMOVAL)
(4) Remove the two fender nuts. (Fi g. 23)
(5) Remove the rear i nner nuts bel ow the tai l
l amp. (Fi g. 24)
(6) Remove the two bol ts at the rear bottom edge.
(7) Remove the two bol ts at the front bottom edge.
(8) Remove the four i nner nuts front edge. (Fi g.
25)
(9) Loosen bol ts and l oosen the two fender support
brackets. (Fi g. 26)
CAUTION: Mask off the surrounding box area to
avoid damage to the painted surfaces.
(10) Li ft the fender up off the support brackets
and remove the fender.
INSTALLATION
CAUTION: Mask off the surrounding box area to
avoid damage to the painted surfaces during instal-
lation.
Fig. 20 TOW PACKAGE MIRROR GLASS
1 - HEATED GLASS ELECTRICAL CONNECTORS (IF EQUIPPED)
2 - MIRROR GLASS
3 - RETAINING CLIP
Fig. 21 STANDARD MIRROR INSTALLATION
1 - MIRROR GLASS
2 - UPPER AND LOWER RETAINING CLIPS
3 - HEATED MIRROR ELECTRICAL CONNECTORS (IF
EQUIPPED)
4 - MIRROR GLASS MOUNTING HOLES (4)
Fig. 22 STANDARD MIRROR ASSEMBLY
1 - HEATED MIRROR ELECTRICAL CONNECTORS (IF
EQUIPPED)
2 - MIRROR HOUSING
3 - HOUSING COVER LOCKING TABS
4 - MIRROR GLASS MOUNTING FEET (4)
23 - 44 EXTERIOR DR
SIDE VIEW MIRROR GLASS (Continued)
(1) Careful l y posi ti on the fender over the support
brackets.
(2) I nstal l the four i nner nuts al ong the front edge
of the fender and ti ghten to 7 Nm (60 i n. l bs.).
(3) I nstal l the two i nner nuts al ong the rear edge
of the fender bel ow the tai l l amp uni t and ti ghten to
7 Nm (60 i n. l bs.).
(4) Ti ghten the si x support bracket bol ts and
(5) I nstal l the bol ts al ong l ower edge of the fender
and ti ghten to 7 Nm (60 i n. l bs.).
(6) Connect the marker l amps el ectri cal connec-
tors.
23 - BODY/EXTERI OR/REAR WHEELHOUSE
(8) I nstal l the two nuts from wi thi n the tai l l amp
openi ng and ti ghten to 7 Nm (60 i n. l bs.).
(9) I nstal l the tai l l amp uni t. (Refer to 8 - ELEC-
Fig. 23 TAIL LAMP OPENING
1 - TAIL LAMP OPENING
2 - FENDER NUTS (2)
Fig. 24 LOWER REAR FASTENERS
1 - REAR FENDER NUTS (2)
2 - PICK-UP BOX INNER PANEL
Fig. 25 LOWER FRONT FASTENERS
1 - PICK-UP BOX INNER PANEL
2 - FRONT FENDER NUTS (4)
Fig. 26 SUPPORT BRACKET
1 - FENDER SUPPORT BRACKET (2)
2 - PICK-UP BOX
3 - BOLTS (3 PER BRACKET)
DR EXTERIOR 23 - 45
REAR FENDER (Continued)
HOOD
TABLE OF CONTENTS
page page
HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
HOOD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
LATCH RELEASE CABLE/HANDLE ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
LATCH STRIKER / SECONDARY CATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
SUPPORT CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
HINGE
REMOVAL
NOTE: It is not necessary to remove the hood to
replace one or both hinges. The hinges can be
replaced one at a time.
(1) Remove the cowl gri l l e. (Refer to 23 - BODY/
EXTERI OR/COWL GRI LLE - REMOVAL)
posi ti on of the hi nge on the hood.
(3) Remove the fender support bol t. (Fi g. 1)
(4) Remove the support cyl i nder. (Refer to 23 -
BODY/HOOD/SUPPORT CYLI NDER - REMOVAL)
(5) Remove the hood nuts.
(6) Remove the wheel house spl ash shi el d. (Refer to
(7) From i nsi de the fender, remove the two hi nge
bol ts. (Fi g. 2)
(8) Sl i de the hi nge forward and remove from the
fender rai l .
INSTALLATION
(1) I nstal l the hi nge and sl i de back i nto posi ti on
on the fender rai l .
(2) From i nsi de the fender, i nstal l the two hi nge
(3) I nstal l the hood nuts and l i ne up the marks
made previ ousl y.
(4) Ti ghten the nuts to 23 Nm (17 ft. l bs.).
(5) I nstal l the support cyl i nder. (Refer to 23 -
BODY/HOOD/SUPPORT CYLI NDER - I NSTALLA-
TI ON)
(6) I nstal l the fender support bol t and ti ghten to
11 Nm (8 ft. l bs.).
(7) Check hood fi t and adjust i f requi red. (Refer to
23 - BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECI FI CATI ONS)
(8) I nstal l the cowl gri l l e. (Refer to 23 - BODY/EX-
TERI OR/COWL GRI LLE - I NSTALLATI ON)
HOOD
REMOVAL
(1) Open the hood.
posi ti on of the hi nges on the hood.
(3) Remove the hood hi nge nuts and remove the
hood.
Fig. 1 HINGE/FENDER BOLT
1 - FENDER
2 - FENDER SUPPORT BOLT
3 - HINGE
23 - 46 HOOD DR
(4) Remove the gri l l e. (Refer to 23 - BODY/EXTE-
RI OR/GRI LLE - REMOVAL)
(5) Remove the hood l amp and ambi ent tempera-
ture sensor.
INSTALLATION
(1) I nstal l the hood l amp and ambi ent temperature
sensor.
(2) I nstal l the gri l l e. (Refer to 23 - BODY/EXTERI -
OR/GRI LLE - I NSTALLATI ON)
(3) I nstal l the hood and i nstal l the nuts.
(4) Li ne up the marks made previ ousl y and
ti ghten the nuts to 23 Nm (17 ft. l bs.).
(5) Check the hood fi t and adjust i f requi red.
(Refer to 23 - BODY/BODY STRUCTURE/GAP AND
LATCH
REMOVAL
(1) Open the hood.
posi ti on of the l atch on the radi ator crossmember.
(4) Di sconnect the hood l atch cabl e and remove the
l atch.
INSTALLATION
(1) Connect the hood l atch cabl e.
(2) I nstal l the l atch l i ni ng up the marks made pre-
vi ousl y and i nstal l the bol ts.
(4) Check hood fi t and adjust i f requi red. (Refer to
23 - BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECI FI CATI ONS)
LATCH RELEASE CABLE/
HANDLE ASSEMBLY
REMOVAL
(1) Remove the hood l atch. (Refer to 23 - BODY/
HOOD/LATCH - REMOVAL)
(2) Remove the batter tray. (Refer to 8 - ELECTRI -
CAL/BATTERY SYSTEM/TRAY - REMOVAL)
(3) Di sconnect the three cabl e push pi n fasteners.
(4) From i nsi de the cab l oosen the two handl e
screws and di sconnect the handl e from the i nstru-
ment panel bracket.
(5) Separate the grommet at the cowl panel and
remove cabl e through the cab.
INSTALLATION
(1) Route the cabl e/handl e assembl y through the
cowl panel and i nstal l the grommet.
(2) Posi ti on the handl e onto the i nstrument panel
bracket and ti ghten the screws.
(3) Route the cabl e al ong the fender rai l s and
i nstal l the three push pi n fasteners.
(4) I nstal l the l atch. (Refer to 23 - BODY/HOOD/
LATCH - I NSTALLATI ON)
(5) I nstal l the battery tray. (Refer to 8 - ELECTRI -
CAL/BATTERY SYSTEM/TRAY - I NSTALLATI ON)
LATCH STRIKER /
SECONDARY CATCH
REMOVAL
(1) Di sconnect and remove the secondary rel ease
handl e. (Fi g. 4)
(2) Remove the two bol ts and remove the stri ker/
catch assembl y.
Fig. 2 HINGE
1 - A-PILLAR
2 - HINGE
3 - BOLTS (2)
Fig. 3 LATCH
1 - HOOD LATCH
2 - HOOD LATCH CABLE
3 - BOLTS (2)
DR HOOD 23 - 47
HOOD (Continued)
INSTALLATION
(1) I nstal l the l atch stri ker/secondary catch and
i nstal l the bol ts.
(3) I nstal l the rel ease handl e and connect to the
secondary catch.
(4) Check the hood fi t and adjust i f requi red.
(Refer to 23 - BODY/BODY STRUCTURE/GAP AND
SUPPORT CYLINDER
REMOVAL
NOTE: The support cylinders can be replaced one
at a time.
(1) Open the hood and support.
NOTE: Lift the clips only enough to release the ball
studs. (Fig. 6)
(2) Usi ng a smal l fl at bl aded tool , or equi val ent,
rel ease the upper retai ni ng cl i ps whi l e pul l i ng the
bal l socket away from the bal l stud. (Fi g. 5)
CAUTION: Do not pull the supports from the middle
while removing.
(3) Pul l i ng at the ends onl y, remove the support
cyl i nder.
INSTALLATION
(1) Make sure the retai ni ng cl i ps are seated i nto
the bal l socket ful l y.
CAUTION: Do not install the support cylinders by
pressing at the center of the cylinder. Press the
ends only.
(2) I nstal l the support cyl i nder over the bal l studs
wi th the thi n end connected to the body si de of the
hi nge and the retai ni ng cl i ps snappi ng i nto pl ace.
Fig. 4 HOOD LATCH STRIKER/SECONDARY CATCH
1 - GRILLE
2 - LATCH STRIKER/SECONDARY CATCH
3 - BOLTS (2)
4 - SECONDARY CATCH RELEASE HANDLE
5 - GRILLE FRAME
Fig. 5 UPPER SUPPORT CYLINDER REMOVAL -
TYPICAL
1 - BALL SOCKET
2 - RETAINING CLIP
3 - FLAT BLADED TOOL
4 - BALL STUD
Fig. 6 UPPER SUPPORT CYLINDER RETAINING
CLIP
1 - RETAINING CLIP
2 - BALL SOCKET
3 - BALL STUD
23 - 48 HOOD DR
LATCH STRIKER / SECONDARY CATCH (Continued)
INSTRUMENT PANEL
TABLE OF CONTENTS
page page
CLUSTER BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
ASH RECEIVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51
CUP HOLDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51
GLOVE BOX
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
GLOVE BOX LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTRUMENT PANEL ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTRUMENT PANEL HEADLAMP SWITCH
BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTRUMENT PANEL CENTER BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTRUMENT PANEL DRIVER SIDE BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTRUMENT PANEL TOP COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTRUMENT PANEL LOWER SURROUND
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 59
STEERING COLUMN OPENING COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60
STEERING COLUMN OPENING SUPPORT
BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60
STORAGE BIN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
CLUSTER BEZEL
REMOVAL
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
AND POSSIBLE PERSONAL INJURY.
(1) Remove the headl amp swi tch bezel . (Refer to
PANEL SWI TCH BEZEL - REMOVAL)
(2) Remove the center bezel . (Refer to 23 - BODY/
I NSTRUMENT PANEL/I NSTRUMENT PANEL
CENTER BEZEL - REMOVAL)
(3) Remove the two top screws. (Fi g. 1)
(4) Usi ng a tri m sti ck C-4755 or equi val ent, sepa-
rate the two l ower cl i ps.
(5) Di sengage the two top attachment bosses and
remove the bezel .
INSTALLATION
(1) Posi ti on the cl uster bezel over the cl uster and
seat the outer bosses over the posts on the l eft and
ri ght si des.
DR INSTRUMENT PANEL 23 - 49
(2) Snap the top edge of the bezel i nto pl ace ful l y.
(3) Seat the two bottom cl i ps ful l y.
(4) I nstal l the two top screws.
(5) I nstal l the center bezel (Refer to 23 - BODY/
CENTER BEZEL - I NSTALLATI ON)
(6) I nstal l the headl amp swi tch bezel . (Refer to 23
PANEL SWI TCH BEZEL - I NSTALLATI ON)
ASH RECEIVER
REMOVAL
(1) Open ash recei ver and pl ace hand i nsi de. (Fi g.
2)
(2) Appl y force wi th an abrupt downward moti on
and rol l rearward. (Fi g. 3)
(3) Di sl odge and rol l ash recei ver out of panel to
remove.
Fig. 1 CLUSTER BEZEL
2 - SCREWS (2)
3 - CLUSTER BEZEL
4 - CLIP FASTENERS (2)
Fig. 2 ASH RECEIVER
1 - ASH RECEIVER
2 - CUP HOLDER
Fig. 3 ASH RECEIVER REMOVAL
1 - LOCKING TABS
2 - CUP HOLDER
3 - ASH RECEIVER
23 - 50 INSTRUMENT PANEL DR
CLUSTER BEZEL (Continued)
INSTALLATION
(1) Seat the bottom of the recei ver i nto posi ti on.
(2) Pi vot the recei ver forward and seat the retai n-
i ng cl i ps ful l y.
CUP HOLDER
REMOVAL
(1) Remove the center bezel .(Refer to 23 - BODY/
(2) Remove the ai rbag control modul e tri m cover.
(Fi g. 4)
(3) Open the cuphol der and fol d down the i nner
panel .
(4) Remove the two i nner screws. (Fi g. 5)
(5) Remove the remai ni ng two top and bottom
screws and remove the cup hol der. (Fi g. 6)
INSTALLATION
Fig. 4 INSTRUMENT PANEL COVERS
1 - TOP COVER
3 - AIR BAG MODULE COVER
4 - END CAP
Fig. 5 CUPHOLDER - INNER FASTENERS
1 - CUPHOLDER
2 - INNER SCREWS (2)
ASH RECEIVER (Continued)
(1) I nstal l the cuphol der and i nstal l the two upper
screws from the l eft to the ri ght.
(2) I nstal l the l ower two screws from the l eft to
the ri ght.
(3) Fol d down the i nner cover and i nstal l the two
i nner screws.
(4) I nstal l the center bezel . (Refer to 23 - BODY/
(5) I nstal l the ai rbag control modul e tri m cover.
GLOVE BOX
REMOVAL
(1) Parti al l y open the gl ove box.
(2) From the i nsi de of the box press down on the
rearward edge of the bi n and l ower the gl ove box
ful l y past the stops.
(3) Li ft the box assembl y off of the hi nges and
remove.
INSTALLATION
(1) Engage the gl ove box hi nges and parti al l y
cl ose.
(2) From the i nsi de of the box press down on the
rearward edge of the bi n and rai se the gl ove box ful l y
past the stops.
(3) Check for proper gl ove box operati on.
GLOVE BOX LATCH
REMOVAL
(1) Remove the gl ove box. (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - REMOVAL)
(2) Remove the 11 screws and separate the box
and i nner panel from the outer door.
(3) Remove the two l atch screws and remove the
l atch.
INSTALLATION
(1) I nstal l the l atch and i nstal l the two screws.
(2) I nstal l the door i nner cover and box and i nstal l
the 11 screws.
(3) I nstal l the gl ove box. (Refer to 23 - BODY/I N-
TI ON)
INSTRUMENT PANEL
ASSEMBLY
REMOVAL
Fig. 6 CUPHOLDER - OUTER FASTENERS
1 - SCREWS (4)
2 - CUPHOLDER
CUP HOLDER (Continued)
(1) Remove the l eft a-pi l l ar tri m. (Refer to 23 -
BODY/I NTERI OR/A-PI LLAR TRI M/GRAB HANDLE
- REMOVAL)
(2) Remove the top cover. (Refer to 23 - BODY/I N-
STRUMENT PANEL/I NSTRUMENT PANEL TOP
COVER - REMOVAL)
(3) Di sconnect the headl i ner harness el ectri cal con-
nector at the a-pi l l ar.
(4) Usi ng a tri m sti ck C-4755 or equi val ent, from
the notch on the bottom, remove the l eft si de cover.
(Fi g. 20)
(5) Remove the steeri ng col umn. (Refer to 19 -
STEERI NG/COLUMN - REMOVAL)
(6) Remove the two bol ts at the col umn support
bracket. (Fi g. 7)
(7) Remove the l eft cowl tri m panel . (Refer to 23 -
BODY/I NTERI OR/COWL TRI M - REMOVAL)
(8) Remove the i nstrument panel dri vers si de
bezel . (Refer to 23 - BODY/I NSTRUMENT PANEL/
I NSTRUMENT PANEL DRI VERS SI DE BEZEL -
REMOVAL)
(9) Remove the l eft si de mounti ng bol ts. (Fi g. 8)
(10) Di sconnect the wi re harness el ectri cal connec-
tors above the brake pedal . (Fi g. 9)
(11) Loosen the screws and remove the hood
rel ease handl e from the bracket.
(12) Di sconnect the park brake rel ease handl e
actuator rod.
(13) Remove the ai r bag control modul e tri m cover,
i f equi pped. (Fi g. 20)
Fig. 7 COLUMN SUPPORT
1 - INSTRUMENT PANEL CLUSTER BEZEL
2 - STEERING COLUMN SUPPORT BRACKET
3 - BOLTS
Fig. 8 LEFT SIDE MOUNTING
1 - A-PILLAR
Fig. 9 WIRE HARNESS CONNECTORS
1 - BULKHEAD CONNECTORS
2 - INSTRUMENT PANEL HARNESS CONNECTORS
INSTRUMENT PANEL ASSEMBLY (Continued)
(14) Remove the fl oor consol e, i f equi pped. (Refer
to 23 - BODY/I NTERI OR/FLOOR CONSOLE -
REMOVAL)
(15) Remove the center bracket bol ts. (Fi g. 10)
(16) Di sconnect the ai r bag control modul e el ectri -
cal connector.
(17) Remove the ri ght cowl tri m cover. (Refer to 23
- BODY/I NTERI OR/COWL TRI M - REMOVAL)
(18) Di sconnect the two el ectri cal connectors. (Fi g.
11)
(19) Di sconnect the radi o antenna. (Fi g. 12)
(20) Remove the one HVAC screw. (Fi g. 13)
(21) Usi ng a tri m sti ck C-4755 or equi val ent, from
the notch on the bottom, remove the ri ght end cap.
(Fi g. 14)
(22) Remove the ri ght a-pi l l ar tri m. (Refer to 23 -
BODY/I NTERI OR/A-PI LLAR TRI M/GRAB HANDLE
- REMOVAL)
Fig. 10 CENTER MOUNTING BOLTS
2 - BOLTS
Fig. 11 RIGHT WIRE HARNESS CONNECTIONS
1 - COWL SIDE PANEL
Fig. 12 ANTENNA CONNECTION
1 - ANTENNA CABLE
2 - RADIO CABLE
Fig. 13 HVAC/INSTRUMENT PANEL MOUNTING
1 - HVAC
2 - MOUNTING SCREW
3 - LOWER SURROUND SCREWS
4 - GLOVE BOX OPENING
(23) Remove the two ri ght si de mounti ng bol ts on
the a-pi l l ar and one ri ght mounti ng bol t on the cowl
si de panel . (Fi g. 14)
(24) Remove the four top i nstrument panel screws.
(Fi g. 15)
(25) Remove the two top i nstrument panel bol ts
and remove the i nstrument panel .
INSTALLATION
(1) Posi ti on the i nstrument panel assembl y i n
vehi cl e.
(2) Route the park brake rel ease rod through the
i nstrument panel . (Fi g. 16)
(3) I nstal l the i nstrument panel onto the l eft si de
gui de pi n and the ri ght si de gui de hook.
(4) I nstal l the l eft si de mounti ng bol ts and ti ghten
to 12 Nm (9 ft. l bs.).
(5) I nstal l the i nstrument panel dri vers si de bezel .
STRUMENT PANEL DRI VERS SI DE BEZEL -
I NSTALLATI ON)
(6) I nstal l the l eft cowl tri m panel . (Refer to 23 -
BODY/I NTERI OR/COWL TRI M - I NSTALLATI ON)
(7) Connect the headl i ner harness el ectri cal con-
nector at the a-pi l l ar.
Fig. 14 PASSENGER SIDE MOUNTING
2 - RIGHT SIDE MOUNTING HOOK
3 - A-PILLAR
4 - END CAP
Fig. 15 UPPER COWL PANEL BOLTS
1 - COWL PANEL
2 - FORWARD MOST SCREWS (4)
3 - BOLT INSERTS (4)
4 - REARWARD BOLTS (2)
Fig. 16 BRAKE RELEASE ROD
1 - PARK BRAKE RELEASE HANDLE
2 - PARK BRAKE RELEASE ROD
(8) I nstal l the l eft a-pi l l ar tri m. (Refer to 23 -
BODY/I NTERI OR/A-PI LLAR TRI M - I NSTALLA-
TI ON)
(9) Posi ti on the l eft end cap and seat the attach-
ment cl i ps ful l y.
(10) I nstal l the ri ght si de mounti ng bol ts on the
a-pi l l ar and one ri ght mounti ng bol t on the cowl si de
panel and ti ghten to 12 Nm (9 ft. l bs.).
(11) I nstal l the ri ght a-pi l l ar tri m panel . (Refer to
23 - BODY/I NTERI OR/A-PI LLAR TRI M - I NSTAL-
LATI ON)
(12) Posi ti on the ri ght end cap and seat the
attachment cl i ps ful l y.
(13) I nstal l the one HVAC mounti ng screw.
(14) Connect the radi o antenna.
(15) Connect the two el ectri cal connectors at the
ri ght cowl panel .
(16) I nstal l the ri ght cowl tri m cover. (Refer to 23 -
(17) Connect the ai r bag control modul e el ectri cal
connector.
(18) I nstal l the center bracket bol ts and ti ghten to
12 Nm (9 ft. l bs.).
(19) I nstal l the fl oor consol e, i f equi pped. (Refer to
23 - BODY/I NTERI OR/FLOOR CONSOLE - I NSTAL-
LATI ON)
(20) I nstal l the ai r bag control modul e cover, i f
equi pped.
(21) Connect the park brake rel ease handl e actua-
tor rod.
(22) I nstal l the hood rel ease handl e and ti ghten
the screws.
(23) I nstal l the two bol ts at the col umn support
bracket and ti ghten to 14 Nm (10 ft. l bs.).
(24) I nstal l the steeri ng col umn. (Refer to 19 -
STEERI NG/COLUMN - I NSTALLATI ON)
(25) Connect the wi re harness el ectri cal connectors
above the brake pedal .
(26) I nstal l the two top i nstrument panel bol ts and
(27) I nstal l the four top i nstrument panel screws.
(28) I nstal l the i nstrument panel top cover. (Refer
PANEL TOP COVER - I NSTALLATI ON)
INSTRUMENT PANEL
HEADLAMP SWITCH BEZEL
REMOVAL
rel ease the top cl i ps on the steeri ng col umn openi ng
cover and the l ower dri vers si de bezel .
rel ease the swi tch bezel . (Fi g. 17)
the bezel .
INSTALLATION
Fig. 17 HEADLIGHT SWITCH BEZEL
1 - SWITCH BEZEL
4 - HEADLIGHT SWITCH
(2) Posi ti on the swi tch bezel and seat the attach-
ment cl i ps ful l y.
(3) Seat the cl i ps on the steeri ng col umn openi ng
cover and the l ower dri vers si de bezel ful l y.
INSTRUMENT PANEL CENTER
BEZEL
REMOVAL
CAUTION: When removing and installing the center
bezel, use tape or other suitable material to protect
the cupholder and ash receiver from damage.
cabl e.
(2) Remove the steeri ng col umn openi ng cover.
I NG COLUMN OPENI NG COVER - REMOVAL)
(3) Open the ashtray and cup hol der.
(4) Remove the one center bezel retai ni ng screw
(Fi g. 18).
CAUTION: Extreme care must be taken not to
scratch the ashtray door while removing the instru-
ment panel center bezel. Apply masking tape to the
ashtray door if the center bezel is not being com-
pletely removed from the instrument panel.
(5) Usi ng a tri m sti ck C-4755 or equi val ent, gentl y
pry the center bezel free from the i nstrument panel .
(6) Worki ng behi nd the center bezel , di sconnect al l
el ectri cal connectors and remove the bezel .
INSTALLATION
CAUTION: When removing and installing the center
bezel, use tape or other suitable material to protect
the cupholder and ash receiver from damage.
(1) Worki ng behi nd the center bezel , connect al l
el ectri cal connectors.
(2) Gentl y i nstal l the center bezel on the i nstru-
ment panel by pushi ng strai ght i n and seat the
(3) I nstal l the one center bezel screw.
(4) I nstal l the steeri ng col umn openi ng cover.
TI ON)
Fig. 18 CENTER BEZEL
2 - CENTER BEZEL
3 - SCREW
INSTRUMENT PANEL HEADLAMP SWITCH BEZEL (Continued)
INSTRUMENT PANEL DRIVER
SIDE BEZEL
REMOVAL
(1) Usi ng a tri m sti ck C-4755 or equi val ent, at
notch i n the bottom, remove the dri vers si de endcap.
(2) Remove the dri vers si de cowl tri m panel . (Refer
to 23 - BODY/I NTERI OR/COWL TRI M - REMOVAL)
(3) Remove the two screws. (Fi g. 19)
rel ease the top cl i ps and ti l t the bezel down.
(5) Di sconnect the adjustabl e pedal swi tch el ectri -
cal connector, i f equi pped.
(6) Lower the bezel down ful l y and remove from
the l ower hooks.
INSTALLATION
(1) Posi ti on the bezel onto the l ower hooks and l i ft
up.
(2) Connect the adjustabl e pedal swi tch el ectri cal
connector, i f equi pped.
(3) Seat the upper attachment cl i ps ful l y.
(4) I nstal l the two screws.
(5) Posi ti on the endcap and seat ful l y.
(6) I nstal l the dri vers si de cowl tri m panel . (Refer
to 23 - BODY/I NTERI OR/COWL TRI M - I NSTALLA-
TI ON)
INSTRUMENT PANEL TOP
COVER
REMOVAL
(1) Usi ng a tri m sti ck C-4755 or equi val ent, pry up
on the rear of the top cover and rel ease the attach-
ment cl i ps.
(2) Pul l the top cover backwards to rel ease the
remai ni ng cl i ps and remove the cover.
Fig. 19 LOWER DRIVERS SIDE BEZEL
1 - SCREWS (2)
2 - ADJUSTABLE PEDAL SWITCH (if equipped)
3 - PEDAL SWITCH ELECTRICAL CONNECTOR
4 - BEZEL
INSTALLATION
(1) Posi ti on the top cover and ful l y seat the front
cl i ps by pushi ng the cover forward and down.
(2) Ful l y seat the rear cl i ps.
INSTRUMENT PANEL LOWER
SURROUND
REMOVAL
(1) Usi ng a tri m sti ck C-4755 or equi val ent, at
notch i n the bottom, remove the passenger si de end-
cap.
(2) Remove the passenger si de cowl tri m panel .
(Refer to 23 - BODY/I NTERI OR/COWL TRI M -
REMOVAL)
(3) Remove the gl ove box. (Refer to 23 - BODY/I N-
STRUMENT PANEL/GLOVE BOX - REMOVAL)
(4) Remove the cup hol der, i f equi pped. (Refer to
23 - BODY/I NSTRUMENT PANEL/CUP HOLDER -
REMOVAL)
(5) Remove the storage bi n, i f equi pped. (Refer to
23 - BODY/I NSTRUMENT PANEL/STORAGE BI N -
REMOVAL)
(6) Remove the ash recei ver. (Refer to 23 - BODY/
I NSTRUMENT PANEL/ASH RECEI VER -
REMOVAL)
(8) Remove the 12 screws around the gl ove box
openi ng.
(9) Remove the ni ne remai ni ng screws around the
cup hol der/storage bi n and ash recei ver area and
remove the surround.
(10) Di sconnect the 12V power outl et el ectri cal
connector.
INSTALLATION
(1) I nstal l the surround and i nstal l al l 21 screws.
TI ON)
Fig. 20 INSTRUMENT PANEL COVERS
1 - TOP COVER
3 - AIR BAG MODULE COVER
4 - END CAP
INSTRUMENT PANEL TOP COVER (Continued)
(3) I nstal l the storage bi n, i f equi pped. (Refer to 23
- BODY/I NSTRUMENT PANEL/STORAGE BI N -
I NSTALLATI ON)
(4) I nstal l the cup hol der, i f equi pped. (Refer to 23
- BODY/I NSTRUMENT PANEL/CUP HOLDER -
I NSTALLATI ON)
(5) I nstal l the gl ove box. (Refer to 23 - BODY/I N-
TI ON)
(6) I nstal l the ash recei ver. (Refer to 23 - BODY/
I NSTRUMENT PANEL/ASH RECEI VER - I NSTAL-
LATI ON)
(7) I nstal l the passenger si de cowl tri m panel .
(Refer to 23 - BODY/I NTERI OR/COWL TRI M -
I NSTALLATI ON)
(8) Posi ti on the passenger si de end cap and seat
ful l y.
STEERING COLUMN OPENING
COVER
REMOVAL
(1) Remove the two l ower screws. (Fi g. 21)
rel ease the upper cl i ps and remove the cover.
INSTALLATION
(1) Posi ti on the cover and seat the upper cl i ps
ful l y.
(2) I nstal l the two l ower screws.
STEERING COLUMN OPENING
SUPPORT BRACKET
REMOVAL
(2) Remove the two screws and remove the di ag-
nosti c connector.
(3) Loosen the screws and remove the hood rel ease
handl e from the bracket.
(4) Remove the two bracket screws and sl i de
upward off the l ocati ng tabs to remove. (Fi g. 22)
INSTALLATION
(1) Posi ti on the bracket onto the l ocati ng tabs and
sl i de down.
(2) I nstal l the two screws.
(3) I nstal l the di agnosti c connector and i nstal l the
two screws.
(4) I nstal l the hood rel ease handl e and ti ghten the
screws.
Fig. 21 STEERING COLUMN OPENING COVER
1 - SCREWS (2)
2 - COVER
INSTRUMENT PANEL LOWER SURROUND (Continued)
TI ON)
STORAGE BIN
REMOVAL
(1) Remove the center bezel . (Refer to 23 - BODY/
(2) Remove the fl oor consol e. (Refer to 23 - BODY/
I NTERI OR/FLOOR CONSOLE - REMOVAL)
(3) Remove the four screws and remove the bi n.
(Fi g. 23)
INSTALLATION
(1) I nstal l the storage bi n and i nstal l the four
screws from l eft to ri ght.
(2) I nstal l the fl oor consol e. (Refer to 23 - BODY/
I NTERI OR/FLOOR CONSOLE - I NSTALLATI ON)
(3) I nstal l the center bezel . (Refer to 23 - BODY/
Fig. 22 COLUMN OPENING BRACKET
1 - LOCATING TABS
3 - REINFORCEMENT BRACKET
4 - SCREWS (2)
Fig. 23 STORAGE BIN
1 - SCREWS (4)
2 - STORAGE BIN
STEERING COLUMN OPENING SUPPORT BRACKET (Continued)
INTERIOR
TABLE OF CONTENTS
page page
INTERIOR
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4WD FLOOR SHIFT BOOT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 62
A-PILLAR TRIM/GRAB HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63
B-PILLAR LOWER TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64
B-PILLAR UPPER TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64
CARPETS AND FLOOR MATS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 65
COAT HOOK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66
COWL TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66
C-PILLAR LOWER TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
C-PILLAR UPPER TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
FLOOR CONSOLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67
HEADLINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68
B-PILLAR GRAB HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68
REAR CAB BACK PANEL TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69
REAR VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION - REAR VIEW MIRROR
SUPPORT BRACKET. . . . . . . . . . . . . . . . . . . 70
SUN VISOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
SUN VISOR SUPPORT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
BODY VENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
REAR DOOR SILL TRIM COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
LOAD FLOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 72
LOAD FLOOR SUPPORT CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 72
INTERIOR
CAUTION
CAUTION:: Do not attempt to remove interior trim
panels/moldings without first removing the neces-
sary adjacent panels. To avoid damaging the pan-
els, ensure that all the screws and clips are
removed before attempting to remove an interior
trim panel/molding. Trim panels are somewhat flex-
ible but can be damaged if handled improperly.
4WD FLOOR SHIFT BOOT
REMOVAL
(1) Usi ng a smal l pry bar or equi val ent, remove
the i nsert, the nut and remove the shi fter knob. (Fi g.
2)
the boot from the consol e. (Fi g. 1)
INSTALLATION
(1) Posi ti on the shi ft boot over the shi fter l ever
ful l y seat onto the consol e.
23 - 62 INTERIOR DR
(2) I nstal l the shi fter knob and nut and ti ghten to
27 Nm (20 ft. l bs.).
(3) Posi ti on the i nsert and seat i nto the knob ful l y.
A-PILLAR TRIM/GRAB HANDLE
REMOVAL
(1) Open the tri m pl ugs and remove the bol ts. (Fi g.
3)
(2) Remove the a-pi l l ar tri m/grab handl e from the
a-pi l l ar.
INSTALLATION
(1) Posi ti on the bottom a-pi l l ar l ocati ng tabs and
i nstal l the a-pi l l ar tri m.
l bs.).
(3) Cl ose the tri m pl ugs.
B-PILLAR LOWER TRIM
REMOVAL
(1) Remove the upper b-pi l l ar tri m. (Refer to 23 -
BODY/I NTERI OR/B-PI LLAR UPPER TRI M -
REMOVAL)
(2) Remove the cowl tri m. (Refer to 23 - BODY/I N-
TERI OR/COWL TRI M - REMOVAL)
STANDARD CAB
(1) Remove the shoul der bel t anchor bol t.
remove the l ower b-pi l l ar tri m. (Fi g. 4)
QUAD CAB
(1) Remove the rear door si l l tri m. (Refer to 23 -
BODY/I NTERI OR/REAR DOOR SI LL TRI M COVER
- REMOVAL)
remove the l ower b-pi l l ar tri m.
Fig. 1 SHIFTER BOOT
1 - CONSOLE
2 - SHIFTER KNOB
3 - SHIFTER BOOT
Fig. 2 SHIFTER KNOB
1 - SHIFTER KNOB
2 - INSERT
3 - NUT
Fig. 3 A-PILLAR TRIM/GRAB HANDLE
1 - A-PILLAR
2 - A-PILLAR TRIM
3 - TRIM PLUG
4 - BOLTS (2)
DR INTERIOR 23 - 63
4WD FLOOR SHIFT BOOT (Continued)
(3) Pul l seat bel t out of the tri m panel through the
sl ot provi ded. (Fi g. 5)
INSTALLATION
QUAD CAB
(1) Route the shoul der bel t through the sl ot i n the
tri m.
(2) Posi ti on the tri m and seat the attachment cl i ps
ful l y.
(3) I nstal l the rear door si l l tri m. (Refer to 23 -
BODY/I NTERI OR/DOOR SI LL TRI M COVER -
I NSTALLATI ON)
STANDARD CAB
ful l y.
(2) I nstal l the seat bel t anchor and bol t and
BOTH BODY STYLES
(1) I nstal l the cowl tri m. (Refer to 23 - BODY/I N-
TERI OR/COWL TRI M - I NSTALLATI ON)
(2) I nstal l the upper b-pi l l ar tri m. (Refer to 23 -
I NSTALLATI ON)
B-PILLAR UPPER TRIM
REMOVAL
(1) Remove the seat bel t turni ng l oop. (Refer to 8 -
ELECTRI CAL/RESTRAI NTS/SEAT BELT TURNI NG
LOOP ADJUSTER - REMOVAL)
(2) Open the tri m pl ugs and remove the grab han-
dl e bol ts, i f equi pped. (Fi g. 6)
remove the upper b-pi l l ar tri m. (Fi g. 7) or (Fi g. 8)
INSTALLATION
(1) Posi ti on the upper b-pi l l ar tri m and seat the
(2) I nstal l the grab handl e bol ts and ti ghten to 6
Nm (55 i n. l bs.).
(3) Cl ose the grab handl e tri m pl ugs.
(4) I nstal l the seat bel t turni ng l oop. (Refer to 8 -
LOOP ADJUSTER - I NSTALLATI ON)
Fig. 4 LOWER B-PILLAR TRIM - STANDARD CAB
1 - SEAT BELT
2 - B-PILLAR
3 - SEAT BELT ANCHOR HOLE
4 - LOWER B-PILLAR TRIM
Fig. 5 LOWER B-PILLAR TRIM - QUAD CAB
1 - SEAT BELT
2 - SEAT BELT SLOT
23 - 64 INTERIOR DR
B-PILLAR LOWER TRIM (Continued)
CARPETS AND FLOOR MATS
REMOVAL
(1) Remove the front seats. (Refer to 23 - BODY/
SEATS/SEAT - FRONT - REMOVAL)
(2) Remove the rear seats, i f equi pped. (Refer to 23
- BODY/SEATS/SEAT - REAR - REMOVAL)
(3) Remove the fl oor consol e, i f equi pped. (Refer to
23 - BODY/I NTERI OR/FLOOR CONSOLE -
REMOVAL)
(4) Remove the l ower b-pi l l ar tri m. (Refer to 23 -
REMOVAL)
(5) On quad cab model s, remove the l ower seat
bel t anchor next to the b-pi l l ar.
remove the rear cup hol der, i f equi pped.
(7) Remove the jack assembl y.
(8) Remove the carpet.
INSTALLATION
(1) I nstal l the carpet.
(2) I nstal l the jack assembl y.
(3) I nstal l the rear cup hol der, i f equi pped.
I NSTALLATI ON)
(5) On quad cab model s, i nstal l the l ower seatbel t
anchor bol t next to the b-pi l l ar and ti ghten to 40 Nm
(30 ft. l bs.).
(6) I nstal l the fl oor consol e, i f equi pped. (Refer to
23 - BODY/I NTERI OR/FLOOR CONSOLE - I NSTAL-
LATI ON)
(7) I nstal l the rear seats, i f equi pped. (Refer to 23
- BODY/SEATS/SEAT - REAR - I NSTALLATI ON)
(8) I nstal l the front seats. (Refer to 23 - BODY/
SEATS/SEAT - FRONT - I NSTALLATI ON)
Fig. 6 GRAB HANDLE
1 - GRAB HANDLE
2 - TRIM PLUGS
3 - BOLTS
Fig. 7 UPPER B-PILLAR TRIM - STANDARD CAB
1 - B-PILLAR
2 - UPPER B-PILLAR TRIM
3 - SEAT BELT TURNING LOOP
Fig. 8 UPPER B-PILLAR TRIM - QUAD CAB
1 - B-PILLAR
2 - UPPER B-PILLAR TRIM
3 - TURNING LOOP
DR INTERIOR 23 - 65
B-PILLAR UPPER TRIM (Continued)
COAT HOOK
REMOVAL
(1) Usi ng a tri m sti ck C-4755 or equi val ent, pry
down the rel ease cl i p and remove the hook. (Fi g. 9)
INSTALLATION
(1) Snap the coat hook i nto the sheet metal and
seat the base of the coat hook ful l y.
(2) Push the upper porti on i n unti l i t snaps or
seats to the base.
COWL TRIM
REMOVAL
remove the cowl tri m panel . (Fi g. 10)
INSTALLATION
(1) Posi ti on the cowl tri m and seat the attachment
cl i ps ful l y.
C-PILLAR LOWER TRIM
REMOVAL
(1) Remove the upper c-pi l l ar tri m. (Refer to 23 -
BODY/I NTERI OR/C-PI LLAR TRI M - REMOVAL)
(2) Remove the seat bel t anchor bol t. (Fi g. 11)
remove the l ower c-pi l l ar tri m.
(4) Pul l seat bel t out of the tri m panel through the
sl ot provi ded.
Fig. 9 COAT HOOK
1 - COAT HOOK
2 - RELEASE CLIP
3 - HEADLINER
Fig. 10 COWL/SILL TRIM PANEL
1 - COWL TRIM PANEL
2 - CLIP INSERTS
3 - DOOR SILL
Fig. 11 C-PILLAR TRIM
1 - C-PILLAR
2 - UPPER C-PILLAR TRIM
3 - SEAT BELT TURNING LOOP
4 - LOWER C-PILLAR TRIM
5 - SEAT BELT
6 - SEAT BELT ANCHOR
23 - 66 INTERIOR DR
INSTALLATION
(1) Route the shoul der bel t through the sl ot i n the
tri m.
ful l y.
(3) I nstal l the seat bel t anchor bol t and ti ghten to
40 Nm (30 ft. l bs.).
(4) I nstal l the upper c-pi l l ar tri m. (Refer to 23 -
BODY/I NTERI OR/C-PI LLAR UPPER TRI M -
I NSTALLATI ON)
C-PILLAR UPPER TRIM
REMOVAL
(1) Remove the seat bel t turni ng l oop. (Refer to 8 -
LOOP ADJUSTER - REMOVAL)
remove the upper c-pi l l ar tri m. (Fi g. 11)
INSTALLATION
(1) Posi ti on the upper c-pi l l ar tri m and seat the
(2) I nstal l the seat bel t turni ng l oop. (Refer to 8 -
LOOP ADJUSTER - I NSTALLATI ON)
FLOOR CONSOLE
REMOVAL
(1) Remove the 4WD shi fter boot. (Refer to 23 -
BODY/I NTERI OR/4WD FLOOR SHI FT BOOT -
REMOVAL)
the transmi ssi on shi fter boot from the consol e.
(3) Remove the transmi ssi on shi fter extensi on.
(4) Remove the consol e i nserts. (Fi g. 12)
(5) Remove and di scard the three bol ts. (Fi g. 13)
(6) Li ft up on the back and remove the consol e.
INSTALLATION
(1) Posi ti on the front of the consol e up under the
i nstrument panel .
(2) Lower the back of the consol e and i nstal l three
new screws.
(3) I nstal l the i nserts.
(4) I nstal l the transmi ssi on shi fter extensi on.
(5) Posi ti on the transmi ssi on shi fter boot i n pl ace
and seat the attachment cl i ps ful l y.
(6) I nstal l the 4WD shi fter boot. (Refer to 23 -
BODY/I NTERI OR/4WD FLOOR SHI FT BOOT -
I NSTALLATI ON)
Fig. 12 FLOOR CONSOLE INSERTS
1 - BIN MAT INSERT
2 - STORAGE BIN/SHIFT BOOT
3 - CUP HOLDER MAT INSERT
4 - FLOOR CONSOLE
Fig. 13 FLOOR CONSOLE
2 - FLOOR CONSOLE
3 - BOLTS (3)
4 - SHIFTER LEVER
DR INTERIOR 23 - 67
C-PILLAR LOWER TRIM (Continued)
HEADLINER
REMOVAL
(1) Remove the a-pi l l ar tri m. (Refer to 23 - BODY/
I NTERI OR/A-PI LLAR TRI M - REMOVAL)
(2) Remove the upper b-pi l l ar tri m. (Refer to 23 -
REMOVAL)
(3) Remove the upper c-pi l l ar tri m, i f equi pped.
(Refer to 23 - BODY/I NTERI OR/C-PI LLAR TRI M -
REMOVAL)
(4) Remove the coat hooks. (Refer to 23 - BODY/
I NTERI OR/COAT HOOK - REMOVAL)
(5) Di sconnect the headl i ner harness el ectri cal con-
nector at the l eft a-pi l l ar.
(6) Remove the dome l amp. (Refer to 8 - ELEC-
TRI CAL/LAMPS/LI GHTI NG - I NTERI OR/DOME
LAMP - REMOVAL)
(7) Remove the overhead consol e. (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE - REMOVAL)
(8) Remove the sun vi sors. (Refer to 23 - BODY/
I NTERI OR/SUN VI SOR - REMOVAL)
(9) Remove the sun vi sor supports. (Refer to 23 -
BODY/I NTERI OR/SUN VI SOR SUPPORT -
REMOVAL)
(10) Lower the headl i ner and di sconnect the center
hi gh mounted stop l i ght.
(11) Lower the front of the headl i ner down to the
fl oor just i n front of the i nstrument panel and
remove through the passenger door.
INSTALLATION
(1) I nstal l the headl i ner i nto the vehi cl e through
the passenger door.
(2) Rai se the headl i ner and i nsert the ri ght si de
above ri ght si de pi l l ar tri m pi eces.
(3) Connect the center hi gh mounted stop l i ght
el ectri cal connector.
(4) I nstal l the sun vi sor supports. (Refer to 23 -
BODY/I NTERI OR/SUN VI SOR SUPPORT - I NSTAL-
LATI ON)
(5) I nstal l the coat hooks. (Refer to 23 - BODY/I N-
TERI OR/COAT HOOK - I NSTALLATI ON)
(6) I nstal l the sun vi sors. (Refer to 23 - BODY/I N-
TERI OR/SUN VI SOR - I NSTALLATI ON)
(7) I nstal l the overhead consol e. (Refer to 8 -
ELECTRI CAL/OVERHEAD CONSOLE - I NSTALLA-
TI ON)
(8) I nstal l the dome l amp. (Refer to 8 - ELECTRI -
CAL/LAMPS/LI GHTI NG - I NTERI OR/DOME LAMP
- I NSTALLATI ON)
(9) Connect the headl i ner harness el ectri cal con-
nector at the l eft a-pi l l ar.
(10) I nstal l the upper c-pi l l ar tri m, i f equi pped.
(Refer to 23 - BODY/I NTERI OR/C-PI LLAR TRI M -
I NSTALLATI ON)
(11) I nstal l the upper b-pi l l ar tri m. (Refer to 23 -
I NSTALLATI ON)
(12) I nstal l the upper a-pi l l ar tri m. (Refer to 23 -
BODY/I NTERI OR/A-PI LLAR TRI M - I NSTALLA-
TI ON)
B-PILLAR GRAB HANDLE
REMOVAL
(1) Open the tri m pl ugs and remove the bol ts. (Fi g.
14)
(2) Remove the grab handl e.
INSTALLATION
(1) I nstal l the grab handl e and i nstal l the bol ts.
(2) Ti ghten the bol ts to 6 Nm (55 i n. l bs.) and
i nstal l the tri m pl ugs.
REAR CAB BACK PANEL TRIM
REMOVAL
(1) Remove the chi l d seat tethers, i f equi pped.
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/CHI LD
TETHER - REMOVAL)
(2) Remove the screws and remove the uti l i ty
hooks/bi n l atch, i f equi pped. (Fi g. 15)
Fig. 14 GRAB HANDLE
1 - GRAB HANDLE
2 - TRIM PLUGS
3 - BOLTS
23 - 68 INTERIOR DR
remove the center seat bel t tri m bezel , i f equi pped.
(4) On quad cab model s, remove the l eft l ower
c-pi l l ar tri m panel . (Refer to 23 - BODY/I NTERI OR/
C-PI LLAR TRI M - REMOVAL)
(5) On standard cab model s, remove the l eft l ower
b-pi l l ar tri m panel . (Refer to 23 - BODY/I NTERI OR/
B-PI LLAR LOWER TRI M - REMOVAL)
(6) Remove the push pi n fasteners, i f equi pped,
and remove the back panel tri m. (Fi g. 16) or (Fi g. 17)
INSTALLATION
(1) Posi ti on the back panel tri m behi nd the ri ght
pi l l ar tri m.
(2) Route the center bel t and tri m bezel through
the back panel , i f equi pped.
(3) On standard cab model s, i nstal l the l eft l ower
b-pi l l ar tri m panel . (Refer to 23 - BODY/I NTERI OR/
B-PI LLAR LOWER TRI M - I NSTALLATI ON)
(4) On quad cab model s, i nstal l the l eft l ower c-pi l -
l ar tri m panel . (Refer to 23 - BODY/I NTERI OR/C-
PI LLAR TRI M - I NSTALLATI ON)
(5) Posi ti on the center bel t tri m bezel , i f equi pped,
and seat the attachment cl i ps ful l y.
(6) I nstal l the uti l i ty hooks/bi n l atch and screws, i f
equi pped.
(7) I nstal l the chi l d seat tethers, i f equi pped.
(Refer to 8 - ELECTRI CAL/RESTRAI NTS/CHI LD
TETHER - I NSTALLATI ON)
REAR VIEW MIRROR
REMOVAL
(1) I f equi pped, di sconnect mi rror harness connec-
tor.
(2) Loosen the mi rror base setscrew (Fi g. 18).
(3) Sl i de the mi rror base upward and off the
bracket.
Fig. 15 UTILITY HOOK/STORAGE BIN LATCH
1 - SCREW
2 - UTILITY HOOK
3 - UTILITY HOOK COVER
4 - COVER LOCK TAB
Fig. 16 CAB BACK PANEL - STANDARD CAB
1 - CAB BACK PANEL
2 - CAB BACK
3 - UTILITY HOOK
4 - STORAGE BIN LATCH
Fig. 17 CAB BACK PANEL - QUAD CAB
1 - PUSH PIN FASTENER
2 - CAB BACK
3 - CAB BACK PANEL
4 - PUSH PIN FASTENER
DR INTERIOR 23 - 69
REAR CAB BACK PANEL TRIM (Continued)
INSTALLATION
INSTALLATION
(1) Posi ti on the mi rror base at the bracket and
sl i de i t downward onto the support bracket (Fi g. 18).
(2) Ti ghten the setscrew 1 Nm (15 i n. l bs.) torque.
(3) I f equi pped, connect mi rror harness connector.
INSTALLATION - REAR VIEW MIRROR
SUPPORT BRACKET
(1) Mark the posi ti on for the mi rror bracket on the
outsi de of the wi ndshi el d gl ass wi th a wax penci l .
(2) Cl ean the bracket contact area on the gl ass.
Use a mi l d powdered cl eanser on a cl oth saturated
wi th i sopropyl (rubbi ng) al cohol . Fi nal l y, cl ean the
gl ass wi th a paper towel dampened wi th al cohol .
(3) Sand the surface on the support bracket wi th
fi ne gri t-sandpaper. Wi pe the bracket surface cl ean
wi th a paper towel .
(4) Appl y accel erator to the surface on the bracket
accordi ng to the fol l owi ng i nstructi ons:
(a) Crush the vi al to saturate the fel t appl i cator.
(b) Remove the paper sl eeve.
(c) Appl y accel erator to the contact surface on
the bracket.
(d) Al l ow the accel erator to dry for fi ve mi nutes.
(e) Do not touch the bracket contact surface
after the accel erator has been appl i ed.
(5) Appl y adhesi ve accel erator to the bracket con-
tact surface on the wi ndshi el d gl ass. Al l ow the accel -
erator to dry for one mi nute. Do not touch the gl ass
contact surface after the accel erator has been
appl i ed.
(6) I nstal l the bracket accordi ng to the fol l owi ng
i nstructi ons:
(a) Appl y one drop of adhesi ve at the center of
the bracket contact-surface on the wi ndshi el d
gl ass.
(b) Appl y an even coat of adhesi ve to the contact
surface on the bracket.
(c) Al i gn the bracket wi th the marked posi ti on
on the wi ndshi el d gl ass.
(d) Press and hol d the bracket i n pl ace for at
l east one mi nute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rapidly.
(7) Al l ow the adhesi ve to cure for 8-10 mi nutes.
Remove any excess adhesi ve wi th an al cohol -damp-
ened cl oth.
(8) Al l ow the adhesi ve to cure for an addi ti onal
8-10 mi nutes before i nstal l i ng the mi rror.
SUN VISOR
REMOVAL
(1) Remove the screws at the vi sor pi vot and
remove the vi sor.
INSTALLATION
(1) I nstal l the vi sor and i nstal l the screws at the
vi sor pi vots.
SUN VISOR SUPPORT
REMOVAL
down the rel ease cl i p and remove the hook. (Fi g. 19)
Fig. 18 REAR VIEW MIRROR
1 - CONNECTOR
2 - SCREW
3 - REAR VIEW MIRROR
4 - SUPPORT BUTTON
5 - WINDSHIELD
Fig. 19 VISOR SUPPORT
1 - VISOR SUPPORT
2 - HEADLINER
3 - RELEASE CLIP
23 - 70 INTERIOR DR
REAR VIEW MIRROR (Continued)
INSTALLATION
(1) Snap the vi sor support i nto the sheet metal
and seat the rel ease cl i p ful l y.
BODY VENT
REMOVAL
(1) Remove the cab back panel tri m. (Refer to 23 -
BODY/I NTERI OR/REAR CAB BACK PANEL TRI M -
REMOVAL)
(2) Whi l e hol di ng the vent, press the tabs to
rel ease the vent i nto the cab back panel . (Fi g. 20)
(3) Twi st the vent and remove through the vent
hol e.
INSTALLATION
(1) Posi ti on the vent i nto the vent hol e i n the cab
back panel .
(2) Twi st the vent and pul l i t i nto the hol e frame
and seat the tabs ful l y.
(3) I nstal l the cab back panel tri m. (Refer to 23 -
BODY/I NTERI OR/REAR CAB BACK PANEL TRI M -
I NSTALLATI ON)
REAR DOOR SILL TRIM COVER
REMOVAL
the si l l tri m and remove. (Fi g. 21)
INSTALLATION
(1) Posi ti on the si l l tri m and seat the attachment
cl i ps ful l y.
LOAD FLOOR
REMOVAL
(1) Fol d the rear seat cushi on up.
(2) Remove the rear nuts i n each corner. (Fi g. 22)
(3) Fol d the l oad fl oor up, remove the front bol ts
and remove the tray. (Fi g. 23)
Fig. 20 BODY VENT
1 - RETAINER TABS
2 - BODY VENT
3 - CAB BACK PANEL
Fig. 21 REAR DOOR SILL TRIM
1 - SILL TRIM
2 - REAR DOOR SILL
Fig. 22 REAR LOAD FLOOR - REAR FASTENERS
1 - REAR SEAT CUSHION
2 - NUTS (2)
3 - STOWAGE TRAY
DR INTERIOR 23 - 71
SUN VISOR SUPPORT (Continued)
INSTALLATION
(1) I nstal l the l oad fl oor and i nstal l the bol ts.
(3) Fol d the l oad fl oor down and i nstal l the nuts.
LOAD FLOOR SUPPORT
CYLINDER
REMOVAL
(1) Open the l oad fl oor.
(2) Remove the snap cl i ps and retai ni ng pi ns. (Fi g.
24)
(3) Remove the support cyl i nder.
INSTALLATION
(1) I nstal l the support cyl i nder wi th the thi n end
down.
(2) I nstal l the retai ni ng pi ns and cl i ps.
Fig. 23 REAR LOAD FLOOR - TYPICAL
1 - REAR STORAGE BIN
2 - LOAD FLOOR
3 - BOLTS (2)
4 - SUPPORT CYLINDER
Fig. 24 LOAD FLOOR SUPPORT CYLINDER
1 - RETAINING PINS/CLIPS (2)
2 - LOAD FLOOR
3 - SUPPORT CYLINDER
23 - 72 INTERIOR DR
LOAD FLOOR (Continued)
PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - PAINT CODES . . . . . . . . . . 73
PAINT CODE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 73
BASECOAT/CLEARCOAT FINISH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 73
PAINT TOUCH-UP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 74
STANDARD PROCEDURE - PAINT TOUCH-UP . 74
FINESSE SANDING/BUFFING & POLISHING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 74
PAINT
SPECIFICATIONS - PAINT CODES
NOTE: Because of late model changes to the avail-
able paint colors (Refer to VEHICLE DATA/VEHICLE
INFORMATION/VEHICLE CERTIFICATION LABEL -
DESCRIPTION) or (Refer to VEHICLE DATA/VEHI-
CLE INFORMATION/BODY CODE PLATE - DESCRIP-
TION) for the correct paint codes for each vehicle.
(Refer to 23 - BODY/PAINT/PAINT CODE - DESCRIP-
TION)
EXTERIOR COLORS
EXTERIOR COLOR DAIMLERCHRYSLER
CODE
Deep Molten Red
Pearlcoat
BR8
Flame Red Clearcoat PR4
Light Almond Pearl
Metallic Clearcoat
ZKJ
Atlantic Blue Pearlcoat ZBJ
Patriot Blue Pearlcoat WBT/WB7
Graphite Metallic
Clearcoat
ZDR
Bright Silver Metallic
Clearcoat
WSB/WS2
Black Clearcoat DX8
Bright White Clearcoat GW7
Timberline Green AGW
INTERIOR COLORS
INTERIOR COLOR DAIMLERCHRYSLER
CODE
Taupe L5
Dark Slate Gray DV
PAINT CODE
DESCRIPTION
Exteri or vehi cl e body col ors are i denti fi ed on the
Vehi cl e Certi fi cati on Label (Refer to VEHI CLE
DATA/VEHI CLE I NFORMATI ON/VEHI CLE CERTI -
FI CATI ON LABEL - DESCRI PTI ON) or the Body
Code Pl ate (Refer to VEHI CLE DATA/VEHI CLE
I NFORMATI ON/BODY CODE PLATE - DESCRI P-
TI ON). The fi rst di gi t of the pai nt code l i sted on the
vehi cl e i ndi cates the sequence of appl i cati on, i .e.: P =
pri mary coat, Q = secondary coat. The col or names
provi ded i n the Pai nt and Tri m Code Descri pti on
chart are the col or names used on most repai r prod-
uct contai ners. (Refer to 23 - BODY/PAI NT - SPECI -
FI CATI ONS)
BASECOAT/CLEARCOAT
FINISH
DESCRIPTION
The ori gi nal equi pment fi ni sh i s a mul ti step pro-
cess that i nvol ves cl eani ng, appl yi ng el ectro de-posi -
ti on (E-coat), anti -chi p pri mer, basecoat, and
cl earcoat steps.
On most vehi cl es a two-part pai nt appl i cati on
(basecoat/cl earcoat) i s used. Col or pai nt that i s
appl i ed to pri mer i s cal l ed basecoat. The cl ear coat
protects the basecoat from ul travi ol et l i ght and pro-
vi des a durabl e hi gh-gl oss fi ni sh.
DR PAINT 23 - 73
CAUTION: Do not use abrasive chemicals or com-
pounds on painted surfaces. Damage to finish can
result.
Do not use harsh alkaline based cleaning solvents
on painted surfaces. Damage to finish or color can
result.
PAINT TOUCH-UP
DESCRIPTION
When a pai nted metal surface has been scratched
or chi pped, i t shoul d be touched-up as soon as possi -
bl e to avoi d corrosi on. For best resul ts, use MOPAR
Scratch Fi l l er/Pri mer, Touch-Up Pai nts and Cl ear Top
Coat. (Refer to VEHI CLE DATA/VEHI CLE I NFOR-
MATI ON/BODY CODE PLATE - DESCRI PTI ON) for
Body Code Pl ate i nformati on.
WARNING: USE AN OSHA APPROVED RESPIRATOR
AND SAFETY GLASSES WHEN SPRAYING PAINT
OR SOLVENTS IN A CONFINED AREA. PERSONAL
INJURY CAN RESULT.
STANDARD PROCEDURE - PAINT TOUCH-UP
(1) Scrape l oose pai nt and corrosi on from i nsi de
scratch or chi p.
(2) Cl ean affected area wi th MOPAR Tar/Road
Oi l Remover or equi val ent, and al l ow to dry.
(3) Fi l l the i nsi de of the scratch or chi p wi th a coat
of fi l l er/pri mer. Do not overl ap pri mer onto good sur-
face fi ni sh. The appl i cator brush shoul d be wet
enough to puddl e-fi l l the scratch or chi p wi thout run-
ni ng. Do not stroke brush appl i cator on body surface.
Al l ow the fi l l er/pri mer to dry hard.
(4) Cover the fi l l er/pri mer wi th col or touch-up
pai nt. Do not overl ap touch-up col or onto the ori gi nal
col or coat around the scratch or chi p. Butt the new
col or to the ori gi nal col or, i f possi bl e. Do not stroke
appl i cator brush on body surface. Al l ow touch-up
pai nt to dry hard.
(5) On vehi cl es wi thout cl earcoat, the touch-up
col or can be l i ghtl y fi nesse sanded (1500 gri t) and
pol i shed wi th rubbi ng compound.
(6) On vehi cl es wi th cl earcoat, appl y cl ear top coat
to touch-up pai nt wi th the same techni que as
descri bed i n Step 4. Al l ow cl ear top coat to dry hard.
I f desi red, Step 5 can be performed on cl ear top coat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN
RESULT.AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
FINESSE SANDING/BUFFING &
POLISHING
DESCRIPTION
CAUTION: Do not remove more than .5 mils of
clearcoat finish, if equipped. Basecoat paint must
retain clearcoat for durability.
Use a Paint Thickness Gauge #PR-ETG-2X or equiv-
alent to determine film thickness before and after
the repair.
Mi nor aci d etchi ng, orange peel , or smudgi ng i n
cl earcoat or si ngl e-stage fi ni shes can be reduced wi th
l i ght fi nesse sandi ng, hand buffi ng, and pol i shi ng. If
the finish has been finesse sanded in the past,
it cannot be repeated. Finesse sanding opera-
tion should be performed by a trained automo-
tive paint technician.
23 - 74 PAINT DR
BASECOAT/CLEARCOAT FINISH (Continued)
SEATS
TABLE OF CONTENTS
page page
CENTER SEAT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76
CENTER ARMREST / SEAT BACK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77
CENTER SEAT BACK INERTIA HINGE COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77
CENTER SEAT BACK HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
CENTER SEAT BACK LID
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
CENTER SEAT CUSHION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
CENTER SEAT CUSHION COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
UNDER SEAT STORAGE BIN LID
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
UNDER SEAT STORAGE BIN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
UNDER SEAT STORAGE BIN COVERING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
UNDER SEAT STORAGE BIN LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
HEADREST
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
HEADREST SLEEVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 81
SEAT - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 81
LUMBAR SUPPORT HANDLE/BEZEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 82
SEAT BACK CUSHION / COVER - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 82
SEAT CUSHION / COVER - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83
SEAT TRACK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83
SEAT - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83
SEAT BACK - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83
SEAT BACK CUSHION / COVER - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
SEAT CUSHION / COVER - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
SEAT CUSHION FRAME - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
SEAT BACK REAR - FOOTMANS LOOP
BRACKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85
CENTER SEAT
REMOVAL
NOTE: Do not reuse the seat fasteners, always
replace with new ones.
(1) Remove and di scard the front bol ts. (Fi g. 1)
(2) Posi ti on the seats forward, remove the rear
bol ts and di scard.
(3) Di sconnect the 12v power suppl y el ectri cal con-
nector, i f equi pped. (Fi g. 2)
(4) Fol d the seat backs forward and rol l the seat
assembl y back i n the vehi cl e.
(5) Remove the nuts attachi ng the center seat to
the dri vers seat and the passenger seat and di scard.
(Fi g. 3)
DR SEATS 23 - 75
(6) Rol l the seat assembl y forward and remove the
center seat porti on.
INSTALLATION
(1) I nstal l the center seat and rol l the seat assem-
bl y back i n the vehi cl e.
(2) I nstal l new nuts attachi ng the center seat to
the dri vers and passenger seat.
(4) Rol l the seat assembl y forward and i nstal l new
rear bol ts.
(5) Connect the 12v power suppl y el ectri cal con-
(6) Ti ghten the rear bol ts to 40 Nm (30 ft. l bs.).
(7) Fol d the seat backs up and sl i de the seats to
the rear.
(8) I nstal l new front bol ts and ti ghten to 28 Nm
(21 ft. l bs.).
CENTER ARMREST / SEAT
BACK
REMOVAL
(1) Remove the center seat. (Refer to 23 - BODY/
SEATS/SEAT - CENTER - REMOVAL)
(2) Di sconnect the storage bi n/cushi on cover
j-straps and posi ti on asi de.
(3) Remove and di scard the hi nge bol ts and sepa-
rate the seat back from the storage bi n/cushi on. (Fi g.
4)
Fig. 1 FRONT SEAT ASSEMBLY
1 - FRONT SEAT ASSEMBLY
2 - REAR BOLTS (4)
4 - FRONT BOLTS (4)
Fig. 2 CENTER SEAT ATTACHMENTS
1 - CENTER SEAT ASSEMBLY
2 - FRONT NUTS (2)
3 - POWER SUPPLY ELECTRICAL CONNECTOR
4 - REAR NUTS (4)
5 - 12V POWER SUPPLY HARNESS
Fig. 3 REAR ATTACHMENTS
2 - CENTER SEAT STORAGE BIN
3 - FRONT SEAT TRACKS
4 - REAR NUTS (4)
23 - 76 SEATS DR
CENTER SEAT (Continued)
INSTALLATION
(1) I nstal l the seat back onto the storage bi n/cush-
i on and i nstal l new hi nge bol ts.
(2) Ti ghten the hi nge to storage bi n/cushi on bol ts
to 25 Nm (18 ft. l bs.).
(3) Connect the storage bi n/cushi on cover j-straps.
(4) I nstal l the center seat. (Refer to 23 - BODY/
SEATS/SEAT - CENTER - I NSTALLATI ON)
CENTER SEAT BACK INERTIA
HINGE COVER
REMOVAL
NOTE: Free pivot hinge cover is removed with the
free pivot hinge. (Refer to 23 - BODY/SEATS/CEN-
TER SEAT BACK HINGE - REMOVAL)
(1) For the i nerti a hi nge cover di sconnect the zi p
stri p. (Fi g. 5)
(2) Posi ti on asi de the storage bi n/cushi on cover.
(3) Remove the pi vot bol t.
(4) Open the hi nge cover at the bottom and remove
the hi nge cover. (Fi g. 6)
INSTALLATION
NOTE: Free pivot hinge cover is installed with the
free pivot hinge. (Refer to 23 - BODY/SEATS/CEN-
TER SEAT BACK HINGE - INSTALLATION)
Fig. 4 CENTER SEAT BACK HINGES
1 - STORAGE BIN/CUSHION COVERING
2 - SEAT BACK HINGE BOLTS (4)
3 - STORAGE BIN/CUSHION FRAME
Fig. 5 HINGE COVER
1 - SEAT BACK COVER ZIP STRIP
2 - CENTER SEAT BACK
3 - HINGE COVER
4 - STORAGE BIN COVER
5 - PIVOT BOLT
Fig. 6 HINGE COVER REMOVAL
1 - HINGE COVER
2 - HINGE
3 - HINGE COVER TABS
5 - STORAGE BIN/CUSHION
DR SEATS 23 - 77
CENTER ARMREST / SEAT BACK (Continued)
(1) Posi ti on the hi nge cover over the hi nge and
cl ose over the l ock tabs.
(2) I nstal l the pi vot bol t and ti ghten to 10 Nm (89
i n. l bs.).
(3) Reposi ti on the storage bi n/cushi on cover.
(4) Connect the zi p stri p.
CENTER SEAT BACK HINGE
REMOVAL
(1) Remove the seat back. (Refer to 23 - BODY/
SEATS/CENTER ARMREST / SEAT BACK -
REMOVAL)
Free Pivot Hinge/Cover
(1) Di sconnect the storage bi n/cushi on cover j-strap
and posi ti on asi de.
(2) Remove and di scard the pi vot bol t. (Fi g. 7)
(3) Remove the hi nge spacer. (Fi g. 8)
(4) Open the hi nge cover fl ap and remove the wi re
harness, i f equi pped. (Fi g. 9)
(5) Remove the cover from the hi nge.
Fig. 7 PIVOT HINGE/COVER
1 - PIVOT BOLT
2 - HINGE COVER
3 - STORAGE BIN COVER
5 - HINGE BOLTS (2)
6 - HINGE
Fig. 8 PIVOT HINGE SPACER
1 - HINGE COVER
2 - SPACER
3 - STOP PIN
Fig. 9 PIVOT HINGE COVER
1 - HINGE COVER FLAP
2 - STOP PIN
3 - HINGE COVER
4 - HINGE
23 - 78 SEATS DR
CENTER SEAT BACK INERTIA HINGE COVER (Continued)
Inertia Hinge
(1) Remove the seat back i nerti a hi nge cover.
(Refer to 23 - BODY/SEATS/CENTER SEAT BACK
I NERTI A HI NGE COVER - REMOVAL)
(2) Remove and di scard the i nerti a hi nge bol ts and
remove the hi nge. (Fi g. 10)
INSTALLATION
Free Pivot Hinge/Cover
(1) Posi ti on the pi vot hi nge cover over the pi vot
hi nge and i nstal l the 12v power suppl y harness i nto
the channel , i f equi pped.
(2) Cl ose the hi nge cover fl at and posi ti on the
spacer i nto pl ace.
(3) Al i gn the stop pi n wi th the spacer and hi nge
and i nstal l the assembl y onto the seat back.
(4) I nstal l a new pi vot bol t and ti ghten to 25 Nm
(18 ft. l bs.)
Inertia Hinge
(1) I nstal l the i nerti a hi nge onto the center seat
back and i nstal l new bol ts.
(3) I nstal l the seat back i nerti a hi nge covers.
(Refer to 23 - BODY/SEATS/CENTER SEAT BACK
I NERTI A HI NGE COVER - I NSTALLATI ON)
(1) I nstal l the center seat back. (Refer to 23 -
BODY/SEATS/CENTER ARMREST / SEAT BACK -
I NSTALLATI ON)
CENTER SEAT BACK LID
REMOVAL
(1) Open the center armrest/seat back.
(2) Remove the four screws attachi ng the hi nge to
the storage bi n/cushi on and remove the l i d.
INSTALLATION
(1) Posi ti on the center seat back l i d onto the stor-
age bi n/cushi on and i nstal l the screws.
CENTER SEAT CUSHION
REMOVAL
(1) Remove the center seat. (Refer to 23 - BODY/
SEATS/CENTER SEAT - REMOVAL)
(2) Remove the center armrest/seat back. (Refer to
23 - BODY/SEATS/CENTER ARMREST / SEAT
BACK - REMOVAL)
INSTALLATION
(1) I nstal l the center armrest/seat back. (Refer to
23 - BODY/SEATS/CENTER ARMREST / SEAT
BACK - I NSTALLATI ON)
(2) I nstal l the center seat. (Refer to 23 - BODY/
SEATS/CENTER SEAT - I NSTALLATI ON)
CENTER SEAT CUSHION
COVER
REMOVAL
(1) Remove the center seat cushi on or underseat
storage bi n l i d. (Refer to 23 - BODY/SEATS/CENTER
SEAT CUSHI ON/UNDERSEAT STORAGE BI N LI D
- REMOVAL)
(2) Di sconnect the zi p stri ps and remove the cover
from the cushi on.
INSTALLATION
(1) I nstal l the cover over the center seat cushi on
and connect the zi p stri ps.
(2) I nstal l the center seat cushi on or under seat
storage bi n l i d. (Refer to 23 - BODY/SEATS/CENTER
SEAT CUSHI ON/UNDER SEAT STORAGE BI N LI D
- I NSTALLATI ON)
Fig. 10 INERTIA HINGE BOLTS
1 - SEAT BACK BOLTS
3 - INERTIA HINGE
DR SEATS 23 - 79
CENTER SEAT BACK HINGE (Continued)
LID
REMOVAL
(1) Open the center seat cushi on/storage bi n.
(2) Posi ti on the seat cushi on cover asi de, remove
the hi nge bol ts and di scard. (Fi g. 11)
(3) Remove the seat cushi on.
INSTALLATION
(1) Posi ti on the center seat cushi on the hi nges and
i nstal l new bol ts.
(3) Posi ti on the cushi on cover back over the
hi nges.
REMOVAL
(1) Remove the center seat cushi on. (Refer to 23 -
BODY/SEATS/CENTER SEAT CUSHI ON - REMOVAL)
(2) Remove the si x screws and remove the bi n.
INSTALLATION
(1) I nstal l the bi n over the seat cushi on hi nges and
i nstal l the si x screws.
(2) I nstal l the center seat cushi on. (Refer to 23 -
BODY/SEATS/CENTER SEAT CUSHI ON - I NSTAL-
LATI ON)
COVERING
REMOVAL
(1) Remove the under seat storage bi n. (Refer to
23 - BODY/SEATS/UNDER SEAT STORAGE BI N -
REMOVAL)
(2) Di sconnect the j-straps and remove the cover.
INSTALLATION
(1) I nstal l the storage bi n cover and connect the
j-straps.
(2) I nstal l the under seat storage bi n. (Refer to 23
- BODY/SEATS/UNDER SEAT STORAGE BI N -
I NSTALLATI ON)
LATCH
REMOVAL
(1) Open the under seat storage bi n.
(2) Remove the two screws and remove the l atch
assembl y.
INSTALLATION
(1) I nstal l the l atch assembl y and i nstal l the screws.
HEADREST
REMOVAL
(1) Rai se the headrest.
(2) Press the headrest rel ease button and remove
the headrest.
INSTALLATION
(1) Posi ti on the headrest.
(2) Press the rel ease button and i nstal l the head-
rest.
Fig. 11 CENTER SEAT CUSHION HINGE
1 - CENTER SEAT CUSHION
2 - HINGE BOLTS
3 - SEAT CUSHION HINGE
4 - STORAGE BIN/CUSHION
23 - 80 SEATS DR
HEADREST SLEEVE
REMOVAL
(1) Remove the headrest. (Refer to 23 - BODY/
SEATS/HEADREST - REMOVAL)
(2) Grasp the sl eeves and pul l up and out of the
seat back to remove.
INSTALLATION
(1) Posi ti on each headrest sl eeve i nto correct seat
back hol e and press i nto pl ace ful l y.
(2) I nstal l the headrest. (Refer to 23 - BODY/
SEATS/HEADREST - I NSTALLATI ON)
SEAT - FRONT
REMOVAL
(1) Remove and di scard the front bol ts. (Fi g. 12)
(2) Posi ti on the seats forward, remove the rear
bol ts and di scard.
(3) Di sconnect the 12v power suppl y el ectri cal con-
nector, i f equi pped. (Fi g. 13)
(4) Fol d the seat backs forward and rol l the seat
assembl y back i n the vehi cl e.
(5) Separate the seat assembl y by removi ng and
di scardi ng the three nuts on ei ther the dri vers or
passengers seat. (Fi g. 14)
(6) Remove each secti on of the seat assembl y from
the vehi cl e.
INSTALLATION
(1) Posi ti on each seat secti on i nto the vehi cl e and
ti p back.
Fig. 12 FRONT SEAT ASSEMBLY
1 - FRONT SEAT ASSEMBLY
2 - REAR BOLTS (4)
4 - FRONT BOLTS (4)
Fig. 13 CENTER SEAT ATTACHMENTS
1 - CENTER SEAT ASSEMBLY
2 - FRONT NUTS (2)
3 - POWER SUPPLY ELECTRICAL CONNECTOR
4 - REAR NUTS (4)
Fig. 14 REAR ATTACHMENTS
2 - CENTER SEAT STORAGE BIN
3 - FRONT SEAT TRACKS
4 - REAR NUTS (4)
DR SEATS 23 - 81
(2) I nstal l the three nuts attachi ng the center seat
secti on to the other seat, and ti ghten to 25 Nm (18
ft. l bs.).
(3) Rol l the seat assembl y forward and i nstal l new
rear bol ts.
(4) Connect the 12v power suppl y el ectri cal con-
nector.
(5) Ti ghten the rear bol ts to 40 Nm (30 ft. l bs.).
(6) Fol d the seat backs up and sl i de the seats to
the rear.
(7) I nstal l new front bol ts and ti ghten to 28 Nm
(21 ft. l bs.).
LUMBAR SUPPORT HANDLE/
BEZEL
REMOVAL
handle or bezel surface when removing.
the manual l umbar knob out of the bezel surround.
(Fi g. 15)
(2) Remove the bezel retai ni ng screws and remove
the bezel . (Fi g. 16)
INSTALLATION
(1) Al i gn the bezel to the seat back and i nstal l the
screws.
(2) Snap the manual l umbar knob onto the shaft of
the dri ve mechani sm i nto the bezel surround.
SEAT BACK CUSHION / COVER
- FRONT
REMOVAL
(1) Remove the front seat. (Refer to 23 - BODY/
(2) Remove the l umbar handl e and bezel , i f
equi pped. (Refer to 23 - BODY/SEATS/LUMBAR
SUPPORT HANDLE/BEZEL - REMOVAL)
(3) Remove the headrest sl eeves. (Refer to 23 -
BODY/SEATS/HEADREST SLEEVE - REMOVAL)
(4) Unzi p the zi p stri p at the l ower end of the seat
back and remove the seat back cover and cushi on.
INSTALLATION
(1) I nstal l the seat back cushi on and cover onto
the seat frame assembl y.
(2) Connect the zi p stri p at the bottom of the seat
back.
(3) I nstal l the headrest sl eeves. (Refer to 23 -
BODY/SEATS/HEADREST SLEEVE - I NSTALLA-
TI ON)
(4) I nstal l the l umbar bezel and handl e, i f
equi pped. (Refer to 23 - BODY/SEATS/LUMBAR
SUPPORT HANDLE/BEZEL - I NSTALLATI ON)
(5) I nstal l the seat. (Refer to 23 - BODY/SEATS/
SEAT - FRONT - I NSTALLATI ON)
Fig. 15 MANUAL LUMBAR KNOB
Fig. 16 MANUAL LUMBAR BEZEL
1 - LUMBAR SHAFT
2 - SCREWS
3 - BEZEL
23 - 82 SEATS DR
SEAT - FRONT (Continued)
SEAT CUSHION / COVER -
FRONT
REMOVAL
(2) Remove the screw and remove the recl i ner han-
dl e.
(3) Remove the two screws and remove the power
seat control s, i f equi pped, and di sconnect the el ectri -
cal connector.
(4) Remove the seat track. (Refer to 23 - BODY/
SEATS/SEAT TRACK - REMOVAL)
(5) Di sconnect the j-straps and remove the seat
cushi on and cover.
INSTALLATION
(1) Posi ti on the seat cushi on and cover onto the
frame assembl y and connect the j-straps.
(2) I nstal l the seat track. (Refer to 23 - BODY/
SEATS/SEAT TRACK - I NSTALLATI ON)
(3) Connect the power seat control swi tch el ectri cal
(4) I nstal l the power seat control swi tch and
i nstal l the two screws, i f equi pped.
(5) I nstal l the recl i ner handl e and i nstal l the
screw.
(6) I nstal l the front seat. (Refer to 23 - BODY/
SEATS/SEAT - FRONT - I NSTALLATI ON)
SEAT TRACK
REMOVAL
(2) Di sconnect the heated seat el ectri cal connec-
tors, i f equi pped.
(3) Remove the four nuts attachi ng the seat track
to the seat and remove the track.
INSTALLATION
(1) Posi ti on the seat track onto the seat and i nstal l
the four nuts.
(2) Ti ghten the four nuts to 25 Nm (18 ft. l bs.).
(3) Connect the heated seat el ectri cal connectors, i f
equi pped.
SEAT - FRONT - I NSTALLATI ON)
SEAT - REAR
REMOVAL
(1) Remove the l oad fl oor. (Refer to 23 - BODY/I N-
TERI OR/LOAD FLOOR - REMOVAL)
(2) Fol d the rear seat cushi ons up and remove the
rear bol ts. (Fi g. 17)
(3) Li ft each seat assembl y up and di sengage the
seat back frame hooks from the footmans l oops bol ted
to the rear cab back. (Fi g. 18)
(4) Remove the seats from the vehi cl e.
INSTALLATION
(1) I nstal l the seats i nto the vehi cl e and engage
the seat back frame hooks wi th the footmans l oops i n
the cab back panel .
(2) I nstal l the rear seat bol ts and ti ghten to 40
Nm (30 ft. l bs.).
(3) I nstal l the l oad fl oor. (Refer to 23 - BODY/I N-
TERI OR/LOAD FLOOR - I NSTALLATI ON)
SEAT BACK - REAR
REMOVAL
(1) Remove the rear seat. (Refer to 23 - BODY/
SEATS/SEAT - REAR - REMOVAL)
(2) Remove the seat back bol ts and remove the
seat back. (Fi g. 19)
INSTALLATION
(1) I nstal l the seat back and i nstal l the bol ts.
Fig. 17 SEAT ATTACHMENT
1 - OUTER BOLTS (2)
2 - REAR SEAT ASSEMBLY
3 - INNER BOLTS (4)
4 - REAR SEAT BACK
5 - OUTER BOLTS (2)
DR SEATS 23 - 83
(3) I nstal l the rear seat. (Refer to 23 - BODY/
SEATS/SEAT - REAR - I NSTALLATI ON)
SEAT BACK CUSHION / COVER
- REAR
REMOVAL
(1) Remove the rear seat back. (Refer to 23 -
BODY/SEATS/SEAT BACK - REAR - REMOVAL)
(2) Remove the headrest sl eeves. (Refer to 23 -
BODY/SEATS/HEADREST SLEEVE - REMOVAL)
(3) Unzi p the zi p stri p at the bottom of the seat
back and remove the cover.
INSTALLATION
(1) I nstal l the seat back cover and connect the zi p
stri p.
(2) I nstal l the headrest sl eeves. (Refer to 23 -
BODY/SEATS/HEADREST SLEEVE - I NSTALLA-
TI ON)
(3) I nstal l the seat back. (Refer to 23 - BODY/
SEATS/SEAT BACK - REAR - I NSTALLATI ON)
SEAT CUSHION / COVER -
REAR
REMOVAL
(2) Separate the zi p stri p at the rear of the seat
cushi on and remove the cushi on and cover.
INSTALLATION
(1) I nstal l the seat cushi on and cover over the
cushi on frame assembl y and connect the zi p stri p.
SEAT - REAR - I NSTALLATI ON)
Fig. 18 SEAT BACK ATTACHMENT
1 - OUTER SEAT BACK FRAME HOOKS (2)
2 - OUTER FOOTMANS LOOP (2)
3 - INNER SEAT BACK FRAME HOOKS (2)
4 - INNER FOOTMANS LOOP (2)
5 - SEAT BACK
Fig. 19 REAR SEAT HINGE
1 - SEAT BACK BOLT (2)
2 - SEAT CUSHION
3 - SEAT BACK/CUSHION HINGE
4 - SEAT BACK
23 - 84 SEATS DR
SEAT BACK - REAR (Continued)
SEAT CUSHION FRAME - REAR
REMOVAL
(1) Remove the seat cushi on/cover. (Refer to 23 -
BODY/SEATS/SEAT CUSHI ON / COVER - REAR -
REMOVAL)
(2) Remove the bol ts and remove the seat cushi on
frame. (Fi g. 20)
INSTALLATION
(1) I nstal l the seat cushi on frame onto the rear
seat hi nges.
(2) I nstal l the bol ts and ti ghten to 32 Nm (24 ft.
l bs.).
(3) I nstal l the seat cushi on/cover. (Refer to 23 -
BODY/SEATS/SEAT CUSHI ON / COVER - REAR -
I NSTALLATI ON)
SEAT BACK REAR -
FOOTMANS LOOP BRACKETS
REMOVAL
(2) Remove bol ts and remove the l oop. (Fi g. 21)
INSTALLATION
(1) I nstal l the l oop and i nstal l the bol ts.
SEAT - REAR - I NSTALLATI ON)
Fig. 20 SEAT CUSHION FRAME ATTACHMENT
1 - REAR SEAT BACK
2 - REAR SEAT CUSHION FRAME
3 - SEAT CUSHION FRAME BOLTS (4)
4 - SEAT CUSHION HINGE
Fig. 21 FOOTMANS LOOP BRACKET
1 - FOOTMANS LOOP (4)
2 - BOLTS (2 PER LOOP)
3 - CAB BACK PANEL
DR SEATS 23 - 85
STATIONARY GLASS
TABLE OF CONTENTS
page page
BACKLITE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 86
BACKLITE VENT GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 87
WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS . . . . . 88
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 88
BACKLITE
REMOVAL
I t i s di ffi cul t to sal vage the backl i te duri ng the
removal operati on. The backl i te i s part of the struc-
tural support for the roof. The urethane bondi ng
used to secure the gl ass to the fence i s di ffi cul t to cut
or cl ean from any surface. Si nce the mol di ng i s set i n
urethane, i t i s unl i kel y i t woul d be sal vaged. Before
removi ng the backl i te, check the avai l abi l i ty from the
parts suppl i er.
The backl i te i s attached to the wi ndow frame wi th
urethane adhesi ve. The urethane adhesi ve i s appl i ed
col d and seal s the surface area between the wi ndow
openi ng and the gl ass. The pri mer adheres the ure-
thane adhesi ve to the backl i te.
(1) Rol l down door gl ass.
(2) Remove headl i ner. (Refer to 23 - BODY/I NTE-
RI OR/HEADLI NER - REMOVAL).
(3) On standard cab model s remove the upper
b-pi l l ar tri m. (Refer to 23 - BODY/I NTERI OR/B-PI L-
LAR UPPER TRI M - REMOVAL)
(4) On quad cab model s remove the upper c-pi l l ar
tri m. (Refer to 23 - BODY/I NTERI OR/C-PI LLAR
UPPER TRI M - REMOVAL)
(5) Bend backl i te retai ni ng tabs (Fi g. 1) i nward
agai nst gl ass.
(6) Di sconnect the rear wi ndow defogger el ectri cal
(7) Usi ng a sui tabl e pneumati c kni fe from i nsi de
the vehi cl e, cut urethane hol di ng backl i te frame to
openi ng fence.
(8) Separate gl ass from vehi cl e.
INSTALLATION
(1) Cl ean urethane adhesi ve from around backl i te
openi ng fence.
(2) I f necessary, appl y bl ack-out pri mer to outer
edge of repl acement backl i te frame.
(3) I f bl ack-out pri mer was pre-appl i ed on backl i te,
cl ean bondi ng surface wi th I sopropyl al cohol and
cl ean l i nt free cl oth. Al l ow 3 mi nutes for dryi ng ti me.
(4) Appl y bl ack-out pri mer to backl i te openi ng
fence.
(5) Appl y a 13 mm (0.5 i n.) bead of urethane
around the peri meter of the wi ndow frame bondi ng
surface (Fi g. 2).
(6) Set gl ass on l ower fence and move gl ass for-
ward i nto openi ng (Fi g. 3).
(7) Fi rml y push gl ass agai nst rear wi ndow gl ass
openi ng fence.
(8) Bend tabs around edges of backl i te openi ng
fence to retai n gl ass.
(9) Cl ean excess urethane from exteri or wi th
MOPAR, Super Cl ean or equi val ent.
(10) Al l ow urethane to cure at l east 24 hours (ful l
cure i s 72 hours).
(11) Water test to veri fy repai r before returni ng
vehi cl e to servi ce.
(12) Connect the rear wi ndow defogger el ectri cal
Fig. 1 Backlite Tabs
1 - BACKLITE
2 - TAB
23 - 86 STATIONARY GLASS DR
(13) On standard cab model s, i nstal l the upper
b-pi l l ar tri m. (Refer to 23 - BODY/I NTERI OR/B-PI L-
LAR UPPER TRI M - I NSTALLATI ON)
(14) On quad cab model s, i nstal l the upper c-pi l l ar
tri m. (Refer to 23 - BODY/I NTERI OR/C-PI LLAR
UPPER TRI M - I NSTALLATI ON)
(15) I nstal l the headl i ner. (Refer to 23 - BODY/I N-
TERI OR/HEADLI NER - I NSTALLATI ON).
BACKLITE VENT GLASS
REMOVAL
(1) Sl i de the upper run channel out of the wi ndow
frame. (Fi g. 4)
(2) Sl i de the vent gl ass upward to remove from the
l ower wi ndow frame.
(3) Lower the gl ass out of the upper wi ndow frame
and remove.
INSTALLATION
(1) Sl i de the vent gl ass upper edge i nto wi ndow
frame and i nsert the l ower edge i nto the l ower mol d-
i ng.
(2) Posi ti on the upper run channel i nto the wi n-
dow frame and sl i de i t i nto pl ace.
(3) Veri fy vent gl ass operati on.
Fig. 2 Urethane Adhesive Application
1 - WINDOW FRAME
2 - GLASS
3 - RETAINER TAB
4 - URETHANE ADHESIVE
Fig. 3 Backlite Installation
1 - BACKLITE
Fig. 4 UPPER GLASS RUN CHANNEL
1 - GLASS RUN CHANNEL
2 - VENT GLASS FRAME
3 - VENT GLASS
DR STATIONARY GLASS 23 - 87
BACKLITE (Continued)
WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A
SYSTEM. USE GLASS CLEANER, GLASS PREP
SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER
AND PINCH WELD (FENCE) PRIMER PROVIDED BY
THE ADHESIVE MANUFACTURER. IF NOT, STRUC-
TURAL INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MAN-
UFACTURERS DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
REMOVAL
(1) Remove i nsi de rear vi ew mi rror. (Refer to 23 -
BODY/I NTERI OR/REAR VI EW MI RROR -
REMOVAL).
(2) Remove cowl gri l l . (Refer to 23 - BODY/EXTE-
RI OR/COWL GRI LLE - REMOVAL).
(3) Remove the a-pi l l ar weatherstri p retai ner.
(Refer to 23 - BODY/WEATHERSTRI P/SEALS/A-
PI LLAR WEATHERSTRI P RETAI NER - REMOVAL)
(4) Remove the a-pi l l ar tri m panel s. (Refer to 23 -
BODY/I NTERI OR/A-PI LLAR TRI M - REMOVAL)
(5) Remove the headl i ner and from the i nsi de of
the vehi cl e, cut the upper urethane bondi ng from
around wi ndshi el d upper edge usi ng a sui tabl e sharp
col d kni fe (C-4849). A pneumati c cutti ng devi ce can
be used but i s not recommended. (Refer to 23 -
BODY/I NTERI OR/HEADLI NER - REMOVAL)
(6) From the outsi de of the vehi cl e, cut urethane
bondi ng from the remai ni ng si des of the wi ndshi el d
usi ng a sui tabl e sharp col d kni fe (C-4849). A pneu-
mati c cutti ng devi ce can be used but i s not recom-
mended.
(7) Separate wi ndshi el d from vehi cl e.
INSTALLATION
WARNING: Allow the urethane at least 24 hours to
cure before returning the vehicle to use.
CAUTION: Roll down the left and right front door
glass and open the rear glass slider (if available)
before installing windshield to avoid pressurizing
the passenger compartment if a door is slammed
before urethane is cured. Water leaks can result.
The wi ndshi el d fence shoul d be cl eaned of most of
i ts ol d urethane bondi ng materi al . A smal l amount of
ol d urethane, approxi matel y 1-2 mm i n hei ght,
shoul d remai n on the fence. Do not gri nd off or com-
pl etel y remove al l ol d urethane from the fence, the
pai nt fi ni sh and bondi ng strength wi l l be adversel y
affected.
(1) Pl ace repl acement wi ndshi el d i nto wi ndshi el d
openi ng and posi ti on gl ass i n the center of the open-
i ng agai nst the support spacers. Mark the outsi de
surface of the gl ass at the support spacers wi th a
grease penci l or pi eces of maski ng tape and i nk pen
to use as a reference for i nstal l ati on. Remove repl ace-
ment wi ndshi el d from wi ndshi el d openi ng (Fi g. 5).
(2) Posi ti on the wi ndshi el d i nsi de up on a sui tabl e
work surface wi th two padded, wood 10 cm by 10 cm
by 50 cm (4 i n. by 4 i n. by 20 i n.) bl ocks, pl aced par-
al l el 75 cm (2.5 ft.) apart (Fi g. 6).
(3) Cl ean i nsi de of wi ndshi el d wi th MOPAR Gl ass
Cl eaner and l i nt-free cl oth.
(4) Appl y cl ear gl ass pri mer 25 mm (1 i n.) wi de
around peri meter of wi ndshi el d and wi pe wi th a new
cl ean and dry l i nt- free cl oth.
(5) Appl y bl ack-out pri mer onto the gl ass usi ng the
wi ndshi el d mol di ng as a gui de. The pri mer shoul d be
15 mm (5/8 i n.) wi de on the top and si des of the gl ass
and 25 mm (1 i n.) on the bottom of wi ndshi el d. Al l ow
at l east three mi nutes dryi ng ti me.
(6) Locate new support spacers on support brack-
ets and adjust to l owest hei ght. (Fi g. 5)
(7) Posi ti on seven new foam spacers on the i nsi de
surface of the wi ndshi el d, fl ush wi th the l ower and
si de edges. (Fi g. 7)
(8) Posi ti on three new foam spacers on the i nsi de
surface of the wi ndshi el d, at a mi ni mum di stance of
3 mm (0.12 i n.) from the top edge of the wi ndshi el d.
(Fi g. 7)
(9) Appl y a 13 mm (1/2 i n.) hi gh and 10 mm (3/8
i n.) wi de bead of urethane around the peri meter of
wi ndshi el d. At the top, appl y the bead 7 mm (1/4 i n.)
i nboard from the gl ass edge. On the other three si des
appl y the bead 14 mm (0.55 i n.) i nboard from the
gl ass edge. The urethane bead shoul d be shaped i n a
tri angul ar cross-secti on, thi s can be achi eved by
notchi ng the ti p of the appl i cator (Fi g. 8).
(10) I nstal l the a-pi l l ar tri m. (Refer to 23 - BODY/
I NTERI OR/A-PI LLAR TRI M - I NSTALLATI ON)
(11) Wi th the ai d of a hel per, posi ti on the wi nd-
shi el d over the wi ndshi el d openi ng. Al i gn the refer-
ence marks at the bottom of the wi ndshi el d to the
support spacers.
(12) Sl owl y l ower wi ndshi el d gl ass to the fence
openi ng gui di ng the l ower corners i nto proper posi -
ti on. Begi nni ng at the bottom and conti nui ng to the
top, push gl ass onto fence al ong the A-Pi l l ars. Push
wi ndshi el d i nward to the fence at the bottom corners
(Fi g. 9).
(13) Push wi ndshi el d upward, setti ng the wi nd-
shi el d to roof gap to 1.5 mm (0.06 i n.) to 3 mm (0.12
i n.) and ratchet up the adjustabl e support brackets.
(14) Usi ng cl ean water, l i ghtl y mi st the support
spacers.
(15) Cl ean excess urethane from exteri or wi th
MOPAR Super Cl ean or equi val ent.
(16) I nstal l cowl gri l l . (Refer to 23 - BODY/EXTE-
RI OR/COWL GRI LLE - I NSTALLATI ON).
(17) I nstal l rear vi ew mi rror support bracket.
(Refer to 23 - BODY/I NTERI OR/REAR VI EW MI R-
ROR - I NSTALLATI ON).
(18) I nstal l rear vi ew mi rror. (Refer to 23 - BODY/
I NTERI OR/REAR VI EW MI RROR - I NSTALLA-
TI ON).
(19) I nstal l the a-pi l l ar weatherstri p retai ner.
(Refer to 23 - BODY/WEATHERSTRI P/SEALS/A-
PI LLAR WEATHERSTRI P RETAI NER - I NSTALLA-
TI ON)
(20) After urethane has cured, remove tape stri ps
and water test wi ndshi el d to veri fy repai r.
Fig. 5 CENTER WINDSHIELD AND MARK AT
SUPPORT
1 - WINDSHIELD
2 - INDEX MARKS
3 - SUPPORT SPACERS
Fig. 6 WORK SURFACE SET UP
1 - WINDSHIELD AND MOLDINGS
2 - URETHANE BEAD AROUND GLASS 7mm (0.3 in.) FROM
EDGE
3 - BLOCKS
DR STATIONARY GLASS 23 - 89
WINDSHIELD (Continued)
Fig. 7 WINDSHIELD FOAM SUPPORT SPACERS
1 - UPPER FOAM SPACERS (3)
2 - SPACER LOCATION 75 MM (2.95 IN)
3 - LOWER FOAM SPACERS (3)
4 - SIDE FOAM SPACERS (4)
Fig. 8 APPLICATOR TIP
1 - APPLICATOR TIP
Fig. 9 LOWER WINDSHIELD INTO POSITION
1 - COMPRESSION SPACER
2 - WINDSHIELD
3 - ADJUSTABLE SUPPORT SPACERS
WINDSHIELD (Continued)
WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
A-PILLAR WEATHERSTRIP RETAINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91
DRIP RAIL WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91
DOOR OPENING SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92
DRIP RAIL WEATHERSTRIP RETAINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92
FRONT DOOR GLASS RUN WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92
FRONT DOOR OUTER BELT MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 93
FRONT DOOR INNER BELT MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 93
REAR DOOR GLASS RUN WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 93
REAR DOOR OUTER BELT MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 94
REAR DOOR INNER BELT MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 94
A-PILLAR WEATHERSTRIP
RETAINER
REMOVAL
(1) Remove the dri p rai l weatherstri p retai ner.
(Refer to 23 - BODY/WEATHERSTRI P/SEALS/DRI P
RAI L WEATHERSTRI P - REMOVAL)
(2) Remove the fi ve screws and remove the weath-
ersti p retai ner. (Fi g. 1)
INSTALLATION
(1) I nstal l the weathersti p retai ner and i nstal l the
screws.
(2) I nstal l the dri p rai l weatherstri p retai ner.
(Refer to 23 - BODY/WEATHERSTRI P/SEALS/DRI P
RAI L WEATHERSTRI P - I NSTALLATI ON)
REMOVAL
(1) Open the doors and separate the weatherstri p
from the dri p rai l and a-pi l l ar retai ners. (Fi g. 1)
INSTALLATION
(1) Posi ti on the weatherstri p onto the dri p rai l and
a-pi l l ar retai ners and seat ful l y.
Fig. 1 DOOR OPENING WEATHERSTRIPS/SEALS
1 - DRIP RAIL WEATHERSTRIP RETAINER
2 - SCREWS (7)
3 - DRIP RAIL WEATHERSTRIP
4 - CAB
5 - REAR DOOR OPENING SEAL
6 - FRONT DOOR OPENING SEAL
7 - A-PILLAR WEATHERSTRIP RETAINER
8 - SCREWS (5)
9 - CORNER SEAL
DR WEATHERSTRIP/SEALS 23 - 91
DOOR OPENING SEAL
REMOVAL
FRONT DOOR SEAL
(1) Remove the cowl tri m panel . (Refer to 23 -
BODY/I NTERI OR/COWL TRI M - REMOVAL)
(2) Remove the l ower b-pi l l ar tri m panel . (Refer to
REMOVAL)
(3) Separate the door openi ng seal from the door
openi ng fl ange. (Fi g. 1)
REAR DOOR SEAL
(1) Remove the l ower b-pi l l ar tri m panel . (Refer to
REMOVAL)
(2) Remove the l ower c-pi l l ar tri m. (Refer to 23 -
BODY/I NTERI OR/C-PI LLAR TRI M - REMOVAL)
(3) Separate the door openi ng seal from the door
openi ng fl ange. (Fi g. 1)
INSTALLATION
FRONT DOOR SEAL
(1) Posi ti on the seal to the bottom of the door
openi ng, wi th bul b faci ng outboard, starti ng the
i nstal l ati on at the center of the l ower fl ange. Press
the seal onto the si l l fl ange and work around the
peri meter of the door openi ng unti l ful l y seated.
Work i n one di recti on, smoothi ng the seal to avoi d
puckers or wri nkl es.
I NSTALLATI ON)
(3) I nstal l the cowl tri m panel . (Refer to 23 -
(4) When i nstal l i ng a new weatherstri p on the
front door openi ng, remove the tear stri p starti ng at
the spl i ce and movi ng around the front of the door to
the back of the openi ng.
REAR DOOR SEAL
(1) Posi ti on the seal to the bottom of the door
openi ng, wi th bul b faci ng outboard, starti ng the
i nstal l ati on at the center of the l ower fl ange. Press
the seal onto the si l l fl ange and work around the
peri meter of the door openi ng unti l ful l y seated.
Work i n one di recti on, smoothi ng the seal to avoi d
puckers or wri nkl es.
(2) I nstal l the l ower c-pi l l ar tri m. (Refer to 23 -
BODY/I NTERI OR/C-PI LLAR TRI M - I NSTALLA-
TI ON)
I NSTALLATI ON)
(4) When i nstal l i ng a new weatherstri p on the rear
door openi ng, remove the tear stri p starti ng at the
spl i ce and movi ng around the back of the door to the
front of the openi ng.
RETAINER
REMOVAL
(1) Separate the dri p rai l weatherstri p from the
weatherstri p retai ner. (Fi g. 1)
(2) Remove the seven screws and remove the
retai ner.
INSTALLATION
(1) I nstal l the weatherstri p retai ner and i nstal l
the seven screws.
(2) Posi ti on the weatherstri p over the retai ner
fl ange and seat ful l y.
FRONT DOOR GLASS RUN
WEATHERSTRIP
REMOVAL
(1) Remove the door gl ass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - REMOVAL)
(2) Separate the weatherstri p out of the door
frame and remove through the wi ndow openi ng. (Fi g.
2)
INSTALLATION
NOTE: A mixture of soap and water may be used to
aid installation of the weatherstrip into the corners.
(1) Posi ti on the gl ass run weatherstri p i nto the
door through the wi ndow openi ng.
(2) Posi ti on the weatherstri p i nto the upper cor-
ners and seat fi rml y.
(3) From back to front, seat the weatherstri p
between the corners and then down the si des fi rml y
(4) I nstal l the door gl ass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - I NSTALLATI ON)
FRONT DOOR OUTER BELT
MOLDING
REMOVAL
(1) Remove the screw and separate the bel t mol d-
i ng from the door fl ange from the back to the front.
(Fi g. 2)
23 - 92 WEATHERSTRIP/SEALS DR
INSTALLATION
(1) Posi ti on the bel t mol di ng onto the door fl ange
and seat ful l y.
(2) I nstal l the screw.
FRONT DOOR INNER BELT
MOLDING
REMOVAL
(2) Separate the bel t mol di ng from the mounti ng
fl ange from the back to the front. (Fi g. 3)
INSTALLATION
(1) Posi ti on the bel t mol di ng and seat onto the
mounti ng fl ange ful l y.
TI ON)
REAR DOOR GLASS RUN
WEATHERSTRIP
REMOVAL
(1) Lower the gl ass.
(2) Separate the weatherstri p out of the door
frame and remove through the wi ndow openi ng. (Fi g.
4)
INSTALLATION
NOTE: A mixture of soap and water may be used to
aid installation of the weatherstrip into the corners.
(1) Posi ti on the gl ass run weatherstri p i nto the
door through the wi ndow openi ng.
(2) Posi ti on the weatherstri p i nto the upper cor-
ners and seat fi rml y.
(3) From back to front, seat the weatherstri p
between the corners and then down the si des fi rml y.
REAR DOOR OUTER BELT
MOLDING
REMOVAL
(1) Remove the screw and separate the bel t mol d-
i ng from the door fl ange from the back to the front.
(Fi g. 4)
Fig. 2 FRONT DOOR GLASS SEALS
1 - OUTER BELT MOLDING
2 - FRONT DOOR GLASS RUN WEATHERSTRIP
3 - LOWER DOOR SEAL
4 - SCREW
5 - FRONT DOOR
Fig. 3 INNER BELT MOLDING
1 - BELT MOLDING
2 - CORNER SEAL
3 - FRONT DOOR
DR WEATHERSTRIP/SEALS 23 - 93
FRONT DOOR OUTER BELT MOLDING (Continued)
INSTALLATION
(1) Posi ti on the bel t mol di ng onto the door fl ange
and seat ful l y.
(2) I nstal l the screw.
REAR DOOR INNER BELT
MOLDING
REMOVAL
BODY/DOORS - REAR/TRI M PANEL - REMOVAL)
(2) Separate the bel t mol di ng from the mounti ng
fl ange from the back to the front. (Fi g. 5)
INSTALLATION
(1) Posi ti on the bel t mol di ng and seat onto the
mounti ng fl ange ful l y.
TI ON)
Fig. 4 REAR DOOR GLASS SEALS
1 - OUTER BELT MOLDING
2 - REAR DOOR
3 - SCREW
4 - LOWER DOOR SEAL
5 - GLASS RUN WEATHERSTRIP
Fig. 5 REAR DOOR INNER SEALS
1 - REAR SECONDARY SEAL
2 - INNER BELT MOLDING
3 - FRONT SECONDARY SEAL
4 - SCREWS
23 - 94 WEATHERSTRIP/SEALS DR
REAR DOOR OUTER BELT MOLDING (Continued)
BODY STRUCTURE
TABLE OF CONTENTS
page page
GAP AND FLUSH
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 95
OPENING DIMENSIONS
SPECIFICATIONS - BODY OPENING
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . 99
SEALER LOCATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 102
STRUCTURAL ADHESIVE LOCATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 112
WELD LOCATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 120
GAP AND FLUSH
SPECIFICATIONS
GAP & FLUSH DIMENSIONS INDEX
DESCRIPTION FIGURE
STANDARD CAB 1
QUAD CAB 2
PICKUP BOX 3
DR BODY STRUCTURE 23 - 95
NOTE:
All measurements are in mm.
O/F = Over Fl ush
U/F = Under Fl ush
DIMENSION DESCRIPTION GAP FLUSH
*1 Bumper to grille 19.0 3.0
*2 Hood to grille 1.5 1.0
Parallel within 2.0
U/F 0.75 1.75
*3 Fender to hood 6.0 2.0
Parallel within 1.0
U/F 3.2 1.5
(Underflush from front of
hood to start of hockey
stick area only)
*4 Fender to hood
(Up/Down surface only)
6.0 1.5
Parallel within 1.0
0.0 1.5
*5 Front door to windshield O/F 20.5 1.5
(Base of windshield)
O/F 9.0 1.5
(Top of windshield)
*6 Roof to front door U/F 6.0 1.5
Parallel within 1.5
7 Quarter to front door 5.0 1.5
Parallel within 1.0
0.0 1.5
8 Front door to quarter character line
alignment
Up/Down 0.0 1.5
*9 Front door to fender character line
alignment
Up/Down 0.0 1.5
*10 Front door to fender 5.0 1.5
Parallel within 1.0
0.0 1.5
*11 Bumper to fender 19.0 3.0
Parallel within 3.0
O/F 5.0 5.0 (SLT)
O/F 14.0 5.0 (SPORT)
*12 Bumper to headlamp 19.0 4.0
* ALL MODELS
Fig. 1 GAP & FLUSH - STANDARD CAB
23 - 96 BODY STRUCTURE DR
GAP AND FLUSH (Continued)
NOTE:
O/F = Over Fl ush
U/F = Under Fl ush
1 Roof to rear door U/F 6.0 1.5
Parallel within 1.5
2 Quarter to rear door 5.0 1.5
Parallel within 2.0
0.0 1.5
3 Rear door to quarter character line
alignment
Up/Down 0.0 1.5
4 Rear door to front door character line
alignment
Up/Down 0.0 1.5
5 Rear door to front door 5.0 1.5
Parallel within 2.0
0.0 1.5
Fig. 2 GAP & FLUSH - QUAD CAB
NOTE:
O/F = Over Fl ush
U/F = Under Fl ush
1 Tailgate to outer box
(Up/Down surface only)
0.0 1.5
Parallel within 1.0
2 Cab Back to box front 31.0 5.0
Parallel within 3.0
3 Fuel door to outer box 5.0 1.5

Parallel within 1.0
0.0 1.5
4 Cab to box side 31.0 5.0
Parallel within 3.0
4.0 2.5 (Standard Cab)
O/F 5.0 2.5 (Quad Cab)
5 Cab to box character line alignment Up/Down 0.0 3.0
6 Tailgate to outer box 5.0 2.0
Parallel within 1.0
U/F 1.5 1.5
7 Bumper to outer box 24.75 5.0 (F/A)
23.75 5.0 (C/C)
Parallel within 5.0
8 Tailgate to outer box character line

adjustment
Up/Down 0.0 1.5
9 Bumper to tailgate 30.25 3.0
Parallel within 4.0
Fig. 3 GAP & FLUSH - PICKUP BOX

OPENING DIMENSIONS
SPECIFICATIONS - BODY OPENING
DIMENSIONS
INDEX
DESCRIPTION FIGURE
WINDSHIELD OPENING 4
DOOR OPENING - STANDARD
CAB
5
DOOR OPENINGS - QUAD CAB 6
REAR WINDOW OPENING 7
ENGINE COMPARTMENT/FRONT
STRUCTURE
8
Fig. 4 WINDSHIELD OPENING
Fig. 5 DOOR OPENING - STANDARD CAB
Fig. 6 DOOR OPENINGS - QUAD CAB
OPENING DIMENSIONS (Continued)
Fig. 7 REAR WINDOW OPENING
Fig. 8 ENGINE COMPARTMENT/FRONT STRUCTURE
OPENING DIMENSIONS (Continued)
SEALER LOCATIONS
SPECIFICATIONS
INDEX
DESCRIPTION FIGURE
LOWER WINDSHIELD PILLAR, LOWER PLENUM AND COWL BAR 9
DASH PANEL, LOWER PLENUM AND COWL SIDE PANEL 10
LOWER DASH PANEL, LOWER COWL SIDE AND FLOOR PAN SUPPORT 11
ROOF PANEL, OUTER BODY SIDE APERTURE AND BACKLITE 12
CAB BACK, BODY SIDE APERTURE - REAR AND BACKLITE LOWER CORNER 13
LOWER DASH PANEL AND FLOOR PAN 14
FLOOR PAN AND BODY SIDE APERTURE 15
FRONT FLOOR PAN AND REAR PAN 16
FLOOR PAN TO CAB BACK 17
PICKUP BOX 18
Fig. 9 LOWER WINDSHIELD PILLAR
Fig. 10 DASH PANEL
SEALER LOCATIONS (Continued)
Fig. 11 LOWER DASH PANEL
Fig. 12 ROOF PANEL
Fig. 13 CAB BACK PANEL
Fig. 14 LOWER DASH PANEL
Fig. 15 FLOOR PAN
Fig. 16 FRONT FLOOR PAN
Fig. 17 FLOOR PAN
Fig. 18 PICKUP BOX
STRUCTURAL ADHESIVE
LOCATIONS
SPECIFICATIONS
INDEX
DESCRIPTION FIGURE
FLOOR PAN AND SEAT MOUNTING FRONT CROSSMEMBER 19
FRONT FENDER 20
FLOOR PAN 21
INNER WHEELHOUSE TO INNER BOX SIDE PANEL 22
INNER BOX SIDE PANEL TO OUTER BOX SIDE PANEL 23
INNER WHEELHOUSE, CROSSMEMBERS AND CROSSMEMBER END SUPPORT
BRACKET TO INNER BOX SIDE PANEL
24
INNER BOX SIDE PANEL TO OUTER BOX SIDE PANEL 25
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (QUAD CAB) 26
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (STANDARD CAB) 27
INNER DOOR PANEL TO OUTER DOOR PANEL - REAR DOOR (QUAD CAB) 28
SILL RAIL - STD CAB 29
SILL RAIL - QUAD CAB 30
Fig. 19 FLOOR PAN
Fig. 20 FRONT FENDER
Fig. 21 FLOOR PAN
STRUCTURAL ADHESIVE LOCATIONS (Continued)
Fig. 22 INNER WHEELHOUSE
Fig. 23 INNER BOX SIDE PANEL
Fig. 24 INNER WHEELHOUSE
Fig. 25 INNER BOX SIDE PANEL
Fig. 26 INNER DOOR PANEL
Fig. 27 INNER DOOR PANEL
Fig. 28 REAR DOOR INNER PANEL
Fig. 29 SILL RAIL - STD CAB
Fig. 30 SILL RAIL - QUAD CAB
WELD LOCATIONS
SPECIFICATIONS
INDEX
DESCRIPTION FIGURE
FENDER BRACE, CLOSURE TUBE AND FRAME MOUNTING BRACKET TO FRONT
FENDER SUPPORT, FRONT FENDER AND RADIATOR TUBE
31
STEERING COLUMN SUPPORT, CONNECTOR WIRING BRACKET AND WELD NUTS
TO LOWER PLENUM PANEL
32
WIPER ATTACHING WELD NUTS AND VACUUM RESERVOIR ATTACHING STUDS TO
COWL PAR PANEL
33
DASH PANEL TO FRONT FLOOR PAN 34
DASH PANEL TO LOWER PLENUM PANEL 35
LOWER PLENUM PANEL TO COWL BACK PANEL 36
FRONT FENDER AND RADIATOR TUBE DASH PANEL, INSTRUMENT PANEL
MOUNTING BRACKET, AND WELD NUTS TO COWL SIDE PANEL - LEFT SIDE
37
DASH PANEL, LOWER PLENUM PANEL AND COWL PANEL BAR TO COWL SIDE
PANEL - LEFT SIDE
38
FRONT FENDER AND RADIATOR TUBE DASH PANEL, INSTRUMENT PANEL
MOUNTING BRACKET AND WELD NUTS TO COWL SIDE PANEL - RIGHT SIDE
39
DASH PANEL, LOWER PLENUM PANEL AND COWL PANEL BAR TO COWL SIDE
PANEL - RIGHT SIDE
40
REINFORCEMENT AND HEADLAMP MOUNTING PANEL TO OUTER FENDER PANEL 41
SEAT MOUNTING FRONT BRACKETS TO SEAT MOUNTING FRONT CROSSMEMBER
TO FRONT FLOOR PAN
42
AIR BAG MODULE BRACKET SHIFTER MOUNTING PLATE AND REAR FLOOR PANE
TO FRONT FLOOR PAN
43
RIGHT TO LEFT REAR FLOOR CROSSMEMBER AND RIGHT TO LEFT SEAT
MOUNTING CROSSMEMBER
44
REAR FLOOR CROSSMEMBER, SEAT MOUNTING CROSSMEMBER AND
UNDERBODY SUPPORT TO FLOOR SILL
45
SEAT MOUNTING FRONT CROSSMEMBER TO FRONT FLOOR PAN TO UNDERBODY
SUPPORT
46
FRONT SEAT MOUNTING CROSSMEMBERS TO FRONT SEAT MOUNTING BRACKET
TO FRONT FLOOR PAN
47
REAR FLOOR CROSSMEMBERS TO REAR FLOOR PAN 48
FLOOR SILL TO FRONT SEAT MOUNTING CROSSMEMBER, FRONT AND REAR
FLOOR PAN
49
AIR BAG MODULE BRACKET, SHIFTER MOUNTING PLATE AND FRONT SEAT
MOUNTING CROSSMEMBER TO FRONT FLOOR PAN
50
REAR SEAT MIDDLE MOUNTING PLATE TO REAR FLOOR PAN TO FRONT FLOOR
PAN
51
REAR FLOOR CROSSMEMBER, SEAT MOUNTING CROSSMEMBER AND
UNDERBODY SUPPORT TO FLOOR SILL
52
LEFT REAR CROSSMEMBER TO RIGHT REAR CROSSMEMBER TO REAR FLOOR
PAN
53
DESCRIPTION FIGURE
STORAGE BIN TO RIGHT AND LEFT REAR FLOOR CROSSMEMBER TO REAR
FLOOR PAN
54
RIGHT REAR FRONT SEAT MOUNTING CROSSMEMBER TO LEFT REAR FRONT
SEAT MOUNTING CROSSMEMBER TO REAR FLOOR PAN
55
FRONT SEAT MOUNTING FRONT CROSSMEMBER AND STORAGE BIN TO FLOOR
SILL TO FRONT AND REAR FLOOR PAN
56
FRONT SEAT MOUNTING FRONT CROSSMEMBER TO UNDERBODY SUPPORT TO
FRONT FLOOR PAN
57
A-PILLAR REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER BODY
SIDE APERTURE
58
A-PILLAR REINFORCEMENT TO FRONT APERTURE EXTENSION TO INNER BODY
SIDE APERTURE TO OUTER BODY SIDE APERTURE
59
INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE 60
SHOULDER BELT REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER
BODY SIDE APERTURE
61
FRONT PILLAR TAPPING PLATES TO INNER BODY SIDE APERTURE TO OUTER
BODY SIDE APERTURE
62
INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE 63
C-PILLAR BAFFLE AND OUTER BODY SIDE APERTURE TO INNER BODY SIDE
APERTURE
64
A-PILLER REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER BODY
SIDE APERTURE
65
FRONT EXTENSION PLATE TO INNER BODY SIDE APERTURE TO OUTER BODY
SIDE APERTURE TO A-PILLAR REINFORCEMENT
66
OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE 67
B-PILLAR REINFORCEMENT TO INNER BODY SIDE APERTURE TO OUTER BODY
SIDE APERTURE
68
UPPER B-PILLAR TAPPING PLATE AND LOWER B-PILLAR TAPPING PLATE TO
OUTER BODY SIDE APERTURE
69
UPPER A-PILLAR TAPPING PLATE AND LOWER A-PILLAR TAPPING PLATE TO INNER
BODY SIDE APERTURE
70
SEAT BELT MOUNTING PLATES AND REINFORCEMENTS TO INNER BODY SIDE
APERTURE
71
OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE 72
C-PILLAR REINFORCEMENTS AND SHOULDER BELT MOUNTING REINFORCEMENT
TO INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE
73
SEAT BELT RETRACTOR PLATE TO FLOOR SILL TO INNER BODY SIDE APERTURE
TO OUTER BODY SIDE APERTURE
74
FLOOR SILL TO INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE 75
BACK REINFORCEMENT AND CAB BACK PANEL TO REAR FLOOR CROSSMEMBER
AND INNER BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE
76
CAB BACK REINFORCEMENT TO CAB BACK PANEL (CHILD TETHERS) 77
COWL SIDE PANEL TO INNER BODY SIDE APERTURE TO OUTER BODY SIDE
APERTURE
78
OUTER ROOF PANEL TO OUTER BODY SIDE APERTURE 79
ROOF HEADER TO OUTER ROOF PANEL TO A-PILLAR REINFORCEMENT TO INNER
BODY SIDE APERTURE TO OUTER BODY SIDE APERTURE
80
WELD LOCATIONS (Continued)
DESCRIPTION FIGURE
REAR ROOF HEADER TO OUTER ROOF PANEL TO INNER BODY SIDE APERTURE
TO OUTER BODY SIDE APERTURE
81
OUTER BODY SIDE APERTURE TO CAB BACK PANEL TO FLOOR SILL, INNER BODY
SIDE APERTURE TO FLOOR SILL
82
OUTER BODY SIDE APERTURE TO INNER BODY SIDE APERTURE TO FLOOR SILL 83
REAR FLOOR CROSSMEMBER AND CAB BACK REINFORCEMENT TO CAB BACK
PANEL TO INNER BODY SIDE APERTURE
84
CAB BACK REINFORCEMENT TO CAB BACK PANEL 85
CENTER SHOULDER BELT REINFORCEMENT AND TAPPING PLATES TO CAB BACK
REINFORCEMENT
86
A-PILLAR REINFORCEMENT TO COWL SIDE PANEL TO OUTER BODY SIDE
APERTURE/APERTURE EXTENSION TO COWL SIDE PANEL
87
B-PILLAR REINFORCEMENT TO OUTER ROOF PANEL TO OUTER BODY SIDE
APERTURE
88
FRONT ROOF HEADER TO OUTER ROOF PANEL/ROOF BOW TO INNER BODY SIDE
APERTURE/FRONT ROOF HEADER TO A-PILLAR REINFORCEMENT
89
INNER BODY SIDE APERTURE TO REAR ROOF HEADER AND OUTER BODY SIDE
APERTURE TO OUTER ROOF PANEL
90
FRONT CROSSMEMBER, WHEELHOUSE CROSSMEMBER AND BRACKET SUPPORT
CROSSMEMBER TO BOX FLOOR PAN
91
LONG CROSSMEMBER AND FLOOR BOX CROSS SILL TO BOX FLOOR PAN 92
TAPPING PLATES AND SUPPORT BRACKETS TO REAR CROSS BOX SILL, FRONT
WHEELHOUSE, LONG AND BRACKET SUPPORT CROSSMEMBERS
93
STAKE POCKET REINFORCEMENTS AND TIE DOWN REINFORCEMENTS TO INNER
BOX SIDE PANEL
94
OUTER BOX SIDE REINFORCEMENT BRACES NUT PLATES TO OUTER BOX SIDE
PANEL MOUNTING
95
OUTER WHEELHOUSE TO OUTER BOX SIDE PANEL 96
WELD NUT STRIKER CAGE NUT, OUTER BOX SIDE PANEL AND NUT PLATE TO BOX
SIDE TAILGATE REINFORCEMENT
97
FRONT BOX PANEL TO FRONT INNER STAKE POCKET REINFORCEMENT TO FRONT
BOX SIDE PANEL
98
FRONT CROSSMEMBER TO FRONT BOX SIDE PANEL AND BOX FLOOR PANEL TO
BOX FRONT PANEL
99
BOX FLOOR PANEL AND INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL 100
FRONT CROSSMEMBER AND END SUPPORT BRACKET TO LONG CROSSMEMBER
TO INNER BOX SIDE PANEL/STAKE POCKET REINFORCEMENT AND BOX FLOOR
SILL TO OUTER TAILGATE PILLAR TO INNER TAILGATE PILLAR
101
STAKE POCKET REINFORCEMENT AND BOX FLOOR SILL CROSSMEMBER TO
INNER TAILGATE PILLAR
102
INNER TAILGATE PILLAR PANEL TO INNER BOX SIDE PANEL TO TIE DOWN
MOUNTING REINFORCEMENT
103
BOX FLOOR SILL CROSSMEMBER TO INNER BOX SIDE PANEL 104
INNER TAILGATE PILLAR TO TAILGATE BOX SIDE REINFORCEMENT TO OUTER
TAILGATE PILLAR
105
BOX SIDE PANEL AND OUTER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 106
FRONT BOX PANEL TO OUTER BOX SIDE PANEL 107
DESCRIPTION FIGURE
INNER BOX SIDE PANEL AND INNER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 108
OUTER WHEELHOUSE PANEL TO INNER WHEELHOUSE PANEL 109
FRONT CROSSMEMBER, LONG CROSSMEMBER, AND WHEELHOUSE
CROSSMEMBER TO FLOOR PAN
110
WHEELHOUSE CROSSMEMBER, LONG CROSSMEMBER AND REAR CROSS BOX
SILL TO BOX FLOOR PAN
111
FRONT AND CENTER STAKE POCKET REINFORCEMENTS AND TIE DOWN
MOUNTING REINFORCEMENT TO INNER BOX SIDE PANEL
112
OUTER FRONT AND CENTER STAKE POCKET REINFORCEMENT AND OUTER TIE
DOWN MOUNTING REINFORCEMENT TO INNER BOX SIDE PANEL
113
OUTER WHEELHOUSE AND OUTER BRACE MOUNTING REINFORCEMENT TO
OUTER BOX SIDE PANEL
114
TAILGATE BOX SIDE PIVOT REINFORCEMENT TO OUTER BOX SIDE PANEL 115
FRONT BOX SIDE PANEL TO FRONT CROSSMEMBER TO INNER BOX SIDE PANEL 116
FRONT BOX SIDE PANEL TO BOX FRONT PANEL TO INNER BOX SIDE PANEL/
FRONT STAKE POCKET REINFORCEMENT TO FRONT BOX SIDE PANEL TO BOX
FRONT PANEL
117
BOX FRONT PANEL TO BOX FLOOR PANEL 118
BOX FLOOR PANEL TO INNER BOX SIDE PANEL 119
LONG CROSSMEMBERS TO CROSSMEMBER END SUPPORT BRACKETS TO INNER
BOX SIDE PANEL
120
INNER WHEELHOUSE PANEL TO INNER BOX SIDE PANEL 121
TAILGATE PILLAR OUTER PANEL TO TAILGATE PILLAR INNER PANEL TO INNER
BOX SIDE PANEL
122
REAR SILL CROSS BOX TO TAILGATE PILLAR OUTER PANEL AND INNER BOX SIDE
PANEL
123
OUTER BOX SIDE PANEL TO BOX FRONT PANEL AND BOX FRONT SIDE PANEL 124
STAKE POCKET REINFORCEMENTS TO INNER BOX SIDE PANEL TO OUTER BOX
SIDE PANEL
125
TAILGATE PIVOT REINFORCEMENT AND INNER TAILGATE PILLAR TO INNER BOX
SIDE PANEL TO OUTER BOX SIDE PANEL
126
INNER WHEELHOUSE TO OUTER WHEELHOUSE/TAILGATE PIVOT
REINFORCEMENT TO OUTER TAILGATE PILLAR TO INNER TAILGATE PILLAR
127
OUTER TAILGATE PILLAR TO OUTER BOX SIDE PANEL 128
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (QUAD CAB) 129
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (STANDARD CAB) 130
INNER DOOR PANEL TO OUTER DOOR PANEL - REAR DOOR (QUAD CAB) 131
Fig. 31 FENDER BRACE
Fig. 32 STEERING COLUMN SUPPORT
Fig. 33 WIPER ATTACHING WELD NUTS
Fig. 34 DASH PANEL
Fig. 35 DASH PANEL
Fig. 36 LOWER PLENUM PANEL
Fig. 38 DASH PANEL
Fig. 40 DASH PANEL
Fig. 41 HEADLAMP MOUNTING PANEL
Fig. 42 SEAT MOUNTING FRONT BRACKETS - STANDARD CAB
Fig. 43 AIR BAG MODULE BRACKET - STANDARD CAB
Fig. 44 001 RIGHT TO LEFT REAR FLOOR CROSSMEMBER - STANDARD CAB
Fig. 45 REAR FLOOR CROSSMEMBER - STANDARD CAB
Fig. 46 SEAT MOUNTING FRONT CROSSMEMBER - STANDARD CAB
Fig. 47 FRONT SEAT MOUNTING CROSSMEMBERS - STANDARD CAB
Fig. 48 REAR FLOOR CROSSMEMBERS - STANDARD CAB
Fig. 49 FLOOR SILL - STANDARD CAB
Fig. 50 AIR BAG MODULE BRACKET - QUAD CAB
Fig. 51 REAR SEAT MIDDLE MOUNTING PLATE - QUAD CAB
Fig. 52 REAR FLOOR CROSSMEMBER - QUAD CAB
Fig. 53 002 LEFT REAR CROSSMEMBER - QUAD CAB
Fig. 54 STORAGE BIN - QUAD CAB
Fig. 55 RIGHT REAR FRONT SEAT MOUNTING CROSSMEMBER - QUAD CAB
Fig. 56 FRONT SEAT MOUNTING FRONT CROSSMEMBER - QUAD CAB
Fig. 57 FRONT SEAT MOUNTING FRONT CROSSMEMBER
Fig. 58 A-PILLAR REINFORCEMENT - STANDARD CAB
Fig. 59 A-PILLAR REINFORCEMENT - STANDARD CAB
Fig. 60 INNER BODY SIDE APERTURE - STANDARD CAB
Fig. 61 SHOULDER BELT REINFORCEMENT - STANDARD CAB
Fig. 62 FRONT PILLAR TAPPING PLATES - STANDARD CAB
Fig. 63 INNER BODY SIDE APERTURE - STANDARD CAB
Fig. 64 C-PILLAR BAFFLE - QUAD CAB
Fig. 65 A-PILLAR REINFORCEMENT - QUAD CAB
Fig. 66 003 FRONT EXTENSION PLATE - QUAD CAB
Fig. 67 OUTER BODY SIDE APERTURE - QUAD CAB
Fig. 68 B-PILLAR REINFORCEMENT - QUAD CAB
Fig. 69 UPPER TAPPING PLATE - QUAD CAB
Fig. 70 UPPER A-PILLAR TAPPING PLATE - QUAD CAB
Fig. 71 SEAT BELT MOUNTING PLATES - QUAD CAB
Fig. 73 C-PILLAR REINFORCEMENT - QUAD CAB
Fig. 74 SEAT BELT RETRACTOR PLATE - STANDARD CAB
Fig. 75 FLOOR SILL - STANDARD CAB
Fig. 76 BACK REINFORCEMENT - STANDARD CAB
Fig. 77 004 CAB BACK REINFORCEMENT - STANDARD CAB
Fig. 78 COWL SIDE PANEL - STANDARD CAB
Fig. 79 OUTER ROOF PANEL - STANDARD CAB
Fig. 80 FRONT ROOF HEADER - STANDARD CAB
Fig. 81 REAR ROOF HEADER - STANDARD CAB
Fig. 83 OUTER BODY SIDE APERTURE- QUAD CAB
Fig. 84 REAR FLOOR CROSSMEMBER - QUAD CAB
Fig. 85 CAB BACK REINFORCEMENT- QUAD CAB
Fig. 86 CENTER SHOULDER BELT REINFORCEMENT- QUAD CAB
Fig. 87 A-PILLAR REINFORCEMENT - QUAD CAB
Fig. 88 B-PILLAR REINFORCEMENT - QUAD CAB
Fig. 89 FRONT ROOF HEADER- QUAD CAB
Fig. 90 INNER BODY SIDE APERTURE- QUAD CAB
Fig. 91 FRONT CROSSMEMBER - SHORT CARGO BOX ONLY
Fig. 92 LONG CROSSMEMBER - SHORT CARGO BOX ONLY
Fig. 93 TAPPING PLATES - SHORT CARGO BOX ONLY
Fig. 94 STAKE POCKET REINFORCEMENTS - SHORT CARGO BOX ONLY
Fig. 95 OUTER BOX SIDE REINFORCEMENT BRACES - SHORT CARGO BOX ONLY
Fig. 96 OUTER WHEELHOUSE - SHORT CARGO BOX ONLY
Fig. 97 005 WELD NUT - SHORT CARGO BOX ONLY - SHORT CARGO BOX ONLY
Fig. 98 FRONT BOX PANEL - SHORT CARGO BOX ONLY
Fig. 100 BOX FLOOR PANEL - SHORT CARGO BOX ONLY
Fig. 102 STAKE POCKET REINFORCEMENT - SHORT CARGO BOX ONLY
Fig. 103 INNER TAILGATE PILLAR PANEL - SHORT CARGO BOX ONLY
Fig. 104 BOX FLOOR SILL CROSSMEMBER - SHORT CARGO BOX ONLY
Fig. 105 INNER TAILGATE PILLAR - SHORT CARGO BOX ONLY
Fig. 106 006 BOX SIDE PANEL - SHORT CARGO BOX ONLY
Fig. 107 FRONT BOX PANEL - SHORT CARGO BOX ONLY
Fig. 108 INNER BOX SIDE PANEL - SHORT CARGO BOX ONLY
Fig. 109 OUTER WHEELHOUSE PANEL - SHORT CARGO BOX ONLY
Fig. 110 007 FRONT CROSSMEMBER - LONG CARGO BOX ONLY
Fig. 111 008 WHEELHOUSE CROSSMEMBER - LONG CARGO BOX ONLY
Fig. 112 FRONT AND CENTER STAKE POCKET REINFORCEMENTS - LONG CARGO BOX ONLY
Fig. 113 OUTER FRONT AND CENTER STAKE POCKET REINFORCEMENT - LONG CARGO BOX ONLY
Fig. 114 OUTER WHEELHOUSE - LONG CARGO BOX ONLY
Fig. 115 TAILGATE BOX SIDE PIVOT REINFORCEMENT - LONG CARGO BOX ONLY
Fig. 116 FRONT BOX SIDE PANEL - LONG CARGO BOX ONLY
Fig. 117 FRONT BOX SIDE PANEL - LONG CARGO BOX ONLY
Fig. 118 BOX FRONT PANEL - LONG CARGO BOX ONLY
Fig. 119 BOX FLOOR PANEL - LONG CARGO BOX ONLY
Fig. 120 LONG CROSSMEMBERS - LONG CARGO BOX ONLY
Fig. 121 INNER WHEELHOUSE PANEL - LONG CARGO BOX ONLY
Fig. 122 TAILGATE PILLAR OUTER PANEL - LONG CARGO BOX ONLY
Fig. 123 REAR SILL CROSS BOX - LONG CARGO BOX ONLY
Fig. 124 OUTER BOX SIDE PANEL - LONG CARGO BOX ONLY
Fig. 125 STAKE POCKET REINFORCEMENTS - LONG CARGO BOX ONLY
Fig. 126 TAILGATE PIVOT REINFORCEMENT - LONG CARGO BOX ONLY
Fig. 127 INNER WHEELHOUSE - LONG CARGO BOX ONLY
Fig. 128 009 OUTER TAILGATE PILLAR - LONG CARGO BOX ONLY
Fig. 129 INNER DOOR PANEL - QUAD CAB
Fig. 130 INNER DOOR PANEL - STANDARD CAB
Fig. 131 INNER DOOR PANEL - QUAD CAB
HEATING & AIR CONDITIONING
TABLE OF CONTENTS
page page
HEATING & AIR CONDITIONING
DESCRIPTION
DESCRIPTION - ENGINE COOLING
SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . 1
DESCRIPTION - HEATER AND AIR
CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION - HEATER AND AIR
CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - A/C
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS - A/C SYSTEM . . . . . . . . . . . . 7
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
HEATING & AIR
CONDITIONING
DESCRIPTION
DESCRIPTION - ENGINE COOLING SYSTEM
REQUIREMENTS
To mai ntai n the performance l evel of the heati ng,
venti l ati on and ai r condi ti oni ng (HVAC) system, the
engi ne cool i ng system must be properl y mai ntai ned.
The use of a bug screen i s not recommended. Any
obstructi ons i n front of the radi ator or A/C condenser
wi l l reduce the performance of the A/C and engi ne
cool i ng systems.
The engi ne cool i ng system i ncl udes the radi ator,
thermostat, radi ator hoses and the engi ne cool ant
pump. Refer to Cool i ng for more i nformati on before
openi ng or attempti ng any servi ce to the engi ne cool -
i ng system.
DESCRIPTION - HEATER AND AIR
CONDITIONER
A manual l y control l ed si ngl e zone type heati ng-ai r
condi ti oni ng system or a manual l y control l ed dual
zone type heati ng-ai r condi ti oni ng system i s avai l abl e
on thi s model .
Al l vehi cl es are equi pped wi th a common heater,
venti l ati on and ai r condi ti oni ng (HVAC) housi ng (Fi g.
1). The system combi nes ai r condi ti oni ng, heati ng,
and venti l ati ng capabi l i ti es i n a si ngl e uni t housi ng
mounted wi thi n the passenger compartment under
the i nstrument panel . The HVAC housi ng i ncl udes:
Bl ower motor
Bl ower motor resi stor bl ock
Heater core
Evaporator coi l
Bl end door and actuator
Defrost door and actuator
Mode door and actuator
Reci rcul ati on door and actuator
Based upon the system and mode sel ected, condi -
ti oned ai r can exi t the HVAC housi ng through one or
a combi nati on of the three mai n housi ng outl ets:
defrost, panel or fl oor. The defrost outl et i s l ocated on
the top of the housi ng, the panel outl et i s l ocated on
the face of the housi ng and the fl oor outl et i s l ocated
on the bottom of the housi ng. Once the condi ti oned
ai r exi ts the uni t housi ng, i t i s further di rected
through mol ded pl asti c ducts to the vari ous outl ets i n
the vehi cl e i nteri or. These outl ets and thei r l ocati ons
are as fol l ows:
Defroster Outlet - A si ngl e l arge defroster out-
l et i s l ocated i n the center of the i nstrument panel
top cover, near the base of the wi ndshi el d.
Side Window Demister Outlets - There are
two si de wi ndow demi ster outl ets, one i s l ocated at
each outboard end of the i nstrument panel top cover,
near the bel t l i ne at the A-pi l l ars.
Panel Outlets - There are four panel outl ets i n
the i nstrument panel , one l ocated near each outboard
end of the i nstrument panel faci ng the rear of the
vehi cl e and two l ocated near the top of the i nstru-
ment panel center bezel .
Front Floor Outlets - There are two front fl oor
outl ets, one l ocated above each si de of the fl oor panel
center tunnel near the dash panel .
OPERATION - HEATER AND AIR CONDITIONER
The heati ng and ai r condi ti oni ng systems pul l s
outsi de (ambi ent) ai r through the cowl openi ng at the
base of the wi ndshi el d, then i nto the pl enum cham-
DR HEATING & AIR CONDITIONING 24 - 1
ber above the heati ng, venti l ati on and ai r condi ti on-
i ng (HVAC) housi ng. On model s equi pped wi th ai r
condi ti oni ng, the ai r passes through the evaporator
coi l . Ai r fl ow can be di rected ei ther through or
around the heater core. Thi s i s done by adjusti ng the
bl end door wi th the temperature control knob on the
A/C-heater control l ocated the i nstrument panel . The
ai r fl ow can then be di rected from the panel , fl oor
and defrost outl ets i n vari ous combi nati ons usi ng the
mode control knob l ocated on the A/C-heater control .
Ai r fl ow vel oci ty can be adjusted wi th the bl ower
speed sel ector l ocated on the A/C-heater control .
NOTE: It is important to keep the air intake opening
clear of debris. Leaf particles and other debris that
is small enough to pass through the cowl opening
screen can accumulate within the HVAC housing.
The closed, warm, damp and dark environment cre-
ated within the housing is ideal for the growth of
certain molds, mildews and other fungi. Any accu-
mulation of decaying plant matter provides an addi-
tional food source for fungal spores, which enter
the housing with the fresh intake-air. Excess debris,
as well as objectionable odors created by decaying
plant matter and growing fungi can be discharged
into the passenger compartment during heater-A/C
operation if the air intake opening is not kept clear
of debris.
The heater and ai r condi ti oni ng systems are bl end-
ai r type systems. I n a bl end-ai r system, a bl end door
control s the amount of uncondi ti oned ai r (or cool ed
ai r from the evaporator on model s wi th ai r condi ti on-
i ng) that i s al l owed to fl ow through, or around, the
heater core. A temperature control knob determi nes
the di scharge ai r temperature by actuati ng an el ec-
tri c motor, whi ch operates the bl end door. Thi s al l ows
an al most i mmedi ate control of the output ai r tem-
perature of the system.
On al l model s, the outsi de ai r i ntake can be shut
off by sel ecti ng the Reci rcul ati on Mode wi th the
mode control knob. Thi s wi l l operate a el ectri c actu-
ated reci rcul ati on ai r door that cl oses off the outsi de
fresh ai r i ntake and reci rcul ates the ai r that i s
al ready i nsi de the vehi cl e.
The ai r condi ti oni ng compressor can be engaged i n
any mode by pressi ng the snowfl ake, A/C on/off but-
ton. I t can al so be engaged by pl aci ng the mode con-
trol i n the mi x to defrost posi ti ons. Thi s wi l l remove
heat and humi di ty from the ai r before i t i s di rected
through or around the heater core. The mode control
knob on the A/C-heater control i s used to al so di rect
the condi ti oned ai r to the sel ected system outl ets.
The mode control swi tch uses an el ectri c motor to
control the mode doors.
The defroster outl et recei ves ai rfl ow from the
HVAC housi ng through the mol ded pl asti c defroster
duct, whi ch connects to the HVAC housi ng defroster
outl et. The ai rfl ow from the defroster outl ets i s
di rected by fi xed vanes i n the defroster outl et gri l l es
and cannot be adjusted. The defroster outl et gri l l es
are i ntegral to the i nstrument panel top cover.
The si de wi ndow demi ster outl ets recei ve ai rfl ow
from the HVAC housi ng through the mol ded pl asti c
defroster duct and two mol ded pl asti c demi ster ducts.
The ai rfl ow from the si de wi ndow demi ster outl ets i s
di rected by fi xed vanes i n the demi ster outl et gri l l es
and cannot be adjusted. The si de wi ndow demi ster
outl et gri l l es are i ntegral to the i nstrument panel .
The demi sters di rect ai r from the HVAC housi ng
through the outl ets l ocated on the top corners of the
i nstrument panel . The demi sters operate when the
mode control knob i s posi ti oned i n the fl oor-defrost
and defrost-onl y setti ngs. Some ai r may be noti ceabl e
from the demi ster outl ets when the mode control i s
i n the bi -l evel to fl oor posi ti ons.
Fig. 1 HVAC Housing - Dual Zone Shown, Single
Zone Typical
1 - NUT
2 - PASSENGER BLEND DOOR ACTUATOR
3 - NUT
4 - INLET BAFFLE
5 - RECIRCULATION DOOR ACTUATOR
6 - RECIRCULATION DOOR
7 - DRIVER SIDE BLEND DOOR ACTUATOR
8 - HVAC HOUSING
9 - BOLT
10 - DEFROSTER DOOR ACTUATOR
11 - MODE DOOR ACTUATOR
24 - 2 HEATING & AIR CONDITIONING DR
HEATING & AIR CONDITIONING (Continued)
The panel outl ets recei ve ai rfl ow from the HVAC
housi ng through a mol ded pl asti c mai n panel duct,
center panel duct and two end panel ducts. The two
end panel ducts di rect ai rfl ow to the l eft and ri ght
i nstrument panel outl ets, whi l e the center panel duct
di rects ai rfl ow to the two center panel outl ets. Each
of these outl ets can be i ndi vi dual l y adjusted to di rect
the fl ow of ai r.
The fl oor outl ets recei ve ai rfl ow from the HVAC
housi ng through the fl oor di stri buti on duct. The front
fl oor outl ets are i ntegral to the mol ded pl asti c fl oor
di stri buti on duct, whi ch i s secured to the bottom of
the housi ng. The fl oor outl ets cannot be adjusted.
The ai r condi ti oner for al l model s i s desi gned for
the use of non-CFC, R-134a refri gerant. The ai r con-
di ti oni ng system has an evaporator to cool and dehu-
mi di fy the i ncomi ng ai r pri or to bl endi ng i t wi th the
heated ai r. Thi s ai r condi ti oni ng system uses a fi xed
ori fi ce tube i n the l i qui d l i ne near the condenser out-
l et tube to meter refri gerant fl ow to the evaporator
coi l . To mai ntai n mi ni mum evaporator temperature
and prevent evaporator freezi ng, a evaporator tem-
perature sensor i s used. The JTEC control modul e i s
programmed to respond to the evaporator tempera-
ture sensor i nput by cycl i ng the ai r condi ti oni ng com-
pressor cl utch as necessary to opti mi ze ai r
condi ti oni ng system performance and to protect the
system from evaporator freezi ng.
PERFORMANCE
The ai r condi ti oni ng system i s desi gned to remove
heat and humi di ty from the ai r enteri ng the passen-
ger compartment. The evaporator, l ocated i n the
HVAC housi ng, i s cool ed to temperatures near the
freezi ng poi nt. As warm damp ai r passes over the
fi ns i n the evaporator, moi sture i n the ai r condenses
to water, dehumi di fyi ng the ai r. Condensati on on the
evaporator fi ns reduces the evaporators abi l i ty to
absorb heat. Duri ng peri ods of hi gh heat and humi d-
i ty, an ai r condi ti oni ng system wi l l be l ess effecti ve.
Wi th the i nstrument control set to Reci rcul ati on
mode, onl y ai r from the passenger compartment
passes through the evaporator. As the passenger com-
partment ai r dehumi di fi es, A/C performance l evel s
ri se.
Humi di ty has an i mportant beari ng on the temper-
ature of the ai r del i vered to the i nteri or of the vehi -
cl e. I t i s i mportant to understand the effect that
humi di ty has on the performance of the ai r condi ti on-
i ng system. When humi di ty i s hi gh, the evaporator
has to perform a doubl e duty. I t must l ower the ai r
temperature, and i t must l ower the temperature of
the moi sture i n the ai r that condenses on the evapo-
rator fi ns. Condensi ng the moi sture i n the ai r trans-
fers heat energy i nto the evaporator fi ns and tubi ng.
Thi s reduces the amount of heat the evaporator can
absorb from the ai r. Hi gh humi di ty greatl y reduces
the abi l i ty of the evaporator to l ower the temperature
of the ai r.
However, evaporator capaci ty used to reduce the
amount of moi sture i n the ai r i s not wasted. Wri ng-
i ng some of the moi sture out of the ai r enteri ng the
vehi cl e adds to the comfort of the passengers.
Al though, an owner may expect too much from thei r
ai r condi ti oni ng system on humi d days. A perfor-
mance test i s the best way to determi ne whether the
system i s performi ng up to standard. Thi s test al so
provi des val uabl e cl ues as to the possi bl e cause of
troubl e wi th the ai r condi ti oni ng system.
PERFORMANCE TEST PROCEDURE
Revi ew Safety Warni ngs and Cauti ons before per-
formi ng thi s procedure (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG - WARNI NG) and
PLUMBI NG - CAUTI ON). Ai r temperature i n test
room and on vehi cl e must be 21 C (70 F) mi ni mum
for thi s test.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer and a mani fol d gauge set
or A/C recycl i ng/chargi ng stati on.
(2) Set the A/C-heater mode control i n the Reci rcu-
l ati on Mode posi ti on, the temperature control knob i n
the ful l cool posi ti on, and the bl ower motor swi tch to
the hi ghest speed posi ti on.
(3) Start the engi ne and hol d at 1,000 rpm wi th
the A/C compressor cl utch engaged.
(4) The engi ne shoul d be warmed up to operati ng
temperature wi th the doors cl osed and wi ndows
open.
(5) I nsert a thermometer i n the dri ver si de center
panel A/C-heater outl et and operate the engi ne for
fi ve mi nutes.
(6) The compressor cl utch may cycl e, dependi ng
upon the ambi ent temperature and humi di ty.
(7) Wi th the compressor cl utch engaged, record the
di scharge ai r temperature and the compressor di s-
charge pressure.
(8) I f the di scharge ai r temperature fai l s to meet
the speci fi cati ons i n the A/C Performance Tempera-
ture chart, refer to the Pressure Di agnosi s chart.
PERFORMANCE TEMPERATURE AND PRESSURE
Ambient Air
Temperature
21C
(70F)
27C
(80F)
32C
(90F)
38C
(100F)
43C
(110F)
Air Temperature at
Center Panel Outlet
7C
(45F)
7C
(45F)
13C
(55F)
13C
(55F)
18C
(64F)
Compressor Inlet
Pressure at Service
Port (low Side)
138 to 207 kPa
(20 to 30 psi)
172 to 241 kPa
(25 to 35 psi)
207 to 276
kPa
(30 to 40 psi)
241 to 310
kPa
(35 to 45 psi)
276 to 345 kPa
(40 to 50 psi)
Compressor
Discharge Pressure at
Service Port (High
Side)
1034 to 1724
kPa
(150 to 250
psi)
1379 to 2068
kPa
(200 to 300
psi)
1724 to 2413
kPa
(250 to 350
psi)
1999 to 2689
kPa
(290 to 390
psi)
2413 to 2965
kPa
(350 to 430 psi)
(9) Compare the compressor di scharge pressure to
the Performance Temperature and Pressure chart. I f
the compressor di scharge pressure i s hi gh, see the
Pressure Di agnosi s chart.
PRESSURE DIAGNOSIS
Constant compressor
engagement and warm air
from passenger vents.
1. Low refrigerant system
charge.
1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
Equal pressures, but the
compressor clutch does not
engage.
1. No refrigerant in the
refrigerant system.
required.
2. Faulty fuse. 2. Check the fuses in the Power Distribution
Center and the junction block. Repair the shorted
circuit or component and replace the fuses, if
required.
3. Faulty A/C compressor
clutch coil.
3. See A/C Compressor Clutch Coil in this group.
Test the compressor clutch coil and replace, if
required.
4. Faulty A/C compressor
clutch relay.
4. See A/C Compressor Clutch Relay in this
group. Test the compressor clutch relay and relay
circuits. Repair the circuits or replace the relay, if
required.
5. Improperly installed or
faulty Evaporator
Temperature Sensor.
5. See Evaporator Temperature Sensor in this
group. Reinstall or replace the sensor as
required.
6. Faulty A/C pressure
transducer.
6. See A/C pressure transducer in this group.
Test the switch and replace, if required.
7. Faulty Powertrain Control
Module (PCM).
7. (Refer to Appropriate Diagnostic Information).
Test the PCM and replace, if required.
Normal pressures, but A/C
Performance Test air
temperatures at center panel
outlet are too high.
1. Excessive refrigerant oil in
system.
1. See Refrigerant Oil Level in this group.
Recover the refrigerant from the refrigerant
system and inspect the refrigerant oil content.
Restore the refrigerant oil to the proper level, if
required.
2. Blend door inoperative or
sealing improperly.
2. See Blend Door in this group. Inspect the
blend door for proper operation and sealing and
correct, if required.
3. Blend door actuator faulty
or inoperative.
3. Perform blend door actuator diagnosis, replace
if faulty.
The low side pressure is
normal or slightly low, and the
high side pressure is too low.
charge.
required.
2. Refrigerant flow through
the accumulator is restricted.
2. See Accumulator in this group. Replace the
restricted accumulator, if required.
3. Refrigerant flow through
the evaporator coil is
restricted.
3. See A/C Evaporator in this group. Replace the
restricted evaporator coil, if required.
4. Faulty compressor. 4. See A/C Compressor in this group. Replace
the compressor, if required.
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.
1. Condenser air flow
restricted.
1. Check the A/C condenser for damaged fins,
foreign objects obstructing air flow through the
condenser fins, and missing or improperly
installed air seals. Refer to Cooling for more
information on air seals. Clean, repair, or replace
components as required.
2. Inoperative cooling fan. 2. Refer to Cooling for more information. Test the
cooling fan and replace, if required.
3. Refrigerant system
overcharged.
3. See Refrigerant System Charge in this group.
Recover the refrigerant from the refrigerant
system. Charge the refrigerant system to the
proper level, if required.
4. Air in the refrigerant
system.
required.
5. Engine overheating. 5. Refer to Cooling for more information. Test the
cooling system and repair, if required.
The low side pressure is too
high, and the high side
pressure is too low.
1. Accessory drive belt
slipping.
1. Refer to Cooling for more information. Inspect
the accessory drive belt condition and tension.
Tighten or replace the accessory drive belt, if
required.
2. Fixed orifice tube not
installed.
2. See A/C Orifice Tube in this group. Replace
the liquid line, if required.
3. Faulty compressor. 3. See A/C Compressor in this group. Replace
the compressor, if required.
The low side pressure is too
low, and the high side
pressure is too high.
1. Restricted refrigerant flow
through the refrigerant lines.
1. See Liquid, Suction, and Discharge Line in this
group. Inspect the refrigerant lines for kinks, tight
bends or improper routing. Correct the routing or
replace the refrigerant line, if required.
through the fixed orifice tube.
2. See A/C Orifice Tube in this group. Replace
the liquid line, if required.
through the condenser.
3. See A/C Condenser in this group. Replace the
restricted condenser, if required.
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST
Revi ew Safety Warni ngs and Cauti ons before per-
formi ng thi s procedure (Refer to 24 - HEATI NG &
AI R CONDI TI ONI NG/PLUMBI NG - WARNI NG) and
PLUMBI NG - CAUTI ON).
Check the cool ant l evel , dri ve bel t tensi on, vacuum
l i ne connecti ons, radi ator ai r fl ow and fan operati on.
Start engi ne and al l ow to warm up to normal tem-
perature.
WARNING: DO NOT REMOVE RADIATOR CAP
WHEN ENGINE IS HOT, PERSONAL INJURY CAN
RESULT.
I f vehi cl e has been run recentl y, wai t 15 mi nutes
before removi ng cap. Pl ace a rag over the cap and
turn i t to the fi rst safety stop. Al l ow pressure to
escape through the overfl ow tube. When the system
stabi l i zes, remove the cap compl etel y.
MAXIMUM HEATER OUTPUT: TEST AND ACTION
Engi ne cool ant i s provi ded to the heater system by
two heater hoses. Wi th the engi ne i dl i ng at normal
operati ng temperature, set the temperature control
to maxi mum heat, the mode control to the fl oor posi -
ti on, and the bl ower i n the hi ghest speed posi ti on.
Usi ng a test thermometer, check the temperature of
the ai r bei ng di scharged from the fl oor outl ets. Com-
pare the test thermometer readi ng to the Tempera-
ture Reference chart.
TEMPERATURE REFERENCE CHART
Ambient Air Temperature
15.5C
(60F)
21.1C
(70F)
26.6C
(80F)
32.2C
(90F)
Minimum Air Temperature at
Floor Outlet
62.2C
(144F)
63.8C
(147F)
65.5C
(150F)
67.2C
(153F)
Both of the heater hoses shoul d be HOT to the
touch (cool ant return hose shoul d be sl i ghtl y cool er
than the suppl y hose). I f the cool ant return hose i s
much cool er than the suppl y hose, l ocate and repai r
the engi ne cool ant fl ow obstructi on i n the heater sys-
tem. I f both heater hoses are cool to the touch,
i nspect the engi ne cool i ng system (Refer to 7 -
COOLI NG - DI AGNOSI S AND TESTI NG).
OBSTRUCTED COOLANT FLOW Possi bl e l oca-
ti ons or causes of obstructed cool ant fl ow are as fol -
l ows:
Pi nched or ki nked heater hoses.
I mproper heater hose routi ng.
Pl ugged heater hoses or suppl y and return ports
at the cool i ng system connecti ons.
Pl ugged heater core.
I f proper cool ant fl ow through the cool i ng system i s
veri fi ed, and heater outl et ai r temperature i s i nsuffi -
ci ent, a mechani cal probl em may exi st.
MECHANI CAL PROBLEMS Possi bl e causes of
i nsuffi ci ent heat due to mechani cal probl ems are as
fol l ows:
Obstructed cowl ai r i ntake.
Obstructed heater system outl ets.
Bl end door not functi oni ng properl y.
TEMPERATURE CONTROL
I f the heater outl et ai r temperature cannot be
adjusted wi th the temperature control knob on the
A/C-heater control , the fol l owi ng coul d requi re ser-
vi ce:
Bl end door bi ndi ng.
Faul ty bl end door motor.
Faul ty A/C-heater control .
Faul ty rel ated wi ri ng harness or connectors.
I mproper engi ne cool ant temperature.
SPECIFICATIONS - A/C SYSTEM
The R-134a refri gerant system charge capaci ty for
thi s vehi cl e can be found on the underhood Speci fi ca-
ti on Label .
A/C SYSTEM SPECIFICATION CHART
Item Description Notes
Compressor Saden SD-7
(5.9L engine)
SP-15 PAG oil
Denso 10S17
(3.7L/4.7L/5.7L
engines)
ND-8 PAG oil
Freezeup
Control
Evaporator
Temperature
Sensor
Evaporator coil
mounted
High psi Control A/C pressure
transducer
Discharge line
mounted
Compressor
Clutch Coil
Draw
2 - 3.9 amps @
12V 0.5V @
21C (70F)
5.9L engine
2.2 amps @
12V 0.5V @
21C (70F)
3.7L/4.7L/5.7L
engines
Compressor
Clutch Air Gap
0.41 - 0.79 mm
(0.016 - 0.031
in.)
5.9L engine
0.35 - 0.65 mm
(0.013 - 0.025
in.)
3.7L/4.7L/5.7L
engines
A/C Compressor Shaft Nut 15-20 11-15
A/C Compressor Bolt-Inner
Front-3.7L,4.7L
40 30
A/C Compressor Bolt-Inner
Rear-3.7L,4.7L
55 41
A/C Compressor Rear Bolt-
3.7L,4.7L
55 41
A/C Compressor Lower Bolts-5.7L 40 30
A/C Compressor Rear Bolt-5.7L 55 41
A/C Compressor Bolts-5.9L Diesel 24 17
A/C Compressor Clutch Coil Wire
Retainer Screw
2.2 20
A/C-Heater Control Screws 2.2 20
Accumulator Bracket Bolts 4.5 40
Blower Motor Screws 2.2 20
Blower Motor Resistor Block
Screws
2.2 20
Center Distribution Duct Screws 2.2 20
Condenser Cooling Fan to A/C
Condenser Screws-3.7L,4.7L,5.7L
2.2 20
Condenser to Charge Air Cooler
Bolts-5.9L Diesel
10.5 95
Condenser/Cooling Fan Assembly
Bolts-3.7L,4.7L,5.7L
10.5 95
Defroster Duct Screws 2.2 20
Defroster Duct Adapter Screws 2.2 20
Demister Duct Screws 2.2 20
Discharge line to Condenser Nut 20 180
Floor Distribution Duct Screws 2.2 20
Heater Core Tube Bracket Screws 2.2 20
HVAC Door Actuators Screws 2 17
HVAC Door Spring Retainer Screws 2.2 20
HVAC Housing Screws 2.2 20
HVAC Housing to Dash Panel Nuts 6.2 55
HVAC Housing to Floor Bracket
Bolt
6.2 55
Liquid Line to Condenser Nut 20 180
Mode Door Adapter Screws 2.2 20
Panel Duct Screws 2.2 20
Recirculation Housing Screws 2.2 20
Refrigerant Lines to Compressor 28 20
CONTROLS
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH/COIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
COMPRESSOR CLUTCH COIL . . . . . . . . . . . 10
STANDARD PROCEDURE - A/C
COMPRESSOR CLUTCH BREAK-IN . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
A/C COMPRESSOR CLUTCH RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C HEATER CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
A/C PRESSURE TRANSDUCER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
BLEND DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
BLOWER MOTOR RESISTOR BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING - BLOWER
MOTOR RESISTOR BLOCK . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
BLOWER MOTOR SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - BLOWER
MOTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . 20
DEFROST DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
MODE DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
RECIRCULATION DOOR ACTUATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
A/C COMPRESSOR CLUTCH/
COIL
DESCRIPTION
The compressor cl utch assembl y consi sts of a sta-
ti onary el ectromagneti c coi l , a pul l ey beari ng and
pul l ey assembl y, and a cl utch pl ate (Fi g. 1). The el ec-
tromagneti c coi l and the pul l ey beari ng and pul l ey
assembl y are each retai ned on the nose of the com-
pressor front housi ng wi th snap ri ngs. The cl utch
pl ate i s keyed to the compressor shaft and secured
wi th a nut. These components provi de the means to
engage and di sengage the compressor from the
engi ne serpenti ne accessory dri ve bel t.
OPERATION
The A/C compressor cl utch provi des the means to
engage and di sengage the A/C compressor from the
engi ne serpenti ne accessory dri ve bel t. When the
cl utch coi l i s energi zed, i t magneti cal l y draws the
cl utch i nto contact wi th the pul l ey and dri ves the
compressor shaft. When the coi l i s not energi zed, the
pul l ey freewheel s on the pul l ey beari ng, whi ch i s
part of the pul l ey assembl y. The compressor cl utch
DR CONTROLS 24 - 9
and coi l are the onl y servi ced parts on the compres-
sor.
A/C compressor cl utch engagement i s control l ed by
several components: the A/C-heater control , A/C pres-
sure transducer, A/C compressor cl utch rel ay, evapo-
rator temperature sensor and the powertrai n control
modul e (PCM). The PCM may del ay compressor
cl utch engagement for up to thi rty seconds (Refer to
ULES/POWERTRAI N CONTROL MODULE -
DESCRI PTI ON).
DIAGNOSIS AND TESTING - A/C COMPRESSOR
CLUTCH COIL
For ci rcui t descri pti ons and di agrams, (Refer to
Appropri ate Wi ri ng I nformati on). The battery must
be ful l y-charged before performi ng the fol l owi ng
tests. Refer to Battery for more i nformati on.
(1) Connect an ammeter (0 to 10 ampere scal e) i n
seri es wi th the cl utch coi l termi nal . Use a vol tmeter
(0 to 20 vol t scal e) wi th cl i p-type l eads for measuri ng
the vol tage across the battery and the compressor
cl utch coi l .
(2) Wi th the A/C-heater control s i n any A/C mode,
and the bl ower motor swi tch i n the l owest speed
posi ti on, start the engi ne and run i t at normal i dl e.
(3) The compressor cl utch coi l vol tage shoul d read
wi thi n 0.2 vol ts of the battery vol tage. I f there i s
vol tage at the cl utch coi l , but the readi ng i s not
wi thi n 0.2 vol ts of the battery vol tage, test the cl utch
coi l feed ci rcui t for excessi ve vol tage drop and repai r
as requi red. I f there i s no vol tage readi ng at the
cl utch coi l , use a DRB I I I scan tool and (Refer to
Appropri ate Di agnosti c I nformati on) for testi ng of the
compressor cl utch ci rcui t and PCM control . The fol -
l owi ng components must be checked and repai red as
requi red before you can compl ete testi ng of the cl utch
coi l :
Fuses i n the juncti on bl ock and the power di stri -
buti on center (PDC)
A/C-heater control
A/C compressor cl utch rel ay
A/C pressure transducer
Evaporator temperature sensor
Powertrai n control modul e (PCM)
(4) The compressor cl utch coi l i s acceptabl e i f the
current draw measured at the cl utch coi l i s wi thi n
speci fi cati ons wi th the el ectri cal system vol tage at
11.5 to 12.5 vol ts (Refer to 24 - HEATI NG & AI R
CONDI TI ONI NG - SPECI FI CATI ONS). Thi s shoul d
onl y be checked wi th the work area temperature at
21 C (70 F). I f system vol tage i s more than 12.5
vol ts, add el ectri cal l oads by turni ng on el ectri cal
accessori es unti l the system vol tage drops bel ow 12.5
vol ts.
(a) I f the cl utch coi l current readi ng i s above
speci fi cati ons, the coi l i s shorted and shoul d be
repl aced.
(b) I f the cl utch coi l current readi ng i s zero, the
coi l i s open and shoul d be repl aced.
STANDARD PROCEDURE - A/C COMPRESSOR
CLUTCH BREAK-IN
After a new compressor cl utch has been i nstal l ed,
cycl e the compressor cl utch approxi matel y twenty
ti mes (fi ve seconds on, then fi ve seconds off). Duri ng
thi s procedure, set the A/C-heater control to the
Reci rcul ati on Mode, the bl ower motor swi tch i n the
hi ghest speed posi ti on, and the engi ne speed at 1500
to 2000 rpm. Thi s procedure (burni shi ng) wi l l seat
the opposi ng fri cti on surfaces and provi de a hi gher
compressor cl utch torque capabi l i ty.
REMOVAL
The refri gerant system can remai n ful l y-charged
duri ng compressor cl utch, rotor, or coi l repl acement.
The compressor cl utch can be servi ced i n the vehi cl e.
cabl e.
(2) Remove the serpenti ne dri ve bel t (Refer to 7 -
REMOVAL).
(3) Di sconnect the compressor cl utch coi l wi re har-
ness connector.
(4) Remove the bol ts that secure the compressor to
the mounti ng bracket.
(5) Remove the compressor from the mounti ng
bracket. Support the compressor i n the engi ne com-
partment whi l e servi ci ng the cl utch.
Fig. 1 Compressor Clutch - Typical
1 - CLUTCH PLATE
2 - SHAFT KEY (not used on KJ)
3 - ROTOR
4 - COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
24 - 10 CONTROLS DR
A/C COMPRESSOR CLUTCH/COIL (Continued)
(6) I nsert the two pi ns of the spanner wrench
(Speci al Tool C-4489 or equi val ent) i nto the hol es of
the cl utch pl ate. Hol d the cl utch pl ate stati onary and
remove the hex nut (Fi g. 2).
(7) Remove the cl utch pl ate.
(8) Remove the compressor cl utch shi ms.
(9) Remove the external front housi ng snap ri ng
wi th snap ri ng pl i ers (Fi g. 3).
(10) I nstal l the l i p of the rotor pul l er (Speci al Tool
C-6141-1 or equi val ent) i nto the snap ri ng groove
exposed i n the previ ous step, and i nstal l the shaft
protector (Speci al Tool C-6141-2 or equi val ent) (Fi g.
4).
(11) I nstal l the pul l er through-bol ts (Speci al Tool
C-6461 or equi val ent) through the pul l er fl ange and
i nto the jaws of the rotor pul l er and ti ghten (Fi g. 5).
Turn the pul l er center bol t cl ockwi se unti l the rotor
i s free.
CAUTION: DO NOT APPLY FORCE TO THE END OF
THE COMPRESSOR SHAFT.
(12) Remove the screw and retai ner from the
cl utch coi l l ead wi re harness on the compressor front
housi ng (Fi g. 6).
(13) Remove the snap ri ng from the compressor
hub and remove the cl utch fi el d coi l (Fi g. 7). Sl i de
the cl utch fi el d coi l off of the compressor hub.
INSPECTION
Exami ne the fri cti on surfaces of the cl utch pul l ey
and the cl utch pl ate for wear. The pul l ey and cl utch
pl ate shoul d be repl aced i f there i s excessi ve wear or
scori ng.
Fig. 2 Clutch Nut Remove - Typical
1 - CLUTCH PLATE
2 - SPANNER
Fig. 3 External Snap Ring Remove - Typical
1 - PULLEY
Fig. 4 Shaft Protector and Puller - Typical
1 - PULLER JAW
2 - SHAFT PROTECTOR
Fig. 5 Install Puller Plate - Typical
1 - PULLER JAW
2 - PULLER
DR CONTROLS 24 - 11
I f the fri cti on surfaces are oi l y, i nspect the shaft
and nose area of the A/C compressor for oi l . Remove
the fel t from the front cover. I f the fel t i s saturated
wi th oi l , the shaft seal i s l eaki ng and the A/C com-
pressor must be repl aced.
Check the pul l ey beari ng for roughness or exces-
si ve l eakage of grease. Repl ace the pul l ey and cl utch
pl ate, i f requi red.
INSTALLATION
(1) I nstal l the cl utch fi el d coi l and snap ri ng.
(2) I nstal l the screw and retai ner on the cl utch coi l
l ead wi re harness on the compressor front housi ng.
Ti ghten screw to 2.2 Nm (20 i n. l bs.).
(3) Al i gn the rotor assembl y squarel y on the front
compressor housi ng hub.
(4) I nstal l the rotor beari ng assembl y wi th the
i nstal l er (Speci al Tool C-6871 or equi val ent) (Fi g. 8).
Thread the i nstal l er on the shaft, then turn the nut
unti l the rotor assembl y i s seated.
(5) I nstal l the external front housi ng snap ri ng
wi th snap ri ng pl i ers. The bevel si de of the snap ri ng
must be faci ng outward. Press the snap ri ng to make
sure i t i s properl y seated i n the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(6) I nstal l the ori gi nal cl utch shi ms on the com-
pressor shaft.
(7) I nstal l the cl utch pl ate. I nstal l the shaft hex
nut and ti ghten to 1520 Nm (1115 ft. l bs.).
(8) Check the cl utch ai r gap wi th a feel er gauge
(Fi g. 9). I f the ai r gap does not meet speci fi cati ons,
add or subtract shi ms as requi red (Refer to 24 -
HEATI NG & AI R CONDI TI ONI NG - SPECI FI CA-
TI ONS).
Fig. 6 Clutch Coil Lead Wire Harness - Typical
1 - COIL
2 - COIL WIRE
3 - RETAINER SCREW
Fig. 7 Clutch Field Coil Snap Ring Remove - Typical
1 - COIL
Fig. 8 Clutch Pulley Install - Typical
1 - ROTOR BEARING ASSEMBLY
2 - INSTALLER
24 - 12 CONTROLS DR
NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, try the original shims first. When install-
ing a new clutch onto a compressor that previously
did not have a clutch, use a 1.0, 0.50, and 0.13 mil-
limeter (0.040, 0.020, and 0.005 inch) shims from the
new clutch hardware package that is provided with
the new clutch.
(9) To compl ete the procedure (Refer to 24 - HEAT-
A/C COMPRESSOR CLUTCH
RELAY
DESCRIPTION
The A/C compressor cl utch rel ay (Fi g. 10) i s a
I nternati onal Standards Organi zati on (I SO) mi cro-re-
l ay. Rel ays conformi ng to the I SO speci fi cati ons have
common physi cal di mensi ons, current capaci ti es, ter-
mi nal patterns, and termi nal functi ons. The I SO
mi cro-rel ay termi nal functi ons are the same as a con-
venti onal I SO rel ay. However, the I SO mi cro-rel ay
termi nal pattern (or footpri nt) i s di fferent, the cur-
rent capaci ty i s l ower, and the physi cal di mensi ons
are smal l er than those of the conventi onal I SO rel ay.
The A/C compressor cl utch rel ay i s l ocated i n the
i ntergrated power modul e (I PM) i n the engi ne com-
partment. See the fuse and rel ay l ayout l abel affi xed
to the i nsi de surface of the I PM cover for A/C com-
pressor cl utch rel ay i denti fi cati on and l ocati on.
The bl ack, mol ded pl asti c case i s the most vi si bl e
component of the A/C compressor cl utch rel ay. Fi ve
mal e spade-type termi nal s extend from the bottom of
the base to connect the rel ay to the vehi cl e el ectri cal
system, and the I SO desi gnati on for each termi nal i s
mol ded i nto the base adjacent to each termi nal . The
I SO termi nal desi gnati ons are as fol l ows:
30 (Common Feed) - Thi s termi nal i s con-
nected to the movabl e contact poi nt of the rel ay.
85 (Coil Ground) - Thi s termi nal i s connected
to the ground feed si de of the rel ay control coi l .
86 (Coil Battery) - Thi s termi nal i s connected
to the battery feed si de of the rel ay control coi l .
87 (Normally Open) - Thi s termi nal i s con-
nected to the normal l y open fi xed contact poi nt of the
rel ay.
87A (Normally Closed) - Thi s termi nal i s con-
nected to the normal l y cl osed fi xed contact poi nt of
the rel ay.
OPERATION
The A/C compressor cl utch rel ay i s an el ectrome-
chani cal swi tch that uses a l ow current i nput from
the powertrai n control modul e (PCM) or engi ne con-
trol modul e (ECM) dependi ng on engi ne appl i cati on,
to control the hi gh current output to the compressor
cl utch el ectromagneti c coi l . The movabl e common
feed contact poi nt i s hel d agai nst the fi xed normal l y
agai nst the fi xed normal l y cl osed contact poi nt. The
resi stor or di ode i s connected i n paral l el wi th the
rel ay coi l i n the rel ay, and hel ps to di ssi pate vol tage
Fig. 9 Check Clutch Air Gap - Typical
1 - FEELER GAUGE
Fig. 10 A/C Compressor Clutch Micro-Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
DR CONTROLS 24 - 13
spi kes and el ectromagneti c i nterference that can be
generated as the el ectromagneti c fi el d of the rel ay
coi l col l apses.
The A/C compressor cl utch rel ay termi nal s are con-
nected to the vehi cl e el ectri cal system through a
receptacl e i n the i ntegrated power modul e (I PM). The
i nputs and outputs of the A/C compressor cl utch
rel ay i ncl ude:
The common feed termi nal (30) recei ves a bat-
tery current i nput from a fuse i n the I PM through a
fused B(+) ci rcui t at al l ti mes.
The coi l ground termi nal (86) recei ves a ground
i nput from the PCM/ECM through the A/C compres-
sor cl utch rel ay control ci rcui t onl y when the PCM/
ECM el ectroni cal l y pul l s the control ci rcui t to
ground.
The coi l battery termi nal (85) recei ves a battery
current i nput from PTC 1 i n the I PM through a
fused i gni ti on swi tch output (run) ci rcui t onl y when
the i gni ti on swi tch i s i n the On posi ti on.
The normal l y open termi nal (87) provi des a bat-
tery current output to the compressor cl utch coi l
through the A/C compressor cl utch rel ay output ci r-
cui t onl y when the A/C compressor cl utch rel ay coi l i s
energi zed.
The normal l y cl osed termi nal (87A) i s not con-
nected to any ci rcui t i n thi s appl i cati on, but provi des
a battery current output onl y when the A/C compres-
sor cl utch rel ay coi l i s de-energi zed.
di agnosi s and testi ng of the mi cro-rel ay and for com-
pl ete HVAC wi ri ng di agrams.
REMOVAL
cabl e.
(2) Remove the cover from the i ntegrated power
modul e (I PM) (Fi g. 11).
(3) Refer to the fuse and rel ay l ayout l abel on the
I PM cover for compressor cl utch rel ay i denti fi cati on
and l ocati on.
(4) Remove the A/C compressor cl utch rel ay from
the I PM.
INSTALLATION
(1) See the fuse and rel ay l ayout l abel affi xed to
the undersi de of the I PM cover for A/C compressor
cl utch rel ay l ocati on.
(2) Posi ti on the A/C compressor cl utch rel ay i n the
proper receptacl e i n the I PM.
(3) Al i gn the A/C compressor cl utch rel ay termi -
nal s wi th the termi nal cavi ti es i n the I PM receptacl e.
(4) Push down fi rml y on the A/C compressor cl utch
rel ay unti l the termi nal s are ful l y seated i n the ter-
mi nal cavi ti es i n the I PM receptacl e.
(5) I nstal l the cover onto the I PM.
A/C HEATER CONTROL
DESCRIPTION
The heater and ai r condi ti oni ng systems use el ec-
tri cal control s. These control s provi de the vehi cl e
operator wi th a number of setti ng opti ons to hel p
control the cl i mate and comfort wi thi n the vehi cl e.
The A/C-heater control for the Si ngl e Zone system
(Fi g. 12) or Dual Zone system (Fi g. 13) i s l ocated to
the ri ght of the i nstrument cl uster on the i nstrument
panel .
The Si ngl e Zone control panel contai ns a rotary-
type temperature control swi tch, a rotary-type mode
control swi tch and a rotary-type bl ower motor speed
swi tch. The A/C-heater control al so has a push but-
ton to acti vate the opti onal heated si de vi ew mi rror
defroster el ements and to turn the A/C on.
The Dual Zone control panel contai ns a pai r of sl i d-
er-type temperature control swi tches, a rotary-type
mode control swi tch and a rotary-type bl ower motor
speed swi tch. The control al so has buttons to acti vate
the opti onal heated si devi ew mi rror defroster el e-
ments, turn the A/C on and set the system to Max
A/C.
The A/C-heater control panel cannot be repai red. I f
faul ty or damaged, the enti re uni t must be repl aced.
Fig. 11 Integrated Power Module (IPM)
1 - BATTERY
24 - 14 CONTROLS DR
A/C COMPRESSOR CLUTCH RELAY (Continued)
The i l l umi nati on l amps are avai l abl e for servi ce
repl acement.
REMOVAL
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
cabl e.
REMOVAL).
(3) Remove the screws that secure the A/C-heater
control to the i nstrument panel (Fi g. 14).
INSTALLATION
(1) Posi ti on the A/C-heater control onto the i nstru-
ment panel center bezel and i nstal l the retai ni ng
screws. Ti ghten the screws to 2.2 Nm (20 i n. l bs.).
(2) I nstal l the i nstrument panel center bezel (Refer
A/C PRESSURE TRANSDUCER
DESCRIPTION
The A/C pressure transducer i s a swi tch that i s
i nstal l ed on a fi tti ng l ocated on the refri gerant di s-
charge l i ne between the compressor and the con-
denser i n the front corner of the engi ne
compartment. An i nternal l y threaded hex fi tti ng on
the transducer connects i t to the external l y threaded
Schrader-type fi tti ng on the di scharge l i ne. A rubber
O-ri ng seal s the connecti on between the transducer
and the di scharge l i ne fi tti ng. Three termi nal s wi thi n
a mol ded pl asti c connector receptacl e on the top of
the transducer connect i t to the vehi cl e el ectri cal sys-
tem through a wi re l ead and connector of the head-
l amp and dash wi re harness.
Fig. 12 Single Zone HVAC Control
2 - A/C BUTTON
3 - SIDEVIEW MIRROR DEFROSTER BUTTON (IF EQUIPED)
4 - MODE CONTROL SWITCH
5 - TEMPERATURE CONTROL SWITCH
6 - BLOWER MOTOR SWITCH
Fig. 13 Dual Zone A/C Control
1 - A/C BUTTON
2 - MAX. A/C BUTTON
3 - SIDEVIEW MIRROR DEFROSTER BUTTON (IF EQUIPED)
4 - MOUNTING TABS (4)
5 - DRIVERSIDE TEMPERATURE CONTROL
6 - PASSENGERSIDE TEMPERATURE CONTROL
7 - MODE CONTROL SWITCH
8 - BLOWER MOTOR SWITCH
Fig. 14 A/C-Heater Control - Typical, Rear View
2 - SCREW (4)
3 - A/C-HEATER CONTROL ELECTRICAL CONNECTOR
4 - HEATED SIDEVIEW MIRROR ELECTRICAL CONNECTOR
5 - A/C-HEATER CONTROL
DR CONTROLS 24 - 15
A/C HEATER CONTROL (Continued)
The A/C pressure transducer cannot be adjusted or
repai red and, i f faul ty or damaged, i t must be
repl aced.
OPERATION
The A/C pressure transducer moni tors the pres-
sures i n the hi gh si de of the refri gerant system
through i ts connecti on to a fi tti ng on the di scharge
l i ne. The transducer wi l l change i ts i nternal resi s-
tance i n response to the pressures i t moni tors. The
Powertrai n Control Modul e (PCM) or the Engi ne
Control Modul e (ECM) dependi ng on engi ne appl i ca-
ti on, provi des a fi ve vol t reference si gnal and a sen-
sor ground to the transducer, then moni tors the
output vol tage of the transducer on a sensor return
ci rcui t to determi ne refri gerant pressure. The PCM/
ECM i s programmed to respond to thi s and other
sensor i nputs by control l i ng the operati on of the ai r
condi ti oni ng compressor cl utch and the radi ator cool -
i ng fan to hel p opti mi ze ai r condi ti oni ng system per-
formance and to protect the system components from
damage. The A/C pressure transducer i nput to the
PCM/ECM wi l l al so prevent the ai r condi ti oni ng com-
pressor cl utch from engagi ng when ambi ent temper-
atures are bel ow about 10 C (50 F) due to the
pressure/temperature rel ati onshi p of the refri gerant.
The Schrader-type val ve i n the di scharge l i ne fi tti ng
permi ts the A/C pressure transducer to be removed
or i nstal l ed wi thout di sturbi ng the refri gerant i n the
system. The A/C pressure transducer i s di agnosed
usi ng a DRBI I I scan tool . Refer to the appropri ate
di agnosti c i nformati on.
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER
The A/C pressure transducer i s tested usi ng a
DRBI I I scan tool . Refer to the appropri ate di agnos-
ti c i nformati on. Before testi ng the A/C pressure
transducer, be certai n that the transducer wi re har-
ness connecti on i s cl ean of corrosi on and properl y
connected. For the ai r condi ti oni ng system to operate,
an A/C pressure transducer vol tage readi ng between
0.451 and 4.519 vol ts i s requi red. Vol tages outsi de
thi s range i ndi cate a l ow or hi gh refri gerant system
pressure condi ti on to the Powertrai n Control Modul e
(PCM) or Engi ne Control Modul e (ECM) dependi ng
on engi ne appl i cati on. The PCM/ECM i s programmed
to respond to a l ow or hi gh refri gerant system pres-
sure by suppressi ng operati on of the compressor.
Refer to the A/C Pressure Transducer Vol tage chart
for the possi bl e condi ti ons i ndi cated by the trans-
ducer vol tage readi ng.
A/C PRESSURE TRANSDUCER VOLTAGE
CHART
Voltage Possible Indication
0.0 1. No sensor supply voltage from
PCM/ECM.
2. Shorted sensor circuit.
3. Faulty transducer.
0.150 TO 0.450 1. Ambient temperature below
10C (50F).
pressure.
0.451 TO 4.519 1. Normal refrigerant system
pressure.
4.520 TO 4.850 1. High refrigerant system
pressure.
5.0 1. Open sensor circuit.
2. Faulty transducer.
REMOVAL
NOTE: Note: It is not necessary to discharge the
refrigerant system to replace the A/C pressure
transducer.
cabl e.
(2) Di sconnect the wi re harness connector from the
A/C pressure transducer.
(3) Remove the A/C pressure transducer from the
fi tti ng on the di scharge l i ne (Fi g. 15).
(4) Remove the O-ri ng seal from the A/C pressure
transducer fi tti ng and di scard.
INSTALLATION
NOTE: Replace the O-ring seal before installing the
A/C pressure transducer.
(1) Lubri cate a new rubber O-ri ng seal wi th cl ean
refri gerant oi l and i nstal l i t on the A/C pressure
transducer fi tti ng. Use onl y the speci fi ed O-ri ngs as
they are made of a speci al materi al for the R-134a
system. Use onl y refri gerant oi l of the type recom-
mended for the A/C compressor i n the vehi cl e.
(2) I nstal l and ti ghten the A/C pressure transducer
onto the di scharge l i ne fi tti ng. The transducer shoul d
be hand-ti ghtened securel y onto the di scharge l i ne
fi tti ng.
(3) Connect the wi re harness connector to the A/C
pressure transducer.
24 - 16 CONTROLS DR
A/C PRESSURE TRANSDUCER (Continued)
BLEND DOOR ACTUATOR
DESCRIPTION
The bl end door actuators are reversi bl e, 12-vol t
Di rect Current (DC), servo motors. Model s wi th the
si ngl e zone heater and ai r condi ti oner system have a
si ngl e bl end door, whi ch i s control l ed by a si ngl e
bl end door actuator. Model s wi th the opti onal dual
zone front heater and ai r condi ti oner system have
dual bl end doors, whi ch are control l ed by two bl end
door actuators. The si ngl e zone bl end door actuator i s
l ocated on the dri ver si de end of the HVAC housi ng,
cl ose to the dash panel . I n the dual zone system, the
same bl end door actuator used for the si ngl e zone
system becomes the dri ver si de bl end door actuator,
and i s mechani cal l y connected to onl y the dri ver si de
bl end door. I n the dual zone system, a second sepa-
rate bl end door actuator i s al so l ocated on the top of
the HVAC housi ng and i s mechani cal l y connected to
onl y the passenger si de bl end door.
The bl end door actuators are i nterchangeabl e wi th
each other, as wel l as wi th the actuators for the
mode door, defrost door and the reci rcul ati on door.
Each actuator i s contai ned wi thi n an i denti cal bl ack
mol ded pl asti c housi ng wi th an i ntegral wi re connec-
tor receptacl e. I ntegral mounti ng tabs al l ow the
actuator to be secured wi th three screws to the
HVAC housi ng. Each actuator al so has an i denti cal
output shaft wi th spl i nes that connects i t to the l i nk-
age that dri ves the proper door. The bl end door
actuators do not requi re mechani cal i ndexi ng to the
bl end door l i nkage, as they are el ectroni cal l y cal i -
brated by the heater-A/C control modul e. The bl end
door actuators cannot be adjusted or repai red and, i f
damaged or faul ty, they must be repl aced.
OPERATION
Each bl end door actuator i s connected to the A/C-
heater control through the vehi cl e el ectri cal system by a
dedi cated two-wi re l ead and connector from the HVAC
wi re harness. The bl end door actuator can move the
bl end-ai r door i n two di recti ons. When the A/C-heater
control pul l s the vol tage on one si de of the motor con-
necti on hi gh and the other connecti on l ow, the bl end-ai r
door wi l l move i n one di recti on. When the A/C-heater
control reverses the pol ari ty of the vol tage to the motor,
the bl end-ai r door moves i n the opposi te di recti on.
When the A/C-heater control makes the vol tage to both
connecti ons hi gh or both connecti ons l ow, the bl end-ai r
door stops and wi l l not move. The motor connecti ons
al so provi de a feedback si gnal to the A/C-heater control .
Thi s feedback si gnal al l ows the A/C-heater

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